300TDI auto won't change when cold!

**JohnE** · 2nd June 2012, 06:28 AM

Thanks in advance for the advice.

I know this question has been asked before, i have researched the WWW about it.
Problem; when I start the disco off when cold it will not change from first gear sometimes has gone to nearly 4k in the rev range and it stays in first gear, i back off and then there is no gear, slow it down give it a rev and it goes back into first gear. Driving up the hill from my place it takes about a km to get it to change via a combination of stopping starting and driving slow, then it changes up and is fine after that. if I drive down the hil and let it idle along it changes up after about 1/2 a km, then is fine after that.
The kickdown wasn;t working too well actually not at all.
The past week sometimes I put it in gear and there is nothing forward or reverse. A bit of gear lever fiddling and it goes into gear.

Living near Lismore there are not a lot of transmission experts about so I went to one that I had spoken to before. I wanted to know if they knew ZF boxes, they told me they did.
This week had it booked it, as all the info I got seemed to point to the govenor having 'crap' in it the 'expert' said that cleaning it would work, Dropped it off and picked it up in the afternoon, still the same problem. Went back and The 'expert' told me all he did was move the kickdown cable to the highest setting and it changed fine for him. The plus side is he didn;t charge me for it. I again explained what it was doing and he then seemed unsure of what it could be and maybe needed a flush or the servo valve might be stuck ( filter and oil were changed about a month ago. And it was doing it before that) The first time I spoke to him he reckoned it was probably the govenor and it needed a clean.

Now i don;t know whether to take it back to them to get them to do what they first were going to do, my confidence in their ability is not too good.

Solution. At this stage have no idea.
has anyone, I know a few have, had the same problem and how did you get it fixed.
Does it mean another transmission?
According to most reports a new one will cost more than the NRMA has valued the car at.
A recoed one from the Ashcrofts is about 700 odd pounds plus freight.
Are there any good honest ZF/4wd experts anywhere south of brissy preferably the gold coast?

john

**Blknight.aus** · 2nd June 2012, 06:36 AM

new filter + oil change....

if you want to bush hack it...

drop the ATF put diesel in it, warm it up with all 4 wheels off the ground)

flush the diesel out with new ATF.

**justinc** · 2nd June 2012, 07:46 AM

John,

Sounds very like the Governor sticking and/or downshift cable sticking/ frayed in the outer. I am concerned they tried the downshift cable in its max position and reported OK

, that is wrong. The governor is a pain to get at due to removing the transfer case first, and I would suggest that coupled with your experience with no gear selection at times at all I would be concerned the problem could be deeper still, trans overhaul imminent?

JC

**bigcarle** · 2nd June 2012, 08:10 AM

i had a problem years ago with a B/W sticking in gear until warm, turned out to be a sticking kick-down cable from too many engine cleans, i would look there as a "quick" fix and also follow blknight suggestions, easier than doing the governor which can be done if all else fails

**Tank** · 2nd June 2012, 03:37 PM

There is a Teflon based oil that you can use in Autos and it can be a temporary fix for the governor sticking, like yours is, this advice was given to me by a local Auto Trans repairer, not a cure but it will keep it going till you need to rebuild, can't think of the name, might be made by Wynns, about $30 a bottle 500ml, Regards Frank.

**JohnE** · 2nd June 2012, 05:32 PM

many thanks for the replies so far, I keep thinking its something simple, and not major. it only started a couple of months ago and yes like big carle mine has been washed regularly under bonnet, after all they all leak!!
the govenor seems free enough even when you run it manually, doesn;t seem to be sticking, but I'l take that suggestion on board, i might even loosen it off because since thursday it has been rough shifting, might be too tight.

Not sure about the wynns product, but there is one out their that I discovered this morning called Lubeguard.its a yank product.
International Lubricants Inc. (ILI) - Makers of LUBEGARD

it reads well and the testimonial page seems ok there are even some comments from transmission repairers in OZ. I have the details of one on the north shore, so will call them on monday to see if their comments are true.

john

**JohnE** · 2nd June 2012, 05:38 PM

one more for Dave, flush it with diesel?
ok so i drop the 5 litres from the pan put in 5 litres
of diesel run it in gear with the wheels of the ground till warm easy enough.
but how mnay flushes will get all the diesel out. It holds 9 litres all up.
a couple of flushes then change the filter??

thanks
john

**justinc** · 2nd June 2012, 05:39 PM

Originally Posted by JohnE

many thanks for the replies so far, I keep thinking its something simple, and not major. it only started a couple of months ago and yes like big carle mine has been washed regularly under bonnet, after all they all leak!!
the govenor seems free enough even when you run it manually, doesn;t seem to be sticking, but I'l take that suggestion on board, i might even loosen it off because since thursday it has been rough shifting, might be too tight.

Not sure about the wynns product, but there is one out their that I discovered this morning called Lubeguard.its a yank product.
International Lubricants Inc. (ILI) - Makers of LUBEGARD

it reads well and the testimonial page seems ok there are even some comments from transmission repairers in OZ. I have the details of one on the north shore, so will call them on monday to see if their comments are true.

john

Kickdown cable replacement in a ZF 4HP requires removal of the valvebody, so no quick fixes there I'm afraid , and you will need to have a surgically clean area to work in, and enjoy lying in a pool of ATF...

JC

**Blknight.aus** · 2nd June 2012, 05:43 PM

Originally Posted by JohnE

one more for Dave, flush it with diesel?
ok so i drop the 5 litres from the pan put in 5 litres
of diesel run it in gear with the wheels of the ground till warm easy enough.
but how mnay flushes will get all the diesel out. It holds 9 litres all up.
a couple of flushes then change the filter??

thanks
john

20-30 liters.

**Tank** · 2nd June 2012, 07:53 PM

Originally Posted by JohnE

many thanks for the replies so far, I keep thinking its something simple, and not major. it only started a couple of months ago and yes like big carle mine has been washed regularly under bonnet, after all they all leak!!
the govenor seems free enough even when you run it manually, doesn;t seem to be sticking, but I'l take that suggestion on board, i might even loosen it off because since thursday it has been rough shifting, might be too tight.

Not sure about the wynns product, but there is one out their that I discovered this morning called Lubeguard.its a yank product.
International Lubricants Inc. (ILI) - Makers of LUBEGARD

it reads well and the testimonial page seems ok there are even some comments from transmission repairers in OZ. I have the details of one on the north shore, so will call them on monday to see if their comments are true.

john

As I said it may be made by Wynns, I do know that it is a Teflon based Auto product that is designed to free up sticky valves and governors, mine does the same, it does it less here on the coast than it does up in Canberra so altitude may have a bearing as well, It only does it once then OK or the rest of the day, for $30 worth trying, regards Frank.

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