the gearbox woes continue to be an issue
General Motors PK5, PK6, PF1, PF6 manual transmission failure common in Vivaro, Movano, Traffic, and Primastar. The 'built-in' fault, which will result in failure, irrespective of how the vehicle is driven or serviced, is that the gearboxes are assembled in such a way that the preload on the bearings is massively over-torqued, which results in bearing failure, and the total destruction of the box from as low as 20k upwards. In some cases the boxes are built up so tight that it makes turning the box over by hand virtually impossible. Once the bearings are replaced, and shimmed correctly, the box will “go on” virtually indefinitely.
Recall 04-04-2003: Possible detachment of brake pedal linage retaining clip.
Recall 15-12-2008: Possible failure of parking brake as cable connector may fracture.
Recall 12-11-2009: Seat may become insecure on second and third row seats if fitted.
Recall 22-07-2010: Steering may fail due to welds on left front suspension turret not being to specification.
Recall 01-03-2011: Handbrake may fail as cable end-piece crimping may become detached.
Recall 07-09-2012: Seatbelt buckle may fail and separate from connector on double-cab models.
There was a report on BBC Watchdog that some 2006 - 2010 Renault Trafic, Vauxhall Vivaro and Nissan Primastar vans fitted with the 2.0 dCi M9R diesel engine were suffering from rainwater dripping from a failed bonnet seal at the base of the windscreen into the valley on the top of the engine containing the injectors. On a van left for long period unused, or used primarily for short runs, this water is not evaporatred off by the heat of the engine and causes corrosion between the injectors and the cylinder head, fusing the injectors to the head (very similar to the notorious problem with Ford Focus 1.6 petrol engines). There is now a new piece of kit that can extract corrosion fused injectors from diesel engines. The current Vauxhall Technical Service Bulletin (published in August 2013) covering injector corrosion states that Vauxhall will make a 100% goodwill contribution to replace the injectors on vehicles up to 7 years old and 248,000 miles. The first Technical Service Bulletin pertaining to this issue (published in June 2010 and effective up to August 2013) stated that vehicles within warranty would be repaired under the conditions of the warranty. Vehicles up to 4 years old/100,000 miles would be repaired with a goodwill contribution of 70% from Vauxhall. Vehicles up to 5 years old/100,000 miles would be repaired with a 50% goodwill contribution from Vauxhall.