B2CJ06K1 - 206 MA GEARBOX

REMOVAL GEARBOX CASING

1 - SPECIAL TOOLS

2 - PRELIMINARY OPERATIONS

Stripping the gearbox .

3 - REMOVAL (MA4/MA5)

Remove :

• the steel casing (1)

4 - REMOVAL OF THE NO. 5 SPEED DRIVE (MA5)

Drift the pin out of the fork (5th) .

Immobilise the output shaft by engaging 2 gears :

• A - select
• B - engage reverse gear
• C - engage 5th by pressing the 5th speed fork

4 - 1 - PRODUCTION FITTING OF THE OUTPUT SHAFT NUT

Slacken the nut (2) .

Position the 5th speed synchroniser in neutral .

Remove :

• the nut (2)
• the thrust washer (3)

Mark the synchroniser hub and sleeve at (D) and (E) .

Cover the sleeve with a cloth to retrieve the balls, springs and fingers .

Remove the 5th speed sleeve (4) and its fork (5) .

4 - 2 - SERVICE FITTING OF THE OUTPUT SHAFT NUT

Unlock the nut (6) .

Slacken the nut (Using the tool [2]) .

Position the 5th speed synchroniser in neutral .

Remove :

• the nut (6)
• the stop washer (7)
• the thrust washer (8)

Mark the synchroniser hub and sleeve at (F) and (G) .

Cover the sleeve with a cloth to retrieve the balls, springs and fingers .

Remove the 5th speed sleeve (9) and its fork (10) .

Extract the 5th speed driven gear and synchro hub assembly with the extractor [1] .

On the input shaft, remove :

• the stop ring (11)
• the spring washer (12)

On the output shaft, remove :

• the needle roller bearing (13)
• the spacer ring (14)
• the spacer washerdistance piece (15)

Extract the 5th speed driving gear with the extractor [1] .

5 - REMOVAL (CONTINUED) (MA4/MA5)

Remove :

• the bolts (16)
• the bearing retaining half rings (17)

NOTE : mark the position of the casing's headless mounting bolts if the gearbox is fitted with them .

Remove :

• the casing bolts
• the gearbox casing (18)

6 - COMPLEMENTARY OPERATION(S)

WARNING : observe the cleaning and refitting conditions .

Refitting the gearbox cover .

Assembling the gearbox .