Peugeot 308: Refitting : MB type manual gearbox

ESSENTIAL : Observe the safety and cleanliness recommendations .

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

1. Replacement of parts in all cases

Description	Quantity
O-ring seal (Extension)	1
Seal (Engagement finger)	1
Pin (Engagement finger)	2
Stop ring (Gearbox casing)	1
Bolt ( input shaft)	1
Bolt (Output shaft)	1
Seal ( drain cap)	1
Seal (Bolt of the reverse gear lever pin)	1
Centralising pin	2

2. Tooling

Presentation : Tooling .

3. Consumables

CAUTION : Use only recommended products.

Sealing paste (index "E10") .

Strong thread lock (index "E6") .

4. Differential housing

CAUTION : Observe the tightening torques .

Check :

• That the centring pins are present (3)
• That the seal face is clean

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

Fit the differential (2) into the housing together with the bearing outer races (1).

Refit the differential housing (4).

Refit (without tightening them) :

• The bolts (6)
• The bolts (8)
• The bolts (7)
• The bolts (5)

4.1. Extension adjustment

"X" = Extension shoulder.

Measure the dimension "X".

4.2. First assembly

Extension shoulder : "X" = 10 mm.

Refit :

• The extension ( 9) fitted with a new O-ring
• The bolts (10)

4.3. Second assembly

Extension shoulder : "X" = 8,65 mm.

Position :

• The tool [0317-L / 7101-TL]
• The extension without O-ring

Progressively tighten the extension screws while turning the differential, to obtain a tightness in rotation in order to position the cage and bearings correctly.

Remove :

• The extension
• The positioning tool [0317-L / 7101-TL]

Using a depth gauge , measure the distance "Y" between the joint face and the external bush of the bearing.

Calculation of the thickness of the positioning shim : .

("Y" - "X") + 0,1 mm = Thickness of the positioning shim.

Refit :

• The positioning shim on the bearing outer race
• The extension (9) fitted with a new O-ring
• The bolts (10)

4.4. Refitting (continued)

Tighten :

• The bolts (6)
• The bolts (8)
• The bolts (7)
• The bolts (7)

N.B. : This order of operations ensures correct alignment of the joint faces.

5. Input and secondary shafts

Refit :

• The reverse gear sliding gear ( 11)
• The reverse gear rocker lever shaft (12)
• The reverse sliding gear (13)

Refit the nut (14).

Refit :

• The input shaft (15)
• The secondary shaft (17)
• The forks (16)

6. Gear selector

Refit the cassette assembly (18) of the manual gearbox.

Remove the gear engagement shaft (19).

Refit the pin (20).

Refit :

• The oil filler neck (21)
• The reverse gear rocker lever shaft (22)

7. Gearbox casing

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

Refit :

• The gearbox casing (23)
• The 12 gearbox casing (24) bolts

CAUTION : Do not refit the spout bolt of the neutral sensor.

Refit the stop ring (25).

Engage a gear ; Using the gear engagement selector.

Put the tool (15) in place on the primary shaft [0343 / DT-52356].

Immobilise the tool [0343 / DT-52356] ; Using an bolt (at "a").

CAUTION : Use only recommended products.

Coat the screw threads with a locking product (index "E6") .

Refit :

• The input shaft bolt (26)
• The secondary shaft bolt (27)

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

Refit :

• The gearbox casing (28)
• The 6 bolts (29)
• The reverse gear shaft bolt (30)

Refit :

• The sheathing (31)
• The bolt (32)

Refit :

• The reverse gear switch (33)
• The gear control neutral sensor (34)
• The bolt (35)

Refit :

• The breather opening (36)
• The drain cap (37)