S3 gearbox like stirring a bag of bolts ...

[vfr800]

Hi

I'm having a little trouble with the gear box on my 2001 AMK S3with 110k on the clock.

Changing 2nd to 3rd crunches if I try to change up over with the engine over 3k. I have to let the engine revs drop below 3k to avoid a crunch.

I've noticed when pulling up at traffic lights etc. I get a bit of a crunch block changing back down to first.

I changed the gear box oil for OE Audi stuff about 3 months ago, I have check the gearbox oil level since this problem started and its fine. The problem has been occurring for about a month now.

I've done some searching on the forum and it sounds like it could be :
synchro going?
engine/gearbox mounts?
linkage cables?

i don't know much about gearboxes so a little advice on trouble shooting or what to change / do first would be appreciated.

Thanks. Liam

 

[[Dave B]]

What dogbone bush are you running?

 

[Alex C]

I would guess synchro if your having to let the revs drop down when changing up a gear
What about changing down - do you have to blip the throttle?

I rekon your having to wait until the input speed of the gearbox matches the output speed of the gearbox so that everything meshes nicely

 

[vfr800]

Hi Dave B,

It's a standard OE dogbone, it's relatively new, being replaced in March/April 2012. The car has done <20k on this dogbone.

Could it be that?

Liam

 

[vfr800]

I would guess synchro if your having to let the revs drop down when changing up a gear
What about changing down - do you have to blip the throttle?

I rekon your having to wait until the input speed of the gearbox matches the output speed of the gearbox so that everything meshes nicely

No changing down from 4th to 3rd is 'ok', it requires a bit of a gentle push but nothing worrying.

Dropping into first once at a stand still causes a bit of a clunk sometimes, it did it several times on the way to work this morning.

Ta, Liam

 

[Alex C]

tbh it sounds like my gearbox. I have to wait a while until i can change from 2 to 3 and from 3 to 4. On the way down i double de-clutch to try and rev match the gearchange

If I'm only pottering about in the car then its not so bad, but if I'm on a mission then its the gearbox that hinders me, particularly changing down braking into corners

I guess mine is worse than yours though. Mines been like that for nearly 20k miles

 

[vfr800]

Alex C, you should work for Audi ... "They all do that sir!" ...

I was wondering if it could be some dodgy fluid in the clutch hydraulic system causing the clutch slave to not fully extend?

 

[Alex C]

Im not saying it should be like that.... But i cant be ***** to get it fixed until it goes bang. I've had a new poly dog bone mount fitted, gearbox fluid changed once and then the second time gearbox fluid changed with a friction reducer added (molyslip) -- still the same............

the scenario you mention would make me ask why a hydraulic issue with the clutch slave would only affect up shifting from 3 to 2 making it crunchy unless you rev match it

 

[vfr800]

Im not saying it should be like that.... But i cant be ***** to get it fixed until it goes bang. I've had a new poly dog bone mount fitted, gearbox fluid changed once and then the second time gearbox fluid changed with a friction reducer added (molyslip) -- still the same............

the scenario you mention would make me ask why a hydraulic issue with the clutch slave would only affect down shifting from 3 to 2 making it crunchy unless you rev match it

I know, I don't exactly understand the mechanics of hundreds of little spinning cogs and stuff in the gearbox so I didn't want to rule it out of my brain. (It's the up shift from 2 to 3 that's the real problem for me.)

So it sounds like it's not the fluid or dog bone causing the issue.

Have you changed the left or right engine mounts? or adjusted the shift cables?

Liam

 

[Alex C]

Sorry, yes up shifting

No, I haven't changed the engine mounts, that is on my list of things to do, even if it doesn't fit the crunchy gearbox it'll improve the feel of the car. I haven't adjusted the shift cables either

 

[kwistof]

I doubt changing the engine mounts would help the problems you are having with your gearbox tbh mate....

I recently had both of my engine mounts changed and they had seen better days in the 185k miles they had been used....but I didn't experience the problems you are describing before they were changed and I'm guessing my engine mounts would have been in a worse state than yours are given my mileage.

 

[JimS3]

Defo try adjusting the shift cables, made a big difference on mine.

There is a good guide on youtube. Costs nothing, easy job.

 

[vfr800]

Hi

I've just done the shift cable adjust/reset and it still crunches on 2nd to 3rd changes.

Guess that leaves mounts or internal gearbox issue ...?

Liam

 

[JimS3]

You could try a powerflex red (diesel version) bush in the dogbone engine mount. Probably worth a try for £20 before thinking about rebuilding the gearbox!

 

[S3_DAVE]

Defo try adjusting the shift cables, made a big difference on mine.

There is a good guide on youtube. Costs nothing, easy job.

Hey Jim do you have a link to the video?

 

[dancuz]

Hey Jim do you have a link to the video?

Look up "diesel geek gearbox adjustment" or similar and you will find it on youtube. On phone so not easy for me to check. Made no difference to my box though, so I eventually bought a second hand low mileage one and had it fitted.

Cheers,

Dan

 

[JimS3]

Hey Jim do you have a link to the video?

Here you go, probably the best guide around:

Shifter Adjustment - YouTube

 

[vfr800]

Hi

I thought it had all settled down, I've not been driving the car much for a month or so, but the change from 2nd - 3rd still has issues when driven with sparkle.

How difficult is a DIY gearbox change? I've found a replacement/used gearbox at a decent price. It's not been tested - seller has 'promised' it's in good nick but I'm on my own generally.

To make the job easier I guess I need a lifting beam?

My clutch is relatively new so I guess I don't need to remove/mess with that?

Liam

 

[vrbob]

Just had my box swapped out as 1st and 2nd disappeared.

It could be done at home I think but it wont be easy at all with basic axle stands etc as its a good 8-9 hour jobby using a lift etc. I was sorta lucky as my clutch was original so took the opportunity to replace this and the DMF whilst getting the box swapped over. I paid about £350 to a local independent garage to do the labour as I provided all the parts.

 

[vfr800]

Just thought I'd post a little update about my gearbox. I took it Voodoo Motorsport in Flaunden and the gear box is now perfect. I was expecting a new gearbox or a rebuild but it turns out the VAG OE oil isn't that good, they put in some different gearbox oil which their gearbox builder recommended and it's all sorted. Gear changes are flawless now for the cost of gearbox oil change. Phew!

Also fixed my flaky haldex and dodgy clutch pedal.

I was expecting a massive bill but no - I have plenty of change left to refresh the suspension, buy my own VCDS cable etc.

Liam

 

[TheRunningMan]

Not often things work out that way. Sounds like a result!

 

[Alex C]

Just thought I'd post a little update about my gearbox. I took it Voodoo Motorsport in Flaunden and the gear box is now perfect. I was expecting a new gearbox or a rebuild but it turns out the VAG OE oil isn't that good, they put in some different gearbox oil which their gearbox builder recommended and it's all sorted. Gear changes are flawless now for the cost of gearbox oil change. Phew!

Also fixed my flaky haldex and dodgy clutch pedal.

I was expecting a massive bill but no - I have plenty of change left to refresh the suspension, buy my own VCDS cable etc.

Liam

Sorry, got some questions, given that mine still crunches and if I can get away with a gearbox oil upgrade...

• Did they do anything mechanical to the gearbox?
• Just upgrade the oil?
• Did they open it up and have a look inside?
• What oil have they put in it?

 

[TwinCamMan]

I'd be interested in what oil they have put in too, as I reckon 15 years is long enough in any car, regardless of mileage.

 

[vfr800]

Hi

Well mine originally started 'crunching' after I refreshed the fluid with brand new original VAG gearbox oil. I assumed the gearbox was on the way out and have been managing it until I had the cash for some real mechanical work. I went to Voodoo Motorsport because they know their stuff and have done some really good work for me in the past. I left it with them with the budget and intention to have the gearbox fixed or replaced + fix the haldex + fix a problem with the clutch + some other niggles. All my problems were solved (even the haldex) for less than £500. Thank god I took it them, can you imagine taking an S3 to a garage that didn't know what they were doing - could have cost me £ thousands ...

So, just oil recommended by their gear box builder, the gearbox wasn't opened up except to drain and fill the box.

I don't know the exact spec of the oil, I will ask, I know it's designed for an auto transmission and it's what their builder puts in after rebuilding the VAG 6 speed boxes.

I'm very very very very happy except I still wince *everytime* I change from second to third out of habit expecting a crunch, I have given it a bit of hard time to test it out and the gear box seems perfect now.

I'll let you know if, obviously, if you try it out it's at your own peril - if your box is screwed it might not fix the problem.

Watch this space ...

Liam

 

[S3_DAVE]

@vfr800 id be interested in the oil that was used also as mines doing the same as yours (only slightly) but I have had the gearbox oil changed and had a new red (diesel) dog mount bush.