I read most of the link than Compu 85 posted & I think it should be mandatory reading for anyone contemplating the purchase of a TDI.

It seems that the most transmission failures were related to the 01A automatic transmission, which according to the link, were installed on the 1998 - 2001 Jettas (possibly other models as well). The link states that it is not a matter of if, but when the trans will go out - due to shoddy parts. Apparently VW used some parts with substandard steel in them. Mentioned chunks of metal in the pan, with little or no warning of failure. Replacement costs ~ $4,500 - there is no "fix". It also stresses the importance of keeping the trans fluid topped off to prevent overheating. That prompted my question about an external cooler, but that would do nothing for faulty parts. VW is not repairing these faulty transmissions, only replacing them. Doesn't say a lot about VW, especially at $4.500 a pop.

I have tried a 5-spd. VW tranny in a local Jetta, but I'm not sure I would be able to handle it every day with my bad shoulder. If I could find a way to shift it with my wrist instead of using my whole arm I'd be in business. I just can't take much movement in my shoulder - even under the influence of Vicoden.

Thanks guys. I'll keep on looking & thinking. If Farm Bureau totals my '87 124 diesel, I'll have to seriously consider the VW. Although I love my Benz & know the VW will never be its equal, I live a long way from anything (65 miles to the nearest WalMart) & my continued trips to the veteran's hospital in Durham (534 mile round trip) may dictate the change.

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1987 300DT
2002 Ford F-250 7.3 Crew Cab Short Bed

Ours motors along at 75-80 MPH delivering better than 40 MPG. Hard to beat that for a commuter. Except for the comfort factor; the Benz is silky smooth going down the road at that speed, the Jetta, well, not so much.

I can't comment on the OP's questions... just wanted to add my two cents.

I had an '85 golf diesel that I liked very much. It was sorta a clown car for me, since I am 6'7".... my friends would laugh at me. But despite low compression it still got 45 mpg. I was always concerned about how well it would perform in an accident. I still liked it tho. It was my first diesel.

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08 R320 CDI current

Past
95 E420
87 300D Turbo 5spd
90 300TE
83 300SD
85 300TD
92 400E
85 190D

My current daily driver is a '91 Jetta IDI that gets close to 50 mpg. It's suits my commute perfectly well and is actually a very well built car (would have been even better without all the extra plastic they added to get the "big bumpers" look). I had been running my Rabbit pickup until some crazy Korean chick rearended me (lightly) at a light and I realized how vulnerable that heap was (the rigid bed ends right at my a$$ and it's a unibody-ouch- still drive it, but it's semi retired). I feel a lot safer in the Jetta as there's a lot of crumple area behind me and I can control things playing out in front of me.

Anyway, the Jetta, with the proper gearbox (this is a code ACH, they came with a lousy AWY one) is more than a match speedwise for a 240D stick. It's feels very competent up close to 70, whereas I would never think of thrashing a 240D like that. Probably a lot like a 190D stick, but I have never driven one.

Of course, this doesn't help the OP, as they didn't come in automatics, but for the rest of you luddites...

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Actually it's the 01M that is the dreaded transmission to watch out for. Used in the 99.5-2003 yeras of Golf, Jetta, and Passat I believe. My 2002 VW Jetta TDI had the 01M that failed, and it got replaced(by me) with a 5-speed with a taller 5th gear. My MPG's went from 45 with the auto to 53 plus with the manual! For me my TDI has been very maintenance intensive, and there are some "gotchas" that have to be tended to. Overall now that I have most issues straightened out with mine I love it. Highest city driving MPG I have gotten are 56 in town, and lowest so far with the 5-speed has been 53 in town. FWIW

I am in the process of looking for a 1999 E300D for my family, and once I have it I plan on implementing a little "out of the box" solutions to increase it's fuel mileage similar to the ones I use on my TDI.




..

Just sold my 1996 Passat TDI with 274k miles cause i found this sweet 1982 240d. I still own a 2001 Beetle TDI 5-speed & 2006 Jetta TDI DSG automatic.
They get great mileage! but agree with the others that the fit and finish of these VW's are not what our Mercedes are. I enjoy them. And will buy another one simply because i wanna hot-rod one and still get 40mpg :-)
The 06 gets about 38mpg with the new type automatic (not the problematic one's of 1999-2003ish). The Beetle gets 48mpg and as high as 58 when driven painfully slow with no AC. The Passat avg was 46mpg with 49.8mpg as my highest tank. And the 96-97 Passats had the largest tanks. I'd average 900 miles per tank. I loved that! I hate the wax feeling coating they put on the interior plastic parts that makes them look like crap! I did have to put a camshaft into the 06 but that is a known issue and i paid a very discounted price buying the car due to this issue. Had two power window issues which was broken wires. And OH YEA lets not for get the foam coming out of the vents!!! I sold mine before the repair was done but they say the foam is covering the blend door for the ac/heat in the dash. You have to take apart the whole dash for this repair!! Can't remember if you loose your heat or AC or both due to this!!??!! The ones i had did not have any more mechanical issues than the Honda's or Toyota's from my past.
But over all I like them if they are 5-speed!
Oh yea the opinion is N E V E R take it to the stealership...eeerrrrr dealership!!! (at least from what i've heard) There are plenty of TDI specific repair shops who will KNOW how to repair or maintain your older TDI's and know of specific issues with each model. And the TDIclub.com website is very informative like Peachparts.com on the forums!
Good luck!

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2006 Jetta TDI DSG 320k miles
1997 Ford F150 325k miles 4.2L V6 "Work Truck"
2008 Tundra 225k miles 5.7L
1982 240D.....sold
1984 300D...Totaled OUCH!
1985 300D Turbo 222k miles "Dos" sold to 79Mercy
1986 300SDL 98K miles "The Beater"....sold
1987 190E 2.3 16v Euro spec 115K miles....sold

have an automatic 2001 golf tdi. hate the transmission. weak, lousy ratios, sloppy as hell now. get a manual!

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George

Vincent: 1984 300D - 255,000 miles - NEW!

Wilbur: 1991 GMC Sonoma 2WD 2.5L 5-speed 250,000 km (top secret project)
Pancho: 1992 Mitsubishi Pajero SWB RHD 2.5L intercooled turbodiesel - 215,000 km