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

Preparation before replacing the box

• Remove the tachometer of the new gear box. Also remove the tach internal fluted ring. More detail in the tutorial "change the drive shafts on a Peugeot 306 1.9L D".
• Change differential output spi seals if the new box is used. For this consult the tutorial "change the drive shafts on a Peugeot 306 1.9L D".
• Remove the threaded support engine of the new box. Use 2 nuts on the rod to block with an against nut. Align the sides of the 2 nuts to unscrew by forcing on the 2 nuts.
• Retrieve the centring rings left on your old box and then replace them to their location on the engine.
• Verify that no centring rings on the new box are on the place of a ring on the engine
• Compare the splines of the axis of two gearboxes. They may be different if you do not have the good gear box. It would be a pity to notice after trying to remount the new box for 3/4 hour.

If you change the clutch or the box, place the stop, linked to the clutch mounted on the box to remount. Press the stop on the axis of the box up to the clip on the control fork. In the case of a Turbo D engine, you may have to remove the threaded rod keeping the clutch on his control rod axis. This allows to rotate the axis of the command and unlock the fork.

In all cases, we must now prepare the reassembly of the box.

• Put a little oil on the ends of the axis of the clutch control. This will not hurt him.
• Put a little grease on the splines of the box axis, the foot of rod and stopper to clutch near the axis and fork (a good package for the clips). Use high temperatures grease like graphited grease or Belleville.

Reassemble the gearbox

Be very careful during the reassembly of the gearbox. Need to handle a very heavy piece, generally above itself, in the engine compartment. This is the kind of situation where you slips quickly with a lot of force on just about anything. During this tutorial, Jeremy made a (normal size) cut rubbing in a necklace of plastic sheath! Imagine if it had been a screw head… Especially be careful not to pinch your fingers between the box and the engine block. The crown tooth of the flywheel are particularly sharp and cuts the fingers with extreme ease. For this reason, always hold the box from beneath.

• position the box in its engine location, on the ground, with the differential on top. The position of the differential is very important because otherwise it will jam on the cradle when you're going to move up the box.
• support the box with the method you have chosen
• move down the engine support to make it lean
• mount the support string of the box until being able to enter the box axis in the clutch
• Rotate the box on its axis to send differential to the rear. You would probably raise then at the same time string of the engine and of the box. The goal is to be high enough to not whacked in the cradle with the differential when it rotates backwards. Use small successive steps for the ascent.
• If necessary change the hook of the support of the box to make it more stable.
• Position the gearbox on the centring rings and tuck the top box.
• Replace the screws of the box by tightening them quickly. The gearbox must be well attached to the engine.
• Replace the threaded rod of the gearbox support and put thread lock. Then tighten using the method of the lock nut.
• Replace the gearbox bracket but put only the rear screw to rotate andof the ear re-enter the gearbox support threaded rod
• Then mount the engine-gearbox assembly passing the threaded rod into the hole in the gearbox support silentbloc. Push the engine back and rotate the gearbox support to get there.
• Replace the second box bracket screw and tighten its screws.
• Remount the silentbloc of gearbox support and tighten its screw.
• Remove the individual supports of engine and box (crosses, hoist, goat, jacks..).

Reconnect the gearbox

To begin, we will reconnect the elements that will allow verification that gears shift well.

• Remount gear shift rods. Use pliers by pressing on the inner ring of the rod.
• Reassemble the clutch cable. To do this, follow the tutorial "Change the clutch on a 306 cable".
• Check the gears shift including reverse.

Fill the gearbox oil

The gearbox oil level must be done by the screw located on the ass of the gear box, visible by the passage of wheel front left. You can not fill as the engine by pouring with a can because this screw is on a vertical wall. Should normally use a syringe, which is moderately useful.

To avoid this, buy a tank with a hose into the CAP. Some cans Norauto including fitted. If you find any others, do pass the info.

Filler screw serves as a level. When oil appears through the hole of the screw, retighten the screw. Do not wait until nothing flows. Note that should be therefore fill the box positionned flat, otherwise the level will be not good.

Remount the ancillary parts

At this time you did the hard work, you have to reconnect and remount all elements that you had deposited or disconnected to access the gearbox and isolate it.

• Remount the electric starter. Pay attention to the position of the screws that have different sizes and centering rings.
• Plug the reverse gear sensor on the gearbox
• Remount air intake and parts deposited to access the gearbox as described in the remount of the tutorial "Change clutch cable".
• Check that there is no more cable or conduit attached during removal and that all sensors are well connected.

Conclusion

You can see that the change of a gearbox is a very heavy operation (in the proper sense). It will take a good day's work by being well prepared. The biggest problem is of course to get it out of the engine compartment and remount it without getting hurt. Note, this engine is present on a wide range of vehicles at Peugeot and Citroën (205, 306, 405, ZX, BX…).

This operation was very long for this very standard engine; more than for a vehicle with longitudinal engine. On an AC Cobra, for example, the operation would normally simpler. As the box is then on the back of the engine, in front of the central tunnel, just remove his box holder and a little switch engine so that the box is out of the vehicle without too much trouble.

Next article in the series of tutorials 306: change the clutch.

In the meantime, good road.

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