2004 Boxer .... gear selection problems.

[Trevor Wbm]

We've had our 2004 Boxer based AutoCruise for two years. The gear change has always been awkward, but I've kept it mobile with spray grease on the links at the gearbox end, and so far it's been usable, other than 5th being a real pig to engage, occasionally.

I have however now got to the point where using the van for three weeks in France left me with repetitive strain problems with my left bicep tendon and rotator cuff, so summat needs to be done.

My tame mechanic had previously told me to get new cables, which I did, but then decided that it was more likely the 'top hat' bearing in the gearbox, gave it a squirt of his special grease and told me to persevere. I've lost a little faith in him, so am seeking opinions from anyone who's had similar issues (with the gearbox, not the arm) and what the remedy was.

So ... cables, gearbox bearing, or is there a 'gate' that's worn?

Thank you in advance.

Edit to add .... I drive 20 and 21 plate Boxers when I'm volunteering .... the difference between the gearchange on them and mine is huge.

Ed

 

[jockaneezer]

You could pop the linkage cables off at the gearbox end and have a wiggle of the lever to see if knackered cables are part of the problem (ignoring the fact for the moment that they might just need adjusting ?)
EBay says the cables are common to Fiats too, so maybe it's the dreaded Fiat "synchromesh" issue, especially if fifth gear is the worst, in which case I'd change the gearbox oil, add in some Molyslip g/box additive plus the consensus is to put a little bit of extra oil in, and try not to change up to fifth till the box has warmed up a bit then you can be sure the oil has circulated properly and lubed 5th too.
You should inspect the drained oil for brass flakes too which would indicate synchromesh wear ?

 

[Janine]

I had the same problem - I practically needed to use both hands to select 5th gear.
The legend that is Dave Newell took the linkage apart and said that the force I had been using had bent something.
He changed it and charged me an hour’s labour.
It’s been a lot better since.

 

[Trevor Wbm]

Biting the bullet: it's going in to a local garage, chosen mainly because it had a Boxer based ambulance parked outside, on Monday.
£75 'diagnostic' fee then we'll see. Hoping it's OK , it was refreshing to talk to a bloke in a boiler suit - I don't get past the ones in the suits who've never had to use Swarfega at the car dealers.

 

[Badknee]

I pulled the gaiter on the gearstick to one side and having taped a drinking straw onto my oilcan spout squirted engine oil in between the inner and outer cables. I did this about three times while still using the moho and the difference after a week was brilliant.

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[golfercol]

Hi, our first van a 2001 boxer had similar gearchange issues, after trying a few 'internet cures' it turned out to be water contamination of the gearbox oil. This was caused by the old problem of the windscreen scuttle water drain, dripping onto the g/box and I think getting in the g/box through the breather. Solution: 1, empty g/box oil and refill with fresh ( check what comes out ! if its grey and thinner than you'd expect the oil to be then that's probably the selection problem) 2, find the windscreen scuttle drain pipe and extend it with a piece of metal pipe and rubber hose and route it well down below the g/box. I think the hard to select gear issue comes about because the oil breaks down on the synchromesh hubs due to the water contamination, thereby blocking the gear selection. Hope this helps

 

[Bessy765]

With respect, are you sure the clutch is fully disengaged when changing gear? Try selecting the gears without the engine running, if the clutch is dragging it will cause the same problem.

 

[Trevor Wbm]

With respect, are you sure the clutch is fully disengaged when changing gear? Try selecting the gears without the engine running, if the clutch is dragging it will cause the same problem.

Could be, to be fair, but it's also difficult actually finding the gears in the first place until everything's warmed up. Don't have the nouse or equipment to tackle it myself so hoping the garage will find the problem and fix it.

 

[Landy Andy]

When stationary and without engine on what is it like selecting gears?

That will tell you if clutch, box, mechanism.

 

[Trevor Wbm]

When stationary and without engine on what is it like selecting gears?

That will tell you if clutch, box, mechanism.

Not easy. Dousing the gearbox end of the linkages in spray lubricant helps a bit, but not for long.

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[Landy Andy]

If it is just as difficult to select the gears whilst the engine isn’t turning it’s not the clutch.

 

[Trevor Wbm]

Verdict from the garage: definitely not the cables, but we don't do gearboxes.

No charge for checking.

Can anyone recommend a gearbox specialist within 50-odd miles of Southampton?

 

[rangi]

Check the oil in the G/Box, is it emulsified? If so makes it difficult to engage 4th&5th, if you have the early Cable Speedo instead of the wire, it will also effect that too

Common Problem with those early Ducattos, water drains from the skuttle and drips onto top of G/Box.

UNLESS!

Either you, or, a past owner have fitted the Peugeot mod which takes the water down past the G/Box

 

[Trevor Wbm]

Just by way of an update ... booked the van into relatively local gearbox specialists, half an hour away by free bus with my Old Farts pass. After describing the problem, agreed that the box would come out, be rebuilt and put back with a new clutch 'cause it seemed daft not to. Resigned myself to a bill not unadjacent to £1500ish.

Took it up there today. Pleased to find a proper workshop with two guys literally elbow deep in rebuilding gearboxes, one of whom stopped what he was doing and booked the van in. He also spent ten minutes in and under the van before telling me it doesn't need a rebuild, it's the cantilever arm on top of the box that's seizing up, and they'll change out the oil too.

Sounds a lot like what Janine mentioned in post three.

My capacity for innovative bookeeping tells me I now have around £1200 to spend .....

If all goes as well as I hope, I'll post the company details here in due course.

 

[Trevor Wbm]

Final update:

Seized linkage arm removed, cleaned and greased and gearbox oil change. I guess a couple of hours labour, plus £12 for oil and disposal of the old stuff, plus VAT. Total £276.

Given that I was expecting to have to fork out for a recon box @ around £1500, and if they'd carried on and done that I'd have been non the wiser, I'm very happy.

GearLink at Whaddon Business Park, Salisbury, SP5 3HF. Handy for the X7 bus between Salisbury and Southampton.