Figure 6.78. 1st and 2nd gear synchronizer (first option): 1 - clutch with gear; 2 - synchronizer hub; 3 - cracker; 4 - spring; 5 - ball
Figure 6.79. 1st and 2nd gear synchronizer (second option): 1 - clutch with gear; 2 - synchronizer hub; 3 - spring; 4 - pin; 5 - cracker; 6 - ball
The Peugeot 206 gearbox is equipped with synchronizers for 1st and 2nd gears of two types (figure 6.78 and 6.79). The design of the synchronizer for 3rd and 4th gears is similar to the design of the second option.
Disassemble the synchronizer in the following order:
- mark the relative position of the coupling 1 (see figure 6.78) and hubs 2 in order to install them in the same position during assembly;
- remove the synchronizer sleeve from the hub and all its parts.
Assemble the synchronizer according to the first option in the following order:
Figure 6.80. Orientation of the synchronizer clutch relative to the hub: A - groove; B - groove
- orient the coupling and synchronizer hub as shown in Figure 6.80: groove A on the hub should be oriented in the same direction as groove B on the coupling, and also orient according to the marks applied during disassembly;
Figure 6.81. Installing the synchronizer clutch and hub: 1 - coupling; 2 - hub; A, B - grooves
- during assembly it is necessary that the groove A of the coupling 1 (figure 6.81) coincided with groove B on hub 2;
- move the coupling relative to the hub;
Figure 6.82. Synchronizer assembly: 1 - hub; 2 - cracker; 3 - spring; 4 - ball; 5 - coupling; 6 - hub
- install crackers 2 in their places in sequence (figure 6.82), springs 3 and balls 4, then move the clutch to the neutral position.
Assemble the synchronizer according to the second option using the device in the following order:
- when assembling, orient the coupling and synchronizer hub as shown in Figure 6.80: groove A on the hub should be oriented in the same direction as groove B on the coupling, and also orient according to the marks applied during disassembly;
- during assembly it is necessary that the groove A of the coupling 1 (see figure 6.81) coincided with groove B on hub 2;
Figure 6.83. Installing the hub into the fixture: 1 - device; 2 - hub; A - groove
- install hub 2 (figure 6.83) into the device so that the groove in the hub coincides with the hole in the device;
Figure 6.84. Installing the spring and pin: 1 - pin; 2 - spring
- install springs 2 in their places (figure 6.84) and pins 1;
Figure 6.85. Installing the cracker: 1 - cracker
- using a screwdriver, press on the pins and insert crackers 1 into the grooves of the hub (figure 6.85);
Figure 6.86. Rotating the fixture: 1 - device
- insert the balls into the holes of the device 1 (figure 6.86), after this, pressing on the balls with a screwdriver, turn the device so that the balls do not jump out;
Figure 6.87. Synchronizer assembly (option 2): 1, 2 - devices; 3 - coupling
- install coupling 3 (figure 6.87) with a serrated surface on the workbench;
- install the assembled device 1 on the coupling, observing the marks made during disassembly;
- insert the synchronizer hub into the coupling 3 by pressing with your hand on the device 2.