Arosa TDI: ESP Gearbox, 3rd Gear Problem

Hello!

As can be seen in various online forums, there are apparently several issues related to problematic gearboxes. In my case, it's a Volkswagen Arosa [6H], 1.4 TDI [AMF] with the 02J gearbox type ESP (mileage: 132,000 km). When downshifting from 4th gear, I can't shift the gear lever into 3rd gear. It seems to be blocked, regardless of whether the gearbox oil is warm or cold. Sometimes, with slight pressure from above and simultaneous movement forward, it can be engaged. Shifting from 2nd to 3rd is possible; all other gears can be shifted smoothly. The problem first appeared suddenly after a long highway drive with the car fully loaded and has persisted since then. The vehicle is mainly driven on long distances; it's not a city car.

verified:

- Disabling the automatic switching system did not resolve the issue.
- Slider between the selector lever/gear shift lever, OK.

Further thoughts:

- I find the presence of air in the hydraulic coupling system to be implausible.
- Hub of the camshaft, as new/in good condition?

-> Or is it more likely that a synchronizing ring is defective? (but suddenly?)


UPDATE 01/20/07:

- The transmission oil is heavily contaminated with fine, gold-colored particles.
- I heard something about a "broken tension ring for locking stones" -> possible cause?


I would be very grateful for constructive suggestions and solutions!

Best regards, Maurizio.

"Final" cause now known? I'm experiencing the exact same symptom at the same mileage.

Hello!

The final diagnosis, which I made myself on June 19, 2007, regarding my problem was: "Broken retaining ring for the 3rd gear lock-out pawls" - see pictures. This is apparently a known issue with VW/Seat transmissions with this specific gearbox code, typically occurring after approximately 130,000 km (80,000 miles).
The successor transmission, the "EXB" (which is available as an automatic for the "ESP" and, according to my information, is standard in the Audi A2 1.4 TDI - which is strange, isn't it?!), probably doesn't exhibit this problem with mechanical durability. Therefore, this shouldn't be an isolated case...
After the affected synchronizers were repaired, the transmission lasted for approximately another 3000 km. After that, all the gears became so jerky that only an automatic transmission could help. At the V.A.G. dealer, the "EXB" automatic transmission was available as an exchange for my defective "ESP" automatic transmission – a complete financial loss!

Best regards, Maurizio.

Würdet Ihr bei dem Symptom das Getriebeöl noch tauschen, um ev. noch nen paar zusätzliche km mit dem Getriebe rauszuschinden oder bringt das eh nix. Habe jetzt 125000, Getriebe hat die Macke seit ca. 50000 km. ÖlThe situation is okay.

Regards,

Olaf.

Update:
I changed the oil and had the 5th gear extended. During the process, the clearance between the two main shafts was measured: everything was perfect.

Bei 147000 läuft das Getriebe jetzt immer noch wie gehabt, d.h. hakelig beim Schalten vom 4. in den 3. Okay.

Update 2:
At 166000 kilometers, it's now becoming difficult to shift into 3rd or 4th gear from either direction when the engine speed is low. Revving the engine doesn't always help.
Sometimes, the car doesn't downshift to 2nd gear without blipping the throttle.
So, I'm slowly getting around to it too...
"Does anyone know if I can convince my specialist workshop to install the EXB mechanism during a gearbox overhaul (to increase its lifespan), or does it not fit within the ESP housing?"