PEUGEOT 404 User Manual

rod
may be
used to free them if
the balls
get
stuck in the
chan nel.
RefeÍ
to
FIG
6:23 and
remove
the locking
needle 1
Írom
the
3rd/4th
gear
fork shaft.
Drive
out the
spiÍal
pin,
2 in FIG
6:24, wirh
a driÍt M
from
the reverse
pinion
shaft 3 and Íorce
this shaft towaros
the inside
of the housing.
All the
parts
should now
be thoroughly
cleaned
and oil
drillings
checked
to
ensure that
they are Íree from
obstÍuction.
Examine
the
splines the
gear
teeth for wear
and
also
the friction
surfaces
oÍ the synchronizing
rings,
comparing
them with new
parts
if
possible.
FIG
6:20 Removing
thè
locking
plug
Key to Fig 6:20 2 1st/2nd
gear
Íork shaÍt 4
3rd/4rh
gear
fork shaft
5
Locking
plug
FIG
6:22
Locking
springs and balls
Renew
any
defective
parts,
obtaining
the help
of
the service
station
iÍ
necessary.
lt is advisable
to
renew
the following
parts
whenever
they are dismantled:
snap
rings,
spring washers
and striking fork
pins,
the
mainshaft
nut
and
oil seal. This latter
is removed
by
prising
out
with
a tyre
lever,
but needs a
press
for reÍitting.
Any other
seals
or non-metallic
washers
should
also be
renewed.
Dio
all
the
components in
clean engine
oil before
assembly.
6
:7
Assembling
the BA7
gearbox
Position
the
gearbox
as in
FIG
6
:25 with
the
drain hote
uppermost
and Íit the reverse
gear pinion
and shiÍting Íork
in
the
direction shown,
then insert
the locking
ball and
spring into
the
channel shown
in FIG
6:26.
Secure with
the
plug
after
smearing
the threads
with sealer
and
tighten
to a torque
oÍ 7.2 lb
ÍÍ. Move
the
shifting
fork
shaft
into the
neutral
position.
TuÍn
the casing into
the
position
shown in FIG
6:27
with
the locking
channel
1 vertical
and fit
the
3rdl4th
and reverse
locking Íinger
2.
Smear
a locking needle
with
tallow and fit
it into rrs
housing
in the
3rdl4th
gear
charge Íork
shaft
as shown in
FIG
6:23.
Now
turn the casing
upright
as in FIG
6:28
and fit
the two
gear
change forks
in the
order shown. That
for the
lst/2nd gear
is
the larger
(item
5)
and is
on the righr
and the
smaller
(item
6) Íor
the
3rd/4th
gear
is
on the
left. Insert
the fork shaft
4
until
it
is
just
flush
with
the
ball lock
hole 7.
lnsert
a
spring and locking
ball into
the channel
1 in
FIG
6:29,
press
the ball
down wirh
a driÍt M
and then
push
the shaft 2
against the drift
and withdraw
the
drift
without releasing
the
pressure
on the
shaft.
Refer to FIG
6:30. move
the shaft into
the
neutral
position
and secure the 3rd/4th fork
3 with
a new locking
ptn.
Roll the
casing on to its righthand
side
(FlG
6:31
)
and insert
a locking
ball
into
the
passage
4
so as to rest
against the
3rdl4th
gear
shaft
2. lnsert the 1
st/2nd
gear
shaft
5 until the neutral
position
is reached
and then
fit
the locking ball 6
and spring 7 into
passage
4.
Secure
with the
plug
8 after applying
a
sealer to the threads
and
Key
to
Fig
6 :21
6 Locking
plug
countershaft
pinion
58
FIG
6
:21
Removing
the rêverse
shiÍting
Íork
7 ShiÍting fork
and

PEUGEOT 404 Specifications

General

Brand	PEUGEOT
Model	404
Category	Automobile
Language	English