Removal and installation the intermediate housing of the MA gearbox (Peugeot 206)

When removing and installing the intermediate gearbox housing at Peugeot service centers, the following special tool is used:

• three-jaw puller - Facom U20;
• sleeve for tightening the secondary shaft nut.

Remove the intermediate gearbox housing in the following order:

• remove stamped cover 1 (figure 6.45);

• knock out the pin securing the 5th gear fork with the rod (figure 6.46);

• secure the secondary shaft from turning by selecting the lever and engaging reverse gear, then 5th gear by pressing the 5th gear engagement fork (figure 6.47);

• unscrew the special nut 2 (figure 6.48) secondary shaft using device 1;

Note: The gearbox design may be available with a standard hex nut without a lock washer.

• remove spring washer 2 (figure 6.49) and support washer 3;
• remove the 5th gear synchronizer clutch 4 together with the 5th gear engagement fork 5;

• using puller 1 (figure 6.50) press the synchronizer hub together with the 5th gear;

• remove retaining ring 6 from the primary shaft (figure 6.51) with spring washer 5;
• remove needle bearing 1, bushing 2 and washer 3 from the secondary shaft;
• press the 4th gear from the primary shaft using a puller;

• unscrew bolts 2 (figure 6.52) fastenings of locking plates 1 of bearings and remove them;

• unscrew the intermediate case mounting bolts 1 (figure 6.53) to the clutch housing with differential;
• remove the intermediate crankcase.

Install the intermediate gearbox housing in the following order:

• lubricate the mating surface of the gearbox housing with a thin layer of E15;

• install the sealing ring 1 in place (figure 6.54) gear shift shaft and set the clutch release lever 3 to the correct position;
• install intermediate crankcase 2;

Note: Install the crankcase mounting bolts with the guide belt according to the markings.

• install the crankcase mounting bolts and tighten them to 17.5 Nm;
• clean the threaded holes in the crankcase with a tap;
• install locking plates 1 (see figure 6.52) bearings with chamfer facing up;
• install new bolts 2 in place, having previously applied grease to them;
• tighten the bolts to 17.5 Nm;

• install end A (figure 6.55) primary shaft on the stop on the press table;

• press on pinion gear 2 (figure 6.56) fifth gear to the primary shaft;
• install a new spring washer 5 (see figure 6.51) on the primary shaft;
• install a new retaining ring 6 using the tool;

• install washer 2 on the secondary shaft (figure 6.57), bushing 1, needle bearing 3;
• install the 4th gear of the fifth gear with the 5th synchronizer ring on the needle bearing;

• install fork 2 (figure 6.58) together with the synchronizer 3 fifth gear in its place;

Caution! Insert the protrusions D of the sleeve into the grooves C of the synchronizer.

• replace nut 1 with friction washer and slotted nut supplied in spare parts;
• replace the thrust washer 4 if it does not have a slot B;

Caution! Position the projection A of the washer opposite the slot B of the support washer. Install nut 1 so that chamfer E is directed towards spring washer 5.

• secure the secondary shaft from turning by selecting the lever and engaging reverse gear, then 5th gear by pressing the 5th gear engagement fork (see figure 6.47);
• tighten the secondary shaft nut to 137.5 N·m, loosen slightly if necessary to align the washer protrusion and the nut notch;
• set the gear shift lever to neutral position;
• lock nut 1 (see figure 6.58) with the projection A of the washer 5 so that it enters the recess of the nut;
• secure the 5th gear shift fork by installing a new pin (see figure 6.46);
• install stamped cover 1 (see figure 6.45) with a new gasket;

Caution: Do not lubricate the gasket.

• tighten the cover mounting bolts to a torque of 23 Nm.