[Vwdiesel] Changing the 5 speed trans fluid

[TexasTDI]

"So in the case of the '91, removing the speedo cable is actually not
needed - you could just remove both 17mm Allen plugs and drain, then fill to
level of filler plug. If you choose to fill this way, then I recommend
removing the fender liner... (which is why I opt for the speedo cable
method."

I haven't been under the car yet.  So I wasn't sure if the transmission had
a "lower drain plug" and an "upper fill plug" like other manual
transmissions do.  The Bentley Manual covers 1985 to 1992 models and doesn't
cover minor model changes like it should.  I would prefer not to mess with
the speedometer cable if possible.  With my luck something will break and
I'll be without a speedometer.

Thanks everybody for all the help.  }:o)

Chris Thornton
1991 VW Jetta 2 Door 1.6 Diesel - 240k miles
2000 VW Golf 1.9 TDI (turbo diesel) - 89k miles
Amsoil Synthetic Lubricants Dealer #1098500
http://www.amsoil.com

----- Original Message -----
From: "Shawn Wright" <swright at zuiko.sls.bc.ca>
To: <vwdiesel at vwfans.com>
Sent: Thursday, October 30, 2003 9:53 PM
Subject: Re: [Vwdiesel] Changing the 5 speed trans fluid


> On 30 Oct 2003 at 18:54, Scott Kair <scott3491 at insightbb.com> wrote:
>
> >     Assuming it's for your 91 A2, it's not that big a deal.  Go to the
> > dealer first and get a couple of the rubber washer/gasket/sealers that
go
> > between the cable securing plate and the transmission.  Old ones will
hold
> > well until you remove the cable, then they split when you put them back
on,
> > causing a noticeable leak. They should be under $5 ea.  While you're
there, it
> > wouldn't hurt to pick up a couple of the little clips that hold the
speedometer
> > gear to the cable.  The cable has to be wiggled out, and if the clip is
weak, it
> > won't be apparent until you try to reinsert it and the gear drops into
the
> > tranny, never to be seen again.  Both parts may have to be ordered.
>
> Good point, I forgot that this seal is often badly mangled...
>
> >     Not sure what size torx screw it is; PO replaced mine with a
> > conventional hex-head.
>
> Hmm... I wonder when they went torx? Both my 85's have 12mm hex
> bolts, and I'm pretty sure they are original.
>
> >     When I changed mine, I drained it by the manual and removed the l/f
tire and
> > had to wiggle the allen head wrench around to get it on the screw.
Tapping it
> > loose wasn't fun, both due to the fender liner.  It might be easier to
drain it
> > from the screw in the bottom, but you might have to remove the bash
plate.
>
> ?? The allen plug on the end is the old filler hole, not the drain, so you
> wouldn't get much out unless you also remove the bottom drain. I don't
> usually bother to remove the filler plug, as it's a pain to get at, and
not
> necessary unless you're checking the level, and this is rarely needed
> unless you have a leak. As of '88 models (or so) the filler hole is
higher, so
> a proper fill comes to the edge; early models require an extra 0.5 liter
after
> reaching the edge of the filler.
> So in the case of the '91, removing the speedo cable is actually not
> needed - you could just remove both 17mm allen plugs and drain, then fill
> to level of filler plug. If you choose to fill this way, then I recommend
> removing the fender liner... (which is why I opt for the speedo cable
> method... ;-)
>
> >     HTH,
> >     Scott Kair
> > ----- Original Message -----
> > From: "TexasTDI" <texasvwdriver at hotmail.com>
> > To: <vwdiesel at vwfans.com>
> > Sent: Thursday, October 30, 2003 8:53 AM
> > Subject: [Vwdiesel] Changing the 5 speed trans fluid
> >
> >
> > > Anybody out there ever change the gear lube in their 5 speed?  Looking
in the
> > > Bentley Manual it says to pour in the new fluid through the hole that
the
> > > speedometer cable goes into.  What size Torx does it take?  Are there
any
> > > special things I need to know when removing and reinstalling the
speedometer
> > > cable?  TIA
> > >
> > > Chris Thornton