Renault

2 Transmission
20A CLUTCH
21A MANUAL GEARBOX
23A AUTOMATIC GEARBOX
29A DRIVESHAFTS
X35
MAY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

SYMBOL - THALIA - Section 2ContentsPage
SYMBOL - THALIA - Section 2
Contents
Page
20A CLUTCH 23A AUTOMATIC GEARBOX
Clutch: Precautions for repair 20A-1 Automatic gearbox:

Precautions for repair 23A-1
Clutch: Specifications 20A-2
Automatic gearbox:
Mechanism / Disk: Removal - Identification 23A-2
Refitting 20A-5
Automatic gearbox:
Clutch thrust bearing: Specifications 23A-3
Removal - Refitting 20A-8
Automatic gearbox: List and
location of components 23A-4
Automatic gearbox: Removal

21A MANUAL GEARBOX - Refitting 23A-6
Manual gearbox oil: Draining Automatic gearbox oil:

- Refilling 21A-1 Draining - Refilling 23A-11
Manual gearbox oil: Automatic gearbox oil:

Specifications 21A-3 Specifications 23A-15
Manual gearbox: Removal - Hydraulic distributor:

Refitting 21A-4 Removal - Refitting 23A-16
5th gear housing: Removal - Hydraulic distributor solenoid

Refitting 21A-34 valves: Removal - Refitting 23A-20
5th gear sprockets and Hydraulic distribution wiring:

synchronisers: Removal - Removal - Refitting 23A-21
Refitting 21A-39
Flow regulation solenoid
Differential output seal: valve: Removal - Refitting 23A-23
Gearbox oil cooler: Removal
Input shaft lip seal: Removal - Refitting 23A-25
- Refitting 21A-52
Differential output seal:
Reverse gear switch: Removal - Refitting 23A-27
Multifunction switch:
Contents
23A AUTOMATIC GEARBOX
Multifunction switch:
Adjusting 23A-31
Speed sensor: Removal -

Refitting 23A-32
Pressure sensor: Removal -

Refitting 23A-35
Converter seal: Removal -

Refitting 23A-37
Automatic transmission
connector: Removal -
Refitting 23A-39
Automatic transmission
computer: Removal -
Refitting 23A-41
29A DRIVESHAFTS
Driveshaft: Precautions for

repair 29A-1
Front left-hand wheel

driveshaft: Removal -
Refitting 29A-2
Front right-hand wheel

driveshaft: Removal -
Refitting 29A-8
Relay shaft bearing:

Front driveshaft gaiter on

wheel side: Removal -
Refitting 29A-13
Front right-hand driveshaft

gaiter on gearbox side:
Front left-hand driveshaft

gaiter on gearbox side:
CLUTCH
Clutch: Precautions for repair 20A
Essential special tooling
Emb. 1780 Set of clutch disc centring

mandrels.
Before removing the clutch, check:

- The direction of fitting for the clutch plate.
Before refitting the clutch, check:
- The flywheel friction track (no scratches or blue
stains),
- The crankshaft bearing (no sticking),
- The engine and gearbox seals (replace if necessary),
- The sliding action of the clutch plate on the output
shaft,
- The thrust bearing guide and the clutch fork (no wear
or scratches).
WARNING
To prevent the clutch from juddering or slipping, do
not grease the output shaft or the clutch plate hub.
During refitting check the following:

Check the direction of the clutch plate.
Centre the clutch plate using the tool (Emb. 1780)
Gradually torque tighten the clutch pressure plate
bolts.
After refitting, check:
- The clutch play (for a cable operated vehicle),
- Bleeding of the hydraulic circuit (for vehicles with hy-
draulic controls).
20A-1
CLUTCH
Clutch: Specifications 20A
JB1 or JB3 or JH3 or JR5
Colour of inner springs: Pale green
K9K
Pressure plate K4M
Pressure plate
108795
Drive plate 125932
Drive plate
126264
Plate external diameter: 220 mm

105680
Plate thickness (under no load): 7.8 mm Plate external diameter: 200 mm
Number of splines: 24 Plate thickness (under load): 6.8 mm
Colour of outer springs: Olive brown Number of splines: 24
20A-2
CLUTCH
Colour of springs: Green Number of splines: 24
Colour of springs: Blue Colour of springs: Silver grey
D4F K7J
Pressure plate Pressure plate
125932 107918
Drive plate Drive plate
105680 105680
Plate external diameter: 181.5 mm Plate external diameter: 181.5 mm

Plate thickness (under load): 6.7 mm Plate thickness: 6.7 mm
20A-3
CLUTCH
Number of splines: 24
Colour of springs: Silver grey
20A-4
CLUTCH
Mechanism / Disk: Removal - Refitting 20A
D4F or K4M or K7J or K9K
- the front right-hand wheel driveshaft (see 29A, Dri-
Essential special tooling veshafts, Front right-hand wheel driveshaft:
Removal - Refitting, page 29A-8) (29A, Drives-
Mot. 582-01 Flywheel locking tool.
hafts),
Emb. 1780 Set of clutch disc centring - the front axle subframe (see Front axle sub-fra-
mandrels. me: Removal - Refitting) (31A, Front axle compo-
nents),
- the manual gearbox (see 21A, Manual gearbox,
Tightening torquesm Manual gearbox: Removal - Refitting, page 21A-
4) (21A, Manual gearbox).
clutch pressure plate 20 N.m
bolts
II - OPERATION FOR REMOVAL OF PART
clutch pressure plate ?? N.m CONCERNED
bolts
clutch pressure plate ?? N.m

bolts
clutch pressure plate ?? N.m

bolts
REMOVAL
I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the battery (see Battery : Removal - Refitting)
(80A, Battery),
- the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
132998
- the air filter unit (see Air filter unit: Removal - Re- a Position the (Mot. 582-01) (1) .
fitting) ,
a Remove:
- the engine undertray bolts,
- the clutch pressure plate bolts (2) ,
- the engine undertray,
- the clutch pressure plate,
- the starter (see Starter: Removal - Refitting) ,
- the clutch plate.
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).
a Drain the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oil: Draining - Refilling,
page 21A-1) (21A, Manual gearbox).
a Remove:
- the front left-hand wheel driveshaft (see 29A, Dri-
veshafts, Front left-hand wheel driveshaft: Re-
moval - Refitting, page 29A-2) (29A, Driveshafts),
20A-5
CLUTCH
REFITTING
I - REFITTING PREPARATION OPERATION

a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
- the flywheel friction face,
- the clutch shaft splines.
WARNING
Do not grease the clutch shaft splines.
II - REFITTING OPERATION FOR PART

CONCERNED
132998
a Refit:
- the clutch pressure plate,
- the clutch pressure plate bolts by gradually tighte-
ning them in a radial pattern.
D4F
a Torque tighten in a star pattern the clutch pressure
plate bolts (20 N.m).
K7J
132331 plate bolts (?? N.m).
a Fit the clutch plate, with the face (3) to the clutch
pressure plate end.
a Centre the clutch plate using the (Emb. 1780).
K4M
plate bolts (?? N.m).
20A-6
CLUTCH
K9K

plate bolts (?? N.m).
a Remove the (Emb. 1780) and (Mot. 582-01).
III - FINAL OPERATION
a Refit:
- the gearbox (see 21A, Manual gearbox, Manual

gearbox: Removal - Refitting, page 21A-4) (21A,
Manual gearbox),
- the front axle subframe (see Front axle sub-fra-

me: Removal - Refitting) (31A, Front axle compo-
nents),
- the front left-hand wheel driveshaft (see 29A, Dri-

veshafts, Front left-hand wheel driveshaft: Re-
moval - Refitting, page 29A-2) (29A, Driveshafts),

veshafts, Front right-hand wheel driveshaft:
Removal - Refitting, page 29A-8) (29A, Drives-
hafts).
a Fill the manual gearbox (see 21A, Manual gearbox,

Manual gearbox oil: Draining - Refilling, page
21A-1) (21A, Manual gearbox).
a Refit:

tion),

- the starter (see Starter: Removal - Refitting) ,
- the air filter unit (see Air filter unit: Removal - Re-
fitting) ,


(80A, Battery).
20A-7
CLUTCH
Clutch thrust bearing: Removal - Refitting 20A
JH3 or JR5
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED

a Remove:
- the engine cover,
(80A, Battery),
- the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),
tion),
108796
- the engine undertray bolts, a Remove the clutch thrust bearing bolts (1) from the
- the engine undertray. clutch housing.

page 21A-1) .
a Remove:
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand wheel driveshaft: Remo-
val - Refitting, page 29A-2) .
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand wheel driveshaft: Remo-
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
nents),
- the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing), 108797
a Remove the clutch thrust bearing (2) .
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
Manual gearbox: Removal - Refitting, page 21A-
4) ,
- the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-48) .
20A-8
CLUTCH
JH3 or JR5
REFITTING - the front wheels (see Wheel: Removal - Refitting)

I - REFITTING OPERATION FOR PART - the battery tray (see Battery tray: Removal - Re-
CONCERNED fitting) (80A, Battery),
a Refit the clutch thrust bearing. - the starter (see Starter: Removal - Refitting)
WARNING
(80A, Battery),
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease. - the engine cover.
a Bleed the clutch circuit (see Clutch circuit: Remo-
val - Refitting) (37A, Mechanical component con-
WARNING trols).
Never operate the system when the slave cylin- a Refit the engine undertray.
der is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the slave cylinder stop will be ejected.
II - FINAL OPERATION
a Refit:
- differential output seals (see 21A, Manual gear-
box, Differential output seal: Removal - Refit-
ting, page 21A-48) ,
4) ,
Washing),
nents),
a Fill up the manual gearbox (see 21A, Manual gear-
page 21A-1) .
a Refit:
tion),
20A-9
CLUTCH
JB1 or JB3
REMOVAL - the left-hand suspended engine mounting (see

Left-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting),
a Position the vehicle on a two-post lift (see Vehicle: - the manual gearbox (see 21A, Manual gearbox,
Towing and lifting) (02A, Lifting equipment). Manual gearbox: Removal - Refitting, page 21A-
4) .
IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap. CONCERNED
a Remove:
- the engine undertray.
a Drain the gearbox oil (see 21A, Manual gearbox,

21A-1) .
a Remove:

(80A, Battery),

- the TDC sensor (see Crankshaft position sen-

sor: Removal - Refitting) (17B, Petrol injection),

107917
- the engine tie-bar (see Lower engine tie-bar: Re-
moval - Refitting) (19D, Engine mounting), a Remove:
- the front left-hand driveshaft (see 29A, Drives- - the rubber protector,
val - Refitting, page 29A-2) . - the clutch fork from the inside the housing,
hafts, Front right-hand wheel driveshaft: Remo- - the clutch thrust bearing.
- the catalytic converter (see Catalytic converter: REFITTING

Removal - Refitting) (19B, Exhaust),

me: Removal - Refitting) (31A, Front axle compo- I - REFITTING PREPARATION OPERATION
nents),
a Check for leaks from the input shaft, replace the gui-
- the starter (see Starter: Removal - Refitting) de tube if necessary (see 21A, Manual gearbox,
(16A, Starting - Charging), Input shaft lip seal: Removal - Refitting, page
21A-52) .
a Coat the guide tube walls and the fork pads with
Washing),
BR2+ GREASE (see Vehicle: Parts and ingre-
- the scuttle panel grille (see Scuttle panel grille: dients for the repairwork) (04B, Consumables -
Removal - Refitting) (56A, Exterior equipment), Products).
20A-10
CLUTCH
JB1 or JB3
II - REFITTING OPERATION FOR PART - the battery tray (see Battery tray: Removal - Re-
CONCERNED fitting) (80A, Battery),
a Refit: - the battery (see Battery : Removal - Refitting)
(80A, Battery).
- the clutch fork,
a Top up the gearbox (see 21A, Manual gearbox,
- the rubber protector, Manual gearbox oil: Draining - Refilling, page
- the thrust bearing on the guide tube. 21A-1) .
a Place the clutch fork in the slot of the thrust bearing. a Refit the engine undertray.
a Make sure that the thrust bearing slides onto the

clutch shaft properly.
a During any operation where the gearbox does not
need to be removed, or after refitting the gearbox, do
not lift the fork, because it could be released from
the thrust bearing slot.

a Refit:
4) ,
- the left-hand suspended engine mounting (see
Washing),
nents),
- the catalytic converter (see Catalytic converter:
moval - Refitting) (19D, Engine mounting),
20A-11
MANUAL GEARBOX
Manual gearbox oil: Draining - Refilling 21A
Mot. 1018 Sump plug tool.
Essential equipment
oil recovery container
Tightening torquesm
drain plug 25 Nm
Oil capacity
Gearbox Capacity (l)
JB1
3.4
JB3
18749
JH3 2.8
a Remove:
JR5 2.5 - the gearbox drain plug (1) using the tool (Mot.
1018),
- the drain plug seal.
IMPORTANT a Let the oil run into the oil recovery container.
Wear leaktight gloves (Nitrile type) for this opera-
tion.
FILLING
DRAINING I - FILLING PREPARATION OPERATION

a parts always to be replaced: mechanism hou-
I - DRAINING PREPARATION OPERATION sing drain plug seal (12,01,02,05).
a Remove:
II - DRAINING OPERATION
a Fit a oil recovery container under the gearbox.
21A-1
MANUAL GEARBOX
Manual gearbox oil: Draining - Refilling 21A
92081
a Fill the gearbox using a syringe containing recom-
mended oil (see 21A, Manual gearbox, Manual
gearbox oil: Specifications, page 21A-3) (Techni-
cal Note 6012A, 04A, Lubricants) until the oil over-
flows out of the filler cap hole.
113764
a Refit the filler plug.
a Position the slot (2) of the new seal towards the
drain plug.
a Refit the drain plug fitted with its new seal.
a Wipe any oil run-off with a cloth.
a Torque tighten the drain plug (25 Nm).
a Remove the oil recovery container.
II - FILLING OPERATION a Refit the engine undertray.
18749
a Remove the filler plug (3) .
21A-2
MANUAL GEARBOX
Manual gearbox oil: Specifications 21A
5 SPEED MANUAL GBOX
I - VEHICLE/GEARBOX TYPE/OIL TYPE III - IDENTIFICATION OF OIL FOR STANDARD
CORRELATIONS: EXCHANGE PK1 GEARBOXES:
GEARBOX TYPE TYPE OF OIL FOR Note:

GEARBOX
For standard exchange PK1 gearboxes, the oil type
JBX TRANSELF TRJ (TRZ or TRP) is shown on a label.
75W80 These two oils are replaced by TRX 75W80 or NFP
JCX
or 75W80.
JRX
TRANSELF NFJ
JHX
75W80
NDX
TL4
PKX TRANSELF TRX

75W80
PFX
or
VMX
TRANSELF NFP
NEX
75W80
NGX
N0X
UNX
ZFX TRANSELF LD
75W80
II - STANDARDS AND PART NUMBERS OF THE

VARIOUS RECOMMENDED OILS:
DESIGNATION STANDARD PART NUM-

BER
TRANSELF APIGL4, 77 11 143 534

TRX 75W80 MIL-L-2105 (5 litres)
C or D
or
TRANSELF
NFP 75W80
TRANSELF APIGL4, May be orde-

red from ELF
TRJ 75W80 MIL-L-2105
C or D
or
TRANSELF
NFJ 75W80
TRANSELF APIGL4, May be orde-

red from ELF
LD 75W80 MIL-L-2105
21A-3
MANUAL GEARBOX
Manual gearbox: Removal - Refitting 21A
K9K, and JH3 or JR5
REMOVAL
Mot. 1453 Multiple-adjusting engine I - REMOVAL PREPARATION OPERATION

mounting support with retai-
ning straps. a Position the vehicle on a two-post lift (see Vehicle:
Mot. 1453-01 Additional winder nut on a Remove:
engine lift support Mot. 1453.
- the engine cover,
Essential equipment - the battery (see Battery : Removal - Refitting)
(80A, Battery),
safety strap(s)
component jack (16A, Starting - Charging),
Tightening torquesm
- the crankshaft position sensor (see Crankshaft
studs 6.5 N.m position sensor: Removal - Refitting) (13B, Pe-
trol injection).
reverse gear switch 23 N.m
manual gearbox upper 44 N.m

bolts
manual gearbox lower 44 N.m

bolts
manual gearbox nuts 44 N.m
earth cable bolt on the 44 N.m

clutch housing
catalytic c o nverter 21 N.m

downstream strut bolt
catalytic c o nverter 21 N.m

downstream strut nut
the earth cable bolt on 21 N.m

the gearbox casingcover
133129
IMPORTANT a Remove the bolt (1) from the thermoplunger unit
Wear leaktight gloves (Nitrile type) for this opera- support.
tion.
a Move aside the thermoplunger unit support.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
21A-4
MANUAL GEARBOX
K9K, and JH3 or JR5
101743 134825
a Disconnect the rev counter connector (3) .
133120
a Unclip the manual gear selector cables (2) by: 133130
- pinching the manual gear selector (A) , a Disconnect the union (4) of the clutch master cylin-
der supply pipe.
- pulling the manual gear selector pin (B) ,
a Fit blanking plugs into the openings of:
- lifting the manual gear selector (C) from the manual
gear selector mounting. - the clutch master cylinder supply pipe union,
a Move aside the manual gear selector cables. - the brake fluid reservoir union.
21A-5
MANUAL GEARBOX
K9K, and JH3 or JR5
134255 133123
a Remove the earth cable bolt (5) from the gearbox a
casing.
Note:
To facilitate the disconnection of the clutch con-
trol line, pull the line straight out.
a Disconnect the clutch control line by:

- pressing on the clip (A) of the clutch thrust bearing,
- while pulling the clutch control line towards (B) .
a Remove:
tion),
133121
page 21A-1) .
a Unclip the clutch control line from the left-hand sus-
pended engine mounting support on the gearbox at a Remove:
(6) . - the front left-hand driveshaft (see 29A, Drives-
21A-6
MANUAL GEARBOX
K9K, and JH3 or JR5
- the front axle subframe (see Front axle sub-fra- a Remove the catalytic converter downstream strut.
nents).
133124
a Disconnect the connector (11) from the reverse gear
133122 switch.
a Remove the exhaust bracket bolts (7) fitted with their
a Unclip the reverse gear switch cable from the fifth
springs.
gear housing.
123816
133125
a Remove the bolt (8) from the catalytic converter
a Remove the earth cable bolt (12) from the clutch
downstream strut.
housing.
a Undo:
- the nut (9) from the catalytic converter downstream
strut,
- the bolt (10) of the catalytic converter downstream
strut.
21A-7
MANUAL GEARBOX
K9K, and JH3 or JR5
a Fit the (Mot. 1453) equipped with (Mot. 1453-01)
and a safety strap(s).
134691
133128
a Remove the left-hand suspended engine mounting

shaft nut (15) .
134688
a Remove:
- the power-assisted steering high pressure pipe bolt

(13) from the gearbox,
- the power-assisted steering high pressure pipe bolt 134688

(14) from the left-hand suspended engine moun-
ting support on the gearbox, a Remove:
- the windscreen wiper arms (see Windscreen wi- - the bolts (16) of the left-hand suspended engine
mounting support on the gearbox,
Washing),
- the scuttle panel grille (see Scuttle panel grille: - the left-hand suspended engine mounting support
Removal - Refitting) (56A, Exterior equipment). on the gearbox.
21A-8
MANUAL GEARBOX
K9K, and JH3 or JR5
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
a Remove the manual gearbox upper bolts. I - REFITTING PREPARATION OPERATION
109399
a Always replace:
- the exhaust bracket ring,
- differential outlet seals,

133126
a Fit a component jack beneath the manual gearbox. - the clutch thrust bearing.
a Remove:
- differential output seals (see 21A, Manual gear-

box, Differential output seal: Removal - Refit-
- the clutch thrust bearing (see 20A, Clutch, Clutch

thrust bearing: Removal - Refitting, page 20A-8)
.
a Refit:
- new differential output seals (see 21A, Manual

fitting, page 21A-48) ,
106202 - the new clutch thrust bearing (see 20A, Clutch,
a Remove the lower bolts (17) from the manual gear- Clutch thrust bearing: Removal - Refitting, page
box. 20A-8) .
a Remove: a Check that the gearbox studs are tightened, and if

necessary torque tighten the studs (6.5 N.m).
- the nuts from the manual gearbox,
- the manual gearbox. a Check that centring rings are in place on the gear-
box.
II - WHEN REPLACING THE PART CONCERNED
a Remove the reverse gear switch from the gearbox.
a Refit the reverse gear switch on the new gearbox.
a Torque tighten the reverse gear switch (23 N.m).
21A-9
MANUAL GEARBOX
K9K, and JH3 or JR5
III - REFITTING OPERATION FOR PART a Refit:
CONCERNED
- the catalytic converter downstream strut,
a Refit:
- the catalytic converter downstream strut bolt.
- the manual gearbox,
a Tighten to torque:
- the manual gearbox nuts.
- the catalytic converter downstream strut bolt
a Remove the component jack from under the ma- (21 N.m),
nual gearbox.
- the catalytic converter downstream strut nut
a Refit: (21 N.m).
- the manual gearbox lower bolts, a Refit the exhaust bracket bolts fitted with their
springs.
- the manual gearbox upper bolts.
a Refit:
- the manual gearbox upper bolts (44 N.m), me: Removal - Refitting) (31A, Front axle compo-
- the manual gearbox lower bolts (44 N.m), nents),
- the manual gearbox nuts (44 N.m). - the front bumper (see Front bumper: Removal -
IV - FINAL OPERATION - the front right-hand driveshaft (see 29A, Drives-

a Refit: val - Refitting, page 29A-8) .
- the left-hand suspended engine mounting support - the front left-hand driveshaft (see 29A, Drives-
on the gearbox, hafts, Front left-hand wheel driveshaft: Remo-
- the bolts of the left-hand suspended engine moun-
ting support on the gearbox, a Fill up the manual gearbox (see 21A, Manual gear-
- the left-hand suspended engine mounting shaft
page 21A-1) .
nut.
a Refit:
a Remove:
- the safety strap(s) from the (Mot. 1453),
- the (Mot. 1453) fitted with the (Mot. 1453-01). tion),
a Refit: - the front wheels (see Wheel: Removal - Refitting)

(35A, Wheels and tyres).
Removal - Refitting) (56A, Exterior equipment), a Connect the clutch control line onto the clutch thrust
bearing.
per arm: Removal - Refitting) (85A, Wiping - a Clip the clutch control line onto the left-hand suspen-
Washing), ded engine mounting support on the gearbox.
- the bolt of the power-assisted steering high pressu- a Torque tighten the earth cable bolt on the gearbox
re pipe on the left-hand suspended engine moun- casingcover (21 N.m).
ting support on the gearbox,
a Remove the blanking plugs from the openings of:
- the bolt of the power-assisted steering high pressu-
- the clutch master cylinder supply pipe union,
re pipe on the gearbox.
- the brake fluid reservoir union.
a Torque tighten the earth cable bolt on the clutch
housing (44 N.m). a Connect the clutch master cylinder supply pipe
union.
a Clip the reverse gear switch cable onto the fifth gear
housing. a Connect the rev counter connector.
a Connect the reverse gear switch connector. a Fit the manual gear selector cables.
21A-10
MANUAL GEARBOX
K9K, and JH3 or JR5
a Clip the manual gear selector cables:
- on the manual gear selector cable mounting,
- on the gear selector of the manual gearbox.
a Fit the thermoplunger unit support.
a Refit:
- the thermoplunger unit support bolt,
position sensor: Removal - Refitting) (13B, Pe-
trol injection),
(80A, Battery),
- the engine cover.
a Perform the following operations:
- fill up the manual gearbox (see 21A, Manual gear-
page 21A-1) ,
- bleed the clutch circuit (see Clutch circuit: Remo-
val - Refitting) (37A, Mechanical component con-
trols).
a Refit the engine undertray.
21A-11
MANUAL GEARBOX
D4F, and JB1
- the lower engine tie-bar (see Lower engine tie-
Essential special tooling bar: Removal - Refitting) (19D, Engine moun-
Mot. 1453 Multiple-adjusting engine ting).
ning straps.
Essential equipment
safety strap(s)
component jack
Tightening torquesm
manual gearbox nuts 44 Nm
manual gearbox lower 44 N.m

bolt
manual gearbox upper 44 N.m

bolts
earth cable bolts on the 21 N.m

manual gearbox
132820
crankshaft position sen- 8 N.m
sor bolts
REMOVAL

a Remove:

(80A, Battery),

- the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),

120407
- the front wheels (see Wheel: Removal - Refitting) a Remove:

- the flywheel cover bolts (1) ,
liner: Removal - Refitting) (55A, Exterior protec- - the flywheel cover.
tion),
- the engine undertray, page 21A-1) .
21A-12
MANUAL GEARBOX
D4F, and JB1
a Remove: - the front axle subframe (see Front axle sub-fra-
- the front left-hand driveshaft (see 29A, Drives- nents),
Washing),
hafts, Front right-hand wheel driveshaft: Remo- - the scuttle panel grille (see Scuttle panel grille:
val - Refitting, page 29A-8) . Removal - Refitting) (56A, Exterior equipment).
132704
a Fit:
- the (Mot. 1453) (2) ,
- a safety strap(s) on the tool (Mot. 1453).
21A-13
MANUAL GEARBOX
D4F, and JB1
132983 132986
a Remove the nut (3) from the left-hand suspended a Remove the bolt (5) from the engine wiring bracket.
engine mounting shaft on the manual gearbox.
a Move the engine wiring away from the suspended
a Slightly lower the manual gearbox. engine mounting rubber pad shaft on the manual
gearbox.
a Remove:
a Remove:
- the nuts (4) from the suspended engine mounting
rubber pad on the manual gearbox, - the bolts (6) from the suspended engine mounting
rubber pad shaft on the manual gearbox,
- the rubber pad from the left-hand suspended engi-
ne mounting on the manual gearbox. - the suspended engine mounting rubber pad shaft
from the manual gearbox.
21A-14
MANUAL GEARBOX
D4F, and JB1
132989 132988
a Unclip the clutch cable (7) from the sheath stop. a Remove the bolts (11) of the power-assisted stee-
ring high pressure pipe on the manual gearbox.
a Remove the clutch cable (8) from the slave cylinder
of the clutch thrust bearing. a Move the power-assisted steering high pressure
pipe away from the manual gearbox.
a Move the clutch cable away from the manual gear-
box.
132995
132992 a
a Disconnect the crankshaft position sensor connector Note:
(9) .
Mark the position of the earth cables on the body
a Remove: using an indelible marker pen.
- the crankshaft position sensor bolts (10) ,
Remove the earth cable bolts (12) from the manual
- the crankshaft position sensor. gearbox.
21A-15
MANUAL GEARBOX
D4F, and JB1
133046 132993
a Remove: a Disconnect the rev counter connector (16) from the

manual gearbox.
- the bolt (13) of the power-assisted steering low
pressure pipe bracket on the power-assisted stee-
ring pump support,
- the bolt (14) of the power-assisted steering low

pressure pipe bracket on the manual gearbox.
a Move the power-assisted steering low pressure pipe

away from the manual gearbox.
132991
switch.
132994
a Remove the rev counter heat shield (15) from the

manual gearbox.
21A-16
MANUAL GEARBOX
D4F, and JB1
CONCERNED
133012
132999
a Remove the manual gearbox upper bolts (18) .
133013
a Remove:
- the manual gearbox nuts (20) ,
133013
- the manual gearbox.
a Remove the lower bolt (19) from the manual gear-
box. a When replacing the manual gearbox, remove from
the gearbox:
a Fit a component jack beneath the manual gearbox.
- the reverse gear switch,
- the rev counter.
21A-17
MANUAL GEARBOX
D4F, and JB1
REFITTING a Connect the crankshaft position sensor connector.

a Fit the clutch cable on the manual gearbox.
I - REFITTING PREPARATION OPERATION a Refit the clutch cable on the slave cylinder of the
a Check that there are centring rings in place on the clutch thrust bearing.
manual gearbox. a Clip the clutch cable on the sheath stop.
a When replacing the manual gearbox, refit on the a Refit the left-hand suspended engine mounting shaft
gearbox: on the manual gearbox.
- the reverse gear switch, a Fit the engine wiring on the suspended engine
- the rev counter. mounting rubber pad shaft of the manual gearbox.
a Raise the engine using the (Mot. 1453).
II - REFITTING OPERATION FOR PART a Refit the left-hand suspended engine mounting rub-
CONCERNED ber pad on the gearbox.
a Position the manual gearbox using the component a Remove:
jack.
- the safety strap(s) from the (Mot. 1453),
a Torque tighten the manual gearbox nuts (44 Nm).
- the (Mot. 1453).
a Remove the component jack from the manual a Refit:
gearbox.
a Tighten to torque: Removal - Refitting) (56A, Exterior equipment),
- the manual gearbox lower bolt (44 N.m), - the windscreen wiper arms (see Windscreen wi-
- the manual gearbox upper bolts (44 N.m). per arm: Removal - Refitting) (85A, Wiping -
Washing),
III - FINAL OPERATION - the front axle subframe (see Front axle sub-fra-
a Connect: nents),
- the reverse gear switch connector, - the front right-hand driveshaft (see 29A, Drives-
- the rev counter connector on the manual gearbox.
a Refit the rev counter heat shield on the manual gear-
box.
a Fit the power-assisted steering low pressure pipe. val - Refitting, page 29A-2) .
a Refit the earth cables on the manual gearbox. a Fill up the manual gearbox (see 21A, Manual gear-
page 21A-1) .
Note:
a Refit:
Refit the earth terminal, aligning the marks made
- the flywheel cover,
during removal, on the gearbox cover.
When reassembling, improper positioning of the
bar: Removal - Refitting) (19D, Engine moun-
earth terminal on the gearbox casing could result
ting),
in damage to the earth terminal or earth wiring.
a Torque tighten the earth cable bolts on the ma-
nual gearbox (21 N.m). - the front wheel arch liners (see Front wheel arch
a Fit the power-assisted steering high pressure pipe tion),
on the manual gearbox.
a Refit the crankshaft position sensor. (35A, Wheels and tyres),
a Torque tighten the crankshaft position sensor - the starter (see Starter: Removal - Refitting)
bolts (8 N.m). (16A, Starting - Charging),
21A-18
MANUAL GEARBOX
D4F, and JB1
(80A, Battery).
21A-19
MANUAL GEARBOX
K7J, and JB1
Mot. 1453 Multiple-adjusting engine

ning straps.
Essential equipment
safety strap(s)
component jack
Tightening torquesm
stud on the engine 8 Nm
stud on the gearbox 8 Nm
gearbox stud nuts 44 N.m
upper and lower gear- 44 N.m 133152

box bolts
a Remove the engine wiring mounting (1) on the gear-
earth mountings on the 44 N.m box.
gearbox a Move aside the engine wiring.
a Unclip the clutch cable from the clutch fork.
REMOVAL a Move the clutch cable away from the gearbox.

IMPORTANT
vehicle lift using a strap.
a Remove:

21A-1) .
a Remove:
133716
- the battery (see Battery: Removal - Refitting) a Remove the earth mountings (2) on the gearbox.
(80A, Battery),
a Move aside the earth cables.

sor: Removal - Refitting) (17B, Petrol injection).
21A-20
MANUAL GEARBOX
K7J, and JB1
a Remove:
- the engine tie-bar mounting bolts on the gearbox,
- the engine tie-bar mounting on the gearbox.
133159
a Disconnect the speed sensor connector (3) .
107933
a Remove:
a Disconnect the reverse gear connector (5) .
a Secure the « radiator - condenser - fan » assembly
to the front panel.
133019 a Remove:
a Move aside the gear lever gaiter (4) . - the catalytic converter (see Catalytic converter:
a Remove the nut from the gearbox control linkage.
nents),
Note:
Never loosen the adjusting bracket nut on the
control linkage.
a Secure the gearbox control linkage at the correct per arm: Removal - Refitting) (85A, Wiping -
height using a safety strap(s). Washing),
21A-21
MANUAL GEARBOX
K7J, and JB1
- the scuttle panel grille (see Scuttle panel grille: a Position the component jack under the gearbox.
Removal - Refitting) (56A, Exterior equipment).

CONCERNED
107936
a Remove:
- the gearbox lower mountings (7) ,

133288
- the gearbox.
a Fit the engine support tool (Mot. 1453) with the sa-
fety strap(s), using the flywheel end lifting eye as an
anchoring point. REFITTING
(see Left-hand suspended engine mounting: Re- I - REFITTING PREPARATION OPERATION
moval - Refitting) (19D, Engine mounting).
a Check for leaks from the input shaft, replace the gui-
de tube if necessary (see 21A, Manual gearbox,
Input shaft lip seal: Removal - Refitting, page
21A-52) .
a Coat the guide tube walls and the fork pads with
BR2+ GREASE (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
Products).
a Position the fork on the clutch thrust bearing not-

ches.
Note:
If a stud loosens during this operation, coat it
with FRENETANCHE (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consu-
mables - Products).
Tighten to torque:
- the stud on the engine (8 Nm),
133286
a Remove the gearbox upper mountings (6) . - the stud on the gearbox (8 Nm).
21A-22
MANUAL GEARBOX
K7J, and JB1
II - REFITTING OPERATION FOR PART - the engine tie-bar (see Lower engine tie-bar: Re-
CONCERNED moval - Refitting) (19D, Engine mounting),
a Ensure that the « engine - gearbox » centring rings - the front wheels (see Wheel: Removal - Refitting)
are in place and correctly positioned. (35A, Wheels and tyres).
a Couple the gearbox to the engine. a Fit the gearbox control linkage.
a Refit the gearbox stud nuts. a Refit the gearbox control linkage nut.
a Torque tighten the gearbox stud nuts (44 N.m). a Refit the gear lever gaiter.
a Refit: a Connect the speed sensor connector.

a Position the earth cables.
- the gearbox lower bolts,
a Torque tighten the earth mountings on the gear-
- the gearbox upper bolts. box (44 N.m).
a Torque tighten the upper and lower gearbox bolts a Fit the clutch cable on the gearbox.
(44 N.m).
a Attach the clutch cable to the clutch fork.
a Refit the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Remo- a Fit the engine wiring.
val - Refitting) (19D, Engine mounting). a Refit the engine wiring bolt to the gearbox.
a Remove the engine support tool (Mot. 1453) and the a Refit:
safety strap(s).
a Refit: fitting) (80A, Battery),
- the scuttle panel grille (see Scuttle panel grille: - the battery (see Battery: Removal - Refitting)
Removal - Refitting) (56A, Exterior equipment), (80A, Battery).
- the windscreen wiper arms (see Windscreen wi- a Top up the gearbox (see 21A, Manual gearbox,
per arm: Removal - Refitting) (85A, Wiping - Manual gearbox oil: Draining - Refilling, page
Washing), 21A-1) .
- the starter (see Starter: Removal - Refitting) a Refit the engine undertray.
nents),
Removal - Refitting) (19B, Exhaust).
a Detach the « radiator - condenser - fan » assembly
from the upper cross member.
a Refit:
val - Refitting, page 29A-8) ,
a Connect the reverse gear connector.
a Refit:
- the engine tie-bar mounting on the gearbox,
21A-23
MANUAL GEARBOX
K9K, and JB3
Essential special tooling (16A, Starting - Charging),
Mot. 1453 Multiple-adjusting engine - the crankshaft position sensor (see Crankshaft
mounting support with retai- position sensor: Removal - Refitting) (13B, Die-
ning straps. sel injection).
Mot. 1453-01 Additional winder nut on

Essential equipment
safety strap(s)
component jack
Tightening torquesm
manual gearbox bolts 44 N.m
earth cable bolt on the 21 N.m

gearbox casing
IMPORTANT 133019
Wear leaktight gloves (Nitrile type) for this opera- a Move aside the gearbox control linkage gaiter (1) .
tion.
a Remove the nut from the gearbox control linkage.
Note:
WARNING
Prepare for the flow of fluid, and protect the sur- Never loosen the adjusting bracket nut on the
rounding components. control linkage.
a Attach the gearbox control linkage.

REMOVAL a Remove the tachometer heat shield.

a Remove:
- the engine cover,
(80A, Battery),
21A-24
MANUAL GEARBOX
K9K, and JB3
a Remove:
(35A, wheels and tyres),
tion).
page 21A-1) .
a Remove:

- the differential output seals (see 21A, Manual
132993 gearbox, Differential output seal: Removal - Re-
fitting, page 21A-48) ,
a Disconnect the tachometer connector (2) .
a Remove the earth cable bolt from the gearbox ca- Refitting) (55A, Exterior protection),
sing.
a Move aside the gearbox earth cable. me: Removal - Refitting) (31A, Front axle compo-
nents).
132989
133124
a Unclip the clutch cable (3) from the sheath stop.
a Remove the clutch cable (4) from the slave cylinder switch.
of the clutch thrust bearing. a Remove:
a Move the clutch cable away from the manual gear- - the power-assisted steering high pressure pipe
box. bolts from the gearbox,
21A-25
MANUAL GEARBOX
K9K, and JB3
- the windscreen wiper arms (see Windscreen wi- - the scuttle panel grille (see Scuttle panel grille:
per arm: Removal - Refitting) (85A, Wiping - Removal - Refitting) (56A, Exterior equipment).
Washing),
132704
a Fit:
- the (Mot. 1453) (6) ,
- a safety strap(s) on the tool (Mot. 1453).
21A-26
MANUAL GEARBOX
K9K, and JB3
- the left-hand suspended engine mounting support
on the gearbox.

CONCERNED
134834
shaft nut (7) .
a Slightly lower the manual gearbox.
a Remove: 132999
- the nuts from the left-hand suspended engine a Remove the manual gearbox upper bolts (9) .
mounting rubber pad on the manual gearbox,
- the rubber pad from the left-hand suspended engi-
ne mounting on the manual gearbox.
133126
a Remove the lower bolts from the manual gearbox.
134688
a Remove:
a Remove:
- the nuts from the manual gearbox,
- the left-hand suspended engine mounting support
bolts (8) on the gearbox, - the manual gearbox,
21A-27
MANUAL GEARBOX
K9K, and JB3
- the clutch thrust bearing (see 20A, Clutch, Clutch a Refit:
thrust bearing: Removal - Refitting, page 20A-8)
.
nents),
REFITTING - the front bumper (see Front bumper: Removal -
I - REFITTING PREPARATION OPERATION - new differential output seals (see 21A, Manual
a parts always to be replaced: Clutch thrust bea-
ring (12,03,01,04). fitting, page 21A-48) ,
a Ensure that the centring dowels are present.
II - OPERATION FOR REFITTING PART
CONCERNED
a Refit: val - Refitting, page 29A-2) .
- a new clutch thrust bearing (see 20A, Clutch, a Fill up the manual gearbox (see 21A, Manual gear-
Clutch thrust bearing: Removal - Refitting, page box, Manual gearbox oil: Draining - Refilling,
20A-8) , page 21A-1) .
a Refit:
a Remove the component jack from under the ma-
nual gearbox.
tion),
a Tighten to torque: - the front wheels (see Wheel: Removal - Refitting)
- the manual gearbox bolts (44 N.m), (35A, Wheels and tyres).
- the manual gearbox nuts (44 N.m). a Clip the clutch cable onto the sheath stop.
a Refit the clutch cable on the slave cylinder of the
clutch thrust bearing.
a Refit the earth wiring bolt on the gearbox casing.
a Refit:
a Torque tighten the earth cable bolt on the gearbox
- the left-hand suspended engine mounting support casing (21 N.m).
on the gearbox,
a Connect the tachometer connector.
- the left-hand suspended engine mounting shaft
nut. a Refit the tachometer heat shield.
a Remove: a Detach the gearbox control linkage.
- the safety strap(s) from the (Mot. 1453), a Refit the gearbox control linkage nut.
a Fit the gearbox control linkage gaiter.
- the (Mot. 1453) fitted with the (Mot. 1453-01).
a Refit:
a Refit:
- the scuttle panel grille (see Scuttle panel grille: position sensor: Removal - Refitting) (13B, Die-
Removal - Refitting) (56A, Exterior equipment), sel injection),
- the windscreen wiper arms (see Windscreen wi- - the starter (see Starter: Removal - Refitting)
per arm: Removal - Refitting) (85A, Wiping - (16A, Starting - Charging),
Washing),
- the bolts of the power-assisted steering high pres- Removal - Refitting) (19B, Exhaust),
sure pipe.
a Connect the reverse gear switch connector. fitting) (80A, Battery),
21A-28
MANUAL GEARBOX
K9K, and JB3
(80A, Battery),
- the engine cover.
21A-29
MANUAL GEARBOX
K4J or K4M, and JB3
Essential equipment
indelible pencil
component jack
Tightening torquesm
manual gearbox bell 44 N.m

housing bolts
earth cable bolts on the 21 N.m

manual gearbox
REMOVAL
138912
I - REMOVAL PREPARATION OPERATION a Move aside the gaiter (1) of the gear selection linka-
a Position the vehicle on a two-post lift (see Vehicle: ge.
Towing and lifting) (02A, Lifting equipment). a Remove the nut (2) from the gear selection linkage.
a Remove: a Move aside the gear selection linkage.
- the battery (see Battery: Removal - Refitting) a Remove:

(80A, Battery), - the front left-hand driveshaft (see 29A, Drives-
- the air filter unit (see Air filter unit: Removal - Re- hafts, Front right-hand wheel driveshaft: Remo-
fitting) (12A, Fuel mixture), val - Refitting, page 29A-8) ,
- the starter (see Starter: Removal - Refitting) - the front axle subframe (see Front axle sub-fra-
(16A, Starting - Charging), me: Removal - Refitting) (31A, Front axle compo-
nents),
(35A, Wheels and tyres), - the windscreen wiper arms (see Windscreen wi-
- the front wheel arch liners (see Front wheel arch Washing),
tion), - the scuttle panel grille (see Scuttle panel grille:
- the engine undertray, Left-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting).

ting),

page 21A-1) .
21A-30
MANUAL GEARBOX
K4J or K4M, and JB3
132989 132988
a Unclip the clutch cable (3) from the sheath stop. a Remove the bolts (5) of the power-assisted steering
a Remove the clutch cable (4) from the slave cylinder high pressure pipe on the manual gearbox.
of the clutch thrust bearing.
a Move the power-assisted steering high pressure
a Move the clutch cable away from the manual gear- pipe away from the manual gearbox.
box.
a Remove the crankshaft position sensor (see
Crankshaft position sensor: Removal - Refitting)
(17B, Petrol injection).
132995
Note:
Mark the position of the earth cables on the body
using an indelible pencil.
a Remove the earth cable bolts (6) from the manual

gearbox.
21A-31
MANUAL GEARBOX
K4J or K4M, and JB3
a When replacing the manual gearbox, remove from
the gearbox:
- the rev counter.
REFITTING

a Check that centring rings are in place on the manual
gearbox.
a When replacing the manual gearbox, refit on the
gearbox:
- the rev counter.
132993 a parts always to be replaced: Clutch thrust bea-

ring (12,03,01,04).
a Disconnect the rev counter connector (7) from the
manual gearbox.
CONCERNED
a Position the manual gearbox using the component
jack.
a Torque tighten the manual gearbox nuts (44 N.m).
a Remove the component jack from the manual
gearbox.
a Torque tighten the manual gearbox bell housing
bolts (44 N.m).

a Connect:
- the reverse gear switch connector,
- the rev counter connector on the manual gearbox.
a Refit the earth cables on the manual gearbox.
132991
Note:
switch. Refit the earth terminal, aligning the marks made
during removal, on the gearbox cover. When
reassembling, improper positioning of the earth
terminal on the gearbox casing could result in
CONCERNED
damage to the earth terminal or earth wiring.
a Remove the manual gearbox bell housing bolts.
a Torque tighten the earth cable bolts on the ma-
nual gearbox (21 N.m).
a Remove:
a Fit the power-assisted steering high pressure pipe
- the nuts from the manual gearbox, on the manual gearbox.
21A-32
MANUAL GEARBOX
K4J or K4M, and JB3
a Refit the crankshaft position sensor (see Cranks- - the battery tray (see Battery tray: Removal - Re-
haft position sensor: Removal - Refitting) (17B, fitting) (80A, Battery),
Petrol injection).
a Fit the clutch cable on the manual gearbox. (80A, Battery).
a Refit the clutch cable on the slave cylinder of the
clutch thrust bearing.
a Clip the clutch cable on the sheath stop.
a Refit:
Washing),
- the gear selection linkage nut.
a Fit the gear selection linkage gaiter.
a Refit:
nents),
page 21A-1) .
a Refit:
ting),
tion),
- the air filter unit (see Air filter unit: Removal - Re-
21A-33
MANUAL GEARBOX
5th gear housing: Removal - Refitting 21A
JB1 or JB3
REFITTING
Tightening torquesm
fifth gear housing moun- 25 N.m.
ting bolts
a Clean the joint faces of the mechanism housing
using SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and ingredients for the
REMOVAL repairwork) .
I - REMOVAL PREPARATION OPERATION.

a WARNING
Do not scrape the joint faces of the aluminium,
Note: any damage caused to the joint face will result in
Consult the safety and cleanliness advice and a risk of leaks.
operation recommendations before carrying out
any repair (see Manual gearbox: Precautions a Remove the residue using a plastic spatula.
for repair)
a Finish cleaning the joint faces using a GREY ABRA-
a Remove the gearbox (see 21A, Manual gearbox, SIVE PAD part number 77 01 405 943.
4) a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) to clean:
a Position the gearbox on the component support (see
Gearbox support equipment: Use)
- the joint face of the fifth gear housing,
II - REMOVAL OPERATION FOR THE FIFTH GEAR - the mechanism housing.

HOUSING
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
a Parts always to be replaced:
- the O-rings.
II - REFITTING OPERATION FOR THE MECHANISM

COVER
a Fit a new O-ring and fit the fifth gear housing.

117504
a Remove the three bolts from the fifth gear housing. a Refit the fifth gear housing.
a Remove the fifth gear housing (1) along the axis of
a Torque tighten the fifth gear housing mounting
the gearbox, as it contains a lubrication channel lo-
bolts (25 N.m.)
cated in the bore of the primary shaft.
a Remove the gearbox from the component support

(see Gearbox support equipment: Use)
a Refit the gearbox (see 21A, Manual gearbox, Ma-

nual gearbox: Removal - Refitting, page 21A-4)
21A-34
MANUAL GEARBOX
JH3 or JR5
Mot. 1453 Multiple-adjusting engine

ning straps.

Essential equipment
safety strap(s)
oil recovery container
Tightening torquesm
5th gear housing bolts 25 N.m
bolt of the left-hand sub- 21 N.m

frame tie-rod 141721
a Undo the nut (1) of the left-hand subframe tie-rod.
nut of the left-hand sub- 62 N.m
frame tie-rod a Remove the bolt (2) from the left-hand subframe tie-
rod.
a Move aside the left-hand subframe tie-rod.
REMOVAL

a Remove:
- the engine cover,
- the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
141720
switch.
21A-35
MANUAL GEARBOX
JH3 or JR5
132608 134834
a Remove: a Remove the left-hand suspended engine mounting

shaft nut (6) .
- the lower engine tie-bar tie rod bolts (4) ,
a Lower the engine using the (Mot. 1453-01).
- the lower engine tie-bar tie rod,
- the lower engine tie-bar bolt (5) , Note:
- the lower engine tie-bar, To avoid damaging the reverse gear switch,
check that it does not touch the subframe when
- the battery (see Battery : Removal - Refitting) the engine is lowered.
(80A, Battery),
- the windscreen wiper arms (see Windscreen wi- II - OPERATION FOR REMOVAL OF PART
per arm: Removal - Refitting) (85A, Wiping - CONCERNED
Washing),
a Fit an oil recovery container under the 5th gear
- the scuttle panel grille (see Scuttle panel grille: housing.
Removal - Refitting) (56A, Exterior equipment).
133127
a Fit the (Mot. 1453) equipped with (Mot. 1453-01)

and a safety strap(s).
21A-36
MANUAL GEARBOX
JH3 or JR5
a Using SURFACE CLEANER (see Vehicle: Parts
mables - Products), clean and degrease the bearing
faces of:
- the 5th gear housing,
- the gearbox.

CONCERNED
a Refit:
- a new seal for the 5th gear housing,
- the 5th gear housing.
a Remove the oil recovery container.

a Torque tighten the 5th gear housing bolts (25
N.m).
141718 a Clip the reverse gear switch wiring onto the 5th gear
housing.
a Raise the engine using the (Mot. 1453-01).

a Refit the left-hand suspended engine mounting shaft
nut.
a Remove the tool (Mot. 1453) fitted with the tool

(Mot. 1453-01) and a safety strap(s).
a Refit:

Washing),

(80A, Battery),
141719
- the lower engine tie-bar,
a Unclip the wiring (7) of the reverse gear switch on
the 5th gear housing. - the lower engine tie-bar tie rod.
a Remove: a Connect the reverse gear switch connector.
- the bolts (8) of the 5th gear housing, a Fit the left-hand subframe tie-rod.
- the 5th gear housing, a Refit the bolt of the left-hand subframe tie-rod.
- the seal of the 5th gear housing. a Tighten to torque:
- the bolt of the left-hand subframe tie-rod (21

I - REFITTING PREPARATION OPERATION N.m),
a parts always to be replaced: 5th gear housing - the nut of the left-hand subframe tie-rod (62
seal (12,01,03,05). N.m).
21A-37
MANUAL GEARBOX
JH3 or JR5
a Refit:
terior protection),
Refitting) (35A, Wheels and tyres).
21A-1) .
a Refit:
- the engine cover.
21A-38
MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
JB1 or JB3
Tightening torquesm
fifth gear kickdown point 20 N.m
input shaft nut 190 N.m
output shaft bolt 80 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION.
Note:
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see Manual gearbox: Precautions 92957
for repair) a Shift to first gear using the gear lever (3) .
a Change into fifth gear by sliding the fifth gear fork
a Remove the gearbox (see 21A, Manual gearbox,
along its shaft.
4)
Note:
a Position the gearbox on the component support (see
The aim of this operation is to lock the shafts in
Gearbox support equipment: Use)
order to make loosening easier.
a Remove the fifth gear housing (see 21A, Manual a Remove:
gearbox, 5th gear housing: Removal - Refitting,
page 21A-34) - the output shaft bolt and its fixed washer (7) ,
- the washer (8) ,
II - REMOVAL OPERATION OF THE FIFTH GEAR - the input shaft nut (6)
PINION AND SYNCHRONISERS - the fifth gear fork and selector rod assembly (4)
a Remove the fifth gear kickdown point (5) .
Note:
When removing the fifth gear kickdown point,
recover one or both 0.30mm washers.
121104
a Drive out the pin of the fifth gear fork (1) using the
tool (2) or a roll pin punch.
21A-39
MANUAL GEARBOX
JB1 or JB3
Removing the fifth gear hub: Removing the fifth fixed gear:
121101 121102
a Position the
a Turn the tool in order to position the grooves of the
tool selector rod opposite the fifth gear hub.
a Remove the fifth gear hub.
121103
a The fifth fixed gear is removed using theand.
a Fit the output shaft bolt and its washer (9) and tigh-
ten it 4 or 5 turns.
a Fit a half-shell of tool (10) Bvi. 1000-01 under the

fifth gear pinion.
a Fit the extractor (11) Bvi 22-01
a Fit the other half-shell
a Remove the fifth gear pinion.
21A-40
MANUAL GEARBOX
JB1 or JB3
REFITTING II - REFITTING OPERATION FOR THE FIFTH GEAR

SYNCHRONISERS AND PINION

a Clean the joint faces of the mechanism housing
using SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and ingredients for the
repairwork) .
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
a Remove the residue using a plastic spatula.

a Finish cleaning the joint faces using a GREY ABRA-
SIVE PAD part number 77 01 405 943.
and ingredients for the repairwork) to clean:
- the shaft ends,
- the mechanism housing. 93462
a Apply three drops of LOCTITE FRENBLOC to the

WARNING grooves on the fifth fixed gear.
To ensure proper sealing, the gasket surfaces a Fit the fifth fixed gear using the tool (12) .
must be clean, dry and not greasy (avoid any fin-
ger marks).

- the O-ring,
- the pin of the fifth gear fork.
114287
a
On the input shaft, refit:
- the lock washer (13) ,

- the idle gear supporting ring (14) ,
- the fifth idle gear (15) with its synchroniser ring,
21A-41
MANUAL GEARBOX
JB1 or JB3
- the fifth gear hub (16) fitted with its synchroniser
spring.
92957
92957
a Shift to first gear using the gear lever (21) .
a a Change into fifth gear by sliding the fifth gear fork

along its shaft (22) .
Place:
- the fifth gear fork and selector rod assembly (17) , a
- the input shaft nut (18) Note:
- the output shaft bolt (19) . The aim of this operation is to lock the shafts in
- the fifth gear kickdown point coated with sealing re- order to make loosening easier.
sin (20) .
tighten to torque:
Note: - the input shaft nut (190 N.m)

When refitting the fifth gear kickdown point, refit - the output shaft bolt (80 N.m)
one or both 0.30mm washers.
a Shift into neutral.
a Torque tighten the fifth gear kickdown point (20
N.m).
121104
a Refit the fifth gear fork pin.
21A-42
MANUAL GEARBOX
JB1 or JB3
a Refit the fifth gear housing (see 21A, Manual gear-
box, 5th gear housing: Removal - Refitting, page
21A-34)
a Remove the gearbox from the component support
(see Gearbox support equipment: Use)
a Refit the gearbox (see 21A, Manual gearbox, Ma-
nual gearbox: Removal - Refitting, page 21A-4)
21A-43
MANUAL GEARBOX
JH3 or JR5
Essential special tooling CONCERNED
Bvi. 31-01 Set of 3 roll pin drifts (5mm

diameter roll pins).
Bvi. 1170 Extractor for 5th speed gear

hub.
Bvi. 1000-01 5th fixed gear extractor.
Bvi. 22-01 Extractor body without cover.
Bvi. 1175 Bolt for fitting 5th speed fixed

gear.
Tightening torquesm
input shaft nut 190 N.m
output shaft bolt 80 N.m 141717
a
REMOVAL
Note:
Take care not to damage the fifth gear lubrication
neck (1) during the entire operation.
Towing and lifting) (02A, Lifting equipment). a Raise the engine using the (Mot. 1453-01).
a Remove:
- the engine cover,
terior protection),
- the 5th gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-34) .
141716
a Remove the pin from the fifth gear fork using the tool
(Bvi. 31-01) (2) .
a Shift to first gear using the gear lever.
21A-44
MANUAL GEARBOX
JH3 or JR5
Note:
To avoid damaging the reverse gear switch,
the engine is lowered.
141714
141715
a Change into fifth gear by moving the fifth gear fork.
Note:
The purpose of this operation is to lock the gear-
box shafts in order to facilitate loosening.
a Remove:
- the output shaft bolt (3) ,
- the input shaft nut (4) ,
- the washer (5) of the input shaft nut,
- the fifth gear fork and selector rod (6) . 114287
a Position the (Bvi. 1170) (7) .
Note:
Turn the tool (Bvi. 1170) in order to position the
splines of the tool selector rod opposite the fifth
gear hub.
a Remove:
- the fifth gear hub fitted with its synchroniser springs

(8) .
21A-45
MANUAL GEARBOX
JH3 or JR5
- the fifth idle gear fitted with its synchroniser ring (9)
,
- the idle gear supporting ring (10) ,
- the lock washer (11) .
141712
a Fit the other half-shell (14) and the ring (Bvi. 1000-
01) of the tool (15) .
a Remove the fifth gear pinion.
141713
a Refit the output shaft bolt, screwing it in a few turns. I - REFITTING PREPARATION OPERATION
a Fit: a Always replace:
- a half-shell (Bvi. 1000-01) of the tool (12) under the - the input shaft nut,
fifth gear pinion,
- the washer of the input shaft nut,
- the (Bvi. 22-01) (13) on the half-shell of the tool
- the output shaft bolt,
(Bvi. 1000-01).
- the pin of the fifth gear fork.
mables - Products) to clean the ends of the gearbox
shaft.

CONCERNED
a Put several drops of FRENETANCHE (see Vehi-
cle: Parts and ingredients for the repairwork)
(04B, Consumables - Products) on the splines of the
fifth gear pinion.
21A-46
MANUAL GEARBOX
JH3 or JR5
Note:
To avoid damaging the reverse gear switch,
the engine is lowered.

a Refit:
- the 5th gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-34) ,
terior protection),
141711
a Refit the fifth gear pinion using the tool (Bvi. 1175)
- the engine cover,
(16) .
a Remove the tool (Bvi. 1175).
a On the input shaft, refit:
- the lock washer,
- the idle gear supporting ring,
- the fifth idle gear fitted with its synchroniser ring,
- the fifth gear hub fitted with its synchroniser

springs.
a Refit:
- the fifth gear fork and selector rod,
- a new washer for the input shaft nut,
- a new nut for the input shaft,
- a new bolt for the output shaft.
a Change into fifth gear by moving the fifth gear fork.
- the input shaft nut (190 N.m),
- the output shaft bolt (80 N.m).
a Put the gearbox in neutral.
a Raise the engine using the (Mot. 1453-01).
a Fit a new pin for the fifth gear fork using the tool (Bvi.
31-01).
21A-47
MANUAL GEARBOX
Differential output seal: Removal - Refitting 21A
JB1 or JB3
REFITTING
Bvi. 945 Mandrel for fitting sunwheel I - REFITTING PREPARATION OPERATION

seal.
a parts always to be replaced: Differential output
Essential equipment seal (12,01,05,10).
roll pin punch II - REFITTING OPERATION FOR PART

CONCERNED
REMOVAL

a Remove:


21A-1) .
86095
a Remove:
a The seal is refitted using the (Bvi. 945) consisting of:
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres), - a seal protector (A) ,
- the front right-hand wheel driveshaft (see 29A, Dri- - a seal fitting tool (B) .
Removal - Refitting, page 29A-8) .

CONCERNED
86122
a Fit the lubricated protector (A) on the sunwheel.
a Position the lubricated seal (C) using the (B) .
86031 III - FINAL OPERATION
a Tap the base of the lip seal using a roll pin punch a Refit:
and a small hammer to rotate it in its housing.
a Remove the differential output seal with pliers, ta- hafts, Front right-hand wheel driveshaft: Remo-
king care not to damage the sunwheel grooves. val - Refitting, page 29A-8) .
21A-48
MANUAL GEARBOX
JB1 or JB3
21A-1) .
21A-49
MANUAL GEARBOX
JH3 or JR5
Bvi. 1666 Tool for fitting differential
seals.
Essential equipment
roll pin punch
REMOVAL

a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the front wheel on the side concerned (see Wheel:
Removal - Refitting) (35A, Wheels and tyres),
109147
a Tap the differential output seal using a roll pin
- the engine undertray. punch and a small hammer to detach it and rotate it
a Drain the manual gearbox (see 21A, Manual gear- in its housing.
box, Manual gearbox oil: Draining - Refilling, a Remove the differential output seal using a large
page 21A-1) . screwdriver, taking care not to damage the mecha-
a Remove the front wheel driveshaft from the side in nism housing.
question (see 29A, Driveshafts, Front left-hand
wheel driveshaft: Removal - Refitting, page 29A-
2 ) or (see 29A, Driveshafts, Front right-hand
wheel driveshaft: Removal - Refitting, page 29A-
8) .
21A-50
MANUAL GEARBOX
JH3 or JR5
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
109407
a Refit the seal using the (Bvi. 1666) (1) suffix A on

the right-hand side, suffix B on the left-hand side.
a Strike the (Bvi. 1666) with a copper hammer (2) to

fully seat the differential output seal.
a Refit the driveshaft on the side concerned (see 29A,

Driveshafts, Front left-hand wheel driveshaft:
Removal - Refitting, page 29A-2) or (see 29A, Dri-
veshafts, Front right-hand wheel driveshaft: Re-
moval - Refitting, page 29A-8) .

page 21A-1) .
a Refit:
- the front wheel on the side concerned (see Wheel:

Removal - Refitting) (35A, Wheels and tyres).
a Connect the battery (see Battery : Removal - Refit-

ting) (80A, Battery).
21A-51
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting 21A
JH3 – JR5
a Replace the lip seal after having opened the gear-
box (see Clutch housing bearing: Removal - Re-
fitting) (Technical Note 6029A, 21A, Manual
gearbox).
21A-52
MANUAL GEARBOX
JB1 or JB3
Essential special tooling per arm: Removal - Refitting) (85A, Wiping -
Washing),
Bvi. 1445 Tool for extracting and fitting
JB gearbox guide tube. - the scuttle panel grille (see Scuttle panel grille:
REMOVAL - the left-hand suspended engine mounting (see

a Position the vehicle on a two-post lift (see Vehicle: Manual gearbox: Removal - Refitting, page 21A-
Towing and lifting) (02A, Lifting equipment). 4) .

IMPORTANT
CONCERNED
vehicle lift using a strap.
a Remove:

21A-1) .
a Remove:

(80A, Battery),


- the front wheels (see Wheel: Removal - Refitting) 99057

(1) tightening clamp
(2) sleeve
(3) gauge
(4) spanner
val - Refitting, page 29A-2) . (5) split ring
- the front right-hand driveshaft (see 29A, Drives- a This operation is carried out after the gearbox has
hafts, Front right-hand wheel driveshaft: Remo- been removed.
val - Refitting, page 29A-8) . a The lip seal and the primary shaft bearing are built
- the catalytic converter (see Catalytic converter: into the thrust bearing guide tube. It is lubricated via
Removal - Refitting) (19B, Exhaust), an aperture into the housing bore.

nents),
21A-53
MANUAL GEARBOX
JB1 or JB3
98936
a Detach the guide tube slightly using a press.
a Degrease the guide tube.
98934
a Position the gearbox on the support.
a Adjust the adjustable support if necessary.
98937
a Place the tightening clamp (7) onto the tube.
a Lock the tightening clamp (7) using the spanner (8) .
a Tighten the nut firmly.
98935
a Mark the guide tube fitting measurement using the
slider (6) on the tool (Bvi. 1445) to ensure it is cor-
rectly positioned when refitting.
21A-54
MANUAL GEARBOX
JB1 or JB3
a Line up the guide tube bearing lubrication hole oppo-
site the clutch housing lubrication hole.
98938
a Position the sleeve and split ring in place.

98935-1
a Turn the upper nut (9) . a Position the part until it is flush with the gauge hou-
a Gently extract the guide tube. sing.
REFITTING III - FINAL OPERATION

a Refit:
I - REFITTING PREPARATION OPERATION - the manual gearbox (see 21A, Manual gearbox,
a parts always to be replaced: Input shaft lip seal 4) ,
(12,01,04,17).
II - REFITTING OPERATION FOR PART val - Refitting) (19D, Engine mounting),
CONCERNED
Washing),
nents),
98939
a Make a mark on the clutch housing in alignment with moval - Refitting) (19D, Engine mounting),
the lubrication hole.
a Position the new part on the clutch housing. (35A, Wheels and tyres),
21A-55
MANUAL GEARBOX
JB1 or JB3
(80A, Battery).
21A-1) .
21A-56
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting 21A
REMOVAL

a Remove:
page 21A-1) .

CONCERNED
132990
a Remove the reverse gear switch (2) .
REFITTING

CONCERNED
a Apply RESIN ADHESIVE (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products) to the threading of the reverse gear
switch.
a Refit the reverse gear switch.
a Connect the reverse gear switch connector.
132991 II - FINAL OPERATION

a Disconnect the connector (1) from the reverse gear a Fill up the manual gearbox (see 21A, Manual gear-
switch. box, Manual gearbox oil: Draining - Refilling,
page 21A-1) .
21A-57
AUTOMATIC GEARBOX
Automatic gearbox: Precautions for repair 23A
DP0
I - PRECAUTIONS DURING REPAIR
Weight: 70 kg
Vehicles fitted with DP0 automatic transmissions use
systems called « Shift lock » and « Lock up » .
The purpose of the « Shift Lock » function is to prevent
the gear lever from being moved without the brake pe-
dal being simultaneously depressed.
Note:
For repair operations when the battery is faulty,
refer to the notice on board the vehicle.
The purpose of the « Lock up » or converter lockup is

to connect the automatic transmission directly to the
engine. This function is carried out by a « mini clutch »
in the converter.
The « Lock up » is driven by the automatic transmis-
sion computer.
As the automatic gearbox is lubricated under pressure,
lubrication is only provided when the engine is running.
Consequently, and to avoid serious damage, it is es-
sential to comply with the following instructions:
- never allow the vehicle to coast with the ignition swit-
ched off (i.e. when going down a hill); the damage that
this may cause cannot be stressed highly enough,
- never push the vehicle (e.g. to get to a petrol station,
unless the precautions in the « Towing » section have
been taken).
The vehicle only has drive when the engine is running.
It is therefore impossible to start the engine in a vehicle
with an automatic transmission by pushing the vehicle.
II - TOWING
The vehicle should preferably be towed in all cases on
a tow truck or with the front wheels raised.
Nonetheless, if this is impossible, in exceptional cir-
cumstances the vehicle may be towed at low speed
(maximum 12mph (20 km/h) over a maximum distan-
ce of 18 miles (30 km) (lever in N position).
23A-1
AUTOMATIC GEARBOX
Automatic gearbox: Identification 23A
DP0
117304
The automatic transmission series number can be
found in two places: on a label on the hydraulic distri-
butor cover (1) and etched onto the outer casing (2) on
the wheel side.
23A-2
AUTOMATIC GEARBOX
Automatic gearbox: Specifications 23A
DP0
Gearbox Suffix
099
DP0 100
101
Gear ratios (epicyclic gear train output)
1st 2nd 3rd 4th Final drive
2.724 1.499 1 0.710 21
23A-3
AUTOMATIC GEARBOX
Automatic gearbox: List and location of components 23A
DP0
127735
(1) DP0 gearbox

(2) Oil overflow pipe
(3) Level-setting cap
(4) Hydraulic distributor
(5) Hydraulic distributor casing seal
(6) Hydraulic distributor housing
(7) Torque converter
(8) Control pinion
(9) Vehicle speed sensor
(10) Multifunction switch
(11) Output lever
(12) Filler plug
(13) Connector support
(14) Sleeve stop
(15) Filter pad
(16) Input speed sensor 13787
(17) Heat exchanger

(21) Modulating solenoid valve
(18) Output speed sensor
(22) « Lock up » solenoid valve
(19) Control solenoid valve (converter lock-up)
(20) Pressure sensor (23) Selector solenoid valve 4
23A-4
AUTOMATIC GEARBOX
Automatic gearbox: List and location of components 23A
DP0
(24) Selector solenoid valve 3

13785
(29) Green connector (multifunction

switch)
(30) Yellow connector (electrohydrau-
lic interface)
(31) Green connector (line pressure)
(32) Yellow connector (turbo input
speed)
(33) Blue connector (output speed)
23A-5
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting 23A
K4J or K4M, and DP0
- the automatic transmission computer (see 23A,
Essential special tooling Automatic gearbox, Automatic transmission
computer: Removal - Refitting, page 23A-41) ,
Mot. 1448 Long nose pliers for hose
clips. - the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
Mot. 1390 Support for removing/refitting jection),
the engine - gearbox assem-
bly. - the battery tray (see Battery tray: Removal - Re-
Essential equipment - the front wheels (see Wheel: Removal - Refitting)

refrigerant charging station
safety strap(s) liner: Removal - Refitting) (55A, Exterior protec-
tion),
workshop hoist - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
Tightening torquesm a Attach the « radiator - condenser » assembly to the
front upper cross member using a safety strap(s).
automatic gearbox bell 44 N.m
a Remove:
housing bolts and nuts
converter nuts 24 N.m moval - Refitting) (19D, Engine mounting),
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle: val - Refitting, page 29A-2) .
Towing and lifting) (02A, Lifting equipment). - the front axle subframe (see Front axle sub-fra-
a Remove: me: Removal - Refitting) (31A, Front axle compo-
nents),
- the « engine - gearbox » assembly (see Engine/
- the engine undertray. gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
a Drain:
- the cooling system (see Cooling circuit: Draining
- Refilling) (19A, Cooling).
- the automatic gearbox (see 23A, Automatic gear-
box, Automatic gearbox oil: Draining - Refilling,
page 23A-11) ,
- the refrigerant circuit using a refrigerant charging
station (see Coolant circuit Draining - Refilling)
(62A, Air conditioning).
a Remove:
- the air resonator (see Air resonator: Removal -

Refitting) (12A, Fuel mixture),
(80A, Battery),
23A-6
AUTOMATIC GEARBOX
K4J or K4M, and DP0
CONCERNED
133274
a Disconnect the connector (3) from the control sole-
132766 noid valve.
a Remove the bolts (1) from the engine wiring harness
channel.
133273
a Disconnect the connector (4) from the tachometer.
133275
a Disconnect the automatic transmission connector by
pulling out the slide (2) .
23A-7
AUTOMATIC GEARBOX
K4J or K4M, and DP0
133276 110230
a Use the tool (Mot. 1448) to separate the clips (6) on a Secure the converter with string to prevent it from
the gearbox oil cooler hoses. being dislodged.
a Disconnect the gearbox oil cooler hoses.
a Remove: REFITTING
position sensor: Removal - Refitting) (17B, Pe- I - REFITTING PREPARATION OPERATION
trol injection), a Always replace the converter nuts.
(16A, Starting - Charging).
a Remove the converter nuts via the starter aperture.
a Remove the « engine - gearbox » assembly from the
(Mot. 1390) using a workshop hoist.
a Fit another workshop hoist on the automatic gear-
box.
a Remove:
- the bolts and nuts from the automatic gearbox bell
housing,
- the automatic gearbox.
110230
a Check that the centring dowels (7) are in place.
23A-8
AUTOMATIC GEARBOX
K4J or K4M, and DP0
a Refit:
position sensor: Removal - Refitting) (17B, Pe-
trol injection).
a Connect the gearbox oil cooler hoses.
a Use the tool (Mot. 1448) to fit the clips on the gear-
box oil cooler hoses.
a Connect:
- the tachometer connector,
- the control solenoid valve connector,

- the automatic transmission connector.
a Refit the bolts of the engine wiring channel.
110228 III - FINAL OPERATION
a check the positioning of the converter in relation to a Refit:

the engine/automatic gearbox coupling face using a - the « engine - gearbox » assembly (see Engine/
ruler and a straightedge; the value should be (X) = gearbox assembly: Removal - Refitting) (10A,
18.22 mm ± 1. Engine and peripherals),
II - REFITTING OPERATION FOR PART me: Removal - Refitting) (31A, Front axle compo-
CONCERNED nents),
a - the front left-hand driveshaft (see 29A, Drives-

Note: val - Refitting, page 29A-2) .
Before fitting the gearbox to the engine, position - the front right-hand driveshaft (see 29A, Drives-
the converter bolts opposite the holes on the hafts, Front right-hand wheel driveshaft: Remo-
drive plate val - Refitting, page 29A-8) .
a Refit:
moval - Refitting) (19D, Engine mounting).
- the gearbox on the engine, a Remove the safety strap(s).
- new converter nuts. a Refit:
a Remove the workshop hoist from the automatic - the front bumper (see Front bumper: Removal -
gearbox. Refitting) (55A, Exterior protection),
a Refit the « engine - gearbox » assembly onto the
(Mot. 1390).
tion),
a Remove the workshop hoist from the « engine and - the front wheels (see Wheel: Removal - Refitting)
gearbox » assembly. (35A, Wheels and tyres),
a Tighten to torque: - the battery tray (see Battery tray: Removal - Re-
- the automatic gearbox bell housing bolts and
nuts (44 N.m), - the petrol injection computer (see Petrol injection
- the converter nuts (24 N.m). jection),
23A-9
AUTOMATIC GEARBOX
K4J or K4M, and DP0
Automatic gearbox, Automatic transmission
(80A, Battery),
Refitting) (12A, Fuel mixture).
a Perform the following operations:
- fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling),
- fill the refrigerant circuit using a refrigerant char-
ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning).
- bleed the power-assisted steering circuit (see
Power-assisted steering circuit: Bleeding)
(36B, Power-assisted steering),
- fill up the automatic gearbox (see 23A, Automatic
gearbox, Automatic gearbox oil: Draining - Re-
filling, page 23A-11) .
23A-10
AUTOMATIC GEARBOX
Automatic gearbox oil: Draining - Refilling 23A
DP0
Tightening torquesm
overflow pipe 9 N.m
level-setting plug 35 N.m
filler cap 35 N.m
Oil capacity (adjust until over-

flows) (litre)
Gearbox
Drain capacity Total capacity
DP0 3.5 6
I - OIL SERVICE
Towing and lifting) (02A, Lifting equipment). 107912
a Remove:
Note: - the level-setting plug (1) ,
Drain the automatic transmission oil when the oil
- the oil overflow pipe (2) using an 8 mm Allen key
is warm (60˚C maximum), in order to remove as (3) .
many impurities as possible.
a Let the oil flow.
a Remove:
- the engine undertray bolts, Note:
- the engine undertray. Always replace the oil overflow pipe with a new
one whenever it is removed.
a Refit a new oil overflow pipe.

- the overflow pipe (9 N.m),
- the level-setting plug (35 N.m).
II - FILLING
a Remove the air resonator (see Air resonator: Re-
moval - Refitting) (12A, Fuel mixture).
23A-11
AUTOMATIC GEARBOX
DP0
110245 110236
a Park the vehicle on level ground.
a It is essential to shift the selector lever to the Park
position.
a Remove the filler cap (5) .
a Use a funnel with a 15:100 filter to prevent impurities
from entering the system.
a Fill the automatic gearbox with 3.5 litres of new oil
recommended by the manufacturer (see 23A, Auto-
matic gearbox, Automatic gearbox oil: Specifica-
tions, page 23A-15) (Technical Note 6012A, 04,
Lubricants).
a Run the engine at idle speed.
a Connect the diagnostic tool.
a Establish dialogue with the automatic gearbox com-
puter.
a Monitor the gearbox oil temperature parameter.
101743 a Wait for the temperature to reach 60˚C ± 1.
a Unclip the gear lever control cable (4) on the gear-
box by:
- squeezing the gear lever control cable clip at (A) ,
- pulling the pin at (B) ,
- lifting the gear lever cable at (C) .
23A-12
AUTOMATIC GEARBOX
DP0
III - LEVEL
a Park the vehicle on level ground.
Note:
The level MUST be checked according to the
procedure described below.
a It is essential to shift the selector lever to the Park

position.
a Fill the automatic transmission with 0.5 litre of new
oil.
a Run the engine at idle speed.
a Connect thediagnostic tool.
a Establish dialogue with the automatic gearbox com-
puter.
a Monitor the gearbox oil temperature parameter.
110252 a Wait for the temperature to reach 60˚C ± 1.
a Place a container under the level-setting plug (6) . a Place a container under the level-setting plug.
a Open the cap again .
a Open the level-setting plug (6) , leaving the engine
running. a If the oil does not flow or if the quantity collected is
below 0.1 litres :
a If the oil does not flow out or the quantity collected is
- Switch off the engine,
below 0.1 litres :
- add 0.5 litre of oil,
- Switch off the engine,
- let the automatic transmission cool to 50˚C,
- add 0.5 litre of oil, - run the engine at idle speed,
- connect the diagnostic tool,
- let the automatic transmission cool to 50˚C,
- establish dialogue with the automatic transmission
- run the engine at idle speed, computer,
- monitor the gearbox oil temperature parameter,
- connect the diagnostic tool,
- wait for the temperature to reach 60˚C ± 1,
- establish dialogue with the automatic transmission
computer, - place a container under the level-setting plug,
- open the level-setting plug.
- monitor the gearbox oil temperature parameter,
a Repeat these operations until more than 0.1 litres of
- wait for the temperature to reach 60˚C ± 1, oil is recovered in the container.
- place a container under the level-setting plug (6) ,

Note:
- open the level-setting plug. When the oil is replaced, the electronic oil ageing
counter must be reset (inside the computer).
a Repeat these operations until more than 0.1 litres of
oil is recovered in the container. a Refit the air resonator (see Air resonator: Removal
- Refitting) (12A, Fuel mixture).
a Refit the level-setting plug (6) .
a Clip the gear lever control cable on to the gearbox.
a Torque tighten the filler cap (35 N.m). a Refit the engine undertray.
23A-13
AUTOMATIC GEARBOX
DP0
a Enter the date of the oil change using the diagnostic
tool(see Fault finding - Configurations and pro-
gramming) (23A, Automatic transmission).
23A-14
AUTOMATIC GEARBOX
Automatic gearbox oil: Specifications 23A
4 SPEED AUTO GBOX
I - GEARBOX TYPE/OIL TYPE CORRELATIONS:
ELF MATIC - May be ordered
from ELF
S6
GEARBOX TYPE TYPE OF OIL FOR (7.6 litres)
GEARBOX
ELF MATIC - May be ordered
DP0/RWX ELF from ELF
CVT
RENAULTMATIC (1 litre)
D3 SYN ESSO - 77 11 172 226
MBX/AD4/AD8/AR4 ELF ATF LT 71141 (2 litres)
RENAULTMATIC
D2
LM0 ESSO
ATF LT 71141
SU0/SU1/SU4 CLIP
oil
AJX ELF MATIC

S6
FKX ELF MATIC

CKX CVT
Note:
ELF RENAULTMATIC D3 SYN oil is not a substitute
for ELF RENAULTMATIC D2.
II - STANDARDS AND PART NUMBERS OF THE

VARIOUS RECOMMENDED OILS:
DESIGNATION STANDARD PART NUMBER
ELF DEXRON II D 77 01 402 037

RENAULTMA- (2 litres)
TIC
D2
ELF DEXRON III May be ordered

from ELF
RENAULTMA-
TIC
D3 SYN
CLIP - 77 11 218 368

oil (2 litres)
23A-15
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting 23A
DP0
Bvi. 1462 Ball plate adjusting screw.
Tightening torquesm
hydra u l i c d i s t ributor 7.5 N.m

bolts
ball detent plate bracket 9 N.m

bolt
ball detent plate bolt 8 N.m
hydra u l i c d i s t ributor 10 N.m

cover bolts
REMOVAL
110245
a Unclip the automatic transmission control cable.
a Remove: CONCERNED
a Drain the automatic gearbox oil (see 23A, Automa-
tic gearbox, Automatic gearbox oil: Draining -
Refilling, page 23A-11) .
a Remove:
(80A, Battery),
- the petrol injection computer (see Petrol injection
jection),
110233
fitting) (80A, Battery).
a Remove:
- the bolts (1) of the hydraulic distributor cover,
- the hydraulic distributor cover.
23A-16
AUTOMATIC GEARBOX
DP0
CONCERNED
110232
a Remove the hydraulic distributor bolts (2) .
13789
a Disconnect the hydraulic distributor solenoid valve
a Connect the connectors of the hydraulic distributor
connectors (3) .
solenoid valves.
a Remove the hydraulic distributor.
a Refit the hydraulic distributor with its reinforcement
plate.
REFITTING

a Always replace the hydraulic distributor cover seal.
110227
a Check that the hydraulic distributor slide is properly
engaged with the notched sector lug (6) .
a Tighten to torque and in order the hydraulic distri-
butor bolts (7.5 N.m).
23A-17
AUTOMATIC GEARBOX
DP0
ADJUSTING THE BALL DETENT PLATE
110229 119433
a Put the multifunction switch lever in the first position a Fit the ball detent plate by fitting the bearing (9) into
selected using a hose clip and a bolt (8) in the me- the groove (12) for the notched sector (13) corres-
chanism housing. ponding to the first selected.
a Remove the bolt (7) . a Fit without tightening the ball detent plate bracket
bolt (10) .
a Fit the tool (Bvi. 1462) (11) in place of the bolt (7) .
a Screw the tool (Bvi. 1462) in fully whilst holding the
ball detent plate.
a Tighten to torque the ball detent plate bracket bolt
(9 N.m).
a Remove the tool (Bvi. 1462).
a Refit the ball detent plate bolt (7) .
a Torque tighten the ball detent plate bolt (8 N.m).
a Refit:
- a new seal on the hydraulic distributor cover,
- the hydraulic distributor cover.
a Torque tighten the hydraulic distributor cover
bolts (10 N.m).

a Clip on the automatic transmission control cable.
a Refit:
jection),
23A-18
AUTOMATIC GEARBOX
DP0
(80A, Battery),
a Top up the automatic transmission (see 23A, Auto-
matic gearbox, Automatic gearbox oil: Draining -
23A-19
AUTOMATIC GEARBOX
Hydraulic distributor solenoid valves: Removal - Refitting 23A
DP0
REFITTING
WARNING
Work as cleanly as possible to prevent foreign
CONCERNED
bodies from entering the system.
a Refit the hydraulic distributor solenoid valves.
REMOVAL II - FINAL OPERATION

a Refit the hydraulic distributor (see 23A, Automatic
I - REMOVAL PREPARATION OPERATION gearbox, Hydraulic distributor: Removal - Refit-
a Remove the hydraulic distributor (see 23A, Auto- ting, page 23A-16) .
matic gearbox, Hydraulic distributor: Removal -
Refitting, page 23A-16) .

CONCERNED
13787
(1) Modulating solenoid valve

(2) « Lock up » solenoid valve (loc-
kup converter)
(3) Sequence solenoid valve 4
a Remove the hydraulic distributor solenoid valves.
23A-20
AUTOMATIC GEARBOX
Hydraulic distribution wiring: Removal - Refitting 23A
DP0
Tightening torquesm
automatic transmission 4.5 N.m

connector bolts
REMOVAL

a Remove:

133277
a Drain the automatic gearbox oil (see 23A, Automa-
tic gearbox, Automatic gearbox oil: Draining -
pulling out the slide (1) .
a Remove the bolts (2) from the automatic transmis-
a Remove: sion connector.

Refitting) (12A, Fuel mixture), II - OPERATION FOR REMOVAL OF PART
CONCERNED
- the battery (see Battery: Removal - Refitting)
(80A, Battery),


jection),



terior protection),
- the hydraulic distributor (see 2 3 A , Automatic 110224

gearbox, Hydraulic distributor: Removal - Refit- a Remove the yellow connector (3) from the automatic
ting, page 23A-16) , transmission connector.
val - Refitting) (19D, Engine mounting).
23A-21
AUTOMATIC GEARBOX
Hydraulic distribution wiring: Removal - Refitting 23A
DP0
terior protection),
jection),
(80A, Battery),
a Top up the automatic transmission (see 23A, Auto-
117300
matic gearbox, Automatic gearbox oil: Draining -
a Remove the clip (4) from the cable feed opening Refilling, page 23A-11) .
using a screwdriver.
a Remove the hydraulic distributor wiring.
REFITTING

CONCERNED
a Refit:
- the hydraulic distributor wiring,
- the clip of the cable feed opening,
- the connector of the hydraulic distributor wiring to

the automatic transmission connector.
a Refit the automatic transmission connector.
a Torque tighten the automatic transmission con-

nector bolts (4.5 N.m).
a Connect the automatic transmission connector.
a Refit:

- the hydraulic distributor (see 2 3 A , Automatic

gearbox, Hydraulic distributor: Removal - Refit-
23A-22
AUTOMATIC GEARBOX
Flow regulation solenoid valve: Removal - Refitting 23A
DP0
CONCERNED
Tightening torquesm
flow control solenoid 10 N.m

valve bolts
REMOVAL

a Remove:
(80A, Battery),
computer: Removal - Refitting, page 23A-41) , 133274
- the petrol injection computer (see Petrol injection a Disconnect the connector (1) from the flow control
computer: Removal - Refitting) (17B, Petrol in- solenoid valve.
jection),
a Unclip the flow control solenoid valve connector
- the battery tray (see Battery tray: Removal - Re- from the automatic transmission connector support.
a Move the flow control solenoid valve wiring away
- the engine undertray bolts, from the automatic transmission wiring channel.
terior protection).
13786-1
a Remove:
- the flow control solenoid valve bolts (2) ,
- the flow control solenoid valve.
23A-23
AUTOMATIC GEARBOX
Flow regulation solenoid valve: Removal - Refitting 23A
DP0
REFITTING

CONCERNED
a Refit the flow control solenoid valve.
a Torque tighten the flow control solenoid valve
bolts (10 N.m).
a Position the wiring of the flow control solenoid valve
in the automatic transmission wiring channel.
a Refit the connector of the flow control solenoid valve
on the automatic transmission connector support.
a Connect the flow control solenoid valve connector.
a Refit:
terior protection),
jection),
(80A, Battery),
23A-24
AUTOMATIC GEARBOX
Gearbox oil cooler: Removal - Refitting 23A
DP0
Mot. 1448 Long nose pliers for hose
clips.
Tightening torquesm
hollow bolt of the gear- 50 N.m

box oil cooler
REMOVAL

a Remove:
- the battery (see Battery : Removal - Refitting) 133276
(80A, Battery), a Separate the clips (1) on the gearbox oil cooler ho-
ses using the tool (Mot. 1448).
Automatic gearbox, Automatic transmission a Disconnect the hoses from the gearbox oil cooler.
a Remove:
- the gearbox oil cooler hollow bolt (2) ,
jection), - the gearbox oil cooler hollow bolt seal,
- the battery tray (see Battery tray: Removal - Re- - the gearbox oil cooler,
- the gearbox oil cooler seals.
- the engine undertray. REFITTING
a Drain the cooling system (see Cooling circuit:
Draining - Refilling) (19A, Cooling). I - REFITTING PREPARATION OPERATION
a Remove: a Always replace:
- the front left-hand wheel (see Wheel: Removal - - the gearbox oil cooler hollow bolt seal,
- the gearbox oil cooler seals.
terior protection). II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- new seals on the gearbox oil cooler,
- a new seal on the hollow bolt of the gearbox oil
cooler,
- the gearbox oil cooler.
a Torque tighten the hollow bolt of the gearbox oil
cooler (50 N.m).
23A-25
AUTOMATIC GEARBOX
Gearbox oil cooler: Removal - Refitting 23A
DP0
a Connect the hoses of the gearbox oil cooler.
a Fit the clips on the gearbox oil cooler hoses using
the tool (Mot. 1448).

a Refit:
terior protection),
jection),
(80A, Battery),
a Fill the cooling circuit (see Cooling circuit: Drai-
ning - Refilling) (19A, Cooling).
23A-26
AUTOMATIC GEARBOX
DP0
Bvi. 1875 Tool for fitting left-hand diffe-

rential seal
REMOVAL

a Remove:
101026
II - OPERATION FOR REMOVAL OF PART a
CONCERNED
WARNING
a Remove the faulty differential output seal using a
Failure to adhere to the following procedure may
screwdriver or a hook, taking care not to scratch the
damage the gearbox.
contact faces.
a Deburr the aluminium gearbox casing around the in-
let chamfer of the differential output seal(left-hand
WARNING
side) using abrasive paper.
Do not drop the seal spring into the automatic
transmission.
Note:
Failure to respect this advice may damage the
REFITTING
seal and prevent it from sealing correctly.
I - PREPARATION OPERATION FOR REFITTING

THE DIFFERENTIAL OUTPUT SEAL
a Use SURFACE CLEANER (see Recommended
products for repairwork) to clean:
- the universal joint shaft,
- the mating face of the seal.
- the lip seal,
23A-27
AUTOMATIC GEARBOX
DP0
II - REFITTING OPERATION FOR PART III - FINAL OPERATION
CONCERNED
a Refit:
117291
117293
a Refit:
- a new right-hand differential output seal using the
tool,
- a new left-hand differential output seal using the
tool (Bvi. 1875).
23A-28
AUTOMATIC GEARBOX
Multifunction switch: Removal - Refitting 23A
DP0
Tightening torquesm

connector bolts
REMOVAL

a Place the control lever in Neutral.
a Remove:
(80A, Battery), 133277
Automatic gearbox, Automatic transmission a Disconnect the automatic transmission connector by
computer: Removal - Refitting, page 23A-41) , pulling the slide (1) .
- the petrol injection computer (see Petrol injection a Remove the bolts (2) from the automatic transmis-
computer: Removal - Refitting) (17B, Petrol in- sion connector.
jection),
fitting) (80A, Battery), II - OPERATION FOR REMOVAL OF PART
CONCERNED
terior protection).
110245
a Unclip the automatic transmission control cable.
a Remove the automatic transmission control cable.
23A-29
AUTOMATIC GEARBOX
Multifunction switch: Removal - Refitting 23A
DP0
REFITTING

CONCERNED
a Refit:
- the multifunction switch in the Neutral position,
- the automatic transmission control linkage.
a Adjust the multifunction switch (see 23A, Automatic

gearbox, Multifunction switch: Adjusting, page
23A-31) .
a Refit the multifunction switch connector to the auto-

matic transmission connector.
a Clip on the automatic transmission control cable.

110224
a Remove the green connector (5) from the automatic II - FINAL OPERATION
transmission connector.

a Refit:

terior protection),



110234 jection),
a Mark the position of the automatic transmission con-
trol linkage (6) .
a Remove: computer: Removal - Refitting, page 23A-41) ,
- the automatic transmission control linkage, - the battery (see Battery: Removal - Refitting)
(80A, Battery),
- the multifunction switch bolts (7) ,
- the multifunction switch. Refitting) (12A, Fuel mixture).
23A-30
AUTOMATIC GEARBOX
Multifunction switch: Adjusting 23A
DP0
Tightening torquesm
multifunction switch 10 N.m

bolts
ADJUSTMENT
110242
a Put the multifunction switch into the Neutral position.
a Place the test probes of an ohmmeter on the multi-
function switch position check tabs.
a Turn the multifunction switch by hand until the elec-
tric contact is closed (resistance at contact terminals
to be measured 0 Ω with a tolerance of 60 Ω)
a Torque tighten the multifunction switch bolts (10
N.m).
a Check that the resistance at the contact terminals is
still 0 Ω with a tolerance of 60 Ω after tightening.
a Check that the system and gear selection are wor-
king correctly.
23A-31
AUTOMATIC GEARBOX
Speed sensor: Removal - Refitting 23A
DP0
Tightening torquesm
input speed sensor bolt 10 Nm
output speed sensor 10 Nm

bolt

connector bolts
REMOVAL

a Remove:
Refitting) (12A, Fuel mixture), 133277
pulling the slide (1) .
(80A, Battery),
sion connector.
jection),
terior protection).
23A-32
AUTOMATIC GEARBOX
DP0
II - OPERATION FOR REMOVAL OF PART 2 - Output speed sensor
CONCERNED
1 - Input speed sensor
110224
a Remove the blue connector (5) from the automatic
110224
a Remove the yellow connector (3) from the automatic
a Unclip the input speed sensor wiring from the auto-
matic transmission wiring channel.
133278
a Remove:
- the output speed sensor bolt (6) ,
- the output speed sensor.
13786-1
a Remove:
- the input speed sensor bolt (4) ,
- the input speed sensor.
23A-33
AUTOMATIC GEARBOX
DP0
REFITTING

CONCERNED
1 - Input speed sensor

a Refit the input speed sensor.
a Torque tighten the input speed sensor bolt (10
Nm).
a Clip the input speed sensor wiring to the automatic
transmission wiring channel.
a Refit the input speed sensor connector to the auto-
2 - Output speed sensor

a Refit the output speed sensor.
a Torque tighten the output speed sensor bolt (10
Nm).
a Refit the output speed sensor connector to the auto-
a Refit:
terior protection),
jection),
(80A, Battery),
23A-34
AUTOMATIC GEARBOX
Pressure sensor: Removal - Refitting 23A
DP0
Tightening torquesm
pressure sensor bolts 8.5 N.m
pressure sensor wiring 9 N.m

bolt

connector bolts
REMOVAL

a Remove:
Refitting) (12A, Fuel mixture), 133277
- the battery (see Battery: Removal - Refitting) a Disconnect the automatic transmission connector by
(80A, Battery), pulling the slide (1) .
- the automatic transmission computer (see 23A, a Remove the bolts (2) from the automatic transmis-
Automatic gearbox, Automatic transmission sion connector.
- the petrol injection computer (see Petrol injection II - OPERATION FOR REMOVAL OF PART
computer: Removal - Refitting) (17B, Petrol in- CONCERNED
jection),
terior protection).
110224
a Remove the green connector (3) from the automatic

a Unclip the oil pressure sensor wiring from the auto-

matic transmission wiring channel.
23A-35
AUTOMATIC GEARBOX
Pressure sensor: Removal - Refitting 23A
DP0
a Refit:
terior protection),
jection),
(80A, Battery),
110251 - the air resonator (see Air resonator: Removal -
a Remove:
- the pressure sensor wiring bolt (4) ,

- the pressure sensor bolts (5) ,
- the pressure sensor.
REFITTING

CONCERNED
a Refit:
- the pressure sensor,
- the pressure sensor wiring bolt.

- the pressure sensor bolts (8.5 N.m),

- the pressure sensor wiring bolt (9 N.m).
a Clip the pressure sensor wiring to the automatic
transmission wiring channel.
a Refit the pressure sensor connector to the automatic


23A-36
AUTOMATIC GEARBOX
Converter seal: Removal - Refitting 23A
DP0
REMOVAL II - REFITTING OPERATION FOR PART

CONCERNED

a Remove the automatic gearbox (see 23A, Automa-
tic gearbox, Automatic gearbox: Removal - Refit-
ting, page 23A-6)
Note:
The converter contains a large amount of oil
which could escape when it is being removed.
a Remove the converter by withdrawing it as far as

possible without deviating from its axis.

CONCERNED 117292
a Remove the seal using a screwdriver, taking care a Refit a new pre-lubricated seal to the stop, using the
not to scratch the contact surfaces. tool (1) .
REFITTING

a Always replace the torque converter seal.
110228
a Check the positioning of the converter in relation to
the engine - automatic gearbox coupling face using
a rule and a slide. The value should be (X) = 18.22
mm ± 1.
23A-37
AUTOMATIC GEARBOX
Converter seal: Removal - Refitting 23A
DP0
a Refit the automatic gearbox (see 23A, Automatic
gearbox, Automatic gearbox: Removal - Refit-
ting, page 23A-6) .
23A-38
AUTOMATIC GEARBOX
Automatic transmission connector: Removal - Refitting 23A
DP0
Tightening torquesm - the front left-hand wheel (see Wheel: Removal -

automatic transmission 4.5 N.m - the front left-hand wheel arch liner (see Front
connector bolts wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).

CONCERNED
13785
(1) Green connector (multifunction

switch)
(2) Yellow connector (electrohydrau-
lic interface)
(3) Green connector (line pressure)
(4) Yellow connector (input speed)
(5) Blue connector (output speed)
133277
REMOVAL pulling the slide (6) .
I - REMOVAL PREPARATION OPERATION sion connector.
a Remove:

(80A, Battery),

jection),
23A-39
AUTOMATIC GEARBOX
Automatic transmission connector: Removal - Refitting 23A
DP0
jection),
(80A, Battery),
110224
a Remove the connectors from the automatic trans-

mission connector.
a Remove the automatic transmission connector.
REFITTING

CONCERNED
a Refit:
- the connectors to the automatic transmission con-

nector,
- the automatic transmission connector.

a Refit:

terior protection),


23A-40
AUTOMATIC GEARBOX
Automatic transmission computer: Removal - Refitting 23A
DP0
Essential equipment
diagnostic tool
REMOVAL


CONCERNED
132693
a Remove:
- the automatic transmission computer retaining

strap (2) ,
- the automatic transmission computer (3) .
REFITTING

CONCERNED
a Refit:
- the automatic transmission computer,
132692
a Disconnect the connector (1) from the automatic - the automatic transmission computer retaining
transmission computer. strap.
a Connect the automatic transmission computer con-

nector.
When replacing the automatic transmission

computer:
a Connect the diagnostic tool.
a Enter the oil age value using the parameter PR133
« Oil age counter » and make a note of the value.
a Copy the value into the memory of the new compu-
ter using the command VP015 « Oil age report » .
23A-41
AUTOMATIC GEARBOX
Automatic transmission computer: Removal - Refitting 23A
DP0
a Verify the entry using the parameter « Oil age
counter » .
a Enter the after-sales operation date using the com-
mand VP009 «Write date of last After-Sales
operation »
a Carry out a road test so that the new computer sto-
res the programming.
23A-42
DRIVESHAFTS
Driveshaft: Precautions for repair 29A
WARNING
A gearbox oil leak at the driveshaft may destroy it.
WARNING
Lubricate the base of the bearing with MOLYKOTE
to prevent the bearing sticking.
Make sure that the O-ring is correctly positioned in
the base of the relay bearing, if the bearing has
one.
WARNING
Always replace seals whenever the driveshaft is
removed.
WARNING
Always replace the left-hand driveshaft lock ring, if
the driveshaft has one.
WARNING
In order to prevent irreversible damage to the front

hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
29A-1
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting 29A
DP0 or JH3 or JR5
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Tightening torquesm
left-hand shock absor- 105 N.m

ber bolts
track rod end nut 37 N.m
hub nut 280 N.m
WARNING

hub bearing: 24800
a Remove:
- Do not place the vehicle with its wheels on the - the hub nut (1) , using the (Rou. 604-01),
- the left-hand track rod end nut (2)
removed.
- the left-hand track rod end using the tool (Tav.
476).
REMOVAL
I - REMOVAL PREPARATION OPERATION WARNING

In order not to damage the brake hose:
- do not tension the hose,
a Remove:
- do not twist the hose,
- check that there is no contact with the surroun-
- the engine undertray, ding components.
ANTI-LOCK BRAKES
JH3 or JR5
a Unclip the front left-hand wheel speed sensor cable
a Drain the manual gearbox (see 21A, Manual gear- at (3) .
page 21A-1) .
a Remove the left-hand shock absorber bolts (4)

CONCERNED
a Push the front left-hand driveshaft back inside the

hub of the front driveshaft hub carrier.
29A-2
DRIVESHAFTS
DP0 or JH3 or JR5
REFITTING
JH3 or JR5
JH3 or JR5
123652
a Remove the front left-hand driveshaft from the gear-
box using a lever (5) .
24719
a Always replace:
- the front left-hand driveshaft ring (6) ,
- the left-hand differential output seal.
a Remove:
- the front left-hand driveshaft ring (6) ,
- the left-hand differential output seal (see 21A, Ma-
nual gearbox, Differential output seal: Removal
- Refitting, page 21A-48) .
a Refit:
- a new left-hand differential output seal (see 21A,
Manual gearbox, Differential output seal: Re-
moval - Refitting, page 21A-48) .
- the front left-hand driveshaft ring.

CONCERNED
a Refit the front left-hand driveshaft into the automatic
gearbox.
a Insert the front left-hand driveshaft into the hub of
the front driveshaft hub carrier.
29A-3
DRIVESHAFTS
DP0 or JH3 or JR5
a Torque tighten the left-hand shock absorber bolts
(105 N.m).
ANTI-LOCK BRAKES
a Clip the front left-hand wheel speed sensor cable
onto the left-hand shock absorber bracket.
- the track rod end nut (37 N.m),
- the hub nut (280 N.m), using the (Rou. 604-01).
JH3 or JR5
page 21A-1) .
a Refit:
29A-4
DRIVESHAFTS
JB1 or JB3
Tightening torquesm
flange bolts 21 Nm
shock absorber base 105 N.m

bolts
track rod end nut 37 Nm
hub nut 280 N.m
WARNING

hub bearing:
24800
- Do not loosen or tighten the driveshaft nut when a Detach the wiring from the wheel speed sensor (1) .
a Remove:
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or - the hub nut (2) by immobilising the hub using the
removed. tool (Rou. 604-01),
- the track rod end nut (3) ,
- the track rod end from the stub axle carrier using
the (Tav. 476),
REMOVAL
- the shock absorber base bolts (4) .
I - REMOVAL PREPARATION OPERATION a Push the front left-hand driveshaft back from the
stub axle carrier by pivoting the stub axle carrier.
a Remove:
21A-1) .
a Remove the front left-hand wheel (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres).
29A-5
DRIVESHAFTS
JB1 or JB3
REFITTING

CONCERNED
Special notes on the front left-hand driveshaft
130489
a Remove:
- the bolts (5) securing the front left-hand driveshaft
to the gearbox,
- the front left-hand driveshaft.
107922
(6) Front left-hand driveshaft

(7) Bearing gaiter (gearbox side)
(8) Gaiter flange
(9) Gaiter lip seal (seal on the gear-
box side)
29A-6
DRIVESHAFTS
JB1 or JB3
a The seal (gearbox side) is made by pushing the gai- a Torque tighten the track rod end nut (37 Nm).
ter lip (9) into its housing on the gearbox, moving the
a Refit the hub nut.
flange (8) .
a Torque tighten the hub nut (280 N.m) using the tool
(Rou. 604-01).
Note:
a Clip on the wheel speed sensor wiring harness.
To provide a good seal when refitting the gaiter to
the gearbox, the flange (8) must be fitted to the
gaiter (7) to act as a shoulder to the lip seal (9) II - FINAL OPERATION
and to correctly seal its mating face on the gear- a Refit the front left-hand wheel (see Wheel: Removal
box. - Refitting) (35A, Wheels and tyres).
a Wipe oil from: a Top up the gearbox (see 21A, Manual gearbox,
- the flange (8) , 21A-1) .
- between the flange and the gaiter, a Refit the engine undertray.
- the seal lip (9) ,
- the face of the lip on the gearbox.
a Refit the driveshaft on the gearbox side (this opera-
tion requires two people):
- Person 1:
• position the driveshaft at the differential input,
• fit the flange (8) on the gaiter (7) ,
• fit the driveshaft into the gearbox whilst keeping
the flange (8) on the gaiter,
• push the flange (8) to insert the gaiter lip (9) in its
housing (do not pinch the gaiter (7) ).
- Person 2:
• pretighten the flange bolts (8) but do not tighten
fully (the flange should still be loose).
- Person 1:
• keep the driveshaft as horizontal as possible (with
respect to the differential).
- Person 2:
• Torque tighten the flange bolts (21 Nm).
Note:
The driveshaft must fit freely into the stub axle
carrier until it protrudes enough for the hub nut to
be fitted.
a Fit the front left-hand driveshaft into the stub axle

carrier.
a Refit the bolts to the shock absorber base.
a Torque tighten the shock absorber base bolts
(105 N.m).
a Position the track rod.
29A-7
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting 29A
DP0 or JH3 or JR5
Tightening torquesm
right-hand shock absor- 105 N.m

ber bolts
right-hand track rod end 37 N.m

nut
hub nut 280 Nm
WARNING
In order to prevent irreversible damage to the front 127729

hub bearing:
a Remove the bolt (1) from the front right-hand drives-
- Do not loosen or tighten the driveshaft nut when haft relay bearing bracket.
a Pivot the front right-hand driveshaft relay bearing
- Do not place the vehicle with its wheels on the bracket (2) .
removed.
REMOVAL

a Remove:
JH3 or JR5
page 21A-1) .
29A-8
DRIVESHAFTS
DP0 or JH3 or JR5
REFITTING

a Always replace the right-hand differential output
seal.
a Remove the right-hand differential output seal (see
21A, Manual gearbox, Differential output seal:
a Refit a new right-hand differential output seal (see
21A, Manual gearbox, Differential output seal:

CONCERNED
a Refit the front right-hand driveshaft into the gearbox.
a Insert the front right-hand driveshaft into the hub of
the front driveshaft hub carrier.
24801
a Remove: III - FINAL OPERATION

- the hub nut (3) using the (Rou. 604-01), a Torque tighten the right-hand shock absorber
bolts (105 N.m).
- the right-hand track rod end nut (4) ,
- the right-hand track rod end, using the tool (Tav.
ANTI-LOCK BRAKES
476).
a Clip the front right-hand wheel speed sensor cable
onto the right-hand shock absorber bracket.
WARNING
In order not to damage the brake hose:

- do not tension the hose, a Tighten to torque:
- do not twist the hose, - the right-hand track rod end nut (37 N.m),
- check that there is no contact with the surroun- - the hub nut (280 Nm), using the (Rou. 604-01).
ding components.
JH3 or JR5
ANTI-LOCK BRAKES a Pivot the front right-hand driveshaft relay bearing
a Unclip the front right-hand wheel speed sensor ca- bracket.
ble at (5) . a Refit the bolt to the front right-hand driveshaft relay
bearing bracket.
a Remove the right-hand shock absorber bolts (6) . page 21A-1) .

CONCERNED
a Refit:
a Push the front right-hand driveshaft back inside the
hub of the front driveshaft hub carrier. - the front right-hand wheel (see Wheel: Removal -
a Remove the front right-hand driveshaft from the
gearbox. - the engine undertray.
29A-9
DRIVESHAFTS
JB1 or JB3
Tightening torquesm
shock absorber base 105 N.m

bolts
track rod end nut 37 Nm
hub nut 280 N.m
WARNING

hub bearing:
the wheels are on the ground. 24801
- Do not place the vehicle with its wheels on the a Detach the wiring from the wheel speed sensor (1) .
ground when the driveshaft has been loosened or a Remove:
removed.
- the hub nut (2) by immobilising the hub using the
tool (Rou. 604-01),
- the track rod end nut (3) ,
REMOVAL - the track rod end from the stub axle carrier using
the (Tav. 476),
I - REMOVAL PREPARATION OPERATION - the shock absorber base bolts (4) .
a Position the vehicle on a two-post lift (see Vehicle: a Push the front right-hand driveshaft back from the
Towing and lifting) (02A, Lifting equipment). stub axle carrier by pivoting the stub axle carrier.
a Remove: a Remove the front right-hand driveshaft.
- the engine undertray. REFITTING
Manual gearbox oil: Draining - Refilling, page I - REFITTING OPERATION FOR PART
21A-1) . CONCERNED
a Remove the front right-hand wheel (see Wheel: Re- a Fit the front right-hand driveshaft to the gearbox su-
moval - Refitting) (35A, Wheels and tyres). nwheel.
Note:
The driveshaft must fit freely into the stub axle
carrier until it protrudes enough for the hub nut to
be fitted.
a Fit the front right-hand driveshaft into the stub axle

carrier.
a Refit the bolts to the shock absorber base.
29A-10
DRIVESHAFTS
JB1 or JB3
a Torque tighten the shock absorber base bolts
(105 N.m).
a Position the track rod.
a Torque tighten the track rod end nut (37 Nm).
a Refit the hub nut.
a Torque tighten the hub nut (280 N.m) using the tool
(Rou. 604-01).
a Clip on the wheel speed sensor wiring harness.
a Refit the front right-hand wheel (see Wheel: Remo-
val - Refitting) (35A, Wheels and tyres).
21A-1) .
29A-11
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting 29A
JH3 or JR5
REMOVAL a Lubricate the mating face of the driveshaft receiving

the deflector and the relay shaft bearing.

a Position the vehicle on a two-post lift (see Vehicle: CONCERNED
a Fit a new relay shaft bearing to the relay shaft.
a Remove:
a Fit the bearing to the end using a tube, so that it
- the engine undertray bolts, rests on the inner bush of the bearing.

a Fit a new deflector to the relay shaft.
page 21A-1) . a Fit the deflector to the end using a tube, so that it
rests on the surface of the deflector.
a Remove:
a Clean and grease the bearing hole into which the
- the front right-hand wheel (see Wheel: Removal - bearing will be inserted.
a Refit:
veshafts, Front right-hand wheel driveshaft: - the front right-hand driveshaft (see 29A, Drives-
Removal - Refitting, page 29A-8) . hafts, Front right-hand wheel driveshaft: Remo-
a Extract the deflector using a press and an extractor.
a Fill up the gearbox (see 21A, Manual gearbox, Ma-
CONCERNED nual gearbox oil: Draining - Refilling, page 21A-1)
.
100642
a Extract the relay shaft bearing (1) using a press and

an extractor.
REFITTING
WARNING
Take care not to scratch the contact surface of
the lip seal on the relay shaft.
29A-12
DRIVESHAFTS
Front driveshaft gaiter on wheel side: Removal - Refitting 29A
DP0 or JB1 or JB3 or JH3 or JR5
a Remove:
Emb. 880 Pin extractor.
Tav. 1796 Driveshaft stub axle bowl - the wheel on the side concerned (see Wheel: Re-
extractors moval - Refitting) (35A, Wheels and tyres),
Tav. 1168 Thermoplastic driveshaft gai- - the driveshaft on the side concerned (see 29A, Dri-
ter clip fitting tool. veshafts, Front left-hand wheel driveshaft: Re-
moval - Refitting, page 29A-2) or (see 29A,
Tav. 1784 Driveshaft gaiter clip tool. Driveshafts, Front right-hand wheel driveshaft:
Essential equipment
parts washer
109634
(1) Big securing clip

(2) Small securing clip
(3) Driveshaft gaiter
(4) Ball hub
(5) Stub axle bowl
(6) Ball race
(7) Propeller shaft
(8) Balls
(9) Locking spring ring
IMPORTANT
tion.
REMOVAL

29A-13
DRIVESHAFTS
CONCERNED
115192
a Remove the stub-axle bowl using the tool (Emb.

880) (3) equipped with the tool (Tav. 1796) (4) .
93034
128411
a Remove:
- the locking spring ring (5) ,
- the driveshaft gaiter.
128415
a Cut the big securing clip (1) and the small securing
clip (2) using side cutters or a metal saw, taking care REFITTING
not to damage the stub axle bowl and the driveshaft.
a Push back the gaiter to release the stub axle bowl. I - REFITTING PREPARATION OPERATION
a Remove as much grease as possible. a Always replace:

- the driveshaft gaiter,
- the big securing clip,
- the small securing clip,
- the locking spring ring.
29A-14
DRIVESHAFTS
a Using a parts washer, clean the driveshaft and the a Spread the quantity of grease around the gaiter and
stub axle bowl. the stub axle bowl.

CONCERNED
109768
a Refit the stub axle bowl (9) to the driveshaft by tap-
ping on the stub axle bowl using a brass drift until the
128412
locking spring ring clicks into place behind the hub
bearing.
a Fit the small securing clip (6) onto the driveshaft.
a Insert the gaiter lip into the groove of the stub axle
a Lightly lubricate the driveshaft using the grease sup- bowl.
plied with the gaiter to facilitate its fitting.
Note:
Check that the gaiter lip is correctly positioned in
the groove of the driveshaft.
a Fit the small securing clip on the driveshaft gaiter.

a Refit the big securing clip on the driveshaft gaiter.
128416
a Refit the gaiter (7) onto the driveshaft.

a Insert the gaiter lip into the groove of the driveshaft.
a Refit a new locking spring ring (8) .
29A-15
DRIVESHAFTS
Clic clip - the removed wheel (see Wheel: Removal - Refit-
ting) (35A, Wheels and tyres),
115197
Clip with profile end
115196
a Tighten the clips using the tool (Tav. 1168) (10) for
clic clips or the tool (Tav. 1784) (11) for profile end
clips.

a Refit:
- the removed driveshaft (see 29A, Driveshafts,
Front left-hand wheel driveshaft: Removal - Re-
fitting, page 29A-2) or (see 29A, Driveshafts,
Front right-hand wheel driveshaft: Removal -
Refitting, page 29A-8) .
29A-16
DRIVESHAFTS
Front right-hand driveshaft gaiter on gearbox side: Removal - Refitting 29A

DP0 or JB1 or JB3
Tav. 1168 Thermoplastic driveshaft gai-
ter clip fitting tool.
Tav. 1784 Driveshaft gaiter clip tool.
Essential equipment
parts washer
JH3 or JR5
2943

109767 (3) Driveshaft gaiter
(4) Yoke sleeve
(1) Deflector
(5) Lock ring
(2) Propeller shaft
(6) Spider
(3) Relay shaft bearing
(7) Cup
(4) Driveshaft yoke sleeve
(8) Cup spring
(5) Spider
(6) Driveshaft gaiter a

(9) Lock ring
REMOVAL
a

IMPORTANT
tion.
a Remove:
29A-17
DRIVESHAFTS
CONCERNED
page 21A-1) .
a Remove:
128487
128486
clip (2) using side cutters or a metal saw, taking care
not to damage the yoke sleeve and the driveshaft.
a Push back the driveshaft gaiter to release the yoke
sleeve.
29A-18
DRIVESHAFTS
DP0 or JB1 or JB3
128793
a Remove the yoke sleeve (3) .
128410
Note: a Remove the cup spring (5) fitted with the cup (6)
from the driveshaft yoke sleeve (4) .
- since the driveshaft yoke sleeve does not have
a stop tab, it can be removed without being for-
ced.
- Do not remove the rollers from their respective a Remove as much grease as possible from inside the
bushings as the rollers and needles are mat- yoke sleeve.
ched and should never be interchanged.
29A-19
DRIVESHAFTS
REFITTING
a Always replace:
- the driveshaft gaiter,
- the locking ring,
- the small securing clip.
DP0 or JB1 or JB3
a Always replace:
- the cup spring,
109409
- the cup.
a Remove the lock ring (7) .
Note:
a Using a parts washer, clean the driveshaft, the spi-
Mark the position of the spider before extracting der and the yoke sleeve.
it.

CONCERNED
90388
a Extract the spider (8) on the press using a releasing
type extractor.
128412
a Remove the driveshaft gaiter from the driveshaft.
a Fit the small securing clip (9) onto the driveshaft.
a Lightly lubricate the driveshaft using the grease sup-

plied with the gaiter to facilitate its fitting.
29A-20
DRIVESHAFTS
128409 109409
a Refit the gaiter (10) onto the driveshaft. a Refit the lock ring (12) .
127992
128488
a Refit the spider (11) in the position marked during re-
a Spread the quantity of grease around the gaiter and
moval.
the yoke sleeve.
a Fit the yoke sleeve (13) onto the spider (14) .
a Insert the gaiter lip into the groove of the yoke slee-
ve.
Note:
29A-21
DRIVESHAFTS
Clic clip
90392
a Insert a smooth rod with a rounded end between the
driveshaft gaiter and the yoke sleeve to evenly distri-
bute the volume of air contained inside the drives-
haft gaiter.
a Fit the small securing clip on the driveshaft gaiter. 115197

Clip with profile end
115196
clips.
a Refit:

29A-22
DRIVESHAFTS

page 21A-1) .
29A-23
DRIVESHAFTS
Front left-hand driveshaft gaiter on gearbox side: Removal - Refitting 29A

DP0 or JH3 or JR5
Tav. 1168 Thermoplastic driveshaft gai-
ter clip fitting tool.
Tav. 1784 Driveshaft gaiter clip tool.
Essential equipment
parts washer
JB1 or JB3
109401

(4) Yoke sleeve
(5) Lock ring
(6) Spider
135513 (7) Cup
(8) Cup spring
(9) Deflector
(10) Propeller shaft
(12) Lock ring
(4) Spider a
(5) Retaining ring
(6) Ball bearing
(7) Deflector
(8) Propeller shaft REMOVAL
a

IMPORTANT
Wear leaktight gloves (nitrile type) for this opera-
tion.
29A-24
DRIVESHAFTS
a Remove: II - OPERATION FOR REMOVAL OF PART
CONCERNED
DP0 or JH3 or JR5

page 21A-1) .
a Remove:
128413
128414
clip (2) using side cutters or a metal saw, taking care
not to damage the yoke sleeve and the driveshaft.
a Push back the driveshaft gaiter to release the yoke
sleeve.
29A-25
DRIVESHAFTS
a Remove as much grease as possible from the yoke
sleeve.
109408
a Remove the yoke sleeve (12) .
Note:
109409
- since the driveshaft yoke sleeve does not have a Remove the lock ring (7) .
a stop tab, it can be removed without being for-
ced.
- Do not remove the rollers from their respective Note:
bushings as the rollers and needles are mat- Mark the position of the spider before extracting
ched and should never be interchanged. it.
128410 90388
a Remove the cup spring (5) fitted with the cup (6) a Remove the spider (8) using a press supported on
from the driveshaft yoke sleeve (4) . an extractor.
29A-26
DRIVESHAFTS
JB1 or JB3 DP0 or JH3 or JR5

a Always replace:
- the cup,
- the cup spring,
- the small securing clip.
a Using a parts washer, clean the driveshaft yoke
sleeve.

CONCERNED
DP0 or JH3 or JR5
85933
a Remove the driveshaft gaiter (9) using a press sup-
ported on an extractor.
DP0 or JH3 or JR5

a Remove the driveshaft gaiter from the driveshaft.
REFITTING

a Always replace: 128412
- the driveshaft gaiter, a Fit the small securing clip (10) onto the driveshaft.
- the lock ring. a Lightly lubricate the driveshaft using the grease sup-
a Using a parts washer, clean the driveshaft and the plied with the gaiter to facilitate its fitting.
spider.
29A-27
DRIVESHAFTS
JB1 or JB3
128409
a Refit the gaiter (11) onto the driveshaft.
a Insert the gaiter lip into the groove of the driveshaft. 86197
a
Note:
Do not fit with a hammer, use the press in order
to obtain a gradual pressure and so avoid cau-
sing any damage to the ball bearing and the lip
seal, which could result in leaks.
29A-28
DRIVESHAFTS
JB1
85884
a Position the driveshaft gaiter in order to obtain a di-
mension (L1) = 115.4 mm between the bearing gui-
de and the end of the driveshaft.
86198
a Lock the driveshaft onto the press by the neck (12)
using an extractor to avoid damaging the driveshaft
gaiter on the wheel side.
29A-29
DRIVESHAFTS
JB3
109409
a Refit the lock ring (14) .
85884
a Position the driveshaft gaiter in order to obtain a di- DP0 or JH3 or JR5
mension (L1) = 117.9 mm between the bearing gui-
de and the end of the driveshaft.
128410
a Refit:
- the cup (15) onto the cup spring (16) ,
- the cup spring fitted with the cup into the driveshaft
yoke sleeve (17) .
127992
a Refit the spider (13) in the position marked during re-
moval.
29A-30
DRIVESHAFTS
Clic clip
109408 115197
a Spread the quantity of grease around the gaiter and

the yoke sleeve. Clip with profile end
a Fit the yoke sleeve (18) onto the spider (19) .
a Insert the gaiter lip into the groove of the yoke slee-
ve.
Note:
115196
clips.
90392
a Insert a smooth rod with a rounded end between the

driveshaft gaiter and the yoke sleeve to evenly distri-
bute the volume of air contained inside the drives-
haft gaiter.
a Fit the small securing clip on the driveshaft gaiter.
29A-31
DRIVESHAFTS
a Refit:

page 21A-1) .
29A-32

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2 Transmission

21A MANUAL GEARBOX

23A AUTOMATIC GEARBOX

MAY 2009 Edition Anglaise

© Renault s.a.s 2008

SYMBOL - THALIA - Section 2

20A CLUTCH 23A AUTOMATIC GEARBOX

Clutch: Precautions for repair 20A-1 Automatic gearbox:

Automatic gearbox: Removal

Manual gearbox oil: Draining Automatic gearbox oil:

Manual gearbox oil: Automatic gearbox oil:

Manual gearbox: Removal - Hydraulic distributor:

5th gear housing: Removal - Hydraulic distributor solenoid

5th gear sprockets and Hydraulic distribution wiring:

23A AUTOMATIC GEARBOX

Speed sensor: Removal -

Pressure sensor: Removal -

Converter seal: Removal -

Driveshaft: Precautions for

Front left-hand wheel

Front right-hand wheel

Relay shaft bearing:

Front driveshaft gaiter on

Front right-hand driveshaft

Front left-hand driveshaft

Emb. 1780 Set of clutch disc centring

Before removing the clutch, check:

During refitting check the following:

Pressure plate K4M

Drive plate 125932

Plate external diameter: 220 mm

Pressure plate Pressure plate

Drive plate Drive plate

Plate external diameter: 181.5 mm Plate external diameter: 181.5 mm

clutch pressure plate ?? N.m

clutch pressure plate ?? N.m

I - REMOVAL PREPARATION OPERATION

I - REFITTING PREPARATION OPERATION

II - REFITTING OPERATION FOR PART

a Torque tighten in a star pattern the clutch pressure

a Remove the (Emb. 1780) and (Mot. 582-01).

III - FINAL OPERATION

- the gearbox (see 21A, Manual gearbox, Manual

- the front axle subframe (see Front axle sub-fra-

- the front left-hand wheel driveshaft (see 29A, Dri-

- the front right-hand wheel driveshaft (see 29A, Dri-

a Fill the manual gearbox (see 21A, Manual gearbox,

- the front wheel arch liners (see Front wheel arch

- the front wheels (see Wheel: Removal - Refitting)

- the starter (see Starter: Removal - Refitting) ,

- the engine undertray,

- the battery tray (see Battery tray: Removal - Re-

- the battery (see Battery : Removal - Refitting)

REMOVAL II - OPERATION FOR REMOVAL OF PART

I - REMOVAL PREPARATION OPERATION

a Drain the manual gearbox (see 21A, Manual gear-

REFITTING - the front wheels (see Wheel: Removal - Refitting)

REMOVAL - the left-hand suspended engine mounting (see

- the engine undertray bolts,

- the engine undertray.

a Drain the gearbox oil (see 21A, Manual gearbox,

- the battery (see Battery : Removal - Refitting)

- the battery tray (see Battery tray: Removal - Re-

- the TDC sensor (see Crankshaft position sen-