Car manual transmission Peugeot 207

General information about transmission
Since the beginning of production, Peugeot 207 cars have been equipped with five-speed manual transmissions BE4/5 and five-speed hydromechanical transmissions MA5. In addition, a four-speed automatic transmission AL4 is...

Gearbox BE4/5
The marking area (A) contains the unit label and factory serial number. Lubricants Oil type: ESSO 75W80 EZL 848 or 1OTAL 75W80 N 6965. Lubrication system capacity: 1.9 l. Oil change is not required throughout the entire...

Gearbox MA5
Identification of KP MA5: a - place for engraving the factory number and brand of the gearbox; b - identification plate. Lubricants Oil type: ESSO 75W80 EZL 848 or TOTAL 75W80 N 6965. Lubrication system capacity: 2 l....

Diagnostics of mechanical elements of manual transmission
Noise Oil leak Difficulty or inability to shift gears Gear Jumping

Gearbox control mechanism
Note. On the BE4/5 gearbox, the gear shift cable is not adjustable. The gear selector drive cable can be adjusted. Gearbox control drive 1 - gear shift tip: diameter 10 mm. 2 - gear shift control cable. 3 - gear shift...

Adjusting the gearbox control mechanism
Adjustment device: 1 - device for removing ball joint retainers with a diameter of 10 mm 0216-G1; 2 - device for locking the lever in neutral position 0216-M. Remove the air filter (if necessary). Remove one or more...

Adjusting the gear selection drive cable of the BE4/5 gearbox
Caution: Poor adjustment may result in difficult gear shifting. Remove the center console (see the corresponding operation). Place the gear shift lever in neutral position. Loosen the gear shift joint (2). Perform the...

Removal and installation the gear shift drive
Removal Disconnect the battery. Remove the air supply pipe. Using tool [1], disconnect the two ball joints (1). Unscrew the casing stoppers (in zone "a"). Remove the center console (see the corresponding operation)....

Draining and filling oil in manual gearboxes MA5 and BE4/5
Oil change To change the oil, unscrew the plug (1). Lubrication system capacity: dry gearbox - 1.9 l; when changing oil - 1.8 liters. Note: The gearbox is lubricated for the entire service life. Perform a visual...

Removal and installation of manual transmission MA5 and BE4/5
Note: The gearbox is removed through the top of the vehicle. Removal Place the car on a lift. Raise and secure it. Remove: protection under the engine; front wheels; CV joints. Remove: air intake hoses (1), (2);...

Disassembling MA5 and BE4/5 manual transmissions
Remove the reverse gear contactor (1). Remove: air breather (2); drain plug (5); Special devices for disassembling the gearbox: 1a - bracket of the universal puller "Facom U53 K2"; 1b - universal puller breaking devices...

Disassembling the clutch housing of the MA5 and BE4/5 manual transmissions
Note: Some BE 4/5 gearboxes are equipped with a 5th/reverse gear inhibit mechanism. System composition: 39 - locking finger; 40 - the locking pin support is secured with two screws in the gearbox housing. Attention. The...

Features of repair of gearboxes with and without a system for prohibiting the inclusion of 5th gear/reverse gear
Gearbox with 5th gear/reverse gear inhibition system Place the grip of the device 5 on the recess of the finger (39). Fix the grips in zone "c" of device 5 on the finger groove (39). Install device 5, observing assembly...

Disassembling the primary shaft of the MA5 and BE4/5 manual transmissions
Secure the end of the shaft by screwing on the nut (11) using the press attachment 1b. Rest against the 3rd gear pinion (60) and remove the rear bearing (59). Note: The flat side "e" of the 1b tool must face the gear so...

Disassembling the secondary shaft of the MA5 and BE4/5 manual transmissions
The 3rd and 4th gear driven gear block is not removed from the secondary shaft (induction heating assembly). Press against the 4th gear pinion (o7) to remove the 5th gear driven pinion (65) and bearing (66) using tool...

Disassembling the differential housing of the MA5 and BE4/5 manual transmissions
Remove the bearings using tools 1a, 1b and 4. Remove: locking pin (80) of the satellite axle (79); satellite axis (79); satellites (78); thrust washers (77); planetary gears (76), on the side opposite the ring gear;...

Assembly of differential manual transmission MA5 and BE4/5
Install the bearing using tool 1. Install: satellite axis (5); satellites (4) and their support washers (3), rotating them; planetary gears (2); centering ring (1), on the side opposite the toothed rim; axle fixing keys...

Adjustment of the console part of the MA5 and BE4/5 manual transmission
"X" is the shoulder of the console part. Measure the size of "X". First installation Shoulder of console part "X": 10 mm. Install: speedometer drive worm(18); console part (16) with seal (17) (new). Tighten: bolts (15)...

Assembly of the secondary shaft of the MA5 and BE4/5 manual transmissions
Replace bearings, snap rings and nuts regularly. Use clean parts that are free from defects. Check the condition of the shaft supports; no impact marks or scratches are allowed! Be sure to lubricate the parts during...

Assembly of the primary shaft of the MA5 and BE4/5 manual transmissions
Install the front bearing (30) using tools 5 and 7b and a press. Note: The flat side "a" of the 7b tool must face the gear so as not to rest against the teeth. Install: 3rd gear drive pinion (34); synchronizer clutch...

Installation of primary and secondary shafts of manual transmissions MA5 and BE4/5
Install the stop guide. Connect the primary shaft (39) and secondary shaft (42) using the 1/2 gear fork. Place the gears in the crankcase. Install the 3/4th gear fork (44). Caution: Install the fork (44) onto the...

Assembly of the clutch housing of the MA5 and BE4/5 manual transmission
Replace gaskets and pins periodically. Install: tighten the gear selection spring support (52) with two bolts to a torque of 15 Nm; seal (53) (new); cassette assembly (51); gear engagement axis. (54).

Features of gearbox assembly with and without a 5th gear/reverse gear interlock system
Gearbox with 5th gear/reverse gear inhibition system Attention: Follow the specified sequence. Remove the threaded pin in area "c". Install the cotter pin (55) and fixture 12. Tighten the four screws "d" to a torque of...

Installing the gearbox housing
Apply E15 sealant to the joint plane of the clutch housing. Install the gearbox housing. Caution: Check for the presence of the oil bushing in the hole "e" of the gearbox housing. Tighten the bolts (71) to 125 Nm....

Gearbox assembly
Install the right drive shaft oil seal (84) (new) using tool 13. Install the left drive shaft seal (85) (new) using tool 14. Install: support of the speed sensor drive gear (87); gearbox drain plug (88), tighten to 35...

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