Gearbox rebuild.

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keithmac

Guru
Hello all, I know there are a few on here who appreciate a bit of engineering!.

Short story, our family car (Mk2 Kuga Powershift) had become undrivable and I'd been quoted over £3k for a gearbox repair (don't have that at the moment so got stuck in!).

How the Kuga has been designed meant I had to basically remove the front of the car for an extra 6cm of clearance to get the gearbox control unit out!.

Valve body control unit out split and cleaned 12 piston assemblies cleaned and inspected, 9 solenoids cleaned and tested.

Took 2 full days and wasn't looking forward to first drive last night but it's a success!.

Some off the engineering thats gone into it is mind boggling really, pistons beautifully made.

Tolerance is that close that a grain of sand would cripple it!

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keithmac

keithmac

Guru
Few more..
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gbb

Legendary Member
Location
Peterborough
Respect :okay:
Did you know it was the valve unit that was faulty ? ...does that control the shifting I wonder ?...I assume the gearbox itself was ok ?
 
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keithmac

keithmac

Guru
I'd had a code for "Shift Solenoid D" a couple of times but that was a generic code so not much use!.

Seen a few similar where people have paid a lot of money for having the wet clutches replace and it was no better. At 67,000 I refuse to believe a wet clutch pack could be worn out!.

I gave all the solenoids a good soak in Seafoam engine treatment and a good workout with an 11v 1amp supply and all appeared good so bit the bullet and put it all back together.

Even the act of pulling all the pistons out completely could have dislodged a small piece of debris although I didn't find anything..

That is the Mecatronic unit, it uses oil pressure (via the solenoids) to control the master pistons that then control bigger slave pistons inside the gearbox to move the shift forks and clamp the clutches (odd and even packs are in one clutch assembly) input shaft is actually a hollow outer "sleeve" with an internal shaft.
 

Venod

Eh up
Location
Yorkshire
That must have been very satisfying, I love a successful bit of fettling.

Much more impressive than a Brifter repair.
 

colly

Re member eR
Location
Leeds
Auto gearboxes are a mystery to me.
At least with a manual gearbox you can see what's happening.
I once stripped down the gearbox of my wife's Triumph Spitfire when it refused to engage. I could find nothing wrong with it.
Cleaned and lubed it fitted new synchomesh cones and put it back in the car. I drove it up the road the changes were as smooth as silk. Then suddenly they weren't.
Gearbox out and stripped again and after much puzzling l zeroed in on what was happening.
When l re assembled it l re used a split washer instead of using a new one. It was weak and as the cogs pressed up against it it was popping out of the groove it was in.
A new10p split ring and bingo. Perfect changes.
 
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