Advice needed: 2002 Colt 2.4 ClubCab 4x4 Gearbox problem





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  1. #1
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    Default Gearbox advice: 2002 Colt 2.4 ClubCab 4x4 Gearbox problem

    Hello all

    My dad is stranded in Knysna with his 2.4 Clubcab. He is being picked up & taken back home this morning by my boet, but this means the end of their Cederberge trip.

    Problem: we've had intermittent issues with the gearbox on the bakkie for a while now, most notably popping out of 5th whilst decelerating. List of work had been done by indie(s), but this one seems to have topped it all.

    Driving on uphill he wanted to shift down from 5th to 4th, but gearlever refused to move with clutch in. He coasted to yellow line, let out the clutch and gearlever popped out of 5th. He stopped, tried selecting gears but nothing. He tried 1st again and with a bit of effort got it selected, but bakkie refused to move and stalled when clutch was let out.

    Stopped & called for a trailer, had to remove prop shaft to get it onto trailer.

    This morning all gears can be selected with engine off, but they don't want to try driving it as help is on the way.

    1. To me this points to a selector that went postal; anyone had something similar happen to them?

    2. Also searched various options for manual, but get so many virus alerts I'm a bit hesitant to download; anyone have a direct link to a manual that is clean and usable?
    Last edited by Theunis Kruger; 2013/03/21 at 09:36 AM.
    2008 9A Discovery 3 TDV6 SE "Binky"
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  2. #2
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    Update:

    Engine started, output shaft turns in 3rd/4th/5th, but 1st/2nd is dead & stalls engine.

    Gearbox fundi's?
    2008 9A Discovery 3 TDV6 SE "Binky"
    2015 Amarok Auto Highline

  3. #3
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    Time for a gearbox overhaul I am afraid to say...


    2002 Colt, 2.8 tdi Rodeo, 4x4, ARB Bull Bar, Excalliber Running Boards, Monroe Gas Magnum Shocks, Cooper AT3's, Excel 53l long range tank, National Luna Dual Battery System, Campmaster 80l Fridge/Freezer Combo, FrontRunner Fridge slide and Bin Slide, Alpha Gte Canopy with FrontRunner Roof Rack and Homemade Awning...Pulling a Caravan sometimes

  4. #4
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    Haydn Keep us updated

  5. #5
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    Klink soos clutch plaat. Veral as jy sÍ jy kry ratte as die enjin af is. Maar sukkel as hy gestart is. As dit die selector was dan sou jy glad nie ratte gekry het al was die enjin af.
    EX PERD

  6. #6
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    En ook die 5de rat dog clutck assembly is worn. Rede vir 5 de rat probleem.

    http://www.4x4community.co.za/forum/...archid=6508745
    EX PERD

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  8. #8
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    Thanks all; I'm going down there this Easter and we'll tackle it; debating whether another fix is best option, but I'll read threads first..
    2008 9A Discovery 3 TDV6 SE "Binky"
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  9. #9
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    Quote Originally Posted by gerhardperth View Post
    Klink soos clutch plaat. Veral as jy sÍ jy kry ratte as die enjin af is. Maar sukkel as hy gestart is. As dit die selector was dan sou jy glad nie ratte gekry het al was die enjin af.
    Update:

    Engine started, output shaft turns in 3rd/4th/5th, but 1st/2nd is dead & stalls engine.

    Gerhard, as above the problem seems to be 1 & 2 now. Popping out of 5th is annoying, but we'll check that as well.
    2008 9A Discovery 3 TDV6 SE "Binky"
    2015 Amarok Auto Highline

  10. #10
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    Further update:

    dropped the box over Easter & my brother took it apart and ... nothing. No bearing damaged, no gears damaged or misaligned, nada...

    Put it back together and it works perfectly. Not a single hitch. Clutch also 100%.

    This means we either a) missed something or b) wear on the gear lever/selectors allowed 2 gears to be simultaneously selected.

    We live & learn.
    2008 9A Discovery 3 TDV6 SE "Binky"
    2015 Amarok Auto Highline

  11. #11
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    There are little ball bearings on the selectors that stop you from being able to select 2 gears at once. Maybe check that return springs haven't collapsed, could be a ball bearing getting stuck.
    2011 Amarok 120kw 4Motion - STT Rocksliders, 265/65 R17 Yokohama Geolander AT G015, In Dash Navi & reverse Cam, Rogue Performance Downpipe.

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    2011 Triton 3.2 DiD D/cab 4x4 - 265/65/R17 Hankook DynaPro AT-M, Viair compressor, Stofpad Rock Sliders, custom rubber mats, Cruise control
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