vito 639 5th gear selection problem - Mercedes-Benz Forum
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post #1 of 12 (permalink) Old 07-01-2011, 01:44 AM Thread Starter
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vito 639 5th gear selection problem

Hi all,

Just bought an 2005 vito and sometimes it will select 5th perfect and drive fine and other times you think it is selected unto you release the cluch and it is not in gear and grinds a little there is about 150000miles on it do you think this is the gearbox or maybe just the gear oil needing changed i will guess it will never have been done?

Any help would be great
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post #2 of 12 (permalink) Old 07-01-2011, 10:50 AM
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Whats 2ed like?
If it's notchy then it could benefit from an oil change.
I have some red line oil for the job, pm me.
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post #3 of 12 (permalink) Old 07-01-2011, 01:02 PM
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they also suffer from selector wear in the selector on the gearbox (connects the cables into the gearbox itself) not difficult to fix and about an hours job (on a 638 its about 20mins)

Also the cables stretch slightly and can be tightened under the gear lever (from underneath) carefully as some adjusters are left hand thread.
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post #4 of 12 (permalink) Old 07-02-2011, 02:33 AM
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they also suffer from selector wear in the selector on the gearbox (connects the cables into the gearbox itself) not difficult to fix and about an hours job (on a 638 its about 20mins)

Also the cables stretch slightly and can be tightened under the gear lever (from underneath) carefully as some adjusters are left hand thread.
where could i get the selector part and what does it look like. my 638 crunches on third gear. thought it was worn syncro
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post #5 of 12 (permalink) Old 07-02-2011, 04:50 AM
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the bit that goes the most (on 638) is the "cage" on top of the selector.

If you look at the engine right hand side, you will see the 2 cables going onto a "cage" on top of the gearbox.

Its the transfer unit and like the selector is merc only and you need to get it using your vin to make sure its the right one.

Don't worry, included are all the "bits" needed and mine cost £28 from merc dealer.

the cables "snap" off the cage -- label them so they go back properly --
the cage is held on with a couple of bolts -- the back one is difficult to get at.

reinstall the same way and the cables just press onto their nipples with finger pressure.

about 20mins start to finish.

If that doesn't improve things and the gearchange seems ok -- it will have "tightened" up with the new cage.. then its the actual selector which is under the "cage" just fitted.

Selector is equally easy but I suggest checking out Wis first and obviously more expensive---- BUT its usually the "Cage"
post #6 of 12 (permalink) Old 07-02-2011, 05:13 AM
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Suddenly thought these 2 pdfs might help

The 1st is the "cage" and cables

The 2nd is the selector but hopefully this one won't be needed
Attached Files
File Type: pdf Unhooking and hooking on shift control cables on transmission.pdf (85.9 KB, 811 views)
File Type: pdf Disassembling, assembling shift shaft.pdf (371.3 KB, 705 views)
post #7 of 12 (permalink) Old 07-20-2011, 03:13 PM Thread Starter
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Hey guys,
Right pulled the gear box out at the start of the week! (drained the oil and 3 ball bearing 3 springs and 3 square locking pins came out with the oil) heance the box coming out, handy out split the box to see were the springs etc went and found than one of the sincro gears was wore and they had fell out! bought a new one for 23quid FROM MERC fitted repaired built back up and refilled and still the 5th gear problem the inners are all fine inside the box so only the cable or lingage bars left to try. think to test the cables is to diconect the cables and try change by hand on the ramp and see if it selects 5th. i'll keep you posted on progress. ps, is there any adjustment on the 639 cables?
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post #8 of 12 (permalink) Old 07-20-2011, 03:57 PM
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Hope you get on ok.

It is common when the selector is badly worn, for the cables etc to be adjusted to take up the slack instead of replacing the selector cage.

When the cage is replaced, nothing else works properly.

The cages wear and are cheap, the cables rarely stretch much (look at their thickness vs length) and a lot of money can be charged continually adjusting them.

Here are the PDFs for cable adjustment
Attached Files
File Type: pdf Adjusting manual transmission shift cables.pdf (398.8 KB, 1067 views)
File Type: pdf Remove_install center console paneling.pdf (364.5 KB, 489 views)
File Type: pdf Remove_install center console.pdf (265.0 KB, 418 views)
File Type: pdf Adjustment tool for shift cable length adjuster.pdf (88.6 KB, 547 views)
File Type: pdf Inserting adjusting tool into length adjuster of shift cables.pdf (86.9 KB, 511 views)
post #9 of 12 (permalink) Old 07-20-2011, 04:07 PM Thread Starter
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good man i'll get it back on the ramp tomorrow let you know how i get on. nice info sheets

Last edited by thegovner; 07-20-2011 at 04:20 PM.
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post #10 of 12 (permalink) Old 07-21-2011, 05:58 AM Thread Starter
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hey malcolm is there any way of adjusting the cables without the adjuster tool?
They are adjustable when you pull back the spring clip and push the black locking pin, and it can be adjusted pretty easy so now trying to get the setting right, another thing the ball on the gear stick seems to have a fair bit of wear and movement on it so this could be contrabuting to the problem.

Last edited by thegovner; 07-21-2011 at 06:33 AM.
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