Well, it looks like my 407 Coupe is terminal...
Over the last few weeks my 407 Coupe 3.0 HDi has started to tug between gear changes on the 2 - 3 and 3 - 4 when changing up. The other changes were still very smooth. I check my levels weekly and noticed nothing wrong and nothing particularly untoward when it started. However, due to work and weather I hadn't checked them for a fortnight this time around.
I'd done a lot of reading on the net and had convinced myself that the fault with my gearbox was valve block related as these Aisin Warner boxes do seem prone to valve block issues.
Last night I decided I was going to get the car in the workshop and onto the ramp and remove the valve block. However, upon opening the bonnet I immediately noticed the coolant bottle had turned brown. When taking the cap off it, it was full of sludge and it stank of ATF. I was certain at this point that the oil cooler had failed.
I took the undertray off the car and got a job, I then removed the sump plug from the gearbox and the crap that drained from it was disgusting.
My car had the coolant flushed and changed when the thermostat housing was done in May and at the same time it had 2 gearbox oil changes done also.
I then removed the oil cooler and blanked one of the coolant ports with my thumb and blew down the other. I could hear air escaping from the oil side so it's definitely got a hole in it.
Looking online, the oil cooler is £480 from Peugeot/Citroen. To flush it properly will cost a couple of hundred quid in oil, and my cooling system, radiator, heater matrix, etc. is all now full of an ATF/Coolant sludge so that's gonna take hours to flush.
I've also been told that these gearboxes despise having water in them and that even if I persevere and sort it, there's a good chance that it won't last anyway. I'm now faced with the dilemma of stripping the car for parts or spending £2.5k on a gearbox rebuild.
Seeing as it's the same gearbox on the C5/C6/407/etc. it makes me wonder if these oil coolers should be considered a service item at circa 100k to prevent catastrophic failure.