While driving, first, second and fourth gears would intermittently lock/freeze up?

Tiny
RYAN SEVERN
  • MEMBER
  • 1997 TOYOTA TACOMA
  • 2.7L
  • 4 CYL
  • 4WD
  • MANUAL
  • 280,000 MILES
Last week my 1997 Toyota Hilux (ta.V.V)
Had a strange fault / issue develop.

When driving, the 1st, 2nd and 4th gear would intermittently lock/ freeze up on me.

Varying speeds, different gears, seemingly at random intervals the car would refuse to switch into gear. Not grinding into gear so much as completely refusing to enter the gear.

I changed out the slave and master cylinders thinking it would solve the issue, but the issue still persists although now it seems to only be 2nd gear that locks out in the same fashion.

So, changing the master and slave seems to have eased the issue so far but not solved it completely.

I did also adjust the free play in the clutch pedal, extending the push rod out as far as I thought possible.

The issue seems to only persist while the car is running, if the engine is off, the gears cycle smoothly..

Also, a friend told me to try coming to a stop, cycle into reverse and then back to second gear and this seems to unlock 2nd gear instantly.

Sometimes 2nd gear grinds a little bit but goes in, others it locks completely out. The problem is intermittent.

I'm worried about causing damage to the gears if I continue to drive in these awkward fashion.

I have checked the transmission fluid and the levels are good.

There was some sludge build up and dark residue in the old master cylinder upon inspection.

I bled the system quite excessively after replacing both cylinders.
Any tips to make the bleeding process more efficient would be greatly appreciated too as 8 must have put at least 1lt of brake fluid through the system during the bleeding process.

I really appreciate this site and the time and energy you guys put in to offering this service! It brings a newfound hope to a budding home mechanic like myself.
Monday, July 10th, 2023 AT 5:13 PM

5 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

If the transmission shifts easily with the engine off, but there is difficulty when it's running, the clutch isn't fully disengaging.

Do you know how old the clutch is in the vehicle? You may have a failing pressure plate or clutch disc.

Let me know.

Joe
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Monday, July 10th, 2023 AT 11:00 PM
Tiny
RYAN SEVERN
  • MEMBER
  • 5 POSTS
The clutch was replaced on 14/6/2017
It was replaced with a 'heavy duty clutch'
The word receipt also states that the following items were replaced
- clutch kit
- flywheel
- rear seal

Thank you for your reply.
It has become apparent that the problem does not occur when starting off in 1st and then in 2nd. But when coming down gears from 3rd/4th into second.

Many thanks,
Ryan
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Tuesday, July 11th, 2023 AT 1:58 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

If it only, does it when downshifting from 4th to 3rd, you may have an internal issue with a synchronizer. Do me a favor. If you haven't already, check the fluid level in the transmission. If it is dirty, change it.

Let me know what you find.

Joe
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Tuesday, July 11th, 2023 AT 7:22 PM
Tiny
RYAN SEVERN
  • MEMBER
  • 5 POSTS
Hey Joe, the problem gear is only 2nd gear. What I meant to say before is that if I try to down shift to 2nd gear from 3rd gear or 4th gear that's where the issue lies. Shifting between 3rd, 4th and 5th seems to be okay at present. I have checked the trans fluid and levels are good and condition was clear.
Greatly appreciate your time with this matter, thanks.
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Thursday, July 13th, 2023 AT 5:31 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

Okay, if that is the only issue, then synchronizers are the likely problem. Does it shift easily from first to second?

I believe on this vehicle the synchronizer for gears 1 and 4 is the same one and 2 and 3 are the same. So, let me know if there are any issues shift to 2nd or 3rd.

Joe
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Thursday, July 13th, 2023 AT 7:16 PM

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