I had gotten my engine swap completed a 20V 1.8T AWW with a 5-speed transmission. Today when I drove it home, I had trouble shifting into 1st and 2nd gear. I suspect that the oil level in the gearbox is low, but I don't know how to check it.

Would love some advice on how to diagnose this problem. 

Not 100% sure about VW box - never done mine - but I know that on lots of cars, there are 2 plugs on gearboxes. The drain plug at the bottom and the fill plug somewhere on the side. The idea is that you fill the box up to the fill hole - i.e. fill it until it comes out!!!!!! So you know where your level should be.

But to be honest mate - from your symptoms - i'd be more worried about the 1st-2nd Synchromesh!!

The 1st-2nd synchromesh...hmm, so you think it may be damaged? As it is it is difficult to go into gear, but after driving for awhile 2nd is ok, but 1st definitely a hard one.

Well I'll check the fluid level for the gear box, first.

 

Thanks for that. 

Is it difficult and notchy into reverse also? If so then the gear control cables need adjusting. There is a factory method for adjusting these which involves putting a locking pin to lock the gears in a known position and adjusting the cables to suit.

Stewart:

Is it difficult and notchy into reverse also? If so then the gear control cables need adjusting. There is a factory method for adjusting these which involves putting a locking pin to lock the gears in a known position and adjusting the cables to suit.

Yeah I do have problems going into Reverse and also 5th gear. So pretty much a mechanic can do that cable adjustments, right?

It's dead easy. Get some one in car, put in 1st. Open bonet. Look at shift linkage on top of box. The up down movement should be obvious from side to side movement of the gearstick. Adjust cable length to give correct side to side movement.

To adjust cable, push collar back against spring, and pull cable in and out to adjust.

Do the same for front to back movement. It rotates the selector shaft. Again put gearstick in 1st, and adjust cable so that selector shaft on box is in 1st. Try in other gears, and adjust to give best possition.

The factory proceedure involves a pin under the gearshift gator, and a pin on the selector shaft. It's more accurate, but you can get it 99% there doing as above.

Found another problem as well, where the clutch pedal housing does not have the filler plate. As a result when the clutch pedal is press the housing bows down before the clutch is engaged. The housing has to be re-enforced with the filler plate (1J1 721 379 B) before I start with your suggestion *Wilko

Thanks. 

i just have problems shifting into 1st , makes a slight difference wen im stationary but not much, all other gears are fine , don't think its the synchro, could it be the shift linkahe needs realignin also/?

This problem was fixed by replacing the converted (from the LHD) clutch pedal with the clutch pedal from a RHD. The pedal housing is shorter on the RHD clutch pedal and as a result does not have a downward movement when the pedal is engaged. The LHD which has a longer housing for the pedal, uses a filler plate at the front of the housing that holds it in place when the pedal is engaged.