Mercedes-Benz Forum banner

1 - 12 of 12 Posts

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #1
My van's REPAIR light went on occasionally. I have noted that it always occurred when 2nd gear into 3rd gear, especially driving uphill.

When the REPAIR light is on, lower gears are not available and the van will stay in 3rd or 4th gear which forces me to stop. Fortunately, the REPAIR light goes off when I turn the ignition key three times without actually starting the van.

If anyone has the answer, please advise the cause of the problem. Many thanks in advance!
 

·
Registered
1999 Vito 113 638.114
Joined
·
37 Posts
My van's REPAIR light went on occasionally. I have noted that it always occurred when 2nd gear into 3rd gear, especially driving uphill.

When the REPAIR light is on, lower gears are not available and the van will stay in 3rd or 4th gear which forces me to stop. Fortunately, the REPAIR light goes off when I turn the ignition key three times without actually starting the van.

If anyone has the answer, please advise the cause of the problem. Many thanks in advance!
You have probably gone into 'limp home mode' for the transmission. This is to protect the gearbox from further damage. I suggest you have the problem attended to urgently as a transmission rebuild is an expensive exercise.
What model gearbox do you have?
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #3
You have probably gone into 'limp home mode' for the transmission. This is to protect the gearbox from further damage. I suggest you have the problem attended to urgently as a transmission rebuild is an expensive exercise.
What model gearbox do you have?
I am not sure about the gear box
it is a 1998 V230, chassis number: VSA638234-23-071305
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #4
I remember some one mentioned ZF 10 years ago, when gearbox was overhauled - dirty job!
 

·
Registered
1999 Vito 113 638.114
Joined
·
37 Posts
Hi Henry,
You may find these (specific to YOUR vehicle VIN number VSA63823423071305) references useful:
https://www.vindecoderz.com/EN/check-lookup/VSA63823423071305 <<Same as your data card that came with the vehicle
https://partsouq.com/en/search/all?q=VSA63823423071305 <<Online parts diagrams. The circled parts in the diagrams are for your vehicle, the others aren't. The left column has the genuine Mercedes Part number that you can order direct from your stealer or eBay and use for cross reference at the wreckers.

For everybody else reading, plug in the VIN number for your vehicle on each website shown to get specific details for your vehicle - very useful. This is why it makes it so much easier to assist if you quote your VIN number in your question as the details specific to your vehicle can be looked up on WIS and EPC.

I'm guessing you have the 722.6 transmission built by ZF. It should be on a sticker visible on the top of the transmission when you raise the hood. You will find lots of interesting stuff about this robust transmission in the search option in most Mercedes Benz forums.

1: Check the transmission oil level first. Some gearboxes involve taking out a plug on the side and checking if the level of oil is correct, and some involve a 'one off' dipstick where you buy a dipstick off eBay and then replace the plastic break off bits every time you check it. If the transmission oil hasn't been changed in the last two years, change it anyway. Use specified fluid for your transmission as it is specified by Mercedes to last 8 years (but the change service interval in your Mercedes service manual is usually two years - strange!)

If the transmission fluid level is too low or too high, or just plain worn out, it could produce the symptoms you are experiencing.

Check the quality of the oil you remove to see if it is milky or has water droplets in it. Some mechanics will put some of the old oil in an old tablespoon and heat it with a lighter - if it spits and splutters it has water mixed with the oil - a bad sign.

2: Check the fat plug that goes in the top of the gearbox with a bunch of wires coming out of it. Twist it anti-clockwise a quarter turn as you gently pull it out by the plastic part - not the wires. It may be full of water or mud. A squirt of electrical contact cleaner (WD40 if you are skint) and a blast from an air nozzle on both the plug and socket can do wonders to clean the contacts, and bring your engine computer out of a confused world of intermittent signals that cause it confusion and drop it into limp-home mode and turn on the error light.

If this plug is dirty and full of mud and water, check your three drain pipes under the windscreen are not blocked, kinked or missing, as this is where the rain water drips right onto the wires and goes directly to this plug if the drain plugs are not working correctly and taking the water away from the engine bay area.

3: Check the oil filler cap. Does it have a milky froth on the underside of the cap? If so, a sign of water in the engine oil.

4: Is your radiator water green, orange, yellow, creamy white, muddy, rusty, brown, or clear? When was the last time it was fully drained and replaced (not just topped up)? How often do you have to top it up?

5: Check the radiator cap. Does it have a milky froth on the underside of the cap? Both of these (4&5) may indicate a breakdown of your radiator and oil transmission cooler which are sometimes one unit, and mean water may have got into the transmission where the internal clutch plates will detach as the glue for the plates is water based. If so, do not continue to drive it as they will continue to disintegrate, involving a transmission internal oil pump replacement on top of the other rebuild expenses.

Be warned that a transmission rebuild often involves removing the entire engine and sub-frame first to get to the transmission unit, often doubling the overall expense due to major labour costs. Easier to do the above first.

Advise results of your checks - list number 1 to 5 and what you have seen.
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #6
Thanks for your extensive advice.

I can tell you that a major service was performed - engine oil, transmission oil and coolant were replaced all together. I can state that the light came on when switching from 2nd to 3rd gear, up hill driving so I am trying to avoid such situation.

I shall present your points to the mechanic by the next opportunity as I am not very good at do it myself. Many thanks for your time and effort rendered to my query. I hope that it has helped other members as well.....
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #7
By the way, my van is 21 years old and the distributor and parts dealers have stopped to keep stock of the parts. We have gear box specialist who overhauled the gear box with packages from overseas.

I have done that 10 years ago when serious problem developed at the gear box. I hope that I do not have to do it again because the interior was sort of dirty after the job was done.
 

·
Registered
1999 Vito 113 638.114
Joined
·
37 Posts
Dirty interior is the least of your worries!

Items 2, 3, 4, 5 you should be able to answer without a mechanic.

Don't continue to drive it until you find out what the problem is. Any crunchy bits inside the gearbox will develop into broken bits without any encouragement, driving up the final repair bill significantly. Tow, rather than drive it to your mechanic.

6: What does your odometer show? How many miles/kilometers since new? Since last service? Since gearbox overhaul?
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #9
Many of your checks points to defective head gasket so that coolant water leaks and mixed with engine oil? Be assured that It is not the case.
There is no strange noise from the gear box. The van has done 106, 000 .00 miles and the last overhaul was carried out at 70,000.00 miles
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #10
Many of your checks points to defective head gasket so that coolant water leaks and mixed with engine oil? Be assured that It is not the case.
There is no strange noise from the gear box. The van has done 106, 000 .00 miles and the last overhaul was carried out at 70,000.00 miles
Major service was carried out and less than 1,000 miles was driven since then. I appreciate very much your eagerness to help me to find the cause of the defect.
 

·
Registered
1999 Vito 113 638.114
Joined
·
37 Posts
I'd have a punt at #2 - the mechanic has accidentally knocked off the windscreen drain hoses and water has got into the plug, your under-engine cover plate is missing and you went over a large puddle, or the engine bay was enthusiastically pressure washed to make everything look shiny and new. Even if you just remove and examine the bottom of the fat plug for dirt or moisture, you can easily eliminate that as one of the causes.

The clutch plates are relatively soft and disintegrate quietly. Your transmission filter clogs up with broken clutch grit, the harsh changes or locking up in one gear become more pronounced, the crunchy noise finally starts and then your filter fails and the auto oil pump very shortly afterwards.

Luckily if the fault is rectified, the error light is cleared after a few off/on cycles.

For your wallet's sake, lets hope it is only a few spots of moisture in the transmission plug!
 

·
Registered
V230 VIN No. VSA638234-23-071305, E230 VIN NO. WDB2110522B345601
Joined
·
229 Posts
Discussion Starter #12
I'd have a punt at #2 - the mechanic has accidentally knocked off the windscreen drain hoses and water has got into the plug, your under-engine cover plate is missing and you went over a large puddle, or the engine bay was enthusiastically pressure washed to make everything look shiny and new. Even if you just remove and examine the bottom of the fat plug for dirt or moisture, you can easily eliminate that as one of the causes.

The clutch plates are relatively soft and disintegrate quietly. Your transmission filter clogs up with broken clutch grit, the harsh changes or locking up in one gear become more pronounced, the crunchy noise finally starts and then your filter fails and the auto oil pump very shortly afterwards.

Luckily if the fault is rectified, the error light is cleared after a few off/on cycles.

For your wallet's sake, lets hope it is only a few spots of moisture in the transmission plug!
I can confirm that it is not the case although the compartment is not completely dry....probably need to replace the rubber seal as soon as possible. I will ask the mechanic to follow your lead of fat plug ( transmission plug ).
 
1 - 12 of 12 Posts
Top