Table of contents: Removal 🠇 Installation 🠇
Gearbox housing unit
1 – clutch housing, 2 – gearbox housing, 3 – rear cover (5th gear unit housing), 4 – differential outer housing, 5 – bearing housing, differential extension, 6 – speedometer drive unit housing, 7 – sealing ring, 8 – oil drain bolt, 9 – oil filler and oil level control bolt, 10 – reversing light switch, 11 – deaerator
Removal
1. Raise the hood and place it in a vertical position.
2. Remove the battery and bracket.
3. Remove the air filter assembly.
4. If equipped, remove the power steering pump without disconnecting the hoses. Remove the power steering pump hanger.
5. Disconnect from gearbox:
- clutch cable;
- braided ground wire;
- reverse light switch wires.
6. Remove the starter.
7. On early model cars, disconnect the reverse gear lock cable from the gearbox by unscrewing the plastic nut and removing the plunger.
8. On XU10J4 models (with 16 valves), unscrew the bolts securing the throttle body and the suspension of the power steering pipe. Also unscrew the suspension mounting stand from the gearbox.
9. Raise the front of the vehicle and place it on stands.
10. Remove the mudguard from the engine.
11. Remove the front wheels and plastic gearbox cover.
12. Unscrew the bolts securing the anti-roll bar links to the lower arms of the front suspension.
13. Using a special ball joint puller, remove the lower ball joints from the steering knuckles.
14. On XU10J4 models (with 16 valves) support the lower frame with a jack, then unscrew the lower frame mounting bolts and the steering gear bolts. Lower the lower frame and remove it from under the car.
15. Drain the oil from the gearbox by unscrewing the bolt located at the bottom of the outer differential housing.
16. Unscrew the central mounting bolt from the rear suspension of the power unit. Loosen the nuts securing the bearing of the intermediate bearing housing and turn the bolts half a turn to release the eccentric heads and separate the right drive shaft from the gearbox.
17. Using a screwdriver, remove the rods from the ball joints of the gear shift lever.
18. Separate the left drive shaft from the gearbox.
19. Disconnect:
- the exhaust inlet pipe from the manifold;
- tDC sensor from the engine cylinder block.
[Original is located at: www.peugeotbook.ru]
20. Unscrew the bolt and remove the speedometer drive together with the circular gasket.
21. Unscrew the bolts and remove the speedometer drive housing.
22. Remove the speedometer drive pinion and adjusting shims.
23. Remove the bracket connecting the gearbox to the body.
24. Attach the winch to the engine and lift it up so that the weight of the engine and gearbox is supported by the winch.
25. Unscrew the nut from the left front suspension, then unscrew the bolt from the suspension to the body.
26. In the place where the suspension is welded to the body, unscrew and remove the rubber cushion.
27. Remove the protective tube (if available) from the mounting stand, then unscrew the stand from the top of the gearbox housing.
28. If the rack does not unscrew, you will need to use a universal stud remover.
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29. On XU10J4 models (with 16 valves) with the clutch release mechanism with the ball end remove the pin (drawing on the left) or unscrew the bolt and remove the clutch release lever from the top of the clutch release fork shaft (drawing on the right).
30. Apply alignment marks (indicated by arrows) in the center of the top of the clutch release shaft and on the gearbox housing. Unscrew the bolts and remove the clutch cable hanger from the top of the gearbox housing.
31. Lower the engine as much as possible without damaging the right engine mount.
32. Support the gearbox with a jack.
33. Unscrew the bolts securing the gearbox to the engine.
34. Move the jack and transmission to the left, remove it from the guide pins and rotate it with the differential facing up to disconnect the transmission from the lower frame.
35. Lower the gearbox and remove it from under the vehicle.
36. On models with a ball-type release mechanism, make a second alignment mark on the transmission housing, noting the relative position of the release fork mark after removal and noting the angle the release fork has rotated. This mark is used to position the release fork before reinstallation to ensure proper engagement with the release bearing.
Installation
1. Installation is carried out in the reverse order of removal, taking into account the following points.
2. Lubricate the input shaft splines, release bearing guide sleeve, clutch release lever ends, and clutch release lever ball joint with a thin layer of Molykote BFF2 plus grease.
3. Make sure the guide pins are in place before installing the transmission.
4. On models with a ball-type release mechanism, install the release bearing with the mark facing up and align the mark on the fork shaft with the second mark made on the transmission housing.
5. Before screwing in the rack, apply a product to the threads to prevent loosening.
6. Replace the drive shaft seals and install the drive shafts.
7. Fill the gearbox with oil.
8. Replace the self-locking nuts.