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2003 Citroen Relay 2.2Hdi Gearbox Issue


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#1 Tetsu0san

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Posted 13 September 2018 - 07:09 PM

Hi all

 

I've got a 53 reg 2.2HDi Relay and I have a funny gearbox issue. The lateral movement through neutral is very very stiff, and it gets worse the less it's used. I've just had it parked up for a couple of months and it had all but seized up solid. Forwards and backwards (1st into 2nd) is very slick.

 

Before anyone says cables, I thought that too and I replaced the existing ones and the made no difference. The original ones I removed were completely free, so it's most certainly in the gearbox, or in the selector unit. I think the best option is to remove the gearbox or the selector part (if possible) and have a good look.

 

Does anyone know of a how-to guide on removing the gearbox or selector unit, or at least has any tips and tricks for doing it? I've worked a lot on cars and vans but I've never tried to remove a transverse gearbox.

 

Any help would be gratefully received. Many thanks


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#2 coastline taxis

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Posted 14 September 2018 - 05:07 AM

you can get to the linkages very easy on these van . If you look at your scuttle panel under the windscreen you will see that the drain plug for it comes out on top off the gear linkage.  Cover the linkages with wd40  dont be scared of it and really soaking it then start working the lever in neutral. then more wd the work it till it becomes free then plenty grease to keep it clear


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#3 Tetsu0san

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Posted 14 September 2018 - 07:33 AM

you can get to the linkages very easy on these van . If you look at your scuttle panel under the windscreen you will see that the drain plug for it comes out on top off the gear linkage.  Cover the linkages with wd40  dont be scared of it and really soaking it then start working the lever in neutral. then more wd the work it till it becomes free then plenty grease to keep it clear

 

Thank you for your reply. I absolutely drenched it in WD40 when I first noticed the problem, and this has made no difference at all unfortunately and as I said above if you leave it it just gets worse. But what you just said about the drain plug being above the linkage might explain it if water is getting into the mechanism.


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#4 heraldsteve

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Posted 15 September 2018 - 06:46 AM

I had a similar issue on my 2006 Relay except with 5th gear. I can't remember the details as it was a couple of years ago but I put it up on ramps and found the linkages had siezed up. I can't remember if I had to strip it or simply work it while applying oil, but I do remember it took a lot of force to get it moving at first.
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#5 Tetsu0san

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Posted 17 September 2018 - 01:08 PM

I had a similar issue on my 2006 Relay except with 5th gear. I can't remember the details as it was a couple of years ago but I put it up on ramps and found the linkages had siezed up. I can't remember if I had to strip it or simply work it while applying oil, but I do remember it took a lot of force to get it moving at first.

 

It sounds very similar to my problem. I think I'll give it a go with some WD40 and brute force again before I go down the more drastic gearbox removal route.


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#6 Tetsu0san

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Posted 18 September 2018 - 07:48 AM

So it turned out that the metal pivot that changes the horizontal movement of the cable to the up and down movement of the selector arm was seized up and took nearly 2 hours of heating, hammering, twisting, cursing, sweating, and praying, to get it off. Once off you could see where the pin it pivots on was pretty rusted and pitted, and the bushes were very dry.

 

Cleaned up the pivot pin and the pivot itself, and then drilled and tapped a hole to fit a grease nipple. Packed it all with grease and fitted it all back in (which took all of about 5 minutes) and now I have a lovely crisp and smooth neutral movement on the gear stick for the first time in my ownership. It has never been right since I got it and just got worse and worse over time.

 

At least I didn't have to take the gearbox out!

 

Anyway, thanks for your help people.


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#7 paul.h

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Posted 18 September 2018 - 02:19 PM

Good to see you have sorted this and at very little cost.



#8 coastline taxis

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Posted Today, 06:16 AM

to stop it  happening again look under the scuttle panel above the gearbox. you see the drain hole. If your luck the rubber pipe will still be there  if so reroute it away from the box. if not then make one and reroute it away from the box


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