2005 Vito jumps out of first gear. (manual 6 speed) - Mercedes-Benz Forum
 
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post #1 of 8 (permalink) Old 07-28-2011, 02:44 AM Thread Starter
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2005 Vito jumps out of first gear. (manual 6 speed)

Hi, I have just bought myself a new van mercedes vito 109 95000miles and very clean. I have had the problem that it jumps out of first gear almost every time (it will only stay in if you are realy smoth and ride the clutch). could any one help how to sort this problem all the other gears seem to be fine.
My thought are the gear cables or gearbox rebuild
I have checked the cables which seem fine but i cant see how to adjust them in case it is just slightly out.
Next thought is a gearbox strip obviously dont want to go down this route if I dont have to but I would like some pointers if i have to.
I am a qualified Industrial maintanance engineer and i wonder can i get an over haul kit for this box in the UK or will it just be a faulty component which i could replace. If so will i need specialist tools and equipment to check the backlash etc as i have done this before but dont own the equipment.
Also if i go down this path where can i get specs such as tourque settings etc.
Or is there a good uk company that could supply a replacement at a reasonable price, or a scottish company that could do a rebuild.

Cheers for any help james.
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post #2 of 8 (permalink) Old 07-30-2011, 01:04 AM
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Hi ya, the easiest way of checking if its the box or cables is to stick it in first and then pop the cables off at the box, if it jumps out of gear you know its the box. They do fail a lot so it could well be a box rebuild but as for people in your area just look in the yellow pages and phone around for quotes or rebuild it yourself. Get a copy of WIS for all the info on the box.

Cheers Martin
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post #3 of 8 (permalink) Old 07-30-2011, 01:37 AM
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Originally Posted by jame$!!! View Post
Hi, I have just bought myself a new van mercedes vito 109 95000miles and very clean. I have had the problem that it jumps out of first gear almost every time (it will only stay in if you are realy smoth and ride the clutch). could any one help how to sort this problem all the other gears seem to be fine.
My thought are the gear cables or gearbox rebuild
I have checked the cables which seem fine but i cant see how to adjust them in case it is just slightly out.
Next thought is a gearbox strip obviously dont want to go down this route if I dont have to but I would like some pointers if i have to.
I am a qualified Industrial maintanance engineer and i wonder can i get an over haul kit for this box in the UK or will it just be a faulty component which i could replace. If so will i need specialist tools and equipment to check the backlash etc as i have done this before but dont own the equipment.
Also if i go down this path where can i get specs such as tourque settings etc.
Or is there a good uk company that could supply a replacement at a reasonable price, or a scottish company that could do a rebuild.

Cheers for any help james.
I think you have some problem with the alignment of the shift cables, this needs to be reset with a special tool fitted to the shift lever while you adjust the cable in the correct position. if that does not solve your problem then maybe the 1st gear synchronizer ringis wornout?
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post #4 of 8 (permalink) Old 08-01-2011, 03:40 PM Thread Starter
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I Dont think its the cables as you cant even hold it in gear and whens you go underneath the selector linkages are moved fully when you select first.
I'm also not sure about the 1st gear syncro as when i neutral it goes into gear quietly and it is as the power is increased and clutch is engaged that it will jump out into neutral.
my thoughts are a damaged first ,worn bearing or dog clutch damaged .
seemingly its a common fault and i have been quoted 600 plus vat for repair.
if it is only a a single worn component has any one stripped their own box down to carry out repairs ? as this is what im thinking of doing
Cheers James.
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post #5 of 8 (permalink) Old 08-02-2011, 12:20 PM
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I know the pdfs are marked 1st 2nd gearchange problem but not getting into 1st can be the result of overadjustment.

give adjustment a try if only because its a lot simpler and cheaper than any of the other causes
Attached Files
File Type: pdf 1st gear and_or reverse gear difficult to engage.pdf (43.8 KB, 1927 views)
File Type: pdf Adjusting manual transmission shift cables.pdf (398.8 KB, 1977 views)
File Type: pdf Adjustment tool for shift cable length adjuster.pdf (88.6 KB, 1400 views)
File Type: pdf Inserting adjusting tool into length adjuster of shift cables.pdf (86.9 KB, 1374 views)
File Type: pdf Remove_install center console paneling.pdf (364.5 KB, 1213 views)
post #6 of 8 (permalink) Old 08-07-2011, 01:37 PM Thread Starter
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Hi thanks for all the replys i have adjusted the cable and now the van is much more drivable, I think the problems inside the box but now i can spend time finding out more about the box and maybee do it myself ill keep you posted .
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post #7 of 8 (permalink) Old 10-11-2012, 12:41 PM
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Great post, my 2006 Vito with 120K miles just developed this fault, adjusted the cables as above and she has been fine all week, not sure how long the fix will last but for now its great not done it once all week. Basically follow the PDF's 4 torx screws holding the lower center console cover, 6 torx screws holding the top one. Then you need to release the gear lever carrier which is held by two lugs at the top and two large T40 Torx at the bottom which are hard to get at and a bit fiddly. Then pull the carrier down and away, the cable you need to adjust is the one furthest away from you (nearest the engine) prise off the ball joint carefully with a large screw driver, then slide the white plastic cover on the end of the cable towards the ball joint, this will enable you too push a collett that clamps the cable out sideways, this is underneath the cover you have slide out the way above, the cable is now free to move up and down, you need to make it longer I made mine about 4mm longer, then push the collet back in to lock the cable in its new position and slide the cover back down to lock it all in place. It would be useful to note the original cable length in case you need to reset it later.

Check you can still select all gears especially 2,4 & 6 as these will now be slightly lower than before. Put the two big T40 screws back in and take for a test drive before putting it all back together as you may need some fine tuning.

No special tools required only difficult bit is getting those two big T40 screws out they are tight and stiff

If your van develops this fault I would adjust the linkage straight away as if it keeps popping out it wears the selectors inside the box, if this happens then adjusting the cables wont help.

My mates van had been popping out of first for 6 months I adjusted his cables straight after the success with mine and sadly made no differnce to his van at all. Mine had only popped out a handful of times before I adjusted it.

There was mention of Syncro rings above cant see how this would cause it to come out of gear that fault would cause problems engaging the gear in the first instance and crunching noises engaging gear. It is normally second and third that have syncro wear not first, but hey I am no mechanic so could be wrong on this one

cheers Ben
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post #8 of 8 (permalink) Old 07-23-2014, 04:19 PM Thread Starter
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For your information people it was a problem with the first gear selection ring and was most cost effective to buy a second hand gearbox.

Sent from AutoGuide.com Free App
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