Hello again guys!
I am starting to suspect my B. hates me. Just as the season started my issues with putting in 2nd gear intensified. It started with reluctant engaging 2nd gear, but now it is almost impossible to engage it without the terrible sound, but even if that was successful the gear does fully sits in and pops out unless the gear stick is held in place.
So immediately I started to suspect to worn clutch, worn gears synchronizers, busted engine/gearbox mount and gear shifting mechanism. I could not confirm the mounts or reject other things. So I started to poke around and found that the shaft that goes into the gearbox and is responsible for gear change is pretty loose and moves about with clanking sound coming from inside the box. Took it to the garage and they also suspected this to be the problem. The garage would change it BUT they could not find replacement parts. At this points they could not guarantee it is the only cause, but recommended to look for the parts by myself and check with the FIAT dealership if they had them. No luck - they do not sell the parts in an assembly and I need to start ordering the parts piece by piece.
Here's a scheme of what goes where:
The shaft (1) moves around but also moves up and down. Up and down movement realizes the gear stick motion from left (1st, 2nd gears) through neutral center to right (5th and reverse). The rotation realizes the rear to front gear stick motion (1st or 2nd gear for instance). The shaft is pretty loose when I move it around with my hand (not while pressing up and down).
The (13) is a o-ring type of gasket. The (3) and (15) are what FIAT calls spacers and my bet is that the two spacers together with springs (14) & (2) are responsible for up and down motion.
By the look of it, the (11) could be a bushing and it is bolted to the gear box case, the shaft goes into it. So, my guess is that this where the shaft got loose - maybe the bushing and the corresponding shaft surface just worn out. However, judged by the fact that the problem with 2nd gear just got worse in 20 km of driving makes me feel uneasy about starting hunting for the parts, order them and start replacing based on a hunch.
Another thing is that at the end of the shaft there is a spline that most like goes into the (4) and it is tightened by bolt (9) and rotation around the shaft is taken away by the pin (10). This surprises me, I thought one could replace the whole thing by undoing the two bolts and pulling out the entire assembly of the shaft. If I were to trust the sizes on the pic, it would seem that the (4) is bigger than (11) and therefore it won't go through the hole that (11) fits into on the gearbox case.
Have anyone had experience with FIAT gearboxes? Can you advise if it is possible to remove the whole thing through the hole I mentioned? Am I on the right track here?
And... a movie I made to show you how does it look like (the broken rubber covers... ugh!)
https://drive.google.com/open?id=0B6BpbUa_rsq5MkE3dGdaMDd3YTg
Michal
I am starting to suspect my B. hates me. Just as the season started my issues with putting in 2nd gear intensified. It started with reluctant engaging 2nd gear, but now it is almost impossible to engage it without the terrible sound, but even if that was successful the gear does fully sits in and pops out unless the gear stick is held in place.
So immediately I started to suspect to worn clutch, worn gears synchronizers, busted engine/gearbox mount and gear shifting mechanism. I could not confirm the mounts or reject other things. So I started to poke around and found that the shaft that goes into the gearbox and is responsible for gear change is pretty loose and moves about with clanking sound coming from inside the box. Took it to the garage and they also suspected this to be the problem. The garage would change it BUT they could not find replacement parts. At this points they could not guarantee it is the only cause, but recommended to look for the parts by myself and check with the FIAT dealership if they had them. No luck - they do not sell the parts in an assembly and I need to start ordering the parts piece by piece.
Here's a scheme of what goes where:
The shaft (1) moves around but also moves up and down. Up and down movement realizes the gear stick motion from left (1st, 2nd gears) through neutral center to right (5th and reverse). The rotation realizes the rear to front gear stick motion (1st or 2nd gear for instance). The shaft is pretty loose when I move it around with my hand (not while pressing up and down).
The (13) is a o-ring type of gasket. The (3) and (15) are what FIAT calls spacers and my bet is that the two spacers together with springs (14) & (2) are responsible for up and down motion.
By the look of it, the (11) could be a bushing and it is bolted to the gear box case, the shaft goes into it. So, my guess is that this where the shaft got loose - maybe the bushing and the corresponding shaft surface just worn out. However, judged by the fact that the problem with 2nd gear just got worse in 20 km of driving makes me feel uneasy about starting hunting for the parts, order them and start replacing based on a hunch.
Another thing is that at the end of the shaft there is a spline that most like goes into the (4) and it is tightened by bolt (9) and rotation around the shaft is taken away by the pin (10). This surprises me, I thought one could replace the whole thing by undoing the two bolts and pulling out the entire assembly of the shaft. If I were to trust the sizes on the pic, it would seem that the (4) is bigger than (11) and therefore it won't go through the hole that (11) fits into on the gearbox case.
Have anyone had experience with FIAT gearboxes? Can you advise if it is possible to remove the whole thing through the hole I mentioned? Am I on the right track here?
And... a movie I made to show you how does it look like (the broken rubber covers... ugh!)
https://drive.google.com/open?id=0B6BpbUa_rsq5MkE3dGdaMDd3YTg
Michal
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