Table of contents: Cars with manual transmission VEZ 🠇 Cars with manual transmission ML5T 🠇 Cars with manual transmission ME5T 🠇
Cars with manual transmission VEZ
1. Open the hood and fix it in this position.
2. Drain the coolant.
3. Remove the battery.
4. Disconnect the air intake 1 (see illustration).
3.4 Disconnect the air intake 1
5. Remove the supply air duct 2 with the mass air flow sensor (if provided) (see illustration 3.4).
6. Remove the air filter 3 (see illustration 3.4).
7. Remove the battery tray.
8. Disconnect the upper radiator hose.
9. Release all wires, plugs, pipes and hoses connected to the gearbox from their holders and move them away from the work area.
10. Install a support beam "a" on the front to lift the engine and relieve the power unit supports, or secure the gearbox to a cable "b" to lift it with a crane (see illustration). If there is no crane to lift the gearbox, the box can be lifted by placing a garage lift under it. When installing the box on the lift, place it on wooden slats or blocks to avoid damaging the crankcase.
3.10 Install a support beam "a" on the front end to lift the engine and relieve the power unit supports, or secure the gearbox to a cable "b" to lift it with a crane
11. Remove the 4 gearbox support bracket (see illustration).
3.11 Remove the 4 gearbox support bracket
12. Remove and replace bushing 5 (see illustration).
3.12 Remove and replace bushing 5
13. Move the starter away from the work area without disconnecting it.
14. Remove the speedometer shaft, washer 6 must be replaced (see illustration 3.12).
15. Unscrew the upper bolts securing the gearbox to the engine.
16. Remove the crankshaft position sensor.
17. Remove the mudguard.
18. Drain the transmission oil.
19. Remove the drive shafts (see illustration).
20. Remove cover 8 of the output shaft (see illustration).
3.20 Remove cover 8 of the output shaft
21. Remove the O-ring 9, remove the clutch housing 10, and then unscrew the lower bolt 11 securing the gearbox to the cylinder block (see illustration 3.20). The tightening torque of bolt 11 is 50 Nm.
22. Raise the engine to relieve the load on the power unit mounts (see illustration 3.10).
23. Disconnect the engine and gearbox and move the gearbox away from the engine as far as possible (see illustration).
3.23 Disconnect the engine and gearbox and move the gearbox back as far as possible
24. Lock the flywheel by installing the FACOM D86 stop in the corresponding hole.
25. Remove the clutch pressure and driven discs.
26. Remove the flywheel.
27. Cover the radiator with cardboard to prevent damage.
28. Make sure the transmission is securely fastened to the lift (depending on whether you are using a garage lift or a crane for removal) and carefully lift the transmission out from under the car.
Cars with manual transmission ML5T
29. Disconnect the wires from the battery and remove it.
30. Remove the air filter.
31. Remove the battery tray.
32. Disconnect the clutch slave cylinder 1 by first pressing on it (see arrow 2 in the illustration), and then turning it counterclockwise (see arrow 3 in the illustration).
3.32 Disconnect the clutch slave cylinder 1 by first pressing it (see arrow 2), and then turning it counterclockwise (see arrow 3)
Caution! Do not depress the clutch pedal with the clutch slave cylinder removed.
33. Remove clamps 4 and 5, then disconnect the cable ends from the spherical heads 6 and 7 of the gear selection and shift rods using pullers 0216-G1 at 10 mm and 0216-G2 at 13 mm (see illustration).
3.33 Remove clamps 4 and 5, then disconnect the cable ends from the spherical heads 6 and 7 of the gear selection and shift rods using pullers
34. Remove the crankshaft speed sensor 8 (see illustration 3.33).
35. Disconnect the plug of the switch 9 of the reversing lights (see illustration 3.33).
36. Disconnect the speedometer sensor.
37. Disconnect, release from the holders and move away from the work area all wire harnesses connected to the gearbox.
38. Loosen the wheel hub nuts.
39. Unscrew bolt 10 (see illustration).
3.39 Unscrew bolt 10
40. Disconnect the tie rods from the steering gear. If necessary, disconnect the power steering pump hose.
41. Unscrew bolts 11 (see illustration 3.39).
42. Unscrew and replace the nuts (2 together with washers 13. as well as the gears 14 located between the steering gear and the subframe (see illustration 3.39).
43. Install the support under the steering gear 15 from the exhaust manifold side (see illustration 3.39).
44. Remove the protective cover 16 (see illustration). The tightening torque of the cover mounting bolts is 18 Nm.
3.44 Remove protective cover 16. Tightening torques: bolts 11 - 90 Nm
45. Unscrew nuts 17 of the ball joints securing the suspension arm to the steering knuckle (see illustration 3.44). The tightening torque of the nuts is 40 Nm.
46. Unscrew bolts 18 securing the anti-roll bar (see illustration 3.44). The tightening torque of the bolts is 50 Nm.
47. Unscrew bolts 19, 21,22 and 23 securing subframe 20 to the body (see illustration 3.44) and remove the subframe.
Tightening torques:
- t9 bolts - 45 Nm;
- bolts 21 and 23 - 65 Nm;
- bolts 22 - 113 Nm.
48. Remove the drive shafts.
49. Raise the gearbox using a hoist or crane, hooking the crane hook onto the eye on the gearbox (see illustration).
3.49 Raise the gearbox using a hoist or crane, hooking the crane hook onto the eye on the gearbox
50. Unscrew nut 24, remove washer 25 and remove support 26 of the gearbox (see illustration 3.49).
You can find the original on the page (peugeotbook.ru)
51. Cover the engine protective cover with a piece of cardboard 27 (see illustration).
3.51 Cover the engine protective cover with a piece of cardboard 27
52. Secure the engine to a hoist or crane, or install a support beam "a" on the front to lift the engine and relieve its supports (see illustration 3.51).
53. Unscrew the gearbox mounting bolts 28 (see illustration 3.51) to the engine and carefully remove the box from under the car.
Cars with manual transmission ME5T
54. Disconnect air duct 1 from the throttle valve (see illustration).
3.54 Disconnect air duct 1 from the throttle valve
55. Remove the air filter 2 (see illustration 3.54).
56. Remove the battery and its tray 3 (see illustration 3.54).
57. Disconnect and move away from the work area all wire harnesses, hoses and pipes connected to the gearbox and preventing its dismantling.
58. Cars with ZPJ series petrol engines. Clamp the throttle valve heating hoses with suitable clamps "a" and disconnect the hoses (see illustration).
3.58 Clamp the throttle valve heating hoses with suitable clamps "a" and disconnect the hoses. Cars with ZPJ series petrol engines
59. Cars with petrol engines of the ZPJ series (except ZPJ4). Remove the throttle valve 4 (see illustration 3.58)
60. Remove the distributor 5 ignition (see illustration 3.58).
61. Raise the gearbox using a hoist or crane, hooking the crane hook onto the eye on the gearbox.
62. Remove the gearbox mount bracket and support.
63. Unscrew the central nut 6 of the gearbox support mount (see illustration). The tightening torque of the nut is 80 Nm.
3.63 Unscrew the central nut b of the gearbox support mount
64. Unscrew the bolts 7 of the support bracket (see illustration 3.63). The tightening torque of the bolts is 30 Nm.
65. Unscrew the bolts securing the clutch housing protective cover.
66. Drain the transmission oil.
67. Remove the drive shafts.
68. Remove the exhaust pipe (see illustration).
3.68 Remove the exhaust pipe
A - cars with petrol engines of the ZPJ series
B - cars with petrol engine ZPJ4
69. Remove the clutch housing protective cover.
70. Unscrew the lower bolts 9 securing the clutch housing (see illustration 3.68).
71. Unscrew bolts 8 (see illustration 3.63) fastening the heat-reflecting shield that covers the starter. The tightening torque of the bolts is 30 Nm.
72. Remove the speedometer sensor.
73. Move the starter away from the work area without disconnecting it.
74. Install a support beam on the front to raise the engine and relieve the load on the power unit mounts.
75. Disconnect the engine and gearbox and move the gearbox away from the engine as far as possible (see illustration).
3.75 Disconnect the engine and gearbox and move the gearbox away from the engine as far as possible
76. Lock the flywheel by installing the FACOM D86 stop in the corresponding hole.
77. Remove the clutch and then the flywheel. The tightening torque of the flywheel mounting bolts is 50 Nm.
78. Cover the radiator and adjacent body parts with cardboard to avoid damage when removing the gearbox.
79. Make sure the transmission is securely fastened to the lift (depending on whether you are using a garage lift or a crane for removal) and carefully lift the transmission out from under the car.
Attention! On cars with MG5T manual transmission, to dismantle the gearbox, you must first remove the power unit, and then disconnect the gearbox and engine.