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pops out of 3rd gear under load


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HI, I borrowed my daughter's car, 2009 Aygo 1.0 petrol, manual. Roughly 109,000 miles on it.

Going down the motorway I noticed it was hard to get into 3rd, when slowing down in some slower traffic.

Next day going up a hill in 3rd at 60mph, it popped out of 3rd gear, and would always pop out when under load.

I guess the gearbox is knackered.

Are they all made of cheese? I'm used to German vehicles, got a VW T4 with 300,000 miles on it, still on the original gearbox (and, I suspect, the original clutch!).

Is it "pick any Aygo gearbox off eBay, and play the Aygo gearbox lottery?"

Try and find the newest and lowest mileage one I can?

I'll replace the clutch too while the gearbox is out.

Or scrap the car and get something German? We paid £900 for it, and the repair will cost a few hundred £££......

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I saw in a movie (car with high mileage tests) that one garage (who does the testing) said they had a gearbox for a car like that in stock.
Somebody asked for a change and didn't turn up for the appointment.
They don't manage to get rid of the gearbox as they never break down.

If the gear pops out of 3th often, i think you need a new one.
In all the km I did I only ruined a gearbox one time.
I know a while before, I tried to pull a car for a long way and start it that way. So I also know (kind of) where i got the broken gearbox.

Of course this is a Toyota group and you will find many people here who are convinced about the far better quality of Toyota in general compared to (f.e.) Volkswagen.
If interested and open to this kind of thing, I could post some lists of reliability where VW ends in the last 5 of 24 brands, where Toyota ends in the first group.

Of course, that doesn't mean that Toyota's will never fail and VW's will always fail.
Luckily it's not like that.

The good old Beetle were good cars for their time but the last 10-15 years, VW made a lot of cars that were too bad to get sold on our market and they are not even shy about it.
The vans are good and strong too but these are expensive 'cars'. The Aygo was made as a good, reliable and most of all cheap small car.
Many things have been designed to be rather light but also are not expensive to replace, compared to f.e. VW.


After 100.000 miles on a car, no technical problem is something to be ashamed of, as not only the build or R&D quality will decide when a vehicle breaks down.
100.000 miles gives a lot of use (sometimes multiple users) that plays a part too.

Do replace the clutch. They are not expensive and are a bit known to wear out, altough the new versions seem to do that less.
100.000 miles is a nice mileage to replace a clutch and it would be a little bit daft to not replace it now.
Gearbox : buy a second hand one, ..  Scrapped item, from a car with not too high mileage.
If it could be found in an accident car, i would always prefer an accident from the back or side, not from the front, if you choose a gearbox.
Don't know if that is scientifically right but just my opinion.
I would prefer to buy it from a specialised scrapper who always adds photo's from the donor vehicle (and mentions mileage) so you can see what's up with it.

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thank you Ivan Haelewyn, I get what you're saying about the reliability. The engine is a cracker, depends who made the gearbox, if its french or japanese.

I'm looking on eBay for low mileage gearboxes now, and will source a clutch.

 

It's a lovely car to drive!

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Honestly, it's (for me) not the best at all that I had for driving, but then again : i paid less than half compared to my last Renault.
That one had the engine replaced around 23000 miles and they still gave me a new engine with the same design faults as a replacement.

It's all a bit : you get what you paid for.  I know I bought CHEAP. I am not expecting a VW Passat driving character 🙂
For me, the price / quality of the car is good.

Engine and gearbox is Toyota in these cars (From my own memory).
In fact, the engine comes from Daihatsu, which is a part of Toyota group.

I did a small look around for you...
I found a gearbox in my country for 200 pounds from a donor car that had 4000 miles.
Several others in this price range from young donor cars 2017-2018.

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7 minutes ago, Catlover said:

Let us all know how you get on Steve. An interesting read.

Will do. Ordered new "uprated" clutch kit too for £49 - seems there was a problem with the original ones. Will be interesting to get it done. Watched it on YouTube, looks fairly straightforward, and took the guy 4 hours. I'll contact garage later. Will get my 2002 E320CDI mercedes back on the road as we have 4 cars and three have faults (Aygo - gearbox, Discovery 3 - oil leak, VW T4, minor fuel leak). 

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This takes me back to the first car I ever owned and Hillman Super Mink.  A lovely car that was great to drive and a very stately one for someone who was so young at the time,  that developed the same fault but I was young and short of money so I drove for a few months with my leg hooked around the gearstick.  It was very much bigger than the Aygo mind.

The question of reliably is always a two edge sword.  I drove an six cylinder Audi 80 for years, not a rare car but not that common either, and it was a great workhorse even though it was well over the magical 100,000 miles.  I had no problems with it for years but then the steering pump started to spew oil and the alternator was showing signs of failing.  For the cost of both at the time I could buy a decent smaller car, which is what I did, after all if I changed both the alternator and steering pump the rest of the car was still the same age.

The Aygo does have a few problems but then the spare parts are relatively cheap even from the dealers and there are so many on the roads getting parts is hardly and issue.  Really a case of swings and roundabouts.

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16 minutes ago, Hornet3D said:

This takes me back to the first car I ever owned and Hillman Super Mink.  A lovely car that was great to drive and a very stately one for someone who was so young at the time,  that developed the same fault but I was young and short of money so I drove for a few months with my leg hooked around the gearstick.  It was very much bigger than the Aygo mind.

The question of reliably is always a two edge sword.  I drove an six cylinder Audi 80 for years, not a rare car but not that common either, and it was a great workhorse even though it was well over the magical 100,000 miles.  I had no problems with it for years but then the steering pump started to spew oil and the alternator was showing signs of failing.  For the cost of both at the time I could buy a decent smaller car, which is what I did, after all if I changed both the alternator and steering pump the rest of the car was still the same age.

The Aygo does have a few problems but then the spare parts are relatively cheap even from the dealers and there are so many on the roads getting parts is hardly and issue.  Really a case of swings and roundabouts.

I have had many many Audis !. G reg 100 2.3e quattro, C reg 80CL, B reg 80 Sport, L reg 80TDI avant, A4 TDI. Plus had a few for spares......

All well over 100k!

Big cars, big bills.

I like the simplicity of the Aygo - would be good if it had A/C.. and cruise control.....

It's the evolution of the 1998 106 Peugeot that was my wife's first car. Not that much to go wrong with it. Cheap tyres, cheap parts.... simple for a mechanic to work on. The Discovery3 is a nightmare - needs to go to a specialist for 4 weeks (as he's so busy) for every little thing that goes wrong..... normal mechanics won't touch it.

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19 minutes ago, itsmydaughterscar said:

I have had many many Audis !. G reg 100 2.3e quattro, C reg 80CL, B reg 80 Sport, L reg 80TDI avant, A4 TDI. Plus had a few for spares......

All well over 100k!

Big cars, big bills.

I like the simplicity of the Aygo - would be good if it had A/C.. and cruise control.....

It's the evolution of the 1998 106 Peugeot that was my wife's first car. Not that much to go wrong with it. Cheap tyres, cheap parts.... simple for a mechanic to work on. The Discovery3 is a nightmare - needs to go to a specialist for 4 weeks (as he's so busy) for every little thing that goes wrong..... normal mechanics won't touch it.

I am lucky in that the Aygo I have was an ex demonstrator so had a lot of the goodies, I have climate control and although there is no cruise control it does have a speed limiter which at least leaves me to set on stretches of road works with speed restrictions, I just need to remember to keep my foot on the accelerator.

I had too Audi 80s, sadly I wrote the first one off, not that there was lot of damage just it was so old that any real repair bill was way passed what it was worth.  The six cylinder Audi 80 was it's replacement.  As to other cars, Hillman Minx, Morris 1100, Vauxhall Chevette, Vauxhall Viva (2), Morris Marina, Austin Montego MG, Vauxhall Carlton, Renault E, Toyota Corolla, Renault Laguna Toyota, MR2, Ford Granada, Honda Civic Jordan, Honda CRV and now the Toyota Aygo.  There was also a couple Bedford based camper vans in there as well and three or four kits cars just to spice things up. 

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Sorry to hear that, not much help, but gearbox issues are rare on these cars, had our similar 107 13 years now and it been very reliable. Early cars had iffy clutches and water pumps, ours one of them, but your 09 should be ok on both counts as they sorted by then, not the water leaks though. Good news is they cheap and easy to fix and being fairly basic less to go wrong. 

Good luck sorting it, keep the faith cos as you say they are great little cars to run and drive.  

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Have you checked the engine mounts, the lower dog bone does tend to wear, the shifter also wear and can cause shifting issues, you can bodge it with screws or do it properly

£49 seem too cheap for a clutch is that the clutch and pressure plate, what about the throw out bearing ?

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2 minutes ago, flash22 said:

Have you checked the engine mounts, the lower dog bone does tend to wear, the shifters also wear and can cause shifting issues, you can bodge it with screws or do it properly

£49 seem too cheap for a clutch is that the clutch and pressure plate, what about the throw out bearing ?

Not checked engine mounts - is this the one? https://www.ebay.co.uk/itm/313586836409?fits=Car+Make%3AToyota|Model%3AAygo&hash=item49033b63b9:g:6uIAAOSwpQ9g3Sxt

 

When you say "the shifters". do you mean the cables going to and from the gear knob?

The clutch is here on eBay, with pressure plate and bearing:

https://www.ebay.co.uk/itm/333792608948?fits=Model%3AAygo&_trkparms=ispr%3D5&hash=item4db79702b4:g:HRsAAOSwdqlh782P&amdata=enc%3AAQAGAAACcPYe5NmHp%2B2JMhMi7yxGiTJkPrKr5t53CooMSQt2orsSprd4IgPv6LBzlteBBg9Pe6nbawpBeO5QVqWER1gl0fHSG%2BUTDYUwRnv0vnvDfoOiQ3qQS8DVFCSWxzzekwMVtbshNoiuVDEwxMP94O%2F7FQPY6XtKnBpoVlPK0rB0cenHeD2gi%2FGCrhgp7IJVGHoxFckUQNY14eQOotFIspxGG3%2FGX32y6RfoTvKGSXSag344QhlUupORfY3JTbbjJhQcZWEGYLpCoCTAsmuoX8IlzEX25dI0G79Odl1S2laoGqieOopFuLjuQmKkck7NDBL0Ga7U%2BZgwRBiWI3lE5IVZG%2BSlOPEkR0IlXcy%2Br8WTWT%2B15b70N9gEaP9loLjt7%2FdV1vJlwvQrVQl0T8HqpchtadEznzFQxuKtPOvyX8Ejo%2Bqh2s%2BzsdaFwPIA%2FcR7G7M0EhxyU8gtgvFrNhajL8ivOBVvblMGie68HJnr9K8hXdGWQ0qH3o3DNEbJl0oM1iKQBbKUOWUPiUz0a5uj0eIA4bN97m7R4nC55IS1MIaG4FdzJT91IfKbTcJxmVOYz1ExPQoD4zRrfQOYosDKZkGiIQFb184oLGFTKa2F9JkRpbW30ZryBbtfX2%2FPiDyMSifkdVqgqMcJn0Qy8ab6v9Ro3agCCIRa6s8gx0SAjF6F3tI8G4KmYD2Qs7un6vcKI17sCAR%2BORZP8oBEm413S4STjeAgjVxKaOEtVGA4l9qT9Qmr9SQ8M5Z3zJQRbYEyB1KHX4o%2BL375o73P6srWQPXNcBNNzyXO74ZWI6E1ca%2F5b2Btcw2Y2WBPUsBozzdXYHXuPQ%3D%3D|clp%3A2334524|tkp%3ABlBMULaBgevpXw

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That's the lower rear engine mount "dog bone" it stops the engine moving/twisting under load

that was a typo, it should have been Shifter, as in the actual selector there is a plastic collar that wears this can give a sloppy gear change and other issues

a company used to make a kit to repair, but i have not seen them in a while

found them https://www.ebay.co.uk/itm/164639941985

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8 minutes ago, flash22 said:

That's the lower rear engine mount "dog bone" it stops the engine moving/twisting under load

that was a typo, it should have been Shifter, as in the actual selector there is a plastic collar that wears this can give a sloppy gear change and other issues

a company used to make a kit to repair, but i have not seen them in a while

found them https://www.ebay.co.uk/itm/164639941985

I'll get that "dogbone" mount as well as the repair kit - got to be worth it while I'm getting the clutch and gearbox done I guess. Will get garage to check mount first though....

 

Thanks for your help,

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3 hours ago, itsmydaughterscar said:

I have found a gearbox from a 2014 car with 54000 miles on it, for £150 (pounds). Will probably buy that one. Many thanks for posting.

I'd recommend a Blue Print clutch kit on Amazon £50 I'm on my 2nd one but my 1st did 155ooo miles and it still had a few thousand miles left on it ...I changed it because I had the gearbox out anyway 😉

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2 minutes ago, Colin J.S said:

I'd recommend a Blue Print clutch kit on Amazon £50 I'm on my 2nd one but my 1st did 155ooo miles and it still had a few thousand miles left on it ...I changed it because I had the gearbox out anyway 😉

Sounds like the cheap ones are OK then - no need to get a LUK one then... I've already ordered one off eBay, but thanks for the recommendations.

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Considering it was a 2009 Aygo, she's done well to last until now before the gearbox starts playing up.

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On 3/3/2022 at 1:36 PM, Wiz201 said:

Considering it was a 2009 Aygo, she's done well to last until now before the gearbox starts playing up.

had to use it to go shopping on the weekend, noticed that 4th is whining a lot too....

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On 3/3/2022 at 8:51 AM, Hornet3D said:

I am lucky in that the Aygo I have was an ex demonstrator so had a lot of the goodies, I have climate control and although there is no cruise control it does have a speed limiter which at least leaves me to set on stretches of road works with speed restrictions, I just need to remember to keep my foot on the accelerator.

I had too Audi 80s, sadly I wrote the first one off, not that there was lot of damage just it was so old that any real repair bill was way passed what it was worth.  The six cylinder Audi 80 was it's replacement.  As to other cars, Hillman Minx, Morris 1100, Vauxhall Chevette, Vauxhall Viva (2), Morris Marina, Austin Montego MG, Vauxhall Carlton, Renault E, Toyota Corolla, Renault Laguna Toyota, MR2, Ford Granada, Honda Civic Jordan, Honda CRV and now the Toyota Aygo.  There was also a couple Bedford based camper vans in there as well and three or four kits cars just to spice things up. 

That’s a heck of a lot of cars Paul, were they all driven by yourself?? You set me thinking about how many cars I’ve driven and owned in my lifetime and I can scarcely believe that I’ve owned and driven at least 18 cars that I can remember. Kettle calling “black bottom” to the pot.😝👍

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1 hour ago, Bernard Foy said:

That’s a heck of a lot of cars Paul, were they all driven by yourself?? You set me thinking about how many cars I’ve driven and owned in my lifetime and I can scarcely believe that I’ve owned and driven at least 18 cars that I can remember. Kettle calling “black bottom” to the pot.😝👍

I think a lot of drivers forget just how many cars they have driven until something makes them stop and think.  Yes they were all driven by me I even missed one, there was a  brand new Hyundai Coupe between the Ford Granada and the Honda Civic in fact I traded it in after eighteen months for the Civic.   The Granada I had less than a year, I took it in exchange for one of the camper vans, it was the first automatic I ever had and it was probably the least liked car I had ever owned.  Then it decided to throw the transmission fluid all over the M4 on the way back home form work one day. I never drove it again after that.

I also drove another Toyota Corolla and a Renault, I think Megane, over about three years but they were leased for me when I worked in Sweden.  The Laguna overlapped with the Honda Civic and the camper vans were never our sole means of transport.  I liked the Hyundai and would have kept it a lot longer had my wife not turned my head towards the Honda Civic which was as limited edition Jordan.  I was a fan of Eddie Jordan at the time so it was an opportunity I could not resist.

DVNside.jpg

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Honestly, a German equivalent will be no better built - they are often worse. After a string of VWs before by Corolla, they aren’t what they used to be back in the 90s. Look at satisfaction surveys such as the one Auto Express did. VW, Audi near the bottom, BMW not great - Lexus, Toyota & Honda at the top

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2 hours ago, Hornet3D said:

I think a lot of drivers forget just how many cars they have driven until something makes them stop and think.  Yes they were all driven by me I even missed one, there was a  brand new Hyundai Coupe between the Ford Granada and the Honda Civic in fact I traded it in after eighteen months for the Civic.   The Granada I had less than a year, I took it in exchange for one of the camper vans, it was the first automatic I ever had and it was probably the least liked car I had ever owned.  Then it decided to throw the transmission fluid all over the M4 on the way back home form work one day. I never drove it again after that.

I also drove another Toyota Corolla and a Renault, I think Megane, over about three years but they were leased for me when I worked in Sweden.  The Laguna overlapped with the Honda Civic and the camper vans were never our sole means of transport.  I liked the Hyundai and would have kept it a lot longer had my wife not turned my head towards the Honda Civic which was as limited edition Jordan.  I was a fan of Eddie Jordan at the time so it was an opportunity I could not resist.

DVNside.jpg

Here are mine - can you see a theme??? Where are you in Wiltshire, we used to live in Calne(fornia!!!)

1.  Audi 80 CL saloon

2. Audi 80 Sport saloon

3. Audi 80 Sport saloon

4. Audi 80 TDI avant

5. Audi 100 quattro avant

6. Audi 100 quattro saloon

7. Audi 100 SE avant

8. Audi 100 turbo avant

9. Audi A4 1.9 TDI SE avant

VW T4 Caravelle

Land Rover Discovery 3 TDV6 HSE

Mercedes E320CDI wagon

Skoda Octavia 1.9TDI

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