MK7 2.2 63kw TDCI FWD Gears won't stay on, why?

[pp5858]

Hi,

I just recently purchased 2007 Transit 300M that has been driven 300 thousand km. It has 2.2 63kw TDCi engina and it is fwd.

The gears go on well and everything works, but there is 2 issues. If you put the gear on carelessly e.g. 2:nd, it might immediately after release of clutch drop off and will make rattling noise and be kind of middle position between neutral and 2:nd. This has happened with 2:nd 3:rd and Reverse at least.

Also if I drive over those 10cm jumps in the roads e.g. with 2:nd or 3:rd gear with low speed, the gear might drop off.

The gear stick is quite preceise and no syncronize problems is visible. I thought that this could be the stick mechanism problem or maybe the engine will move too much on accelerating and breaking or so. I didn't yet find any similar stories, could anyone help.

btw. the car is in Finland.
btw2. really like this forum

br,
PP

[loot]

Stretched cables?

[pp5858]

Ok, that sounds possible. Does it sound like so common symptoms and issue that I could order the cables and arrange change for them or could it be something else?

I have 0 knowledge on the newer MK7 model so I really don't know much on this.

[Altransit]

It could be cable, or problems with the selector unit on top of the gearbox

[pp5858]

This is actually guite bad, today it happened several times when running really low torque on 2:nd gear. It drops of from the gear and then stays there close to 2:nd gear but rattling and making anoying noise (not like metallic extra bad noise).

I thought that this surely is like common problem but it seems it's not. Some people here said that it could be corrected by skilled mechanic by tuning the cable or something.

[pp5858]

Some repair shop even suggested that it could be actually transmission failure that it kicks off the gear, but it doesn't feel like that to me.

I have scanned the fault codes with FORScan but it only gave EGR 0404 and some old brakefluid errors, but nothing on transmission. Would there be any pointers, fault codes or numbers that could distinquish and help to locate the problem. So if it would be transmission, will there be any fault codes on that.

Is there any way for me to detect that is it the cables, the upper part mechanism or the lower part mechanism outside the gearbox that has the issues. I have opened the leather over the gearstick but didn't much understood from there and put it back. If it is tuning the cables, is it done from inside the cabin? Is there any way to measurre it or is it just trial and error and testing?

[Altransit]

My first call would be to remove the selector unit and fit a new bearing, because it's such a common fault, and does indeed stop it going into gear properly.
The bearing is only available as a spare part, for the Mk6 selector, but is exactly the same part as the Mk7 one. You could also check that the pinch bolt on top of the selector is fully tightened

[Punto443]

viewtopic.php?f=18&t=111349
The selector would be my first port of call, even just for an inspection

After that you could try adjusting or replacing the cables.

[pp5858]

Tnx, for really good pointers to previous thread + the MK6 sparepart info. I will have to look those threads throughly (only gave quick view so far) and look can I get the sparepart from dealer.

Also this morning related to this same thing I noticed that cold car (4 deg celsius in Finland) this morning, it was bit hard to get 1:st gear on until the car warmed up. I started to think that could this be also clutch problem, but I still think that the selector bearing is now pretty safe to replace anyway. If there is any ideas on how to rule out the clutch or the whole transmission that could help also.

But anyway have got really good help so far so thank you on those.

[pp5858]

phew, ordered 6 152 850 bearing 10.7EUR, the whole top would have been 500+EUR for MK7. It though takes 1wk to arrive and I have 5h reserved at my friends shop for repairs tomorrow, so will have to try to have him something else to work with. It has to be the non working Eberspächer heater for tomorrow.

[pp5858]

Friday the repairshop informed that their diagnostics is that the gearbox itself is gone, and suggested to search used gearbox and replace it. They did some tuning that could help the problem, but I don't know yet what (will get the car today) and hear more monday.

Will it function like that if the synchro has gone on the gearbox? In my opinion, the gears will go on pretty smoothly and the gearbox sounds really ok. But the gears just sometimes drops off. Will keep updated here how it goes.

[pp5858]

It didn't get any better with the work they did with the cables. I'm not sure did they do it exactly as it should be as they said that there was no possibility to adjust them.

[Altransit]

Friday the repairshop informed that their diagnostics is that the gearbox itself is gone, ...........................................They did some tuning that could help the problem,

What diagnostics did they do?
What tuning did they do?

I'm slightly concerned that they're jumping to conclusions before checking the simple stuff

[ake]

I would change the bearing first
Then change the cables

[pp5858]

Some update on this on the current status

What diagnostics did they do?
What tuning did they do?

I'm slightly concerned that they're jumping to conclusions before checking the simple stuff

I'm not sure exactly what they did. I just asume that they looked that the cables are moving and maybe tried to ease up by lubricating + if there is something to adjust but I clearly got the feeling that they didn't exactly know how to handle it.

Yes I didn't neighter like the thing that they promptly informed that it is the gearbox (althoug at the current info, it might be actually so, but simple things still not done [more later in this thread]).

I would change the bearing first
Then change the cables

Yes, so I found out (called 20+ places) one place that actually was familiar with this, they offered 3h with quite high hourly price 85€ to lubricate the selector + change the bearing + sealing that I already purchased. I informed that to the seller company and they said that it is expensive and they have cheaper repairshop and wanted me to return the car for repairs.

Took the car 100km+ back to shop and train back. Waited 2+ wk and then they informed.

They have changed the stick + the mechanics to new because that was the fault and now it is working. I said good, took train there and the man was waiting me in the station. Within 1km the seller missed 2:nd gear once and had problems getting gear on and kept hand on the stick.

Ok took the car back and it is exactly the same. They still didn't change the selector bearings even though I mentioned that to them.

Now the situation is, no-one has opened selector or changed bearings. When I drive the car if I put to reverse, fully clutch down, gear fully place, release the clutch the gear 30% of the time jumps back and is in middle of R and N giving sprocket rolling noice (not loud) and I will have to put gear again to R. If I keep it there, of course it stays there.

Same happends at least for 2:nd gear similariliy 30%.

Problems getting 1:st gear on, it is kind of that something is blocking while trying to engage 1:st and have to try to find out with stick or moving car gently forward (seems maybe to work). Had to start with 2:nd sometimes as I couln't get 1:st on.

If having 1:st gear on and clutch fuly down the car doesn't crawl forward. If I release clutch like 6cm then it starts gently moving forward, so it seems to me that clutch should be ok.

So now the seller offered to puchase car back as they don't want to do 3000€+ transmission repair for it.

Still tried to offer the selector repair but they didn't somehow liked that at least for now..

Still bit puzzled how to continue as I have invested effort + repaired myself other things on the car as if it would be easy cheap fix I would happily keep the car but if it is really the synchronization on the gearbox or flywheel or clutch then it is not worth keeping it.

Sorry for long post, wanted to be thorough.