Technical No 4th Gear

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Technical No 4th Gear

Joined
May 10, 2007
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101
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Just a heads-up for people doing a search for this problem.
Been having a problem, getting worse over the last few weeks.
My '04 1.9JTD, 74k miles, was getting more and more reluctant to go into 4th gear, and sometimes would slip out of gear.
For the last week it just would not go into 4th gear at all, with the engine off or on, clutch up or down. It wasn't just reluctant to engage, it would NOT go in. All the other gears were OK, so I didn't think it was the clutch not disengaging, or the gearchange cables wrongly adjusted.
Looking back through the forum posts, I came across someone who suggested that the gearbox was also used in an Alfa model, and that not engaging 4th gear was a common problem for Alfa owners.

This is the thread:
https://www.fiatforum.com/multipla/170168-multipla-will-not-go-into-4th-gear.html

which refers to this cure:
http://www.alfaworkshop.co.uk/alfa_4th_gear.shtml

So today I drained the gearbox fluid (needed to butcher a 10mm Allen key to get it to fit), took off the cover plate (simple 6 bolts), and tested the gears- immediately it slotted into 4th as easy as pie!
There was a bit of crud in the cover plate - looked like gasket sealant, so I assume some of this had got in the works and jammed the selector???
Gave it a good clean up, new sealant, and refilled with decent quality oil, which seemed a lot thicker than the stuff I drained off, and went for a drive.
All gears seemed smoother to select, and 4th was working perfectly- no difficulty engaging, and no slipping out of gear. Result!
 
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