Selector shaft installation
1 – axis
2 – spacer element
1. Replace the outer race of the primary shaft tapered bearing. Use tool 8.0317 A for removal and tools 8.0317 A and E for installation.
2. Check the condition of the plastic element (indicated by the arrow) supply oil to the secondary shaft, and then install the selector pin.
3. Install the differential in the outer housing, lubricate the cover surfaces with the product "Loctite Formetanch". Secure the lid.
4. Install the sealing ring (fixture 8.0317 G).
5. Measure the differential bearing tension (if necessary). Install gasket 8.0317 L (2.2 mm thick), and then the bearing housing without the speedometer drive link and without the round sealing ring. Gradually tighten the bolts to the required torque, turning the differential all the time, and then unscrew and remove the bearing housing.
6. Remove gasket 8.0317 L and measure the distance between the outer bearing ring and the mating surface of the differential outer housing (a depth gauge should be used).
7. Measure the bearing housing seat height.
8. Find the difference between the two measured values. To find the thickness of the gasket that should be installed to ensure the required bearing tension, add 0.1 mm to the value found.
9. Install the speedometer drive unit on the bearing housing, insert the round sealing ring and secure the bearing housing to the outer differential housing. Tighten the bolts to the required torque.
10. Install the sealing ring in the bearing housing.
11. Install the release bearing guide sleeve and bearing outer race.
12. Install the rear gear frame (if it was removed).
13. Prepare the selector shaft: using tool 0317 C, compress the spring together with its two plastic cups, align the selector pin and the locking clamp (tube with a diameter of 13 mm and a length of 34.5 mm).
14. Insert the selector shaft, remove the spring compressor, install the pins.
15. Install the intermediate connector for the selector shaft lever, the O-ring, the remaining components, as well as the connector, gasket and nut.
16. Install the special selector shaft seal (fixture 8.0317 B), and then the axle plug.
[Text taken from the website: PEUGEOTBOOK]
17. Place a magnetized plate in the crankcase and install the crankcase. Lubricate the surface with "Loctite Formetanch".
18. Assemble the primary and secondary shafts with the forks and their axles and install everything together in the crankcase.
19. Install the axle and the reverse gear pinion. The axle pinion should be positioned properly and the bevel of the gear teeth should be facing upwards (to facilitate installation of the gear, the rear gear frame should be raised).
Attention! Screw in the rear gear axle mounting bolt (tightening torque – 20 Nm).
20. Install the fixed axle retaining latch, secondary shaft bearing spring ring. Raise the entire unit to facilitate installation. Tighten the two bearing retaining bolts to 15 Nm.
21. Install the 5th gear of the secondary shaft; the flange must be on the bearing side.
22. Install the thrust ring of the outer ring of the clutch shaft bearing. Pay attention to the correct installation.
23. Install the 5th gear sleeve, then the 5th gear and the sliding sleeve together with the hub.
24. Engage two gears, tighten the secondary shaft nut (50 Nm) and secure it from unscrewing.
25. Remove the 5th gear shift sleeve, insert the forks, and then secure it all with the ball and locking spring.
26. Engage two gears again and tighten the input shaft nut (50 Nm), then secure it from unscrewing.
27. Disengage 5th gear and then secure the pin.
28. Lubricate with the product "Loctite Formetanch" and install the 5th gear unit cover.