Manual Gear Selection Problem

[Guest dbc]

Friday night - looking forward to the weekend... then my wife 'phoned:"The gearbox has gone and I'm stuck at the bottom of the hill." As you can guess instant depression struck...

 

Thanks to the help of a local farmer (and his superb 1960's cow crap covered Land Rover) I was soon on site...

 

Discovered that can actually get just two gears -think it's third and fourth, judging by the struggle I had getting the car on the move. Anyone experienced similar problem with 1996/7 manual 2 ltre Galaxy?

 

Had some problems with the search engine - this morning - but would appreciate ANY help or pointers. Needless to say I've had the Haynes manual out and it seems to be suggesting that it's unlikely to be as simple as removing the gear lever console cover and making minor adjustments!!

 

Well that's me depressed for the rest of the weekend...

 

Advice, Valium supplies or free beers would be most welcome

 

Depressed Dave <_<

[Guest vr6galaxy]

Have you checked the selector cables are still connected at the gear box end? there have been a couple of post on this occurance before <_< it seems the cables ends unclip and you loose the abillity to select gears :angry:

[Guest dbc]

Thanks for the suggestion. Much appreciated. I will keep my fingers crossed!

 

I'm hopeful that as I can still get two gears it's unlikely to be the dreaded "selector bolt in the gearbox syndrome" as suffered by one member.

 

I've set aside Sunday to check things out....so - in the meantime - any more useful pointers would be gratefully received.

 

Thanks

 

Dave C

[Guest MATT]

i had trouble with my corsa, would not go into 1st and 2nd, but would in 3rd, 4th, and 5th, found out that it was the gear linkages, that go from the gear stick, to a box near the engine - got it to a 're-pair' man, who replaced the links and now the gears are brilliant!!

 

matt <_<

[Guest dbc]

Thanks Matt. Thing is I will be fixing the fault - whatever the cause - myself as I just can't afford to pay garage prices these days.

 

Do hope I don't have to spend two days working on it in the freezing cold driveway!

 

By the way anyone got/used the special tool for setting the gear lever in neutral(No 16-083) or can give me an idea of the likely price?

 

Any help/advice appreciated.

 

TTFN

 

Dave C

[Guest MATT]

don't know about the galaxies manual box, (because ive got an Auto, hehehe), but you may find that their is a load of 'arms' near the gear box, all having 'joints', these were worn out on my corsa, giving too much play, they replaced them, and it really tightened up the gear stick, making it a joy to drive.

 

matt.

 

if you want me to post a picture - just say!!!

[Guest vr6galaxy]

Unlike a corsa a manual Galaxy has a cable operated selector system, no selector linkage arms or links to wear only cable to stretch or snap, although the most common failure is the connector clips on the gearbox end

[Guest dbc]

Thanks for your input guys!

[Guest neil_wiles]

DBC

 

If the cables are still attached to the linkage and there appears to be selection only for two gears it may be the screw which holds the selector to the shaft has sheared. I hav this on my MK1 1.9 Tdi. There is one on the external selector shaft where the cables connect to the sahft and one inside the gearbox where the actual selector connects to the shaft. They are 7mm Metric Fine bolts very rare and if you cannot get one from the Ford dealers they are the same as fitted on the deisel pump of a 406 !

 

If it is the selector shaft let me know I beleive I have the list of instructions to change the bolt without removing the engine/gearbox assembly from the vehicle.

[Guest dbc]

Thanks for the info Neil...I will let you know! Should have been under the car today - but my wife decided we needed a 12 mile walk in the Dales!! Decided it sounded much better than getting further depressed about what I'll find!!

[Masked Marauder]

They are 7mm Metric Fine bolts very rare and if you cannot get one from the Ford dealers they are the same as fitted on the deisel pump of a 406 !

 

They are used (various lengths) on the endplate and selector housing of just about every Vauxhall gearbox made.

[Guest dbc]

FOR THOSE UNFORTUNATE TO ENCOUNTER THIS PROBLEM IN THE FUTURE I'VE ADDED THE FOLLOWING:

 

 

The problem turned out to be a detached selector cable - at the gearbox end. Clipped the plastic socket back onto the metal ball-joint - having given area liberal spray of WD40 - and was back in business. Thanked those who'd offered advice and then crossed fingers in vain hope that problem wouldn't re-occour

 

Three days later same problem - so will need to find a way of securing worn socket to ball joint (otherwise whole selector cable mec., will have to be replaced expensive and time consuming to fit!!)

 

One suggestion has been to use super glue in socket to re-build worn plastic. Once glue setsocket then re-attached to oiled balljoint...

 

ANY OTHER THOUGHTS - SUGGESTIONS TO HELP PREVENT RE-OCCURANCE OF PROBLEM?

 

Dave C

[Masked Marauder]

No, you put the glue into the socket and then fit it onto the oiled balljoint, youd don't wait for the glue to dry first. But I don't know that that would be hard wearing enough.

 

Perhaps a two-pack epoxy may work, I would take care that the glue does not bond to the ball though.

[Guest dbc]

Apologies for the Chinese whispers MM...

[Guest dbc]

For information:

 

Skipton Ford has confirmed that if a socket fails - at the gearbox end - then new cables are the only option...new parts wise. Current cost (inc VAT) just short of

[Guest vr6galaxy]

WHOA!!!!!!!! BE WARNED! the bolts that hold the battery tray in place are the engine/gearbox mount bolts! you remove these without supporting the gearbox and you will be having a bad day at the office :ph34r:

 

 

just an idea, what about wrapping the ball in PTF tape? the tape will pack out the ball and yet still allow movement, how long this would last I dont know but it may work as a temporary fix for while?

[Guest dbc]

Promised I would give feedback on any DIY fix which avoided cable replacement - here it is:

 

Firstly - didn't see your posting before starting, VR6Galaxy, but realised - once I'd lifted the battery out -that the base was used as a mounting point for the gearbox! Intuition rather than knowledge saved my bacon on this occasion!!

 

The selector cable that had sprung off is a real ball-ache to get too. Access from underneath car (no real advantage taking off undertray).

 

THE FIX:

 

1) Coated ball joint in silicone grease then covered it with small piece of cling-wrap and popped socket back. MUCH FIRMER FIX.

 

2) The socket sits in a recess in the centre of a large cast metal disc. The disc and ball socket all move as one. Using plastic ties I created a "web" around the socket. Two vertical ties were fastened around the casting (one third in from either side) then a I slipped a tie over the back and one over the front and tensioned them to ensure that the web held the socket in place. Because the socket is recessed in the casting the joint can still move freely with the ties gently holding the socket in place.Fixing the ties WAS a VERY fiddly job but replacing the cable is a four hour job and will cost

[Ivor_E_Tower]

Did you leave the cling-wrap in place

:D

[Guest adiick100]

Hi there,

 

just on my way to the Charlton-Man City game when .... you guessed it ! only 3rd and 4th gears available.

 

Managed to get there and back home afterwards (about 15 miles, very interesting)

 

Read these postings then had a look and yes the cable had come off at the gearbox end.

 

What a pain to get to though!

 

I've managed to get a bit of PTFE over the ball and pushed the socket back on. I've also looped a cable tie sort of round the back of the selector bit and back over the cable.

 

Let you know how long it lasts. :(