HDI Gearbox Issue

[Cheese]

Had a loud rumbling noise on the car for the last couple of days. Happens in a straight line and when turning. At low speeds it's like a knock and at motorway speed it's making all kinds of rumbling noises. At one point it sounded like a plane taking off!

Jacked the front of the car up today to check it out. Both hub bearings are nice and tight (was hoping this would be source!). Bottom ball joints are fine. Inner & outer CV joints on both sides also feel fine.

With the wheels off the ground when spinning one wheel by hand (in 4th gear) there is a constant click from the box. In neuteral it's silent.
In gear with the engine running there is a noise, but difficult to tell exactly what it is over the diesel chatter!

There's little or no vibration coming through the car at any speed. N/S drive shaft seal is weeping a bit of oil, but not enough to drip off the car, so may just be residue.

Thinking either the diff or a bearing inside the box is on its way out.

Anyone got any other suggestions?

[Cheese]

Car was dropped at a local garage this morning, and they have just called confirming its the gearbox! Another job for the weekend!

[Cheese]

Are the older 1.9 TD boxes fully compatible with the HDi engine? Can I literally unbolt the original HDi box and replace it with the TD one? Clutch, drive shafts, linkage, mounts, and reverse switch all work / fit?

Think I read in another post that the ratios are slightly lower, which I'm not really worried about.

Cheers

[aggyj17]

The clutches are different the 1.9 is a pull type and the hdi is a push type but if you use the clutch fork from the hdi box it should work fine

[Just Sean]

theirs a hdi boxfor sale on here mate

[Cheese]

theirs a hdi boxfor sale on here mate

Already on the case! The TD box is the back up plan!

[Cheese]

2 quick questions which hopefully some one will know the answers to!

Does the 206 2.0 HDi gearbox fit the 306 mounts and drive shafts? Guessing the block is the same so thinking any difference will be in making it work with the rest of the chassis components.

Secondly, drive shaft hub nut size? 32mm?

Cheers

[DeeTurbo]

The 206 has a hydraulic clutch not a cable like ours.

The hub nut is 35mm.

[Cheese]

The 206 has a hydraulic clutch not a cable like ours.

The hub nut is 35mm.

Nice one! 206 FB is out then, looking for a quick fix not hours making stuff fit.

35mm. Better go shopping!

[DeeTurbo]

If it helps you can use a 36mm, I've used one in the past with no ill effect.

[miles]

Not much goes wrong with the BE box's bar the sun and planet gears can break up, Bearings last for a good 300k normally