I bought my car last year with the hope of enjoying driving a manual, after a long break driving variants of automatic (including DSG). The car I bought was a 2006 GTI that clearly had money lavished upon it, but it very definitely wasn't an 'enthusiast' car. Lots of receipts from specialists, but none of the fixes that you read about on forums, if that makes sense. It had 145k on the clock and I strongly suspect the gearbox, shifter and everything else were the same parts that left the factory.
I'd describe the original shift as being OK but definitely at the 'stirring porridge' end of the spectrum. The car went into gears smoothly, but there was a massive amount of play in the shifter.
I wanted to tighten the shift up to reduce play and have already done all of the following:
- Bar-Tek Aluminium shifter bracket bushings
- Bar-Tek Aluminium shifter cable bushing inserts (the type that slot into the ends of the shifter cable)
- Dieselgeek upgraded shifter bush bearings
- VW shifter slider (the white plastic part at the gearbox end)
- Meyle/Febi engine and gearbox mounts
- Powerflex dogbone insert
- Check for end shaft float (there was none -
https://www.mk5golfgti.co.uk/forum/index.php/topic,132441.0.html)
- Alignment using a proper T10027 alignment tool
Although a lot of the play has been removed, what I am left with is a shift that is a bit reluctant to go into some gears, particularly first and second. I'd describe all shifts as a being a bit notchy and not that enjoyable. Warming up the oil doesn't really have a massive impact. It's a shame because the car was bought for me to enjoy driving a manual.
I think what has happened is that the play in the shift has been masking some underlying issue. I've now removed that play and that is causing a problem. A number of the changes I have made will contribute to some degree of notchiness (like the aluminium parts) but that said, I haven't fitted a short shift kit, which is probably the greatest contributor to notchiness.
I'd really like to get to the bottom of the shift quality although I must admit, anything that requires the box to come out will probably wait until I need a clutch.
Possible causes:
- Gearbox cables are misaligned (although I did follow the Dieselgeek video)
- Bushes at the shifter end - there are quite a few underneath the shifter that I haven't touched. I'm confident that they are past their best
- Gearbox oil needs to be changed - I have three bottles of VW stuff in the garage
- Something inside the gearbox - this is probably the worry. Selector forks could be it.
In terms of function, the box works fine through the gears and doesn't make any untoward noises. No crunches, which often points to a synchro issue. Clutch is working perfectly and is not slipping. I'd describe the issue as being in the selection of gears.
Thoughts?
As in my other thread, 145k isn't terrible for a gearbox, but I must admit I am hoping it is something else!
