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2002 D4D auto gearbox faulty - flush procedure?

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Paulmc
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Joined: 05 Feb 2021
Posts: 14
Location: West Midlands

PostPosted: Tue Apr 06, 2021 14:36    Post subject: Reply with quote

mks wrote:
Mine suffered the dreaded coolant in the ATF box a few years back at around 130K miles. I did several complete flushes after replacing the radiator
First I removed the old rad and noticed that it was full of crud and the oil cooler pipes literally fell off.
I took them off, araldited patches on the holes reconnected the radiator and flushed the cooling system with jizer to get all the crud out of the cooling system including heater hoses
For this exercise I connected both ends of the the atf feed together effectively bypassing the radiator
Next was a radiator replacement
Then got the engine hot and ran atf through the gearbox not connected to the rad, loads of emulsion flushed out, was a real mess
Fluid was pumped into a bucket and fresh fluid added, either via the dipstick or you could put the other tube from the gearbox into a container of fresh fluid. I didn't try that, as I recall I went for adding via the dipstick, allow about 5 litres to pump through and repeat.
I put about 20 litres of dexron 3 through the gearbox.
That got the car going again
I ran it for a few days and did the same again
Fluid was pretty clear by then but I did repeat the whole procedure again after a few weeks.
so about 60 litres of dextrin used but saved an expensive rebuild or replacement gearbox.
I got the dextrin from Smith and Allan at very reasonable prices
Since then the car has run fine, now at 215K miles
Fluid still very clean and no issues with the gearbox
I'm thinking it might be time to repack the radiator again soon to avoid that whole palaver again


That's a very informative post & just what I was looking for, thank you. I will be doing this myself also so it looks like I will need some more fluid. Strangely enough, I've now driven the vehicle for more than 30 miles with not one gearbox issue. I'm not quite sure why that is, as the seller clearly stated it was not drivable only onto a trailer. Surly I didn't get that lucky did I?
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Paulmc
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Joined: 05 Feb 2021
Posts: 14
Location: West Midlands

PostPosted: Mon May 10, 2021 17:29    Post subject: Reply with quote

I have an update on my gearbox. I've been driving it around the last 6 weeks with zero issue so I decided to take it for a good run. it was a planned round trip of 250 miles, I did around 75 miles on one long stretch at around 70 mph for just over an hr & I noticed the drive was getting a little rougher. I pulled over in a lay-by & checked drive...... I had none & could smell the gearbox & I could smell a faint smell of coolant I think.

I gave it 10 mins then I had drive again so I found a nice spot to spend the morning & let it cool down for few hrs. Started back up & it drove fine for around 30 miles & then I could feel it again, struggling up hills, rough drive & no reverse in the services till it cooled down. So I would do 15 miles then pull over for 15 mins to let the box cool & then go again till I made it home.

If you kept driving it would keep going until you stop then it would slip badly, just by my house I hit some traffic lights & had no drive so I shifted into 2nd gear & it pulled off with a bang! Started it today & it seems ok when cold but I only moved it round to my garage.
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mks
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Joined: 20 Aug 2007
Posts: 151
Location: kent

PostPosted: Mon May 10, 2021 17:33    Post subject: Reply with quote

Paulmc, check the water for oil/emulsion and check the gearbox water/mush etc. When my oil cooler in the rad failed it did eventually lose drive. As it was less than a mile I towed it home. I know not advised for an auto but it wasn't far. If you have water in the aft I wouldn't use the car until it is fixed, that isn't a very good lubricant
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2002 LWB LC Colorado VX D4D
2014 LC 200 4.5 V8 Diesel
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Paulmc
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Joined: 05 Feb 2021
Posts: 14
Location: West Midlands

PostPosted: Thu Jun 24, 2021 11:21    Post subject: Reply with quote

An update on this issue!

In the end I took it to the gearbox specialist as I figured the box just needed a rebuild. So out came the box, inside was all rusty, the filter was extremely rusty indicating it has had the coolant in the box issue.

So they rebuild gets done, I calls up this morning to ask why is it still not ready as they have had it 1 month now. I get told, you better pop down as it still has the issue & we don’t know why. They think it has an electrical fault. Apparently it still loses drive but if you turn it on or off, it’s ok again. I’m going down now to find out exactly what’s what!
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Paulmc
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Joined: 05 Feb 2021
Posts: 14
Location: West Midlands

PostPosted: Fri Jun 25, 2021 11:09    Post subject: Reply with quote

Ok I have been down & test drove it but it did not give the fault for me, it seems this vehicle only likes to play up for other people. He assures me the fault happened to him a good few times, absolutely no good reason for the garage to tell me that if its not true, normally the other way round. I did see the old oil filter which was rusty & I also seen the box internals throughout the rebuild which were also rusty.

So its still there but they are scratching their heads, maybe a wiring issue or gearbox ECU they think. We don't even know where the ECU for box is located, he wants to check the plug etc.

Any ideas from anybody here what could be the issue?
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