Gearbox problem

[Capncol]

A few weeks ago I posted about the problems I had to solve with a car I had just bought for my wife. I got it cheap because of the faults.
One of the problems is the famously weak MA gearbox.
It was making an ominous knocking noise in reverse (as if a tooth was missing) but it was fine in every other gear, with no other noises.
These are an easy box to work on, so just for you, I thought I would give you a step-by-step stripdown.

Firstly, drain the oil & thoroughly clean the outside to keep the work as contamination free as poss. Cleanliness next to Godliness and all that!





Starting with a clean work surface covered in clean news paper, remove the 3 bolts holding on the end cover.




Then remove the 2 clips on the end of the 2 gear shafts using circlip pliers. You will replace these with new so don't worry about damaging them.




Next knock out the "roll" pin that holds the selector fork to the shaft. Then carefully pull off the complete selector and gear assembly. Be careful of the selector as there are a few small bits inside that will fly everywhere if you don't take it off as a complete unit




You will need a puller to get the other gear off as it is a press fit.




So you should end up with a collection of parts like this.


CONT...................................

[Capncol]

Next, undo the 2 horseshoe shaped bearing retainers by removing the 4 "torx" head bolts.




Then undo the 17 (I think) bolts around the perimeter. There are a few different length bolts used, so take note of which bolt goes where.



Then remove the reversing light switch



Prise off the casing using the specially provided levering points located in 3 or 4 places around the join. Don't force a screwdriver in the mating surfaces or it will leak when you reassemble. It will part quite easily.



Then lift the casing off revealing the gear clusters






This is the reverse gear shaft & gear, and as suspected was damaged. The shaft simply pulls out and the gear can then be removed.




2 damaged teeth can be just about made out




I will of course strip the rest of the box down to check it out and replace seals etc:
If anyone is interested, I will post the rest of the strip/rebuild.

[Thar]

Thanks for going to the trouble of uploading the photos, very interesting. I wish I was brave enough to take that on.

[Capncol]

Some more strip down

























Gearbox now stripped to it's major components and cleaned for inspection.
When I get a bit of time over the next few days, I will finish the rebuild and post it here for you.
This gearbox is a spare so It's an "as & when" job. Gearbox will be for sale when done.

[Capncol]

Right. Now Christmas is out of the way, and I have got the parts, the reassembly can commense

[Capncol]

All done!! Now in for sale section.

[minx69]

Don't suppose you would like to work your magic on mine too please?


Had to replace an ma5 box on my old 206sw (1.6 xsi)

Now my 206cc (1.6 sport) is making those familiar noises ...... Surely with the amount of failures pug should have been challenged about them???


gearbox! Will be the last Peugeot I ever own that's for sure!

[Capncol]

I can if you want, but I'm in Reading. Is that too far for you?

[minx69]

It's a fair trek from mine (hinckley) and I'm guessing its a heck of a job even if I source a refurb its gotta be a full day to swap em out right?

Shall pop it into a local trusted garage to see what he thinks can be done x

Thanks for the offer though

[Has]

Hi, I'm having the same problem plus it keeps popping out of reverse all the other gears are working fine.
Was wondering if you could help seeing as I'm based in Reading also.

[Capncol]

Yes no problem. I will PM you my number.

[photomike65]

Hi i haven't bought gearbox part before, can you only get them from main dealer or can you get them else where, thanks mike

[Capncol]

Main dealer or gearbox specialist.

[daniboy123]

Hi there just noticed this thread after searching for information regarding a gearbox problem I'm having on my 2004 206 sw 1.4 16v. The car has covered 120,000 miles and has had a new clutch fitted around a year ago.
It's the MA5 box with cable clutch. The problems started with it not going into second gear at all. After a while it then started jumping in and out of gears with a terribly loud banging noise. Firstly I suspected the linkage, replaced the three rods to no avail. With the car jacked up off the ground I could select all gears at the gearbox and start engine with clutch in, release clutch and wheels would spin okay. Obviously there us no load on the box doing this. It was still difficult to engage second even at the gearbox but it would go in.
I've bit the bullet and pulled the box out in order to open it up. Is there any technical information available for this box, torque settings etc?. I was thinking it may be something to do with the diff as the problem occurs in any gear. Hope someone can help, thanks.

[Capncol]

Hi and welcome. Most of the info is on our site.
http://www.peugeot206cc.co.uk/repair-206/ just follow the link to gearbox.