BE4/5 gearbox

[Pluggit]

Anyone have any experience of working on the 5th gear from the wheel arch. When the liner is taken out the gearbox end cover looks clear and possible to work on. Any advice?

[Oldpug]

It’s a long time since I did this. ( long retired )
Back in my Peugeot workshop days I can remember it was easy to remove the metal end cover and the 5th gear etc.

[CitroJim]

As Oldpug says, it's easy to get at and easy enough to remove the 5th gear pinion and synchro hub.

Just be aware of the springs and balls in the synchro hub making bids for freedom and the spring and ball detent on the 5th gear selector fork shaft doing the same. Make up a mandrel of the same diameter as the selector fork shaft to slide the fork off and back onto the shaft, thus keeping the detent depressed.

[Pluggit]

Ok. Thank you both. 5th failed on way back from the coast. Got back on 4th... rattling all the way.
Mandrel ? Spring and ball detent ? What is the nature of the item(s) I am going to hold back ?

Im happy that I can do the remedial work but a bit apprehensive about the things that "pop off" while im not looking. Think I know what you are talking about but tell me how to fabricate it.

Cheers. Chris

[CitroJim]

Although for a BE3/5 Chris, this guide here will help illustrate the basics of the job...

https://www.eastment.net/BE3%20Gearbox%20Strip.htm

In the pictures, you'll see the mandrel in use to prevent springs and balls going off in their own direction!

Hope it helps...

[RichardW]

The most likely cause of the 5th failure is the nut on the end of the shaft coming undone and the gears going out of mesh. If you're really lucky there will be no damage and you can just tighten the nut up again.

[Pluggit]

Got it all apart accessing thru the wheel-arch.

Oh dear. Both cogs have chewed up and bits of teeth from both the cogs dropped out when the end cover was parted. Something stopped turning somewhere in there - its catastrophic.

Just getting some extra tools together and will then pull the assembly apart and assess the parts needed. I cant see me getting away with any less than the drive pair and the retaining nuts. Hopefully the broken bits were big enough to just drop to the bottom of end-cap and go no further. Have to get the syncro off and see if its undamaged. Could be looking at a full repair kit. May be better off getting a second hand box complete and using it as a doner. Just out of interest, what are the two shafts that the cog pair are attached to. Do either of them attach to the main drive shaft because when I limped back yesterday, even though I never used 5th, I was still getting a rattling in the other gears.

I bought this car as a run-around. It was a nice looker and worth a punt. On the test drive I said there was a wining/whistling noise. Cut a long story short(and some basic maintenance), the guy had been running it for what was likely to be quite a time with a gearbox void of oil. Not many miles after refilling it, the driveshaft was leaking - probably the reason why the box was empty. I reckon that didnt help the 5th gear assembly.

Trying to find the gearbox part number and type. All I can see is 160R stamped on the casing. Does this mean anything to anyone ?

Thanks very much for all your advice. Its much appreciated.

[CitroJim]

Oh dear! Lack of oil the very likely cause... I once saw what happened to a BE3/5 in a 306 diesel that had been run dry and for ages, under light load it was fine - until, the day the car was needed to do a rescue tow of another... The 'box died gear-by-gear... It was quite a mess inside...

Best to source a replacement 'box from a breakers; the cost of parts to fix yours will be way beyond what a complete one rescued from a scrapper will cost...

The forum staff should be able to advise what you need to look for...

[Pluggit]

Yep. The damage looks to be to the main cog pair but its what caused it and/or what damage may have been done to the shaft bearings etc whilst these cogs were destroying themselves. Im trying to get details for this box: servicebox cant be accessed and ssg.asia gives a code according to my vin but I dont recognise it. I can see very little stamped on the housing either. Nothings easy is it.

[RichardW]

We can help if you need an original genuine part number, part diagram or vehicle factory build sheet and can't already find the info you need on the Forum. For this service, we do ask for a membership upgrade for official parts data as we are in turn charged for this. It will cover you for future part number requests for up to 3 years, so excellent value.

If interested, links are below, then provide your vehicle's VIN in full, which will be masked automatically when you submit your post.

A response to your question by a Forum Admin requiring parts or specific vehicle information requires you to have made a current contribution (Min. £10 / €11.48 or equivalent) to the Forum.

To Upgrade Your Membership & Donate Click Here For Further Information About Vehicle Parts and VIN Numbers Click Here

[Pluggit]

Just donated. A good service at a very fair price.

Vin is VF3**************[VIN obfuscated, can be read by forum staff]

Useful info :

Engine code
Gearbox type( I think its a BE4/5)
Gearbox code and part number
Schematic for the box
Any other info I might need to give a (used) part supplier to enable the correct box to be sourced.

[RichardW]

Here is the gearbox diagram

It gives info about the markings, but it's not always clear where these are marked on the box!!

5th gear parts and prices

[Pluggit]

Yep. Thats the fella. CP19X72 has kept on coming up so it looks about right.

Ive had some good fortune in that the work to the 5th gear assembly has been easy from the wheel arch. I had my reservations but was pleasently surprised. It got even better when all the bits came off with the minimum of fuss (the BE3 strip-down guide from Chris the other member was invaluable). The cog-pair were mashed well beyond fubar - I accounted for 10 teeth out of 12 and expect the other 2 to be ground to powder and suspended in the oil or clinging to the magnet. The shaft bearings were all clean and fine and no play and it all turned nicely. I think I have got away with the price of the gear pair, some new oil, a few days of my own time and the skin off 3 of my knuckles. It could have been a hell of a lot worse. Running it with no oil by the last owner has definately been the cause of this but I think Ive got away with it. I would rather take a punt at this box on 120k with my repairs rather than a scrapper that may have done another 60k. At least I have now pinned it down to some details and if it does need a complete box in the near future I can get the correct kit.

Thanks very much for this info. I,ll run it off on the printer.

Cheers

Chris

[Pluggit]

Message to Jim if you are reading this.. I just called you Chris. Thanks for the strip-down guide.

Made a mandrel but the fork came off without sliding onto it. Thought it was a potential catastrophe but the ball and spring were still secure in the fork. They may have realised there was a problem and modified it on this BE4/5.

Regards

[CitroJim]

No worries at all Chris! I'm just delighted it was of value to you

Good to know the BE4/5 has been modded to avoid a 'pingf**kit' moment!