B2CG6UK1 - 206 MA GEARBOX

REMOVAL - REFITTING GEARBOX

1 - SPECIAL TOOLS

[1] Tool for unclipping 10 dia. ball joints (-).0216 G1 .

[2] Tool for unclipping 13 dia. ball joints (-).0216 G2 .

[3] Clip pliers CLIC (-).0172 .

[4] Chain .

[5] Shackles .

[6] Workshop hoist .

[7] Power train support crossmember (-).0009 Z .

[8] Bonnet stay (-).1347 C .

2 - REMOVAL

Place the bonnet in the garage position, using tool [8] .

Place the vehicle on a two-post ramp (To make the operation easier) .

TU1JP ENGINE TU3JP ENGINE EMISSION CONTROL CEE 95

Remove :

- the collar (1) (using the tool [3])
- tool for fitting the automatic gearbox adapter sleeve (at (A))
- the air cleaner assembly (2)

TU5JP ENGINE EMISSION CONTROL CEE 95

Remove :

- the collars (1) (using the tool [3])
- the oil vapour breather pipes ( at (A))
- the air cleaner (2)
- the air outlet union

ALL MODELS

Remove :

- the battery cover
- the clamp (3)
- the battery and its tray
- the battery support

Pull the clutch cable to remove it from the clutch lever .

NOTE : if this is not possible (automatic take-up mechanism jammed) unscrew bolt (4) to create a minimum clearance at the clutch pedal .

Remove (In the following order) :

- the cable sleeve end piece (5)
- the pad (6)
- the clutch cable from the cable sleeve stop support

Remove :

- the bolt (7)
- the nut (8)
- the connector (9)

Remove :

- the connector (10)
- the bolts (11)
- the bolt (12)

Unclip the connecting rods using tools [1]-[2] .

Raise the vehicle .

Remove the drive shafts .

Remove the bolt (13) .

Lower the vehicle .

Position : The tools [3], [4], [5], [6] .

Hook the gearbox at (B) .

Remove :

- the flexible mounting (14)
- the bracket (15)

Remove the clip (16) .

Remove :

- the bolts (17)
- the gearbox

3 - REFITTING

Check :

- there are no oil leaks at the stop guide (18)
- there are no oil leaks at the crankshaft seal (19)
- the state of wear of the clutch

Replace the differential outlet seals (Refer to the relevant procedure) .

Apply a fine coat of MOLYKOTE BR2 PLUS to the clutch stop guide .

NOTE : do not grease the input shaft splines .

Fit :

- the gearbox
- the bolts securing the gearbox to the engine : tightening torque : 4 da.Nm
- the bracket (15) : tightening torque : 2.5 da.Nm
- the flexible mounting (14)
- the nut (20) : tightening torque : 6.5 da.Nm

Relieve the pressure on the flexible shim using the power train support crossmember .

Reposition the flexible shim in contact with its support .

Refit the bolts (21) : Tightening torque : 3 da.Nm .

Remove the tools [3], [4], [5], [6] .

Coat the contact surface of the washer with TOTAL N3945 multi-purpose grease at (C) .

Coat the pad (6) at (D) with tyre fitting compound .

IMPERATIVE : do not use grease .

Refit the clutch cable .

Apply and release the clutch several times fully .

Check :

- no points of resistance
- pedal position

Refit the starter motor : Tightening torque : 2.2 da.Nm .

Continue the fitting operations in the reverse order to removal .

Before refitting the air filter, check that the following components are present and positioned correctly :

- seal (E)
- the stop (F)