Nasr

Hilux sr5 gearbox issues

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Hi guys,

My names John im the "new guy" and it's the first time posting on this thread so please give us a heads up if I'm doing anything wrong..

So I'll cut straight to it. I was exiting the m4 motorway at prospect last night and all of a sudden I lost gears 3 and 4 completely (gears weren't engaging at all. No resistance and could move gear shift into three and four with my foot OFF the clutch). Prior to this I had noticed on that drive that in gears three and four when I would take my foot off the gas I could hear a slap noise coming from the engine bay or like metal hitting on something in the engine. Here's the weird part. Gears 1,2 and 5 still worked perfectly so being 15km away from home I drove home shifting from 2nd straight through to 5th as I don't have nrma and really didn't want to get a tow it the other gears worked fine. A friend of mine who's a mechanic seems to think since it's only gears 3 and 4 that it could possibly be my "bow synchro" for 3 and 4 or possibly the selector.

If anybody knows what my issue could be any help would be appreciated before I take it into the shop. I've managed to source a 2nd hand gearbox without crank case off another Hilux which has only done 51000km for $900 delivered. (Mates rates through mates workshop) p.s my lux has 221000km on the clock probably about 20k towing.. I've owned this ute since new so I know what limits Its been pushed to and I've never towed more than I should have or neglected to service everything so it's a bit of a shock to have my gearbox seem to fail at just 221km. Thanks

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Welcome to the club! be nice to have a year and which motor, but its ok. It does sound like selector failure, but either way, it's prob going to have to come out to fix it. pls check your clutch for wear and replace the clutch bearing before refitting. If you're anywhere near 200,00km or more, pls replace front and rear gearbox and motor seals unless recently done. it will save pulling down again just to do them - they are cheapish. .

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Thanks manxman,

My bad completely forgot to add that in. It's a 2008 d4d 3.0l turbo diesel. The clutch was replaced at 150,000km (was on its way) but will have it checked nonetheless. Good point you make about the seals will definitely have them replaced as I've had them fail in a previous car. Currently driving a 2011 79 series v8 land cruiser and let me tell you I miss the hilux so much. Thanks for your reply mate!

Edited by Nasr

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i think you may be onto something Trent this link experienced the same sound I did before my gears went on deceleration.

http://ths.gardenweb.com/discussions/2269388/broken-shift-fork

Thanks for the heads up on the shift fork. Hoping to drop the gearbox after the long weekend and hopefully I won't need to replace the whole thing fingers crossed

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Just an update on the gearbox issue turns out it wasn't the selector or the shift fork or the synchros. Turns out the whole gearbox had to be pulled apart as the internal gear hub was somehow cracked $1320 later and the gearbox is as good as new very smooth shifting

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