Peugeot 308: Removing - refitting : Reverse gear rocker switch

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

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 reverse gear position.

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 tray
• The scuttle panel
• The front left-hand wheel
• The front left-hand mud guard
• The under-engine protector (depending on equipment)
• The front left subframe extension

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 nuts (1).

Remove the 2 bolts (2).

Position the tool [0014-AD] on the support of the ancillaries battery .

Position and screw in the tools [0014-AC] and [0014-AH] on the internal combustion engine support (3).

Position :

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

Hold :

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

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

Remove the jack.

Slightly tilt the engine/gearbox assembly ; Using tools [0014] and [0014-AA], [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 (4)
• The gearbox mounting (5)

Remove :

• The bolts (7)
• The manual gearbox cover (6)

Remove :

• The bolt (9)
• The stop ring (8)

Remove :

• The bolts (10)
• The nuts (11)
• The studs (12)

Remove :

• The bolts (10)
• Nut (11)
• The stud (12)

Remove the manual gearbox casing (13).

Remove :

• The reverse gear rocker lever shaft (14)
• The reverse gear (15)

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

Refit :

• The reverse gear (15)
• The reverse gear rocker lever shaft (14)

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

Refit :

• The gearbox casing (13)
• The bolts (10)
• The studs (12)
• The nuts (11)
• The bolt (9)(with a new seal )
• The new stop ring (8)

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

Refit :

• The manual gearbox cover (6) (New)
• The bolts (7)
• The gearbox mounting (5)
• The 3 bolts (4)

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].

Refit :

• The 2 bolts (2)
• The 2 nuts (1)

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 scuttle panel
• The ancillaries battery and its tray
• The engine management ECU
• The engine cover(depending on equipment)
• The front left subframe extension
• The front left-hand mud guard
• The under-engine protector (depending on equipment)
• 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 .