Transmission R 19

Transmission
CLUTCH
MANUAL GEARBOXES
AUTOMATIC TRANSMISSION
DRIVESHAFTS
77 11 190 841 NOVEMBER 1996 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes by the manufacturer in the reference numbering system is forbidden without the prior written authority of
production of the various component units and accessories from which his vehicles Renault.
are constructed".
C Renault S.A. 1988

EXPLODED VIEW
PRD2013
Transmission
Contents
Pages Pages
20 CLUTCH 23 AUTOMATIC TRANSMISSION

Identification 20-1 AD4 automatic transmission
Side views 20-4 Exploded view 23-23
Exploded view 20-4 Use 23-24
Consumables 20-5 Identification 23-25
Mechanism - Clutch plate 20-6 Gear ratios 23-26
Thrust pad - Fork 20-10 Gear change thresholds 23-27
Consumables 23-29
Parts which must be changed
21 MANUAL GEARBOXES automatically 23-29
Oil 23-29
Identification 21-1 Oil drain intervals 23-30
Gear ratios 21-2 Oil draining 23-31
Capacities - Lubricants 21-5 Filling - Levels 23-32
Special features 21-7 Oil pressure 23-33
Consumables 21-8 Changing the strainer 23-34
Parts which must be changed Hydraulic distributor 23-36
automatically 21-8 Automatic transmission (Removal -
Gearbox (Removal - Refitting) 21-9 Refitting) 23-41
5th gear linkage in situ 21-23 Full-load validation 23-57
Differential output seal 21-29 Load potentiometer 23-58
Speedometer drive 21-32 Computer (119) 23-60
Line pressure sensor (8) 23-61
Multifunction switch (485) 23-62
23 AUTOMATIC TRANSMISSION Vehicle speed sensor (250) 23-63
Solenoid valve 23-64
MB automatic transmission Engine torque reduction 23-65
Exploded view 23-1 Special features 23-66
Use 23-2
Identification 23-3
Gear ratios 23-4
Gear change thresholds 23-5
Consumables 23-6 29 DRIVESHAFTS
Parts which must be changed
automatically 23-6 Consumables 29-1
Oil Driveshafts 29-2
Draining - Filling - Levels 23-7 Gaiter at wheel end 29-9
Checking and adjusting the Gaiter at gearbox end 29-19
potentiometer 23-8 Gaiter - bearing assembly 29-26
Oil pressure 23-11
Strainer 23-13
Automatic transmission (Removal -
Refitting) 23-15
CLUTCH
Identification 20
ENGINE
Mechanism Plate
TYPE
C1G
C1J
C2J
C3J 85873S 90693R 76906R
E6J
180 CP 3300 26 splines B = White

E = 7.7 mm GB= Blue grey
D = 181.5 mm V = Green
F2N
F3N
76907S 90693R1 76906R
2000 CP 4000 26 splines

M= 6 pale pink springs
E = 7.7 mm
D = 200 mm
20-1
CLUTCH
Identification 20
ENGINE
MECHANISM CLUTCH PLATE
TYPE
F7P
76907S 93813R 76906R
200 CP 4400 26 splines R = 4 red springs

D = 200 mm J = 4 yellow springs
E = 7.7 mm
Special feature: 2 additional springs on the hub.
F8Q
76907S 90693G1 76906R
200 CPV 3500 26 splines R = Red

D = 200 mm J = Yellow
E = 7.7 mm V = Green
20-2
CLUTCH
Identification 20
ENGINE
MECHANISM CLUTCH PLATE
TYPE
Special feature: 2 additional springs on the hub.
F8Q
Turbo
76907S 90693-2G2 76906R
200 CPV 4400 26 splines J = 4 yellow springs

D = 200 mm G = 4 grey springs
E = 7.7 mm
20-3
CLUTCH
Side view 20
Single plate, dry, clutch, cable operated.
Diaphragm spring clutch plate.
Clutch plate with rubber hub.
Self-centring, guided, ball type thrust pad in

constant contact.
Automatic wear take-up mechanism.
DI2001
Exploded view
PRD2012
20-4
CLUTCH
Consumables 20
Type Pack size Unit
Right hand sunwheel splines

Shaft splines
MOLYKOTE BR2 1 kg tin Fork pivot
Release bearing guide Clutch
Fork pads
RHODORSEAL 5661 100 g tube Ends of driveshaft roll pins.
LOCTITE 518 24 ml syringe Housing assembly faces.
20-5
CLUTCH
Mechanism - Clutch plate 20
ALL TYPES
IMPORTANT PRECAUTIONS WHICH MUST BE

FOLLOWED WHEN REPAIRING THE CLUTCH
In order to improve the sliding of the clutch

plates, their hubs are nickel-plated.
Clean the clutch shaft splines and refit the assem-

bly without any lubricant.
Special features of "diesel" clutch plates
These are fitted with a damping pre-hub which is

most efficient when its internal units are dry.
20-6
CLUTCH
Mechanism - clutch plate 20
CHANGING
This operation is carried out after the gearbox has been removed.
ESSENTIAL SPECIAL TOOLS
Mot. 582 Locking sector

Plus the tools required to remove the gearbox
TIGHTENING TORQUES (in daN.m) REFITTING
7 mm diameter unit securing bolts Degrease the flywheel mounting face.

for 180 mm diameter clutch 1.8
Use the plastic locating device supplied in the kit
8 mm diameter unit securing bolts
to fit the plate.
for 200 mm diameter clutch 2.5
REMOVAL
Fit locking sector Mot. 582.
Remove the mounting bolts from the mechanism

and remove the unit and the clutch plate.
Check and change the faulty parts.
94135S
92170R
20-7
CLUTCH
74413R
Gradually screw up then torque tighten the bolts

securing the mechanism.
Remove locking sector Mot. 582.
Coat the bore of the thrust pad, guide tube and

clutch shaft splines with grease MOLYKOTE BR2 .
20-8
CLUTCH
94235S
REMOVAL
F engines
Degrease the crankshaft bore which receives the centring bush.
Coat the external diameter of the bushing with Loctite FRENBLOC.
Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore.
Observe the direction of fitting of the bush and check that it is fitted correctly.
C and E engines
The centring bush will not be used for these engines.
20-9
CLUTCH
Thrust pad - fork 20
CHANGING Ensure that the assembly slides properly.
This operation is carried out when the gearbox NOTE: when carrying out operations which do not
has been removed. require removal of the gearbox or after fitting the
gearbox, DO NOT RAISE the fork as there is a risk
REMOVAL of it lifting out of catch (A) on the thrust pad.
Remove:
- the thrust pad by tilting the fork,
- the rubber protector, and pull the fork to- Check the extent of fork travel.
wards the inside of the clutch casing.
It should be:
REFITTING X = 17 to 18 mm
Coat the walls of the guide tube and the fork pads
with grease MOLYKOTE BR2.
Fit the fork and refit the rubber protector.
Fit the thrust pad on the guide tube, placing catch

(A) in the fork.
91830R1
90300G1
After refitting the gearbox, re-set the toothed
quadrant and check that the wear take-up mecha-
nism operates correctly.
20-10
MANUAL GEARBOXES
Identification 21
Repair manual which deals
Gearbox type
with the gearbox concerned
JB B.V. JB
JC B.V. JC
87227G
An identification plate on the clutch housing shows:
At A : the gearbox type A J B0 0 0 0 B

At B : the gearbox suffix
At C : the fabrication number
D X 000000 C
At D : the production factory E
At E : a notch is used when the gearbox has been
assembled with a C or E type engine.
90775
TWO-COLOUR MARKING
JB0 - JB1 - JB3 - JC5
Two-thirds of the surface are painted with a colour which is peculiar to each gearbox type, enabling the gear-
box to be matched with the driveshaft.
The remaining one-third of the surface is painted with a specific colour according to the gearbox suffix.
JB4 - JB5
Two-colour marking (green and pink) in the form of two bands of equal width.
21-1
MANUAL GEARBOXES
Gear ratios 21
JB0
Final drive Speedo
Index Vehicle 1st 2nd 3rd 4th Reverse
set drive set
B531 - B532 - B537

16
017 C531 - C532
L531 - L532 - L537 57
B534 15
019
L53H 56 21 11 21 28 31 11
26
B530 - C530 - L530 15 19 41 43 37 28 39
023
S530 58
B53W - C53W 15
035
L53W 61
JB4
Final drive Speedo
Index Vehicle 1st 2nd 3rd 4th Reverse
set drive set
B530 - C530 - L530 15

000
S530 - C531 58 21 11 19 25 31 11
26
B531 - L531 16 19 41 39 33 28 39
006
B53P - C53P - L53P 57
JB1
Final drive Speedo
Index Vehicle 1st 2nd 3rd 4th 5th Reverse
set drive set
B532 - C532 - L532 15

023
B535 - C535 - L535 58
B530 - C530 - L530 21 11 21 28 30 39 11
26
S530 - B537 - C537 15 19 43 43 37 29 31 39
025
L537 - S537 - B53A 61
C53A - B53G
B53H 15
027
L53H 58
15
029 L53G
61 21 11 21 28 30 39 11
26
16 19 41 43 37 29 31 39
034 B531 - C531 - L531
57
B53W - C53W 14
047
L53W 63
B530 - C530 - L530
S530 - B535 - C535 15 21 11 21 28 30 39 11
070 L535 - S535 - B537 26
61 19 45 43 37 29 31 39
C537 - L537 - B53A
C53A - L53A
21-2
MANUAL GEARBOXES
Gear ratios 21
JB3
Final drive Speedo
set drive set
B533 - C533 - L533

059
D53C
B533 - C533 - L533 15 21 11 22 28 30 41 11

26
B53C - C53C - L53C 61 19 34 41 37 29 31 39
027
D53C
B53M - C53M
353A - 453A - 553A

853A
062
B53C - D53C - L53C
B53Y - D53Y - L53Y
B538 - C538 - L538

094 B53F - C53F - L53F
S53C - S53D
14 21 11 22 28 30 41 11
353C - 453C - 553C 26
59 19 34 41 37 29 31 39
853C - 353D - 453D
095 553D - 453H - 553H
B538 - C538 - L538
S53C - S53D
B538 - C538 - L538

B53C - C53C - D53C
037
L53C - B53F - C53F
L53F - B53Y - L53Y
071 B53D - C53D - L53D

15 21 11 22 28 34 34 11
26
61 19 34 41 37 35 28 39
083 B53D - C53D - L53D
B533 - L533 - B53B

C53B - L53B - B53I - 16
060
C53I - L53I - B53J - 57 21 11 22 28 30 39 11
C53J - L53J - S53J 26
19 41 43 37 29 31 39
15
061 B533
58
353A - 453A - 553A
067 853A - B53Y - C53Y
D53Y - L53Y 16 21 11 21 28 30 39 11
26
55 19 41 43 37 29 31 39
B53B
047
B53Y - C53Y - L53Y
21-3
MANUAL GEARBOXES
Gear ratios 21
JB3
Final drive Speedo
set drive set
017 L532
B539 - C539 - B53D 15 21 11 19 25 30 33 11

051
C53D - D53D - L53D 26
61 19 34 35 33 29 25 39
B539 - C539 - L539
044 B53D - C53D -
D53D - L53D
15 21 11 21 28 30 39 11
031 B533 - B536 - L536 26
58 19 34 43 37 29 31 39
15 21 11 22 28 34 34 11
053 B53D - C53D - L53D 26
61 19 34 41 37 35 28 39
B532 - B533 - L533
C534 - L534 - S534
B53B - C53B - L53B
16 21 11 21 28 30 39 11
028 B53C - L53C - B53E 26
57 19 41 43 37 29 31 39
C53E - B53I - C53I -
L53I - B53J - C53J -
L53J - S53J
JB5
Final drive Speedo
set drive set
B531 - C531 - L531 16 21 11 19 25 30 34 11

006 26
B53P - C53P - L53P 57 19 41 39 33 29 27 39
B530 - C530 - L530 15 21 11 19 25 30 34 11
000 26
S530 61 19 41 39 33 29 27 39
JC5
Final drive Speedo
set drive set
B532 - C532 - L532

17 21 11 21 28 35 41 11
B53K - L53K - S53K 26
002 56 19 41 43 37 34 31 39
B53T - C53T - L53T
B53Z
21-4
MANUAL GEARBOXES
Capacities - Lubricants 21
CAPACITY (in litres) Plug (B) with dipstick
4-speed gearbox 5-speed gearbox
JB0 JB1
3.25 3.40
JB2 JB3
JB4 2.75 JB5 2.90
JC5 3.10
CHECKING THE LEVEL

DI2123
There are two ways of checking the level.
Wipe the dipstick section.

Plug (A) without dipstick
Refit the plug, without screwing it up, with the
dipstick pointing downwards.
Remove the plug, the level should be on the boss

(2).
OIL VISCOSITY GRADE
Tranself TRX 75/80 W
92081R
Fill to the level of the opening.
21-5
MANUAL GEARBOXES
Lubricants 21
Precautions (TRX and TRZ oils)
"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in order
to prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and result
in seizure of the gearbox or of the final drive.
STORAGE AND USE
Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of mate-
rials or water.
In particular:
Storing oil cans
The cans must be stored:

- sheltered from bad weather (rain, snow, outside splashes),
- in a dry area (avoid storing in the vicinity of a washing area),
- tightly sealed.
Storing units (gearbox or final drive)
When storing a gearbox or final drive which has not been drained, close the air inlets.
Store the unit in a dry area.
Using the oil
The oil cans must be resealed each time they have been used.
In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil into
a larger container.
When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil.
The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time.
Washing under pressure (of the vehicle or of a unit)
Close the gearbox and final drive breather.
If the gearbox is removed, correctly close all of the openings to prevent the entry of water.
21-6
MANUAL GEARBOXES
Special features 21
The gearboxes of the following types:
JB0
JB4 4 forward gears
JB2 1 reverse
JB1
JB3 5 forward gears
JB5 1 reverse
JC5
are fitted with BORG-WARNER synchronisers.
GEAR CHANGE PATTERN
R 1 3 5
2 4
To select reverse, raise ring (A) and move the le-

ver.
DI2118
21-7
MANUAL GEARBOXES
Consumables 21
TYPE PACK SIZE UNIT
Clutch fork pivot

Thrust pad guide tube bore
MOLYKOTE BR2 1 kg sachet
Clutch shaft splines
Right hand sun wheel splines
Loctite 518 24 ml syringe Housing joint faces
5th speed fixed gear

5th speed synchroniser hub
LOCTITE FRENBLOC 24 cc bottle
Primary shaft nut
Secondary shaft bolt
Ends of roll pins on driveshafts

RHODORSEAL 5661 100 g tube
Screw threads on switches
Parts which must be changed automatically
When they have been removed:

- the lip seals,
- the O-rings,
- the thrust pad guide tubes,
- the secondary shaft and differential nuts,
- the speedometer gear and its shaft,
- the speedometer crown wheel,
- the roll pins,
- the bushes under the gears.
21-8
MANUAL GEARBOXES
C
engines Gearbox (Removal - Refitting) 21
B.Vi. 31-01 Set of pin punches

T.Av. 476 Ball joint extractor
MATERIALS
Loctite FRENBLOC
Brake caliper securing bolts
RHODORSEAL 5661
Ends of pins on driveshafts
MOLYKOTE "BR2"
Clutch shaft and sun wheel splines
TIGHTENING TORQUES (in daN.m) 85965R
Brake caliper securing bolts 10

Shock absorber lower securing bolts 11
- the three bolts holding the driveshaft gaiter,
Steering ball joint nut 3.5
- the two bolts securing the brake caliper and se-
Nut holding key on stub axle carrier 5.5 cure the caliper to the suspension spring so as
Mounting securing bolts 4 to 5 to avoid stretching the hose,
Wheel bolts 8 - the protective casing (side).
Left hand driveshaft gaiter securing bolt 2.5
REMOVAL
The gearbox can be removed alone.
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the front wheels.
On the left hand side of the vehicle
Remove:
- the steering tie rod ball joint using tool
T.Av. 476.
92122R2
21-9
MANUAL GEARBOXES
C
Remove: On the right hand side of the vehicle
- the two bolts (2) securing the base of the shock
absorber, Remove the driveshaft roll pins using tool
- the nut and key (1), B.Vi. 31-01
90130R2 91755R
- the driveshaft - stub axle carrier assembly from Slacken lower bolt (3) on the base of the shock ab-
the lower ball joint, sorber and remove upper bolt (4).
90311S 91758R4
Check that the driveshaft rollers do not come out Tilt the stub axle carrier and uncouple the drives-
manually. If they do, on reassembly, check that haft.
the needle bearings have not fallen into the gear-
box.
21-10
MANUAL GEARBOXES
C
Under the vehicle, remove bolt (H) from the en- Disconnect:
gine - gearbox tierod. - the starter leads,
- the connector on the reversing light switch.
On vehicles fitted with power assisted steering,

remove the two clamps securing the power
assisted steering pipes to the gearbox.
Remove:
- the air filter unit and its mounting,
92028R2
Slacken:
- the two mounting bolts on the engine,
- the clutch protection plate,
- the gear lever.
92031S
- the integral electronic ignition (A.E.I.) sensor,

- the bolts from around the gearbox and from
the starter.
85966R
21-11
MANUAL GEARBOXES
C
Disconnect: Lift the engine using a tool specific to this purpose
- the clutch cable, (example: desvil 300B).
89204S
92110S
- the speedometer pin and cable.

Petrol engines - all types
Remove:
- the front mounting,
- the earthing braid.
92108-1R1
92112R
21-12
MANUAL GEARBOXES
C
Remove the three bolts securing the rear centre
mounting and move it back as far as possible.
92108R1
92903S
NOTE: to make it easier to remove the bolts, raise
the gearbox slightly with a component jack.
Uncouple the gearbox from the engine, sliding

the 5th speed housing between the vehicle side-
member and the engine cradle.
Raise the engine.
Turn the gearbox to the front slightly so as to free

the final drive section then remove the gearbox
from the vehicle.
After uncoupling the gearbox from the engine,

attach it to a workshop crane securing the eyes in
place of two bolts around the gearbox.
21-13
MANUAL GEARBOXES
E
REMOVAL Remove the idle speed regulation valve moun-
ting.
The gearbox is removed alone.
Disconnect the starter and oil pressure sensor
Remove the radiator after first draining the co- wires.
oling system.
To detach the wiring, disconnect the connectors

on:
- the ignition power module,
- the throttle housing,
92904R
Disconnect the two side bolts which secure the en-

gine - gearbox tierod, starter end torx bolt (T).
using a suitable spanner.
92817S
- the idle speed regulation valve.
92904R1
92826S
21-14
MANUAL GEARBOXES
E
Disconnect the fan motor and thermal switch After uncoupling the gearbox from the engine,
connectors. attach it to a workshop crane securing the eyes in
place of two bolts around the gearbox.
Unfasten the radiator mountings and move it to
the right hand side (without removing any of the
hoses or pipes), protecting the sides with card-
board.
Remove studs (A) and (B) using a nut and lock-nut,

using an angled spanner and a ball joint ratchet.
92903S
86308R1
21-15
MANUAL GEARBOXES
F
The gearbox cannot be removed alone. The en- Uncouple the gear lever at the gearbox outlet le-
gine - gearbox assembly must be removed first (re- ver after detaching the protective gaiter.
fer to section 10) and then uncoupled.
TIGHTENING TORQUES (in daN.m)
Bolt which secures the pendulum

mounting system to the gearbox 3.5
Nuts and bolts which secure the clutch
housing to the engine 5
Bolt which secures the clutch
protector 2.5
Drain plug 1.8
Filler plug 0.15
Bolt which secures the left hand
driveshaft 2.5
Removal (Special points) 85966R
Speedometer cable mounting. Pinch the tabs (ar-

rows) and remove the cable. Remove the starter plate.
98865R2 93902S
21-16
MANUAL GEARBOXES
F
Disconnect the starter leads. After uncoupling the gearbox from the engine,
attach it to a workshop crane securing the eyes in
From the lower section, remove: place of two bolts around the gearbox.
- nut (E) which secures the engine - gearbox,
85812-1R
- the tierod - clutch protector assembly.

92903S1
Place the engine on a stand.
Remove the bolts from around the gearbox and

from the starter.
Vehicles fitted with power assisted steering, re-

move the two clamps (C) which secure the power
assisted steering pipe.
92028R3
21-17
MANUAL GEARBOXES
F
engines
Gearbox (Removal - Refitting) 21
REFITTING
Ensure that the engine - gearbox locating rings

are present and correctly positioned:
- at A : gearbox assembled with a C or E type
engine,
- at B : gearbox assembled with an F type en-
gine.
90300G1
86415R
Do not raise the fork since there is a risk of it lif-
ting out of catch (A) on the thrust pad. To prevent
this, immobilise the thrust pad - fork assembly by
Fit the thrust pad to the guide tube placing catch inserting a tube (example: tool Elé. 1382) bet-
(A) in the fork, ensure that it slides correctly. ween the fork and the sheath end on the housing
to prevent any movement of the thrust pad while
the gearbox is fitted.
Coat the walls of the guide tube and the fork pads
with MOLYKOTE BR2 grease .
21-18
MANUAL GEARBOXES
F
Fit the gearbox in place.
92903R1
Assemble the engine - gearbox.
Ensure that the locating rings are fitted correctly

in their locations.
Refit studs (A) and (B) in the same way as on remo-

val. These studs and the bolts around the gearbox
are used for alignment and centring.
Fit the fork and refit the rubber protector.
21-19
MANUAL GEARBOXES
All types
WARNING: fit bolt (V) and starter locating pin (D) Reconnect the speedometer cable ensuring that
correctly. the pin is in the correct position (C and E type en-
gines).
C and E type engines
92108-1S
Speedometer cable mounting. Pinch the tabs (ar-

rows) and remove the cable (F type engine).
86070R3
F type engine
93909S
86070-1R1
21-20
MANUAL GEARBOXES
All types
Position the driveshaft in relation to the sun
wheel, pivot the stub axle carrier engaging the
driveshaft in the sun wheel using the angled drift
B. Vi. 31-01 to align the holes.
91830R1
Pull the cable at the clutch fork on the gearbox.
The cable should have at least 2 cm of slack.

74937-4S
There is an inlet chamfer on the sun wheel to

make it easier to fit new roll pins.
Seal the ends of the pins (RHODORSEAL 5661 ).
After refitting the engine - gearbox assembly to

the vehicle, check the extent of the fork travel.
It should be: X = 17 to 18 mm
89204S
These checks enable the correct operation of the

clutch automatic wear take-up system to be veri-
fied.
21-21
MANUAL GEARBOXES
F
Check the setting of the upper mountings (refer
to section 10).
Ensure that the engine movement limiter is fitted

the correct way: the nuts should be fitted at the
exhaust pipe end.
92661S
Fill the cooling system.
All types
Fit the brake caliper mounting bolts with Loctite

FRENBLOC and torque tighten them.
Press on the brake pedal several times to bring the

pistons into contact with the brake pads.
Tighten the bolts and nuts to the specified torque.
Fill the gearbox.
21-22
MANUAL GEARBOXES
5th speed linkage in situ 21
B.Vi. 28-01 Extractor body

B.Vi. 31-01 Drifts for fitting roll pins
B.Vi. 1003 5th speed hub extractor
B.Vi. 1007 Jaws for B.Vi. 28-01, 02, 03
B.Vi. 1175 5th speed fixed gear mounting bolt
Primary shaft nut 13.5

Secondary shaft nut 7
MATERIALS
Loctite FRENBLOC :
Primary shaft nut
Secondary shaft bolt
5th speed fixed gear
5th speed hub
REMOVAL
Remove the front left hand wheel. 87180R
Remove the side housing.
Drain the gearbox.
The rear housing must be removed horizontally as

it has a lubricating duct (A) which goes into the
primary shaft.
21-23
MANUAL GEARBOXES
Fit:
- a drainage tray under the rear housing and re-
move it,
- a wooden block between the 5th speed fork
and the leading gear to act as a counter-force;
then remove the fork roll pin using tool B.Vi.
31-01.
It is easier to remove the roll pin if the drift of tool

B.Vi 31-01 is bent slightly to avoid having to raise
the gearbox.
DI2122
Select 5th gear by sliding the fork on its shaft and

1st gear with the gear lever.
85979R
NOTE:
Do not pull the 5th speed fork shaft outwards as
there is a risk that the prohibiting lock may move
and prevent refitting of the shaft. As a safety
measure, engage a gear (3rd or 4th) when remo- 85966R2
ving - refitting the roll pin.
Slacken and remove the primary shaft nut and

secondary shaft bolt.
Return the gearbox to neutral.
21-24
MANUAL GEARBOXES
On the primary shaft: Fit the rounded housing of the tool on the slide
gear, turn it as far as possible and then extract the
Remove the 5th speed fork and the slide gear. hub.
Extract the synchroniser hub using tool B.Vi. 1170.
93190R
93237R
Fit the slide gear of tool B.Vi. 1170 as for selecting

5th gear and turn it so as to position the splines of
the slide gear and the hub opposite each other. Remove the 5th gear assembly.
86045R2
93189S
21-25
MANUAL GEARBOXES
On the secondary shaft: REFITTING
Remove shouldered washer (64). On the secondary shaft:
Put three drops of Loctite FRENBLOC on the fixed

gear splines.
Fit the fixed gear using tool B. Vi. 1175 and shoul-
dered washer (64).
PRG21.1
Remove the fixed gear using tool B.Vi. 28-01-02-

03 fitted with its jaws B.Vi. 1007.
93462R
Remove tool B. Vi. 1175.
88575R
21-26
MANUAL GEARBOXES
On the primary shaft: On the secondary shaft:
Refit parts (21) (shoulder facing bearing (22), (23), Fit shouldered washer (64).
(24) and (8)) in order.
Fit the fork on slide gear (26) fitted with part (25).
Put three drops of Loctite FRENBLOC on the hub

and refit the slide gear - hub assembly and fork.
Fit the bosses on the synchro ring in the notches

on the hub.
PRG21.1
Put three drops of Loctite FRENBLOC:

- on nut (27) of the primary shaft and torque
tighten it to 13.5 daN.m,
- on bolt (65) and torque tighten it to 7 daN.m .
86045R1
Select 1st gear at the gear lever and 5th gear at

the gearbox, sliding the 5th speed fork on its
shaft.
21-27
MANUAL GEARBOXES
Place a wooden block between the 5th speed fork Fit a new O-ring seal to ensure that the rear hou-
and the primary gear as a counter-force and fit a sing is leaktight.
new roll pin in the 5th speed fork using tool B.Vi.
31-01 ensuring that it is fitted the correct way Fit the rear housing engaging duct (A) in the pri-
round, with the slot in the centreline of the shafts. mary shaft and the lubricating channel in oil inlet
rail (B) and torque tighten the bolts to 2.5 daN.m.
90498-1S
87180R6
Fill the gearbox with oil.
85979R1
Return the gearbox to neutral and check that all

of the gears can be selected.
If there are any difficulties, ensure that reverse

gear is not engaged.
21-28
MANUAL GEARBOXES
Differential output seal 21

B.Vi. 945 Plug for fitting the differential seal
B.Vi. 1058 Plug for fitting the differential seal

Shock absorber lower securing bolts 11
Steering ball joint 3.5
Wheel bolts 8
MATERIALS
Loctite FRENBLOC :
Brake caliper securing bolts
RHODORSEAL 5661 :
Ends of driveshaft roll pins
MOLYKOTE BR2 :
Splines on right hand sun wheel 91755R
Remove:
- the steering ball joint (tool T.Av. 476),
REMOVAL
Remove the protective casing from under the en-

gine.
Drain the gearbox.
Place the front of the vehicle on stands on the side

in question.
Remove the wheel.
Knock out the driveshaft roll pins using tool B.Vi.

31-01.
85965R
21-29
MANUAL GEARBOXES
- the two bolts (A) securing the brake assembly.
86031S
REFITTING
Grease protector (A) of B. Vi. 945 and fit it on the

sun wheel. Position the greased seal using B. Vi.
1058.
90149R1
Fix the brake caliper to the suspension spring in

order to avoid stretching the hose.
Slacken lower bolt (3) on the shock absorber base

and remove upper bolt (4).
Tilt the stub axle carrier and uncouple the drives-

haft (take care not to damage the gaiters during
this operation).
Remove the O-ring seal from the sun wheel.
Knock the base of the lip seal using a pin drift and
a small hammer so that it turns in its housing.
When the seal has been loosened, take it out

using a pair of pliers, taking care not to damage
the sun wheel splines.
92111R
21-30
MANUAL GEARBOXES
Fit the O-ring seal on the sun wheel and coat the Fit new roll pins and seal the ends (RHODORSEAL
splines with grease MOLYKOTE BR2. 5661).

wheel.
Turn the stub axle carrier engaging the driveshaft

in the sun wheel using drift B.Vi. 31-01 in order to Tighten the bolts and nuts to the recommended
align the holes. torque.
Fit the brake caliper in place and coat the bolts

with Loctite FRENBLOC.
Fill the gearbox.
74937-3S
21-31
MANUAL GEARBOXES
Speedometer drive 21
CHANGING REFITTING
1st possibility: Refit the new speedometer drive using pliers with
Only the speedometer drive or shaft is damaged. a long, flat nose.
The drive gear and its shaft are refitted by hand.

REMOVAL The shaft must be positioned correctly in relation
to the locating notches on the drive gear, owing
It is not necessary to dismantle the entire gearbox. to the elasticity of the shaft lips.
Uncouple the left hand driveshaft.
Remove the spider sun wheel.

CORRECT INCORRECT
Turn the differential by hand so that the speedo-
meter drive gear can be reached.
Unclip the shaft, pulling it vertically using long no-

sed pliers.
Using the same pliers, remove the drive gear from

its location.
86053S
Ensure that it is properly clipped in place.
Refit the spider sun wheel.
2nd possibility:
The speedometer drive gear and crown wheel are
damaged.
88577S
The gearbox must be removed and the final drive
dismantled.
21-32
MB AUTOMATIC TRANSMISSION
Exploded view 23
DI2325
23-1
Use 23
DRIVING
The automatic transmission is greased under pres-

sure and therefore only while the engine is run-
ning.
Consequently, in order to avoid serious damage,

the following recommendations must be follo-
wed:
- never drive with the ignition switched off (on a

downwards slope, for example), the danger of
such a practice cannot be emphasised enough.
- never push the vehicle (for example: to reach a

petrol station), except in the situation where
the precautions stated in the section below on
"Towing" are observed.
Furthermore, the vehicle can only be driven if the

engine is running. It is therefore impossible to
start the engine of an automatic transmission ve-
hicle by pushing it.
TOWING
The front of the vehicle should be lifted. However,

if this is not possible, the vehicle may, in exceptio-
nal circumstances, be towed with four wheels on
the ground under the following conditions:
1. Add an additional two litres of automatic

transmission oil ELF RENAULTMATIC D2 or
MOBIL ATF 220.
2. Only tow the vehicle at a speed of less than

20 mph (30 km/h) over a distance of less than
30 miles (50 km) (lever in"N")
DO NOT FORGET TO REMOVE THE EXCESS OIL

AFTER TOWING.
23-2
Identification 23
STEP
AUTO FINAL
DOWN SPEEDOMETER OIL
VEHICLE TRANS ENGINE DRIVE COMPUTER
GEAR DRIVE RATIO PRESSURE*
TYPE RATIO
RATIO
B53A
C53A MB1 E7J 29/24 15/58 21/19 4.4±0.1 138
L53A
B537
C537 MB1 E6J 29/24 15/58 21/19 4.4±0.1 138
L537
B53B
C53B MB3 F3N 29/24 16/57 21/19 4.4±0.1 132
L53B
(*) On the road, with the lever in 2nd at 50 mph (80 km/h).
Converter drive plate:
• Maximum permissible run-out: 0.3 mm
• Tightening torque:
- Bolt for securing to the crankshaft: 6.5 daN.m
- Bolt for securing to the converter: 2.5 daN.m
23-3
Gear ratios 23
For vehicle types B53A - C53A - L53A - B537 - C537 - L537
Gear ratios 1st 2nd 3rd Reverse
Gear reduction 2.5 1.5 1 2
Gear reduction +step down 2.069 1.241 0.828 1.655
Gear reduction + stepdown + final drive 7.999 4.799 3.199 6.399
Speed in km/h for 1000 rpm * 12.937 21.562 32.343 16.171
For vehicle types B53B - C53B - L53B
Gear ratios 1st 2nd 3rd Reverse
Gear reduction 2.5 1.5 1 2
Gear reduction + stepdown 2.069 1.241 0.828 1.655
Gear reduction + stepdown + final drive 7.370 4.422 2.948 5.896
Speed in km/h for 1000 rpm * 14.042 23.403 35.105 17.552
* For vehicles fitted with 165/70 R13 tyres.
23-4
Gear change thresholds 23
Gear change thresholds in km/h for vehicle types B53B - C53B - L53B
POSITION OF FOOT 1 → 2 2 → 3 3 → 2 2 → 1
No-load (PL) 23 40 27 15
Full-load (PF) 72 118 102 63
Kickdown 72 118 102 63
Gear change thresholds in km/h for vehicle types B537 - C537 - L537 - B53A - C53A - L53A
POSITION OF FOOT 1 → 2 2 → 3 3 → 2 2 → 1
No-load (PL) 23 46 26 13
Full-load (PF) 62 102 74 40
Kickdown 67 109 94 54
No-load (PL) Foot off accelerator pedal

Full-load (PF) Accelerator pedal fully depressed
NOTE: The kickdown switch is incorporated in the computer via the load potentiometer. In the event of a
fault refer to workshop repair manual T.A. M.
23-5
Consumables 23
DESCRIPTION COMPONENT CONCERNED
RHODORSEAL 5661 Sealing of the driveshaft roll pins
- Sun wheel splines

Grease MOLYKOTE BR2
- Converter locating device
Loctite FRENBLOC Brake caliper securing bolt
Parts which must be changed once they have been

removed:
- the roll pins,

- the self-locking nuts,
- the copper seals.
Oil
The MB automatic transmission is a gearbox which has only one level and one grade of oil (converter, final
drive, mechanical section).
GRADE (for example) : ELF RENAULTMATIC D2.
If this is not available, use (example) :
- MOBIL ATF 220D

- TOTAL DEXRON
CAPACITY IN LITRES :
Theoretical total: 4.5 litres
After draining: 2 litres
23-6
Draining - Filling - Levels 23
DRAINING - FILLING Start the engine and wait one or two minutes for
the converter and cooler to fill up.
Draining must be carried out when cold, dipstick
and plug (A) removed. The oil is at an ambient temperature of 20°C.
Change the strainer. Pull out the dipstick while the engine is running.
The level should not be below mark (1) MINIMUM

WHEN COLD (risk of damage) and should not ex-
ceed mark (2) MAXIMUM WHEN COLD (risk of da-
mage).
Never exceed the "MAXIMUM WHEN COLD"

level.
WARNING
Too much oil results in:

- overheating of the oil,
- leaks.
Too little oil results in:

- damage to the mechanisms.
93609R
Refit the plug together with a new seal.
Fill with the recommended oil via the dipstick

tube.
Use a funnel fitted with a 15/100 filter in order to

prevent the entry of impurities.
Run the engine at idle speed.
Check the level and top up if necessary.
CHECKING THE OIL LEVEL WHEN COLD

85935R
With the vehicle empty, place it on a even, hori-
zontal surface.
Position the selector lever in "PARK" (P). CHECK THE LEVEL WHEN COLD.
1. MINIMUM WHEN COLD
2. MAXIMUM WHEN COLD
23-7
Checking and adjusting the potentiometer 23
1st METHOD
B.Vi. 958 Checking unit
ADVICE
With the vehicle stationary and the ignition off,

check that the accelerator cable is adjusted cor-
rectly.
Disconnect the 3-way connector (10) for the wi-

ring which connects the computer to the poten-
tiometer.
85651-1R
CHECKING
Press the accelerator pedal down Indicator

fully light 9
*
CORRECT
INCORRECT or maladjusted
93698R
Slightly slacken the two bolts (V) which secure the

Connect the potentiometer connector (10) to the potentiometer.
B.Vi. 958 connector (16).
Keep the throttle fully open via the accelerator
Supply the B.Vi. 958 from the battery. pedal and slowly turn the potentiometer to illumi-
nate indicator light (9) and retighten the two
Reversing switch "I2" on "Y". bolts (V)
If indicator light (9) cannot be illuminated by this

adjustment, check its wiring and if the potentio-
meter is faulty, change it.
Whenever the potentiometer is changed or remo-

ved, adjust it.
NOTE: if the carburettor is cleaned, dismantle

the load potentiometer or avoid splashing clea-
ning fluid on it.
23-8
2nd METHOD
XR25
ADVICE
With the vehicle stationary and the ignition off,

check that the accelerator cable is adjusted cor-
rectly.
Disconnect the 3-way connector (10) of the wiring

which connects the computer to the potentiome-
ter.
93607R
Connect:
- the round plugs to the battery (red on "+",
black on "-"),
- the three-way connector (16) to the
potentiometer connector (10).
93608R
Connect the XR25, the three-way extension lead

and the two round plugs.
23-9
93606S
On the XR25 keypad, press key "V" then "1";
Reading the numerical values on the display:
At full-load, the display should show a value bet-

ween "0" and "3"; ignore any "-" signs which
may be displayed to the right of the value.
For the adjustment procedure, refer to workshop

repair manual MR T.A. M or the previous page.
23-10
Oil pressure 23
B.Vi. 466-06 Adaptor

B.Vi. 466-07 Oil pressure gauge
CHECKING ADJUSTING
Meauring conditions Remove the stop (1) and turn the capsule. By scre-
wing in the capsule, the pressure in increased and
Ensure: vice versa.
- that the normal operating temperature is
80° C,
- that the accelerator cable is adjusted correctly.
Connect oil pressure gauge B.Vi. 466-07 to

adapter B.Vi. 466-06 at (A).
88967G
88990R
Measuring
Place the selector lever in 2nd.
Accelerate fully and apply the brake at the same

time to stabilise the speed at 50 mph (80 km/h).
The pressure should be 4.4 ± 0.1 bars 85393S
NOTE: 2 notches = approximately 0.08 bar.
23-11
Oil pressure 23
To make this operation easier, a tool can be made:
A = 8/30 mm diameter washer, thickness 1.5 mm

B = 6 mm round rod
88862R1
23-12
Strainer 23
The strainer should be changed every 36,000 or Lift the engine - gearbox assembly to a dimension
40,000 miles (50,000 km) depending on servicing of approximately 135 mm.
programme applicable and when any significant
work is carried out on the mechanism.
CHANGING
Drain the automatic transmission.
Remove the gearbox silent block nut (A).
93605R
88170R
Place a lifting device under the gearbox at (B).
85546R
23-13
Strainer 23
Remove the sump and the strainer fitted with its
seal.
Clean the sump and its magnets and refit them (so
that the grooved surface is fitted against the
panel).
93618S
Fit the new strainer fitted and its seal and torque
tighten to 0.9 daN.m.
Refit the sump and fill with oil.
23-14
Automatic transmission (Removal - Refitting) 23
Removal of the MB type automatic transmission requires the removal of the engine - automatic transmission
assembly.
Mot. 453-01 Hose clamps

Mot. 582 Converter locking sector
Mot. 878 Engine lifting eyes and chain
B.Vi. 465 Tool for replacing the torque
converter seal
TIGHTENING TORQUES (in daN.m) Remove:

- the cooling system radiator and the expansion
Brake caliper securing bolts 10 bottle,
Shock absorber base securing bolts 11
Special point for the E engine
Lower ball joint nut 6 Remove :
Driveshaft gaiter securing bolts 2.5 - the integral electronic ignition (A.E.I.),
Wheel bolts 8 - hot air tube (A) then the air filter complete,
Oil cooler bolts 4
Converter drive plate bolts 2.5
Bolts around the automatic
transmission mounting 4
Depending on specification, remove the self-

contained air bag in order to eliminate any risk of
triggering it (refer to the first generation air bag
manual).
Removal of the assembly does present any special

points, however observe the points below:
REMOVAL
Drain:
- the cooling system (lower radiator flexible DI2326
hose),
- the automatic transmission oil.
- the bar between the shock absorber turrets,

- the front wheels.
23-15
Special point for the F3N engine - the power assisted steering hose securing
plate (1).
Remove:
- the ignition power module,
93601R
93603S
Fit clamps Mot. 453-01 to the steering pump re-
- the air filter complete, servoir hoses and then remove the steering pump
- the absolute pressure sensor and its moun- reservoir pipes and the front wheels.
ting,
93602S
23-16
Remove (all types) : - the steering ball joint using extractor tool
T.Av. 476,
On the left hand side of the vehicle
- the brake caliper bolt (A) and attach it to the

body,
BENDIX series IV
85965-1R
- the three driveshaft gaiter securing bolts,

90149R
GIRLING
85678R
91758R
23-17
- the lower ball joint and shock absorber base - the upper bolt (1) and slacken the lower bolt
bolts, (2).
- the transmission - stub axle carrier assembly,
taking care to protect the spider.
90311S 90259R
On the right hand side of the vehicle: Tilt the stub axle carrier and uncouple the drives-
haft.
It is not necessary to remove the brake caliper.
Disconnect the hoses for the heater matrix on the
Extract: coolant pump and the automatic transmission oil
- the driveshaft roll pin using drift tool cooler, the fuel circuit hoses and the brake servo
B.Vi. 31-01, braking vacuum hoses.
93710R
23-18
Remove (all types) : - the injection computer connector,
- the electrical connectors,
93598S
- the oxygen sensor (1): this is located on the

exhaust manifold upstream of the clamp
which connects the primary down-pipe.
92056S
- the earthing braids.
Special point for the F3N engine
Disconnect:
- the three hoses (A) (it is advisable to mark
them before disconnecting them),
89091R
93600R
23-19
Remove: Figure 2
- the earthing braids (engine and automatic
transmission),
- the following cables:
• accelerator cable,
• rev counter cable,
• gear selection cable at attachment points
(A) and (B).
DI2327
- the front and rear rubber mounting nuts (E).
93604R
Remove :
- the computer retaining strap,
- the exhaust clamp (for F3N engine figure 1)
- the exhaust pipe (for E engine figure 2), 92108R
Figure 1
91128S
23-20
Attach tool Mot. 878 to the engine lifting eyes. Fit torque converter tool B.Vi. 465 and uncouple
the automatic transmission from the engine.
Lift the engine - automatic transmission assembly
and remove bolts (E).
Remove the engine - automatic transmission as-

sembly from the engine compartment.
86724R
REFITTING (Special points)

93599S
Lower the engine - automatic transmission assem-
Remove: bly, align it using the front rubber mountings and
- the starter motor, secure the two bolts for the rear rubber moun-
- the converter protective plate. tings.
Fit locking sector tool Mot. 852 and remove the Torque tighten the bolts and nuts.
bolts for the drive plate on the converter. Fit the brake caliper securing bolts with
adhesive (Loctite FRENBLOC) and torque
tighten them.
Press the brake pedal several times to bring the

pistons into contact with the brake pads.
Apply RHODORSEAL 5661 to the driveshaft roll
pin holes.
Adjust the accelerator and choke cables.
86511R
23-21
Carry out the following:
- fill the automatic transmission,
- fill and bleed the cooling system (refer to sub-
section 19),
- fill and bleed the power-assisted steering
pump circuit,
- retighten the exhaust flange.
85915-1S
To ensure correct sealing, do not forget to fit the

O-ring seals (T) on each side of the oil cooler. 92323R
Gradually tighten the bolts to a torque of

4 daN.m.
NOTE: the exhaust down-pipe flanges are fitted
with spacers (1) which determine the tension of
the springs.
Tighten until the spacers are in contact.
Start the engine and check that the assembly is

perfectly sealed.
89010R
23-22
AD4 AUTOMATIC TRANSMISSION
Exploded view 23
DI2302
23-23
Operation 23
DRIVING
The automatic transmission is greased under pres-

sure and therefore only while the engine is run-
ning.
Consequently, in order to avoid serious damage,

the following recommendations must be follo-
wed:
- never drive with the ignition switched off (on a

downwards slope, for example), the danger of
such a practice cannot be emphasised enough.
- never push the vehicle (for example: to reach a

petrol station), unless the precautions descri-
bed in the "Towing" section below are taken.
Moreover, the vehicle canonly be driven if the en-

gine is running. It is therefore impossible to start
the engine of an automatic transmission vehicle
by pushing it.
TOWING
It is always preferable to tow the vehicle on a flat

bed trailer or with the front wheels lifted.
However, if this is not possible, the vehicle may, in
exceptional circumstances, be towed under the
following conditions:
1- rear wheels lifted by 15 cm or all four wheels

on the ground (without adding any oil to the
mechanism),
2. Only tow the vehicle at a speed of less than

25 mph (40 km/h) over a distance of less than
15 miles (25 km) (lever in"N")
23-24
Identification 23
AUTO STEP FINAL
SPEEDOMETER
VEHICLE TRANS ENGINE CONVERTER DOWN DRIVE COMPUTER
RATIO
TYPE RATIO RATIO
B533
F2N 721
C533 AD4 001 227 D AA 69/77 17/64 18/16 100
F2N 727
L533
B536
AD4 001 F2N 725 227 D AA 69/77 17/64 18/16 103
L536
B53C
C53C
AD4 004 F3N 743 227 D AA 69/77 17/64 18/16 101
D53C
L53C
353F
453F
553F
853F
AD4 014 F3P 765 227 D AA 69/77 17/64 18/16 108
B53V
C53V
D53V
L53V
B53Y
C53Y F3P 705
AD4 004 227 D AA 69/77 17/64 18/16 103
D53Y F3P 707
L53Y
F3P 705 111

D53Y AD4 004 227 D AA 69/77 17/64 18/16
F3P 707 118
115
D53V AD4 014 F3P 765 227 D AA 69/77 17/64 18/16
122
103
B53Y AD4 014 F3P 705 227 D AA 77/71 17/64 18/16 111
118
B533 AD4 001 F3P 765 227 D AA 77/71 17/64 18/16 100
353H
AD4 014 F3P 682 227 D AA 69/77 19/65 18/16 122
453H
* For identification using the XR25 refer to the FAULT-FINDING section.
23-25
Gear ratios 23
For vehicle types X533, X536, X53C, X53F, X53V, X53Y, 053H
Gear ratio 1st 2nd 3rd 4th Reverse
Gear reduction 2.71 1.55 1 0.68 2.11
Overall reduction 11.40 6.51 4.20 2.85 8.86
Speed in km/h for 1000 rpm with

9.26 16.20 25.13 37.04 11.90
1.76 tyres
23-26
AUTO ACCELER-ATOR 1 2 2 3 3 4 4 3 3 2 2 1
VEHICLE TRANS POSITION
TYPE A B A B A B A B A B A B
No-load 17 20 35 40 60 70 46 51 31 10
AD4 000
X533 Full-load 41 46 76 83 120 130 103 112 46 68 26 30
AD4 001 Kickdown 48 88 136 130 133 85 41 45
No-load 16 20 35 39 56 60 48 30 10
X536 AD4 001 Full-load 41 44 68 79 100 120 81 103 43 28
Kickdown 48 86 126 135 117 130 78 83 38 41
No-load 17 20 35 40 60 70 47 50 30 10
X53C AD4 004 Full-load 36 42 70 80 117 128 103 112 52 68 26 30
Kickdown 42 44 80 131 130 78 81 40
No-load 18 40 62 65 50 55 32 12 15
X53Y AD4 004 Full-load 40 47 75 87 122 140 108 120 70 75 20 30
Kickdown 50 90 144 135 85 45
No-load 10 20 45 47 69 75 55 61 36 40 6 14
X53F
X53H AD4 014 Full-load 45 51 85 95 138 152 114 132 68 79 21 36
X53V
Kickdown 53 98 157 149 93 48
23-27
The figures shown in the table are average theoretical values of gear change speeds in km/h
tolerances = ± 10 %.
No-load (PL) : Accelerator pedal released.

Full-load (PF) : Accelerator pedal fully pressed.
Kickdown : Kickdown (changing to a lower gear).
A : Lower gear change thresholds. The gears change to lower gear ratio. Switch (1) is not operated and the
EXC warning light is extinguished.
B : Higher gear change thresholds. The gears change to a higher gear ratio. Switch (1) is operated and the
EXC warning light is illuminated.
91115-1R
23-28
Consumables 23
DESCRIPTION COMPONENT CONCERNED
RHODORSEAL 5661 Sealing of the driveshaft roll pins
Sun wheel splines

Grease MOLYKOTE BR2
Converter locating device
Loctite FRENBLOC Brake caliper securing bolt
Parts which must be changed once they have been

removed:
- the roll pins,

- the self-locking nuts,
- the copper seals.
Oil
The AD4 automatic transmission is a gearbox which has two grades of oil and two levels.
MECHANICAL SECTION : ELF RENAULTMATIC D2 (D20104).
If this is not available, use:
- MOBIL ATF 220 D (D 20104 or D 21412).

- TEXAMATIC 4011.
FINAL DRIVE: TRANSELF TRX 80W.
23-29
Oil drain intervals 23
For draining of the mechanical section, refer to the warranty and servicing booklet for the vehicle.
The oil level must be checked every 10,000 miles (15,000 km) in case there is a slight oil leak.
The final drive is not drained; it is filled for life.
The level can be topped up if there is a slight leak.
Oil capacity
TOTAL volume Volume after draining
MECHANICAL 5.7 litres 3.5 litres

SECTION
FINAL DRIVE 1 litre -
NOTE : If the automatic transmission is changed, only carry out the level checking operation, as the
transmission is supplied filled by the Parts Department.
23-30
Oil drain 23
B.Vi. 1213 Automatic transmission drain

plug spanner
M.S. 1019-10 XR25
DRAINING Final drive:
Mechanical section : The final drive is filled and topped up via plug (C)
by filling with oil until it overflows.
There are two plugs on the mechanical section
cover :
A : Oil level top-up plug.

B : Oil drain plug (triangular imprint on it).
The unit is drained by removing plug (B).
94882R
Reminder:
The final drive is not drained, it is filled for life.
94882R2
23-31
Filling - Levels 23
FILLING - LEVELS 1 - The vehicle must be on a four post lift and the
transmission at ambient temperature.
Filling is via tube (D).
2 - Switch on the engine with the selector lever
in park.
3 - Connect the XR25 and enter:
D 0 4 then # 0 4
4 - Lift the vehicle and run the engine until a tem-

perature of 60 °C is reached
5 - When the required temperature has been

reached, with the engine running, open the
oil top-up plug; allow the excess oil to flow
out for approximately 20 seconds (this excess
should exceed 0.1 litres). Refit the plug.
6 - If the volume of oil recovered is less than 0.1

litres, the level is not correct, repeat the ope-
ration.
In this case, add 1 litre of the recommended oil

94845R1
and leave the automatic transmission to cool be-
fore carrying out the operations which follow.
Use a funnel fitted with a 15/100 filter to prevent

the entry of impurities.
The level is MUST be checked in accordance with

the procedure described below:
Before carrying out this procedure:

- if the gearbox has been drained, fill it with
3.5 litres of oil,
- if the gearbox is simply to be checked, 0.5 litres
of the recommended oil must be added.
23-32
Filling - Levels 23
ELECTRONIC FAULT WARNING LIGHT MESSAGE
- When the ignition is switched on, with the vehicle stationary and the engine
stopped, in position P or N, the warning light illuminates.
Operation with no fault - When the starter is operated, the warning light remains illuminated.
- When the key is released, with the ignition on and the engine running, the
warning light extinguishes approximately 3 seconds after starting the engine.
- When the vehicle is stationary with the engine running or when driving, the
warning light is permanently illuminated.
Fault present - When the vehicle is moving the warning light illuminates and extinguishes
with no operation of the ignition key.
- When the vehicle is moving, the warning light illuminates briefly.
- When the vehicle is moving or stationary, the warning light flashes with a
Oil temperature
frequency of approximately 1 flash per second. In this case, reduce the
<- 20°C or >+140°C
performance requirement by reducing the acceleration.
Oil pressure
The transmission is fitted with an oil pressure

socket. Connect tool B.Vi. 1215 for checking the
automatic transmission pressure sensor only.
The oil pressure cannot be adjusted.
Its value is determined by the computer.
94845-1R
23-33
Changing the strainer 23
This filters the oil and assures correct operation of For models with ABS
the automatic transmission.
Remove:
- the nut (C) which secures the ABS electro-
pump assembly to the silent block.
Strainer securing bolts 0.50 +0.10

Casing securing bolts 1 ± 0.1
Bolts securing the rubber
mounting to the sidemember 2
Rear mounting securing bolts 6.5
Wheel bolts 9
REMOVAL
94933R
Place the vehicle on a two post lift and fit the til-
ting prevention claws to the pads (see Technical
Note 1168). - the front left hand wheel and remove the pla-
stic deflector in the wheel arch (to enable the
Drain the automatic transmission (mechanical sec- two automatic transmission sump rear secu-
tion; triangular imprint on the drain plug). ring bolts to be extracted later).
Remove: Using the component jack, lift the automatic

- the expansion bottle, transmission.
- the air filter,
- the two upper rubber mount bolts (A) and
slacken the other two (B), without removing
them.
94933-1R 94887S
23-34
Changing the strainer 23
Remove
- the automatic transmission sump,
- the strainer and its seal (bolts 1).
94933-1S
On models with ABS
Refit the nut (C) which secures the ABS electro-

pump assembly to the silent block.
92084R
Before refitting, clean the sump and its magnet.
Check the condition of the sump seal and the

drain and top-up plugs.
REFITTING
Fit the new strainer and its seal.

94933R
+0.1
Torque tighten the bolts to 0.5 0 daN.m.
Fit the sump and torque tighten the bolts to Refit:

1±0.1 daN.m. - the plastic deflector in the front left hand
wheel arch,
Lower the transmission and remove the compo- - the front left hand wheel,
nent jack. - the air filter,
- the expansion bottle.
Refit the transmission rubber mounting bolts.
Fill with oil and check the level.
23-35
Hydraulic distributor 23
TIGHTENING TORQUES (in daN.m) - the selector lever (2) to enable the lever to tra-
vel beyond the "Park" position.
Casing securing bolts 1 ± 0.1
+0.1
Strainer securing bolts 0.50 0
+0.1
Distributor securing bolts 0.50 0
Removal
This operation is carried out with the selector le-

ver in position "P" (Park).
Drain the transmission.
Remove:
- the sump (refer to the section on "Changing
the strainer"),
- the strainer (bolts 1),
94845-2R
This excess travel is necessary to release the drive

for the manual valve control sector.
94840R
- the gear selector lever cable,
94841R
23-36
Disconnect the sealed connector cable by pressing - the selector from the manual valve (4) by de-
on the locking ring. taching first at (A) and then at (B).
Extract the hydraulic distributor manual valve.
94925S
Remove:
- the sealed connector after removing bolt (3),
94848R
Remove the 16 bolts which secure the hydraulic

distributor. Bolts (X) remain in place and secure
the closing plate to the distributor.
94848-1R
94841-1R
23-37
Push the selector lever to the stop and disconnect REFITTING
the hydraulic distributor by releasing the modula-
ting solenoid valve from the casing. Ensure that the F1 supply tube (8), the modulating
solenoid valve filter (7), and the system inserts (6)
are present.
91724R
94852R1
Ensure that the inserts (6) and the filter (7) remain
in place in the hydraulic circuit of the casing.
Engage the hydraulic distributor.
Push the gear selector lever to the stop taking

care to correctly engage the modulating solenoid
valve in the casing.
94852R2
23-38
Fit the manual valve and the selector (4) by first
engaging section (A) and then section (B).
91724R
Fit the 16 bolts securing the distributor to the ca-

sing and torque tighten them to 0.5 daN.m in the
order shown. 91350R4
Refit the sealed connector with its O-ring seal and

bolt (3).
94841-1R1
94848-1R
23-39
Fit a new strainer and a new seal.
Torque tighten to 0.5 +0.1

0 daN.m.
94845-2R
Refit the control cable.
Fill with oil and check the level.

94840R
NOTE:
Whenever the hydraulic distributor is changed or
removed, change the modulating solenoid valve
Fit the sump (check that the seals are in good filter, the strainer and its seal.
condition and that the magnet is present).
+0.1 daN.m.
Torque tighten bolts (1) to 1 0
Refit the automatic transmission (refer to the

section on "Changing the strainer").
Reconnect the sealed connector.
Refit the gear selector lever (2).
23-40

Mot. 582 Locking sector
Mot. 1202 Hose clamp grips
Shock absorber securing bolts 11

Transmission securing bolts 3.5
Wheel bolts 9
Bolts securing the automatic
transmission to the engine 4
Bolt securing the rubber mounting to the
sidemember 2
Rear mounting securing bolts 6.5
Oil cooler bolts 2.5
Converter drive plate bolts 1.5
IN ORDER TO REMOVE THE AUTOMATIC

TRANSMISSION, THE ENGINE - AUTOMATIC
TRANSMISSION ASSEMBLY MUST BE REMOVED.
Depending on equipment level, remove the self-

triggering (refer to the first generation air bag
manual).
REMOVAL
Drain:
- the automatic transmission (only if it is to be
changed),
- the cooling system.
Remove:
- the bonnet,
- the air filter and its mounting,
- the antipercolation air duct.,
- the bar (if fitted).
23-41
94948R
Disconnect the accelerator cable (2) from the carburettor after dis-
connecting the kickdown switch connector (1).
Carburation system
94932R
23-42
Injection system
94927S
94930R
transmission),
Disconnect: - the AEI (integral electronic ignition) or,
- the choke cable (depending on type), - the MPA (ignition power module) and the
- the speedometer cable after unscrewing it oxygen sensor connector (depending on vehi-
from the automatic transmission, cle type).
94834-1S
- the engine wiring harness connectors in the

box on the left hand wheel arch and the auto-
matic transmission computer connectors, 94929S
23-43
Remove the following pipes: Remove:
• fuel pipe, - the 35-way injection computer connector (5),
• vacuum pipe on the brake servo, - the purge canister solenoid valve supply
connector (6),
(Depending on vehicle type) - the engine harness connection connector (7),
• remove the pipes for the automatic
transmission accelerated idle solenoid valves
(2) and the power-assisted steering (3),
94931R 94928-1R
• bleed canister (A), (all types)

• bleed canister solenoid valve(B).
- the following hoses:
• radiator,
• heater,
• power assisted steering pump reservoir af-
ter fitting tool Mot. 453-01.
94928R
23-44
- the oil cooler,
86511R
Remove: 94835S
- the starter motor heat shield,
- the starter motor,
- the bolts securing the automatic transmission
to the engine.
Remove the transmission from the engine taking

care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the

engine, check the presence of the centring pins on
the block.
Grease the device which locates the converter in

the crankshaft with Molykote "BR2" .
Fit the automatic transmission to the engine and

torque tighten the securing bolts to 4 daN.m .
Fit the nuts which secure the drive plate to the

94890S converter using Loctite FRENBLOC and torque
tighten them to 1.5 daN.m.
Refit:
- the oil cooler and torque tighten the bolts to
2.5 daN.m,
- the starter motor and the heat shield,
- the converter protective plate.
Refit the engine - automatic transmission assem-

bly in the engine compartment.
Refit in the reverse order to removal.
23-45
Remove: 1st type assembly: Hexagonal socket-type screws.
- the power assisted steering reservoir, (For removal and refitting it is advisable to use, for
- the power assisted steering high pressure pipe example, socket FACOM J 235 and the 6 mm hexa-
(detach it from the retaining plate under- gonal male adaptor).
neath the vehicle),
2nd type assembly: 12-sided socket-type screws.
(For removal and refitting it is advisable to use, for
example, 12-sided male socket FACOM SV. 8L).
Right hand side
94949S
- the gear selector lever,

- the radiator,
- the exhaust clamp
94838-2S
Left hand side
91128S
- the front wheels,

- the 6 bolts which secure the driveshafts to the
sun wheel outlet flanges.
94837S
23-46
On each side of the vehicle remove: Remove :
- the steering ball joint using extractor tool - the driveshafts on the side,
T. Av. 476, - the engine - automatic transmission rubber
mountings.
Fit the load positioner to the engine - automatic

transmission assembly.
Remove the assembly from the engine compart-

ment.
85965-1R
- the upper bolt (1) and slacken the lower bolt

(2) for the shock absorber base.
91131S
90259R
23-47
Remove the converter protective plate. REFITTING
Special points:
Before refitting the driveshafts, fill the sun wheel

outlet flanges with Molykote "BR2" grease .
94885S
Fit locking sector tool Mot. 582 and remove the

three nuts which secure the drive plate to the
converter.
94890-2S
IMPORTANT:
When refitting the accelerator cable, adjust it cor-

rectly as this is important to ensure correct opera-
tion of the kickdown switch.
Carry out the following operations:

- fill and bleed the cooling system,
- top up the power assisted steering,
- top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO

VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load poten-
tiometer travel.
23-48
ABS version AD4 AUTOMATIC TRANSMISSION
On vehicles fitted with ABS, the automatic transmission is removed after removing the engine-gearbox
drive assembly.
Mot. 1040-01 Dummy engine cradle for

removing - refitting the engine-
gearbox drive assembly
TIGHTENING TORQUES (in daN.m) REMOVAL

Front engine sub-frame mounting bolts 4
Rear engine sub-frame mounting bolts 8.5 Remove the bumper at (A).
Upper shock absorber mounting bolts 2.5
Steering universal joint securing bolt 3
Wheel bolts 9
Driveshaft mounting bolts 3.5
Shock absorber base mounting bolts 11
Bolts securing the automatic
transmission to the engine 4
Oil cooler bolts 2.5
Converter drive plate bolts 15
92054R
Depending on equipment level, remove the self-

triggering (refer to the 1st generation air bagma-
nual).
92058R
23-49
Remove:
- the interior wheel arch trim,
92057R
- the air filter and its mounting.
Remove the separating bar and the antipercola-

tion pipes (if fitted).
94948S
23-50
Disconnect:
- the accelerator cable from the carburettor af-
ter disconnecting connector (1) from the ki-
ckdown switch (2).
94927S
94932R

- the choke cable (depending on type of carbu- transmission),
ration), - the integral electronic ignition (AEI) and re-
- the speedometer cable after unscrewing it move it,
from the automatic transmission, - the following pipes :
• fuel pipes,
• vacuum pipes on the brake servo,
• remove the pipes for the automatic trans-
mission accelerated idle solenoid valves (2)
and the power-assisted steering (3),
94834-1S
- the engine wiring harness connectors in the

box on the left hand wheel arch and the auto- 94931R1
matic transmission computer connectors,
• radiator hoses,
• heater pipes.
23-51
Remove (depending on vehicle type) : - the engine wiring harness connectors in the
- the air filter and its mounting, box on the left hand wheel arch and the auto-
- the antipercolation air duct. matic transmission computer connectors,
Disconnect:
- the accelerator cable from the throttle hou-
sing after disconnecting connector (1) for the
kickdown switch (2),
94927S
- the 35-way injection computer connector (5),

- the bleed canister solenoid valve supply
94930R
connector (6),
- the engine wiring harness connection connec-
tor (7).
- the speedometer cable after unscrewing it
from the automatic transmission,
94834-1S 94928-1R
23-52
Disconnect the oxygen sensor connector.
Remove:
- the earthing braids (motor and automatic
transmission),
- the ignition power module (MPA),
- the following pipes :
• fuel pipes,
• vacuum pipes on the brake servo,
• bleed canister (A),
• bleed canister solenoid valve (B).
92059S
Fit tool Mot. 1040-01.
94928R
• radiator hoses,
• heater pipes.
ALL TYPES
Unhook:
- the power assisted steering reservoir,
- the gear selector lever cable.
Refit:
- the radiator,
- the brake calipers and attach them to the ve-
hicle body,
- the tie rods connecting the sub-frame to the 92061S
body,
- the primary exhaust down-pipe,
- the cam bolt for the universal joint.
Lower the vehicle to the ground.
23-53
Remove: With the fan assembly removed.
- the upper shock absorber bolts,
92382S
92114R
Separate the engine - automatic transmission as-
sembly from the engine sub-frame.
- the bolt securing the rubber mounting to the
automatic transmission, Remove the converter protective plate.
94933-2R
- the four engine sub-frame mounting bolts.
Lift the body and remove the engine-gearbox

drive assembly. 94885S
Fit locking sector tool Mot. 582 and remove the

three nuts which secure the drive plate to the
converter.
23-54
86511R 94835S
Remove: - the bolts securing the automatic transmission

- the starter motor heat shield, to the engine.
- the starter motor,
Separate the transmission from the engine taking
care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the

engine, check the presence of the locating pins on
the block.
Grease the device which locates the converter in

the crankshaft with Molykote "BR2" .
Fit the automatic transmission to the engine and

torque tighten the securing bolts to 4 daN.m .
Fit the nuts which secure the drive plate to the

converter using Loctite FRENBLOC and torque
tighten them to 1.5 daN.m.
Refit:
- the oil cooler and torque tighten the bolts to
94890S 2.5 daN.m,
- the starter motor and the heat shield,
- the converter protective plate.
- the oil cooler,
Refit the engine - automatic transmission assem-
bly to the engine sub-frame.
Refit in reverse order to removal.
23-55
Special points Position the upper mountings in the appropriate
drilled hole.
Before refitting the driveshafts, fill the sun wheel A = Manual steering
outlet flanges with Molykote "BR2" grease . B = Power assisted steering
94890-2S 92114-1R
The alignment of the body with the engine sub- IMPORTANT

frame is made easier by using threaded rods
which are approximately 100 mm long. When refitting the accelerator cable, adjust it cor-
rectly as this is important to ensure correct opera-
tion of the kickdown switch.
Carry out the following operations:

- fill and bleed the cooling system (refer to sec-
tion 19),
- top up the power assisted steering,
- top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO

VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load poten-
tiometer travel.
85742S
Tighten the brake caliper securing bolts to a tor-

que of 10 daN.m.
23-56
Full-load validation 23
Connect the XR25 to the vehicle diagnostic socket. Switch on the ignition without starting the en-
gine.
The diagnostic socket (1) is located in the passen- Enter the "A" transmission code on the keypad:
ger compartment, under the dashboard, in the re-
lay and fuse compartment. D 0 4
On the bargraph displays only bargraphs 1 - 3 - 4 -

5 - 6 - 11 remain illuminated either on the right or
on the left hand side.
Validate the full-load position by pressing the ac-

celerator pedal for 5 seconds.
Bargraph 2 illuminates.
Bargraph 6 extinguishes.
When the accelerator pedal is released, only bar-

graphs 1 - 3 - 4- 5 - 11 should remain illuminated.
VERY IMPORTANT: switch off the ignition.
Switch the ignition on again and enter the "A"

transmission code to check whether the validation
has been carried out.
(Repeat the operation if necessary).
92827R Switch off the ignition and disconnect the XR25.
WARNING: If the full-load is validated incorrectly,

Place the selector in position S4. this may cause:
- permanent illumination of the warning light,
- gear change difficulties,
- incorrect gear change thresholds,
- difficulties in the operation of the kickdown
function,
- uncomfortable driving conditions.
92655R1
23-57
Load potentiometer 23
Connect the XR25 to the vehicle diagnostic socket Slacken the idle screw fully until the flap is
(located under the dashboard, in the relay and completely closed.
fuse compartment).
Switch on the ignition without starting the en-

gine.
Enter the "A" transmission code on the keypad:

D 0 4
The computer number is displayed.
Example :
Computer
identification 4-speed
number auto trans
Enter on the keypad # 0 2

90034
The potentiometer setting value in % appears on

the central display.
Slacken the potentiometer securing bolts (V).
Example :
ADJUSTMENT
According to type (carburation)
THE LOAD POTENTIOMETER IS SPECIFIC TO THIS

ENGINE AS IT HAS A LONGER TRACK.
THEREFORE IT IS NOT INTERCHANGEABLE WITH

ANOTHER TYPE OF POTENTIOMETER.
VERY IMPORTANT: Is is essential that the poten-

tiometer adjustment procedure described below
is applied.
94922R
Rotate the potentiometer body until a value is ob-

tained on the central display of between 89.7 and
92.1 %.
23-58
Load potentiometer 23
Retighten securing bolts (1).
(If adjustment is not possible, check the feed).
Readjust the idle speed to 800±50 rpm with the se-

lector lever in neutral.
Then erase the memory and programme the

"Full-load" value.
Depending on vehicle type (Injection)
Slacken the potentiometer securing bolts (V).
94915R
With the accelerator cable at rest, rotate the po-

tentiometer body until a value is obtained on the
central display of between 89.7 and 92.1 %.
Retighten the securing bolts (V).

(If adjustment is not possible, check the feed).
Then erase the memory and programme the

"Full-load" value.
23-59
Computer (119) 23
94926R
When the computer is changed or the memory is

erased, do not forget to carry out a full-load vali-
dation.
23-60
Line pressure sensor (8) 23
94884R
The sensor is secured to the automatic transmis-

sion casing by two bolts.
It is directly accessible from underneath the vehi-

cle, after removing the protective sleeve.
After changing it, do not forget to erase the me-

mory and carry out a full-load validation.
23-61
Multifunction switch (485) 23
94837-1R
The switch is secured to the automatic transmis-

sion casing.
It is accessible from above or underneath the ve-

hicle, after removing the securing plate and the
earth wire (A).

23-62
Vehicle speed sensor (250) 23
94845-3R1
The speed sensor is secured to the top of the auto-

matic transmission.
It is accessible after removing:

- the expansion bottle,
- the rubber mounting bracket.

23-63
Solenoid valves 23
±0.1
Solenoid valve securing bolts 0.9
±0.1
Distributor plate securing bolts 0.5
+0.1
Hydraulic distributor bolts 0.5 0
The sequence and modulating solenoid valves and

the temperature sensor can only changed after re-
moval of the hydraulic distributor.
Remove:
- bolts (A) which secure the distributor closing
plate(B),
- the bolts securing the sequence solenoid
valves (C) and modulating solenoid valve bolt
(D).
Remove the solenoid valve - sensor assembly from

the distributor.
91367R
Refitting the assembly does not present any parti-

cular difficulties. proceed in reverse order to re-
moval.
Retighten the bolts to the recommended torque

(very important).
NOTE:
Each sequence solenoid valve is fitted to its own
mounting. Check to make sure that they are
fitted to the correct mounting.
23-64
Engine torque reduction 23
The purpose of engine torque reduction during gear changes is:
1) to ensure smooth gear change,
2) to reduce the theoretical load of the hydraulic slave cylinders which are operated during gear changes,
3) to relieve the mechanical units.
The torque is reduced by action on the point of advance.
The torque reduction signal is supplied by the automatic transmission computer to the injection computer.
Throughout the duration of the gear change, the point of advance is moved back by 35°.
CHECKING THE CONNECTION BETWEEN THE AUTOMATIC TRANSMISSION COMPUTER AND THE INJECTION
COMPUTER
Display on
Condition Selection on the XR25 Note
the XR25
Gear change pattern selector Enter D03 # 51 Brief change to zero on

in position "EXC". the checking equipment
display.
Automatic transmission in 3rd.
With the vehicle at

approximately 35 mph
(60km/h) in 2nd, change from
2nd → 3rd under light
throttle.
23-65
Special features 23
KICKDOWN FUNCTION ADJUSTING THE CABLE
In order to trigger the kickdown switch on the Connect the XR25 to the diagnostic socket on the
AD4 automatic transmission, two pieces of infor- vehicle.
mation are required.
Place the selector in position S4.
1st piece of information
Accelerator pedal fully depressed to obtain load

potentiometer information (value less than 6%).
The value displayed on the XR25 at # 12 ).
2nd piece of information
The kickdown switch fitted to the accelerator ca-

ble detects excess accelerator pedal travel which,
when it compresses, creates an earth connection
to the automatic transmission computer.
92655R1
Switch on the ignition without starting the en-

gine.
Enter the "A" transmission code D04 on the key-

pad and read # 22 .
94932S1
This methods enables the kickdown function to be

used at higher engine speeds.
In order for the accelerator cable over travel to be

fully effective, check to make sure that the accele-
rator cable is correctly adjusted.
23-66
Special features 23
TEST CONDITIONS DISPLAY ON THE XR25 NOTES
Accelerator pedal released If value 1 is not displayed, check the electrical

(No-load) (PL) connection on the kickdown switch.
Accelerator pedal pressed If value 0 is not displayed at Full-load, check the

(Full-load) (PF) adjustment of the accelerator cable.
23-67
DRIVESHAFTS
Consumables 29
TYPE QUANTITY COMPONENT CONCERNED
Loctite SCELBLOC Coating Stub axle splines
RHODORSEAL 5661 Coating Pins on driveshaft at gearbox end
MOLYKOTE BR2 Coating Splines on coupling at gearbox end
FRENBLOC Coating Brake caliper bolt
MOBIL CVJ 825 320 g Joint GE 86

Black Star 140 g Joint AC 1700
or 160 g Joint RC 490
MOBIL EXF 57C 130 g Joint GI 62
Allocation of seals on the vehicle
Right hand Left hand

JOINTS Wheel end Gearbox
driveshaft driveshaft
end
GE 86 X X X
AC 1700 X X X
RC 490 X X
GI 62 X X
GI 69 X X
29-1
DRIVESHAFTS
Driveshafts 29
Rou. 604 -01 Hub locking tool

T.Av. 1050-02 Hub extractor
B.Vi. 31-01 Pin drift
TIGHTENING TORQUES(en daN.m) On the left hand side
Driveshaft nut 25 Drain the gearbox.

Bolts securing gaiter to gearbox 2.5
Remove the three bolts.
Wheel bolts 9
Nuts securing bottom of shock absorber 17
Steering ball joint nuts 3.5
REMOVAL
Remove:
- the brake assembly (suspend it from the chas-
sis so as not to damage the brake hose),
- the driveshaft nut using tool Rou. 604-01. 85678R
On the right hand side
Remove the rollpin using tool B.Vi. 31-01.
85876-1R 91755R
29-2
DRIVESHAFTS
Driveshafts 29
On both sides: Remove the lower bolt securing the bottom of the
shock absorber and take out the driveshaft.
Remove:
- the steering ball joint nut using tool T.Av. 476,
91691S
85965-1R
Take care not to damage the gaiters during this

- the upper bolt securing the bottom of the operation.
shock absorber.
These vehicles have bonded driveshafts which,

therefore, must be pushed back using tool T.Av. REFITTING
1050-02.
NOTE: The Parts Department now supplies drives-

hafts equipped with protectors and supplied with
fitting instructions which MUST be followed to
ensure correct assembly with the highest degree
of QUALITY. The slightest knock on the gaiters
will damage them sooner or later and lead to des-
truction of the driveshaft.
91750R1
29-3
DRIVESHAFTS
Driveshafts 29
ESSENTIAL FITTING INSTRUCTIONS
DI2905
29-4
DRIVESHAFTS
Driveshafts 29
Never remove the cardboard protectors until the On the left hand side
very end of the refitting operation. Remove the plastic protector from the gaiter and
engage the driveshaft keeping it as horizontal as
possible.
91630R 85677S
Never use a sharp instrument as this could da-

mage the gaiters.
91629R
29-5
DRIVESHAFTS
Driveshafts 29
On the right hand side On both sides
With the protector fitted, smear the driveshaft Coat the stub axle splines with Loctite SCELBLOC.
splines at the gearbox end with MOLYKOTE BR2
grease.

wheel and insert it.
Check its position using the angled drift from tool

B.Vi. 31-01.
Fit two new rollpins using tool B.Vi. 31-01. Seal

the pin holes using RHODOSEAL 5661.
NOTE: the inlet chamfers on the sun wheels make

it easier to fit new rollpins.
91749S
Engage the driveshaft stub axle in the hub.
91691R
74937-4S
29-6
DRIVESHAFTS
Driveshafts 29
On the left hand side
Clean the area where the gaiter bears against the

gearbox, re-fasten the gaiter and the plate.
Keep the gaiter as horizontal as possible and tor-

que tighten the three bolts.
91691-1S
Re-secure:
- the two bolts for the bottom of the shock
absorber to the stub able carrier and torque
tighten them,
- the steering ball joint and torque tighten its
nut.
Torque tighten the driveshaft nut using tool Rou. 85678R

604-01.
85876-1R
29-7
DRIVESHAFTS
Driveshafts 29
On both sides With the vehicle on its wheels, remove the card-
board protectors, tearing them as shown in the
Fit the brake calipers, coat the bolts with Loctite diagram.
FRENBLOC and torque tighten them.
Put the vehicle back on its wheels.
91693R 91633S
Never use a sharp instrument as this could da-

mage the gaiter.
91631S 91632R
Press on the brake pedal several times so that the

piston makes contact with the shoes.
If the left hand driveshaft is being changed, top

up the oil in the gearbox.
29-8
DRIVESHAFTS
Joint GE 86
Gaiter at wheel end 29
T. Av. 537 -02 GE 86 expander

T. Av. 1168 CAILLAU click collar tool
T. Av. 1256 OETIKER collar crimping tool
1 Bell-shaped stub axle DISMANTLING

2 Retaining star plate
3 Spider Remove the existing collars taking care not to da-
4 Shaft yoke mage the grooves in the bell-shaped stub axle.
5 Retaining collar
6 Rubber gaiter
7 Retaining collar
88578R
88638S
29-9
DRIVESHAFTS
Joint GE 86
Remove as much grease as possible. REASSEMBLING
Free the bell-shaped stub axle from the driveshaft Expander tool TAv. 537-02 must be used when re-
by raising the star plate arms (2) one by one. fitting the GE 86 gaiter.
74650R
DO NOT TWIST THE STAR PLATE ARMS. 78411R
Retain the thrust ball, spring and shim under the

ball joint (B). Hold the driveshaft at a convenient angle in a vice
fitted with soft jaws.
NOTE: the thickness of the shim under the ball
joint is adapted to the original clearance. Fit the expander on the end of the yoke (if it will
not fit, deburr the inside of the cylindrical section
This shim must be retained and reused on reas- of the tool with emery cloth).
sembly.
88579R
78408-1R
Remove all traces of grease.
29-10
DRIVESHAFTS
Joint GE 86

It is essential to make sure that there are no sharp Wrap a piece of clean rag round one hand and
edges on yoke (A) (deburr lightly with emery cloth grip the gaiter so that the first fold will stretch
if necessary). when it is slid on.
Carefully and generously lubricate the following

with clean engine oil:
- the whole expander (stems and centre), Incorrect Correct
- inside the gaiter and in particular the neck.
Place a thumb over the bottom hole, pour some

oil into the gaiter and spread it round the inside.
80040
78409G
Lean against the edge of the vice.
80158S Place one hand over the other and pull taking
care that the first fold does not double back.
Slip the gaiter over the end of the expander. Pull the gaiter as close as possible to the cylindrical
section of the expander and then let it return half-
way.
Repeat this operation several times (maximum 5

times ) to make the rubber of the gaiter more plia-
ble (relubricate the stems during the operation if
necessary).
78410S
29-11
DRIVESHAFTS
Joint GE 86
When the gaiter slides more freely, with one Insert the driveshaft yoke in the bell-shaped stub
continuous pull, fit the gaiter on the cylindrical axle.
section of the expander.
Tilt the shaft to fit one arm of the retaining star
plate in a slot in the yoke and press in to locate it
correctly.
78412-2S
Fit the spring and thrust ball in the spider. 74653S
Move the roller cages towards the centre.
Position retaining star plate (2) so that each arm is

central between each spider trunnion.
74652R
29-12
DRIVESHAFTS
Joint GE 86
The other two arms may be fitted easily by using,
for example, a screwdriver with the tip ground as
shown
A = 5 mm B = 3 mm
Ensure that each arm of the retaining star plate is

located in its slot.
Tilt the shaft in the plane of one of the star plate

arms and the ball joint will be freed under the ac-
tion of the spring.
88668S
74697R
Insert the shim under the top of the ball joint (the
shim should not project above the top of the ball
joint).
29-13
DRIVESHAFTS
Joint GE 86
Check the operation of the spider coupling by
hand.
No tight spots should be apparent.
Distribute the sachet of grease evenly between

the gaiter and the bell-shaped stub axle.
NOTE: make sure that you use the amount of

grease specified in the "Consumables" section.
Position the gaiter lips in their grooves in the stub

axle and driveshaft.
88601R
Correct Incorrect
88578S
88639R
Insert a smooth round-edged piece of rod bet-

ween the gaiter and the stub axle to restrict the
amount of air inside.
Fit the collars and tighten them using tool T. Av.

1034.
29-14
DRIVESHAFTS
Joint AC 1700
T. Av. 1168 CAILLAU click collar tool

T. Av. 1256 OETIKER collar crimping tool
A driveshaft can be partially repaired at the wheel

end:
- a coupling change,
- a gaiter change.
6-BALL COUPLING AT THE WHEEL END
1 Bell-shaped stub axle

2 Balls
3 Ball cage
4 Retaining ring
5 Driveshaft
6 Gaiter 78616R
7 Ball hub
A ABS crown wheel (option)
REASSEMBLING
Slide onto the shaft:

- the small collar,
- gaiter (3).
Slide the ball coupling (1) complete with retaining

ring (new) onto the shaft splines until the retai-
ning ring locates in the shaft groove (B).
98824R
DISMANTLING
Cut the clip and gaiter all the way along.
Remove as much grease as possible.
Spread retaining ring (7) and tap the exposed

face of ball hub (5) at the same time.
Separate the coupling from the shaft. 78615R2
29-15
DRIVESHAFTS
Joint AC 1700
Spread the sachet of grease round inside the gai-
ter and the bell-shaped stub axle.
NOTE: it is essential to use the amount of grease

specified in the "Consumables" section.
Position the lips of the gaiter in the grooves in the

bell-shaped stub axle (1) and the driveshaft (2).
98824R
Fit the collars and tighten them using the tool

which corresponds to the type of collars supplied
in the kit (click CAILLAU or OETIKER).
29-16
DRIVESHAFTS
Joints AC 1700
and GE 86 Gaiter at wheel end 29
OETIKER COLLAR ESSENTIAL SPECIAL TOOLS
T.Av. 1256 OETIKER collar crimping tool
96048S
POSITION 1 - Pre-crimping and positioning of the collar
DI2901
Fit connecting rod (A) in the lower notch and close the tool fully. The pre-crimped collar slides onto the gaiter
and can be positioned.
POSITION 2 - Crimping
DI2902
Fit connecting rod (A) in the upper notch and close the tool fully.
29-17
DRIVESHAFTS
Joints AC 1700
and GE 86 Gaiter at wheel end 29
CAILLAU CLICK COLLAR
T.Av. 1168 CAILLAU click collar tool
DI2903
93039R 93040S
NOTE: CAILLAU click type collars cannot be re-used.
29-18
DRIVESHAFTS
Joint RC 490
Gaiter at gearbox end 29
T.Av. 1034 Driveshaft collar crimping

tool
1 Yoke Cut the retaining collar and gaiter along its entire
2 Spider length.
3 Metal cover
4 Rubber gaiter
5 Retaining collar
6 Driveshaft
7 Metal insert
92045S
Remove as much grease as possible.

92303R
Remove the metal cover.
DISMANTLING
Uncrimp the three points on the cover using

pliers.
92046S
92044S
29-19
DRIVESHAFT
Joint RC 490
Remove the yoke. Never use thinners to clean the component parts.
On the press, extract the spider, using a stripping

extractor for support.
89145S
NOTE: as the yoke is not fitted with an anti-

separation pate, it can be removed without force.
Do not remove the roller cages from their respec-

tive trunnions since the cages and rollers are mat-
ched and must never be mixed.
Remove the circlips (depending on vehicle model). 90388S
REASSEMBLY
Grease the driveshaft and slide on:

- the new retaining collar,
- rubber gaiter (4) with metal insert (7) and me-
tal cover (3).
90387S 92048-1R
29-20
DRIVESHAFTS
Joint RC 490
Fit the spider onto the splined shaft. Spread the contents of the sachet of grease inside
the gaiter and the yoke.

Position:
- the gaiter and its metal insert in the metal co-
ver,
- the metal cover, sliding it on until the guide
plate is flush with the yoke.
In this position, crimp three points in the locations

provided for this on the guide plate.
90389S
Refit the retaining circlips or make 3 crimping

points 120° apart, pushing back the metal on the
driveshaft splines.
92050S
Insert a smooth rod with a rounded end between

the gaiter and the shaft to restrict the amount of
air inside.
90391S
Grease the yoke and engage it on the spider as-

sembly.
29-21
DRIVESHAFTS
Joint RC 490
92051R 88601R
Lengthen or shorten the coupling until dimension

A = 156 ± 1 mm is obtained (distance measured
between the end of the gaiter and the matched
face, with largest diameter, of the yoke).
In this position, remove the rod.
Fit the collar on the gaiter and tighten it using

tool T.Av. 1034.
92052R
29-22
DRIVESHAFTS
Joint GI 62
1 Yoke Using a pair of pliers, raise each end of the anti-
2 Spider separation plate (C), then remove the yoke.
3 Metal cover
4 Retaining spring
5 Rubber gaiter
6 Retaining collar
7 Driveshaft
88648R 74655R
Do not remove the roller cages from their respec-

DISMANTLING tive trunnions since the cages and rollers are mat-
ched and must never be mixed.
Cut the crimped collar and the gaiter along its en-
tire length. Never use thinners to clean the component parts.
Remove as much grease as possible. Remove the circlips depending on the type of as-
sembly.
75936-1S1
90387S
29-23
DRIVESHAFTS
Joint GI 62
gaiter at gearbox end 29
Extract the spider in a press, using a stripping ex- Refit the retaining circlips or make 3 crimping
tractor for support. points 120° apart, pushing back the metal on the
driveshaft splines.

90388S
REASSEMBLING
Lubricate the driveshaft and slide on the new re-

taining clip and gaiter. 90391S
Fit the spider onto the splined shaft.
Insert a 2.5 mm wedge (B), made as shown in the

sketch, between the anti-separation plate and
yoke.
90389S 75434-1R
29-24
DRIVESHAFTS
Joint GI 62
Carefully tap the anti-separation plate into its ori- Insert a smooth round-ended piece of rod bet-
ginal position with a bronze drift, then remove ween the gaiter and yoke so as to restrict the
wedge (B). amount of air retained inside the coupling.
Lengthen or shorten the coupling to obtain di-

mension A = 153,5 ± 1 mm (dimension measured
between the gaiter end face and the largest dia-
meter machined face on the yoke).
74867R
Locate the gaiter lips in the groove on the drives-

haft and on the metal cover.
90390R
In this position, remove the rod and fit the retai-

ning collar.
Tighten it using tool T. Av. 1034.
75434-1S
88601R
29-25
DRIVESHAFTS
Joint GI 69
Gaiter - bearing assembly 29
T.Av. 944 Mandrel for fitting bearing to

shaft
REMOVAL
Never use thinners for cleaning component parts.
Remove the circlip depending on the type of as-

sembly.
90388S
Remove the gaiter and bearing assembly in the

same way as the spider.
90387S
Remove the spider, on the press, using an extrac-

tor for support.
85933S
29-26
DRIVESHAFTS
Joint GI 69
REFITTING
For it to be in its correct position on the shaft, the

bearing must be inserted until dimension
L = 148,5 mm is obtained between the front sec-
tion of the bearing and the end of the shaft.
This dimension is obtained when the end of tool

T.Av. 944 is flush with the end of the shaft.
86197S
85884-1R1
The bearing is fitted with a lip seal. To avoid dis-

tortion and consequent leakage, it must never be
driven in with a hammer. Fit it on the press so as
to apply a gradual pressure.
29-27
DRIVESHAFTS
Joint GI 69
Furthermore, secure the driveshaft on the press
via its groove (G) using an extractor to avoid da-
maging the coupling at the wheel end.
86198R
Refit the spider on the splined shafts and refit the

retaining clrclips (depending on the type of as-
sembly).
29-28

Transmission R 19

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Transmission

77 11 190 841 NOVEMBER 1996 Edition Anglaise

C Renault S.A. 1988

20 CLUTCH 23 AUTOMATIC TRANSMISSION

180 CP 3300 26 splines B = White

2000 CP 4000 26 splines

76907S 93813R 76906R

200 CP 4400 26 splines R = 4 red springs

Special feature: 2 additional springs on the hub.

76907S 90693G1 76906R

200 CPV 3500 26 splines R = Red

Special feature: 2 additional springs on the hub.

76907S 90693-2G2 76906R

200 CPV 4400 26 splines J = 4 yellow springs

Diaphragm spring clutch plate.

Clutch plate with rubber hub.

Self-centring, guided, ball type thrust pad in

Automatic wear take-up mechanism.

Right hand sunwheel splines

RHODORSEAL 5661 100 g tube Ends of driveshaft roll pins.

LOCTITE 518 24 ml syringe Housing assembly faces.

IMPORTANT PRECAUTIONS WHICH MUST BE

In order to improve the sliding of the clutch

Clean the clutch shaft splines and refit the assem-

Special features of "diesel" clutch plates

These are fitted with a damping pre-hub which is

ESSENTIAL SPECIAL TOOLS

Mot. 582 Locking sector

TIGHTENING TORQUES (in daN.m) REFITTING

7 mm diameter unit securing bolts Degrease the flywheel mounting face.

Fit locking sector Mot. 582.

Remove the mounting bolts from the mechanism

Check and change the faulty parts.

Gradually screw up then torque tighten the bolts

Remove locking sector Mot. 582.

Coat the bore of the thrust pad, guide tube and

Degrease the crankshaft bore which receives the centring bush.

Coat the external diameter of the bushing with Loctite FRENBLOC.

The centring bush will not be used for these engines.

Fit the fork and refit the rubber protector.

Fit the thrust pad on the guide tube, placing catch

An identification plate on the clutch housing shows:

At A : the gearbox type A J B0 0 0 0 B

JB0 - JB1 - JB3 - JC5

B531 - B532 - B537

B530 - C530 - L530 15

B532 - C532 - L532 15

B533 - C533 - L533

B533 - C533 - L533 15 21 11 22 28 30 41 11

353A - 453A - 553A

B538 - C538 - L538

B538 - C538 - L538

071 B53D - C53D - L53D

B533 - L533 - B53B

B539 - C539 - B53D 15 21 11 19 25 30 33 11

B531 - C531 - L531 16 21 11 19 25 30 34 11

B532 - C532 - L532

4-speed gearbox 5-speed gearbox

JB4 2.75 JB5 2.90

CHECKING THE LEVEL

Wipe the dipstick section.

Remove the plug, the level should be on the boss

OIL VISCOSITY GRADE

Tranself TRX 75/80 W