05 Dispatch van - gear selection probs after clutch replaced

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nginmu
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05 Dispatch van - gear selection probs after clutch replaced

Post by nginmu »

2005 Dispatch van. Initially no problems, other than, the clutch release was feeling increasingly 'sticky/clanky' at the bottom of it's travel.

Put it into independant garage, they removed clutch / gearbox & fitted a 'clutch kit', allegedly including a pressure plate, a friction plate, a release bearing and the replaceable guide for the release bearing.

Now, the gears feel much 'sloppier' than before & it won't stay in 3rd, 4th or 5th gear.

Pops out on the overrun markedly in 3rd, easy to reproduce. Go to reapply some gas & the revs go sky high because it's dropped back into neutral. Every time.

the problem seems less severe in 4th and 5th, but it regularly just decides to let go on long stretches at constant speed. Just drops out into neutral all by itself.

Had a look at the linkage on top of the gearbox. It seems to wacker about all over the place rather than rotate around a pivot. Almost as if it once rotated circularly around a post, but the post itself has come loose to rock around the clock.

The gearchange mechanism area atop the box seems flooded with oil, don't know if that's coincidental.

Took it back to the garage but the guy says he thinks that the linkage on the top of the gearbox is the same as all other Dispatches, they all wacker about and seem to pivot around more than one axis according to him.

Does anybody have any thoughts as to why it's suddenly decided to not want to stay in 3rd 4th or 5th

Thanks
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nginmu
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Post by nginmu »

Sorry to bump but may have fixed it. I noticed the brake servo vacuum hose had not been replaced into it's restraining clip and was fouling the counterweight on the gearchange mechanism - in 1st, 3rd and 5th gear.

4th gear I'm willing to discount as a red herring, and 1st, well you mostly are only in 1st very briefly.. leaving 3rd and 5th which were deffo affected.

Hoping that replacing the rigid vacuum hose into it's clip cures it. Hope this infop helps someone else if it does.


[edit] - no such luck :( pinned it down to a big problem on 3rd and a minor problem on 5th, 4th is ok I think..
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nginmu
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Post by nginmu »

Sorry, this'll be the third and last bump I promise :oops: Had the great big swingy linkage on top of the gearbox replaced,

Image

.. which was very definitely worn to hell and wackering about all over the shop, was convinced that would fix it.. so was the garage that did the replacement. No joy at all. Still just as bad. Go into 3rd, then back off the revs even just a bit, it just falls out into neutral then crunches like hell if you try and jam it back in.

Does anyone know where I can get hold of an exploded diagram of the gearbox fitted on these vehicles? Or have some direct experience of the anatomy of one? I'm beginning to wonder if there is a detent spring spring somewhere in the box I might be able to 'stretch & freshen up' or replace, with not too much work.

Not sure if it's the same box that's fitted to any other DW8-powered Citroens.

I have an old Mk1 Toyota MR2 & the boxes on those suffer from 5th gear popout a lot - you just have to remove the end cap off the box on those & replace a few bits, you don't have to go to all the trouble of disconnecting the halfshafts etc & actually removing the whole box from the vehicle. Wondered if there were spring loaded ball bearings in the dispatch gearbox that were as easily accessible maybe?
Last edited by nginmu on 19 Mar 2010, 22:04, edited 1 time in total.
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Post by Gammy leg »

nginmu wrote:(de-munge the addy, rude to hotlink directly)

:?: :?: :?: :?:
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Post by myglaren »

Newspeak. Watch out for the thought police 8-)
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Post by Gammy leg »

myglaren wrote:Newspeak. Watch out for the thought police 8-)
I'm afraid I'm still none the wiser

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nginmu
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Post by nginmu »

sorry to confuse. fixed

Got a nasty feeling the detent springs and balls are right down deep in the gearbox, as part of the selector forks though. gah :x
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Post by flying clutchman »

Not sure if you've fixed it, but if not here's a suggestion. When the bearing sleeve is removed there is a shim behind it. This can easily be lost or not noticed. This happened to me, I put it to one side to avoid losing it and then forgot it. Result-jumping out of gear on the overrun. Simple to fix, gearbox out, undo sleeve put shim in gearbox back, fixed.
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nginmu
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Post by nginmu »

Really?

Thanks for that info. It's at a gearbox specialists as we speak, he's had half a day on the job so far, I expect he's got so far as to remove the box from the vehicle but not open it up.

I will ring him very first thing in the morning & relay what you've said & see what he thinks - might save some unneccessary work. Thanks :P
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Post by flying clutchman »

will definitely save a lot of work, I only realised what had happened by chance, I saw the shim lying where I'd put it to keep safe as I was looking at the gear linkage!
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nginmu
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Post by nginmu »

I'm trying to visualise what this shim is like. So I can describe it better when I ring the gearbox guy later.. can you give me any more detail about it? Where it fits exactly, what shape, what it presses against etc..

Not sure if I'm looking at the right gearbox here but, right now I'm imagining what you're describing is a circular washer-type springy shim that sits beneath the clutch release bearing guide, and presses onto the centre race of the gearbox main ball bearing, preventing endfloat? I can see that something of that nature being missing sure might cause these symptoms..

http://media.photobucket.com/image/Peug ... earbox.jpg

[edit] spoke to gearbox man - gearbox man understands the issue & says you have a damn good point there, he's on the case. Big thanks for the headsup clutchman, 2 thumbs up
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Post by flying clutchman »

although your pic shows a different gearbox, it's shim marked 'A'. It's just a flat shim, quite thin fits under the bearing guide sleeve. Without it the gear train becomes sloppy and one or more gears can jump out on the overrun.
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nginmu
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Post by nginmu »

According to the gearbox specialist, the shim was indeed missing. The lack of it has led to further wear problems, he's going to detail it all on the invoice for me & hopefully back me up when I go back to the garage that did the clutch to begin with.

Recon box, it's ended up as :evil:
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Post by flying clutchman »

lot of aggro for one little shim! Very easy mistake to make, odd arrangement.
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