Peugeot Boxer 1996 2.5td crunching in 3rd and 5th

barryd

barryd

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I have noticed this for a while. Gears work ok but 3rd is always a bit crunchy as is fifth but not so much.

Quick search search reveals some saying its an issue with water getting into the box and there was a fix from Fiat? at some point. One guy ended up have to have a new box fitted though. Others say they had garages try various things like fitting new Syncromesh (I think).

Not sure if its a big issue I need to worry about but just looking for opinions. I imagine if I take it to my garage it will be another one where they scratch their heads.

What do you experts think?
 
Fiat used ml and me gearboxes on Ducatos 3 rd and 5 th synchromesh gave up the ghost. A specialist gearbox repairer ideally should do the job most garages including main dealers sub contract out ...mine went and it was a £600 repair

Note the issues on these boxes is totally different to the infamous bolt on 5th gears

I used Doncaster transmissions to fix mine on recommendation from a mechanic I know
 
Think it's a common fault on these Vans the synchromesh goes on certain gears we test drove a few and they all seemed to crunch into 3rd gear so decided to buy a newer model panel Van conversation instead
 
Its a Peugeot Boxer 2.5td but I think it will be the same as a Fiat of that era. Im just wondering could it be a linkage / lubrication issue. Its really had very little use for two years. It was just serviced in March though but maybe they dont do the gearbox / oil. Ill call them in the morning and ask.
 
600 squidles.o_O it is Barry the wallet gripper that is asking.

Seriously when has it been serviced ,will an oil change help?
 
I Called the garage and mentioned the water ingress thing. They just check for leaks when its serviced. I was directed at another thread on "Fun" which kind of backs this up that there is a fault with this model where water can get in over time. One guy said his oil was like water and after a change it was fine after 50 miles of running the new oil in. I bet its never been changed.
 
I'd get the gearbox oil changed and see if it cure's it. If it doesn't then a gearbox overhaul will be needed which won't be cheap
 
I have a crunch on 4th gear on our Boxer TD. Had the gearbox oil changed and it was grey and watery. I've had two gearbox oil changes since and it's still there, resigned to the fact that down the road it'll be a gearbox recon and clutch change of course at the same time. The water ingress is this instance was from the windscreen scuttle, the water was flowing down the outside of the pipe and dripping down (at the elbow on the pipe) onto the breather on the gearbox. I removed the pipe, cleaned all surfaces and made a good seal with silicon. I change gear carefully and hope the swear box eventually covers the costs. :rolleyes:
 
Thanks. Ill get it booked in tomorrow. See what they can do. The answers are useful as I can forward them onto our garage who wont deal with this kind of vehicle on a daily basis. Its probably only going to have to get us to Flamborough head this year again and is long over due to be replaced but I cant sell it with a dodgy gearbox so hopefully an oil change will cure it.
 
Drain gearbox oil yourself and check old oil for bronze filings/residue or any other metal decision will be easy then
 
synchro rings are very susceptible to the wrong type (or contaminated) hypoid oil, or if gl5 has been used instead of gl4.
However the damage may already have been done.
A quick oil change will tell as others have said.
 
Only ever let two garages work on my stuff,first one wrecked my new gilera moped when i was 16, second workshop vastly over charged for welding work on van which i should have done in hind sight but was doing other jobs.
 
Just a query is their a Drain plug? Is replacing gear box oil a service item?
 
Update

Vans been at the garage a couple of days. Passed on all the info but they think the gearbox or something in it is knackered. Oil has been changed and the old oil was quite manky apparently, bit of a funny redish tinge to it and thin. They gave it a test ride and said it was just the same and i just drove it home 16 miles and it is. However someone on this thread or another thread said it took 50 miles for the new oil to bed in and make a difference. The Mechanic said he doubts it will but I guess ill have to wait and see. So no further forward really. If your gentle and slow with the change to third its ok. Its mainly at higher revs when you change normally to third and fifth there is a bit of a crunch.
 
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