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Author Topic: Can only select 5th gear and neutral. mk 1 Galaxy TDI  (Read 1223 times)

Offline benja

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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Can only select 5th gear and neutral. mk 1 Galaxy TDI
« on: March 04, 2018, 08:24:08 PM »
Hello, I'm new here.. had a look but could find anything specific on your forum regarding this type of gear selector problem.
It was all working fine until suddenly the gear shifter wont move left of right and I can only select 5th or neutral. Not even reverse.  It was an interesting drive home!

Normally I'm pretty handy at fixing things... but if anyone has any suggestions this could save me some time.

I guess one of the linkages has broken or popped off... but where and how to repair?
Thanks
Benja

Offline johnnyroper

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  • Posts: 2946
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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #1 on: March 05, 2018, 06:05:41 AM »
You need to access the linkage to check for damage,free movement and cables securely connected to start with. That way you can narrow it down to a problem with the gear selection system or internal problem with the box.

Best to get battery and battery tray out to get some space to see what’s going on.

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #2 on: March 05, 2018, 08:32:50 AM »
Thanks for the quick reply..
I've removed the battery and tray etc.. and the cowling around the shifter inside the car.

The cables and connecions seem fine, the shifter inside the car fine. The problem appears to be the selector connected to the blue cable,  (interior), seems to be blocked.

Attached is a video showing the limited range of movement.

What next? Is this a common problem? What normally causes this? Could it be as simple as a stone or something dropped inside and blocked it?
The last few weeks it was getting a bit tighter moving the shifter left and right.. but then yesterday no movement at all!

Maybe I'm regretting not having a splash guard under the motor...

Thanks for any helpful advice.


Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #3 on: March 05, 2018, 08:40:24 AM »
Have you popped the gear cables off and checked to see if the stick inside moves freely and also manually moved selector on gearbox?
Also worth a check of this pin on selector as they are known to seize up. See picture.

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #4 on: March 05, 2018, 09:04:50 AM »
Yes I popped off the cable lug next to the shifter inside the car. The shifter moves fine. The interior selector still won't budge.

I failed to upload the video but it probably isn't necessary. More importantly I can't see the photo that you mentioned.

What pin are you talking about?

Access is diabolical.. I realize that the metal plate is welded onto the chassis..

Do people have to remove the gearbox to work on the selector?

Thanks

Offline benja

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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #5 on: March 05, 2018, 09:05:44 AM »
Now I see the picture

Offline benja

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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #6 on: March 05, 2018, 09:20:31 AM »
Each time I attach a photo it doesn't appear on the forum. I tried sending a photo because the selector linkage is different to the linkage in your diagram.

Do I need to remove the gearbox to work on the selector?
Thanks

Offline benja

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  • Model: Galaxy Mk1
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  • First Name: Benja
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Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #7 on: March 05, 2018, 09:23:06 AM »
Photo..

Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #8 on: March 05, 2018, 09:35:53 AM »
Pop the cables off gearbox end and try to move selector on box with your hand.
Can’t really tell from picture but on the cable closest what is the metal clip type thing on the left? Hard to tell from picture but it doesn’t look like it should be there to me.

The pin that seizes is the one with circling on in your picture. But if you take cables off and gearbox linkage moves freely,along with the free moving shifter you have already checked then it only leaves a cable problem.

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #9 on: March 05, 2018, 10:40:43 AM »
It's that time of year when all that road salt gets into the gearbox turret, the selector shaft has a habit of seizing in the casing have a look below.

https://www.fordmpv.com/smf2/ford-galaxy-vw-sharan-seat-alhambra/mk1-1-9-tdi-stiff-gears/




2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline benja

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  • Posts: 13
  • Thanked: 0
  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #10 on: March 05, 2018, 10:55:15 AM »
Thanks for the helpful link.

Yes lots of rain/mud recently.. I tried freeing it with wd40 but no luck.

I easily removed the outer cable from the ball joint. But so far have failed to remove the inner cable end. Terrible access. I'm not sure whether to lever the whole rubber unit off (easier access) or just the cable end (hidden and no access)?
Does it just need brute force? I dont want to bugger it completely!

Then I plan to remove the selector turret... Clean and grease it up.

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #11 on: March 05, 2018, 11:26:58 AM »
Success with removing the cables..

Now for the turret..

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #12 on: March 05, 2018, 11:58:37 AM »
That was bloody awkward to remove the turret.

Any suggestions how to free it up?

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #13 on: March 05, 2018, 12:34:54 PM »
With a heap of wd40 I've got it moving.. but it doesn't move smoothly.. and the coil spring seems to do nothing.

I don't know if this is normal or not?

Offline johnnyroper

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  • Posts: 2946
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #14 on: March 05, 2018, 12:46:59 PM »
Just keep loading it with WD40 and leave to penetrate it will free it up but will just take a bit of time. Once it’s free moving again try using some spray grease to keep it lubricated.

Offline benja

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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #15 on: March 05, 2018, 01:02:42 PM »
Isn't the spring supposed to hold it in the 3rd/4th gear plane. Well it hasn't done that for years. Maybe the spring is broken and jamming/grinding against the shaft. The spring does nothing now as there is never compression tension on it.

I've used a heap of wd40 and it's still as rough as hell..

I'm reluctant to dismantle it further as I doubt if I can set it up correctly.

Maybe I need to get a replacement turret from the wreckers..? Are all the TDI 5 speed turrets the same?  Is mk 2 the same turret as mk 1?

Thanks

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 3024
  • Thanked: 112
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #16 on: March 05, 2018, 01:24:37 PM »
The MK2 is a six speed box and is different
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline benja

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  • Posts: 13
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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #17 on: March 05, 2018, 07:27:20 PM »
Stripped it down and found that the uppermost bearing is shagged.

Will order a new bearing tomorrow..

Offline johnnyroper

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  • Posts: 2946
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #18 on: March 05, 2018, 07:35:19 PM »
At least you found the problem, can you get a replacement bearing for it or is it a selector unit complete job?

Offline benja

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  • Model: Galaxy Mk1
  • Spec: 1998 TDI 110
  • First Name: Benja
  • Region: Non UK
Re: Can only select 5th gear and neutral. mk 1 Galaxy TDI
« Reply #19 on: March 07, 2018, 06:15:05 PM »
In the end I chose to get a bronze bush machined and fitted. Only cost20€ here in Spain. I figured that it might last longer than the bearing.  I hope I don't regret that decision. So I put it all back together last night outside in the rain... And it works!

Figure that I'll occasionally need to smear some grease so it can enter where the new bush is.

The cause of the problem was that I have no splash guard.. and that bearing is susceptible to dirt and water ..

Thanks for all the advice. Much appreciated.

I'm sure that I'll be back on this forum again soon as the clutch bearing in the AC compressor has been squeeling like a pig for months... That's the next job but  less urgent . At least I can drive with more than just 5th gear now.

 

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