Boxer gear oil level and hard change

I have some thoughts on raising the level of the gear oil in Boxer type boxes.

Some years ago we raised axle oil level on some Seddon Atkinson tractors. These had reduction hubs that seemed to run a little dry.

A simple fix was to fit a M and F elbow into the filler hole, turn the elbow to the vertical and close it with a pipe plug. In this case the filler had a standard BSP thread.

I think I will check out the thread on the Boxer and see if a similar, but much smaller elbow could be fitted.

My gear change is too stiff when moving across to 5th and reverse. That both gears are a problem tells me that this is most likely a spring problem, rather than sychro hub. I have lubed the cable ends and all linkages; the other gears are slick and easy.

Has anyone tried to lighten the spring on this change? Any info most welcome.

I have tennis elbow in my left arm!

This had me thinking.
These vehicles are for the most part left hand drive. I suspect that the whole change assembly is a fudge to provide right hand steering. Further, changing with your right hand would be a more natural action, pushing away from the body, rather than towards it. I am thinking about cranking the change lever by about 30 degrees, making a change more of a lift than a push.

Any experiences would be of interest.

Bill Silvester

Bill,

Just clarifying, your issue is going three notches across the gate from R on the left to 5 on the right? If so then I think you must have the improved later gearbox, which ought to be a positive thing!

I share your view that the Boxer shift is engineered for LHD and so Reverse always feel a little too strong (due to selector spring forces) to engage pushing away from one whereas it would be fine pulling it towards one. However I would take another look at the mechanism outwith of the gearbox. When I serviced my clutch I took the opportunity to dismantle the 'bell crank' type mechanism close to the gearbox which translates the movement of the cables. The bearing surfaces within were in a very poor dry state on examination. So I cleaned it all up, heavily greased it and the gear shift was transformed.

I personally don't feel that raising the gearbox oil level would bring the benefits you seek. The selector mechanism inside the box ought to already be splash lubricated by the general revolving of gears etc. Further, some seals which are currently above the oil level may then be immersed in oil risking seepage.

Hope this helps?

Bartfarst

Bartfarst wrote: Further, some seals which are currently above the oil level may then be immersed in oil risking seepage.

Bartfarst

I refill my box with 3 ltrs of oil instead of the 1.75ltr<?> recommended. I was advised to do this years ago by someone who had had a gearbox failure in France and the mechanic told him to overfill the box in future.I have a slight weep around the diff seals but that is all.
Can't say that the box is any better or worse than one with the normal amount in because I don't have another to compare it with.
Mine's the early type box.

Frank

Frank, I recall one weakness with these boxes, other than letting water in, was keeping fifth gear  appropriately lubricated. I think the issue is that fifth gear is 'grafted' onto the outside of what was originally a four speed box. I suspect this to be the motive for over filling in this case: do you agree?

Good to hear that oil doesn't come out the seals when you overfill though.

Bartfarst

Yes Stuart, that's what i reckoned when Brian told me about it. I think you know me enough by now to know that I don't follow blindly

Frank

Absolutely Frank. I think we both recognise the need to establish the real 'Why and Wherefore' before reaching for the spanners!

Stuart

My gearbox has 5th and reverse over to the right. That is why I suspect that it is a spring problem rather than a hub problem.

I have had another idea.

Could drill the 5th gear cover and weld in a higher level filler point

Another thought.

I used to drive a Boxer that was a friend's work van. This was in daily use and that also made my arm ache!  I think that blaming lack of regular use is therefore a red herring.

As an aside.
I few years ago I drove a Mercedes truck with electric gear shift. The gear stick had a damper to give it some feel and slow the change. Between Bristol and Manchester and back I had an aching arm! 

Maybe it is my problem,

Bill Silvester wrote:Could drill the 5th gear cover and weld in a higher level filler point

If your gearbox is the early type, fill it through the reverse light switch hole.

Frank