Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

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Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by flywheel1935 on Mon May 08, 2017 10:45 pm

Is there a general problem with Pug Boxer Gearboxes, ??? there seems to be a general thread that these are weak g/boxes ? and my recently purchased Executive (1998 model)
is showing signs of with clutch-drag when hooking 3rd gear or the syncro ring is worn /failed . Super van is being compromised by this, as low power engine 108bhp needs lots of g/box changes in town driving to keep on the boil. Advice appreciated, or decent g/box specialist in Norfolk (Kings Lynn )or 75 mile radius.
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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by roli on Tue May 09, 2017 6:24 am

I think the problem lies with Peugeot, they are never that sharp on spares (compared with Ford) and for these older vans they are non existent. You are therefore dependent on other suppliers who generally are not that keen on making or stocking parts like gearbox components. This of course means the transmission re-conditioners cant get parts.
There does however seem to be an odd outbreak of gearbox related problems  at the moment

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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by alythian on Wed May 10, 2017 7:42 pm

Hi flywheel, I can only say that I share your despair. My own van, a 1995 Pug Exec. had blown 2nd gear synchro, totally useless for forays into the Highlands of Scotland or indeed the Yorkshire moors. Thought I had nothing to do but put it into reputable motor engineer to sort problem. It took 4-5 weeks and an £1100.00 + VAT reconditioned gearbox from London area to get it back on the road. I wish that I had not been so hasty in putting Hector in for repair as opposed to locating bits first. In your case , I might be tempted to have the gearbox oil changed and start a search for bits. Having synchro on 2nd gear makes your Exec useable, with double declutching into 3rd a skill you might want to practice. They are superb wee Vans.  Alythian.

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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by meanchris on Wed May 10, 2017 7:48 pm

I would definitely change the oil and lubricate the linkages before spending big money.

P.S. If you think the 108HP Turbo is hard work, you should try the non turbo 75ish HP version like we had. rolleyes
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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by harry h on Wed May 10, 2017 7:54 pm

Its a well known problem in the trade. You could try HL Smith commercial gearbox rebuilds. They mainly cover heavy truck and bus transmissions but also light commercials including Ford Merc etc.
Telephone 01902373011. Good luck.
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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by flywheel1935 on Thu May 11, 2017 8:57 pm

Hi Guys, thanks for the replays, Firstly, yes I will change oil, as get less problems when box is cold, gets worse the longer the journey, and I also double de-clutch, as my weekend toy is a 1935 Austin 7 Ruby, so plenty of practise !!!
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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by meanchris on Thu May 11, 2017 10:14 pm

flywheel1935 wrote:Hi Guys, thanks for the replays, Firstly, yes I will change oil, as get less problems when box is cold, gets worse the longer the journey, and I also double de-clutch, as my weekend toy is a 1935 Austin 7 Ruby, so plenty of practise !!!

It's worth checking the exact type of gearbox and relevant oil, as for example, the older gearboxes don't like the newer revised oil spec.

Ours was a 5 speed BVM-ME, but I think that there are at least 3 different variants of the BVM box (BVM MG5t - ML5t IIRC?)

I still have some gearbox exploded diagrams, kindly sent to me by someone here when I was doing my own oil change on a '95 2.5D Exec.

I also have some photos if any of these things would help.

Our box was baulky and stiff before the oil change and linkage lube, it was pretty good afterwards, though not quite as good as our current 2005 X244 box.

EDIT: I found my original thread (and of course there are others in the same vein if you search for them)

http://www.autosleeper-ownersforum.com/t12174-95-executive-2-5d-gearbox-oil-type
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Re: Pug Boxer Gearbox Issues ??? 2.5TD 1998 Execu

Post by flywheel1935 on Fri May 12, 2017 10:31 pm

I,ve been told by the mechanic who MOT,s my vehicles that a company trading as Ace Gearboxes, based in Northampton are very good,
so I'll try the oil change first before heading south to N/hampton
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