Gear Selection Problems

[aahridey]

Hi,

I'm having gear selection problems - i've just checked the Wiki and can't find an answer so thought I'd ask you all.

I've got a 1984 T25 with a 1.6td JX engine fitted. When starting and pulling away everything seems fine until I go to change from 3rd to 4th and it doesn't want to come out of 3rd.

If while moving I press the clutch in and get it out of 3rd gear it only seems like it "half" comes out of gear and isn't in neutral as such. No other gear can then be selected unless you stop the vehicle, wiggle the gear lever with the clutch in until it feels free and finds neutral again. You can then start off again as before.

If stopping isn't an option then you can put it back into 3rd while moving with a slight crunch until you can find a place to stop.

You can however change from 2nd to 4th and back again without too many problems although occasionaly it does the same thing in that gear too.

Recently had a new clutch and slave cylinder so that should all be fine. The fluid level remains unchanged so I don't suspect the clutch to be at fault.

Occasionally when moving off I can get through the gears and into 4th no problem but again when it comes to changing into 3rd it doesn't want to come out of gear.

Otherwise all sounds and feels good when driving, though reverse is hard to find.

This problem has kind of come on over night and hasn't been a gradual deterioration which makes me think I may have bent something when finding reverse when i parked up.

Hope this all made sense.

I'm hoping it's a linkage problem and not something much worse. Does anyone have any ideas where I should start?

Many thanks, Mark

[Aidan]

Mark is this a four or five speed box ?

[aahridey]

Ah sorry, it's a 4 speed box.

[wiggy]

hi had the same problem it turned out to be the cup at the end of the rod which also had a little bend on it all good now

[aahridey]

Ah ha, this sounds promising but not sure what you mean. Where abouts in the linkage is this?
Manmy thanks, Mark

[aahridey]

Any further info, opinions or advice would be appreciated.
Cheers, Mark

[Ralf85]

There is a nylon ball and other bits at the base of the gear lever. It might just be this. This wears out over time and can cause gear selection problems. Mine fell apart and was replaced by my garage in less than an hour. If it is that replacement kits are readily available. On Brickwerks it is called a gear lever repair kit and costs £21 but make sure you buy the right one. If you e-mail Brickwerks and give them details of engine type, gear box type eg 4 speed and age of vehicle within 24 hours they can advise if you are not sure. Check it out. My gear change tightened up a lot after the changeover.

[aahridey]

Hi,

I think I've worked out that the problem is happening because when the vehicle is travelling in 3rd gear the gear lever is "flopping" to the right and getting stuck in a notch it shouldn't be in.

I've just ordered the gear lever repair kit from Brickwerks so am hoping that will help. Measured the gear lever as 14mm so hopefully got the right one

Do you all reckon that'll do it or should I also be looking elsewhere. God (gearbox) willing we're going away this weekend so I want to stand the best chance possible of getting there!!

Thanks, Mark

[Ralf85]

That is the cheapest and easiest problem to fix. Even if it's not the total answer, it will tighten up the gear change. Most of our vans are so old these bits will fail at any time soon if not replaced and suddenly you can't change gear at all, so a good job done anyway. Let us know if it works out.