The clutch plate and pressure stay in if you want them to the thrust bearing come out with the box now if your going to keep the berlingo change the lot if your going too get rid put it back in and sell asap
I think this might be my first post on this forum, so if it is, hello all..
Regarding your 3rd gear crunch. I have just bought a 2004HDI berlingo for my other half to replace the one she crashed (long story, not really relevant) and it has the same issue.. the syncro on 3rd is very weak. 4th is also quite weak.
Having had a good look at this issue with my Engineer's hat on, it's actually quite easy to see what's happened: The BE range of gearboxes are slightly odd in that they have two of the selector hubs on the input shaft, and two of the selectors on the output shaft. 1/2 is on the output shaft and 3/4 is on the input shaft. Critically, the input shaft is higher in the gearbox than the output shaft, so if the box is run low on oil, the 3/4 selectors (which includes the synchroniser hubs) will run dry.
Now also bear in mind that 3rd is the most changed-into gear in the gearbox, it will see the most wear anyway. Couple that with the synchroniser being starved of lubrication, and there's no surprise that it starts to wear out very quickly.
.... which is a shame really, as the BE range of gearboxes is usually remarkably tough.
Anyway. First thing to do is to check the gearbox oil level and fill it up if it's empty. You'll not be able to recover the syncro rings, but at least they won't get any worse. To fix it, the only thing you can really do is change the gearbox for a known-good one. The strip-and-rebuild option is very expensive.
That said, if you were to use a slightly heavier oil in the gearbox (EP 90 or similar), you may find that the syncro is quieter (better, whatever) but it will never be quite right.
The good news, however, is that the very minimal amount of shrapnel that will be created by worn out syncro rings will have been caught by the magnetic sump plug, so simply changing the oil (and cleaning off the plug magnet of course) will mean there's no damage to any other part of the gearbox.
Regarding your clutch.. while the Box is out, it's only about £50 for a three-part clutch and it would make absolute sense to change it : at least 60-70% of the cost of a clutch change is the labour, which is taking the box out. With the box out it's a 5 minute job....
Cheers David. That makes sense. As to my progress I have spoken to 2 gearbox specialists. One wants to drop out the box fix the syncro will be 200 for removal and refit 200 for syncro fix bbbbbbbuut if any other issues are found it mmmmmay cost more. The other 595 for a recon fitted. In the mean time my mechanic is putting out feelers for a lower millage salvage although that's a gamble. Have a good day people....t
(19-01-2015, 03:18 PM)David_R Wrote: I think this might be my first post on this forum, so if it is, hello all......
Thanks for the very concise and helpful post David........Welcome to the forums, it's good here!
The Older I get the Better I Was!