Polo Lost 5th Gear

[jdabney]

I've only just joined in the hope amongst other things that someone may help me with my lost 5th gear! At first my 6 year old (UK X reg) 1.4 SE kept dropping out of 5th gear on motorways if I slowed down slightly. Initially it was easy enough to get back in, however I then found I had to double de-clutch and now it simply grinds whatever I do as I try to get into 5th. Is this likely to be a big problem or something reasonably easy to deal with?

I'm due to drive from Basel to London next week and I don't fancy doing it in 4th all the way!

Any suggestions gratefully received

[Crasher]

That’s a typical failure with an 085 box. It was designed as the 084 4 speed and they popped another gear on the end to make it 5 speed. If the oil level drops, 5th is the first to lose lube and gets cooked. When you take them out, they are often blue with heat damage. It will mean a full box rebuild though.

[jdabney]

Thanks Crasher for the explanation. Not much solace. Will it affect the other gears in time? Will I be asking for trouble if I try to drive it 750 miles without having it totally rebuilt? In the meantime if it's a question of the gearbox oil being low, can this be topped up easily enough and might it make a difference?

[Crasher]

It's too late for anything other than a rebuild but checking the level won't hurt.

[jdabney]

Oh well, expensive no doubt! As I'm in Switzerland, just about to drive back to London, with no time to do anything now, do you think I'll make it in 4th without destroying the whole box? Sorry to ask so many questions, in a bit of a quandary!

[Crasher]

It won’t do the fuel consumption any good at the higher revs but as long as the gear hasn't stripped you may make it. I wouldn't recommend it though, if it seizes at speed it could be lethal.

[jdabney]

To me, the car or both?!! Sorry to keep asking, but I can't get anything done in time to go back to UK next week. The VW place here says they can't strip it down till next week and then they will have to order parts. If I know I can nurse the car home gently say no more than 60 in 4th, without being likely to kill myself, that is really my only option, or.......I don't know what! By the way I am very grateful for your help.

[Crasher]

If the box were to seize at 60 mph it would lock the front wheels so that could cause and accident. If you want to drive it, that is up to you. I would recommend you had a genuine VW recon box fitted locally. There is no way I would do the trip, put it that way.

[jdabney]

Crasher, I have now spoken with ASAG the main Basel VW dealership and service centre and they tell me that the clutch is fine but the 5th gear is broken. They also say that I can drive back in 4th as long as I keep the revs below 4000 or so and there is no chance that 4th will go. They also say that the front wheels cannot lock up. Do I take the chance on that basis? The problem is they are saying probably 3 weeks to deal with it and I don't have that much time!!

[Crasher]

Well as long as you are happy but I would never advise a customer to do that. For one, even if it doesn’t lock up it is possibly going to damage the box further making a repair impossible meaning you do need an exchange unit. And why below 4000rom? What difference does that make?