Mk 9 Problem

[Oldwrench]

Changing gears and everything went well, even the last 1/2 inch, until the nuts attaching the bearing carrier to the case are tightened down. Then it locks up. With the nuts finger tight it's fine; can select all four gears and the car rolls freely in neutral. Any ideas?

[Purple Frog]

What about reverse?

[scotty82]

Good chance the 4/5 gear thrust washer has came out of the pocket in the bearing carrier .

[Robert J. Alder]

Good chance the 4/5 gear thrust washer has came out of the pocket in the bearing carrier .

That would be my guess also. That thing won't come out when you want it to (e.g when inspecting everything) and will come out and roll across the floor (e.g. when intersecting the case or stuffing the gear stack) when you don't want it to.

Put some axle grease on that thrust washer before stack and stuffing the gears so it won't accidentally get displaced when stuffing the box.

[Oldwrench]

Yes, it was the thrust washer. All good now. Thanks!