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 Posted: Tue Aug 05, 2014 7:07 am |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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Hi all
At the weekend me and my brother tried to replace the clutch on my 1.6 16v (JP4), everything, including the gearbox, is off and the clutch is changed, but we cannot get the gearbox back on.
I don't know if this is a clutch alignment issue (it seems ok) or just the weight and awkwardness of the box itself.
My question is, does anyone have any tips or advice for getting the box back on (everything else I'm fine with) or even anyone that could lend a hand in the Nottingham/Mansfield area, it would be much appreciated as the car is currently just sitting in my garage and I cant even get it to a mechanic to sort it.
Thanks in advance
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Posted: Tue Aug 05, 2014 9:13 am |
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Joined: Feb 16, 2010
Posts: 440
Trade Rating: +2
Location: Devon
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Do you have a clutch alignment too? could use a deep socket on a extension if not.
They are awkward but I done my 2.0 hdi the other day and the box on that is fair weight when your on your own. make sure all the dowels are greased up so they slide into the box locating holes nicely. can put a smear of grease on the input shaft of the box to help.
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Posted: Tue Aug 05, 2014 11:12 am |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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I don't have an alignment tool, i used an extension bar with tape round it though it the right place, I'm going to reattempt it again soon but if anyone still has tips please keep em coming, i think i need all the help i can get.
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Posted: Tue Aug 05, 2014 11:42 am |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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| josh206xsi wrote: |
| I don't have an alignment tool |
There's normally a plastic alignment tool included in the clutch kit, well there is if you buy a decent clutch kit.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Tue Aug 05, 2014 12:14 pm |
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Joined: Feb 16, 2010
Posts: 440
Trade Rating: +2
Location: Devon
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I know valeo give you one but the luk one I bought the other day didn't. Its probably the splines not matching together as well.
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Posted: Tue Aug 05, 2014 1:57 pm |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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The kit I've got is a LUK.
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Posted: Tue Aug 05, 2014 4:53 pm |
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Joined: Oct 01, 2011
Posts: 168
Trade Rating: 0
Location: norfolk
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Line it up by eye and carefully slide the gearbox on. I no its awkward, I have done many clutches and duel mass flywheels. The best things that can be of help when puting a googl box back on. Is bracing, jack, frend and a lot of patience. Im not saying aliment tools are not needed. If you have 1 use it by all means. But the right size bolt throught the middle helps indicate its lined up. Works for me
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Posted: Tue Aug 12, 2014 4:49 am |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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Hi again all,
Just a quick thanks for the advice, once again the members of this site have been a great help, I have completely got my 206 back together and on the road.
However one last question on this topic, the clutch is working well and doesn't slip at all like the old one did, but there is still a rattle when the clutch pedal is up which disappears when pressed down, I assume this is the release/thrust bearing, but it is a brand new one and wondered if this is going to be a problem or a small rattle i should just live with, as like I said everything works perfectly.
thanks again
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Posted: Tue Aug 12, 2014 5:32 am |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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Did you replace the input shaft guide bush with the clutch kit?
Guide bush is a separate part & doesn't come with a clutch kit.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Tue Aug 12, 2014 5:40 am |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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No I didn't, is that likely to cause issues?
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Posted: Tue Aug 12, 2014 11:26 am |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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| josh206xsi wrote: |
| No I didn't, is that likely to cause issues? |
I think we have just found the source of your rattle 
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Wed Aug 13, 2014 2:26 am |
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Joined: Apr 09, 2013
Posts: 23
Trade Rating: 0
Location: Nottinghamshire
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Yeah I guess it must be that, do you think that will definitely need changing imminently? Its just I really don't fancy taking the gearbox off again anytime soon.
thanks again for the help
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Posted: Mon Aug 24, 2015 2:30 pm |
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Joined: Jun 19, 2010
Posts: 1600
Trade Rating: +4
Location: South Bucks
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| MrBSI wrote: |
Did you replace the input shaft guide bush with the clutch kit?
Guide bush is a separate part & doesn't come with a clutch kit. |
Anyone know the part no for the guide bush for the BE box (2.0 138bhp)? Can find the MA version online but unlikely to be same ... or is it?
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| Down to just the 1.4 HDi. Cayman Green 2.0i CC sold. | |
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Posted: Mon Aug 24, 2015 3:02 pm |
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Joined: Apr 01, 2014
Posts: 668
Trade Rating: 0
Location: Cornwall
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Just ring your local Peugeot garage they will sort it for you asap. Its only cheep aswell.
Just ask him for the guide / nose cone. Soon as you tell them you've changed the clutch they will know what you on about.
Nightmare to take it all apart again .
Could that rattle be the release bearing as it's come off the folk. Why is there no rattle while the clutch is not compressed .
When you press the clutch it applys pressure & squeezes the bearing into the pressure plate = no play no rattle?
Was just a throught .
The only issue the guide/ nose cone would have was if the surface of the guide had been damaged .
As the clutch went & the release bearing did not destroy itself? I would say it wouldn't rattle plus it's probably still smooth so it shouldn't be an issue.
I've got one here you can have for free, its used thou. Smooth as no wear on it at all.
If it helps
When changing it don't over tighten the 3 11mm bolts.
Easily yo rip the threads if no to careful n
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| If it aint broke dont fix it ! | |
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Posted: Tue Aug 25, 2015 6:59 am |
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Joined: Jun 19, 2010
Posts: 1600
Trade Rating: +4
Location: South Bucks
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For the BE gearbox, it's part no 2105 35 and I've been quoted £17.49 ... seems to come with the input shaft seal too so not a bad price. Some on fleabay are cheaper, but the quality is unknown and I don't want to do this job twice!
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| Down to just the 1.4 HDi. Cayman Green 2.0i CC sold. | |
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