VW Sharan's Rough Shifting Signals Transfer Case Trouble

I experienced identical symptoms with my 2015 VW Touran TDI at 155000km. The rough shifting between gears started gradually, especially noticeable during cold starts. Initially, a transfer case oil change was attempted, but this only provided temporary relief. After two weeks, the symptoms returned. A thorough inspection revealed worn gears in the transfer case, which had caused metal particles to contaminate the gear oil. The repair required complete disassembly of the transfer case to replace several damaged gears and bearings. The mechanical wear was significant enough that simply changing the oil would not have solved the underlying problem. The gear wear pattern indicated the issue had been developing for some time. Given your symptoms and mileage, I recommend getting a second opinion. Request that they check for metal particles in the transfer case oil, this is a reliable indicator of internal gear wear. A simple oil change might mask the symptoms temporarily, but won't address potential internal damage. This is considered a serious mechanical issue that typically requires prompt attention to prevent further transmission damage.

Thanks for sharing your experience with the transfer case issue. The gear grinding and rough shifting you described matches exactly what I went through. Did you remember the total repair cost for the transfer case overhaul? Also curious if youve noticed any oil leakage or other transmission problems since getting it fixed. My mechanic quoted quite a high price but Id like to compare before proceeding. My VW Sharan is still shifting roughly in the mornings and Im worried about causing more gear wear if I keep driving it like this. Hard to tell if its getting worse or if Im just paying more attention to it now.

Had the transfer case repair done last month, total cost was 330€ for replacing the defective gears. The gear grinding and rough shifting completely disappeared after the fix. The mechanic found significant mechanical wear inside the transfer case, confirming oil wear was the root cause. No transmission problems or oil leakage since the repair. The shifting is now smooth, even during cold starts. Looking back, I should have addressed it sooner, driving with worn gears risks more extensive damage to the transfer case and transmission. The repair cost was worth it to prevent bigger issues down the line. These symptoms typically worsen over time as gear wear accelerates, so getting it fixed promptly is important. The presence of metal particles in the gear oil confirmed replacing the gears was necessary rather than just an oil change.

Thanks for the helpful advice. I finally got the transfer case issue sorted out last week. After getting a second opinion, they confirmed significant mechanical wear inside the transfer case, exactly as suggested. The repair ended up costing 450€, a bit more than expected but worth every cent. The mechanic showed me the worn gears they removed, and there was obvious damage that no amount of oil changes would have fixed. They also found metal particles in the old oil, which explained the gear grinding I was hearing. The difference after repair is night and day. No more rough shifting or strange noises, even on cold mornings. They did a complete oil change while everything was apart, and checked for any oil leakage around the seals. Really glad I addressed this before it caused more extensive transmission damage. The car shifts perfectly now, feels almost like new. Definitely learned my lesson about not ignoring early warning signs of gear wear.