Boxer gearbox oil capacity

[LesB]

Hi. I have a 2.0 HDI 5 speed manual gearbox in my 2004 motorhome. The speedo sensor has leaked oil badly so I am fitting a new one. I can't find out how much oil to put in when I refill. I read 1.85 or 2.1 litres from different sources but I don't want to put too much or too little.

Oil specification would help and if anyone can advise the best way to get it in the gearbox that would be great. Is through the breather best?

Many thanks.

[GiveMeABreak]

Pop your VIN up as there are different variants of the gearbox.

The gearbox oil ideally should be measured when taken out and the same amount returned, but if it has been leaking, then of course you need to drain and refill. This is where the conflicting information is, as one quantity will be for a new gearbox and the other when drained and then refilled as there will be a quantity of oil in the gearbox than can't be removed.

I'll know what the correct volume is when you supply the info.

[LesB]

Thanks. The code is
VF3**************[VIN obfuscated, can be read by forum staff]

[GiveMeABreak]

Here you go, you have an MLUC gearbox on this model, so not the same as you expected.

(1) Filling and venting hole.
(2) drain plug.

Always fit a new seal after draining at (2)
You refill it via the venting hole (1) using a gravity fed container and tube.

Recommended oils:
ESSO 75w80 EZL 848
TOTAL 75w80 H 6965

Quantity of oil to be replaced:
After draining: 2,1 litres
After overhaul: 2,4 litres

[LesB]

Hi Marc.
Thanks muchly for your input but I think it's different. I just crawled under and took these pics. One shows the end cover which is significantly different to the illustration and I think the other picture shows the top of the box. Difficult to say as it was at arm's reach between other bits. Whiich leads me to the next question; how on earth do you get to the top of the box to find the refill point? I tried taking the air filter off but it doesn't help at all and taking the air filter canister off is difficult in the extreme as the three bolts in the bottom of the canister are pretty rusted up. (The main pic seems to be upside down until you click on it to enlarge)

Edit; I can reach the breather from the front by fumbling about with my finger tips. Getting a tube into that is going to be fun.

[GiveMeABreak]

Strange, as your Specs state the MLUC version, but in case here is the MLGU version and please note the revised differences:

(1) Breather hole (Filler hole).
(2) Drain plug.
(3) Level plug.

Note: Do not use the level plug to fill the gearbox or to top up (New angle of inclination of the engine).

Oil Quantity after draining: 2,7 litres if this is your box.

[LesB]

Hi Marc.
As far as you are aware, are there just these two gearbox options? My gearbox certainly has the appearance of the second example as the steel end cover is so significantly different. Using my reg number only, the local Peugeot main dealer has told me capacity is 2.1 litres but if they have assumed I have the MLUC gearbox that would clearly leave me with a gearbox that is inadequately filled if it really needs 2.7. I'm concerned as much about overfilling as I am underfilling. Arggh!

What do you think? Your input is much appreciated.

Les

[GiveMeABreak]

Hi Les

The dealer would be seeing the same info as me - see below extract from PSA's own server based on your VIN - as you can see where I have highlighted, it clearly states MLUC, which is why I put the original picture up. The only other thing I can think of is if the gearbox has been replaced at some point with another version.....

Click Images to Zoom

Again, if we look at the specs of the available gearboxes below for this Boxer, you can see that only the top table refers to the 2.0HDi engine and also the final drive and ratio data also corresponds with the specs extract above. The other tables and gearboxes are only relevant to the 2.2, 2.8 HDi engines and the 2.0 petrol.... so in other words the MLUC gearbox was only fitted to the 2.0 HDi (90 BHP) version.

[LesB]

Thanks again Marc.
It's a real can of worms. We've had the camper in the family since new and as far as I'm aware it's not had another gearbox fitted. If that had ever happened it would have been in the first couple of thousand miles as I've driven all of the other 50k.

If I read correctly then, there are only two possible gearboxes and I have the one in the second photo so I'll be putting 2.7litres in it.

EDIT: I've also found the attached now that refers to a gearbox of my visual type. Maybe MLGU5 or MLUC5. Maybe I should play safe and just go for 2.4 litres. In my position, what would you go for lol.

Les

[GiveMeABreak]

I would stick to 2.4l - down the line as it's not technically an overhaul where the gearbox has been out and disassembled - only drained. So there's 300 ML in it really.

[LesB]

Thanks Marc. I really appreciate your input.

I feel much better informed now and confident this is going to be much better than the original 1.85 litres I was advised.

[LesB]

I know the speedo sensor had a pretty bad leak as not only was it obvious but the garage replacing the driveshaft mentioned it. I guess they didn't have a sensor to fit at the time or didn't want to spend time on it. Either way, they told me it had been refilled with the correct amount. How they knew how much that is I don't know. Anyway, I've drained it and the oil is quite clean. Trouble is there was only just under a litre of it! It didn't look like much when I pulled the drain out. Not good.

Hopefully I'm now going to get 2.4 litres of nice fresh new oil in there and that's it.