Disassembly and assembly of the secondary shaft of the MA gearbox (Peugeot 206)

When disassembling and assembling the secondary shaft, Peugeot service centers use the following special tool:

• universal puller Facom U53T;
• device for installing the secondary shaft bearing from the 4th gear side - 0317-B, 7.101T-B;
• retaining ring remover — 0317-P, 4508T-V;
• intermediate washer remover — 0317-Q, 4508T-U;
• device for installing the secondary shaft bearing from the 1st gear side — 0317-E, 7.101T-E;
• device for installing secondary shaft retaining rings 0317-R, 4508-T.T.

Disassemble the secondary shaft in the following order:

• disassemble the gearbox as described above and remove the primary, secondary shafts and differential;

• press bearing 1 (figure 6.72) from the secondary shaft using the device shown in the figure;

• remove washer 1 (figure 6.73) from the secondary shaft;
• remove the 4th gear;
• remove synchronizer 4 of third and fourth gears together with rings 3 and 5;

Attention! It is forbidden to disassemble the synchronizer, as in this case the balls and springs may fall out.

• remove retaining ring 1 (figure 6.74) using a device;

(Article republished from the website: peugeotbook)

• remove driven gear 1 (figure 6.75) 3rd gear;
• remove retaining ring 2;
• remove the driven gear 3 of the second gear;
• remove synchronizer 5 of first and second gears together with rings 4 and 6;
• remove retaining ring 7;
• remove the 1st gear driven gear;
• remove retaining ring 9;
• remove tip 11 for lubrication;

Attention! It is forbidden to disassemble the synchronizer, as in this case the balls and springs may fall out.

• press bearing 1 (figure 6.76).

Assemble the secondary shaft in the following order:

Caution! Removed bearings must be replaced each time. Check the teeth of the gears installed on the secondary shaft and the bearing surfaces of the shaft.

• press in new bearing 1 (see figure 6.76) on the secondary shaft;
• install a new retaining ring 9 (see fig 6.75) and a new plastic tip 11 for lubrication;
• install driven gear 8;
• install a new retaining ring 7;
• assemble the 1st and 2nd gear synchronizer with rings 4 and 6 so that the synchronizer crackers fit into the grooves of the rings, then install the synchronizer assembly on the secondary shaft;
• install driven gear 3 2nd gear;
• install new retaining ring 2;
• install driven gear 1 3rd gear;
• assemble synchronizer 4 (see figure 6.73) 3rd and 4th gears with rings 3 and 5 so that the synchronizer crackers enter the grooves of the rings, then install the synchronizer assembly on the secondary shaft;
• install driven gear 2 4th gear;
• install washer 1;

• press in new bearing 1 (figure 6.77) onto the secondary shaft with groove A facing upwards.

Caution: When pressing the bearing, do not rest against the grease nipple.