VW Fox Diesel Gearbox Slippage Haunts Shifting

Had similar symptoms with my 2013 VW Polo TDI at 115k km. The transfer case showed significant gear wear when inspected, causing rough shifts and occasional slipping between gears. Initially thought it was just a gear oil issue, but the problem persisted after an oil change. The mechanic found severe mechanical wear on multiple gear sets inside the transfer case. The worn components were allowing metal particles to contaminate the gear oil, creating a cycle of increasing wear. The transfer case needed a complete rebuild due to damaged bearings and gear teeth. This was a serious repair requiring specialized tools and extensive labor. Oil leakage around the seals had allowed contamination to enter, accelerating the internal wear. The symptoms you describe match exactly what I experienced, especially the unclear shifts that persisted after just changing the transfer fluid. Would strongly recommend having the transfer case opened and inspected rather than just addressing the fluid. This type of gear wear typically indicates an advanced problem that will only worsen without proper repair. Getting it diagnosed properly now could prevent more extensive damage to the transmission.

Thanks for sharing your experience with the Polo. Seems like we had nearly identical issues with the gear grinding and transmission problems. My Fox needed similar major work done too. Since you got yours fixed, did you notice any other transmission issues coming up afterwards? Also wondering what the total repair cost was for rebuilding your transfer case? Would help me budget for what I might be facing.

Finally had the Fox back from the repair shop after dealing with the transfer case oil wear problems. Happy to report zero grinding or slipping since the fix, it shifts smoothly now like new. The repair involved replacing several defective gears in the transfer case that had developed excessive wear patterns. The total came to 330€ for parts and labor, which included a complete system flush and fresh oil change. This was actually less than expected given the extent of gear wear they found inside. The original leaking seals had allowed contaminants to damage multiple gear sets, but catching it when we did prevented additional transmission damage. No transmission issues have surfaced in the months since the repair. The gear engagement is crisp and precise now, completely different from the vague shifting we discussed earlier. Getting the transfer case properly rebuilt rather than just changing fluids was definitely the right call.

Taking it to the mechanic turned out to be eye-opening. After hearing your similar experience, I had them do a full inspection of the transfer case. Just as you warned, they found significant gear wear and metal contamination in the gear oil. The mechanic showed me the worn gear teeth and explained how oil leakage had allowed dirt to enter the system. The repair took 3 days but cost 850€ total, more than I planned but worth every cent to prevent further transmission damage. The difference is remarkable, no more gear grinding or slipping between gears. The shifts are crisp and smooth like when the car was new. Really glad I got the complete rebuild instead of another basic oil change that wouldnt have fixed the underlying mechanical wear. Thanks again for sharing your experience. It helped me push for the right repair instead of another temporary fix.