Tu5jp4 engine, be4 gearbox conversion

[n0v0s]

Hi, need some help from gearbox boffins...

Car is a peugeot 206 with the 1.6 16v engine, fitted with the chocolate ma5 box. I want to swap the ma5 out for the stronger be4 box as found on Citroen Picasso's. I know this is a popular mod with the Saxo/106 lot, but can't really find any info for conversion on 206/306's. I think the berlingos use the be4/tu5 engine combos too, so I'd imagine it should be easier to bolt up the be4 to a tu5jp4 converted 306 instead of the 206? With regards to readily available shafts and hubs, linkages?

Basically, I haven't a clue as of yet. I've still got to look into it all properly. I know the gear sets can be swapped to help make the ratios more suitable. What's involved? Can it be done cheaply? 

The idea being, I have a 206 xsi lying dormant with this engine and a knackered box. If I can get a stronger be4 mounted, then I can look into lashing a turbo on it and mega squirt it for all it's 206 gayness and sins. A test mule before the setup possibly finds it way into a 306! It's a non starter without the be4 though.

Cheers,

[welshpug]

cup cars ran a 6 speed Peugeot sport be box, based on the xsi sp with the tu engine.

I think the cheapest option for gear linkages is the cable setup from a 180, Im not sure the gear rods from a dw/ew 206 will fit past the tu exhaust. (pug sport stuff would, but expensive and rare)

driveshafts may well be straight fit from dw/ew 206 if the TU-BE4 Bolts up to the transmission mounting.

dont forget to get the intermediate bearing carrier from the same donor as the box.

[Ruan]

Picasso is surely cable shift anyway - that would be the box to use? Therefore wouldn't the 180 linkages fit on a Picasso TU5/BE4 box straight off with no piss about... Hmm...

Find out whether driveshafts are same in a TU5/BE4 Picasso/206 in length as a BE4 DW/EW Picasso/206 as transmission mounting point should be the same... Should mean you can just use the shafts from a DW/EW powered 206.

EDIT: Same as above then basically.

[welshpug]

yes, exactly why I suggested that.

fact they have cable linkages doesn't mean they myst be cable in what you fit them into, swap the top arm and youll be able to use gear rods, which is how every saxo/106 conversion is done, but no subframe mounted gear linkage to ger in the way of the front pipe.

[adam b]

Easy enough to put cable shift into a 306

[n0v0s]

Thanks for that gents, very helpful!

So I'd need;

gti180 shifter/cable linkage set up, roughly £30 ebay
Ew/dw driveshafts assuming same length/mounting position £50ish
Be4 Gearbox; £80
206 ew/dw hubs?

How about clutch/flywheel? Pull/push fork? I'm a noob sooo :S

Anything else? I'm surely missing something...

I have a friend with a 206 hdi 2.0 so I'll see if i can measure driveshafts.

[Ruan]

yes, exactly why I suggested that.

fact they have cable linkages doesn't mean they myst be cable in what you fit them into, swap the top arm and youll be able to use gear rods, which is how every saxo/106 conversion is done, but no subframe mounted gear linkage to ger in the way of the front pipe.

Sorry, didn't see your post when I posted

WRT Clutch: The 206 will be hydraulic I'd guess?

If not, hydraulic pedal box from BE4 engined car and put in - the BE4 box I don't think has the holes/mounts for a cable fork.

[welshpug]

stock clutch & flywheel, you can fit all thr hydraulic setup from another 206.

hubs depends what you have currently, if you have 35 mm hub nuts then no need to change them.

[n0v0s]

From brief pic comparison - i'd hazard a guess that the hub's may well be the same size (VERY reliable method I know). I'll measure up the hubs to check. 

Although it's been parked up for over 5 years now (was my first car!), I'm quite certain the 206 is hydraulic. So even less to convert. 

This is looking promising! And quite cheap too which is the main objective. The 206 was supposed to be sold, but it looks like it might be sticking around. I think I'll investigate under the bonnet tomorrow and start her up 50k miles, pre multiplexed. Slammed on hot tunning coilovers, decatted with magnex exhaust. Well fast innit! Until i destroyed the gearbox

[n0v0s]

I recall there being a table of the different ratios for the Peugeot gearboxes somewhere, maybe 205 gti drivers forum? Can't seem to find it.

Would be interesting to see the ratios for the Picasso be4, if it's even suited to a boosted tu5?

[bashbarnard]

Quick google found this http://www.saxperience.com/forum/showthr...p?t=261617