505 Gti gearbox
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Thread: 505 Gti gearbox

  1. #1
    Fellow Frogger!
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    Default 505 Gti gearbox

    How do you identify which version of the manual 5 speed a 505 has? The car in question is a french built 89 505Gti which I have been asked to take the gearbox out of, also any advice on the best method for this?

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  2. #2
    Demannu-facturing! Demannu's Avatar
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    All 505 GTi 5 speeds had a BA7/5 gearbox.
    Scotty

    Melbourne - Dandenong Ranges

    1956 Peugeot 403 - 'Francois' - resto project

    1969 Peugeot 504 - 'Pascal' - daily driver project

    1970 Peugeot 404 Utility - 'Brutus' - resto project

    1978 Peugeot 604 - as yet unnamed - V6 on straight LPG

    1987 Peugeot 505 - as yet unnamed - project car

    1999 Peugeot 406 Coupé - 'Chloe' - 5 speed manual

    2011 Peugeot 3008 XTE HDi - 'Zoe' - hatchback on steroids

    2014 Peugeot RCZ - 'Remy'

    1999 Range Rover 4.6 HSE - 'Grover' - tow car

  3. #3
    Demannu-facturing! Demannu's Avatar
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    I'll read the rest of the message now

    Assuming that the car is a sedan, to take the gearbox out, do the following in this order:

    • Jack the car up and secure on jackstands.
    • Undo the exhaust system engine pipe from the manifold, and then unbolt it wherever it is bolted to the underbody and drivetrain
    • Unbolt the diff mounts from the underbody of the car
    • Remove the circular vibration damper from the link tube, and also the bracket to the rear crossmember if fitted
    • NOTE: Sometimes I've had to lower the rear crossmember to drop the link tube far enough
    • Remove the centre console, and remove the cover over the gear selector
    • Disconnect the gear linkages at the gearbox end
    • Disconnect reversing light switch wires from gearbox
    • Undo the top 2 link tube bolts (8mm allen key) from the back of the gearbox, accessed through the centre console
    • Undo the bottom 2 link tube bolts from underneath the car
    • Slide the diff, link tube and tailshaft towards the back of the car until it disengages completely from the gearbox. Push the torque tube upwards so that it is above the level of the gearbox
    • Remove the radiator cooling fan shroud
    • Disconnect the hose from the intake manifold to the air flow meter
    • Disconnect the steering column at the rubber flector plate
    • Place a second jack underneath the engine crossmember and raise it just enough to take the weight
    • Unbolt the 4 crossmember to chassis bolts (19mm) and replace one on each side with an XN cylinder head bolt.
    • Lower the second jack down about 7 inches (any further and you start damaging things, any less and there isn't enough space)
    • Remove the clutch slave cylinder from the bell housing (2x 11mm bolts)
    • Remove 3x dust covers from bell housing to reveal flywheel. You may also have to disconnect the TDC sensor if it is fitted and still connected!
    • Remove 3x 17mm starter motor securing bolts and 8x 8mm allen key bolts holding engine to gearbox
    • Find yet another jack and place it under the gearbox, about halfway between the back of the bell housing and the front of the extension housing, and take the weight
    • Pull the gearbox backwards and allow the jack to take the weight
    • WARNING - It's bloody heavy.
    • Lower the jack and drag gearbox from under the car.

    To quote just about every procedure in a Haynes manual - Installation is Reversal of Removal.

    Just to add, if the car is a wagon, by far the easiest way is to simply remove the engine. Mucking around with that rear axle is a death trap.

    I've got the whole gearbox remove and install again down to about 6 hours, plus whatever needs doing in the middle. Good luck.
    Scotty

    Melbourne - Dandenong Ranges

    1956 Peugeot 403 - 'Francois' - resto project

    1969 Peugeot 504 - 'Pascal' - daily driver project

    1970 Peugeot 404 Utility - 'Brutus' - resto project

    1978 Peugeot 604 - as yet unnamed - V6 on straight LPG

    1987 Peugeot 505 - as yet unnamed - project car

    1999 Peugeot 406 Coupé - 'Chloe' - 5 speed manual

    2011 Peugeot 3008 XTE HDi - 'Zoe' - hatchback on steroids

    2014 Peugeot RCZ - 'Remy'

    1999 Range Rover 4.6 HSE - 'Grover' - tow car

  4. #4
    Fellow Frogger!
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    Default

    Thanks for such a detailed response, very much appreciated.

  5. #5
    Fellow Frogger!
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    Default 505 box removed!

    Demannu, thanks again, you did not slip in that this job is a PITA!

  6. #6
    Fellow Frogger! Uffee's Avatar
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    Unbolt the 4 crossmember to chassis bolts (19mm) and replace one on each side with an XN cylinder head bolt.
    Do the cylinder head bolts make a suitable substitute?
    504 GL Coupe '73 Silver
    504 GTDT Pickup Mini-Motorhome '83 Coral Red
    407 HDi Sedan '05

  7. #7
    Demannu-facturing! Demannu's Avatar
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    Quote Originally Posted by kiwia110
    Demannu, thanks again, you did not slip in that this job is a PITA!
    Yeah, it can be a bit of a nightmare first time round. You get the hang of it, though.

    Quote Originally Posted by Uffee
    Do the cylinder head bolts make a suitable substitute?
    The cylinder head bolts are much longer (nearly three times the length) and allow you to lower the engine down without dropping it out completely by accident, and also allows you to just jack it straight back up and it will stay in line with the holes.
    Scotty

    Melbourne - Dandenong Ranges

    1956 Peugeot 403 - 'Francois' - resto project

    1969 Peugeot 504 - 'Pascal' - daily driver project

    1970 Peugeot 404 Utility - 'Brutus' - resto project

    1978 Peugeot 604 - as yet unnamed - V6 on straight LPG

    1987 Peugeot 505 - as yet unnamed - project car

    1999 Peugeot 406 Coupé - 'Chloe' - 5 speed manual

    2011 Peugeot 3008 XTE HDi - 'Zoe' - hatchback on steroids

    2014 Peugeot RCZ - 'Remy'

    1999 Range Rover 4.6 HSE - 'Grover' - tow car

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