Happy birthday .... You need a new gearbox....

Discussion in 'Base Chassis Section' started by danielf, Nov 22, 2015.

  1. danielf

    danielf Funster

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    Hi all,

    Was having a nice weekend away down in Yeovil for my birthday (today).

    Decided to drive along the a30 to Salisbury for a mooch around.

    Had to stop at the brow of a hill as a tractor got stuck turning into a green lane , I did a hill start and it seemed a bit clunky and into second was stiff then bang nothing.

    Coasted down the hill to have a look in a safe place , with all kinds of grinding whining noises, and a smell of gear oil.

    Net result inside bits of gearbox have made a bid for freedom and the casing is cracked .

    It's only just had a new clutch in the spring and just had anew driveshaft a couple of months ago after the spring failed on that.

    Does anyone have any idea of a reasonable supplier for replacement gearboxes ??

    The van is currently dumped in disgrace at my tame garage.

    I am fed up now as I have been looking forward to a weekend away , I wouldn't mind if I drive it like an idiot and never looked after it ...


    Daniel.
     

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  2. Gizmouk

    Gizmouk Funster

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    I would try local scrapyards.
    If you go for a recon box, they'll expect yours to be serviceable - that from experience, after I left several bits of my old XR4i gearbox (inc some casing) on the M1 :(
     
  3. davidbaldam

    davidbaldam Funster

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    That's a tough one, hope you get it sorted with out too much expense.
     
  4. Cavs

    Cavs Funster

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    Sorry to hear of your grief. I know nothing about your specific vehicle, but it seems mighty coincidental that you've had work on your clutch and driveshaft, then the gearbox fails. :confused: I'd do a little digging if I were you.:cautious:
     
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  5. DavidG58

    DavidG58 Funster

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    Massive sympathy, thought mine had gone a few weeks ago, at least you know for certain what is wrong, we are stuck with an intermittent issue and a rising bill

    Best of luck for a reasonably priced solution (y)
     
  6. tofo

    tofo Funster

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    Breakers be best bet
    Case needs to be good order for recon
    I think

    I'm thinking fiat Ducatto 1.9 td or 2.5
     
  7. tonyidle

    tonyidle Funster

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    I have a 2.5td gearbox bought as a spare for my van and unproven other than I can select all 5 gears & it works smoothly (by hand).
     
  8. Wildbill

    Wildbill Funster

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  9. jollyrodger

    jollyrodger Funster Life Member

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    There is a firm on eBay (scrap yard) specializes in your type vehicle ,petrol or diesel boxes interchangeable ,I believe. Just make sure you get the correct ratio on 5th gear .
    On and happy,ish birthday (y)
     
  10. danielf

    danielf Funster

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    Morning,

    Thanks all for your kind words and offers

    The van is 1998 Peugeot boxer 1.9td has xud engine not fiat one.

    I am going to garage this morning to talk to them about the best option.

    I am sure if they had done something wrong with the clutch it would have come up as I have done 4000 miles since then . The driveshaft failed the day after we came back form Croatia. The spring clip that holds it in snapped, and allowed the shaft to move. So hopefully unrelated to this...... I will ask their opinion as to what they think has gone wrong.

    Even the breakdown guy said he had never seen a cracked case like that.

    Thanks

    Daniel.
     
  11. maxsdad

    maxsdad Funster

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    By spring clip I assume you mean the circlip that holds the drive shaft into the gearbox that broke.
    It's possible that a part of this clip has been left in the gearbox and been picked up between the gear teeth.
    Very unusual for such a major failure without any prior warning.
     
  12. Minxy Girl

    Minxy Girl Funster Life Member

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    I'd be tempted to take it to another garage rather than the one that did the original work ... if it hasn't been done correctly, ie by leaving a bit in the gears, you would then have a case against them for not doing a proper job. However, as I'm no gearbox specialist it might be worth having a shuftie round the web to see if this can happen anyway.
     
  13. danielf

    danielf Funster

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    Thanks all for the replies

    I trust the garage as they have always treated me ok. Even to extent of not charging extra after hey quoted me for clutch replacement and it took longer due to replacing seals etc.

    Thinking about it the gears got a little stiff that morning but I put it down to the cold weather as is sometimes is stiff when cold But no weird noises.

    I don't think the spring clip that holds the drive shaft in was left as they always show me the bits and pieces when they do anything

    It wasn't a circlip more of a round finger clip built into seal like a sprung washer.

    On the same unit there is a gearbox specialist who they get to do all their stuff like this, and he is going to look at it and give an opinion as to what went wrong. Van had 99,000 miles in it.

    It is going to be expensive though .....
     
  14. tonyidle

    tonyidle Funster

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    To remove the clutch it is necessary to disconnect the driveshafts from the gearbox to allow enough movement to separate it from the engine. If a driveshaft has come out of the gearbox it is possible it wasn't pushed in far enough for the snap ring to engage. It is perfectly possible that the shaft would not detach for some time. There would be no audible warning until it actually came out and that could (did) happen after the vehicle had been driven for a considerable distance.
     
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  15. danielf

    danielf Funster

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    Hi all,

    Small update....

    The garage has examined the gearbox...

    It seems the differential threw a tooth ( about the size of a finger ) and this then got into the rest of the gearbox causing it to jam everything, and this then caused it to Jam solid and to unseat all the gear shafts and selectors and crack the casing open. Neither they nor the gearbox specialist have seen this before !

    They have had to remove all the gearbox piece by piece from the engine and have had to extract the input shaft from the gearbox from the flywheel as it was jammed in there stopping them for removing the gearbox relatively whole... they think the engine is ok , but I do need a new clutch etc as the newish one is destroyed.

    I am now waiting for the gearbox specialist to source a gearbox to check and rebuild as needed as mine is total scrap....

    They have taken pictures apparently for their rouges gallery , I will share some when and if I get them....

    Thanks all for your support and words , all i need to do now is pay the bill as and when a new gearbox arrives...

    Daniel.
     
  16. kaasbroodje

    kaasbroodje Funster

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    This might be useful ?

    I recently needed a replacement gearbox for a 2011 Vauxhall Vivaro.

    Gloucester Road gearboxes carried out the work, it took less than 24hrs from diagnosis to being back on the road.

    Not cheap but I was most impressed with their service / quality of work. Also comes with warranty.

    http://www.grgb.org.uk/
     
  17. danielf

    danielf Funster

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    Thanks Moho for the recommendation...

    They don't have a suitable gearbox either... The problem I am coming up with is that mine is totally destroyed so cant be rebuilt...

    I and the garage and gearbox specialist have been trying to source one to be rebuilt second hand from breakers - but two have arrived neither of which are correct.

    The first turns up, two days late after UPS lost it , and started to be stripped down, and it has totally different gear and diff ratios to the one that was taken off. Despite having the same numbers etc. stamped into the outer casing. The second turned and isn't even the same casing or gear selectors despite being promised it was correct and had correct part numbers etc.

    There are no new gearboxes or gearbox parts available seemingly. In my search I only turned up 3 gearboxes on part searches and eBay, most of which when you drill down seem unsuitable for my van. A couple at over £1,000 and in Denmark... not sure about that one. Most of the available ones seem to be hydraulic clutch ones from later vans.

    We have tried breakers, Fiat, Peugeot and Citroen for the parts... none any where.

    My wife and I are now seriously contemplating writing the van off , and claiming it as a loss on my insurance. The garage , gearbox specialist and I cant believe how hard it is to find a gearbox.

    To cap it all I use it as my car everyday to get to work and it s leaving stranded and begging lifts at Christmas working shifts....

    Daniel.
     
  18. Minxy Girl

    Minxy Girl Funster Life Member

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  19. Figaro

    Figaro Funster

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    @danielf that's a really grim tale, feel for you
    Would engine & gearbox be an option? I'm sure you looked into it already
    Hope you can get it sorted
    Chris
     
  20. CHRI$

    CHRI$ Funster

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