Anyone know where my 5th gear has gone? (1 Viewer)

[gordoncbrown]

Hi, I was driving back from Edinburgh today. I just got over the Forth road bridge when I noticed the revs shoot up and the speed start to drop. 5th gear had gone. I can get all the other gears but nothing for 5th. Can any one suggest what has happened? Peugeot Boxer 2003 2.0 31,000.

Thanks

 

[MikeD]

Water in the gear box

I suspect that there is water in the gearbox.

I am no expert but there have been issues with the scuttle drain tube not being sealed and allowing rain water to enter the gearbox through the gearchange shaft.

Do a google search "water ingress into gearbox of peugeot boxer"

Hope this helps :thumb::thumb:

 

[jonandshell]

Maybe it voted for independance!

Fifth gears on older boxes were prone to failure due to fact they were sometimes an add-on to a four speed design.
Hopefully its just a selector linkage problem, but if not I read somewhere that the fifth gear 'pod' is easy to access and strip for inspection without removing the gearbox.

Hopefully someone who has experience of these units will be along soon.

Edit, info here-

http://www.seered.co.uk/fiat_mmm.htm

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[dave newell]

Earlier incarnations of the Boxer/Ducato/Relay had an occasional issue with fifth gear because it was outside of the main box casing and had a propensity to come undone and drop off, which is almost cetainly what yours has done. Its a reltively easy fix as long as you didn't do many miles afterwards as that can cause swarf to accumulate in the box which then needs to be stripped and checked. Geo probably has more experience than myself.

D.

 

[Tea Bag]

Hi.
dave newell beat me to it,i was going to suggest that had you pulled up and got out,taken your shovel from the motor,walked back up the road and...... Result
Tea Bag

 

[gordoncbrown]

Thanks for your replies. I've just called the garage that I use and booked in gfor it's MOT next week and they will look at the 5th gear at the same time. They have had to sort this before on others so at least they know where to start looking. No smiley yet until I see the bill.........

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[pappajohn]

no smiley for this Gordon.....plus labour.

Ad says ducato but they are the same part.

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[buffallobill]

a bit of interesting reading here.
http://www.seered.co.uk/fiat_mmm.htm

 

[TheBig1]

a member on here repaired his himself and chronicled his progress including photos

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will give you a good idea what will be involved

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[gordoncbrown]

Well. Into the garage on Monday . Will let you know how it goes.

 

[gordoncbrown]

Absolutely sailed through the MOT. However, when they had a look at hte 5th gear issue the nut and everything seems to be tight. They can see it selecting 5th gear ok it is just not driving... They are awaiting an expanded gearbox pic and some more info from Peugeot. Anyone got one tucked away?:thumb:

 

[gordoncbrown]

The plot thickens. The garage has got the drawings but they don't seem to shed any light on the subject. It is definitely not the nut that has come off. They say that the older ones that had the issue with the nuts falling off were double nutted where this one is a nut and a circlip and is a newer version. Any one able to come up with another suggestion?

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[gordoncbrown]

Ah well, looks like it's going to get expensive. Booked into a gearbox specialist for Thursday. :Sad:

 

[pappajohn]

i think one of the problems was oil feed to the 5th gear extension.
Wouldnt be surprised if the shaft splines or gear wheel internal splines hadnt worn and broken off leaving the gear to spin on the shaft.

 

[gordoncbrown]

i think one of the problems was oil feed to the 5th gear extension.
Wouldnt be surprised if the shaft splines or gear wheel internal splines hadnt worn and broken off leaving the gear to spin on the shaft.

Thanks Papajohn, any idea how much that sort of thing typically costs to sort?

I'm sitting down......

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[JockandRita]

Gordon,

Did you have a look at the link Big1 put up for you?
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The 2 x sets of 5th gear replacement parts alone, from Fiat/Citroen/Peugeot, are just short of £635 including VAT.

Good luck with it. :thumb:

Jock.

 

[DP+JAY]

I have 2 sets of 5th gears for sale (one set high & one set low ratios) if anyone's interested.
As new very low miles, used them when experimenting with gear ratios on last van(05 Fiat).

 

[gordoncbrown]

I have 2 sets of 5th gears for sale (one set high & one set low ratios) if anyone's interested.
As new very low miles, used them when experimenting with gear ratios on last van(05 Fiat).

I will let the garage know. I may be in touch. Thanks

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[gordoncbrown]

Well, it's repaired and I pick it up after work tonight. I might need picked up once they hand me the bill though.......

 

[gordoncbrown]

Back on the drive now. £550 lighter but all seems well. Ready to roll for the season. If anyone in Scotland has gearbox issues I can recommend Charles Butler in Forfar. Reasonably priced I think, and I know a few people from Forfar and they seem to have a good reputation. :thumb:

 

[JockandRita]

Back on the drive now. £550 lighter but all seems well. Ready to roll for the season. If anyone in Scotland has gearbox issues I can recommend Charles Butler in Forfar. Reasonably priced I think, and I know a few people from Forfar and they seem to have a good reputation. :thumb:

You did well there Gordon. It cost me nearer £650 just for the 5th gear and syncro gear sets.

Cheers,

Jock.

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[Tootles]

Back on the drive now. £550 lighter but all seems well. Ready to roll for the season. If anyone in Scotland has gearbox issues I can recommend Charles Butler in Forfar. Reasonably priced I think, and I know a few people from Forfar and they seem to have a good reputation. :thumb:

Heard of this chap. He has a padlock on his sporran, it seems......

 

[freelanderuk]

Well, it's repaired and I pick it up after work tonight. I might need picked up once they hand me the bill though.......

tell us all what was wrong with it then

 

[gordoncbrown]

tell us all what was wrong with it then

It had stripped the 5th gear and synchro. As expected the most expensive bit of the bill was parts. I suppose as they are transmission specialists they know their way round gearboxes and get the job done quite quickly , probably quicker than a general garage that wants to stretch themselves a bit.

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