Hello everyone, I am new here and hoping someone might be able to give me a steer...
I am based in the UK and running a 2007 Outlander 2.0 Di-D Elegance manual. Its been a great car and always had servicing done by the book. It has just tipped 128k miles and the gearbox has died
The car was in cruise on the motorway (highway) and we had been going about 2hrs when it just stopped pulling.... I thought the cruise control had dropped out, so I pressed the throttle to hear a nasty buzzing noise and the engine just revved. Luckily traffic was light and I was able to make it to the hard shoulder and coast. I then found I had the other five gears, but 6th was toasted. Luckily I was only a mile from a junction so was able to limp off the motorway and park at some services (huge relief - sleeping family on board)... where we were rescued by recovery.
On further inspection it appears that the 5 lowest of the 6 gears are present, but 6th just makes a hideous grinding buzzing noise. The gearbox also makes some real nasty chattering / grinding noises with the engine running and the car in neutral. Dipping the clutch quietens it down (as expected). So it sounds like the gearbox has eaten itself

Are there any known failures with these manual Outlander gearboxes?

In all probability I am going to need to source a replacement manual gearbox - does anyone have any contacts for some specialist Mitsubishi breakers or ANY breaker in the UK that might have a gearbox for one of these? I am not inclined to take it to the main Mitsubishi dealer locally and really can't stretch to main dealer prices for replacement parts of this magnitude.
I have now had the car recovered straight to another garage to be assessed and make a plan.
Help!

 

Hmmmm... bit of a mystery this. Garage have called, they have dropped the gearbox oil and there are no clues at all. Oil qty. is correct, oil is clean, no foreign objects came out in the oil.
Only thing to do now is drop the gearbox out and take a look inside....
The failure was spontaneous - no clues, noise or warning, it just failed. So it must be something inside the 'box.
Anyone ever heard of anything like this before??

 

That is an odd one for sure. Please keep us up to date.

My wildest guess would be a hairline fracture in a sprocket and it finally came apart in large chunks. Some chunks may be rattling around while the clutch is engaged...stopping when you press on the peddle. Bent gear forks would affect all gears, so wouldn't be something like that. Probably not gaulded bearings/bushings...no filings in the oil.

If they haven't drained all the oil, may not be a bad idea to have them take a sample directly into a non-contaminiated plastic bottle. May want to do an oil sample analysis at some point to determine if there were any microscopic wear materials in there. Have you been keeping up with maintenance of the oil?

 

Maybe the gears are ok but the selector hub / ring is broken with the parts still captive as such.

 

Thanks, yeah it really is odd There were no clues or early warnings at all, I am pretty mechanically sympathetic and tend to notice changes in feel / noise etc. and there was absolutely nothing.
The garage are taking the 'box out now and I guess we will have to open it up and have a look.
Anyone know any Mitsubishi breakers in the UK?

 

Great garage have the gearbox out.... dual mass flywheel is also toasted This is rapidly turning expensive.....
So now the gearbox has to go off to the reconditioners for assessment and its time to price up a new flywheel and clutch. Again, any pointers here guys?

 

Don't buy junk. If you do, you will only have to do it again. Junk parts might offer a ganantee, but they don't pay labor. Buy good stuff and don't be afraid to pay a little extra.

 

The gearbox is apart for inspection and deemed unserviceable 6th gear gone, input shaft gone, 3rd, 4th and 5th all need replacing too. So I have had to source a 2nd hand replacement 'box from a crash damaged Outlander. Ouch. The breaker is also telling me that the gearboxes seem to be a weak point as he has sold the 'box from every Outlander he has broken Awaiting the replacement 'box now.

 

Just to bring this to a close - my Outlander 2.0 Di-D is back on the road! Although my wallet feels very bruised I ended up sourcing a 2nd hand gearbox from a vehicle breakers, which was the only viable option and stumped up for a new LUK dual mass flywheel.
The original failure was the gearbox - the 6th gear cog which is a splined fit onto the input shaft, had stripped the internal splines. Its a failure neither I nor the gearbox rebuilder had ever seen before, basically the gear was just spinning on the input shaft and had rendered the input shaft and gear cog useless - it looked like the splines had just worn out. The dual mass flywheel was also worn out - whether this was the cause of the gearbox failure or just incidental is unknown.
In the course of finding a new flywheel there was also some to and fro to LUK, who seem to list two part no.s for it. They confirmed that the correct part no. for the replacement dual mass flywheel was 415044110 (the original Mitsubishi flywheel removed was manufactured by LUK and carried the Mitsubishi part no. 1120A063 - this x-referenced to 415044110).
The LUK part no. that came up from the various motor factors looking to supply was LUK 415043710, but LUK were NOT able to confirm if this was the correct part for the Outlander 2.0 Di-D, defaulting to 415044110 as being the right one. It looks like there is an anomoly somewhere in the LUK parts catalogue as they couldn't confirm what that 3710 number would fit (two different motor factors working independently gave me the same outcome having spoken to LUK direct), so if you find yourself in a similar position check carefully. This was also all sourced in the UK.
For clarity, this car is a BSY engine code, CW8W chassis code.
Hopefully this is the end of the saga for me, but it has badly shaken my faith in the car as I never would have expected a component as major as this to have failed at this mileage.