2002 - 2006 Gearbox Oil Capacity ?

[Wooie]

This is one for Nick ( euroserv ) please.

 

I am about to change the Oil in my Gearbox again.

 

Peugeot Boxer ( X244 ).... 2006....... 2.8HDi..........5 Speed Box.

 

The User Manual does not show the capacity for Gear Oil, it only shows the grade EP 75W80.

 

The first time i changed the Oil i rang the Peugeot Dealer where the van had been PDI`d and

they told me the capacity was 1.85 Litres of EP 75W80 Gear Oil and so that`s what i used.

 

This time whilst ordering my Gear Oil the supplier told me that i was not ordering enough when

i asked for 2 Litres and they told me it was 2.7 Litres of Oil.

 

Seeing as that was " Quite A Difference " i decided to ring some other Peugeot Dealers who

have all given me different capacities which has now really confused me.

 

I`ve now had ( 1.85L.....2.0L.......2.5L......2.7L......3.5L ) all from different dealers.

 

Regards.

 

Graham.

 

 

[Basil]

Hi, I know you have asked for Nick who will no doubt answer when he sees this, for information according to Autodata Disc

 

Manual gearbox 4/5 speed

SAE 75W/80

2.7 litres

 

Hope that helps.

 

Bas

[Wooie]

After investigating further i`ve found 3 different capacities on Oil Companies Fluid Charts.

 

All of the following are for the Peugeot Boxer 2002 - 2006.

 

Transmission Code :- ML5T 5 / 1...................1.85 Litres.

 

Transmission Code :- MLGU5 5 / 1................2.7 Litres.

 

Transmission Code :- MLUC 5 / 1 .................2.1 Litres...Service Fill...2.4 Litres.......Dry Fill.

 

 

 

So the next question has to be which is which ?

 

How and where do i find these codes on the Gearbox if they are on it in the first place ?

[Basil]

Again Autodata show diagrams of three different gearboxes, plus auto boxes, but it is saying 2.7 is the capacity for all. Two of them have oil level plugs as well.

 

 

Bas

[Derek Uzzell]

As far as I can make out, the manual gearbox that would have been fitted to a 2006 X244 Boxer with 2.8HDI motor would have been an MLGU-5V. There's a lot of on-line contradiction about the oil capacity, but 2.7litres seems right.

 

I understand that, after this gearbox has been drained of oil, it must not be refilled via the oil-level plug's aperture. Instead, a measured quantity of oil should be put in via the breather on the gearbox's upper surface.

[rolandrat]

If there is any doubt about how much to put in then measure what comes out when it's drained off then put the same amount back in. On some gearboxes there isn't a level plug, just a drain plug. I was once advised to put 2 ltrs in. It's assuming that there isn't an obvious leak.

[Wooie]

Hi Bas,

 

Mine definitely " Has Not " got a Level Plug. It is filled from the top via the Breather with a

measured quantity.

 

Awkward to get to but possible once you take off the Air Filter Box and move some of the Ducting

out of the way.

 

I`ve also made a Filler Pipe using some new hose pipe and a funnel that fits into the breather

hole because there is no way you can get the Oil Bottle anywhere near it.

 

I`m getting more intrigued by the hour as to why there are so many different quantities quoted.

 

If it hadn`t have been for the supplier saying i wasn`t ordering enough i`d have just done the same

as before and put 1.85 Litres in that would be that.

 

I`m looking forward to Nick`s answer and what he has to say ( if anything ) on what already on here.

[Dave Newell]

One has to ask why you are changing gearbox oil at all? These boxes are designed to run "for life" with the original oil content. The only occasions when it should need changing are if the box has to be removed for either a clutch replacement or gearbox repair.

 

D.

[Wooie]

The reasons why i am changing the Gear Oil are as follows,

 

From new i struggled with a very awkward and stiff Gear Change until everything had warmed

up especially if the van hadn`t been used for a month or so and the first use after winter was

not a good experience at all.

 

I went back to the dealer who`s answer was ........." Yeah they can be like that, USE IT more ".

 

Then i was told that the Linkages would be rusty and full of grit and grime and needed

cleaning and lubricating which they duly did ( allegedly ) because it looked and smelt like

they had just given it a good spraying with WD40 and made no difference at all !

 

It was then suggested that i needed New Cables and because the warranty didn`t cover them

they quoted me over £300 to replace. I declined.

 

Then talking to a friend they said they new someone that knew someone that had suffered the

same problem and it was suggested that they changed the Gear Oil.

 

I looked into it and after after not being able to find a quantity in my User Manuals i rang the

Peugeot dealer than had done the PDI and they told me ( 1.85 Litres ) so that`s what i ordered

and used.

 

It worked almost instantly and even after the winter lay up it is absolutely fine with the changes

being very smooth and a pleasure to use.

 

So for the sake of £13.10 ( £6.55 / Litre if bought when on offer ) i decided to do it regular at

the same time as i change the Oil, Oil Filter and Fuel Filter for which the Air Filter box has to

come off anyway which then makes it easier to access.

 

I use Valvoline HP 75W80 GL-5 Gear Oil and not some cheap crappy substitute from say

ALDI or LIDL.

[Wooie]

To save any confusion this is the Oil i use :-

 

http://www.valvoline.rs/download/27801.pdf

[Mickt]

Re stiff gear change. I have a 2003 Fiat 2.8jtd. The gear change got very stiff and the garage i normaly

 

use told me new gear cables was the answer.this got me thinking. I then took the MH to a Fiat main

 

dealer . After talking to the mechanic we agreed to disconnect the cables to see what the linkage

 

(quadrant) was like . He could not move it by hand. Answer took quadrant off , cleaned it and greased.

 

Now drives like new , cost half hour work

[Wooie]

Does anyone know where the " Code " is marked on the 2006 Boxer Gearbox ?

 

There are 3 possibly 4 different Gearboxes showing for this van all with different capacities.

 

The " System " is contradicting itself like it does when i order Oil and Fuel filters and insists that

my van uses the 3/4 UNF Oil Filter when it actually uses the M22 Metric and it also says my van

uses the Screw On Fuel Filter when it actually uses the Element Insert.

[Derek Uzzell]

Unfortunately rolandrat's earlier idea is a non-starter (Sorry!).

 

Even if one were to assume that Graham's Boxer left the factory with the correct quantity of oil in its gearbox, Graham did not record how much oil came out when he first changed the oil. Having put 1.85 litres of oil in when he changed the oil, if (say) 1.70 litres of oil now drains out, putting 1.70 litres back in won't necessarily be correct. If Graham should have put 2.7 litres of oil in at the first oil-change, he's been driving around since then with the gearbox 0.85 litres under-filled and, if that's the case, it wants rectifying.

 

If Graham's gearbox had an oil-level plug it would be easy to just put oil in until it starts to come out from the level-plug's hole. But apparently there is no level plug.

 

I've looked at a LOT of on-line stuff and (as I said earlier) I think Graham's gearbox is an MLGU-5V with an oil capacity of 2.7 litres.

 

One might reasonably expect the 5-speed gearbox fitted to a 2002-2006 X244 2.8litre Peugeot Boxer to be identical to the gearbox fitted to a 2002-2006 X244 2.8litre Fiat Ducato or to a 2002-2006 X244 2.8litre Citroen Relay and, consequently, to have the same oil capacity, but there's no consensus of on-line opinion/advice that this is so.

 

Perhaps Nick Fisher (euroserv) can adjudicate, but one might reasonably expect that a Peugeot agent, provided with a Boxer's VIN number, should be able to identify a) which gearbox it has and b) how much oil should be put in it.

 

Graham could ask this how-much-oil question on any number of vehicle-related internet forums and get a selection of answers. But, unless he can get some credible advice from Peugeot, it's difficult to see how he's going to be able to know which answer is correct and which is well-meaning opinion.

 

 

[euroserv]

Hello folks,

 

I missed this one, so apologies for the late arrival.

 

First, and most importantly, the Peugeot Boxer will have exactly the same gearbox as a Ducato when the 2.8 engine is fitted. The oil is added via the speedometer drive and you stop when it is running out of the hole. I could not say how much that is because we have a large drum of the stuff and we just pump it in.

 

Earlier Fiats and alternative engines may have alternative methods of adding oil and the capacities will vary but we deal with them very little and could not comment beyond the data that has been discussed already. We would usually use Auto Data as a guide and then study the vehicle. Dealers are neither use nor ornament, I am afraid.

 

Whoever it was that is changing the oil at every service is wasting his money. I don't agree that the box should run for life on the same oil though; I recommend a change of gear oil every 4 years or so under normal circumstances and more frequently if used in very dusty or very wet conditions. It is possible that the original oil had been contaminated in some way. Some of the Peugeot boxes have a tendancy to take on water through breathers that the Fiat boxes do not. The 2.0JTD is well known for it. Who is to say that the base vehicle was not driven through or stored in a flooded area prior to delivery? We have dropped some very milky substances out of Peugeot gearboxes in the past!

 

Nick

 

[spospe]

Am I alone in being dismayed that such a simple question should take such a lot of effort to produce an answer? (well not an answer really as we still do not have any real quantity figure for the volume of oil).

 

Why do not manufacturers have an enquiry service to answer questions like this, which should be in the driver's handbook anyway?

 

Why is it so difficult to get a simple answer to a simple question?

[Wooie]

euroserv - 2013-01-29 6:10 PM

 

Hello folks,

 

I missed this one, so apologies for the late arrival.

 

First, and most importantly, the Peugeot Boxer will have exactly the same gearbox as a Ducato when the 2.8 engine is fitted. The oil is added via the speedometer drive and you stop when it is running out of the hole. I could not say how much that is because we have a large drum of the stuff and we just pump it in.

 

Earlier Fiats and alternative engines may have alternative methods of adding oil and the capacities will vary but we deal with them very little and could not comment beyond the data that has been discussed already. We would usually use Auto Data as a guide and then study the vehicle. Dealers are neither use nor ornament, I am afraid.

 

Whoever it was that is changing the oil at every service is wasting his money. I don't agree that the box should run for life on the same oil though; I recommend a change of gear oil every 4 years or so under normal circumstances and more frequently if used in very dusty or very wet conditions. It is possible that the original oil had been contaminated in some way. Some of the Peugeot boxes have a tendancy to take on water through breathers that the Fiat boxes do not. The 2.0JTD is well known for it. Who is to say that the base vehicle was not driven through or stored in a flooded area prior to delivery? We have dropped some very milky substances out of Peugeot gearboxes in the past!

 

Nick

 

 

 

Hi Nick.

 

Thank you for the response ( i think......LOL ) because as for filling via the Speedo Drive is another option that hasn`t been mentioned by anyone else on this age of van.

 

This will be the 3rd time i`m changing the Oil and the Gearbox is smoother and better that when

i first bought it especially after a month or so of not using it.

 

It costs me just over £13 to re-new the Oil ( if bought on offer) which i think is well worth it.

 

As i`ve already said i fill mine via the Breather ( black plastic cap ) that is on top of the box and use

the 1.85 Litres that the dealer told me to.

 

The first time i changed my Oil i was amazed at the " Disgusting Liquid " that actually came out of it.

 

Then 2 years back i changed it again and the Oil that came out wasn`t that bad at all.

 

I was surprised when the dealer told me i wasn`t ordering enough and that`s when i rang round

a bit and got all the different answers which prompted this thread.

 

I spoke to a " Gearbox Specialist " today who told me to look for a code on the rear of the casing

that will be " Punch Marked " into it ?

 

He said the code will be ............. 20UM?? ...............and the last 2 numbers will determine which

box i actually have fitted because he has come across numerous vehicles that haven`t got what

the System says is fitted.

 

Weather permitting i`ll have a look underneath tomorrow and see if i can find this code.

 

Once again Thanks for the response.

[Wooie]

spospe - 2013-01-29 6:51 PM

 

Am I alone in being dismayed that such a simple question should take such a lot of effort to produce an answer? (well not an answer really as we still do not have any real quantity figure for the volume of oil).

 

Why do not manufacturers have an enquiry service to answer questions like this, which should be in the driver's handbook anyway?

 

Why is it so difficult to get a simple answer to a simple question?

 

 

 

I fully agree with what you say.

 

The handbook shows the Grade 75W80 but nothing for the quantity and that`s why i rang the dealer

in the first place ( 4 years back ) and they told me 1.85 Litres and yet this time when i rang them they

told me 2.7 Litres.

 

I`ve E-mailed Peugeot twice now and i`m still waiting for a response.

 

The different quantities i mention earlier in this thread all came from Peugeot Dealers in and around

my area.

 

One of them could not find my vehicle on their system even though i gave them the V.I.N. and both Registrations ( Personal Reg on now and the Original Reg had the van from new ). The same dealer

then said " Put about 2 Litres in and it`ll be alright "

 

I honestly think they do not know their " Arse from their Elbow " and this is why you hear so many

horror stories about Main Dealers.

 

Why do they insist on trying to make things better by " Improving Techniques " ?

 

Life would be so much easier if they`d have stuck with the old way of filling via the Level Plug and

when it ran out that was that................LOL

[Harvey]

Wooie, are you *absolutely* sure that you do not have a level plug?

 

Basil posted illustrations from Autodata but they are too small to see detail and his picture will not enlarge.

 

I have looked at Autodata and there are two illustrations showing the gearbox from the nearside end / rear and one showing a gearbox from the bell housing end.

 

Of the first two, one shows a filler low down at the rear of the 'box. The other shows a 'level' plug at this point and the fill point being what looks like the breather, at the top.

 

If you have one of these 'boxes these illustrations show differences which will enable you to determine which you have.

 

If yours is the latter then removing the level plug and filling from the breather until oil comes out of the level hole will do the biz won't it? This will also determine the quantity: well, that is what I would do ....... this gearbox has the end plate fairly flat whereas the former mentioned has a quite large domed end cover.

 

The gearbox shown from the bell housing end has a low level filler point adjacent to what I think is the offside drive shaft connection point.

 

Autodata mentions two different engine codes but nothing about gearbox codes and as has been said the capacity is stated as 2.7 litres.

 

hth a bit ...........

 

Harvey

[Derek Uzzell]

Wooie - 2013-01-29 6:59 PM

 

...Thank you for the response ( i think......LOL ) because as for filling via the Speedo Drive is another option that hasn`t been mentioned by anyone else on this age of van....

 

Filling throgh the gearbox's 'speed sensor's' aperture is referred to in this Ducato-related MHF thread:

 

http://www.motorhomefacts.com/ftoptitle-82135-fiat-ducato-gearbox.html

 

I didn't bother to mention it because a) there was nothing to indicate that one filled through the aperture until oil ran out and b) on-line received wisdom (plus all the 'official' advice) was that an appropriate quantity of oil be introduced into the gearbox via its breather.

 

While I acknowledge Nick's practical experience of Fiat Ducatos, I'd be interested to know if the technique he uses is the procedure specified by Fiat.

 

I'm reasonably comfortable with the empirical approach, where a simplistic methodology proves to work in practice, but I'd rather have back-up data if it's possible to obtain it. Filling the gearbox with oil until it runs out of the speed-sensor hole plainly works for Nick, but I'd still prefer to know how much oil Citroen/Fiat/Peugeot say should be put in this gearbox.

 

2.7litres of oil seems to be the best bet for being right for this gearbox. Let's assume that 2.7litres is correct and try to put that quantity into the gearbox via the speed-sensor aperture. If oil starts to come out when (near enough) 2.7litres have gone in, then the assumption that 2.7litres is the right quantity complements Nick's technique. If oil starts to pour out well before 2.7litres goes in, or there's no sign of oil coming out when 2.7litres of oil have been introduced, then Nick's technique may be respectively under-filling or over-filling the gearbox.

 

My Transit's Owners' handbook provides no details of gearbox oil capacity. Ford clearly does not expect Transit owners to be changing their vehicle's gearbox-oil themselves and it would not surprise me if other manufacturers' owners' handbooks only included engine-oil capacity data. I have a Haynes manual covering my Transit that does provide the gearbox-oil quantity to be used, but (as the gearbox is filled through a combined oil-filler/level-plug 'hole') whether the Haynes figure is correct doesn't much matter.

 

If there's a means of checking a gearbox's correct oil-level - either via a dedicated oil-level point or by using a fill-till-it-runs-out technique like Nick's - knowing the quantity of oil that should be put in is not that important.

 

When I was running a kit-car in the 1960s I broke the final-drive unit. Having decided to raise the vehicle's final-drive ratio I scrounged a replacement unit from a mechanic pal. Having fitted the new unit I realised that the rear axle came in two versions, one with an oil-filler/level-plug on the axle casing, the other with the oil-filler/level-plug on the final-drive unit's casing. My axle had no oil-filler/level-plug and neither did the replacement final-drive unit. That's the sort of situation where knowing how much oil to put in (through the axle's breather in that instance) becomes critical.