Dq200 7 speed dsg synchromesh

[Rawcpoppa]

I have a 2012 VW with a 1.4l twinchargers coupled with a 7 speed dsg. Over the last six months I would hear grating noises intermittently on gears 2 and 4 just after engaging them but saw no error codes in vcds. The noises were not consistently replicable. I tried a clutch adaptation and the procedure would successfully complete but the noises remained.

Sounded like a manual transmission where you changed gears without fully sinking the clutch pedal.

Anyways the sound has now disappeared from 2 and 4 but is waaays worse and only shows up in gear 3.

Gear 3 sometimes engages after a loud grating sound or sometimes never engages and the car then only allows even gears to be used till car is switched off and back on. I tried a clutch adaptation and the procedure halts on error 255/84 which in a document here says 3rd synchro timeout. I guess it is taking too long to move into a position and the system stops the adaptation. However the auto/trans in vcds shows no error.

I need help. Can anyone say if synchros are hard to replace? Any part numbers? Should I also replace the clutch pack one time since I'll be going into the gearbox?

I will be uploading a video so sound can be heard.

[Rawcpoppa]

Pic of basic setting attempt being interrupted with error code.

[Rawcpoppa]

https://vimeo.com/196395171

Car is being driven in manual mode but the noise also occurs in D3 as well.

[CraigR]

Sounds like a new gearbox is needed. Pretty sure it's not a syncro as the next gear is already pre-selected, but I don't think the drive is being fully disconnected before engaging the other drive shaft/gears drive.

[Rawcpoppa]

Yeah it would seem new gearbox needed. The fault error in the adaptation points to synchromesh though. Pre selected doesn't mean selected so when you try to engage 3rd the synchromesh comes into play but isn't working properly.

[AdamD]

Pre selected doesn't mean selected so when you try to engage 3rd the synchromesh comes into play but isn't working properly.

The next gear is selected on that input shaft before the gear is audibly "changed" and you should never be aware of that action as a driver - that's when the synchromesh comes into play. When the apparent gearchange occurs, all that's happening is that one clutch is engaging and another is releasing - the gears on both shafts should have been selected well in advance.

[Rawcpoppa]

Ok by the time gear 2 is selected the synchromesh for gear 3 has already done it's work then?

Does anyone think the symptoms are related to the clutch pack?

[Rawcpoppa]

Just to provide follow up info: VW agreed to replace my gearbox. They paid 100% on parts and 30% on labour. Car is back on the road and working fine again.

Goodwill was offered even though I do not service by the dealer regularly and the car is out of warranty over 3 years now. Car is 5 years old now.