C8 gearbox / clutch advice please

[ozfish1969]

Hello all,

I'm new to the forum having just bought a low mileage 2006 2.0 16v petrol C8 which was in need of a clutch, the release bearing having failed.

I've managed (eventually) to get the box off and removed the clutch, which looking at the date stamp was the original. I must say that I have never had such 'fun' removing a gearbox in all my life, it was an absolute nightmare compared to any box/clutch I've done before.

Can anyone of you good people help with the following questions,

How much gearbox oil does the manual box hold ? Am I right in thinking that the correct gearbox oil is 75W-80W ? I can't see a bolt on the gearbox which would show the level, as for filling I assume its filled via the plastic breather at the top.

Does anyone know what the torque settings are for (1) the clutch plate bolts, (2) the driveshaft hub bolts (boy were they tight to remove even with an impact driver), (3) the gearbox to engine bolts.

I can't seem to find much about the above on line so I'm turning to yourselves for advice and help.

Once the clutch has been renewed its the timing belt next, hopefully that will be a bit easier, though looking at the space to carry it out it may be wishful thinking

Thanks.

[ozfish1969]

Think I've found the capacity for the gearbox since posting, 2 litres of 75w-80.

[Hell Razor5543]

That sounds about right. You can get that oil from GSF for around £10 per litre (made by Total). A dealership will charge more.

[RichardW]

Post up the VIN and I'll see what I can find.

[ozfish1969]

Thanks,

VIN is XXXXXXXXXXX277508.

Further inspection today has revealed the clutch guide tube has been totally wrecked too. Anyone know where the best place to source one would be ? GSF etc don't stock them. Are the petrol and diesel ones the same.

Just waiting for the new clutch kit and clutch fork to arrive, decided to go with a Valeo kit as worth the extra few pounds I think, having read about cheaper kits failing in a little as a few thousand miles.

[RichardW]

OK, BE4R gearbox, so 1.8 litres of 75W80 oil. There should be a filler plug on the end casing - the bolt that looks different to all the others!

Guide tube (with seal) is part no 210535, costs 20.64 from the dealer. Plenty on e-bay at less than that if you search on the part no.

Info says clutch bolts to 2 daNm; box to engine 6 daNm, drive shaft nuts to 10 daNm + 60°. I'll leave you to convert into some sensible units!!!

[ozfish1969]

Richard,

Many thanks for the info, just ordered the clutch tube now using the part number.

[ozfish1969]

Picked up the clutch kit today, got home and have noticed that the clutch plate has no markings as to which side faces gearbox / engine. Its a Valeo kit and looking on their technical website there are no instructions for the kit at all. The similar kits (i.e for diesel models, not for petrol) do not give any advice either, just simple fitting instructions and torque settings.

The old clutch I took out, also Valeo, has no markings either !

The only stamps on the clutch plate are 'L' on one side and 'U' on the other. The clutch plate splines are longer on one side than the other, but I've never taken notice of this on other cars where I have changed a clutch as the 'gearbox' or 'engine' facing side is always clearly marked.

I was hoping to put it back together tomorrow.

Any ideas people.

[GiveMeABreak]

Here's the diagram for your car - not sure if this helps, they say underneath "Caution: When refitting, place the face of the clutch disc, where the No PSA ******80 is marked, gearbox end".

I know you have a Valeo, but maybe the pic will help. What about the markings on the plate (the grooves) from the picture they seem to angle to the right.

[ozfish1969]

Marc,

Thanks for that, a great help.

I did email the Valeo technical department for advice but they closed at 17.30 so still waiting.

The picture makes it crystal clear now, as the plate is quite distinctive on one side to the other. Its going to be the side with the longer shaft towards the engine, and the stamped 'Made in France' towards the gearbox.

Other than 'Made in France' and a serial number, my plate has no other markings. I even checked its validity on the Valeo site as there are copies out there, though I did buy it from GSF so would expect it to be genuine.

Why they can't simply stamp engine or gearbox on the plate, or even a 'E' and 'G' is beyond me.

Thanks again.

[GiveMeABreak]

No worries, just happened to have the service docs opened and saw your VIN, so only a couple of minutes to snapshot and post. I know it can be frustrating to hang about - especially now they have closed for the day!

[ozfish1969]

Now I'm confused !

Found some instructions online for clutch replacement on a Peugeot 407 which states the plate fits the other way around than above. Wish I never looked now.

My kit also fits a 407, among other French cars, and as we know a lot of the engines and gearboxes were shared between the manufacturers.

The picture above sent by Marc certainly looks right in so much as the visible clutch plate is identical to the one in my kit so with that in mind I will fit is as such.

[Hell Razor5543]

It would be nice if the clutch plates had a clear way of indicating which way round they go, but as the manufacturers will make parts to be used across the world using letters probably would not work. Now, if there were internationally accepted symbols for engines and gearboxes, and these were used (and clearly explained in the paperwork provided with the parts) that should work.

[ozfish1969]

Just realised the 407 is a 'pull' type clutch not a 'push' type as is in my C8.

As such, I am thinking, a 407 pull clutch is actuated sort of back to front hence the clutch plate being installed the opposite way to Marc's diagram for the C8.

[RichardW]

Offer it up to the flywheel - it will probably only fit one way round - at a first pass I would fit it with the more domed side towards the gearbox.