Santa gave me a f*cked gearbox for Christmas

On Christmas eve, went into town and there was a slight rattly noise coming from the engine bay area. To be honest at first I thought it was a loose heatshield from the cat area. It suddenly got louder as I reached town, 2 miles later. Pulled over to hear this:



Nice.

Is it a horrific meltdown of the gearbox internals (that's what it sounds like)? Or is it anything to do with the clutch assembly?

Additional clues with which to work out an answer:
-Highly likely to be the original clutch, on 142,000 miles.
-Selecting gears is still possible but is very notchy and 3rd *almost* crunches.
-The clutch does not slip.
-Cluch pedal has been stiff for ages.
-I've had low-level clutch judder for ages when setting off.
-When stationary, in neutral and with the clutch engaged, the noise is apparent.
-When stationary, in neutral and the clutch is disengaged the noise stops.
-When driving in any gear, clutch engaged, the noise is apparent.
-When coasting with the clutch disengaged the noise is still apparent. Drive shafts are turning the diff/gears - is it therefore gear/cog realed?

I'm braced for an expensive repair, do your worst

Cheers dood

My father and I had an inkling it was the clutch assembly, even though it sounds like it's a more serious component. It's the lesser of two evils I suppose! I plan to do the whole shebang on it TBH: cable, bushes, driveshaft oil seals etc.

You know what? I read your recent threads about 'box woes and wondered if mine was the same noise! Thought I'd rather clarify with a vid to make sure though

I'm going to get myself a shiny new Valeo clutch kit and all the associated parts/consumables from Peugeot I think. I won't have the 'box off again anytime soon so require the parts to last. I'm hoping Mr Jenks can provide a fine discount when the time comes

Anyway, glad you've got an answer to your own problem too.

Had the 'box off today and noticed very minor weeping of engine oil from behind the flywheel, so I think I'm going to change the seal. When I'm actually changing the seal, will all/some of my engine oil pour out? I need to know whether to drain the sump first!

Do I need to fabricate a tool for locking the flywheel teeth (as Haynes suggests) when removing it, or will the inertia and compression of the engine be enough to undo and re-torque the bolts considering they're only 50nm each?

I was experiencing judder when setting off in 1st with my old clutch and have read that this is often down to the flywheel. Is it prudent, considering the 'box is off, to get this machined at the same time? Or may the old clutch assembly be the sole cause of the judder?

Cheers

Brilliant, cheers for that. As much as I'd like the lightened flywheel, I'm trying to keep a lid on the costs to an extent.

Hey Chris, thanks for the offer but I've sourced a new Valeo unit for the job. The costs are staying down in relation to a £200+ lightened flywheel, but they're staying up in relation to long term component durability, ie: seals, bushes and the unit itself. Trying hard to strike a good balance

Cheers anyway dude

Hey Seany, I'm still in the process as I can only fix the car at weekends due to my working hours.

I ordered these from Peugeot:

- A genuine Valeo clutch kit (2051 T2)
- Both fork bearings (2175 54 and 2175 55 - cost pence and really worth doing)
- Both driveshaft oil seals (3121 44 and 3121 46), optional; one of mine was leaking slightly.
- 2 litres of Total BV 75W80 oil
- Left crank seal (0127 28), optional; mine was slightly leaking.
- 8 new flywheel bolts (8 of 0537 40), beacuse the flywheel's off for machining work.

Also:
- New clutch cable from GSF.
- New pinch bolts from Mr Swampy.

I followed Welly's ye olde thread and after researching the pitfalls of the 'box removal procedure on previous threads, I bent the clutch arm up slightly to allow enough movement because there was no way the pin was coming out. Once the box is off, the pin can be tapped through from the other side easily enough. The gearbox mount stud was a f*cker, so out came the hacksaw. Hope to procure a replacement soon!

Other than that, it's straightforward. I've managed fine on my own (sans an engine hoist or even a 2nd trolley jack!) the whole time.

Enjoy