AWD 91 tsi awd tranny problem wont shift.

[napkinthief]

My friend just picked up one horrible condition tsi awd and is begging me for help.

The car came with the turbo and ic ripped out, no intake pipes but the manifolds were there. So we picked a nice t3/t4 turbo, front mount off ebay, and a whole pipe kit. Finally get the thing running into decent conditon after 2 weeks.

The tranny was running fine, minus a syncho problem which req. you to push the clutch, shift into second then first to avoid grinding. He drove it like this for about 4-5 days. Now, he cant shift into second. It just feels like theres no gear there. The actual shift knob doesnt grab into 2nd it just wiggles around when you try to put it in gear. You still have to do the 2nd to 1st shift to avoid grinding though.


I drove it for about 20 minutes and noticed if I grind 3rd on purpose (dont push the clutch all the way and shift) then quickly shift into second before re-engaging the clutch, it will go into second gear fine and drive normally. That is until you shift out of second, it disappears again.

Anyone know whats going on?

 

[mindset]

Sounds like you need a tranny rebuild.

Check shift linkage first.

 

[napkinthief]

Do you think the bad synchos could have messed the gears?

When the gear is engaged be it 1st or 2nd, it does not pop out of gear. On a downhill i can hold the clutch to the floor in 2nd. Stop then continue rolling and pickup perfectly fine skipping first. Once i pull it out of 2nd or first, I have to do my little dance moves to get it to drive again.

 

[talondave]

Do you have trouble with it going into fourth gear?

 

[napkinthief]

3rd 4th 5th and reverse work perfectly. I can downshift 5th to 4th, 4th to 3rd, or upshift without any special moves. Its just 2nd and 1st.

Like I mentioned, I can get 2nd to work if I grind third purposely, by not pushing the clutch all the way, but I cant imagine this is good for a tranny.

 

[napkinthief]

I removed the linkage completely today and put it back in. Problem is still the same so the linkage seems to be fine.

Another method to get the car into 2nd gear is to hold the clutch down, shift to first then second. It takes between 1 and 3 attempts to actually grab 2nd. I feel it in the shifter when it grabs I have to almost force it into second. If I try just to go into second its like theres nothing there at all. The shifter just wiggles around.

 

[Gooberlog]

I am dealing with a similar problem on my '92 awd 5speed. Driving normal (shifting around 3000 rpms) it goes into the gears fine, MOST OF THE TIME. Sometimes durring normal driving when going 2nd to 3rd it will lock me out of third, but if i pull back and try third again sometimes it will go in fine. Other times it will still lock me out and then sometimes go into first!!!! 4th to 3rd always seems to go in fine, but i want to primarily race the car 1/4 mile so 4th to 3rd is not an option for this car.

I launched the car a couple times and at WOT it doesn't not want to go in 3rd.

Also, the shifter in the neutral is floppy like you described side to side. The previous owner installed a ACT 2100, RRE lightened stock flywheel, new clutch realease fork, throw out bearing, pivot ball and prothane trans mount.

Anyone have any ideas what may be causing our similar issues?
Thanks

 

[napkinthief]

Ive taken the car to 4 places so far. Everyones telling me its an internal problem.

Im guessing its the synchros but what else? Since first and second have been grinding im going to need gears too most likely. Not sure though, since when it does catch the gear, it doesnt pop out, grind, or anything.

If i come to stop in first or second, clutch down and dont pull it out of gear, I can drive off normally. Once I pull it out of gear though, it wont go back in. If I am rolling in 3rd at say 25 mph, and I have to slow down, I must clutch down and roll then accelerate again in 3rd. Downshift to 2nd is impossible if im moving. Can only get into 2nd from a stop.

 

[napkinthief]

Pulled the tranny and had it rebuilt by a friend of mine. We put it back in and its works! The synchros were all kinds of broken. 1st gear had no teeth left.

Small problem now in reverse. If you rev too much while letting out the clutch clouds of smoke come out. Light grey color and smells. whats up with this?

 

[Gooberlog]

Only in reverse that's strange. But smoke and a funny smell sounds like the clutch is slipping.

 

[napkinthief]

Weird because when the trans was apart, it looked like the clutch was almost new. I dont know know what it looks like new or used, thats what I was told by the rebuilder. He put a clueless face on when the smoke came out. Kind of looked like when I blew my hg on my 420a but the smoke was grey instead of black

Will probably pull it apart again next week and see. I really hope he put everything back in order and didnt leave out any important washers or something.

 

[Gooberlog]

maybe not a bad clutch but could be a clutch related issue. Maybe the clutch isn't releasing on the output shaft smoothly and it's dragging producing a slipping symtom. Make sure there is lube where there is supposed to be and none where it shouldn't. Inspect the flywheel too while your in there.