2.0 CRTD with manual gearbox, sometimes difficult to get into 3rd gear. All other gears are fine.

Seems ok from cold but soon starts to give trouble.

I know there are problems with this box but these are usually 1 & 2nd I understand.

So any ideas? The box, the cable linkage, the transmission oil?

I went to change the oil but what I think is the fill plug seems to be in a strange location on the front of the bell housing. It is a very long plug and slopes up towards the engine and is a small hole. Certainly no chance of checking the level with my finger as suggested everywhere, and it will be a bugger to fill through such a small hole sloping upwards! You reckon I got the right bolt?

Any suggestions welcomed. Any ideas on price of a new box if it comes to that?

Ta,

Mike, UK

Well, may as well add what I have found out. That screw is the wrong one! It is the reverse locator or something not the oil top up!

Dealer mechanic said do not remove that whatever you do. TOO LATE! it had been out and back twice already. Still seems to work ok though! Whoops!

OK he also told me that 1st and 2nd gear would start to fail soon and the only solution was a recon box. Suggested I go to a gearbox specialist as dealer would be too expensive.

At least I can take £30 of gearbox oil back to Halfrauds.

Looks like about £1000 at a specialist. £300-400 will be labour to get it out and back in. Also they have to wreck the clutch to get the gearbox off, so need a new clutch as well. Still, at 60k miles it would make sense to fit one while the box is off anyway.

Nobody has a recon in stock so it will take a few days to get it off, recon it and get it back on.

As if £1000 was not bad enough, it is a big job to trust to an unknown garage. I'll let you know how I go on.

Mike

I had problems with second gear 5 weeks ago (Trajet 2.0 CRDI 153.000 km). All of a sudden the gear lever wouldn't move into any gear. After stoppin finally managed to get all gears working again except second. Shifting towards second gear (from first or third) did not synchronise anymore.
My garage did a perfect job in repairing the gearbox in 4 days. Lots of work to get the gearbox back in, steeringhouse and drive shafts had to be removed and put back in.
Two gear and synchromesh assemblies had to be replaced. It appeared that the replacement assemblies had different partnumbers from the originally fitted ones. Hope this indicates an improved design.
Costs were EUR 1500,-. Replacement gearboxes were not available or far more expensive than overhauling.

You mentioned that problems with this gearbox are well known. Any experiences here? It is the first timeI was confronted with this.

Sparks

hi,

had the same problem with 1st and 2nd the car was bought second hand from a dealer and was still under warranty, got a replacement gearbox thank god but felt as if the dealer expected it to go. so my good luck his bad, but why do they sell a car that has a proven track record with the problem

I am a hyundai Tech-Where are you in the UK

A quick update. I had a mechanic look at this problem again as the lack of 'graunching' when failing to get third, made me think that the synchromesh was not the problem. Hi confirmed that and says it is the cable linkage from the lever to the selector, and is now pricing the parts needed to fix it.

I am hoping this is goinf to be a whole lot cheaper than getting the box reconditioned!

He said it was an old Vauxhall (GM) box on my model. Anyone confirm this?

Will post again if and when I get it sorted.

Mike

I thought Hyundai always uses Mitsubishi gearbox? Never heard about GM... :)

Hi,
I had the second gear shifting problem on my Jet couple months ago. Then I tried changed the oil spec. using Shell Spirax 75W/90. My problem was solved.