Gearbox Failure on ERF Trucks

Hello everyone,
After performing the inspection on my G4 ASZ yesterday and letting it run for a bit while stationary, I noticed a scraping and occasional clacking noise coming from the area around the transmission. I've also noticed that the noise level inside the cabin has been getting louder lately. I always assumed it was due to worn engine mounts or carbon buildup in the injectors, but it's probably been the transmission all along.
I made a short video, but you can't really hear the sound in it.
What could be broken? Is it worth repairing, or would it be better to just install a used one?

Regards,
Reuselkopp.

Hello,

First, drain the oil and see what comes out...

Best regards, Rainer.

Hmm, well, I can definitely confirm that the transmission fluid was changed by me.
Can I refill the old oil, even if there are metal shavings in it? I don't want to spend any more money on new oil for a faulty transmission.
I'm actually ruling out the clutch and dual-mass flywheel because they were probably replaced around 250,000 km. The noise seems to be coming from the transmission area, near the drain plug.
"You don't notice it while driving; shifting is still working fine as usual. It's only when the car is idling that you hear the noise and those scraping sounds."

Regards,
Reuselkopp.

Hi!
Well, let's see what happens first.

A small amount of metal dust (steel) in the form of very fine particles is normal.

It becomes critical when there are larger metal fragments, parts of bearing cages, or aluminum debris or aluminum shavings present.

The transmission oil is generally much cleaner than engine oil. A slight golden film on top is also normal; it's wear debris from the brass synchronizer rings.

Aluminum shavings from the casing should not be included.
Then the oil will appear white, and you'll have a hard time getting your hands verschandeln again.

If new oil is too expensive for you, you can filter it using a coffee filter or something similar.
Then the bulk of the dirt is gone.

Hello everyone,
Thank you for the explanation. However, I don't quite understand the reasoning behind it. Am I supposed to prove that the transmission is defective because draining the oil will reveal wear particles and debris, or is it about the *type* of wear? Please don't misunderstand me, but I would like to understand this better. What if the oil is verschandeln and shows no signs of contamination? Where would the noises then be coming from?

Regards,
Reuselkopp.

Hello!

We don't know that either.
If chunks, shavings, or solid metal debris come out...
Do you at least know that the transmission is definitely broken?
Depending on what results, i.e., which larger particles are produced,
Can we do that based on a high-quality photo?
perhaps even assess whether the transmission can be salvaged at all.
If hardened steel fragments are floating around in the oil, it's reasonable to assume that these fragments have also damaged bearings, gears, and other components.

If nothing like that emerges, then the guessing game continues.

It would be beneficial if you could run the engine for a while before draining the transmission fluid.
The oil is thinner there, and more dirt comes out.

You can only hear a diesel engine there.
A faulty gearbox bearing will produce noise that changes with the engine speed. Do you hear anything like that? If the gears shift normally, then the synchronizer rings are likely still in good condition.
Your description sounds more like a belt drive, possibly with a torsional vibration damper (ZMS), if present.
hg
Herbert.

Search Google for: "Golf 4 transmission rivet problem".

You can also contact Volkswagen to inquire whether your vehicle might potentially be affected.

Currently, I wouldn't drive the Golf, nor would I let it idle while stopped.

Hi!

Insiderwissen. Great.
I didn't know that; I only know it from Opel.
"That's where I saw the hole in the transmission, which was caused by the broken rivet..."

Doesn't that affect the pinion gear of the differential?
hg
Herbert.

Quote:

Doesn't that affect the pinion gear of the differential?

That is absolutely correct.

In case of repair, the rivets will be replaced with screws and nuts.

It would be necessary to use an endoscope to inspect the inside... to see if any rivet heads are missing or if any rivets are protruding.

It's clear that the disc brake rotor will remain stationary when idling if the front wheels are not turning, and therefore won't produce any noise itself. It's possible that a rivet head is located in an unfavorable position.

If it were a bearing for the transmission shaft, the gearbox would only start making noise under load.

I would get a used one, add a clutch, and possibly a dual-mass flywheel (DMF), drive it until it's almost completely broken, and then replace it.

Of course, just a used gearbox where the rivets have already been replaced with screws .
hg
Herbert.

vag-driver wrote:

Search Google for: "golf 4 transmission rivet problem"

Does this only apply to the 5-speed transmissions of the smaller gasoline engines? As far as I know, the ERF (Extended Range Functionality) is not involved in this.

"However, I don't hear anything unusual either. Does the sound change when you press or hold down the clutch pedal?"

Roger wrote:

vag-driver wrote: Search Google for: "golf 4 transmission rivet problem" Does this only apply to the 5-speed transmissions of the smaller gasoline engines?

No. A colleague experienced the same issue with his G4 1.9L TDI. That's why I suggested checking with Volkswagen first.

Hi!
You wrote that people should use Google sometimes.

I did it.
There was quite a bit to read.
You can also find more detailed information there, including the year of manufacture, etc.

I was previously unaware of this problem, even though I have worked with similar cars quite a bit.

Finding a used gearbox where the rivets have been replaced with screws is...
That would certainly be difficult.
"Car recyclers probably won't know what kind of transmissions they are selling either."

I think we should wait and see what kind of particles are found in the oil sample first.

It's also always a bad idea to just keep driving like that; if it really is the case, you often leave behind a significant oil trail, which isn't much fun either.

Wenn es mein eigenes Auto wäre, würde ich vielleicht versuchen, ein Getriebe zu bekommen, was passt, aber die grösseren Nieten hat. WeYes, something like that exists.

Or, alternatively, disassemble the transmission itself and install the screws.
Although this is definitely not for beginners. Anyone who has never done anything like this will likely fail.