1996 Jetta GL - 2 questions - exhaust & manual trans oil

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JM_newsgroups - 22 Jan 2009 14:46 GMT

Hello,

1. The car has about 83,000 miles. It's a southern car; not sure if
the exhaust is original. The exhaust gets noisy at around 2600 RPM,
but not the type of noise when holes are present (I inspected the
system - no holes). I'm assuming it's the muffler. That middle
"muffler" is a resonator, right? Should I try just replacing the
rearward muffler?

2. It's hard to shift into first, but I can find nothing in the
manual about the manual transmission oil. The shifting is smooth
otherwise; would swapping out that gear oil possibly make the
engagement into first easier?

Thanks,

JM

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JM_newsgroups - 22 Jan 2009 15:21 GMT

> Hello,
>
[quoted text clipped - 13 lines]
>
> JM

I forgot to mention - the noise is an annoying "droning" that goes
away mostly at about 3000 RPM. I don't like the free-flow exhaust
sound, and that's what it sounds like. This car is not a showpiece,
and I'm on a budget. Thanks again.

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Mark - 22 Jan 2009 16:26 GMT

In article <e6956edb-2dc0-426c-a87c-
62fb978b20ab@m15g2000vbl.googlegroups.com>, jm_newsgroups@yahoo.com
says...

> 1. The car has about 83,000 miles. It's a southern car; not sure if
> the exhaust is original. The exhaust gets noisy at around 2600 RPM,
> but not the type of noise when holes are present (I inspected the
> system - no holes). I'm assuming it's the muffler. That middle
> "muffler" is a resonator, right? Should I try just replacing the
> rearward muffler?

In the USA, there's a cat (up close to the engine) and a muffler. Don't
recall there being a resonator, but I never messed with the exhaust.

> 2. It's hard to shift into first, but I can find nothing in the
> manual about the manual transmission oil. The shifting is smooth
> otherwise; would swapping out that gear oil possibly make the
> engagement into first easier?

This one I think I've got. There's a 'ball' in the shift linkage that's
gone bad. It's on 'top' of the transaxle, back behind the engine a bit.
If all you see is a toothed cylinder, the 'rubber' ball has come off
it's center and you need to replace it.

See the shaft on the right side of this photo?
http://www.germanautoparts.com/images/7607a6e2030303839373139313/f
That white ball is what you need to check. May as well get the whole
kit and do everything that's easy to get at. In the kit is a ball in
for the shift lever inside too, but it never needed it on mine, and it's
a PITA to get too unless you drop the exhaust... ;)

Here's their shifter rebuild kit. ~$50.
http://www.germanautoparts.com/Volkswagen/Jetta/Transmission/186/3
You could just replace the ball, but if anything else is even suspect,
I'd just pay the extra $20 and get it all done for the next 10 years.

Get some moly brake pin grease or similar for the ball & socketed parts.
Napa, Pep Boys, Autozone, maybe even Wal Mart will have it.

If the valve cover gasket it leaking, I'm told the engine oil will eat
the ball. May as well fix the leak unless you really like doin' this
job. :P IIRC they have a kit for that job too. Take pictures, be
methodical as you take it apart and you shouldn't have problems.

Mark
'95 Jetta GLS (sold)
'08 Jetta SLE

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dave AKA vwdoc1 - 23 Jan 2009 03:41 GMT

Check for loose or rusting shields over the exhaust manifold and at the
catalytic converter.
Also check the shield over the entire exhaust system.
Listen for the noise to locate where it is coming from. ;-)

Select 2nd gear before selecting 1st gear or reverse.

Post findings!

> In article <e6956edb-2dc0-426c-a87c-
> 62fb978b20ab@m15g2000vbl.googlegroups.com>, jm_newsgroups@yahoo.com
[quoted text clipped - 42 lines]
> '95 Jetta GLS (sold)
> '08 Jetta SLE

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Mark - 23 Jan 2009 13:40 GMT

> Check for loose or rusting shields over the exhaust manifold and at the
> catalytic converter.
> Also check the shield over the entire exhaust system.
> Listen for the noise to locate where it is coming from. ;-)

There are heat shields on the front of the 'firewall' too. May as well
check those while you're there. Use your F15T (closed hand) to induce
vibrations in the parts you're checking too and see if something rattles
when you gently punch it...

> Select 2nd gear before selecting 1st gear or reverse.

If that works, it'll tend to confirm the diagnosis. It can buy time
until you get the parts, but eventually it'll get so bad that 2nd is
difficult to get to. BTDT.

Mark
couple of VWs

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JM_newsgroups - 24 Jan 2009 19:16 GMT

Thanks Mark, Dave. Yes, the "ball" is missing from the shifter
linkage as suggested.

Regarding exhaust shields, etc., what I can see all looks pretty
solid. It's not a buzzing like exhaust shields make. It's a "crappy
muffler" droning, but I can't discount that there could be a hole
under a shield somewhere. I'll try to pinpoint the sound better. The
rear muffler looks like a generic replacement, so I'll try and replace
that one. I patched one small exhaust leak at a joint earlier, and
that didn't make any difference. I think the muffler just doesn't
dampen at a particular RPM

> In article <C%ael.18538$Ws1.10...@nlpi064.nbdc.sbc.com>,
> vwdoc1nos...@pleasehotmail.com says...
[quoted text clipped - 17 lines]
> Mark
> couple of VWs

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