406 HDI gear box problem 2003 reg

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bozaedwards - 05 Mar 2007 05:30 GMT

I developed a problem with the gearbox on my 406 HDI. Every now and
again it would not go from 3rd gear into 4th. If you tried to force it
in it would just grind the gears so I’d have to put it into 5th
instead. I put the car into our local garage who took the gear box off
and sent it to a transmissions repairs unit. They diagnosed the
problem as the synchromesh,which they renewed.I also asked the garage
to put in a new clutch. On picking the car up and £700 lighter in my
pocket, I found that I now had a gear box that was very notchy and
felt catchy throught all the gears. It sometimes wouldn’t go into 1st
gear from neutral unless I put it into 2nd gear first and then into
1st. It then started not going into 4th gear again. The garage done
the whole job again and to my surprise, the transmissions place said
they couldn’t find anything wrong in the gear box, but they’d replaced
the bits that could cause these symptoms. I got the car back and yet
again, a very catchy notchy gear change with all usual problems. The
car is currentlt back at the garage and the mechanic is driving it for
few days to get some idea of whats the cause. Does anyone have any
ideas? does the 406 have a very very catchy notchy gear change, which
is what they tried to palm me off with? and has anyone any ideas about
it not going into 4th gear from time to time? many thanks,john

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Keith Willcocks - 05 Mar 2007 09:06 GMT

>I developed a problem with the gearbox on my 406 HDI. Every now and
> again it would not go from 3rd gear into 4th. If you tried to force it
[quoted text clipped - 16 lines]
> is what they tried to palm me off with? and has anyone any ideas about
> it not going into 4th gear from time to time? many thanks,john

Occasionally I find that, when I am driving my wife's 306 the gearbox gets
"notchy" and it dislikes going into some gears. This is cured by moving
the rug back from under the clutch pedal. I am not saying that your rug is
rucked under your pedal stopping it going down fully but it could indicate a
problem with your new clutch. Possibly it is sticking or (assuming the
design is as I remember they used to be) the front shaft seizing in its
bearing in the flywheel boss.

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Keith Willcocks
(If you can't laugh at life, it ain't worth living!)

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Brian - 05 Mar 2007 18:56 GMT

> >I developed a problem with the gearbox on my 406 HDI. Every now and
> > again it would not go from 3rd gear into 4th. If you tried to force it
[quoted text clipped - 24 lines]
> design is as I remember they used to be) the front shaft seizing in its
> bearing in the flywheel boss.

In my experience, the PSA 5 speed box is very smooth in operation. I would
also suspect the clutch, or the clutch operating hydraulics.

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Keith Willcocks - 06 Mar 2007 17:11 GMT

>> >I developed a problem with the gearbox on my 406 HDI. Every now and
>> > again it would not go from 3rd gear into 4th. If you tried to force it
[quoted text clipped - 30 lines]
> In my experience, the PSA 5 speed box is very smooth in operation. I would
> also suspect the clutch, or the clutch operating hydraulics.

I had forgotten the clutch was hydraulically actuated. Sounds like the
system could be leaky or a seal is knackered.

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Keith Willcocks
(If you can't laugh at life, it ain't worth living!)

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markmtbanks - 06 Mar 2007 19:47 GMT

>>> >I developed a problem with the gearbox on my 406 HDI. Every now and
>>> > again it would not go from 3rd gear into 4th. If you tried to force it
[quoted text clipped - 4 lines]
>I had forgotten the clutch was hydraulically actuated. Sounds like the
>system could be leaky or a seal is knackered.

Just seems strange, that all of a sudden after a new clutch and box repair
it could all of a sudden develop a hydraulic prob

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Keith Willcocks - 07 Mar 2007 08:57 GMT

>>>> >I developed a problem with the gearbox on my 406 HDI. Every now and
>>>> > again it would not go from 3rd gear into 4th. If you tried to force
[quoted text clipped - 9 lines]
> repair
> it could all of a sudden develop a hydraulic prob

But they do happen, and with unnerving regularity. Presumably also the
hydraulic system would at the very least have been wrenched about a bit
during the repair.

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Keith Willcocks
(If you can't laugh at life, it ain't worth living!)

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markmtbanks - 07 Mar 2007 19:18 GMT

>>>>> >I developed a problem with the gearbox on my 406 HDI. Every now and
>>>>> > again it would not go from 3rd gear into 4th. If you tried to force
[quoted text clipped - 5 lines]
>hydraulic system would at the very least have been wrenched about a bit
>during the repair.

i agree keith they do happen ,the slave cylinder should have just been moves
away without breaking into the circuit to remove.. mark

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markmtbanks - 05 Mar 2007 20:47 GMT

>I developed a problem with the gearbox on my 406 HDI. Every now and
>again it would not go from 3rd gear into 4th. If you tried to force it
[quoted text clipped - 16 lines]
>is what they tried to palm me off with? and has anyone any ideas about
>it not going into 4th gear from time to time? many thanks,john

If this problem has developed since your new clutch fitment then logic says
its looking like a prob with that.It sounds like they have replaced 3rd/4th
syncro EVEN if they didn't get ALL the swarf out of the gearbox ,(from the
old syncro etc..) you've gotta be pretty unlucky for it to get in the rest
of the syncros/ gears etc.... !!!!! like i say sounds like poss clutch ...
all the best mark

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