Gearbox fault diagnosis

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Colston
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Gearbox fault diagnosis

Post by Colston » Mon Feb 19, 2018 9:28 pm

:) :) Hi all!

Joined the site some time ago but this is the first time that I've posted. Would be very pleased to receive some advice, or a steer, on a problem that I've been having with 'Woody', my Bongo.

First, a bit of background info; I'm situated in North Somerset and own a 1997 2.5TD which, although having covered 286k kms, is in really good condition. At the end of last summer, I had Clearcut Coversions of Barnstaple fit one of their 'Weekender' rear kitchen conversions, and it's now a brilliant vehicle for my wife and I to just head off whenever we choose. The year before last, we toured Spain, Andorra (that didn't take too long!), and Portugal, with Woody covering well over 4000 kms without so much as a missed heartbeat. Additionally, it used not one drop of oil or coolant...faultless! However, I did notice one 'issue' that I'd like some advice on.

The automatic gearbox doesn't always seem to know which gear it should be in, if that makes any sense. It's not during initial accleration, but more so at greater speeds. So, starting from cold, it changes gear OK, sequentially, up through the box without any particular clunkiness, and finally moves into top gear. However, if, say, I was then cruising along at 60mph in top gear and driving circumstances in front of me required me to back off of the throttle, with a resultant loss of, say, 15mph, reapplying the throttle would cause the gearbox to appear to be uncertain about which gear it should get back into. So, it would probably select too low a gear and then momentarily 'sort itself out' by subsequently engaging a higher, more appropriate gear. Although climbing the Pyrenees appeared to present no problem to 'Woody', upon my return I asked my local garage mechanic to check the gearbox out with a test drive. He came back to me and reported that he could find no issue or fault with the box at all. He also checked the oil and said that it was a perfect cherry red with absolutely no signs of degradation or overheating.

Looking through the experiences of other Bongo owners and their gearboxes, I can't find any reference to any report of the exact same issue as mine, although I do see that the Throttle Position Sensor and the Gearbox Solenoids seem to figure in some gearchange problems.(Perhaps I ought to mention at this point that the 'Hold' light has only ever flashed the once of its own accord in the 3 years that I've had the vehicle). Of course, both of these components are expensive, so I'm not really in a position whereby I can easily buy and try new ones of each to see if this cures the problem. I did take the vehicle to a local auto-electrician to see if he could diagnose any fault codes, but he said that the van was too old to gather sufficient information. So, I feel a bit stuck in trying to resolve this matter.

Can anyone please point me in the direction of a reputable or reliable specialist in North Somerset who could provide me with a reliable diagnosis of the fault, or does anybody have any other suggestions as to what my next course of action might be? We're looking to repeat the Iberian road trip again this Autumn (the ferry's already booked!) but I'd feel a lot happier knowing that any potential gearbox problem had been eliminated.

Keep up the good work, guys, and thanks in advance for any help or advice that you might have for me.
Bob
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Re: Gearbox fault diagnosis

Post by Bob » Mon Feb 19, 2018 9:45 pm

Might be worth a PM to Forum member Alacrity. He's our auto box expert, based in Eastbourne (from memory) so not on your doorstep, but very knowledgeable.

Closer to home Gloucester Rd Gearboxes seem well thought of. Based on Midland Rd, not Gloucester Rd. :?

And welcome aboard. 8)
Colston
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Re: Gearbox fault diagnosis

Post by Colston » Mon Feb 19, 2018 9:59 pm

Hi Bob

Blimey, what a prompt response! Very grateful for your help and advice....many thanks!
Bob
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Re: Gearbox fault diagnosis

Post by Bob » Mon Feb 19, 2018 10:00 pm

Just pot luck we're home. :)

We're in Nailsea. 8)
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Northern Bongolow
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Re: Gearbox fault diagnosis

Post by Northern Bongolow » Tue Feb 20, 2018 4:08 am

just to help a little, not all gearbox problems are actually gearbox problems at all. lots of things affect when the gearbox changes.

fuel filter, banjo filter in the top of the fuel pump, throttle position sensor worn or out of adjustment or corroded wiring,turbo pipework leaks, all can fool the gearbox into conflict.

first cheap things i would try are clean out the fuel system and run the best quality fuel you can afford, maybe with an additive in it.
remove the crank shaft sensor at the front of the engine, one bolt, clean its face and remove oil that collects behind in the socket, this helps the engine ecu tell the gearbox ecu what gear is needed.
check the plug wiring on the driverside side of the gearbox, both this and the crank sensor above are prone to weather so need to be cleaned occasionally.
if non of the above helps then it starts to get a little more serious, but i like to try the cheaper things first.
Flanners
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Re: Gearbox fault diagnosis

Post by Flanners » Tue Feb 20, 2018 8:55 am

This post solved my problem, there should be some stickies on the Forum for common issues imo.

viewtopic.php?f=3&t=18421

After having been told from so called Specialists it was the TB, MAF, possible gearbox rebuild (yes an apparent auto specialist quoted £2000+) et al. My gearbox would over rev from 1st to 2nd and also could not decide what gear it liked on 60mph roads constantly switching in and out of lock-up for no apparent reason. My mpg was also horrendous it is now driving beautifully and returning 28-31mpg on a run (2.0), 1000miles subsequent to the TPS tweak.
2002 2.0 Aero with Outback Conversion and Roof Top Tent
Bob
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Re: Gearbox fault diagnosis

Post by Bob » Tue Feb 20, 2018 10:05 am

Well done remembering, and finding, that one. =D>
Katka
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Re: Gearbox fault diagnosis

Post by Katka » Tue Feb 20, 2018 12:11 pm

there should be some stickies on the Forum for common issues imo
+1

There's a huge amount of info hidden away in the forum but finding it can be quite difficult. Not sure if Stickies are the way though as a thread will have lots of branches and off topic items (like this one), but if when a good idea / solution is found a summary of it is put into a Bongo Bible to sit alongside the fact sheets.
Ian
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Re: Gearbox fault diagnosis

Post by Ian » Tue Feb 20, 2018 12:29 pm

I am, as they say, on the case.
668. The Neighbour of The Beast.
Ian
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Re: Gearbox fault diagnosis

Post by Ian » Tue Feb 20, 2018 12:46 pm

668. The Neighbour of The Beast.
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Alacrity
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Re: Gearbox fault diagnosis

Post by Alacrity » Mon Mar 05, 2018 3:27 pm

It doesn't sound as if you have an issue at all.

The transmission has 4 gears & a lockup clutch in the torque converter. On a typical cold start it will shift 1 - 2 - 3 then hold third until a certain engine temp is reached when 4th engages. It will then wait until the temperature gets higher still & lockup will come in - feels a bit like a 5th gear but with a smaller ratio drop. Once operational it goes on & off all the time depending on throttle opening & it ALWAYS releases when you lift off the throttle. If you lift off momentarily them reapply there will be a delay of a second or so before it re engages. This is, I believe, what you are experiencing.
35+ years working with autogearboxes - all day every day......for my sins
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mikeonb4c
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Re: Gearbox fault diagnosis

Post by mikeonb4c » Mon Mar 05, 2018 4:56 pm

Alacrity wrote: Mon Mar 05, 2018 3:27 pm It doesn't sound as if you have an issue at all.

The transmission has 4 gears & a lockup clutch in the torque converter. On a typical cold start it will shift 1 - 2 - 3 then hold third until a certain engine temp is reached when 4th engages. It will then wait until the temperature gets higher still & lockup will come in - feels a bit like a 5th gear but with a smaller ratio drop. Once operational it goes on & off all the time depending on throttle opening & it ALWAYS releases when you lift off the throttle. If you lift off momentarily them reapply there will be a delay of a second or so before it re engages. This is, I believe, what you are experiencing.
The usual great explanation from Geoff =D> =D> =D>
Peterr
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Re: Gearbox fault diagnosis

Post by Peterr » Thu May 24, 2018 5:00 pm

There are many threads on this problem, with many solutions, it seems. I did a couple of checks eg mesh inline filter, vacuum hose, and when all back together noticed a drip from the body of the fuel pump. Garage said it was nothing I'd done, and suggested a reconditioned pump. Ouch, not cheap at over £700 including fitting, but what a difference! I now understand why people enjoy their Bongos so much. Just back from over 2000 mile tour from Cornwall to Scotland, all the power I need, overall 28 mpg with just over 30 at around the legal limit for 350 miles of motorway, and perhaps the most comfortable vehicle I have ever driven. Previously the thing showed all the signs described above with struggling to get 22mpg.
So get the fuel pump checked out before assuming the problem is the gearbox.
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