broken gearbox {mk1 galaxy 1.9 tdi part 2 }

[allbluedave]

hey guys.  so as most of you know. my gear box when bang recently so it was replaced with a second hand unit from the breakers yard. not long after that i lost the gears due to the selector on top of the gear box partly seizing up so it was removed. greased up and refitted which has been fine till now.......... now while out and about in rush hour traffic. i lost my gears again and could only get second gear so had to limp the car home doing under 30 mph on a motorway with my hazards on .me thinking that the gear linkage cables had broke so i started pulling the car apart only to find that the pinch bolt on the gear selector has sheared off again falling into the gearbox.  on the plus side of things ive removed the selector today . removed the threads off the pinch bolt that had sheared off so that only leaves me with fishing out the head of the bolt from the gear box.  the question is......... i have 2 ideas but which will work? first one if i drop the gear box oil will the pinch bolt head come out with the oil? other idea was to fish about with a magnet to see if i can retrieve it that way. do you think any of these ideas will work guys? also there is a d shaped plate on the end of the gear box. could this be removed to fish about with a magnet? guys. rant over lol..

[insanitybeard]

If you've got the selector mechanism unbolted from the top of the 'box, then I reckon your first call would be to get the slimmest flexible type magnet you can and have a good fish about, hopefully that will get the remains of the bolt, draining the oil may be worthwhile to remove any remaining swarf but you'd be very fortunate (in my opinion) for the draining oil to carry the bolt head to the drain hole and out of the transmission! More likely it'll be lodged somewhere and unable to move anyway!

[allbluedave]

Cheers insanity. I'm getting quite an expert at pulling the gear selector out of the car lol. I've had a fish about in the top of the gearbox where the selector fits with a telescopic rod  with a magnet on the end and no Joy.  also took the drain plug out expecting the oil to come  out but it was parked half on the kerb so non come out lol. My other ideas was to remove the end plate on the gearbox and fish about in there. Ain't done that yet. Last resort was to split the box to see if it falls out. Doable? If its lodged somewhere what's the chances of it staying there if I just replace the pinch bolt and box it up? Cheers guys.

[Chrispb]

Can you not try a piece of welding wire through the drain plug (surprised you didn't get oil out even though on the kerb)
Do recall someone splitting the box with success, but of course just depends where the bolt head is.
Wouldn't advise leaving it in there as it could destroy the box if picked up between gears.
Taking the box out and shake it out as another option.

[allbluedave]

I was shocked no oil come out too Chris. There's deffently oil in there lol though when the replacement box was fitted the drive shaft passenger  side leaked which overtime pretty much stopped to a seap.I was planning on having a progg around in the sump plug hole but with a metal coat hanger. If I unbolted the box from the engine and left a gap between the engine and box do you recon I could get the telescopic magnet in there to fish it out. I don't have the time or facility's to remove the drive shafts. Any ideas guys. ? I'm so selling this now when its fixed. 

[Chrispb]

You won't get it from there you need to separate the two halfs of the box.
What your suggesting would only give you access to the clutch housing.

[allbluedave]

Cheers Chris. I realized that after I said that  lol. Think I need more sleep hehe. So what's the d shaped plate on the end of the gear box? Can that be removed to have a poke about with a magnet?. If all else fails today its Going as spares or repair online. I'm going to see a vw Passat tomorrow so hopefully  I'll be mobile again. Cheers for the help  Chris 

[kbenne20]

Hi did you have any luck getting the bolt head out? I lost all but 3rd gear on mine today, after much swearing got the mechanism out to find the complete bolt was missing.  Similar attempts with magnets and draining oil to no success.