GAZZUZZ:


The oil weight can make gear selection seamless, but it should still shift. I had this gear oil issues with the Peugeot 406 manual back in the days, but it still selected with thicker oil.

Feedback will drop after clutch lever is adjusted.

Just for the sake of justina, I'll try find the manual spec oil, change to it and test, before adjusting the clutch lever. update will drop when done.

Thank you Sir.



UPDATE: clutch got adjusted, problem stayed. Ultimately, went and requested the gearbox seller to send his own mechanic to come see and test the bus and come give his own assessment. Seller's mechanic was driven in the car and after seeing the parts already changed (pressure plate and clutch disc-plate), decided it was time to ask a gear-master (gearbox repair specialist), cos bros still never sure say na gearbox be the issue.

Gear-master (selected by the seller's mechanic) was explained the car-situation by my own mechanic (we never even tell gear-master say we change clutch disk & plate, just the state of the car), gear-master no talk 2 words before he landed with:

"The Problem Is with the gearbox, people even make the mistake of going to change clutch plate and pressure plate. The gearbox is faulty".
case dismissed.

seller mechanic reports to seller,
seller shake head "how can, on a tokunbo gearbox",
las las, gearbox returned, refund incoming.

me who thought buying tokunbo will settle issue once & for all, issue became issues.

The gearbox that came with the bus has been jejely repaired and remounted. Car tested, gears selected back & forth, with small knock sound on engaging gear, my mechanic said the clutch will be readjusted.

@GAZZUZZ thank for the responses & pointers, Twale sir. Airtime incoming Sir.

GAZZUZZ:


Great attetion to detail. Sadly you are just working with a lot of bad parts.

The gears are either not properly disengaged or the gearbox is bad.

Try adjusting the clutch lever if this does not work, replace gearbox .

Sir @GAZZUZZ I hail, thanks for the response.

Clutch will be adjusted.
Also "working with a lot of bad parts", please explain.

on the research side,
1. any chance bad or low gear oil could also cause this.
asking cos the car manual (got online via search) says SAE 90 GL-4 and the one I got b4 getting the manual is a SAE 140 GL-1

cant attached manual (9MB) due to nairaland file size limit (250KB)

Greetings House,
Help needed on a Suzuki Every MiniVan (Korope)

Car Details
Name: Suzuki Every (DA52V)
Year: 2001
Engine type: F6A
Transmission: Manual 5speed & reverse

Problem Point: Gear and gear shifting

Problem History:
Before any work was done, the original issue was on the gear 1,
In a normal working manual gear, the car moves as you lift and throttle after putting in gear 1 and hands-off the gear stick.
in this car, the car just stands and stalls when put in gear 1, any throttling just produces a humming sound (separate from the revving of the engine), no movement forward. The gear stick still stays in gear 1 position, it doesnt pull out or returns to neutral.
I noticed when the gear 1 is initially shifted into and throttle pressed, the gear stick heads just pops back 1inch, like a little nod back, like its about to return to neutral but it does not and remains there.

BUT BUT

while still in that same gear 1 position, any extra touch on the gear stick, liking pushing it forward more into the gear 1 position, the gear 1 responds and the car moves as normal. ALL other gears shift and enter smoothly and the ride is smooth until there's need to use gear 1 again and this dance repeats.

WORK HISTORY:
First the gear cable hanger close to the gearbox was adjusted to lie back a bit more, like towards the gear box, problem stayed, then the drive-gear cable that has been with the car was said to be slacked by the mechanic1 so another was gotten, problem stayed. Then a gear cable guy (who came and tried setting the drive-gear cable to match, since he said the gears 1-5 were selecting on the gearbox) now said the cable length was too long.
To avoid damaging the new cable, he said the previous one can be repaired well and reduced in length to do the job, cable got repaired & reduced, problem stayed. Cable guy said problem was with the gearbox.

Took gearbox for repair and was told by gear-man that the gears inside are arranged such that 1&2 are together, 3&4 together, 5 & reverse separate and I have to find gear 1&2 to change mine.

Thing is: gear-man said gear 1 teeth is washing, and so I asked to see it, but all the tooths on the gear shaft were in the same health state all round ( including the perfect gear-2,3,4,5,reverse), so I wasnt convinced, especially with his gra-gra to do change. Oya, how do we do the change, he said parts is scarce so he's suggesting I go buy the 4wd drive gear box (which is cheaper than my 2wd gearbox), he'll take some parts inside and repair my gearbox, okay I hear you, what level of guarantee is there that this problem is surely gone with that method, he cant give guarantee of how long this method will last me (meaning I could be back with this problem in few months time or may be weeks sef). So I took the budget overshoot and got a tokunbo 2wd gearbox, let matter settle for mathias once and for all.

Sidenote: The engine crankshaft was due for change so the engine was dropped and overhauled. Tokunbo crankshaft, New Conrods, Piston&rings, tokunbo top cylinder, gaskets, fresh oil. So engine has been done but could not be properly tested due to gear yawa. Engine-Mechanic 1 did the overhaul and left b4 the full testing due to this gear issue.

In getting tokunbo gearbox, seller gave me wereybox that was not entering gear1 during testing, returned it and got another one, second one no gree enter gear2, to climb small hill during testing, mechanic2 (a more experienced hand with korope) rev motor until clutch plate burn, so tokunbo clutch plate enter the show (ONLY CLUTCH plate, i didnt replace the pressure plate),

Third gearbox (ticked-off as good tokunbo grade gear by mechanic2) was mounted, car went for testing and it wasnt picking up speed as a car shud, to allow you upshift gears, and in trying to fix this, top cylinder was grounded and revalved. Another more experienced gear-cable man was brought to set cables and we ended changing both drive & reverse cables to another tokunbo (bought personally by the gear-cable man). Fuel injector mouth was changed and car went for testing

CURRENT PROBLEM STATE:
Now the car picks speed as it shud and the gears UPSHIFT smoothly BUT it doesnt DOWNSHIFT eg from 3 to 2, even when the car has slowed down to the right speed to allow downshift. UNLESS the car comes to a complete stop or near complete stop before its allows a DOWNSHIFT, at this point, you basically start from gear 1 again and upshift until problem repeats.

PLEASE OOO, WHAT WOULD CAUSE A GEAR TO UPSHIFT FINE AND SMOOTH BUT NOT DOWNSHIFT UNLESS THE CAR COMES TO A DEAD STOP OR NEAR-COMPLETE STOP.

@GAZZUZZ
@nurey
@kingreign
@AutoConsult
@Jceesquare

PIX 1 & 2 - CAR MODEL
PIX 3 & 4 - Gearbox and Injector Mouth