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Issues with 5th/6th gear (and 1st/2nd)

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Finally checking up on this thread now that I'm hoping to get driving a little more again. I have definite issues 5th & 6th, missed multiple changes at high speed (overtaking etc) due to gear just not wanting to go in.
I also mentioned 1st & 2nd when it was last in and they noted both issues but wanted me to stick with it to see if it changed.
I'm on 9k miles and once things are less stressed I will be asking them to do the 5th & 6th Synchros and then will see how the cables are - think I might measure the gaps before and after it's been in too 🤔
 
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On Saturday we tried adjusting the cables with the method from @Jajodu ,but with the forge short shifter installed.

Turns out the shorter throw makes it impossible to do the proper adjustment because the plastic holes do not match up anymore. The hole on the side of the shifter assembly can still be used with an Allen key, the one on the back of it does not line up anymore. Nevertheless we tried keeping it in position as good as we could and then released the pressure off the cables from within the engine bay. We noticed a small enhancement. But it's nothing that can be done real quick. You need time to find a proper throw adjustment of the forge shifter which works well enough with the adjusted cable lengths.

We now just need some kind of tool to keep the shifter locked in position without utilizing the holes, this would make the process a whole lot easier.
 
Bu11eT said:
On Saturday we tried adjusting the cables with the method from @Jajodu ,but with the forge short shifter installed.

Turns out the shorter throw makes it impossible to do the proper adjustment because the plastic holes do not match up anymore. The hole on the side of the shifter assembly can still be used with an Allen key, the one on the back of it does not line up anymore. Nevertheless we tried keeping it in position as good as we could and then released the pressure off the cables from within the engine bay. We noticed a small enhancement. But it's nothing that can be done real quick. You need time to find a proper throw adjustment of the forge shifter which works well enough with the adjusted cable lengths.

We now just need some kind of tool to keep the shifter locked in position without utilizing the holes, this would make the process a whole lot easier.
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You need to make a tool with a 4.5mm diameter that spans the two holes in the gearshift housing with a branch off that goes forward to the gearstick hole like an allan key with the short part of the L through the gearlever.
 
Why not use the drill bit as normal and cable tie the gearstick to the drill bit and wedge it so it can't move backwards, the cable tie will stop it going forwards, Allen key in the selector actuator and that should immobilise the stick, then do the cable adjustment.
 
I did my short-shifter first to find a position and distance that felt nice, then I went ahead and played around a bit with the cables until they were the way I liked them.

With the short-shifter installed it is quite a bit harder to dial in the cable length correctly, but it seems to need a bit more play.
 
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Jajodu said:
I think these drift out of adjustment over a period of time, mine started off really good then after about 10k miles it began to become notchy, my gearbox serial number was not in the affected range regarding 5/6 synchros so I suspected cable issues. It's bloody lovely now.
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I agree, it's cable stretch. Considering its location and amount of heat there is in the area, it's a very good likelyhood. :)
 
After some 10kkms+ my 5th/6th issue returned(swapped it around 13k initially(now have 31k on the clock)... Went to the dealer, they drove it and issue was identified even on the test drive, they will write to Hyundai that i demand a new gearbox. Hope it's approved, if not then i only get the gear swaps again...Which doesnt make sense to me but better than nothing i guess. Hope i get a new gearbox ✌
 
PeterP said:
After some 10kkms+ my 5th/6th issue returned(swapped it around 13k initially(now have 31k on the clock)... Went to the dealer, they drove it and issue was identified even on the test drive, they will write to Hyundai that i demand a new gearbox. Hope it's approved, if not then i only get the gear swaps again...Which doesnt make sense to me but better than nothing i guess. Hope i get a new gearbox ✌
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So you've already had the gear synchros replaced before?
 
PeterP said:
Idk i leave the decision to my dealer... If that's what will be suggested by Hyundai then so be it. I just want a normal working gearbox 🤷‍♂️
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That's a fair point. Maybe just ask them to look at the gear change cables first, as this one is a way easier job and will not require a disassembly of half the vehicle. Thinking about technicians who forget to tighten bolts when re-assembling the vehicle...
 
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Bu11eT said:
That's a fair point. Maybe just ask them to look at the gear change cables first, as this one is a way easier job and will not require a disassembly of half the vehicle. Thinking about technicians who forget to tighten bolts when re-assembling the vehicle...
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Yeah i get what you mean, will give them a call tomorrow. Today is a bit late already. Even though they already did it once so the second time should be even easier 🤔 :p
 
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Quick update, as i couldnt get a call on them on Friday and i also forgot cuz im nightshift i was too late. Gave them a call today and the news are the following. The gearbox claim was denied, we got a 3rd, 5th and 6th gear and syncros approved. So when those will arrive the car will go to the shop and get those replaced. They will also check the gear change cables because i mentioned to them what was statted above 👍 hope this will be my last issues i have with the gearbox and after i get it back it will stop ✌ 😁
 
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PeterP said:
Got a call yesterday, car is going in on Monday and will take 2 days approximately to do the change. Will get a replacement car meanwhile. ✌
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This was false forgot to update, just dropped the car off because the parts arrived today. Got an i20 with 120 hp woohoo 😬 😁 ✌ 😆 He said he will call me when they finish, approx. 2 days. So should get it back on thursday.
 
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