A4 5sp manaul gear selection problem

[rowdy-999]

Ignore my sig its an b6 A4 1.9 tdi130 with a 5sp box.
I accidentally stalled the engine (with a bit of a bang/jolt) whilst the car was still moving by selecting 5th not 3rd. After this happened i'm now having problems selecting gears. The clutch pedal feels normal, and i can engage ok when the engine is switched off. The clutch doesn't slip.
The clutch was replaced by the previous owner fairly recently apparently (which i can believe due to how it feels and the bite point). Prior to the stall everything was silky smooth.
Any ideas please?

[Vagnuts]

can you get all gears when engine is running ???

[rowdy-999]

can you get all gears when engine is running ???

Yes, but it's stiff and difficult to engage, almost like the clutch isn't fully engaged.

[Vagnuts]

Yes, but it's stiff and difficult to engage, almost like the clutch isn't fully engaged.

might sound silly--try bleeding the cluch-ie-if brakes have worn down a wee bit the fluid level may have dropped below the take off point for the clutch--I say this cause I had a car in yesterday with just that same thing- take off for clutch is quite high up the brake fluid reservoir !!! sorry just noticed that yours is auto--check atf level(auto trance fluid level) if you havent allready !!I am brain dead--its actually 5spd-but yeh fluid level is a first !!

[rowdy-999]

Thanks, I'll have a look. Just thought it odd it occurred straight after stall.

[arman123]

could the stall have knocked the selector alignment try this if it helps

Adjusting selector mechanism Note t The following are prerequisites for correct gear lever alignment: t Gear selector linkage must be in proper condition and undamaged. t Selector mechanism must move freely. t Gearbox, clutch and clutch mechanism must be in proper condition. t Gearbox in neutral.

– Lift off cover for centre console -arrows- and pull cover up and over gear knob.

Gear knob with locking mechanism: – Release connecting piece -1- in direction of arrow and pull gear knob off upwards together with gear lever boot.

Gear knob with clip: – Cut through clip -arrow- using side-cutting pliers or similar and detach gear knob together with gear lever boot upwards. Vehicles with large radio slot: – Remove operating and display unit for air conditioner → Air conditioning system; Rep. Gr.87.

Vehicles with small radio slot: – First lift trim panel -1- in direction of -arrow A-, then pull it out in direction of -arrow B-. All models: – Unscrew bolts -arrows C- and then pull ashtray -2- out of centre console.

– Lift out the damping washer -1- and the noise insulation -2-.

– Unscrew noise insulation for selector housing -arrows-.

– Measure distance -a- between the two studs in the selector mechanism. l Specification: distance -a- = 85 mm Note Measure from centre of one stud to centre of the other. If distance -a- does not meet specification: – Loosen bolt -arrow- for push rod. l Gear lever bearing (in selector mechanism) should move freely in both directions on slide. – Set to distance -a- by moving gear lever bearing (in selector mechanism). – Tighten bolt for push rod -arrow- to specified torque.

– Loosen bolt for selector rod -arrow-. l Connection between selector rod and selector mechanism should move freely.

Align the gear lever as follows: – Centre the bottom of the gear lever in the centre of the ball guide. l Distance between ball guide and bottom of gear lever -arrows- must be the same at all points. l Gear lever is vertical in direction of travel. – Hold gear lever in this position.

– Tighten securing bolt for selector rod -arrow- to torque. Note The gear lever must remain in the same position while the bolt is being tightened. – Now check adjustment of selector mechanism → .

– Secure noise insulation for selector housing -arrows-. l Installation position: arrow marked on noise insulation points in direction of travel.

Gear knob with locking mechanism: – Push gear knob together with boot onto gear lever and screw down connecting piece -1- in direction of -arrow- as far as stop.

Gear knob with clip: – Fit gear knob with new clip -arrow- onto gear lever and secure using hose clip pliers -V.A.G 1275-. Tightening torques

Component		Nm
Selector rod to selector fork/gear lever		25
Push rod to gear lever bearing		25
Noise insulation to selector housing		10

Checking adjustment of selector mechanism l The gear lever should rest in the 3rd/4th gear gate when the gearbox is in neutral. – Depress clutch. – Check that all gears can be engaged. l When changing through the gears the gear lever must not touch the centre console cover. l The gear lever should return by itself from the 5th/reverse gate into the 3rd/4th gate. l It should only be possible to engage reverse gear after moving the gear lever into the 3rd/4th gate in neutral. l It should not be possible to select reverse gear directly from 5th gear. Note If it is possible to select reverse gear directly from 5th gear, or if only 5th gear and reverse cannot be engaged, the locking unit for 5th and reverse gear should be checked and if necessary renewed→ .

Power transmission > 5-speed manual gearbox 012, 01W, 0A9, front-wheel drive > Gearbox mechanics,operation, construction,diff. > Servicing selector mechanism > Adjusting selector mechanism

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[Vagnuts]

just been told that you may have a gearbox prob-ie-the selector fork inside the box is secured by grub screw and may have sheered-causing the probs you are having !! it may not be the case tho-but my old boy 90 yrs young now(time served mechanic) seems to think it a good probability !!!

[rowdy-999]

It sounds feasible. I can select the gears perfectly without the engine running though.....would that be the case?

[Vagnuts]

Hmmmm, in that case it may be that clutch has suffered some sort of damage-IE- jolted by taking 5th instead of third ( what -if you can remember -were the revs at time??)-maybe damaged spring in clutch plate- poss sheered a bolt,or damage to the slave release maybe even just the pressure plate fingers ??? to be honest if I were down that way I would nip in and test drive just to feel the symptoms-can u select the gears with engine running ?-scratch that I remember you saying you can but feels like clutch not fully engaging- did ya bleed clutch ? was it ok bleed wise ? selector mec at gearbox--is it all dry-ie-we bit of spray grease -is it cable or rods ???

[rowdy-999]

Hmmmm, in that case it may be that clutch has suffered some sort of damage-IE- jolted by taking 5th instead of third ( what -if you can remember -were the revs at time??)-maybe damaged spring in clutch plate- poss sheered a bolt,or damage to the slave release maybe even just the pressure plate fingers ??? to be honest if I were down that way I would nip in and test drive just to feel the symptoms-can u select the gears with engine running ?-scratch that I remember you saying you can but feels like clutch not fully engaging- did ya bleed clutch ? was it ok bleed wise ? selector mec at gearbox--is it all dry-ie-we bit of spray grease -is it cable or rods ???

Thanks for the advice. I was doing about 15mph when it happened. From having been driving it a few days now..........its worst when stationary with the engine running either selecting 1st or reverse. With the engine off it feels completely normal. Once up and going the gears feels better but a bit notchy still at times. The pedal feel hasn't changed at all.....bite point everything are dentical. There's plenty of fluid in the reservoir....i can't see how air could have got in? I haven't bleed it......

No noise/vibration. Im thinking with the clutch 'feeling' so normal it could be a gearbox problem.