Tutorial: Change the gearbox (Peugeot 306 1.9 L D – XUD engine)
In this tutorial you'll see how to change a gearbox on a Peugeot 306 1.9L D of 1994 (XUD engine). It is a fairly heavy intervention and which requires a good experience and a good equipment. Think that it will have to maneuver the gearbox under the car and she weighs between 30 and 40kg. The equivalent would be to make the ABS with a weight of 30 kg to be lift and go insert into a hole which you will not see.
If you have ever changed a geardbox and that you can only remember one piec of advice, hold this one: to change a gearbox, plan to be 2 to tinker.
The intervention will take place in four stages: undress, unmount, remount, re – dress. To start, lift the car of about thirty centimetres on candles or car lift.
Isolate the gearbox
The box is covered by various part that you will have to remove to access. More, it is connected to different elements also to remove before the filing.
Remove the top of the gearbox
Remove air intake, the battery and its support as detailed in the tutorial "change clutch cable". Once done you will clearly see the box and his silentbloc support. For our case, do not totally unmount the clutch cable. Disconnect it simply of the gear box and place it on the side of the engine compartment.
Remove the electric starter. Note the location of the 3 screws which have different sizes. Step back a little the starter and attach it to avoid that it damages the radiator. Verify that no centering ring of the starter remains attached to the box. If this is the case, remove the rings remained with pliers.
Disconnect the wiring harness and reverse gear sensor plug. It is located on the gearbox, under the clutch rod. It is maintained by a metal clip to hold with a flat screwdriver to disconnect the sheath.
Disconnect the speedometer cable. To unlock, pull the plastic pin that holds it. Then pull up the speedometer cable and place it on the engine after cleaned it.- Observe the small duct next to the speedometer cable. It comes to the TDC (Top Dead Center) sensor. You will subsequently deposit. Just beware not to damage him for the moment.
Remove the depression of the master vac hose. This will prevent break its connection when the engine will move later in the operation. To do this, run your finger behind the hose near the connection and swing the fitting. This causes a leak that allows air to enter the vac master. Once filled with air, the hose easily detaches from master vac.
Disconnect the box control rods. Note that these are fragile elements that can break or bend. If a head of rod is damaged, it will not remain locked anymore and pop alone. As these are fragile elements, a tool is needed: tire changer. Made lever an the tip of the rod. Do not attack the rod by the side otherwise it will rotate on its head or snatch the silentbloc. The rods are composed of two concentric rings connected by a silentbloc. Made much lever on the inner ring because it is the one attached to the ball. Making lever on the outer ring could cut the silent block of rod.
Loosen the 2 screws on the silentbloc box support. Loosen also the three fixing screws of the box located at the top of the box. Only unlock them because the box is not yet drained.
Finally on top, attach the cables and hoses lying to avoid an accidental pulling and not be embarrassed during the installation/replacing the box. Caution, do not overtighten these elements because the engine will going down a lot when removing the box.
Undress the bottom of the gearbox
In order to finally isolate the gearbox, position yourself under the engine.
Remove the TDC sensor. It is maintained by a small hex head screw on the back of the box, near the differential. Remove this screw before removing the sensor, otherwise it comes out without his support that may fall into the clutch housing. Remove the sensor and attach it to the engine to avoid crushing it during the reassembly of the box.
Remove the flywheel metal housing. One of its screw also holds the power steering pump high pressure hose .
Detach the power steering hose of the PIN that holds it on the front of the engine. Then attach the accessory belt idler arm. This will prevent damaging the hose thereafter.- Then remove the drive shafts as detailed in the tutorial 'Change the gimbal'. Be sure well to drain the box and remove the tachometer of the differential. It is required for the removal of the box.
Drop the torqe rod located next to intermediate landing of the right drive shaft, behind the engine. This will allow to move the engine later.- Then loosen the last screw from the gear box. Only unlock it.
At this time, the gearbox is only related to the vehicle by its engine block fixing screws and its support silentbloc.