The solution.
It took me ages to fix the gearbox but I wanted to have all things sorted out.
It's not something I want to do twice.
I took my gearbox from the 1.6 (1981) apart.
Synchro 2e and 2e gear together.
It is warned out as we saw before.
New synchro on the old gear.
Ther is only 0.6 mm between synchro and gear so a problem to reuse.
Ater spitting out all documentation from Citroen CX1 and CX2 I found out that you can use the second gear wheel from this cars but need to be later then 1980 construction date.
To get a better gearwheel I made use of a old friend, Leontien at
http://www.hydraulique.nl/She is a lovely specialist on Citroen.
She looked up some gears and syncro's from the spare parts room.
Here you see 2 Murena gears left and 1 CX gear on the right.
0.95mm with the new synchro.
It is pretty clear the CX-gear is the better one but would it fit the Murena box?
I desided to use this gear in the box and replace top primary bearing and seals.
I mounted the 2nd gear on the axle.
Because of the new gear a little to much play was here.
It has to be no higher then 0.05mm but it was almost 0.1 mm.
I ordered new rings at Simon and he has them in several sizes as pointed out in the doc.
Now it is OK.
Seal at the primary. (21.9x47x8/6.3 mm) odd Americain size so I used standard 22x47x8.
Also in the differential 2 pieces (35x50x7)
New primary bearing.
Another warned out part.
The fork of the 2nd gear.
I used one from a 2.2 gearbox and it fitted OK.
Mounted all parts with new seals.
Replaced this for better one and mounted the modification seals and rubber.
Feels very tight and good.
Ready to build in.
Test movie.
http://www.youtube.com/watch?v=_ZR_YGUX7UU&feature=em-upload_ownerMounting the box in the car.
Everything ready to mount including new clutch set and new axles.
The car runs very well with the CX gear and silent bearings.
But now the clue.
What went wrong with the gears you may ask.
Some info came from a fellow member of the club that bought a new 2.2 1982 Murena in Brussel.
After a few months he received a letter (NB:it is in my posession now) where he was asked to bring the car in for a new gearbox.
There was no problem with the car but the car was in warranty and as he was a good friend of the car-dealer he was one of the few that had the problem sorted out.
After the year warranty most owners could shake it.
Harry Martens from Limmen is a specialist in CX Gearboxes provided me some info.
It seems that CX gearboxes produced before 1980 had gears and synchro's with a different angle on the synchro part.
This is what Roy also pointed out.
It is logical that this gears and syncro's can't be mixed up.
That is exactly what happened.
A second problem is that Peugeot synchro-rings have the same ordering number for old and new synchro.
You can recognise the old type rings.
The old type ring has the 3 dips in the ring (white marks) and are produced before 1980.
The solution is to find newer gears from CX (after 1980) and use the newer type synchro.
If you have the newer set and not enough space between synchro and gear, you can machine a bit of from the ring to make it work again.
(This tip came from Harry Martens himself)
Didn't try that yet, but have some gearboxes around here with the same problems to play with.
I hope this clears things out.
Best regards Herman