Gearbox Issue??

Crasher

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All looks good from what I can see, the BKD is Golf 5 platform (PQ35) 2.0 16v TDI PD and the BDK is Golf 5 2L 8v TDI PD, I can’t remember the SDI code for yours and since I cleared all my history settings last night I can’t access any of my systems!
 

Keithuk

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That is the problem finding his engine and gearbox code, it like dragging blood from a stone.

Manufacturer: VW, Date(s) Used: 06/2005-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BST, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 12/2003-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BDJ, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt

Manufacturer: VW, Date(s) Used: 11/1995-09/2000, Model: Caddy, Engine Code: AEY, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 06/1996-12/2000, Model: Caddy, Engine Code: AEF, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 09/2000-06/2003, Model: Caddy, Engine Code: AYQ, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
 

Gozzy

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All looks good from what I can see, the BKD is Golf 5 platform (PQ35) 2.0 16v TDI PD and the BDK is Golf 5 2L 8v TDI PD, I can’t remember the SDI code for yours and since I cleared all my history settings last night I can’t access any of my systems!

I've found 2 different positions that I can I set it at, I'm trying to upload the images to show you but I've exceeded my quota. Can my limit be increased please or can my previous image uploads be removed?
 

Gozzy

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That is the problem finding his engine and gearbox code, it like dragging blood from a stone.

Manufacturer: VW, Date(s) Used: 06/2005-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BST, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 12/2003-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BDJ, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt

Manufacturer: VW, Date(s) Used: 11/1995-09/2000, Model: Caddy, Engine Code: AEY, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 06/1996-12/2000, Model: Caddy, Engine Code: AEF, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 09/2000-06/2003, Model: Caddy, Engine Code: AYQ, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt


The Gearbox code is definitely HHN and the only 3 digit code on the engine is HGL

I've just found the following though:
038021AT
90HBH
V602

There references on a few of the wiring covers and they all start with 1K0 and the original engine was a BST according to the log book.
 

Keithuk

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So we have finally got there. ;)

I don't think engine codes are shown on the V5 log book its isn't on mine.

Manufacturer: VW, Date(s) Used: 06/2005-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BST, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
 

Gozzy

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So we have finally got there. ;)

I don't think engine codes are shown on the V5 log book its isn't on mine.

Manufacturer: VW, Date(s) Used: 06/2005-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BST, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt

Woohoooooo :) So based on that last code I sent my engine is definitely a BST with a HHN gearbox! I will celebrate by updating my sig correctly later ;-)

Thanks
 

Gozzy

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Where are you now?

Knackered....

Fitted the seal (after removing the sump I could see up in the engine and could see the 2 pistons were at the highest point in cylinder 1 and 4, the 2 middle ones were at the bottom)
Fitted the sump and skimmed flywheel, new clutch and started on the gearbox.

Engine and gearbox are really close but can't manage to get them to mate but I've ran out of time and my arms are like Spaghetti so will have another crack tomorrow ��

I'm fully preparing myself to get it back together and for it not to start due to that feckin seal.

I also found some broken plastic pieces in the sump which had clogged the oil sucker upper thing (sorry tired haha)

If it does start any other jobs should be a peice of p155 :p
 

Gozzy

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Well it's all back together again and the gearbox is rattling so I think I've messed something up :confused:

After I got most of it back together I started it up without any drive shafts attached and let it idle for a while. There was a noise coming coming from the flywheel but it turned out to be the metal gasket was slightly catching it. Then I put it in first gear and checked for any noises and all seemed OK.

As soon as I attached the drive shafts and tested it (car is on jack stands with no wheels) I can hear a rattling coming from the gearbox cover plate. I never heard this noise before the gearbox was removed so its something I've missed (most likely) or the garage who sorted my gearbox messed up (doubtful).

I sent the gearbox off to a company who checked it an just did the minimum repairs due to money. They said the gearbox was fine it just needed a new ****** and a part inside the diff replacing. Only cost £180 Inc collection and delivery, they do a full recon for £600 but as they checked it and said it was fine I just went for the quick fix.

The gearbox oil leak is gone and theres no leaks from the sump or oil seal as far as I can see. Only error codes are an egr one and the feckin wiper motor issue.

I took it out for a test drive and it ran fine, 2nd to 3rd is hard to find but maybe I need to do some tweaking with the setup? Its pretty nippy low end to be fair. Went through all the gears fine and when I got back jacked it up and no leaks anywhere so far.

When I was fitting the gearbox I messed about with it for ages to make sure all the holes were lined up, then got under the car and lifted the gearbox a slight wiggle and I felt it slot home. I don't think I've done any damage attaching it.
When fitting the flywheel there's only one way it can go on, the new clutch came with a new clutch fork with the metal clip attached so that went on fine. I used one of them universal laser clutch alignment tools which seemed straight forward. The input shaft that the clutch fork and throwout bearing attaches has no play in it at all so even if there was an issue with the clutch plate setup that shouldn't manifest itself in the gearbox would it?

Any ideas what the issue could be, I'm fully expecting to have to remove the gearbox again but really hoping it's just some tweak on the gear selector levels is needed :rolleyes:

In other news at least that seal must be OK seen as it started and didn't throw any error codes. (every cloud) :p

Btw thanks to both of you for all your help, wouldn't have got this far without it.
 

Crasher

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That sounds like the dual bearing cartridge that supports the end of the input and output shafts has failed, very common and makes a terrible noise.

0AFbearings_zpsfb23d246.jpg
 

Gozzy

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That sounds like the dual bearing cartridge that supports the end of the input and output shafts has failed, very common and makes a terrible noise.


That does sound like where its coming from and would make sense considering it happens on all gears. The thing is it wasn't happening before I sent the gear box away and they said everything was fine. I'd it possible to replace that part with the gearbox still in the engine? Seems like you could remove the cover, remove the 5th gear and get to it that way?

One other thought is, if I hadn't lined up the clutch plate exactly right could that send vibrations through the gearbox and cause the noise?

Also how much damage would it cause to keep driving it for a month? Say another 500 miles?

Thanks
 

Crasher

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I can’t see it being friction plate alignment, even if it is slightly out you can’t get the box back in and if it was just the smallest amount out of line and the box slotted in cleanly (no naughty pulling it in on the bolts) then the instant you press the clutch pedal it finds its own happy place. The box has to come completely apart as it is bolted inside the main gear housing, part number 02T311206J and £73.03 genuine. To be honest, no matter what, a company who knows these boxes with THAT bearing is stupid not to replace it when the box is apart as Febi offer these for a little less than genuine, not much but appreciable


bc8a378d9711dbfb64b9d4e446d25361092290c5.jpg
 

Gozzy

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Yea I was thinking the same about alignment, "no naughty pulling it in on the bolts" I'm pretty sure the gearbox was sitting flush before I tightened the bolts. I definitely felt the gearbox mate with the clutch plate but if I have have fecked it up would an alignment/flywheel issue make its way to the gearbox? I wouldn't have though it would as the dampening the clutch plate and input shaft bearing should suppress it enough.

As soon as I touch the clutch pedal it starts to bite but I do get a vibration through the pedal even when the clutch is fully depressed (a bit like I'm getting haha)

I wouldn't even know the rattling was there if it wasn't for testing it, I can't hear it over the engine noise when I test drove it.

If I drained the gear oil and removed the cover plate I could test for play in the 5th gear cogs to prove if its that seal?

Cheers
 

Calv72

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Can anyone help me I have a 05 Caddy SDI struggling to get a gear box can anyone tell me if the tdi same year fits it it’s to do with codes but most people in speaking to don’t know the codes etc so struggling to know exactly what I need thanks.
 

Crasher

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This is a common question and correct or even barely suitable used boxes are in short supply, various boxes will fit but if the ratios are wrong the ECU can pick it up and bring on the engine warning light. Firstly we need to know what you have so private message me the REG number.
 

Keithuk

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Can anyone help me I have a 05 Caddy SDI

First posts normally go in introductions else you could get a free fix and we never see you again!!!

Your car spec says 0, only what I've added from your 2 threads. Which SDI?

Manufacturer: VW, Date(s) Used: 09/2000-06/2003, Model: Caddy, Engine Code: AYQ, 47Kw, 64PS, 1.9 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt

Manufacturer: VW, Date(s) Used: 12/2003-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BDJ, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
Manufacturer: VW, Date(s) Used: 06/2005-05/2008, Model: Caddy/Caddy Maxi, Engine Code: BST, 51Kw, 70PS, 2.0 Ltr, 4 Cyls, Remarks: Suction Diesel Injection (SDI) Timing belt
 
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