MK4 gearbox probs

[bmkev]

Well the box has bit the dust with what appears to be a common problem i.e the rivets falling out of the diff.

Having searched this place I feel that I can repair this myself. The box has a very small hole inside the bellhousing which is not a problem to get welded. The box never locked up or jammed and to be honest if the clutch had not been slipping then I would not have been any the wiser.

What I would like to know (pretty pretty please) if anyone here has any info on splitting the box apart or if there is anything I should look out for when trying to do so. Or ultimately if anyone here has one for sale.

Any help would be greatly appreciated :1zhelp::1zhelp::1zhelp::1zhelp::1zhelp::1zhelp:

Kev.

[carebabe]

what engine do you have? a similar thing happened to my mark1v recently but with more damage by the sound of things.

[Crasher]

I guess this is an 02K DUU box on a 1.6 Golf 4? Welding magnesium is not easy and rebuilding these boxes properly is time consuming but if you just pull it apart to fit a diff rivet kit and don't replace any bearings you won't need to do any shim work. I don't know how good the Haynes manual is but if you PM me your chassis number and email address I will mail you some info.

[bmkev]

@ carebabe, it is a 1.4 8 valve mate.

@ Crasher, you are a star mate I'll pm you later.

[Crasher]

1.4 8v Golf 4?

[bmkev]

1.4 8v Golf 4?

1.6 8valve Golf mk4 :Blush2::Blush2::Blush2::Blush2::Blush2::Blush2::B lush2::Blush2::Blush2::Blush2:

[Crasher]

What year is it? I would guess it is an AKL engine but if you PM me the details I will send you some info.

[bmkev]

@ Crasher PM sent mate.

[bmkev]

@Crasher: You are a flipping star mate. I owe you big time :beerchug:


I'll post up how I get on for anyone interested.

[bmkev]

Well I did it :biglaugh::biglaugh::biglaugh::biglaugh:

Removed the box, stripped it, replaced diff rivets with VW bolts, repaired the slight hole in gearbox casing and the put the whole lot back together with a new clutch.

Result......works perfect :biglaugh:

I must add that without the info from Crasher I could have not done the above so I owe that guy :beerchug::beerchug::beerchug::beerchug:

Whilst all of the above was completed by myself I don't to make it sound easy as it was not.

Better at paying out approx £150 in parts for the clutch and diff kit that £600 for another box.

[Crasher]

But did you enjoy it?

[bmkev]

But did you enjoy it?

Enjoy?? not really but job satisfaction 100,000,000 %.

Thanks again mate your info was invaluable.

[Crasher]

I love building gearboxes. I have nearly finished the one for my 72 1302LS semi automatic Beetle, with help from a chap in London as he had the measuring jigs I needed.

[Simon1985]

not sure how old this thread is but is it possible to have the gear box rivit issue 'fixed' before it breaks?

I will only hold onto my Golf if this is the case otherwise i think i'll be getting rid of it asap :P

Cheers

Simon

[Crasher]

Yes, it means an almost full strip down of the box to remove the differential, drill out the rivets and fit the bolt kit. Then rebuild with new gaskets and bearings if you can afford it plus second gear synchromesh as they are prone to failure.

[Simon1985]

already have abit of difficulty getting it into 2nd gear.... How much would that all cost?

[Crasher]

It varies tremendously, from say £400 to £1500 depending on who does it and how well you want it doing.

[Simon1985]

ah ****, spent about 600 quid since having this damn car :) Think i'm gonna get the cam belt done and new brakes then get it sold!

Only prob now is I have to find a car that i still like but actually is reliable!

Cheers for the replies!

[fireant]

My sisters bora 1600 has the same fault, but we can't split the box? any ideas?

[fireant]

are there any drawings available:D

[Crasher]

I have all the drawings and diagrams you need but do you have bearing pulling tools? The first job is to extract 5th gear (which can stick on the shaft and break when being pulled off like one I did this the week) and then you can get into the main gear set to allow you to get at the diff.

[fireant]

Thanks crasher.

[fireant]

My dad took the box to work, last night.
He say's he has managed to strip it. But it's had it.
The diff housing was cracked anyway, looks like we need to find a scrapper.

[fireant]

We would appreciate the help with drawings etc, as when we find another box it will need the rivets doing?

[Crasher]

PM sent

[fireant]

Superb, thanks Crasher that will help Tons:beerchug:What a guy.:D

[jnunn]

Hello.

I know this is an old thread but does anyone know if this gearbox problem affected the 2.0se petrol model.
The clutch on my Bora has been slipping for a while but recently has started to make a noise when accelerating. I dont know if its coming from the gearbox or the clutch.

I have ordered a new clutch so will be getting that fitted soon. Is it worth checking anything else when changing the clutch.
The clutch I bought was just a cheap one off e-bay so i hope it is ok.

http://cgi.ebay.co.uk/VW-BORA-BEETLE-GOLF-1-8-1-6-2-0-i-CLUTCH-KIT-VAP130_W0QQitemZ220322324216QQcmdZViewItemQQptZUK_ CarsParts_Vehicles_CarParts_SM?hash=item2203223242 16&_trksid=p3286.c0.m14&_trkparms=72%3A1301%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318

Cheers

James

[Crasher]

That cars has the 02J box which is far less susceptible to diff rivet failure than the 02K but it does still happen.

[spesh1967]

where abouts is the gearbox number?
as i want to check my pile of **** golf

the things been playing up with the throttle body and today i took it out after the wife said it made a whirring noise
and the thing whines under load but not when you put the clutch in and still rolling
any ideas?

[Crasher]

Stamped on the lower area of the bell housing and printed on the data sticker on the boot floor and in the service book front cover.

[WAYNEGOLF]

Just picked myself up a cheap MK 4 Golf, and blow me there is a lot of vibration metal on metal which I thought was the exhaust. I am very concerned it is the diff.
Could someone advise me method of removal and repairt technique and where to obtain diff kit.
It is a 16v 1.4cc, I believe the diff is fully intact.
So I want to get it repaired before it totally fails.
Any help would be highly appreciated.
Thanks,

Wayne

[Crasher]

The diff rivets on those are very prone to failure, it may be too late to save the box casing though, only after removal and strip down will you know.

[WAYNEGOLF]

Thanks Crasher for coming back so soon.
Are you able to provide me detailed method on how to remove gearbox and strip down.

Also how can I be 100% sure the diff is definetely on its way out.
Thanks,
Wayne

[Crasher]

You need to have it diagnosed by a mechanic. You don’t sound as though you have done any major work on a car and diving in on an 02K box rebuild is not the place to start. Perhaps you could remove the box but have it rebuilt by a gearbox reconditioning shop as it does require quite a few special tools.

[spesh1967]

hi mate my 1.6 was the same made a whinning noise like a straight cut box so i took it to a mechanic and he stripped the box,a rivit had punched its way out of the case between the diff housing and the clutch house so the hole was not visible until it was stripped
good news is he repaired it by having the cases welded and remachined and new bearings and some other bits
i also had a new clutch and timing belt with water pump and a new throttle body(which the car was originally going in for until the gearbox played up the day before)
total bill was £1500 but i had a perfectly mechanical mk4 golf which i wanted to keep forever until 48 hours later

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when a car in the outside lane of the m3 lost control at 80mph and side swiped/t-boned me ,i was in the inside lane doing 55mph i bounced off him across the hard shoulder into a tree see result below
so if you can find my car in a scrapper somewhere in chertsey it has a refurbed gearbox and a brand new throttle body

http://i58.photobucket.com/albums/g279/spesh1967/100_1218.jpg
http://i58.photobucket.com/albums/g279/spesh1967/100_1214.jpg
http://i58.photobucket.com/albums/g279/spesh1967/100_1216.jpg
http://i58.photobucket.com/albums/g279/spesh1967/100_1223.jpg

[avfan]

I have this same rivet problem on my 1999 AKL engine/ DUU box. I would like to have a go at replacing the rivets with the bolts, but I will need the instructions/diagram. Can any one please help?

[Crasher]

When you have enough posts, PM me your email and cars reg number.

[herby0001]

total bill was £1500 but i had a perfectly mechanical mk4 golf which i wanted to keep forever until 48 hours later


That is gutting! Sorry to hear that.

[avfan]

Crasher, thank you very much for the offer. I will pm you as soon as the system will allow.

[wadey5187]

We have got a recon box from Cleckheaton, will keep you posted as to how the fitting goes but have put some photos here, hope they help somebody
http://www.flickr.com/photos/rossendalewadey/4545709964/

[wadey5187]

We have got a recon box from Cleckheaton, will keep you posted as to how the fitting goes but have put some photos here, hope they help somebody
http://www.flickr.com/photos/rossendalewadey/4545709964/
Box now fitted and (touch wood) seems OK, we were not able to see if the failure of the reversing lights was linked, any ideas?