Gearbox failure

[Scatmans3]

Anyone ever had problems with their S3 gearbox? Mine failed two days ago and still delaying the inspection, hoping to find more information before lashing out US$500,00+ just to take it off and disassemble it. I know now for a fact that S4/RS4 gearboxes are quite sensitive, for I have seen with my own eyes two failures that were covered by warranty, even though they were way off (a 2000 S4 two months ago), but nothing on S3(02M) gearboxes.

Problem consists of failure to engage either reverse, first or second gear. Third, fourth, fifth and sixth still engage, but do not disengage when lever is pulled to neutral position and clutch disengaged, so I have to turn off the car before releasing the clutch. I know there are many things that can go wrong, from gears, synchro, etc, just trying to narrow it down and get an idea of what I should expect. And if it helps, I have been using a ceramic clutch disc for the last 18.000 miles, experiencing some trepidation when launching fast in the last couple of weeks.

I would hate (or love) having to switch a Lancer Evo or even a *sigh* Impreza WRX... even though it's third Audi for me, and second in the annoying-problematic-ones list.
I do still love the neat little toys [img]images/graemlins/kissmyrings.gif[/img] , but patience will run out eventually (read: tolerance for opening wallet wider than necessary under normal conditions).

I seem to have found a gear replacement kit from Autotech wich runs around US$4500,00, so that could be an option.
Anyone has anything to say on the original gearbox and it's possible problems and/or the Autotech replacement kit?

Thanks.
Alexander

[Bushy]

My RS4 had a new gearbox after synchromesh failed, I had it replaced under warranty, havent really heard of any S3 gearbox problems

SOrry I cant be much more help

Good luck

Bushy

[AL_B]

My S3 gearbox has been making a "nice" crunch sound when changing up from 2nd to 3rd at high revs, 5000rpm+. Its been doing it for about 2000 miles (car currently on 14800). It doesn't do the crunch below those revs, nor does it do it in any other gears.

I did a massive search one evening of all the Audi sites and found its a quite a common problem with S3's and TT's. Its something to do with the synchromesh.

Anyway, dealer has investigated the problem. 1st step was to change the gearbox oil - didn't cure the problem. Next step was either new gearbox or strip and rebuild gearbox.

The dealer told me they could change the gearbox for a new one, but even a new one could start to do the same thing in 6 months to a year. So I opted for my 'box to be stripped and synchro's (and other bits) to be replaced. If this doesn't fix it, then I'll get a new gearbox anyway. (All under warranty, thank God)

Anyway, the job was done last week, and as soon as I get more details about what parts were replaced I'll let you know.

AL

[AL_B]

For those who are interested...

Got my car back from the dealer today after its gearbox had been repaired and initial signs are good. Its early days I know, but at the moment, the 2nd-to-3rd gear crunch has now gone.

This is what was replaced:-

1st 2nd 3rd baulk rings with synchro's and
1st and 2nd gears

Perhaps some other stuff too, but not sure.

AL

[Riz_RS4]

Cheers for the info AL,
I reported to my dealer a while ago that sometimes my gear wont go into 5th or 6th but the master technician said the double checked and could not replicate the problem, it happens very rarely. [img]images/graemlins/confused.gif[/img]

[AL_B]

Yeah. Thats the hard part, replicating the problem for the dealer. "Luckily" for me, the problem was easy to replicate.

A gearbox oil change to fully synthetic may help resolve your problem though.

Good luck. [img]images/graemlins/smile.gif[/img]

AL

[Riz_RS4]

I will remind them next time im in.

Cheers

Riz

[Hopsta]

Al, I know this was done under warranty but do you know how much that would have cost normally ?

[Mo_S3]

Hi Al, any chance u knowing what the make and viscosity of the synthetic oil they use for the gearbox is ?

Cheers

[AL_B]

Hopsta,

Roughly £1800 +VAT for the labour and parts that my car needed. [img]images/graemlins/shocked.gif[/img] If all gears and synchro's had needed replacing, you need to add about another £400 quid.

MO,

Sorry MO, I don't no. Not sure what oil they've put in. But I was assured by "you know who" that its now fully synthetic stuff.

Cheers

AL

[grahampking]

sometimes my gear wont go into 5th or 6th

My S3 has occaisionally resisted going into 5th. More of a "do I have to ?" than a "I will NOT do this" resistance. Happens so rarely that would never have been able to recreate for a dealer. Car has done 45k now. It has done this since we first got it when it was 3 months old with 3k miles on it.