GEARBOX - URGENT HELP NEEDED

Hi.
I've been having some problems with gear changes on my Rambler 2000 X reg 2 litre petrol so put it into a gearbox specialist in Swansea.

seems the 1st & 2nd gears & syncros are a bit worn - but the 4th gear & syncro are really worn (crunching badly going into that gear).

Seems Peugeot no longer can supply the 4th gear & they can't supply a recon box any longer either

I gather a box from a diesel has incompable ratios

Can anybody tell me if the gearbox used on the Fiat Ducato / Citreon Relay petrol versions (as they were all made in the Sevel factory) is compatable ?

Please can any body help with suggestions as my wife and I are desperate to get it back on the road

From research I think my gearbox is a ML5TU

Unless I can get this sorted I'll be stuck with an unuseable MH

I have checked with Citroen their gearbox is apparently the same - they cannot supply the 4th gear either - but they do have the 4th syncro .

Still not sure about the Fiat Ducato gearbox compatibility

Might have to get a gear made by a specialistif thats feasable

DreamMachine wrote:Still not sure about the Fiat Ducato gearbox compatibility

I don't think there is a petrol 'Boxer shape' Ducato   

Frank

We have just had our ml5 gearbox for 2001 petrol Symbol rebuilt by Mackies in Glasgow. It needed a new 4th gear set. Mackies said they had difficulty getting the parts but they did get them and the gearbox was refitted last week. I've only driven the van back from our local garage but it seems fine. So my advice would be to go direct to a gearbox rebuild specialist rather than Peugeot.

Good luck!!

May I ask what it cost to have the box rebuilt pls? and was that including remove/replace?

Frank

Mackies charged £795 + a pickup and delivery charge + vat which all worked out to just over a grand. This did not include fitting which I had done by my local garage. I had clutch, pedal and cable changed while the box was out so my total cost would not be useful. Also local labour rates vary dramatically. I think I'm reasonably lucky at £41/hr.

Mikebro  

Forgot to add - rebuild included complete recon, new bearings, baulk rings, gaskets, seals, the usual.

mikebro wrote:We have just had our ml5 gearbox for 2001 petrol Symbol rebuilt by Mackies in Glasgow. It needed a new 4th gear set. Mackies said they had difficulty getting the parts but they did get them and the gearbox was refitted last week. I've only driven the van back from our local garage but it seems fine. So my advice would be to go direct to a gearbox rebuild specialist rather than Peugeot.

Good luck!!

Yes this is the best way to go. Use a gearbox specialist.
Some parts have to be made.
Not sure if the design fault of water poured over the gearbox has not caused some of these problems.I have fitted a LH drain and had the oil changed  as a precaution.

Regards

Mike

mikebro wrote:Mackies charged £795 + a pickup and delivery charge + vat which all worked out to just over a grand. This did not include fitting which I had done by my local garage. I had clutch, pedal and cable changed while the box was out so my total cost would not be useful. Also local labour rates vary dramatically. I think I'm reasonably lucky at £41/hr.

Mikebro  

Thanks    I would probably remove/ fit the box myself (or with the aid of a strong grandson) so it was the rebuild price I was really interested in.
NOT that I'm in a rush to change it, it clatters at tickover but apart from that ... Handy to know how much these jobs cost JIC.

Thanks again

Frank

Hi, From what i know I would say £500 and up.
Once the gearbox is out its worth considering clutch and release bearing.
Many parts have to be made.
Start saving Frank.
ps Have you changed oil and modified water drain?

best regards

Mike

I had already had the drain pipe checked & it's already been fitted with the longer version & no sign of water in the box.

By the way the Citroen Relay has been confirmed uses same gearbox although they are even rarer.

Local Citroen dealer checked & they can't supply the 4th gear either nor a recon box.


Thanks for all the usefull info - there's hope yet then in solving my problem - I'm getting back to my local gearbox guy today & hope it can now progress.

If necessary will get a part made but that won't be cheap.

mikethebike wrote:.
Start saving Frank.
ps Have you changed oil

several times, (I've had it quite a while)

and modified water drain?

No Need, mine never did drain onto the box, it drains behind it, and I've never had water in the box. Checked every oil change.

Frank

That's good.You must use yours the most,being your only transport.

Regards

Mike

Well it's finally back on the road - phew.

It seems that Peugeot (and Citreon) have stopped making many parts for the early 1996 - 2002 model Boxers & Relays.
I gather there are a limited amount of 1st & 2nd gears + syncro still available but 4th gear are all gone & they can't supply a factory recon gearbox either.

Only way My Gearbox guy (Jon The Box alias 'Manual Gearbox Repairs' Swansea) eventually could sort it was tracking down a decent condition s/h gearbox - stripping & recon that.

All told it's cost me £1000 including fitting and a new clutch which made sense to change at the same time.

If you are having gear problems with your MK1 Boxer then I suggest you get it to a gearbox specialist quick because as time goes on there will be less & less decent s/h boxes around.

Failing that they will have to get parts specially made by a specialist gear engineer - dread to think what the cost would be.