Problem with transmission hard shifting and clunking all the time

Tiny
GEORGARAS
  • MEMBER
  • 2003 HYUNDAI COUPE
  • 1.6L
  • 4 CYL
  • 2WD
  • 85,000 MILES
1. I bought the car new in 2003 it is the GK European edition model with manual transmission.
2 after 50.000 (year 2008) I change original gear oil with Eneos 75w90 gl-5
3. At 75.000 miles (year 2014) its started grinding in second gear and nothing more. Then I start asking mechanics why it is ridding second gear?
4. I change gear oil with Castrol multi-vehicle 100% 75w90 gl4, then hard shifting begun and grinding second gear and fifth gear some times, I the middle time I change clutch set and the lower engine mounts and the gear problem persist.
5. After 4.000 miles change two times gear oil using Korean zic 75w85 gl-4 semi-synthetic the problem persist.
6. After 5.000 I change gear oil with motul motylgear 75w90 gl-4/gl5 semi-synthetic, the grinding problem went away but hard shifting insist at second and third gears.
7. After 3.000 I changed with comma semi-synthetic sx75w90 gl4, that I can see that second gear some times grinding, a little better at the hard shifting second gear and third gear, but hard shifting is there together with clunk noise as you put the gear in. In city daily drive became very frustrating because for first to second, I have to wait two to three seconds for the gear to come in.
thanks, George in Athens Greece. Any ideas?
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Friday, October 21st, 2016 AT 3:59 AM

7 Replies

Tiny
HMAC300
  • EXPERT
This can be anything from a cable/linkage problem to shift forks or syncros in transmission. Check all your hookups for proper adjustment and if it still grinds then the transmission has to come apart. Transmission should use api GL-4 75-90 W.
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Friday, October 21st, 2016 AT 6:47 AM
Tiny
GEORGARAS
  • MEMBER
Is surely, not cable linkage problem, but here nobody wants to talk for tarnsmission opening, only for used trasmission. To but on.
Better to wait utill the trasmission die.
Thanks for you answer, good day to you all.
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Sunday, October 23rd, 2016 AT 11:06 PM
Tiny
KEN
  • ADMIN
Hi GEORGARAS,

It sounds like a second gear synchro problem, not letting the gear slow down enough to engage, the transmission must be rebuilt to fix it.

Please let us know what you find so it will help others.

Best, Ken
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Monday, October 24th, 2016 AT 7:34 PM
Tiny
GEORGARAS
  • MEMBER
Ok, but why do I have hard shifting to third and fourth gear?And some times to fifth. Gear likes idle engine revolution to get in. Is it a posibility for the synchros to accelerate more than unusual because the previous gear oil castrol was fully synthetic and motul was gl5 which means more slipper oils?
Comma sx75w90 semi synthetic. Is the proper oil for that transmission and cheap 6 euro per litter, but how long is going to get rid of the other (previous) that possisby stack in the synchro cones.
Should I change 1 more time with new comma, or should I use redline 75w90 gl4 witch is expessive 22 euro per 0.95 litter? Hoping to see any difference.
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Tuesday, October 25th, 2016 AT 2:57 AM
Tiny
HMAC300
  • EXPERT
I think it's worn out and your syncros are shot. The only way to tell is for trans to come apart. If synchros work right they don't care what speed engine is but if it wears or bearings wear then it screws up everything or if a fork is bent or worn out causes your problem. That is assuming everything else is ok like linkage etc. Like you say it is.
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Tuesday, October 25th, 2016 AT 5:44 AM
Tiny
GEORGARAS
  • MEMBER
When you say fork? Do you mean the fork out the transmission that push the clutch bearing? Or the fork inside that moves the synchros? As the matter of clutch set, I did my self new clutch set installation a year ago and everythink looked ok. Another think to ask. Next week iam doing left and right upper engine mounts installation. Specialy the right that contain oil, spleeded some oil around causing some small vibration during driving not at idle. Does a bent engine mount affect gear shhifting? If it does I will see. The 2 lower engine mounts frond and back was replaced, a year ago and I noticed a little inprovement at gear shifting. Sorry for my bad english!
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Wednesday, October 26th, 2016 AT 11:21 PM
Tiny
HMAC300
  • EXPERT
I'm taking about the shift fork for the synchro they can bend and wear out as well as plastic on them breaks off the motor mount may effect it but if it's cable shift then not a lot. I doubt your engine mount is bent more like broken if anything as that is what they do.
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Thursday, October 27th, 2016 AT 5:38 AM

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