Gearbox woes / Citroen Synergie 1.9td (ML5?)

macmilm · Post by **macmilm** » 09 Feb 2011, 11:34

Completely lost 1st and 2nd gears.. narrowed problem to being inside gearbox (syncro hub).
Have now removed gearbox and split it.. turns out the syncro hub had jammed.. bit of crap in it ?? the 6 ballbearings inside the hub looked a bit worn so gonna replace just the ball bearings and try that as new snycro hub was quoted at £450 +vat (main dealer.. cant find elsewhere)

Anyway, just wondered if anyone can offer any advice tips or recommend a supplier for the bits e.t.c

Positive it is an ML5.. its a 2000 synergie (cable clutch, cable selectors etc)

Any links to ML5 stuff would be appreciated.

Thanks all

Post by **Peter.N.** » 09 Feb 2011, 15:22

I have in the past had one or two spare gearboxes that I have robbed for parts- by far the cheapest way. The last gearbox job I did was on a CX about 25 years ago, they just don't normally seem to go wrong now.

The only other places I would try wold be a gearbox recon specialist, they would probably be cheaper tha Citroen or may even have some secondhand bits, or a scrap yard, you could probably get an untested or faulty one for very little money, the odds of it having the same fault are probably not much better than winning the lottery.

Peter

macmilm · Post by **macmilm** » 09 Feb 2011, 15:34

Was thinking that might have to be an option but also strugglin to find an ML5 gearbox at scrapyards too..... all ones i have phoned around me (suffolk) aint got one ... still got to phone some more tho..

thanks

Post by **Peter.N.** » 09 Feb 2011, 16:36

Try ebay.

Post by **CitroJim** » 09 Feb 2011, 17:46

Robbing another scrap 'box is the best answer; spares for PSA gearboxes are always prohibitively expensive sadly.

ML5s were fitted in the following vehicles (amongst others)

Xantia Activa, 2.1TD, CT Turbo Estate, 110 HDi, V6 manual (almost non-existent in the UK!)

Pug 406 2.0 SRi, 2.0 Excexutive (both with the TCT engine), 2.1TD and 110 HDi. The 406 Coupe V6 with manual 'box also has an ML5.

Check the synchro clutch cones and baulk rings for wear as well as for damaged/broken balls and springs. The clutch cones should grip each other very tightly and be quite hard to separate.

Post by **Peter.N.** » 09 Feb 2011, 18:34

... and look on 'teeth' on the synchro gear, if the cone or ring is worn it will take the leading edge off, compare it with the others.

Peter

macmilm · Post by **macmilm** » 14 Feb 2011, 13:19

Cheers mate,there are several ML5 boxes on ebay but some are cable operated whilst others have control rods for gear selection. My box (broken) is cable operated. are the external selector mecs interchangable?

Post by **CitroJim** » 14 Feb 2011, 17:21

Pass but maybe. I know that even some ML5s fitted to the same breed of car can have different selector mechanisms.

Xantiaman and I once found this when swapping an ML5 between Activas. The 'box went in fine but with the particular combination of selector mechanism, reverse ended up in the middle of the driver's seat

A swap of the mechanism on the top of the 'box saw it all good again and reverse restored to it's accepted position.

I'd reckon there's a good chance the mechanisms will swap Ok as after all, the basic change method remains the same whether cable or rod operated.

macmilm · Post by **macmilm** » 14 Feb 2011, 18:51

Thanks CitroJim.... very helpfull so my guess is so long as it is an ML5 even if the selector mechs differ if should be able to swap bits to get it working even if i have to open it up e.t.c

Thanks for your help you and others have been very helpfull and have saved my skin lol

Cheers