Problem with shifting gears in my ageing Hyundai i20 manual

While driving, I was stuck in the 3rd gear. I am not facing any issues in engaging / disengaging any of the other gears, it gets stuck / fails to disengage from 3rd gear.

BHPian pb65wala recently shared this with other enthusiasts.

Hi all.

I own a 2010 model Petrol i20 (MT). Of late, I have been facing problems in shifting gears - the gear won't engage sometimes. Around 1 month back, suddenly the clutch stopped functioning due to a faulty clutch cylinder leading to leakage of brake oil. On replacing the clutch cylinder, the issues faced in gear shifting were 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 off the engine.

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

In view of the above, please guide me 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 gearbox repaired?

Thanks.

Here's what BHPian sameerpatel90 had to say about the matter:

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 for your reference:

• Link 1
• Link 2
• Link 3

Here's what BHPian pb65wala replied:

Thank you for your input. I visited an FNG, and the spillage and malfunctioning were due to a damaged gearbox casing. I am attaching photos of the same for reference.

As per the mechanic, a bolt permanently fixed on the casing 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 the loosened bolt. Repairing the gearbox 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 the 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 a 3-month 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?

Here's what BHPian scorpian had to say about the matter:

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 an option to look at.

In case you go for a used gearbox, cleaning and replacing it with fresh oil/clutch/pressure plates/bearing/seals should set you up comfortably for the rest of the life of the vehicle.

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