Replacing 5th gear - removing selector

[xsaras4ever]

Thanks Jim , you're a star

[RichardW]

Hadn't realised it was an ML box. I had a look at the procedure for stripping the box, but it doesn't specifically mention that part on the 5th gear - however, it does mention it on stripping the main shaft, and shows it in exactly in the position shown on the diagram. I think it's odds on you've got it in the wrong place....

[xsaras4ever]

Hello Richard and thank you for the post.

We spoke to a friend last night who works on CamperVans. Because of the weight of them, they are famous for stripping the 5th gear.

He sais that the diagram was wrong and our assembly was correct.

Part "J" sits inside part "I" and part "K" sits between "11" and the "I and J" assembly.

When the selector fork pulls "I and J" onto "11", the ring ("K") slows "11" down so that the whole lot can mesh together smoothly.

Does this make sense how we have described it ?

Clucking into 5th means that "K" is worn and does not slow "11" down enough.

The oil in our gearbox was grey and only 1 year old and about 6000km, so its possible that "K" is also worn and has contaminated the oil, as its a phosphor-bronze part.

All an education to us , to be honest.

Going to take it for a test drive, fingers crossed.

As usual, the forum has once again been a great help.

Thanks to all.

[Justthelad]

Hi I have Peugeot expert 1.6hdi 2011 in need to repair the 5th gear in the box does anyone know if I need to remove box from the van are can it be done with box still fitting thanks for any help

[wheeler]

Can be replaced in situ

[Justthelad]

Situ ???

[GiveMeABreak]

He means with the gearbox in place (without removing).

[Justthelad]

Spot on thanks wheeler and marc

[Peter.N.]

I did that on my last CX, lost synchro and repaired in situ, cant remember how, it was a long time ago, I only remember that every time I tried to put it back together ball bearings flew out everywhere, I eventually put a large piece of rag round it to catch them, I would think they have probably improved them by now.

Peter

[wheeler]

I would think they have probably improved them by now.

Nope, one wrong move and the detents & springs are everywhere

[Justthelad]

Any one no the name of the proper socket to take 5th gear of

[wheeler]

It's just a regular double hex socket that is used, cant remember the size off hand 26mm or 28mm maybe.

[Justthelad]

28 but can get one to go on

[wheeler]

Never used anything special for this, just a normal bi hex socket. Done plenty of them, I always undo it with an impact wrench though. Maybe try the next size up?

[Justthelad]

Will do cheers