scenic ii pt3 transmission
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© Renault s.a.s 2008
"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.
77 11 322 042 FEBRUARY 2009 Edition Anglaise
X84, and J84
2 Transmission
20A CLUTCH
21A MANUAL GEARBOX
23A AUTOMATIC GEARBOX
29A DRIVESHAFTS
Scénic II - Section 2
Contents
Page
Scénic II - Section 2ContentsPage
20A CLUTCH
Clutch: Precautions for repair 20A-1
Identification 20A-2
Mechanism / Disk: Removal - Refitting 20A-4
Clutch thrust bearing: Removal - Refitting 20A-14
21A MANUAL GEARBOX
Manual gearbox: Parts and consumables for the repair work 21A-1
Identification 21A-2
Manual gearbox: Specifications 21A-3
Manual gearbox oil: Specifications 21A-12
Manual gearbox oil: Draining - Refilling 21A-13
Manual gearbox: Removal - Refitting 21A-21
Differential output seal: Removal - Refitting 21A-45
Input shaft lip seal: Removal - Refitting 21A-56
23A AUTOMATIC GEARBOX
Automatic gearbox: Precautions for repair 23A-1
Automatic gearbox: Identification 23A-3
Automatic gearbox: Specifications 23A-5
Automatic gearbox: List and location of components 23A-7
Automatic gearbox: Parts and consumables for the repair work 23A-10
Automatic gearbox: Removal - Refitting 23A-12
Automatic gearbox oil: Draining - Refilling 23A-24
Hydraulic distributor: Removal - Refitting 23A-31
Solenoid valves: Removal 23A-40
Hydraulic distribution wiring: Removal - Refitting 23A-41
Hydraulic distributor internal wiring: Removal - Refitting 23A-48
Flow regulation solenoid valve: Removal - Refitting 23A-54
Differential output seal: Removal - Refitting 23A-56
Multifunction switch: Removal - Refitting 23A-62
Contents
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
29A 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
23A AUTOMATIC GEARBOX
20A-1
CLUTCHClutch: Precautions for repair 20A
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 bluestains),
- The crankshaft bearing (no sticking),
- The engine and gearbox seals (replace if necessary),
- The sliding action of the clutch plate on the outputshaft,
- The thrust bearing guide and the clutch fork (no wearor scratches).
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 platebolts.
After refitting, check:
- The clutch play (for a cable operated vehicle),
- Bleeding of the hydraulic circuit (for vehicles with hy-draulic controls).
Essential special tooling
Emb. 1518 Set of clutch disc centr ingmandrels
WARNING
To prevent the clutch from juddering or slipping, donot grease the output shaft or the clutch plate hub.
20A-2
CLUTCHIdentification 20A
Pressure plate
Drive plate
Plate external diameter: 200 mm
Plate thickness: 6.9 mm
Number of splines: 26
Colour of the springs (1) and (2) : Grey
Pressure plate
Drive plate
Plate outer diameter: 215 mm
Plate thickness: 6.8 mm
Number of splines: 26
K4J or K4M
102143
102142
K9K
102143
102142
20A-3
CLUTCHIdentification 20A
Colour of springs (3) : Red and Black
Colour of springs: (4) Grey
Pressure plate
Drive plate
Plate outer diameter: 239 mm
Plate thickness: 7.8 mm
Number of splines: 21
F4R or F9Q or M9R
22428
22429
20A-4
CLUTCHMechanism / Disk: Removal - Refitting
F4R or F9Q
20A
REMOVALa Remove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-21) .
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.
REFITTING
EMB. 1604
a
a Lock the base plate of the (Emb. 1604) in a vice.
Essential special tooling
Mot. 1677 Flywheel locking tool.
Emb. 1604 Clutch compression tool forresetting retrofit system.
Emb. 1518 Set of clutch disc centr ingmandrels
Tightening torquesm
pressure plate moun-ting bolts
1.2 daNm
16180
19919
Note:
For automatic wear compensation mechanisms,compress the clutch pressure plate using tool(Emb. 1604).
20754
20A-5
CLUTCHMechanism / Disk: Removal - Refitting
F4R or F9Q
20A
a Fit the pressure plate onto the base, then fit thethrust bearing (1) and the nut (2) .
a Tighten the nut (2) fully.
a Insert the circlip pliers at (3) .
a Compress the springs (4) .
a Slacken off the nut (2) completely (springs com-pressed).
a Release the pressure plate.
20755
20756
20757
20759
20A-6
CLUTCHMechanism / Disk: Removal - Refitting
F4R or F9Q
20A
a Remove the pressure plate from the base plate(checking that the springs are properly com-pressed).
a Position the driven plate (small hub diameter (5) onflywheel end).
CENTRING
a Centre the clutch plate using the (Emb. 1518).
a Refit the pressure plate on the flywheel.
a Gradually tighten the pressure plate mountingbolts (1.2 daNm).
20758
WARNING
Clean the clutch shaft splines and refit theassembly without lubricant.
Degrease the friction face of the flywheel.
102695
22695
20A-7
CLUTCHMechanism / Disk: Removal - Refitting
JH3 or JR5
20A
REMOVAL
a Remove the gearbox (see 21A, Manual gearbox,Manual gearbox: Removal - Refitting, page 21A-21) .
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.
Essential special tooling
Mot. 582-01 Flywheel locking tool.
Emb. 1518 Set of clutch disc centr ingmandrels
Tightening torquesm
pressure plate moun-ting bolts
2 daNm
16180
20A-8
CLUTCHMechanism / Disk: Removal - Refitting
JH3 or JR5
20AREFITTING
a Clean the clutch shaft splines.
a Refit the assembly without lubricant.
a Position the clutch plate with the shoulder on the
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
20A-9
CLUTCHMechanism / Disk: Removal - Refitting
M9R, and PK4
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) .
II - REMOVAL OPERATION FOR PART CONCERNED
a Fit the (Mot. 1431) (1) .
a Remove
- the mechanism bolts ,
- the mechanism,
- the friction plate.
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
a Place the base of tool (Emb. 1604) in a vice.
Essential special tooling
Mot. 1431 Flywheel locking tool.
Emb. 1604 Clutch compression tool forresetting retrofit system.
Emb. 1780 Set of clutch disc centr ingmandrels.
Tightening torquesm
pressure plate moun-ting bolts
12 Nm
114917
19919
Note:
For automatic wear compensation mechanisms,compress the clutch pressure plate using tool(Emb. 1604).
20754
20A-10
CLUTCHMechanism / Disk: Removal - Refitting
M9R, and PK4
20A
a Fit the pressure plate onto the base, then fit thethrust bearing (2) and the nut (3) .
a Tighten the nut fully.
a Insert the circlip pliers at (4) .
a Compress the springs (5) .
a Slacken off the nut (3) completely (springs com-pressed).
a Release the pressure plate.
20755
20756
20757
20759
20A-11
CLUTCHMechanism / Disk: Removal - Refitting
M9R, and PK4
20A
a Remove the pressure plate from the base plate(checking that the springs are properly com-pressed).
a Position the driven plate (small hub diameter (6) onflywheel end).
II - REFITTING OPERATION
Centring
a Refit the clutch plate.
a Centre the clutch plate using tool (Emb. 1780) (2)Emb. 1780 .
a Refit the pressure plate on the flywheel.
a Fit the (Mot. 1431).
a Tighten the pressure plate bolts until contact is ma-de.
a Gradually tighten to torque the pressure platemounting bolts (12 Nm).
III - FINAL OPERATION.
a Remove tool (Mot. 1431).
a Refit:
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).
20758
Note:
Clean the clutch shaft splines and refit theassembly without lubricant.
Degrease the friction face of the flywheel.
102695
114916
20A-12
CLUTCHMechanism / Disk: Removal - Refitting
K9K, and TL4
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the gearbox (see 21A, Manual gearbox,Manual gearbox: Removal - Refitting, page 21A-21) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Lock the engine using the (1) (Mot. 582-01).
a Slide the bolts (2) out of the mechanism.
a Remove the mechanism.
a Remove the clutch plate.
REFITTING
I - REFITTING PREPARATION OPERATION
a Degrease the flywheel friction face.
a Clean the clutch shaft splines.
Essential special tooling
Mot. 582-01 Flywheel locking tool.
Emb. 1780 Set of clutch disc centr ingmandrels.
Tightening torquesm
clutch pressure platebolts
12 N.m
123518
102143
117628
20A-13
CLUTCHMechanism / Disk: Removal - Refitting
K9K, and TL4
20AII - REFITTING OPERATION FOR PART CONCERNED
a Position the clutch plate.
a Centre the clutch plate using the (Emb. 1780).
a Tighten to torque and in order the clutch pressureplate bolts (12 N.m).
a Position the clutch plate with the section (10) againstthe flywheel.
III - FINAL OPERATION
a Remove the (Mot. 582-01) then the (Emb. 1780).
a Refit the gearbox (see 21A, Manual gearbox, Ma-nual gearbox: Removal - Refitting, page 21A-21) .
108798
102143
117628
20A-14
CLUTCHClutch thrust bearing: Removal - Refitting
JH3 or JR5 or ND0
20A
REMOVAL
a Remove:
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the two hydraulic union bolts (1) ,
- the hydraulic union,
- the two clutch thrust bearing mounting bolts (2) onthe clutch housing,
- the clutch thrust bearing.
a Remove:
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the hydraulic union clip (1) ,
- the hydraulic union,
- the two clutch thrust bearing mounting bolts (2) onthe clutch housing,
- the clutch thrust bearing.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten:
- the hydraulic union mounting bolts (0.9 daNm),
- the bolts mounting the clutch thrust bearing tothe clutch housing (2.1 daNm).
Tightening torquesm
hydraulic union moun-ting bolts
0.9 daNm
bolts mounting theclutch thrust bearing tothe clutch housing
2.1 daNm
JH3 or JR5
18439
ND0
101223
JH3 or JR5
20A-15
CLUTCHClutch thrust bearing: Removal - Refitting
JH3 or JR5 or ND0
20A
a Torque tighten the clutch thrust bearing mountingbolts on the clutch housing (2.1 daNm).
a
a Bleed the clutch control ( (see 37A, Mechanicalcomponent controls) ).
ND0
WARNINGTo avoid damaging the clutch slave cylinder, donot lubricate the clutch shaft.
Never operate the system while the slave cylin-der is removed.
Note:
Always replace the hydraulic union.
20A-16
CLUTCHClutch thrust bearing: Removal - Refitting
PK4
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) .
a Remove the hydraulic union retaining clip (1) .
a Unclip the clutch hydraulic pipe.
a Move the hydraulic union away.
II - REMOVAL OPERATION FOR PART CONCERNED
a Remove:
- the bolts (2) mounting the clutch thrust bearing onthe clutch housing,
- the clutch thrust bearing.
REFITTING
I - REMOVAL PREPARATION OPERATION
a Check the condition of the input shaft seal. Replaceit if necessary.
Tightening torquesm
bolts mounting theclutch thrust bearing onthe clutch housing
21 Nm
114915
114914
WARNING
To avoid damaging the clutch slave cylinder, donot lubricate the clutch shaft.
Always replace the clutch thrust bearing with anew one when the clutch is replaced.
20A-17
CLUTCHClutch thrust bearing: Removal - Refitting
PK4
20AII - REFITTING OPERATION FOR PART CONCERNED
a Refit the new clutch thrust bearing.
a Tighten the bolts mounting the clutch thrust bearingon the clutch housing until they just make contact.
a Tighten to torque the bolts mounting the clutchthrust 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, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).
a Bleed the clutch control (see Clutch circuit: Blee-ding) (MR 370, 37A, Mechanical component con-trols).
114914
21A-1
MANUAL GEARBOXManual gearbox: Parts and consumables for the repair work
M9R, and 700, and PK4
21A
Parts always to be replaced when they have been re-moved:
- lock rings,
- differential output seals,
- input shaft output seal,
- pins.
- hydraulic tappet.
Type Packaging Part no. Component
GEARBOX OIL Immerse all parts
SILICONE ADHESIVE SEA-LANT
100g cartridge 77 11 227 484 Housing assembly
LOCTITE 518 24 ml syringe 77 01 421 162 Switch threading
21A-2
MANUAL GEARBOXIdentification
M9R, and 700, and PK4
21A
105538
(1) Identification label
(2) Identification inscription
21A-3
MANUAL GEARBOXManual gearbox: Specifications
PK4
21AI - IDENTIFICATION
II - GEAR RATIOS
PF6 gearbox
105538
(1) Identification label
(2) Etching.
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
Tacho-meter
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-4
MANUAL GEARBOXManual gearbox: Specifications
PK4
21A
PK4 gearbox
PA0 gearbox
023 11/43 31/43 41/40 41/31 47/28 16/67
024 11/43 31/43 41/40 41/31 47/28 16/67
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
Tacho-meter
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
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
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
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
Tacho-meter
21A-5
MANUAL GEARBOXManual gearbox: Specifications
PK4
21A
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
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
21A-6
MANUAL GEARBOXManual gearbox: Specifications
JH3 or JR5
21AI - IDENTIFICATION
A marking (1) on the gearbox casing indicates:
- (A) Gearbox type
- (B) Gearbox suffix
- (C) Fabrication number
- (D) Factory of manufacture
II - GEAR RATIOS
109167
19860
Suffix First Second Third Fourth Fifth Reversegear
Finaldrive
Tacho-meter
JA3 sequential gearbox
JA3-001 11/41 21/43 28/39 34/35 39/32 11/39 14:61 None
JA5 sequential gearbox
JA5-001 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None
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-7
MANUAL GEARBOXManual gearbox: Specifications
JH3 or JR5
21A
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
Suffix First Second Third Fourth Fifth Reversegear
Finaldrive
Tacho-meter
21A-8
MANUAL GEARBOXManual gearbox: Specifications
JH3 or JR5
21A
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
JH3-156
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
Suffix First Second Third Fourth Fifth Reversegear
Finaldrive
Tacho-meter
21A-9
MANUAL GEARBOXManual gearbox: Specifications
JH3 or JR5
21A
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
JR5-184
JR5-193 11/41 21/43 28/37 35/34 41/31 11/39 17/56 None
Suffix First Second Third Fourth Fifth Reversegear
Finaldrive
Tacho-meter
21A-10
MANUAL GEARBOXManual gearbox: Specifications
TL4
21AI - IDENTIFICATION
II - GEAR RATIOS
111646
(1) Identification plate
(2) Etching
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
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-11
MANUAL GEARBOXManual gearbox: Specifications
TL4
21A
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
Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive
Reversegear
21A-12
MANUAL GEARBOXManual gearbox oil: Specifications
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
21AI - VEHICLE/GEARBOX TYPE/OIL TYPE CORRELATIONS:
II - STANDARDS AND PART NUMBERS OF THE VARIOUS RECOMMENDED OILS:
III - IDENTIFICATION OF OIL FOR STANDARD EXCHANGE PK1 GEARBOXES:
GEARBOX TYPE TYPE OF OIL FORGEARBOX
JBX
JCX
JRX
JHX
NDX
TL4
T R A N S E L F TRJ75W80
or
TRANSELF NFJ75W80
PKX
PFX
VMX
NEX
NGX
N0X
UNX
TRANSELF TRX75W80
or
TRANSELF NFP75W80
ZFX T R A N S E L F L D75W80
DESIGNATION STANDARD PART NUM-BER
TRANSELF
TRX 75W80
or
TRANSELF
NFP 75W80
APIGL4,
MIL-L-2105C or D
77 11 143 534
(5 litres)
TRANSELF
TRJ 75W80
or
TRANSELF
NFJ 75W80
APIGL4,
MIL-L-2105C or D
May be orde-red from ELF
TRANSELF
LD 75W80
APIGL4,
MIL-L-2105
May be orde-red from ELF
Note:
For standard exchange PK1 gearboxes, the oil type(TRZ or TRP) is shown on a label.
These two oils are replaced by TRX 75W80 or NFP75W80.
21A-13
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
PK4
21A
CAPACITY
I - OIL CHANGE
a Unscrew the drain plug (1) using the (Mot. 1018).
a Let the oil run into a drain tray.
a Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.
a Torque tighten the drain plug (24 N.m).
II - FILLING
a Undo the filler cap (3) .
Essential special tooling
Mot. 1018 Sump plug tool.
Tightening torquesm
drain plug 24 N.m
Gearbox type Capacity in litres
PK4 2.4
114652
113764
114772
21A-14
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
PK4
21A
a Fill the gearbox until the oil overflows via the oil fillercap opening using a syringe containing the recom-mended oil (see 21A, Manual gearbox, Manualgearbox oil: Specifications, page 21A-12) (Tech-nical Note 6012A, 04A, Lubricants).
a Tighten the filler cap.
92081
21A-15
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
TL4
21A
CAPACITY
I - OIL CHANGE
a Unscrew the drain plug (1) using the (Mot. 1018).
a Let the oil run into a drain tray.
a Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.
a Torque tighten the drain plug (24 N.m).
II - FILLING
a Undo the filler cap (3) .
Essential special tooling
Mot. 1018 Sump plug tool.
Tightening torquesm
drain plug 24 N.m
Gearbox type Capacity in litres
TL4 2
113928
113764
113928
21A-16
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
TL4
21A
a Fill the gearbox until the oil overflows via the oil fillercap opening using a syringe containing the recom-mended oil (see 21A, Manual gearbox, Manualgearbox oil: Specifications, page 21A-12) (Tech-nical Note 6012A, 04A, Lubricants).
a Tighten the filler cap.
92081
21A-17
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
ND0
21A
CAPACITY
I - OIL CHANGE
a Unscrew the drain plug (1) using the (Mot. 1018).
a Let the oil run into a drain tray.
a Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.
a Torque tighten the drain plug (24 N.m).
II - FILLING
a Undo the filler cap (3) .
Essential special tooling
Mot. 1018 Sump plug tool.
Tightening torquesm
drain plug 24 N.m
Gearbox type Capacity in litres
ND0 2.1
101532
113764
101532
21A-18
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
ND0
21A
a Fill the gearbox to overflow via the oil filler cap ope-ning using a syringe containing the recommendedoil (see 21A, Manual gearbox, Manual gearboxoil: Specifications, page 21A-12) (Technical Note6012A, 04A, Lubricants).
a Tighten the filler cap.
92081
21A-19
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
JH3 or JR5
21A
CAPACITY
I - OIL CHANGE
a Unscrew the drain plug (1) using the (Mot. 1018).
a Let the oil run into a drain tray.
a Unscrew the drain plug (2) using the (Mot. 1018).
a Let the oil run into a drain tray.
a Refit the new seal on the plug, positioning the groo-ve (3) towards the plug.
a Torque tighten the drain plug (24 N.m).
Essential special tooling
Mot. 1018 Sump plug tool.
Tightening torquesm
drain plug 24 N.m
Gearbox type Capacity in litres
JH3 2.8
JR5 2.5
JH3
109488
JR5
110256
113764
21A-20
MANUAL GEARBOXManual gearbox oil: Draining - Refilling
JH3 or JR5
21AII - FILLING
a Undo the filler cap (4) .a Undo the filler cap (5) .
a Fill the gearbox until the oil overflows via the oil fillercap opening using a syringe containing the recom-mended oil (see 21A, Manual gearbox, Manualgearbox oil: Specifications, page 21A-12) (Tech-nical Note 6012A, 04A, Lubricants).
a Tighten the filler cap.
JH3
18749
JR5
110256
92081
21A-21
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21AREMOVAL
a Position the vehicle on a two-post lift.
a Disconnect the battery, starting with the negativeterminal.
a Remove the scuttle grille ( (see 85A, Wiping -Washing) ).
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
a Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel partition,
- the scuttle panel,
- the engine undertray.
a Drain the gearbox.
a Remove:
- the front wheels,
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Mot. 1453 Multiple-adjusting enginemounting support with retai-ning straps.
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 mountingbolts
2.1 daNm
starter and gearbox bellhousing bolts
4.4 daNm
engine tie-bar bolts onthe engine
10.5 daNm
engine tie-bar bolts onthe subframe
10.5 daNm
gearbox suspendedmounting bolts
18 daNm
suspended mountingnut on the rubber pad
6.2 daNm
cooling radiator crossmember front mountingbolts
10.5 daNm
gearbox drain plug 2.5 daNm
gearbox filler plug 0.3 daNm
battery cover mountingbolts
0.4 daNm
104343
104246
21A-22
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21A- the engine covers,
- the battery,
- the battery mounting,
- the injection computer with its support,
- the air flowmeter,
- the air inlet pipe.
a Remove the wiring harness mountings.
a Unclip the gear control cables from the gearbox.
a Disconnect:
- the ABS sensor wiring,
- the xenon bulb adjustment sensor wiring harnes-ses (if fitted to the vehicle).
a Remove the wheel arch liners.
I - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
- 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.
a Release the stub axle carrier from the driveshaft.
a Remove the left-hand driveshaft.
101821
104086
102129
21A-23
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21AII - RIGHT-HAND SIDE OF THE VEHICLE
a Remove:
- 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 uppercross member using rope.
a Remove the side stiffeners.
a Remove the cooling radiator cross member.
101819
101212
102009
21A-24
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21A
a Remove the catalytic converter support from theclutch housing.
a Remove the engine tie-bar.
a Disconnect the reversing connector.
a Disconnect the TDC sensor.
106199
102115
106204
106200
21A-25
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21A
a Disconnect:
- the starter (4) ,
- the diesel fuel pressure sensor (5) .
a Disconnect the earth strap from the gearbox.
a Disconnect the oil level sensor.
a Remove:
- the starter mounting bolts (6) ,
- the starter.
a Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.
106205
106203
106201
14853
21A-26
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21A
a Disconnect the hydraulic union by removing the clip(7) .
a Set up the engine support tool (Mot. 1453).
a Remove the gearbox support rubber pad.
a Remove:
- the three gearbox support bolts,
- the gearbox support.
101701
102449
106195
106194
21A-27
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21A
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.
106193
21A-28
MANUAL GEARBOXManual gearbox: Removal - Refitting
K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5
21AREFITTING
a
a Check that the engine - gearbox centring rings are inplace and correctly positioned.
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 (4.4daNm),
- the engine tie-bar bolts on the engine (10.5daNm),
- the engine tie-bar bolts on the subframe (10.5daNm),
- the gearbox suspended mounting bolts (18daNm),
- the suspended mounting nut on the rubber pad(6.2 daNm),
- the cooling radiator cross member front moun-ting bolts (10.5 daNm),
- the gearbox drain plug (2.5 daNm),
- the gearbox filler plug (0.3 daNm).
a Top up the gearbox oil.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
WARNING
Do not coat:
- the gearbox output shaft with grease to avoiddamaging the clutch slave cylinder,
- the clutch shaft splines.
Note:
To avoid any risk of leakage, the hydraulic unionmust always be replaced after the clutch pres-sure plate is replaced.
WARNING
Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:
- Add brake fluid to the reservoir.
- Bleed the hydraulic circuit ( (see 37A, Mechani-cal component controls) ).
- Top up the brake fluid level.
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
21A-29
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
REMOVAL
a Position the vehicle on a two-post lift.
a Disconnect the battery, starting with the negativeterminal.
a Refit the scuttle panel grille (see Scuttle panelgrille: Removal - Refitting) (MR 371, 55A, Exterioraccessories).
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the mounting bolt (2) from the scuttle panel parti-tion.
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Mot. 1453 Multiple-adjusting enginemounting support with retai-ning straps.
Essential equipment
component jack
Tightening torquesm
driveshaft nut 280 Nm
lower ball joint nut 62 Nm
track rod end nut 37 Nm
anti-roll bar ball joint nut 44 Nm
side panel mountingbolts
21 Nm
starter and gearbox bellhousing bolts
44 Nm
engine tie-bar bolts onthe engine
180 Nm
engine tie-bar bolts onthe subframe
105 Nm
gearbox suspendedmounting bolts
180 Nm
suspended mountingnut on the rubber pad
44 Nm
steering shaft yokemounting stud
21 Nm
cooling radiator crossmember front mountingbolts
105 Nm
cooling radiator crossmember rear mountingbolts
21 Nm
subframe cross mem-ber mounting bolts
62 Nm
subframe rear moun-ting bolts
140 Nm
subframe tie-rod moun-ting bolts
105 Nm
gearbox drain plug 25 Nm
gearbox filler plug 3 Nm
wheel mounting bolts 130 Nm
battery cover mountingbolts
4 Nm
104343
Tightening torquesm
21A-30
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
a Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel,
- the engine undertray.
a Drain the gearbox.
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.
a Remove the wiring harness mountings.
a Unclip the gear control cables from the gearbox.
104246
101821
104085
21A-31
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
a Disconnect the heat exchanger - turbocharger air pi-pe.
a Remove the air filter hose.
a Disconnect:
- the ABS sensor wiring,
- the xenon bulb adjustment sensor wiring harnes-ses (if fitted to the vehicle).
a Remove the wheel arch liners.
I - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
- 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.
a Remove the stub-axle carrier from the driveshaft.
a Remove the driveshaft.
F9Q
102244
102129
21A-32
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21AII - RIGHT-HAND SIDE OF THE VEHICLE
a Remove:
- 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 uppercross member using rope.
a Remove the side stiffeners.
a Remove:
- the cooling radiator cross member.
- the catalytic converter support from the clutch hou-sing,
- the starter mounting bolts,
- the starter.
101819
101212
102009
21A-33
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
a Remove the engine upper tie-bar.
a Remove the lower engine tie-bar.
a Remove the steering shaft yoke.
a Remove the sub-frame angle bracket (4) .
102452
102312
101354
101208
21A-34
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
a Strap the sub-frame to the component jack.
a Remove the sub-frame.
101209
21A-35
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21A
a Disconnect:
- the reversing connector,
- the TDC sensor.
a Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.
a Disconnect the hydraulic union by removing clip (5) .
a Set up the engine support tool (Mot. 1453).
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,
- the gearbox.
102485
101701
102449
102112
21A-36
MANUAL GEARBOXManual gearbox: Removal - Refitting
F4R, and 770 – F9Q, and 812
21AREFITTING
a
a Check that the engine - gearbox centring rings are inplace and correctly positioned.
a Proceed in the reverse order to removal.
a Always replace the steering shaft yoke stud after re-moval.
a Torque tighten:
- 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 (44Nm),
- the engine tie-bar bolts on the engine (180 Nm),
- the engine tie-bar bolts on the subframe (105Nm),
- the gearbox suspended mounting bolts (180Nm),
- the suspended mounting nut on the rubber pad(44 Nm),
- the steering shaft yoke mounting stud (21 Nm),
- the cooling radiator cross member front moun-ting bolts (105 Nm),
- the cooling radiator cross member rear moun-ting bolts (21 Nm),
- the subframe cross member mounting bolts (62Nm),
- the subframe rear mounting bolts (140 Nm),
- the subframe tie-rod mounting bolts (105 Nm),
- the gearbox drain plug (25 Nm),
- the gearbox filler plug (3 Nm),
- the wheel mounting bolts (130 Nm).
a Top up the gearbox oil.
a Connect the battery, starting with the positive termi-nal.
a Torque tighten the battery cover mounting bolts(4 Nm).
WARNING
Do not coat:
- the gearbox output shaft with grease, to avoiddamaging the clutch slave cylinder,
- the clutch shaft splines.
Note:
To avoid leaks, the hydraulic union must alwaysbe replaced after the clutch mechanism is repla-ced.
WARNING
For information on refitting the sub-frame (see31A, Front carrier components, Axle assem-bly sub-frame).
WARNING
Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:
- Add brake fluid to the reservoir.
- Bleed the hydraulic circuit (see 37A, Mechani-cal component controls, Clutch circuit: Blee-ding).
- Top up the brake fluid level.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting).
21A-37
MANUAL GEARBOXManual gearbox: Removal - Refitting
M9R, and 700, and PK4
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the « engine - gearbox » assembly (seeEngine/gearbox assembly: Removal - Refitting)(MR 370, 10A, Engine and peripherals).
II - REMOVAL OPERATION FOR PART CONCERNED
a Disconnect the connector (1) from the reverse gearswitch.
a Unpick the reverse gear switch wiring harness fromthe gearbox.
a Unpick the wiring harness (2) from the Top DeadCentre sensor and the oil level sensor on the gear-box.
a Unclip the breather pipe from the gearbox.
Tightening torquesm
gearbox mounting bolts 44 Nm
starter mounting bolts 44 Nm
115004
115005
21A-38
MANUAL GEARBOXManual gearbox: Removal - Refitting
M9R, and 700, and PK4
21A
a Remove:
- the starter mounting bolts (3) ,
- the gearbox mounting bolts (4) ,
- the gearbox.
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:
- the reverse gear switch wiring harness to the gear-box,
- the TDC sensor and oil level sensor wiring harnessto the gearbox.
a Clip the breather pipe onto the gearbox.
a Refit the « engine - gearbox » assembly (see Engi-ne/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).
115211
115210
21A-39
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21A
REMOVAL
REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02, Lifting equip-ment).
a Remove:
- the battery (see Battery : Removal - Refitting)(MR 370, 80A, Battery),
- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (MR 370, 13B,Diesel injection),
- the battery tray (see Battery tray: Removal - Re-fitting) (MR 370, 80A, Battery),
- the air filter box (see Air filter unit: Removal - Re-fitting) (MR 370, 12A, Fuel mixture),
- the engine cover,
- the engine undertray.
a Drain the gearbox (see 21A, Manual gearbox, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) .
a Remove:
- the front section of the left and right-hand wheelarch liners (see Front wheel arch liner: Removal- Refitting) (MR 371, 55A, Exterior protection),
- the front bumper (see Front bumper: Removal -Refitting) (MR 371, 55A, Exterior protection).
a Attach the cooling assembly using a safetystrap(s).
a Remove:
- the radiator mounting cross member (see Radiatorsupport cross member: Removal - Refitting)(MR 371, 41A, Front lower structure),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) ,
- the rear suspended engine mounting (see Lowerengine tie-bar: Removal - Refitting) (MR 370,19D, Engine mounting).
Essential special tooling
Mot. 1453 Multiple-adjusting enginemounting support with retai-ning straps.
Bvi. 1718 Support plate for the gearboxremoval/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 gearboxexhaust strut
21 Nm
bolts on the gearboxexhaust strut
21 Nm
115217
21A-40
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21A
a Remove:
- 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-fra-me: Removal - Refitting) (MR 370, 31A, Frontaxle components),
- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (MR 371, 56A, Exterior equi-pment).
a Fit the (Mot. 1453) with a safety strap(s).
a Remove the left-hand suspended engine mounting(see Left-hand suspended engine mounting: Re-moval - Refitting) (MR 370, 19D, Engine moun-ting).
a Disconnect the clutch control pipe (2) by pressing onthe clip (3) .
117776 104865
112868
21A-41
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21A
a Unclip the two gear control cables (4) from the gear-box at:
- the anchoring ball joints (5) ,
- the cable sleeve stops (6) .
a Disconnect the reverse gear sensor connector (7) .
a Unclip the breather pipe from the gearbox.
a Remove:
- the upper bolt (8) from the starter,
- the gearbox upper bolts (9) .
118832
101743
117335
116340
21A-42
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21A
a Disconnect the engine speed and position sensorconnector.
a Remove:
- the bolt from the engine speed and position sensor,
- the engine speed and position sensor (10) .
a Remove:
- the earth wiring bolt,
- the earth wiring (11) ,
- the starter lower bolt,
- the gearbox lower bolts.
a Fit the (Bvi. 1718) on a component jack.
a Fit:
- the (Bvi. 1718) and the component jack under thegearbox,
- the bracket (12) using the nuts (13) ,
118894 116440
116711
21A-43
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21A
a Tap the hole (14) using a self-tapping bolt (Part no.:77 03 002 244) to attach the gearbox to the supportusing the rod (15) .
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 toprevent the gearbox from tilting.
a
a Remove the gearbox using the (Bvi. 1718).
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
a Replace the left-hand and right-hand differential out-put seals (see 21A, Manual gearbox, Differentialoutput seal: Removal - Refitting, page 21A-45) .
a Refit the gearbox studs.
116713 118833
Note:
Make sure that the air conditioning compressorpulley does not rest against the impact absorbermounting unit on the right-hand side of the vehi-cle when the engine and transmission assemblyis lowered.
WARNING
Do not grease the clutch shaft splines.
WARNING
To prevent leaks, replace the slave cylinder afterreplacing the clutch pressure plate.
WARNING
It is essential to replace the differential output lipseal each time the driveshafts are removed.
21A-44
MANUAL GEARBOXManual gearbox: Removal - Refitting
TL4
21Aa Check the condition of the centring devices on the
gearbox.
II - REFITTING OPERATION FOR PART CONCERNED
a Position the gearbox using the (Bvi. 1718).
a Refit a gearbox bolt.
a Remove the (Bvi. 1718) from the gearbox.
a Refit the gearbox lower bolts.
a Torque tighten:
- the gearbox bolts (44 Nm),
- the gearbox nuts (44 Nm).
a Refit:
- the starter lower bolt,
- the earth wiring,
- the earth wiring bolt,
- the speed and position sensor,
- the engine speed and position sensor bolt,
a Connect the engine speed and position sensor con-nector.
a Refit:
- the gearbox upper bolts,
- the starter upper bolt.
a Torque tighten the starter bolts (44 Nm).
a Clip the breather pipe onto the gearbox.
a Connect the reverse gear sensor connector.
a Clip the gear control cables on the gearbox.
a Connect the clutch control pipe.
a Refit the left-hand suspended engine mounting (seeLeft-hand suspended engine mounting: Remo-val - Refitting) (MR 370, 19D, Engine mounting).
a Remove the (Mot. 1453) and the safety strap(s).
III - FINAL OPERATION.
a Refit:
- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (MR 371, 56A, Exterior equi-pment),
- the front axle subframe (see Front axle sub-fra-me: Removal - Refitting) (MR 370, 31A, Frontaxle components),
- the support strut on the gearbox,
- the nut to the gearbox exhaust strut,
- the bolts to the gearbox exhaust strut.
a Torque tighten:
- the nut on the gearbox exhaust strut (21 Nm),
- the bolts on the gearbox exhaust strut (21 Nm).
a Refit:
- the rear suspended engine mounting (see Lowerengine tie-bar: Removal - Refitting) (MR 370,19D, Engine mounting),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) ,
- the radiator mounting cross member (see Radiatorsupport cross member: Removal - Refitting)(MR 371, 41A, Front lower structure).
a Remove the safety strap(s) from the cooling as-sembly.
a Refit:
- the front bumper (see Front bumper: Removal -Refitting) (MR 371, 55A, Exterior protection),
- the front section of the left and right-hand wheelarch liners (see Front wheel arch liner: Removal- Refitting) (MR 371, 55A, Exterior protection).
- the air filter box (see Air filter unit: Removal - Re-fitting) (MR 370, 12A, Fuel mixture),
- the battery tray (see Battery tray: Removal - Re-fitting) (MR 370, 80A, Battery),
- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (MR 370, 13B,Diesel injection),
- the engine cover.
a Perform the following operations:
- fill the gearbox (see 21A, Manual gearbox, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) ,
- bleed the clutch circuit (see Clutch circuit: Blee-ding) (MR 370, 37A, Mechanical component con-trols).
a Refit:
- the engine undertray,
- the battery (see Battery : Removal - Refitting)(MR 370, 80A, Battery).
21A-45
MANUAL GEARBOXDifferential output seal: Removal - Refitting
JH3 or JR5
21A
REMOVAL
a Position the vehicle on a two-post lift.
a Disconnect the battery, starting with the negativeterminal.
a Remove the engine undertray.
a Drain the gearbox.
a Remove:
- the wheel,
- the wheel arch liner,
- the hub nut,
- the track rod end,
- the anti-roll bar ball joint,
- the lower ball joint.
a Disconnect:
- the wheel speed sensor connector,
- the xenon bulb adjustment sensor wiring harnes-ses (if fitted to the vehicle).
a Remove the relay bearing bracket.
a Remove the driveshaft.
REPLACING THE SEAL
a Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.
a Remove the seal with pliers, taking care not to da-mage the splines of the sunwheel.
Essential special tooling
Bvi. 1666 Tool for fitting differentialseals.
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 28 daNm
relay bearing bracketnut
2.1 daNm
engine tie-bar bolts 10.5 daNm
subframe - engine tie-bar bolts
10.5 daNm
battery cover mountingbolts
0.4 daNm
102129
101819
21A-46
MANUAL GEARBOXDifferential output seal: Removal - Refitting
JH3 or JR5
21AREFITTING
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 markingA 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 (10.5 daNm),
- the subframe - engine tie-bar bolts (10.5 daNm).
a Top up the gearbox oil.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
21503
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
21A-47
MANUAL GEARBOXDifferential output seal: Removal - Refitting
ND0
21A
REMOVAL
a Position the vehicle on a two-post lift.
a Disconnect the battery, starting with the negativeterminal.
a Remove the engine undertray.
a Drain the gearbox.
a Remove:
- the wheel,
- the wheel arch liner,
- the hub nut,
- the track rod end,
- the anti-roll bar ball joint,
- the lower ball joint.
a Disconnect:
- the wheel speed sensor connector,
- the xenon bulb adjustment sensor wiring harnes-ses (if fitted to the vehicle).
a Remove the relay bearing bracket.
a Remove the driveshaft.
REPLACING THE SEAL
a Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.
a Remove the dislodged seal with pliers, taking carenot to damage the sunwheel splines.
Essential special tooling
Bvi. 1689 Differential output seal fittingtool.
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 28 daNm
relay bearing bracketnut
2.1 daNm
engine tie-bar bolts 18 daNm
subframe - engine tie-bar bolts
10.5 daNm
battery cover mountingbolts
0.4 daNm
102129
101819
21A-48
MANUAL GEARBOXDifferential output seal: Removal - Refitting
ND0
21AREFITTING
a Oil the seal before inserting it onto the splined part ofthe sunwheel.
a Refit the seal using the tool (Bvi. 1689), with themarking A on the right-hand side and marking B onthe 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.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
102260
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
21A-49
MANUAL GEARBOXDifferential output seal: Removal - Refitting
M9R, and 700, and PK4
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .
II - OPERATION FOR REMOVAL OF PART CONCERNED (RIGHT-HAND SIDE)
a Remove the protective ring (1) from the driveshaft.
III - OPERATION FOR REMOVAL OF PART CONCERNED (LEFT-HAND SIDE)
a Extract the seal using a screwdriver, taking care notto damage the casing.
Essential special tooling
Bvi. 1774 Right-hand transmission sealfitting tool.
Bvi. 1719 Left-hand side differential oilseal fitting tool
Bvi. 1419 Bearing cage positioning tool.
21490
106885
21A-50
MANUAL GEARBOXDifferential output seal: Removal - Refitting
M9R, and 700, and PK4
21AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED (RIGHT-HAND SIDE)
a Refit the right-hand seal using the (Bvi. 1774) (1) .
a Clean the driveshaft using degreaser.
a Slide on the protective ring (2) and clip it onto the dri-veshaft.
II - REFITTING OPERATION FOR PART CONCERNED (LEFT-HAND SIDE)
a Refit the left-hand seal using the (Bvi. 1719) (2) and (Bvi. 1419) (3) .
21493
Note:
Do not lubricate the seal.
21494
106886
21A-51
MANUAL GEARBOXDifferential output seal: Removal - Refitting
M9R, and 700, and PK4
21AIII - FINAL OPERATION.
a Refit:
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) ,
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) .
a Top up the gearbox (see 21A, Manual gearbox,Manual gearbox oil: Draining - Refilling, page21A-13) .
21A-52
MANUAL GEARBOXDifferential output seal: Removal - Refitting
TL4
21A
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, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) .
1 - When replacing the differential output seal on the left-hand side
a Remove:
- the front left-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - 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, Dri-veshafts, Front right-hand wheel driveshaft:Removal - Refitting, page 29A-3) .
II - REMOVAL OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL
Left-hand differential output seal
Right-hand differential output seal
a Tap the base of the lip seal using a roll pin punchand a small hammer to release it and make it turn inits housing.
a Remove the lip seal using a large screwdriver, ta-king care not to damage the differential housing.
Essential special tooling
Bvi. 1854 Differential output seal fittingtool TL4
Essential equipment
roll pin punch
125894
125896
21A-53
MANUAL GEARBOXDifferential output seal: Removal - Refitting
TL4
21AREFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Differential outputseal (12,01,05,10).
21A-54
MANUAL GEARBOXDifferential output seal: Removal - Refitting
TL4
21AII - REFITTING OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL
Refitting the right-hand side differential output seal
Refitting the left-hand side differential output seal.
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 outputseal.
a Fit:
- the new differential output seal on the gearbox,
- the mandrel (2) or (3) of the tool (Bvi. 1854) on thenew differential output seal.
a Tap the tool (1) with a copper hammer to fit the newdifferential output seal fully.
III - FINAL OPERATION
1 - Refitting the left-hand driveshaft
a Refit:
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - 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, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
103191
125895
125893
21A-55
MANUAL GEARBOXDifferential output seal: Removal - Refitting
TL4
21A- 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, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .
a Refit the engine undertray.
21A-56
MANUAL GEARBOXInput shaft lip seal: Removal - Refitting
M9R, and 700, and PK4
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove:
- the « engine - gearbox assembly » (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the clutch thrust bearing (see 20A, Clutch, Clutchthrust bearing: Removal - Refitting, page 20A-14) .
II - REMOVAL OPERATION FOR PART CONCERNED
a Drill a hole in the seal, using a 2.5 mm drill bit.
a Fit a bolt in seal (1) .
a Extract the seal (1) using pliers.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Fit a new seal with its protector using the (Bvi.1236).
a Remove the protector.
II - FINAL OPERATION.
a Refit:
- the clutch thrust bearing (see 20A, Clutch, Clutchthrust bearing: Removal - Refitting, page 20A-14) ,
- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,
- the « engine - gearbox assembly » (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).
Essential special tooling
Bvi. 1236 Primary shaft oil seal fittingtool.
WARNING
Do not scratch the shaft or mating face.
20714
18061
23A-1
AUTOMATIC GEARBOXAutomatic gearbox: Precautions for repair
AJ0
23AI - 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 le-ver unless the brake pedal is depressed simultaneous-ly. To unlock the lever when the battery is faultyand carry out repair operations, refer to the Dri-ver's Handbook.
The aim of converter Lock Up is to connect the auto-matic gearbox directly to the engine. This function iscarried out by a "mini clutch" in the converter. Lock Upis 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:
- never allow the vehicle to coast with the ignition swit-ched off (e.g. when going down a hill); we cannotstress too strongly the harm that this may cause,
- never push the vehicle (i.e. to get to a petrol station,unless the precautions in the Towing section havebeen taken).
In addition, the vehicle is only under traction if the engi-ne is running. It is therefore impossible to start the en-gine of a vehicle with an automatic gearbox by pushingthe vehicle.
II - TOWING
III - STORING COMPONENTS THAT HAVE BEEN REMOVED
Store components that have been removed in storagecontainers so as not to damage or misplace them.
WARNING
Vehicles should preferably be moved on a flatbed ortowed with the front wheels raised. If this is not pos-sible, towing may be carried out in exceptional cir-cumstances 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 theDriver's Handbook).
116357
23A-2
AUTOMATIC GEARBOXAutomatic gearbox: Precautions for repair
DP0
23AI - PRECAUTIONS DURING REPAIR
Weight: 70 kg
Vehicles fitted with DP0 automatic transmissions usesystems called « Shift lock » and « Lock up » .
The purpose of the « Shift Lock » function is to preventthe gear lever from being moved without the brake pe-dal being simultaneously depressed.
The purpose of the « Lock up » or converter lockup isto connect the automatic transmission directly to theengine. This function is carried out by a « mini clutch »in the converter.
The « Lock up » is driven by the automatic transmis-sion 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 es-sential to comply with the following instructions:
- never allow the vehicle to coast with the ignition swit-ched off (i.e. when going down a hill); the damage thatthis 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 havebeen taken).
The vehicle only has drive when the engine is running.It is therefore impossible to start the engine in a vehiclewith an automatic transmission by pushing the vehicle.
II - TOWING
The vehicle should preferably be towed in all cases ona tow truck or with the front wheels raised.
Nonetheless, if this is impossible, in exceptional cir-cumstances the vehicle may be towed at low speed(maximum 12mph (20 km/h) over a maximum distan-ce of 18 miles (30 km) (lever in N position).
Note:
For repair operations when the battery is faulty,refer to the notice on board the vehicle.
23A-3
AUTOMATIC GEARBOXAutomatic gearbox: Identification
AJ0
23A
The gearbox is identified by an engraved marking (1)located underneath the gearbox and by a self-adhesivelabel (2) on the hydraulic distributor casing.
117777
23A-4
AUTOMATIC GEARBOXAutomatic gearbox: Identification
DP0
23A
The automatic transmission series number can befound in two places: on a label on the hydraulic distri-butor cover (1) and etched onto the outer casing (2) onthe wheel side.
117304
23A-5
AUTOMATIC GEARBOXAutomatic gearbox: Specifications
F9Q, and DP0
23A
Gearbox Gearboxsuffix
1st 2nd 3rd 4th Final drive Lowering
DP0 083 2.724 1.499 1.000 0.710 25/68 52 : 67
23A-6
AUTOMATIC GEARBOXAutomatic gearbox: Specifications
AJ0
23A
Gearbox Suffix
AJ0 001
Gear ratios (epicyclic gear train output)
1st 2nd 3rd 4th 5th 6th Reversegear
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 Reversegear
8.989 15.696 23.842 32.506 44.119 55.037 10.918
23A-7
AUTOMATIC GEARBOXAutomatic gearbox: List and location of components
AJ0
23A
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 measure-ment plug
(13) Hydraulic distributor O-rings
(14) Hydraulic distributor
(15) Hydraulic distributor casing seal
(16) Hydraulic distributor housing118831
(17) Solenoid valve
(18) Automatic gearbox oil tempera-ture sensor
(19) Pressure sensor
23A-8
AUTOMATIC GEARBOXAutomatic gearbox: List and location of components
DP0
23A
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
(21) Modulating solenoid valve
(22) « Lock up » solenoid valve(converter lock-up)
(23) Selector solenoid valve 4
23A-9
AUTOMATIC GEARBOXAutomatic gearbox: List and location of components
DP0
23A (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 (multifunctionswitch)
(30) Yellow connector (electrohydrau-lic interface)
(31) Green connector (line pressure)
(32) Yellow connector (turbo inputspeed)
(33) Blue connector (output speed)
23A-10
AUTOMATIC GEARBOXAutomatic gearbox: Parts and consumables for the repair work
DP0
23A
The following parts must be replaced with new ones af-ter being removed:
- the self-locking nuts,
- the seals,
- the rubber seals,
- the converter bolts.
Description Component concerned
BR2 + grease Converter centring fitting
High resistance threadlock Brake calliper bolt
23A-11
AUTOMATIC GEARBOXAutomatic gearbox: Parts and consumables for the repair work
AJ0
23AI - 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 Convertercentring fit-ting
77 01 421 145
23A-12
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
REMOVALa Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negativeterminal.
a Remove the scuttle grille ( (see 85A, Wiping -Washing) ).
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Mot. 1453 Multiple-adjusting enginemounting support with retai-ning straps.
Bvi. 1531 Tool for centring the torqueconverter for the automatictransmission converter.
Essential equipment
component jack
Tightening torquesm
wheel bolts 13 daNm
brake calliper guide pinbolts
0.7 daNm
track rod end nut 3.7 daNm
lower ball joint nut 6.2 daNm
engine tie-bar bolts onthe subframe
10.5 daNm
starter and gearbox bellhousing bolts
4.4 daNm
suspended mountingnut on the gearbox
4.4 daNm
track rod end nut 6.2 daNm
drive plate convertermounting nut
3.7 daNm
modular connectormounting bolts
2 daNm
engine speed sensormounting bolts
1 daNm
engine tie-bar bolts on Fengines
18 daNm
engine tie-bar bolts on Kengines
10.5 daNm
suspended mountingnut on the rubber pad
18 daNm
battery cover mountingbolts
0.4 daNm
101821
Tightening torquesm
23A-13
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
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.
a Remove:
- 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 modularconnector support plate.
104343
104246
103409
WARNING
Protect the connector by sliding it into a water-proof plastic bag.
23A-14
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
a Remove the engine speed sensor.
a Remove the engine speed sensor.
a Fit the hose clamps.
a Disconnect the heat exchanger.
a Unclip the wiring harness from the gearbox.
a Remove:
- the two bolts (8) from the starter,
- 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).
K4M
103753
F4R
103420
103423
Note:
The discharge bulb beam adjustment sensor isfitted onto the left-hand lower wishbone.
23A-15
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23AI - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
- the hub nut using the (Rou. 604-01),
- the track rod end using the (Tav. 476),
- 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.
a Remove:
- the clip (10) from the gearbox computer wiring har-ness,
- the side reinforcement (9)
a Open the gearbox computer wiring harness moun-ting bracket (11) .
a Disconnect the connector (12) from the gearboxcomputer.
102129
103412
103413
23A-16
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23AII - RIGHT-HAND SIDE OF THE VEHICLE
a Remove:
- the hub nut using tool (Rou. 604-01),
- the track rod end using the (Tav. 476),
- the anti-roll bar ball joint using the (Tav. 476),
- the lower ball joint.
a Remove 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 uppercross member using rope.
a Remove the side stiffener.
102129
103418
101212
23A-17
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
a Remove the cooling radiator lower cross member.
a Remove:
- the exhaust mounting nuts (13) ,
- the engine tie-bar.
a Remove:
- the lower engine - manifold strut,
- the starter mounting bolt (15) ,
- the starter,
- the three converter nuts.
102009
103421
103418
Note:
The converter nuts are accessed by removingthe starter. Rotate the crankshaft clockwise toaccess the three starter plate - converter connec-ting nuts and remove them.
23A-18
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
a Remove the upper studs (16) from the gearbox bellhousing.
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,
a Secure the converter with string to prevent it beingdislodged.
REFITTING
a
103423
102449
13790
WARNING
- Do not reuse the converter mounting nuts or theinertia flywheel nuts if they have been removed:always use new nuts.
- Check that the centring rings are in place.
23A-19
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
a Refit the inertia flywheel on the converter using tool(Bvi. 1531) ;.
a To refit, proceed in the reverse order of removal.
When refitting the automatic transmission on the en-gine, make sure that the converter is properly enga-ged on the input shaft pin.
16361
WARNING
Check that the centring dowels are in place.
23A-20
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
K4M, and 761 – F4R, and 771
23A
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 (10.5daNm),
- the starter and gearbox bell housing bolts (4.4daNm),
- the suspended mounting nut on the gearbox(4.4 daNm),
- the track rod end nut (6.2 daNm),
- the drive plate converter mounting nut (3.7daNm),
- the modular connector mounting bolts (2daNm),
- the engine speed sensor mounting bolts (1daNm),
- the engine tie-bar bolts on F engines (18 daNm),
- the engine tie-bar bolts on K engines (10.5daNm),
- the suspended mounting nut on the rubber pad(18 daNm).
a Fill up the automatic transmission and check the le-vel (see Filling - Levels) .
a If replacing the oil, reset the auto-adaptives usingcommand RZ005: « Clear auto-adaptives » andreset the automatic transmission computer oilageing counter with command CF074: « Enter dateof gearbox oil change » .
After using command RZ005, it is important to carryout a test drive performing all gear changes, both upand down, several times in order to store the newvalues.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
13790
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-21
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
M9R, and AJ0
23A
REMOVAL
a In order to remove and refit the automatic gearbox,the "engine - gearbox" assembly must be removed(see Engine/gearbox assembly: Removal - Refit-ting) (10A, Engine and peripherals).
a Separate the pipes and wirings fixed all around theautomatic gearbox.
a Remove the starter (see Starter: Removal - Refit-ting) (16A, Starting - Charging).
a Remove the nuts from the converter (1) through thestarter opening.
a Lift the engine using a workshop hoist and a loadpositioner.
a Remove:
- the bolts and nuts from the automatic gearbox bellhousing (2) ,
- the automatic gearbox using a workshop hoistand a load positioner.
Essential equipment
workshop hoist
diagnostic tool
Tightening torquesm
gearbox bell housingbolts
44 Nm
converter nuts 44 Nm
Note:
Replacing the automatic gearbox AJ0 requiresthe automatic gearbox computer to be replaced(see 23A , Automatic gearbox, A utomatictransmission computer: Removal - Refitting,page 23A-81) .
118394
118393
118394
23A-22
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
M9R, and AJ0
23AREFITTING
a Check that the drive plate is not damaged or runout(0.2 mm permitted runout).
a Check that the torque converter is coupled correctlyonto the automatic gearbox using a flat ruler and atape measure. The distance (X) between the con-verter maintenance bolt bead and the cover shouldbe at least 20.5 mm.
a Mount the gearbox and finger tighten the automaticgearbox bell housing bolts.
11911
Note:
Failure to observe this procedure can lead to thedestruction of the gearbox.
118394
Note:
Align the converter blots with their location on thedrive plate before fitting the automatic gearbox.
23A-23
AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting
M9R, and AJ0
23A
a Position the converter retaining nuts (3) through thestarter 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 - Refit-ting) (80A, Battery).
a Perform the programming procedure using the dia-gnostic tool (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).
118393
23A-24
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
DP0
23A
I - OIL SERVICE
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) .
a Remove the engine undertray.
1 - Former assembly
a Remove:
- the level-setting plug (1) ,
- the oil overflow pipe (2) .
2 - New assembly
a Remove:
- the level-setting plug (3) ,
- the oil overflow pipe (4) using (5) an 8 mm Allenkey.
Essential equipment
diagnostic tool
Tightening torquesm
oil overflow pipe (oldassembly)
25 N.m
oil overflow pipe (newassembly)
9 N.m
level-setting plug (oldassembly)
25 N.m
level-setting plug (newassembly)
35 N.m
Gearbox
Oil capacity (adjust until over-flows) (litre)
Drain capacity Total capacity
DP0 3.5 6
WARNING
For both assemblies, when draining - refilling or top-ping up the oil level, it is essential to put the gearcontrol lever in Park « P » position.
IMPORTANT
Wear heat protective gloves during the operation.
Note:
Drain the automatic transmission oil when the oilis warm (60˚C maximum), in order to remove asmany impurities as possible.
2316
107912
23A-25
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
DP0
23Aa Let the oil flow.
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).
a Fit a new seal on the level-setting plug with the sealgroove 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).
II - FILLING
a Position the vehicle on a horizontal surface.
a Unclip the gear lever control cable (7) on the gear-box by:
- squeezing the gear lever control cable clip at (A) ,
- pulling the pin at (B) ,
- lifting the gear lever cable at (C) .
Note:
Always replace the oil overflow pipe each time itis removed for the new assembly.
113764
110245
101743
23A-26
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
DP0
23A
a Remove the filler cap (8) .
a Use a funnel with a 15:100 filter to prevent impuritiesfrom entering the system.
a Fill the automatic gearbox with 3.5 litres of new re-commended oil (see Automatic gearbox oil: Spe-ci f icat ions ) (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 transmissioncomputer.
a Monitor the automatic transmission oil temperatureparameter.
a Wait for the temperature to reach 60˚C ±±±± 1.
1 - Former assembly
a Remove the level-setting plug (9) , leaving the engi-ne running.
2 - New assembly
a Remove the level-setting plug (10) , leaving the en-gine 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,
103407
2316
107912
23A-27
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
DP0
23A- 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 transmissioncomputer,
- monitor the automatic gearbox oil temperature pa-rameter,
- 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 ofoil 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).
3 - Level
a
Note:
When replacing the oil, reset the electronic oilageing counter (within the computer) (see Faultfinding - Replacement of components) (MR366, 23A, Automatic transmission).
Note:
To fill up the automatic transmission oil, apply thefilling procedure using 0.5 litres of oil instead of3.5 litres.
23A-28
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
AJ0
23A
Capacity
I - DRAINING
a Position the vehicle on a lift.
a The control lever must be in the Park position whendraining, filling or checking the level.
a Remove the engine undertray.
a Remove:
- the level-setting plug (1) ,
- the oil overflow pipe (2) .
a Let the oil flow.
a Refit and torque tighten the overflow pipe (8 N.m).
a Refit and torque tighten the level-setting plug (7.5N.m).
Essential equipment
diagnostic tool
Tightening torquesm
overflow pipe 8 N.m
level-setting plug 7.5 N.m
filler pipe closure panelbolt
6 N.m
Gearbox
Oil capacity (adjust until over-flows) (litre)
Drain capacity Total capacity
AJ0 3.5 7.6
Note:
The level must be checked at a temperature of 40˚C±±±± 2.
Note:
The automatic transmission oil should preferably bechanged when the oil is warm (approximately 60˚Cmaximum) in order to remove as many impurities aspossible.
118160
23A-29
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
AJ0
23AII - FILLING
a Filling is carried out through an internal pipe in themechanism housing (3) .
a Remove the pipe closure panel (4) .
a Use a flexible pipe fitted with a funnel (with a 1:100filter) (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 oilrecommended by the manufacturer (see Automaticgearbox oil: Specifications) (Technical Note6012A, 04A, Lubricants).
a Run the engine at idle speed.
a Connect the diagnostic tool.
a Establish dialogue with the automatic gearbox com-puter.
a Monitor the automatic transmission oil temperatureparameter.
117251
116343
116345
23A-30
AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling
AJ0
23Aa 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 run-ning.
a If the oil does not flow out or the quantity collected is below 0.1 litres :
- Switch off the engine,
- refit the level plug,
- add 0.5 litre of oil,
- let the automatic transmission cool to 30˚C,
- 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 ofoil is recovered in the container.
a Refit and torque tighten the level-setting plug (7.5N.m).
a Refit the closure panel and torque tighten the fillerpipe closure panel bolt (6 N.m).
IV - LEVEL CHECKING PROCEDURE OUTSIDE OIL CHANGE - FILLING OPERATIONS
a
a Fill the automatic transmission with 0.5 litre of newoil.
a Run the engine at idle speed.
a Connect the diagnostic tool.
a Establish dialogue with the automatic gearbox com-puter.
a Monitor the automatic transmission oil temperatureparameter.
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 run-ning.
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,
- let the automatic transmission cool to 30˚C,
- Run the engine at idle speed,
- wait for the temperature to reach 40˚C ±±±± 2,
- place the container under the level plug,
- remove the level plug.
a Repeat these operations until more than 0.1 litre ofoil is recovered in the container.
a Refit and torque tighten the level-setting plug (7.5N.m).
a Refit the closure panel and tighten the filler pipeclosure panel bolt (6 N.m).
118161
WARNING
It is essential to shift the selector lever to thePark position.
23A-31
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
DP0
23A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 364, 02A, Lifting equip-ment).
a Drain the automatic gearbox oil (see 23A, Automa-tic 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 - Re-fitting) (MR 364, 80A, Battery).
a Separate the control cable from the multifunctionswitch (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 archliner (see Front wheel arch liner: Removal - Re-fitting) (MR 365, 55A, Exterior protection).
Essential special tooling
Bvi. 1462 Ball plate adjusting screw.
Tightening torquesm
hydraul ic d is t ributorbolts
7.5 Nm
locating ball spring brac-ket bolt
9 Nm
locating ball spring bolt 8 Nm
hydraul ic d is t ributorcover bolts
10 Nm
110245
110243
23A-32
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
DP0
23A
a Unclip the wiring harness (3) on the left-hand sidestiffener.
a Remove:
- the left-hand side reinforcement bolts (2) ,
- the left-hand side stiffener.
a Disconnect the electric coolant pump connector.
a Remove the clips (4) from the electric coolant pumpmounting.
a Move aside the electric coolant pump (5)
103412
F9Q, and 803
117330
23A-33
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
DP0
23AII - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove the hydraulic distributor cover bolts (6) (oilmay flow out).
a Remove the hydraulic distributor bolts (7) .
a Disconnect the hydraulic distributor solenoid valveconnectors (8) .
a Remove the hydraulic distributor.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Fit the hydraulic distributor with its reinforcementplate, centring it using the bolts (6) and (7) .
a
a Refit the other bolts on the hydraulic distributor.
a Tighten to torque and in order the hydraulic distri-butor bolts (7.5 Nm).
110233
110232
13789
110227
WARNING
Check that the distributor slide is properly enga-ged with the notched sector lug (9) .
23A-34
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
DP0
23AADJUSTING THE LEAF SPRING LEVER
a Put the multifunction switch lever in the first positionselected using a hose clip and a bolt (11) in the me-chanism housing.
a Remove the bolt (10) .
a Fit the locating ball spring by fitting the bearing (12)into the groove (15) for the notched sector (16) cor-responding to first selected.
a Fit without tightening the locating ball spring bracketbolt (13) .
a Fit the (Bvi. 1462) (14) in place of the bolt (10) .
a Screw the tool in fully whilst holding the locating ballspring.
a Tighten to torque the locating ball spring bracketbolt (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 anew seal.
a Torque tighten the hydraulic distributor coverbolts (10 Nm).
II - FINAL OPERATION
a Fit the electric coolant pump.
a Refit the clips on the electric coolant pump moun-ting.
a Connect the electric coolant pump connector.
a Clip the wiring harness on the left-hand side stiffe-ner.
a Refit:
- the left-hand side stiffener,
- the left-hand side stiffener bolts,
- the front section of the front left-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (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 (seeAutomatic gear control cable: Adjusting)(MR364, 37A, Mechanical component controls).
a Refit:
- the battery tray (see Battery tray: Removal - Re-fitting) (MR 364, 80A, Battery),
- the battery (see Battery : Removal - Refitting)(MR 364, 80A, Battery).
a Perform the following operations:
- fill the automatic gearbox (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Re-filling, page 23A-24) ,
110229
119433
F9Q, and 803
23A-35
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
DP0
23A- the necessary programming (see Fault finding -Configuration and programming) (MR 366, 23A,Automatic transmission).
23A-36
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
M9R, and AJ0
23A
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 - Re-fitting) (80A, Battery).
a Remove the engine undertray.
a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
a Remove the front bumper (see Front bumper: Re-moval - Refitting) (55A, Exterior protection).
a Drain the cooling system (see Cooling circuit:Draining - Refilling) (19A, Cooling).
a Rotate the intercooler air inlet pipe clip, on the turbo-charger side.
a Remove the air pipe bolts at the intercooler inlet.
a Loosen the clip on the intercooler air inlet pipe on theexchanger side.
a Disconnect the intercooler air inlet pipe on the ex-changer side.
a Remove the air pipe at the intercooler inlet.
Essential equipment
diagnostic tool
Tightening torquesm
hydraul ic d is t ributorbolts
8 Nm
hydraul ic d is t ributorhousing bolts8 Nm
.
113282
113155
119834
23A-37
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
M9R, and AJ0
23A
a Remove the cooling assembly.
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.
a Place a clean container under the automatic gear-box to collect the oil.
a Remove:
- the hydraulic distributor housing bolts,
- the hydraulic distributor housing,
- the hydraulic distributor housing seal.
106275
118391
117250
23A-38
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
M9R, and AJ0
23A
a Loosen the hydraulic distributor bolts (5 bolts size70.1 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 itin order to disconnect the automatic gear lever (7) .
a Remove the hydraulic distributor O-rings (8) .
REFITTING
a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and on the hydraulic distributorhousing, taking care not to damage the contact sur-faces.
a Always replace:
- the hydraulic distributor O-rings,
- the hydraulic distributor housing seal.
- the air pipe seal at the intercooler inlet on the turbo-charger side.
a Refit the new hydraulic distributor O-rings.
a Tilt the hydraulic distributor slightly when refitting it inorder to engage it with the automatic gearbox lever(9) .
a Torque tighten the hydraulic distributor bolts (8Nm).
a Connect the hydraulic distributor connector (10) .
117254
117253
117254
23A-39
AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting
M9R, and AJ0
23A
a Fit the hydraulic distributor metal housing (11) withits new seal.
a Torque tighten the hydraulic distributor housingbolts8 Nm (.)
a Remove the intercooler air inlet pipe seal on the tur-bocharger side using a .
a
a Fit a new seal to the intercooler air inlet pipe on theturbocharger side.
a Proceed in the reverse order to removal.
a Fill the automatic gearbox (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .
a Refit the engine undertray.
a Connect the battery (see Battery: Removal - Refit-ting) (80A, Battery).
a When replacing the hydraulic distributor, carry outthe necessary operations using the diagnostic tool(see Fault finding - Replacement of components)(23A, Automatic gearbox).
117250
115068
115069
Note:
Check that the intercooler air inlet pipe seal onthe turbocharger side is fitted in its groove theright way round.
23A-40
AUTOMATIC GEARBOXSolenoid valves: Removal
DP0
23A
REMOVAL
a Remove the hydraulic distributor (see 23A, Auto-matic gearbox, Hydraulic distributor: Removal -Refitting, page 23A-31)
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) toremove the solenoid valves (6) and (7) ,
- the mounting bolt (12) to remove the solenoid valve(8) ,
- the mounting bolt (13) to remove the solenoid valve(2) ,
- the mounting bolt (14) to remove the solenoid valve(1) .
REFITTING
a To refit, proceed in the reverse order of removal.
WARNING
Work as cleanly as possible to prevent foreignbodies from entering the system.
13787
(1) Modulating solenoid valve
(2) « Lock up » solenoid valve (loc-kup 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
Note:
Apply vaseline to the solenoid valve seals toease fitting.
23A-41
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
DP0
23AREMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 364, 02A, Lifting equip-ment).
a Remove:
- the battery (see Battery : Removal - Refitting)(MR 364, 80A, Battery),
- the battery tray (see Battery tray: Removal - Re-fitting) (MR 364, 80A, Battery),
- the multifunction connector (see 23A, Automaticgearbox, Automatic transmission connector:Removal - Refitting, page 23A-79) .
a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
a Remove the hydraulic distributor (see 23A, Auto-matic gearbox, Hydraulic distributor: Removal -Refitting, page 23A-31)
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove the cable feed opening locking clip (1) witha screwdriver.
a Remove:
- the electronic interface connector (2) ,
- the cable by feeding the electro-hydraulic interfaceconnector via the cable feed opening.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the cable by feeding the electro-hydraulic interfaceconnector via the cable feed opening,
- the electro-hydraulic interface connector,
- the cable feed opening locking clip with a screwdri-ver.
II - FINAL OPERATION.
a Refit:
- the hydraulic distributor (see 23A , Automaticgearbox, Hydraulic distributor: Removal - Refit-ting, page 23A-31)
- the multifunction connector (see 23A, Automaticgearbox, Automatic transmission connector:Removal - Refitting, page 23A-79) ,
- the battery tray (see Battery tray: Removal - Re-fitting) (MR 364, 80A, Battery),
- the battery (see Battery : Removal - Refitting)(MR 364, 80A, Battery),
117300
103248
23A-42
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
DP0
23Aa Top up the automatic transmission (see 23A, Auto-
matic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
23A-43
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
M9R, and AJ0
23A
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)
- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery),
- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (13B, Diesel in-jection),
- the engine undertray.
a Drain the gearbox (see 23A, Automatic gearbox,Automatic gearbox oil: Draining - Refilling, page23A-24) .
a Remove the front bumper (see Front bumper: Re-moval - Refitting) (55A, Exterior protection).
a Drain the cooling system (see Cooling circuit:Draining - Refilling) (19A, Cooling).
a Rotate the clip on the air pipe at the intercooler inletat the turbocharger end.
a Remove the air pipe bolts at the intercooler inlet.
a Loosen the clip on the air pipe at the intercooler inletat the exchanger end.
a Disconnect the air pipe at the intercooler inlet at theexchanger end.
Essential equipment
diagnostic tool
Tightening torquesm
wiring routing retainerbolt
7 N.m
hydraul ic d is t ributorhousing bolts
8 Nm.
113282
113155
119834
23A-44
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
M9R, and AJ0
23A
a Remove the cooling assembly.
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.
a Place a clean container under the automatic gear-box to collect the oil.
a Remove:
- the hydraulic distributor housing bolts,
- the hydraulic distributor housing,
- the hydraulic distributor housing seal.
a Disconnect the internal wiring connector (4) .
106275
118391
117250
117254
23A-45
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
M9R, and AJ0
23A
a Remove the protection plate from the wiring (5) .
a Remove the cable routing retaining bolt (6) .
a Disconnect the connectors (7) from the hydraulicdistributor wiring.
a Remove the hydraulic distributor wiring (8) .
REFITTING
a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and the hydraulic distributor housing,taking care not to damage the contact surfaces.
a Always replace the hydraulic distributor housingseal.
a Fit the wiring (9) .
a Connect the hydraulic distributor wiring connectors.
a Pass the wiring through the inside of the automaticgearbox.
a Torque tighten the wiring routing retainer bolt (7N.m) (10) .
118390
118388
118388
23A-46
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
M9R, and AJ0
23A
a Connect the internal wiring connector (11) .
a Fit the hydraulic distributor housing with of a newseal.
a Torque tighten the hydraulic distributor housingbolts (8 Nm.)
a Remove the intercooler air inlet pipe seal at the tur-bocharger end using a .
a
a Refit a new seal to the intercooler air inlet pipe at theturbocharger end.
a Proceed in the reverse order to removal.
117254
117250
115068
115069
Note:
Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted in its groove theright way round.
23A-47
AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting
M9R, and AJ0
23Aa Fill the automatic gearbox with oil and check the le-
vel (see 2 3 A, Automatic gearbox, Automaticgearbox oil: Draining - Refilling, page 23A-24) .
a Refit:
- the engine undertray,
- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (13B, Diesel in-jection),
- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery),
- the battery (see Battery: Removal - Refitting)(80A, Battery).
a Connect the diagnostic tool for the programmingprocedure (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).
23A-48
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
AJ0
23AREMOVAL
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 - Re-fitting) (80A, Battery),
- the air filter unit (see Air filter unit: Removal - Re-fitting) (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 archliner: Removal - Refitting) (55A, Exterior protec-tion),
- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection),
-
23A-49
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
M9R, and AJ0
23A
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 gear-box, Automatic gearbox oil: Draining - Refilling,page 23A-24) ,
- the cooling system (see Cooling circuit: Draining- Refilling) (19A, Cooling).
- the refrigerant circuit (see Coolant circuit Drai-ning - Refilling) (62A, Air conditioning).
a Rotate the clip on the air pipe at the intercooler inletat the turbocharger end.
a Remove the bolts (1) from the air pipe at the turbo-charger outlet.
Essential equipment
oil recovery container
Tightening torquesm
hydraul ic d is t ributorinternal wiring earthbolts
8 N.m
retaining bolt for thetemperature sensor
8 Nm
hydraul ic d is t ributorhousing bolts
8 Nm 113282
113155
23A-50
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
M9R, and AJ0
23A
a Loosen the clip on the air pipe at the intercooler inletat the exchanger end.
a Disconnect the air pipe at the intercooler inlet at theexchanger end.
a Remove the air pipe at the intercooler inlet.
a Remove the cooling assembly.
a Move the cooling and air pipes (2) aside from the tur-bocharger (3) .
a Fit a oil recovery container beneath the automaticgearbox.
a Remove:
- the hydraulic distributor housing (4) ,
- the hydraulic distributor housing seal.
119834
106275
118391
117250
23A-51
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
M9R, and AJ0
23AII - OPERATION FOR REMOVAL OF PART CONCERNED
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.
a Disconnect the solenoid valve connectors (8) .
a Remove:
- the bolts (9) from the earths,
- the bolt (10) from the temperature sensor,
- 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 repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and the hydraulic distributor housing,taking care not to damage the contact surfaces.
a Always replace the hydraulic distributor housingseal.
II - REFITTING OPERATION FOR PART CONCERNED
a Fit the hydraulic distributor internal wiring.
118831
118831
23A-52
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
M9R, and AJ0
23A
a
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 earthbolts (8 N.m),
- the retaining bolt for the temperature sensor (8Nm).
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,
- the hydraulic distributor housing.
a Torque tighten the hydraulic distributor housingbolts (8 Nm).
a Remove the intercooler air inlet pipe seal at the tur-bocharger end using a .
118831
Note:
The earth terminal at (12) must be positionedbetween the distributor and the temperature sen-sor retaining plate so that the earth terminal doesnot break when the bolt is tightened.
115068
23A-53
AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting
M9R, and AJ0
23A
a
a Refit a new seal to the intercooler air inlet pipe at theturbocharger end.
a Fit the cooling and air pipes onto the turbochargeroutlet.
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 - Refit-ting) (80A, Battery).
a Refill:
- the cooling system (see Cooling circuit: Draining- Refilling) (19A, Cooling),
- the refrigerant circuit (see Coolant circuit Drai-ning - Refilling) (62A, Air conditioning),
- the automatic gearbox (see 23A, Automatic gear-box, Automatic gearbox oil: Draining - Refilling,page 23A-24) .
115069
Note:
Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted in its groove theright way round.
23A-54
AUTOMATIC GEARBOXFlow regulation solenoid valve: Removal - Refitting
DP0
23A
REMOVALa Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negativeterminal.
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.
Tightening torquesm
exchanger flow controlsolenoid valve moun-ting bolt
1 daNm
battery cover mountingbolts
0.4 daNm
Note:
The radiator flow control solenoid valve can beremoved without draining or removing the auto-matic transmission.
103434
13786-1
23A-55
AUTOMATIC GEARBOXFlow regulation solenoid valve: Removal - Refitting
DP0
23Aa Torque tighten the exchanger flow control sole-
noid valve mounting bolt (1 daNm).
a Torque tighten the battery cover mounting bolts(0.4 daNm).
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-56
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
DP0
23A
REMOVALa This operation is done after removing the correspon-
ding 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 negativeterminal.
a Remove the engine undertray.
a Drain the automatic transmission through the plug(1) .
a Remove the faulty differential output seal using ascrewdriver or a hook, taking care not to scratch thecontact faces.
Essential special tooling
Bvi. 1459 Fitting right-hand transmis-sion output seal.
Bvi. 1460 Fitting left-hand transmissionoutput seal.
Tightening torquesm
wheel bolts 13 daNm
lower ball joint nut 6.2 daNm
bolts mounting the tor-que reaction on the sub-frame
10.5 daNm
engine tie-bar bolts on Kengines
10.5 daNm
engine tie-bar bolts on Fengines
18 daNm
track rod end nut 3.7 daNm
hub nut 28 daNm
battery cover mountingbolts
0.4 daNm
13791
WARNING
Do not drop the seal spring into the automatictransmission.
23A-57
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
DP0
23AREFITTING
a Fit the seal using the (Bvi. 1459) or the (Bvi. 1460).
a Guide the assembly until the tool is resting on theautomatic 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 thesub-frame (10.5 daNm),
- the engine tie-bar bolts on K engines (10.5daNm),
- the engine tie-bar bolts on F engines (18 daNm),
- the track rod end nut (3.7 daNm),
- the hub nut (28 daNm).
a
Fill the automatic transmission and check the level(see Filling - Levels) .
a Torque tighten the battery cover mounting bolts(0.4 daNm).
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-58
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
F9Q, and DP0
23A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see 02A, Lif-ting, Vehicle: Towing and lifting).
a Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting).
a Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .
a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove:
- the right-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces,
- the left-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the right-hand differential output seal using the(Bvi. 1459) (1) ,
- the left-hand differential output seal using the (Bvi.1460) (2) .
Essential special tooling
Bvi. 1459 Fitting right-hand transmis-sion output seal.
Bvi. 1460 Fitting left-hand transmissionoutput seal.
117291
117293
23A-59
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
F9Q, and DP0
23AII - FINAL OPERATION
a Refit:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .
a Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting).
a Fill the automatic transmission (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .
23A-60
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
AJ0
23A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).
a Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .
a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
II - REMOVAL OPERATION FOR PART CONCERNED
a Remove:
- the right-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces,
- the left-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the right-hand differential output seal using the to-ols from the kit (Bvi. 1804) (1) ,
- the left-hand differential output seal using the toolsfrom the kit (Bvi. 1804) (1) and the spacer (2) .
Essential special tooling
Bvi. 1804 Kit for fitting differential andconverter seals (AJ0).
118354
118353
23A-61
AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting
AJ0
23AII - FINAL OPERATION.
a Refit:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
a Fill the automatic transmission (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .
a Carry out the necessary programming, following re-moval of the battery (see : Battery - Initialisation))(MR 372, 80A, Battery).
23A-62
AUTOMATIC GEARBOXMultifunction switch: Removal - Refitting
DP0
23A
REMOVAL
a Shift the lever to neutral: « N » .
a Disconnect the battery, starting with the negativeterminal.
a Remove:
- the air intake sleeve,
- the battery,
- the battery tray,
- the injection computer and its support,
- the air filter box,
- the wiring harness mountings.
a Disconnect:
- the multifunction switch cable ball joint (1) ,
- the control cable from the sheath stop (2) on themodular connector support.
a Remove the lever and the two mounting bolts (3)from the multifunction switch.
a Disconnect the modular connector (4) by releasingthe connector slide mechanism.
a Remove the three mounting bolts (5) from the modu-lar connector support plate.
a Remove the two modular connector mounting platebolts.
a Remove the green connector (6) from the multifunc-tion switch (12 track).
Tightening torquesm
selector lever nut 1 daNm
101821
103409
13785
23A-63
AUTOMATIC GEARBOXMultifunction switch: Removal - Refitting
DP0
23AREFITTING
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, Automaticgearbox, Multifunction switch: Adjusting, page23A-66)
a Check that the system and gear selection are wor-king correctly.
a Proceed in the reverse order to removal.
23A-64
AUTOMATIC GEARBOXMultifunction switch: Removal - Refitting
AJ0
23A
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 - Refit-ting) (80A, Battery),
- the protection plate from the multifunction switch.
a Disconnect:
- the control cable ball joint on the multifunctionswitch (1) using an open-jawed spanner size 12mm,
- the gear lever nut (2) ,
- the gear lever on the multifunction switch.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove:
- the multifunction switch connector (3) ,
- 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 tighteningthem.
Essential special tooling
Bvi. 1805 Multifunction switch adjust-ment lever (AJ0)
Tightening torquesm
mult i funct ion switchbolts
6 Nm
gear lever nut17 Nm
118389
118388
23A-65
AUTOMATIC GEARBOXMultifunction switch: Removal - Refitting
AJ0
23A
a Position the (Bvi. 1805) (5) .
a Align the tool shaft with the relevant hole on the mul-tifunction switch (6) .
a Torque tighten the multifunction switch bolts (6Nm) (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 - Refit-ting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)(80A, Battery)
a Check that the gear selection is working correctly.
118387
23A-66
AUTOMATIC GEARBOXMultifunction switch: Adjusting
AJ0
23A
Adjust the multifunction switch using the tool (Bvi.1805) when removing and refitting the multifunctionswitch or during fault finding.
a With the multifunction switch loosened and in posi-tion "N", place the tool (Bvi. 1805) (1) on the controllever and align the shaft of the tool opposite the rele-vant hole on the multifunction switch (2) .
a Torque tighten the multifunction switch bolts (6Nm) (3) .
a Remove the.
Essential special tooling
Bvi. 1805 Multifunction switch adjust-ment lever (AJ0)
Tightening torquesm
mult i funct ion switchbolts
6 Nm
118387
23A-67
AUTOMATIC GEARBOXMultifunction switch: Adjusting
DP0
23A
ADJUSTMENT
a Put the multifunction switch into the Neutral position.
a Place the test probes of an ohmmeter on the multi-function switch position check tabs.
a Turn the multifunction switch by hand until the elec-tric contact is closed (resistance at contact terminalsto be measured 0 Ω with a tolerance of 60 Ω)
a Torque tighten the multifunction switch bolts (10N.m).
a Check that the resistance at the contact terminals isstill 0 Ω with a tolerance of 60 Ω after tightening.
a Check that the system and gear selection are wor-king correctly.
Tightening torquesm
mult i funct ion switchbolts
10 N.m
110242
23A-68
AUTOMATIC GEARBOXSpeed sensor: Removal - Refitting
DP0
23A
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negativeterminal.
a Remove the engine undertray.
a Disconnect the connector (1) .
a Remove the output speed sensor (2) .
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the output speed sensor mountingbolt (1 daNm).
a Torque tighten the battery cover mounting bolts(0.4 daNm).
Tightening torquesm
output speed sensormounting bolt
1 daNm
battery cover mountingbolts
0.4 daNm
Note:
The speed sensor can be removed without drai-ning or removing the automatic gearbox.
103417
Note:
When replacing a sensor, always remove thegearbox connector (see 23A, Automatic gear-box, A utomatic transmission connector:Removal - Refitting, page 23A-79) .
WARNING
Protect the connector by sliding it into a water-proof plastic bag.
13786-1
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-69
AUTOMATIC GEARBOXPressure sensor: Removal - Refitting
DP0
23A
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 ty-res, Wheel: Removal - Refitting),
- the front left-hand wheel arch liner (see MR Bo-dywork, 55A, Exterior protection, Wheel archliner: Removal - Refitting),
- the engine undertray.
a Remove:
- the battery tray (see 80, Battery, Battery tray: Re-moval - Refitting),
- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting).
a Disconnect the modular connector (1) by pulling thesliding (2) .
a Disconnect the gearbox connector from the moun-ting plate by pulling the slide (3) .
a Remove the gearbox connector mounting bolts (4)from the plate.
Tightening torquesm
pressure sensor moun-ting bolts
8 N.m
pressure sensor wiringharness mounting bolts
8 N.m
gearbox connec to rmounting bolts
20 N.m
110246
110225
23A-70
AUTOMATIC GEARBOXPressure sensor: Removal - Refitting
DP0
23A
a Remove the green connector (3-track) (5) from thegearbox connector on the mounting plate.
a Release the pressure sensor wiring harness fromthe automatic transmission wiring duct.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove:
- the wiring harness mounting bolt (6) ,
- the pressure sensor mounting bolts (7) ,
- the pressure sensor (8) .
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 mountingbolts (8 N.m).
a Connect the pressure sensor harness from the auto-matic transmission wiring duct.
110224
110251
WARNING
Protect the connector by sliding it into a water-proof plastic bag.
23A-71
AUTOMATIC GEARBOXPressure sensor: Removal - Refitting
DP0
23AII - FINAL OPERATION
a Refit the gearbox connector mounting plate moun-ting bolts.
a Torque tighten the gearbox connector mountingbolts (20 N.m).
a Connect the gearbox connector on the mountingplate by pulling out the slide.
a Refit:
- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting),
- the battery protective base (see 80A, Battery, Bat-tery tray: Removal - Refitting),
a Connect the modular connector by reinserting theslide.
a Refit the battery shield (see 80A, Battery, Batterytray: Removal - Refitting).
a Refit:
- the front left-hand wheel arch liner (see 55A, Bo-dywork, Exterior protection, Wheel arch liner:Removal - Refitting),
- the engine undertray,
- the front left-hand wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting).
a Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting).
a Check the gearbox oil level (see 23A, Gearbox oil:Draining - Filling).
23A-72
AUTOMATIC GEARBOXGearbox temperature sensor: Removal - Refitting
M9R, and AJ0
23AThe gearbox temperature sensor can only be replacedwith the hydraulic distributor internal wiring (see 23A,Automatic gearbox, Hydraulic distributor internalwiring: Removal - Refitting, page 23A-48) .
a
118831
(1) Gearbox temperature sensor
Note:
In order to avoid breakage of the earth terminal(2) when the bolt is tightened, position it betweenthe distributor and the retaining plate of the gear-box temperature sensor.
23A-73
AUTOMATIC GEARBOXOil pressure switch: Removal - Refitting
M9R, and AJ0
23A
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)
- the battery tray (see Battery : Removal - Refit-ting) (80A, Battery),
- the engine undertray.
a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .
a Remove the front bumper (see Front bumper: Re-moval - Refitting) (55A, Exterior protection).
a Drain the cooling system (see Cooling circuit:Draining - Refilling) (19A, Cooling).
a Drain the refrigerant circuit (see Coolant circuitDraining - Refilling) (62A, Air conditioning).
a Rotate the clip on the air pipe at the intercooler inletat the turbocharger end.
a Remove the air pipe bolts at the intercooler inlet.
a Loosen the clip on the air pipe at the intercooler inletat the exchanger end.
a Disconnect the air pipe at the intercooler inlet at theexchanger end.
a Remove the air pipe at the intercooler inlet.
Essential equipment
diagnostic tool
Tightening torquesm
oil pressure switch con-cerned
4 Nm
hydraul ic d is t ributorhousing bolts8 Nm
.
113282
113155
119834
23A-74
AUTOMATIC GEARBOXOil pressure switch: Removal - Refitting
M9R, and AJ0
23A
a Remove the cooling assembly.
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.
a Place a clean container under the automatic gear-box to collect the oil.
a Remove:
- the hydraulic distributor housing bolts,
- the hydraulic distributor housing,
- the hydraulic distributor housing seal.
a Disconnect the oil pressure switch connector (4) .
a The oil pressure switch (5) concerned.
106275
118391
117250
118831
23A-75
AUTOMATIC GEARBOXOil pressure switch: Removal - Refitting
M9R, and AJ0
23AREFITTING
a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and on the hydraulic distributorhousing taking care not to damage the contact surfa-ces.
a Always replace:
- the hydraulic distributor housing seal,
- the intercooler air inlet pipe seal at the turbochar-ger end.
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.
a Fit the hydraulic distributor housing with its new seal.
a Torque tighten the hydraulic distributor housingbolts8 Nm (.)
a Remove the intercooler air inlet pipe seal at the tur-bocharger end using a .
117254
117250
115068
23A-76
AUTOMATIC GEARBOXOil pressure switch: Removal - Refitting
M9R, and AJ0
23A
a
a Fit a new seal to the intercooler air inlet pipe at theturbocharger end.
a Proceed in the reverse order to removal.
a Fill the automatic gearbox with oil and check the le-vel (see 2 3 A, Automatic gearbox, Automaticgearbox oil: Draining - Refilling, page 23A-24) .
a Refit:
- the engine undertray,
- the battery tray (see Battery : Removal - Refit-ting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)(80A, Battery).
a Perform the programming procedures using the dia-gnostic tool (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).
115069
Note:
Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted on its groove theright way round.
23A-77
AUTOMATIC GEARBOXConverter seal: Removal - Refitting
DP0
23A
REMOVAL
a This operation is carried out after the automatictransmission and converter have been removed.
a Remove the converter by withdrawing it as far aspossible without deviating from its axis.
a Using tool (Mot. 587), remove the seal, taking carenot to scratch the contact faces.
REFITTINGa
a Refit:
- the new pre-lubricated seal to the end, using the(Bvi. 1457),
- the converter.
a The distance between the base of the threading (1)and the engine coupling face (2) should be 17 mm.
a To refit, proceed in the reverse order of removal.
Essential special tooling
Mot. 587 Oil seal extractor
Bvi. 1457 Fitting converter lip seal.
WARNING
The converter contains a large amount of oil,which may spill when it is being removed.
WARNING
- Work as cleanly as possible to prevent foreignbodies penetrating the system.
- Lubricate all the contact faces.
13790
23A-78
AUTOMATIC GEARBOXConverter seal: Removal - Refitting
AJ0
23A
REMOVAL
a This operation is carried out with the gearbox andconverter removed.
a Remove the converter seal (1) using a screwdriver,taking care not to damage the input shaft splines.
REFITTING
a Refit the seal using the (2) contained in the kit (Bvi.1804)
a Refit the converter (3) .
a Check that the converter is correctly inserted using asurfaced ruler and a steel rule.
a Check that the distance (X) between the bead andthe ruler is at least 20.5 mm.
a Refit the gearbox (see: Automatic gearbox: Remo-val - Refitting).
Essential special tooling
Bvi. 1804 Kit for fitting differential andconverter seals (AJ0).
117248
11954
117252
11911
23A-79
AUTOMATIC GEARBOXAutomatic transmission connector: Removal - Refitting
DP0
23AConnector numbering
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the engine covers.
a Shift the lever to neutral: « N » .
a Disconnect the battery, starting with the negativeterminal.
a Remove:
- the air intake sleeve,
- the battery,
Tightening torquesm
battery cover mountingbolts
0.4 daNm
13785
(1) Green connector (multifunctionswitch)
(2) Yellow connector (electrohydrau-lic interface)
(3) Green connector (line pressure)
(4) Yellow connector (turbo speed)
(5) Blue connector (exchanger flowcontrol solenoid valve)
Note:
These connectors may be removed separately fromthe gearbox connector when certain componentsare replaced.
103248
101821
23A-80
AUTOMATIC GEARBOXAutomatic transmission connector: Removal - Refitting
DP0
23A- the battery tray,
- the injection computer and its support,
- the air filter box,
- the wiring harness mountings.
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 connec-tor slide valve.
a Remove:
- the three mounting bolts (9) from the gearbox con-nector support plate,
- the two gearbox connector mounting bolts,
- the connector of the colour concerned from thegearbox connector.
a Follow the five wiring harnesses connected to thegearbox connector.
a Remove the five wiring harnesses.
These wiring harnesses are either connected via aconnector to or directly to the components. If theyare connected to a component directly, the compo-nent should also be removed.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
103409
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-81
AUTOMATIC GEARBOXAutomatic transmission computer: Removal - Refitting
DP0
23A
The computer is located behind the left-hand wheelarch.
REPLACEMENTa
a Use the following procedure.
a Read the oil ageing value from the memory of thecomputer being replaced using parameter PR133:« Oil ageing counter » and note down the value.
a Replace the computer.
a Enter the oil ageing value in the memory of the newcomputer using command CF320: « Oil ageingcounter report » .
a Confirm entry using the parameter « Oil ageingcounter » .
a Enter the After Sales operation date using commandCF320 « Enter After-Sales operation date » .
a Carry out a road test so that the new computer sto-res the programming.
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negativeterminal.
a Remove the front bumper.
a Disconnect the computer connector.
a Remove the resonator .
a Remove:
- the two computer mounting nuts ,
- the computer.
Tightening torquesm
battery cover mountingbolts
0.4 daNm
Note:
When the automatic gearbox computer is repla-ced, it is necessary to enter the age of the auto-matic gearbox oil stored in the memory of thecomputer to be replaced in the memory of thenew computer.
103414
103415
23A-82
AUTOMATIC GEARBOXAutomatic transmission computer: Removal - Refitting
DP0
23AREFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the battery cover mounting bolts(0.4 daNm).
REPLACING THE COMPUTER
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).
23A-83
AUTOMATIC GEARBOXAutomatic transmission computer: Removal - Refitting
AJ0
23A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).
a Remove the front bumper (see Front bumper: Re-moval - Refitting) (MR 371, 55A, Exterior protec-tion).
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove:
- the automatic transmission computer nuts,
- the automatic transmission computer (1) .
a Disconnect the computer connector.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Connect the computer connector.
a Refit:
- the computer,
- the computer nuts.
II - FINAL OPERATION.
a Refit the front bumper (see Front bumper: Remo-val - Refitting) (MR 371, 55A, Exterior protection).
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
a Carry out the necessary programming, following re-moval of the battery (see Battery - Initialisation))(MR 372, 80A, Battery).
a Connect the diagnostic tool for programming pro-cedures (see Replacement of components)) (MR372, 23A, Automatic transmission).
Essential equipment
diagnostic tool
103415
23A-84
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
DP0
23A
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 negativeterminal.
a Remove:
- the battery,
- the cowl grille ( (see 85A, Wiping - Washing) ).
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
a Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel partition.
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.
Tightening torquesm
control unit mountingnuts
2.1 daNm
104343
104246
101822
23A-85
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
DP0
23A
a Unclip:
- the control cable (5) from the gearbox lever balljoint,
- the control cable from the sleeve stop.
2 - In the passenger compartment
a Unclip the gear lever gaiter.
a Rotate the part (6) clockwise.
a Remove the gear lever knob by lifting it.
a Remove the mounting bolts (7) from the central con-sole.
a Unclip:
- the mounting brackets (8) ,
- the clip (9) .
105107
105109
105110
104033
23A-86
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
DP0
23A
a Disconnect the connector (10) .
a Remove:
- the three control unit mounting bolts (11) ,
- the three bulkhead seal mounting bolts,
- the engine undertray.
a Disconnect:
- the exhaust pipe from the exhaust manifold,
- the centre bracket.
a Move the exhaust pipe to one side.
a Disconnect the oxygen sensor connector.
a Remove the heat shield mounting bolts.
a Move the heat shield towards the rear of the vehicleto gain access to the gearbox control cable routing(12) .
a Remove the « control unit-cable » assembly via thepassenger compartment.
II - REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the control unit mounting nuts (2.1daNm).
ADJUSTING THE CONTROL CABLE
a - In the passenger compartment
a Put the lever in « Drive » position.
b - In the engine compartment
a Put the gearbox lever in « Drive » position.
a Clip the control cable into the sleeve stop.
105108
WARNING
Do not open the automatic transmission controlunit, this could cause damage (infrared system).
105105
23A-87
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
DP0
23A
a Slide on part (13) by compressing the control cablespring.
a Unlock the adjustment mechanism by sliding thecatch (14) .
a Adjust the length of the cable accordingly.
a Fit the end of the control cable (5) on the gearbox le-ver ball joint.
a Lock the adjustment mechanism by pushing thecatch (14) back to its original position.
a Check that the system and gear selection are wor-king correctly.
104733
104736
105107
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).
23A-88
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see 02A, Lif-ting, Vehicle: Towing and lifting).
a Carefully mark the position of the automatic gearboxcontrol lever before the operation: if not, position thegear selector and the multifunction switch in neutral« N » .
a Remove the engine covers.
a Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting).
a Remove:
- the multifunction switch cable ball joint (1) ,
- the control cable from the sheath stop (2) on themodular connector support.
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 control unit lever knob (5) by lifting it.
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
103408
103424
103425
23A-89
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
a Unclip the console trim (6) .
a Disconnect the connector (7) .
a Open the glove compartment.
a Unclip the handbrake surround trim at (8) and (9) .
a Unclip the lower cover (10) .
a Unclip the cigarette lighter mounting.
a Disconnect the cigarette lighter connector.
103426
103427
101322
101319
101321
23A-90
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
a Disconnect the heated seat connectors (if fitted tothe vehicle).
a Remove the two front seats (see MR 365 Bo-dywork, 75A, Front seat frames and runners,Complete front seat: Removal - Refitting).
a Remove the bolts from the console (11) .
a Remove:
- the console carefully (12) ,
- the gear lever console.
a Disconnect the connector (13) .
a Remove the sensor (14) using the (Mot. 1495-01).
a Remove the nuts (15) from the exhaust bracket.
a Remove the bolts (16) from the rubber mountingbush.
101320
101504
101793
101818
23A-91
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
a Remove:
- the bolt (17) ,
- the front section of the heat shield.
a Pull back the carpet.
a Remove the soundproofing (18) .
a Remove the protector (19) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove the bolts (20) from the automatic gearboxcontrol unit.
a Hold the control lever rod steady and release thecontrol unit clips.
a Take out the « unit-control cable » assembly.
102117
103428
103429
103431
23A-92
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Position the « unit-control cable » assembly.
a Hold the control lever rod steady and lock the controlunit clips.
a Refit the bolts (21) to the automatic gearbox controlunit.
II - FINAL OPERATION
a Refit the protector (22) .
a Refit the soundproofing (23) .
a Pull the carpet forwards.
103431
103429
103428
23A-93
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
a Refit:
- the front section of the heat shield,
- the bolt (24) .
a Refit the bolts (25) to the rubber mounting bush.
a Refit the nuts (26) to the exhaust bracket.
a Torque tighten the exhaust bracket nuts (21 Nm).
a Refit the oxygen sensor (27) .
a Torque tighten the oxygen sensor (45 Nm).
a Connect the connector (28) .
102117
101818
101793
101504
23A-94
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23Aa Refit the two front seats (see MR 365 Bodywork,
75A, Front seat frames and runners, Completefront seat: Removal - Refitting).
a Refit:
- the centre console,
- the centre console bolts.
a Connect the heated seat connectors (if fitted to thevehicle).
a Connect the cigarette lighter connector.
a Clip on the cigarette lighter mounting.
a Clip on the handbrake surround trim.
a Connect the connector (29) .
a Clip on the console trim (30) .
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.
101321
103427
103426
103424
23A-95
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
F9Q, and DP0
23A
a Refit:
- the sheath stop control cable (32) on the modularconnector support,
- the multifunction switch cable ball joint (33) .
a Refit the battery (see 80A, Battery, Battery: Remo-val - Refitting).
a Refit the engine covers.
103408
23A-96
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
AJ0
23A
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 negativeterminal.
a Remove:
- the battery,
- the cowl grille ( (see 85A, Wiping - Washing) ).
a Remove:
- the two air filter access panel mounting bolts,
- the air filter access panel,
- the scuttle panel partition mounting bolt.
a Remove:
- the scuttle panel partition mounting bolts,
- the scuttle panel partition.
a Disconnect the computer connectors.
a Remove:
- the battery tray bolts ,
- the battery tray,
- the computer with its support,
- the air filter outlet duct.
Tightening torquesm
control unit mountingnuts
2.1 daNm
104343
104246
101822
23A-97
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
AJ0
23A
a Unclip:
- 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.
a Rotate part clockwise.
a Remove the gear lever knob by lifting it.
a Remove the mounting bolts from the central console.
a Unclip:
- the mounting brackets ,
- the clip.
105107
105109
105110
104033
23A-98
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
AJ0
23A
a Disconnect the connector.
a Remove:
- the three control unit mounting bolts ,
- the three bulkhead seal mounting bolts,
- the engine undertray.
a Disconnect:
- the exhaust pipe from the exhaust manifold,
- the centre bracket.
a Move the exhaust pipe to one side.
a Disconnect the oxygen sensor connector.
a Remove the heat shield mounting bolts.
a Move the heat shield towards the rear of the vehicleto gain access to the gearbox control cable routing.
a Remove the « control unit-cable » assembly via thepassenger compartment.
II - REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the control unit mounting nuts (2.1daNm).
ADJUSTING THE CONTROL CABLE
a - In the passenger compartment
a Put the lever in « Drive » position.
b - In the engine compartment
a Put the gearbox lever in « Drive » position.
a Clip the control cable into the sleeve stop.
105108
WARNING
Do not open the automatic transmission controlunit, this could cause damage (infrared system).
105105
23A-99
AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting
AJ0
23A
a Slide on part by compressing the control cablespring.
a Unlock the adjustment mechanism by sliding thecatch.
a Adjust the length of the cable accordingly.
a Fit the end of the control cable on the gearbox leverball joint.
a Lock the adjustment mechanism by pushing thecatch back to its original position.
a Check that the system and gear selection are wor-king correctly.
104733
104736
105107
WARNING
Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).
29A-1
DRIVESHAFTSDriveshaft: Precautions for repair 29A
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 inthe base of the relay bearing, if the bearing hasone.
Note:
Always replace:
- the O-ring, if fitted to the bearing,
- the relay bearing support plate,
- the left-hand driveshaft locking spring ring, if thedriveshaft 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 whenthe wheels are on the ground.
- Do not place the vehicle with its wheels on theground when the driveshaft has been loosened orremoved.
29A-2
DRIVESHAFTSFront left-hand wheel driveshaft: Removal - Refitting 29A
REMOVAL
I - WHEEL SIDE
a Position the vehicle on a two-post lift.
a Remove:
- the front left-hand wheel,
- the hub nut using tool (Rou. 604-01).
a Disconnect the wheel speed sensor.
a Remove:
- the track rod end nut (1) ,
- the stub axle carrier ball joint using the (Tav. 476),
- the upper nut of the anti-roll bar (2) ,
- the lower ball joint stud (3) .
a Push back the driveshaft from the stub axle carrierby pivoting the stub axle carrier.
a Remove the driveshaft (wheel side).
II - GEARBOX SIDE
a Drain the gearbox (see 21A, Manual gearbox, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) .
a Remove the driveshaft (gearbox side).
REPLACEMENT
a
a With the protector in place, coat the splines of theseal on the gearbox side with MOLYKOTE BR2.
a Position and insert the driveshaft into the final drivesunwheel.
a Insert the stub-axle into the hub.
The driveshaft must go in freely until it protrudesenough 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),
- the lower ball joint nut (6.2 daNm),
- the anti-roll bar nut (4.4 daNm),
- the driveshaft bearing bolts (4.4 daNm),
a Fill and check the gearbox oil level (see 21A, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
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
101213
JH3 or JR5 or ND0
Note:
Check the condition of the contact surfaces ofthe lip seal.
Always replace the differential output lip seal(see 21A, Manual gearbox, Differential outputseal: Removal - Refitting, page 21A-45) .
29A-3
DRIVESHAFTSFront right-hand wheel driveshaft: Removal - Refitting 29A
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).
a Disconnect the wheel speed sensor.
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 carrierby pivoting the stub axle carrier.
a Remove the driveshaft (wheel side).
II - GEARBOX SIDE
a Drain the gearbox.
a Remove the two bolts (4) from the driveshaft bea-ring.
a Remove the driveshaft (gearbox side).
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
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
101213
JH3 or JR5 or ND0
101819
Note:
If the bearing is seized in the relay bearing, thebearing must be replaced.
29A-4
DRIVESHAFTSFront right-hand wheel driveshaft: Removal - Refitting 29A
REPLACEMENT
a Clean and grease the bearing hole into which thebearing will be inserted.
a With the protector in place, coat the splines of theseal on the gearbox side with MOLYKOTE BR2.
a Position and insert the driveshaft into the final drivesunwheel.
a Insert the stub-axle into the hub.
The driveshaft must go in freely until it protrudesenough 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),
- the lower ball joint nut (6.2 daNm),
- the anti-roll bar nut (4.4 daNm),
- the driveshaft bearing bolts (4.4 daNm),
a Fill and check the gearbox oil level (see 21A, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .
REMOVING THE RELAY SHAFT BEARING
a Remove the complete driveshaft.
a Remove the bearing using a press.
a Take care not to score the contact surface of the lipseal on the relay shaft.
REFITTING
a Lubricate the contact surface of the shaft into whichthe bearing is inserted.
a Insert the new bearing.
a Fit the bearing to the end using a tube, so that itrests on the inner bearing race.
a Clean and grease the bearing hole into which thebearing will be inserted.
a Refit the driveshaft.
Note:
- Replace the O-ring at the base of the relay shaftbearing if it is damaged.
- Check the condition of the contact surfaces ofthe lip seal.
- The differential output lip seal must always bereplaced (see 21A, Manual gearbox, Differen-tial output seal: Removal - Refitting, page21A-45) .
100642
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