Crack in gearbox

RockyII · 09-28-2011, 01:40 PM

I have a Peugeot 307 2002 1.6 manual.

I had a oil leak, the car was running fine there were no other symptoms other than the leak. The car was put in for service.

The mechanic found it was coming from the gearbox. The gearbox was removed, there is a crack between the gearbox and differential. My mechanic cannot explain it, he believes there is a fault in the aluminum casing. The crack is like a blister blowing out from the diff. The clutch plate has had diff oil spilt over it from the diff.

How could this happen other than by a faulty casting of the gearbox case?

I am just trying to understand how this could happen. The cost of repairs are exorbitant; not sure what to do?

Thanks Ron

DGH308 · 09-28-2011, 02:05 PM

I had a similar problem on my 405 years ago.
The diff went and put a hole in the gear casing and pi**ed oil all over the clutch.
I just rivet a thin metal plate on the clutch side, put some filler on the diff side and all was well again. (no leaks)
Not sure if this helps but i'm just letting you know it's possible to patch it up yourself, depending on your level mechanical knowledge. (although I guess it is quite a big job)

RockyII · 10-05-2011, 09:34 AM

It took some time but I now know what happened. A tooth on the crown had broken off ( about 75%, some tooth left) and became wedged on the side and eventually caused a crack in the casing where it separates Diff and Bell housing gear box.

My question is we have removed the tooth fragment can we repair the crack (as suggested) and put it back together? I have found someone who is prepared and capable of welding the crack up.

Thanks everyone

battlestar · 10-05-2011, 11:04 AM

I had a somewhat similar problem when my driveshaft broke and cracked the gearbox casing on 407, so after repairing driveshaft i noticed that my oil was leaking after car was running for a bit. But luckily i noticed before it had time to throw out all of the oil so just took it for repair and they patched it up with liquid metal thing, whetever that is. and it was fairly large crack. Not sure if that is applicable to your situation.

RockyII · 10-06-2011, 10:21 AM

Thanks for your feedback and comments.

I think a safer route will be a second hand gearbox, does anyone know where I might find one at a reasonable price?

Thanks in advance

elmafudd · 10-06-2011, 02:42 PM

eBay - one of the UK's largest shopping destinations

09-28-2011, 01:40 PM	#1
RockyII Junior Member Join Date: Sep 2011 Posts: 3	Crack in gearbox I have a Peugeot 307 2002 1.6 manual. I had a oil leak, the car was running fine there were no other symptoms other than the leak. The car was put in for service. The mechanic found it was coming from the gearbox. The gearbox was removed, there is a crack between the gearbox and differential. My mechanic cannot explain it, he believes there is a fault in the aluminum casing. The crack is like a blister blowing out from the diff. The clutch plate has had diff oil spilt over it from the diff. How could this happen other than by a faulty casting of the gearbox case? I am just trying to understand how this could happen. The cost of repairs are exorbitant; not sure what to do? Thanks Ron Share Share this post on Digg Del.icio.us Technorati Twitter Last edited by RockyII; 09-28-2011 at 01:43 PM.

09-28-2011, 02:05 PM	#2
DGH308 Senior Member Join Date: Jul 2011 Location: Manchester Posts: 143	I had a similar problem on my 405 years ago. The diff went and put a hole in the gear casing and pi**ed oil all over the clutch. I just rivet a thin metal plate on the clutch side, put some filler on the diff side and all was well again. (no leaks) Not sure if this helps but i'm just letting you know it's possible to patch it up yourself, depending on your level mechanical knowledge. (although I guess it is quite a big job) Share Share this post on Digg Del.icio.us Technorati Twitter __________________ 308 1.6 HDi 110 SE

10-05-2011, 09:34 AM	#3
RockyII Junior Member Join Date: Sep 2011 Posts: 3	It took some time but I now know what happened. A tooth on the crown had broken off ( about 75%, some tooth left) and became wedged on the side and eventually caused a crack in the casing where it separates Diff and Bell housing gear box. My question is we have removed the tooth fragment can we repair the crack (as suggested) and put it back together? I have found someone who is prepared and capable of welding the crack up. Thanks everyone Share Share this post on Digg Del.icio.us Technorati Twitter

10-05-2011, 11:04 AM	#4
battlestar Senior Member Join Date: Jul 2011 Posts: 831	I had a somewhat similar problem when my driveshaft broke and cracked the gearbox casing on 407, so after repairing driveshaft i noticed that my oil was leaking after car was running for a bit. But luckily i noticed before it had time to throw out all of the oil so just took it for repair and they patched it up with liquid metal thing, whetever that is. and it was fairly large crack. Not sure if that is applicable to your situation. Share Share this post on Digg Del.icio.us Technorati Twitter

10-06-2011, 10:21 AM	#5
RockyII Junior Member Join Date: Sep 2011 Posts: 3	Thanks for your feedback and comments. I think a safer route will be a second hand gearbox, does anyone know where I might find one at a reasonable price? Thanks in advance Share Share this post on Digg Del.icio.us Technorati Twitter

10-06-2011, 02:42 PM	#6
elmafudd Senior Member Join Date: Jan 2011 Location: leicester Posts: 576	eBay - one of the UK's largest shopping destinations Share Share this post on Digg Del.icio.us Technorati Twitter __________________ Current planet owner.....

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