Xsara BE3 Clutch Trouble

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dandare1980
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Xsara BE3 Clutch Trouble

Post by dandare1980 »

Hi,

I've had issues with my clutch/gearbox over the last 4 months.

It first started with a snatchy uptake in first gear. Next the gears became increasingly difficult to select (as though the clutch was dragging) and depressing the pedal felt heavy. Finally as I attempted to change gear yesterday the clutch pedal shot to the floor and stayed there. I switched off, selected first gear and after a jumpy start luckily got home.

At first I thought it was the clutch cable snapping, however on inspection today the cable appears to operate the clutch release lever on the gearbox fine........

That is with the exception that the clutch pedal seems to prefer not to spring back to it's usually position and feels notchy or even sticky.

So I started the engine and depressed the clutch. I could feel a very pronounced vibration from the pedal, almost like a wobble. There was also a very noticeable screeching noise coming from the engine bay which changed pitch when I depressed the clutch pedal.

I tried to select a gear but none would engage whilst the engine was running (fine when off though).

I guess this means a new clutch assembly? I've had a quote from my local independent Citroen specialist in Northampton and I'm looking at £500.

I've been studying the Haynes manual and some internet guides, but anyone with hints or tips they can share on replacement will be most welcome.

I'm time rich, money poor currently so feel giving it a go is worth it.

Thanks for any advice,

Dan.
1998 Citroen Xsara 1.9 D Estate (XUD9A indirect injection engine DJY with Bosch XUD 211 injection pump).
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oneday
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Re: Xsara BE3 Clutch Trouble

Post by oneday »

yep sounds like a new clutch is in order. buy a good one oem or luk available on ebay or local parts agent. not to hard to do it yourself just follow the books instructions. you will also need gearbox oil and driveshaft seals as these will probably be no good after removeing the drive shafts
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Re: Xsara BE3 Clutch Trouble

Post by citronut »

sounds like the thrust bearing has worn its way through the pressure plate fingers,

it is best to fit new diff seal as oneday say and mind you only us a BV spec gear oil as PSA box's a fussy,
also it pays to fit the for pivot nylon bush's whilst its apart,

give Malcolm Lockwood a call on 01274 640590 for the parts as he is a CCC member and is very competitive with his pricing, and very prompt delivery/carriage,

otherwise i would expect the job to be not much more that £300 or there abouts,
Regards, malcolm.

current ride a BX 1.7 TZD estate
1986 MK1 BX 1.9na D Auto(in Mothman Andy's stable )
layed up roppy 1.9TD XANT estate, now gone to meet her maker
purple and lilac metalic 2CV(VIOLET)registered to her in doors
1972 DS special been layed up aprox 31 years
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dandare1980
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Re: Xsara BE3 Clutch Trouble

Post by dandare1980 »

Thank you for the info.

I've seen a Sachs 3 piece clutch kit which looks about right price vs quality wise.

I'll track down some drive shaft oil seals plus some plastic clutch fork arm bearings too.

Is any gear oil of the 75W/80 variety safe to use in the BE3 box, such as this stuff on eBay?: http://www.ebay.co.uk/itm/250775160017? ... 1438.l2649

Dan.
1998 Citroen Xsara 1.9 D Estate (XUD9A indirect injection engine DJY with Bosch XUD 211 injection pump).
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Re: Xsara BE3 Clutch Trouble

Post by oneday »

when i did mine it only holds 1.75 ltr used 75w/80 synthetic
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Re: Xsara BE3 Clutch Trouble

Post by citronut »

it seems that if you dont use a BV spec gear oil in PSA box's you end up with damage syncro's

also my first choice of clutch would be OE or VALEO and second choice LUK,

although Sach's clutch's should be ok i find them a little heavier than my first two choice's
Regards, malcolm.

current ride a BX 1.7 TZD estate
1986 MK1 BX 1.9na D Auto(in Mothman Andy's stable )
layed up roppy 1.9TD XANT estate, now gone to meet her maker
purple and lilac metalic 2CV(VIOLET)registered to her in doors
1972 DS special been layed up aprox 31 years
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Re: Xsara BE3 Clutch Trouble

Post by dandare1980 »

Thanks for the tips,

I've managed to locate and order the correct LUK clutch kit (according to Citroen Service using my VIN anyway) for around £80. The release bearing is slightly different depending on when my car was built, everything else should be the same.

Got a pair of the plastic clutch fork bearings and a pair of drive shaft seals on their way too.

Going to try and buy 2 litres of BV 75W-80 transmission oil from my local TOTAL garage tomorrow.

Now to plan for a break in the weather.............
1998 Citroen Xsara 1.9 D Estate (XUD9A indirect injection engine DJY with Bosch XUD 211 injection pump).
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Re: Xsara BE3 Clutch Trouble

Post by RichardW »

35mm socket (and big breaker bar!) required for the hub nuts
Getting the ball joint pins out of the bottom of the hubs can be a challenge - they bind up as the angle changes. You can either use a big lever against the bottom of the car, or push the hub inwards (quite hard!) whilst levering out the pin.
I did one of these on a 306 HDi - getting the clutch operating arm off the release shaft to replace the bushes and input shaft seal required drilling out the cotter pin - I'd just leave as they are if they are in reasonable condition!
The HDi has the electric water heater bolted to the top of the box, and it's a right PITA to remove, but you probably won't have one on a 1.9.
Decent stud remover required to remove the gearbox mounting stud on the top of the box
It's much easier with an overhead lift of some sort to support the box - must be damn near impossible to get the box in / out and remounted on jacks.
It's a lot easier to put the oil in if it's been at room temperature, rather than stood all night at about freezing.... :o
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Re: Xsara BE3 Clutch Trouble

Post by dandare1980 »

Thanks Richard,

I must admit the thought of the job is a bit daunting.......

I shall pour through the various sections of the Haynes manual and then post back to see if their version of events makes sense with those with the relevant experience on here.

Haynes: "Remove the retaining pin from the fork" = 4 hours later with lot's of rude words and bleeding knuckles.......

Dan :)
1998 Citroen Xsara 1.9 D Estate (XUD9A indirect injection engine DJY with Bosch XUD 211 injection pump).
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Re: Xsara BE3 Clutch Trouble

Post by myglaren »

dandare1980 wrote:
Going to try and buy 2 litres of BV 75W-80 transmission oil from my local TOTAL garage tomorrow.
They are very unlikely to have any - the last place to have Total oil is a Total garage - guess how I know.

Go to thge Citroen or Puegeot dealer, they are no more expensive than other retail outlets and often cheaper.

I have a couple of litres waiting to be screwed into my gearbox, bought from the local dealer.
I can't say how much it was but that and a Litre of Citroen Antigel coolant was just under £20.
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Re: Xsara BE3 Clutch Trouble

Post by flying clutchman »

The basic clutch change is quite straightforward. Changing the plastic pivot bushes can be very challenging, only bother if they're badly worn. I personally don't bother with driveshaft oil seals, taking the view that if they subsequently leak it's only a 15 minute job to take out the driveshaft anyway. I've only needed to change the seal half a dozen times in 30 years. Handy to have them though! The gearbox mounting stud is easily removed with a deep 16mm socket. It's usually loctited in.
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Re: Xsara BE3 Clutch Trouble

Post by citronut »

you dont need to try and specifically find Total BV oil,

most motor factors sell a BV spec oil,
i usually buy a 4.5 or 5lt can from the likes of GSF,
works out retail about £6 quid a liter,

its so easy to fit new diff seals whilst the shafts are out and done in about two minutes,

if your that tight just look to see if there is gear oil leaking around the seals before removing the shafts,
Regards, malcolm.

current ride a BX 1.7 TZD estate
1986 MK1 BX 1.9na D Auto(in Mothman Andy's stable )
layed up roppy 1.9TD XANT estate, now gone to meet her maker
purple and lilac metalic 2CV(VIOLET)registered to her in doors
1972 DS special been layed up aprox 31 years
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Re: Xsara BE3 Clutch Trouble

Post by CitroJim »

dandare1980 wrote: Haynes: "Remove the retaining pin from the fork" = 4 hours later with lot's of rude words and bleeding knuckles.......
:lol: Some are easy to shift and others can be a trial. On one I've even had to resort to heat which in turn destroyed the nylon fork shaft bearing... Grab the end of the pin with small Mole Grips and then use a hammer on the grips to knock the pin out...

Comma and Valvoline are two that do a perfectly acceptable 75W/80 BV Spec oil. The bottle should say it's oil specifically for certain Peugeot/Citroen gearboxes...
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Re: Xsara BE3 Clutch Trouble

Post by RichardW »

1.9 uses a 'normal' push clutch, so it's not necessary to remove the operating arm to get the box off (fortunately!). The pin is different - more of a flat sided cotter pin (like what we used to use to hold cranks on bikes!) and we found virtually impossible to remove - despite a good talking to with the Oxy-Acetylene torch - withouth partially drilling it out so we could give it a good whack!
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Re: Xsara BE3 Clutch Trouble

Post by myglaren »

CitroJim wrote:
dandare1980 wrote: Comma and Valvoline are two that do a perfectly acceptable 75W/80 BV Spec oil. The bottle should say it's oil specifically for certain Peugeot/Citroen gearboxes...
I have used Comma previously but the Total product was only £5.71 + VAT.
Found the receipt yesterday but then couldn't see it as I left my specs at work.
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