[pta320]

Just accept the total loss and get rid of the clunker. For 5L there are much better used cars available than Polo. You can pick an excellent well maintained low run 2012-2013 Honda Civic top end model which I feel is leagues above Polo in every aspect.

Rest is your decision, I won't suggest getting it repaired outside. A critical part like DSG gearbox which is already prone to problems is not worth repairing and then expecting it to last. There is a possibility that a stone damage strong enough to gape through the casing would have damaged a lot more than you think and sooner than later it will snowball into a huge debt. Just get rid of that thing unless you have some emotional attachment with the car, in that case, there are already suggestions given by others here.

[iron.head]

IMHO i would try to get a weld repair done instead of a housing change. Reinstalling the GB in a new housing in itself may be very complex. It might just be a crack so just weld it on the outside (considering this is something doable and an expert welder is available).

I once stripped the threads on the engine side of an oil drain nut and consistently did the m-seal fix for 2 years and it never leaked. Considering GB fluid is replaced even less often it might be the perfect fix.

[satyabrata.dash]

I faced a gearbox damage, 2 months back. TC AT Gearbox on my Figo broke when I hit a stone, I didn't realize there was a leak until the pickup and gear changes became very slow. Estimate of repair was about 4.5 lacs, but insurance company insisted on opening the gearbox and checking actual damage. It was just the casing, which got replaced in under 1 lac.

A local mechanic actually told me to get it welded and it shouldn't be a problem. But I still have warranty on the car and didn't want to void it. Because of the push and pull between insurance company and the service center, it took one whole month for the repair.

[vvbkumar]

Apologies for the delay in posting the update, i was bogged down on office and personal front on few engagements.

First of i would like to thank the community for the support and advice. I have heard from surveyor, VW SA and the VW service centre guys about this thread and had received multiple calls especially from VW guys regarding this thread.

I though the best way forward would be to replace the GB as suggested by many and after going through the process with multiple FNGs, it did give me a bit of confidence.

I have approached couple of FNGs for the repair/replacement of GB and got the quotes for repair. they ranged from 2.0 - 2.5 L. Post that i gave the details to surveyor/claims manager to ensure the claim can be processed. We identified one and then car was towed to the FNG from the workshop.

Gearbox was replaced for around 2.2 L (inclusive of GB oil, reset/coding of mechatronics and labour charges). My claim went through and it was approved for around 1.8 L (post negotiation).

Except a micro second lag when i accelerate (hope it is not my imagination), i am not seeing any significant difference pre and post incident. However, i have decided to treat it like a new car and want to give some "run in time" for the gearbox to settle. After driving close to 200 kms (city & ORR), so far i can find little to no issues with the gear box.

Even though it was quite a hassle, i felt that this was best course of action.

Next steps: FNG SA recommended to do a GB oil flush & change after 2-3 months or 1000 kms (which ever is earlier).

Once again i appreciate all the support, advice and hoping my other interactions/contributions in this forum will be more positive ones .