Hi all Urgent advice and thoughts required.......

Submitted: Tuesday, Aug 23, 2011 at 20:01
ThreadID: 88647 Views:2485 Replies:6 FollowUps:2
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Know its been done to death, but have had problems with the 5th gear in My '03 Ford Courier TDi whilst running around this great country.

Am now camped up waiting till I can get someone to look at the gearbox, but I think that pehaps the 5th gear has gone whilst towing our jayco dove.

Can anyone advise whether it is still OK to keep driving it but in 4th gear??

I did do this for about 150 klm's to get closer to some help here at Katherine NT, but want to know if it's safe to continue for a much greater distance?

Any thoughts and info would be greatly appreciated.



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Reply By: Member Bushy 04(VIC) - Tuesday, Aug 23, 2011 at 20:27

Tuesday, Aug 23, 2011 at 20:27
Wozzie, we have a 2005 courier TD 2.5D and had the g/box rebuilt after 200,000klm and was told in no uncertain terms that towing in 5th gear is a no-no with this gbox. best get it checked.
That would be what I would do.
Hope that Helps.
AnswerID: 463376

Reply By: fisho64 - Tuesday, Aug 23, 2011 at 21:45

Tuesday, Aug 23, 2011 at 21:45
You havent actually said what has happened to it, only "perhaps its gone".
So Im assuming its a similar problem to G52 hiluxs.
5th gear is on a shaft on one side of the central gearbox carrier plate and is on a stub of a shaft with no bearing on the otherside.
When its strained too much, the shaft shears clean off and the spur gear drops into the bottom of the box.
Its as if there is no 5th gear at all.
Some people (including myself) drive around for months like that before deciding to fix it.

Itd be pretty unlikely while bathed in 80W-90 oil to be able to bounce up and cause any problems. I only drove on sealed roads though.

However as your description is similar to that of my missus (phone call-it wont go, whats wrong with it!!?? or "the oil light was on so I covered it with a bandaid"), I'll add that if "gone" means its making funny noises then it is rapidly self-destructing and any driving will hasten its demise and $.
AnswerID: 463382

Reply By: Member Andys Aussie Adventure - Tuesday, Aug 23, 2011 at 22:08

Tuesday, Aug 23, 2011 at 22:08
Hi Wazzie, I have a triton that lost 5th gear up Cape York last year. It has now done 10,000 kls with only 4th and no problems, and still going. I just keep the speed down and it uses a little more fuel, but otherwise fine.

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Reply By: Dennis Ellery - Tuesday, Aug 23, 2011 at 22:18

Tuesday, Aug 23, 2011 at 22:18
I own a 2008 Toyota Troopy (5 speed manual box).
Done the big loop twice around Australia towing a 3 tonne van in 4th gear- during my travels talked to owners and professional repairers of gearboxes for these vehicles and the advice is don't tow heavy loads in 5th gear.
I have tested my 4th and 5th gear fuel economy towing a 3 tonne van and the difference is negligible.
Also have met owners of other makes that have damaged 5th gear towing caravans.
If you want to play it safe - tow in 4th.
AnswerID: 463386

Follow Up By: Hairs & Fysh - Wednesday, Aug 24, 2011 at 10:26

Wednesday, Aug 24, 2011 at 10:26
Agree with you Dennis,
I tow in 4th, 80 series GXL 1hd-t, on the odd occasion I'll grab 5th down a long hill, for the rest it's in 4th.
The difference in fuel economy is one fifth of buggar all.
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Reply By: John Robo - Wednesday, Aug 24, 2011 at 18:20

Wednesday, Aug 24, 2011 at 18:20
Wozzie dont tow in 5th Gear at all use 4th only gearboxes not made to use 5th gearwhen pulling anything heavy Regards john Robo
AnswerID: 463451

Reply By: fisho64 - Wednesday, Aug 24, 2011 at 19:31

Wednesday, Aug 24, 2011 at 19:31
mmm-the advice cant have been required too urgently-24hrs, 6 replies and not a peep...
AnswerID: 463458

Follow Up By: wozzie (WA) - Wednesday, Aug 24, 2011 at 20:10

Wednesday, Aug 24, 2011 at 20:10
My sincere apologies Fisho, but I lost internet connectivity shortly after I posted. Have been out of mobile/3g range all day and just reconnected.

Mind you I was'nt aware that there was a certain time limit on the word urgent..


There were some good advice that has been posted, although searching through my owners manual for the vehicle, only mentions going down to a lower gear ( a natural thing to do anyway, and something I have managed to grasp over the past 46 or so years of driving ) when ascending a hill.

The only other mention of the overdrive gear (5th gear) is that it there to enhance fuel economy.

If it should be a requirement to only use 4th gear when towing, it should be mentioned in their literature.

From my limited research that I have managed to do this evening, I see that there are quite a few references to stripping/breaking the 5th gear.

It seems that when they upgrade motors for different models and fit turbo chargers as standard , they often neglect to strengthen the transmission to account for the extra power.

Ho Hum, we'll see what the service dept's have to say on friday when I get them to look at it.

Thanks all that gave good and sensible advice.

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