B2CG6HK1 - 406D9 BE3 GEARBOX BE4R GEARBOX

REMOVAL - REFITTING GEARBOX CASING

1 - PRELIMINARY OPERATIONS

Stripping the gearbox .

2 - REMOVAL

Remove :

• the bolts (1)
• the casing (2)

A: First assembly .

B: Second assembly .

Engage : The 5th gear and remove the fork retaining pin (3) .

Return to neutral (The fork must remain in position) .

Engage : Another gear to lock the shafts in rotation .

Remove :

• the circlip (4)
• the nut (5)

First assembly: Unlock the nut (6) .

Second assembly: Remove the nut (6) .

A: First assembly .

B: Second assembly .

First assembly :

• remove the nut (6) using the tool [6]
• remove the lock washer (7)

Second assembly :

• extract the hub (8) using the tool [16]

A: First assembly .

B: Second assembly .

Mark the position of the hub (8) in relation to the synchroniser (9) .

A: First assembly :

• remove the synchroniser (9) fitted with its fork (10)

B: Second assembly :

• remove the hub-synchroniser assembly (8)+(9) together with the fork (10)

First assembly .

WARNING : position the arms [7] of the extractor correctly so as not to press on the teeth (C) .

extract the assembly of hub (8) and 5th speed gear (11) using tools [7] and [8] .

A: First assembly .

B: Second assembly .

A: First assembly :

• remove the synchroniser hub (8)

Remove The 5th speed driving gear (11) :

• the thrust washer (12)
• the spacer (13)

Remove :

• the output shaft bearing stop bolts (14)
• the fork shaft stop plate (15)
• the reverse idler gear shaft securing bolt (16)
• the bolts (17)

Remove :

• the ring (18) (use two tapering points and if necessary, raise the shaft to ease its removal)
• the gearbox casing (use a mallet to free the casing from the snap rings)

3 - REFITTING

coat the clutch housing mating surface with sealing compound E15 .

Refit the gearbox casing .

WARNING : check the fitting of the oil filler tube in hole (19) on the housing .

Tighten the bolts (17) to 1.25 ± 0.25 daN.m .

Tighten the bolt (16) fitted with a new washer to 2.0 ± 0.50 da.Nm .

Position :

• the fork shaft stop plate (15) (flat part (A) in the shaft groove)
• tighten the bolt (5) to 1.5 ± 0.30 da.Nm
• gear (18) in the bearing groove
• the bolts (14) (tightening torque 1.5 ± 0.30 da.Nm)

Fit :

• the spacer washer (13), the step against the bearing
• the thrust washer (12)
• the 5th speed driving gear (11)
• the hub-synchroniser (8)

Refit the synchroniser (9) fitted with its fork (10) .

NOTE : respect the marks made on dismantling .

Compress the locking ball (20) by pushing the fork/synchroniser assembly .

Engage :

• a gear (3rd or 4th)
• 5th gear manually
• the spacer (13)

coat the threads of the output shaft with product E6 .

Tighten the output shaft nut to 6.5 ± 1.4 da.Nm and lock it by pushing metal into the shaft grooves .

Position the new lock washer (7) in the 5th gear synchroniser hub .

coat the threads of the input shaft with E6 .

Fit a new nut (6) .

Tighten the nut (6) using tool [6] (Tightening torque : 7.25 + 1.08 / -0.72 da.Nm) .

WARNING : fold back the lug correctly to prevent it from coming into contact with the rear housing .

Lock the nut (6) by folding back the lug of the lock washer (7) .

Fit a new circlip (4) .

Using a lever, refit the 5th gear fork .

Assemble the fork and its shaft with a new pin (3) .

coat the rear housing with sealing compound E15 .

Screw, with tightening, the level plug (21) (alignment of the housings) .

Fit and tighten the bolts (1) (Tightening torque : 1.25 ± 0.40 da.Nm) .

Tighten the level plug to 1.0 daN.m (21) .