Will it FIT! - Was --- 02a (cable) Gearbox Selector tower play

[Manxmann]

Hi Folks,

Yet again I'm after some advice from you guys in the know.

Long story short, swapped my 02a gerabox (GTI 16v) with no 1st for a lowish mileage box (60k) the other day.

After fitting the gear change was floppier than a eunuch in a harem. If you grabbed hold of the balance weight if would flop around all over.

Now before the swap the old box was sweet, apart from no 1st gear a syncromesh problem I'm told, i.e. no flop very positive easy change etc. etc.

So we took the entire selector mech, balance weight etc. from the old box and fitted this to the new box.

The result is a MUCH improved gear change however its still pretty bad.

If I select '3rd' using the weight, pulling directly towards me the box goes into gear smoothly however I can then rotate the balance weight and selector mech back about 30degrees without pulling the box out of gear  .

The box also has an annoying habit of jumping out of 2nd and 3rd when not under load and every now and them be a complete pig to select 1st i.e. it won't select.

Now the annoying bit everything else is good, i.e. I CAN get all gears without issue including reverse and 5th, most of the time, and the box is quiet and smooth when driving.

Should I forget about this box, didn't cost me anything and look for another one? Is the 'slack' in the selector related to any one component and could this be replaced? If I do go the route of another used box how can I avoid this?

How much do 02a recon boxes cost and where's the best place to go. I'd need to get an exchange, being on the Isle of Man I couldn't send my box off for reconditioning as that would take too long.

Cheers guys.

Simon

[rubjonny]

if you look on the bottom of the box there is a plate with a VW logo on, this is the lower bearign for the selector, could be down to that. also the selectors themselves run on pins screwed thru the casing, 2 on top and 2 on the bottom, maybe check they are tight?  Dont think there is much you can do if the selector bearings are shot, but afaik opening the 02a box to get to them isnt too bad, you could have a play on your old knackered box

some pics of what I'm on about in here:
http://www.clubgti.com/forum/showthread.php?t=159557

[Manxmann]

if you look on the bottom of the box there is a plate with a VW logo on, this is the lower bearign for the selector, could be down to that. also the selectors themselves run on pins screwed thru the casing, 2 on top and 2 on the bottom, maybe check they are tight?  Dont think there is much you can do if the selector bearings are shot, but afaik opening the 02a box to get to them isnt too bad, you could have a play on your old knackered box

some pics of what I'm on about in here:
http://www.clubgti.com/forum/showthread.php?t=159557

Star! thank you.

[Manxmann]

Quick update, I've just driven a 95 VR6 Passat with a genuine 55k on the clock.

The G/Box was very sweet to no play etc and would seem an ideal solution, I can then sell the rest as spares, bit of a shame to break but hey needs must.

However......

The selector/tower mech is slightly different from the one on my valver i.e. the most noticeable (the only thing I noticed to be honest  ) is that the balance weight is shaped like a wedge of cheese and is very low profile as opposed to looking like and upturned golf club on the current g/box. Unfortunately I couldn't read the code on the side of the box.

Will this box fit on my 16v? Will I have any problems, not really too bothered about the drive ratio's at present at 3000rpm my car is doing 65ish.

Thanks again for all the help.

[rubjonny]

no as being a VR6, the belhousing is a completly different shape
internals can be swapped around though