106 Gearbox/Linkage Problems

Batf1nk · 19 Sep 2010 at 19:23

Right. The last month or 2 my gf has struggling to get her pug 106D into 1st (and sometimes 2nd) gear. It will go in but you really have to force it in.

Now, im pretty sure the clutch is fine. The bite is not high and its not slipping at all. Doesnt crunch going into 1-5th (although does more often than not into reverse).

The clutch cable is less than a year old.

Gearbox oil has been changed twice (halfords crap the 1st time and millers the 2nd) with no/minimal improvements.

I've gave the gear linkages a good spray of WD40 but again, no/minimal improvements.

After a bit of googling, 'worn linkages' seem to be popping up quite a lot. Im not able to get under the car to have a proper look atm.

Has anyone else came across this problem in the past? Similar symptoms/solutions? Wondering whether to order now before looking properly or wait and get under there first.

-westy- · 19 Sep 2010 at 19:25

Where on the pedal travel does the clutch bite?

Defcon5 · 19 Sep 2010 at 19:28

Linkages are a common problem, and cause the symptoms you describe

Batf1nk · 19 Sep 2010 at 19:39

-westy- said:
Where on the pedal travel does the clutch bite?

I'd say in the middle of the travel. Definately not high at all.

Doughnut007 · 19 Sep 2010 at 20:05

I had a 106 D (MReg) and had the same problem. It was the linkage

-westy- · 19 Sep 2010 at 20:53

Batf1nk said:
I'd say in the middle of the travel. Definately not high at all.

I'd agree with the linkages being at fault then. Have a look on http://forum.205gtidrivers.com - get hold of a bloke called Miles and ask for a set of his linkages. Definitely worth the money, and they give a very tight and precise gearchange

Leeum · 19 Sep 2010 at 21:14

I've been told by a few people that rose jointed gear linkages on the Saxo/ 106 are crap as they tend to pop off - if the linkages need replaced, genuine parts are the way to go.

I would dismantle the linkages to free them off, and grease them up. This may be some use:

There's also the selector on the gearbox which has a split pin through it. If the gears feel vague and the stick has lots of side to side movement (when in a gear), it's best to drill it out and fit a larger pin.

Fuzz · 19 Sep 2010 at 23:35

Just a quick test..

Put it in reverse..
Leave it there a second or two
Keep your foot fully on the clutch
Take it out of gear
Still keeping your foot fully on the clutch
Wait say five seconds
then try to put it back into reverse..
Does it crunch?

Batf1nk · 20 Sep 2010 at 00:21

Will give that a try tomorrow. I guess that'll indicate the clutch not dis-engaging properly?

Fuzz · 20 Sep 2010 at 00:29

Batf1nk · 29 Sep 2010 at 10:23

Update. New gearbox linkages fitted. Problem is still there! :mad:

Tried what Scubascorpion suggested and the gearbox does still crunch. Also, the car will go straight into gear when the engine is turned off which now leads me to believe there's a clutch issue!

Is there a way to adjust the clutch. I cant tighten the clutch cable as its a stupid-ass auto adjusting one?

Need to fix it by before friday.

Fuzz · 29 Sep 2010 at 18:04

Gearbox off then as the clutch is dragging, probably broken one of the fork / springs

Batf1nk · 29 Sep 2010 at 19:12

The fork that pushes the clutch plate and flywheel apart when the pedal is pressed? Are peugeot likely to stock these?

Wondering whether I should risk the drive to Manchester and back (just over 200 miles) and do it when I get back?

I don't mind doing the work but the car needs to be done for Friday and I don't want a completely non-working car.

Fuzz · 29 Sep 2010 at 19:20

One other thing that is quite common before you take the gearbox off is the clutch arm bends at the pivot point where it goes into the gearbox..
Check for signs of stretching / cracking of metal there. That's quite a common failure also.
You'll need to force it back straight and get it weld strengthened (or buy a new one, which will require gearbox removal.

If that is straight and is moving freely then it's very likely to be the clutch cover forks / internal spring

GT3 · 29 Sep 2010 at 21:06

I had exactly this problem on my 106 diesel. 2 weeks of ramming it into gear and the whole clutch exploded on the m1.

Batf1nk · 29 Sep 2010 at 21:51

GT3 said:
I had exactly this problem on my 106 diesel. 2 weeks of ramming it into gear and the whole clutch exploded on the m1.

****! Guess I shouldnt risk the drive then?! ****!

How heavy is the 106 'box? Would I have much trouble relocating it on my own (with the aid of a jack)?

I need to leave at 4am on fri for manchester airport so need this done in a day!

GT3 · 29 Sep 2010 at 21:58

I managed it myself fairly easily with a jack on a saxo, the only problem I had was with the intermediate bearing on o/s driveshaft and powersteering pump in the way. However I imagine yours won't have these being a lower spec model so should be pretty straight forward.

Fuzz · 29 Sep 2010 at 22:01

It's tiny, you can bench press it with ease.
I wouldn't attempt it with you being so short on time, get a back up plan organised now!
Coach / taxi / train / parent with car..

Wings · 29 Sep 2010 at 22:03

I can be of no assistance, but when I saw the title of this thread, my first thought was "wow... that's a lot of problems..." Actually laughed. Out loud. Thanks!

Batf1nk · 29 Sep 2010 at 22:05

Found a pic of the arm and fork (A&B + 5,6,7). Anything alse likely to be borked? The bearing isnt noisy so should be ok.