[pb65wala]

Hi all.

I own a 2010 model Petrol i20 (MT). Of late, i had been facing problem in shifting gears as in the gear won't engage sometimes. Around 1 month back, suddenly the clutch stopped functioning due to faulty clutch cylinder leading to leakage of brake oil. On replacing the clutch cylinder, the issues faced in gear shifting got resolved.

However, a few days before, while driving, the gear got stuck in 3rd gear. While I am not facing any issue in engaging/ disengaging any of the other gears, it gets stuck/ fails to disengage from 3rd gear. It only disengages after a lot of hit & trial i.e., pressing and releasing the clutch multiple times while trying to disengage the gear. It also fails to disengage from the 3rd gear by turning the off the engine.

On inspection, the mechanic told that the gear oil level was very low (only a few hundred millilitres approximately) and advised to get it changed. However, after topping-up the gear oil, it started leaking drop-by-drop at a very fast pace from the gear box. Strangely, I had never noticed the leakage ever in past. The mechanic then told that the leakage was due to a broken seal inside the gear box. And the gear stuck issue was due to damaged gear resulting from low level of gear oil. He has suggested replacement of the entire gear box with a second hand gear box which will cost anywhere between ten to twelve thousand rupees.

In view of the above, please guide as to whether the mechanic’s diagnosis of the problem is correct and if yes, would it be better to replace the entire gearbox with a functional old gearbox or get the present gear box repaired?

Thanks.

[sameerpatel90]

Originally Posted by pb65wala

In view of the above, please guide as to whether the mechanic’s diagnosis of the problem is correct and if yes, would it be better to replace the entire gearbox with a functional old gearbox or get the present gear box repaired?.

It's truly disheartening to learn about your situation. It appears that the technician who worked on your vehicle didn't properly inspect the gearbox initially. After reviewing your description, it seems that mishandling during the repair process led to the spillage of gear oil, resulting in the vehicle's performance deviating from its intended behavior.

In my assessment, this spillage occurred due to negligence, causing the observed issues with your vehicle. To address this, I recommend seeking out a reputable FNG where the gearbox can be dismantled and repaired at a potentially lower cost. Additionally, consider reaching out to Hyundai Mobis for assistance. They can provide you with pricing information and confirm the availability of necessary parts.

Based on the analysis, the required parts may include the 2nd and 3rd gears, gear synchronizer hub and rings (if needed), and oil seals. It's advisable to replace both gearbox and driveshaft oil seals to prevent potential future issues.

Links attached here for your ready reference.

https://hyundaimobisin.com/locate-us...ibutor-locator

https://boodmo.com/catalog/3700-gear...undai_i20-1_2/

https://oriparts.com/8/61/143/451852

[pb65wala]

Thank you sameerpatel90 for your inputs. I visited a FNG, the spillage and malfunctioning was due to damaged gearbox handi (casing). I am attaching photos of the same for reference. As per the mechanic, a bolt permanently fixed on on the handi broke and kept rotating in the gearbox leading to cuts/ damage inside the gearbox as can be seen in the photos. Additionally, he quoted that a bearing and some other parts will also be replaced due to the damage caused by loosened bolt. Repairing the gearbox shall with welding and replacement of parts shall cost anywhere between 7-8 thousand rupees with no warranty of future malfunctioning. Instead, he suggested replacing the gearbox with a second hand gearbox (to be procured from scrap market) which shall cost 12 thousand rupees.
Now I am in a dilemma as to whether i should go for repair or replacement? The FNG is giving 3 months warranty on the replaced gearbox and as per him, it is a sealed/ non-repaired gearbox.
Further, if I go for a replacement, what are the things, if any, that should be checked by me in the used gearbox that the FNG will provide.
Thanks for the inputs.

[scorpian]

In my opinion if there are no cracks etc in the casing then the same can be reused without any issue. I see no reason for it to be replaced, to me the damages look superficial.
If in case it is cracked then yes welding/replacing would be a option to look at.
Incase you go for used gearbox, cleaning and replacing it fresh oil/clutch/pressure plates/bearing/seals should set you up comfortable for the rest of the life of the vehicle.