Judder, judder stall: the Final Solution?

Technical questions and answers about the Mazda Bongo

Moderators: Doone, westonwarrior

Post Reply
User avatar
Jaws
Bongolier
Posts: 179
Joined: Mon Nov 09, 2009 12:04 am
Location: Doncaster, South Yorkshire

Judder, judder stall: the Final Solution?

Post by Jaws » Sat Mar 22, 2014 7:10 pm

I posted about this some time ago: http://igmaynard.co.uk/bongo/forum/view ... =3&t=52712

Unfortunately the problem recurred with a vengeance a couple of months ago. By this time time I had pursued all leads offered including replacing coolant temperature sensors. It got to the point where Jaws was pretty much undriveable even when fully warmed up. On the day I booked into the (trans)mission hospital, reverse gear failed entirely. :(

Upshot was new 'box needed. Lovely replacement unit imported from JATCO and fitted. Unfortunately she stalled again in the same way before I could drive home. So after research and prompting the Transmission Control Unit (TCU) was investigated. Corroded pins were cleaned up and hey presto a big improvement. But still not right. A swap of TCU made no difference so the wiring loom was checked. After stripping it out, checking patiently pin to pin and multiple repairs normality has been restored :D (That said I have only had her back a few days)

It seems the solenoids in the 'box are controlled by switching them to earth and back as appropriate. Poor insulation, corrosion or broken wires with intermittent contact play havoc with a carefully programmed sequence of changes. I assume that the link to temperature was that once the loom dried out, the 'short' caused by moisture resolved.

So beware. Erratic gear changes might be wiring or TCU related and if not sorted can lead to expensive gearbox failure.
Live Bongo and prosper.
User avatar
haydn callow
Supreme Being
Posts: 5777
Joined: Mon Jan 08, 2007 9:50 pm
Location: Somerset
Contact:

Re: Judder, judder stall: the Final Solution?

Post by haydn callow » Sat Mar 22, 2014 11:10 pm

So, was a perfectly good gearbox removed for no reason as the fault was later traced to faulty wiring??
http://www.coolantalarm.co.uk
Developer of the Mazda Bongo Coolant loss Alarm
Also BMW Clocks
User avatar
Jaws
Bongolier
Posts: 179
Joined: Mon Nov 09, 2009 12:04 am
Location: Doncaster, South Yorkshire

Re: Judder, judder stall: the Final Solution?

Post by Jaws » Sun Mar 23, 2014 1:42 pm

haydn callow wrote:So, was a perfectly good gearbox removed for no reason as the fault was later traced to faulty wiring??
No. Faulty wiring ruined a perfectly good gearbox which had to be replaced due to mechanical failure. Then the fault was found.
Live Bongo and prosper.
Post Reply

Return to “Techie Stuff”