Peugeot - 2000 1.9TD Boxer Van jumps out of 5th gear

Honest John Back Room » Technical matters
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Tue 27 May 2008 17:14
2000 1.9TD Boxer Van jumps out of 5th gear - doctorchris
Ok, the next issue on my uncle's camper van is that it now occasionally jumps out of 5th gear. We are aware that this is a common design fault following a re-design of the gearbox. My uncle has rejected my suggestion of using an elastic bungee on the gear lever when 5th is engaged.
I won't touch gearboxes these days without a manual. We have a good local gearbox specialist. Does it make more sense to fit a recon box or ask the local specialist to repair the box?
Camper vans do my head in. They are built onto cheap chassis that are designed to run up 150,000 miles in 3 years commercially, then be sold for peanuts at auction. However, the campervan fraternity expect them to cope with tiny miles over many years and are then surprised that they deteriorate faster than cars.
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Wed 28 May 2008 00:14
2000 1.9TD Boxer Van jumps out of 5th gear - Peter.N.
If it is of the same design as some of the early 5 speed boxes, you can remove 5th gear without taking the gearbox out as its housed in an extension bolted to the end. I repaired the synchro on one of my CX's like that. That is assuming of coures that you can get to the end of the gearbox.
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Fri 30 May 2008 00:35
2000 1.9TD Boxer Van jumps out of 5th gear - doctorchris
Again, good advice from this site.
My uncle was terrified as he read a tale in his campervan mag of this problem ultimately resulting in a repair bill of £1200 and, I think, on another occasion the van being repatriated from abroad.
He has contacted a local transmission specialist and the fault can be repaired for £350.
I suspect that it is a fault that, if neglected, causes 5th gear to break up and fill the box with broken metal, hence the horror stories he has read.
He and my aunt clock up big miles in Europe in this 8 yr old van and I always try to persuade him to ensure it is first class condition before he sets off.
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