B2CG6TK1 - 406D9 BE4 GEARBOX

DISMANTLING - ASSEMBLY CLUTCH HOUSING

1 - IDENTIFICATION INHIBITOR SYSTEM FOR 5TH GEAR / REVERSE

Certain gearboxes BE4/5 are fitted with an inhibitor system for 5th gear / reverse .

Composition of the system :

• inhibitor pin (1)
• inhibitor bracket (2) retained by 2 bolts in the gearbox housing

NOTE : the pin when fitted on must project beyond the clutch housing joint face : distance 8 + 0 / -0.5 mm .

Use of the [17] tool gurantees this fitting-on dimension .

NOTE : gearboxes with no inhibitor system for 5th gear / reverse are fitted with a traditional double pin system (3) - (4) .

2 - PRELIMINARY OPERATIONS

Stripping the gearbox .

Remove :

• gearbox casing
• input and output shafts
• release bearing guide

3 - DISMANTLING

Remove :

• the reverse gear fork (5) with its shaft (6)
• the locking finger (7)
• the spring (8)
• the magnetic plate (9)
• the output shaft bush (10)

Drive out the mounting pins (11) from the selector lever (12) .

Remove :

• the selection lever (12)
• the spring (13)
• the washer (14)
• the seal (15)
• the selection shaft (16)

3 - 1 - GEARBOX WITH INHIBITOR SYSTEM FOR 5TH GEAR / REVERSE

Fit tool [18a] on pin (17) .

Immobilise the claws of tool [18a] in the groove of the pin (17) .

Fit tool [18b] observing the stacking order of the pieces .

Extract pin (17) by turning the nut of tool [18b] clockwise .

3 - 2 - GEARBOX WITHOUT INHIBITOR SYSTEM FOR 5TH GEAR / REVERSE

Position the gear engagement shaft (18) against the housing .

Drift out the gear lever pins (19) and the gear engagement finger pins (20) (Drift out the pins in turn) .

Remove :

• the gear selection shaft (18)
• the cassette assembly (21)

WARNING : the cassette assembly cannot be disassembled .

Extract the gear engagement shaft seal (22) .

Remove the gear selection spring bracket (23) .

BE3R GEARBOX

Detach the bearing (24) .

Move the shaft (22) to release it from the bearing (25) .

Remove the shaft (22) .

Detach the bearing (25) .

ALL MODELS

4 - ASSEMBLY

Always renew :

• the seals
• the pins

BE3R GEARBOX

Always renew : The bearings .

ALL MODELS

Fit :

• the gear selection spring bracket (23)

Tighten the 2 bolts to 1.5 ± 0.3 da.Nm. .

Fit :

• the new seal (22)
• the cassette assembly (21)
• the gear selection shaft (18)

4 - 1 - GEARBOX WITH INHIBITOR SYSTEM FOR 5TH GEAR / REVERSE

IMPERATIVE : follow the order indicated .

remove the threaded rod [17b] .

Position :

• the pin (17)
• the tool [17a]

Tighten the 4 bolts (18) to 1.5 ± 0.3 da.Nm. .

fit the tool [17b] .

fully screw tool [17b] .

IMPERATIVE : this position of tool [17b] guarantees the fitting of pin (17) .

4 - 2 - GEARBOX WITHOUT INHIBITOR SYSTEM FOR 5TH GEAR / REVERSE

Replace the 19) - (20 pins in turn .

Fit :

• the output shaft bush (10)
• the magnetic plate (9)
• the spring (8)
• the locking finger (7)
• the reverse gear fork (5) with its shaft (6)

Tighten the nut to 4.5 ± 0.9 da.Nm .

Fit : The selection shaft (26) .

Fit :

• the new seal (15)
• the washer (14)
• the spring (13)
• the selection lever (12)
• the pins (27)

BE3R GEARBOX

Identification :

• fork shaft top bearing (24)
• fork shaft lower bearing (25)

Fit and clip the bearing (25) .

Insert the shaft (22) in the clutch housing .

Position the shaft (22) in the bearing (25) .

Fit and clip the bearing (24) .

ALL MODELS

IMPERATIVE : ensure that the magnetic plate (9) is still in place .

5 - COMPLEMENTARY OPERATION(S)

Observe the cleaning and refitting conditions .

Refitting the bearing guide tube .

Checking-adjustment of the input shaft bearings .

Refitting the input and output shafts .

Refitting the gearbox cover .

Reassembling the gearbox .