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2001 1.9L Non Turbo Diesel 5 spd Manual transmission troubles

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96 views 7 replies 6 participants last post by  TurboSLover  
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#1 ·
Trouble started with a hard shift to 5th gear while driving. Drove about 25 miles in 5th gear and then the last leg of the trip in 4th because I had to downshift for an off ramp. It moved just fine, and I got it home and parked. In the morning I started it up with it in neutral, clutch depressed. When I let out the clutch (still in neutral) it feel like it wants to move forward. If I put it in first or reverse, it will move but is bogging down.

Because it is the non turbo 1.9L I have been told the transmissions that fit the 1.9 TDI are not compatible. I have searched and a transmission to fit my Beetle is unobtanium.

I would rather fix it than replace it.
 
#2 ·
Based upon your symptoms, it could be something like the clutch, the hydraulic clutch system or the shifter assembly has gotten worn or something broke, Something internal to the transmission is wrong, etc.?

Narrowing down what specifically it’s causing the problem may be a bit of a challenge; I would be looking at the shifter assembly, the bushings, at the shifter assembly the cable ends in the shift tower in the engine department. Rebuilding the whole shifter assembly and cable ends can many times fix shifting specific issues; Dieselgeek cells bushing kits and you can rebuild everything yourself.

dieselgeek.com

Shifter Bushings for VW Audi Seat and Skoda

Make your VW shifter feel like new! Our VAG shifter bushings cures sloppy shifters and will get your shifter working like new! You'll save a ton time and money!
dieselgeek.com dieselgeek.com

On the Hydraulics side of things I would be looking at how the clutch pedal feels, and if there are any hydraulic leaks at the slave or master cylinder.

As to the transmission or the clutch itself; how many miles are on it, has the clutch been replaced ever and have you had any history, long-term of issues, etc.?

Common 02J 5 speed problems:

 
#3 ·
There were no non turbo diesels in 2001. Look at the back of the engine. There should be a turbo tucked under the intake.

My wife has a 2001 beetle, she definitely has a turbo. The older VW diesels were non turbo but not the new beetles starting in 98.

Unless someone transplanted an older diesel engine into your car. Post a pic of the engine bay.

It sounds as though your clutch is going out. If you click the link Billy gave you above, scroll to the bottom, dieselgeek has some videos on how the clutch works and how to adjust it. You might just need adjustment.
 
#4 ·
Thejarhead said:
There were no non turbo diesels in 2001. Look at the back of the engine. There should be a turbo tucked under the intake.

My wife has a 2001 beetle, she definitely has a turbo. The older VW diesels were non turbo but not the new beetles starting in 98.

Unless someone transplanted an older diesel engine into your car. Post a pic of the engine bay.
Click to expand...
The last non-turbo TDIs in the US at least were in the mk2 cars, so early 90's at latest. The mk3s got the TDIs. And there were even turbo diesel motors in the mk1s (we have one!).

I very much agree that you have a turbo. Why do you say its non-turbo?
 
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#7 ·
Image


Our TD, along with our Rabbit Pickup.
 
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