3.0 citroen relay gearbox rebuild

[chrishart]

Hi, I am a new member here, so please be gentle with me. I have a broken M40 gearbox I have taken out of my 2008 Relay 6 speed 3 litre diesel. Does anyone know how I can get a manual on rebuilding it, or an exploded diagram telling me the part numbers and how it goes together? Thank you, Chris.

[Hell Razor5543]

While I cannot help you with the gearbox, I can welcome you to the forum.

[Peter.N.]

Most of the old car manuals gave you detailed information about stripping and rebuilding gearboxes but they obviously don't expect you to do it now, I have done a fair few in the past and the construction was similar on all of them.

The usual things that need replacing are bearings and synchro rings but if the synchro has been bad for a while possibly the relevant gear as well. Parts have always been fairly expensive and I have used scrap gearboxes for spares, if you can get one and take it apart you will see how it goes together. There are certain operations you need a press for but I have always managed with a large hammer and an assortment of drifts.

What actually is wrong with it?

Peter

[spider]

I know what you mean about the 'detail level' in them. I still have a few older Haynes where they would spend 3 or 4 pages explaining just how the carburettor worked in intimate detail along with overhaul instructions etc...

[Peter.N.]

The first manual I bought is for a 1950 Hillman Minx and it shows you how to set a up crownwheel and pinion, regrind the crankshaft, rebuild the starter and dynamo and 10 pages on rebuilding the gearbox.

Peter

[RichardW]

Hi Chris,

Welcome! I've managed to print off a copy of the Cit workshop manual for stripping / rebuilding the box. PM your e-mail address and I'll send it over (it's a PDF).