So, first post here but long time lurker!
I own a MK4 Golf 1.8t (:o) but both these & the TDI's of the same era use the same transmission setups, so I'm hoping that someone over here may have the answer to my woes.
Long story short: shifting (intermittently) feels like I'm trying to shift through a brick wall that suddenly turns into liquid a few seconds later, allowing me to move into the gear I was attempting to shift into - this is pretty intermittent though & seems to happen more in winter than in summer.
In an attempt to fix my issue, I have so far:
Thankfully I have been able to do most of this myself so it hasn't cost me much in labour & my local dealer gives me a decent discount, so I can't complain, but as you can imagine it's really starting to wear away at my love for my car.
One thing I have noticed is that the clutch bites higher than it used to (about 1/3rd pedal travel before it bites), but I put this down to the VR6/G60 combo, meaning it has to travel further to bite - is this correct?
The next and final thing on my list is to completely drain the clutch/brake hydraulics, replace all the fluid with brand new DOT5 and re-bleed everything in hopes that there is somehow water or air in the fluid as this has not been changed at all in my ownership. My train of thought here is that water/air is compressible & that it will slow the operation of the slave cylinder, meaning the clutch is still engaged when I am attempting to shift?
Sorry for the long post, I just wanted to make sure I covered everything I have attempted to fix this issue - any input would be greatly appreciated!
Cheers,
Dan
I own a MK4 Golf 1.8t (:o) but both these & the TDI's of the same era use the same transmission setups, so I'm hoping that someone over here may have the answer to my woes.
Long story short: shifting (intermittently) feels like I'm trying to shift through a brick wall that suddenly turns into liquid a few seconds later, allowing me to move into the gear I was attempting to shift into - this is pretty intermittent though & seems to happen more in winter than in summer.
In an attempt to fix my issue, I have so far:
- Replaced the clutch/flywheel with the VR6/G60 setup.
- Replaced the shift cup with the later MK5 version & shimmed shift cup.
- Replaced shift tower bushings (02A301320B / 02A311648C / 02A301227M)
- Replaced all perishables surrounding the shifter (1J0711047, 357711145C, 1J0711124, 1J0711067Q, 1J0711067K, 1J0711067N & 1J0711217)
- Completely rebuilt everything on top of the shift tower (Brand new TT short shift counter-weight, later clip type bowden catches, shift tower top O2J 301 232 B) .
- Installed DieselGeek First Gear Getter (Previous and Current Revision), Cable Saver Bushings & S2S Shifter Pivot Bushes (1J0 711 067L) & aligned with alignment pin multiple times.
- Installed 42DD bushing kit for the shift cable relay bracket.
- Installed 42DD bushing kit for both shift cable ends.
- Installed new clutch slave cylinder & bled all air from the system.
- Installed new clutch master cylinder & bled all air from the system.
- Installed new throwout bearing & clutch fork.
- Replaced both selector cables & selector box.
- Dropped gearbox, completely disassembled & inspected selector forks, synchro's and gears to check for damage or wear, to no avail.
Thankfully I have been able to do most of this myself so it hasn't cost me much in labour & my local dealer gives me a decent discount, so I can't complain, but as you can imagine it's really starting to wear away at my love for my car.
One thing I have noticed is that the clutch bites higher than it used to (about 1/3rd pedal travel before it bites), but I put this down to the VR6/G60 combo, meaning it has to travel further to bite - is this correct?
The next and final thing on my list is to completely drain the clutch/brake hydraulics, replace all the fluid with brand new DOT5 and re-bleed everything in hopes that there is somehow water or air in the fluid as this has not been changed at all in my ownership. My train of thought here is that water/air is compressible & that it will slow the operation of the slave cylinder, meaning the clutch is still engaged when I am attempting to shift?
Sorry for the long post, I just wanted to make sure I covered everything I have attempted to fix this issue - any input would be greatly appreciated!
Cheers,
Dan
O2J Shift Issues
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