1.8t Won't go into 2nd and 4th gear

[nrinaldi33]

Hello, I am fairly new to AZ. I have used the search and have seen some results but nothing particularly specific to my situation. ( I have a 5 speed manual by the way)

Ok, so I was driving on the highway in 5th gear for about 20 min. (car was driving fine) or so, go to get off the exit and downshift to 4. car would not go into 4th gear. it was like it was being blocked off. same thing with 2nd gear, however 1st, 3rd, 5th and reverse work. I talked to a guy who often works on these 1.8's and he sounded pretty sure it was my fork? not sure if he meant clutch fork or ?? he then went on to tell me that in order to fix this he would have to replace the whole transmission and most likely clutch. Anyone know what's wrong with my car?

[gregory.fazekas]

Sounds like a bent shift fork to me.

[nrinaldi33]

Sounds like a bent shift fork to me.

where is the fork ? in the tranny ? and how difficult is it to replace ?

[SJorge3442]

where is the fork ? in the tranny ? and how difficult is it to replace ?

pretty difficult. The whole transmission needs to be disassembled

[nrinaldi33]

pretty difficult. The whole transmission needs to be disassembled

Would it be more costly to have someone dissassemble the tranny and replace the fork or to just drop a new tranny in it?

[Audiguy1234]

Labor will be the same for both. Parts cost will be significantly different. The fork is pretty easy to replace once the transmission or engine is removed. It shouldn't cost more than a clutch job I would guess.

Sent from my SAMSUNG-SM-N900A using Tapatalk

[nrinaldi33]

Thanks, another guy with an s4 was having almost same exact problem and people were telling him to check the alignment of the linkage. does anyone know of any DIY's on how adjust the alignment on the b6's? thanks

[old guy]

I suspect the problem is with the linkage and not the transmission. Is your neutral gate a little further back than usual?

[nrinaldi33]

I suspect the problem is with the linkage and not the transmission. Is your neutral gate a little further back than usual?

Maybe a little bit, nothing really noticeable though.

[old guy]

Maybe a little bit, nothing really noticeable though.

If the neutral gate has moved at all that would be a good thing. That would be an indication that you have a shifter or shifter linkage problem rather than a transmission problem. Much cheaper and easier to address.

[walky_talky20]

I think this may be an issue with the shifter relay shaft "Stop Screws" (aka "Slider Bolts"). This is a somewhat common failure item on the 01A 5-speed manual transmission.

Your first step is to check the external linkage. The best way to do this is to check what is going on directly at the transmission, where the shifter shaft enters the housing. You should be able to manipulate it by hand there to put it in each gear. Ideally you would completely disconnect the rod to the floor shifter so you are only dealing with transmission directly.

If there is nothing obvious wrong with the external linkage and shifting manually is still not possible, you can check (and even replace) the "Stop Screws" without dropping the transmission out of the car. They are externally accessible. The failure mode is that the bolts shear off internally, and thus no longer keep the relay shaft in place properly. Like so:



Here are some threads with info:
http://www.audizine.com/forum/showth...Shifting-issue
http://www.audizine.com/forum/showth...nsmission-woes!
http://www.audizine.com/forum/showth...fter-or-tranny
http://www.audizine.com/forum/showth...-why-it-is-bad

[nrinaldi33]

so if the neutral gate has barely moved or not at all . it would most likely be transmission ? and how would I be able to check if something is wrong with the shifter or shift linkage ?

[nrinaldi33]

I think this may be an issue with the shifter relay shaft "Stop Screws" (aka "Slider Bolts"). This is a somewhat common failure item on the 01A 5-speed manual transmission.

Your first step is to check the external linkage. The best way to do this is to check what is going on directly at the transmission, where the shifter shaft enters the housing. You should be able to manipulate it by hand there to put it in each gear. Ideally you would completely disconnect the rod to the floor shifter so you are only dealing with transmission directly.

If there is nothing obvious wrong with the external linkage and shifting manually is still not possible, you can check (and even replace) the "Stop Screws" without dropping the transmission out of the car. They are externally accessible. The failure mode is that the bolts shear off internally, and thus no longer keep the relay shaft in place properly. Like so:



Here are some threads with info:
http://www.audizine.com/forum/showth...Shifting-issue
http://www.audizine.com/forum/showth...nsmission-woes!
http://www.audizine.com/forum/showth...fter-or-tranny
http://www.audizine.com/forum/showth...-why-it-is-bad

Alright thank you I will check this in a little bit when I get off of work. thanks for the suggestions . how easily accessible are the stop screws and about how much do the cost?

[old guy]

so if the neutral gate has barely moved or not at all . it would most likely be transmission ? and how would I be able to check if something is wrong with the shifter or shift linkage ?

Do what Walky suggested and disconnect the shift rod from the transmission gear selector shaft and see if you can manually move the shaft in and out as well as rotate it clockwise and back to neutral and then counterclockwise and back to neutral.

[walky_talky20]

On a B6 with a factory-installed 5-speed manual, the stop Screws should not be too bad. Other models have side-located mount brackets that impede access, but the B6 does not have these, so it shouldn't be too hard.

The price of the bolts isn't bad. About $15 each:
http://www.ecstuning.com/Search/ES266240_ES266241/

[nrinaldi33]

So It's a good thing if I can manually shift through the gears by manipulating the shift rod ?

[old guy]

So It's a good thing if I can manually shift through the gears by manipulating the shift rod ?

Yes that's a good thing. Now you need to concentrate on the shifter mechanism in the cabin. It probably needs a little adjustment and TLC.

This should help:

[nrinaldi33]

Yes that's a good thing. Now you need to concentrate on the shifter mechanism in the cabin. It probably needs a little adjustment and TLC.

This should help:

alright thanks old guy I will try adjusting it.

[nrinaldi33]

On a B6 with a factory-installed 5-speed manual, the stop Screws should not be too bad. Other models have side-located mount brackets that impede access, but the B6 does not have these, so it shouldn't be too hard.

The price of the bolts isn't bad. About $15 each:
http://www.ecstuning.com/Search/ES266240_ES266241/

Do you know what size key this is walky?

[nrinaldi33]

Okay guys I have an update. was messing around adjusting linkage like in the video old guy sent. the car now goes into 4th gear and sometimes second if I shift it hard, however I cant shift from first to second or it won't go in gear it will grind. I have to go in from neutral and bang it in. any other suggestions?
Here is a pic of the shift knob. there are little shavings of what looks to be a rubber/ plasticy material. seems like its coming from that ball/bushing in the middle (sorry not sure of the name). can this be a possible problem? by the way thank you guys for the help so far.

Ps. - all of the gears are shifting a little rougher?

[old guy]

Well considering that you couldn't get it into 4th gear before and you can now I think it is very likely to be a shifter problem. If you don't have enough throw on the shifter the shift rod can't fully engage the gear selector shaft in the transmission. I would recommend removing the shifter completely and examining all the components for wear. Since it occurred all at once I have to assume you will find a damaged component or loose component.

This thread might help if it's a loose shifter stabilizing rod: Clicky click

[nrinaldi33]

[IMG]shifter[/IMG] sorry didnt post before

[nrinaldi33]

Well considering that you couldn't get it into 4th gear before and you can now I think it is very likely to be a shifter problem. If you don't have enough throw on the shifter the shift rod can't fully engage the gear selector shaft in the transmission. I would recommend removing the shifter completely and examining all the components for wear. Since it occurred all at once I have to assume you will find a damaged component or loose component.

This thread might help if it's a loose shifter stabilizing rod: Clicky click

When I feel inside of the boot that the shifter stabilizing rod goes into it seems very loose like its not connected to anything. Is that normal? sorry I can't seem to figure out how to post pictures.

[old guy]

When I feel inside of the boot that the shifter stabilizing rod goes into it seems very loose like its not connected to anything. Is that normal? sorry I can't seem to figure out how to post pictures.

No that is not normal. The shifter carriage is mounted on slide rails so the shifting mechanism can remain stable relative to the transmission. This allows for movement of the carriage as the drivetrain moves around. The stabilizer rod is what keeps the carriage anchored to the transmission. If it is loose than the carriage can move independently of the transmission which will limit the amount of movement available for the shifter rod.

You need to find what came loose on the stabilizer rode.

[nrinaldi33]

No that is not normal. The shifter carriage is mounted on slide rails so the shifting mechanism can remain stable relative to the transmission. This allows for movement of the carriage as the drivetrain moves around. The stabilizer rod is what keeps the carriage anchored to the transmission. If it is loose than the carriage can move independently of the transmission which will limit the amount of movement available for the shifter rod.

You need to find what came loose on the stabilizer rode.

Sorry forgot to mention that I took the whole shifter assembly out in order to inspect it. (the same procedure as if I were going to put a short throw in) . so nothing is connected in the cabin. Would this make the stabilizer rod loose in the boot ? or still not normal ? Also, the two bushings that are on those rods that slide back and fourth seem to be very worn. would this cause problems?
Really wish I could figure out pics

[coowhip]

Sorry, no help to the OP but I'm having a similar issue. Cold days or sometimes in general I have a hard time getting it into 2nd gear as if the clutch isn't all the way disengaged. Not a full grind but rocky slide into 2nd. I'm thinking that may be a shifter linkage problem as well. Clutch, fluid, and all mounts were replaced not too long ago and same issue is still there. Seems like a decent amount of play when in gear too, the shifter moves about 1/4" when letting go of accelerator and stepping back on it.

[walky_talky20]

^All of that is normal. Your 2nd gear synchro is worn out. A common issue on the 01A 5-speed. What kind of gear oil did you put into the transmission, exactly?

OP: I wish you could figure out pics. And video.

Use Photobucket for pics. Use Youtube for video. Both are setup to give you easy access to links for use with forum posting activities.

Yes, if the bushings are all worn out, you won't get as much "throw" as you ought to have. If you center everything up so you have equal throw forward and back, whilst still crappy, everything generally continues to work. Yours may be more womped than usual.

[coowhip]

I think I used Motul 75w90. Could have been MT-90

[nrinaldi33]

here is a short video I took. sorry for quality. and I said it in the video but is there any diy or video I can watch to get a look inside of that black boot the shifter rod and stabilizer lead to ? what is that anyway ?

[walky_talky20]

I think I used Motul 75w90. Could have been MT-90

Both of those are too thick.

Drain it and put in OEM G052-911: http://www.ecstuning.com/Audi-B5_A4-...sion/ES465417/
Or equivalent: http://advancedautomotion.com/shop/p...roducts_id/139

[coowhip]

I might be thinking I did the rear diff with MT-90 and Motul Gear 300 for tranny.

[walky_talky20]

OP: Pause video at 0:01. See that long oval hole at the bottom of the video? That's where the stationary rod is supposed to attach. That gives the shifter a position reference with the transmission.

This one:



Here you can see both rods, shifter rod and stationary rod:



That picture *is* the inside of that black boot.

[old guy]

This video may help explain how the stabilizer rod functions. It should be securely anchored to the shifter carriage on one end and attached to the transmission with a rubber bushing on the other end. If you can move your stabilizer arm front to back you may have a worn out bushing or a loose bolt on the transmission mount end of the rod.

[nrinaldi33]

Problem is fixed! You were right old guy it was the bushing inside of the transmission that the shift rod goes into. thank you for all of your help guys!

[SJorge3442]

Problem is fixed! You were right old guy it was the bushing inside of the transmission that the shift rod goes into. thank you for all of your help guys!

another win for Audizine