Peugeot Boxer 4th gear synchro gone

Hi,

This post is a sequel to an earlier post where a generally notchy gearchange (manual 5-speed) seemed to be improved after changing the gearbox oil and adjusting the clutch cable. There had previously been water in the gearbox. It has since run fine for about another 3000 miles. However, on a trip down to Norfolk in May, we started to have trouble with 4th gear. Basically it feels like the synchro has failed. It goes into 4th gear easily enough, but graunches unless you carefully match the gearbox layshaft  and road speeds. All other gears are perfectly fine. We have the correct Peugeot spec oil in the box, and there is no water in it (checked that today). I have also today re-checked the clutch adjustment. It's still no better. Has anyone else had this problem? Has anyone done a DIY gearbox removal/strip-down/replace and if so what sort of job is it? Any recommendations for where to get the gearbox rebuilt? I think the gearbox is a ML5T but I'm not certain about that. The base vehicle is a Boxer 1 with a 2.0i petrol engine.

All help appreciated.

Best regards

Mikebro  

No answer was the loud reply!! I have decided to go for a full recon on my gearbox. It will be done in July when we are away on a non-van holiday. Without any recommendations I will probably use one of the Glasgow based companies specialising in gearbox recons.

Rgds

Mikebro

Hi Mikebro
Strangely, just been having a conversation with a neighbour who used to have problems with his gearbox.
Can't answer your question regarding gearbox reconditioning, but I don't know whether you have found out why there was water in the gearbox ?

My neighbour found that the drain from the scuttle had rusted around the top of pipe connection into the engine bay. Water was running down the outside of this pipe and onto the engine, finally settling on top of the gearbox where there is a breather hole. this water was then being drawn into the gearbox when the engine/gearbox cooled down. he cured the drain problem by fixing a funnel to the scuttle and then attaching the drain pipe to that.

Doesn't answer your query but might be of interest !

Cheers

Hubert

Thanks Hubert - yes I did know about the water drain problem which I fixed some time ago but thanks anyway.

Best regards

Mikebro