Peugeot 308: Dismantling : manual gearbox

ESSENTIAL : Observe the safety and cleanliness recommendations .

1. Tooling

Presentation of the equipment .

2. Removing

2.1. gearbox casing

Remove :

• The release fork (1)
• The clutch bearing
• The clutch stop guide
• The reverse gear switch (2)
• The 3 locking caps (3)  (save the springs and the balls)
• The bolts (4)
• The steel casing (5)  (not to be re-used)

N.B. : Depending on version, the declutch fork ( 1) is mounted either on the ball-joint or on the shaft ; In the second case : Use tool [0332-R].

"A" Output shaft lock ring.

"B" Input shaft lock ring.

Fit tool [0343] / [DT-52356] on the input shaft (Position "A" ).

Engage a gear.

Remove the secondary shaft screw ( 8).

Fit tool [0343] / [DT-52356] on the input shaft (Position "B" ).

Remove the primary shaft screw ( 11) ; Using the tool [0332-U].

Set the gearbox in neutral.

Remove :

• The tool [0343] / [DT-52356]
• The bolts (10)
• Bearing stop ring ( 9)
• The bolts (7)
• The gearbox casing (6)

N.B. : Detach the gearbox casing, using a non-cutting lever in the locations provided.

CAUTION : Recover the magnetic disc.

2.2. Input and secondary shafts

Remove :

• The lubrication spouts (12)
• The reverse gear rocker lever shaft ( 14)
• The reverse gear sliding gear ( 13)

Remove :

• The reverse gear shaft ( 15)
• The thrust washer (16)
• The reverse gear intermediate pinion ( 17) and its needle cage  (mark to distinguish the elements of the reverse gear synchronizer)
• The reverse gear fork (18) and the synchronizer sleeve (19)
• The reverse gear return pinion ( 20) and its needle cage
• The thrust stop under the reverse idling gear

Remove :

• The casing centring pin (21)
• The external lever and its shaft (22)
• The bolts (23)

Engage 2nd, 4th and 6th gears.

Lift the gear control plate ( 24) and disengage the centring pins.

Remove the gear control plate ( 24).

Remove the assembly of the following components :

• The input shaft (26)
• The secondary shaft (25)
• The shaft and the fork (29)  (1st and 2nd gears)
• The shaft and the fork (28)  (third and fourth gear)
• The shaft and the fork (27)  (fifth and sixth gear)

2.3. Differential housing

Remove :

• The bolts (31)
• The bearing thrust plate ( 30)
• The bolts (32)
• Differential housing half ( 33)

Remove :

• The gearbox output seal ( 37)  (speedometer drive end)
• The differential (35)
• The external bushes of the (34) and (36) bearings

3. Gearbox control plate

Gearbox control plate .

3.1. Description

(38) Plate .

(39) Centralising pin.

(40) Bearing .

(41) Pin .

(42) seal.

(43) Gear engagement shaft.

(44) Gear engagement eye.

(45) spring .

(46) bolts .

3.2. Stripping

Remove :

• The pin (41)
• The bolt (46)
• The gear selection shaft ( 43)
• The gear engagement eye ( 44)  (retain the spring)
• The centring pin (39)
• The plate (38)
• The bearings (40)
• The spring (45)