Removal
1. Disconnect the negative battery terminal.
2. Raise the front of the car and secure it on stands. Remove the front wheels and wheel arch guards.
3. Drain the oil from the gearbox, tighten the drain and filler plugs to the required torque.
4. Remove both drive shafts.
5. Under the vehicle, unscrew the bolts securing the intermediate drive shaft bearing housing to the engine mount and lower frame. Move the mount to the side.
6. Remove the air filter housing and intake pipe system.
7. Remove the clutch slave cylinder by pressing it inwards and turning it 90° counterclockwise in this position. Remove the slave cylinder together with the pushrod.
8. Using a rubber band, secure the pushrod to the cylinder. Support the clutch pedal with a wooden block.
9. Using a lever, remove the two ball joints of the cable from the selector levers on the gearbox. Remove the cable from the mounting brackets on the gearbox.
10. Disconnect electrical connectors from the transmission, such as the reverse light switch, speedometer sensor and ground bus (the arrow indicates the location of the ground bus connection). Unscrew the bolt and remove the TDC sensor from the top of the transmission.
11. Unscrew the starter mounting bolts and move the starter to the side without disconnecting the wires from it.
12. Remove the turbocharger air intake pipe located between the oil pan and the transmission.
13. Unscrew the mounting bolts and remove the flywheel protective plate.
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14. Unscrew the mounting bolts (indicated by arrows in the photo on the left) power steering pipes. The arrow in the photo on the right shows the location of the bolt on the housing.
15. Remove the front suspension lower frame.
16. Use the winch to lift the left side of the power unit so that the weight of the power unit is supported by the winch.
17. Place a jack under the gearbox and raise it enough so that the weight of the gearbox is supported by the jack.
18. Unscrew the central nut (indicated by the arrow) from the left suspension of the power unit installation. Unscrew the bolts and remove the rubber suspension cushion. Unscrew the bolts and remove the suspension.
19. Lower the jack slightly so that it still supports the gearbox and unscrew the bolts securing the gearbox to the engine block.
20. Lower the engine and jack, move the transmission to the left and remove it from the guide pins. Lower the jack supporting the transmission and remove the transmission from under the car.
Preparing for gearbox installation
Peugeot 0216E special tool for connecting the release bearing to the pressure plate
1. Remove the release bearing from the clutch pressure plate and reinstall it on the transmission before reinstalling the transmission. This will ensure that the release bearing is correctly installed on the pressure plate using the special tool.
2. The special Peugeot 0216E tool for installing the release bearing in place consists of a T-handle, a universal joint and a special tip. The tool is inserted through the hole for the slave cylinder in the gearbox housing so that the working part of the tool enters the groove of the release fork. When the tool is turned 90°, the working end closes the ends of the locks in the grooves of the release fork. Pulling the tool rotates the release fork and installs the release bearing in the lock of the pressure plate.
3. Remove the clutch assembly.
4. Using a screwdriver, remove the release bearing by pressing the compression ring (1) off the inside of the pressure plate diaphragm spring.
5. Remove the release bearing from the pressure plate, then install the compression ring (1) into the groove of the release bearing housing (2).
6. Install the clutch assembly.
7. Install the release bearing onto the transmission input shaft and connect it to the clutch release fork. Check that the clutch release fork moves the release bearing easily and smoothly and that the fork claws are correctly positioned on the bearing lugs.
8. Check that the Peugeot special tool fits into the groove of the release fork and locks into place when turned 90°. Remove the special tool.
9. Replace the crankshaft sealing rings.
Installation
Installation is carried out in the reverse order of removal, taking into account the following points:
- check that the release bearing is correctly installed on the transmission input shaft;
- check that the guide pins are in place;
- once the gearbox is bolted to the engine, fit the Peugeot special tool as described previously, pull the tool towards you so that the release bearing compression ring engages with the clutch pressure plate
- install the lower frame of the front suspension;
- tighten all nuts and bolts to the specified torque;
- install the clutch slave cylinder, having previously lubricated the plunger with molybdenum disulfide grease. Install the slave cylinder on the gearbox housing, press it in until it stops and at the same time turn it 90° clockwise. Slowly press the clutch pedal and lift it back manually. Repeat this operation after 10 seconds. Press the clutch pedal again, release it and check that it returns to its original position;
- install the cables so that the 13mm ball joint connects to the upper arm and the 10mm ball joint connects to the side arm;
- add oil to the gearbox.