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

Your syncromesh is failing the bronze bit on cog within gearbox ( reddish tint ) - you need to to keep the engine revs lower when changing gear as you know - double clutch as suggested - i believe it is too get gearbox speed and engine revolutions speed closer ( similar )

Someone will pick me up on this if i've got it wrong
 
At the age of vehicle complete gearbox reconditioned will probably be very hard to locate if it fails ( if you cant repair yourself ) - other option may be to find something that will fit maybe with the use of an adaptor plate
 
barryd said:
Thats pressing the clutch twice? If so I did try it once, didnt make any difference.
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witzend said:
Down once out of gear into neutral then clutch up then down again and select next gear taking your time don't rush it
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It is the into neutral bit that is important.

It is the way we used to change gears before the introduction of synchromesh.

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What Is Double Clutching and How Does It Work?

Demystifying the manual transmission driving technique.
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Thanks. Garage reckoned they could get it sorted if its the gearbox. Sent to a specialist I think. They said anywhere between £250-£800. Ill use it to go to Flamborough (if we are allowed out) and if it doesnt improve (which I dont think it will). I guess ill have to get it done. If we dont go away I may well finally sell it but I guess ill either have to get it done or declare it in the advert. Ill then wait until winter to buy a new van when the lockdown surge is well and truly over. I think chances are we will get away though mid July.
 
Try flogging with dodgy gearbox you'll only get spares or repair money or sorted market value dont think you will have much choice on getting done or not - or put it in px to a dealer and plead ignorance if he catches you out with it
 
Just going to resurrect this thread. I still have the crunchy gear box in 3rd and 5th mainly on the down change. Its become an issue while I was trying to part ex or sell the van which now looks doubtful anyway. An oil change made no difference. My usual garage directed me to the specialist gear box repairer Easi Gears in Thornaby Teesside but they just said its too old and we cant get the parts. Sounded like a bit of a fob off to me, maybe.

Its looking like we will once again be keeping the van this year as a replacement is looking unlikely but either way I should get it sorted. It was suggested to me recently by a mechanic that it might just be cables or that a recon or second hand gear box might be an option. Any thoughts? Ive used it on and off since I Started this thread in 2020 and its not got any worse or better. If I cant get it fixed ill use it this summer also but I am likely to do a few more miles this year.

Just to remind you its a 1996 2.5td Peugeot Boxer
 
I tried double de clutch, dont think it works or I am doing it wrong. To be honest Im now thinking I may as well use it as it is all summer as I bet its going to be a right mess on getting it done. It looks like our plans for a new van are not going to materialise either. My thoughts were to just put it all on hold until the back end, go away and either sell the van as is when we get back at a reduced price or get the work done then and if it takes weeks or months it wont matter. Its perfectly drivable, just a bit of a crunch when changing down to third so if possible I avoid it and just stay in fourth or drop to second.

What is the likelihood of it failing completely mid trip? I envisage us being away a fair few months but probably will only do 2000 miles in that time. Its been like this a couple of years or so now at least.
 
I seemed to remember that some Fiat/Peugeot gearboxs needed overfilling found this with a Google search
I have a 1999 Fiat Ducato 2.8. Secondly, the gearbox only has 2.5 litres in it (this was the original spec from Fiat) but around 2003 a correction was issued by Fiat to increase the oil to 3 litres.
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witzend said:
I seemed to remember that some Fiat/Peugeot gearboxs needed overfilling found this with a Google search
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Yup heard and read that before....

From the Web

I have a 1999 Murvi Morello based on the Fiat Ducato 2.8. After the engine got hot the gears were crunching, particularly the 3rd, 4th and 5th changes. Changing was also generally very stiff and the gears were not disengaging quickly. I thought that it was going to mean a new gear box! However, my local mechanic suggest we first change the oil in the gearbox before considering anything more expensive. He changed the oil and found two problems: firstly, the oil had completely broken down, it was like water in viscosity. Secondly, the gearbox only has 2.5 litres in it (this was the original spec from Fiat) but around 2003 a correction was issued by Fiat to increase the oil to 3 litres.

It took about 50 miles to run in the new oil but the result was a complete correction of the fault. Now 5000 miles later and I still have a smooth running and easy changing gearbox. So if your Ducato gearbox start playing up try changing the oil as the first option!
 
Yes, that was mentioned further up the thread before I think. I am sure when the garage changed the oil to try that I suggested putting in the extra half a litre but whether they did or not I cant remember. I suppose there is no way of checking now.
 
I've had the same problem for 13 years, though not driven it much in the last two years. Provided your gentle, it's manageable. Something I have noticed is that when it's cold it isn't quite so bad. Had oil changed and cables checked but never made a difference. Talking it over the last time it was taken for MOT, and the mechanic said to carry on using it , the problem becomes a bigger problem when you want to sell, that's my dilemma at the moment. A secondhand gearbox may be the answer but I would be afraid of wasting money, knowing my luck I would end up with something worse than I've already got.
 
yorkslass said:
I've had the same problem for 13 years, though not driven it much in the last two years. Provided your gentle, it's manageable. Something I have noticed is that when it's cold it isn't quite so bad. Had oil changed and cables checked but never made a difference. Talking it over the last time it was taken for MOT, and the mechanic said to carry on using it , the problem becomes a bigger problem when you want to sell, that's my dilemma at the moment. A secondhand gearbox may be the answer but I would be afraid of wasting money, knowing my luck I would end up with something worse than I've already got.
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Well thats kind of encouraging that you have run it for 13 years! Its days of running over the Alps are over so this year it will just be down to The Cotswolds, Devon and Cornwall then maybe the Yorkshire Coast, Isle of Arran and the Lake district. Sounds a lot but basically the van just trundles to a CL or wild spot and the scooter does all the miles. I bet it will be 2000 miles tops over four or five months, if that. Everything else has been done. Welding, wheel bearing. I was 90% there in getting a newer van last week and it got sold from beneath me so Im kind of stuffed now until the back end where maybe there might be more stuff about and perhaps I can concentrate on getting it sorted or just sell it as it is.
 
barryd said:
Yes, that was mentioned further up the thread before I think. I am sure when the garage changed the oil to try that I suggested putting in the extra half a litre but whether they did or not I cant remember. I suppose there is no way of checking now.
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look at the bill they'd not have give you 500ml of oil
 
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