Replacing the BE4R gearbox housing (Peugeot 307)

To remove the gearbox housing:

- remove the gearbox;

Caution! When disassembling and repairing the gearbox, observe the following requirements:

• - Do not use abrasives or tools that leave scratches on the mating surfaces;
• - clean the threaded surfaces of bolts and holes from dirt;
• - When assembling, install clean parts that are free of defects (cracks, burrs, impact marks);
• - lubricate parts as they are installed.

When installing, use only new parts of the following:

• - gaskets;
• - cotter pins;
• - bearings;
• - shaft tightening nuts;
• - differential housing tightening bolts;
• - thrust sleeve of 5th gear;
• - lock washer of the primary shaft nut.

When installing, ensure that the following parts are in pairs:

• - clutch housings, gearbox and differential;
• - lever and shift axis;
• - forks and axles;
• - hubs and synchronizers.

• unscrew bolts 1 (figure 5.33) and remove the rear cover from the gearbox housing;

• engage 5th gear and remove cotter pin 1 (figure 5.27), shift fork retainer;
• set the gearbox to neutral position, while the 5th gear engagement fork should remain in place. Engage any other gear to lock the gearbox shafts;
• remove retaining ring 4;
• unscrew and remove the 5th gear mounting nuts;

Original publication on the website: PeugeotBook.ru

• using puller 0317-Y 1 (figure 5.28) remove the 5th gear hub;

• use a marker or paint to mark the position of the synchronizer hub 1 (figure 5.29) in relation to synchronizer 2;
• remove the synchronizer hub 1, synchronizer 2 and 5th gear engagement fork 3 as a whole;

• remove the 5th gear pinion 1 (figure 5.30), pressure ring 2 and spacer 3;

• unscrew the locking bolts 3 (figure 5.31) secondary shaft bearing mounts;
• unscrew bolt 4 securing the reverse gear axle;
• remove the locking plate 2 from the fork shaft;
• unscrew the bolts 1 securing the gearbox housing;

• using special pliers or two pointed rods, remove ring 1 (figure 5.32) bearing fixation. To facilitate removal of the ring, lift the gearbox shaft;
• remove the gearbox housing. If necessary, use a wooden hammer to loosen the crankcase from the centering bushings.

To install the gearbox housing:

• apply E15 sealant to the mating surface of the clutch housing;
• install the gearbox housing;
• check that the oil supply chute is 5 (see Figure 5.27) aligned with the gearbox housing hole;
• screw in bolts 1 (see Figure 5.31) gearbox housing mounts and tighten them to a torque of 12.5 N·m;
• screw in bolt 4 of the reverse gear pinion axle and tighten it to a torque of 20 N·m;
• install the locking plate 2 of the fork axle so that the flat part of the plate is located in the groove of the axle;
• install ring 1 (see Figure 5.32) into the bearing groove;
• screw in bolts 3 (see Figure 5.31) secondary shaft bearing fasteners and tighten them to a torque of 15 Nm;
• install spacer 3 (see Figure 5.30) so that the protrusion is located on the bearing side;
• install thrust sleeve 2 and 5th gear drive gear 1;
• install the 5th gear pinion together with the synchronizer;
• simultaneously engage 3rd or 4th and 5th gears to lock the gearbox shafts;
• unscrew the gearbox input shaft mounting nut. Apply E6 locking compound to the nut threads to prevent them from loosening;
• tighten the secondary shaft nut to a torque of 65 Nm and lock it by bending the metal plates so that they fit into the splined grooves of the shaft;
• remove the 5th gear drive gear together with the synchronizer;
• set the 5th gear shift fork to the correct position;
• reinstall the 5th gear pinion together with the synchronizer and fork. When installing, align the previously applied marks;
• install the locking ball and press it into the socket, pushing the clutch with the synchronizer;
• simultaneously engage 3rd or 4th and 5th gears to lock the gearbox shafts;
• apply E6 locking compound to the threaded portion of the input shaft;
• screw on nut 3 (see Figure 5.27) onto the input shaft, tighten it to 72.5 Nm and lock it;
• install a new cotter pin 1 holding the gear shift fork;
• apply E15 sealant to the mating surface of the rear crankcase;
• screw in plug 2 without tightening (see Figure 5.33) checking the oil level, which also involves centering the crankcases;
• install the rear crankcase cover and secure it with bolts 1, tightening them to a torque of 12.5 Nm;
• tighten the level check plug to 10 Nm;
• install the gearbox.