Van trouble

My 56 plate vauxhall combo has started making a noise shifting into 3rd. If I am really careful with timing the change and gently tease it in then half the time I can get a silent shift. It’s not a full on grinding just sounds like something slightly clashing. 115k on the clock. Is this the start of something serious and expensive? I’ve had trouble with local garage so can’t use them (they missed a seized alternator on this van and diagnosed a whole new engine!) but I  have a semi retired trust worthy mechanic who will do work for me but only really when I’m desperate so would be useful to have some prior understanding of what might be the issue.

If you blip the revs before changing gear or double declutch is it smooth? Could be worn synchromesh – had similar on a 205 bitd.

I just ignored it and double declutched but I was also skint so that may not be the most sensible long term plan!

worth doing a bit of model-specific research online (owners forums or similar) for any issues related specifically to 3rd gear on that model.

A problem with the gearbox is sort of pretty likely to be ‘the gearbox’ but it could be clutch related – the clutch isnt releasing properly to allow the gear change –  or it could be an issue with the gear selector – something stiff/slack/worn/loose between the gear stick and the gearbox that means the gear isnt being selected properly. The route from the gear stick to the gearbox can sometimes be pretty indirect so there can be linkages and cables going round bends and any of them being stiff, worn, dirty could be the issue

So a first step might be to get a garage to check everything external to the gearbox is adjusted and lubricated properly and nothing is worn. If thats ruled out then it’s probably an exchange / refurbished gearbox. Often a local garage won’t do this themselves and they’ll take it to a local specialist, so if you don’t get on with your local garage maybe look up local gearbox specialists and deal with them direct – they usually replace them on an exchange basis, taking your old gearbox as effective part payment for reconditioned on. A recon box will usually cost about £300-400 plus labour. It’s the sort of thing where you’re as well getting the clutch done too while it’s accessible.

All the signs of a worn synchro ring on the affected gear. The synchro speeds up the gear prior to engagement & makes the shift silent & smooth.

I’d drain out the gearbox oil & filter it through some kitchen paper. If there anything resembling glitter in there it needs investigating.

Thanks synchro sounds likely then. I will have a go at the double declutch and see if my friendly mechanic feels like investigating at some point. If not I will investigate the gearbox specialists. This van has been a bit of a pain. Only just had 2 injectors replaced.

If slowing your gearstick/clutch movement down (count 1 sec to Neutral and 1 sec to gear) doesn’t help, try double declutching

IME only down-changes (4>3) benefit from adding revs

How is the clutch actuated on these? Cable or hydraulic? My Berlingo gets a notchy box when the cable needs (manually) adjusting.

Also as mentioned above – my Berlingo has a series of links/linkages for the gearshift. The pivot points wear and can impede gear changes. If it’s cable gearshift then like my transit it might need resynchronizing/resetting.

Google the fault though – the van is old enough for it have lots of forum chatter if loosing 3rd is ‘a thing’.

How is the clutch actuated on these? Cable or hydraulic?

Actually on an old astra I had – notchy/ crunchy gear changes was a prelude to the clutch cable snapping

I had almost exactly this on an old Fiesta, it was the clutch and if failed completely not long after (I think as above it was the cable, it was years ago now).  But I wouldn’t take a sample size of “one” as any sort of reliable indication of anything.