Auto gearbox 2.5TD 1996

[hijimhere]

Since I acquired the Bongo it developed a noise like something inside an exhaust rattle - well a bit more - at times it was like an idler gear rattle. This stopped as soon as you moved in drive. Really not sure if this is relevant to what started today.

Did a journey of 30 mile early on and left bongo until 3.30 so she would have been completely cold. Starting was normal & I moved off.
As I progressed a noise appeared, like a gushing cold tap, as the the next gear was selected then come in again and go as we went up the box. However I noticed in 3rd & 4th I couldn't get above 2000 rpm. The noise was coming in at about 1600/1700rpm. I nursed her back home gently. I got home engaged park then tried running up the engine which was fine, no noise.

I believe the gearbox may have a problem - my first thoughts are low/no atf. There are no warning lights showing. I decided to leave it for today as it was getting dark. My question is there a straight forward way to check the ATF level? Is there anyone who recognises the symptoms? Thanks

[Simon Jones]

Factsheet here for checking / changing ATF: http://www.igmaynard.co.uk/bongo/member ... ts/atf.pdf

If the engine is not revving above 2000rpm it could be a problem with the turbo or inlet pipework. A faulty gearbox sensor could potentially limit engine speed, but I would want to rule out problem with the engine before pulling gearbox apart.

[Northern Bongolow]

my first thoughts would be turbo too as it starts to come into play at around 16-1700 revs, then should be at a good speed by around 2000 revs.
is your coolant level correct and the engine oil ok etc. if they both are fine the wastegate maybe stuc or a foreign object stuck in the turbo.
remove the turbo air pipes and see iff the turbo spins freely..

[hijimhere]

Thanks - will start looking tomorrow and up date - I though turbo but when I was in park & run the engine up there was no noise and the engine did seem to progress but I agree turbo has to be looked at

[hijimhere]

Just wondering - I had been stuck in traffic, temp gauge reach reading of 1/3, (I was expecting to hear cooling fans but didn't notice any) fairly early on say 5/10 mins I could smell something - not like hot coolant, not as pungent as melting rubber, more like hot plastic. Is there a possibility that the turbo could get excessively hot at idle and knock out the bearing seals? The noise is similar to a dry bearing but not as rough if you can understand that???????????? I suppose the proof in the puddding is to get the covers of and have a look at the turbo spinning freely!

[Northern Bongolow]

try removing all the belts then check the idler pulley,the water pump bearing, and the alternator bearing. if one of these is seized or on its way out, that may give you your noise.

low oil or an air lock in the coolant system or low coolant may lead to the turbo overheating, as i said earlier if you remove the air pipes to and after the turbo you can get to the turbo innards, spin it, then look for lift in the bearing. oil in this region may not be an oil seal failure as they suck in the crankcase/rocker cover gasses behind the cylinder head so if you see oil dont panic.

[hijimhere]

The AA man comheth - he had a look Once I showed him the noise he target turbo and/or
intercooler ---- engine covers up, bonnet up, poor guy ended up crawling underneath. I was stood by the bonnet, I had put some ready mixed anti freeze on the left side in front of the battery--- I noticed this had moved IN FRONT OF THE AIR INTAKE PIPE --- yes stupid me --- the air volume was sucking the bottle against the pipe entrance and causing it to restrict the air flow DOOOOOOOhhhhhhh . Problem solved. Thanks everyone for your help At least I diagnosed it myself, yes the AA man wrote it on his report.

[Driver+Passengers]