![]() ![]() First and second gear syncro sets are easily $200+, 3rd and 4th were $120 for both. I'm not going to throw any more money on those syncros since they look good. Mine measured at 0.051" +- 0.002 depending on gear. Say that a new syncro dimension for 3rd and 4th is from 1.0mm to 1.7mm. I've also had this car for almost 1 year, so who knows what the previous owner did. I re-aligned the shifter to the instructions and double checked it before. My wife is even learning heel-toe downshifting (very difficult with the VW pedals though, in comparison to BMW). Well I did think about possible tension on the shifter.īy hand, no my wife and I both know manual very well. It's like they were milled down completely by the hub. To my surprise, the shift segments for 3rd and 4th (pegs on shift fork that move hub up or down) were ground down to almost non existent. The syncros are not the issue, as they are perfect, and within good measurements (1.3 mm space). I took out the transmission, and opened it up. What a pain.Īnyways, a few days later 4th gear completely stopped engaging, so I figured it may be worse than I thought, and waited to the syncros to arrive. I was planning to take the transmission off AGAIN, after the recent clutch/flywheel update. I went and ordered new syncros (3rd and 4th: PN 02A311269E to fit the original 02A syncro hub). It got so bad, that I started avoiding 3rd to prevent damage. It would take some playing around to get it to go in, with slight grinding. ![]() So 2 weeks ago my 3rd gear got progressively worse to go into gear. Some very mild 3rd gear grind noticed on downshifts (4th to 3rd) since I bought the car. ![]() 681 5th gear (with Pennzoil synchromesh oil done at swap), new upgraded G60 single mass flywheel and upgraded clutch (10,000 miles ago).2003 Jetta TDI Manual with 02J EGR transmission,. ![]()
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