peugeot boxer gearbox noise and wiring problem

[ollski]

Hi, got a 2007 boxer and am getting a whine and tapping from the gearbox. The van has done 85k miles and never had the gearbox oil changed as far as I can tell. If I dip the clutch the noise disappears and also if I take my foot off the gas the noise disappears again.

With the electrics some of the bulbs are going on and off at the wrong settings, I'm sure I could sort this if I could find some sort of a wiring centre. ie l/h wing mirror indicator works but not l/h in the headlight unit despite having a new bulb....couldnt I just link mirror ind to headlight ind and if so where would I do it?

Thanks.

 

[Burnerman]

Electrics first ......use a 12v tester to see if there is a voltage getting to the headlamp indicator bulb, as their could easily be an earth fault.
Gearbox.....well it's not strictly necessary to change the gearbox oil, but it's not a bad move.
Anyway, I'd like to have the wheel bearings and driveshafts checked out first as they can complain when under load.....I may be a mile off here but having had transmission issues myself recently, I'd want them to be given a clean bill of health. I'm not sure about the clicking noise though - whines, fair enough, but not clicks ......that does point towards a driveshaft cv joint.
John

 

[ollski]

Thanks John, I picked it up from a coachbuilder who converted it into a horsebox. All the new rear lights work fine but now the faulty side indicator operates at twice the speed of the correct side. Does that point to earth fault? coachbuilder 250 miles away btw so if i can sort myself then all the better.

The tapping noise sounds a bit like when you used to put a bit of card in your bike spokes as a kid and its mainly under hard acceleration

 

[Burnerman]

If you can sort out the front indicator, the side repeater will automatically start to flash at the correct speed.
If you can use a length of wire with one end connected to the car metal body, touch the other onto the metal side of the bulb.....if it starts to flash then it is an earth fault.
As for the gearbox noise, thats really got me foxed! I would initally suspect a diff bearing problem but do you think the noise could be from the wheels / tyres at all? There's really not much in a gearbox to click!
John

 

[ollski]

The noises may be unrelated john, I'm wondering if the tapping is more from the top of the engine.....maybe injectors although it only seems to be under load?

 

[Burnerman]

It could be an injector issue, but I'd look at the exhaust manifold gasket first - just to see that its not blowing. Under load, any leak sounds like a crackle to some degree.
Is there any exhaust smoke when this happens?
John

 

[Mursal]

The tapping:
As above also try an oil treatment or if it has been lying up, give it a good long drive.

The Electrics:
Test the bulb connected across the battery, or change it with a known good bulb? It will need to be identical to the original one.
You will need 12Volts across the good bulb for it to light, so you either have a bad connection to the body as John said. Or you haven't power coming to the bulb? Sometimes its worth giving the connections a wiggle to see if things reconnect?

 

[ollski]

Cheers guys, wierd thing with the electrics. I was getting 12v to the holder connection and continuity through the holder so I took the bulb out and put it to a known 12v connection and earth.....nothing. Bought a full set of new bulbs and just refitted them and everything works perfectly!

Gearbox oil check next, hopefully engine and gearbox oil change may possibly make me good to go.

 

[ollski]

I looked up some specs on the engine aswell and it claims to rev up to 3500 rpm, if I drop my foot to the floor on mine I get a maximum of 2800rpm and when I was pushing her down the motorway last week I thought I got a couple of power drops. My max speed is about 73 which is ok as its a horsebox but I'm wondering if the clicking noise may be turbo related?

Anyone know where the level check for the gearbox oil is on the 2.2 120 bhp diesel?

 

[Burnerman]

The turbo does have a device called an actuator, which varies the vane pitch within the turbo.....obviously this could cause the lack of power but I'm really not sure about the noise!
I don't think your turbo will have a waste gate either - all exhaust gas is directed through it.
Are there any diesel diagnostic specialists near you that can check the turbo boost and EGR function?
Regarding the gearbox oil level, the usual place is on the near side of the gearbox, within the wheel arch......look for a filler/level plug. The drain should be at the bottom of the box with a large hexagon nut incorporating a square hole within it.
Any pics could help!
John

 

[ollski]

Hi tapping noise was a total lack of exhaust rubbers and the gearbox whine is bearings so currently undergoing a gearbox strip down to see how much needs doing. The lack of power isn't diagnosed yet.