Let's face it, your Can-Am Commander isn’t just a machine; it’s your trusty steed for conquering trails, hauling gear, and getting work done. So, when its gearbox starts acting up, it can throw a serious wrench in your plans. Understanding the common issues, what causes them, and how to address them is crucial to keeping your Commander running smoothly and avoiding costly repairs.

What's Up With My Can-Am Commander's Gearbox?

The gearbox, or transmission, in your Can-Am Commander is responsible for transferring power from the engine to the wheels. It allows you to select different gear ratios for varying speeds and terrain. Because it deals with immense force and heat, problems are bound to arise eventually. Recognizing the symptoms early can save you a lot of grief down the road.

Common symptoms of gearbox trouble include:

  • Difficulty shifting: This could manifest as hard shifting, grinding noises when shifting, or the inability to shift into certain gears.
  • Popping out of gear: This is when the transmission unexpectedly jumps out of the selected gear, often under load.
  • Unusual noises: Whining, grinding, or clunking sounds coming from the gearbox area are definite warning signs.
  • Slipping: This is when the engine revs up but the vehicle doesn't accelerate properly, indicating a loss of power transfer within the gearbox.
  • Leaking fluid: Gearbox fluid leaks can lead to low fluid levels and eventual damage to internal components.
  • Overheating: Excessive heat can damage seals and other components within the gearbox.

The Usual Suspects: Common Gearbox Issues

Several factors can contribute to gearbox problems in your Can-Am Commander. Let's break down some of the most common culprits:

1. Low or Contaminated Gearbox Oil:

This is perhaps the most frequent offender. Gearbox oil lubricates and cools the internal components, preventing wear and tear.

  • Low oil level: Caused by leaks or simply not topping off the fluid regularly. Low fluid means less lubrication and increased friction, leading to overheating and damage.
  • Contaminated oil: Dirt, water, and metal particles can contaminate the oil, reducing its lubricating properties and accelerating wear. This often happens when the vent line is submerged in water.

2. Worn or Damaged Gears:

The gears inside your gearbox are subject to tremendous stress. Over time, they can wear down or even break due to:

  • Normal wear and tear: Especially with heavy use or aggressive driving.
  • Impact damage: From hard landings or hitting obstacles.
  • Improper shifting: "Forcing" the gears can lead to chipping or breaking.

3. Faulty Shift Linkage:

The shift linkage connects the shift lever to the gearbox, allowing you to select different gears.

  • Loose or damaged linkage: Can result in difficulty shifting or the inability to select certain gears.
  • Worn bushings: Bushings help to reduce friction and vibration in the linkage. When they wear out, it can lead to sloppy shifting.

4. Issues with the One-Way Bearing:

The one-way bearing is a critical component within the gearbox, especially in models with engine braking. It allows the vehicle to coast freely when decelerating, preventing the engine from abruptly slowing down the wheels.

  • Failure of the one-way bearing: Can cause jerky deceleration, a clunking noise when coasting, or even difficulty shifting.

5. Problems with the Belt:

Although the CVT belt is not part of the internal gearbox, a worn or damaged belt can put excessive strain on the transmission, leading to premature wear and tear.

  • Slipping belt: A slipping belt requires the transmission to work harder, generating more heat and stress.
  • Incorrect belt tension: Improper belt tension can also contribute to gearbox problems.

6. Water Ingress:

Water is the enemy of any gearbox. It can contaminate the oil, causing rust, corrosion, and reduced lubrication.

  • Submerging the gearbox: During water crossings, water can enter through the vent lines or seals.
  • Damaged seals: Worn or damaged seals can allow water to seep into the gearbox.

Diagnosing the Problem: Getting to the Root Cause

Before you start tearing apart your Can-Am Commander's gearbox, it's essential to accurately diagnose the problem. Here's a step-by-step approach:

1. Visual Inspection:

  • Check the gearbox oil level: Use the dipstick (if equipped) or the fill plug to check the oil level.
  • Inspect for leaks: Look for signs of oil leakage around the gearbox housing, seals, and vent lines.
  • Examine the shift linkage: Check for loose or damaged components.
  • Inspect the vent lines: Ensure they are properly connected and not clogged.

2. Listen Carefully:

  • Pay attention to noises: Try to pinpoint the source and type of noise (whining, grinding, clunking). Does the noise change with speed or gear selection?
  • Test drive: Carefully observe how the transmission performs under different conditions. Note any difficulty shifting, slipping, or popping out of gear.

3. Check the Gearbox Oil:

  • Drain a small sample of the oil: Inspect the color and consistency. Is it milky, indicating water contamination? Does it contain metal particles?
  • Smell the oil: A burnt or foul odor can indicate overheating or excessive wear.

4. Consult the Service Manual:

  • Refer to the Can-Am Commander service manual: This invaluable resource provides detailed troubleshooting procedures and diagnostic information.

5. Consider Professional Help:

  • If you're not comfortable performing the diagnosis or repair yourself: Take your Can-Am Commander to a qualified mechanic. They have the expertise and specialized tools to accurately diagnose and fix the problem.

Fixing the Issue: Repair or Replace?

Once you've diagnosed the problem, you'll need to decide whether to repair or replace the gearbox.

Repair:

  • Suitable for: Minor issues like leaks, faulty shift linkage, or a worn one-way bearing.
  • Cost-effective: Can be cheaper than replacing the entire gearbox.
  • Requires: Mechanical skills and access to replacement parts.

Replace:

  • Suitable for: Major damage like broken gears, a severely damaged housing, or extensive internal wear.
  • More expensive: But can be the most reliable option in the long run.
  • Consider a remanufactured gearbox: A remanufactured gearbox is a used gearbox that has been rebuilt with new or refurbished parts. It can be a more affordable alternative to a brand-new gearbox.

Preventing Future Gearbox Problems: Proactive Maintenance

Prevention is always better than cure. Here are some tips to keep your Can-Am Commander's gearbox in top condition:

  • Regularly check and change the gearbox oil: Follow the manufacturer's recommended service intervals. Use the correct type of oil specified in the service manual.
  • Inspect for leaks: Address any leaks promptly to prevent low oil levels.
  • Keep the vent lines clean and properly routed: This will prevent water from entering the gearbox.
  • Avoid aggressive shifting: Shift smoothly and avoid "forcing" the gears.
  • Don't overload the vehicle: Overloading puts extra strain on the gearbox.
  • Inspect the CVT belt regularly: Replace the belt if it's worn or damaged.
  • Consider installing a snorkel kit: If you frequently ride in deep water, a snorkel kit will raise the vent lines and prevent water from entering the gearbox.
  • Use a high-quality gearbox oil: A good quality oil will provide better lubrication and protection against wear.

Frequently Asked Questions

  • How often should I change my Can-Am Commander's gearbox oil? Consult your owner's manual, but generally, every 100 hours of riding or once a year is a good rule of thumb.
  • What type of oil should I use in my Can-Am Commander's gearbox? Use the oil specified in your owner's manual. Using the wrong type of oil can damage the gearbox.
  • My gearbox is making a whining noise. What could be the cause? A whining noise could indicate low oil level, contaminated oil, or worn gears.
  • Why is my Can-Am Commander popping out of gear? This could be due to worn gears, a faulty shift linkage, or a worn detent mechanism.
  • Is it okay to use aftermarket gearbox parts? It's generally recommended to use OEM (Original Equipment Manufacturer) parts for critical components like gears.

Final Thoughts

Gearbox problems can be a major headache for Can-Am Commander owners. By understanding the common issues, diagnosing problems early, and performing regular maintenance, you can keep your gearbox running smoothly and enjoy many years of reliable performance from your machine. Remember, preventative maintenance is key to avoiding costly repairs down the road.