Common Transmission and Drivetrain
M46 manual gearbox issues
Symptoms
Difficult or noisy gear selection, especially into reverse. Crunching when changing gear. Overdrive not engaging or cutting out.
Cause
Synchromesh wears out (especially on second gear). Clutch doesn't fully disengage. Overdrive solenoid or relay fails. Gearbox oil is old or incorrect spec.
Fix
Check and adjust clutch pedal free play.
Change the gearbox oil, use the correct grade (usually SAE 80W or ATF depending on spec).
If synchros are worn, the box needs a rebuild.
Overdrive issues are often electrical, check the relay, wiring, and solenoid.
The overdrive can be rebuilt separately.
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