[pullitt73]

is there a 6 speed gearbox i can put into my 05 807 SE as the box in it is u/s.
only just got car don't know numbers on box but does have a speedo drive on diff not abs sensors.will new 2.0l hdi box out of expert be any good ratio wise? thanks bob

 

[reliable406]

expert boxes are different but could be made to fit needs clutch hydraulics altered and expert clutch though.

dont be tempted by a 2.2 6 speed they dont fit as bellhousing is bigger

 

[pullitt73]

2006- onwards

Gearbox code 20MB12
SUBMIT GEARBOX CODE 20MB12 REQUESTSEARCH GEARBOX CODE 20MB12 STOCK
Make
Year of construction Engine capacity
Peugeot 807
2006 2,000 cc
2007 2,000 cc
2008 2,000 cc
2009 2,000 cc
Peugeot Expert
2006 2,000 cc
2007 2,000 cc
Citroen C8
2006 2,000 cc
2007 2,000 cc
2008 1,997 cc, 2,000 cc
2009 2,000 cc
Citroen Jumpy
2008 2,000 cc
2009 1,997 cc, 2,000 cc
Fiat Scudo
2006 2,000 cc
2008 1,997 cc, 2,000 cc
2010 2,000 cc
found this on a site called proxyparts.com lots of codes and relevant vehicle and engine sizes dutch vehicle breaker

 

[reliable406]

Yes thats what i mean the 2005 expert models are 5 speed 2006/7 ONWARDS are 6 speed but your 2005 model 807 uses the older style box so to fit the later box you need various other parts.

To be honest the 407 box could be fitted as could 6 speed 307 but again alterations are needed nothing will bolt straight in

 

[pullitt73]

Looking at the pictures of the six speed except 2.2 none have crank sensor hole in top of bell housing

 

[pullitt73]

flywheel measurements

can any one give me the diameter of a 2.2 hdi 807 flywheel please.
also does anyone know of a push type clutch cover for Peugeot that will fit a 226-230 mm centre plate please thanks

307 1.6 hdi clutch cover fits release bearing does not, ml5c shaft is bigger than the be4r input shaft.

 

[pullitt73]

2.2 6 speed conversions

just a thought when people did 6 speed conversions did they change flywheel as well as gearbox. just i'm looking at flywheels etc and 2.2 runs 240mm dia flywheel and 2.0 uses 230mm if they did change both g/box and flywheel then the starter motor maybe wrong as i have a 2.0 tdci focus 05 plate starter using pug engine but 6 speed box starter is completely different (to my 2.0 5 speed 55 plate 807) but it did have the bigger flywheel and i have measured g/boxes and they appear the same that is my 07 box 6 speed to my 55 box 5 speed thanks bob

 

[reliable406]

People generally DONT do 6 speed conversions due to the fact its hard to find 6 speed boxes to suit the 2 litre

2.2 flywheel is bigger because 2.2 gearbox is bigger as is 2.2 engine block its ALL different

Fords set up uses a peugeot engine with a ford clutch flywheel and starter in the ford you can use a 5 speed or 6 speed flywheel but you must use the starter to suit the flywheel we have a 1.8 tdci mondeo here with 6 speed box and we fitted a 5 speed clutch as the box fits either in the peugeot its not that simple.

Peugeot use the same starter design in all DW series cars the 2.2 has a more powerful 1 but it fits the 2 litres

 

[pullitt73]

yeah i sort of found that out after i wrote the post just before going to bed i read up and did a search on parts etc but thanks for the reply

 

[reliable406]

It can be done though i have looked into it for our 406 and it will work but you need to drill a hole in the bellhousing for the crank sensor the clutch system needs changed to the later style cylinder and cables may need to be mixed and matched for a good gearchange.

For your application a whole 2.2 conversion would be best option as 2.2 is a nicer drive

 

[pullitt73]

i have 2007 gearbox out of 2.0lhdi 807. the gear selector mech fits off my five speed onto six as this was missing. the only thing is the clutch i dont want to put a new flywheel etc on car had new engine 30000 miles ago with new fly and clutch,the 2007 807 is 136 hp uses a push clutch dia 240mm same size as 2.2. i have a 05 109 hp 807 uses pull system and is 226-230mm dia.
parts i have gearbox ,307 1.6hdi clutch cover (bearing is to small shaft dia centre plate 18 splines),new slave cylinder,new pipe to slave (only 38 quid impressed),new release bearing for 2007 version.
my only problem is the release bearing it a larger dia compared to the one with the kit my worry is the outer casing touching clutch fingers. i'm looking into the petrol version 2.0l 16v release bearing maybe same as 307 1.6 hdi clutch cover size but with bigger centre dia for support sleeve.

 

[reliable406]

136 = 2.2 hence the bigger clutch the box wont bolt on to your 2 litre block if it does its from an RHK type 2 litre 136 engine and wont have the sensor in the bellhousing.

Have you checked the gearbox code to see what it came from

 

[pullitt73]

yes it came from the 136 2.0l 2007 version I've measured the diameter and its the same the hole is drilled a spacer block made also as the five speed is thicker where the sensor goes, its bolted in place i'm just sorting release bearing and then i'll shove it all in

 

[reliable406]

Thats fine that box will fit but not sure your clutch plan will work all the later pivot arm style release bearings are the same style so if the 1 you have you need the correct 1 for the expert gearbox.

 

[pullitt73]

hi there everyone the six speed box is in and working but it is a ball ache to do
the only major problem is the flywheel/clutch. i used the original flywheel and clutch centre plate and a 1.6 hdi 110 cover plate with a Renault 11 Volvo 440 release bearing and making it fit a new bearing carrier sleeve by using emery cloth to get a smooth travel. thanks to all for your help and in put cheers bob

 

[pullitt73]

update

i have had the car mot'd and i'm now using it clutch is a little bit heavier than normal otherwise car drives nice thanks to everyone's input it's all been helpful

 

[cambgeot]

I'm not sure if it is possible, but I have an 03 2.2hdi 807 with 4HW engine and 5 speed box. I have bought a replacement complete engine and gearbox (due to blown headgasket) from an 04 C8. The engine code matches, but the new engine has a 6 speed box. If it fits I intend to use the 6 speed box. I will post here with result.

 

[cambgeot]

I'm not sure if it is possible, but I have an 03 2.2hdi 807 with 4HW engine and 5 speed box. I have bought a replacement complete engine and gearbox (due to blown headgasket) from an 04 C8. The engine code matches, but the new engine has a 6 speed box. If it fits I intend to use the 6 speed box. I will post here with result.

Engine on right out of the car. After some prep work the engine on the left will be installed.