Gearbox input shaft shim and cap size

[breeze]

I'm going to check for float on my input shaft. I also have a funny feeling I have a leak from the cap. It's a 2006 GTI.

Does anybody know what size I need?

• 02M301211B   79.35mm - Small
  
• 02M301211D  84.5mm - Large

Looking at previous posts, I can see that the small size part number appears a few times. Did these cars ever come with the large cap?

[pudding]

You have to get out there and measure it.  It's not as simple as model year.

[breeze]

You have to get out there and measure it.  It's not as simple as model year.

Thanks. Finally got out and measured and it was the 79mm cap. I ordered a shim kit and it came with three shims. Most of the videos online show only one being installed so I suspect there will be a bit of trial and error.

[pudding]

Aye.  If you can't get any of the shims in, it was already shimmed at the factory.  The input shaft needs a hefty shove to move it enough to measure the play. 

[breeze]

Have been out in the rain having a play with this.

I was really hoping that I could get a shim or two in but it looks like the gearbox was shimmed from the factory. It's a 2006 '06' registered car. There is a small amount of play (almost zero) but sadly not enough to squeeze a shim in and fit the retaining clip. That includes trying to work the shaft out with my fingers and then fit the retaining clip.

Frustrating. Not happy with the gear change but I am running out of options. I have three bottles of the official VW oil to use, just wondering if it will be a waste if I need to replace the box after all that. 145k so not a terrible innings but other than the change it works perfectly and doesn't make any scary noises.

 

I had a mild leak and the new cap should fix that. So not a complete waste of time at least.

[pudding]

2006 was the year they started adding the shims, so late 2005/early 2006 might not be shimmed.  Yours was 

It's a weird gearbox.  Mega strong because of the big semi helical gears, but some truly sh1t design and materials choices let it down. Such as brass selector forks secured with roll pins, and no taper bearings on the gear shafts 

I have a MK6 gearbox in mine, and I refreshed the gearstick wear parts I could access (the rest have to be replaced after dropping the exhaust and tunnel shield), and it's a very good shift indeed. 

It's no MK7+, but it's better than it was with the MK5 gearbox.  Mine also felt knackered at the same mileage as yours. The layshaft bearings wear out on them, in as little as 30K miles.  It causes a whirring noise when hot, that goes when pressing the clutch pedal.  Nothing you can do about that, but it doesn't cause any harm, it's just an irritant.