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mk1 1.9 tdi stiff gears (VXT-75 gearbox)

Started by allbluedave, February 18, 2014, 06:00:58 PM

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February 18, 2014, 06:00:58 PM
hey guys. :) ok so ive just been out to use my car which was fine on the journey there but on the way back i missed 3rd gear which i thought was down to my error but as i drove further it was clear it was the car at fault. 1st is very difficult 2nd is just as bad 3 is hard to get 4thwas bad too and because the way the car was driving i didnt try 5th but when i finally limped the car home i had no reverse either. any idea whats causing this guys? cheers  8-)
February 18, 2014, 06:08:58 PM #1
Does it go in gear OK without the engine running?
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
February 18, 2014, 06:28:25 PM #2
hey chris.  :) i tryed it with the engine turned off and it was just the same. first thing that jumped in my mind was gearlinkage rods starting to sieze?
February 18, 2014, 07:28:20 PM #3
Maybe but I think more likely the turret on the top of the box (the lump the cables are attached to) the shaft is dry in the ally casing, probably not been helped by all the rain we've had.
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
February 18, 2014, 08:03:27 PM #4
cheers chris. im gunna rip the battery tray out tomorrow and see whats up.  8-)
February 19, 2014, 02:03:39 PM #5
hey guys.  :) :) ok a quick update. ive took the battery tray out and had a look and it appears to be the gear selector on top of the gearbox. can these seize up? reason i ask i because the black cable works fine but the linkage that the blue cable is connected to wont budge. is there a easy way to remove the inkage for inspection/replacement? cheers guys  :)  8-)
February 19, 2014, 02:29:20 PM #6
The top end of the selector shaft is not actually in the box so gets no lubrication from the gearbox oil, it's that end that seizes up.
Will have a look at TIS see if it shows it.
I only have the MK2 Haynes and its not in there.
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
February 19, 2014, 02:37:44 PM #7
cheers chris. guna see if i can find me haynes to see if it says owt about it.  :)
February 19, 2014, 03:01:46 PM #8
Dave sending you an email

Have only sent you up to step 3 as you shouldn't need to go further

Make sure that clamp bolt is tight (no1 in step 3) when reassembling this is the one that can come undone and fall into the box
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
February 19, 2014, 04:43:29 PM #9
is it a secret then! :D cant we all share?
Toot-Toot! Beep-Beep!
February 19, 2014, 05:27:28 PM #10
cheers for the how to chris.  :) after lots of swearing. and skinning of my knuckles ive managed to get it out and after lashing loads of wd40 on it ive managed to free it. there was alot of brown sludge in the recess where the reversing switch sits. i havent refitted it yet as i was planning on greasing it up before i refit it tomorrow as i ran out of daylight.im a little worried about refitting it as it was a pain in the a%%e to to get out. i,ll add some pictures of the linkage shortly  8-) cheers again
February 19, 2014, 11:17:43 PM #11
Dave are you going to do your own how to with your pics for the ref library can i ask that you change the thumb nail pics to the full size inline.

Cheers Chris
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
February 20, 2014, 12:19:39 PM #12
just a quick update. all boxed up and working. cheers for the help chris.  :)

The upper selector shaft bush was completely rusted up, this area is exposed to the weather unlike the lower bush which is lubricated by the gearbox oil, ideally the shaft should be removed from the housing for cleaning up and greasing but in this case grease and oil was worked in to bush and eventually freed off nicely.

Note the clamp bolt this is the one that can fall out and drop down into the box so make sure this is tight before refitting to gearbox

[attachimg=1]

[attachimg=2]
February 20, 2014, 09:03:11 PM #13
And some more views of the selector housing.

[attachimg=1]

[attachimg=2]

[attachimg=3]

[attachimg=4]

[attachimg=5]
December 24, 2014, 08:22:06 AM #14
Hi guys and merry Christmas! I know this is an ołd post but I think it is a common problem and I have a question about Some of the advice given here.
I'm on my third mk1 that has a seizing gear selector esp in damp weather. Fortuneatly I kept hold of an old gearbox that was replaced in error and have been able to examine the selector area at leisure. This has helped me identify where exactly to squirt wd40 into the in-car gearbox past all the cables and pipes etc to the gear selector shaft. I also found that by taking out the reversing light sensor and squirting into this hole, the shaft movement could be helped immensly.
My question is this: how to get access to the reversing light switch to a gearbox in the car?
After repeated sticky episodes I decided to go at it and after removing the battery tray found that this hardly made any improvement to the access as there is an under tray that is welded to the chassis and is the part the gearbox bolts on to. The reversing light sensor seems so far down and buried beneath cables and pipes I can't see how to get to it.
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