MK1 2.0HDI gearbox oil change, here's how

[steve valentine]

Todays job was changing the gearbox oil on my 2002 2.0HDI van

You will need;

17mm spanner
10/13/19/21mm socket
18" hose pipe
funnel
flat bladed screwdriver
phillips screw driver
receptacle to catch used oil (I used an old 5 litre oil drum with the side cut off)
Plasters, I always cut myself somehow when working on the van.

Ok, jack up the passenger side front of the vehicle and remove the front passenger road wheel then remove the plastic undercarriage guard.

Look into the wheel well you will see a small plastic cover to the left, once removed it will reveal the gearbox, there are four plastic rivets, remove these (mine wouldn't come out so I beat them into submission, I had spares)

one at the bottom;
[Image: 197962_1780582626737_1004576529_31992549_1531876_n.jpg]

two at the top;
[Image: 200450_1780582266728_1004576529_31992548_4993692_n.jpg]

And one hidden at the end of my finger;

[Image: 197316_1780581866718_1004576529_31992547_3424196_n.jpg]

To get to the breather which is where I filled from, you will need to remove the airbox, firstly, remove the five screws holding the top and and remove the filter, next, using a phillips screwdriver, unfasten the large jubilee clip to allow you to remove the top of the airbox;
[Image: 190718_1780581226702_1004576529_31992545_2263811_n.jpg]

Next, the bottom of the airbox is secured by a 10mm nut, remove this and lift off the base of the airbox;
[Image: 200259_1780581026697_1004576529_31992544_4970314_n.jpg]

This will reveal the breather, remove this with a 17mm spanner, it's plastic so is not tight, breather shown on the end of the spanner for clarity;
[Image: 189140_1780580346680_1004576529_31992543_2734993_n.jpg]

Now, back to the wheel well, you will see the level plug removed;
[Image: 198879_1780578146625_1004576529_31992538_7773541_n.jpg]

And here if you squint, at the lowest part of the gearbox, the drain plug;

[Image: 196049_1780578546635_1004576529_31992539_463753_n.jpg]


So, once the oil has been drained, replace the plug and commence replacing the oil, I used a bit of hose taped onto a funnel to make it easier;
[Image: 198599_1780579986671_1004576529_31992542_632356_n.jpg]

Once oil starts to flow from the level plug, replace the plug and put your van back to gether by reading this post backwards

It took me 55 minutes, but that included two cups of coffee, a toilet break, finding some hose and the funnel and 7 trips back and forth from the garage 20 yards away to get the tools I needed, and fielding questions from my 4 year old Grace, what you doing dad, why dad, you're dirty dad, are you coming to play dad, where do babies come from dad.

Whilst the wheel was off I also checked the brake pads, it's only one bolt to remove the calliper on a berlingo.

I hope this is of use to someone, it's a very easy job, now I know what tools I need I could easily do this in 30 minutes.

[Chris]

Great write up and thanks for taking the time to put this together. I am sure lots of people will find it useful.

[Andre]

Our very first in house 'How To'! Cannot thank you enough steve, takes some effort, but its brill!

P.S: Nice air horn

[steve valentine]

I actually took the photos during refitting as I forgot to take them as I was disassembling, hence the dirty fingers!

Happy to help, I'm a firm believer in giving as well as receiving help. Hopefully it will save someone a trip to a mechanic.

I used automatic transmission fluid as it is a recommended replacement for 75/80 gear oil.

http://www.wilcodirect.co.uk/index.php?m...ts_id=2099

I know my local parts shop quite well so got 2L for £10

If I do any more jobs, I'll do a write up, jobs to do soon will be rear shoes, brake fluid change, power steering fluid change and coolant change.

[NikolasTesla]

I found the answer in google, remove the topic pls.

[2cvxm]

Halfords sells 75-80W, specially for Citroen/Peugeot says the label for 8 pounds 50 a liter. A tenner for 2 liters is great haggling I would say.unny:

I actually took the photos during refitting as I forgot to take them as I was disassembling, hence the dirty fingers!

Happy to help, I'm a firm believer in giving as well as receiving help. Hopefully it will save someone a trip to a mechanic.

I used automatic transmission fluid as it is a recommended replacement for 75/80 gear oil.

http://www.wilcodirect.co.uk/index.php?m...ts_id=2099

I know my local parts shop quite well so got 2L for £10

If I do any more jobs, I'll do a write up, jobs to do soon will be rear shoes, brake fluid change, power steering fluid change and coolant change.

---

Can't access the pics. Have you got a clue why? Thanks,

Todays job was changing the gearbox oil on my 2002 2.0HDI van

You will need;

17mm spanner
10/13/19/21mm socket
18" hose pipe
funnel
flat bladed screwdriver
phillips screw driver
receptacle to catch used oil (I used an old 5 litre oil drum with the side cut off)
Plasters, I always cut myself somehow when working on the van.

Ok, jack up the passenger side front of the vehicle and remove the front passenger road wheel then remove the plastic undercarriage guard.

Look into the wheel well you will see a small plastic cover to the left, once removed it will reveal the gearbox, there are four plastic rivets, remove these (mine wouldn't come out so I beat them into submission, I had spares)

one at the bottom;
[Image: 197962_1780582626737_1004576529_31992549_1531876_n.jpg]

two at the top;
[Image: 200450_1780582266728_1004576529_31992548_4993692_n.jpg]

And one hidden at the end of my finger;

[Image: 197316_1780581866718_1004576529_31992547_3424196_n.jpg]

To get to the breather which is where I filled from, you will need to remove the airbox, firstly, remove the five screws holding the top and and remove the filter, next, using a phillips screwdriver, unfasten the large jubilee clip to allow you to remove the top of the airbox;
[Image: 190718_1780581226702_1004576529_31992545_2263811_n.jpg]

Next, the bottom of the airbox is secured by a 10mm nut, remove this and lift off the base of the airbox;
[Image: 200259_1780581026697_1004576529_31992544_4970314_n.jpg]

This will reveal the breather, remove this with a 17mm spanner, it's plastic so is not tight, breather shown on the end of the spanner for clarity;
[Image: 189140_1780580346680_1004576529_31992543_2734993_n.jpg]

Now, back to the wheel well, you will see the level plug removed;
[Image: 198879_1780578146625_1004576529_31992538_7773541_n.jpg]

And here if you squint, at the lowest part of the gearbox, the drain plug;

[Image: 196049_1780578546635_1004576529_31992539_463753_n.jpg]


So, once the oil has been drained, replace the plug and commence replacing the oil, I used a bit of hose taped onto a funnel to make it easier;
[Image: 198599_1780579986671_1004576529_31992542_632356_n.jpg]

Once oil starts to flow from the level plug, replace the plug and put your van back to gether by reading this post backwards

It took me 55 minutes, but that included two cups of coffee, a toilet break, finding some hose and the funnel and 7 trips back and forth from the garage 20 yards away to get the tools I needed, and fielding questions from my 4 year old Grace, what you doing dad, why dad, you're dirty dad, are you coming to play dad, where do babies come from dad.

Whilst the wheel was off I also checked the brake pads, it's only one bolt to remove the calliper on a berlingo.

I hope this is of use to someone, it's a very easy job, now I know what tools I need I could easily do this in 30 minutes.

[steve valentine]

Not sure what's happened to the photos cratch:

Can't remember where I hosted them either illyme:

[jamesg]

Looks like the images were hosted on facebook.

[steve valentine]

Theyve gone! cratch:

[petrolhead]

Opps................