Peugeot Boxer 1.9TD 2002 Gearbox Replacement (1 Viewer)

[Henri37]

Hi All,
This is my first post, so pls bear with me if I do something wrong.
We recently bought a 2002 Peugeot Boxer 270 MWB Pioneer motorhome which had a bit of crunching between 1st/2nd gear change. We thought because the van was very low mileage ie 15K the gearbox would be fine with a refurbishment, unfortunately that is not the case due to necessary parts being unavailable. Trying to find a similar gearbox (Part Number is 20UE01 and ML5) is proving impossible. I've surfed everywhere, and been conned out of over £300 so I'm losing faith and thinking the van will end up being scrapped.

Can anyone tell me if there is any other gearbox that would suffice? Could we change/upgrade engine and gearbox to something more readily available/repairable?

Thanks in advance.

 

[StitchesnFluff]

Hi!
Someone will answer the above soon

 

[gus-lopez]

Surely the gearbox can be rebuilt by a specialist ? The parts should still be available as 14 years is usually the minimum. Might need to have a look on the European sites.

This chap might be able to help you out with some info on what is about.
Link Removed

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[Henri37]

That's what we thought gus-lopez, and we took it to a specialist recommended, and we trust him. The parts that are needed (not syncro but the gearing itself) he has tried and failed because they are just no longer available.

 

[Dilbert]

Hi Henri 37 I've got a petrol boxer the same age and it seems just to be a newer version of the old Talbot engine/ gearbox that I had years ago. That one had a long gear lever rather than the cable system . I wonder if a Talbot lump would fit? There's many rusted out oldies with useable engine/ transmission units just a thought

 

[Henri37]

Thanks Dilbert. Maybe worth a thought, I know that Fiat Ducato and Citroen Relay seem to be mentioned in the same breath as our Peugeot Boxer but even they are hard to find. Alden Transmissions say they could make one up cost of £650, but I've seen some very bad reviews about them and after being conned previously I'm very wary.

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[jollyrodger]

I may be wrong but Pugeot,Citroen,is the same box .
These guys maybe able to help



Maybe not the same box but they should have the knowledge

 

[shinysideup]

Call Gloucester Road gearboxes in Bristol. Just had mine rebuilt ,,,, on the kindle right now , but will look for the link to my post last week with details.


http://www.motorhomefun.co.uk/forum/threads/peugeot-boxer-gearbox-rebuild.152878/

Steve

 

[Henri37]

Hi Steve,

I did see your post, and have been in contact with Leigh from Gloucester Road. Just waiting on him getting back to me with delivery details, etc.

Thanks to everyone who gave advice. It would appear that due to the known problems with these gearboxes a rebuild by Gloucester Road, or Bexhill Gearboxes is the way to go. Even if we found a replacement gearbox, it would still probably have to be rebuilt. I'm guessing these guys either have stocks of the parts needed, or do something magical to the original parts.

Regards to all.

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[rangi]

Gear/box fella on Falmouth Quoted my fella at Lanner Moor Garage £800 for a recon.

 

[DL42846]

Hi All,
This is my first post, so pls bear with me if I do something wrong.
We recently bought a 2002 Peugeot Boxer 270 MWB Pioneer motorhome which had a bit of crunching between 1st/2nd gear change. We thought because the van was very low mileage ie 15K the gearbox would be fine with a refurbishment, unfortunately that is not the case due to necessary parts being unavailable. Trying to find a similar gearbox (Part Number is 20UE01 and ML5) is proving impossible. I've surfed everywhere, and been conned out of over £300 so I'm losing faith and thinking the van will end up being scrapped.

Can anyone tell me if there is any other gearbox that would suffice? Could we change/upgrade engine and gearbox to something more readily available/repairable?

Thanks in advance.

I have a 2009 Fiat Ducato 130 Multyjet that has the same problem. Crunches between 1st and 2nd. Mine has 24 thousand miles. I'm told the Fiat, Citroen and Peugeot have the same gear box. I'm not sure about a 2002 one. I would imagine they are the same. Basically the gearboxes are rubbish. Mine is going in next Monday to Fiat to get the box rebuilt. I'm told it will be between one to one and a half thousand Euros. I have contacted Fiat and registered my disgust. They have given me an incident number and are awaiting a report from the Fiat garage. I might get a contribution from Fiat. Watch this space.
Whilst I was researching my options I did see on Ebay syncro repair kits for Fiat's and gearing cogs. It is a common problem. When I took mine into Fiat the Guy tried to look surprised when I told him of my problem. I told him if he didn't know Fiat, Citroen and Peugeot had a problem he should look on the internet as it was full of the problems people have been having.
Some people have 1st to 2nd problems, some its 5th to 6th problems and others have experienced problems with getting reverse. I think the reverse is just an adjustment problem on the linkage.

I did read one thread somewhere where the guy claims the syncro gears are normally made from a different type of metal to what Fiat etc use. In there wisdom Fiat went for something cheaper.
I had thought of getting mine done on the cheap somewhere but decided to go to Fiat on the off chance that I might get a contribution from them. Plus with Fiat I will have a two year guarantee.
The service guy did say with great pride " We use genuine Fiat parts" to which I replied that was no f----g good as there original parts have only lasted 24 thousand miles.

 

[rangi]

Same old problem that has caused it.

Water leaking into the Gear Box from Skuttle which drains onto top of G/Box. Get the Macnic to fit the Peugeot Modification that takes the water away to the other side of the engine About £30

Tiz the same engine/g/box combo in all of them, Fiat, Citroen, Pug

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[Henri37]

We know what caused it, and how to fix it. Problem is we can't get anyone to repair/refurbish the original gearbox up here in Scotland, and can't find a used 1.9TD box either. Couple of suggestions for rebuilders down south of England but we need to pallet ours up and send it to them, then also pay for carriage of repaired one back up, which could be adding £100s on the £1200 - £1300 rebuild cost.

 

[Boringfrog]

I have a 2009 Fiat Ducato 130 Multyjet that has the same problem. Crunches between 1st and 2nd. Mine has 24 thousand miles. I'm told the Fiat, Citroen and Peugeot have the same gear box. I'm not sure about a 2002 one. I would imagine they are the same. Basically the gearboxes are rubbish. Mine is going in next Monday to Fiat to get the box rebuilt. I'm told it will be between one to one and a half thousand Euros. I have contacted Fiat and registered my disgust. They have given me an incident number and are awaiting a report from the Fiat garage. I might get a contribution from Fiat. Watch this space.
Whilst I was researching my options I did see on Ebay syncro repair kits for Fiat's and gearing cogs. It is a common problem. When I took mine into Fiat the Guy tried to look surprised when I told him of my problem. I told him if he didn't know Fiat, Citroen and Peugeot had a problem he should look on the internet as it was full of the problems people have been having.
Some people have 1st to 2nd problems, some its 5th to 6th problems and others have experienced problems with getting reverse. I think the reverse is just an adjustment problem on the linkage.

I did read one thread somewhere where the guy claims the syncro gears are normally made from a different type of metal to what Fiat etc use. In there wisdom Fiat went for something cheaper.
I had thought of getting mine done on the cheap somewhere but decided to go to Fiat on the off chance that I might get a contribution from them. Plus with Fiat I will have a two year guarantee.
The service guy did say with great pride " We use genuine Fiat parts" to which I replied that was no f----g good as there original parts have only lasted 24 thousand miles.

Totally redesigned gearbox 2006 onwards, I think you have been unlucky to have the problem you described.

 

[Henri37]

Yep, Boringfrog - Wish we'd left the gearbox in situ and tried some heavier duty oil like others suggested. At least it would maybe still be usable. Now looking like it needs to be scrapped. Expensive lesson.

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[DL42846]

Totally redesigned gearbox 2006 onwards, I think you have been unlucky to have the problem you described.

Whilst carrying out various searches on line I came across quiet a few others with models after 2006 that had the same problem. Some from 1st to 2nd and some from 5th to 6th or reverse.
Plus I know a guy who works as a mechanic for Citroen and he said they still have lots of problems with gear boxes.
The tire fitting guy who came round to my place to fit some new tires had a Citroen, which was only a couple of years old, he had to have a complete new gear box fitted to his at 50 thousand kilometers. I think the problem has improved , but not gone away yet.
Its a pity as otherwise the Fiat is a nice drive.

 

[Henri37]

Hello Motorhome Funsters,
Just wanted to update you on our saga with the Peugeot Boxer 2002 1.9TD gearbox debacle.
We have now got our van on the road with its original gearbox fully refurbished. Yippee!!
Remember we are based in Scotland near Glasgow and had tried several recommended Gearbox Specialists to no avail - because the parts are no longer available. But, then another friend told us to contact Alpine Transmissions Ltd, Blantyre which we did, and after inspection of the current dismantled gearbox he told us he had the parts and would be able to rebuild it. We now have our Van back on the road and thoroughly road tested by Alpine Transmissions.

I cannot recommend Allan and his workforce highly enough for the excellent service provided, and for saving our Van's life. I am so happy!!

 

[Bobby22]

Result, good to get good news for a change. Hope you get to enjoy your van with no more glitches

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[DL42846]

Hello Motorhome Funsters,
Just wanted to update you on our saga with the Peugeot Boxer 2002 1.9TD gearbox debacle.
We have now got our van on the road with its original gearbox fully refurbished. Yippee!!
Remember we are based in Scotland near Glasgow and had tried several recommended Gearbox Specialists to no avail - because the parts are no longer available. But, then another friend told us to contact Alpine Transmissions Ltd, Blantyre which we did, and after inspection of the current dismantled gearbox he told us he had the parts and would be able to rebuild it. We now have our Van back on the road and thoroughly road tested by Alpine Transmissions.

I cannot recommend Allan and his workforce highly enough for the excellent service provided, and for saving our Van's life. I am so happy!!

I am happy for you also. Great result. Wishing you happy travels.

 

[Megascout15]

Hello Motorhome Funsters,
Just wanted to update you on our saga with the Peugeot Boxer 2002 1.9TD gearbox debacle.
We have now got our van on the road with its original gearbox fully refurbished. Yippee!!
Remember we are based in Scotland near Glasgow and had tried several recommended Gearbox Specialists to no avail - because the parts are no longer available. But, then another friend told us to contact Alpine Transmissions Ltd, Blantyre which we did, and after inspection of the current dismantled gearbox he told us he had the parts and would be able to rebuild it. We now have our Van back on the road and thoroughly road tested by Alpine Transmissions.

I cannot recommend Allan and his workforce highly enough for the excellent service provided, and for saving our Van's life. I am so happy!!

Hi henri37 just wondered how the gearbox was holding up? Contacted alpine tonight about doing mine and was just wanted a bit of reassurance before I spend that much money

 

[Henri37]

Hi Megascout15, glad you read my post and got in touch. Our gearbox has been running very well, and I cant praise Alpine, Alan and his workforce enough. They are excellent, and once you've seen their set-up you will be very impressed. If he has the parts he will have it rebuilt i no time and running like a sweetie. Hope you go with him, and altho it is a lot of money your MH is no use without it, and you get 12mth gaurantee. Remember me too him but say Etta not Henri37. Good luck.

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[wigster]

Its great to have feedback from a problem first asked about, fair play @Henri37 it helps people in the future with similar issues and makes Fun such a useful resource

 

[Henri37]

Absolutely Funster, glad to have been able to help another Motorhome Funster.☺

 

[Chris51]

Same old problem that has caused it.

Water leaking into the Gear Box from Skuttle which drains onto top of G/Box. Get the Macnic to fit the Peugeot Modification that takes the water away to the other side of the engine About £30

Tiz the same engine/g/box combo in all of them, Fiat, Citroen, Pug

+1 get rid of the leaks. A cover over engine to take water away to either end can be made up cheaply--similar problem with later vans leaking on n/s electrics.

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[Deleted member 55490]

Hi, I'm new here and I have the same problem with my 2002 Starfire 1.9 TD, second gear, no parts so I've booked it into Alpine on 15th August after reading your posts.
Are you still happy Etta? It's a big bill and a 191 mile trek with no second gear, (well occasionally) and I'm trying to be as sure as I can.
Thanks, Tom.

 

[fifthwheel]

Call Gloucester Road gearboxes in Bristol. Just had mine rebuilt ,,,, on the kindle right now , but will look for the link to my post last week with details.


http://www.motorhomefun.co.uk/forum/threads/peugeot-boxer-gearbox-rebuild.152878/

Steve

A Kindle with a gearbox???

 

[Gardner]

Hi I know this is post is over a year old but I too was trying to find a gearbox,for our Peugeot boxer 1.9 TD ( which seemed hopeless) found this site in my search.....then I found EG Rose in Mansfield and a really knowledgable and helpful man who has rebuilt our gear box if this could be any help to anyone the number is 07720965877

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[SEP555]

And I'm 6yrs late to the conversation ...

We also have a Peugeot boxer 1.9TD 2002 that needs a gearbox replacement. Unfortunately I believe once all the oil drained out it damaged the casing in a kinda "throwing a rod" way. Is this something a specialist could repair or is our only option a new reconditioned box?

​

 

[Brendan Stone]

I had to get a reconditioned box for mine (1.9td) that had water damage.
Found https://gearboxuk.com/ at Doncaster. Selling recon boxes on eBay.
Really helpful chap (Joe). I drove my old box up (from Devon!) 10mins on site to drop of old one and put new one in boot and home to get my garage to fit.
My garage was impressed with the quality of the recon box. Box was £1300 Inc swap of mine.
Worth giving Joe a ring to find out what they can do.
Found a couple of other places by googling but these guys had one in stock which meant I could do a straight swap rather than waiting for them to fix mine.
My garage charged £800 to remove old and fit new box Inc new clutch. But they fitted a new radiator at the same time so just the box might have been about £600 to replace?
New box drives much sweeter.
Good luck!

 

[SEP555]

Brendan Stone Thanks Brendan, will try them. Have tried many places no luck so far. Trying to work out whether an identical gearbox ID replacement is needed or a newer equivalent is ok.

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