2004 Toyota Hilux stuck in neutral
Submitted: Tuesday, Jul 22, 2025 at 21:55
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heath1
Hello everyone, I have a 2004 4x4 single cab 5l-e Hilux which is unfortunately having gear box dramas. I was driving on the highway a few days ago, pulled off to
check something, (would have only been stopped a minute or two) and when I went to go again the gearbox was stuck in neutral and would not budge. I found that the shifter bushing (part no. 33548-31010) was deformed and stretched, I had only replaced it a few days prior but stupidly forgot to grease it which I am assuming is why it failed after a few days. I replaced it again the next day (and greased it this time), but the ute was still having the same issue. I was able to get into 5th gear once, and when I let the clutch out it was trying to move under its own power, went back to neutral and it has not been able to engage a gear since. Despite the issue, there wasn't any worrying noises, until I was pushing it while the engine was running, (to get lined up to winch onto a car trailer) when a high pitched grinding noise started. The noise has persisted and only goes away when the clutch is pressed down. Any ideas as to what I may be dealing with here, I was thinking something wrong with selectors/forks as the noise only started while it was being pushed with the motor on, sounds like its now stuck halfway between neutral and one of the gears. Any input is greatly appreciated.
Reply By: Member - LeighW - Wednesday, Jul 23, 2025 at 14:21
Wednesday, Jul 23, 2025 at 14:21
Sounds like its not lined up properly for some reason, have you tried removing the gear stick and putting the selectors into neuteral?
AnswerID:
648313
Follow Up By: heath1 - Wednesday, Jul 23, 2025 at 15:20
Wednesday, Jul 23, 2025 at 15:20
Hi LeighW, I've pulled the gear stick out and the top housing for the stick off, I can see inside the box where the selector shafts are attached to the selector "box" not sure if thats the correct name for it. I will attach a few images so you can see what I am talking about.

Gearbox selector arms

Reverse and 5th selectors

1st and 2nd selectors
FollowupID:
929592
Reply By: RMD - Wednesday, Jul 23, 2025 at 22:12
Wednesday, Jul 23, 2025 at 22:12
Heath.
Is this problem ONLY when the engine is running OR can you select gear positions when engine is OFF.
If you can select gears , ENGINE OFF then maybe the detents in the selector rods are SUS.
If it is blocking GEAR selection with ENGINE RUNNING and seeing you mentioned a WHINING NOISE. I would think your clutch has disembowelled itself and constantly trying to turn the input shaft to some degree, That WILL DEFINITELY CAUSE THE SYNCHROS to BLOCK gear engagement/ full throw of selector travel, and some whining complaints from synchros, would be heard as
well, with engine running!
AnswerID:
648316
Follow Up By: heath1 - Thursday, Jul 24, 2025 at 00:57
Thursday, Jul 24, 2025 at 00:57
The problem is present regardless of if the engine is on or off, and the grinding began abruptly whistling the ute was being pushed (to load onto a trailer) with the engine running. I did get the gearbox to engage 5th gear once, with the clutch pushed in and the motor running, With it in 5th gear I held the clutch on the edge of the bite point and it tried to move under its own power. My clutch still feels exactly how it used to.
FollowupID:
929594
Reply By: RMD - Saturday, Jul 26, 2025 at 16:41
Saturday, Jul 26, 2025 at 16:41
Heath.
The shifter bush as you mention should never be deformed UNLESS someone is using a LARGE FORCE on the gearstick. If it does not change gears with just 1 finger pressure on the stick knob, then something is wrong. Having replaced the bush and now had it deformed means some serious energy is being applied to the stick/lever. forgetting to grease it should make almost NO DIFFERENCE.
If tremendous force has been applied to the selectors, via the gear stick, WHO KNOWS what might be damaged in the selector forks etc. If one has been twisted and IT is trying to select a gear although the stick is NOT, then that would/could cause a synchro to begin screaming as it is being forced onto it's CONE but the gear cannot be selected, ie the SYCHRO will BLOCK the selection.
To me, the box seems to have had someone absolutely abusing the stick and selectors instead of a GENTLE change of gears. The GRINDING noise WILL of course STOP when the clutch is depressed as the input shaft is then NOT ROTATING and the GEARBOX has STOPPED moving inside.
AnswerID:
648329
Follow Up By: heath1 - Sunday, Jul 27, 2025 at 14:02
Sunday, Jul 27, 2025 at 14:02
Hi RMD,
I appreciate your responses, it would appear you were correct; I took it to a mechanic who promptly drained the oil and watched as gears and synchros fell out of the gearbox alongside the oil which he described as having the viscosity of
water. He tested the condition of the oil using a testing strip and it would appear the oil is so old it may even be the oil the vehicle came with from the dealership. I bought this vehicle from the original owner around a year ago and assumed that the oil had been changed at some point not too long ago, it appears I was wrong. And you would be correct about the bushing, I would say the box was letting go for a little while; as long as I owned the vehicle, there has always been noticeable whine/howl in 4th and 5th, which I assumed was normal but now i’m second guessing that. Regardless, I’m having the gearbox and transfer replaced with a reconditioned one, I may even pull the old one to bits and post on here what failed. I guess the old saying is true, oil is cheap, motors (in this case gearboxes) are expensive.
FollowupID:
929608
Follow Up By: RMD - Monday, Jul 28, 2025 at 09:53
Monday, Jul 28, 2025 at 09:53
Heath.
TOTAL lack of servicing is quite prevalent throughout the industry. it makes the reliance on A LogBook of Servicing, simply nonsense. The system relies on people believing that the BOOK actually means something, WHICH IS DOES NOT. People even pay more dollars for vehicles which have an immaculate Logbook but the vehicle is doomed. Being from that system I know of MERCEDES vehicles which never had an oil change in 50,000km or more. Holden Colorados of120,000km and NEVER had any Gearbox or transfer case or diff oil changes. most vehicles will get through a warranty period without proper servicing and that is what is relied on by the dealer.
In 2018 I bought a 2010 Corolla and it's aircon was LOW FLOW of air, Even though it was Dealer serviced, the Cabin air filter was so FILTHY, ie, original, the cabin airflow was almost stopped. Servicing proof in book immaculate, but NEVER CHANGED in reality.
FollowupID:
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