Peugeot 308: Refitting : Manual gearbox

ESSENTIAL : Observe the safety and cleanliness recommendations .

CAUTION : Observe the tightening torques .

1. Tooling

Presentation : Tooling .

2. Refitting : differential box

Refit :

• The differential (3) fitted with its crown wheel (2)
• The external bushes of the (1) and (4) bearings

CAUTION : Apply a sealing bead of type "E10" to the joint face of the differential half-casing (9).

Refit :

• Differential housing half ( 9)
• The bolts (7), (8)

CAUTION : Apply a sealing bead of type "E10" to the joint face of the differential bearing stop plate (5).

Refit :

• The bearing thrust plate (5) ; Using the tool [0332-A]
• The bolts (6)

Tighten :

• The bolts M8 (7), (8)
• The bolts M10 (7), (8)
• The bolts (6)

Refit the gearbox seal , RH side ; Using the tool [0332-X].

3. Assembling : Control pad

3.1. Description

(10) Plate .

(11) Centralising pin.

(12) Bearing .

(13) Pin .

(14) seal.

(15) Gear engagement shaft.

(16) Gear engagement eye.

(17) spring .

(18) bolts .

3.2. Assembling

Refit :

• The spring (17)
• The bearings (12)
• The plate (10)
• The centring pin (11)
• The gear engagement eye ( 16) (Retain the spring )
• The gear selection shaft ( 15)
• The bolt (18)
• The pin (13)

4. Refitting : Input and secondary shafts

Assemble the following components :

• Input shaft (19)
• Secondary shaft ( 20)
• 1st and 2nd gear shaft and fork ( 21)
• 3rd and 4th gear shaft and fork ( 22)
• 5th and 6th gear shaft and fork ( 23)

Position the prepared assembly in the gearbox casing ( 24).

Position :

• The thrust washer under the reverse gear pinion
• The reverse gear (25) and its needle roller bearing cage
• The reverse gear fork (27) and the synchronizer sleeve (26)
• The reverse gear intermediate pinion ( 28) and its needle cage
• The reverse gear shaft ( 30)
• The thrust washer (29)

CAUTION : When refitting the reverse gear shaft ( 30), take care to place its anti-rotation nipple in the slot on the clutch housing.

Press in the two centring needles ( 31) until they contact with the face of the gear control plate.

Fit the gear control plate.

Engage 2nd, 4th and 6th gears.

Position the gear control plate (10) on the gear engagement fingers  (at "a").

Set the gearbox in neutral.

Position the gear control plate by means of the two screws ( 32).

CAUTION : Use a punch to press in the two centring pins at " a".

Tighten the 5 bolts (32).

Refit :

• The reverse gear sliding gear ( 34)
• The rocking lever shaft ( 35)
• The lubrication spouts (33)

CAUTION : After fitting the gear control plate and then the reverse gear rocker lever, check that the 1st/2nd, 3rd/4th, 5th/6th and reverse gear forks are correctly positioned in the grooves of the gears . Before continuing with the refitting, check the engagement of each gear.

5. Refitting : Gearbox casing

(36) Stop ring.

(37) Screw  (Stop ring ).

(38) Output shaft bolt.

(39) Input shaft bolt.

Check that the gearbox casing centring pins are present and that the magnetic disc is in its location.

Coat the joint face of the casing with a thin, even layer of sealing compound index "E10".

Fit the gearbox casing ( 41) on the clutch housing.

Fit a new gear selection shaft seal  (at "b").

Tighten the bolts (40).

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

Engage a gear.

Tighten the primary shaft fixing screw ( 39) to 8 daNm ; Using the tool [0332-U].

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

Tighten the output shaft bolt (38).

Reposition the gearbox to neutral.

Remove the tool [0343].

Refit :

• The bearing locking ring ( 36)
• The bolts (37)

Refit :

• The locking balls and springs
• The locking caps (45)

Coat the joint face of the casing with a thin, even layer of sealing compound index "E10".

Refit :

• The steel casing (44)  (new)
• The bolts (43)
• The reverse gear switch (46)
• The release fork (42) : Fitting on shaft or ball joint  (depending on version)
• The hydraulic clutch bearing  (depending on version)
• The bearing guide