S3 4sp manual question

[jagwit]

I'm having to help a friend with his 4-sp manual.

When you shift into first, it goes in, but its possible to move the gear lever even further forward and then there a slight grating of gears that one can hear.

1) Is this problem in the selector mechanism or deeper inside the gearbox?
2) Do you think it will require removal of the gearbox to fix this?

[politeperson]

Sounds like a detent spring might have broken in the gear selector mechanism the sits on top of the gearbox.

If it is like an S2, the top of the gearbox lifts off in situ. Certainly the S3 manual suggests it is the same.

Seats out, radio and centre console out, trans tunnel off and unbolt the selector mechanism.

It can be disassembled on the bench and you can use the opportunity to change the O rings on the selector rods which can get hard and leak.

Took me about an hour to remove mine the other day.

[MarekH]

Dear Philip,

If the gear lever is going further forward, then the rod is being pulled further back. There ought to be some photos of a gearbox top cover somewhere on the web so you can see what you are up against.

The seats can stay in, but you need to get the console off over the handbrake lever. Pull the end off the handbrake lever and have it fully "up" and it'll still be hard to get the plastic console over the handbrake.

You can then look to see what is wrong with the underside of the gearbox cover plate selector rod.

Bleed the clutch whilst you are there - it'll stop the bottom of the slave cylinder from rusting out.

kind regards
Marek

[jagwit]

Thanks all!!

I was dearly hoping the issue is in the top section of the box so that it wont be necessary to remove the transmission.

I have to remove the seats anyway as someone decided to raise the seat height. Not good for present owner 6' 4".

[Hugo]

It isn't the detent spring that limits the travel, so I think that's probably wishful thinking. The fact that you can hear a 'grating' noise (is that what you said?) suggests that a rotating item is rubbing against something stationary. In other words, the mainshaft first gear (the one at the rear of the box) is probably hitting the casing. That should not be possible, so it suggests that whatever holds that gear on (I'm afraid I'm not familiar with these boxes at all) is not longer holding it on properly. Or maybe the rear bearing is moving in its housing.
I would also expect to feel the lever move backwards and forwards more than is usual when held in first gear and thrust is applied then reversed (by applying and releasing the throttle).

[jagwit]

Looking at the parts manual, I see two items which might be the cause of the problem??

1) C20066: Interlocking pin
2) C20314: Screws (qty 4) that fasten the selectors onto the selector shafts.

When you shift into 1st, the gear lever goes to the point where 1st's natural end position would be. But then, if you apply just slightly more pressure, the lever can be made to go further forward and when pushed far enough, a soft grating noise can be heard.

[Hugo]

.... But then, if you apply just slightly more pressure, the lever can be made to go further forward and when pushed far enough, a soft grating noise can be heard.

So what is hitting what?