Mitsubishi L200 & Fiat Fullback Gearbox Issues | 3rd Gear Crunch & Disengagement

Introduction

A common issue we see in the workshop with the L200 & Fullback models is the gearbox jumping out of 3rd gear once selected. Originally covered under manufacturer’s warranty for a certain period, this issue is now catching out owners in the second-hand market.

What are the symptoms?

Stage 1

The initial stages of this fault present itself with a grinding/graunching sound when selecting 3rd gear. A noise most of us will be familiar with whilst trying to perfect the clutch pedal action as a learner driver.

Stage 2

The grinding noise is caused by the gear and hub colliding at two different speeds. Each time this happens the hardened parts wear down and these fragments are released into the oil.

After a short while, the gear and hub become worn to the point they no longer hold each other in place when selected. This results in the hub jumping off the gear and the gearstick inside the vehicle moving into the neutral position.

It is usually at this stage that the customer gets in touch for advice and to discuss options to repair their unit.

3rd Gear Repair Options

1. Reconditioned Gearbox

Sometimes a quicker replacement option is more desirable as units can be prebuilt and ready to go, so a reconditioned unit is a popular choice for some customers over repair.

The downside of reconditioning a gearbox is that they do end up being more expensive than repairing the faulty parts alone. This is because the customer is paying for a complete unit and the warranty extends to the whole item, opposed to the parts replaced.

2. 3rd Gear Repair Kit

This fault was identified by the manufacturer where they produced an inclusive repair kit containing all the parts needed to resolve this particular issue.

This also has the added benefit of being much more cost effective than buying the parts individually.

This repair can usually be completed in 1-2 days with the gearbox on the vehicle. We recommend replacing the clutch and dual mass flywheel as required, however as most vehicles see this issue around 30k miles onward, it is usually beneficial to have these replaced at the same time.

Get In Touch

Have you had any issues with your L200/Fullback? We would love to hear from you - just leave a comment below with any feedback you may have. We look forward to hearing your views and experiences!

For specific enquiries, we ask that you contact us directly via the details below.

For more information contact Eco Torque today

Tel: 01462 835335

Email: info@eco-torque.co.uk

Eco Torque Ltd, Unit 1A Portland Industrial Estate, Hitchin Road, Arlesey, United Kingdom, SG15 6SG

Frequently Asked Questions (FAQ)

Q: What causes the L200/Fullback gear lever to disengage from 3rd gear?
A: A grinding noise occurs when selecting 3rd gear due to misalignment between the gear and hub. The resulting friction wears components until the hub can no longer engage, causing the gear to pop into neutral.

Q: Why does selecting 3rd gear produce a graunching sound?
A: Because the gear and hub are rotating at different speeds, they collide and grind. Over time, this causes wear and metal fragments contaminate the gearbox oil.

Q: What repair options are available for this issue?
A: Two main options:

1. A reconditioned gearbox — convenient and comes with a full-unit warranty, but more costly.

2. The manufacturer’s 3rd Gear Repair Kit — contains all necessary parts and is more cost-effective. Most work can be done in 1–2 days with the gearbox still in the vehicle.

Q: Should I replace the clutch and dual mass flywheel when fixing this issue?
A: It’s recommended, especially since most units fail after around 60,000 miles. Replacing these components at the same time helps prevent future problems.