Straight-Cut Synchromesh Gear Set for Peugeot-Citroën BE4R Gearbox

The gear ratios and RPM drops have been carefully designed to closely match those used in top R2-spec rally cars, such as the Peugeot 208 R2.

To keep the overall cost as low as possible, we developed our BE4R close-ratio gear set to work with OE BE4R final drives. This provides two major advantages:

1️⃣ Cost Efficiency – Retaining the OE final drive helps keep the overall conversion cost as low as possible.

2️⃣ Reliability & Availability – OE BE4R final drives are reliable, affordable and readily available, with a wide range of ratios available (12 different options identified so far).

This wide choice of final drive ratios allows the top speed to be adapted to different applications, stages and circuits, making the gear set particularly suitable for rallying and hill climbs.

The gear set retains the OE mainshaft clutch spline: 21 mm × 18 teeth, allowing compatibility with clutch discs using the original BE4R spline specification.

Advanced Lubrication Features

This gear set incorporates several design features specifically intended to improve gear lubrication and reduce friction and wear, including:

• Parkerized mainshaft (phosphate conversion coating) – Helps retain an oil film on the mainshaft surface while providing additional protection against wear.
• Honed internal gear surfaces – The internal running surfaces of the gears are honed to provide a smoother and more uniform finish, helping to reduce friction between the gears and mainshaft.
• Lubrication holes and grooves – The floating gears incorporate specially designed holes and internal grooves to improve oil flow and distribution between the gears and mainshaft.
• Needle bearings on 3rd and 5th gears – Needle bearings are used between the mainshaft and the 3rd and 5th gears to significantly improve lubrication and reduce friction and wear in these critical areas.

📌 The attached speed chart shows the OE BE4R final drive ratios that we have identified on the market, allowing you to select the most suitable ratio for your required top speed.

Gear Ratios

• 1st: 34/12 – 2.833
• 2nd: 32/15 – 2.133
• 3rd: 29/17 – 1.706
• 4th: 27/19 – 1.421
• 5th: 26/21 – 1.238

Material, Finishing & Heat Treatment

✔ Material: Billet and forged high-strength nickel-chromium-molybdenum (Ni-Cr-Mo) alloy steel

✔ Finishing Processes: Gear grinding

✔ Surface Treatments: Sandblasting, shot peening and Parkerizing

✔ Heat Treatments: Carburizing and cryogenic treatment

✔ Surface Hardness: HRC 56–60

Additional Part Included – Free of Charge

BE 5th gear aluminum cover

The aluminium 5th gear cover is included free of charge with the gear set.

Important – Gear Oil Specification

For correct lubrication and long-term reliability, this gear set must be used with SAE 80W-90 gear oil:

• SAE 80W-90 LS → When used with a plate-type LSD
• SAE 80W-90 without LS additives → When used with a Torsen/gear-type LSD or OE open differential