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grey gear cable alterations

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grey gear cable alterations

Postby bertsta2002 » Mon Jul 13, 2009 8:09 pm

well im still having problems with my gears not going into 2nd to well, crunchin sometimes and poppin back into neutral it happend alot more in the winter when the van was colder ,ive tried to alter the grey gear cable as little as 1mm at a time but without much luck, seems to be difficult because once i alter it it goes into 2nd as i stated before its not as if i cant get 2nd gear then i have to drive the van for a while before it crunches again , the vans a 2001 swb,

anyhow im wondering would it be advisable to get the garage to alter for me at a cost ?

im also thinkin of replacing the cable at a cost of the £85+ of the dealer but them im still in the similar spot of do i try adjustin it or get a garage to do it for me ,

any help on this matter would be grateful thanks brett
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Re: grey gear cable alterations

Postby winterheating » Mon Jul 13, 2009 8:36 pm

the grey cable needs to be adjusted longer,
fully pull the cable back, if it still doest go into 2nd easy, the cable has squashed too much, and you'll have to buy new one.

if it now goes into 2nd ok, check all foward gears, if now it doesnt go into forward gears, adjust 1mm a time till you get forward gears again.
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Re: grey gear cable alterations

Postby nokites » Mon Jul 13, 2009 9:34 pm

Raise and support the vehicle.
Remove the gearshift lever cover.
Shift the gearshift and selector levers into NEUTRAL
Using a suitable M10 x 30 mm bolt, lock the gearshift lever in NEUTRAL.

NOTE: The gearshift cables adjust automatically, when the retaining plates are released from the housings.


To adjust the gearshift cables.
Remove the clips.
Pull the retaining plates out of the housings.
Lock the gearshift cables.
Push the retaining plates fully inwards.
Install the clips.
Remove the bolt.
Install the gearshift lever cover.
Lower the vehicle.
OLD CHINESE PROVERB

Man who works for nothing and women who f****s for nothing ---------ALLWAYS GOT PLENTY TO DO
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Re: grey gear cable alterations

Postby bertsta2002 » Mon Jul 13, 2009 9:54 pm

thank you very much guys you both been a really big help and maybe saved me £90+ .
shame u cant buy ppl beers on here to say thanks :D ,
anyhow irll give the info a go and see how i get on
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Re: grey gear cable alterations

Postby Dan T » Mon Jul 13, 2009 11:45 pm

The problem is, it will need a new cable soon anyway, so you have the choice wether to get the thing sorted now and pay £84+VAT or fix it for a couple of months before you'll need to buy a new one anyway.
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Re: grey gear cable alterations

Postby Wares » Wed Oct 06, 2010 2:55 pm

Dan T wrote:The problem is, it will need a new cable soon anyway, so you have the choice wether to get the thing sorted now and pay £84+VAT or fix it for a couple of months before you'll need to buy a new one anyway.


Sorry for dragging up an old post but does most people find that adjusting it to be a short term fix?
Current stockist price in my area is £111 inc VAT and if it's a short term fix I'd rather just get it sorted.

Thanks in advance.
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Re: grey gear cable alterations

Postby winterheating » Thu Oct 14, 2010 12:54 am

Wares wrote:
Dan T wrote:The problem is, it will need a new cable soon anyway, so you have the choice wether to get the thing sorted now and pay £84+VAT or fix it for a couple of months before you'll need to buy a new one anyway.


Sorry for dragging up an old post but does most people find that adjusting it to be a short term fix?
Current stockist price in my area is £111 inc VAT and if it's a short term fix I'd rather just get it sorted.

Thanks in advance.


depends on what the cause of cable squashing, if its just age like adjusting cured it for couple of years, but if its because of gearselector turret stiffness or looseness then adjusting will only be short fix even replacing may not cure if you have these problems.
Also the outer cable can become loose which would certainly require a new one, as adjusting would only be short term, or even not work.

so best to take selector turret off and check condition, replace lower pinch bolt for stronger one, then check cable condition, especially the ends and the outer cable ends for loosness, then decide what to do.
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Re: grey gear cable alterations

Postby Mikey B » Thu Oct 14, 2010 9:09 am

Thing is im not convinced its the cable when its just crunching into 1 gear. If its a cable problem i find its hard to select all the back gears (2nd, 4th + reverse)
Im not saying its never the cable but in my experience i have found it to be a fault inside the gearbox when only one gear crunches.
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Re: grey gear cable alterations

Postby jacko1611 » Thu Oct 14, 2010 7:50 pm

same ere mikey. done quite a few first and reverse synchros recently on fwd.
not another E G F*****G R!
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Re: grey gear cable alterations

Postby winterheating » Thu Oct 14, 2010 8:29 pm

but normally synchros only fail because of the above problems and they get left crunching forever, until its to late.
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Re: grey gear cable alterations

Postby chriswalk » Tue Feb 15, 2011 2:49 am

Mikey B wrote:Thing is im not convinced its the cable when its just crunching into 1 gear. If its a cable problem i find its hard to select all the back gears (2nd, 4th + reverse)
Im not saying its never the cable but in my experience i have found it to be a fault inside the gearbox when only one gear crunches.


hve the same problem ith mine. pain in arse getting 2nd 4th and reverse. not all the time but its a daily event ealing with gears.

glad to read so many posts regarding this and to read what the most likely problem will be. will mention the grey gear cable to mechanic tomorrow.

repeating myself i know, but like i mentioned in other posts. i paid a garage 26 october 2010 £271.00 to fit a new gear selector to my van, £161.00 for the part.
same problem with gears came back recently and then thats when i found out the part was not new, and in my opinion not even a recon part. ive noticed that the so called reconed gear selector and the gear change cable have some red paint on them. that says me that it my old part still on the van because if it had been replaced then the selector wouldnt have paint on like the cable does.

saw the garage boss today and he fobbed me off saying the red stuff is the red sealent used when refitting the reconed part.
taking the van to a transit specialist tomorrow to fix problem and to ask his advice on whether or not the selector is a recon part or my old one.

then its legal action time, trading standards etc if he says its my old one.
might only be £161, but i will go on and on till i get my money back.

ps, sorry to go on and on lol.
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Re: grey gear cable alterations

Postby winterheating » Tue Feb 15, 2011 4:45 pm

chriswalk wrote:
Mikey B wrote:Thing is im not convinced its the cable when its just crunching into 1 gear. If its a cable problem i find its hard to select all the back gears (2nd, 4th + reverse)
Im not saying its never the cable but in my experience i have found it to be a fault inside the gearbox when only one gear crunches.


hve the same problem ith mine. pain in arse getting 2nd 4th and reverse. not all the time but its a daily event ealing with gears.

glad to read so many posts regarding this and to read what the most likely problem will be. will mention the grey gear cable to mechanic tomorrow.

repeating myself i know, but like i mentioned in other posts. i paid a garage 26 october 2010 £271.00 to fit a new gear selector to my van, £161.00 for the part.
same problem with gears came back recently and then thats when i found out the part was not new, and in my opinion not even a recon part. ive noticed that the so called reconed gear selector and the gear change cable have some red paint on them. that says me that it my old part still on the van because if it had been replaced then the selector wouldnt have paint on like the cable does.

saw the garage boss today and he fobbed me off saying the red stuff is the red sealent used when refitting the reconed part.
taking the van to a transit specialist tomorrow to fix problem and to ask his advice on whether or not the selector is a recon part or my old one.

then its legal action time, trading standards etc if he says its my old one.
might only be £161, but i will go on and on till i get my money back.

ps, sorry to go on and on lol.

Getting confused over selector turret and cable problems.

The slector turret wont cause that anyway, what happens to the turret is the shaft siezes and you cant get any gears or if its still able to spin but jammed up and down will be able to get a front gear and back, whever the shaft is stuck, normally at neutral position so only get 3rd and 4th.

If the selector is stiff like they are when the bearing seal is failing before totally seizing solid then that can cause to much force on the cables, the outer cables can come apart and not get full selection, the grey (back and forward cable) gets squashed so not enough length to reach furthest reached gear, which is 2nd then reverse, 4th is always ok as its not as far to travel as the cable is in the middle not stretching to one side, the difference between going in and crunching in is litterally 05mm of cable length.

If it were just wear and the grey cable were squashed, then 2nd would start playing up first, then driver would get used to it and force it in a bit more, all the time cable getting worst when it starts to affect reverse its pretty bad, and the constant use like this will damage synchros, so even after new cables, and selector if needed, the synchros will be goosed....

omeone who left his a least 2 years crunching into 2nd :roll: , i checked adjustment but it was the outer cable coming loose on one of the ends, a new cable and no problems with synchros or anything.

selector stiff, pinch bolt loose, outer cables loose, inner cable squashed or synchro failed it could be any of them.
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Re: grey gear cable alterations

Postby mobilemaddness » Thu Jan 23, 2014 7:46 pm

Hi all new to this site so please let me say thanks in advance for any help.

I have a 2006-06 reg transit tourneo GLX SWB (NOT the face lift one with big square). Sometimes it makes a slight grinding noise when selecting first gear. If you put it in really slow it doesn't usually do it. but no matter how fast you do it, it doesn't feel like its gone in fully but it has. All the other gear work fine and go in really easily. Looking at the paper work it had a new pinch bolt fitted 2 months ago. Please can anyone advise as whether or not it is the cables or the box thanks.
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Re: grey gear cable alterations

Postby robnw21 » Fri May 16, 2014 10:00 am

Hello swb transit frint wheel drive
Driving along can get all gears fine
Occasionaly ill go to change gear and the gear leaver goes all sloppy and wont change gear
Then after a wiggle I can reselect gears
Am I right thinking gear linkage cables have stretched ???

Thanks for any replys cheers
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Re: grey gear cable alterations

Postby bob builder » Wed May 21, 2014 4:08 am

Can be a loose selector bolt , can be outside or inside the box,worst way its a half hour job if you know how to do it. When in 4th gear the gear knob should only move about 10 mm left to right with very light finger pressure,any more and i would check the bolts . Loose bolt can drop into the box and wreck the gears or diff.Cost can write off the van.I was very lucky ,stopped van and recovered bolt after a lot of effort with a camera and magnet. 2 minuits to check the outside bolt.
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