ML5 Gearbox/selector/gears

[DorsetRich1]

Hello all,
I've been through the board looking for solutions (some come close). Could anyone give me some ideas?

The car in question is a 2002, 406 2.2l HDi.

A while back I parked up, returned to my car and went to pull away. I couldn't get the car into gear! Eventually I managed to get into R and then what felt like 3rd and crawl home (much to the distress of the clutch as I pulled away leaving a lovely clutch burn in my wake).

Finally I've got 'round to having a look at getting the car back on the road. I can select all gears (with some effort) EXCEPT 4th (the stick feels like it's hitting a brick wall).
I've checked the lever arm (removed, cleaned greased, refitted) which seems to be OK (bit clunky).
Drained the oil (seemed in good nick with only minor fillings on the drain plug).
Admittedly the box is currently dry (as I popped the cover to check for a loose 5th gear fork pin) but as I say, I can get all gears with the exception of 4th.

Any ideas? (I'm loathed to get a new box or drop this one out if I can help it).

Cheers all.

Rich

[DorsetRich1]

For future ref. If it's helpful to anyone doing similar things;
The nightmare that is the gearbox filler plug, I found an old imperial sized spanner (not ring) fitted really well and was thing enough to allow access.
The drain plug I found I needed to grind an 8mm square drain socket down to 7mm (which fitted perfectly).
Removing the lever arm I used a long 16mm ring spanner put on backwards (anything else wouldn't fit or got blocked by various bits of car).
Swearing at a gearbox doesn't make it work

[CitroJim]

More than likely problems with the selector cables... Either one or the other has stretched or the outer one or the other has become detached from its mounting plate and is allowing too much lost motion as a result...

I never worry about the ML5 filler plug... I just drain it fully and then refill 1.8l of Total BV 75w/80 through the reversing light switch hole...

These 'boxes are very critical of oil and only the above or an equivalent 75w/80 is suitable... Anything else really upsets the sweetness of the gearchange...

[white exec]

That oil is now Total Transmission 8 gear oil (spec, as Jim says, 75W-80, and importantly GL-4).
Citroen/Peugeot parts counters will have it. It's not expensive.

[CitroJim]

That oil is now Total Transmission 8 gear oil (spec, as Jim says, 75W-80, and importantly GL-4).
Citroen/Peugeot parts counters will have it. It's not expensive.

Thanks Chris, didn't realise they'd changed the name of it

[DorsetRich1]

Many thanks for the advise. I'll avoid the Halfords 75/80 oil then.
The cables are both secured to their bracket. I'll have a look at the other end (stick end).
Seems a bit odd that I can get it into 5th and 1st & 2nd ok if it's a cable issue (the lever arm has to lift fully for 5th and swing fully for 2nd).

[DorsetRich1]

Odd related Q...

On the end of the selection arm is a short ball and socket rod that seems to go down to the mount. What is it's actual purpose? it doesn't appear to do anything other than anchor the arm.

[CitroJim]

That's a new one on me... Normally there is what looks like a counterweight in the position indicated...

What's on the other end of that rod exactly?

[DorsetRich1]

The counterweight is there (follow the arrow further and you'll see it). The other side is where the cable connects for the horizontal movement of the arm (ie fwd back on the stick).