Hilux D4D gearbox problems

[JacMar]

Hi

I own a Hilux Legend 40 D4D, 4X4, DC 2011 with 50 000km bought new

I have trouble shifting up from 1st, 2nd to 3rd and down gears especially noticable in the morning (cold) which it never did. From 3rd, 4th & 5th no problem. Once warmed up the problem improves slightly but still very noticeable (wife refuses to drive vehicle as she struggles too much).

Problem started directly after 50 000km service, had it back to Hatfield Toyota, dealer informed me that clutch needs to be replaced - this is not covered by warranty ±R8 000.
How can this be as one day it was fine before servicing and couple of days later problem starts?
Any suggestions or advise??

Leading up to this issue on four occasions on long trips not towing, towing a Gypsey Romany caravan or a Wildebeest Kalfie trailer the gearbox oil would blow out through breather on the gearbox - each time I was told and also saw for myself that the gearbox was overfilled, oil was drained.
Is there any correlation between these issues??

I had asked on all occasions that a note be made regarding the overfilling of the gearbox.
I asked to see my record on their system when I reported the gearbox issue, miraculously no evidence that I had any complaints or issues were to be found.

I have done a couple of 4X4 routes but nothing serious 99% is tar road use so vehicle was not been abused at all!

Thanks
Jacques

[Haydn]

I bet they changed the gearbox oil at the last service...

Incorrect viscosity oil has been used...

[BarOne]

Quick question: how do you overfill a gearbox? I thought the filler hole is at the "full" level.

[observer]

I'm sure you can fight that clutch replacement. Already had 4 + clutches on my 2011 replaced.

Clutch is most likely not the issue in any case

[Haydn]

Over filling can come from the transfer box or from poor supervision and bad habits I am afraid....

If the center seal, between the gearbox and transfer box has worn out, the oil transfers from one to the other. If yours is a 4x4, check both oil levels. One will be low on oil, whilst the other too fill.

I have also seen "mechanics" fill the gearbox from the top, where the gear levers go in, without checking the oil level through the filler plug. This is because the filler plug is so hard to get to.

I really doubt the clutch is the issue here. I believe the wrong spec oil has been used.

[Basson K]

Hi,

This sounds like the typical example of putting GL5 oil into the gearbox. GL5 has additives added to it that is harmfull for the synchro gears in the g/box.The gearbox should only take a GL4 spec gear oil--nothing else.
Go to their workshop and ask to see the drums from which they have decanted the oil for the gearbox and check the spec on the side of the can or top of the drum---after the 75W90 there should be a specification code that has either GL5 or GL4 in it. If it is not a GL4 spec have them drain the oil and flush it with the correct oil.

You can also call the technical dept of Toyota SA for confirmation if they argue with you.

[JacMar]

Thanks I will follow-up with the dealer hope they are more helpful than they have been thus far.

I had my vehicle at a gearbox specialist and he also advised that I should try a "thinner oil"

Friendly regards

[superhansie]

Thanks I will follow-up with the dealer hope they are more helpful than they have been thus far.

I had my vehicle at a gearbox specialist and he also advised that I should try a "thinner oil"

Friendly regards

Vat jou bakkie na toyota handelaar dat hulle die fout opspoor en regmaak, as hulle uitvind jy het self ander olie gebruik verloor jy jou waarborg.

[Errol]

If the problem is incorrect oil in the gearbox, could damage not have occurred to the bearings etc inside the gearbox?

It may be an idea to discuss this with an independant gearbox specialist and then discuss this with the dealer in case of possible future gearbox problems.

[JonnyAfrikaans]

Hi,

This sounds like the typical example of putting GL5 oil into the gearbox. GL5 has additives added to it that is harmfull for the synchro gears in the g/box.The gearbox should only take a GL4 spec gear oil--nothing else.
Go to their workshop and ask to see the drums from which they have decanted the oil for the gearbox and check the spec on the side of the can or top of the drum---after the 75W90 there should be a specification code that has either GL5 or GL4 in it. If it is not a GL4 spec have them drain the oil and flush it with the correct oil.

You can also call the technical dept of Toyota SA for confirmation if they argue with you.

Hi All,

Couple of months ago I had my D4D's gearbox rebuilt @ 100 000km's (replaced gears 1,2,3 & 5) due to whining. After the fix, the whining seemed fixed, but not for long. It soon started again and has progressively gotten worse, this time including 4th gear whine and a whistling sound from the gears when cruising at say 120km/h. Also the clutch makes a squeaky sound when changing gears quickly/under hard acceleration.

I'm planning to take the tuna in soon to have this all checked out but first wanted some advice from fellow forum members.

Are all of these problems related and does this have anything to do with the use of incorrect gearbox oil?

[Apologies if I hijacked this thread!]

[kmyburgh]

Hi

I own a Hilux 3.0 D4D, 4X4, DC 2011 with 50 000km bought new.

Took it for it's 50 000 km service last week at Hatfield Toyota. This weekend I saw a small bit of oil on my garage floor. I checked service items, and they did replace the gearbox oil. I think they overfilled it... Oil is leaking from the clutch housing.

My first thought was that it is the back crank seal leaking. But why after only 50 000 km. After reading a bit I do think they overfilled the gearbox. There was definitely no oil leak before the service.

I will monitor the oil leak. How much overfill will cause a leak through the breather. Will the leak go away after a few kilometres.

Regards
Kobus

[CAT920 Driver]

I would try and get them to drain and refill oils to right spec after making sure the levels are correct. However I had clutch shudder on my 2010 Legend 40 4x4 dc that refused to go after Toyota changed clutch twice finally it was the fly wheel.
Now my sister's 2014 4x4 has the same issue and its going in for new clutch.
The Toyota gearboxes are not troublesome but I think the clutch shudder is common.
I have opted for automatic in 2014 so going well so far.

[Gengis]

Are these perhaps R151 gearboxes??