The pictures below are reverse idler gears found in an 020 VW transmission. The same gear is used in all 020 gearboxes. This includes the 1975 VW Rabbit 4 speed and all the way up the 2001 VW Cabrio 5 speed. The idler gear stood up fairly well in the early cars. The old Rabbit didn't weigh much and was fairly low on torque compared to its heavier Mrk II & III cousins. As the VW got heavier and engine torque was increased reverse problem started to surface. About 75% of the transmission problems we see in Mrk III cars emanate from reverse.

One issue is the gear tooth width is a little less than 3/8". Its also a non-synchromesh gear. Meaning if the gears aren't stopped or nearly stopped they will grind when shifting into reverse. You can see evidence of small grinds allowed by swallow engagement or rushed shifting. For best results stop the car, shift into 2nd gear then reverse. This stops rotation in the gearbox ensuring reverse engagement is complete, without grinding.

Since most "DFQ" & "CHE" transmissions come to us with reverse gear failure issues we feel it imparative to start with new reverse gears. They have a finite life in your transmission. Starting with new parts gives you the best value for your money. No other gears simply "wear" out in an 020 gearbox. Make sure you're getting new revese gears in your rebuild.

This is a very typical gear found in a "DFQ" core sent back by a customer. The bits made it through the ring & pinion, lower pinion bearing and popped a hole in the case.

This unit may have been an accidental foot slip off of the clutch. It came from a "CHE" unit. The teeth have been cleaned off at the root. Needless to say the big pieces did even more damage to the rest of the greabox.

Just two little chips on this unit. It was pulled from a '81 "F" series 020 5 speed gearbox. Fairly typical and would work. The only issue is it would greatly shorten the life of any '93 and newer rebuild.