2011 C4 2.0 HDI hard gear change

[xantos]

Hi everyone!

About 2 months ago I (we) bought a C4 Mk2 2.0HDI Exclusive with 130k km, for my girlfriend. It's a lovely car and I much enjoy driving it. Maybe even more than my Xantia (darn I never thought I would say that ).

But as it is a Citroen well something must go wrong as otherwise life would be boring

All of a sudden it happened that gear change became stiff and hard. No strange noise from the gearbox, but sometimes you must force the gear stick to engage gear and sometimes it slips into gear with no problem.
I did a bit of research and it came to a solution to grease the gear linkages (cables) that supposedly get dry with time. I did that and also greased the mechanism under the gear stick and ball joints (where the cables are connected to the gearbox) with no result...

Anyone any thoughts? Is maybe the gear linkage worn to the point of no return? Synchros worn? Oil needing replacement (didn't check oil level )?

As always help is much appreciated!

[GiveMeABreak]

Have a look at this post. A similar situation on his C5:

viewtopic.php?f=3&t=60496

[white exec]

And fill with Total Transmission 8, 75W-80 gear oil, which is the correct GL-4 spec.
This gives easier gear changes than GL-5 in PSA's manual boxes.

[xantos]

Thank you!

I had in plan to change the oil anyway, so will do so and report back. Hopefully it will help. But I have a feeling that the linkages are the problem...

EDIT: Can someone tell me how much oil it goes to the gearbox? VIN VF7**************[VIN obfuscated, can be read by forum staff]**********

[GiveMeABreak]

Type of oil for the MLC 6 Speed Box on your C4 (B7) is:
Either ESSO 75W80 EZL 848 or TOTAL 75W80 H6965.

Capacities:

Note you have the 'DW' engine in this table so the values marked in red.

Quantity of oil to fill after draining
Engines:	EW	DW
Gearbox casing with fins	1.7 l	1.9 l
Gearbox casing without fins	2.4 l	2.6 l

The following is only if undertaking a full overhaul, otherwise for draining and refilling use the table above.

Quantity of oil to fill after an overhaul
Engines:	EW	DW
Gearbox casing with fins	2.0 l	2.2 l
Gearbox casing without fins	2.7 l	2.9 l

Remove the under engine protection Remove the Drain Plug (1) fitted with its seal	Refilling Refit the Drain Cap with a NEW seal Fit the cap Remove the air filter housing if necessary Refill tthe gearbox via the vent hole (a)

[xantos]

Another thing... I have access to Citroen Service but limited. Does anyone have access to this diagnostic guide and can get me a print screen or send me the file?

[GiveMeABreak]

Check your email

[xantos]

Thank you very much!

It wouldn't be to cheeky to ask for the next 3 files on the list would it?

[GiveMeABreak]

I have 2 - they're on their way.

[xantos]

Thank you again! It never stops to amaze me how people on this forum are willing to be helpful!

[GiveMeABreak]

No problems, I hope they help get it sorted

[xantos]

Well I did change the gearbox oil (Total Gear 8 75W/80). According to specification I have gearbox with fins (if I understand right fins means ribs for better cooling), so I put 2 liters through the vent. Old oil volume was in total about 1.8 liters. I drained the old oil and then forced the gearbox a few degrees so I could get out as much oil as possible.

Result? At first it looked like this is it, but then 5th and 6th were starting to get stiff again (did drive about 50km). It is better though...

So then I parked the car and engine off and went through all the gears. Sometimes all six gears engage smoothly, but sometimes it is hard to engage reverse and as I said 5th and 6th.

Did a clutch test (brake on, 3rd gear and then smoothly disengaging the pedal). Clutch starts to grip when you release about 1cm of the pedal...

Sooooooooo... Is there a way to adjust gear lever controls? As I had everything apart when lubricating the control linkage cables I saw that the mechanism looked like it could be adjustable... I just hope it's not the gearbox itself...

Citroen, creative technologie

[white exec]

Is that clutch bite (engagement) point really 1cm from the floor? Sounds rather low down, so perhaps clutch isn't adequately disengaging, making gear changes/engagement difficult.
Is there a clutch (pedal height, etc) set-up procedure and dimensions?

Marc,
I believe the Total 8 gear oil and the Total oil ref H6965 are to the same spec - PSA B71 2330.
Put me right if incorrect.

[xantos]

Well after driving another 400km it seems that the problem is gone... Smooth gear change with all gears. Looks like it took some time for the new oil to take affect.

Hopefully it stays this way

[white exec]

Well, a nice surprise! Hope it continues the same.
Might still be worth checking the clutch pedal operating height - 1cm from the floor is very low for engagement, and therefore disengagement (easy gear changes) too.
_______________

I have refilled a couple of gearboxes with the proper recommended GL-4 oil (Total Transmission 8), which had accidentally been previously filled with GL-5. I was surprised at the noticeable difference, with the synchromesh obviously working more effectively.

My understanding is that some of the brass and phosphor-bronze parts of the synchro' rings actually absorb/hold the lubricant, so it could make sense for a change of oil to take some time to have effect. Someone here will know all about this, I'm sure!