Peugeot Boxer water leak onto gearbox

Hi all, I have started a new thread to try to help those people like myself who are suffering problems with water going on and around the gearbox on a 2000 Boxer van conversion. This can cause a multitude of problems, speedo packing up, water in the oil, stiff gear change, third and forth gear syncro problems.
After a lot of calls to my local Peugeot Dealer I thing I have come up with a solution which unfortunately will cost a few bob and about 2 hours of your time but I think it is worth it. I did mine today at 1 degree and was I cold.

Right, first off you will need a new modified "water evacuation pipe", I kid you not - at £18.50 plus vat Part no. P00006448L6 plus some sealant.

Now this pipe is modified and twice as long as the original and goes behind the Air filter that you will have to remove, I will post some pictures shortly. The pipe is routed far away from the gearbox but you have to seal it into the drain hole under the scuttle otherwise you will be back to square one.
Stay tuned Picture to follow.

Best regards, Mike and Winnie

Right , first off you have to remove the wiper arms, and undo 10 Allen key bolts from the top of the scuttle (Part no; P00008546L1 if they are rusty and remove the lower philips screw (3). Mark the wiper blades before you remove them and make sure they are in park then turn the ignition off, mark where the blade sit and undo them giving a gently wiggle.
The scuttle will be stuck at the point by the bonnet stay as there is sealant to prise off. Remove the scuttle. WATCH THE WASHER PIPES, gently remove the pipes from the jets

Remove the air filter, 3 nuts inside and the air hoses.

Next remove the offending pipe. a chuck in the bin, the new one will be twice as long ending up by the radiator on the near side front of the vehicle.

Right, now to try to get some pictures up, please bear with me.

Regards Mike

I don't seem to have any pipes, just a crude channel/slot either side so looking forward to the pics. Where did you order the part from, was a garage, 'tinternet or a Peugeot dealer ?

Dealer Terry, still trying to get pics up, I think they are to big.

Regards Mike.

Okey Dokey, if you still can't get the pics up, you can always PM me with attachments if you like. I'll leave it up to you.
Cheers.

Hi, I also had water in my gearbox oil. Water was dripping onto the gearbox because the scuttle had rusted and water was able to run on the outside of the drain pipe.
I managed to clean & treat the rust on the scuttle and seal the pipe with sikaflex. I've checked many times for water laying on the gearbox fins and it seems to have stopped the problem. I managed to do the entire job from underneath the scuttle by just moving out of the way the pipe that runs between air cleaner and the turbo.

Any progress on getting pictures up yet? Would love to see them.
I have had a few ideas about how to solve this problem but didn't know there was a 'kit' available.

Enn

No cant get them on, can someone help? uploaded to photobucket cant get them o to here

Flying High wrote:No cant get them on, can someone help? uploaded to photobucket cant get them o to here

Click on the photo in Photobucket
On the right hand side there is a menu box
Where it says IMG code click in the oblong box
It will turn yellow and say "copied"
After your text in the Forum........right click and select "paste"

Your picture will appear (trust me)

PB

Url removed

Well, what a game, rather fly to the moon, can anyone see these???????????????????

Sorry, I cant spend anymore time on this tonight.

wish I could just drop the photos in.

sorry, goodnight Mike

Just been looking Mike and the pics are fine, I just clicked on the link and up they came.2 of each!
Bert

My hair has just fallen out, I hope this is worth it.

The new pipe, see beginning of the thread is twice as long as the original and goes under the air filter housing and down to the radiator thus being a long way from the gearbox, once the air filter case is removed it all makes sense.

The scuttle has to be removed to seal the pipe otherwise you are back to square one and water will drip on the greabox.

Best regards Mike with a headache

bertb wrote:Just been looking Mike and the pics are fine, I just clicked on the link and up they came.2 of each!
Bert

Does this all make sense Bert

Mike, cracking job, I'll be printing this lot off and having a good look under my bonnet on Friday and get my bearings. Having had a look I might come back with a silly question or two !!

Well worth the effort, thank you.

Terry

Thanks PB for your help with the pictures.

Now to fit the new speedo drive

Best regards Mike.

Thanks very much for posting this up Mike. I see you have a Symbol. Does this problem exist on various Autosleeper models and years, on Boxers?

Marc

Yes Mike, many thanks for your efforts!
Bert

marc4242 wrote:Thanks very much for posting this up Mike. I see you have a Symbol. Does this problem exist on various Autosleeper models and years, on Boxers?

Marc

Hi Marc, not sure. I only got mine in November so I am new at this but learning fast.

I think this is related to the older Boxer Van. 2000 is my year but forget about the model and just look at it as a Peugeot Boxer Van. After doing a bit of research I think the gearbox is Fiat and seems to be the Achilles heal of the van. The engine is a tried and tested lump mine is a 1.9 TD.

Love the conversion and I hope that once the bugs are ironed out it will do me good service.

Best regards Mike, Sue ( the wife) and Winnie (the van)

I will look forward to using your photos to have a look at mine. We bought it in the summer last year (a Symphony). I haven't see inside a Symbol but I assume it's similar. They are wonderful conversiuons, I agree. We spent ages looking at coachbuilt motorhomes, getting ever bigger, but as our main usage is music festivals, we finally went off the coachbuilt idea completely and now love the fact that we can (almost) fit in normal parking spaces.

Flying High wrote:
Love the conversion and I hope that once the bugs are ironed out it will do me good service.

Best regards Mike, Sue ( the wife) and Winnie (the van)

Yes thanks for persevering with the photo's. I am slightly confused however, surely if water can get in the gearbox all the oil can get out, or am I being really stupid ??

Please go gently with any answers I'm a sensitive sort.

Enn

[quote="Enn"]Yes thanks for persevering with the photo's. I am slightly confused however, surely if water can get in the gearbox all the oil can get out, or am I being really stupid ??

Please go gently with any answers I'm a sensitive sort.

Enn[/quote
Hi,
The consensus of opinion is that any water falling on the gearbox can seep inside through the breather or the linkage points, it doesn't have to have a lot to cause a problem. The gearbox only has a relatively small quantity of oil which splashes around inside and it would take a great deal of water to displace it.
Great photo's thanks Mike do you think there is any chance Peugeot will admit a design fault and recall all vans for modification
Chris V