I have a Audi A3 1.6 Sport (5sp man) with a gearbox problem. I have a
hole in the casing caused by something inside the box, not external
damage... Any ideas on how long a box should last ?
Thanks for your thoughts so far, I've not actually seen the casing,
but I'm told the hole was made from the inside out. The head machanic
at my dealer has been looking into the problem and came up with the
diaognosis. I do drive my car, i.e. I do rev it, but not excessively,
I feel the red line is there to be approached at times, but reved up
to all the time.
As for the car, the 1600, is the base engine in the UK model range,
103bhp i think, the car is a 5sp manual, with a Sport spec, which I
understand means lower and firmer suspension, (I recall but I'm not
100% sure, a shorter throw gearbox), a sports steering wheel and
sports seats. I test drove the SE spec, which is the luxo one for all
you non UK residents and it felt soft and sloopy in my opinion, the
sport spec was better.
The car is serviced every 10,000 miles at a well respected UK dealer,
the car has everything is ever needed and I'm damn annoyed that the
box failed at 90,000 miles or four years of age. I'd say the mileage
is mixed, with maybe 50% on motorways at high speed, and the other 50%
a mix of motorway queues, city driving and medium to high speed county
The catostrophic news is that a new gearbox will cost me £1370, plus
another £180 for a clutch which is contaminated by the gearbox fluid
all on top of my cambelt which I have just discovered should be
changed at 80k not 90k as the car booklet tells me and a 90k service
that was due this week... I will be about £2000 down by the end of
Any nice person out there who wants to help me ! LOL
In this context, "forever".
Might need new gears every so often (they wear), but an explosive event is..
erm.. kinda rare.
I've only ever seen failure due to a lack of oil in the 'box, although it's
always /possible/ that something could break on its own with such violence.
Have you /seen/ how thick the average casing is..?
Hairy One Kenobi
Disclaimer: the opinions expressed in this opinion do not necessarily
Since I see no replies, I'll tell give you the general picture.
Manual gearboxes -especially of German cars like Audis- should and do last
for a lifetime. Nearly 1 million kilometers without anyone touching it is an
exception but happens -this was an Audi 100 Avant of '89.
But shit happens. You can torture the gearbox yourself revving 6500 and
driving 200 Km/h and switching to second f.e.
Also there can be made a manufacturing fault which happens a lot in newer
cars and is the main cause of problems on Audis. The design of all parts is
very good but third parties can produce low quality sometimes.
If a hole is made from the inside or outside is hard to tell IMO. But if you
say so, a part(icle) must be missing in there.
Is the Audi A3 1600 a manual? All manual gearboxes i have ever known from
multiple makers can take a huge amount of abuse and but they do also wear.
Most problems relate to teeth on the synchromesh gears and the bearing
arrangements for components such as layshafts etc. Why an A3 has blown a
hole through its casing i hate to think of but i certainly would love to
know. Any pictures? Must have been something very catastrophic.
In the situation of the '89 100 Avant, i gather it is an automatic so will
have the the 087 series transaxle and we all know about that piece of
engineering brilliance.... I am currently rebuilding one of these messes
from a 1989 100 2.2 EE Sedan after the pinion transmission-end bearing
grenaded and the driver continued to use the car.!The pinion and crownwheel
chewed their teeth off . Eventually it wouldn't shift up out of 1st and i
found the centrifugal valves and weights off the smashed governor (which had
NO teeth) all the way back in the trans oil pan. The car had done
130,000miles. Take a look at:
Had this same thing happen to my 85 Jetta, one month after the
warrenty ended. The dealer scratched his head and said he never saw
this happen before. I put a junkyard tranny in it and sold it.
Years later, I learned that it was caused by a clip falling off a
shaft. VW did a recall on it, but it was too late for me. Could it
be the same thing again?
On Mon, 24 Nov 2003 14:25:25 +0000, Haydn Vernals
I recall from the back of my mind the story of the self-machining gearboxes
in VWs of this era. IIRC, it was the gear for 5th speed that was pressed
onto the shaft. The axial force on it (due to the spiral cut gears) would
force it down the shaft whence it would start machining the gearbox case. I
believe the problem was solved with a circlip in a groove on the shaft.
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