02T gearbox issues on 1.2 TSI
Discussion
Hello everyone:
I want to share my experience with a recent breakdowon of my 5-speed manual gearbox on a Seat Toledo 1.2TSI (90 hp, CJZC).
This gearbox has been the only source of "breakdowns" in this car in 350000km (217000miles), mostly a very minor leak of the right-hand side seal of the gearbox toward the driveshaft that I had to chage three times, but the leak was never concerning, and oil level of the gearbox was never low. The engine has never given an problem or leak so far.
Right before getting to 350000km I noticed a noise idling in neutral. The noise was similar to the natural "knocking" noise of the engine (the 1.2TSI is noisy due to the injectors and fuel pump), but this new noise was cyclic, and the frequence was proportional to the engine speed in neutral.
I first suspected of the fuel pump, but I quickly identified the noise was actually coming from the gearbox, since the noise dissapeared when pushing the clutch. I aso noted that the noise was present when driving in 1st and 2nd gear, and could not be distinguished in the other speeds. The gearbox worked normally apart from this, but the noise quickly started to go louder and include some subtle grinding noise to the knocking noise in just 800-1000km.
A quick Google search confirmed that the 5-speed gearbox of this engines (02T code, very common in many Seat/VW/Skoda/Audi cars) is prone to failing due to the bearings, in fact the rebuild kit is easily available and there are plenty of videos in Youtube. The gearbox in my car is marked 02T 301 103 AB (code PNZ). I'm not impressed with the durability of this gearbox, but at the same time I have to accept that 350000km is not a small figure, but the engine has been remapped from 90hp to 135hp since the car had 170000km, and the car has been used extensively on mountain roads, so I can't really complain too much.
I decided to buy a used gearbox from a nearby scrapyard, apparently 65000km old and totally compatible (same car/model/year). I considered buying a 6speed gearbox (code PRQ), but for some reason these gearboxes are more than twice the price of a 5 speed (900 to 1000€ for a 6 speed) and given that there were no units available nearby I decided to go for the 5 speed. The 6 speed gearboxes seem to last longer because they have another additional set of bearings that support the axles better.A new 5 sp box from the dealer is over 4000-5000€, so I discarded this option.
I then changed the gearbox with the help of a friend (amateur home-mechanics, equipped with jackstands). It is not an easy job, but we had done this in the past when we changed the clutch at 240000km (which was not worn, but we did it preventively and for learning). If you are considering doing this job, please check the channel of Kevin Albert Williams (https://www.youtube.com/@WMCS , massive thanks to this guy), but don't try to do it without a helper, this man is from another planet.
The original noise is gone and the gearbox works fine, but the problem now is that I have a slight whine on 5th gear with the "new" box, noticeable on slight throttle and acceleration, but not cruising on flat roads.
I suspect we made a mistake when refilling the gearbox, since we topped it all the way to the filling hole with the car not flat, but lifted on the front axle. We did a small 3-4 mile test drive and we then rechecked the oil level (this time with the car level tothe ground), and it was a little low (not sure by how much), but I can't believe this short run could damage the gears. Not sure if the gearbox was already like this, but this is the magic of scrapyard parts.
The bearings are good, the gearbox is completely silent in neutral. The oil is freassh and it is the appropriate one (VW G 052 527 A1).
I've checked the internet and it looks like the gears of the 5th gear could be a little worn, but some 02T boxes (and many others) do this noise, the concept of "fifth gear whine" gives a lot of results in Google, but not many trustworthy answers though.
Now I'm wondering whether simply ignore the noise or try and change the gears of the fifth gear, which can be changed without dismantling the whole box. only removing the cover, and even with the geabox in the car (I have to confirm this).
Any experience will be apreciated, thanks for those who read ths far, I hope this may help other in the future.
I want to share my experience with a recent breakdowon of my 5-speed manual gearbox on a Seat Toledo 1.2TSI (90 hp, CJZC).
This gearbox has been the only source of "breakdowns" in this car in 350000km (217000miles), mostly a very minor leak of the right-hand side seal of the gearbox toward the driveshaft that I had to chage three times, but the leak was never concerning, and oil level of the gearbox was never low. The engine has never given an problem or leak so far.
Right before getting to 350000km I noticed a noise idling in neutral. The noise was similar to the natural "knocking" noise of the engine (the 1.2TSI is noisy due to the injectors and fuel pump), but this new noise was cyclic, and the frequence was proportional to the engine speed in neutral.
I first suspected of the fuel pump, but I quickly identified the noise was actually coming from the gearbox, since the noise dissapeared when pushing the clutch. I aso noted that the noise was present when driving in 1st and 2nd gear, and could not be distinguished in the other speeds. The gearbox worked normally apart from this, but the noise quickly started to go louder and include some subtle grinding noise to the knocking noise in just 800-1000km.
A quick Google search confirmed that the 5-speed gearbox of this engines (02T code, very common in many Seat/VW/Skoda/Audi cars) is prone to failing due to the bearings, in fact the rebuild kit is easily available and there are plenty of videos in Youtube. The gearbox in my car is marked 02T 301 103 AB (code PNZ). I'm not impressed with the durability of this gearbox, but at the same time I have to accept that 350000km is not a small figure, but the engine has been remapped from 90hp to 135hp since the car had 170000km, and the car has been used extensively on mountain roads, so I can't really complain too much.
I decided to buy a used gearbox from a nearby scrapyard, apparently 65000km old and totally compatible (same car/model/year). I considered buying a 6speed gearbox (code PRQ), but for some reason these gearboxes are more than twice the price of a 5 speed (900 to 1000€ for a 6 speed) and given that there were no units available nearby I decided to go for the 5 speed. The 6 speed gearboxes seem to last longer because they have another additional set of bearings that support the axles better.A new 5 sp box from the dealer is over 4000-5000€, so I discarded this option.
I then changed the gearbox with the help of a friend (amateur home-mechanics, equipped with jackstands). It is not an easy job, but we had done this in the past when we changed the clutch at 240000km (which was not worn, but we did it preventively and for learning). If you are considering doing this job, please check the channel of Kevin Albert Williams (https://www.youtube.com/@WMCS , massive thanks to this guy), but don't try to do it without a helper, this man is from another planet.
The original noise is gone and the gearbox works fine, but the problem now is that I have a slight whine on 5th gear with the "new" box, noticeable on slight throttle and acceleration, but not cruising on flat roads.
I suspect we made a mistake when refilling the gearbox, since we topped it all the way to the filling hole with the car not flat, but lifted on the front axle. We did a small 3-4 mile test drive and we then rechecked the oil level (this time with the car level tothe ground), and it was a little low (not sure by how much), but I can't believe this short run could damage the gears. Not sure if the gearbox was already like this, but this is the magic of scrapyard parts.
The bearings are good, the gearbox is completely silent in neutral. The oil is freassh and it is the appropriate one (VW G 052 527 A1).I've checked the internet and it looks like the gears of the 5th gear could be a little worn, but some 02T boxes (and many others) do this noise, the concept of "fifth gear whine" gives a lot of results in Google, but not many trustworthy answers though.
Now I'm wondering whether simply ignore the noise or try and change the gears of the fifth gear, which can be changed without dismantling the whole box. only removing the cover, and even with the geabox in the car (I have to confirm this).
Any experience will be apreciated, thanks for those who read ths far, I hope this may help other in the future.
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