'97 boxer leaking gearbox end cap.

This is the Forum for all your Peugeot Technical Questions, Problems or Advice.

Moderator: RichardW

Post Reply
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

'97 boxer leaking gearbox end cap.

Post by boxerbean »

The gearbox on my boxer motorhome is leaking from the end cap, it has been bodged with some unidentified hard gunk but I'd quite like to get a new end cap. Does anyone know what gearbox and oil goes in a '97 5 speed 1.9td boxer van and where I might find a new end cap? There was one on ebay a while back but the bolt pattern looked a bit different to mine...

Here's a pic.
20180408_084531.jpg
Hell Razor5543
Donor 2023
Posts: 13726
Joined: 01 Apr 2012, 09:47
Location: Reading
My Cars: C5 Mk2 VTX+ estate.
x 2993

Re: '97 boxer leaking gearbox end cap.

Post by Hell Razor5543 »

The two likely options are the BE3 gearbox and the ML5T gearbox (or derivatives of).
James
ex BX 1.9
ex Xantia 2.0HDi SX
ex Xantia 2.0HDi LX
Ex C5 2.0HDi VTR
Ex C5 2.0HDi VTR

C5 2.2HDi VTX+
Yes, I am paranoid, but am I paranoid ENOUGH?
Out amongst the stars, looking for a world of my own!
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

Yeah, I had thought it was an ML5T, it has a cable operated clutch though. As a temporary measure was thinking of replacing/topping up the oil, is that the level/filler plug on the lower left hand side?
Hell Razor5543
Donor 2023
Posts: 13726
Joined: 01 Apr 2012, 09:47
Location: Reading
My Cars: C5 Mk2 VTX+ estate.
x 2993

Re: '97 boxer leaking gearbox end cap.

Post by Hell Razor5543 »

If you were to post up the VIN somebody with the right level of access could lookup your vehicle and let you know what it had when it left the factory. I don't have such access.
James
ex BX 1.9
ex Xantia 2.0HDi SX
ex Xantia 2.0HDi LX
Ex C5 2.0HDi VTR
Ex C5 2.0HDi VTR

C5 2.2HDi VTX+
Yes, I am paranoid, but am I paranoid ENOUGH?
Out amongst the stars, looking for a world of my own!
RichardW
Forum Treasurer
Posts: 10812
Joined: 07 Aug 2002, 17:12
Location: United Kingdom
My Cars: MK2 '17 C4GP 1.6 BlueHDi 120
'13 3008 1.6 HDi GripControl
x 983

Re: '97 boxer leaking gearbox end cap.

Post by RichardW »

That doesn't look like a BE3 or an ML5 to me... I think it's an ME box. As said, post up the VIN and we can have a look.

Depending on the age of the box it might have a dipstick on the OS of the diff! I can't see that plug in the parts diagram, it does look like the drain plug. All PSA boxes use 75W/80 oil. Not sure on the capacity for an ME box.

The end cover is part no 220778 - not available anymore. Only used on Boxer, 605, Relay and XM.... If you could scrape the carp off, you might be able to get it welded up?
Richard W
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

Not sure if this is the vin palate, on cross member above radiator.
VF3**************[VIN obfuscated, can be read by forum staff]
20180409_133652.jpg
Cheers.
RichardW
Forum Treasurer
Posts: 10812
Joined: 07 Aug 2002, 17:12
Location: United Kingdom
My Cars: MK2 '17 C4GP 1.6 BlueHDi 120
'13 3008 1.6 HDi GripControl
x 983

Re: '97 boxer leaking gearbox end cap.

Post by RichardW »

That's it... although even Citroen doesn't know which box is fitted :lol: However, the mount just up and left of the end casing is not on the ML5 box, so it must be ME. It says 1.85l of 75W80. That bolt at the bottom left of the end cover doesn't get a mention anywhere; I wouldn't remove it in case.... There should be 2 drain plugs - one on the diff, and one on the bottom of the main casing just next to the join.
Richard W
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

I've taken some more pics, what would really help would be models of potential donor vehicles since that part isn't available new anyway, does anyone have those?
Is the plastic plug the fill point?



20180409_165717.jpg
20180409_165759.jpg
20180409_165809.jpg
20180409_165648.jpg
User avatar
Oldpug
Posts: 481
Joined: 07 Aug 2010, 11:15
Location: Berkshire
My Cars: Peugeot 406 GLX
Audi A3 TFSI S Line
Mercedes SL320
(In the past,just about every old Peugeot you can think of.)
x 64

Re: '97 boxer leaking gearbox end cap.

Post by Oldpug »

Have a word with Dean Hunter, http://www.peugeotparts.co.uk/ I`m sure he will have a second hand one,he may even have a new one.
Peter.N.
Moderating Team
Posts: 11563
Joined: 02 Apr 2005, 16:11
Location: Charmouth,Dorset
My Cars: Currently:

C5 X7 VTR + Satnav Hdi estate Silver
C5 X7 VTR + Hdi Estate 2008 Red

In the past: 3, CX td Safaris and about 7, XM td estates. Lovely cars.
x 1199

Re: '97 boxer leaking gearbox end cap.

Post by Peter.N. »

Failing that it looks like a steel cover so should be possible to weld it up, it certainly looks battered.

Peter
User avatar
Oldpug
Posts: 481
Joined: 07 Aug 2010, 11:15
Location: Berkshire
My Cars: Peugeot 406 GLX
Audi A3 TFSI S Line
Mercedes SL320
(In the past,just about every old Peugeot you can think of.)
x 64

Re: '97 boxer leaking gearbox end cap.

Post by Oldpug »

Peter.N. wrote: 11 Apr 2018, 10:55 Failing that it looks like a steel cover so should be possible to weld it up, it certainly looks battered.

Peter


It's very thin metal as well,it's just a tin cap held on with a few screws. Easily removed,I bet when it's all cleaned up you will find its rusted and perforated.
If you do find a good second hand one(or a new ?) give the outside a good clean and lots of coates of hamerite.
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

Oldpug wrote: 11 Apr 2018, 10:16 Have a word with Dean Hunter, http://www.peugeotparts.co.uk/ I`m sure he will have a second hand one,he may even have a new one.
Thanks for that, I hope he has one!
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

I rang Dean, he didn't have one but has been very helpful and thinks this is the box, also found on Citroen XM and Peugeot 605. There's got to be one somewhere (I've rang half the scrapyards in Britain) might try France next! 😂 I can't quite make out the details on the photo he provided...
IMG_7092.JPG
RichardW
Forum Treasurer
Posts: 10812
Joined: 07 Aug 2002, 17:12
Location: United Kingdom
My Cars: MK2 '17 C4GP 1.6 BlueHDi 120
'13 3008 1.6 HDi GripControl
x 983

Re: '97 boxer leaking gearbox end cap.

Post by RichardW »

As I posted further up the page.... :)

Here's a better pic:
boxerbox.JPG
That's doesn't look exactly like your box; as there is no drain plug in the end, but it's got the right no of bolts (7) in it.

You could try messaging member citroenXM (Paul) - he's got a large stash of XM spares; but don't know if he's got a suitable box, or would be willing to let an end cover go.

I reckon it will be weldable, I'm not that far from you, and could possibly have a go at it...
Richard W
User avatar
boxerbean
Posts: 44
Joined: 04 Aug 2017, 11:45
Location: carlisle UK
My Cars: Renault traffic
Peugeot boxer
x 8

Re: '97 boxer leaking gearbox end cap.

Post by boxerbean »

I just checked, has to be my cover - you were right first time Richard.

I'll ask Paul. There's an XM on ebay over in Newcastle but has a 2.1 and already is a few hundred quid.

The problem I have is getting the cover off without knacking those torx bolts and when I do keeping the gearbox dry - the motorhome is nearly ten foot high. There's a garage just down my road I will ask them to remove it/ weld it and keep the vehicle under cover because I have a feeling it will fall to bits at the first sign of a spanner!

Apparently welding things that have spent a long time coated in oil is troublesome although I've just watched a guy on youtube doing a tig repair on a hydraulic line and making a final pass with stainless to reduce porosity.
Post Reply