Scenic II PT3 Transmission
January 13, 2017 | Author: Alen Tutić | Category: N/A
Short Description
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Description
2
Transmission 20A
CLUTCH
21A
MANUAL GEARBOX
23A
AUTOMATIC GEARBOX
29A
DRIVESHAFTS
X84, and J84 77 11 322 042
FEBRUARY 2009
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."
Edition Anglaise
All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.
© Renault s.a.s 2008
Scénic II - Section 2
Scénic II - Section 2 ContentsPage
Contents Page
20A
CLUTCH Clutch: Precautions for repair
20A-1
Identification
20A-2
Mechanism / Disk: Removal Refitting Clutch thrust bearing: Removal - Refitting
21A
23A
20A-4 20A-14
Input shaft lip seal: Removal - Refitting
Automatic gearbox: Specifications
23A-5
Automatic gearbox: List and location of components
23A-7
Automatic gearbox oil: Draining - Refilling
23A-24
Hydraulic distributor: Removal - Refitting
23A-31
21A-12
Solenoid valves: Removal
23A-40
21A-13
Hydraulic distribution wiring: Removal - Refitting
23A-41
21A-21
Hydraulic distributor internal wiring: Removal - Refitting
23A-48
21A-45
Flow regulation solenoid valve: Removal - Refitting
23A-54
21A-56
Differential output seal: Removal - Refitting
23A-56
Multifunction switch: Removal - Refitting
23A-62
21A-2
Differential output seal: Removal - Refitting
23A-3
23A-12
Identification
Manual gearbox: Removal Refitting
Automatic gearbox: Identification
Automatic gearbox: Removal - Refitting
21A-1
Manual gearbox oil: Draining - Refilling
23A-1
23A-10
Manual gearbox: Parts and consumables for the repair work
Manual gearbox oil: Specifications
Automatic gearbox: Precautions for repair
Automatic gearbox: Parts and consumables for the repair work
MANUAL GEARBOX
Manual gearbox: Specifications
AUTOMATIC GEARBOX
21A-3
Contents
23A
29A
AUTOMATIC GEARBOX Multifunction switch: Adjusting
23A-66
Speed sensor: Removal Refitting
23A-68
Pressure sensor: Removal Refitting
23A-69
Gearbox temperature sensor: Removal - Refitting
23A-72
Oil pressure switch: Removal - Refitting
23A-73
Converter seal: Removal Refitting
23A-77
Automatic transmission connector: Removal Refitting
23A-79
Automatic transmission computer: Removal Refitting
23A-81
Automatic transmission control unit: Removal Refitting
23A-84
DRIVESHAFTS Driveshaft: Precautions for repair
29A-1
Front left-hand wheel driveshaft: Removal Refitting
29A-2
Front right-hand wheel driveshaft: Removal Refitting
29A-3
CLUTCH Clutch: Precautions for repair Essential special tooling Emb. 1518
Set of clutch disc centring mandrels
Before removing the clutch, check: - The direction of fitting for the clutch plate. Before refitting the clutch, check: - The flywheel friction track (no scratches or blue stains), - The crankshaft bearing (no sticking), - The engine and gearbox seals (replace if necessary), - The sliding action of the clutch plate on the output shaft, - The thrust bearing guide and the clutch fork (no wear or scratches).
WARNING To prevent the clutch from juddering or slipping, do not grease the output shaft or the clutch plate hub. During refitting check the following: Check the direction of the clutch plate. Centre the clutch plate using the tool (Emb. 1518) Gradually torque tighten the clutch pressure plate bolts. After refitting, check: - The clutch play (for a cable operated vehicle), - Bleeding of the hydraulic circuit (for vehicles with hydraulic controls).
20A-1
20A
CLUTCH Identification
20A Colour of the springs (1) and (2) : Grey
K4J or K4M Pressure plate
K9K Pressure plate
102143
Drive plate 102143
Drive plate
102142
Plate external diameter: 200 mm Plate thickness: 6.9 mm 102142
Number of splines: 26
Plate outer diameter: 215 mm Plate thickness: 6.8 mm Number of splines: 26
20A-2
CLUTCH Identification Colour of springs (3) : Red and Black
20A Number of splines: 21
Colour of springs: (4) Grey
F4R or F9Q or M9R Pressure plate
22428
Drive plate
22429
Plate outer diameter: 239 mm Plate thickness: 7.8 mm
20A-3
CLUTCH Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q
REFITTING
Essential special tooling Mot. 1677
Flywheel locking tool.
Emb. 1604
Clutch compression tool for resetting retrofit system.
Emb. 1518
Set of clutch disc centring mandrels
EMB. 1604
Tightening torquesm pressure plate mounting bolts
1.2 daNm
REMOVAL
19919
a Remove the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A21) .
a Note: For automatic wear compensation mechanisms, compress the clutch pressure plate using tool (Emb. 1604).
16180
a Lock the engine using tool (Mot. 1677) (1) . a Remove the pressure plate mounting bolts. a Remove the friction plate. a Replace any faulty parts.
20754
a Lock the base plate of the (Emb. 1604) in a vice.
20A-4
CLUTCH Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q
20757
a Insert the circlip pliers at (3) .
20755
a Fit the pressure plate onto the base, then fit the thrust bearing (1) and the nut (2) .
20759
a Compress the springs (4) . a Slacken off the nut (2) completely (springs compressed). a Release the pressure plate.
20756
a Tighten the nut (2) fully.
20A-5
CLUTCH Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q CENTRING
20758
a Remove the pressure plate from the base plate (checking that the springs are properly compressed).
22695
a Centre the clutch plate using the (Emb. 1518). a Refit the pressure plate on the flywheel. a Gradually tighten the pressure plate mounting bolts (1.2 daNm).
WARNING Clean the clutch shaft splines and refit the assembly without lubricant. Degrease the friction face of the flywheel.
102695
a Position the driven plate (small hub diameter (5) on flywheel end).
20A-6
CLUTCH Mechanism / Disk: Removal - Refitting JH3 or JR5 Essential special tooling Mot. 582-01
Flywheel locking tool.
Emb. 1518
Set of clutch disc centring mandrels
Tightening torquesm pressure plate mounting bolts
2 daNm
REMOVAL a Remove the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A21) .
16180
a Lock the engine using the (Mot. 582-01) (1) . a Remove the pressure plate mounting bolts. a Remove the friction plate. a Replace any faulty parts.
20A-7
20A
CLUTCH Mechanism / Disk: Removal - Refitting
20A
JH3 or JR5
REFITTING
flywheel end
b (1) .
a Centre the clutch plate using the (Emb. 1518). a Screw into place gradually in a radial pattern. a Torque tighten the pressure plate mounting bolts (2 daNm). a Remove tool (Mot. 582-01).
95414
118975
a Clean the clutch shaft splines. a Refit the assembly without lubricant. a Position the clutch plate with the shoulder on the
20A-8
CLUTCH Mechanism / Disk: Removal - Refitting
20A
M9R, and PK4 a Remove
Essential special tooling
- the mechanism bolts , Mot. 1431
Flywheel locking tool.
Emb. 1604
Clutch compression tool for resetting retrofit system.
Emb. 1780
Set of clutch disc centring mandrels.
- the mechanism, - the friction plate.
REFITTING I - REFITTING PREPARATIONS OPERATION
Tightening torquesm pressure plate mounting bolts
12 Nm
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the « engine - gearbox » assembly (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals), - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) .
19919
a Note: For automatic wear compensation mechanisms, compress the clutch pressure plate using tool (Emb. 1604).
II - REMOVAL OPERATION FOR PART CONCERNED
114917
a Fit the (Mot. 1431) (1) .
20754
a Place the base of tool (Emb. 1604) in a vice.
20A-9
CLUTCH Mechanism / Disk: Removal - Refitting
20A
M9R, and PK4
20757
a Insert the circlip pliers at (4) .
20755
a Fit the pressure plate onto the base, then fit the thrust bearing (2) and the nut (3) .
20759
a Compress the springs (5) . a Slacken off the nut (3) completely (springs compressed). a Release the pressure plate.
20756
a Tighten the nut fully.
20A-10
CLUTCH Mechanism / Disk: Removal - Refitting
20A
M9R, and PK4 II - REFITTING OPERATION Centring
20758
a Remove the pressure plate from the base plate (checking that the springs are properly compressed).
114916
a Refit the clutch plate. a Centre the clutch plate using tool (Emb. 1780) (2) Emb. 1780 .
Note:
a Refit the pressure plate on the flywheel.
Clean the clutch shaft splines and refit the assembly without lubricant.
a Fit the (Mot. 1431). a Tighten the pressure plate bolts until contact is made.
Degrease the friction face of the flywheel.
a Gradually tighten to torque the pressure plate mounting bolts (12 Nm). III - FINAL OPERATION. a Remove tool (Mot. 1431). a Refit: - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the « engine - gearbox » assembly (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals).
102695
a Position the driven plate (small hub diameter (6) on flywheel end).
20A-11
CLUTCH Mechanism / Disk: Removal - Refitting
20A
K9K, and TL4 Essential special tooling Mot. 582-01
Flywheel locking tool.
Emb. 1780
Set of clutch disc centring mandrels.
Tightening torquesm clutch pressure plate bolts
12 N.m
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A21) .
102143
a Slide the bolts (2) out of the mechanism.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove the mechanism.
123518
a Lock the engine using the (1) (Mot. 582-01).
117628
a Remove the clutch plate.
REFITTING I - REFITTING PREPARATION OPERATION a Degrease the flywheel friction face. a Clean the clutch shaft splines.
20A-12
CLUTCH Mechanism / Disk: Removal - Refitting
20A
K9K, and TL4 II - REFITTING OPERATION FOR PART CONCERNED
117628 108798
a Position the clutch plate. a Centre the clutch plate using the (Emb. 1780).
a Position the clutch plate with the section (10) against the flywheel. III - FINAL OPERATION a Remove the (Mot. 582-01) then the (Emb. 1780). a Refit the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) .
102143
a Tighten to torque and in order the clutch pressure plate bolts (12 N.m).
20A-13
CLUTCH Clutch thrust bearing: Removal - Refitting
20A
JH3 or JR5 or ND0
ND0
Tightening torquesm hydraulic union mounting bolts
0.9 daNm
bolts mounting the clutch thrust bearing to the clutch housing
2.1 daNm
REMOVAL JH3 or JR5
101223
a Remove: - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the hydraulic union clip (1) , - the hydraulic union, - the two clutch thrust bearing mounting bolts (2) on the clutch housing, 18439
- the clutch thrust bearing.
a Remove: - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the two hydraulic union bolts (1) , - the hydraulic union,
REFITTING
- the two clutch thrust bearing mounting bolts (2) on the clutch housing,
a To refit, proceed in the reverse order of removal.
- the clutch thrust bearing.
JH3 or JR5 a Torque tighten: - the hydraulic union mounting bolts (0.9 daNm), - the bolts mounting the clutch thrust bearing to the clutch housing (2.1 daNm).
20A-14
CLUTCH Clutch thrust bearing: Removal - Refitting JH3 or JR5 or ND0
ND0 a Torque tighten the clutch thrust bearing mounting bolts on the clutch housing (2.1 daNm).
a WARNING To avoid damaging the clutch slave cylinder, do not lubricate the clutch shaft. Never operate the system while the slave cylinder is removed.
Note: Always replace the hydraulic union. a Bleed the clutch control ( (see 37A, Mechanical component controls) ).
20A-15
20A
CLUTCH Clutch thrust bearing: Removal - Refitting
20A
PK4 II - REMOVAL OPERATION FOR PART CONCERNED Tightening torquesm bolts mounting the clutch thrust bearing on the clutch housing
21 Nm
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the « engine - gearbox » assembly (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals), - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) .
114914
a Remove: - the bolts (2) mounting the clutch thrust bearing on the clutch housing, - the clutch thrust bearing.
REFITTING I - REMOVAL PREPARATION OPERATION a Check the condition of the input shaft seal. Replace it if necessary. WARNING 114915
a Remove the hydraulic union retaining clip (1) .
To avoid damaging the clutch slave cylinder, do not lubricate the clutch shaft. Always replace the clutch thrust bearing with a new one when the clutch is replaced.
a Unclip the clutch hydraulic pipe. a Move the hydraulic union away.
20A-16
CLUTCH Clutch thrust bearing: Removal - Refitting PK4 II - REFITTING OPERATION FOR PART CONCERNED
114914
a Refit the new clutch thrust bearing. a Tighten the bolts mounting the clutch thrust bearing on the clutch housing until they just make contact. a Tighten to torque the bolts mounting the clutch thrust bearing on the clutch housing (21 Nm). III - FINAL OPERATION. a Refit the clip. a Connect the hydraulic union. a Position the clutch hydraulic pipe. a Refit: - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the « engine - gearbox » assembly (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals). a Bleed the clutch control (see Clutch circuit: Bleeding) (MR 370, 37A, Mechanical component controls).
20A-17
20A
MANUAL GEARBOX Manual gearbox: Parts and consumables for the repair work
21A
M9R, and 700, and PK4
Type
Packaging
Part no.
GEARBOX OIL
Component Immerse all parts
SILICONE ADHESIVE SEALANT
100g cartridge
77 11 227 484
Housing assembly
LOCTITE 518
24 ml syringe
77 01 421 162
Switch threading
Parts always to be replaced when they have been removed: - lock rings, - differential output seals, - input shaft output seal, - pins. - hydraulic tappet.
21A-1
MANUAL GEARBOX Identification M9R, and 700, and PK4
105538
(1)
Identification label
(2)
Identification inscription
21A-2
21A
MANUAL GEARBOX Manual gearbox: Specifications
21A
PK4 I - IDENTIFICATION (1)
Identification label
(2)
Etching.
II - GEAR RATIOS
105538
PF6 gearbox Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
Tachometer
001
11/43
19/40
31/40
45/40
45/31
51/28
15/73
27/47
23/17
002
11/43
19/40
31/40
45/40
45/31
51/28
15/73
27/47
23/17
003
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
none
004
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
none
005
11/46
17/38
31/43
41/40
41/31
47/30
16/71
27/47
none
006
11/46
17/38
31/43
41/40
41/31
47/30
16/71
27/47
none
007
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
24/18
008
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
none
009
11/46
17/38
31/43
41/40
41/31
47/28
16/67
27/47
24/18
010
11/46
17/38
31/43
41/40
41/31
47/28
16/67
27/47
none
011
11/43
19/40
31/43
41/40
41/31
47/28
16/67
27/47
24/18
012
11/43
19/40
31/43
41/40
41/31
47/28
16/67
27/47
none
013
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
none
014
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
none
021
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
none
022
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
none
21A-3
MANUAL GEARBOX Manual gearbox: Specifications
21A
PK4 Suffix
1st
023 024
2nd
3rd
4th
5th
6th
Final drive
11/43
31/43
41/40
41/31
47/28
16/67
11/43
31/43
41/40
41/31
47/28
16/67
Reverse gear
Tachometer
PK4 gearbox Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
Tachometer
001
11/43
19/40
31/43
43/44
43/35
46/31
18/59
27/47
none
002
11/43
19/40
31/43
43/44
43/35
46/31
18/62
27/47
none
004
11/43
19/40
31/43
41/40
41/31
47/30
19/64
27/47
none
005
11/43
19/40
31/43
43/44
43/35
46/31
19/73
27/47
none
006
11/43
19/40
31/43
43/44
43/35
46/31
18/59
27/47
none
007
11/43
19/40
31/43
43/44
43/35
46/31
19/64
27/47
none
008
11/43
19/40
29/43
39/43
39/35
41/31
17/64
27/47
none
009
11/43
19/40
31/43
43/44
43/35
46/31
18/62
27/47
none
012
11/43
19/40
31/43
41/40
41/31
47/30
17/64
27/47
none
013
11/43
19/40
31/43
43/44
43/35
46/31
18/62
27/47
none
014
11/43
19/40
31/43
38:39
38/31
47/30
19/73
27/47
none
015
11/43
19/40
31/43
38/39
38/31
46/31
18/62
27/47
none
016
11/43
19/40
29/43
39/43
39/35
41/32
19/73
27/47
none
017
11/43
19/40
29/43
39/43
39/35
41/29
17/64
27/47
none
018
13/40
19:37
31/43
38:39
38/31
46/31
16/71
27/47
none
019
13/40
19/37
31/43
38/39
38/31
46/31
16/71
27/47
none
020
11/43
19/40
31/43
38/39
38/31
46/31
19/64
27/47
none
022
11/43
19/40
31/43
43/44
43/35
46/31
18/62
27/47
none
PA0 gearbox Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
001
11/43
19/40
31/43
41/40
41/31
47/28
16/67
27/47
002
11/43
19/40
31/43
41/40
41/31
47/28
16/67
27/47
003
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
21A-4
MANUAL GEARBOX Manual gearbox: Specifications
21A
PK4 Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
004
11/46
17/38
31/43
41/40
41/31
47/30
16/67
27/47
005
11/46
17/38
31/43
41/40
41/31
47/30
16/71
27/47
006
11/46
17/38
31/43
41/40
41/31
47/30
16/71
27/47
007
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
008
11/46
17/38
31/43
41/40
41/31
47/28
16/71
27/47
009
11/46
17/38
31/43
41/40
41/31
47/28
16/67
27/47
010
11/46
17/38
31/43
41/40
41/31
47/28
16/67
27/47
21A-5
MANUAL GEARBOX Manual gearbox: Specifications
21A
JH3 or JR5 I - IDENTIFICATION
19860
A marking (1) on the gearbox casing indicates: - (A) Gearbox type - (B) Gearbox suffix - (C) Fabrication number 109167
- (D) Factory of manufacture II - GEAR RATIOS
Suffix
First
Second
Third
Fourth
Fifth
Reverse gear
Final drive
Tachometer
11/39
14:61
None
41/31
11/39
16/55
None
JA3 sequential gearbox JA3-001
11/41
21/43
28/39
34/35
39/32
JA5 sequential gearbox JA5-001
11/41
21/43
28/37
35/34 JH1 manual gearbox
JH1 -004
11/37
22/41
28/37
34/35
39/32
11/39
14/59
21/19
JH1 -013
11/37
22/41
28/37
34/35
39/32
11/39
15/61
21/19
JH1 -014
11/37
22/41
28/37
30/29
39/32
11/39
15/58
21/19
JH1 -015
11/37
22/41
28/37
30/29
41/31
11/39
15/56
21/19
JH1 -016
11/37
22/41
28/37
34/35
39/32
11/39
14/59
None
JH1 -017
11/37
22/41
28/37
34/35
39/32
11/39
15/61
None
JH1-019
11/37
22/41
28/37
34/35
39/32
14/59
14/59
21/19
JH1 -018
11/37
22/41
28/37
30/29
41/31
11/39
15/56
21/19
JH1 -020
11/41
21/43
28/39
34/35
39/31
11/39
14/59
None
JH1-021
11/41
21/43
28/39
34/35
39/31
11/39
14/59
None
21A-6
MANUAL GEARBOX Manual gearbox: Specifications
21A
JH3 or JR5 Suffix
First
Second
Third
Fourth
Fifth
Reverse gear
Final drive
Tachometer
JH1 -053
11/41
21/43
28/39
34/35
39/31
11/39
14/59
22/18
JH1-054
11/41
21/43
28/39
34/35
39/31
11/39
15/56
21/19
JH1-055
11/37
21:41
28/37
34/35
39/31
11/39
16/55
21/19
JH3 manual gearbox JH3-050
11/41
21/43
28/39
34/35
39/31
11/39
15/56
21/19
JH3-052
11/41
21/43
28/39
34/35
39/32
11/39
14/59
22/18
JH3-053
11/37
22/41
28/37
30/29
42:41
11/39
15/58
22/18
JH3-054
11/41
21/43
28/37
30/29
41/31
11/39
14/63
22/18
JH3-055
11/41
21/43
28/37
30/29
39/31
11/39
14/63
22/18
JH3-056
11/41
21/43
28/37
30/29
41/31
11/39
14:61
22/18
JH3-057
11/41
21/43
28/39
34/35
39/31
11/39
14/59
None
JH3-058
11/41
21/43
28/39
34/35
39/32
11/39
14/59
22/18
JH3-059
11:45
22:47
28/39
34/35
37/33
11/39
14/69
22/18
JH3-060
11/41
21/43
28/39
34/35
39/31
11/39
14/59
22/18
JH3-061
11/41
21/43
28/39
34/35
39/31
11/39
14:61
22/18
JH3-062
11/41
21/43
28/39
34/35
39/31
11/39
14:61
22/18
JH3-063
11/41
21/43
28/39
34/35
39/32
11/39
14:61
22/18
JH3-064
11/41
21/43
28/39
34/35
39/32
11/39
14/59
22/18
JH3-065
11/41
21/43
28/39
34/35
39/32
11/39
14/59
22/18
JH3-066
11/41
21/43
28:29
34/35
39/31
11/39
14/63
22/18
JH3-067
11/37
22/41
28/37
34/35
39/32
11/39
14/63
22/18
JH3-068
11/41
21/43
28/39
34/35
39/32
11/39
14/59
22/18
JH3-071
11/41
21/43
28/37
30/29
39/31
11/39
14/63
22/18
JH3-072
11/41
21/43
28/37
34/35
39/32
11/39
14/59
22/18
JH3-105
11/41
21/43
28/39
31/34
37/33
11/39
14/59
None
JH3-106
11/41
21/43
28/39
34/35
39/32
11/39
14/63
None
JH3-128
11/41
21/43
28/39
34/35
39/32
11/39
14:61
None
JH3-129
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-131
11/41
21/43
28/39
31/34
37/33
11/39
15/58
None
JH3-132
11/37
22/41
28/37
30/29
42:41
11/39
15/58
None
21A-7
MANUAL GEARBOX Manual gearbox: Specifications
21A
JH3 or JR5 Suffix
First
Second
Third
Fourth
Fifth
Reverse gear
Final drive
Tachometer
JH3-137
11/41
21/43
28/39
31/34
37/33
11/39
14/59
None
JH3-141
11/37
22/41
28/37
30/29
42:41
11/39
15/58
None
JH3-142
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-143
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-144
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-145
11/37
22/41
28/37
30/29
42/31
11/39
16/57
None
JH3-150
11/37
22/41
28/37
30/29
42:41
11/39
15/58
None
JH3-154
11/41
21/43
28/39
31/34
37/33
11/39
16/61
None
JH3-155
11/41
21/43
28/39
31/34
37/33
11/39
15/58
None
JH3-160
11/41
22/41
28/37
30/29
42/31
11/39
15/58
22/18
JH3-166
11/41
21/43
28/37
30/29
42/31
11/39
16/55
None
JH3-169
11/41
21/43
28/39
34/35
39/31
11/39
14/59
None
JH3-170
11/41
21/43
28/39
34/35
39/32
11/39
14/63
None
JH3-171
11/37
22/41
28/37
34/35
39/31
11/39
15/61
None
JH3-172
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-173
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-174
11/37
22/41
28/37
30/29
42/31
11/39
15:68
None
JH3-175
11/37
22/41
28/37
30/29
42/31
11/39
15:68
None
JH3-176
11/41
21/43
28/39
34/35
39/32
11/39
14:61
None
JH3-177
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JH3-179
11/41
21/43
28/39
31/34
37/33
11/39
15:68
None
JH3-183
11/41
21/43
28/39
34/35
39/32
11/39
14/59
None
JH3-184
11/41
21/43
28/39
34/35
39/32
11/39
15/58
None
JH3-185
11/41
21/43
28/39
34/35
39/32
11/39
15/58
None
JH3-186
11/41
21/43
28/39
34/35
39/32
11/39
15/58
None
JH3-187
11/41
21/43
28/39
34/35
39/32
11/39
15/58
None
JH3-189
11/37
22/41
28/37
30/29
42/31
11/39
15/56
None
JH3-190
11/37
22/41
28/37
30/29
42/31
11/39
15/56
None
JH3-193
11/41
21/43
28/37
30/29
42/31
11/39
16/55
21/19
JH3-156
21A-8
MANUAL GEARBOX Manual gearbox: Specifications
21A
JH3 or JR5 Suffix
First
Second
Third
Fourth
Fifth
Reverse gear
Final drive
Tachometer
JR5 manual gearbox JR5-003
11/37
22/41
28/37
34/35
39/32
11/39
15/61
None
JR5-004
11/41
21/43
28/37
35/34
41/31
11/39
16/55
None
JR5-008
11/41
21/43
29:39
31/34
37/33
11:39
15/58
None
JR5-015
11/41
21/43
28/39
31/34
37/33
11/39
15/58
None
JR5-016
11/41
21/43
28/37
35/34
41/31
11/39
16/55
None
JR5-017
11/41
21/43
28/39
31/34
37/33
11/39
15/61
None
JR5-018
11/37
22/41
28/37
34/35
39/32
11/39
15/61
None
JR5-113
11/41
21/43
28/37
35/34
41/31
11/39
16/57
None
JR5-116
11/41
21/43
28/37
35/34
41/31
11/39
16/55
21/19
JR5-124
11/41
21/43
28/37
35/34
41/31
11/39
16/55
None
JR5-126
11/37
21:41
28/37
35/34
42/31
11/39
15/58
21/19
JR5-144
11/37
21:41
28/37
35/34
42/31
11/39
15/58
21/18
JR5-145
11/41
21/43
28/37
35/34
41/31
11/39
16/55
21/19
JR5-147
11/41
21/43
28/37
35/34
42/31
11/39
15/58
22/18
JR5-149
11/41
21/43
28/39
31/34
42/31
11/39
15/58
22/18
JR5-151
11/41
21/43
28/37
35/34
39/31
11/39
14/63
22/18
JR5-152
11/41
21/43
28/37
35/34
39/32
11/39
14/63
None
JR5-158
11/41
21/43
28/37
35/34
42/31
11/39
15/61
22/18
JR5-165
11/41
21/43
28/37
35/34
42/31
11/39
14/69
22/18
JR5-166
11/41
21/43
28/37
35/34
42/31
11/39
16/57
22/18
JR5-168
11/41
21/43
28/37
35/34
41/31
11/39
14/69
None
JR5-169
11/41
21/43
28/37
35/34
42/31
11/39
14:73
22/18
JR5-170
11/41
21/43
28/37
35/34
42/31
11/39
14/69
22/18
JR5-175
11/41
21/43
28/37
35/34
42/31
11/39
15/56
None
11/41
21/43
28/37
35/34
41/31
11/39
17/56
None
JR5-184 JR5-193
21A-9
MANUAL GEARBOX Manual gearbox: Specifications
21A
TL4 I - IDENTIFICATION (1)
Identification plate
(2)
Etching
II - GEAR RATIOS
111646
Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
000
11/41
19/37
31/41
40/39
38/29
47/30
15/59
11/28
001
11/41
19/37
31/41
40/39
38/29
47/30
15/56
11/28
002
11/41
19/37
31/41
40/39
38/29
47/30
16/57
11/28
003
11/35
19/37
29/43
34/41
38/39
39/34
16/69
11/23
008
11/37
19/37
28/39
35/39
35/32
43/33
15/59
11/25
013
11/41
19/37
31/41
40/39
38/29
47/30
15/59
11/28
014
11/41
19/37
31/41
40/39
38/29
47/30
15/59
11/28
015
11/41
19/40
31/45
35/39
35/32
43/33
16/71
11/28
016
11/41
19/40
31/45
35/39
35/32
43/33
16/71
11/28
017
11/37
19/37
28/39
35/39
35/32
43/33
16/69
11/25
018
11/41
19/37
31/41
40/39
38/29
47/30
16/66
11/28
019
11/41
19/40
31/45
35/39
35/32
43/33
15/71
11/28
020
11/41
19/40
31/45
35/39
35/32
43/33
16/71
11/28
021
11/41
19/40
31/45
35/39
35/32
43/33
15/71
11/28
022
11/41
19/37
31/41
40/39
38/29
47/30
15/59
11/28
024
11/35
19/37
29/43
34/41
35/34
37/30
16/69
11/23
026
11/41
19/37
29/43
40/39
38/29
47/30
15/59
11/28
21A-10
MANUAL GEARBOX Manual gearbox: Specifications
21A
TL4 Suffix
1st
2nd
3rd
4th
5th
6th
Final drive
Reverse gear
027
11/41
19/37
31/41
40/38
39/29
47/30
14/59
11/28
028
11/41
19/40
31/45
35/28
39/34
41/30
14/64
11/28
029
11/41
19/40
31/45
38/39
35/32
43/33
15/71
11/28
030
11/41
19/40
31/45
35/39
35/32
41/30
16/71
11/28
031
11/37
19/40
27/41
34/41
35/34
37/30
16/69
11/23
032
11/37
19/37
28/39
35/39
35/32
43/33
16/66
11/28
033
11/37
19/37
28/39
35/39
35/32
43/33
16/69
11/28
034
11/41
19/37
31/41
40/39
38/29
47/30
16/66
11/39
035
11/41
19/40
31/45
35/39
35/32
43/33
16/69
11/28
036
11/41
19/40
31/45
35/38
39/34
41/30
14/64
11/28
037
11/41
19/40
31/45
35/28
39/34
41/30
15/71
11/28
038
11/41
19/40
31/45
35/39
35/32
43/33
14/64
11/28
039
11/37
19/37
28/39
35/39
35/32
43/33
16/69
11/25
040
11/41
19/37
31/41
40/39
38/29
47/30
15/56
11/28
041
11/41
19/37
31/41
40/39
38/29
47/30
16/66
11/39
042
11/41
19/40
31/45
35/39
35/32
41/30
15/71
11/39
045
11/41
19/37
31/41
40/39
38/29
47/30
15/59
11/28
21A-11
MANUAL GEARBOX Manual gearbox oil: Specifications
21A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX I - VEHICLE/GEARBOX TYPE/OIL TYPE CORRELATIONS:
GEARBOX TYPE JBX JCX JRX JHX
III - IDENTIFICATION OF OIL FOR STANDARD EXCHANGE PK1 GEARBOXES:
TYPE OF OIL FOR GEARBOX TRANSELF 75W80
Note: For standard exchange PK1 gearboxes, the oil type (TRZ or TRP) is shown on a label.
TRJ
These two oils are replaced by TRX 75W80 or NFP 75W80.
or TRANSELF 75W80
NFJ
TRANSELF 75W80
TRX
NDX TL4 PKX PFX VMX NEX
or TRANSELF 75W80
NFP
TRANSELF 75W80
LD
NGX N0X UNX ZFX
II - STANDARDS AND PART NUMBERS OF THE VARIOUS RECOMMENDED OILS:
DESIGNATION
STANDARD
PART BER
TRANSELF
APIGL4,
77 11 143 534
TRX 75W80
MIL-L-2105 C or D
(5 litres)
TRANSELF
APIGL4,
TRJ 75W80
MIL-L-2105 C or D
May be ordered from ELF
or
NUM-
TRANSELF NFP 75W80
or TRANSELF NFJ 75W80 TRANSELF
APIGL4,
LD 75W80
MIL-L-2105
May be ordered from ELF
21A-12
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling
21A
PK4 Essential special tooling Mot. 1018
Sump plug tool.
Tightening torquesm drain plug
24 N.m
CAPACITY Gearbox type
Capacity in litres
PK4
2.4
I - OIL CHANGE
113764
a Refit the new seal on the plug, positioning the groove (2) towards the plug. a Torque tighten the drain plug (24 N.m). II - FILLING
114652
a Unscrew the drain plug (1) using the (Mot. 1018). a Let the oil run into a drain tray.
114772
a Undo the filler cap (3) .
21A-13
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling PK4
92081
a Fill the gearbox until the oil overflows via the oil filler cap opening using a syringe containing the recommended oil (see 21A, Manual gearbox, Manual gearbox oil: Specifications, page 21A-12) (Technical Note 6012A, 04A, Lubricants). a Tighten the filler cap.
21A-14
21A
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling
21A
TL4 Essential special tooling Mot. 1018
Sump plug tool.
Tightening torquesm drain plug
24 N.m
CAPACITY Gearbox type
Capacity in litres
TL4
2
I - OIL CHANGE
113764
a Refit the new seal on the plug, positioning the groove (2) towards the plug. a Torque tighten the drain plug (24 N.m). II - FILLING
113928
a Unscrew the drain plug (1) using the (Mot. 1018). a Let the oil run into a drain tray.
113928
a Undo the filler cap (3) .
21A-15
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling TL4
92081
a Fill the gearbox until the oil overflows via the oil filler cap opening using a syringe containing the recommended oil (see 21A, Manual gearbox, Manual gearbox oil: Specifications, page 21A-12) (Technical Note 6012A, 04A, Lubricants). a Tighten the filler cap.
21A-16
21A
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling
21A
ND0 Essential special tooling Mot. 1018
Sump plug tool.
Tightening torquesm drain plug
24 N.m
CAPACITY Gearbox type
Capacity in litres
ND0
2.1
I - OIL CHANGE
113764
a Refit the new seal on the plug, positioning the groove (2) towards the plug. a Torque tighten the drain plug (24 N.m). II - FILLING
101532
a Unscrew the drain plug (1) using the (Mot. 1018). a Let the oil run into a drain tray.
101532
a Undo the filler cap (3) .
21A-17
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling ND0
92081
a Fill the gearbox to overflow via the oil filler cap opening using a syringe containing the recommended oil (see 21A, Manual gearbox, Manual gearbox oil: Specifications, page 21A-12) (Technical Note 6012A, 04A, Lubricants). a Tighten the filler cap.
21A-18
21A
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling
21A
JH3 or JR5 Essential special tooling JR5 Mot. 1018
Sump plug tool.
Tightening torquesm drain plug
24 N.m
CAPACITY Gearbox type
Capacity in litres
JH3
2.8
JR5
2.5
I - OIL CHANGE JH3 110256
a Unscrew the drain plug (2) using the (Mot. 1018). a Let the oil run into a drain tray.
109488
a Unscrew the drain plug (1) using the (Mot. 1018). a Let the oil run into a drain tray.
113764
a Refit the new seal on the plug, positioning the groove (3) towards the plug. a Torque tighten the drain plug (24 N.m).
21A-19
MANUAL GEARBOX Manual gearbox oil: Draining - Refilling
21A
JH3 or JR5 II - FILLING JR5 JH3
110256 18749
a Undo the filler cap (4) .
a Undo the filler cap (5) .
92081
a Fill the gearbox until the oil overflows via the oil filler cap opening using a syringe containing the recommended oil (see 21A, Manual gearbox, Manual gearbox oil: Specifications, page 21A-12) (Technical Note 6012A, 04A, Lubricants). a Tighten the filler cap.
21A-20
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
REMOVAL
Essential special tooling
a Position the vehicle on a two-post lift.
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting engine mounting support with retaining straps.
a Disconnect the battery, starting with the negative terminal. a Remove the scuttle grille ( (see 85A, Wiping Washing) ).
Essential equipment component jack
Tightening torquesm wheel bolts
13 daNm
driveshaft nut
28 daNm
lower ball joint nut
6.2 daNm
track rod end nut
3.7 daNm
anti-roll bar ball joint nut
4.4 daNm
side panel mounting bolts
2.1 daNm
starter and gearbox bell housing bolts
4.4 daNm
engine tie-bar bolts on the engine
10.5 daNm
engine tie-bar bolts on the subframe
10.5 daNm
gearbox suspended mounting bolts
18 daNm
suspended mounting nut on the rubber pad
6.2 daNm
cooling radiator cross member front mounting bolts
10.5 daNm
104343
a Remove: - the two air filter access panel mounting bolts (1) , - the air filter access panel, - the scuttle panel partition mounting bolt (2) .
104246
a Remove:
gearbox drain plug
2.5 daNm
gearbox filler plug
0.3 daNm
- the scuttle panel partition,
battery cover mounting bolts
0.4 daNm
- the scuttle panel,
- the scuttle panel partition mounting bolts (3) ,
- the engine undertray. a Drain the gearbox. a Remove: - the front wheels,
21A-21
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5 a Disconnect:
- the engine covers, - the battery,
- the ABS sensor wiring,
- the battery mounting,
- the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle). a Remove the wheel arch liners.
- the injection computer with its support, - the air flowmeter,
I - LEFT-HAND SIDE OF THE VEHICLE
- the air inlet pipe.
102129 101821
a Remove: - the hub nut using the (Rou. 604-01),
a Remove the wiring harness mountings.
- the track rod end using the (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint. a Release the stub axle carrier from the driveshaft. a Remove the left-hand driveshaft.
104086
a Unclip the gear control cables from the gearbox.
21A-22
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5 II - RIGHT-HAND SIDE OF THE VEHICLE
101212 101819
a Remove:
a Remove the side stiffeners.
- the hub nut using the (Rou. 604-01), - the track rod end using the (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint, - the relay bearing bracket. a Release the stub axle carrier from the driveshaft. a Remove the right-hand driveshaft. a Attach the cooling radiator assembly to the upper cross member using rope. 102009
a Remove the cooling radiator cross member.
21A-23
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
106204
a Disconnect the reversing connector.
106199
a Remove the catalytic converter support from the clutch housing.
106200
a Disconnect the TDC sensor.
102115
a Remove the engine tie-bar.
21A-24
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
106201
a Disconnect the oil level sensor.
106205
a Disconnect: - the starter (4) , - the diesel fuel pressure sensor (5) .
14853
a Remove: - the starter mounting bolts (6) ,
106203
a Disconnect the earth strap from the gearbox.
- the starter. a Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.
21A-25
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
101701
a Disconnect the hydraulic union by removing the clip (7) .
106195
a Remove the gearbox support rubber pad.
102449
a Set up the engine support tool (Mot. 1453).
106194
a Remove: - the three gearbox support bolts, - the gearbox support.
21A-26
MANUAL GEARBOX Manual gearbox: Removal - Refitting K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
106193
a Remove the upper gearbox bell housing bolts. a Position the component jack under the gearbox a Remove: - the lower gearbox bell housing bolts, - the gearbox.
21A-27
21A
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
REFITTING WARNING
a WARNING
Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:
Do not coat:
- Add brake fluid to the reservoir.
- the gearbox output shaft with grease to avoid damaging the clutch slave cylinder,
- Bleed the hydraulic circuit ( (see 37A, Mechanical component controls) ).
- the clutch shaft splines.
- Top up the brake fluid level.
Note:
WARNING
To avoid any risk of leakage, the hydraulic union must always be replaced after the clutch pressure plate is replaced.
Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ).
a Check that the engine - gearbox centring rings are in place and correctly positioned.
a Torque tighten the battery cover mounting bolts (0.4 daNm).
a To refit, proceed in the reverse order of removal. a Torque tighten: - the wheel bolts (13 daNm), - the driveshaft nut (28 daNm), - the lower ball joint nut (6.2 daNm), - the track rod end nut (3.7 daNm), - the anti-roll bar ball joint nut (4.4 daNm), - the side panel mounting bolts (2.1 daNm), - the starter and gearbox bell housing bolts (4.4 daNm), - the engine tie-bar bolts on the engine (10.5 daNm), - the engine tie-bar bolts on the subframe (10.5 daNm), - the gearbox suspended mounting bolts (18 daNm), - the suspended mounting nut on the rubber pad (6.2 daNm), - the cooling radiator cross member front mounting bolts (10.5 daNm), - the gearbox drain plug (2.5 daNm), - the gearbox filler plug (0.3 daNm). a Top up the gearbox oil.
21A-28
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812 Essential special tooling
Tightening torquesm
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting engine mounting support with retaining straps.
subframe tie-rod mounting bolts gearbox drain plug
25 Nm
gearbox filler plug
3 Nm
wheel mounting bolts Essential equipment
battery cover mounting bolts
component jack
4 Nm
a Position the vehicle on a two-post lift. 280 Nm
lower ball joint nut
62 Nm
track rod end nut
37 Nm
anti-roll bar ball joint nut
44 Nm
side panel mounting bolts
21 Nm
starter and gearbox bell housing bolts
44 Nm
engine tie-bar bolts on the engine
180 Nm
engine tie-bar bolts on the subframe
105 Nm
gearbox suspended mounting bolts
180 Nm
suspended mounting nut on the rubber pad
44 Nm
steering shaft mounting stud
21 Nm
yoke
130 Nm
REMOVAL
Tightening torquesm driveshaft nut
105 Nm
a Disconnect the battery, starting with the negative terminal. a Refit the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 371, 55A, Exterior accessories).
104343
a Remove: - the two air filter access panel mounting bolts (1) , - the air filter access panel,
cooling radiator cross member front mounting bolts
105 Nm
cooling radiator cross member rear mounting bolts
21 Nm
subframe cross member mounting bolts
62 Nm
subframe rear mounting bolts
140 Nm
- the mounting bolt (2) from the scuttle panel partition.
21A-29
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812
104246
a Remove: - the scuttle panel partition mounting bolts (3) , - the scuttle panel, - the engine undertray. a Drain the gearbox.
101821
a Remove the wiring harness mountings.
a Remove: - the front wheels, - the engine covers, - the battery, - the battery mounting, - the injection computer with its support, - the air flowmeter, - the air inlet pipe.
104085
a Unclip the gear control cables from the gearbox.
21A-30
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812 I - LEFT-HAND SIDE OF THE VEHICLE F9Q
102129 102244
a Remove:
a Disconnect the heat exchanger - turbocharger air pipe.
- the hub nut using the (Rou. 604-01), - the track rod end using the (Tav. 476),
a Remove the air filter hose.
- the anti-roll bar ball joint, - the lower ball joint. a Remove the stub-axle carrier from the driveshaft.
a Disconnect:
a Remove the driveshaft.
- the ABS sensor wiring, - the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle). a Remove the wheel arch liners.
21A-31
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812 II - RIGHT-HAND SIDE OF THE VEHICLE
101212 101819
a Remove:
a Remove the side stiffeners.
- the hub nut using the (Rou. 604-01), - the track rod end using the (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint, - the relay bearing bracket. a Remove the stub-axle carrier from the driveshaft. a Remove the driveshaft. a Attach the cooling radiator assembly to the upper cross member using rope. 102009
a Remove: - the cooling radiator cross member. - the catalytic converter support from the clutch housing, - the starter mounting bolts, - the starter.
21A-32
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812
101354
a Remove the steering shaft yoke.
102452
a Remove the engine upper tie-bar.
101208
a Remove the sub-frame angle bracket (4) .
102312
a Remove the lower engine tie-bar.
21A-33
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812
101209
a Strap the sub-frame to the component jack. a Remove the sub-frame.
21A-34
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812
102449
a Set up the engine support tool (Mot. 1453).
102485
a Disconnect: - the reversing connector, - the TDC sensor. a Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.
102112
a Remove: - the gearbox support rubber pad, - the gearbox suspended mounting, - the upper gearbox bell housing bolts. a Position the component jack under the gearbox a Remove: - the lower gearbox bell housing bolts, 101701
a Disconnect the hydraulic union by removing clip (5) .
21A-35
- the gearbox.
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
F4R, and 770 – F9Q, and 812
REFITTING
- the subframe cross member mounting bolts (62 Nm),
a
- the subframe rear mounting bolts (140 Nm), WARNING
- the subframe tie-rod mounting bolts (105 Nm),
Do not coat:
- the gearbox drain plug (25 Nm),
- the gearbox output shaft with grease, to avoid damaging the clutch slave cylinder,
- the gearbox filler plug (3 Nm), - the wheel mounting bolts (130 Nm).
- the clutch shaft splines.
a Top up the gearbox oil.
Note:
WARNING
To avoid leaks, the hydraulic union must always be replaced after the clutch mechanism is replaced.
Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions: - Add brake fluid to the reservoir.
a Check that the engine - gearbox centring rings are in place and correctly positioned.
- Bleed the hydraulic circuit (see 37A, Mechanical component controls, Clutch circuit: Bleeding).
a Proceed in the reverse order to removal.
- Top up the brake fluid level. WARNING
a Connect the battery, starting with the positive terminal.
For information on refitting the sub-frame (see 31A, Front carrier components, Axle assembly sub-frame).
WARNING
a Always replace the steering shaft yoke stud after removal. a Torque tighten:
Carry out the necessary programming (see 80A, Battery: Removal - Refitting). a Torque tighten the battery cover mounting bolts (4 Nm).
- the driveshaft nut (280 Nm), - the lower ball joint nut (62 Nm), - the track rod end nut (37 Nm), - the anti-roll bar ball joint nut (44 Nm), - the side panel mounting bolts (21 Nm), - the starter and gearbox bell housing bolts (44 Nm), - the engine tie-bar bolts on the engine (180 Nm), - the engine tie-bar bolts on the subframe (105 Nm), - the gearbox suspended mounting bolts (180 Nm), - the suspended mounting nut on the rubber pad (44 Nm), - the steering shaft yoke mounting stud (21 Nm), - the cooling radiator cross member front mounting bolts (105 Nm), - the cooling radiator cross member rear mounting bolts (21 Nm),
21A-36
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
M9R, and 700, and PK4
Tightening torquesm gearbox mounting bolts
44 Nm
starter mounting bolts
44 Nm
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals). II - REMOVAL OPERATION FOR PART CONCERNED
115005
a Unpick the wiring harness (2) from the Top Dead Centre sensor and the oil level sensor on the gearbox. a Unclip the breather pipe from the gearbox.
115004
a Disconnect the connector (1) from the reverse gear switch. a Unpick the reverse gear switch wiring harness from the gearbox.
21A-37
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the gearbox, - the gearbox mounting bolts, - the starter mounting bolts. a Torque tighten: - the gearbox mounting bolts (44 Nm), - the starter mounting bolts (44 Nm). II - FINAL OPERATION. a Connect the reverse gear switch connector. a Clip: 115211
- the reverse gear switch wiring harness to the gearbox, - the TDC sensor and oil level sensor wiring harness to the gearbox. a Clip the breather pipe onto the gearbox. a Refit the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals).
115210
a Remove: - the starter mounting bolts (3) , - the gearbox mounting bolts (4) , - the gearbox.
21A-38
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4 a Remove:
Essential special tooling Mot. 1453
- the front section of the left and right-hand wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 371, 55A, Exterior protection),
Multiple-adjusting engine mounting support with retaining straps.
Bvi. 1718
- the front bumper (see Front bumper: Removal Refitting) (MR 371, 55A, Exterior protection).
Support plate for the gearbox removal/refitting tool. Essential equipment
safety strap(s) component jack
Tightening torquesm gearbox bolts
44 Nm
gearbox nuts
44 Nm
starter bolts
44 Nm
nut on the gearbox exhaust strut
21 Nm
bolts on the gearbox exhaust strut
21 Nm 115217
a Attach the cooling assembly using a safety strap(s).
REMOVAL
a Remove: REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 370, 02, Lifting equipment). a Remove: - the battery (see Battery : Removal - Refitting) (MR 370, 80A, Battery), - the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 370, 13B, Diesel injection), - the battery tray (see Battery tray: Removal - Refitting) (MR 370, 80A, Battery), - the air filter box (see Air filter unit: Removal - Refitting) (MR 370, 12A, Fuel mixture), - the engine cover, - the engine undertray. a Drain the gearbox (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A13) .
21A-39
- the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (MR 371, 41A, Front lower structure), - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) , - the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (MR 370, 19D, Engine mounting).
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4
117776
a Remove:
104865
a Fit the (Mot. 1453) with a safety strap(s). a Remove the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 370, 19D, Engine mounting).
- the bolts from the gearbox exhaust strut, - the nut to the gearbox exhaust strut, - the support strut (1) from the gearbox, - the front axle subframe (see Front axle sub-frame: Removal - Refitting) (MR 370, 31A, Front axle components), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 371, 56A, Exterior equipment).
112868
a Disconnect the clutch control pipe (2) by pressing on the clip (3) .
21A-40
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4
118832
117335
a Disconnect the reverse gear sensor connector (7) . a Unclip the breather pipe from the gearbox.
101743
a Unclip the two gear control cables (4) from the gearbox at: 116340
- the anchoring ball joints (5) ,
a Remove:
- the cable sleeve stops (6) .
- the upper bolt (8) from the starter, - the gearbox upper bolts (9) .
21A-41
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4
118894
a Disconnect the engine speed and position sensor connector.
116440
a Remove: - the earth wiring bolt,
a Remove:
- the earth wiring (11) ,
- the bolt from the engine speed and position sensor,
- the starter lower bolt,
- the engine speed and position sensor (10) .
- the gearbox lower bolts. a Fit the (Bvi. 1718) on a component jack.
116711
a Fit: - the (Bvi. 1718) and the component jack under the gearbox, - the bracket (12) using the nuts (13) ,
21A-42
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4
116713
a Tap the hole (14) using a self-tapping bolt (Part no.: 77 03 002 244) to attach the gearbox to the support using the rod (15) .
118833
a Note: Make sure that the air conditioning compressor pulley does not rest against the impact absorber mounting unit on the right-hand side of the vehicle when the engine and transmission assembly is lowered.
a Fit: - the shim (16) , - the shim (17) , - the rod (15) using the bracket (18) and the bolt (14) . a Tighten the rod (15) in an anti-clockwise direction to prevent the gearbox from tilting.
a Remove the gearbox using the (Bvi. 1718).
REFITTING I - REFITTING PREPARATIONS OPERATION a WARNING Do not grease the clutch shaft splines.
WARNING To prevent leaks, replace the slave cylinder after replacing the clutch pressure plate.
WARNING It is essential to replace the differential output lip seal each time the driveshafts are removed. a Replace the left-hand and right-hand differential output seals (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-45) . a Refit the gearbox studs.
21A-43
MANUAL GEARBOX Manual gearbox: Removal - Refitting
21A
TL4 a Check the condition of the centring devices on the gearbox.
- the nut to the gearbox exhaust strut, - the bolts to the gearbox exhaust strut. a Torque tighten:
II - REFITTING OPERATION FOR PART CONCERNED
- the nut on the gearbox exhaust strut (21 Nm),
a Position the gearbox using the (Bvi. 1718).
- the bolts on the gearbox exhaust strut (21 Nm).
a Refit a gearbox bolt.
a Refit:
a Remove the (Bvi. 1718) from the gearbox.
- the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (MR 370, 19D, Engine mounting),
a Refit the gearbox lower bolts. a Torque tighten:
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) ,
- the gearbox bolts (44 Nm), - the gearbox nuts (44 Nm).
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) ,
a Refit: - the starter lower bolt, - the earth wiring,
- the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (MR 371, 41A, Front lower structure).
- the earth wiring bolt, - the speed and position sensor,
a Remove the safety strap(s) from the cooling assembly.
- the engine speed and position sensor bolt, a Connect the engine speed and position sensor connector.
a Refit: - the front bumper (see Front bumper: Removal Refitting) (MR 371, 55A, Exterior protection),
a Refit: - the gearbox upper bolts,
- the front section of the left and right-hand wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 371, 55A, Exterior protection).
- the starter upper bolt. a Torque tighten the starter bolts (44 Nm).
- the air filter box (see Air filter unit: Removal - Refitting) (MR 370, 12A, Fuel mixture),
a Clip the breather pipe onto the gearbox. a Connect the reverse gear sensor connector.
- the battery tray (see Battery tray: Removal - Refitting) (MR 370, 80A, Battery),
a Clip the gear control cables on the gearbox. a Connect the clutch control pipe.
- the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 370, 13B, Diesel injection),
a Refit the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 370, 19D, Engine mounting).
- the engine cover. a Perform the following operations:
a Remove the (Mot. 1453) and the safety strap(s).
- fill the gearbox (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A13) ,
III - FINAL OPERATION. a Refit: - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 371, 56A, Exterior equipment), - the front axle subframe (see Front axle sub-frame: Removal - Refitting) (MR 370, 31A, Front axle components),
- bleed the clutch circuit (see Clutch circuit: Bleeding) (MR 370, 37A, Mechanical component controls). a Refit:
- the support strut on the gearbox,
21A-44
- the engine undertray, - the battery (see Battery : Removal - Refitting) (MR 370, 80A, Battery).
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
JH3 or JR5 Essential special tooling Bvi. 1666
Tool for seals.
fitting differential
Tightening torquesm wheel bolts
13 daNm
lower ball joint nut
6.2 daNm
track rod end nut
3.7 daNm
anti-roll bar ball joint nut
4.4 daNm
hub nut relay bearing bracket nut
28 daNm 2.1 daNm
engine tie-bar bolts
10.5 daNm
subframe - engine tiebar bolts
10.5 daNm
battery cover mounting bolts
0.4 daNm
102129
a Remove the relay bearing bracket.
REMOVAL a Position the vehicle on a two-post lift. a Disconnect the battery, starting with the negative terminal. a Remove the engine undertray. a Drain the gearbox. a Remove: - the wheel, - the wheel arch liner, 101819
- the hub nut,
a Remove the driveshaft.
- the track rod end,
REPLACING THE SEAL
- the anti-roll bar ball joint,
a Tap the base of the lip seal using a drift and a small hammer to pivot it in its housing.
- the lower ball joint.
a Remove the seal with pliers, taking care not to damage the splines of the sunwheel.
a Disconnect: - the wheel speed sensor connector, - the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle).
21A-45
MANUAL GEARBOX Differential output seal: Removal - Refitting JH3 or JR5
REFITTING
21503
a Lubricate the seal. a Insert the seal onto the splined part of the sunwheel. a Refit the seal using the (Bvi. 1666), with the marking A on the right-hand side and marking B on the lefthand side. a Position the driveshaft in relation to the sunwheel. a To refit, proceed in the reverse order of removal. a Torque tighten: - the wheel bolts (13 daNm), - the lower ball joint nut (6.2 daNm), - the track rod end nut (3.7 daNm), - the anti-roll bar ball joint nut (4.4 daNm), - the hub nut (28 daNm), - the relay bearing bracket nut (2.1 daNm), - the engine tie-bar bolts (10.5 daNm), - the subframe - engine tie-bar bolts (10.5 daNm). a Top up the gearbox oil. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm).
21A-46
21A
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
ND0 Essential special tooling Bvi. 1689
Differential output seal fitting tool.
Tightening torquesm wheel bolts
13 daNm
lower ball joint nut
6.2 daNm
track rod end nut
3.7 daNm
anti-roll bar ball joint nut
4.4 daNm
hub nut relay bearing bracket nut engine tie-bar bolts
28 daNm 2.1 daNm 18 daNm
subframe - engine tiebar bolts
10.5 daNm
battery cover mounting bolts
0.4 daNm
102129
a Remove the relay bearing bracket.
REMOVAL a Position the vehicle on a two-post lift. a Disconnect the battery, starting with the negative terminal. a Remove the engine undertray. a Drain the gearbox. a Remove: - the wheel, - the wheel arch liner, 101819
- the hub nut,
a Remove the driveshaft.
- the track rod end,
REPLACING THE SEAL
- the anti-roll bar ball joint,
a Tap the base of the lip seal using a drift and a small hammer to pivot it in its housing.
- the lower ball joint.
a Remove the dislodged seal with pliers, taking care not to damage the sunwheel splines.
a Disconnect: - the wheel speed sensor connector, - the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle).
21A-47
MANUAL GEARBOX Differential output seal: Removal - Refitting ND0
REFITTING
102260
a Oil the seal before inserting it onto the splined part of the sunwheel. a Refit the seal using the tool (Bvi. 1689), with the marking A on the right-hand side and marking B on the left-hand side. a Position the driveshaft in relation to the sunwheel. a To refit, proceed in the reverse order of removal. a Torque tighten: - the wheel bolts (13 daNm), - the lower ball joint nut (6.2 daNm), - the track rod end nut (3.7 daNm), - the anti-roll bar ball joint nut (4.4 daNm), - the hub nut (28 daNm), - the relay bearing bracket nut (2.1 daNm), - the engine tie-bar bolts (18 daNm), - the subframe - engine tie-bar bolts (10.5 daNm). a Top up the gearbox oil. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm).
21A-48
21A
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
M9R, and 700, and PK4 III - OPERATION FOR REMOVAL OF PART CONCERNED (LEFT-HAND SIDE)
Essential special tooling Bvi. 1774
Right-hand transmission seal fitting tool.
Bvi. 1719
Left-hand side differential oil seal fitting tool
Bvi. 1419
Bearing cage positioning tool.
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . 106885
a Extract the seal using a screwdriver, taking care not to damage the casing.
II - OPERATION FOR REMOVAL OF PART CONCERNED (RIGHT-HAND SIDE)
21490
a Remove the protective ring (1) from the driveshaft.
21A-49
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING I - REFITTING OPERATION FOR PART CONCERNED (RIGHT-HAND SIDE)
21494
a Slide on the protective ring (2) and clip it onto the driveshaft. 21493
a Refit the right-hand seal using the (Bvi. 1774) (1) .
II - REFITTING OPERATION FOR PART CONCERNED (LEFT-HAND SIDE)
Note: Do not lubricate the seal. a Clean the driveshaft using degreaser.
106886
a Refit the left-hand seal using the (Bvi. 1719) (2) and (Bvi. 1419) (3) .
21A-50
MANUAL GEARBOX Differential output seal: Removal - Refitting M9R, and 700, and PK4 III - FINAL OPERATION. a Refit: - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) , - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) . a Top up the gearbox (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A-13) .
21A-51
21A
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
TL4 II - REMOVAL OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL
Essential special tooling Bvi. 1854
Differential output seal fitting tool TL4
Left-hand differential output seal
Essential equipment roll pin punch
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the engine undertray bolts, - the engine undertray. a Drain the gearbox (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A13) . 125894
1 - When replacing the differential output seal on the left-hand side
Right-hand differential output seal
a Remove: - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . 2 - When replacing the differential output seal on the right-hand side a Remove: - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front right-hand wheel driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) . 125896
a Tap the base of the lip seal using a roll pin punch and a small hammer to release it and make it turn in its housing. a Remove the lip seal using a large screwdriver, taking care not to damage the differential housing.
21A-52
MANUAL GEARBOX Differential output seal: Removal - Refitting TL4
REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Differential output seal (12,01,05,10).
21A-53
21A
MANUAL GEARBOX Differential output seal: Removal - Refitting
21A
TL4 II - REFITTING OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL
Refitting the left-hand side differential output seal.
103191
Refitting the right-hand side differential output seal 125893
a The new differential output seal is refitted using the tool (Bvi. 1854) (1) consisting of: - a mandrel (2) for the right-hand side, - a mandrel (3) for the left-hand side. a Oil the internal surface of the new differential output seal. a Fit: - the new differential output seal on the gearbox, - the mandrel (2) or (3) of the tool (Bvi. 1854) on the new differential output seal. a Tap the tool (1) with a copper hammer to fit the new differential output seal fully. III - FINAL OPERATION 125895
1 - Refitting the left-hand driveshaft a Refit: - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) , - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres). 2 - Refitting the right-hand driveshaft a Refit: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) ,
21A-54
MANUAL GEARBOX Differential output seal: Removal - Refitting TL4 - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres). 3 - Final operation a Fill the gearbox and check the level (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A-13) . a Refit the engine undertray.
21A-55
21A
MANUAL GEARBOX Input shaft lip seal: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING
Essential special tooling Bvi. 1236
Pr imary shaft oil seal fitting tool.
I - REFITTING OPERATION FOR PART CONCERNED
REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the « engine - gearbox assembly » (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals), - the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the clutch thrust bearing (see 20A, Clutch, Clutch thrust bearing: Removal - Refitting, page 20A14) .
18061
a Fit a new seal with its protector using the (Bvi. 1236). a Remove the protector.
II - REMOVAL OPERATION FOR PART CONCERNED
II - FINAL OPERATION.
a Drill a hole in the seal, using a 2.5 mm drill bit.
a Refit: - the clutch thrust bearing (see 20A, Clutch, Clutch thrust bearing: Removal - Refitting, page 20A14) ,
WARNING Do not scratch the shaft or mating face.
- the gearbox (see 21A, Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-21) , - the « engine - gearbox assembly » (see Engine/ gearbox assembly: Removal - Refitting) (MR 370, 10A, Engine and peripherals).
20714
a Fit a bolt in seal (1) . a Extract the seal (1) using pliers.
21A-56
AUTOMATIC GEARBOX Automatic gearbox: Precautions for repair
23A
AJ0 III - STORING COMPONENTS THAT HAVE BEEN REMOVED
I - TECHNICAL SPECIFICATIONS Weight: 100 kg The AJ0 is fitted with systems known as: "Shift Lock" and "Lock Up". "Shift Lock" inhibits movement of the gear selector lever unless the brake pedal is depressed simultaneously. To unlock the lever when the battery is faulty and carry out repair operations, refer to the Driver's Handbook. The aim of converter Lock Up is to connect the automatic gearbox directly to the engine. This function is carried out by a "mini clutch" in the converter. Lock Up is controlled by the automatic gearbox computer. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. As a result of this fact, and to avoid serious damage, it is essential to comply with the following instructions:
116357
- never allow the vehicle to coast with the ignition switched off (e.g. when going down a hill); we cannot stress too strongly the harm that this may cause,
Store components that have been removed in storage containers so as not to damage or misplace them.
- never push the vehicle (i.e. to get to a petrol station, unless the precautions in the Towing section have been taken). In addition, the vehicle is only under traction if the engine is running. It is therefore impossible to start the engine of a vehicle with an automatic gearbox by pushing the vehicle.
II - TOWING
WARNING Vehicles should preferably be moved on a flatbed or towed with the front wheels raised. If this is not possible, towing may be carried out in exceptional circumstances at a speed below 15 mph (25 km/h) and for a maximum distance of 30 miles (50 km) (gear lever in Neutral).
WARNING Towing weight (trailer, caravan, boat, etc.): (see the Driver's Handbook).
23A-1
AUTOMATIC GEARBOX Automatic gearbox: Precautions for repair DP0 I - PRECAUTIONS DURING REPAIR Weight: 70 kg Vehicles fitted with DP0 automatic transmissions use systems called « Shift lock » and « Lock up » . The purpose of the « Shift Lock » function is to prevent the gear lever from being moved without the brake pedal being simultaneously depressed.
Note: For repair operations when the battery is faulty, refer to the notice on board the vehicle. The purpose of the « Lock up » or converter lockup is to connect the automatic transmission directly to the engine. This function is carried out by a « mini clutch » in the converter. The « Lock up » is driven by the automatic transmission computer. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. Consequently, and to avoid serious damage, it is essential to comply with the following instructions: - never allow the vehicle to coast with the ignition switched off (i.e. when going down a hill); the damage that this may cause cannot be stressed highly enough, - never push the vehicle (e.g. to get to a petrol station, unless the precautions in the « Towing » section have been taken). The vehicle only has drive when the engine is running. It is therefore impossible to start the engine in a vehicle with an automatic transmission by pushing the vehicle. II - TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. Nonetheless, if this is impossible, in exceptional circumstances the vehicle may be towed at low speed (maximum 12mph (20 km/h) over a maximum distance of 18 miles (30 km) (lever in N position).
23A-2
23A
AUTOMATIC GEARBOX Automatic gearbox: Identification
23A
AJ0
117777
The gearbox is identified by an engraved marking (1) located underneath the gearbox and by a self-adhesive label (2) on the hydraulic distributor casing.
23A-3
AUTOMATIC GEARBOX Automatic gearbox: Identification DP0
117304
The automatic transmission series number can be found in two places: on a label on the hydraulic distributor cover (1) and etched onto the outer casing (2) on the wheel side.
23A-4
23A
AUTOMATIC GEARBOX Automatic gearbox: Specifications
23A
F9Q, and DP0
Gearbox
Gearbox suffix
1st
2nd
3rd
4th
Final drive
Lowering
DP0
083
2.724
1.499
1.000
0.710
25/68
52 : 67
23A-5
AUTOMATIC GEARBOX Automatic gearbox: Specifications
23A
AJ0
Gearbox
Suffix
AJ0
001 Gear ratios (epicyclic gear train output) 1st
2nd
3rd
4th
5th
6th
Reverse gear
4.199
2.405
1.583
1.161
0.855
0.685
3.457
Speeds in mph (km/h) at 1000 rpm (Tyre: 205/60R 16) 1st
2nd
3rd
4th
5th
6th
Reverse gear
8.989
15.696
23.842
32.506
44.119
55.037
10.918
23A-6
AUTOMATIC GEARBOX Automatic gearbox: List and location of components
23A
AJ0
117734
(1)
AJ0 gearbox
(2)
Oil overflow pipe
(3)
Level-setting plug
(4)
Torque converter
(5)
Filler pipe closure panel
(6)
Oil cooler
(7)
Output speed sensor
(8)
Input speed sensor
(9)
Multifunction switch
(10)
Control lever
(11)
Electrical wiring
(12)
Hydraulic pressure measurement plug
(13)
Hydraulic distributor O-rings
(14)
Hydraulic distributor
(15)
Hydraulic distributor casing seal
(16)
Hydraulic distributor housing
118831
23A-7
(17)
Solenoid valve
(18)
Automatic gearbox oil temperature sensor
(19)
Pressure sensor
AUTOMATIC GEARBOX Automatic gearbox: List and location of components
23A
DP0
127735
(1)
DP0 gearbox
(2)
Oil overflow pipe
(3)
Level-setting cap
(4)
Hydraulic distributor
(5)
Hydraulic distributor casing seal
(6)
Hydraulic distributor housing
(7)
Torque converter
(8)
Control pinion
(9)
Vehicle speed sensor
(10)
Multifunction switch
(11)
Output lever
(12)
Filler plug
(13)
Connector support
(14)
Sleeve stop
(15)
Filter pad
(16)
Input speed sensor
(17)
Heat exchanger
(18)
Output speed sensor
(19)
Control solenoid valve
(20)
Pressure sensor
13787
23A-8
(21)
Modulating solenoid valve
(22)
« Lock up » solenoid valve (converter lock-up)
(23)
Selector solenoid valve 4
AUTOMATIC GEARBOX Automatic gearbox: List and location of components DP0 (24)
Selector solenoid valve 3
(25)
Selector solenoid valve 1
(26)
Selector solenoid valve 2
(27)
Selector solenoid valve 6
(28)
Selector solenoid valve 5
13785
(29)
Green connector (multifunction switch)
(30)
Yellow connector (electrohydraulic interface)
(31)
Green connector (line pressure)
(32)
Yellow connector (turbo input speed)
(33)
Blue connector (output speed)
23A-9
23A
AUTOMATIC GEARBOX Automatic gearbox: Parts and consumables for the repair work DP0
Description
Component concerned
BR2 + grease
Converter centring fitting
High resistance threadlock
Brake calliper bolt
The following parts must be replaced with new ones after being removed: - the self-locking nuts, - the seals, - the rubber seals, - the converter bolts.
23A-10
23A
AUTOMATIC GEARBOX Automatic gearbox: Parts and consumables for the repair work AJ0 I - PARTS ALWAYS TO BE REPLACED Parts to be replaced with new ones if removed: - the self-locking nuts, - the differential output seals, - the converter seal, - O-rings, - the four hydraulic distributor O-rings, - the converter nuts, - the hydraulic distributor metal casing seal, - the level-setting plug seal. II - CONSUMABLE FOR REPAIR
Description
Component
Part no.
BR2 + grease
Converter centring fitting
77 01 421 145
23A-11
23A
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771 Essential special tooling
Tightening torquesm
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting engine mounting support with retaining straps.
Bvi. 1531
Tool for centring the torque converter for the automatic transmission converter.
suspended mounting nut on the rubber pad
18 daNm
battery cover mounting bolts
0.4 daNm
REMOVAL a Position the vehicle on a two-post lift. a Remove the engine covers.
Essential equipment component jack
Tightening torquesm wheel bolts
13 daNm
brake calliper guide pin bolts
0.7 daNm
track rod end nut
3.7 daNm
lower ball joint nut
6.2 daNm
engine tie-bar bolts on the subframe
10.5 daNm
starter and gearbox bell housing bolts
4.4 daNm
suspended mounting nut on the gearbox
4.4 daNm
a Disconnect the battery, starting with the negative terminal.
track rod end nut
6.2 daNm
drive plate converter mounting nut
3.7 daNm
a Remove the scuttle grille ( (see 85A, Wiping Washing) ).
modular connector mounting bolts
2 daNm
engine speed sensor mounting bolts
1 daNm
engine tie-bar bolts on F engines
18 daNm
engine tie-bar bolts on K engines
10.5 daNm
101821
23A-12
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771
104343
a Remove: - the two air filter access panel mounting bolts (1) , - the air filter access panel,
103409
a Remove:
- the scuttle panel partition mounting bolt (2) .
- the multifunction switch cable ball joint (4) , - the wiring (5) from the multifunction switch cable, unlocking the cable sleeve stop, - the wiring harness mountings. a Disconnect: - the engine speed sensor, - the connector (6) by detaching the connector slide. a Remove the mounting bolts (7) from the modular connector support plate. WARNING 104246
a Remove: - the scuttle panel partition mounting bolts (3) , - the scuttle panel partition, - the air intake sleeve, - the battery, - the battery tray, - the injection computer and its support, - the air inlet pipe, - the wiring harness mountings.
23A-13
Protect the connector by sliding it into a waterproof plastic bag.
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771
K4M
103753
a Remove the engine speed sensor. 103423
a Remove: - the two bolts (8) from the starter, F4R
- the engine undertray. a Drain the gearbox. a Remove: - the wheels, - the wheel arch liners. a Disconnect: - the ABS system sensor wiring, - the discharge bulb beam adjustment sensor wiring (if fitted to the vehicle). Note: The discharge bulb beam adjustment sensor is fitted onto the left-hand lower wishbone.
103420
a Remove the engine speed sensor.
a Fit the hose clamps. a Disconnect the heat exchanger. a Unclip the wiring harness from the gearbox.
23A-14
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771 I - LEFT-HAND SIDE OF THE VEHICLE
103412 102129
a Remove:
a Remove:
- the hub nut using the (Rou. 604-01),
- the clip (10) from the gearbox computer wiring harness,
- the track rod end using the (Tav. 476),
- the side reinforcement (9)
- the anti-roll bar ball joint using the (Tav. 476), - the lower ball joint. a Release the stub axle carrier from the driveshaft. a Remove the left-hand driveshaft.
103413
a Open the gearbox computer wiring harness mounting bracket (11) . a Disconnect the connector (12) from the gearbox computer.
23A-15
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771 II - RIGHT-HAND SIDE OF THE VEHICLE
103418 102129
a Remove:
a Remove the relay bearing bracket. a Release the stub axle carrier from the driveshaft.
- the hub nut using tool (Rou. 604-01),
a Remove the right-hand driveshaft.
- the track rod end using the (Tav. 476),
a Attach the cooling radiator assembly to the upper cross member using rope.
- the anti-roll bar ball joint using the (Tav. 476), - the lower ball joint.
101212
a Remove the side stiffener.
23A-16
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771
102009
a Remove the cooling radiator lower cross member.
103418
a Remove: - the lower engine - manifold strut, - the starter mounting bolt (15) , - the starter, - the three converter nuts. Note: The converter nuts are accessed by removing the starter. Rotate the crankshaft clockwise to access the three starter plate - converter connecting nuts and remove them.
103421
a Remove: - the exhaust mounting nuts (13) , - the engine tie-bar.
23A-17
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771
103423
13790
a Remove the upper studs (16) from the gearbox bell housing.
a Secure the converter with string to prevent it being dislodged.
REFITTING a WARNING - Do not reuse the converter mounting nuts or the inertia flywheel nuts if they have been removed: always use new nuts. - Check that the centring rings are in place.
102449
a Open the cover (13) . a Remove cover (14) . a Fit the (Mot. 1453). a Remove the gearbox support rubber pad. a Fit the component jack under the gearbox. a Remove: - the lower gearbox bell housing bolts, - the studs, - the converter - starter plate bolts, - the automatic transmission,
23A-18
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting K4M, and 761 – F4R, and 771
16361
a Refit the inertia flywheel on the converter using tool (Bvi. 1531) ;. a To refit, proceed in the reverse order of removal. WARNING Check that the centring dowels are in place. When refitting the automatic transmission on the engine, make sure that the converter is properly engaged on the input shaft pin.
23A-19
23A
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
K4M, and 761 – F4R, and 771 a If replacing the oil, reset the auto-adaptives using command RZ005: « Clear auto-adaptives » and reset the automatic transmission computer oil ageing counter with command CF074: « Enter date of gearbox oil change » . After using command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm).
13790
a The distance between the base of the threading (17) and the engine coupling face (18) should be 17 mm. a Torque tighten: - the wheel bolts (13 daNm), - the brake calliper guide pin bolts (0.7 daNm), - the track rod end nut (3.7 daNm), - the lower ball joint nut (6.2 daNm), - the engine tie-bar bolts on the subframe (10.5 daNm), - the starter and gearbox bell housing bolts (4.4 daNm), - the suspended mounting nut on the gearbox (4.4 daNm), - the track rod end nut (6.2 daNm), - the drive plate converter mounting nut (3.7 daNm), - the modular connector mounting bolts (2 daNm), - the engine speed sensor mounting bolts (1 daNm), - the engine tie-bar bolts on F engines (18 daNm), - the engine tie-bar bolts on K engines (10.5 daNm), - the suspended mounting nut on the rubber pad (18 daNm). a Fill up the automatic transmission and check the level (see Filling - Levels) .
23A-20
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
M9R, and AJ0
Essential equipment workshop hoist diagnostic tool
Tightening torquesm gearbox bell housing bolts
44 Nm
converter nuts
44 Nm
REMOVAL a In order to remove and refit the automatic gearbox, the "engine - gearbox" assembly must be removed (see Engine/gearbox assembly: Removal - Refitting) (10A, Engine and peripherals).
118393
a Remove the nuts from the converter (1) through the starter opening.
Note: Replacing the automatic gearbox AJ0 requires the automatic gearbox computer to be replaced (see 2 3 A , Automatic gearbox, A utomatic transmission computer: Removal - Refitting, page 23A-81) .
118394
a Lift the engine using a workshop hoist and a load positioner. a Remove: 118394
a Separate the pipes and wirings fixed all around the automatic gearbox.
- the bolts and nuts from the automatic gearbox bell housing (2) ,
a Remove the starter (see Starter: Removal - Refitting) (16A, Starting - Charging).
- the automatic gearbox using a workshop hoist and a load positioner.
23A-21
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting
23A
M9R, and AJ0
REFITTING a Check that the drive plate is not damaged or runout (0.2 mm permitted runout).
118394
a Mount the gearbox and finger tighten the automatic gearbox bell housing bolts. 11911
a Check that the torque converter is coupled correctly onto the automatic gearbox using a flat ruler and a tape measure. The distance (X) between the converter maintenance bolt bead and the cover should be at least 20.5 mm. Note: Failure to observe this procedure can lead to the destruction of the gearbox.
23A-22
Note: Align the converter blots with their location on the drive plate before fitting the automatic gearbox.
AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting M9R, and AJ0
118393
a Position the converter retaining nuts (3) through the starter opening. a Tighten to torque: - the gearbox bell housing bolts (44 Nm), - the converter nuts (44 Nm). a Refit the starter (see Starter: Removal - Refitting) (16A, Starting - Charging). a Proceed in the reverse order to removal. a Refit the engine - gearbox assembly (see Engine/ gearbox assembly: Removal - Refitting) (10A, Engine and peripherals). a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a Perform the programming procedure using the diagnostic tool (see Fault finding - Replacement of components) (23A, Automatic gearbox).
23A-23
23A
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
DP0 1 - Former assembly Essential equipment diagnostic tool
Tightening torquesm oil overflow pipe (old assembly)
25 N.m
oil overflow pipe (new assembly)
9 N.m
level-setting plug (old assembly)
25 N.m
level-setting plug (new assembly)
35 N.m
2316
a Remove: - the level-setting plug (1) ,
Gearbox
DP0
- the oil overflow pipe (2) .
Oil capacity (adjust until overflows) (litre) Drain capacity
Total capacity
3.5
6
2 - New assembly
WARNING For both assemblies, when draining - refilling or topping up the oil level, it is essential to put the gear control lever in Park « P » position.
IMPORTANT Wear heat protective gloves during the operation. I - OIL SERVICE a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) . 107912
Note:
a Remove:
Drain the automatic transmission oil when the oil is warm (60˚C maximum), in order to remove as many impurities as possible.
- the level-setting plug (3) , - the oil overflow pipe (4) using (5) an 8 mm Allen key.
a Remove the engine undertray.
23A-24
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
DP0 a Let the oil flow. Note: Always replace the oil overflow pipe each time it is removed for the new assembly. a Refit the new oil overflow pipe for the new assembly. a Torque tighten: - the oil overflow pipe (old assembly) (25 N.m), - the oil overflow pipe (new assembly) (9 N.m).
110245
113764
a Fit a new seal on the level-setting plug with the seal groove facing the top-up cap. a Refit the level-setting plug. a Torque tighten: - the level-setting plug (old assembly) (25 N.m), - the level-setting plug (new assembly) (35 N.m). 101743
II - FILLING a Position the vehicle on a horizontal surface.
a Unclip the gear lever control cable (7) on the gearbox by: - squeezing the gear lever control cable clip at (A) , - pulling the pin at (B) , - lifting the gear lever cable at (C) .
23A-25
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
DP0 1 - Former assembly
2316
a Remove the level-setting plug (9) , leaving the engine running. 103407
2 - New assembly
a Remove the filler cap (8) . a Use a funnel with a 15:100 filter to prevent impurities from entering the system. a Fill the automatic gearbox with 3.5 litres of new recommended oil (see Automatic gearbox oil: Spec i f i c a t i o n s ) (Technical Note 6012A, 04A, Lubricants). a Refit the filler cap. a Fit the gear lever control cable. a Run the engine at idle speed. a Connect the diagnostic tool. a Establish dialogue with the automatic transmission computer. a Monitor the automatic transmission oil temperature parameter. a Wait for the temperature to reach 60˚C ± 1. 107912
a Remove the level-setting plug (10) , leaving the engine running. a If the oil does not flow out or the quantity collected is below 0.1 litres : - Switch off the engine, - refit the level-setting plug, - unclip the gear lever control cable, - remove the filler plug, - add 0.5 litre of oil, - refit the filler plug fitted with a new seal,
23A-26
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling DP0 - fit the gear lever control cable, - let the automatic transmission cool to 50˚C, - run the engine at idle speed, - connect the diagnostic tool, - establish dialogue with the automatic transmission computer, - monitor the automatic gearbox oil temperature parameter, - wait for the temperature to reach 60˚C ± 1, - remove the level-setting plug (9) or (10) . a Repeat these operations until more than 0.1 litres of oil is recovered in the container. a Refit the level plug fitted with a new seal. a Torque tighten: - the level-setting plug (old assembly) (25 N.m), - the level-setting plug (new assembly) (35 N.m). Note: When replacing the oil, reset the electronic oil ageing counter (within the computer) (see Fault finding - Replacement of components) (MR 366, 23A, Automatic transmission). 3 - Level a Note: To fill up the automatic transmission oil, apply the filling procedure using 0.5 litres of oil instead of 3.5 litres.
23A-27
23A
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
AJ0
Essential equipment diagnostic tool
Tightening torquesm overflow pipe
8 N.m
level-setting plug
7.5 N.m
filler pipe closure panel bolt
6 N.m
Capacity
Gearbox
AJ0
Oil capacity (adjust until overflows) (litre) Drain capacity
Total capacity
3.5
7.6
118160
a Remove: - the level-setting plug (1) , - the oil overflow pipe (2) .
Note:
a Let the oil flow.
The level must be checked at a temperature of 40˚C ± 2.
a Refit and torque tighten the overflow pipe (8 N.m). a Refit and torque tighten the level-setting plug (7.5 N.m).
Note: The automatic transmission oil should preferably be changed when the oil is warm (approximately 60˚C maximum) in order to remove as many impurities as possible. I - DRAINING a Position the vehicle on a lift. a The control lever must be in the Park position when draining, filling or checking the level. a Remove the engine undertray.
23A-28
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
AJ0 II - FILLING
116343
117251
a Filling is carried out through an internal pipe in the mechanism housing (3) . a Remove the pipe closure panel (4) .
116345
a Use a flexible pipe fitted with a funnel (with a 1:100 filter) (5) and connect it to the filling pipe (6) . III - FILLING PROCEDURE a The control lever must be in the Park position a Fill the automatic gearbox with 3.2 litres of new oil recommended by the manufacturer (see Automatic gearbox oil: Specifications) (Technical Note 6012A, 04A, Lubricants). a Run the engine at idle speed. a Connect the diagnostic tool. a Establish dialogue with the automatic gearbox computer. a Monitor the automatic transmission oil temperature parameter.
23A-29
AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling
23A
AJ0 a Wait for the temperature to reach 40˚C ± 2.
a Fill the automatic transmission with 0.5 litre of new oil. a Run the engine at idle speed. a Connect the diagnostic tool. a Establish dialogue with the automatic gearbox computer. a Monitor the automatic transmission oil temperature parameter. a Wait for the temperature to reach 40˚C ± 2. a Place a container under the level-setting plug. a Remove only the level plug, leaving the engine running. a If the oil does not flow out or the quantity collected is less than 0.1 litre : - Switch off the engine, - refit the level plug, - add 0.5 litre of oil,
118161
a Place a container under the level-setting plug.
- let the automatic transmission cool to 30˚C,
a Remove only the level plug, leaving the engine running.
- Run the engine at idle speed,
a If the oil does not flow out or the quantity collected is below 0.1 litres :
- place the container under the level plug,
- Switch off the engine,
- wait for the temperature to reach 40˚C ± 2,
- remove the level plug. a Repeat these operations until more than 0.1 litre of oil is recovered in the container.
- refit the level plug,
a Refit and torque tighten the level-setting plug (7.5 N.m).
- add 0.5 litre of oil, - let the automatic transmission cool to 30˚C,
a Refit the closure panel and tighten the filler pipe closure panel bolt (6 N.m).
- run the engine at idle speed, - wait for the temperature to reach 40˚C ± 2, - place a container under the level-setting plug , - remove the level plug. a Repeat these operations until more than 0.1 litres of oil is recovered in the container. a Refit and torque tighten the level-setting plug (7.5 N.m). a Refit the closure panel and torque tighten the filler pipe closure panel bolt (6 N.m). IV - LEVEL CHECKING PROCEDURE OUTSIDE OIL CHANGE - FILLING OPERATIONS a WARNING It is essential to shift the selector lever to the Park position.
23A-30
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
DP0 Essential special tooling Bvi. 1462
Ball plate adjusting screw.
Tightening torquesm hydra u l i c bolts
d i s t ributor
7.5 Nm
locating ball spring bracket bolt
9 Nm
locating ball spring bolt
8 Nm
hydra u l i c cover bolts
d i s t ributor
10 Nm
REMOVAL 110245
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 364, 02A, Lifting equipment). a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) . a Remove: - the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery).
110243
a Separate the control cable from the multifunction switch (1) by pressing on (A) . a Remove: - the front left-hand wheel (see Wheel: Removal Refitting) (MR 364, 35A, Wheels and tyres), - the front section of the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 365, 55A, Exterior protection).
23A-31
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
DP0
F9Q, and 803
103412
a Unclip the wiring harness (3) on the left-hand side stiffener. a Remove: - the left-hand side reinforcement bolts (2) , - the left-hand side stiffener.
117330
a Disconnect the electric coolant pump connector. a Remove the clips (4) from the electric coolant pump mounting. a Move aside the electric coolant pump (5)
23A-32
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
DP0
REFITTING
II - OPERATION FOR REMOVAL OF PART CONCERNED
I - REFITTING OPERATION FOR PART CONCERNED
110233
a Remove the hydraulic distributor cover bolts (6) (oil may flow out). 13789
a Fit the hydraulic distributor with its reinforcement plate, centring it using the bolts (6) and (7) .
110227 110232
a Remove the hydraulic distributor bolts (7) .
a WARNING
a Disconnect the hydraulic distributor solenoid valve connectors (8) .
Check that the distributor slide is properly engaged with the notched sector lug (9) .
a Remove the hydraulic distributor.
a Refit the other bolts on the hydraulic distributor. a Tighten to torque and in order the hydraulic distributor bolts (7.5 Nm).
23A-33
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
DP0 a Screw the tool in fully whilst holding the locating ball spring.
ADJUSTING THE LEAF SPRING LEVER
a Tighten to torque the locating ball spring bracket bolt (9 Nm). a Remove the (Bvi. 1462). a Refit the locating ball spring bolt (10) . a Torque tighten the locating ball spring bolt (8 Nm). a Refit the hydraulic distributor cover complete with a new seal. a Torque tighten the hydraulic distributor cover bolts (10 Nm). II - FINAL OPERATION F9Q, and 803 110229
a Put the multifunction switch lever in the first position selected using a hose clip and a bolt (11) in the mechanism housing.
a Fit the electric coolant pump. a Refit the clips on the electric coolant pump mounting. a Connect the electric coolant pump connector.
a Remove the bolt (10) . a Clip the wiring harness on the left-hand side stiffener. a Refit: - the left-hand side stiffener, - the left-hand side stiffener bolts, - the front section of the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 365, 55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (MR 364, 35A, Wheels and tyres). a Adjust the automatic gearbox control cable (see Automatic gear control cable: Adjusting) (MR364, 37A, Mechanical component controls). a Refit: 119433
- the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery),
a Fit the locating ball spring by fitting the bearing (12) into the groove (15) for the notched sector (16) corresponding to first selected.
- the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
a Fit without tightening the locating ball spring bracket bolt (13) .
a Perform the following operations:
a Fit the (Bvi. 1462) (14) in place of the bolt (10) .
23A-34
- fill the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) ,
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting DP0 - the necessary programming (see Fault finding Configuration and programming) (MR 366, 23A, Automatic transmission).
23A-35
23A
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
M9R, and AJ0
Essential equipment diagnostic tool
Tightening torquesm hydra u l i c bolts
d i s t ributor
8 Nm
hydra u l i c d i s t ributor housing bolts8 Nm
.
REMOVAL a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). 113155
a Remove the engine undertray. a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) .
a Remove the air pipe bolts at the intercooler inlet.
a Remove the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). a Drain the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling).
119834 113282
a Rotate the intercooler air inlet pipe clip, on the turbocharger side.
a Loosen the clip on the intercooler air inlet pipe on the exchanger side. a Disconnect the intercooler air inlet pipe on the exchanger side. a Remove the air pipe at the intercooler inlet.
23A-36
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
M9R, and AJ0
106275
a Remove the cooling assembly.
117250
a Place a clean container under the automatic gearbox to collect the oil. a Remove: - the hydraulic distributor housing bolts, - the hydraulic distributor housing, - the hydraulic distributor housing seal.
118391
a Disconnect: - the cooling radiator bottom hose (1) , - the oil/water cooler outlet and inlet hoses (2) . a Unclip all the hoses from their support (3) . a Move all the hoses aside to facilitate access.
23A-37
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
M9R, and AJ0
REFITTING a Clean the joint faces using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) on the automatic gearbox and on the hydraulic distributor housing, taking care not to damage the contact surfaces. a Always replace: - the hydraulic distributor O-rings, - the hydraulic distributor housing seal. - the air pipe seal at the intercooler inlet on the turbocharger side. a Refit the new hydraulic distributor O-rings.
117254
a Loosen the hydraulic distributor bolts (5 bolts size 70.1 mm (4) and 4 bolts size 50.8 mm (5) ). a Detach the internal wiring connector (6) . a Remove the hydraulic distributor bolts. a Tilt the hydraulic distributor slightly when removing it in order to disconnect the automatic gear lever (7) .
117254
a Tilt the hydraulic distributor slightly when refitting it in order to engage it with the automatic gearbox lever (9) . a Torque tighten the hydraulic distributor bolts (8 Nm). a Connect the hydraulic distributor connector (10) .
117253
a Remove the hydraulic distributor O-rings (8) .
23A-38
AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting
23A
M9R, and AJ0
117250
a Fit the hydraulic distributor metal housing (11) with its new seal.
115069
a Note:
a Torque tighten the hydraulic distributor housing bolts8 Nm (.)
Check that the intercooler air inlet pipe seal on the turbocharger side is fitted in its groove the right way round. a Fit a new seal to the intercooler air inlet pipe on the turbocharger side. a Proceed in the reverse order to removal. a Fill the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) . a Refit the engine undertray. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a When replacing the hydraulic distributor, carry out the necessary operations using the diagnostic tool (see Fault finding - Replacement of components) (23A, Automatic gearbox).
115068
a Remove the intercooler air inlet pipe seal on the turbocharger side using a .
23A-39
AUTOMATIC GEARBOX Solenoid valves: Removal
23A
DP0 - the mounting bolt (13) to remove the solenoid valve (2) , WARNING
- the mounting bolt (14) to remove the solenoid valve (1) .
Work as cleanly as possible to prevent foreign bodies from entering the system.
REFITTING REMOVAL
a To refit, proceed in the reverse order of removal.
a Remove the hydraulic distributor (see 23A, Automatic gearbox, Hydraulic distributor: Removal Refitting, page 23A-31)
Note: Apply vaseline to the solenoid valve seals to ease fitting.
13787
(1)
Modulating solenoid valve
(2)
« Lock up » solenoid valve (lockup converter)
(3)
Sequence solenoid valve 4
(4)
Sequence solenoid valve 3
(5)
Sequence solenoid valve 1
(6)
Sequence solenoid valve 2
(7)
Sequence solenoid valve 6
(8)
Sequence solenoid valve 5
a Remove: - the mounting bolt (9) to remove the solenoid valves (3) and (4) , - the mounting bolt (10) to remove the solenoid valve (5) , - the mounting bolt and the retaining bracket (11) to remove the solenoid valves (6) and (7) , - the mounting bolt (12) to remove the solenoid valve (8) ,
23A-40
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting
23A
DP0
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 364, 02A, Lifting equipment). a Remove: - the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery), - the multifunction connector (see 23A, Automatic gearbox, Automatic transmission connector: Removal - Refitting, page 23A-79) . a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) .
103248
a Remove: - the electronic interface connector (2) , - the cable by feeding the electro-hydraulic interface connector via the cable feed opening.
a Remove the hydraulic distributor (see 23A, Automatic gearbox, Hydraulic distributor: Removal Refitting, page 23A-31)
REFITTING II - OPERATION FOR REMOVAL OF PART CONCERNED
I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the cable by feeding the electro-hydraulic interface connector via the cable feed opening, - the electro-hydraulic interface connector, - the cable feed opening locking clip with a screwdriver. II - FINAL OPERATION. a Refit: - the hydraulic distributor (see 2 3 A , Automatic gearbox, Hydraulic distributor: Removal - Refitting, page 23A-31) - the multifunction connector (see 23A, Automatic gearbox, Automatic transmission connector: Removal - Refitting, page 23A-79) , 117300
- the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery),
a Remove the cable feed opening locking clip (1) with a screwdriver.
- the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery),
23A-41
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting DP0 a Top up the automatic transmission (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) .
23A-42
23A
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting
23A
M9R, and AJ0
Essential equipment diagnostic tool
Tightening torquesm wiring routing retainer bolt
7 N.m
hydra u l i c d i s t ributor housing bolts
8 Nm.
REMOVAL a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the battery (see Battery: Removal - Refitting) (80A, Battery)
113155
a Remove the air pipe bolts at the intercooler inlet.
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the diesel injection computer (see Diesel injection computer: Removal - Refitting) (13B, Diesel injection), - the engine undertray. a Drain the gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) . a Remove the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). a Drain the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling).
119834
a Loosen the clip on the air pipe at the intercooler inlet at the exchanger end. a Disconnect the air pipe at the intercooler inlet at the exchanger end.
113282
a Rotate the clip on the air pipe at the intercooler inlet at the turbocharger end.
23A-43
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting
23A
M9R, and AJ0
106275
a Remove the cooling assembly.
117250
a Place a clean container under the automatic gearbox to collect the oil. a Remove: - the hydraulic distributor housing bolts, - the hydraulic distributor housing, - the hydraulic distributor housing seal.
118391
a Disconnect: - the cooling radiator bottom hose (1) , - the oil/water cooler outlet and inlet hoses (2) . a Unclip all the hoses from their support (3) . a Move all the hoses aside to facilitate access.
117254
a Disconnect the internal wiring connector (4) .
23A-44
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting
23A
M9R, and AJ0
REFITTING a Clean the joint faces using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) on the automatic gearbox and the hydraulic distributor housing, taking care not to damage the contact surfaces. a Always replace the hydraulic distributor housing seal.
118390
a Remove the protection plate from the wiring (5) .
118388
a Fit the wiring (9) . a Connect the hydraulic distributor wiring connectors. a Pass the wiring through the inside of the automatic gearbox. a Torque tighten the wiring routing retainer bolt (7 N.m) (10) .
118388
a Remove the cable routing retaining bolt (6) . a Disconnect the connectors (7) from the hydraulic distributor wiring. a Remove the hydraulic distributor wiring (8) .
23A-45
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting
23A
M9R, and AJ0
117254
a Connect the internal wiring connector (11) .
115068
a Remove the intercooler air inlet pipe seal at the turbocharger end using a .
117250
a Fit the hydraulic distributor housing with of a new seal. a Torque tighten the hydraulic distributor housing bolts (8 Nm.)
115069
a Note: Check that the intercooler air inlet pipe seal at the turbocharger end is fitted in its groove the right way round. a Refit a new seal to the intercooler air inlet pipe at the turbocharger end. a Proceed in the reverse order to removal.
23A-46
AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting M9R, and AJ0 a Fill the automatic gearbox with oil and check the level (see 2 3 A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) . a Refit: - the engine undertray, - the diesel injection computer (see Diesel injection computer: Removal - Refitting) (13B, Diesel injection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery: Removal - Refitting) (80A, Battery). a Connect the diagnostic tool for the programming procedure (see Fault finding - Replacement of components) (23A, Automatic gearbox).
23A-47
23A
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting AJ0
REMOVAL REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the battery (see Battery: Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the air filter unit (see Air filter unit: Removal - Refitting) (12A, Fuel mixture), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray bolts, - the engine undertray, - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), -
23A-48
23A
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting
23A
M9R, and AJ0
Essential equipment oil recovery container
Tightening torquesm hydra u l i c d i s t ributor internal wiring earth bolts
8 N.m
retaining bolt for the temperature sensor
8 Nm
hydra u l i c d i s t ributor housing bolts
8 Nm
113282
a Rotate the clip on the air pipe at the intercooler inlet at the turbocharger end.
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the engine undertray bolts, - the engine undertray, - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection). a Drain: - the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) , - the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling).
113155
a Remove the bolts (1) from the air pipe at the turbocharger outlet.
- the refrigerant circuit (see Coolant circuit Draining - Refilling) (62A, Air conditioning).
23A-49
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting
23A
M9R, and AJ0
119834
118391
a Loosen the clip on the air pipe at the intercooler inlet at the exchanger end.
a Move the cooling and air pipes (2) aside from the turbocharger (3) .
a Disconnect the air pipe at the intercooler inlet at the exchanger end.
a Fit a oil recovery container beneath the automatic gearbox.
a Remove the air pipe at the intercooler inlet.
106275
a Remove the cooling assembly.
117250
a Remove: - the hydraulic distributor housing (4) , - the hydraulic distributor housing seal.
23A-50
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting
23A
M9R, and AJ0 II - OPERATION FOR REMOVAL OF PART CONCERNED
- the temperature sensor retaining plate, - the earth terminal (10) , - the hydraulic distribution internal wiring.
REFITTING I - REFITTING PREPARATION OPERATION a Clean the joint faces using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) on the automatic gearbox and the hydraulic distributor housing, taking care not to damage the contact surfaces. a Always replace the hydraulic distributor housing seal. II - REFITTING OPERATION FOR PART CONCERNED a Fit the hydraulic distributor internal wiring. 118831
a Move the retaining clips (5) from the internal wiring. a Disconnect: - the connector (6) from the external wiring, - the connectors (7) from the pressure sensors.
118831
a Disconnect the solenoid valve connectors (8) . a Remove: - the bolts (9) from the earths, - the bolt (10) from the temperature sensor,
23A-51
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting
23A
M9R, and AJ0 - the hydraulic distributor housing. a Torque tighten the hydraulic distributor housing bolts (8 Nm).
118831
a Note:
115068
a Remove the intercooler air inlet pipe seal at the turbocharger end using a .
The earth terminal at (12) must be positioned between the distributor and the temperature sensor retaining plate so that the earth terminal does not break when the bolt is tightened. a Refit: - the bolts (11) to the earths, - the earth terminal (12) , - the temperature sensor retaining plate, - the bolt (12) to the temperature sensor. a Tighten to torque: - the hydraulic distributor internal wiring earth bolts (8 N.m), - the retaining bolt for the temperature sensor (8 Nm). a Connect the connectors to the solenoid valves. a Connect: - the pressure sensor connectors, - the external wiring connector. a Fit the maintenance clips for the internal wiring. III - FINAL OPERATION. a Refit: - a new seal on the hydraulic distributor housing,
23A-52
AUTOMATIC GEARBOX Hydraulic distributor internal wiring: Removal - Refitting M9R, and AJ0
115069
a Note: Check that the intercooler air inlet pipe seal at the turbocharger end is fitted in its groove the right way round. a Refit a new seal to the intercooler air inlet pipe at the turbocharger end. a Fit the cooling and air pipes onto the turbocharger outlet. a Refit the air pipe bolts at the turbocharger outlet. a Refit the cooling assembly. a Refit: - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the engine undertray. a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). a Refill: - the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling), - the refrigerant circuit (see Coolant circuit Draining - Refilling) (62A, Air conditioning), - the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) .
23A-53
23A
AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal - Refitting
23A
DP0
Tightening torquesm exchanger flow control solenoid valve mounting bolt
1 daNm
battery cover mounting bolts
0.4 daNm
REMOVAL a Position the vehicle on a two-post lift. a Remove the engine covers. a Disconnect the battery, starting with the negative terminal. Note: 103434
The radiator flow control solenoid valve can be removed without draining or removing the automatic transmission.
13786-1
a Remove: - the two solenoid valve bolts (1) , - radiator flow control solenoid valve (2) .
REFITTING a To refit, proceed in the reverse order of removal.
23A-54
AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal - Refitting DP0 a Torque tighten the exchanger flow control solenoid valve mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm).
23A-55
23A
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting
23A
DP0 Essential special tooling Bvi. 1459
Fitting right-hand transmission output seal.
Bvi. 1460
Fitting left-hand transmission output seal.
Tightening torquesm wheel bolts lower ball joint nut
13 daNm 6.2 daNm
bolts mounting the torque reaction on the subframe
10.5 daNm
engine tie-bar bolts on K engines
10.5 daNm
engine tie-bar bolts on F engines
18 daNm
a Drain the automatic transmission through the plug (1) .
3.7 daNm
a Remove the faulty differential output seal using a screwdriver or a hook, taking care not to scratch the contact faces.
13791
track rod end nut hub nut battery cover mounting bolts
28 daNm 0.4 daNm
WARNING Do not drop the seal spring into the automatic transmission.
REMOVAL a This operation is done after removing the corresponding driveshaft ( (see 29A, Driveshafts) ). a Position the vehicle on a two-post lift. a Remove the battery cover. a Disconnect the battery, starting with the negative terminal. a Remove the engine undertray.
23A-56
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting DP0
REFITTING a Fit the seal using the (Bvi. 1459) or the (Bvi. 1460). a Guide the assembly until the tool is resting on the automatic transmission casing. a To refit, proceed in the reverse order of removal. a Torque tighten: - the wheel bolts (13 daNm), - the lower ball joint nut (6.2 daNm), - the bolts mounting the torque reaction on the sub-frame (10.5 daNm), - the engine tie-bar bolts on K engines (10.5 daNm), - the engine tie-bar bolts on F engines (18 daNm), - the track rod end nut (3.7 daNm), - the hub nut (28 daNm). a WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). Fill the automatic transmission and check the level (see Filling - Levels) . a Torque tighten the battery cover mounting bolts (0.4 daNm).
23A-57
23A
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting
23A
F9Q, and DP0
REFITTING
Essential special tooling Bvi. 1459
Fitting right-hand transmission output seal.
Bvi. 1460
Fitting left-hand transmission output seal.
I - REFITTING OPERATION FOR PART CONCERNED
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see 02A, Lifting, Vehicle: Towing and lifting). a Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting). a Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) .
117291
II - OPERATION FOR REMOVAL OF PART CONCERNED a Remove: - the right-hand differential output seal using a screwdriver, without scratching the contact surfaces, - the left-hand differential output seal using a screwdriver, without scratching the contact surfaces.
117293
a Refit: - the right-hand differential output seal using the (Bvi. 1459) (1) , - the left-hand differential output seal using the (Bvi. 1460) (2) .
23A-58
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting F9Q, and DP0 II - FINAL OPERATION a Refit: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . a Connect the battery (see 80A, Battery, Battery: Removal - Refitting). a Fill the automatic transmission (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) .
23A-59
23A
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting
23A
AJ0
REFITTING
Essential special tooling Bvi. 1804
Kit for fitting differential and converter seals (AJ0).
I - REFITTING OPERATION FOR PART CONCERNED
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 370, 02A, Lifting equipment). a Disconnect the battery (see Battery : Removal Refitting) (MR 370, 80A, Battery). a Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) .
118354
II - REMOVAL OPERATION FOR PART CONCERNED a Remove: - the right-hand differential output seal using a screwdriver, without scratching the contact surfaces, - the left-hand differential output seal using a screwdriver, without scratching the contact surfaces.
118353
a Refit: - the right-hand differential output seal using the tools from the kit (Bvi. 1804) (1) , - the left-hand differential output seal using the tools from the kit (Bvi. 1804) (1) and the spacer (2) .
23A-60
AUTOMATIC GEARBOX Differential output seal: Removal - Refitting AJ0 II - FINAL OPERATION. a Refit: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand wheel driveshaft: Removal - Refitting, page 29A-3) , - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand wheel driveshaft: Removal - Refitting, page 29A-2) . a Connect the battery (see Battery : Removal - Refitting) (MR 370, 80A, Battery). a Fill the automatic transmission (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) . a Carry out the necessary programming, following removal of the battery (see : Battery - Initialisation)) (MR 372, 80A, Battery).
23A-61
23A
AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting
23A
DP0
Tightening torquesm selector lever nut
1 daNm
REMOVAL a Shift the lever to neutral: « N » .
103409
a Disconnect: - the multifunction switch cable ball joint (1) , - the control cable from the sheath stop (2) on the modular connector support.
101821
a Remove the lever and the two mounting bolts (3) from the multifunction switch.
a Disconnect the battery, starting with the negative terminal.
a Disconnect the modular connector (4) by releasing the connector slide mechanism.
a Remove: - the air intake sleeve,
a Remove the three mounting bolts (5) from the modular connector support plate.
- the battery, - the battery tray, - the injection computer and its support, - the air filter box, - the wiring harness mountings.
13785
a Remove the two modular connector mounting plate bolts. a Remove the green connector (6) from the multifunction switch (12 track).
23A-62
AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting DP0
REFITTING a Move the multifunction switch to the neutral position «N». a Torque tighten the selector lever nut (1 daNm). a Adjust the multifunction switch (see 23A, Automatic gearbox, Multifunction switch: Adjusting, page 23A-66) a Check that the system and gear selection are working correctly. a Proceed in the reverse order to removal.
23A-63
23A
AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting
23A
AJ0 II - OPERATION FOR REMOVAL OF PART CONCERNED
Essential special tooling Bvi. 1805
Multifunction switch adjustment lever (AJ0)
Tightening torquesm multifunction bolts
switch
gear lever nut17
6 Nm Nm
REMOVAL I - REMOVAL PREPARATION OPERATION a Move the gear lever to position N. a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery) - the battery tray (see Battery : Removal - Refitting) (80A, Battery),
118388
a Remove: - the multifunction switch connector (3) ,
- the protection plate from the multifunction switch.
- the multifunction switch (4) .
REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Move the multifunction switch to the N position. a Fit the multifunction switch bolts without tightening them.
118389
a Disconnect: - the control cable ball joint on the multifunction switch (1) using an open-jawed spanner size 12 mm, - the gear lever nut (2) , - the gear lever on the multifunction switch.
23A-64
AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting AJ0
118387
a Position the (Bvi. 1805) (5) . a Align the tool shaft with the relevant hole on the multifunction switch (6) . a Torque tighten the multifunction switch bolts (6 Nm) (7) . a Remove the (Bvi. 1805). a Connect the multifunction switch connector. II - FINAL OPERATION. a Refit the gear lever on the multifunction switch. a Torque tighten the gear lever nut17 (Nm). a Refit: - the control cable to N position, - the protection plate to the multifunction switch, - the battery tray (see Battery : Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery) a Check that the gear selection is working correctly.
23A-65
23A
AUTOMATIC GEARBOX Multifunction switch: Adjusting AJ0 Essential special tooling Bvi. 1805
Multifunction switch adjustment lever (AJ0)
Tightening torquesm multifunction bolts
switch
6 Nm
Adjust the multifunction switch using the tool (Bvi. 1805) when removing and refitting the multifunction switch or during fault finding.
118387
a With the multifunction switch loosened and in position "N", place the tool (Bvi. 1805) (1) on the control lever and align the shaft of the tool opposite the relevant hole on the multifunction switch (2) . a Torque tighten the multifunction switch bolts (6 Nm) (3) . a Remove the.
23A-66
23A
AUTOMATIC GEARBOX Multifunction switch: Adjusting DP0
Tightening torquesm multifunction bolts
switch
10 N.m
ADJUSTMENT
110242
a Put the multifunction switch into the Neutral position. a Place the test probes of an ohmmeter on the multifunction switch position check tabs. a Turn the multifunction switch by hand until the electric contact is closed (resistance at contact terminals to be measured 0 Ω with a tolerance of 60 Ω) a Torque tighten the multifunction switch bolts (10 N.m). a Check that the resistance at the contact terminals is still 0 Ω with a tolerance of 60 Ω after tightening. a Check that the system and gear selection are working correctly.
23A-67
23A
AUTOMATIC GEARBOX Speed sensor: Removal - Refitting
23A
DP0
Tightening torquesm output speed sensor mounting bolt
1 daNm
battery cover mounting bolts
0.4 daNm
REMOVAL a Position the vehicle on a two-post lift. a Remove the engine covers. a Disconnect the battery, starting with the negative terminal.
Note:
13786-1
a Remove the output speed sensor (2) .
The speed sensor can be removed without draining or removing the automatic gearbox.
REFITTING
a Remove the engine undertray.
a To refit, proceed in the reverse order of removal. a Torque tighten the output speed sensor mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm).
103417
a Disconnect the connector (1) .
Note: When replacing a sensor, always remove the gearbox connector (see 23A, Automatic gearbox, A utomatic transmission connector: Removal - Refitting, page 23A-79) .
WARNING Protect the connector by sliding it into a waterproof plastic bag.
23A-68
AUTOMATIC GEARBOX Pressure sensor: Removal - Refitting
23A
DP0
Tightening torquesm pressure sensor mounting bolts
8 N.m
pressure sensor wiring harness mounting bolts
8 N.m
gearbox connector mounting bolts
20 N.m
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on the two-post lift (see 02A, Lifting equipment, Vehicle: Towing and lifting). a Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting). a Remove: - the front left-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting),
110246
a Disconnect the modular connector (1) by pulling the sliding (2) .
- the front left-hand wheel arch liner (see MR Bodywork, 55A, Exterior protection, Wheel arch liner: Removal - Refitting), - the engine undertray. a Remove: - the battery tray (see 80, Battery, Battery tray: Removal - Refitting), - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting).
110225
a Disconnect the gearbox connector from the mounting plate by pulling the slide (3) . a Remove the gearbox connector mounting bolts (4) from the plate.
23A-69
AUTOMATIC GEARBOX Pressure sensor: Removal - Refitting
23A
DP0 II - OPERATION FOR REMOVAL OF PART CONCERNED
110224
a Remove the green connector (3-track) (5) from the gearbox connector on the mounting plate. a Release the pressure sensor wiring harness from the automatic transmission wiring duct.
110251
a Remove: - the wiring harness mounting bolt (6) , - the pressure sensor mounting bolts (7) , - the pressure sensor (8) .
WARNING Protect the connector by sliding it into a waterproof plastic bag.
REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the pressure sensor, - the pressure sensor mounting bolts, - the wiring harness mounting bolt. a Tighten to torque: - the pressure sensor mounting bolts (8 N.m), - the pressure sensor wiring harness mounting bolts (8 N.m). a Connect the pressure sensor harness from the automatic transmission wiring duct.
23A-70
AUTOMATIC GEARBOX Pressure sensor: Removal - Refitting DP0 II - FINAL OPERATION a Refit the gearbox connector mounting plate mounting bolts. a Torque tighten the gearbox connector mounting bolts (20 N.m). a Connect the gearbox connector on the mounting plate by pulling out the slide. a Refit: - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting), - the battery protective base (see 80A, Battery, Battery tray: Removal - Refitting), a Connect the modular connector by reinserting the slide. a Refit the battery shield (see 80A, Battery, Battery tray: Removal - Refitting). a Refit: - the front left-hand wheel arch liner (see 55A, Bodywork, Exterior protection, Wheel arch liner: Removal - Refitting), - the engine undertray, - the front left-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting). a Connect the battery (see 80A, Battery, Battery: Removal - Refitting). a Check the gearbox oil level (see 23A, Gearbox oil: Draining - Filling).
23A-71
23A
AUTOMATIC GEARBOX Gearbox temperature sensor: Removal - Refitting M9R, and AJ0 The gearbox temperature sensor can only be replaced with the hydraulic distributor internal wiring (see 23A, Automatic gearbox, Hydraulic distributor internal wiring: Removal - Refitting, page 23A-48) .
118831
(1)
Gearbox temperature sensor
a Note: In order to avoid breakage of the earth terminal (2) when the bolt is tightened, position it between the distributor and the retaining plate of the gearbox temperature sensor.
23A-72
23A
AUTOMATIC GEARBOX Oil pressure switch: Removal - Refitting
23A
M9R, and AJ0
Essential equipment diagnostic tool
Tightening torquesm oil pressure switch concerned
4 Nm
hydra u l i c d i s t ributor housing bolts8 Nm
.
REMOVAL a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery)
113155
a Remove the air pipe bolts at the intercooler inlet.
- the battery tray (see Battery : Removal - Refitting) (80A, Battery), - the engine undertray. a Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-24) . a Remove the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). a Drain the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling). a Drain the refrigerant circuit (see Coolant circuit Draining - Refilling) (62A, Air conditioning).
119834
a Loosen the clip on the air pipe at the intercooler inlet at the exchanger end. a Disconnect the air pipe at the intercooler inlet at the exchanger end. a Remove the air pipe at the intercooler inlet.
113282
a Rotate the clip on the air pipe at the intercooler inlet at the turbocharger end.
23A-73
AUTOMATIC GEARBOX Oil pressure switch: Removal - Refitting
23A
M9R, and AJ0
106275
a Remove the cooling assembly.
117250
a Place a clean container under the automatic gearbox to collect the oil. a Remove: - the hydraulic distributor housing bolts, - the hydraulic distributor housing, - the hydraulic distributor housing seal.
118391
a Disconnect: - the cooling radiator bottom hose (1) , - the oil/water cooler outlet and inlet hoses (2) . a Unclip all the hoses from their support (3) . a Move all the hoses aside to facilitate access.
118831
a Disconnect the oil pressure switch connector (4) . a The oil pressure switch (5) concerned.
23A-74
AUTOMATIC GEARBOX Oil pressure switch: Removal - Refitting
23A
M9R, and AJ0
REFITTING a Clean the joint faces using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) on the automatic gearbox and on the hydraulic distributor housing taking care not to damage the contact surfaces. a Always replace: - the hydraulic distributor housing seal, - the intercooler air inlet pipe seal at the turbocharger end.
117250
a Fit the hydraulic distributor housing with its new seal. a Torque tighten the hydraulic distributor housing bolts8 Nm (.)
117254
a Refit the oil pressure switch (6) concerned. a Torque tighten the oil pressure switch concerned (4 Nm). a Connect the oil pressure switch connector.
115068
a Remove the intercooler air inlet pipe seal at the turbocharger end using a .
23A-75
AUTOMATIC GEARBOX Oil pressure switch: Removal - Refitting M9R, and AJ0
115069
a Note: Check that the intercooler air inlet pipe seal at the turbocharger end is fitted on its groove the right way round. a Fit a new seal to the intercooler air inlet pipe at the turbocharger end. a Proceed in the reverse order to removal. a Fill the automatic gearbox with oil and check the level (see 2 3 A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling, page 23A-24) . a Refit: - the engine undertray, - the battery tray (see Battery : Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery). a Perform the programming procedures using the diagnostic tool (see Fault finding - Replacement of components) (23A, Automatic gearbox).
23A-76
23A
AUTOMATIC GEARBOX Converter seal: Removal - Refitting
23A
DP0 Essential special tooling Mot. 587
Oil seal extractor
Bvi. 1457
Fitting converter lip seal.
REMOVAL a This operation is carried out after the automatic transmission and converter have been removed. a Remove the converter by withdrawing it as far as possible without deviating from its axis. WARNING The converter contains a large amount of oil, which may spill when it is being removed. a Using tool (Mot. 587), remove the seal, taking care not to scratch the contact faces. 13790
a The distance between the base of the threading (1) and the engine coupling face (2) should be 17 mm.
REFITTING a
a To refit, proceed in the reverse order of removal. WARNING - Work as cleanly as possible to prevent foreign bodies penetrating the system. - Lubricate all the contact faces.
a Refit: - the new pre-lubricated seal to the end, using the (Bvi. 1457), - the converter.
23A-77
AUTOMATIC GEARBOX Converter seal: Removal - Refitting
23A
AJ0 Essential special tooling Bvi. 1804
Kit for fitting differential and converter seals (AJ0).
REMOVAL a This operation is carried out with the gearbox and converter removed.
117252
a Refit the converter (3) .
117248
a Remove the converter seal (1) using a screwdriver, taking care not to damage the input shaft splines.
REFITTING
11911
a Check that the converter is correctly inserted using a surfaced ruler and a steel rule. a Check that the distance (X) between the bead and the ruler is at least 20.5 mm. a Refit the gearbox (see: Automatic gearbox: Removal - Refitting).
11954
a Refit the seal using the (2) contained in the kit (Bvi. 1804)
23A-78
AUTOMATIC GEARBOX Automatic transmission connector: Removal - Refitting
23A
DP0 Connector numbering Tightening torquesm battery cover mounting bolts
0.4 daNm
103248
13785
(1)
Green connector (multifunction switch)
(2)
Yellow connector (electrohydraulic interface)
(3)
Green connector (line pressure)
(4)
Yellow connector (turbo speed)
(5)
Blue connector (exchanger flow control solenoid valve)
REMOVAL a Position the vehicle on a two-post lift. a Remove the engine covers. a Shift the lever to neutral: « N » .
Note: These connectors may be removed separately from the gearbox connector when certain components are replaced.
101821
a Disconnect the battery, starting with the negative terminal. a Remove: - the air intake sleeve, - the battery,
23A-79
AUTOMATIC GEARBOX Automatic transmission connector: Removal - Refitting
23A
DP0 - the battery tray,
REFITTING
- the injection computer and its support,
a To refit, proceed in the reverse order of removal.
- the air filter box,
WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ).
- the wiring harness mountings.
a Torque tighten the battery cover mounting bolts (0.4 daNm).
103409
a Disconnect: - the multifunction switch cable ball joint (6) , - the wiring (7) from the multifunction switch cable, unlocking the cable sleeve stop, - the gearbox connector (8) by releasing the connector slide valve. a Remove: - the three mounting bolts (9) from the gearbox connector support plate, - the two gearbox connector mounting bolts, - the connector of the colour concerned from the gearbox connector. a Follow the five wiring harnesses connected to the gearbox connector. a Remove the five wiring harnesses. These wiring harnesses are either connected via a connector to or directly to the components. If they are connected to a component directly, the component should also be removed.
23A-80
AUTOMATIC GEARBOX Automatic transmission computer: Removal - Refitting
23A
DP0
Tightening torquesm battery cover mounting bolts
0.4 daNm
The computer is located behind the left-hand wheel arch.
REPLACEMENT a Note: When the automatic gearbox computer is replaced, it is necessary to enter the age of the automatic gearbox oil stored in the memory of the computer to be replaced in the memory of the new computer. a Use the following procedure.
103414
a Read the oil ageing value from the memory of the computer being replaced using parameter PR133: « Oil ageing counter » and note down the value.
a Disconnect the computer connector. a Remove the resonator .
a Replace the computer. a Enter the oil ageing value in the memory of the new computer using command CF320: «Oil ageing counter report » . a Confirm entry using the parameter « Oil ageing counter » . a Enter the After Sales operation date using command CF320 « Enter After-Sales operation date » . a Carry out a road test so that the new computer stores the programming.
REMOVAL a Position the vehicle on a two-post lift. a Remove the engine covers. a Disconnect the battery, starting with the negative terminal. a Remove the front bumper.
103415
a Remove: - the two computer mounting nuts , - the computer.
23A-81
AUTOMATIC GEARBOX Automatic transmission computer: Removal - Refitting DP0
REFITTING a To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ). a Torque tighten the battery cover mounting bolts (0.4 daNm). REPLACING THE COMPUTER
23A-82
23A
AUTOMATIC GEARBOX Automatic transmission computer: Removal - Refitting
23A
AJ0
REFITTING Essential equipment I - REFITTING OPERATION FOR PART CONCERNED
diagnostic tool
a Connect the computer connector.
REMOVAL
a Refit: - the computer,
I - REMOVAL PREPARATION OPERATION
- the computer nuts.
a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 370, 02A, Lifting equipment).
II - FINAL OPERATION.
a Disconnect the battery (see Battery : Removal Refitting) (MR 370, 80A, Battery).
a Refit the front bumper (see Front bumper: Removal - Refitting) (MR 371, 55A, Exterior protection).
a Remove the front bumper (see Front bumper: Removal - Refitting) (MR 371, 55A, Exterior protection).
a Connect the battery (see Battery : Removal - Refitting) (MR 370, 80A, Battery).
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Carry out the necessary programming, following removal of the battery (see Battery - Initialisation)) (MR 372, 80A, Battery). a Connect the diagnostic tool for programming procedures (see Replacement of components)) (MR 372, 23A, Automatic transmission).
103415
a Remove: - the automatic transmission computer nuts, - the automatic transmission computer (1) . a Disconnect the computer connector.
23A-83
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
DP0
Tightening torquesm control unit mounting nuts
2.1 daNm
I - REMOVAL 1 - In the engine compartment a Position the vehicle on a two-post lift. a Remove the engine covers. a Disconnect the battery, starting with the negative terminal. a Remove:
104246
a Remove: - the scuttle panel partition mounting bolts (3) ,
- the battery,
- the scuttle panel partition.
- the cowl grille ( (see 85A, Wiping - Washing) ).
104343
a Remove: - the two air filter access panel mounting bolts (1) , - the air filter access panel, - the scuttle panel partition mounting bolt (2) .
101822
a Disconnect the computer connectors. a Remove: - the battery tray bolts (4) , - the battery tray, - the computer with its support, - the air filter outlet duct.
23A-84
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
DP0
105107
105110
a Remove the gear lever knob by lifting it.
a Unclip: - the control cable (5) from the gearbox lever ball joint, - the control cable from the sleeve stop.
2 - In the passenger compartment a Unclip the gear lever gaiter.
104033
a Remove the mounting bolts (7) from the central console. a Unclip: - the mounting brackets (8) , - the clip (9) .
105109
a Rotate the part (6) clockwise.
23A-85
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
DP0
105105
a Move the heat shield towards the rear of the vehicle to gain access to the gearbox control cable routing (12) . 105108
a Remove the « control unit-cable » assembly via the passenger compartment.
a Disconnect the connector (10) . a Remove: - the three control unit mounting bolts (11) , - the three bulkhead seal mounting bolts,
II - REFITTING a To refit, proceed in the reverse order of removal. a Torque tighten the control unit mounting nuts (2.1 daNm).
- the engine undertray. ADJUSTING THE CONTROL CABLE WARNING Do not open the automatic transmission control unit, this could cause damage (infrared system).
a - In the passenger compartment a Put the lever in « Drive » position.
a Disconnect: - the exhaust pipe from the exhaust manifold,
b - In the engine compartment
- the centre bracket.
a Put the gearbox lever in « Drive » position.
a Move the exhaust pipe to one side.
a Clip the control cable into the sleeve stop.
a Disconnect the oxygen sensor connector. a Remove the heat shield mounting bolts.
23A-86
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
DP0
104733
105107
a Fit the end of the control cable (5) on the gearbox lever ball joint. a Lock the adjustment mechanism by pushing the catch (14) back to its original position. a Check that the system and gear selection are working correctly. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
104736
a Slide on part (13) by compressing the control cable spring. a Unlock the adjustment mechanism by sliding the catch (14) . a Adjust the length of the cable accordingly.
23A-87
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0 Essential special tooling Mot. 1495-01
22 mm socket for removing/ refitting oxygen sensors.
Tightening torquesm exhaust bracket nuts
21 Nm
oxygen sensor
45 Nm
REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see 02A, Lifting, Vehicle: Towing and lifting). a Carefully mark the position of the automatic gearbox control lever before the operation: if not, position the gear selector and the multifunction switch in neutral «N».
103424
a Remove the diagnostic socket access cover (3) . a Turn the part (4) a quarter of a turn. a Remove the part.
a Remove the engine covers. a Remove the battery (see 80A, Battery, Battery: Removal - Refitting).
103425
a Remove the control unit lever knob (5) by lifting it. 103408
a Remove: - the multifunction switch cable ball joint (1) , - the control cable from the sheath stop (2) on the modular connector support.
23A-88
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0
101322
a Unclip the handbrake surround trim at (8) and (9) .
103426
a Unclip the console trim (6) .
101319
a Unclip the lower cover (10) .
103427
a Disconnect the connector (7) . a Open the glove compartment. 101321
a Unclip the cigarette lighter mounting. a Disconnect the cigarette lighter connector.
23A-89
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0
101320
a Disconnect the heated seat connectors (if fitted to the vehicle). a Remove the two front seats (see MR 365 Bodywork, 75A, Front seat frames and runners, Complete front seat: Removal - Refitting).
101793
a Remove the nuts (15) from the exhaust bracket.
a Remove the bolts from the console (11) . a Remove: - the console carefully (12) , - the gear lever console.
101818
a Remove the bolts (16) from the rubber mounting bush.
101504
a Disconnect the connector (13) . a Remove the sensor (14) using the (Mot. 1495-01).
23A-90
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0
102117
a Remove:
103429
a Remove the protector (19) .
- the bolt (17) , - the front section of the heat shield.
II - OPERATION FOR REMOVAL OF PART CONCERNED
103428
a Pull back the carpet. a Remove the soundproofing (18) .
103431
a Remove the bolts (20) from the automatic gearbox control unit. a Hold the control lever rod steady and release the control unit clips. a Take out the « unit-control cable » assembly.
23A-91
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0
REFITTING
II - FINAL OPERATION
I - REFITTING OPERATION FOR PART CONCERNED
103429
a Refit the protector (22) . 103431
a Position the « unit-control cable » assembly. a Hold the control lever rod steady and lock the control unit clips. a Refit the bolts (21) to the automatic gearbox control unit.
103428
a Refit the soundproofing (23) . a Pull the carpet forwards.
23A-92
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0
102117
a Refit:
101793
a Refit the nuts (26) to the exhaust bracket. a Torque tighten the exhaust bracket nuts (21 Nm).
- the front section of the heat shield, - the bolt (24) .
101818
a Refit the bolts (25) to the rubber mounting bush.
101504
a Refit the oxygen sensor (27) . a Torque tighten the oxygen sensor (45 Nm). a Connect the connector (28) .
23A-93
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
F9Q, and DP0 a Refit the two front seats (see MR 365 Bodywork, 75A, Front seat frames and runners, Complete front seat: Removal - Refitting). a Refit: - the centre console, - the centre console bolts. a Connect the heated seat connectors (if fitted to the vehicle).
103426
a Clip on the console trim (30) .
101321
a Connect the cigarette lighter connector. a Clip on the cigarette lighter mounting. a Clip on the handbrake surround trim.
103424
a Refit the control unit lever knob (31) by lowering it. a Fit the part. a Turn the part a quarter of a turn. a Refit the diagnostic socket access cover.
103427
a Connect the connector (29) .
23A-94
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting F9Q, and DP0
103408
a Refit: - the sheath stop control cable (32) on the modular connector support, - the multifunction switch cable ball joint (33) . a Refit the battery (see 80A, Battery, Battery: Removal - Refitting). a Refit the engine covers.
23A-95
23A
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
AJ0
Tightening torquesm control unit mounting nuts
2.1 daNm
I - REMOVAL 1 - In the engine compartment a Position the vehicle on a two-post lift. a Remove the engine covers. a Disconnect the battery, starting with the negative terminal. a Remove:
104246
a Remove: - the scuttle panel partition mounting bolts,
- the battery,
- the scuttle panel partition.
- the cowl grille ( (see 85A, Wiping - Washing) ).
104343
a Remove: - the two air filter access panel mounting bolts, - the air filter access panel, - the scuttle panel partition mounting bolt.
101822
a Disconnect the computer connectors. a Remove: - the battery tray bolts , - the battery tray, - the computer with its support, - the air filter outlet duct.
23A-96
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
AJ0
105107
a Unclip:
105110
a Remove the gear lever knob by lifting it.
- the control cable from the gearbox lever ball joint, - the control cable from the sleeve stop. 2 - In the passenger compartment a Unclip the gear lever gaiter.
104033
a Remove the mounting bolts from the central console . a Unclip: - the mounting brackets , 105109
a Rotate part clockwise.
23A-97
- the clip.
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
AJ0
105105
a Move the heat shield towards the rear of the vehicle to gain access to the gearbox control cable routing. a Remove the « control unit-cable » assembly via the passenger compartment. 105108
a Disconnect the connector.
II - REFITTING
a Remove:
a To refit, proceed in the reverse order of removal.
- the three control unit mounting bolts , - the three bulkhead seal mounting bolts, - the engine undertray.
a Torque tighten the control unit mounting nuts (2.1 daNm). ADJUSTING THE CONTROL CABLE
WARNING
a - In the passenger compartment
Do not open the automatic transmission control unit, this could cause damage (infrared system).
a Put the lever in « Drive » position.
a Disconnect:
b - In the engine compartment
- the exhaust pipe from the exhaust manifold,
a Put the gearbox lever in « Drive » position.
- the centre bracket.
a Clip the control cable into the sleeve stop.
a Move the exhaust pipe to one side. a Disconnect the oxygen sensor connector. a Remove the heat shield mounting bolts.
23A-98
AUTOMATIC GEARBOX Automatic transmission control unit: Removal - Refitting
23A
AJ0
104733
105107
a Fit the end of the control cable on the gearbox lever ball joint. a Lock the adjustment mechanism by pushing the catch back to its original position. a Check that the system and gear selection are working correctly. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
104736
a Slide on part by compressing the control cable spring. a Unlock the adjustment mechanism by sliding the catch. a Adjust the length of the cable accordingly.
23A-99
DRIVESHAFTS Driveshaft: Precautions for repair
Note: A gearbox oil leak at the driveshaft may destroy it.
Note: Grease the base of the bearing using BR 2 + grease to prevent the bearing from sticking. Make sure that the O-ring is correctly positioned in the base of the relay bearing, if the bearing has one.
Note: Always replace: - the O-ring, if fitted to the bearing, - the relay bearing support plate, - the left-hand driveshaft locking spring ring, if the driveshaft has one, - the seals whenever the driveshaft is removed.
WARNING In order to prevent irreversible damage to the front hub bearing: - Do not loosen or tighten the driveshaft nut when the wheels are on the ground. - Do not place the vehicle with its wheels on the ground when the driveshaft has been loosened or removed.
29A-1
29A
DRIVESHAFTS Front left-hand wheel driveshaft: Removal - Refitting
a Remove the driveshaft (wheel side).
Essential special tooling Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
29A
II - GEARBOX SIDE
JH3 or JR5 or ND0 a Drain the gearbox (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A13) .
Tightening torquesm wheel bolts
13 daNm
hub nut
28 daNm
track rod end nut
3.7 daNm
lower ball joint nut
6.2 daNm
anti-roll bar nut
4.4 daNm
driveshaft bearing bolts
4.4 daNm
a Remove the driveshaft (gearbox side).
REPLACEMENT a
REMOVAL
Note:
I - WHEEL SIDE
Check the condition of the contact surfaces of the lip seal. Always replace the differential output lip seal (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-45) .
a Position the vehicle on a two-post lift. a Remove: - the front left-hand wheel,
a With the protector in place, coat the splines of the seal on the gearbox side with MOLYKOTE BR2.
- the hub nut using tool (Rou. 604-01). a Disconnect the wheel speed sensor.
a Position and insert the driveshaft into the final drive sunwheel. a Insert the stub-axle into the hub. The driveshaft must go in freely until it protrudes enough for the hub nut to be mounted. a To refit, proceed in the reverse order of removal. a Torque tighten: - the wheel bolts (13 daNm), - the hub nut (28 daNm), - the track rod end nut (3.7 daNm),
101213
a Remove:
- the lower ball joint nut (6.2 daNm),
- the track rod end nut (1) , - the stub axle carrier ball joint using the (Tav. 476),
- the anti-roll bar nut (4.4 daNm),
- the upper nut of the anti-roll bar (2) ,
- the driveshaft bearing bolts (4.4 daNm),
- the lower ball joint stud (3) . a Push back the driveshaft from the stub axle carrier by pivoting the stub axle carrier.
a Fill and check the gearbox oil level (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A-13) .
29A-2
DRIVESHAFTS Front right-hand wheel driveshaft: Removal - Refitting
a Remove the driveshaft (wheel side).
Essential special tooling Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
29A
II - GEARBOX SIDE JH3 or JR5 or ND0 a Drain the gearbox.
Tightening torquesm wheel bolts
13 daNm
hub nut
28 daNm
track rod end nut
3.7 daNm
lower ball joint nut
6.2 daNm
anti-roll bar nut
4.4 daNm
driveshaft bearing bolts
4.4 daNm
REMOVAL I - WHEEL SIDE a Position the vehicle on a two-post lift. a Remove: - the front right-hand wheel, - the hub nut using tool (Rou. 604-01). 101819
a Disconnect the wheel speed sensor.
a Remove the two bolts (4) from the driveshaft bearing. a Remove the driveshaft (gearbox side). Note: If the bearing is seized in the relay bearing, the bearing must be replaced.
101213
a Remove: - the track rod end nut (1) , - the stub axle carrier ball joint using the (Tav. 476), - the upper nut from the anti-roll bar (2) , - the lower ball joint stud (3) . a Push back the driveshaft from the stub axle carrier by pivoting the stub axle carrier.
29A-3
DRIVESHAFTS Front right-hand wheel driveshaft: Removal - Refitting REPLACEMENT
29A
REMOVING THE RELAY SHAFT BEARING
a Clean and grease the bearing hole into which the bearing will be inserted. Note: - Replace the O-ring at the base of the relay shaft bearing if it is damaged. - Check the condition of the contact surfaces of the lip seal. - The differential output lip seal must always be replaced (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-45) . a With the protector in place, coat the splines of the seal on the gearbox side with MOLYKOTE BR2. a Position and insert the driveshaft into the final drive sunwheel. a Insert the stub-axle into the hub. The driveshaft must go in freely until it protrudes enough for the hub nut to be mounted. a To refit, proceed in the reverse order of removal.
100642
a Remove the complete driveshaft. a Remove the bearing using a press. a Take care not to score the contact surface of the lip seal on the relay shaft.
REFITTING a Lubricate the contact surface of the shaft into which the bearing is inserted.
a Torque tighten:
a Insert the new bearing.
- the wheel bolts (13 daNm),
a Fit the bearing to the end using a tube, so that it rests on the inner bearing race.
- the hub nut (28 daNm), - the track rod end nut (3.7 daNm), - the lower ball joint nut (6.2 daNm),
a Clean and grease the bearing hole into which the bearing will be inserted.
- the anti-roll bar nut (4.4 daNm),
a Refit the driveshaft.
- the driveshaft bearing bolts (4.4 daNm), a Fill and check the gearbox oil level (see 21A, Manual gearbox, Manual gearbox oil: Draining - Refilling, page 21A-13) .
29A-4
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