MA gearbox bolts that hold clips locking shafts into the 5th gear housing

Hi,

Rebuilding my gearbox as te input shaft bearing has gone. I struggled to get the bolts undone that hold the clips locking the shafts into the 5th gear housing. The heads are now mangled as they seem to be somewhere between T40 & T45. Any ideas on where I can get replacments or P/Ns. This is the 2nd one of these gearboxes I have done. The first one the bolts came out relatively easily. This one seems to have used the worlds strongest loctite!

zebedee2001 wrote: ↑Sat Sep 05, 2020 10:50 am Hi,

Rebuilding my gearbox as te input shaft bearing has gone. I struggled to get the bolts undone that hold the clips locking the shafts into the 5th gear housing. The heads are now mangled as they seem to be somewhere between T40 & T45. Any ideas on where I can get replacments or P/Ns. This is the 2nd one of these gearboxes I have done. The first one the bolts came out relatively easily. This one seems to have used the worlds strongest loctite!

Hi zebedee2001



I would be very interested to see a guide to doing these jobs (with pictures), did you take any more on your gearbox repair journey?


Screws are showing as part number 2313.62 (original parts, on eBay)

8x125 - 15 torx head screw.

Cheers! Off to the delaer on Monday then to be promised they will be in stock the next next & a week later they finally turn up!

I have plenty of pics from the fist time & a few from this time. There are guides on the web. THis gets you into the main gearbox:

http://www.peugeot206cc.co.uk/repair-20 ... cj06k3.htm

I will post links to the others later, I have a gearbox to take apart!

OK, a few more things:-

1. The black plastic cog on the end of the diff shaft I believe is the speedo drive on certain models. The hole that the speedo is blanked. Oned of the plastic clips broke off. I have started re-assembling the gearbox without it I don't see why I need it! Have I dropped a clanger?

2. This time I am using a LUK kit. Done most of the assembly before finding that there is an online guide for the kit (nothing on the box!) https://www.repxpert.com/en/mediadocume ... SAMA-PC/en

3. Anyone thinking of doing half a job by just replacing the input shaft bearing....beware. When you take apart the other shaft you will find al the bits of the bearing cage in the oil ways & between the teeth/synchros!

4. The plate you have to remove to get to the diff has bolts that are threadlocked. I ended up using my 3ft breaker bar to get them undone. Unfortunately I have one stripped thread which was the last bolt I re-tightened it on a very thin bit of metal by the clutch fork ball. I've left it out for the moment & will address in the morning. I need a solution that doesn't inolve undoing the other bolts as the threads may not survive!

5. The diff bearings are a pig to change. There isn't much of a flange to get the bearing puller to attach to. My neighbour (& friend) is a toolmaker & has a comprehensive workshop. He made up a special tool to get it off for me!

That's enough for tonight!

zebedee2001 wrote: ↑Sat Sep 05, 2020 7:45 pm
1. The black plastic cog on the end of the diff shaft I believe is the speedo drive on certain models. The hole that the speedo is blanked. Oned of the plastic clips broke off. I have started re-assembling the gearbox without it I don't see why I need it! Have I dropped a clanger?

The plastic speedo gear would be for non-ABS cars. The non ABS cars have an electrical sender that fits in where the blanking cap goes. I cant see why you would need it either.

All back together & running! Some pics attached. For those who intend to do this & use the LUK instructions watch out! ON my 59 plate diesel C3 the gearbox selector shaft was different, luckily I had a couple of pictures to help get it back together! On the wife's sensodrive C3 it had a similar selector but the external bit was different.

Wow! That's a big job. Good work.
Wish I had a workshop.
Bit of a Buffy fan Eh?

Ozvtr wrote: ↑Mon Sep 14, 2020 12:21 am Wow! That's a big job. Good work.
Wish I had a workshop.
Bit of a Buffy fan Eh?

It probably took me 24hrs in total including the trouble of getting the bolts out & changing the diff bearings. Well worth doing. 2nd one I have done & both times stripped a thread on the the plate holding the diff in. The pics of the gearbox are in my garage which is 1.5X the normal width of a garage. I have an adjoining car port that has had a garage door fitted to it making another larger than normal garage. That is where the car was. I bought the house mainly for the garage space!

Rebuilding a gearbox is relatively straight forwards if you are an average home mechanic especially if you leave out changing the diff bearings. I'm not a mechanic I'm an Eletronics Engineer!

The Buffy posters are from my uni years. I found them while I was tidying up all the stuff from when I moved in during lockdown (I've lived in the house 12 years!) Thought I would make use of them so attached to the garage door. Wife didn't complain!