TD21 auto gearbox reconditioning (Borg Warner DG 150)

My TD21 is finding it increasingly difficult to change up to top gear from a cold start - it used to take 2 to 3 miles, now it takes 6 to 8 miles, during which I am sure I am putting stress on the engine at high revs in 2nd gear. I guess at some point I will need to get it reconditioned. Does anyone have similar experience or recommendations for someone to do the job, preferably in South East? I've asked Whitehouse Autos who advertise in the Bulletin, but I'd like to see if I can learn from another AOC member. Comments, guidance, recommendations gratefully received. Posted by Philip 14/05/2013 16:08:50

I have only read good reports about Whitehouse.  But before getting an overhaul, have you checked the transmission-fluid specification is correct? Incorrect fluid type can cause a lot of problems with changing up and down. Also, transmission-fluid can suffer from `Ageing´, it has quite a tough job to do.  I found greatly improved change-characteristics after draining + refilling my BW box with correct spec. fluid.  Transmission fluid-change is not difficult, one just has to be aware of the 3 separate drain-points, work very `cleanly´ and to be precise when re-filling as the BW transmission is quite sensitive to fluid-level.  A readily available (from motor factors) transmission fluid is Comma AQF, having Ford ESP-M2C-33F/G spec. You would need 2x 5 litre containers of it, leaving a little spare for top-ups.  Of course you may have done all this, in which case a rebuild is a good idea.  Hope this helps, Giles Lacey Posted by lacey giles 15/05/2013 09:10:19

A second thought: If the BW box will not change up, it is also worth checking that the Intermediate-hold linkage is operating correctly, and that the Intermediate-hold operating lever (small cranked arm at top NS rear of gearbox) is not `floating´ with no set position.  Especially check that the ball-joint connecting the long rod to the gearbox operating-arm has not become disconnected, and that return-spring on the linkage-rod is OK, and that the linkage rod is not fouling anywhere.  GL Posted by lacey giles 15/05/2013 12:55:37

Thank you Giles. I do have the correct Comma AQF fluid, and it is full and clean. So, I have found a local specialist in Tonbridge (Stanton Automatics) and I will take it to them to see if they can diagnose why it is worse than before. Many thanks again for you helpful advice. Posted by Philip 17/05/2013 10:44:31