ML5C gearbox rebuild

[fynnbar]

Anyone out there know of a workshop manual / instruction / any info / pictures on rebuilding this 'box please ?

[CitroJim]

No, but it's not a difficult 'box to do. I have one on my bench right now ready for overhaul before it forms part of my V6 Activa Conversion project...

If you think of it as a big over-grown MA gearbox you won't go far wrong...

If your are in no vast hurry I can do a photo-strip of mine as it comes to bits.

Basically, to dismantle, remove the tin end cover, remove the 5th gear synchro and pinion being careful tthe synchro detent balls and springs don't make a bid for freedom, release the two bearing retainers, remove the reverse pinion shaft bolt, remove the diff, undo the main casing bolts and lift off..

Then it's really pretty standard gearbox stuff..

It's not too dissimilar to the BE 'box in many ways and my photo-strip of one of those detailed here may be helpful too but be aware the gear selection arrangements on the ML are totally different.

Why are you feeling the need to overhaul yours?

[fynnbar]

Thanks Jim
Bought a C5 one to put in my Expert van. The diff's noisy and a couple of synchros have gone - plus I'd like the higher final drive ratio. However, after removing my 'box, it transpires that the external selector mechanism, cable holder and cables are totally different.
Gonna try putting the C5 internals in my casing, but using the Expert selectors.
We've stripped my 'box (and yes, the three ball bearings fell out - oh, and there's no reverse pinion shaft bolt), but it's all a bit daunting tbh - the shafts and selectors kinda fell out of the casing after a good deal of head scratching.
Don't wanna spoil my chances, 'cos it looks difficult and fiddly to get it all back together properly. It was bad enough stripping mine down !
Used your photo strip, which was useful for the 5th gear part, but as you say, totally different from there on in ...

[CitroJim]

Excellent...

Sorry for the reverse pinion shaft I was doing it from pure memory and couldn't recalll if it had or not so I thought I'd play safe...

That's my excuse anyway!

[fynnbar]

So, any tips for the swap we're planning for next week?
Bit worried about how you get two gear shafts plus the selector shafts to locate all at once - or do they go back into the casing separately in some special way?
Is it correct that the Haynes Peugeot 205 manual has a useful gearbox rebuild section, which may be of some use?

[CitroJim]

Is it correct that the Haynes Peugeot 205 manual has a useful gearbox rebuild section, which may be of some use?

Only for the BE3 gearbox and that guide is absolutely excellent.. It's only in the thick Orange Haynes for the 205, not the later thinner red one...

If push comes to shove I have a scan of it somewhere...

[fynnbar]

Well, we managed it, and all working fine in the van now.
Weren't any major problems, although it wasn't a rebuild as such, just an 'internals swap'.
Held the two gearsets and selector shafts together with cable ties. It's still a juggling act to fit them all into the middle casing together, and it really does need two of you. One good tip is that we used 15mm copper heating pipe to locate the three ball bearings and springs. As the end casing slides on, the selector shafts push the copper tubes out, whilst keeping the balls/springs in place. Lovely

[CitroJim]

Excellent work Well done!

Good tip on the copper pipe to hold to balls in place

[daviemck2006]

Excellent work Well done!

Good tip on the copper pipe to hold to balls in place

Sounds painful [emoji31] [emoji49]

[addo]

Malcolm probably would have said something about it, too!

[CitroJim]

Malcolm probably would have said something about it, too!

We're doing a fine job of keeping his spirit alive

[addo]

I think a "Citronut" response would have probably included the bierkrug lady

[CitroJim]

Yes!!!! It would have and one of these

And not forgetting one of these:

[addo]

...and Percywotsit, of course.

[harryp]

Wonderful way to remember "Citronut"