Peugeot 308: Removing - refitting : Reverse gear rocker shaft

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the conditions for cleaning and refitting the gearbox .

CAUTION : Mark the positions of the components prior to removal.

1. Replacement of parts in all cases

Description	Quantity
Stop ring (Gearbox casing)	1
Drain cap seal	1
Seal (Reverse gear rocker shaft bolt)	1
Manual gearbox cover	1 (*)
(*) If necessary

2. Tooling

Workshop equipment :

• Jack
• Rubber shim

Tool	Reference	Description
	[0014-A]	Engine support crossmember adaptor
	[0014-AA]	support
	[0014-AB]	Plate
	[0014-AC]	engine support
	[0014-AD]	engine support
	[0014-AE]	engine support
	[0014-AF]	engine support
	[0014-AG]	Bolt
	[0014-AH]	engine support
	[0014]	cross beam for support of engine
	[1350-ZZ] (*)	Stripping tool
(*) Use standard workshop equipment if the special tool is not available

3. Consumables

N.B. : Use only recommended products.

gearbox oil : Index "B1" .

Sealing paste (index "E10") .

4. Preliminary operations

CAUTION : Perform the operations that are required prior to a disconnection of the ancillaries battery .

Disconnect the ancillaries battery .

Place the vehicle on a 2-post lift.

Put the manual gearbox in neutral.

Lift and support the vehicle .

Remove :

• The engine cover (depending on equipment)
• The engine management ECU
• The air inlet manifold
• The air inlet pipe
• The ancillaries battery and its support
• The front left-hand wheel
• The front left-hand mud guard
• The under-engine protector (depending on equipment)

5. Removing

CAUTION : It is necessary to drain the gearbox and put back the exact quantity of oil, in the event of an external leak or a repair.

Drain the manual gearbox.

Refit the drain cap (with a new seal ).

Support the manual gearbox ; Using a workshop jack and a rubber shim.

Remove :

• The bolts (3)
• The bolts (2)
• The nuts (4)
• The gearbox mounting (1)

Remove the 2 bolts (5).

Position and screw in :

• The tools [0014-AB] and [0014-AD] on the front left chassis leg
• The tools [0014-AC] and [0014-AH] on the internal combustion engine support (6)

Position :

• The tool [0014-AA] on the tools [0014-AC] and [0014-AH]
• The tool [0014-AA] on the tools [0014-AD] and [0014-AD]

Hold :

• Tools [0014-AA] and [0014-AC], [0014-AH] ; Using tools [0014-AB] and [0014-AG]
• Tools [0014-AA] and [0014-AD], [0014-AD ] ; Using tools [0014-AB] and [0014-AG]

Support the engine-gearbox assembly in this position ; Using tools [0014] and [0014-AA].

Remove the jack.

Slightly tilt the engine/gearbox assembly ; Using tools [0014] and [0014-AA].

Disconnect :

• The electrical harness connector (at "b")
• The electrical harness connector (at "c")

Unclip the electrical harness (at "a").

Remove :

• The 3 bolts (7)
• The gearbox mounting (8)

Remove :

• The bolts (10)
• The manual gearbox cover (9)

Remove :

• The bolt (12)
• The stop ring (11)

Remove :

• The bolts (13)
• The nuts (14)
• The studs (15)

Remove the bolts (13).

Move aside the manual gearbox casing (16) (in the direction of the arrow ).

N.B. : When removing the reverse gear rocker shaft (17), support the reverse gear (18) pinion.

Remove the reverse gear rocker shaft (17).

6. Precautions to be taken before refitting

N.B. : Protect the internal components of the manual gearbox ; Using a lint-free cloth.

Clean the joint faces.

7. Refitting

CAUTION : Observe the tightening torques.

Tightening torques :

• Manual gearbox
• Engine-gearbox assembly mounting
• Wheels

N.B. : When refitting the reverse gear rocker shaft (17), support the reverse gear (18) pinion.

Refit the reverse gear rocker shaft (17).

Coat the joint face with a thin, even layer of sealing paste (index "E10") .

Refit :

• The gearbox casing (16)
• The bolts (13)
• The studs (15)
• The nuts (14)
• The bolt (12) (with a new seal )
• The new stop ring (11)

Apply sealing product to the gearbox cover joint face (index "E10") .

Refit :

• The manual gearbox cover (10) (New if necessary)
• The bolts (9)
• The gearbox mounting (8)
• The 3 bolts (7)

Reconnect :

• The electrical harness connector (at "b")
• The electrical harness connector (at "c")

Clip the electrical harness (at "a").

Support the manual gearbox ; Using a workshop jack and a rubber shim.

Remove tools [0014] and [0014-A].

N.B. : 2 operators are required for this operation.

Refit :

• The bolts (5)
• The gearbox mounting (1)
• The nuts (4)
• The bolts (2)
• The bolts (3)

CAUTION : It is necessary to drain the gearbox and put back the exact quantity of oil, in the event of an external leak or a repair.

N.B. : Use only recommended products.

Refill the manual gearbox ‎ with oil via the breather opening.

8. Additional operations

Refit :

• The air inlet manifold
• The air inlet pipe
• The ancillaries battery and its support
• The engine management ECU
• The engine cover (depending on equipment)
• The under-engine protector (depending on equipment)
• The front left-hand mud guard
• The front left-hand wheel
• The vehicle to its wheels

CAUTION : Perform the operations that are required after reconnecting the ancillaries battery .

Reconnect the ancillaries battery .