Honestly, this is one of the most frustrating situations and way more common than people realize. The good news — you don't necessarily need your old employer to cooperate anymore. EPFO made it easier a few years back.
First thing: go to the EPFO Unified Member Portal (unifiedportal-mem.epfindia.gov.in) and log in with your UAN. Check if your old employer has linked and verified your KYC — Aadhaar, PAN, bank account. If all three are verified, you can actually raise a transfer claim (Form 13) online WITHOUT the old employer's approval. The claim goes to either your old employer or new employer for approval — choose new employer since your old one is ghosting you.
But here's the thing most people miss — if your UAN was activated and KYC was seeded by the old employer, the transfer can be approved by your NEW employer's HR alone. Go tell your new employer's HR department this specifically. Many new-employer HRs don't know they can approve on their end.
If that doesn't work, file a grievance on EPFIGMS (epfigms.gov.in). Be specific: write the old establishment code, your PF account number, date of leaving, and that employer is non-responsive. EPFO Regional Commissioner offices actually act on these — they can mark the employer as defaulter and process your transfer anyway. I've seen this work within 45-60 days when the grievance is written properly.
Also call 1800-118-005, the EPFO toll-free. Morning between 9-10 AM has shorter wait times. Keep your UAN ready.
About the tax concern — you're right to be careful. Withdrawal before 5 years of continuous service attracts tax. But transfer is not withdrawal, so transfer this amount freely, no tax issue at all.
My strong recommendation: raise the online transfer claim today itself choosing new employer as approving authority. Simultaneously file on EPFIGMS. These two together usually break the deadlock within 2 months.