Peugeot 308: Stripping-assembling : Components internal to the gearbox ("MB6" type)

ESSENTIAL : Observe the safety and cleanliness recommendations .

CAUTION : 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
Input shaft bolt	1
Input shaft front bearing	1
Input shaft rear bearing	1
Output shaft bolt	1
Output shaft front bearing	1
Output shaft rear bearing	1
Pin (Gear lever shaft)	1
Input shaft stop ring	3
Secondary shaft stop ring	2
differential gearwheel screw	8
Differential bearing	2
Pins (Differential satellites axle)	2
Driveshaft seal	2

2. Consumables

N.B. : Use only recommended products.

gearbox oil : Index "B1" .

3. Tooling

The recommended tools should be used .

4. Stripping : INPUT SHAFT

CAUTION : The flat surface of the universal extractor must be directed to the gear side so as not to press on the teeth.

Support the base of the sixth gear pinion (2) and remove the rear bearing (1) ; By means of tools [U53P / DT-22912-B], [0317-AF], [0317-F / DT-52163] and a press.

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

(10)Input shaft .

Remove :

• The sixth speed gear (9)
• The stop ring (5) ; Using the tool [0345-J]
• The fifth/sixth gear synchroniser (8)
• The fifth speed driving gear (7)
• The stop ring (5) ; Using the tool [0345-J]
• The fourth speed gear (6)
• The stop ring (5) ; Using the tool [0345-J]
• The third/fourth gear synchroniser (4)
• The third speed gear (3)

Remove the front bearing (11) ; By means of tools [U53P / DT-22912-B], [0317-AF] and a press.

5. Stripping : Output shaft

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

CAUTION : The flat surface of the universal extractor must be directed to the gear side so as not to press on the teeth.

Support under the bearing (12).

Remove the bearing (12) ; By means of tools [U53P / DT-22912-B], [0317-AF], [0317-F / DT-52163] and a press.

Support the base of the fifth and sixth gear slave pinion (13) ; Using the tool [U53P / DT-22912-B].

Remove the fifth and sixth gear slave pinion (13) ; By means of tools [0317-AF], [0317-F / DT-52163] and a press.

Support the base of the third and fourth gear slave pinion (14) ; Using the tool [U53P / DT-22912-B].

Remove the third and fourth gear slave pinion (14) ; By means of tools [0317-AF], [0317-F / DT-52163] and a press.

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

(19)Output shaft.

Remove :

• The second speed driven gear (18)
• The stop ring (15) ; Using the tool [0345-K]
• The first/second gear synchroniser (17)
• The first speed driven gear (16)
• The stop ring (15) ; Using the tool [0345-K]

Remove the bearing (20) ; By means of tools [U53P / DT-22912-B], [0317-AF] and a press.

6. Stripping : differential box

Remove the bearings (21) ; Using the tool [U53P / DT-22912-B].

CAUTION : Do not separate the planet gears from their thrust washers and the sun wheels from their friction washers.

Remove :

• The stop pin (26)
• The planet wheels shaft (27)
• The satellites (25) complete with their thrust cups (24)
• The sun wheels (23) (On the side opposite the crown wheel)
• The planet gear centring ring (22) (On the side opposite the crown wheel)

Remove :

• The fixing screws of the differential gearwheel
• Differential crown wheel (28)

7. Assembling : differential box

Fit the bearing (21) (new) ; By means of tool [0317-D / DT-52168] and a press.

Refit :

• The planet gear centring ring (22) (On the side opposite the crown wheel)
• The sun wheels (23)
• The planet gears (25) and their cup washers (24) by pivoting them
• The planet gear pin (27)
• The shaft stop pins (26) (new)

Fit the crown wheel (28).

CAUTION : Always replace : The fixing screws of the differential gearwheel.

8. Assembling : synchroniser

N.B. : Use only recommended products.

CAUTION : Oil the components as you fit them Index "B1" .

Refit :

• The synchro hub sleeve (30)
• The synchronizer hub (31)
• The synchroniser fingers (32)
• The exterior synchronizer ring (29)

9. Assembling : Output shaft

N.B. : Use components that are clean and free from defects.

N.B. : Check the condition of the shaft bearing faces, there should not be any signs of impacts or scratches.

N.B. : Match up the marks made during removal.

N.B. : Use only recommended products.

CAUTION : Oil the components as you fit them Index "B1" .

Always replace :

• The bearings
• The bearing retaining half rings

Fit the new bearing (20) ; By means of tool [0317-EZ / DT-52196] and a press.

Refit :

• The stop ring (15) (new) ; Using the tool [0345-K]
• The first speed driven gear (16)
• The first/second gear synchroniser (17)
• The stop ring (15) (new) ; Using the tool [0345-K]
• The second speed driven gear (18)
• The third/fourth gear slave pinion (14) ; By means of tool [0317-EZ / DT-52196] and a press
• The fifth/sixth gear slave pinion (13) ; By means of tool [0317-EZ / DT-52196] and a press

Fit the bearing (12) (Groove upwards) (new) ; By means of tool [0317-F / DT-52196] and a press.

10. Assembling : INPUT SHAFT

N.B. : Use components that are clean and free from defects.

N.B. : Check the condition of the shaft bearing faces, there should not be any signs of impacts or scratches.

N.B. : Match up the marks made during removal.

N.B. : Use only recommended products.

CAUTION : Oil the components as you fit them Index "B1" .

Always replace :

• The bearings
• The bearing retaining half rings

CAUTION : The flat surface "a" of the universal extractor must be directed to the gear side so as not to press on the teeth.

Refit the front bearing (11) (new) ; By means of tools [U53T / DT-22912-B], [0317-F / DT-52196] and a press.

Refit :

• The third speed gear (3)
• The third/fourth synchroniser ring (4)
• The stop ring (5) ; Using the tool [0345-J]
• The fourth speed gear (6)
• The stop ring (5) ; Using the tool [0345-J]
• The fifth speed driving gear (7)
• The fifth/sixth gear synchroniser (8)
• The stop ring (5) ; Using the tool [0345-J]
• The sixth speed gear (9)

CAUTION : The flat surface "a" of the universal extractor must be directed to the gear side so as not to press on the teeth.

Refit the rear bearing (1) (new) ; By means of tools [U53T / DT-22912-B], [0317-F / DT-52196] and a press.