D4d 2ltr, 5th Gear Keeps Popping Out?

[t100nym]

Hi all,

I have got a D4D 2ltr Avensis TX3 53 plate done 84000 mls, Yesterday I was on the motorway and 5th just pops out! But all other gears are fine just 5th want go in does any one have any ideas what this could be? And if where is the best place to take it? And how much it may cost to repair??????

Regards

Tony

[marama32]

Hi all,

I have got a D4D 2ltr Avensis TX3 53 plate done 84000 mls, Yesterday I was on the motorway and 5th just pops out! But all other gears are fine just 5th want go in does any one have any ideas what this could be? And if where is the best place to take it? And how much it may cost to repair??????

Regards

Tony

Hi,

Don't know what is causing it, but it could be the selector or clutch cable, but that is a guess. As to the cost, it depends on the problem. It could be as simple as adjusting the clutch cable( but I doubt it) to a gearbox rebuild or replacement.

If all the other gears are working fine, try living without 5th & jump from 4th to 6th.

I had an Alfa 156 that had a common fault with 4th gear. Bits of the selector would break off & jam 4th gear, which was a relatively easy fix in about 1/2 to 3/4 hour, even for a mechanical novice. I eventually had it replaced after it jammed again & could not get used to missing 4th.

I would suggest taking it to a good independent Toyota specialist as they will be a lot cheaper than a main agent.

If you find out what it is, please advise.

Marv

[irishjay]

the non facelift 2ltr dosent have 6 gears

[t100nym]

the 2ltr dosent have 6 gears

Hi there,

No my car has 5 gears!

[t100nym]

Hi all,

I have got a D4D 2ltr Avensis TX3 53 plate done 84000 mls, Yesterday I was on the motorway and 5th just pops out! But all other gears are fine just 5th want go in does any one have any ideas what this could be? And if where is the best place to take it? And how much it may cost to repair??????

Regards

Tony

Hi,

Don't know what is causing it, but it could be the selector or clutch cable, but that is a guess. As to the cost, it depends on the problem. It could be as simple as adjusting the clutch cable( but I doubt it) to a gearbox rebuild or replacement.

If all the other gears are working fine, try living without 5th & jump from 4th to 6th.

I had an Alfa 156 that had a common fault with 4th gear. Bits of the selector would break off & jam 4th gear, which was a relatively easy fix in about 1/2 to 3/4 hour, even for a mechanical novice. I eventually had it replaced after it jammed again & could not get used to missing 4th.

I would suggest taking it to a good independent Toyota specialist as they will be a lot cheaper than a main agent.

If you find out what it is, please advise.

Marv

Hi Marv

My car has 5 gears but i havent notice any slipping with the clutch!!!

[Mkuk0]

Sounds like the selector forks worn in gearbox, which means a strip down. I don't think its gonna be cheap :(

[jed50]

the 2ltr dosent have 6 gears

It doesnt have a cable either, its hydraulic. It will be the selector pins, take it to a decent gearbox man or the dealer

[selfbuild]

the 2ltr dosent have 6 gears

Mine does :P

[irishjay]

lol cool

[rob virgo]

the 2ltr dosent have 6 gears

Mine does :P

selfbuild ,

if i had to change the box whats the advantage of going 6 speed

rob

[t-spiritpete]

the 2ltr dosent have 6 gears

Mine does :P

selfbuild ,

if i had to change the box whats the advantage of going 6 speed

rob

Some say it's a better gearbox, my 6 speed has a very silky feel to the gearchange no complaints at all and i would think it will help MPG around town etc. :)

Pete.

[rob virgo]

is it a like for like swap

rob v

[pritesh295]

Am having the same problem on my 2004 Toyota Avensis 2.0 D4D. It’s also slipping out of 5th. Drives fine in 1-4 but have to hold it in 5th or else it will slip out.

Been to a local garage that advised it’s the selector just as mentioned on this topic and was advised the garage will have to remove the box and call in a specialist who will replace all parts required and the garage cannot give me a price on that. He quoted me £120 + vat to remove and replacing gearbox.

Could someone please give me an indication as the sort of cost is likely to incur once the box is opened?

Or if only the selector is required what would that cost.

I have also read on other post that 5^th gear wears out on Avensis, if this is the case does that mean a replacement box? If so how much are they?

Thanks in advance guys, any help would be great. Just want a good idea as to how much am going to have to spend.

[nhealth]

Hi All

I am having exactly this problem with my car and getting very little help and information from the garages unless I pay them a considerable amount to remove the box to just diagnose the problem.

Did anybody with this problem get a resolution and find out what it was and the cost to repair?

Thanks

N x

[Various]

My '06 2.0D4D did exactly this last year, it was sorted with a new 5th being fitted and been great ever since. I'll see if I can dig out the invoice and give you an idea of cost. It was less than £500 I'm sure (not Toyota garage!).

The garage owner showed me the old 5th gear, it was worn/chamfered on the face of the gears - he said the gear is so narrow that a small amount of wear causes it to slip out. It had done 150,000miles at the time. The gearbox did not need to come out (he said).

[nhealth]

Great thanks for your help, its much appreciated.

Most places had been quoting more than that just to work out what the problem is. I have spoken to a good independent garage that specialise in Toyotas and he thought he had one a couple of years ago but couldn't remember and said if it needed to come out it would be nearer £1k but hopefully knowing this it wont. Will take it to him rather than a dealer to check over and let you know how I get on.

[cooper12000]

although im not a gearbox expert i susspect it will be the "dog tooth" worn ie the bit that holds the gear in on the layshaft by far the cheapest option would be to get a recon box no idea how much one for a toyota is but i bought one for my skoda fabia estate last year for 500

hope this helps

coop

[nhealth]

Thanks for the feedback its going into the garage this week so will let you know what the diagnosis is...

[richgar]

Have you got a diagnosis yet Nhealth? Hope so as it's been 3 years! My 2004 Avensis has also just started popping the 5th gear out. I'm interested to know the best/quickest/value option. Thank you.

[Dai84b]

On 08/04/2013 at 6:13 PM, Various said:

My '06 2.0D4D did exactly this last year, it was sorted with a new 5th being fitted and been great ever since. I'll see if I can dig out the invoice and give you an idea of cost. It was less than £500 I'm sure (not Toyota garage!).

The garage owner showed me the old 5th gear, it was worn/chamfered on the face of the gears - he said the gear is so narrow that a small amount of wear causes it to slip out. It had done 150,000miles at the time. The gearbox did not need to come out (he said).

My 53 plate Avensis did this yesterday for the first time. So I am a little distressed as we're close to main summer holiday trip. I shall make a PDF of this page and see if I can find that independent Toyota specialist in the Wolverhampton area.

David