5th Gear on Citroen Xsara 2.0hdi 2003 (not picasso)

[white exec]

Sounds like a plan.
You might only have to inspect and adjust the gear linkage, if that's the fault.
Watch out for those seagulls...

[neil108]

So, that's the gear linkages changed, the engine mount replaced and guess what! Still no 5th gear!!!!

Time to evaluate my options

[RichardW]

These boxes are everywhere; it should be possible to pick up a used box for not too much, and transplant the 5th gear cluster and fork. Similar thread here: http://www.frenchcarforum.co.uk/forum/v ... =3&t=52099

[neil108]

Thanks Richard.

Just out of interest, so I know I am doing things correctly, I have put new gear linkage on, but what is the actual process to ensure they are correctly adjusted as I have noticed since putting the new ones on the car stays in fith longer than it was doing, so it is making me think may be the linkages are not adjusted correctly. Would really appreciate some pointers.

When I put the new ones on i just made sure the length matched the old ones, but there wasn't an adjuster on the old ones so I thought this would be the correct process.

[white exec]

The gear linkage will push/pull a gear rod into/out of the gearbox casing. Look to see which one is pushed/pulled when 5th is selected.
When you've done this, disconnect the gear linkage, and allow the control rod to fully engage/disengage (whichever selects 5th) into the box. It should plop into place positively, and resist being pulled out/in by hand. This is called a "positive detent", and means the gear is being "locked in", usually by a ball-and-spring arrangement. It should not easily pull out of gear.
Then, adjust the length of the control linkage to allow the linkage to be re-connected to the rod WITHOUT pulling it either way. In other words, the gear linkage is neither holding the rod back, not pushing it unnaturally forward/in - i.e. it's allowing the rod to take up its comfortable, fully-engaged, position.
Try all this first, and let's see how it goes.

[neil108]

Thanks Chris, this makes sense, I'll have a go over the weekend as it's due to rain tomorrow

[white exec]

I've seen the promised rain. We could do with some of that down here!

[neil108]

OK, so I have now checked everything over and have had a garage look at it too before i went further.

The diagnosis is a problem with the gearbox (quoted £1300 for recon. After coming round, I said I would consider it! )

I have found a guy near me that will do the repair, but requires the gearbox removed from the car. I am thinking of trying this myself. (thankfully work have lent me the pool car) Is there anything I should be aware of before tackling this as i have never removed a gearbox before ever, so any pointers would be much appreciated. Everything I seem to find is for the picasso not the normal xsara.

Thanks Again,

Neil

[neil108]

Gearbox is now removed and box at repairer. He has found a problem with the 5th Gear syncro and a damaged gear. So all being well I’ll get it back soon. Getting it off wasn't too bad, lets hope putting it back on goes just as well.

[Paul-R]

It's a relatively light weight unit so it shouldn't be too troublesome. It also has a regular clutch release so you don't have to worry about getting it assembled just-so.

[neil108]

Always like to give the result...

In my case it was the 5th Gear and the Syncro worn. Used a great Guy, P and R Gearboxes in Crawley, Sussex, UK. He stripped the gearbox for me and checked it all over and replaced a few bits, and I had change from £250. I have now put it all back together, with new driveshaft's and also did the front discs and pads (had advisories) and of course clutch, took a little time as I'm not a mechanic, but back on the road and working now.

Things I will suggest, remove the gearbox stud as it make it easier to get it out, also once loose rotate the whole box anticlockwise so it can go over the sub frame at the rear, also found filling the box through the reverse light switch is easy, all though be aware that the reverse light switch is easily shear off as I found to my perille!

Thankfully the gearbox guy had one laying around.

Just glad to have it back with a £1000 saving from the garage price, so thanks everyone for their advice