6 Speed Gearbox problems

My partners 54 plate Touran 1.9 TDi with 48,000 on the clock has just had a complete gearbox and clutch failure. VW wanted £3,500 for a new gear box so we had the original reconditioned at an indipendent garage, even so with a new clutch it came to £2000.

The car was with he garage for 2 weeks as they had problems getting a new gear box casing from VW, due a shortage, this implies to me that this may be a common problem! Does any one know if this is the case and if it is worth us perusing VW for some of the cost?

ma pals dad has one of them and his gearbox and clutch went
Alot quicker than yours did mind u

and he had to for out alot more for the clutch and 4000 for the gearbox :|

Ohh it certainly is an issue with the 02S series boxes, in fact I would go as far as saying it is a major problem with them.

Any way of telling if a car has an 02S series box (other than taking it out or going underneath the car?)

By the gearbox code sticker on the boot floor or on the inside front cover of the service book. Common 02S version codes are GQN, FYG, GQL, JYK, JYH, KRX, JXR, JCN, GQP, HYG, JXP, GXV, JCP, JYL, JCP, GQM, JCL, JWN, JYJ, JAU, JYG, JAU and plenty more but I am getting bored looking them up now.

Thanks, I'll take a look.

hello to everyone cause i am new to this forum.
I own a VW golf mk5 2005 1.9 TDI PD with a 6 speed gearbox.
My gearbox code number is GQM and i experienced a gearbox failure,
symptons: gearbox jams and oil pouring from the casing due to hole punctured in it.I dismantle the gearbox and found sheared rivets of the differential and i checked on the web and this seems to be a common problem.Does anybody knows from where i can buy a bolt kit for the differential instead of the rivets and gearbox casing ????

The GQM is an 02S series box which is a development of the 02J which itself was derived from the 02A. VAG do not list diff bolt kits for the 02S but they do for the 02J, part number 02A 498 088 A. I have never tried this myself as when an 02S goes pop we fit a genuine exchange box but you could see if this bolt kit will work. VAG only list a complete differential for the GQM box but as the part number is 02J 409 021 AQ, you can probably see my idea. The only trouble is that the bolt kit is about £130 in the UK so it is expensive.

thanks a lot for the information and for your support.but thats the problem cause i can't risk to buy the bolt kit and then it won't fit cause probably won't.but if i replace the differential only i still need the bell housing cause its punctured.you know the part number of it also? and if i decide to replace the whole box like you told me you know any place from where i can get a complete GQM gearbox on the web ?

also can you tell me if i can fit a different type of gearbox like a 5 speed instead of my 6 speed ? will it fit the same ? or else another 6 speed gearbox with different code letters ? because if i don't find a secondhand gearbox with the same codes like mine i have to fit another type but the problem are the fittings and the gear ratios that probably won't match

When you have made 5 posts, send me the vehicles chassis (VIN) number by private message and I will see what I can work out. I don't know of anywhere to buy the box on the internet as I o not do that. If I need a box rebuilding I do it myself if it is a very special job, send it to a specialist for rebuilding if I need it doing cheaper or I buy one from VAG UK.

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Originally Posted by il_boost

hello to everyone cause i am new to this forum.
I own a VW golf mk5 2005 1.9 TDI PD with a 6 speed gearbox.
My gearbox code number is GQM and i experienced a gearbox failure,
symptons: gearbox jams and oil pouring from the casing due to hole punctured in it.I dismantle the gearbox and found sheared rivets of the differential and i checked on the web and this seems to be a common problem.Does anybody knows from where i can buy a bolt kit for the differential instead of the rivets and gearbox casing ????

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Hi there, you should be able to get a kit from these guys

http://www.volkswagenspares.com/page.php?page=Gearboxes

this is also a good write up on how to drill the old rivets out and replace them with peloquin bolt kit.

http://www.brokevw.com/020diff.html

http://www.brokevw.com/020diff2.html
hth

I.

thanks a lot for the support guys.I will drill the rivets out and install new hardened bolt and nuts instead and just replace the bell housing or else weld it.what do you think is the best material to use for the bolts that can withstand shear stress ?? is it high tensile steel the best material for this purpose ?

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Originally Posted by Crasher

By the gearbox code sticker on the boot floor or on the inside front cover of the service book. Common 02S version codes are GQN, FYG, GQL, JYK, JYH, KRX, JXR, JCN, GQP, HYG, JXP, GXV, JCP, JYL, JCP, GQM, JCL, JWN, JYJ, JAU, JYG, JAU and plenty more but I am getting bored looking them up now.

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Can i be cheeky and ask you to see if JMA is an 02S?

Cheers

JMA is an 02Q which is a development of the 02M.

Hi, I am new to this forum. I have a VW Touran with a DSG gearbox that fails with no drive when it warms up. I know from the internet that this is not an uncommon fault. I have had the gearbox diagnosed by a VW dealer and they said the Mechatronics unit had to be replaced at a cost of over £2000.

I have also had the Mechatronics control unit independently tested and no fault was found. Does anybody have any idea what is causing the problem?

I have looked around on the internet for a replacement gearbox and have not found an exact match for mine which is type GYP. Does anybody know whether other types e.g. KPT are interchangeable? What is the significance of the gearbox codes?

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Originally Posted by Crasher

JMA is an 02Q which is a development of the 02M.

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Much obliged: If anyone knows on an GQM 6 Speed I'm in the market for one :D

hi everyone im new to this, is it worth welding a crack in my gearbox as i don't have any money to buy a new one and its hard to find another gearbox that's similar ?

I THINK these boxes have a magnesium case which is incredibly difficult and dangerous to weld. Even then it would have to be stripped down if it was ally or mag.

I had a fault where 6th gear kept popping out. U removed the end cover replaced the 6th gear synchro (Easy job) and put back together. The part was £36.

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