Tutorial: Change the gearbox (Peugeot 306 1.9 L D – XUD engine)

Support the set engine / gearbox

If you put down the support silentbloc at this time, the engine falls / would fail because it would be only supportde by its right holder. It could also break on this occasion. But in order to drop the gearbox, you need to unmount its silentbloc support. The solution is to separately support the engine and the gearbox.

Another way to tackle the problem would be to remove the assembly engine + gearbox then to the change the gearbox. This tutorial will not address this method.

To exit the box leaving the engine installed, several solutions are then available to you.

• You can use hydraulic jacks with shims positioned under the engine and the gearbox. This will allow unloaded independently from the other. There are even jacks special box with some sort of big claw at four branches on top for fixing the gearbox.
• You can use 2 strings with independent hoists or 2 goats and attach to the engine hook and the gearbox. In this case you may need to remove the hood to move the strings. In our case, it absolutely should not be this way because we are on a car lift. If one supports the engine and the gearbox with hoists, this will remove the weight on the bridge and the car may switch!
• You can use a motor mount crossbar. It is a kind of bridge that you place on the inside of the wings and which supplied points of attachments for strings for the engine and the gearbox. These fixing points are on threaded rods to be descended and assembled easily. So you can support the engine and gearbox independently while keeping the weight on the vehicle. Only the weight of the unmounted gearbox will be removed off the car lift but it will be negligible.

It is the last method that we'll see here but you will see that the instructions easily adapt to other methods. The rail engine compartment that we will use here is homemade with remnants of scrap metal for the construction of a metal gate. The engine will be suspended by a string on his hook of bracket located near the intake manifold.

Change gearbox Peugeot 306 1.9L D

The clutches of the 1.9 L D and TD engines are different and that impacted strongly the installation/removal of the gearbox.

• On D, the clutch is "pushed". The clutch stop is clipped on the fork of command and slide on the gearbox main shaft. The fork of clutch control pushes the stopper which pushes itself lamellae. The gearbox is therefore independent of the clutch and removal/reassembly of box is only "quite complicated".
• On the Turbo D, the clutch is said "pulled". The clutch fork is attached to the fins of the mechanism. The clutch fork is therefore stuck behind the stop to pull it and therefore to draw the strips at the same time. This makes the gearbox solidary of the clutch mechanism and makes removal/reassembly of the set more tricky.
• For removal, you need to remove the threaded rod located on the axis of the clutch rod, on top of the gearbox. This allows to remove the control rod and rotate a bit more on his axis and then loosen the fork.
• When remount the gearbox, you'll need to set the fork at 60 ° so that it is just behind the stop at the point where you push the gearbox on the motor. This manipulation will be very complicated if you remove/replace the gearbox in the engine compartment. For the 1.9 L TD, it is advisable to file the whole engine + box to work.

Remove the gear box

Now comes a much harder step, removal of the box itself. The idea is you to disconnect the engine, then the make swivel to position the differential at the top. We will then have to lower the engine to exit the box by wheel front left way. During this stage the box would block on the cradle at the level of the torque rod. On the other side, the engine may press the engine compartment at the level of the alternator pulley. It will also need to be careful not to damage the radiator during movements of the engine. That happiness…

• Reminder: Support the box independently according to the method you have chosen (Jack, goat, hoist, cross…)
• Drop the silentbloc of gearbox
• Remove the bracket of the silentbloc box
• Unscrew the threaded rod of the silentbloc and remove the box. It can be glued and difficult to remove because its base 6 hex has chamfered corners. Put 2 nuts to make an against-nut on the threaded rod and use it to unscrew the stem with a ratchet.
• Remove the screws of the gearbox. From now pay close attention to the box that is no more attached to the engine and could therefore move or fall if its support fail. (Ex: a floor Jack with a wooden wedge)
• Pull the box on the left side of the vehicle for you to disconnect the engine about 1 cm to disengage locating rings. Leave it a bit in the clutch in order to support its weight more evenly.
• Rotate the box around its axis to bring the differential above the box. So bring the back of the box at the top. This is only possible if you have properly filed the tachometer.
• If you support the box with a string it would be nice to change the hook point and pick one up now located above the box.
• Scroll down the support of the engine. The engine is still supported by its motor bracket right. It will therefore lean and the box will follow the slope. Be careful to not get the engine too low as this will press the pulley alternator on the car body. Get down the gear box support at the same time. The 2 at the same time, step by step so.
• Slightly pull the engine forward to avoid blocking on the cradle near the torque rod that you removed. On the other hand, do not pull too much in order not to damage the radiator.
• Completely remove the clutch box by tilting the head of the box down. Get off the box and get it out there at the bottom of the wheel arch. You can now see the clutch. Note that if you had not removed the threaded rod of the box support, the maneuver would be more difficult.
• Reassemble the engine in the normal position for not to tire the right silent bloc engine. It is made of plastic, is not mean to work in this position and probably already old and so tired. This piece should be verified before any dismantling of the box because it would not it loose during the procedure.

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