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Gearbox noise led to finding input shaft nut with free play
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Bordonbert

Posted: Sun Apr 13, 2025 2:32 pm

Joined: Jul 05, 2022
Posts: 19
Trade Rating: 0

Hi guys. 2002 206 GTi 2.0l with BE4 (I believe) box with 96k on it. Driving shows no obvious gearbox issues but that is "yet".

While working on the front brakes I noticed an obvious light tinkling noise from under my left wheel arch with the engine idling. It sounded like something the size of a washer being rattled about in a metal container. I reckoned it was a gearbox issue and was a bit panicked by it.

I drained the box, the oil was in good condition and not overly blackened, and I pulled the end cover off. There were no parts lying around and no metal shards or swarf obvious either. So I tried just fingering parts. There is a lot of end play type movement in the 5th gear synchro parts, not sounding good. The frightening thing is that the stake nut on the end of the input shaft is still staked up in place but feels fairly loose so the nut can be rocked a little around the shaft as much as the staked areas allow.

I cannot believe this is normal. I have found a reference in Peugeot's documentation to this being torqued to 72Nm. Can anyone confirm that this is not right and needs to be torqued up tight?


	They mock and say ask a stupid question? "A moment of embarrassment is better than a lifetime of ignorance".

Bordonbert

Posted: Sun Apr 13, 2025 4:53 pm

Joined: Jul 05, 2022
Posts: 19
Trade Rating: 0

I've taken the plunge and removed the stake nut which definitely was slack. However, it doesn't tighten up having moved on enough to get a safe distance past the current staking section. It really needs a new nut. I can order one from my local dealer who is waiting for me to pick up new gearbox oil from them. They are cheaper than any outside source I can find even before postage!


	They mock and say ask a stupid question? "A moment of embarrassment is better than a lifetime of ignorance".

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