Polo Gearbox Problem - Crunch

[Steve126]

I have a year 2000 6n2 Polo 1.4 16v which needed a new gearbox because the bearings were badly worn. I got what was meant to be a good used box from a VW specialist, fitted it along with a new clutch and release bearing, but I have a problem.

I can select all gears without any trouble when the car is stationary, but when on the move it will go into 2nd, 4th and 5th perfectly, but will only go into 1st and 3rd with a crunch.

I'd be interested to hear what other people think is the likely cause of this. I was thinking worn synchromesh but don't want to say anything to the company I bought it from when I'm not certain I'm right. I don't see how it could be the linkage because it does go into gear and is fine when stationary, the clutch doesn't seem likely to be the problem to me but I adjusted that just in case and it made no difference.

Thanks in advance

[E-bmw]

Gear lever alignment/bearing/bush issue, get it up in the air, check for slop in all gearbox linkages/have someone move it between gears to see if everything is moving correctly etc.

[Mr2Mike]

Gear lever/cable alignment can cause selection problems but won't cause crunching whilst selecting a gear. That is a typical sign of worn synchromesh.

[zebedee]

Is it a crunch or a grind? If it Is only just about going in, it could be cables couldn't it?

[Steve126]

I'd say it's a crunch. It still goes into every gear easily, you just hear a slight crunch and feel it through the gear lever.

I thought it was unlikely to be the linkage/cables because if that was the problem I don't see why it would go into every gear without a problem when stationary, but not when on the move. The linkage is the same in both situations, so if it was the linkage I'd surely get the noise in both situations?

Everything from the gear lever to the part that connects to the gearbox is the same as when the old box was fitted and I didn't have this problem then.

[zebedee]

Fair enough, mine is grinding or not going at all on 2 4 and reverse, am hoping cables, but sometimes it does go in, so I guess more likely an internal problem too

[Polome]

Had a similar problem a few years ago after gearbox rebuild...turned out it the release bearing had jumped out of one side of retaining fork during reassembly...the release bearing then didn't have enough travel to open the clutch making changes difficult. Unfortunately the only way to check this is gearbox removal so hope it's some of the easier faults described here...but worth keeping in mind....Good luck. Ian