2
Transmission
20A
CLUTCH
21A
MANUAL GEARBOX
23A
AUTOMATIC GEARBOX
29A
DRIVESHAFTS
X84, and B84 or C84 or G84 or S84
77 11 318 042
MARCH 2003
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
© Renault s.a.s. 2005
Mégane II - Section 2
Mégane II - Section 2ContentsPage
Contents
Page
20A
21A
CLUTCH
23A
Identification
20A-1
Mechanism / Disk: Removal Refitting
20A-4
AUTOMATIC GEARBOX
Identification
23A-1
Gears
23A-2
Lubricants
23A-3
Clutch thrust bearing:
Removal - Refitting
20A-15
Consumables
23A-4
Flywheel: Removal - Refitting
20A-19
Changing the oil
23A-5
Filling - Levels
23A-7
MANUAL GEARBOX
Manual gearbox: Precautions
for repair
21A-2
Consumables
21A-4
Manual gearbox:
Specifications
21A-5
Gears
21A-7
Identification
21A-8
Lubricants
21A-9
Manual gearbox oil: Draining
- Refilling
23A-10
Checking the converter
setting point
23A-11
Line pressure measurement
23A-12
Hydraulic distributor:
Removal - Refitting
23A-13
Automatic gearbox: Removal
- Refitting
23A-18
Drive plate: Removal Refitting
23A-34
Differential output seal:
Removal - Refitting
23A-36
Converter seal: Removal Refitting
23A-38
Multifunction switch:
Removal - Refitting
23A-39
Automatic transmission
computer: Removal Refitting
23A-41
21A-1
Manual gearbox: Parts and
consumables for the repair
work
Special notes
Parts to be replaced
systematically
21A-10
21A-12
Input shaft lip seal:
Replacement
21A-14
Input shaft lip seal: Removal
- Refitting
21A-15
Speed sensor: Removal Refitting
23A-43
Differential output seal:
Removal - Refitting
21A-16
Flow regulation solenoid
valve: Removal - Refitting
23A-45
Manual gearbox: Removal Refitting
21A-23
Contents
23A
29A
AUTOMATIC GEARBOX
Solenoid valves: Removal
23A-47
Automatic transmission
connector: Removal Refitting
23A-48
DRIVESHAFTS
Identification
29A-1
Consumables
29A-4
Front left-hand wheel
driveshaft: Removal Refitting
29A-5
Front right-hand wheel
driveshaft: Removal Refitting
29A-10
CLUTCH
Identification
20A
Colour of springs (1) and (2) : Grey
K4J or K4M
Pressure plate
K9K
Pressure plate
102143
Driven plate
102143
1
Driven plate
3
2
4
102142
Plate outer diameter: 200 mm
Plate thickness: 6.9 mm
Number of splines: 26
102142
Plate outer diameter: 215 mm
Plate thickness: 6.8 mm
Number of splines: 26
20A-1
CLUTCH
Identification
20A
Number of splines: 21
Colour of springs: (3) Red and grey
Colour of springs: (4) Grey
F4R or F9Q or M9R
Pressure plate
22428
Driven plate
22429
Plate outer diameter: 239 mm
Plate thickness: 7.8 mm
20A-2
CLUTCH
Identification
B84 or C84, and F4R, and 774
Pressure plate
22428
Driven plate
22429
Plate outer diameter: 239 mm
Plate thickness: 7.8 mm
Number of splines: 21
20A-3
20A
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
K4J or K4M or K9K
REFITTING
Special tooling required
Mot. 582-01
Flywheel locking tool.
Emb. 1518
Set of clutch disc centring mandrels
Tightening torquesm
2
pressure plate mounting bolts (K4J and K4M
engines)
2 daNm
pressure plate mounting bolts (K9K engine)
1.5 daNm
REMOVAL
Remove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A23) .
95414
WARNING
Clean the clutch shaft splines and refit the
assembly without lubricant.
Position the clutch driven plate.
Centre the clutch driven plate using the (Emb. 1518)
(2) .
Gradually screw into place in a star pattern.
K4J or K4M
Tighten to torque the pressure plate mounting
bolts (K4J and K4M engines) ( 2 daNm ) .
1
16180
Position the (Mot. 582-01) (1) .
K9K
Tighten to torque the pressure plate mounting
bolts (K9K engine) ( 1.5 daNm ) .
Remove the pressure plate mounting bolts.
Remove the friction plate.
Replace any faulty parts.
Remove the (Mot. 582-01) .
20A-4
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q
REFITTING
Special tooling required
Mot. 1677
Flywheel locking tool.
Emb. 1604
Clutch compression
tool for resetting retrofit system.
Emb. 1518
Set of clutch disc centring mandrels
EMB. 1604
Tightening torquesm
pressure plate mounting bolts
1.2 daNm
19919
REMOVAL
Remove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A23) .
Note:
For automatic wear compensation mechanisms,
compress the clutch pressure plate using the
(Emb. 1604) .
1
16180
Position the (Mot. 1677) (1) .
Remove the pressure plate mounting bolts.
20754
Place the base of the (Emb. 1604) in a vice.
Remove the friction plate.
Replace any faulty parts.
20A-5
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q
3
2
1
20757
Place circlip pliers at (3) .
20755
Fit the pressure plate on the base, then fit the thrust
ball bearing (1) and the nut (2) .
4
20759
Compress the springs (4) .
Loosen the nut (2) completely (compressed
springs).
Release the plate.
20756
Tighten the nut (2) as far as possible.
20A-6
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
F4R or F9Q
CENTRING
20758
Remove the pressure plate from the base (checking
that the springs are properly compressed).
22695
Use the plastic centring tool supplied in the clutch kit
(Emb. 1518) .
WARNING
Refit the pressure plate on the flywheel.
Clean the clutch shaft splines and refit the
assembly without lubricant.
Gradually torque tighten the pressure plate mounting bolts ( 1.2 daNm ) .
Degrease the friction face of the flywheel.
5
102695
Position the driven plate (small hub diameter (5) on
flywheel end).
20A-7
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
M9R, and 700, and PK4
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Special tooling required
Mot. 1431
Flywheel locking tool.
Emb. 1604
Clutch compression
tool for resetting retrofit system.
Emb. 1780
Set of clutch disc centring mandrels.
Tightening torquesm
clutch pressure plate
mounting bolts
12 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove:
114917
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
Position the (Mot. 1431) (1) .
Remove
- the pressure plate mounting bolts,
- the pressure plate,
- the friction plate.
20A-8
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
M9R, and 700, and PK4
REFITTING
I - REFITTING PREPARATION OPERATION
19919
20755
Note:
Fit the pressure plate on the base, then fit the thrust
ball bearing (2) and the nut (3) .
For automatic wear compensation mechanisms,
compress the clutch pressure plate using the
(Emb. 1604) .
20756
Tighten the nut fully.
20754
Position the base plate of the (Emb. 1604) in the vice.
20A-9
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
M9R, and 700, and PK4
20757
Insert the circlip pliers at (4) .
20758
Remove the pressure plate from the base (checking
that the springs are properly compressed).
WARNING
Clean the clutch shaft splines and refit the
assembly without lubricant.
Degrease the friction face of the flywheel.
20759
Compress the springs (5) .
Loosen the nut (3) completely (springs compressed).
Release the plate.
102695
Position the driven plate (small hub diameter (6) on
flywheel end).
20A-10
CLUTCH
Mechanism / Disk: Removal - Refitting
M9R, and 700, and PK4
II - REFITTING OPERATION
Centring
114916
Refit the clutch driven plate.
Centre the clutch driven plate using the (Emb. 1780)
(2) .
Refit the pressure plate on the flywheel.
Fit the (Mot. 1431) .
Tighten the clutch pressure plate mounting bolts until they make contact.
Gradually tighten to torque the clutch pressure plate mounting bolts ( 12 Nm ) .
III - FINAL OPERATION
Remove the (Mot. 1431) .
Refit:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
20A-11
20A
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
B84 or C84, and F4R, and 774
REFITTING
Special tooling required
Mot. 1677
Flywheel locking tool.
Emb. 1604
Clutch compression
tool for resetting retrofit system.
Emb. 1518
Set of clutch disc centring mandrels
EMB. 1604
Tightening torquesm
clutch pressure plate
mounting bolts
12 Nm
19919
REMOVAL
Remove the manual gearbox (see 21A, Manual
gearbox, Manual gearbox: Removal - Refitting ).
Note:
For automatic wear compensation mechanisms,
compress the clutch pressure plate using the
(Emb. 1604) .
16180
Position the (Mot. 1677) (1) .
Remove the pressure plate mounting bolts.
20754
Remove the friction plate.
Place the base of the (Emb. 1604) in a vice.
Replace any faulty parts.
20A-12
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
B84 or C84, and F4R, and 774
20757
Insert the circlip pliers at (4) .
20755
Fit the pressure plate on the base, then fit the thrust
ball bearing (2) and the nut (3) .
20759
Compress the springs (5) .
Loosen the nut (3) completely (springs compressed).
Release the plate.
20756
Tighten the nut (3) fully.
20A-13
CLUTCH
Mechanism / Disk: Removal - Refitting
20A
B84 or C84, and F4R, and 774
CENTRING
20758
Remove the pressure plate from the base (checking
that the springs are properly compressed).
22695
Use the plastic centring tool supplied in the clutch kit
(Emb. 1518) .
WARNING
Refit the pressure plate on the flywheel.
Clean the clutch shaft splines and refit the
assembly without lubricant.
Gradually tighten to torque the clutch pressure plate mounting bolts ( 12 Nm ) .
Degrease the friction face of the flywheel.
102695
Position the driven plate (small hub diameter (6) on
flywheel end).
20A-14
CLUTCH
Clutch thrust bearing: Removal - Refitting
20A
JH3 or JR5 or ND0
ND0
Tightening torquesm
hydraulic union mounting bolts
9 Nm
bolts mounting the
clutch thrust bearing on
the clutch housing
21 Nm
REMOVAL
JH3 or JR5
101223
Remove:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting, page 21A-23) ,
- the hydraulic union clip (1) ,
- the hydraulic union,
- both bolts (2) securing the clutch thrust bearing on
the clutch housing,
- the clutch thrust bearing.
18439
Remove:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting, page 21A-23) ,
- both bolts (1) from the hydraulic union,
REFITTING
- the hydraulic union,
Check the condition of the seals.
- both bolts (2) securing the clutch thrust bearing on
the clutch housing,
To refit, proceed in the reverse order to removal.
- the clutch thrust bearing.
JH3 or JR5
Tighten to torque:
- the hydraulic union mounting bolts ( 9 Nm ) ,
- the bolts mounting the clutch thrust bearing on
the clutch housing ( 21 Nm ) .
20A-15
CLUTCH
Clutch thrust bearing: Removal - Refitting
JH3 or JR5 or ND0
ND0
Tighten to torque the bolts mounting the clutch
thrust bearing on the clutch housing (21 Nm).
WARNING
To avoid damaging the clutch slave cylinder, do
not lubricate the clutch shaft.
Never operate the system while the slave cylinder is removed.
Bleed the clutch control (see 3 7 A, Mechanical
component controls) .
20A-16
20A
CLUTCH
Clutch thrust bearing: Removal - Refitting
20A
M9R, and 700, and PK4
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
bolts mounting the
clutch thrust bearing on
the clutch housing
21 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove:
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
114914
Remove:
- the bolts (2) mounting the clutch thrust bearing on
the clutch housing,
- the clutch thrust bearing.
REFITTING
I - REMOVAL PREPARATION OPERATION
Check the condition of the input shaft seal. Replace
it if necessary.
WARNING
114915
Pull the retaining clip (1) out of the hydraulic union.
To avoid damaging the clutch slave cylinder, do
not lubricate the clutch shaft.
Always replace the clutch thrust bearing with a
new one when the clutch is replaced.
Unclip the clutch hydraulic pipe.
Move the hydraulic union away.
20A-17
CLUTCH
Clutch thrust bearing: Removal - Refitting
M9R, and 700, and PK4
II - REFITTING OPERATION FOR PART
CONCERNED
114914
Refit the new clutch thrust bearing.
Tighten the bolts mounting the clutch thrust bearing
on the clutch housing until they just make contact.
Tighten to torque the bolts mounting the clutch
thrust bearing on the clutch housing ( 21 Nm ) .
III - FINAL OPERATION
Reposition the retaining clip.
Connect the hydraulic union.
Position the clutch hydraulic pipe.
Refit:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
Bleed the clutch control (see 37A, Mechanical
component control, Clutch circuit: Bleeding ).
20A-18
20A
CLUTCH
Flywheel: Removal - Refitting
20A
- the (Mot. 582-01) (8) .
Special tooling required
Mot. 582-01
Flywheel locking tool.
Mot. 1677
Flywheel locking tool.
F4R or F9Q
Tightening torquesm
engine flywheel mounting bolts (K engines)
6.5 daNm
engine flywheel mounting bolts (F4R engine)
7 daNm
engine flywheel mounting bolts (F9Q engine)
9 daNm
REMOVAL
Remove:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting, page 21A-23) ,
- the clutch pressure plate (see 20A, Clutch, Mechanism / Disk: Removal - Refitting, page 20A4) .
9
22698
K4J or K4M or K9K
Fit the (Mot. 1677) (9) .
Remove:
- the flywheel mounting bolts,
- the flywheel,
- the (Mot. 1677) (9) .
Note:
The engine flywheel is of the dual-mass type.
8
REFITTING
22698
Position the (Mot. 582-01) (8) .
Remove:
Clean the threads of the flywheel mounting bolts on
the crankshaft.
Degrease the bearing face of the flywheel on the
crankshaft.
- the flywheel mounting bolts,
Check the condition of the flywheel.
- the flywheel,
20A-19
CLUTCH
Flywheel: Removal - Refitting
20A
Always replace the mounting bolts with new ones.
Coat the new flywheel bolts with LOCTITE FRENETANCH.
K9K
2
7
4
5
10
6
3
1
23325
23326
Tighten to torque and in order:
- the engine flywheel mounting bolts (K engines)
( 6.5 daNm ) ,
WARNING
Do not remove the flywheel drive plate mounting
bolts (10) .
- the engine flywheel mounting bolts (F4R engine) ( 7 daNm ) ,
- the engine flywheel mounting bolts (F9Q engine) ( 9 daNm ) ,
11
101356
Refit the spacer (11) observing the direction of fitting
of the chamfer on the flywheel end.
20A-20
CLUTCH
Flywheel: Removal - Refitting
20A
M9R, and 700
Remove:
Special tooling required
- the flywheel mounting bolts,
Mot. 1431
Flywheel locking tool.
- the flywheel,
- the (Mot. 1431) .
Tightening torquesm
flywheel mounting bolts
Note:
25 Nm + 45˚ ±
6
The engine flywheel is of the dual-mass type.
REFITTING
REMOVAL
I - REFITTING PREPARATION OPERATION
I - REMOVAL PREPARATION OPERATION
Clean the threads of the flywheel mounting bolts on
the crankshaft.
Remove:
Degrease the bearing face of the flywheel on the
crankshaft.
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
Check the condition of the flywheel.
Always replace the mounting bolts with new ones.
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the pressure plate and the driven plate (see 20A,
Clutch, Pressure plate - Driven plate: Removal Refitting ).
II - REFITTING OPERATION FOR PART
CONCERNED
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114913
Refit the engine flywheel.
Coat the new flywheel bolts with LOCTITE FRENETANCH .
Finger tighten the new mounting bolts.
Fit the (Mot. 1431) .
114913
Position the (Mot. 1431) (1) .
20A-21
Tighten to torque and in order the flywheel mounting bolts ( 25 Nm + 45˚ ± 6 ) .
CLUTCH
Flywheel: Removal - Refitting
M9R, and 700
III - FINAL OPERATION
Remove the (Mot. 1431) .
Refit:
- the driven plate and the pressure plate (see 20A,
Clutch, Pressure plate - Driven plate: Removal Refitting ).
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the « engine and gearbox » assembly (see 10A,
Engine and peripherals, Engine and gearbox
assembly: Removal - Refitting ).
20A-22
20A
CLUTCH
Flywheel: Removal - Refitting
20A
B84 or C84, and F4R, and 774
Degrease the bearing face of the flywheel on the
crankshaft.
Special tooling required
Mot. 1677
Flywheel locking tool.
Check the condition of the flywheel.
Tightening torquesm
flywheel mounting bolts
70 Nm
REMOVAL
Remove:
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the clutch pressure plate (see 20A, Clutch, Pressure plate - Driven plate: Removal - Refitting ).
101356
Refit the spacer (2) observing the direction of fitting
of the chamfer on the flywheel end.
Always replace the mounting bolts with new ones.
Coat the new flywheel bolts with LOCTITE FRENETANCH .
WARNING
When replacing an engine following overrevving,
always replace the flywheel.
22698
Position the (Mot. 1677) (1) .
Remove:
- the flywheel mounting bolts,
- the flywheel,
- the (Mot. 1677) (1) .
Note:
The engine flywheel is of the dual-mass type.
REFITTING
Clean the threads of the flywheel mounting bolts on
the crankshaft.
20A-23
CLUTCH
Flywheel: Removal - Refitting
B84 or C84, and F4R, and 774
23326
Tighten to torque and in order the flywheel mounting bolts ( 70 Nm ) .
20A-24
20A
MANUAL GEARBOX
Manual gearbox: Precautions for repair
21A
B84 or C84, and F4R, and 774
I - PARTS ALWAYS TO BE REPLACED
Replace the following parts after removal:
- lip seals,
- O-rings.
II - GEAR SELECTION GATE
101221
102448
WARNING
The breather valve (2) must not be removed in
order to fill up the oil.
2118
To select reverse gear, lift the collar (1) and shift the lever.
21A-1
MANUAL GEARBOX
Manual gearbox: Parts and consumables for the repair work
21A
B84 or C84, and F4R, and 774
Type
Packaging
Part no.
Component
LOCTITE 518
24 ml syringe
77 01 421 162
Threaded plugs and switches
LOCTITE 5970
300 g tube
77 11 219 705
ND0 housing assembly surfaces
21A-2
MANUAL GEARBOX
Manual gearbox: Parts and consumables for the repair work
21A
M9R, and 700, and PK4
Type
Packaging
Part no.
GEARBOX OIL
Component
Immerse all parts
SILICONE ADHESIVE SEAL
100g cartridge
77 11 227 484
Housing assembly
LOCTITE 518
24 ml syringe
77 01 421 162
Switch threading
Parts always to be replaced when they have been removed:
- lock rings,
- differential output seals,
- input shaft output seal,
- pins.
- hydraulic tappet.
21A-3
MANUAL GEARBOX
Consumables
21A
JH3 or JR5 or ND0
Type
Packaging
Part no.
Component
MOLYKOTE BR2
1 kg can
77 01 421 145
Splines
LOCTITE 518
24 ml syringe
77 01 421 162
JH and JR housing assembly surfaces
RHODORSEAL 5661
100 g tube
77 01 404 452
Threaded plugs and switches
LOCTITE 5970
300 g tube
77 11 219 705
ND0 housing assembly surfaces
21A-4
MANUAL GEARBOX
Manual gearbox: Specifications
21A
M9R, and 700, and PK4
PK4 gearbox ratios
Suffix
1st
2nd
3rd
4th
5th
6th
Final
drive
Reverse
gear
Tachometer
001
11 : 43
19 : 40
31 : 43
43 : 44
43 : 35
46 : 31
18 : 59
27 : 47
none
21A-5
MANUAL GEARBOX
Manual gearbox: Specifications
21A
B84 or C84, and F4R, and 774, and ND0
Suffix
1st
2nd
3rd
4th
5th
6th
Reverse
gear
Differential ratio
000
13 : 41
18 : 35
28 : 39
36 : 39
42 : 34
49 : 33
37 : 38
14 : 57
Capacity (l)
ND0
2.1
I - GRADE, VISCOSITY
See Technical Note Gearbox oil .
II - CHECKING THE LEVEL (IN THE EVENT OF A
LEAK)
92081
Fill up to the level of the opening.
106084
21A-6
(1)
Drain plug
(2)
Filler plug
MANUAL GEARBOX
Gears
JH3
21A
JR5
ND0
Suffix
105
142
102
001
014
Vehicle
B/C M0B
B/C M0C
B/C/S M0F
B/C M0G
B/C MOU
Differential ratio
14 : 59
15 : 61
15 : 56
15 : 58
16 : 70
First
11 : 41
11 : 41
11 : 41
13 : 41
13 : 41
Second
21 : 43
21 : 43
21 : 43
19 : 34
18 : 35
Third
28 : 39
28 : 39
28 : 37
31 : 37
28 : 39
Fourth
31 : 34
31 : 34
35 : 34
40 : 34
36 : 38
Fifth
37 : 33
37 : 33
41 : 31
47 : 31
52 : 45
Sixth
-
-
-
50 : 27
56 : 41
Reverse gear
11 : 39
11 : 39
11 : 39
37 : 38
37 : 38
21A-7
MANUAL GEARBOX
Identification
M9R, and 700, and PK4
105538
(1)
Identification label
(2)
Identification inscription
21A-8
21A
MANUAL GEARBOX
Lubricants
21A
JH3 or JR5 or ND0
Capacity (in litres)
JR5
2.5
JH3
2.8
ND0
2.1
(1)
Drain plug
(2)
Filler plug
ND0
I - GRADE, VISCOSITY
TRANSELF TRJ 75 W80W to be ordered from ELF
4
II - CHECKING THE LEVEL IN THE EVENT OF A
LEAK
3
101532
92081
Fill up to the level of the opening.
JH3 or JR5
2
1
18749
21A-9
(3)
Drain plug
(4)
Filler plug
MANUAL GEARBOX
Special notes
21A
I - PARTS TO BE REPLACED SYSTEMATICALLY
After they have been removed, replace the following
parts with new parts:
JH3 or JR5
- the lip seals;
- the O-rings.
II - GEAR SELECTION GATES
ND0
102896
To select reverse gear, return to neutral and select reverse like any other gear.
JH3 or JR5
102448
2
1
2118
To select reverse gear, lift the collar (1) and shift the lever.
2176
21A-10
MANUAL GEARBOX
Special notes
ND0
2
101221
WARNING
It is forbidden to remove the breather valve (2) to fill
the gearbox with oil.
21A-11
21A
MANUAL GEARBOX
Manual gearbox oil: Draining - Refilling
21A
M9R, and 700, and PK4
Special tooling required
Mot. 1018
Sump plug tool.
Tightening torquesm
drain plug
24 Nm
CAPACITY
Gearbox type
Capacity in litres
PK4
2.4
I - GRADE, VISCOSITY
TRANSELF TPR 78W80 to be ordered from ELF .
113764
II - OIL CHANGE
Refit the new seal on the plug, positioning the groove (2) towards the plug.
Tighten to torque the drain plug ( 24 Nm ) .
III - FILLING
114652
Unscrew the drain plug (1) using the (Mot. 1018) .
Let the oil run into a drain tray.
114772
Undo the filler cap (3) .
21A-12
MANUAL GEARBOX
Manual gearbox oil: Draining - Refilling
M9R, and 700, and PK4
92081
Fill the gearbox using a syringe containing recommended oil until the oil overflows out of the filler cap
hole.
Tighten the filler cap.
21A-13
21A
MANUAL GEARBOX
Input shaft lip seal: Replacement
REPLACEMENT
JH3 or JR5
Replace the lip seal after opening the gearbox.
See Technical Note 3661A : JH - JR gearboxes.
ND0
Replace the lip seal after opening the gearbox.
See Technical Note 3663A : ND0 gearbox
21A-14
21A
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING
Special tooling required
Bvi. 1236
Primary shaft oil seal
fitting tool.
I - REFITTING OPERATION FOR PART
CONCERNED
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove:
- the « engine - gearbox » assembly (see 10A Engine and peripherals, Engine - gearbox assembly: Removal - Refitting ).
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the clutch thrust bearing (see 20A, Clutch, Clutch
thrust bearing: Removal - Refitting ).
18061
Fit a new seal with its protector using the (Bvi. 1236)
.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Remove the protector.
Drill a hole in the seal, using a 2.5 mm diameter drill
bit.
II - FINAL OPERATION
Refit:
- the clutch thrust bearing (see Clutch, Clutch
thrust bearing: Removal - Refitting ).
WARNING
Do not scratch the shaft or mating face.
- the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting ).
- the « engine - gearbox » assembly (see 10A Engine and peripherals, Engine - gearbox assembly: Removal - Refitting ).
20714
Fit a bolt in seal (1) .
Extract the seal (1) using pliers.
21A-15
MANUAL GEARBOX
Differential output seal: Removal - Refitting
21A
JH3 or JR5
Special tooling required
Bvi. 1666
Tool for fitting differential seals.
Tightening torquesm
wheel bolts
11 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 bracket
nut
2.1 daNm
engine tie-bar bolts
10.5 daNm
sub-frame engine tiebar bolts
10.5 daNm
battery cover
102129
Remove the relay bearing bracket.
0.4 daNm
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
Drain the gearbox.
Remove:
- the wheel,
- the wheel arch liner,
101819
- the hub nut,
Remove the driveshaft.
- the track rod end,
REPLACING THE SEAL
- the anti-roll bar ball joint,
- the lower ball joint.
Tap the base of the lip seal using a drift and a small
hammer to pivot it in its housing.
Disconnect:
Remove the dislodged seal with pliers, taking care
not to damage the sunwheel splines.
- the wheel speed sensor connector,
- the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle).
21A-16
MANUAL GEARBOX
Differential output seal: Removal - Refitting
JH3 or JR5
REFITTING
21503
Oil the seal.
Refit the seal using the (Bvi. 1666) (suffix A: righthand side, suffix B: left-hand side).
Position the driveshaft in relation to the sunwheel.
To refit, proceed in the reverse order to removal.
Tighten to torque:
- the wheel bolts ( 11 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 sub-frame engine tie-bar bolts ( 10.5 daNm )
.
Top up the gearbox oil.
WARNING
Connect the battery; carry out the necessary programming (see (see 80A, Battery) ).
Tighten to torque the battery cover ( 0.4 daNm ) .
21A-17
21A
MANUAL GEARBOX
Differential output seal: Removal - Refitting
21A
ND0
Special tooling required
Bvi. 1689
Differential output seal
fitting tool.
Tightening torquesm
wheel bolts
11 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 bracket
nut
2.1 daNm
engine tie-bar bolts
18 daNm
sub-frame engine tiebar bolts
battery cover
102129
Remove the relay bearing bracket.
10.5 daNm
0.4 daNm
REMOVAL
Put the vehicle on a two-post lift.
Remove the battery cover.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
Drain the gearbox.
Remove:
- the right-hand wheel,
- the right-hand wheel arch liner,
101819
- the hub nut,
Remove the driveshaft.
- the track rod end,
REPLACING THE SEAL
- the anti-roll bar ball joint,
Tap the base of the lip seal using a drift and a small
hammer to pivot it in its housing.
- the lower ball joint.
Remove the dislodged seal with pliers, taking care
not to damage the sunwheel splines.
Disconnect:
- the wheel speed sensor connector,
- the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle).
21A-18
MANUAL GEARBOX
Differential output seal: Removal - Refitting
ND0
REFITTING
102260
Oil the seal before inserting it onto the splined part of
the sunwheel.
Refit the seal using the (Bvi. 1689) (suffix A: righthand side, suffix B: left-hand side).
Position the driveshaft in relation to the sunwheel.
To refit, proceed in the reverse order to removal.
Tighten to torque:
- the wheel bolts ( 11 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 sub-frame engine tie-bar bolts ( 10.5 daNm )
.
Top up the gearbox oil.
WARNING
Connect the battery; carry out the necessary programming (see (see 80A, Battery) ).
Tighten to torque the battery cover ( 0.4 daNm ) .
21A-19
21A
MANUAL GEARBOX
Differential output seal: Removal - Refitting
21A
M9R, and 700, and PK4
III - OPERATION FOR REMOVAL OF PART
CONCERNED (LEFT-HAND SIDE)
Special tooling required
Bvi. 1774
Right-hand transmission seal fitting tool.
Bvi. 1719
Left-hand side differential oil seal fitting
tool
Bvi. 1419
Bearing cage positioning tool.
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove:
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal Refitting ).
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft: Removal - Refitting ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED (RIGHT-HAND SIDE)
21490
Remove the protection ring (1) on the transmission.
21A-20
106885
Extract the seal using a screwdriver, taking care not
to damage the casing.
MANUAL GEARBOX
Differential output seal: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED (RIGHT-HAND SIDE)
21494
Slide on the protective ring (2) and clip it onto the driveshaft.
21493
Refit the right-hand seal using the (Bvi. 1774) (1) .
II - REFITTING OPERATION FOR PART
CONCERNED (LEFT-HAND SIDE)
Note:
Do not lubricate the seal.
Clean the driveshaft using degreaser.
106886
Refit the left-hand seal using the (Bvi. 1719) (2)
and the (Bvi. 1419) (3) .
21A-21
MANUAL GEARBOX
Differential output seal: Removal - Refitting
M9R, and 700, and PK4
III - FINAL OPERATION
Refit:
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft: Removal - Refitting ).
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal Refitting ).
Fill the gearbox with oil (see 21A, Manual gearbox:
Draining-refilling ).
21A-22
21A
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
Special tooling required
Tightening torquesm
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps.
steering wheel lock
component jack
sub-frame rear mounting bolts
140 Nm
sub-frame
mounting bolts
105 Nm
tie-rod
25 Nm
gearbox filler plug
3 Nm
battery cover
4 Nm
WARNING
Tightening torquesm
wheel mounting bolts
110 Nm
driveshaft nut
280 Nm
track rod end nut
62 Nm
gearbox drain plug
Equipment required
lower ball joint nut
sub-frame cross member mounting bolts
Observe the following instructions to avoid damaging the rotar y switch beneath the steering
wheel:
- Before the steering column and the steering
rack are uncoupled, the steering wheel must be
immobilised with the wheels straight for the
duration of the operation using a steering
wheel lock .
62 Nm
(37 Nm)
anti-roll bar ball joint nut
44 Nm
side panel mounting
bolts
2 Nm
gearbox edge and starter motor bolts
44 Nm
bolts securing the
engine tie-bar to the
engine
180 Nm
bolts securing the
engine tie-bar to the
sub-frame
105 Nm
gearbox suspended
mounting bolts
62 Nm
nut securing the suspended engine mounting to the rubber pad
180 Nm
steering shaft yoke
mounting bolt
21 Nm
radiator cross member
front mounting bolt
105 Nm
radiator cross member
rear mounting bolts
21 Nm
- Any doubt regarding the correct alignment of
the rotary switch necessitates removal of the
steering wheel to apply the centring procedure
(see 84A, Control - Signalling, Rotary switch
).
In this case, only qualified personnel who have
received training may carry out the operation.
REMOVAL
Position the vehicle on a two-post lift.
Remove the battery cover.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
Drain the gearbox.
Remove:
- the front wheels,
- the engine covers,
- the battery,
- the battery mounting,
- the injection computer with its support,
21A-23
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
- the flowmeter,
- the air inlet pipe.
101699
101821
Remove the electrical harness mountings.
Unclip the gear control cables from the gearbox.
B
A
C
A
101743
Unclip the two gear lever cables on the gearbox:
- clip the gearbox control at (a) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
21A-24
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
I - LEFT-HAND SIDE OF THE VEHICLE
F9Q
102129
102244
Remove:
Disconnect the intercooler - turbocharger air pipe.
- the hub nut using tool (Rou. 604-01) ,
Remove the air filter hoses.
- the track rod end using tool (Tav. 476) ,
- the anti-roll bar ball joint,
- the lower ball joint.
Disconnect:
Release the stub axle carrier from the driveshaft.
- the ABS sensor wiring,
Remove the driveshaft.
- the xenon headlight adjustment sensor wiring harnesses (if fitted).
Remove the wheel arch liners.
21A-25
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
II - RIGHT-HAND SIDE OF THE VEHICLE
101212
101819
Remove the side reinforcements.
Remove:
- the hub nut using tool (Rou. 604-01) ,
- the track rod end using tool (Tav. 476) ,
- the anti-roll bar ball joint,
- the lower ball joint.
- the relay bearing bracket.
Release the stub axle carrier from the driveshaft.
Remove the driveshaft.
Attach the cooling radiator assembly to the upper
cross member using rope.
102009
Remove the radiator cross member
Remove:
- the catalytic converter support from the clutch housing,
- the starter mounting bolts,
- the starter motor.
21A-26
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
101354
Remove the steering shaft yoke.
102452
Remove the upper engine tie-bar.
101208
Remove the sub-frame angle bracket.
102312
Remove the lower engine tie-bar.
21A-27
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
101209
Remove the sub-frame.
21A-28
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
102449
Set up the engine support tool (Mot. 1453) .
102485
Disconnect:
- the reversing connector,
- the TDC sensor.
Drain the brake fluid reservoir down to the clutch
master cylinder pipe union using a syringe.
1
102112
Remove:
- the gearbox support rubber pad,
- the gearbox suspended mounting,
- the gearbox edge upper bolts.
Position component jack underneath the gearbox.
101701
Disconnect the clutch slave cylinder by removing the
clip (1) .
Remove:
- the gearbox edge lower bolts,
- the gearbox mounting studs,
- the gearbox.
21A-29
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
F4R or F9Q
REFITTING
,
- the gearbox drain plug ( 25 Nm ) ,
- the gearbox filler plug ( 3 Nm ) .
WARNING
Top up the gearbox oil.
Do not coat:
- the gearbox output shaft with grease, to avoid
damaging the clutch slave cylinder,
WARNING
- the clutch shaft splines.
Be sure to bleed the hydraulic clutch control circuit in accordance with the following instructions:
- Add brake fluid to the reservoir.
Note:
- Bleed the circuit (see 37A, Mechanical component controls, Bleeding the clutch circuit
).
To avoid leaks, always replace the clutch hydraulic receiver after replacing a clutch mechanism.
Check that the engine / gearbox alignment dowels
are in place and correctly positioned.
Proceed in the reverse order to removal.
It is essential to replace the steering shaft yoke bolt
when refitting.
Tighten to torque:
- Top up the brake fluid level.
Connect the battery, starting with the positive terminal.
WARNING
carry out the necessary programming (see 80A,
Battery: Remove and Refit ).
- the wheel mounting bolts ( 110 Nm ) ,
Tighten to torque the battery cover ( 4 Nm ) .
- the driveshaft nut ( 280 Nm ) ,
- the lower ball joint nut ( 62 Nm ) ,
- the track rod end nut ( (37 Nm) ) ,
- the anti-roll bar ball joint nut ( 44 Nm ) ,
- the side panel mounting bolts ( 2 Nm ) ,
- the gearbox edge and starter motor bolts ( 44
Nm ) ,
- the bolts securing the engine tie-bar to the engine ( 180 Nm ) ,
- the bolts securing the engine tie-bar to the subframe ( 105 Nm ) ,
- the gearbox suspended mounting bolts ( 62 Nm
),
- the nut securing the suspended engine mounting to the rubber pad ( 180 Nm ) ,
- the steering shaft yoke mounting bolt ( 21 Nm ) ,
- the radiator cross member front mounting bolt (
105 Nm ) ,
- the radiator cross member rear mounting bolts
( 21 Nm ) ,
- the sub-frame cross member mounting bolts (
62 Nm ) ,
- the sub-frame rear mounting bolts ( 140 Nm ) ,
- the sub-frame tie-rod mounting bolts ( 105 Nm )
21A-30
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
REMOVAL
Special tooling required
Put the vehicle on a two-post lift.
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps.
Remove the battery cover.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
Drain the gearbox.
Remove:
Equipment required
- the front wheels,
- the engine covers,
component jack
- the battery,
- the battery mounting,
Tightening torquesm
wheel bolts
11 daNm
driveshaft nut
28 daNm
lower ball joint nut
6.2 daNm
track rod end nut
3.7 daNm
anti-roll bar ball joint nut
4.4 daNm
side panel mounting
bolts
2.1 daNm
gearbox bell housing
and starter bolts
4.4 daNm
engine tie-bar bolts on
the engine
10.5 daNm
engine tie-bar bolts on
the sub-frame
10.5 daNm
gearbox suspended
mounting bolts
6.2 daNm
suspended mounting
nut on the rubber pad
18 daNm
radiator cross-member
front mounting bolt
10.5 daNm
gearbox drain plug
(2.5 daNm)
- the injection computer with its support,
- the flowmeter,
- the air inlet pipe.
101821
gearbox filler plug
0.3 daNm
battery cover
0.4 daNm
Remove the electrical harness mountings.
21A-31
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
I - LEFT-HAND SIDE OF THE VEHICLE
101699
102129
Unclip the gear control cables from the gearbox.
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.
Release the stub axle carrier from the driveshaft.
Remove the left-hand driveshaft.
101743
Disconnect:
- the ABS sensor wiring,
- the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle).
Remove the wheel arch liners.
21A-32
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
II - RIGHT-HAND SIDE OF THE VEHICLE
101212
101819
Remove the side reinforcements.
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.
Release the stub axle carrier from the driveshaft.
Remove the right-hand driveshaft.
Attach the cooling radiator assembly to the upper
cross member using rope.
102009
Remove the radiator cross member
21A-33
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
14853
Remove:
102115
Remove the engine tie-bar.
- the catalytic converter support from the clutch housing,
- the starter motor mounting bolts,
Disconnect:
- the reversing connector,
- the starter motor.
- the TDC sensor.
Drain the brake fluid reservoir down to the clutch
master cylinder pipe union using a syringe.
1
101701
Disconnect the clutch slave cylinder by removing the
clip (1) .
21A-34
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
102449
Set up the engine support tool (Mot. 1453) .
Remove:
- the gearbox support rubber pad,
- the upper gearbox bell housing bolts.
Position the component jack underneath the gearbox.
Remove:
- the gearbox edge lower bolts,
- the gearbox mounting studs,
- the gearbox.
21A-35
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5
REFITTING
WARNING
WARNING
Be sure to bleed the hydraulic clutch circuit
accordance with the following instructions:
Do not coat:
- Add brake fluid to the reservoir.
- the gearbox output shaft with grease to avoid
damaging the clutch slave cylinder,
- Bleed the hydraulic circuit ( (see 37A, Mechanical component controls) ).
- the clutch shaft splines.
- Top up the brake fluid level.
Note:
WARNING
To prevent any risk of leaks, the clutch slave
cylinder must always be replaced after a clutch
mechanism is replaced.
Connect the battery; carry out the necessary programming (see (see 80A, Battery) ).
Tighten to torque the battery cover ( 0.4 daNm ) .
Check that the engine - gearbox centering rings are
in place and correctly positioned.
To refit, proceed in the reverse order to removal.
Tighten to torque:
- the wheel bolts ( 11 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 gearbox bell housing and starter bolts ( 4.4
daNm ) ,
- the engine tie-bar bolts on the engine ( 10.5
daNm ) ,
- the engine tie-bar bolts on the sub-frame ( 10.5
daNm ) ,
- the gearbox suspended mounting bolts ( 6.2
daNm ) ,
- the suspended mounting nut on the rubber pad
( 18 daNm ) ,
- the radiator cross-member front mounting bolt (
10.5 daNm ) ,
- the gearbox drain plug ( (2.5 daNm) ) ,
- the gearbox filler plug ( 0.3 daNm ) .
Top up the gearbox oil.
21A-36
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
M9R, and 700, and PK4
Tightening torquesm
gearbox mounting bolts
44 Nm
starter mounting bolts
44 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the « engine - gearbox » assembly (see
10A, Engine and peripherals, Engine - gearbox
assembly: Removal - Refitting ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
115005
Unpick the TDC sensor and oil level sensor wiring
harness (2) from the gearbox.
Unclip the breather pipe from the gearbox.
115004
Disconnect the reverse gear switch connector (1) .
Unpick the reverse gear switch wiring harness from
the gearbox.
21A-37
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
M9R, and 700, and PK4
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
Refit:
- the gearbox,
- the gearbox mounting bolts,
- the starter mounting bolts.
Tighten to torque:
- the gearbox mounting bolts ( 44 Nm ) ,
- the starter mounting bolts ( 44 Nm ) .
II - FINAL OPERATION
Connect the reverse gear switch connector.
Clip:
115211
- the reverse gear switch wiring harness to the gearbox,
- the TDC sensor and oil level sensor wiring harness
to the gearbox.
Clip the breather pipe onto the gearbox.
Refit the « engine - gearbox » assembly (see 10A,
Engine and peripherals, Engine - gearbox assembly: Removal - Refitting ).
115210
Remove:
- the starter mounting bolts (3) ,
- the gearbox mounting bolts (4) ,
- the gearbox.
21A-38
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
Special tooling required
Mot. 1453
Tightening torquesm
Multiple-adjusting
engine mounting support with retaining
straps.
sub-frame
mounting bolts
Equipment required
steering wheel lock
tie-rod
105 Nm
gearbox drain plug
35 Nm
bolts securing the strut
onto the sub-frame stiffener
62 Nm
component jack
WARNING
Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel:
Tightening torquesm
wheel bolts
130 Nm
side panel mounting
bolts
21 Nm
gearbox bell housing
bolts
44 Nm
starter motor mounting
bolts
38 Nm
bolts securing the lower
engine tie-bar onto the
engine
180 Nm
bolts securing the
upper engine tie-bar
onto the engine
105 Nm
bolts securing the
engine tie-bar onto the
sub-frame
105 Nm
bolts securing the suspended mounting onto
the gearbox
62 Nm
nut securing the suspended mounting on the
rubber pad
62 Nm
steering shaft yoke
mounting bolt
21 Nm
radiator cross member
front mounting bolts
105 Nm
radiator cross member
rear mounting bolts
21 Nm
sub-frame
mounting bolts
62 Nm
- Before the steering column and the steering rack
are uncoupled, the steering wheel must be immobilised with the wheels set straight-ahead for the
duration of the operation using the steering wheel
lock .
- if there is any doubt regarding the correct centring
of the rotary switch, the steering wheel must be
removed to apply the centring procedure (see
84A, Control - Signalling ).
In this case, only qualified personnel who have
received training may carry out the operation.
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Vehicle: Towing and lifting ).
Remove the battery cover.
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove the engine undertray.
Drain the gearbox.
Remove:
- the front wheels,
- the engine covers,
- the battery,
- the battery tray,
- the injection computer with its support,
bracket
- the air box,
- the wiring harness mountings.
21A-39
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
106091
Unclip the gear control cables from the gearbox.
106082
Disconnect:
- the ABS sensor wiring harness at (1) ,
- the xenon bulb adjustment sensor wiring harness.
Remove the wheel arch liners.
106085
101743
Remove:
- the sub-frame stiffener strut (2) ,
Note:
- the driveshafts (see 29A, Driveshafts ).
Do not touch the slide.
Attach the cooling radiator assembly to the upper
cross member using rope.
21A-40
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
106077
102452
Remove the upper engine tie-bar.
Remove:
- the side reinforcements (3) ,
- the radiator cross member (4) .
102313
Remove the lower engine tie-bar (6) .
106212
Remove:
- the catalytic converter retaining bracket (5) from
the clutch sump,
- the starter mounting bolts.
Remove the starter.
21A-41
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
101354
Remove the steering column universal joint.
Position the component jack under the sub-frame.
Strap the sub-frame to the component jack .
101208
Remove the sub-frame angle bracket (7) .
106086
Remove the sub-frame mounting bolts (8) .
Remove the sub-frame.
21A-42
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
102449
Set up the engine support tool (Mot. 1453) .
102485
Disconnect:
- the reversing connector,
- the TDC sensor.
Drain the brake fluid reservoir down to the clutch
master cylinder pipe union using a syringe.
102419
Remove:
- the gearbox support rubber pad,
- the gearbox suspended mounting,
- the gearbox edge upper bolts.
102513
Disconnect the clutch slave cylinder by removing the
clip (9) .
Position the component jack underneath the gearbox.
Remove:
- the gearbox edge lower bolts,
- the gearbox mounting studs,
- the gearbox.
21A-43
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
21A
B84 or C84, and F4R, and 774
REFITTING
- the bolts securing the engine tie-bar onto the
sub-frame ( 105 Nm ) ,
- the bolts securing the suspended mounting
onto the gearbox ( 62 Nm ) ,
WARNING
Do not coat:
- the nut securing the suspended mounting on
the rubber pad ( 62 Nm ) ,
- the gearbox output shaft with grease, to avoid
damaging the clutch slave cylinder.
- the steering shaft yoke mounting bolt ( 21 Nm ) ,
- the radiator cross member front mounting bolts
( 105 Nm ) ,
Note:
- the radiator cross member rear mounting bolts
( 21 Nm ) ,
To prevent any risk of leaks, the clutch slave
cylinder must always be replaced after a clutch
mechanism is replaced.
- the sub-frame bracket mounting bolts ( 62 Nm )
,
- the sub-frame tie-rod mounting bolts ( 105 Nm )
,
- the gearbox drain plug ( 35 Nm ) ,
- the bolts securing the strut onto the sub-frame
stiffener ( 62 Nm ) .
Top up the gearbox oil.
WARNING
It is essential that the hydraulic clutch circuit is
bled in accordance with the following instructions:
- add brake fluid to the reservoir,
- bleed the circuit (see 37A, Mechanical components controls ).
- top up the brake fluid level.
106087
Check that the engine - gearbox locating rings (10)
are present and correctly positioned.
Proceed in the reverse order to removal.
Refit the sub-frame (see 31A, Front axle component, Sub-frame: Removal - Refitting ).
Tighten to torque:
- the wheel bolts ( 130 Nm ) ,
- the side panel mounting bolts ( 21 Nm ) ,
- the gearbox bell housing bolts ( 44 Nm ) ,
- the starter motor mounting bolts ( 38 Nm ) ,
- the bolts securing the lower engine tie-bar onto
the engine ( 180 Nm ) ,
- the bolts securing the upper engine tie-bar onto
the engine ( 105 Nm ) ,
21A-44
Connect the battery (see MR 364, 80A, Battery,
Battery: Removal - Refitting ).
AUTOMATIC GEARBOX
Identification
23A
DP0
Identification engraving on the automatic transmission.
- never push the vehicle (i.e. to get to a petrol station,
unless the precautions in the « Towing » section have
been taken).
The vehicle only has drive when the engine is running.
It is therefore impossible to start the engine of a vehicle
with an automatic transmission by pushing the vehicle.
II - TOWING
The vehicle should preferably be towed in all cases on
a tow truck or with the front wheels raised.
Nonetheless, if this is impossible, in exceptional circumstances, the vehicle may be towed at low speed
(maximum 12 mph (20 km/h)) over a maximum distance of 18 miles (30 km) (lever in N position).
WARNING
Towing weight (trailer, caravan, boat, etc.): see the
vehicle Owner's Manual.
13786
I - SPECIFICATIONS
Weight: 154 lbs (70 kg) .
Vehicles fitted with DP0 automatic transmissions use
systems called « Shift lock » and « Lock up » .
The purpose of the « Shift lock » function is to prevent
the gear selector lever from being moved without the
brake pedal being simultaneously depressed.
Note:
For repair operations when the battery is faulty,
refer to the notice on board the vehicle.
The purpose of the « Lock up » or converter lockup is
to connect the automatic transmission directly to the
engine. This function is performed by a « mini clutch »
located on the converter.
The « Lock up » is controlled by the automatic transmission computer.
As the automatic transmission is lubricated under pressure, lubrication is only provided when the engine is
running.
Consequently, and to avoid serious damage, it is essential to comply with the following instructions:
- never allow the vehicle to coast with the ignition switched off (i.e. when going down a hill); the damage that
this may cause cannot be stressed highly enough,
23A-1
AUTOMATIC GEARBOX
Gears
23A
DP0
Vehicle
Engine
Gearbox
Gearbox suffix
Reduction
Final drive
046
52 / 67
20 / 73
047
52 / 67
21 / 73
050
52 / 67
21 / 73
049
52 / 67
20 / 70
Automatic
BMOC/
CMOC
BMOU/
CMOU
K4M 761
F4R 771
DP0
DP0
052
054
DP0
Suffix
046
047
049
050
052
054
Vehicle
BMOC/
CMOC
BMOC/
CMOC
BMOU/
CMOU
BMOC/
CMOC
BMOU/
CMOU
BMOU/
CMOU
First
2.724
2.724
2.724
2.724
2.724
2.724
Second
1.499
1.499
1.499
1.499
1.499
1.499
Third
1.000
1.000
1.000
1.000
1.000
1.000
Fourth
0.710
0.710
0.710
0.710
0.710
0.710
Reduction
52 / 67
52 / 67
52 / 67
52 / 67
52 / 67
52 / 67
Final drive
20 / 73
21 / 73
21 / 73
21 / 73
21 / 73
21 / 73
Reverse gear
3.177
3.177
3.177
3.177
3.177
3.177
23A-2
AUTOMATIC GEARBOX
Lubricants
DP0
The DP0 automatic gearbox is greased for life and
does not require any maintenance: It is only necessary
to top up the level in the event of a slight leak.
I - OIL SPECIFIED:
ELF RENAULT MATIC D3 SYN (can be ordered from
ELF ) DEXRON III standard
II - CAPACITY IN LITRES
Total volume: 6 litres .
23A-3
23A
AUTOMATIC GEARBOX
Consumables
DP0
Description
Component concerned
Grease
Centring tool
M O L Y KOTE
BR2
LOCTITE FRENBLOC
Brake calliper mounting bolt
23A-4
23A
AUTOMATIC GEARBOX
Changing the oil
23A
DP0
Former assembly
Tightening torquesm
level-setting plug (old
assembly)
25 Nm
overflow
assembly)
(old
35 Nm
level-setting plug (new
assembly)
35 Nm
overflow pipe (new
assembly)
9 Nm
pipe
2
1
2316
WARNING
The cap has two functions:
For both assemblies, when changing engine oil or
topping up, the control lever must be in the Parking
position.
- level-setting plug (1) ,
- overflow pipe (2) .
The engine oil change and topping-up caps have evolved.
The level check and bleeding procedure is the same
for both assemblies.
Bleed the automatic gearbox when the oil is warm (
60˚C maximum ) in order to remove as many impurities as possible.
Position the vehicle on a lift.
Remove the engine undertray.
23A-5
Remove the assembly (1) and (2) to carry out the
complete gearbox oil change.
Remove only the cap (1) for topping-up.
AUTOMATIC GEARBOX
Changing the oil
DP0
New assembly
4
5
3
107912
Remove:
- the level-setting cap (3) ,
- overflow pipe (4) using an Allen key (5) with diameter of 8 mm.
Let the oil flow.
Note:
Always replace the overflow pipe each time it is
removed.
Refit the new overflow pipe.
Tighten to torque:
- the level-setting plug (old assembly) ( 25 Nm )
- the overflow pipe (old assembly) ( 35 Nm )
- the level-setting plug (new assembly) ( 35 Nm )
- the overflow pipe (new assembly) ( 9 Nm )
Fill up the gearbox and check the level (see 23A,
Automatic gearbox, Filling - Levels ).
23A-6
23A
AUTOMATIC GEARBOX
Filling - Levels
23A
DP0
Equipment required
diagnostic tool
Tightening torquesm
level-setting plug
35 Nm
2
WARNING
It is essential to shift the selector lever to the Park
position.
I - FILLING
101822
Disconnect the computer connectors.
Remove:
- the battery tray mounting bolts (2) ,
- the battery tray,
- the computer mounting.
Remove the turbocharging pressure regulation solenoid valve (if fitted in the vehicle).
1
103407
3
Fill through the hole (1) .
Use a funnel with a 15/100 filter to prevent impurities
from entering the system.
II - FILLING PROCEDURE
Park the vehicle on level ground.
Disconnect the battery, starting with the negative
terminal.
110245
Remove gearbox control (3) .
23A-7
AUTOMATIC GEARBOX
Filling - Levels
23A
DP0
former assembly
B
A
C
4
2316
A
Open the cap again (4) .
New assembly
101743
Unclip the gearbox lever cable:
- clip the gearbox control at (a) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
Fill the automatic transmission with 3.5 litres of new
oil.
Connect the battery, starting with the positive terminal.
WARNING
5
carry out the necessary programming (see 80A,
Battery: Remove and Refit ).
Run the engine at idle speed.
Connect the diagnostic tool ( CLIP ).
107912
Establish dialogue with the automatic transmission
computer.
Monitor the gearbox oil temperature parameter.
Once a temperature of 60˚C +/- 1 is reached, open
the level-setting plug.
23A-8
Open the cap again (5) .
AUTOMATIC GEARBOX
Filling - Levels
23A
DP0
III - LEVEL CHECKING PROCEDURE OUTSIDE
FILLING OPERATIONS
Note:
The level must be checked following the procedure described below:
Park the vehicle on level ground.
Fill the automatic transmission with 0.5 litre of new
oil.
Run the engine at idle speed.
Connect diagnostic tool ( CLIP ).
Establish dialogue with the automatic transmission
computer.
Monitor the gearbox oil temperature parameter.
13792
Use a container if the oil does not flow out or the volume collected is less than 0.1 litre .
Once a temperature of 60˚C +/- 1 is reached, open
the level-setting plug.
- Switch off the engine,
If the oil does not flow out or the quantity collected is
below 0.1 litre :
- add 0.5 litre of oil,
- let the automatic transmission cool to 50˚C ,
- switch off the engine,
- run the engine at idle speed,
- add 0.5 litre of oil,
- connect diagnostic tool ( CLIP ).
- let the automatic transmission cool to 50˚C ,
- establish dialogue with the automatic transmission
computer,
- run the engine at idle speed,
- monitor the automatic gearbox oil temperature parameter,
- once a temperature of 60˚C ± 1 is obtained, open
the level-setting plug,
- connect the diagnostic tool ( CLIP ).
- establish dialogue with the automatic transmission
computer,
- monitor the automatic gearbox oil temperature parameter,
- position a container.
Repeat these operations until more than 0.1 litre of
oil is obtained in the container.
- Once a temperature of 60˚C +/- 1 is reached, open
the level-setting plug,
Refit the cap again.
- position a container.
Tighten to torque the level-setting plug ( 35 Nm ) .
Repeat these operations until more than 0.1 litre of
oil is obtained in the container.
Note:
When the oil is replaced, the electronic oil ageing
counter must be reset (inside the computer).
Enter the oil change date using the CF074 Enter
gearbox oil change date command on the diagnostic tool ( CLIP ).
23A-9
AUTOMATIC GEARBOX
Parts to be replaced systematically
DP0
The following parts must be replaced after being removed:
- self-locking nuts,
- the seals,
- rubber seals,
- converter bolts.
23A-10
23A
AUTOMATIC GEARBOX
Checking the converter setting point
23A
DP0
A setting point outside the tolerance requires the
converter to be replaced.
Equipment required
diagnostic tool
Note:
A setting point which is too low may be linked to
a lack of engine power.
Put the vehicle on a two-post lift.
Lift the vehicle until the wheels are raised off the
ground by a few centimetres.
Connect the diagnostic tool ( « CLIP » ).
Establish dialogue with the automatic transmission
computer,
Monitor the automatic gearbox oil temperature parameter.
The check should be done at an oil temperature of
between 60˚C and 80˚C .
Start the engine and put the lever in D.
Monitor the engine speed parameter:
Establish dialogue with the computer.
Accelerate fully keeping the brakes applied.
The front wheels should not rotate.
WARNING
- The full load position must not be held for more
than 5 seconds . Beyond this, there is a high
risk of destroying the converter or the automatic
gearbox.
- Once the measurement has been taken,
release the accelerator and keep the brakes on
until the engine speed stabilises to idle speed
(there is a risk of damaging the automatic gearbox if this is not complied with).
K4M
The engine speed should stabilise at 2700 rpm +/150 .
F4R
The engine speed should stabilise at 2500 rpm .
23A-11
AUTOMATIC GEARBOX
Line pressure measurement
DP0
Special tooling required
Bvi. 1215-01
Automatic transmission oil pressure
gauge kit. (in a kit), 25
bar pressure gauge.
Some fault finding procedures on the automatic gearbox involve taking the line pressure using a pressure
gauge.
The pressure measurement tapping is located close to
the pressure sensor.
1
103420
Remove the bolt (1) to take the line pressure.
Remove the pressure tapping union (466-06) from
the kit (Bvi. 1215-01) and place it in position (
Workshop Repair Manual 366 « Fault finding » ).
23A-12
23A
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting
23A
DP0
Special tooling required
Bvi. 1462
Ball plate adjusting
screw.
Equipment required
diagnostic tool
Tightening torquesm
1
distributor mounting
bolts
0.75 daNm
ball detent plate bracket
mounting bolt (12)
0.9 daNm
ball detent plate mounting bolt
0.8 daNm
cover mounting bolts
1 daNm
rechargeable battery
4 daNm
13792
Drain the automatic gearbox using the plug (1) .
Remove:
reinforcement plate
mounting bolts
2.1 daNm
battery cover
0.4 daNm
- the wheels,
- the air intake duct.
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Remove the battery cover
Disconnect the battery starting with the negative terminal.
Remove the engine undertray.
23A-13
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting
23A
DP0
4
6
2
5
3
101821
103412
Remove the electrical harness (5) on the side reinforcement.
Release the electrical harness:
- from the battery (2) ,
Remove:
- from the battery tray (3) ,
- the bolts (6) on the side reinforcement plate,
- from the injection computer (4) .
- the side reinforcement.
Remove:
- the battery,
- the computer,
- the battery mounting.
7
14783
Remove the four retaining bolts (7) on the hydraulic
distributor cover (be careful as oil may run out).
23A-14
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting
23A
DP0
REFITTING
13788
Remove the seven mounting bolts on the hydraulic
distributor.
13789
Disconnect the solenoid valve connectors.
Fit the distributor and centre it using bolts (4) and
(5).
Remove the hydraulic distributor.
Refit the other bolts.
Tighten to torque and in the correct order the distributor mounting bolts ( 0.75 daNm ) .
ADJUSTING THE BALL DETENT PLATE
14782
Hold the multifunction lever switch in the end position (1st selected) using a plastic clip and a bolt in
the mechanism housing.
23A-15
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting
23A
DP0
10
9
8
12
13788-1
14785
Position the ball detent plate bracket mounting bolt
(12) but do not tighten it.
Position the tool (Bvi. 1462) in place and fit the bolt
(8) .
Screw the tool in fully whilst holding the ball detent
plate.
Tighten to torque the ball detent plate bracket
mounting bolt (12) ( 0.9 daNm ) .
Remove the tool (Bvi. 1462) .
10
Remove the ball detent plate mounting bolt (8) .
11
2318
Remove the bolt (8) .
Position the ball detent plate by placing the roller (9)
in the hollow (11) of the sector (10) corresponding to
the 1st gear selected position.
23A-16
Tighten to torque the ball detent plate mounting
bolt ( 0.8 daNm ) .
When replacing the oil distributor, the auto-adaptives must be reset using command RZ005: « Erase
auto-adaptives » and the oil age counter of the
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting
DP0
automatic gearbox computer must be reset using
the diagnostic tool , use command CF074: « Enter
date of gearbox oil change » .
After using command RZ005 , it is important to carry
out a test drive performing all gear changes, both up
and down, several times in order to store the new
values.
Tighten to torque:
- the cover mounting bolts ( 1 daNm ) ,
- the rechargeable battery ( 4 daNm ) ,
- the reinforcement plate mounting bolts ( 2.1
daNm ) .
To refit, proceed in the reverse order to removal.
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Torque tighten the battery cover ( 0.4 daNm ) .
23A-17
23A
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
Special tooling required
Tightening torquesm
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps.
Bvi. 1531
nut securing the suspended mounting on the
rubber pad
18 daNm
battery cover
0.4 daNm
Special notes for vehicles fitted with a driver's airbag
WARNING
Tool for centring the
torque converter for
the automatic transmission converter.
Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel:
- Before the steering column and the steering rack
are uncoupled, the steering wheel must be immobilised with the wheels straight for the duration of
the operation using a steering wheel locking tool.
Equipment required
component jack
- If there is any doubt about the correct alignment of
the rotary switch, it is necessary to remove the
steering wheel to apply the centring procedure (
(see 84A, Controls - signals) ). In this case, only
qualified personnel who have received training
may carry out the operation.
Tightening torquesm
wheel bolts
11 daNm
brake calliper guide pin
bolts
0.7 daNm
track rod end nut
3.7 daNm
lower ball joint nut
6.2 daNm
engine tie-bar bolts on
the sub-frame
10.5 daNm
gearbox bell housing
and starter bolts
4.4 daNm
nut securing the suspended mounting on the
gearbox
6.2 daNm
track rod end nut
6.2 daNm
converter - starter plate
mounting nut
3.7 daNm
modular connector support bolts
2 daNm
engine speed sensor
mounting bolts
1 daNm
engine tie-bar bolts on
K engines
10.5 daNm
engine tie-bar bolts on
F engines
18 daNm
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
23A-18
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
2
3
4
1
101821
Disconnect the battery, starting with the negative
terminal.
Remove:
- the air inlet sleeve,
103409
Remove:
- the multifunction switch cable ball joint (1) using the
tool,
- the wiring harness (2) for the multifunction switch
cable by removing the sleeve stop,
- the battery,
- the wiring harness mountings.
- the battery tray,
Disconnect:
- the injection computer and its support,
- the engine speed sensor,
- the air inlet pipe,
- the connector (3) by removing the connector slide.
- the electic wiring harness mountings.
Remove the mounting bolts (4) from the modular
connector support plate.
WARNING
Protect the connector by sliding it into a waterproof plastic bag.
23A-19
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
K4M
5
103753
Remove the engine speed sensor.
103423
Remove:
- the two bolts (5) from the starter,
F4R
- the engine undertray.
Drain the gearbox.
Remove:
- the wheels,
- the wheel arch liners.
Disconnect:
- the ABS system sensor wiring,
- the discharge bulb beam adjustment sensor wiring
(if fitted to the vehicle).
Note:
The discharge bulb beam adjustment sensor is
fitted onto the left-hand lower wishbone.
103420
Remove the engine speed sensor.
Fit the hose clamps.
Disconnect the heat exchanger.
Unclip the wiring harness from the gearbox.
23A-20
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
I - LEFT-HAND SIDE OF THE VEHICLE
7
6
103412
102129
Remove:
- the xenon bulb sensor linkage (if fitted to the vehicle),
Remove:
- the clip (7) from the gearbox computer wiring harness,
- the side reinforcement (6)
- 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.
8
Release the stub axle carrier from the driveshaft.
Remove the left-hand driveshaft.
9
103413
Open the retaining bracket (8) on the gearbox computer wiring harness.
Disconnect the gearbox computer connector (9) .
23A-21
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
II - RIGHT-HAND SIDE OF THE VEHICLE
103418
102129
Remove:
Remove the relay bearing bracket.
Release the stub axle carrier from the driveshaft.
- the hub nut using the (Rou. 604-01) ,
Remove the right-hand driveshaft.
- the track rod end using the (Tav. 476) ,
Attach the cooling radiator assembly to the upper
cross member using rope.
- the anti-roll bar ball joint using the (Tav. 476) ,
- the lower ball joint.
101212
Remove the side stiffener.
23A-22
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
F4R
102009
Remove the radiator lower cross member.
K4M
11
10
103421
Remove:
- the exhaust mounting nuts (10) ,
- the engine tie-bar.
10
103749
Remove:
- the exhaust mounting nuts.
- the engine tie-bar.
23A-23
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
12
11
103418
Remove:
103423
- the lower engine/manifold strut,
Remove the upper studs (12) around the edge of the
gearbox.
- the starter mounting bolt (11) ,
Strap the bonnet down.
- the starter,
- the three converter nuts.
Note:
The nuts on the converter can be accessed by
removing the starter motor. Rotate the crankshaft
clockwise to access the three starter plate - converter connecting nuts and remove them.
13
14
102449
Open the cover (13) .
Remove the cover (14) .
Fit the (Mot. 1453) .
Remove the gearbox support rubber pad.
Fit the component jack tool beneath the gearbox.
Remove:
- the gearbox edge lower bolts,
- the gearbox mounting studs,
- the automatic transmission,
23A-24
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
13790
16361
Secure the converter with string to prevent it being
dislodged.
Refit the flywheel nuts on the converter using the
(Bvi. 1531) .
REFITTING
WARNING
- Do not reuse the converter mounting nuts or the
inertia flywheel nuts if they have been removed:
always use new nuts.
- Check that the centring rings are in place.
23A-25
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
F4R or K4M, and DP0
puter oil ageing counter must be reset using command CF074: « Enter date of gearbox oil
change » .
To refit, proceed in the reverse order to removal.
WARNING
Check that the centring dowels are in place.
When refitting the automatic transmission on the engine, make sure that the converter is properly engaged on the input shaft pin.
Tighten to torque:
- the wheel bolts ( 11 daNm ) ,
After using command RZ005 , it is important to carry
out a test drive performing all gear changes, both up
and down, several times in order to store the new
values.
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Tighten to torque the battery cover ( 0.4 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 sub-frame ( 10.5
daNm ) ,
- the gearbox bell housing and starter bolts ( 4.4
daNm ) ,
- the nut securing the suspended mounting on
the gearbox ( 6.2 daNm ) ,
- the track rod end nut ( 6.2 daNm ) ,
- the converter - starter plate mounting nut ( 3.7
daNm ) ,
- the modular connector support bolts ( 2 daNm )
,
- the engine speed sensor mounting bolts ( 1
daNm ) ,
- the engine tie-bar bolts on K engines ( 10.5
daNm ) ,
- the engine tie-bar bolts on F engines ( 18 daNm
),
- the nut securing the suspended mounting on
the rubber pad ( 18 daNm ) .
Fill up the automatic transmission and check the level (see 23A, Automatic gearbox, Filling - Levels,
page 23A-7) .
When changing the oil, the auto-adaptives must be
reset using command RZ005: «Clear autoadaptives » and the automatic transmission com-
23A-26
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
K9K, and DP0
Special tooling required
Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps.
Mot. 1453-01
Additional winder nut
on engine lift support
Mot. 1453.
Equipment required
safety belt
component jack
Tightening torquesm
gearbox edge upper
mounting bolts
44 Nm
converter mounting
nuts
25 Nm
nuts securing the
exhaust pipe onto the
catalytic converter
21 Nm
half sub-frame front
mounting bolts
165 Nm
half sub-frame rear
mounting bolts
21 Nm
front wheel bolts
101822
Disconnect the computer connectors (1) .
Unpick the wiring harness.
Move the turbocharging pressure regulator solenoid
valve to one side.
Remove:
- the battery tray mounting bolts (2) ,
- the battery tray,
- the computer and its mounting.
Disconnect:
- the air flowmeter connector,
110 Nm
- the air duct between the air filter unit and the turbocharger on the air unit.
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove:
- the air inlet sleeve,
- the battery (see 80A, Battery, Battery: Removal Refitting ).
23A-27
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
K9K, and DP0
112657
104553
Move the air filter unit upstream air duct retaining
tabs (3) slightly to one side.
Remove:
- the air filter unit upstream air duct,
- the air filter unit.
23A-28
23A
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
K9K, and DP0
(7) .
Disconnect the hoses (7)
Move the hoses to one side.
Remove:
- the starter (see 16A, Starting-charging, Starter:
Removal - Refitting ).
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting ).
Fit the cooling assembly to the upper cross member
using the safety belt .
Note:
103409
When fitting the safety strap, take care:
- not to crush the cooling hoses,
- not to strap up the half sub-frame.
101743
Disconnect:
- the modular connector (4) by releasing the connector slide,
- the flywheel sensor connector.
Remove:
- the multifunction switch control (5) ,
- the modular connector support plate mounting
bolts (6) .
Remove the modular connector support plate.
Fit a set of 2 hose clamps onto the exchanger hoses
23A-29
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
K9K, and DP0
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Remove:
- the torque converter mounting nuts on the flywheel
through the starter opening,
- the gearbox upper mounting bolts.
101212
110249
103412
Unclip the wiring harness.
Remove:
- the reinforcement mounting bolts,
- the side reinforcements,
- the half sub-frame,
110247
- the left-hand driveshaft (see 29A, Driveshafts,
Front left-hand driveshaft: Removal - Refitting
).
- the right-hand driveshaft (see 29A, Driveshafts,
Front right-hand driveshaft: Removal - Refitting
).
23A-30
Remove the mounting bolt (8) from the earth on the
gearbox.
Move the earth harness (9) to one side.
Remove
- the gearbox mounting nut (10) ,
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
K9K, and DP0
- the gearbox mounting stud (11) ,
- the scuttle panel grille (see MR 365, Bodywork,
Exterior protection, Scuttle panel grille: Removal - Refitting ).
102449
Fit the (Mot. 1453) fitted with the (Mot. 1453-01) .
110230
Secure the converter to prevent it being dislodged.
Remove
- the nuts mounting the exhaust pipe on the catalytic
converter,
- the mounting bolts and nuts from the catalytic converter reinforcing bracket
- the catalytic converter reinforcing bracket,
- the rear suspended mounting (see 19D, Engine
suspension, Rear suspended mounting: Removal - Refitting ).
Fit the component jack tool beneath the gearbox.
110253
Remove
- the gearbox mounting nut (12) then the mounting
stud (13) ,
- the gearbox lower mounting bolts (14) ,
- the gearbox.
23A-31
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
23A
K9K, and DP0
REFITTING
- the gearbox upper mounting bolts,
Remove the (Mot. 1453) fitted with the (Mot. 145301) .
I - PREPARATION BEFORE REFITTING
OPERATION
Refit the gearbox upper mounting bolts
Tighten to torque the gearbox edge upper mounting bolts ( 44 Nm )
Refit the converter mounting nuts through the starter
opening.
Tighten to torque the converter mounting nuts ( 25
Nm ) .
III - FINAL OPERATION
Refit:
- the starter (see 16A, Starting-charging, Starter:
Removal - Refitting ).
- the modular connector support plate,
- the modular connector plate mounting bolts,
- the modular connector,
- the exchanger hoses,
110230
- the multifunction switch control,
- the scuttle panel grille (see MR 365, Bodywork,
Exterior protection, Scuttle panel grille: Removal - Refitting ).
Note:
Do not reuse the converter mounting nuts or the
inertia flywheel nuts if they have been removed:
always use new nuts.
- the air filter unit,
- the air filter unit upstream air duct,
- the engine management computer and its support,
WARNING
- the battery tray,
Check that the centring dowels (15) are in place.
- the battery tray mounting bolts.
Connect:
II - REFITTING OPERATION FOR PART
CONCERNED
- the engine management computer connectors,
- the air flowmeter connector,
Refit the gearbox
- the flywheel sensor connector.
Refit:
Fit the wiring harness into its housing
- the gearbox lower mounting bolts,
Refit:
- the gearbox rear mounting stud,
- the battery (see 80A, Battery, Battery: Removal Refitting ).
- the gearbox rear mounting nut,
- the rear suspended engine mounting (see 19D,
Engine mounting, Rear suspended engine
mounting: Removal - Refitting ).
- the gearbox front mounting stud,
- the air inlet sleeve,
- the earth strap on the gearbox,
- the gearbox earth strap mounting bolt,
- the catalytic converter reinforcing bracket,
- the gearbox front mounting nut,
- the mounting bolts and nuts to the catalytic converter reinforcing bracket
- the gearbox suspended engine mounting,
23A-32
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting
K9K, and DP0
- the exhaust pipe mounting nuts to the catalytic converter,
Tighten to torque the nuts securing the exhaust
pipe onto the catalytic converter ( 21 Nm )
Refit:
- the right-hand driveshaft (see 29A, Driveshafts,
Front right-hand driveshaft: Removal - Refitting
).
- the left-hand driveshaft (see 29A, Driveshafts,
Front left-hand driveshaft: Removal - Refitting
).
- the half sub-frame,
- the half sub-frame front mounting bolts,
- the half sub-frame rear mounting nuts.
Tighten to torque:
- the half sub-frame front mounting bolts ( 165
Nm ) ,
- the half sub-frame rear mounting bolts ( 21 Nm
).
Remove the retaining belt from the cooling assembly.
Refit the side reinforcements.
Refit:
- the right-hand and left-hand wheel arch liners,
- the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting ).
- the engine undertray,
- the front wheels,
- the front wheel bolts.
Tighten to torque the front wheel bolts ( 110 Nm )
Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).
Check the gearbox oil level (see 23A, Automatic
transmission, Automatic transmission oil: Draining-refilling ).
Refit the engine covers.
23A-33
23A
AUTOMATIC GEARBOX
Drive plate: Removal - Refitting
23A
F4R or K4M, and DP0
Special tooling required
K4M
Mot. 1677
Flywheel locking tool.
Mot. 582-01
Flywheel locking tool.
Equipment required
diagnostic tool
1
1
Tightening torquesm
drive plate bolts (F4R
engine) then tighten to
torque
4.5 daNm +
50˚ ± 5
drive plate bolts (K4M
engine) then tighten to
torque
5.5 daNm +
50˚ ± 5
1
1
This operation can be performed after the automatic
gearbox has been removed.
103752
Position the tool (Mot. 582-01) .
REMOVAL
F4R
Remove:
- the bolts (1) ,
- the drive plate,
- the tool (Mot. 1677) or (Mot. 582-01)
1
REFITTING
1
2
Check that the drive plate is not damaged (warping
tolerance 0.2 mm on the external diameter).
Fit the drive plate, ensuring it is correctly positioned
in relation to the centring pins (2) .
2
1
Note:
Apply LOCTITE FRENBLOC to the bolt threads.
1
Tighten the bolts on the drive plate.
103245
Position tool (Mot. 1677) to immobilise the starter
motor ring gear.
23A-34
AUTOMATIC GEARBOX
Drive plate: Removal - Refitting
F4R or K4M, and DP0
F4R
Angular tighten the drive plate bolts (F4R engine)
then tighten to torque ( 4.5 daNm + 50˚ ± 5 ) locking the starter motor ring gear using tool (Mot.
1677) .
K4M
Angular tighten the drive plate bolts (K4M engine)
then tighten to torque ( 5.5 daNm + 50˚ ± 5 ) locking the starter motor ring gear using tool (Mot. 58201) .
To refit, proceed in the reverse order to removal.
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Connect the diagnostic tool for the conformity
check.
23A-35
23A
AUTOMATIC GEARBOX
Differential output seal: Removal - Refitting
23A
DP0
Special tooling required
Bvi. 1459
Fitting right-hand
transmission output
seal.
Bvi. 1460
Fitting left-hand transmission output seal.
Tightening torquesm
wheel bolts
lower ball joint nut
(11 daNm)
6.2 daNm
engine tie-bar mounting
bolts on the sub-frame
10.5 daNm
engine tie-bar bolts on
the K engine
10.5 daNm
engine tie-bar bolts on
the F engine
18 daNm
Drain the automatic gearbox through plug (1) .
track rod end nut
3.7 daNm
Remove the faulty differential output seal using a
screwdriver or a hook, taking care not to scratch the
contact faces.
1
13791
hub nut
battery cover
(28 daNm)
0.4 daNm
WARNING
Do not drop the spring of the seal into the automatic gearbox.
REMOVAL
This operation takes place after the relevant driveshaft has been removed (see Workshop Repair Manual 364, Section 2 ).
Put the vehicle on a two-post lift.
Remove the battery cover.
Disconnect the battery starting with the negative terminal.
Remove the engine undertray.
23A-36
AUTOMATIC GEARBOX
Differential output seal: Removal - Refitting
DP0
REFITTING
The seal should be fitted using either tool (Bvi.
1459) or tool (Bvi. 1460) on the left-hand and righthand sides.
Guide the assembly until the tool is in contact with
the automatic gearbox housing.
To refit, proceed in the reverse order of removal.
Tighten to torque:
- the wheel bolts ( (11 daNm) ) ,
- the lower ball joint nut ( 6.2 daNm ) ,
- the engine tie-bar mounting bolts on the subframe ( 10.5 daNm ) ,
- the engine tie-bar bolts on the K engine ( 10.5
daNm ) ,
- the engine tie-bar bolts on the F engine ( 18
daNm ) ,
- the track rod end nut ( 3.7 daNm ) ,
- the hub nut ( (28 daNm) ) .
Fill the automatic gearbox and check the level (see
23A, Automatic gearbox, Filling - Levels, page
23A-7) .
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Torque-tighten the battery cover ( 0.4 daNm ) .
23A-37
23A
AUTOMATIC GEARBOX
Converter seal: Removal - Refitting
DP0
Special tooling required
Mot. 587
Oil seal extractor
Bvi. 1457
Fitting converter lip
seal.
REMOVAL
This operation is performed after the automatic
gearbox and converter have been removed.
Remove the converter by withdrawing it as far as
possible without deviating from the course of the
shaft.
WARNING
The converter contains a large amount of oil
which may escape when it is being removed.
Using the tool (Mot. 587) , remove the seal, taking
care not to scratch the contact faces.
REFITTING
WARNING
- Work as cleanly as possible to prevent foreign
bodies from entering the system.
- Oil all the contact faces.
Position the new prelubricated seal as far as the
stop using the tool (Bvi. 1457) .
Check that the converter is correctly positioned.
To refit, proceed in the reverse order of removal.
23A-38
23A
AUTOMATIC GEARBOX
Multifunction switch: Removal - Refitting
23A
DP0
4
Tightening torquesm
selector lever nut to torque
(1 daNm)
multifunction switch
mounting bolts to torque
(1 daNm)
battery cover bolts to
torque
(0.4 daNm)
2
5
1
REMOVAL
Select neutral « N »
3
103409
Disconnect:
- the multifunction switch cable ball joint (1) ,
- the control cable from the sleeve stop (2) on the
modular connector support.
Remove the lever and the two multifunction switch
mounting bolts (3) .
Disconnect the modular connector (4) by releasing
the slide mechanism on the connector.
Remove the three modular connector support plate
mounting bolts (5) .
101821
Disconnect the battery starting with the negative terminal.
Remove:
- the air intake duct,
- the battery,
- the battery tray,
- the injection computer and its mounting,
6
- the air filter unit,
- the wiring harness mountings.
13785
Remove the two modular connector mounting plate
bolts.
Remove the green connector (6) on the multifunction switch (12-track).
23A-39
AUTOMATIC GEARBOX
Multifunction switch: Removal - Refitting
DP0
REFITTING
Set the multifunction switch to neutral « N » .
Adjust the multifunction switch.
To refit, proceed in the reverse order to removal.
Tighten the selector lever nut to torque ( (1 daNm)
).
Check that the system and gears are working.
ADJUSTING THE MULTIFUNCTION SWITCH
With the gearbox selector shaft in neutral, place two
electric terminals on the position control tabs.
103411
Switch the multimeter to the « ohmmeter » position.
Turn the multifunction switch by hand until the switch
is closed (resistance at contact terminals: 0 Ω ).
Tighten the multifunction switch mounting bolts
to torque ( (1 daNm) ) .
WARNING
After tightening, the electrical switch must be
closed ( 0 Ω ).
Check that the system and gears are working.
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Tighten the battery cover bolts to torque ( (0.4
daNm) ) .
23A-40
23A
AUTOMATIC GEARBOX
Automatic transmission computer: Removal - Refitting
23A
DP0
Tightening torquesm
battery cover to torque
(0.4 daNm)
4
The computer is located behind the left-hand wheel
arch.
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery starting with the negative terminal.
3
Remove the front bumper.
103415
Remove:
- the two computer mounting nuts (3) ,
- the computer (4) .
REFITTING
To refit, proceed in the reverse order to removal.
1
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
2
Tighten the battery cover to torque ( (0.4 daNm) ) .
103414
Disconnect the computer connector (1) .
Remove the resonator (2) .
REPLACING THE COMPUTER
Note:
When the automatic gearbox computer is replaced, the age of the automatic gearbox oil stored
in the memory of the computer to be replaced
must be entered in the memory of the new computer.
Use the following procedure.
Read the oil ageing value from the memory of the
computer being replaced using parameter PR133:
« Oil ageing counter » and note down the value.
Replace the computer.
23A-41
AUTOMATIC GEARBOX
Automatic transmission computer: Removal - Refitting
DP0
Call up the oil ageing value in the memory of the new
computer using command CF320: «Oil ageing
counter report » .
Confirm entry using the « Oil ageing counter » parameter.
Enter the after-sales operation date using command
CF320 « Enter after-sales operation date » .
Carry out a road test so that the new computer stores the programming.
23A-42
23A
AUTOMATIC GEARBOX
Speed sensor: Removal - Refitting
23A
DP0
I - INPUT SPEED SENSOR
Tightening torquesm
output speed sensor
mounting bolt
1 daNm
input speed sensor
mounting bolt
1 daNm
battery cover bolts
0.4 daNm
REMOVAL
1
Put the vehicle on a two-post lift.
Remove the engine covers.
103416
Disconnect the battery starting with the negative terminal.
Note:
The speed sensors can be removed without draining or removing the automatic gearbox.
1
When replacing a sensor, always remove the
gearbox connector (see 23A, Automatic gearbox, A utomatic transmission connector:
Removal - Refitting, page 23A-48) .
Remove the engine undertray.
103419
Remove the connector (1) from the gearbox connector support plate.
23A-43
AUTOMATIC GEARBOX
Speed sensor: Removal - Refitting
23A
DP0
4
2
13786-1
103420
Remove the input speed sensor (2) .
Remove the output speed sensor (4) .
WARNING
WARNING
Protect the connector by sliding it into a waterproof plastic bag.
Protect the connector by sliding it into a waterproof plastic bag.
II - OUTPUT SPEED SENSOR
REFITTING
To refit, proceed in the reverse order of removal.
Tighten to torque:
- the output speed sensor mounting bolt ( 1
daNm ) ,
- the input speed sensor mounting bolt ( 1 daNm
)
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
3
103417
Disconnect the connector (3) .
23A-44
Torque-tighten the battery cover bolts ( 0.4 daNm
).
AUTOMATIC GEARBOX
Flow regulation solenoid valve: Removal - Refitting
23A
DP0
Tightening torquesm
radiator flow control
solenoid valve mounting bolt
1 daNm
battery cover bolts to a
torque of
0.4 daNm
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery starting with the negative terminal.
Note:
103434
The radiator flow control solenoid valve can be
removed without draining or removing the automatic gearbox.
2
1
13786-1
Remove:
- the two solenoid valve bolts (1) ,
- radiator flow control solenoid valve (2) .
REFITTING
To refit, proceed in the reverse order to removal.
23A-45
AUTOMATIC GEARBOX
Flow regulation solenoid valve: Removal - Refitting
DP0
Tighten to torque the radiator flow control solenoid valve mounting bolt ( 1 daNm ) .
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Tighten the battery cover bolts to a torque of ( 0.4
daNm ) .
23A-46
23A
AUTOMATIC GEARBOX
Solenoid valves: Removal
DP0
WARNING
Work as cleanly as possible to prevent foreign
bodies from entering the system.
REMOVAL
2
1
3
4
5
6
7
8
13787
(1)
Modulating solenoid valve
(2)
« Lock up » solenoid valve
(converter by-pass)
(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:
This operation can be performed after the
hydraulic distributor has been removed.
23A-47
23A
AUTOMATIC GEARBOX
Automatic transmission connector: Removal - Refitting
23A
DP0
Connector numbering
Tightening torquesm
battery cover bolts to a
torque of
0.4 daNm
1
2
1
2
3
3
4
4
5
5
13785
(1)
Green connector (multifunction
switch)
(2)
Yellow connector
hydraulic interface)
(3)
Green connector (line pressure)
(4)
Yellow connector (turbine speed)
(5)
Blue connector (radiator flow
control solenoid valve)
103248
REMOVAL
Put the vehicle on a two-post lift.
(electro-
Remove the engine covers.
Select neutral « N »
Note:
These connectors may be removed separately from
the gearbox connector when certain components
are replaced.
101821
Disconnect the battery starting with the negative terminal.
Remove:
- the air intake duct,
- the battery,
23A-48
AUTOMATIC GEARBOX
Automatic transmission connector: Removal - Refitting
23A
DP0
REFITTING
- the battery tray,
To refit, proceed in the reverse order to removal.
- the injection computer and its mounting,
- the air filter unit,
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
- the wiring harness mountings.
Tighten the battery cover bolts to a torque of ( 0.4
daNm ) .
7
8
9
6
103409
Disconnect:
- the ball joint (6) from the multifunction switch cable,
- the wiring harness (7) from the multifunction switch
cable by loosening the sleeve stop,
- the unit connector (8) by releasing the slide valve
on the connector.
Remove:
- the three mounting bolts (9) from the unit connector
support plate,
- the two unit connector mounting bolts,
- the connector in the colour that appears on the
gearbox connector.
Follow the five wiring harnesses connected to the
gearbox connector.
Remove the five wiring harnesses.
These wiring harnesses are either connected to
components directly or via a connector. If they are
connected to a component directly, the component
should also be removed.
23A-49
DRIVESHAFTS
Identification
29A
DRIVESHAFTS FOR MANUAL GEARBOXES JR JH - ND - DP0
102209
Driveshaft seal
Vehicle type
Engine
Gearbox
XM0B
XM0H
K4J 730
JH3 105
XM1A
XM08
K4J 732
JH3 105
XM0C
XM0J
XM1B
K4M 760
JH3 142
Left-hand driveshaft
Right-hand driveshaft
Wheel
end
Gearbox
end
Wheel
end
Gearbox
end
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 82
RC 465
EBJ 82
RC 462
29A-1
DRIVESHAFTS
Identification
29A
Driveshaft seal
Vehicle type
Engine
XM0C
K4M 761
XM0J
XM1B
XM0U
XM05
XM1M
Gearbox
Left-hand driveshaft
Right-hand driveshaft
Wheel
end
Gearbox
end
Wheel
end
Gearbox
end
DP0 46
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 47
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 50
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 46
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 47
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 50
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 46
BJ 87
RC 463
BJ 87
RC
AR
462
DP0 47
BJ 87
RC 463
BJ 87
RC 462
DP0 50
BJ 87
RC 463
BJ 87
RC 462
ND0 004
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 014
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 016
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 014
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 016
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 016
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 014
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
ND0 016
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
F4R 770
XM1N
29A-2
DRIVESHAFTS
Identification
29A
Driveshaft seal
Vehicle type
Engine
XM0U
XM05
F4R 771
XM1M
Gearbox
Left-hand driveshaft
Right-hand driveshaft
Wheel
end
Gearbox
end
Wheel
end
Gearbox
end
DP0 049
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 052
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 54
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 049
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 052
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 054
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 052
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 053
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 054
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 052
EBJ 92
RC 463
EBJ 92
RC
AR
462
DP0 054
EBJ 92
RC 463
EBJ 92
RC
AR
462
XM1N
XM0W
F4R 776
ND0 009
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
XM0F
K9K 722
JR5 102
EBJ 82
RC 465
EBJ 82
RC 462
EBJ 92
RC 465
EBJ 92
RC
AR
465
EBJ 92
RC 465
EBJ 92
RC
AR
465
BJ 87
RC 463
BJ 87
RC
AR
462
EBJ 95
TJ 92
EBJ 95
TJ 92
EBJ 95
TJ 92
EBJ 95
TJ 92
EBJ 95
TJ 92
EBJ 95
TJ 92 AR
XM02
K9K 728
JR5 108
XM013
XM02
K9K 729
DP0 051
F9Q 800
ND0 001
XM0G
XM1G
XM00
F9Q 808
ND0 008
29A-3
DRIVESHAFTS
Consumables
29A
Component concerned
Type of product
Quantity
Gearbox side seal splines
MOLYKOTE BR2 grease
Coat
Brake calliper bolt
FRENBLOC cement
Coat
RC 462 seal
110 cm 3
RC 463 seal
110 cm 3
RC 465 seal
110 cm 3
EBJ 82 seal
MOBIL CVJ 825 Black Star or
MOBIL EXF 57C grease
70 cm 3
EBJ 92 seal
105 cm 3
EBJ 95 seal
110 cm 3
TJ 92 seal
135 cm 3
29A-4
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting
29A
Push the driveshaft away from the stub axle carrier
by pivoting the stub axle carrier.
Special tooling required
Remove the driveshaft (wheel end).
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
II - GEARBOX END
Drain the gearbox( (see Gearbox) .
Tightening torquesm
Remove the driveshaft (gearbox end).
wheel bolts
11 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
REPLACEMENT
Note:
Check the condition of the contact surfaces of
the lip seal.
Always replace the differential output lip seal
(see 21A, Manual gearbox, Differential output
seal: Removal - Refitting, page 21A-16) .
REMOVAL
With the protector in place, coat the splines of the
gearbox end seal with MOLYKOTE BR2 .
I - WHEEL END
Position and insert the driveshaft into the final drive
sunwheel.
Put the vehicle on a two-post lift.
Remove the xenon bulb sensor linkage (if fitted to
the vehicle).
Remove:
Insert the stub-axle into the hub.
The driveshaft must go in freely until it protrudes
enough for the hub nut to be mounted.
To refit, proceed in the reverse order to removal.
- the front left-hand wheel,
Tighten to torque:
- the hub nut using the (Rou. 604-01) .
- the wheel bolts ( 11 daNm ) ,
Disconnect the wheel speed sensor.
- the hub nut ( 28 daNm ) ,
- the track rod end nut ( 3.7 daNm ) ,
1
2
- the lower ball joint nut ( 6.2 daNm ) ,
- the anti-roll bar nut ( 4.4 daNm ) ,
- the driveshaft bearing bolts ( 4.4 daNm ) ,
Fill and check the gearbox oil level( (see Gearbox) .
3
101213
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) .
29A-5
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
Special tooling required
Rou. 604-01
Hub locking tool.
Tightening torquesm
shock absorber turret
bolts
21 Nm
pivot support bolts
72 Nm
lower linkage nut
100 Nm
brake calliper bolts
170 Nm
anti-roll bar return tierod ball joint nut
44 Nm
track rod end nut
37 Nm
driveshaft nut
280 Nm
wheel mounting bolts
130 Nm
105891
Remove:
- the hub nut (1) using the (Rou. 604-01) ,
- the track rod end nut (2) ,
REMOVAL
- the anti-roll bar tie-rod upper nut (3) .
Drain the gearbox.
I - WHEEL END
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Vehicle: Towing and lifting ).
Remove:
- the engine undertray,
- the front left-hand wheel,
Disconnect the wheel speed sensor.
105893
Remove the lower linkage nut (4) .
29A-6
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
106114
101210
Compress the driveshaft by approximately 10 cm .
Remove the seal (9) .
Extract the lower linkage ball joint.
Cut the flap at (8) .
Remove the pivot support bolts (5) .
Remove the plastic rivets from the flap.
Relax the driveshaft by raising the lift by 50 cm .
Remove the sub-frame reinforcement bar.
101211
Remove the shock absorber turret bolts (10) .
106245
Remove the pivot (7) from its support (6) using a
hammer.
29A-7
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
II - GEARBOX END
106126
106642
In place of bolt (11) , screw in an M8x30 bolt by letting the head extrude by 20 mm .
Remove the driveshaft (gearbox end).
Remove the turret bolts (12) .
REFITTING
Note:
Check the condition of the lip seal contact surfaces.
The differential output lip seal must always be
replaced.
With the protector in place, lubricate the gearbox
side seal grooves with MOLYKOTE BR2 grease.
Position and insert the driveshaft into the final drive
sunwheel.
Insert the stub-axle into the hub.
The driveshaft should go in freely, until it is in far
enough for the hub nut to be fitted.
Proceed in the reverse order to removal.
106641
Remove the spring, shock absorber and pivot assembly.
Extract the hub driveshaft.
29A-8
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting
B84 or C84, and F4R, and 774
101211
Position the indexing (13) in its housing.
Fill and check the gearbox oil level.
Tighten to torque:
- the shock absorber turret bolts ( 21 Nm ) ,
- the pivot support bolts ( 72 Nm ) ,
- the lower linkage nut ( 100 Nm ) ,
- the brake calliper bolts ( 170 Nm ) ,
- the anti-roll bar return tie-rod ball joint nut ( 44
Nm ) .
- the track rod end nut ( 37 Nm ) ,
- the driveshaft nut ( 280 Nm ) ,
- the wheel mounting bolts ( 130 Nm ) .
Connect the battery (see MR364, 80A, Battery,
Battery: Removal - Refitting ).
Note:
It is essential to initialise the xenon bulb system.
29A-9
29A
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
- the lower ball joint bolt (3) .
Special tooling required
Rou. 604-01
Hub locking tool.
Push the driveshaft away from the stub axle carrier
by pivoting the stub axle carrier.
Tav. 476
Ball joint extractor.
Remove the driveshaft (wheel end).
II - GEARBOX END
Tightening torquesm
Drain the gearbox.
driveshaft bearing bolts
44 Nm
d riveshaft
mounting bolt
21 Nm
M9R, and 700
bearing
track rod end nut
37 Nm
lower ball joint nut
62 Nm
anti-roll bar nut
44 Nm
hub nut
280 Nm
wheel bolts
110 Nm
REMOVAL
I - WHEEL END
Put the vehicle on a two-post lift.
Remove:
- the front right-hand wheel,
114927
- the hub nut using the (Rou. 604-01) .
Remove the driveshaft bearing mounting bolt (4) .
Disconnect the wheel speed sensor.
Move the driveshaft bearing bracket to one side.
2
1
3
101213
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) ,
29A-10
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
Proceed in the reverse order to removal.
Tighten to torque the driveshaft bearing bolts ( 44
Nm ) .
M9R, and 700
Fit the driveshaft bearing bracket.
Tighten to torque the driveshaft bearing mounting
bolt ( 21 Nm ) .
Tighten to torque:
- the track rod end nut ( 37 Nm ) ,
- the lower ball joint nut ( 62 Nm ) ,
101819
- the anti-roll bar nut ( 44 Nm ) ,
Remove both the driveshaft bearing bolts (5) .
- the hub nut ( 280 Nm ) ,
Remove the driveshaft (gearbox end).
- the wheel bolts ( 110 Nm ) .
Note:
Fill and check the gearbox oil level( (see Gearbox) .
If the bearing is seized in the relay bearing, it
must be replaced( (see Relay shaft bearing:
Removal - Refitting) .
REMOVING THE RELAY SHAFT BEARING
REFITTING
Clean and grease the bearing hole into which the
bearing will be inserted.
Note:
- Replace the O-ring at the base of the relay shaft
bearing if it is damaged.
- Check the condition of the contact surfaces of
the lip seal.
- The differential output lip seal must always be
replaced (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page
21A-16) .
100642
Remove:
With the protector in place, coat the splines of the
seal on the gearbox side with MOLYKOTE BR2 .
- the complete driveshaft,
Position and insert the driveshaft into the final drive
sunwheel.
- the lock ring (6) .
Insert the stub-axle into the hub.
Remove the bearing using a press.
The driveshaft should go in freely, until it is in far
enough for the hub nut to be fitted.
Take care not to score the contact surface of the lip
seal on the relay shaft.
29A-11
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
REFITTING
Lubricate the contact surface of the shaft into which
the bearing is inserted.
Insert the new bearing.
Fit the bearing to the end using a tube, so that it
rests on the inner bearing race.
Refit the new lock ring.
Clean and grease the bearing hole into which the
bearing will be inserted.
Refit the driveshaft.
29A-12
29A
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
Special tooling required
Rou. 604-01
Hub locking tool.
Tightening torquesm
relay bearing bracket
mounting bolts
44 Nm
shock absorber turret
bolts
21 Nm
pivot support bolts
72 Nm
lower linkage nut
100 Nm
brake calliper bolts
170 Nm
anti-roll bar return tierod ball joint nut
44 Nm
track rod end nut
37 Nm
105891
Remove:
driveshaft nut
280 Nm
- the hub nut (1) using (Rou. 604-01) ,
wheel mounting bolts
130 Nm
- the track rod end nut (2) ,
- the anti-roll bar tie-rod upper nut (3) .
REMOVAL
Drain the gearbox.
I - WHEEL END
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Vehicle: Towing and lifting ).
Remove:
- the engine undertray,
- the front left-hand wheel,
Disconnect the wheel speed sensor.
105893
Remove the lower linkage nut (4) .
29A-13
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
106114
101210
Compress the driveshaft approximately 10 cm .
Remove the seal (9) .
Extract the lower linkage ball joint.
Cut the flap at (8) .
Remove the pivot support bolts (5) .
Remove the plastic rivets from the flap.
Relax the driveshaft by raising the lift by 50 cm .
Remove the sub-frame reinforcement bar.
101211
Remove the shock absorber turret bolts (10) .
106245
Remove the pivot (7) from its support (6) using a
hammer.
29A-14
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
II - GEARBOX END
106126
In place of bolt (11) , screw in an M8x30 bolt, letting
the head extrude by 20 mm .
Remove the turret bolts (12) .
106093
Remove the relay bearing bracket mounting bolts
(13) .
106642
106641
Remove the spring, shock absorber and pivot assembly.
Remove the driveshaft (gearbox end).
Note:
Extract the hub driveshaft.
If the bearing is seized in the relay bearing, it
must be replaced.
29A-15
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting
29A
B84 or C84, and F4R, and 774
REFITTING
Tighten to torque:
- the relay bearing bracket mounting bolts ( 44
Nm )
Clean and grease the relay bearing hole into which
the bearing is inserted.
- the shock absorber turret bolts ( 21 Nm ) ,
- the pivot support bolts ( 72 Nm ) ,
Note:
- the lower linkage nut ( 100 Nm ) ,
Replace the relay shaft bearing O-ring if it has
deteriorated.
- the brake calliper bolts ( 170 Nm ) ,
Check the condition of the lip seal contact surfaces.
- the anti-roll bar return tie-rod ball joint nut ( 44
Nm ) .
The differential output lip seal must always be
replaced.
- the track rod end nut ( 37 Nm ) ,
- the driveshaft nut ( 280 Nm ) ,
With the protector in place, grease the gearbox side
seal grooves with MOLYKOTE BR2 grease.
- the wheel mounting bolts ( 130 Nm ) .
Connect the battery (see MR364, 80A, Battery,
Battery: Removal - Refitting ).
Note:
Note:
The relay bearing bracket must be refitted with
the driveshaft.
It is essential to initialise the xenon bulb system.
Position and insert the driveshaft into the final drive
sunwheel.
I - REMOVING THE RELAY SHAFT BEARING
Insert the stub-axle into the hub.
The driveshaft should go in freely, until it is in far
enough for the hub nut to be fitted.
Proceed in the reverse order to removal.
100642
Remove the complete driveshaft.
Remove the bearing with the press.
Take care not to score the contact surface of the lip
seal on the relay shaft.
II - REFITTING
Lubricate the contact surface of the shaft into which
the bearing is inserted.
Insert the new bearing.
101211
Position the indexing (14) in its housing.
Position the bearing as far as the stop using a tube
supported by the inner bearing race.
Fill and check the gearbox oil level.
Refit the driveshaft.
29A-16