Pic. 6.21. Place marking gearbox BE4/5
The gearbox is marked in the area shown in fig. 6.21. The marking of the unit and the factory serial number are indicated.
When removing and installing the gearbox at Peugeot service centers, use the following special tool:
- tools for removing ball bearings - 0216G1, 0126G2;
- mandrels for installing axle shaft seals - 0317U, 0317T;
- mandrel for removing the gearbox suspension axle - 0317 AB;
- cross member to hold the power unit;
- mandrel for centering the clutch disc.
Remove the gearbox in the following order:
- remove the air filter with air supply pipes;
- remove the battery;
- remove the stand under the battery;
- remove the left mudguard;
- disconnect, release from the fasteners and move the wiring harnesses connected to the gearbox;
Pic. 6.22. Removing the engine speed sensor: 1 - sensor
- remove sensor 1 (pic. 6.22) engine crankshaft speed;
- unscrew the three starter mounting bolts and take it aside without disconnecting the wires;
Pic. 6.23. Removing the shift rods: 1 - gearshift rod; 2 - jet thrust; 3 - driving lever
- disconnect rod 1 (pic. 6.23) gear shifting with the help of the device;
- disconnect the driving lever 3 using the tool;
- disconnect reactive draft 2 by means of adaptation;
Pic. 6.24. Cross bar installation: A - place of installation of stops
- install the crossbar as shown in fig. 6.24;
Attention! Install the stops in places A (see fig. 6.24).
Pic. 6.25. Gearbox support: 1, 2, 6, 8 - bolts; 3 - gearbox axle bracket; 4 - gearbox axis; 5 - spacer; 7 - rubber cushion; 9 - nut; 10 - support
- unscrew bolts 1 (pic. 6.25) fastening of a support of the accumulator battery;
- remove the battery support 10;
- unscrew the nut 9 of the axis of the gearbox support with the washer;
- turn away bolts 8 fastenings of a pillow;
- remove the rubber cushion of the gearbox support;
- unscrew bolts 6;
- remove the bracket 3 axles of the transmission support;
- remove spacer 5;
- remove the axis 4 of the gearbox support with the washer using the tool;
Cable drive clutch
Pic. 6.5. Cable drive clutch (gearbox BE4): 1 - tip of the cable sheath; 2 - bushing; 3 - support; 4 - sleeve
- move tip 1 (see fig. 6.5) and bushing 2 supports 3 cables;
- remove bushing 4 from the clutch release fork;
Clutch hydraulic
Pic. 6.26. Removing the clutch slave cylinder: 1 - working cylinder
- disconnect the working cylinder 1 (pic. 6.26) clutch drive from the crankcase without disconnecting from the hose;
All drives
- - Remove the front wheels;
- remove the front wheel drive shafts;
Pic. 6.27. Power unit sway limiter: 1, 3 - bolts; 2 - limiter
- unscrew bolts 1 and 3 (pic. 6.27) and remove the rocking limiter of the power unit;
Pic. 6.28. Differential extension: 1 - sealing ring; 2, 4 - bolts; 3 - speedometer drive gear support; 5 - differential extension; 6 - speedometer drive gear
- unscrew bolt 2 (pic. 6.28) speedometer drive gear supports and remove gear 6 from the crankcase;
- unscrew bolts 4 and remove the differential extension;
- remove sealing ring 1;
Pic. 6.29. Lower gearbox mounting bolts: 1 - bolts
- unscrew the lower bolts 1 (pic. 6.29) gearbox mountings;
- slightly lower the power unit using the cross member (see fig. 6.24);
- hook the lifting cables to the gearbox with a hook;
Pic. 6.30. Upper gearbox mounting bolts: 1 - bolts
- unscrew the top bolts 1 (pic. 6.30) fastening the gearbox housing from the engine and remove the box;
Pic. 6.31. Bearing with clutch release fork: 1 - bearing; 2 - clutch release fork
- remove bearing 1 (pic. 6.31) clutch release and fork 2.