1996 313kmile Xantia 1.9TD lost pops popping out of 5th fifth gear

[Hell Razor5543]

Re the linkages. Item 11 is a Citroen only part, but Item 12 may be available from GSF. I had item 11 fail on my Xantia a couple of years ago, and I could only get it from a Citroen/Peugeot dealership. While I was hunting around CSF said that they had item 12 in stock, as it was a part that was often required.

[romie]

heya
soo, I've finally got round to looking at this again.

You guys were right.
The nut on the end of the fifth gear shaft was slightly loose.
I could wiggle it back and fourth with my fingers, only slightly as the pinch points were still fully locked in.
So I wouldn't be able to just tighten it up more than a millimetre or so before hitting the pinch points again.

So reasoning is that there's been wear behind the nut which has allowed sufficient play to eventually allow the fifth gear to slip on it's teeth.
Once slipped, the now sloping surface on all of the teeth of the gear and the synchro now, when under load, act to just push themselves apart.

Just a theory, what you think?

On a side note.
I was able to remove both the synchro and fifth gear by only removing the gear box cover, the fifth gear shaft nut and removing the cir-clip on the selector fork, (I didn't need to punch the selector fork pin out).

Here's a vid of the fifth gear and synchro. Bit difficult to show the teeth.
https://vid.me/XeOm

Cheers for thoughts

[demag]

Yes they look well chewed up.

[romie]

cool so now I just gotta figure out which of the fifth gears from this list, mine is
I think it's something to do with a number on the gearbox somewhere :/

And where I get the fifth gear and synchro from :/

I suspect Citroen will want blood

]

[CitroJim]

You're best off getting all those bits from a scrap 'box. Fifth cogs and synchro are often the least worn...

[romie]

on closer inspection, these cogs are def worn and yup, it's looking like just getting hold of another gearbox is the way to go, I've just got prices back from Citroen!

£177.82 - just for the Synchroniser!!!!!!!!!!!!!!?

Between £82 and £147 for the Fifth gear!!!!!!!????
(I don't know which part number it is yet)

Crikey!

Does anyone know how I tell which part number fifth gear is?
Cheers :/

[elma]

I think the numbers in brackets are the amount of teeth on each cog. Should just need to count yours and match up.

[romie]

yes!
There is 47 teeth on the cog, but there is more than one part with 47 teeth! Nuts :/

[romie]

I was measuring the dimensions and couldn't figure out what the other number meant? hmm

[elma]

Count the teeth on the smaller cog as well, should be 31 or 37. By the smaller cog I mean the bit at the top of your pic that your thumbs are pointing at and looks like it is in a saucer.

[romie]

I got the microscope out.
Out of interest, here are some shots of the worn surfaces to show that they create sloping sides and so end up 'pushing' each other apart!

fifth gear




synchro

[romie]

Count the teeth on the smaller cog as well, should be 31 or 37. By the smaller cog I mean the bit at the top of your pic that your thumbs are pointing at and looks like it is in a saucer.

24 teeth :/
So that doesn't match (47x35) or (47x31)

nuts

[elma]

Maybe the other numbers a diameter or profile then. I'm baffled.
I like your microscope pictures, they really tell the story.

[romie]

Maybe the other numbers a diameter or profile then. I'm baffled.
I like your microscope pictures, they really tell the story.

Cheers!
It's a shame you can't really see the 'slope' that both worn parts create and so make the 'pushing' apart action.
But I tried to show it in the video I posted.

I'm only just now putting this all together to form the, problem, cause and solution

I'd like to see the teeth on new parts to match up.
But I think I'll end up getting second hand gearbox in, in the end as these prices are crazy
Only problem is I'll not be sure I'm getting exactly the same parts I need in a second hand box

[romie]

ok, that was a while. But finally got the new parts. Fingers crossed this is the issue :p