Happy birthday .... You need a new gearbox.... (1 Viewer)

Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
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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Nov 6, 2013
1,403
3,106
S. Ayrshire
Funster No
28,914
MH
The usual
Exp
Since the beginning
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 :(
 
Oct 15, 2012
10,129
56,788
Market Harborough
Funster No
23,304
MH
C Class Laika Ecovip 7R
Exp
2012
That's a tough one, hope you get it sorted with out too much expense.

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Apr 10, 2010
548
538
Bedfordshire
Funster No
10,998
MH
Carthago
Exp
Since Sept 2003
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:
 
Feb 24, 2013
12,991
101,181
Bolsover, Derbyshire
Funster No
24,833
MH
Hymer S800
Exp
not long enough
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)
 
Oct 1, 2007
7,063
13,963
Kirby cross further from londin
Funster No
504
MH
Between Motor homes
Exp
since 08
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

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Aug 6, 2013
11,941
16,533
Kendal, Cumbria
Funster No
27,352
MH
Le-Voyageur RX958 Pl
Exp
since 1999
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).
 

jollyrodger

LIFE MEMBER
Oct 1, 2012
6,264
26,386
Devon/Cornwall
Funster No
23,107
MH
'Obby
Exp
Since 1968'ish
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)

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OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
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.
 
Oct 5, 2009
348
315
anglesey
Funster No
8,762
MH
Autotrail Delaware
Exp
since 1999
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.
 

Minxy

LIFE MEMBER
Aug 22, 2007
32,489
66,013
E Yorks
Funster No
149
MH
Carthago Compactline
Exp
Since 1996, had Elddis/Swift/Rapido/Rimor/Chausson MHs. Autocruise/Globecar PVCs/Compactline i-138
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.

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OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
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 .....
 
Aug 6, 2013
11,941
16,533
Kendal, Cumbria
Funster No
27,352
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Le-Voyageur RX958 Pl
Exp
since 1999
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.
 
OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
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.

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D

deleted-member02

Deleted User
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/
 
OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
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.
 
Feb 22, 2011
9,637
19,812
Newcastle under Lyme
Funster No
15,397
MH
Hymer B544 A Class
Exp
Since 2015
@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
 
Aug 6, 2013
11,941
16,533
Kendal, Cumbria
Funster No
27,352
MH
Le-Voyageur RX958 Pl
Exp
since 1999
What gearbox. I have one off a 2.5td. It's the type with the alternator on the RHS as you look under the bonnet.

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OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
Hi all ,

Small (very) update ...


Van is still at garage no gearboxes to be found anywhere. Have ordered 4 now and each has been incorrect.

@tonyidle thanks for the offer. I have only just come back having been away My van is a 1998 1.9 xud if your gearbox is correct I would gladly buy it.

Any gearboxes I can find and the gearbox specialist and garage find are all incorrect. Apparently my van is a 320 Short wheelbase with a 1.9 engine as opposed to the normal 270 short wheelbase. This means the gearbox is different according to Peugeot.

It seems we are now waiting for someone to write off in an accident a similar van (probably unfortunately another camper ). As all scrap yards etc just laugh when I say I want commercial parts for 1998 boxer. .....

If anyone spots a peugoet boxer of that age breaking let me know !!

In the mean time back to Ebay etc
Thanks

Daniel
 

Al-Di

LIFE MEMBER
Mar 15, 2014
3,050
28,479
prestwich
Funster No
30,545
MH
Eura Mobil A Class
Exp
since 2013
hi have just done a quick search on talbot forums and the xud was used in pug and Citroen with only a couple of different boxes

cannot get my head round what the wheelbase has got to do with the g/box

hope you get sorted
have you looked at an upgrade using complete eng/box of a newer model
 
OP
OP
danielf
Jul 11, 2009
330
764
Basingstoke
Funster No
7,443
MH
Concorde Compact
Exp
Since I was 18.... 1996....
Thanks @aldi , aparently mine has different gear ratios and diff from 270 chassis. Casing are the same . Though according to Peugeot mine shouldn't have an intercooler but has ....

The three gearboxes that we have got hold of so far have had massively smaller diffs in. I have been to garage and seen them !

Though tonight three vans the same age as mine have been listed in eBay so I have emailed them all keeping everything crossed !

One looks particularly a good bet and seems to have the same engine as mine ....

Daniel.

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