One more AUDI A2 1.2TDI problem

I now have a strange gear crunching noise when trying to engage 3rd gear. If I manually shift and skip 3rd gear, all is OK. If I leave it in E (drive) once it tried and failed to engage 3rd it won't drive at all. Does this sound like a mechanical gearbox problem???
 
John90 said:
I now have a strange gear crunching noise when trying to engage 3rd gear. If I manually shift and skip 3rd gear, all is OK. If I leave it in E (drive) once it tried and failed to engage 3rd it won't drive at all. Does this sound like a mechanical gearbox problem???
Click to expand...

I've repaired gearboxes with this fault before, it's most likely the gear shift fork, it snaps of.
Part was ~80£ last time I performed this procedure, takes about 12+ hours to fix depending on skill level and tools available.

I'd say this is an advanced/expert level task. Pm me if you're thinking about doing the repair your self, I can give you some hints and a bunch of pictures.
 
Just had the oil service done on my Lupo 3L, and on my way from the mechanic, I noticed a buzz in the cabin in the 1500-2000rpm range that wasnt there before the service :( It is present when driving, or when stationary in neutral, and sounds like it is making the dash buzz... Starts at 1500-1800 and goes at 2500ish rpm. I know my hydro mount is not the best one, and i am probably going to order a new one, even though it's rediculously expensive, as were the shocks btw.... Any ideas? I have tested all the hoses i could, and its not them. Also, I have noticed that the hose at the top of the engine is folded incorrectly, does it matter? Please check the plumbing and the position of the engine and tell me if something is wrong. Ty guys.... Cheers guys...
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A larger picture would be helpful. The hose from the turbo to the intercooler doesn't look right. It could be constricting air flow. Are you sure you don't have a leak somewhere? What is the hose/tube that passes under the EGR cooler hoses? I don't have that on either of our two Lupos!

RAB
 
Sorry Rab i didnt see your reply. Well go back to this but now I have major problems. This morning my Lupo started judddering, the gear selector went berserc, the car lost throttle response and stopped, the engine running. The pump works, actuator is fine. I could start the car, but the car wouldnt select the first gear. It showed it was in D but i couldnt hear the click and the first gear selected, and the car didnt respond to throttle, it simply idled. I left it and when i returned a couple of hours later, it was the same, but after a couple of tries i heard the click and reverse selecred. I reversed it, put it in D it selected the first gear and i thought to myself, sweet... But after half a kilometer the same..... I put. it in N quickly, but then foolishly put it in D and it stopped and turned off with a horrible scary thud (I hope i didnt break gearbox??! ) I started it and again the same, couldnt select 1 or R, the car not trying to select either in all instances. Then all of a sudden it would again, but i left it on the road for the fear of making more damage. With the engine turned off, I could select D or R once more, (tried a dozen times) , and once more I could select gears in tiptronic mode as if all is just fine (could make 5 changes before I could hear the pump) Any ideas? Ty...

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There were no error codes associated with anything related to gearbox, but the diag. tool was not vagcom. I made a couple of km and the car drives like nothing happened. But there has to be a problem...?!

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The symptoms suggest a low hydraulic oil level. In terms of km., when was the last basic setting done?

RAB
 
Basic setting was done 21000km ago. Oil level is fine, pressure accumulator is 1 year old, pump works fine. Im going to have the car scaned with a proper diag. tool on tuesday. Perhaps we shouldnt have deleted the errors that some Delphi diagnostic tool found. I remember that last time we scanned with vcsd there was an error that you said was the poor connection, but i didnt have any problems up until now! Thanks a lot Rab. Ill come back with the screenshots of errors, if any come up. So far, the car drives perfectly fine...

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Maybe a poor (oily) connection somewhere? No harm done by deleting errors but it is useful to keep a record before you delete. If they are significant, they will re-appear. A scan with VCDS or equivalent will possibly point you in the right direction.

RAB
 
Problems presist... Lupi started jerking at the trafic lights, i pulled over, it wouldnt even start instop or neutral. I disconnected the battery and continued for the next 20km without problems. I wont have vag com scan until tuesday or wednesday :) Thanks a lot!!!!!!
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I googled out one of your explanations that may pertain to my problem.... Should I take a look at the condition of my clutch and flywheel, maybe they are worn out?

"00511 is poor connection somewhere. For 00263, the speed of one of the shafts in the gearbox is monitored by a sensor on top of the gearbox to make sure that the clutch is not slipping; this can be reached through the LH wheel arch. Unlikely to be a faulty sensor but it is possible. Check the connector and also the connectors under the hydraulic station that connect the actuators etc to the car loom; the latter are quite likely to be contaminated with hydraulic oil. If the sensor does not provide a steady signal, the system assumes the worst and dis-engages.

RAB"

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Hi, just to report back. It is the clutch cylinder that is a gonner... The new one is more than 300euros i think...
I just stumbled across this for 100e. Whats better, this or 300e for the new one? If they are probne to failure, maybe better to buy the new one and be safer?

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It will be the potentiometer that has failed. This is wearing part. I wouldn't buy a used one. Mankmil on the German forum will replace the potentiometer on your existing clutch actuator with a Hall (non-wearing) sensor. Cheaper than a new one and a permanent solution.

RAB
 
Well, I already ordered the used part..... I was impatient and didnt expect the reply quickly. I could take the used part and send it to be refurbished, if thats the case.... What is the price to fit the new potentiometer? Whoa, didnt know it was possible :)
Is there a life expectsncy? I will cancel the order if its unwise!? The Lupo it is from has like 300k km, and it failed on mine at 230k...
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Ok, well in fact i will have 3 now, the broken one, the spare one that is being used right now, and this one i bought to be next spare one... :) When I saw that people sell just the pump for 200e I went for it without much thinking.... Its kind of lame to back out on a deal now... Ty for the link. I will inquire about the price.

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I cancelled the order for the used part Rab and went for the new part. I contacted the guy on the german forum. Its not cheap, 220e plus shippping if not from Germany, but he says it will be better than the new part.... I may send the old part if not physically damaged....

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Have you done the gear actuator adjustment? You have to remove the cover from under the engine. It's a vital part of the basic setting. A failing clutch actuator always (in my experience) does not allow starting in Park. Has the gear actuator been removed?

RAB
 
By gear actuator you mean the dogbone for the gear robot, right? You asked if it was removed during the clutch cylinder install or during the basic settiing? I has never been replaced, but the mechanic told me it is not loose. Maybe to replace it nevertheless, it should be around 30e? Ive been googling out all that i could. The voltage to the clutch needs to be set by turning the 13mm nut, right? Does it need to be set at 1.85 sharp? Is it true that the battery should give more than 12.8v, one wheel off the ground and such things? Two issues that i would like to mention that may have something to do with the error, or maybe not: when everything was Ok, the car would occasionally fail to shift into reverse immediatelly, but would do so after 2 or 3 clicks. Upon changing the reverse switch, the situation remained the same, click click tgen R would show up. I ignored this because it was really a minor
thing... Olso, a scan during an oil change revealed that poor connection 00511 error. The car drove fine though and changed. gears nicely. Can the rtfm 12 mean something electrical like gear lever problem, or similar, do we focus strictly on gangstaller? Sorry for lots of questions.... I have a complete spare robot, and tge mechanic is tempted to swap it all and see what happens, i personally dont like the idea...
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