D2 gearbox issues

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Stanleysteamer said:
Yes and they are cheapish. When I did mine one of the six mounting fittings was bust so some other cackhanded tw@t had been in there at some point. So I cleaned it very carefully and glued it together with JB weld, it's held ever since. I also couldn't get the new sump gasket to stay straight on it so put the old one back on, it has never leaked.
If the colour is at all brown, change it.
As you can see I have been ruminating about the temp at which you did it and i am sure it wasn't anywhere near too hot. Maybe the not being in P would make a difference but I honestly don't think so. Only you having another bash at it will enlighten us. And my memory may be playing up and I may put it back into P after leaving it in Neutral while I ready my kit, you have got me wondering now!
I also was thinking, what if the previous owner took the box off, held it vertical with the rear flange and whatever on the floor or bench and just poured a bit of ATF in? that could over fill it for sure.
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Easily but a mechanic did this for me on Monday and is a second hand box



For science or something I will get a catch can and this time let it clear itself out and then drive it a bit if it shows symptoms of low fluid then I'll do a new filter if not I'll just run it for now and do a service later


I only have 4 liters of fluid in my stocks too

I used the rags (old t-shirts) laid on top just to cover the puddle
 
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Icantthinkofagoodusername said:
Easily but a "mechanic" did this for me on Monday and is a second hand box



For science or something I will get a catch can and this time let it clear itself out and then drive it a bit if it shows symptoms of low fluid then I'll do a new filter if not I'll just run it for now and do a service later


I only have 4 liters of fluid in my stocks too

I used the rags (old t-shirts) laid on top just to cover the puddle
Click to expand...
Best of luck mate. It's not fun crawling around in ATF, it is such slippery feckin stuff! It does sound like a load came out. and yes I've had it on my face and in my eyes. right pain!
 
I commonly work in my cars and have a few project cars so I get most stuff except auto boxes which due to their inherent complexity scare me so any advice is appreciated


The truck has been remapped and all was fine with the running until the old box wore out

If you are in the UK you might know these guys but from memory the mapping was done by a Scottish company (I think it was called 'Alive "something") it was written on the floor mats
 
Icantthinkofagoodusername said:
I commonly work in my cars and have a few project cars so I get most stuff except auto boxes which due to their inherent complexity scare me so any advice is appreciated


The truck has been remapped and all was fine with the running until the old box wore out

If you are in the UK you might know these guys but from memory the mapping was done by a Scottish company (I think it was called 'Alive "something") it was written on the floor mats
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You and me both re autoboxes, especially electric controlled ones. I've rebuilt standard manual boxes, no problem. But I don't think I'd even want to take the cover off the valve chest of an auto.:eek::eek::eek::eek:
Probably these people
https://www.alivetuning.com/
Must get some kip so will catch up with you later!
Stan!;)
 
Stanleysteamer said:
You and me both re autoboxes, especially electric controlled ones. I've rebuilt standard manual boxes, no problem. But I don't think I'd even want to take the cover off the valve chest of an auto.:eek::eek::eek::eek:
Probably these people
https://www.alivetuning.com/
Must get some kip so will catch up with you later!
Stan!;)
Click to expand...


Think it was them yeah and I probably need to do the same I'm sure from them the ecu is solid I'll put some updates on in the morning after I've messed with it
 
sierrafery said:
So do you think that if there is a vent pipe in the rear output housing the oil has no pressure within the box? The breather has nothing to do with the lubrication circuit's pressure, it has to do with air, if you remove the filler plug of a running gearbox after it was filled and closed oil will come out every time unless it ddnt leak out some of it especially if the filter is full of muck, two relevant quotes:

1. The gearbox features a pressure lubrication system and is cooled by pumping the lubricant through an oil cooler.
2. Breather allows the transmission to breathe air when the air inside transmission expands or contracts due to heating and cooling of lubricating oil during vehicle running. Breather allows the hot air to escape and cool air to enter into the transmission to prevent overheating issue.
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Then I am afraid I will have to respectfully disagree with you on this.

It's called a level/filler plug for those reasons. It has nothing to do with the "pressure" side of the gearbox operation as the plug is in the sump on the "suction" side of the circuit or should we say the vented atmospheric side.
The procedure for checking the level is with the engine running and removing the level plug. I have never seen a warning of oil under pressure.
I have the luxury of having a dipstick on 1 of my autoboxes so why doesn't oil come up the tube?

The breather is there to let the air and oil expand and not pressurize the box otherwise it would leak oil out seals?

The OP problems will really only become clear when he drops the sump, changes the filter and fills with the correct amount of fluid.
Then finds out that he gets 10-11L out from a drain instead of the 4-6L. Then we know the guys that fitted the box knew nothing and wears spurs;).


J
 
marjon said:
Then I am afraid I will have to respectfully disagree with you on this.

It's called a level/filler plug for those reasons. It has nothing to do with the "pressure" side of the gearbox operation as the plug is in the sump on the "suction" side of the circuit or should we say the vented atmospheric side.
The procedure for checking the level is with the engine running and removing the level plug. I have never seen a warning of oil under pressure.
I have the luxury of having a dipstick on 1 of my autoboxes so why doesn't oil come up the tube?

The breather is there to let the air and oil expand and not pressurize the box otherwise it would leak oil out seals?

The OP problems will really only become clear when he drops the sump, changes the filter and fills with the correct amount of fluid.
Then finds out that he gets 10-11L out from a drain instead of the 4-6L. Then we know the guys that fitted the box knew nothing and wears spurs;).


J
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I've just checked because all this was making me wonder, and yes the filler/level plug IS in the sump and thus below or at least occupying the same space as the filter.
 
marjon said:
1.....having a dipstick on 1 of my autoboxes so why doesn't oil come up the tube?
2. The breather is there to let the air and oil expand and not pressurize the box otherwise it would leak oil out seals?
Click to expand...
1. exactly cos the breather system has nothing to do with the oil only with air that's why IMO .
2. IMO it's there to let only air to expand hence it's name and the explanation in the quote in my previous post

we can agree that we disagree but try to explain how can you overfill the autobox through the filler hole without wanting to do that on purpose cos i doubt that those who filled the box did it with some pressure system through the cooler pipes or some other way
 
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I tested the car this morning after it kicked out the fluid and it was even worse with trying to engage gears it took 10 mins before the box would engage

So i sat thinking I'm going to have to spend more money on this, then i noticed the word 'more' i haven't paid the mechanic who did the job yet and since he got this box and fitted it, it's going back to him to fixed as it's his parts and his problem to fix and I'm not messing with it any further. Something is wrong with this box and it goes deeper than it being greatly overfilled i think and overfilling it had made it work enough to be sold to my mechanic and satisfy him that it was good


So this me finished working on the cars gearbox for now, i can force it to drive to his workshop then I'm going to let him fix it

Thanks for everyone's advice and help on this and making a massive amount of information about these gearboxes in this thread and i hope it helps others that are working on their D2 s like it helped me
 
Icantthinkofagoodusername said:
I tested the car this morning after it kicked out the fluid and it was even worse with trying to engage gears it took 10 mins before the box would engage

So i sat thinking I'm going to have to spend more money on this, then i noticed the word 'more' i haven't paid the mechanic who did the job yet and since he got this box and fitted it, it's going back to him to fixed as it's his parts and his problem to fix and I'm not messing with it any further. Something is wrong with this box and it goes deeper than it being greatly overfilled i think and overfilling it had made it work enough to be sold to my mechanic and satisfy him that it was good


So this me finished working on the cars gearbox for now, i can force it to drive to his workshop then I'm going to let him fix it

Thanks for everyone's advice and help on this and making a massive amount of information about these gearboxes in this thread and i hope it helps others that are working on their D2 s like it helped me
Click to expand...


Also im not holding back money to the mechanic for this, i only picked it up on Friday and he hadn't invoiced it then
 
Icantthinkofagoodusername said:
I tested the car this morning after it kicked out the fluid and it was even worse with trying to engage gears it took 10 mins before the box would engage

So i sat thinking I'm going to have to spend more money on this, then i noticed the word 'more' i haven't paid the mechanic who did the job yet and since he got this box and fitted it, it's going back to him to fixed as it's his parts and his problem to fix and I'm not messing with it any further. Something is wrong with this box and it goes deeper than it being greatly overfilled i think and overfilling it had made it work enough to be sold to my mechanic and satisfy him that it was good


So this me finished working on the cars gearbox for now, i can force it to drive to his workshop then I'm going to let him fix it

Thanks for everyone's advice and help on this and making a massive amount of information about these gearboxes in this thread and i hope it helps others that are working on their D2 s like it helped me
Click to expand...
So it WAS overfilled and being in P made no difference?
It is impossible to overfill unless you do what I said about holding the box upright and fill it like that.
This is totally mad, and the person who flogged the box is a crook.
At least it looks like it.
Sorry for you, mate.:(:(:(:(
I have heard that secondhand boxes are as rare as rocking horse poop.
What happened to the original one? Might be worth getting it rebuilt by Ashcrofts or someone, if you can still get hold of it.
Whatever, best of luck.;)
 
Stanleysteamer said:
So it WAS overfilled and being in P made no difference?
It is impossible to overfill unless you do what I said about holding the box upright and fill it like that.
This is totally mad, and the person who flogged the box is a crook.
At least it looks like it.
Sorry for you, mate.:(:(:(:(
I have heard that secondhand boxes are as rare as rocking horse poop.
What happened to the original one? Might be worth getting it rebuilt by Ashcrofts or someone, if you can still get hold of it.
Whatever, best of luck.;)
Click to expand...


My old box started pouring smoke on the m25 pulling an empty car transporter 2 hours into the home journey after 4 hours loaded on the way there (with a Ford sierra for weight reference) and it when completely dead with no gears at all (i forced it to a services still with drive up until i stopped) somehow i got it to engage after it sat on my driveway for a bit and i needed it moved but it had drive for less than a minute the old box is shot for sure but could be salvaged

It is annoying that i was caught out with the 2nd hand box but maybe it's a lesson that i should have got the old one refurbished from the get go
 
I am wondering if, when one was removed the person doing it accdentally let the torque converter fall out and/or didn't put it back in properly and fecked the pump. Too easy to do that. But might account for why the box don't work well until it's been running a while even when overfilled.
Just saying, as autoboxes are a black art to me!
 
Stanleysteamer said:
I am wondering if, when one was removed the person doing it accdentally let the torque converter fall out and/or didn't put it back in properly and fecked the pump. Too easy to do that. But might account for why the box don't work well until it's been running a while even when overfilled.
Just saying, as autoboxes are a black art to me!
Click to expand...

I'm not sure one it's going it shifts fine and goes on the torque converter as normal but takes ages of idling before the gearbox will engage in the first place it just sits there and after a while I'll shift to drive again and the revs drop as it finally engages but now it takes 15 min and last time i had to rev it up a bit in park then go to drive for it to engage

Like I'm spinning up a low efficiency pump because of damage to it....

I spoke to the mechanic to day and he filled it so ikd how but the may have filled it wrong

He taking the truck tomorrow so I'll mention the torque converter and pump to him
 
Icantthinkofagoodusername said:
I'm not sure one it's going it shifts fine and goes on the torque converter as normal but takes ages of idling before the gearbox will engage in the first place it just sits there and after a while I'll shift to drive again and the revs drop as it finally engages but now it takes 15 min and last time i had to rev it up a bit in park then go to drive for it to engage

Like I'm spinning up a low efficiency pump because of damage to it....

I spoke to the mechanic to day and he filled it so ikd how but the may have filled it wrong

He taking the truck tomorrow so I'll mention the torque converter and pump to him
Click to expand...
Hope he is an honest bloke because being dishonest may well save him money, and cost you money.
Crossed fingers for you!!;)
 
Kenbo said:
Interesting thread, please come back to tell us of the outcome. (Many don't bother, that's why I ask)
Click to expand...

Yeah who would do such a thing?

So I have an excuse at least.
So nothing really happened I borrowed a ranger to do the towing I needed and just left it


Just recently I decided that I should fix it and I brought fresh oil and a filter and I am going to start work on it today I'll put an update on with what happens

My mechanic told me it was filled properly as he filled it through the dipstick tube... that it doesn't have (funny that) so I'm going to fix it myself

Oddly enough he hasn't asked for any money yet? (Also funny)

Just wondering now should it be in neutral or park to top up fully? (While the engine is running)

Thanks
 
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