Transmission Disassembly
- Place transmission on holding fixture with right side facing away from fixture. From extension housing, remove speedometer driven gear set screw and gear. Place shift control levers in neutral position.
- Mark and remove reverse lock-out plunger. Turn transmission so extension housing is facing up. Remove extension housing bolts. Remove inspection plate on rear of housing and mount Extractor (.0314-M).
- Insert extractor bolt into extractor body. To remove extension housing, turn bolt and tap sides of housing with plastic mallet.
- Remove snap ring from mainshaft. Using a puller, remove 5th driven gear and speedometer drive gear. Remove 5th-reverse countergear shaft adjusting shim and washer. Lift off 5th drive gear. Remove snap ring from mainshaft.
- Index mark position of 5th-reverse synchronizer sleeve to its hub for reassembly reference. Engage 5th gear and mount Holding Plate (.0314W) over 5th gear selector fork shaft. Attach plate to housing with 2 bolts. Drive out 5th-reverse fork roll pin without damaging face of housing. Remove holding plate.
- Return transmission to Neutral position. Remove 5th-reverse selector fork and collar and synchronizer hub. Lift 5th-reverse intermediate shaft from housing. Disengage selector fork fingers from shift rail. Remove intermediate housing bolts and housing.
- Remove clutch release fork and release bearing. Remove clutch housing bolts and clutch housing. Engage 4th gear and lock input shaft using splined socket (.0520-M). Loosen nut from cluster shaft. Remove reverse gear from intermediate shaft. Remove 4 bearing retainer plate Allen screws. See Fig 1.
Courtesy of PEUGEOT MOTOR OF AMERICA, INC.
- Turn holding fixture until right side of case is facing up. Remove right side transmission case bolts and case half. Lift and remove entire gear assembly. Mark and remove countergear shaft end bearings. Slide synchronizer sleeve on mainshaft into 3rd gear position. Separate input shaft from mainshaft and place needle bearing aside. See Fig 2.
Courtesy of PEUGEOT MOTOR OF AMERICA, INC.
Courtesy of PEUGEOT MOTOR OF AMERICA, INC.