citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear

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Fri 12 Sep 2014 15:44
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

my van is jumping out of top gear when under power, is ok going downhill or under light revs, but as soon as i give it heavy pedal it jumps out, any body out there know the problem and haw much to get fixed,,thanks,,John

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Fri 12 Sep 2014 23:29
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - Peter.N.

Don't know that its a common problem but I have heard of it. The good news is that I think you can get to the 5th gear without removing the gearbox, but removing the end plate.

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Sat 13 Sep 2014 11:45
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

Edited by johnmac185 on 13/09/2014 at 11:59

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Sat 13 Sep 2014 11:52
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

thanks for reply Peter.N. i have heard that the end plate comes of for access, but i wondered if may'be any other things like the cable change could be worn or faulty in some other way before i start tackling directly into the box,,,any other ideas out there would also be much appreciated,,,John

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Sat 13 Sep 2014 23:37
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - Peter.N.

Does it feel as though its going right in? if not it could possibly be the cable, but a worn synchro hub or gear could cause it to drop out, or even the detent ball/spring but that is rare.

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Sun 14 Sep 2014 14:56
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

Does it feel as though its going right in? if not it could possibly be the cable, but a worn synchro hub or gear could cause it to drop out, or even the detent ball/spring but that is rare.

Hi Peter,

yes it does appear to be going all the way in, i have the side pan off and access to the synchro, it is going all the way in but i can't decide if there is any wear in the hub, there is some slack sideways but not up and down on the hub but friend who is college instructor/mechanical says that is normal, but i would need to get the hub off to check the bronze part of unit, if this has worn teeth he recons that is the prob,,,John

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Sun 14 Sep 2014 15:33
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - Peter.N.

Can you not see the teeth with a lamp and small mirror? If its synchro wear you will find the teeth are worn more on one edge than the other.

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Sun 14 Sep 2014 16:09
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

Can you not see the teeth with a lamp and small mirror? If its synchro wear you will find the teeth are worn more on one edge than the other.

Peter, i can't see much, weather has turned and i am outside, i see an odd looking circlip which don't have holes at the end to grab with the plyers it just looks like a round ring not the conventional circlip, if i can get the hub off i will be able to see more, will try later if i can,,,John

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Sat 20 Sep 2014 11:52
citroen relay 2.2hdi 2004 lwb van - jumping out of 5th gear - johnmac185

problem fixed, got new synchro hub and replaced it during the week, bit of a mess the old one, now to get other things checked over Mot due next month,,,John

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