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8.1.9. Mechanical ML5T transmission

Removal
PERFORMANCE ORDER
1. Disconnect the negative plug of the accumulator.
2. Lift a forward part of the car and record it on supports. Remove forward wheels and protection of arches of wheels.
3. Merge oil from the transmission, screw up drain and jellied traffic jams the required moment.
4. Remove both power shafts.
5. Under the car unscrew bolts of fastening of the case of the intermediate bearing of a power shaft to an engine mount and the lower frame. Displace a suspension bracket aside.
6. Remove the case of the air filter and system of inlet pipes.
7. Remove the working cylinder of coupling, having pressed it inside and in this situation having turned on 90 ° counterclockwise. Remove the working cylinder together with a pusher.
8. Using an elastic band, fix a pusher on the cylinder. Prop up a coupling pedal wooden whetstone.
9. By means of the lever remove two spherical hinged connections of a cable from selector levers on the transmission. Take a cable from fastening brackets on the transmission.
10. Disconnect from the transmission electric sockets – such as backing lamp switch, sensor of the drive of a speedometer and tire of grounding (the arrow specified the place of connection of the tire of grounding). Unscrew a bolt and remove the TDC sensor from the top part of the transmission.
11. Unscrew bolts of fastening of a starter and move a starter aside, without disconnecting from it a wire.
12. Remove the turbocharger air inlet pipe located between the pallet of a case and the transmission.
13. Unscrew bolts of fastening and remove a protective plate of a flywheel.
14. Unscrew fastening bolts (are specified by shooters a photo at the left) pipes of the amplifier of steering. On a photo on the right the arrow showed a bolt arrangement on the case.
15. Remove the lower frame of a forward suspension bracket.
16. The winch lift the left side of the power unit so that the weight of the power unit was perceived by the winch.
17. Establish a jack under the transmission and lift it so that the weight of the transmission was perceived by a jack.
18. Unscrew the central nut (it is specified by an arrow) from the left suspension bracket of installation of the power unit. Unscrew bolts and remove a rubber pillow of a suspension bracket. Unscrew bolts and remove a suspension bracket.
19. Slightly you priopustit a jack that it still supported the transmission, and unscrew bolts of fastening of the transmission to the block of cylinders of the engine.
20. Lower the engine and a jack, move the transmission to the left and remove it from the directing pins. Lower the jack supporting the transmission and take the transmission from under the car.

Preparation for installation of the transmission

The special Peugeot 0216E tool for connection of the release bearing with a press disk

PERFORMANCE ORDER
1. Remove the release bearing from a press clutch plate and repeatedly establish it on the transmission before installation of the transmission into place. In this case the release bearing will correctly be installed on a press disk when using the special tool.
2. The special Peugeot 0216E tool for installation of the release bearing into place consists of the T-shaped handle, the cardan hinge and a special tip. The tool is inserted through an opening for the working cylinder in a transmission case so that a working part of the tool entered a coupling switching off fork groove. When the tool is turned on 90 °, the working end closes the ends of locks in coupling switching off fork grooves. The pulling of the tool turns a fork of switching off of coupling and installs the release bearing in the lock of a press disk.
3. Remove coupling knot.
4. Using the screw-driver, remove the release bearing, having wrung out a blooming ring (1) from an internal part of a diaphragm spring of a press disk.
5. Remove the release bearing from a press disk, then establish a blooming ring (1) in a flute of the case of the release bearing (2).
6. Establish coupling knot.
7. Install the release bearing on a main shaft of the transmission and connect it to a coupling switching off fork. Check that the coupling switching off fork easily and smoothly moves the release bearing and that captures of a fork are correctly established on bearing ledges.
8. Check that the special Peugeot tool entered a groove of a fork of switching off of coupling and was recorded in it at turn on 90 °. Remove the special tool.
9. Replace sealing rings of the crankshaft.

Installation

PERFORMANCE ORDER
Installation is made in the sequence, the return to removal, taking into account the next moments:
      – check that the release bearing is correctly installed on primary to a transmission shaft;
      – check that the directing pins are on the places;
      – after the transmission is screwed on the engine, install the special Peugeot tool as it is described earlier, pull the tool on yourself so that the blooming ring of the release bearing connected to a press clutch plate
      – establish the lower frame of a forward suspension bracket;
      – tighten all nuts and bolts the required moment;
      – install into place the working cylinder of coupling, previously having greased a pusher with lubricant on the basis of a molybdenum disulfide. Install the working cylinder on a transmission case, press it against the stop and at the same time turn on 90 ° clockwise. Slowly press a pedal of coupling and lift it back manually. In 10 seconds repeat this operation. Again press a coupling pedal, release it and check that it returned to a starting position;
      – establish cables so that spherical hinged connection with a diameter of 13 mm connected to the top lever, and spherical hinged connection with a diameter of 10 mm – with the side lever;
      – add oil in the transmission.