Can only select 5th gear and neutral. mk 1 Galaxy TDI

[benja]

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

[johnnyroper]

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 whatââ,¬â,,¢s going on.

[benja]

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.

[johnnyroper]

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.

[benja]

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

[benja]

Now I see the picture

[benja]

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

[benja]

Photo..

[johnnyroper]

Pop the cables off gearbox end and try to move selector on box with your hand.
Canââ,¬â,,¢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 doesnââ,¬â,,¢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.

[Chrispb]

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/

[benja]

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.

[benja]

Success with removing the cables..

Now for the turret..

[benja]

That was bloody awkward to remove the turret.

Any suggestions how to free it up?

[benja]

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?

[johnnyroper]

Just keep loading it with WD40 and leave to penetrate it will free it up but will just take a bit of time. Once itââ,¬â,,¢s free moving again try using some spray grease to keep it lubricated.

[benja]

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

[Chrispb]

The MK2 is a six speed box and is different

[benja]

Stripped it down and found that the uppermost bearing is shagged.

Will order a new bearing tomorrow..

[johnnyroper]

At least you found the problem, can you get a replacement bearing for it or is it a selector unit complete job?

[benja]

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.