On my way home Wednesday & the Medway Handy Van lost 3rd, 4th 5th & reverse
Needs a recon box costing & arm and a leg & 7 hours+ labour to de & re.
I'm not a happy handyman :-(
I don't recommend trying to run a Handyman service using SWMBO's Vauxhall
Corsa 2 door!
I was offered one tonight funnily enough. Existing customer wanted some
'fencing' done. Turned out to be a 7 acre paddock :-)
Whats the point in taking on bigger jobs that earn less money than smaller
I only do around 100 miles a week anyway, so it makes little difference. My
pricing is 'front loaded' so 2 x 3 hour jobs in a day earn me more than 1 x
8 hour job. Thats the crux of the 'little job' ploy.
That sounds very much like a gear lever linkage and not a gearbox
Does the gear lever operate normally and the gears not engage, or does
the lever feel "odd"?
I had very similar happen on my van (VW Transporter T4, lost all but
3rd and 4th) and it was simply the pivot point for the side to side
movement of the gear lever that had broken. Cost to repair, zero - I
made a little bracket to repair the broken pivot.
o Gearbox oil level -- low oil usually means pops out of 5th
o Gearbox linkage -- external to box (& also engine mounts)
o Shifter fork alignment/bent -- internal to box I'm afraid
Many FWD have weak engine mounts and excessive play
will prevent gear engagement in certain conditions. This is
more likely with steering at full lock, but still possible.
I assume no obvious whining initially (gear hardening worn
and wearing through or thrust bearing wear), in neutral (input
shaft bearing), under load (input/output shaft bearing),
(excessive) gear whine when in gear, no synchro probs
(requiring double declutching due to difficult engagement).
Many gearboxes do not have forged shifter forks even on
quite high-end cars/engines (thus will bend very easily). If
it will not go in then double declutch and try again.
Whine or screech during reverse when cold is typically a
throw-out bearing (clutch), external to gearbox. Rarely it
can be rear engine seal letting oil seep onto the clutch etc.
If the clutch is not fully disengaging (cable or bleed) then
on some boxes it can prevent certain gears being selected.
Use the right oil for the gearbox, do not get too smart as
certain friction additives are corrosive to some parts (eg,
synchros) and gearboxes can be very fussy re oil weight.
If you always cold-start and find shifting into 2nd is a
pain then investigate a compatible synthetic oil. Can
turn a rubber-gearbox into a butter-gearbox instantly.
I would try anything before a rebuilt box and even try a
main dealer - in case a known fault a) warranty b) scream
blue murder at them/GM re any TSB covering it and c)
it may be a quite simple fix. 8hrs to crack most boxes.
Most dealers are criminals on leave, care in community...
Rebuilt factory gearboxes are ok, but anyone else worries
me because there can be faults with its original manufacture.
Check for TSB, Tech Service Bulletin, along with any web
forums for any known causes & faults with a gearbox.
I had exactly this happen on a FWD Fiat van a few years back. AA bloke
tightened up some bolts that had worked loose and I was back in business.
IME when things *suddenly* go without any nasty noises it usually means
something needs reassembling rather than replacing
Thanks for sucha comprehensive reply, I appreciate it. First port of call
my regular garage who are brilliant. I assumed it might be a transverse
linkage but they checked everything out & diagnosed a gearbox problem -
didn't even charge me. Trasmission people reckon a shaft of some sort has
In article ,
Basically a gear box has three shafts. Input layshaft and output. The
input drives the lay gear cluster which has one 'half' of all the gears as
a one piece forging. There is usually a direct gear - 1:1 ratio, usually
4th, which simply locks input and output together while the lay idles
round. All the others are in constant mesh revolving round the output
shaft and are locked to that as required by the synchromesh mechanism.
The gears - or rather the synchromesh units - are moved by forks mounted
on selector rods. Usually three or more. The gearlever selects the one
needed and moves it back or forward from a neutral position to give you
1&2, 3&4, reverse, etc. It sounds very much to me like the selector
mechanism has failed in some way - hence only 1&2 being available. But on
every box I've seen the selector mechanism has to be removed before
dismantling the actual box so obviously can be repaired without the need
for a full re-con.
What you need is a specialist who fixes their own boxes. Many just fit
re-cons done elsewhere and are merely fitters. And those re-cons done
elsewhere are often of very poor quality. Since your van is low mileage
I'd be far happier having its own gearbox fixed rather than getting a so
called recon that could have done a very high mileage.