Removal the BE4/5 gearbox (Peugeot 206)

The gearbox is marked in the area shown in Figure 6.21. The unit marking and factory serial number are indicated.

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

• ball joint removal tools - 0216G1, 0126G2;
• mandrels for installing axle shaft flange seals — 0317U, 0317T;
• gearbox suspension axle removal tool — 0317 AB;
• cross member for holding the power unit;
• mandrel for centering the driven clutch disc.

[Information copied from the resource: PEUGEOTBOOK]

Remove the gearbox in the following order:

• remove the air filter with air supply pipes;
• remove the battery;
• remove the battery tray;
• remove the left mudguard;
• disconnect, release from fasteners and move aside the wiring harnesses connected to the gearbox;

• remove sensor 1 (figure 6.22) engine crankshaft speed;
• unscrew the three bolts securing the starter and move it to the side without disconnecting the wires;

• disconnect rod 1 (figure 6.23) gear shifting with a device;
• disconnect the drive lever 3 using the device;
• disconnect the jet thrust 2 using the device;

• install the crossbar as shown in Figure 6.24;

Attention! Install the stops in places A (see figure 6.24).

• unscrew bolts 1 (figure 6.25) battery support mounts;
• remove support 10 of the battery;
• unscrew nut 9 of the gearbox support axle with washer;
• unscrew the 8 bolts securing the cushion;
• remove the gearbox support rubber cushion;
• unscrew bolts 6;
• remove the 3rd axle bracket of the gearbox support;
• remove spacer 5;
• remove axle 4 of the gearbox support with the washer using a tool;

Cable clutch drive

• move tip 1 (see figure 6.5) and bushing 2 supports 3 cables;
• remove bushing 4 from clutch release fork;

Clutch hydraulic drive

• disconnect slave cylinder 1 (figure 6.26) clutch drive from the crankcase without disconnecting from the hose;

All drives

• - remove the front wheels;
• remove the front wheel drive shafts;

• unscrew bolts 1 and 3 (figure 6.27) and remove the powertrain swing limiter;

• unscrew bolt 2 (figure 6.28) speedometer drive gear supports and remove gear 6 from the crankcase;
• unscrew bolts 4 and remove the differential extension;
• remove sealing ring 1;

• unscrew the lower bolts 1 (figure 6.29) gearbox mounts;
• lower the power unit slightly using the crossbar (see figure 6.24);
• hook the lifting cables to the gearbox;

• unscrew the top bolts 1 (figure 6.30) fasten the gearbox housing to the engine and remove the gearbox;

• remove bearing 1 (figure 6.31) clutch release and fork 2.