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Bora 1.6SE 99T Clutch and Gearbox problem! :

Last post Tue, Dec 27 2005 10:47 AM by shiuming. 24 replies.
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  • Tue, Feb 4 2003 3:26 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    ultra238a
    • Joined on Fri, Sep 13 2002
    • Posts 4
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    With this being my first VW I thought I would be getting a reliable car.

    Whilst I am the second owner of the car, it was previously owned by VW and has a full VW service history (and 65k miles).

    After me doing 1k miles in it something started leaking oil which turned out to be the gearbox. The oil had also gone onto the clutch.

    I was told by the garage that one of the cogs in the gearbox had sheared off and punctured the gearbox housing causing the oil leak which had gone onto the clutch and destroyed the clutch.

    I have been told by two sources that this is a common problem!

    Anybody any ideas on where I can get a used working gearbox and clutch for my Bora as I don't want to pay the £1300 the garage wanted to fix it since the car only cost me £5500.

    Any help would be much appreciated.

    Many thanks

    Paul
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  • Tue, Feb 4 2003 3:29 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    Mikedav
    • Joined on Wed, Jul 24 2002
    • Location: Central London
    • Posts 5,553
    • Top 25 Contributor
    1) The car was only £5500?!?!?!
    2) Youve scared the hell out of me now, mines a 1999T SE with 38K on the clock
    3) Sorry, I cant actually help
  • Tue, Feb 4 2003 3:40 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    ultra238a
    • Joined on Fri, Sep 13 2002
    • Posts 4
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    Yep 'fraid so. The car was up at £6250 but I had no PX and I paid cash.

    Two garages and one place that fixes, repairs and replaces gearboxs have all told me that this is a known fault with Bora's.

    I am really Removed off about it because the car even with the high'ish miles (only 20k a year) is fab otherwise

    :(

    Paul
  • Tue, Feb 4 2003 3:46 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    Mikedav
    • Joined on Wed, Jul 24 2002
    • Location: Central London
    • Posts 5,553
    • Top 25 Contributor
    quote:
    Originally posted by ultra238a

    Yep 'fraid so. The car was up at £6250 but I had no PX and I paid cash.

    Two garages and one place that fixes, repairs and replaces gearboxs have all told me that this is a known fault with Bora's.

    I am really Removed off about it because the car even with the high'ish miles (only 20k a year) is fab otherwise

    :(

    Paul



    Well mine was up for £8995 at a maindealer, and I paid £8,400 no P/X. It had 27,000 miles at the time, and wa around book value...yours was a steal at that price.

    As for the box...hmm. Your best bet is one of the VAG specific scrap yards such as www.vwaudibreakers.co.uk ... a 1.6 Golf box would fit too presumerably. Is yours the 8v or 16v?

    You will still need to find a reputan=ble local garage to do the work, but I avoid main dealers like the plague. I had an accident on the 12TH Dec, towed it to a VW dealer and they said they couldnt even LOOK at it until January 8th. I took it to my local guy, he had it fixed by 5th January. Moral: screw main dealers.

    Good Luck
  • Tue, Feb 4 2003 3:52 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    ultra238a
    • Joined on Fri, Sep 13 2002
    • Posts 4
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    I agree, screw main dealers.

    The £1300 cost for a new gearbox and clutch was from a very reputable garage who I have used for many years. Unf. he won't source and fit second hand parts.

    Even with the high miles I thought I was getting a good deal. Shame about the problems as it has put me right of VW's

    I forgot to say, the 1.6 Bora can't use a 1.6 Golf gearbox or clutch as the are different (and prob. only slightly).

    It is an 8V

    Thanks for your help

    Paul
  • Tue, Feb 4 2003 3:58 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    smithy
    • Joined on Tue, Jul 9 2002
    • Location: United Kingdom
    • Posts 134
    • Not Ranked
    Sorry to hear your troubles mate.
    You could try. www.vwspares.co.uk is a good place to start.
    The owner is a member on hear. I think it is enzo.
    Like mike said that was a cheap car you bought.
    I paid 8500 for my T 1.6 SE with 12000 on the clock.
    Just makes you wonder what can happen with a good car like ours.

    You could also try 1stchoice.co.uk is a good one as well.
  • Sun, Feb 23 2003 9:48 AM Bora 1.6SE 99T Clutch and Gearbox problem! :

    Enzo
    • Joined on Mon, Oct 21 2002
    • Location: United Kingdom
    • Posts 24
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    [qoute]I forgot to say, the 1.6 Bora can't use a 1.6 Golf gearbox or clutch as the are different (and prob. only slightly).


    Who told you that? Because they are wrong.

    There are two different clutches for the 1600 and it just depends on your engine code, AEH, AKL & APF have one clutch, and the ATN & AUS have another.
  • Tue, Jul 1 2003 4:19 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    K13SHN
    • Joined on Thu, Dec 26 2002
    • Location: United Kingdom
    • Posts 7
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    Funy post...

    Well not funny actually, same thing happened to mine around 10 days ago..

    I was told by the garage that one of the cogs in the gearbox had sheared off and damaged.... gear 1, 2, 3, 4, 5 and the crown pinion wheel thing...also had to have a new cluth as mine was worn.

    i know the guy at the garage, so the cost wasnt tooo much, but alot for me as im only a student

    £100 clutch
    £270 gearbox reconditioned
    £100 labour
    all plus VAT

    he did it for £550.00 :(

    I dont understand how it can cost £1300! unless its a whole new gearbox ... just get the gearbox recon-ed
  • Tue, Jul 1 2003 4:20 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    K13SHN
    • Joined on Thu, Dec 26 2002
    • Location: United Kingdom
    • Posts 7
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    btw - i bought mine with 50k on the clock around 8 months ago, it now has 65k....
  • Fri, Aug 15 2003 4:04 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    MagicBoy
    Bora S 1.6 8v APF 100PS
    • Joined on Thu, Nov 21 2002
    • Location: United Kingdom
    • Posts 52
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    I had exactly the same problem as ultra238a.

    '99 1.6 8v Bora (Wolfsberg built), gearbox started leaking oil 6 days before the warranty was up @ 24k miles. Replacement was faulty also - major clutch slip due to faulty oil seal in the new gearbox causing contamination, so it was replaced again a week later.

    No problems since, and the cars done 16k miles in the 10 months since the new gearbox was fitted. The dealer tech told me off the record (when he took me out in my car) that there were a batch of faulty gearboxes from the late 99 Bora 1.6s.
    99 Jazz Blue Bora 1.6S - now departed...
    05 Skoda Fabia vRS - newly arrived (3 years ago!)
  • Sat, Aug 16 2003 4:09 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    Mikedav
    • Joined on Wed, Jul 24 2002
    • Location: Central London
    • Posts 5,553
    • Top 25 Contributor
    quote:
    Originally posted by MagicBoy

    The dealer tech told me off the record (when he took me out in my car) that there were a batch of faulty gearboxes from the late 99 Bora 1.6s.


    Mines done 45k now. Im hoping my car isnt one of them - its a May 1999? Selling it soon anyway so as long as it doesnt go before then!
  • Thu, Aug 21 2003 1:40 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    Toff
    • Joined on Thu, Jul 11 2002
    • Location: Manchester [Northern Moor]
    • Posts 356
    • Not Ranked
    Did you get a gear box in the end mate?

    I may have a 23000 mile 5-speed with clutch (from a 2.0 2001 Golf.) You say that the Golf one won't fit the Bora.. do you know why this is?

    I'll ask the guy whos trying to fit my 6-speed and see what he says.

    - Toff.
    Current Cars: [ 2005 A4 B7 3.0 TDI Quattro S-Line Tiptronic ]
    Past VAGs: [ Mk1 GTI Cabrio | Mk3 2.0 Cabrio | Mk3 VR6 | Mk4 R32 | Mk4 V6 MoFo | Mk4 Supercharged 2.0 6-speed | Audi S6 4.2 Quattro | Audi A4 B6 2.5 V6 TDI Quattro Sport Saloon ]
  • Thu, Mar 4 2004 2:43 AM Bora 1.6SE 99T Clutch and Gearbox problem! :

    andy_not_happy
    • Joined on Thu, Mar 4 2004
    • Location: England
    • Posts 143
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    I have a Seat Toledo 1.6 1999 V reg that has just had the same problem with the gearbox. It has a VW engine (AKL) and gearbox (DUU) the same one as the Bora 1.6 and some Golfs.

    Just under 50k miles and the gearbox has been punctured by broken rivets and lost all the oil and contaminated the clutch. Will cost about £1000 (including labour) to repair everything at gearbox specialist. (Costs over £900 for just a new gearbox from VW). Apparently it is difficult to find a second hand gearbox because many have failed.

    Checking on the internet and with gearbox place this is a common problem. The final drive gear is attached to the differential by soft rivets that break off - damaging the gears and the gearbox casing.
    The final drive gear in the repaired gearbox is attached with nuts and bolts. This is a defective design and it is unacceptable that the gearbox fails catastrophically at this mileage.


    Final drive gear showing bolts used to replace rivets

    I bought the car second hand from a Seat dealer with a warranty, it is now 6 months out of warranty. Of course the dealer is not interested and told me to contact Seat UK.

    I am annoyed that if I had done higher mileage or driven it harder it would have failed within the warranty and be replaced for free.

    Andy
  • Fri, Mar 26 2004 6:48 PM Bora 1.6SE 99T Clutch and Gearbox problem! :

    KennyW
    • Joined on Mon, Jan 5 2004
    • Location: Hook, Hampshire
    • Posts 8
    • Not Ranked
    Had to get my 1.6 golf towed home tonight, Lots of revving and smoke from under the bonnet [:(!]

    AKL engine with 62k on the clock

    I can select gears (I think!) but car does not budge

    No real warning other than slipping last night, hope it is just the clutch and not oil contamination from a leaking G.Box or Seal
  • Wed, Mar 31 2004 4:54 AM Bora 1.6SE 99T Clutch and Gearbox problem! :

    MK3GtiWannabe
    • Joined on Thu, Jan 16 2003
    • Location: N. Ireland
    • Posts 29
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    The way to tell if it is about to go is when you are driving the car let it come to a rest without accelerating, you will hear what sounds like a flat tyre coming from the front passenger side of the car, this is the damaged gearbox. I know, was the main sympton on mine.
  • Tue, Dec 20 2005 10:56 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    Sapg
    • Joined on Tue, Dec 20 2005
    • Posts 5
    • Not Ranked

    This just happened to my Bora too.  I guess there is nothing I can do but shell out the £1000 pounds that they want to charge to replace the gearbox.

    Sapan
  • Tue, Dec 20 2005 11:32 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    Sapg
    • Joined on Tue, Dec 20 2005
    • Posts 5
    • Not Ranked

    I've just registered a complaint with VW, I think you should do the same, my reference number is 4105633.

  • Tue, Dec 20 2005 11:53 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    BORA_TOM
    Golf IV GTI 1.8T 20v AGU 150PS
    • Joined on Wed, Apr 7 2004
    • Location: Stansted Airport
    • Posts 2,876
    • Top 75 Contributor
    you could always source a second hand box from one of the numerous vw/audi breakers
    For sale

    25mm H&R 5x100 to 5x112 PCD
    16" Merc alloys in need of refurb

    PM me if interested
  • Wed, Dec 21 2005 5:15 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    Sapg
    • Joined on Tue, Dec 20 2005
    • Posts 5
    • Not Ranked
    I've already had it done at a Renault garage near my work place, I couldn't afford the time, £1900 along with the £500 VW charged to replace the sump because they threaded the plug during a routine oil change!  I've also had the electric window winder mechanism replaced twice on the driver's side.  The car is only worth about £4000 now!

    VWs kinda suck.

  • Wed, Dec 21 2005 6:57 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    shiuming
    • Joined on Thu, May 19 2005
    • Posts 8,518
    • Top 10 Contributor
    That's bad news. I wonder if they improved the design like they did with window regulator clips. I'm off to my local VW service centre to pick their brains about this...
  • Wed, Dec 21 2005 8:38 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    Sapg
    • Joined on Tue, Dec 20 2005
    • Posts 5
    • Not Ranked
    Good luck, they probably treat you like you are stupid and then get you to fill in a customer survey.  Customer services keep insisting my car is a 2.0 litre, its a 1.6, it even says so on the engine! 
  • Wed, Dec 21 2005 9:31 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    shiuming
    • Joined on Thu, May 19 2005
    • Posts 8,518
    • Top 10 Contributor

    Mine treat me very well and always remember little details about my car, that's why I keep using them Smile [:)]

  • Wed, Dec 21 2005 10:53 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    Sapg
    • Joined on Tue, Dec 20 2005
    • Posts 5
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    Out of interest which dealer to you use?  I use Ridgeway Volkswagen in Reading, they used to be called Timothy Green.
  • Tue, Dec 27 2005 9:42 AM Re: Bora 1.6SE 99T Clutch and Gearbox problem! :

    James G60
    • Joined on Tue, Mar 23 2004
    • Location: England
    • Posts 25
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