Installation of gearbox BE4/5 (Peugeot 206)

Install the gearbox in the following order:

replace with new axle shaft flange seals, extension sleeve, self-locking nuts and lock washers;
check the technical condition of the fork ball joint insert;

Figure 6.32. Clutch release fork: 1 - clutch release bearing; 2 - protrusions; 3 - fork support; A - lubrication points

lubricate the ends of the fork in places A with a thin layer of MOLYKOTE BR2 PLUS grease (figure 6.32);
install the clutch release bearing so that its protrusions 2 enter the fork tips;
lubricate the clutch release bearing guide bush with a thin layer of MOLYKOTE BR2 PLUS grease;

Caution: Do not lubricate the gearbox input shaft splines.

Caution: Make sure the pins are present to install the gearbox. Be careful not to pinch the wiring harnesses when installing the gearbox.

fill the space between the edges of the seals with grease;
connect the gearbox to the engine;
reinstall the top bolts 1 (see figure 6.30) and tighten them to a torque of 55 Nm;
clean the threads of the axis 4 (see figure 6.25) and lubricate it;
install the axle with the washer in place;
tighten the axle to 50 Nm;
install spacer 5;
install bracket 3;
tighten bolts 6 to 60 Nm;
install rubber cushion 7 of gearbox support;
"tighten" nut 9 and bolts 8 of the cushion;
center the position of the power unit before final tightening of the support cushion fastening elements;
tighten bolts 8 to 30 Nm and nut 9 to 65 Nm;
install support 10 of the battery and tighten bolts 1 to a torque of 20 N·m;

Cable clutch drive

install bushing 4 (see figure 6.5) on the clutch release fork;
lubricate the flange of the bushing 2 and the cylindrical end of the tip 1 of the cable sheath with consistent grease;
insert bushing 2 into support 3 of the cable and then tip 1 of the sheath into the bushing;
install the coupling into the retainer at location A;

install slave cylinder 1 in place (see figure 6.26) clutch and tighten the mounting bolts to 20 Nm;

tighten the lower bolts 1 (see figure 6.29) fastening the gearbox to the engine with a torque of 55 Nm;
install sealing ring 1 (see figure 6.28);
install gear 6 of the speedometer drive;
install extension 5 and tighten bolts 4 to a torque of 15 Nm;
install support 3 of the speedometer drive gear and tighten bolt 2;
set limiter 2 (see figure 6.27) rocking the power unit and tighten bolt 3 to a torque of 35 N·m and bolt 1 to a torque of 50 N·m;
complete the installation of the gearbox in the reverse order of removal;
fill the gearbox with fresh oil of the recommended brand and check the level;
adjust the clutch drive.