I bought a 2017 Citroen E-Berlingo electric van as a non-runner at a disposal auction - see my posting on the "Christmas gift" thread:
It is suffering from a known issue - the splined sleeve that joins the 50kW ( 66 BHP ) 200Nm 9,000rpm electric motor to the single-speed transmission has lost it's teeth at the g'box end, and taken the splines on the transmission input shaft with it.
The end of the sleeve that joins to the motor shaft is still OK:
The motor end of the sleeve is about 25mm deep, the end that mates with the transmission is only 20mm deep.The overall diameter of both shafts is ( or should be ) 28mm, but the transmisson shaft has been abraded down to 25mm. There are 26 splines. The full length of the splined sleeve is 50mm. The outer end of the transmission shaft has ( had ) a circlip to locate the coupling sleeve, and there is ( was ) a rubber O-ring between the sleeve and the outer bearing in the transmisson case. Without the O-ring, the worn sleeve can be seated flush with the bearing face, and pick up enough unworn spline to locate concentrically.
These Mk.2 E-Berlingos ( and the similar Peugeot "E-Partner" ) are rare in the UK, but there is a fair amount of info about them on French and German user forums. Apparently this fault occurs after 20,000 miles - this one has done 21,500. A new improved coupling made of "hardened steel" is available for about £75. A few used transmissions are for sale from UK breakers, from £1,000 to £1,400.
The van was owned by Guildford Borough Council, and MOT'd in August 2023. Just 250 miles later, it broke down. From the noise when trying to drive, it is apparent what has gone wrong. I suppose the owners were discouraged by the cost of the repair - no attempt has been made to fix it, they just scrapped it. Apart from the mechanical fault, this low-mileage van is fine. The electronics and the traction battery are OK, there are no error codes, and it goes into "Ready to Drive" mode. I would welcome any suggestions how to fix this splined coupling issue.
Starting the "what did you get for Christmas" thread early
What did I get for Christmas? Covid, that’s what! My wife went down with it first on the Saturday, the me on Christmas Eve. Crimbo was rather subdued there after.
www.mig-welding.co.uk
It is suffering from a known issue - the splined sleeve that joins the 50kW ( 66 BHP ) 200Nm 9,000rpm electric motor to the single-speed transmission has lost it's teeth at the g'box end, and taken the splines on the transmission input shaft with it.
The end of the sleeve that joins to the motor shaft is still OK:
The motor end of the sleeve is about 25mm deep, the end that mates with the transmission is only 20mm deep.The overall diameter of both shafts is ( or should be ) 28mm, but the transmisson shaft has been abraded down to 25mm. There are 26 splines. The full length of the splined sleeve is 50mm. The outer end of the transmission shaft has ( had ) a circlip to locate the coupling sleeve, and there is ( was ) a rubber O-ring between the sleeve and the outer bearing in the transmisson case. Without the O-ring, the worn sleeve can be seated flush with the bearing face, and pick up enough unworn spline to locate concentrically.
These Mk.2 E-Berlingos ( and the similar Peugeot "E-Partner" ) are rare in the UK, but there is a fair amount of info about them on French and German user forums. Apparently this fault occurs after 20,000 miles - this one has done 21,500. A new improved coupling made of "hardened steel" is available for about £75. A few used transmissions are for sale from UK breakers, from £1,000 to £1,400.
The van was owned by Guildford Borough Council, and MOT'd in August 2023. Just 250 miles later, it broke down. From the noise when trying to drive, it is apparent what has gone wrong. I suppose the owners were discouraged by the cost of the repair - no attempt has been made to fix it, they just scrapped it. Apart from the mechanical fault, this low-mileage van is fine. The electronics and the traction battery are OK, there are no error codes, and it goes into "Ready to Drive" mode. I would welcome any suggestions how to fix this splined coupling issue.