Anton green 12 1 Cars Posted July 15, 2006 What would I need to do to put a 5th gear from a pug 405 into my 205 1.9 gearbox with Mi16 CWP (and reverse gear being towards the offside rear end of the car)? 1= jack up car 2= drain gear oil 3= take end of gearbox off (??) 4= .........? . .. ... 999= I havent ever done gearbox work before, can you put me in the right direction, thanks Share this post Link to post Share on other sites
Sandy 191 Posted July 15, 2006 You're gonna need new nuts (230443 x2) for the end of the shafts. 4= Select fifth gear and drive the roll pin out of the 5th gear selector fork to disengage the fork from the selector shaft. 5= Being careful not to un-select 5th, select fourth, the idea being that having both gears selected at once will lock the gear shafts. 6= Using an air gun (they're bloody difficult to impossible, to undo by hand) undo the 28mm nut on the end of each shaft. 7= Carefully Remove the 5th gear synchro assembly and fork, keeping the internal hub aligned with the outer part (this might be a simple slide off, it might need a puller, it varies! But levering it will make it stuck!!) 8= Remove the gears Refitting is reverse of etc. Share this post Link to post Share on other sites
Miles 331 1 Cars Posted July 15, 2006 Sandy's pretty much spot on, But I would to add or differ 4. Undo 5th Gear nut using a air gun, saves the steps above. 5. Watch out for the ball bearing in the selector when removing it, loose this and you can't put it back together. 6. It's a good idea to keep the hub aligned, But if lost it doesn't matter, just like replacing it, also worth checking the spline here, as they wear Share this post Link to post Share on other sites
Anton green 12 1 Cars Posted July 15, 2006 thanks all. I am going to have to leave it or pay someone else to do it as Im not confident it will happen. I wouldnt know how to select 4th and 5th gear at the same time, or have an air gun, or know where the ball bearing in the selector is which is a good idea to look out for. Oh, I dont have a puller either. Im thinking that by the time I have bought an air gun and gear puller I could just pay a specialist for their time and labour. Thanks for outling the process Share this post Link to post Share on other sites
