Mercedes vito 109cdi W639 2nd gear not smooth

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Christosfazer

Member
Joined
Apr 16, 2020
Messages
35
Location
Greece
Car
Mercedes Vito 109cdi MY2008
Good evening to all from Greece,
Hope this thread finds you all full of health instead of this new "virus"
First of please do not laught with my english
I have just purchased a mercedes vito 109cdi w639 with 200000km (125000 miles) on clock.
Its a wonderful car but im having trouble with 2nd gear especially when car is cold or when i quick shift between 1st to 2nd.
I changed the transmission oil to RED LINE MTL 75w80 which improoved the performance of my gbx a lot BUT i still have some noise when quickshift from 1st to 2nd....
If i shift with delay from 1st to 2nd the shifting is perfect due to the RED LINE!

If someone has any advice please share it with me because i dont like to hear anything from my car :(

Thanks in advance,
Chris
 
I have had this issue with my Vito.

I replaced the selector forks inside the box (very worn)
I replaced the cables and the gear selector too.
 
Thanks for the quick reply,
What are these forks? Google camt find something for it :(
What was the cost for the replace?
 
They are inside the gearbox. It will have to removed and stripped to see if they are worn.

I would replace the cables first as they are common to wear.

A gearbox re-build, new clutch, selector cables and duel mass flywheel cost me about £1000 IIRC. No labour as I did it myself.
 
Is there any way to check if those cables needs to be replaced without disconnect them?
I ask because i have no joint on the lever handle :(
 
It is difficult to check the cables. They are adjustable though. Its very fiddly to do. I would get under the van and get someone to select 2nd for you while you watch the mechanism on the side of the box operate. It may give you a clue.
 
Thanks for the advices!
I will give a check tomorrow morning and i will try to spray some WD40 on there
 
Don't use WD. Thats just for expelling water. Use a spray grease if you can.
 
Ok i will try!
Is there any grease point on the gearbox?
Can i grease it to see if something change?
 
The mechanism on the side of the box you can grease.
 
Hello BlackC55 and all community again,
I tried to find the grease niple or grease point (dont know its name :) ) without luck so i greased the mechanism from the outer side (fitting points)

I thought that maybe its a good try to bleed the clutch and hope that will pop air bubbles (pray dor that :) )

Could you please help me ho can i bleed from air the clutch susyem?
Its fluid reservoir is the same as brakes?

Thanks,
 
Use a pressure bleeder on the brake fluid reservoir and open the bleed nipple on the clutch cylinder. Its behind a rubber bung on the side of the gearbox.
 
Just to add my experience. Worn 2nd gear synchros are quite common on Vitos. I’ve had mine since new in 2005 and I’m on my 3rd gearbox what Ive found is they are all worn and crunchy and have come across many in my job as a mobile mechanic. I’m sure that resting arm on gear-lever whilst driving RHD adds to it, I replaced my lever very expensive but well worth it.
also there is a big pendulum weight at the back of the gearbox, remove this and you’ll find a ball socket that’s normally quite loose tighten this up and you’ll make a great improvement lube all the selector linkages aswell.
check you prop shaft linkages also as the 2nd and 3rd are quite common to fail.
 
Just to add my experience. Worn 2nd gear synchros are quite common on Vitos. I’ve had mine since new in 2005 and I’m on my 3rd gearbox what Ive found is they are all worn and crunchy and have come across many in my job as a mobile mechanic. I’m sure that resting arm on gear-lever whilst driving RHD adds to it, I replaced my lever very expensive but well worth it.
also there is a big pendulum weight at the back of the gearbox, remove this and you’ll find a ball socket that’s normally quite loose tighten this up and you’ll make a great improvement lube all the selector linkages aswell.
check you prop shaft linkages also as the 2nd and 3rd are quite common to fail.

Leaning on the gear lever I am sure wore out the selector forks on my Vito.
 
It’s funny how common fault identification comes about with certain models etc
What really interests me is fellow Mercedes specialists experiences.
Vitos are great I’ve facelifted my 2005 that I’ve had from 2007 and done pretty much every repair on it but due to the emission control in London where I work it’s getting tough to work with financially and conscientiously. But my options are limited......where are you based c55
 
Portsmouth.
We look after a 2007 Vito with 815,000 on it with minimul work done. Only had one starter and alternator. Original turbo too!
 
Use a pressure bleeder on the brake fluid reservoir and open the bleed nipple on the clutch cylinder. Its behind a rubber bung on the side of the gearbox.

I have to open the bleed niple until its draining clear brake fluid?
 
What is the Mercedes Vito w639 recommended transmission oil?
Its a 6 manual with code

716637 00 672397

 
?
 

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