406oc.co.uk

The gearbox on my 02 HDI 90 estate started making a hell of a noise, like a bolt was flying around loose in there. Shortly after the noise stopped leaving me with no 5th.

Does this mean the box will need replacing or is the a quick fix. If the box has got to be replaced, apart from the weight, is this a reasonably doable job for the average DIY mechanic.

Thanks in advance

No idea if it can be repaired, but you'd need to remove the gearbox to do it, and the parts will probably cost more than a 2nd hand box.

Replacing the gearbox can be done by a DIYer with plenty of free time - have a look at my clutch change howto in the knowledge base. It's for a V6 petrol but the procedure's pretty much identical, maybe easier with the smaller engine. In fact if the BE gearbox is smaller than the V6's ML5, you *may* have room to do it without removing the driver's side driveshaft - a royal ballache - or even the subframe

Consider a new clutch while you're at it, and if you do need the o/s driveshaft out, definitely replace the bottom engine mount!

Thanks Steve.

Phoning the breakers now for a box. That's sound advice about the clutch and mount. Thank you.

years ago we had a 305 (see i said it was years ago) that had no 5th gear and there was a cover that could be removed to access the gearcog. Now i have no idea wether this is the case on a 406, i suspect not but might be worth asking a garage or someone with knowledge of gearbox's

i don't think you have to remove 5th gear as the is a cover for it on the end of the box just take the passenger wheel and arch liner off and there is, it's quite hard to get individual gears for the public that are cheap so it may be more economical to get a second hand box and refurbish the one you have


also if you just remove the gear there may be bearing damage as all the metal bit will have gon into the oil