Gear Changing Issue

domderbyshire · Sep 5, 2018

Evening, All.

My 90 200 Tdi has recently developed a strange problem. Gear changing has become difficult, especially third gear. When in third, if I can find it, the gear lever has a lot of play. When trying to select first, reverse is often engaged. I’m either fighting to get the thing in gear, or can’t find first and third at all. Changing from fourth to fifth seems fine; first to second is not smooth.

The clutch master cylinder and slave cylinder are not particularly old and I’ve checked the adjustment inside the pedal box on the MS shaft. The MS is not leaking. The clutch pedal action seems normal.

This has all happened quite suddenly and I’m stumped as to what might be the cause of the problem. I need the car every day and have got a feeling that it’s going to break soon!

Any thoughts?

All the best,

Dom

Scooby22 · Sep 5, 2018

Check your gear lever selector housing for wear. Easy thing to check first.

This may help, depending on which gearbox you have but it gives an indiction of where to look, there are other video's on youtube of other gear selectors.

jamesmartin · Sep 5, 2018

domderbyshire said:
Evening, All.

My 90 200 Tdi has recently developed a strange problem. Gear changing has become difficult, especially third gear. When in third, if I can find it, the gear lever has a lot of play. When trying to select first, reverse is often engaged. I’m either fighting to get the thing in gear, or can’t find first and third at all. Changing from fourth to fifth seems fine; first to second is not smooth.

The clutch master cylinder and slave cylinder are not particularly old and I’ve checked the adjustment inside the pedal box on the MS shaft. The MS is not leaking. The clutch pedal action seems normal.

This has all happened quite suddenly and I’m stumped as to what might be the cause of the problem. I need the car every day and have got a feeling that it’s going to break soon!

Any thoughts?

All the best,

Dom

check yoke under turret is tight ,then look at rev plunger and turret bias springs

flat · Sep 6, 2018

What James Martin said, the reverse/1st fear thing is also probably the detent is stuck or the spring failed - I stripped mine down and regressed and order is restored.

The detent is the bit that sticks off the side of the gearbox turret

domderbyshire · Sep 6, 2018

Great and thank you for your suggestions. Well, I’ve fallen at the first hurdle. When I got all security conscious after my mate’s Defender was stolen I fitted a lock between the two gear levers that employs a special nut to stop people getting round the lock by simply removing the main gear lever. The trouble is, I can’t get the gear lever off, either... Theefore I haven’t properly investigated yet, although I suspect that when I do get in there your thoughts will be correct. Any ideas on removing the high security nut?

flat · Sep 6, 2018

The reverse of how you put it on?

domderbyshire · Sep 6, 2018

It’s one of those nuts that shears off leaving a smooth, circular surface with no purchase points or flats.

domderbyshire · Sep 6, 2018

Ok, got the nut off. They’re not that secure, after all. Everything looked ok, but the 5mm Allen grub screw on the shaft coming from the low/high ratio stick was suspiciously loose. Also, the metal bit with the big spring on is worn and the part where the ball sits into into at the top, I presume, has a plastic receiver that could also be very worn. I’m afraid I don’t know the correct part names. Anyway, I think with a new aluminium casting part and plastic bush thingy, all could be well. Off to drive it now to see if, in the short term, the grub screw was the issue, but the other parts will need replacing soon.

domderbyshire · Sep 6, 2018

Right, looks like I need a new FRC7155. Is there a bush that the ball sits into in the top of this part, or is it metal on metal? Also, is it worth replacing the bottom bush that the lower ball sits into while I’m at it, part http://www.onlinegearboxparts.com/product/defender-selector-nylon-cup-frc-5859/?

jamesmartin · Sep 6, 2018

no bush in that housing, lower one can be replaced

domderbyshire · Sep 6, 2018

Great. Thanks for that. I’ll get the parts ordered.

domderbyshire · Sep 6, 2018

Last question: is the nut that holds the gear lever on the spline M10?

Many thanks for all your help. I’ve got all the new bits I need on the way, but in the meantime the car is perfectly driveable and it’s a relief the issue wasn’t too serious or expensive!

jamesmartin · Sep 6, 2018

domderbyshire said:
Last question: is the nut that holds the gear lever on the spline M10?

Many thanks for all your help. I’ve got all the new bits I need on the way, but in the meantime the car is perfectly driveable and it’s a relief the issue wasn’t too serious or expensive!

yes its a m10 nyloc

domderbyshire · Sep 6, 2018

Thank you.

domderbyshire · Sep 15, 2018

Everything replaced and refreshed, including thread lock on the grub screw. After adjusting the bias spring a few times the gear change is much more precise and reliable. Hopefully all is good for the next 25 years! Thank you for all your help. Much appreciated.

Gear Changing Issue

domderbyshire

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Scooby22

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jamesmartin

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flat

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domderbyshire

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flat

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domderbyshire

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domderbyshire

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domderbyshire

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jamesmartin

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