1800E Gearbox Problems
 

Can any members recommend a garage or repair shop for removal and overhaul of my M41 gearbox ( with overdrive). Bearing in mind that I live in Southampton Hampshire UK.
Having finally got my car running smoothly and ticking over nicely,
(31 mpg whooo) my wife and went out for a nice run in the country yesterday. 30 miles from home the car jumped out of 3rd gear and despite my best efforts would not go in any other then 4th.
With a very small and odd movement of the gear lever I am able to get the car into neutral, but I say it is not the normal movment and does not feel at all right.
Some how, don’t ask me how, I managed to limp her home where she now sits awaiting repair.
Without further investigation I can only surmise that something has gone in the gear selector mechanism or the synchromesh has decide to give out. As I can not move the gear lever up into 3rd or left across the box to 1st or 2nd I would suspect the former.
Either way, I take it the gearbox has to come out …. oh hum !!
It is the kind of job I would like to tackle myself, (with guidance from fellow members). However I don’t have any garage facility’s at the moment so it looks like a trip to the repair shop. Can any one recommend such a repairer local to me .
Many Thanks.
Clive Foreman
sea4man@hotmail.com

One small tip based on a similar experience a number of years ago; check the engine mounts (rubber cushions). On my car both of them was broken and this caused the engine and gearbox to move out of position. It turned counter-clockwise thereby making only 3rd and 4th gear possible to reach.

If this happened suddenly, without any disturbing noises beforehand, I suspect the nylon bushing underneat the gearshift is worn or a loose connection of the gearshift linkage. Check them first by removing the gearshifter.

This takes be back a bit , the gearbox isnt too difficult to dismantle i think you will find a broken circlip on the mainshaft might not be expensive to fix . but it needs to be dismanted to investigate , use engine oil in the gearbox with OD ...

Thank you
 

Thank you all for your advice, the engine alinement one is very interesting, I will check them all out .. as soon as it stops rainning.

A "cost you nothing" check - Remove the gearshft boot and any other seals, rubbers and bits of sound proofing felt, (NOTE HOW THEY ARE ALL FITTED). These can shift around and restrict the movement of the gearlever, especially if it's all been out and it was all put back by someone who didn't realise there would be a problem. The position of the "rubber hat" seal which keeps the noise and fumes out isn't obvious apparently (opinion Mike?). If it's all pressing on one side of the stick it can knock it out of gear when the box moves when going over a bump. Worse if the rear mounting rubber has got a bit soft due to oil. If you now seem to be able to get all the gears, give it a run around the block to see how much the stick jumps around.
Of course I could be entirely wrong............

Big Thank You
 

First of all may I say a big thank you to all who have replied to my post.
Unfortunately it hasn’t stop raining here for 24 hours and if, as is being forecasted, our local stream busts it banks .. well.. lets just say my gearbox problem will be the least of my worries. She is safely out of harms way at the moment and can stay that way till things improve.
This saga will have to be put on hold for the time being but I will keep you posted as soon as I can get under the bonnet.
Once again many thank to you all.

You are not in the ulu being in Hampshire! For gearbox work try the Bosch garage at the top of Bevois valley rd in Southampton. Failing that try BGH gearboxes(try internet) somewhere near .If all else fails my lodger can do ford gearboxes in his sleep so a volvo should not be a nightmare,rain due to stop in August.:wink_smile:

"These can shift around and restrict the movement of the gearlever, especially if it's all been out and it was all put back by someone who didn't realise there would be a problem. The position of the "rubber hat" seal which keeps the noise and fumes out isn't obvious apparently (opinion Mike?). If it's all pressing on one side of the stick it can knock it out of gear when the box moves when going over a bump"

Dead right it can - I think I have had this problem lately as I have two layers of carpet and the rubber gaitor on my transmissiojn tunnel. But I think this is a selector problem. Any transmission specialist should be able to sort it.
One other thought - some 1800E's came with the 164 gearbox, not the M41, and this was more prone to selector problems.

Essentially the 1800E did use the 164 M410 box, but it is a different version, and not interchangeable. As well as the bell housing being different a 164 also has a bigger diameter input shaft.