VW Polo 1999 - Replacement Gearbox

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Fri 25 Jan 2013 16:41
VW Polo 1999 - Replacement Gearbox - AdrianR

Hi All,

5th gear has disintegrated in my Polo. All the othergears work but with not 5th and there are noises now since the 5th gear failing.

I need to source a gearbox - Any advice?

I have been told that you can replace the 5th gear by taking the end of the gearbox - is that true?

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Fri 25 Jan 2013 16:47
VW Polo 1999 - Replacement Gearbox - skidpan

I have been told that you can replace the 5th gear by taking the end of the gearbox - is that true?

Unlikely, most gearboxes require a complete strip down to replace gears

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Fri 25 Jan 2013 17:22
VW Polo 1999 - Replacement Gearbox - 659FBE

You can indeed replace 5th gear in-situ as long as there is no other damage. The gear pair is carried on extensions of the mainshaft and output shafts and is sited under a pressed steel cover at the free end of the transmission. Pullers will be needed to get the gears free of the shafts.

I would give this job to a knowledgeable/interested Independent. They will have met this problem before and will have the thought processes in place to deal with it. A dealer would just replace the transmission - more profit.

659.

Believe it or not, g e a r s e t failed the swear filter....

Edited by 659FBE on 25/01/2013 at 17:23

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Fri 25 Jan 2013 17:28
VW Polo 1999 - Replacement Gearbox - thunderbird

Believe it or not, g e a r s e t failed the swear filter....

Its because you said "a r s e".

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Fri 25 Jan 2013 17:54
VW Polo 1999 - Replacement Gearbox - Cyd

I would say that there is bound to be swarf or bits flying around the inside of your 'box now so IMO a stripdown and cleanout is warranted even if you can change the broken gears in situ.

It might be more economical to obtain a secondhand 'box and simply have them swapped over.

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Fri 25 Jan 2013 18:36
VW Polo 1999 - Replacement Gearbox - Collos25

You not say what size engine or type of gearbox .I have provided a link which shows the Golf gearbox 5 gear replacement .The same box was fitted in many Polos and Golf petrols.

http://www.myturbodiesel.com/1000q/multi/5th-gear-swap-VW.htm

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Fri 25 Jan 2013 23:46
VW Polo 1999 - Replacement Gearbox - Peter.N.

How about this:

http://www.ebay.co.uk/itm/99-VW-POLO-1-0-8V-5-SPEED-MANUAL-GEARBOX-REF-T969-/150984745413?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item23276461c5

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Fri 25 Jan 2013 23:53
VW Polo 1999 - Replacement Gearbox - Crasher

All 1999 UK manual trans Polo 6N1’s used 085 series boxes, not an 020, 02K, 02A, 02J or 0A4 (not OA4) so taking a typical version with the 1.4 engine, this would have something like a DHB box and these boxes like eating themselves, they are the Polo 6N Achilles Heel. Yes you can do some work on 5th in situ with special pulling tools but trying this is going to turn around and bite you on the tailgate. Pull the box and have it professionally rebuilt. Second hand boxes are often a disaster and I have given up trying used 085’s.

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