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Peugeot Boxer 2.5TD 2000 reg, 2nd gear become difficult to engage, some crunching now and again, I've adjusted the gear lever linkage so the lever to centre of steering wheel is 304mm, still no joy. In fact after driving another 20 miles or so the lever doesn't want to go into 2nd period, all other gears are fine.

It's like this with the engine running or not, what do you guys reckon? Could there be a problem with the levers on the actual gearbox housing or is it the syncro inside the box? The linkages at the gear lever end itself seem to be free/OK,......I could replace those cables first I guess? The one that's not adjustable could have stretched in 12 years??

Edit: I've just removed the cables, one measures 10mm shorter than what the workshop manual states.
 

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Discussion Starter #2
Well the problem was within the gearbox itself, 2nd gear needed to be replaced, Peugeot sell this has a complete 'hub', it cost just over £400!

Apparently it's a common fault on these gearboxes, that and 5th, going by the paint (re con look) on our box I'm guessing that it's now on it's 3rd gearbox,......not good/what I would expect on a van that's just shy of 38000 miles.

If anyone is going to attempt to remove their gearbox, here's a few tips, the Peter Russek manual does not say anything about removing the front sub frame, it does need to be removed or at least remove all but one of the bolts on the nearside, that way you can swivel it a few inches towards the rear of the van, out of the way, no way could you remove the gearbox otherwise.

If you have a 'pull' clutch follow the advice in the link below, the bolt you need to use is a M6X1.0, the long socket from my set didn't have a large enough hole for this bolt to pass through so I used a 'sleeve' from a section of suitable tube I had.

http://www.howtomend...rs.php?id=69255



 

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Discussion Starter #3
Well two years on with another two thousand or so miles on the clock, guess what, 3rd gear is starting crunch.:mygod:

These gearboxes are not fit for purpose.:mad:
 

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the picture is not second gear its 1st & 2nd syncro hub, what you need now is a 3rd & 4th hub. I fitted one to an expert in july and it cost £200 for a new 1st& 2nd hub. are you using the proper gearbox oil?. its probably only the syncro ring at fault but you have to buy the whole hub. I have opened scrap boxes and used second hand rings in the past with no problems.
 

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the picture is not second gear its 1st & 2nd syncro hub, what you need now is a 3rd & 4th hub. I fitted one to an expert in july and it cost £200 for a new 1st& 2nd hub. are you using the proper gearbox oil?. its probably only the syncro ring at fault but you have to buy the whole hub. I have opened scrap boxes and used second hand rings in the past with no problems.
Are you sure that it's not 2nd gear? I were told that the syncro were part of it and that it came as a 'hub' assembly which cost £400 on it's own, I double checked that price at a Peugeot dealer parts department here in London, sure enough that were the price.

I were told to use this particular transmission fluid.
Experienced oil blenders, Morris Lubricants are a supplier and manufacturer of lubricants, oils and fluids for cars, motorcycles, fleet, metalworking, industrial machinery and agricultural plant. Call us today to discuss your individual requirements.


Got any idea how much this 3rd/4th hub is going to cost? I'm hoping that it's not going to be another £400 on it's own! I'm thinking of having all the syncros replaced and the bearings that hold the shafts etc.
I don't suppose you can point me in the direction of an exploded diagram of this gearbox? I would rather ask the gearbox specialist to do a 'belt & braces' job so that I (hopefully) don't have to remove this gearbox every two years.

I know that's going to add up in parts, would just like to check the cost of those parts at a main dealer first, no repairer can seem to give me an inclusive price at the moment.
 

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that is defo not second gear, its the hub, I can only assume that the two hubs would be the same price.
Oh bugger,.....not another £400 just for another hub part,.....you mention £200 but that were for the smaller van, an Expert.

So is there a 4th/5th hub in there too? I know that the speedo drive in there needs replacing too, that went the same time 3rd started to crunch, coincidence or not??

Any other information/links to the internals of this gearbox would be very helpful to me.:)
 
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