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Gearbox, clutch and transmission

Problems with the manual gearbox: symptoms, cost and affected models

We have documented 106 faults with the manual gearbox in 10 engines and gearboxes and 95 cars, affecting 176 models of car in our database. The most important by severity and frequency: noise and premature wear of the manual gearbox and clutch (MINI Cooper R56), gear lever shudder and risk of M32 manual gearbox failure (Opel Astra J) and stiff or non-engaging manual gearbox (synchros and bearings) (Suzuki Grand Vitara II). At an independent garage, the repair costs from €340 to €4,000 depending on the engine or car.[1][2][3]

Documented faults
106
24 of high or critical severity
Engines and gearboxes
10
with at least one fault on this part
Affected models
176
car generations in our database
Garage repair
€340–€4,000
Depending on engine and car, including VAT

7 sourcesHow we work

How it works and why it fails

Manual gearbox

Manual gearboxes are generally very durable, but some have bearings, synchromesh or linkages with documented abnormal wear. The typical symptom is a noise that increases with speed or gears that grind or will not engage.

What to do

If a gear grinds when you select it, the lever wobbles or the gearbox makes a bearing noise, check the gearbox oil level and get a diagnosis early: a bearing that breaks can wreck the whole gearbox.

General explanation by MotorFiable. The specific faults of each engine and car, with their sources, are on the linked pages.

Common symptoms

The symptoms that come up most often in the documented faults with the manual gearbox. Open each one to see what other faults cause it.

Problems with the manual gearbox by engine

From most to least important (severity × frequency). Each page details the affected versions and years, symptoms, cost and how to check for it.

  1. 1High severityFrequency: OccasionalZF 8HPMechatronic failure as the gearbox ages (sometimes with reverse)Yes, although in a minority of cases: there are documented ZF 8HP mechatronic failures on BMW after 120,000-130,000 km, costing €1,400 to €3,500, and also control unit or electronic selector faults on Audi and Land Rover.Repair: €1,400–€3,500
  2. 2Medium severityFrequency: CommonDSG7 DQ200Reverse and 6th gear selector fork bearing failureYes, mainly on 0AM units: the bearing that guides the reverse and 6th gear selector fork can wear and leave the fork unsupported, so that the car stops engaging those gears or loses reverse, with fault warnings in the instrument cluster.
  3. 3Medium severityFrequency: CommonBMW N47Dual-mass flywheel wear (manual gearbox versions)Yes: on manual-gearbox BMW N47s, the dual-mass flywheel can wear, especially after a lot of town mileage or driving in high gears at low revs; the typical symptoms are vibrations, a metallic rattle at idle and jerking when pulling away.Appears at around 150,000 km
  4. 4Medium severityFrequency: CommonBMW M47Dual-mass flywheel wear (manual gearbox versions)On BMWs with the M47 engine and a manual gearbox, the dual-mass flywheel can wear with mileage, especially with a lot of urban use or long spells in high gears at low revs; typical symptoms are vibrations, a metallic rattle at idle and jerking when pulling away.Appears at around 150,000 km
  5. 5Medium severityFrequency: Common1.9 JTD/Multijet and 2.4 JTDDual-mass flywheel wear on manual gearbox versionsYes: the dual-mass flywheel on manual gearbox versions wears with mileage and is usually replaced together with the clutch. On the Opel Zafira B there are several documented replacements between 105,000 and 195,000 km, one of them with a dealer invoice of around €1,900.Repair: €1,900Appears at around 105,000 km
  6. 6Medium severityFrequency: CommonM272/M273Broken flaps and lever in the variable intake manifoldThe M272/M273's variable intake manifold can break the lever or the shafts of the swirl flaps, with loss of power, rough idle and codes P2004-P2006; if a piece comes loose it can end up in the cylinder.
  7. 7Medium severityFrequency: Occasional1.6 and 2.0 MultiJet IIDual-mass flywheel wear in manual versionsThe dual-mass flywheel on manual versions is one of the weak points flagged in the 1.6 and 2.0 MultiJet II after a certain mileage. When it wears it causes vibrations and metallic noises at idle and when using the clutch, and replacing it is not cheap.
  8. 8Medium severityFrequency: Rare7G-DCTWorn synchroniser: reverse or a specific gear won't engageOne case documented on a Mercedes GLA describes wear of the 3rd gear synchroniser from 50,000 km, with difficulty engaging it; we have not found more cases with the same exact diagnosis on other models of the family, so we treat it as a possible but minority fault.
  9. 9Low severityFrequency: Occasional1.4, 1.6 and 1.8 VVT-iPremature clutch wear on the manual gearboxOn a minority of Corolla, Avensis and Corolla Verso cars with this engine and a manual gearbox, owners document a clutch replaced earlier than expected, in some cases already at 49,000-53,000 km; the sources describe no cause other than normal wear of the clutch disc.Repair (garage): €1,300–€1,700Appears at around 49,000 km
  10. 10Low severityFrequency: Occasional1.6 Dual VVT-iPremature clutch wear on the manual gearboxOn a minority of Auris and Verso cars with this engine and a manual gearbox, owners document a clutch replaced sooner than expected; the sources describe no mechanical cause other than normal disc wear, and there is no sign that it is a factory defect.

Engines and gearboxes with faults with the manual gearbox

Problems with the manual gearbox by car

Faults documented on specific cars, which occur with any engine. From most to least important.

  1. 1High severityFrequency: CommonMINI Cooper R56Noise and premature wear of the manual gearbox and clutchIt is the most frequently cited non-engine fault of the Cooper R56: the manual gearbox can become noisy, whine or be hard to get into gear through wear of the bearings and synchromesh, sometimes with an oil leak; the clutch and, on diesels, the dual-mass flywheel also wear out early.
  2. 2High severityFrequency: CommonOpel Astra JGear lever shudder and risk of M32 manual gearbox failureBefore the 2012 redesign, the Astra J's M32 manual gearbox (petrol turbos from the 1.4T and diesels) could signal an impending failure with a gear lever shudder when accelerating or braking; fiches-auto.fr records gearbox and clutch/flywheel faults in a noticeable proportion of its respondents.
  3. 3High severityFrequency: CommonSuzuki Grand Vitara IIStiff or non-engaging manual gearbox (synchros and bearings)The Grand Vitara's manual gearbox can stiffen or fail to engage gears because of worn bearings and synchros; AUTO BILD adds that the gear lever feels imprecise.
  4. 4High severityFrequency: CommonVolkswagen Touran INot very robust 5-speed manual gearboxYes: fiches-auto.fr describes the Touran I's 5-speed manual gearbox as not very robust, with 44 owner reports, and gebrauchtwagenberater.de independently documents grinding noises in 3rd and 4th and a 6th gear (on 6-speed versions) that tends to jump out or is hard to engage.
  5. 5Critical severityFrequency: OccasionalFord Transit ConnectGear selector lever faultFord recalled 145,182 Transit Connect vans built between April 2013 and April 2021 because the gear selector lever can fail and cause unintended vehicle movement, according to Safety Gate alert 1/2022 (A12/00027/22). The sources do not detail the repair.
  6. 6High severityFrequency: OccasionalAudi A3 IIDual-mass flywheel breakage and clutch wear on manual gearbox versionsOn 2003 to 2005 vehicles, Germany's KBA attributed a risk of damage to the dual-mass flywheel to an incorrectly sized pressure reducer, according to gebrauchtwagenberater.de. Apart from that specific batch, numerous owners quoted by fiches-auto.fr document dual-mass flywheel and clutch breakages over a much wider range, between 35,000 and 165,000 km.Repair (garage): €4,000Appears at around 35,000 km
  7. 7High severityFrequency: OccasionalBMW Serie 3 F30Campaign over the clutch pressure plate bolts (manual gearbox)Yes: in July 2013 BMW recalled 3 Series F30 cars with a manual gearbox over a risk related to the clutch pressure plate bolts. Check with the chassis number whether your car has already been repaired.
  8. 8High severityFrequency: OccasionalFord Galaxy IIIClutch pressure plate breakage on the manual gearboxAccording to the fiches-auto.fr page, Ford has issued two campaigns over the clutch pressure plate, which can break and cause a loss of drive while the car is moving. They affect cars built between 2014 and 2018, depending on the campaign date.
  9. 9High severityFrequency: OccasionalJeep Wrangler JLClutch pressure plate breaking from overheating on a manual gearboxYes: between 2021 and 2024 there were several recalls of the Wrangler JL (and Gladiator) with manual gearbox, because the clutch pressure plate can overheat through friction and break. The Safety Gate alert of December 2024 covers vehicles built from 23/08/2017 to 16/02/2023 and flags a fire risk.
  10. 10High severityFrequency: OccasionalKia Cerato IWear of bearings, synchronisers and differential in the M5CF1 and M5CF2 manual gearboxesThe used Kia Cerato I press review calls the manual gearboxes unreliable, especially the M5CF1 and M5CF2: the bearings tend to start whining at around 100,000 km and the synchronisers to wear at around 150,000 km. The M5BF2 is considered the best, with a life of around 300,000 km, although its seals tend to leak oil.Appears at around 100,000 km
  11. 11High severityFrequency: OccasionalMINI Cooper F56The 6-speed manual gearbox can become noisy and end up being replacedIt is one of the most cited non-engine faults on the Cooper F56: the 6-speed manual gearbox can start to whine when hot, become noisy on the motorway and, in the most advanced cases, need replacing because of internal wear in bearings, shafts or synchronisers.
  12. 12High severityFrequency: OccasionalNissan Juke IPremature clutch wear and, in serious cases, manual gearbox breakageFiches-auto.fr documents a clutch that slipped from 3,000 rpm in 3rd gear until it "died" at 50,000 km on a Juke 1.6 DIG-T 190, and a misaligned flywheel at 20,000 km on a 1.5 dCi. Caradisiac adds gears that are hard to engage on several engines and a manual gearbox that broke at 77,000 km with no manufacturer cover on another 1.6 DIG-T 190.Appears at around 20,000 km
  13. 13High severityFrequency: OccasionalOpel Astra HGear lever rocking and risk of failure of the M32 manual gearboxOn the more powerful versions with the 6-speed M32 manual gearbox, excessive preload can break the surface of the tapered rollers in the bearings and end up damaging the gearbox; Gebrauchtwagenberater.de describes it as a known weak point of this gearbox, with rocking of the lever as an early warning.
  14. 14High severityFrequency: OccasionalOpel Vectra CBearing problem in the M32 manual gearboxThe M32 six-speed manual gearbox fitted to the Vectra C is known for bearing problems: excessive preload can crack the surface of the tapered rollers and end up damaging the gearbox, according to gebrauchtwagenberater.de.
  15. 15High severityFrequency: OccasionalOpel Zafira BGear lever shudder and risk of failure of the M32 manual gearboxOn the more powerful versions with the 6-speed M32 manual gearbox, excessive preload can break the surface of the tapered rollers in the bearings and end up damaging the gearbox; Gebrauchtwagenberater.de describes it as a known weak point of this gearbox, with gear lever shudder as the advance warning.
  16. 16High severityFrequency: OccasionalRenault Clio IVClutch pedal that loses travel and, in isolated cases, manual gearbox failureFiches-auto.fr records a Clio IV 1.5 dCi 90 whose clutch pedal went 'to the floor' at 35,000 km and another 1.5 dCi 75 that needed its manual gearbox replaced at 40,000 km. Caradisiac adds a clutch pedal that starts to squeak and a clutch that slips on a high-mileage car.Appears at around 35,000 km
  17. 17High severityFrequency: OccasionalToyota Auris IThe manual gearbox can wear and fail prematurelyFiches-auto.fr records nearly 30 accounts of manual gearbox faults on the first-generation Auris: bearings, synchromesh and selector linkages that fail, with symptoms such as grinding, jumping out of gear or the car being immobilised; the documented cases range from 60,000 to 118,000 km.Appears at around 60,000 km
  18. 18Medium severityFrequency: CommonCitroën C5 IIClutch and dual-mass flywheel wear on manual dieselsOn manual-gearbox diesel versions, the clutch and the dual-mass flywheel account for a very high number of cases in the reliability survey -up to 54 of 117 reports on the 2.0 HDi 140 hp-, wear that a German used-car guide confirms as a known weak point of the generation; the BVA6 automatic gearbox does not show the same pattern.Appears at around 20,000 km
  19. 19Medium severityFrequency: CommonDacia JoggerMismatch between fuel injection and the manual gearbox (EEB3 campaign)Yes: in April 2024 Dacia launched the EEB3 campaign to reprogramme the injection computer on manual-gearbox units, the Jogger included, after finding that insufficient torque delivered to the transmission caused whistling, a stiff shift and difficulty engaging gears.
  20. 20Medium severityFrequency: CommonDacia Sandero IIIMismatch between the injection and the manual gearbox (EEB3 campaign)Yes: in April 2024 Dacia launched the EEB3 campaign to reprogram the injection computer on cars with a manual gearbox, after finding that insufficient torque delivered to the transmission caused difficulty changing gear and, in some cases, clutch slip.
  21. 21Medium severityFrequency: CommonHyundai i20 IPremature clutch wear and difficulty engaging gears when coldThe clutch is the most frequently cited mechanical fault on the first-generation i20: fiches-auto.fr documents 12 cases out of 128 reports, with difficulty engaging reverse and fourth when cold; gebrauchtwagenberater.de independently confirms higher-than-usual clutch wear together with difficulty engaging first.
  22. 22Medium severityFrequency: CommonKia Rio IIIPremature clutch wear and difficulty engaging first or reverseThe clutch is the most frequently cited mechanical fault on the Kia Rio III: fiches-auto.fr records 35 cases out of 174 accounts (mainly on the 1.2 85 hp, with replacements from 2,500 km in one case), and gebrauchtwagenberater.de independently confirms above-average clutch wear along with difficulty engaging first gear when cold.
  23. 23Medium severityFrequency: CommonRenault Laguna IClutch wear and manual gearbox faultsAccording to the owner reports collected by fiches-auto.fr, the clutch wears or slips and the gearbox becomes noisy, stiff or loses gears (for example fifth). No official recall is on record.
  24. 24Medium severityFrequency: CommonSeat MiiManual gearbox hard to engage (first and reverse) and clutch wearThe manual gearbox is the weak point owners of this city car mention most: first and reverse are hard to engage, especially when cold, with crunching, and some clutches wear out early. It is a pattern in testimonials, not a manufacturer campaign.
  25. 25Medium severityFrequency: CommonŠkoda CitigoManual gearbox hard to engage (first and reverse) and clutch wearThe manual gearbox is the weak point that owners of this city car mention most: first and reverse are hard to select, especially when cold, with crunching, and some clutches wear out early. It is a pattern in testimonials, not a manufacturer campaign.
  26. 26Medium severityFrequency: CommonToyota Corolla VersoPremature clutch and flywheel wear on the manual gearboxAccording to the testimonies collected by fiches-auto.fr, the clutch of the Corolla Verso (bearing, disc and flywheel) is one of the most cited faults, with cases of replacement earlier than usual. It refers to the manual gearbox, not the robotised one.
  27. 27Medium severityFrequency: CommonVolkswagen Golf IVThe clutch, dual-mass flywheel and manual gearbox can fail earlier than expectedYes: the clutch, the dual-mass flywheel (on diesels) and the 5-speed manual gearbox are, taken together, the non-engine fault most often cited by Golf IV owners. gebrauchtwagenberater.de also documents a specific pinion in that gearbox that can break on units with the 1.4, 1.6 petrol or 1.9 SDI engine built before July 2001.
  28. 28Medium severityFrequency: CommonVolkswagen Golf VThe clutch, dual-mass flywheel and manual gearbox can wear earlier than expectedYes: on the MANUAL gearbox (the DQ250 DSG6 automatic has its own fault page), the clutch and dual-mass flywheel wear earlier than expected on both petrol and diesel, with noise at low revs on diesels when the dual-mass flywheel starts to fail.
  29. 29Medium severityFrequency: CommonVolkswagen Polo IVThe manual gearbox, clutch and dual-mass flywheel can fail earlier than expectedYes: the manual gearbox is the most-cited non-engine fault among Polo IV owners, with internal noises and difficulty selecting gears; the clutch wears at around 100,000 km and, on diesels, the dual-mass flywheel can fail earlier than expected.
  30. 30Medium severityFrequency: CommonVolkswagen up!Manual gearbox hard to engage (first and reverse) and clutch wearThe manual gearbox is the weak point that owners of this city car mention most: first gear and reverse are hard to select, especially when cold, with grinding, and some clutches wear out early. It is a pattern in testimonies, not a manufacturer campaign.
  31. 31Medium severityFrequency: OccasionalBMW X1 E84Premature wear of the clutch and flywheel on the manual X1According to the reports collected by fiches-auto.fr, the clutch is the most cited point on the manual X1 E84: 48 mentions out of 315 reports, with vibrations, noise in first gear and wear between 32,000 and 95,000 km. There is no known official campaign.Appears at around 32,000 km
  32. 32Medium severityFrequency: OccasionalBMW Z4 E85/E86Noises and difficulty engaging gears in the manual gearboxAccording to the reports collected by fiches-auto.fr, 7 of 78 Z4 E85 owners cite noises or difficulty engaging gears in the manual gearbox and 2 more cite differential faults, between 65,000 and 258,000 km.
  33. 33Medium severityFrequency: OccasionalCitroën Berlingo IIIDifficulty engaging gears in the manual gearbox and clutch vibrationA reliability survey documents 4 cases of difficulty engaging gears (mainly 3rd, 4th and reverse) from 35,000 km, and 2 cases of clutch vibration or seizing with premature flywheel cracking from 28,000 km.Appears at around 28,000 km
  34. 34Medium severityFrequency: OccasionalCitroën C3 PicassoClutch wear and manual gearbox faultsThe page records 26 clutch cases (between 15,500 and 128,000 km) and 24 gearbox cases with difficulty engaging gears, mainly on the diesels.
  35. 35Medium severityFrequency: OccasionalCitroën C4 CactusPremature clutch wear and failure on the manual gearboxSeveral owners of manual C4 Cactus cars document clutch failures (the disc or the hydraulic release bearing mechanism) between 60,000 and 65,000 km, a short life for this type of part.Appears at around 60,000 km
  36. 36Medium severityFrequency: OccasionalDacia Logan IIDifficulty engaging fifth gear and reverse, with premature clutch wearOn some Logan II units it is hard to engage fifth gear and, above all, reverse, and there are cases of the clutch and flywheel being replaced after very few kilometres; the rest of the gearbox works normally according to the testimonies consulted.
  37. 37Medium severityFrequency: OccasionalFiat CromaPremature wear of the Fiat Croma manual gearboxAl Volante identifies premature wear of the manual gearboxes as the main fault on a Croma that it otherwise considers one of the most reliable Fiats. The source does not specify which part wears, in which years, or at what mileage.
  38. 38Medium severityFrequency: OccasionalFiat Punto IIIClutch wear and stiffness of the manual gearboxThe Fiat Punto (Grande Punto/Punto Evo/Punto) with the conventional manual gearbox has accumulated testimonials of clutches that wear out early and of stiff gearboxes or faulty selector cables.
  39. 39Medium severityFrequency: OccasionalFord FusionClutch wear and Durashift manual gearbox faultsAccording to owner reports collected by fiches-auto.fr, the clutch and gearbox are the most frequently cited non-engine fault on the Fusion (28 of 206): clutches replaced at around 90,000 km, gears that stick and a reverse gear that grinds.
  40. 40Medium severityFrequency: OccasionalFord Ka IIPremature clutch wear and noises from the manual gearboxAccording to testimonies collected by fiches-auto.fr, the Ka II has a number of cases of clutches worn out early (12 cases across both engines) and of a manual gearbox that is noisy or hard to engage (11 cases on the 1.2 69 hp).
  41. 41Medium severityFrequency: OccasionalHonda CR-V IVPremature wear of the manual gearbox clutch and synchronisersAccording to the fiches-auto.fr entry, 8 of 142 CR-V IV reports mention the clutch or manual gearbox (heavy clutch, wear, synchronisers), with a clutch replaced at 75,000 km on a 1.6 i-DTEC 160 hp.
  42. 42Medium severityFrequency: OccasionalKia Rio IVThe clutch, the weak point of the manual gearboxSeveral owner accounts point to the clutch as the Kia Rio IV's weakest point, with occasional difficulty engaging first or reverse and the odd case of jerking when pulling away, according to fiches-auto.fr and Gebrauchtwagenberater.de.
  43. 43Medium severityFrequency: OccasionalLotus Elise S22nd-to-3rd synchro wear on supercharged ElisesOn Elise S2s with the supercharged Toyota engine, evo and PistonHeads point to synchro wear, which shows up as a crunch when shifting from second to third.
  44. 44Medium severityFrequency: OccasionalMercedes-Benz Clase B W246Premature clutch and dual-mass flywheel wear on manual diesel versionsOn diesel versions with a manual gearbox, especially the B 180 CDI, several testimonies describe earlier-than-normal wear of the clutch and dual-mass flywheel, with vibrations and metallic noises; it does not affect versions with the 7G-DCT automatic gearbox.
  45. 45Medium severityFrequency: OccasionalMitsubishi Colt VIClutch that is not robust and stiff manual gearboxA German analysis describes the Colt VI clutch as not robust, with premature failures, and a manual gearbox with gears that are hard to engage, especially reverse.
  46. 46Medium severityFrequency: OccasionalMitsubishi Eclipse Cross IHarsh manual gearbox and grinding from 1st to 2ndOwners of the 1.5 T Eclipse Cross with manual gearbox describe abrupt engagement of 2nd and grinding when shifting from 1st to 2nd, and a German analysis also cites difficulty starting due to poor clutch modulation.
  47. 47Medium severityFrequency: OccasionalOpel CascadaSix-speed manual gearbox (M32) that does not last long, with hard second and reverseAUTO BILD describes the Cascada's six-speed manual gearbox as not long-lasting, and a German guide links the M32 with a hard shift into second and reverse. There is no official campaign and no frequency figures.
  48. 48Medium severityFrequency: OccasionalOpel Meriva BPremature clutch wear and manual gearbox noisesThe fiches-auto.fr page lists 13 clutch and manual gearbox cases on the Meriva B (out of 238 testimonials): a failed clutch at 90,000 km, reverse gear noise, the gearbox locking up on the motorway and gear lever wear at 25,000 km.
  49. 49Medium severityFrequency: OccasionalOpel Zafira Tourer CManual gearbox clutch that wears out quickly on the Zafira CGebrauchtwagenberater says the manual gearbox clutch on the Zafira C does not last long and needs replacing more often than usual; the fiches-auto.fr entry records clutch and flywheel cases, and the ADAC lists it among the fault points in its statistics.
  50. 50Medium severityFrequency: OccasionalPeugeot 108Premature wear of the manual gearbox clutchAccording to testimonies on fiches-auto.fr, the clutch is the most frequently cited non-engine fault on the 108: 10 cases out of 75, with wear between 20,000 and 52,000 km, slipping and a biting point that is hard to judge.
  51. 51Medium severityFrequency: OccasionalPeugeot 207Premature wear of the clutch and manual gearboxOn diesel versions, the clutch (and the dual-mass flywheel that goes with it) can wear sooner than expected, with vibrations when pulling away or a heavier pedal than normal; the manual gearbox can also become noisy or hard to get into reverse.
  52. 52Medium severityFrequency: OccasionalRenault Clio IIWear of the manual gearbox and clutchThe Clio II's manual gearbox can become stiff and noisy because of wear in the bearings and synchronisers, while the clutch slips or fails to disengage fully when the cable or mechanism becomes fatigued.
  53. 53Medium severityFrequency: OccasionalRenault Kangoo IPremature clutch wear and manual gearbox faultsThe testimonies record clutches failing from 78,000 km on a 1.4 and gearboxes breaking down around 100,000-120,000 km on diesel engines. One owner cites €1,300 (in Spain) for gearbox and clutch, but it is an isolated case.
  54. 54Medium severityFrequency: OccasionalRenault Koleos IPremature clutch wearAccording to the owner reports collected by fiches-auto.fr, 12 owners of the Koleos I cite clutch problems, including one clutch that failed several times in two months and another that made noises at 900 km. There is no official recall.
  55. 55Medium severityFrequency: OccasionalRenault Mégane IClutch wear and manual gearbox faultsAccording to the testimonies collected by fiches-auto.fr, the clutch wears or slips and the gearbox becomes noisy, stiff or loses gears (for example fifth). No official recall is recorded.
  56. 56Medium severityFrequency: OccasionalRenault Mégane IIWear of the manual gearbox, especially the 6-speedThe Megane II's manual gearbox, especially the 6-speed, can wear out early: bearings and synchromesh with play, difficulty selecting gears and whining when driving.
  57. 57Medium severityFrequency: OccasionalRenault ModusPremature clutch wear and noise in the manual gearboxOn the Modus, especially on diesel versions used in town, the clutch can slip, judder or wear out sooner than expected; the manual gearbox can also become noisier or find it hard to engage a gear as the mileage builds up.
  58. 58Medium severityFrequency: OccasionalRenault Scénic IClutch wear and manual gearbox faultsAccording to the testimonies collected by fiches-auto.fr, the clutch wears or slips and the gearbox becomes noisy, stiff or loses gears (for example fifth). No official recall is recorded.
  59. 59Medium severityFrequency: OccasionalRenault Twingo IIIDifficulty engaging gears and noise in 5th gear on the BVM5 manual gearboxA French reliability guide documents difficulty engaging gears in the Twingo III's 5-speed manual gearbox up to October 2017, noise in 5th gear between 2016 and 2018, and a clutch pedal that returns slowly up to mid-2018.
  60. 60Medium severityFrequency: OccasionalSeat ExeoPremature failure of the clutch, dual-mass flywheel and manual gearboxAccording to the fiches-auto.fr reports, there is a 2.0 TDI 143 hp with a failed dual-mass flywheel and clutch at 46,000 km and another with a gearbox replaced at 1,790 km and persistent noises. These are specific owner cases, not a recall.
  61. 61Medium severityFrequency: OccasionalSeat Ibiza IVThe clutch and manual gearbox can fail at low mileageOn the manual gearbox (not the DSG, which has its own page), several owners report the clutch and gearbox failing between 7,000 and 60,000 km, much earlier than normal, with noise, difficulty selecting a gear or a broken release bearing.
  62. 62Medium severityFrequency: OccasionalSeat León IIIClutch and dual-mass flywheel wear on the manual gearboxOn the 6-speed manual gearboxes, the Leon III's clutch and dual-mass flywheel show their age with a higher biting point and, in some cases, a metallic rattle from cold. A specialist workshop puts their typical life at between 80,000 and 130,000 km.Repair (garage): €340–€520Appears at around 80,000 km
  63. 63Medium severityFrequency: OccasionalSeat Toledo IIPremature clutch wear and manual gearbox synchromesh wearAccording to fiches-auto.fr, several owners replaced the clutch at around 110,000 km, with three mentions of a slipping clutch and another three of synchromesh or manual gearbox problems (up to 135,000 km). This is a pattern drawn from owner reports, not a manufacturer recall.
  64. 64Medium severityFrequency: OccasionalŠkoda Fabia IIThe clutch, dual-mass flywheel or manual gearbox can fail earlier than expectedOn the manual gearbox (not the DSG, which has its own page), several owners report the gearbox becoming progressively noisy or breaking between 67,000 and 150,000 km, along with a worn clutch and dual-mass flywheel.
  65. 65Medium severityFrequency: OccasionalŠkoda Octavia IIIDual-mass flywheel and clutch wear on manual dieselsOn diesel versions with a manual gearbox, a specialist garage documents premature dual-mass flywheel wear, more common if the car does short urban journeys and many cold starts, which shows up as a metallic knocking on starting or when pressing the clutch.Repair (garage): €700–€900
  66. 66Medium severityFrequency: OccasionalSuzuki Ignis IManual gearbox synchromesh (second gear)In the first-generation Ignis, the synchromesh in the five-speed manual gearbox wears, especially second gear's, and can leave the gear hard or impossible to engage.
  67. 67Medium severityFrequency: OccasionalSuzuki S-Cross IManual gearbox linkage problems on 2013 and 2014 vehiclesAccording to the ADAC breakdown statistics reported by dpa, the S-Cross's only weak point on the road is the gear linkage on 2013 and 2014 cars; otherwise its reliability is "very good". Caradisiac adds that some noisy manual gearboxes have been replaced.
  68. 68Medium severityFrequency: OccasionalSuzuki SplashPremature manual gearbox failureAccording to reports on fiches-auto.fr, some manual gearboxes fail at low mileage (bearings broken at 34,000 km on a 1.2), with bearing noise or difficulty engaging gears. There is no official recall.
  69. 69Medium severityFrequency: OccasionalSuzuki Swift IIIPremature manual gearbox failureAccording to the fiches-auto.fr testimonies, some manual gearboxes fail at low mileage (a broken gearbox at 25,000 km in one case), with bearing noise or difficulty engaging gears. There is no official campaign.
  70. 70Medium severityFrequency: OccasionalSuzuki Swift IVPremature manual gearbox failureAccording to the owner reports on fiches-auto.fr, some manual gearboxes fail at low mileage (49,000, 64,000 and 75,000 km in three cases), with bearing noise or difficulty engaging gears. There is no official campaign.
  71. 71Medium severityFrequency: OccasionalVolkswagen Beetle IIClutch and 5-speed manual gearboxFiches-auto records 7 clutch cases and 8 gearbox cases among 81 Beetle testimonies, and describes the 5-speed manual as rather fragile, with oil leaks.
  72. 72Medium severityFrequency: OccasionalVolkswagen BoraClutch and manual gearbox wear on a 20-year-old carOn the Golf IV, the Bora's sister platform, fiches-auto.fr records 46 clutch cases and 44 manual gearbox cases with play in the synchronisers and bearings on high-mileage cars. This is indirect data, not for the Bora.
  73. 73Medium severityFrequency: OccasionalVolkswagen Golf VIWear of the clutch, flywheel and manual gearboxAdding up clutch, flywheel and manual gearbox, the transmission accounts for 141 of the 666 Golf VI owner responses in a fiches-auto.fr reliability survey, with the source not distinguishing which gearbox or engine version predominates in each report.
  74. 74Medium severityFrequency: OccasionalVolkswagen Polo VThe clutch, dual-mass flywheel or manual gearbox can fail sooner than expectedOn the manual gearbox (not the DSG automatic, which has its own page), several owners report gearbox noise, difficulty engaging a gear, or a worn clutch and dual-mass flywheel between 25,000 and 90,000 km, well below what is normal for these parts.
  75. 75Medium severityFrequency: OccasionalVolvo S40 IIGear selector ball joint working loose and able to jam the Volvo S40's gear leverA part of the gear selection mechanism can work loose over time and jam the lever, so that you cannot change gear or select neutral. UK campaign R/2010/071, which includes the S40, V50 and C30, checks that the selector ball joint is properly secured.
  76. 76Medium severityFrequency: OccasionalVolvo S80 IILoose gear selector ball joint on the Volvo S80: the gear lever can lock upIn 2010 Volvo recalled cars of several models, including the Volvo S80 (reference R49111; R/2010/071 in the UK), because over time a part of the gear change mechanism can work loose and jam it, so that you cannot change gear or select neutral.
  77. 77Medium severityFrequency: OccasionalVolvo V50Gear selector ball joint working loose and able to jam the Volvo V50's gear leverA part of the gear selection mechanism can work loose over time and jam the lever, so that you cannot change gear or select neutral. UK campaign R/2010/071, which includes the S40, V50 and C30, checks that the selector ball joint is properly secured.
  78. 78Medium severityFrequency: OccasionalVolvo V70 IIILoose gear selector ball joint on the Volvo V70: the gear lever can lock upIn 2010 Volvo recalled cars of several models, including the Volvo V70 (reference R49111; R/2010/071 in the UK), because over time a part of the gear change mechanism can work loose and jam it, so that you cannot change gear or select neutral.
  79. 79Medium severityFrequency: OccasionalVolvo XC70 IIILoose gear selector ball joint on the Volvo XC70: the gear lever can jamIn 2010 Volvo recalled cars of several models, including the Volvo XC70 (reference R49111; R/2010/071 in the United Kingdom), because over time a part of the gear change mechanism can work loose and jam it, so that it is not possible to change gear or select neutral.
  80. 80Medium severityFrequency: OccasionalVolvo XC90 IGear lever ball joint that can come loose due to incorrect tightening torqueA German buying guide reports a recall of XC90s from the 2009 and 2010 model years: due to an incorrect tightening torque, a gear lever ball joint could come loose and leave the driver unable to change gear.
  81. 81High severityFrequency: RareFiat TipoPremature clutch wear on the manual gearboxTestimonies from Fiat Tipo owners with a manual gearbox describe clutch failures from around 38,000 km, with cases at 52,000 and 66,000 km, as well as occasional jamming when selecting third gear; there is no official campaign or specialist press to confirm it.Appears at around 38,000 km
  82. 82High severityFrequency: RareFord Kuga IIClutch pressure plate breakage on EcoBoost versions with a manual gearboxFord recalled Kuga models with the EcoBoost engine and six-speed manual gearbox built between August 2013 and June 2016, and again between June 2016 and May 2018, because the clutch pressure plate could fracture.
  83. 83High severityFrequency: RareRenault Clio VClutch that slips or breaks prematurely on the manual gearboxSeveral Clio V owners with a manual gearbox describe a clutch that slips or even breaks at very low mileage, and gears that are hard to select; one case mentions replacing the whole gearbox at 15,000 km. There are no official campaigns or specialist press to confirm it.
  84. 84High severityFrequency: RareRenault Scénic IVStiff manual gearbox with stickingTestimonies from Scenic IV owners with a manual gearbox describe stiff shifts, sticking or crunching when engaging a gear, with at least one case of total gearbox failure shortly after purchase; there are no official campaigns or specialist press to confirm it.
  85. 85High severityFrequency: RareSeat León IAn incorrectly sized manual gearbox rivet could break on the first unitsThe KBA confirmed that, in the manual gearbox of the León I built up to 11 July 2001 with the 1.4, 1.6 and 1.9 SDI engines, an incorrectly sized internal rivet could break and seriously damage the gearbox.
  86. 86High severityFrequency: RareVolkswagen BoraRivet in the 02K manual gearbox that may break (up to July 2001)Gebrauchtwagenberater warns that in the 02K manual gearbox, fitted to the older 1.4 and 1.6 and the 1.9 SDI built up to 11 July 2001, a rivet of weak design can break and damage the gearbox. It is a single source.
  87. 87Medium severityFrequency: RareFord Ka+Clutch and manual gearbox: early failures, noises and difficult reverse gearAccording to testimonials on fiches-auto.fr, the Ka+ racks up clutch failures (one at 10,100 km, another at 50,000 km) and manual gearbox faults, with clicks, jerks and difficult reverse gear on the 1.2 Ti-VCT 85 hp.
  88. 88Medium severityFrequency: RareHonda CR-V IIIClutch judder on manual gearboxes (and dual-mass flywheel on diesels)According to gebrauchtwagenberater.de, clutch judder on manual gearboxes is a classic Honda problem, fixed by replacing the clutch. On diesels, the dual-mass flywheel usually has to be replaced at the same time, which makes the repair more expensive.
  89. 89Medium severityFrequency: RareNissan PrimastarProblems with the optional automated manual gearboxA 2013 Auto Express review warns that problems have been reported with the Primastar's optional automated transmission, a six-speed manual gearbox with automatically operated clutch and selector, and that it can fail when selecting gears. It gives no mileages, causes or costs.
  90. 90Medium severityFrequency: RareŠkoda Fabia IIIReverse gear hard to engage and manual gearbox faultsThere are testimonies of a reverse gear that is hard to engage (with the engine switched off to get it in, at 30,000 km on a 1.2 TSI) and of a manual gearbox that failed at 40,000 km on a 1.0 MPI. These are isolated cases among 117 testimonies.
  91. 91Medium severityFrequency: RareToyota Avensis T27Broken manual gearbox linkage pin and synchroniser failure on the AvensisAccording to the fiches-auto.fr page, there are reports of a broken manual gearbox linkage pin that prevented first gear from engaging (1.8 VVT-i, at 102,000 km) and of synchroniser problems (2.2 D-4D 150 hp, at 66,000 km). These are isolated cases.
  92. 92Low severityFrequency: OccasionalAlfa Romeo 147Vague gearchange with slack: gear cables and selector mechanism on manual gearboxesMotori Magazine lists among the common problems of the Alfa 147 a vague manual gearchange, with the gear lever very loose even in neutral and gears that are hard to engage; it points to the gear cables or the selector mechanism and, if the fault is mainly in first and reverse, to the clutch.
  93. 93Low severityFrequency: OccasionalFiat SediciStiff gear lever, especially from 1st to 2ndSeveral Sedici owners describe a stiff manual gearbox, especially from first to second with the engine cold, which does not always improve with a gearbox oil change.
  94. 94Low severityFrequency: OccasionalHyundai i10 IIManual gearbox that is hard to engage, especially reverseOn the i10 II some owners describe difficulty engaging reverse or a gear, and the German press warns of weak points in the manual and automatic gearboxes inherited from the previous model. No cause is documented and there are no serious consequences.
  95. 95Low severityFrequency: OccasionalToyota RAV4 IVVibrations in the gear lever and dashboardSeveral owners notice perceptible vibrations in the gear lever and, in some cases, also in the dashboard, sometimes with extra rattles, without the source consulted specifying the exact origin.
  96. 96Low severityFrequency: RareSuzuki SX46-speed manual gearbox on the diesels with first gears that are hard to engagegebrauchtwagenberater.de notes that on diesel SX4 models (1.9 and 2.0 DDiS) the 6-speed manual gearbox shifts stiffly and that the first two gears sometimes only go in with force. It is the comment of a single source, with no figures or campaign.

Problems with the manual gearbox by make

Problems with the manual gearbox in your car

33 cars have several documented faults with the manual gearbox. Choose yours to see only the ones that affect them, by engine and by year.

Alfa Romeo 1
Audi 1
BMW 9
Fiat 4
Lotus 1
Mercedes-Benz 1
MINI 1
Opel 3
Seat 2
Škoda 1
Suzuki 1
Toyota 3
Volkswagen 5

How much it costs to repair a fault with the manual gearbox

Sorted from the most expensive repair to the cheapest. Prices in Spain including VAT (parts and labour); what each figure includes is on its page.

How we calculate costs · The most expensive repairs across all engines

OBD fault codes with the manual gearbox

The codes the ECU usually stores when this part fails: what they mean, causes and what to check.

Frequently asked questions

Which engines have the most faults with the manual gearbox?

By severity and frequency, the ZF 8HP (mechatronic failure as the gearbox ages (sometimes with reverse), high severity), the DSG7 DQ200 (reverse and 6th gear selector fork bearing failure, medium severity), the BMW N47 (dual-mass flywheel wear (manual gearbox versions), medium severity), the BMW M47 (dual-mass flywheel wear (manual gearbox versions), medium severity), the 1.9 JTD/Multijet and 2.4 JTD (dual-mass flywheel wear on manual gearbox versions, medium severity) and the M272/M273 (broken flaps and lever in the variable intake manifold, medium severity). In total we have documented 10 engines and gearboxes with faults with the manual gearbox.

Which cars have problems with the manual gearbox?

Among those we have analysed: MINI Cooper R56 (noise and premature wear of the manual gearbox and clutch), Opel Astra J (gear lever shudder and risk of M32 manual gearbox failure), Suzuki Grand Vitara II (stiff or non-engaging manual gearbox (synchros and bearings)), Volkswagen Touran I (not very robust 5-speed manual gearbox), Ford Transit Connect (gear selector lever fault), Audi A3 II (dual-mass flywheel breakage and clutch wear on manual gearbox versions), BMW Serie 3 F30 (campaign over the clutch pressure plate bolts (manual gearbox)) and Ford Galaxy III (clutch pressure plate breakage on the manual gearbox). In total, 95 cars with documented faults with the manual gearbox.

How much does it cost to repair a fault with the manual gearbox?

It depends a lot on the engine or car. At an independent garage, from €340 to €4,000; at a dealer, from €1,400 to €3,500, including VAT, based on the 6 faults with a documented cost. The most expensive is dual-mass flywheel breakage and clutch wear on manual gearbox versions (Audi A3 II).

What symptoms does a fault with the manual gearbox cause?

The most frequently cited in the documented faults: gearbox will not select gears or drops into neutral, gearbox or clutch noise or rattle, clutch slipping, clutch pedal heavy, juddering or not returning, abnormal vibrations or unstable idle and jerking or juddering when accelerating.

Sources

Every fact on this page links to its source. If you find an error, let us know.

  1. Problemas Seat Leon 3 | Fallos y averías más frecuentesTotal Renting · Other source · consulted 26 September 2026 · in Spanish
  2. Posible fallo en volante bimasa o collarín...Club de Propietarios del Seat León · Owners' forum · consulted 26 September 2026 · in Spanish
  3. Fiabilité Audi A3 (2003-2012): pannes et avis de propriétairesFiches-auto.fr · Other source · consulted 27 September 2026 · in French
  4. Fiabilité BMW Série 5 (2010-2016), pannes et témoignagesFiches-auto.fr · Owners' forum · consulted 27 September 2026 · in French
  5. Opel Zafira 2 : les plus et les moinsFiches-auto.fr · Motoring press · consulted 27 September 2026 · in French
  6. Toyota Corolla Verso (2004-2009) : fiabilité, pannes et rappelsFiches-auto.fr · Motoring press · consulted 27 September 2026 · in French
  7. Skoda Octavia Problemas | Fallos y averías más frecuentesTotal Renting · Other source · consulted 26 September 2026 · in Spanish