Gearbox removal & installation: Peugeot 208 BE4R (DV6DTED)

🧭 Before you start

Fits: platform codes 1.6, HDIF

• Opens: clutch fluid

Don't miss

• Use the special tool to counterhold

🔧 Engine codes this applies to

📐 32 workshop diagrams for DV6DTED(9HP)

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Special tool:
2. Disconnect the battery
3. Ball joint splitting tool:
4. Raise and support the vehicle with the front wheels suspended
5. Remove the engine lower cover

6. Remove the air inlet resonator
7. Reversing light switch:
8. Remove the air inlet hose
9. Neutral position sensor:
10. Remove the battery tray
11. Remove the earth cable from the gearbox
12. Disconnect the reversing light switch
13. Disconnect the neutral position sensor
14. Disconnect the gear-shift cables from the gearbox
15. Use the special tool
16. Unclip the clutch hydraulic line
17. Remove the clutch slave cylinder from the gearbox
18. Without disconnecting the system, place the pump aside
19. Disconnect the engine wiring loom
20. Remove the bolts from the engine wiring bracket
21. Move the harness aside
22. Remove the nut
23. Remove the stud
24. Remove the bolt
25. Lower arm ball joint:
26. Note: Move it aside
27. Secure to the vehicle
28. Stabiliser links:
29. Remove the reinforcement brace
30. Wheel bolts
31. Remove the drive shaft nuts
32. Use the special tool to counterhold
33. Disconnect the track rod ends
34. Use the special tool
35. Unclip the brake hose(s)
36. Disconnect the ABS wires from the suspension
37. Disconnect the stabiliser link(s)
38. Disconnect the lower arm ball joints
39. Starter motor
40. Remove the left drive shaft
41. Remove the intermediate shaft bracket
42. Remove the right-hand drive shaft
43. Renew the gaskets
44. Plug the gearbox drive shaft hole
45. Disconnect the exhaust clamp
46. Remove the pendulum support
47. Remove the engine/gearbox attaching bolts, except the top bolt
48. Use a trolley jack to support the engine
49. Use a hoist to support the gearbox
50. Remove the gearbox support bracket
51. Lower the gearbox slightly
52. Remove the gearbox support
53. Remove the engine/gearbox attaching bolts
54. Separate the gearbox from the engine
55. Remove the gearbox

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