General JTD Manual Gear Selector Failure ..

[Shadeyman]

Driving home a few minutes ago the gear selector felt strange, longer, loose and wobbly? 100 yards from my house and I couldn't select any gear, the selector was seriously loose, felt like it was completed diconnected.

Managed to coast onto my drive and into the garage.

I can pull the selector knob up and down 2 inches and it flops all over the place. there's a small elongated hole in the shaft, drivers side that looks as though a pin may have sheared off.

I plan to remove it tomorrow, is it repairable or does it need replacing?

 

[Shadeyman]

Update.

No, its not repairable.

Complete selector mechanism from Fiat £93, picking it up in the morning.

Its quite common for this to happen according to the guy in the parts department, but I can't find anything on here about it.

 

[Yellow Peril]

Hmmm looks like a lot of potential stress on a small area. What does the smaller pin do I wonder? Is this arrangement common to all Stilo models or just diesels?

A good argument for stripping back the gaiter from time to time, and keeping everything well lubricated...

 

[Shadeyman]

Hmmm looks like a lot of potential stress on a small area. What does the smaller pin do I wonder? Is this arrangement common to all Stilo models or just diesels?

A good argument for stripping back the gaiter from time to time, and keeping everything well lubricated...

I'll do my best to explain what/how the small pin does.

By pushing the gear stick forward the lever pulls on a cable and gears 1, 3 and 5 can be selected.

By pushing the gear stick to the side(away from the driver) the small pin pulls on a cable and allows 1st gear to be selected.

By just pushing the gear stick froward the small pin does nothing and allows 3rd gear to be selected.

By pulling the gear stick to the side(towards the driver) the small pin pushes on a cable and allows 5th gear to be selected.

I'll not bother with 2nd or reverse as I'm sure you get the idea now.

As you say there is a lot of stress on the small pin, it looks to me like it was spot welded into postion and this weld failed.

As far as I can tell from the ePER its common to most Stilos.

I'm not sure lube would help as theres not much inside, I'll upload a few photo's of the new one tomorrow so you can see for yourself. Its a very simple setup, looks like it would cost £25 max, can't believe they charged me £93.

 

[rattystilo]

so an item that is spot welded has broken. can it not be spot welded back in place?

 

[Shadeyman]

so an item that is spot welded has broken. can it not be spot welded back in place?

I suppose it could but the pin runs through the center of a plastic ball joint, not sure how or if I'd be able to reassemble the ball joint afterwards. It looks like the ball joint may have been molded around it after the pin was welded on.

 

[rattystilo]

oh, i see. it might be different to ones i have seen which didn't have a lift up reverse.

 

[Shadeyman]

oh, i see. it might be different to ones i have seen which didn't have a lift up reverse.

Mines the Multiwagon, same part number as the 5 door, it doesn't have the lift up reverse.

I believe the 3 and 5 door are different as they have different part numbers.

So I guess 3 door Stilos have lift for reverse?

 

[Yellow Peril]

Mines the Multiwagon, same part number as the 5 door, it doesn't have the lift up reverse.

I believe the 3 and 5 door are different as they have different part numbers.

So I guess 3 door Stilos have lift for reverse?

Just been out and checked mine (2.4 lift-up reverse) and it's quite different, with no side pin like yours.

 

[Shadeyman]

I'll upload a few photo's of the new one tomorrow

As promised, attached is a photo of the insides of the gear selector mechanism.

As you can see there's not much in there, simple but effective.

 

[Shadeyman]

Thought I share this info, someone may find it usefull.

1 - Gearbox control lever
2 - Support for gear selector and engagement cables
3 - Gear engagement cable
4 - Gear selector cable
5 - Gear engagement lever
6 - Selector lever on gearbox

 

[Yellow Peril]

Thanx. I assume this is for the JTD?

 

[Shadeyman]

Thanx. I assume this is for the JTD?

Yes ..