2

Transmission
20A

CLUTCH MANUAL GEARBOX AUTOMATIC GEARBOX DRIVESHAFTS

21A

23A

29A

X84, and B84 or C84 or G84 or S84
77 11 318 042 MARCH 2003
All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

© Renault s.a.s. 2005

Mégane II - Section 2ContentsPage

Mégane II - Section 2
Contents
Page

20A

CLUTCH Identification Mechanism / Disk: Removal Refitting Clutch thrust bearing: Removal - Refitting Flywheel: Removal - Refitting 20A-1 20A-4 20A-15 20A-19

23A

AUTOMATIC GEARBOX Identification Gears Lubricants Consumables Changing the oil Filling - Levels Parts to be replaced systematically Checking the converter setting point 23A-1 23A-2 23A-3 23A-4 23A-5 23A-7 23A-10 23A-11 23A-12 23A-13 23A-18 23A-34 23A-36 23A-38 23A-39

21A

MANUAL GEARBOX Manual gearbox: Precautions for repair Manual gearbox: Parts and consumables for the repair work Consumables Manual gearbox: Specifications Gears Identification Lubricants Special notes Manual gearbox oil: Draining - Refilling Input shaft lip seal: Replacement Input shaft lip seal: Removal - Refitting Differential output seal: Removal - Refitting Manual gearbox: Removal Refitting

21A-1 Line pressure measurement 21A-2 21A-4 21A-5 21A-7 21A-8 21A-9 21A-10 21A-12 21A-14 21A-15 21A-16 21A-23 Differential output seal: Removal - Refitting Converter seal: Removal Refitting Multifunction switch: Removal - Refitting Automatic transmission computer: Removal Refitting Speed sensor: Removal Refitting Flow regulation solenoid valve: Removal - Refitting Hydraulic distributor: Removal - Refitting Automatic gearbox: Removal - Refitting Drive plate: Removal Refitting

23A-41 23A-43 23A-45

Contents

23A

AUTOMATIC GEARBOX Solenoid valves: Removal Automatic transmission connector: Removal Refitting 23A-47

23A-48

29A

DRIVESHAFTS Identification Consumables Front left-hand wheel driveshaft: Removal Refitting Front right-hand wheel driveshaft: Removal Refitting 29A-1 29A-4

29A-5

29A-10

8 mm Number of splines: 26 102142 20A-1 .CLUTCH Identification Colour of springs (1) and (2) : Grey K4J or K4M Pressure plate 20A K9K Pressure plate 102143 Driven plate 102143 1 Driven plate 3 2 4 102142 Plate outer diameter: 200 mm Plate thickness: 6.9 mm Number of splines: 26 Plate outer diameter: 215 mm Plate thickness: 6.

8 mm 20A-2 .CLUTCH Identification Colour of springs: (3) Red and grey Colour of springs: (4) Grey Number of splines: 21 20A F4R or F9Q or M9R Pressure plate 22428 Driven plate 22429 Plate outer diameter: 239 mm Plate thickness: 7.

8 mm Number of splines: 21 20A-3 . and F4R.CLUTCH Identification B84 or C84. and 774 Pressure plate 20A 22428 Driven plate 22429 Plate outer diameter: 239 mm Plate thickness: 7.

582-01) . 1 16180 K9K Tighten to torque the pressure plate mounting bolts (K9K engine) ( 1.Refitting. K4J or K4M Tighten to torque the pressure plate mounting bolts (K4J and K4M engines) ( 2 daNm ) .Refitting K4J or K4M or K9K Special tooling required Mot. 1518 Flywheel locking tool. Manual gearbox. Remove the (Mot. Set of clutch disc centring mandrels 20A REFITTING Tightening torquesm pressure plate mounting bolts (K4J and K4M engines) pressure plate mounting bolts (K9K engine) 2 daNm 2 1. Manual gearbox: Removal . page 21A23) . 582-01) (1) . 1518) (2) .5 daNm REMOVAL Remove the gearbox (see 21A. Centre the clutch driven plate using the (Emb. Position the (Mot.5 daNm ) . 582-01 Emb.CLUTCH Mechanism / Disk: Removal . Replace any faulty parts. Gradually screw into place in a star pattern. 95414 WARNING Clean the clutch shaft splines and refit the assembly without lubricant. 20A-4 . Remove the pressure plate mounting bolts. Position the clutch driven plate. Remove the friction plate.

page 21A23) . 20754 20A-5 . Note: 19919 For automatic wear compensation mechanisms. 1604) .CLUTCH Mechanism / Disk: Removal . 1604) in a vice. 1677 Emb. Remove the pressure plate mounting bolts. Set of clutch disc centring mandrels 20A REFITTING EMB. 1 16180 Position the (Mot. Place the base of the (Emb.Refitting. Remove the friction plate. 1604 Emb.2 daNm REMOVAL Remove the gearbox (see 21A. Manual gearbox. 1677) (1) . Clutch compression tool for resetting retrofit system. compress the clutch pressure plate using the (Emb. Replace any faulty parts. 1518 Tightening torquesm pressure plate mounting bolts 1. 1604 Flywheel locking tool.Refitting F4R or F9Q Special tooling required Mot. Manual gearbox: Removal .

20755 Fit the pressure plate on the base. 20756 Tighten the nut (2) as far as possible.Refitting F4R or F9Q 20A 3 2 1 20757 Place circlip pliers at (3) . Loosen the nut (2) completely (compressed springs). then fit the thrust ball bearing (1) and the nut (2) .CLUTCH Mechanism / Disk: Removal . Release the plate. 4 20759 Compress the springs (4) . 20A-6 .

1518) .Refitting F4R or F9Q CENTRING 20A 20758 Remove the pressure plate from the base (checking that the springs are properly compressed). Refit the pressure plate on the flywheel. Gradually torque tighten the pressure plate mounting bolts ( 1. 22695 Use the plastic centring tool supplied in the clutch kit (Emb.CLUTCH Mechanism / Disk: Removal . Degrease the friction face of the flywheel. 5 102695 Position the driven plate (small hub diameter (5) on flywheel end). WARNING Clean the clutch shaft splines and refit the assembly without lubricant.2 daNm ) . 20A-7 .

and PK4 Special tooling required Mot. 114917 20A-8 .REMOVAL PREPARATION OPERATION Remove: . Manual gearbox. Set of clutch disc centring mandrels. Position the (Mot. Engine and gearbox assembly: Removal . and 700. . 1431) (1) .CLUTCH Mechanism / Disk: Removal .the « engine and gearbox » assembly (see 10A.Refitting M9R. .the gearbox (see 21A. Manual gearbox: Removal .Refitting ). 1604 Flywheel locking tool. 1431 Emb. Remove . . 1780 Tightening torquesm clutch pressure plate mounting bolts 12 Nm REMOVAL I .Refitting ). Engine and peripherals.the friction plate.the pressure plate mounting bolts. 20A II .OPERATION FOR REMOVAL OF PART CONCERNED Emb. Clutch compression tool for resetting retrofit system.the pressure plate.

20A-9 . 20756 Tighten the nut fully. compress the clutch pressure plate using the (Emb. Fit the pressure plate on the base. 1604) . and 700. and PK4 20A REFITTING I .CLUTCH Mechanism / Disk: Removal .Refitting M9R. 20754 Position the base plate of the (Emb. then fit the thrust ball bearing (2) and the nut (3) .REFITTING PREPARATION OPERATION 19919 20755 Note: For automatic wear compensation mechanisms. 1604) in the vice.

WARNING Clean the clutch shaft splines and refit the assembly without lubricant. Release the plate. 20758 Remove the pressure plate from the base (checking that the springs are properly compressed). and PK4 20A 20757 Insert the circlip pliers at (4) . 20A-10 . 102695 Position the driven plate (small hub diameter (6) on flywheel end).CLUTCH Mechanism / Disk: Removal . Degrease the friction face of the flywheel. 20759 Compress the springs (5) . and 700. Loosen the nut (3) completely (springs compressed).Refitting M9R.

and 700. Tighten the clutch pressure plate mounting bolts until they make contact.Refitting ). 1431) .the gearbox (see 21A. Engine and peripherals.Refitting ).FINAL OPERATION Remove the (Mot.the « engine and gearbox » assembly (see 10A. . Engine and gearbox assembly: Removal .CLUTCH Mechanism / Disk: Removal . Gradually tighten to torque the clutch pressure plate mounting bolts ( 12 Nm ) . III . Manual gearbox: Removal . and PK4 II . 1431) . Refit the pressure plate on the flywheel. 20A-11 .REFITTING OPERATION Centring 20A 114916 Refit the clutch driven plate. 1780) (2) . Fit the (Mot. Manual gearbox. Centre the clutch driven plate using the (Emb.Refitting M9R. Refit: .

Manual gearbox: Removal . Manual gearbox. Clutch compression tool for resetting retrofit system. 1518 Tightening torquesm clutch pressure plate mounting bolts 12 Nm REMOVAL Remove the manual gearbox (see 21A. and F4R. compress the clutch pressure plate using the (Emb.Refitting B84 or C84.CLUTCH Mechanism / Disk: Removal . 20754 Place the base of the (Emb. 1677 Emb. and 774 Special tooling required Mot. 1604 Flywheel locking tool. 20A-12 . 1604 Emb. Note: 19919 For automatic wear compensation mechanisms.Refitting ). 1604) . Remove the pressure plate mounting bolts. 1677) (1) . Remove the friction plate. Set of clutch disc centring mandrels 20A REFITTING EMB. 1604) in a vice. Replace any faulty parts. 16180 Position the (Mot.

Loosen the nut (3) completely (springs compressed). and 774 20A 20757 Insert the circlip pliers at (4) . Release the plate.CLUTCH Mechanism / Disk: Removal . then fit the thrust ball bearing (2) and the nut (3) . 20755 Fit the pressure plate on the base. 20A-13 .Refitting B84 or C84. 20759 Compress the springs (5) . and F4R. 20756 Tighten the nut (3) fully.

22695 Use the plastic centring tool supplied in the clutch kit (Emb. Degrease the friction face of the flywheel.Refitting B84 or C84. Gradually tighten to torque the clutch pressure plate mounting bolts ( 12 Nm ) . and 774 CENTRING 20A 20758 Remove the pressure plate from the base (checking that the springs are properly compressed). 1518) . Refit the pressure plate on the flywheel. and F4R. 102695 Position the driven plate (small hub diameter (6) on flywheel end).CLUTCH Mechanism / Disk: Removal . 20A-14 . WARNING Clean the clutch shaft splines and refit the assembly without lubricant.

Manual gearbox. .both bolts (2) securing the clutch thrust bearing on the clutch housing.the gearbox (see 21A.the clutch thrust bearing.the gearbox (see 21A. page 21A-23) . . To refit. REFITTING Check the condition of the seals. 18439 . Manual gearbox: Removal .Refitting JH3 or JR5 or ND0 20A Tightening torquesm hydraulic union mounting bolts bolts mounting the clutch thrust bearing on the clutch housing 9 Nm 21 Nm ND0 REMOVAL JH3 or JR5 101223 Remove: .the hydraulic union.CLUTCH Clutch thrust bearing: Removal . . . .Refitting. . Remove: .the hydraulic union clip (1) .Refitting. proceed in the reverse order to removal. Manual gearbox.the hydraulic union mounting bolts ( 9 Nm ) . .the bolts mounting the clutch thrust bearing on the clutch housing ( 21 Nm ) .both bolts (1) from the hydraulic union.both bolts (2) securing the clutch thrust bearing on the clutch housing.the clutch thrust bearing. . JH3 or JR5 Tighten to torque: .the hydraulic union. 20A-15 . page 21A-23) . Manual gearbox: Removal .

Refitting JH3 or JR5 or ND0 20A ND0 Tighten to torque the bolts mounting the clutch thrust bearing on the clutch housing (21 Nm).CLUTCH Clutch thrust bearing: Removal . Mechanical component controls) . 20A-16 . WARNING T avoid damaging the clutch slave cylinder. do o not lubricate the clutch shaft. Never operate the system while the slave cylinder is removed. Bleed the clutch control (see 3 7 A.

REFITTING I . do not lubricate the clutch shaft. 20A-17 .REMOVAL PREPARATION OPERATION Check the condition of the input shaft seal.the clutch thrust bearing. Engine and gearbox assembly: Removal . Move the hydraulic union away. and PK4 20A II . and 700.CLUTCH Clutch thrust bearing: Removal . Manual gearbox. 114914 Remove: . Unclip the clutch hydraulic pipe. . Pull the retaining clip (1) out of the hydraulic union. Engine and peripherals. Replace it if necessary. WARNING 114915 To avoid damaging the clutch slave cylinder.the bolts (2) mounting the clutch thrust bearing on the clutch housing. .REMOVAL PREPARATION OPERATION Remove: . Manual gearbox: Removal . Always replace the clutch thrust bearing with a new one when the clutch is replaced.OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm bolts mounting the clutch thrust bearing on the clutch housing 21 Nm REMOVAL I .Refitting ).the gearbox (see 21A.Refitting M9R.the « engine and gearbox » assembly (see 10A.Refitting ).

CLUTCH Clutch thrust bearing: Removal .the gearbox (see 21A. and 700. Connect the hydraulic union.the « engine and gearbox » assembly (see 10A.Refitting ). and PK4 II . Clutch circuit: Bleeding ). Tighten to torque the bolts mounting the clutch thrust bearing on the clutch housing ( 21 Nm ) .REFITTING OPERATION FOR PART CONCERNED 20A 114914 Refit the new clutch thrust bearing.Refitting M9R. Position the clutch hydraulic pipe. Bleed the clutch control (see 37A. Manual gearbox: Removal . Engine and gearbox assembly: Removal . 20A-18 . III . Engine and peripherals. Tighten the bolts mounting the clutch thrust bearing on the clutch housing until they just make contact. Mechanical component control. Manual gearbox.FINAL OPERATION Reposition the retaining clip. Refit: . .Refitting ).

Refitting Special tooling required Mot.the flywheel. 20A-19 . 1677) (9) .the flywheel mounting bolts.the (Mot. Note: The engine flywheel is of the dual-mass type.Refitting. 1677 Flywheel locking tool.CLUTCH Flywheel: Removal . 1677) (9) . page 21A-23) . 582-01) (8) . Clutch. Check the condition of the flywheel. Position the (Mot. Flywheel locking tool.the clutch pressure plate (see 20A. . 20A REMOVAL Remove: . Remove: .the flywheel. . page 20A4) . Manual gearbox: Removal . F4R or F9Q Tightening torquesm engine flywheel mounting bolts (K engines) engine flywheel mounting bolts (F4R engine) engine flywheel mounting bolts (F9Q engine) 6. Degrease the bearing face of the flywheel on the crankshaft. 8 22698 REFITTING Clean the threads of the flywheel mounting bolts on the crankshaft.Refitting.5 daNm 7 daNm 9 daNm .the gearbox (see 21A. K4J or K4M or K9K 9 22698 Fit the (Mot. 582-01) (8) . Mechanism / Disk: Removal .the flywheel mounting bolts. . Remove: . Manual gearbox.the (Mot. 582-01 Mot. .

the engine flywheel mounting bolts (F9Q engine) ( 9 daNm ) . 11 101356 Refit the spacer (11) observing the direction of fitting of the chamfer on the flywheel end. 20A-20 .the engine flywheel mounting bolts (F4R engine) ( 7 daNm ) . .CLUTCH Flywheel: Removal .5 daNm ) .the engine flywheel mounting bolts (K engines) ( 6. 2 7 4 10 5 6 3 1 23325 23326 Tighten to torque and in order: WARNING Do not remove the flywheel drive plate mounting bolts (10) .Refitting 20A Always replace the mounting bolts with new ones. . . K9K Coat the new flywheel bolts with LOCTITE FRENETANCH.

1431 Flywheel locking tool. Remove: .the pressure plate and the driven plate (see 20A. Tighten to torque and in order the flywheel mounting bolts ( 25 Nm + 45˚ ± 6 ) . . 20A-21 .CLUTCH Flywheel: Removal . .REFITTING PREPARATION OPERATION Clean the threads of the flywheel mounting bolts on the crankshaft. . Clutch. II . 1431) .the flywheel mounting bolts. Check the condition of the flywheel.Driven plate: Removal Refitting ). Coat the new flywheel bolts with LOCTITE FRENETANCH .the flywheel. .OPERATION FOR REMOVAL OF PART CONCERNED 114913 Refit the engine flywheel.the (Mot. Finger tighten the new mounting bolts. Always replace the mounting bolts with new ones. Tightening torquesm flywheel mounting bolts 25 Nm + 45˚ ± 6 Note: 20A The engine flywheel is of the dual-mass type. 114913 Position the (Mot. 1431) (1) . and 700 Special tooling required Mot. Manual gearbox.Refitting ). REFITTING I . Pressure plate .Refitting ).Refitting M9R. Fit the (Mot. Degrease the bearing face of the flywheel on the crankshaft.REMOVAL PREPARATION OPERATION Remove: . Engine and peripherals. 1431) . Engine and gearbox assembly: Removal . Manual gearbox: Removal .the « engine and gearbox » assembly (see 10A. REMOVAL I .the gearbox (see 21A.REFITTING OPERATION FOR PART CONCERNED II .

FINAL OPERATION Remove the (Mot. Manual gearbox: Removal .Refitting ).Driven plate: Removal Refitting ). 20A 20A-22 . Clutch. Engine and peripherals. Refit: . . Engine and gearbox assembly: Removal .the « engine and gearbox » assembly (see 10A. and 700 III .Refitting ).CLUTCH Flywheel: Removal .the gearbox (see 21A.Refitting M9R. 1431) . Pressure plate . Manual gearbox.the driven plate and the pressure plate (see 20A. .

always replace the flywheel. REFITTING Clean the threads of the flywheel mounting bolts on the crankshaft. . Check the condition of the flywheel. 1677 Flywheel locking tool.Driven plate: Removal . .the flywheel.Refitting B84 or C84. 20A-23 . 1677) (1) . 101356 Refit the spacer (2) observing the direction of fitting of the chamfer on the flywheel end. and F4R.Refitting ). Manual gearbox.the gearbox (see 21A.the clutch pressure plate (see 20A. . 1677) (1) .the flywheel mounting bolts. Pressure plate . Coat the new flywheel bolts with LOCTITE FRENETANCH . WARNING When replacing an engine following overrevving. Tightening torquesm flywheel mounting bolts 70 Nm REMOVAL Remove: .CLUTCH Flywheel: Removal . Manual gearbox: Removal . Clutch. Remove: . 20A Degrease the bearing face of the flywheel on the crankshaft. Always replace the mounting bolts with new ones.the (Mot. and 774 Special tooling required Mot. Note: The engine flywheel is of the dual-mass type.Refitting ). 22698 Position the (Mot.

20A-24 .Refitting B84 or C84.CLUTCH Flywheel: Removal . and F4R. and 774 20A 23326 Tighten to torque and in order the flywheel mounting bolts ( 70 Nm ) .

lip seals. 2118 To select reverse gear. lift the collar (1) and shift the lever. II . and F4R. 21A-1 .O-rings.MANUAL GEARBOX Manual gearbox: Precautions for repair B84 or C84.GEAR SELECTION GATE 21A 101221 102448 WARNING The breather valve (2) must not be removed in order to fill up the oil.PARTS ALWAYS TO BE REPLACED Replace the following parts after removal: . . and 774 I .

and 774 21A Type LOCTITE 518 LOCTITE 5970 Packaging 24 ml syringe 300 g tube Part no. 77 01 421 162 77 11 219 705 Component Threaded plugs and switches ND0 housing assembly surfaces 21A-2 .MANUAL GEARBOX Manual gearbox: Parts and consumables for the repair work B84 or C84. and F4R.

and 700. .input shaft output seal.hydraulic tappet.MANUAL GEARBOX Manual gearbox: Parts and consumables for the repair work M9R.pins.differential output seals. Component Immerse all parts 100g cartridge 24 ml syringe 77 11 227 484 77 01 421 162 Housing assembly Switch threading Parts always to be replaced when they have been removed: . 21A-3 . . . . and PK4 21A Type GEARBOX OIL SILICONE ADHESIVE SEAL LOCTITE 518 Packaging Part no.lock rings.

77 01 421 145 77 01 421 162 77 01 404 452 77 11 219 705 21A-4 .MANUAL GEARBOX Consumables 21A Component Splines JH and JR housing assembly surfaces Threaded plugs and switches ND0 housing assembly surfaces JH3 or JR5 or ND0 Type MOLYKOTE BR2 LOCTITE 518 RHODORSEAL 5661 LOCTITE 5970 Packaging 1 kg can 24 ml syringe 100 g tube 300 g tube Part no.

MANUAL GEARBOX Manual gearbox: Specifications M9R. and 700. and PK4 PK4 gearbox ratios Suffix 001 1st 11 : 43 2nd 19 : 40 3rd 31 : 43 4th 43 : 44 5th 43 : 35 6th 46 : 31 Final drive 18 : 59 21A Reverse gear 27 : 47 Tachometer none 21A-5 .

and F4R. and 774.MANUAL GEARBOX Manual gearbox: Specifications B84 or C84.1 (2) Drain plug Filler plug 92081 Fill up to the level of the opening.CHECKING THE LEVEL (IN THE EVENT OF A LEAK) 2. and ND0 21A Reverse gear 37 : 38 Differential ratio 14 : 57 Suffix 000 1st 13 : 41 2nd 18 : 35 3rd 28 : 39 4th 36 : 39 5th 42 : 34 6th 49 : 33 Capacity (l) (1) ND0 I . II .GRADE. 106084 21A-6 . VISCOSITY See Technical Note Gearbox oil .

MANUAL GEARBOX Gears 21A ND0 001 B/C M0G 15 : 58 13 : 41 19 : 34 31 : 37 40 : 34 47 : 31 50 : 27 37 : 38 014 B/C MOU 16 : 70 13 : 41 18 : 35 28 : 39 36 : 38 52 : 45 56 : 41 37 : 38 JH3 Suffix Vehicle Differential ratio First Second Third Fourth Fifth Sixth Reverse gear 105 B/C M0B 14 : 59 11 : 41 21 : 43 28 : 39 31 : 34 37 : 33 11 : 39 142 B/C M0C 15 : 61 11 : 41 21 : 43 28 : 39 31 : 34 37 : 33 11 : 39 JR5 102 B/C/S M0F 15 : 56 11 : 41 21 : 43 28 : 37 35 : 34 41 : 31 11 : 39 21A-7 .

MANUAL GEARBOX Identification M9R. and PK4 21A 105538 (1) (2) Identification label Identification inscription 21A-8 . and 700.

5 2.GRADE. VISCOSITY TRANSELF TRJ 75 W80W to be ordered from ELF II .1 ND0 (2) Drain plug Filler plug 21A I .MANUAL GEARBOX Lubricants JH3 or JR5 or ND0 Capacity (in litres) (1) JR5 JH3 ND0 2.CHECKING THE LEVEL IN THE EVENT OF A LEAK 4 3 92081 101532 Fill up to the level of the opening. (3) (4) Drain plug Filler plug JH3 or JR5 2 1 18749 21A-9 .8 2.

II . lift the collar (1) and shift the lever.the lip seals. JH3 or JR5 102448 2 1 2118 To select reverse gear.PARTS TO BE REPLACED SYSTEMATICALLY After they have been removed. . replace the following parts with new parts: . return to neutral and select reverse like any other gear.MANUAL GEARBOX Special notes I .GEAR SELECTION GATES ND0 JH3 or JR5 21A 102896 To select reverse gear.the O-rings. 2176 21A-10 .

21A-11 .MANUAL GEARBOX Special notes 21A ND0 2 101221 WARNING It is forbidden to remove the breather valve (2) to fill the gearbox with oil.

Tighten to torque the drain plug ( 24 Nm ) .GRADE. 21A-12 . II .OIL CHANGE 113764 24 Nm Capacity in litres 2. and PK4 Special tooling required Mot. and 700. 1018) . 114772 Undo the filler cap (3) . III . 1018 Sump plug tool. positioning the groove (2) towards the plug.FILLING 114652 Unscrew the drain plug (1) using the (Mot.4 Refit the new seal on the plug.MANUAL GEARBOX Manual gearbox oil: Draining . Let the oil run into a drain tray.Refilling M9R. VISCOSITY TRANSELF TPR 78W80 to be ordered from ELF . 21A Tightening torquesm drain plug CAPACITY Gearbox type PK4 I .

and PK4 21A 92081 Fill the gearbox using a syringe containing recommended oil until the oil overflows out of the filler cap hole. 21A-13 . Tighten the filler cap. and 700.MANUAL GEARBOX Manual gearbox oil: Draining .Refilling M9R.

See Technical Note 3661A : JH .JR gearboxes. 21A ND0 Replace the lip seal after opening the gearbox. See Technical Note 3663A : ND0 gearbox 21A-14 .MANUAL GEARBOX Input shaft lip seal: Replacement REPLACEMENT JH3 or JR5 Replace the lip seal after opening the gearbox.

21A-15 .the gearbox (see 21A. 1236) . . .gearbox assembly: Removal . Clutch.Refitting ). Manual gearbox: Removal .MANUAL GEARBOX Input shaft lip seal: Removal .gearbox » assembly (see 10A Engine and peripherals. Clutch thrust bearing: Removal . Manual gearbox: Removal .Refitting ).5 mm diameter drill bit. Manual gearbox. Engine . 18061 Fit a new seal with its protector using the (Bvi. 21A REFITTING I . Extract the seal (1) using pliers.FINAL OPERATION Refit: . Engine . II .Refitting ).Refitting ).gearbox assembly: Removal .the « engine . 1236 Primary shaft oil seal fitting tool. and 700. II .the clutch thrust bearing (see 20A.Refitting M9R.REFITTING OPERATION FOR PART CONCERNED REMOVAL I . Clutch thrust bearing: Removal . WARNING Do not scratch the shaft or mating face.the clutch thrust bearing (see Clutch. 20714 Fit a bolt in seal (1) .the « engine . Manual gearbox.gearbox » assembly (see 10A Engine and peripherals. and PK4 Special tooling required Bvi. .OPERATION FOR REMOVAL OF PART CONCERNED Drill a hole in the seal.Refitting ). Remove the protector.the gearbox (see 21A.Refitting ). . using a 2.REMOVAL PREPARATION OPERATION Remove: .

. .1 daNm 10. REPLACING THE SEAL Tap the base of the lip seal using a drift and a small hammer to pivot it in its housing.4 daNm 28 daNm 2.MANUAL GEARBOX Differential output seal: Removal . .the hub nut.the wheel. Disconnect the battery. Remove: . 21A-16 . Remove the engine undertray.5 daNm 0. . 102129 REMOVAL Put the vehicle on a two-post lift.2 daNm 3. starting with the negative terminal.4 daNm Remove the relay bearing bracket.the anti-roll bar ball joint. .the wheel arch liner. . 1666 Tool for fitting differential seals.the lower ball joint.the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle). Remove the dislodged seal with pliers.7 daNm 4.the wheel speed sensor connector. taking care not to damage the sunwheel splines. Drain the gearbox.Refitting JH3 or JR5 Special tooling required Bvi. 101819 Remove the driveshaft.the track rod end. Disconnect: .5 daNm 10. 21A Tightening torquesm wheel bolts lower ball joint nut track rod end nut anti-roll bar ball joint nut hub nut relay bearing bracket nut engine tie-bar bolts sub-frame engine tiebar bolts battery cover 11 daNm 6.

4 daNm ) . 1666) (suffix A: righthand side.5 daNm ) . .the wheel bolts ( 11 daNm ) . suffix B: left-hand side).the lower ball joint nut ( 6.5 daNm ) .MANUAL GEARBOX Differential output seal: Removal . Refit the seal using the (Bvi. carry out the necessary programming (see (see 80A.Refitting JH3 or JR5 21A REFITTING 21503 Oil the seal. proceed in the reverse order to removal.2 daNm ) . WARNING Connect the battery. .1 daNm ) .4 daNm ) .the sub-frame engine tie-bar bolts ( 10.7 daNm ) .the relay bearing bracket nut ( 2. Tighten to torque: . 21A-17 . Top up the gearbox oil. Tighten to torque the battery cover ( 0. . . Position the driveshaft in relation to the sunwheel.the anti-roll bar ball joint nut ( 4. . . To refit.the hub nut ( 28 daNm ) . Battery) ). .the engine tie-bar bolts ( 10.the track rod end nut ( 3.

4 daNm Remove the relay bearing bracket. Disconnect: . Remove the driveshaft.MANUAL GEARBOX Differential output seal: Removal .2 daNm 3. Remove the battery cover. . 102129 REMOVAL Put the vehicle on a two-post lift.the anti-roll bar ball joint. 21A-18 .4 daNm 28 daNm 2.the right-hand wheel arch liner. Drain the gearbox. 101819 REPLACING THE SEAL . 1689 Differential output seal fitting tool.the lower ball joint. Remove: .the hub nut.the wheel speed sensor connector.the right-hand wheel.the track rod end. 21A Tightening torquesm wheel bolts lower ball joint nut track rod end nut anti-roll bar ball joint nut hub nut relay bearing bracket nut engine tie-bar bolts sub-frame engine tiebar bolts battery cover 11 daNm 6.5 daNm 0.the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle). Remove the engine undertray. Disconnect the battery. starting with the negative terminal. . Tap the base of the lip seal using a drift and a small hammer to pivot it in its housing. .Refitting ND0 Special tooling required Bvi. taking care not to damage the sunwheel splines. .1 daNm 18 daNm 10. Remove the dislodged seal with pliers. .7 daNm 4.

the wheel bolts ( 11 daNm ) . . 1689) (suffix A: righthand side. Top up the gearbox oil.the lower ball joint nut ( 6.the engine tie-bar bolts ( 18 daNm ) . WARNING Connect the battery. .the relay bearing bracket nut ( 2.Refitting ND0 21A REFITTING 102260 Oil the seal before inserting it onto the splined part of the sunwheel.MANUAL GEARBOX Differential output seal: Removal . 21A-19 .the anti-roll bar ball joint nut ( 4.7 daNm ) . . . Refit the seal using the (Bvi. proceed in the reverse order to removal. To refit.the sub-frame engine tie-bar bolts ( 10. carry out the necessary programming (see (see 80A. Tighten to torque the battery cover ( 0.5 daNm ) .2 daNm ) . . Tighten to torque: .the hub nut ( 28 daNm ) . suffix B: left-hand side). .4 daNm ) .the track rod end nut ( 3.4 daNm ) .1 daNm ) . Battery) ). Position the driveshaft in relation to the sunwheel. .

Front left-hand driveshaft: Removal . 1419 REMOVAL I .the front left-hand driveshaft (see 29A. 21A-20 .REMOVAL PREPARATION OPERATION Remove: . 21490 Remove the protection ring (1) on the transmission. Driveshafts. 1774 Bvi. 1719 Right-hand transmission seal fitting tool. Left-hand side differential oil seal fitting tool Bearing cage positioning tool.OPERATION FOR REMOVAL OF PART CONCERNED (RIGHT-HAND SIDE) 106885 Extract the seal using a screwdriver. and 700. Driveshafts. . II .Refitting ).MANUAL GEARBOX Differential output seal: Removal .OPERATION FOR REMOVAL OF PART CONCERNED (LEFT-HAND SIDE) Bvi. and PK4 Special tooling required Bvi.the front right-hand driveshaft (see 29A.Refitting M9R. 21A III . Front right-hand driveshaft: Removal Refitting ). taking care not to damage the casing.

21A-21 . 1719) (2) and the (Bvi.REFITTING OPERATION FOR PART CONCERNED (RIGHT-HAND SIDE) 21494 Slide on the protective ring (2) and clip it onto the driveshaft. 21493 Refit the right-hand seal using the (Bvi.MANUAL GEARBOX Differential output seal: Removal . Clean the driveshaft using degreaser. Note: Do not lubricate the seal.REFITTING OPERATION FOR PART CONCERNED (LEFT-HAND SIDE) 106886 Refit the left-hand seal using the (Bvi. 1774) (1) . 1419) (3) . and PK4 21A REFITTING I . II .Refitting M9R. and 700.

and PK4 III . Driveshafts. Fill the gearbox with oil (see 21A.Refitting ).MANUAL GEARBOX Differential output seal: Removal . 21A 21A-22 . Driveshafts.Refitting M9R. and 700. Front left-hand driveshaft: Removal . Manual gearbox: Draining-refilling ). . Front right-hand driveshaft: Removal Refitting ).FINAL OPERATION Refit: .the front left-hand driveshaft (see 29A.the front right-hand driveshaft (see 29A.

1453 Hub locking tool.the injection computer with its support. Equipment required steering wheel lock component jack 21A 62 Nm 140 Nm 105 Nm 25 Nm 3 Nm 4 Nm Tightening torquesm sub-frame cross member mounting bolts sub-frame rear mounting bolts sub-frame mounting bolts tie-rod gearbox drain plug gearbox filler plug battery cover Tightening torquesm wheel mounting bolts driveshaft nut lower ball joint nut track rod end nut anti-roll bar ball joint nut side panel mounting bolts gearbox edge and starter motor bolts bolts securing the engine tie-bar to the engine bolts securing the engine tie-bar to the sub-frame gearbox suspended mounting bolts nut securing the suspended engine mounting to the rubber pad steering shaft yoke mounting bolt radiator cross member front mounting bolt radiator cross member rear mounting bolts 110 Nm 280 Nm 62 Nm (37 Nm) 44 Nm 2 Nm 44 Nm 180 Nm WARNING Observe the following instructions to avoid damaging the rotar y switch beneath the steering wheel: . In this case. . Drain the gearbox. the steering wheel must be immobilised with the wheels straight for the duration of the operation using a steering wheel lock . starting with the negative terminal. 476 Mot. . 21A-23 .the battery. 21 Nm 105 Nm 21 Nm Remove: .the battery mounting. Multiple-adjusting engine mounting support with retaining straps. 604-01 Tav.the front wheels. .Before the steering column and the steering rack are uncoupled. Remove the battery cover. Rotary switch ).MANUAL GEARBOX Manual gearbox: Removal . only qualified personnel who have received training may carry out the operation. Disconnect the battery.the engine covers. Ball joint extractor. 105 Nm REMOVAL Position the vehicle on a two-post lift.Refitting F4R or F9Q Special tooling required Rou. . Control .Signalling.Any doubt regarding the correct alignment of the rotary switch necessitates removal of the steering wheel to apply the centring procedure (see 84A. . 62 Nm 180 Nm Remove the engine undertray.

Refitting F4R or F9Q . 21A-24 .MANUAL GEARBOX Manual gearbox: Removal . 21A 101699 101821 Remove the electrical harness mountings.pull the pin at (B) .raise the gearbox control at (C) .the flowmeter. B A C A 101743 Unclip the two gear lever cables on the gearbox: . . . Unclip the gear control cables from the gearbox. .the air inlet pipe.clip the gearbox control at (a) .

.the xenon headlight adjustment sensor wiring harnesses (if fitted). Remove the air filter hoses.turbocharger air pipe.MANUAL GEARBOX Manual gearbox: Removal . 604-01) .the hub nut using tool (Rou. . . 21A-25 . Remove the wheel arch liners. Remove the driveshaft.LEFT-HAND SIDE OF THE VEHICLE F9Q 102129 102244 Remove: .the anti-roll bar ball joint.the track rod end using tool (Tav.the lower ball joint. 476) .Refitting F4R or F9Q 21A I . Release the stub axle carrier from the driveshaft. . Disconnect: .the ABS sensor wiring. Disconnect the intercooler .

the lower ball joint. 21A-26 . . .the anti-roll bar ball joint.the hub nut using tool (Rou.Refitting F4R or F9Q II .the catalytic converter support from the clutch housing.the starter mounting bolts. 604-01) . . Release the stub axle carrier from the driveshaft. Remove: . . .RIGHT-HAND SIDE OF THE VEHICLE 21A 101212 101819 Remove the side reinforcements.the track rod end using tool (Tav. Remove the driveshaft. Attach the cooling radiator assembly to the upper cross member using rope.the starter motor. 476) .MANUAL GEARBOX Manual gearbox: Removal .the relay bearing bracket. 102009 Remove the radiator cross member Remove: . .

102452 Remove the upper engine tie-bar.MANUAL GEARBOX Manual gearbox: Removal . 101208 Remove the sub-frame angle bracket. 102312 Remove the lower engine tie-bar. 21A-27 .Refitting F4R or F9Q 21A 101354 Remove the steering shaft yoke.

Refitting F4R or F9Q 21A 101209 Remove the sub-frame. 21A-28 .MANUAL GEARBOX Manual gearbox: Removal .

MANUAL GEARBOX Manual gearbox: Removal . . 102485 Disconnect: . 101701 Disconnect the clutch slave cylinder by removing the clip (1) . 21A-29 .the gearbox edge lower bolts. Position component jack underneath the gearbox.the gearbox support rubber pad.the gearbox suspended mounting. 1453) .the TDC sensor.Refitting F4R or F9Q 21A 102449 Set up the engine support tool (Mot. . Remove: . Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.the gearbox. . . 1 102112 Remove: . .the gearbox mounting studs.the reversing connector.the gearbox edge upper bolts.

the gearbox edge and starter motor bolts ( 44 Nm ) . 21A-30 . .MANUAL GEARBOX Manual gearbox: Removal . Connect the battery. Mechanical component controls.the sub-frame rear mounting bolts ( 140 Nm ) . . . .the radiator cross member front mounting bolt ( 105 Nm ) .the sub-frame tie-rod mounting bolts ( 105 Nm ) . Tighten to torque the battery cover ( 4 Nm ) . .the steering shaft yoke mounting bolt ( 21 Nm ) .the sub-frame cross member mounting bolts ( 62 Nm ) . Check that the engine / gearbox alignment dowels are in place and correctly positioned.the wheel mounting bolts ( 110 Nm ) . .the bolts securing the engine tie-bar to the engine ( 180 Nm ) . Battery: Remove and Refit ).the clutch shaft splines.the side panel mounting bolts ( 2 Nm ) .the anti-roll bar ball joint nut ( 44 Nm ) . always replace the clutch hydrauo lic receiver after replacing a clutch mechanism.Top up the brake fluid level. .the gearbox filler plug ( 3 Nm ) . . Top up the gearbox oil.the gearbox output shaft with grease. . . .Bleed the circuit (see 37A.Refitting F4R or F9Q 21A REFITTING . Proceed in the reverse order to removal. to avoid damaging the clutch slave cylinder. Tighten to torque: .the track rod end nut ( (37 Nm) ) . .the gearbox suspended mounting bolts ( 62 Nm ). . Note: T avoid leaks. . . It is essential to replace the steering shaft yoke bolt when refitting.the nut securing the suspended engine mounting to the rubber pad ( 180 Nm ) .the lower ball joint nut ( 62 Nm ) . .the radiator cross member rear mounting bolts ( 21 Nm ) . starting with the positive terminal.the gearbox drain plug ( 25 Nm ) . . . WARNING Do not coat: . WARNING Be sure to bleed the hydraulic clutch control circuit in accordance with the following instructions: .the driveshaft nut ( 280 Nm ) .Add brake fluid to the reservoir.the bolts securing the engine tie-bar to the subframe ( 105 Nm ) . . . Bleeding the clutch circuit ). WARNING carry out the necessary programming (see 80A.

MANUAL GEARBOX Manual gearbox: Removal - Refitting
REMOVAL
Put the vehicle on a two-post lift. Rou. 604-01 Tav. 476 Mot. 1453 Hub locking tool. Ball joint extractor. Multiple-adjusting engine mounting support with retaining straps. Equipment required component jack Remove the battery cover.

21A

K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5 Special tooling required

Disconnect the battery, starting with the negative terminal. Remove the engine undertray. Drain the gearbox. Remove: - the front wheels, - the engine covers, - the battery,

Tightening torquesm wheel bolts driveshaft nut lower ball joint nut track rod end nut anti-roll bar ball joint nut side panel mounting bolts gearbox bell housing and starter bolts engine tie-bar bolts on the engine engine tie-bar bolts on the sub-frame gearbox suspended mounting bolts suspended mounting nut on the rubber pad radiator cross-member front mounting bolt gearbox drain plug gearbox filler plug battery cover 11 daNm 28 daNm 6.2 daNm 3.7 daNm 4.4 daNm 2.1 daNm 4.4 daNm 10.5 daNm 10.5 daNm 6.2 daNm 18 daNm

- the battery mounting, - the injection computer with its support, - the flowmeter, - the air inlet pipe.

101821

10.5 daNm (2.5 daNm) 0.3 daNm 0.4 daNm

Remove the electrical harness mountings.

21A-31

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5 I - LEFT-HAND SIDE OF THE VEHICLE

101699

Unclip the gear control cables from the gearbox. Remove: - the hub nut using the (Rou. 604-01) , - the track rod end using the (Tav. 476) , - the anti-roll bar ball joint, - the lower ball joint.

102129

Release the stub axle carrier from the driveshaft. Remove the left-hand driveshaft.

101743

Disconnect: - the ABS sensor wiring, - the xenon bulb adjustment sensor wiring harnesses (if fitted to the vehicle). Remove the wheel arch liners.

21A-32

MANUAL GEARBOX Manual gearbox: Removal - Refitting
II - RIGHT-HAND SIDE OF THE VEHICLE

21A

K4J, and 730 or 732, and JH3 – K4M, and 760 or 761 or 764, and JH3 – K9K, and 722 or 724 or 728, and JR5

101212 101819

Remove the side reinforcements.

Remove: - the hub nut using the (Rou. 604-01) , - the track rod end using the (Tav. 476) , - the anti-roll bar ball joint, - the lower ball joint. - the relay bearing bracket. Release the stub axle carrier from the driveshaft. Remove the right-hand driveshaft. Attach the cooling radiator assembly to the upper cross member using rope.
102009

Remove the radiator cross member

21A-33

the reversing connector. .the catalytic converter support from the clutch housing. and JH3 – K9K. 1 101701 Disconnect the clutch slave cylinder by removing the clip (1) . Remove the engine tie-bar. and JH3 – K4M. Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe. and 722 or 724 or 728.Refitting 21A K4J.the starter motor mounting bolts. . and JR5 14853 102115 Remove: . and 760 or 761 or 764.the starter motor.MANUAL GEARBOX Manual gearbox: Removal . .the TDC sensor. 21A-34 . Disconnect: . and 730 or 732.

Refitting 21A K4J. .the upper gearbox bell housing bolts. and 722 or 724 or 728. and 730 or 732.the gearbox.MANUAL GEARBOX Manual gearbox: Removal . Remove: . 21A-35 .the gearbox mounting studs.the gearbox edge lower bolts. Remove: . . 1453) . and JH3 – K4M. and JH3 – K9K. Position the component jack underneath the gearbox.the gearbox support rubber pad. . and JR5 102449 Set up the engine support tool (Mot. and 760 or 761 or 764.

.5 daNm ) .Bleed the hydraulic circuit ( (see 37A.5 daNm ) . .5 daNm) ) . and 760 or 761 or 764. and 730 or 732.7 daNm ) . Note: T prevent any risk of leaks. Tighten to torque: .the side panel mounting bolts ( 2. .the radiator cross-member front mounting bolt ( 10. Tighten to torque the battery cover ( 0.the gearbox filler plug ( 0.gearbox centering rings are in place and correctly positioned. .3 daNm ) . Check that the engine .MANUAL GEARBOX Manual gearbox: Removal .the gearbox output shaft with grease to avoid damaging the clutch slave cylinder.5 daNm ) .4 daNm ) . the clutch slave o cylinder must always be replaced after a clutch mechanism is replaced. Top up the gearbox oil.the track rod end nut ( 3. . . Mechanical component controls) ). .the anti-roll bar ball joint nut ( 4. and JH3 – K9K.the suspended mounting nut on the rubber pad ( 18 daNm ) . and JR5 Be sure to bleed the hydraulic clutch circuit accordance with the following instructions: .the wheel bolts ( 11 daNm ) . .the gearbox bell housing and starter bolts ( 4.the gearbox drain plug ( (2.Top up the brake fluid level.the engine tie-bar bolts on the engine ( 10. Battery) ).the gearbox suspended mounting bolts ( 6. and JH3 – K4M.the lower ball joint nut ( 6. .2 daNm ) . . To refit.4 daNm ) . 21A-36 .1 daNm ) . WARNING Connect the battery.Refitting REFITTING WARNING WARNING Do not coat: . .the clutch shaft splines.2 daNm ) . 21A K4J.Add brake fluid to the reservoir.4 daNm ) .the driveshaft nut ( 28 daNm ) . and 722 or 724 or 728. proceed in the reverse order to removal.the engine tie-bar bolts on the sub-frame ( 10. . . carry out the necessary programming (see (see 80A. . . .

Unpick the reverse gear switch wiring harness from the gearbox.MANUAL GEARBOX Manual gearbox: Removal . II . Unclip the breather pipe from the gearbox.Refitting ).REMOVAL PREPARATION OPERATION Remove the « engine . Engine and peripherals.gearbox assembly: Removal . and PK4 21A Tightening torquesm gearbox mounting bolts starter mounting bolts 44 Nm 44 Nm REMOVAL I . Engine . and 700. 21A-37 .gearbox » assembly (see 10A.Refitting M9R.OPERATION FOR REMOVAL OF PART CONCERNED 115005 Unpick the TDC sensor and oil level sensor wiring harness (2) from the gearbox. 115004 Disconnect the reverse gear switch connector (1) .

the gearbox. Clip: 115211 .the gearbox mounting bolts ( 44 Nm ) . Engine and peripherals. . . . and 700.the TDC sensor and oil level sensor wiring harness to the gearbox. .the reverse gear switch wiring harness to the gearbox.Refitting ).FINAL OPERATION Connect the reverse gear switch connector.the gearbox mounting bolts (4) .the gearbox. Engine .the gearbox mounting bolts.the starter mounting bolts. Refit the « engine . II .the starter mounting bolts (3) . 21A-38 . and PK4 21A REFITTING I . Tighten to torque: .Refitting M9R.gearbox assembly: Removal . . Clip the breather pipe onto the gearbox. .gearbox » assembly (see 10A. 115210 Remove: .REFITTING OPERATION FOR PART CONCERNED Refit: .the starter mounting bolts ( 44 Nm ) .MANUAL GEARBOX Manual gearbox: Removal .

Battery. Lifting equipment. 105 Nm REMOVAL Position the vehicle on a two-post lift (see 02A.the wiring harness mountings. Battery: Removal . 1453 Multiple-adjusting engine mounting support with retaining straps. Control .the battery tray. the steering wheel must be removed to apply the centring procedure (see 84A. Remove the engine undertray.Refitting B84 or C84.Before the steering column and the steering rack are uncoupled. 62 Nm Drain the gearbox.the injection computer with its support.the battery.the air box. . and F4R. only qualified personnel who have received training may carry out the operation. .if there is any doubt regarding the correct centring of the rotary switch. Remove: 21 Nm 105 Nm 21 Nm 62 Nm . Remove the battery cover. . the steering wheel must be immobilised with the wheels set straight-ahead for the duration of the operation using the steering wheel lock . . .Refitting ). and 774 Special tooling required Mot. 21A-39 . . 105 Nm 62 Nm Disconnect the battery (see 80A.the front wheels. Vehicle: Towing and lifting ).Signalling ).the engine covers. In this case. .MANUAL GEARBOX Manual gearbox: Removal . Equipment required steering wheel lock component jack WARNING Tightening torquesm wheel bolts side panel mounting bolts gearbox bell housing bolts starter motor mounting bolts bolts securing the lower engine tie-bar onto the engine bolts securing the upper engine tie-bar onto the engine bolts securing the engine tie-bar onto the sub-frame bolts securing the suspended mounting onto the gearbox nut securing the suspended mounting on the rubber pad steering shaft yoke mounting bolt radiator cross member front mounting bolts radiator cross member rear mounting bolts sub-frame mounting bolts bracket 130 Nm 21 Nm 44 Nm 38 Nm 180 Nm 21A 105 Nm 35 Nm 62 Nm Tightening torquesm sub-frame mounting bolts tie-rod gearbox drain plug bolts securing the strut onto the sub-frame stiffener Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel: .

and F4R. Disconnect: .the ABS sensor wiring harness at (1) .the xenon bulb adjustment sensor wiring harness.the driveshafts (see 29A. . Remove the wheel arch liners.Refitting B84 or C84. 106085 101743 Remove: .the sub-frame stiffener strut (2) . . Driveshafts ). 21A-40 . Note: Do not touch the slide.MANUAL GEARBOX Manual gearbox: Removal . Attach the cooling radiator assembly to the upper cross member using rope. and 774 21A 106091 106082 Unclip the gear control cables from the gearbox.

the radiator cross member (4) .the catalytic converter retaining bracket (5) from the clutch sump.MANUAL GEARBOX Manual gearbox: Removal . Remove the starter. and F4R. . .the starter mounting bolts. and 774 21A 106077 102452 Remove: . 102313 Remove the lower engine tie-bar (6) . Remove the upper engine tie-bar.the side reinforcements (3) .Refitting B84 or C84. 106212 Remove: . 21A-41 .

21A-42 . 101208 Remove the sub-frame angle bracket (7) . Position the component jack under the sub-frame. Remove the sub-frame. and 774 21A 101354 Remove the steering column universal joint.MANUAL GEARBOX Manual gearbox: Removal . Strap the sub-frame to the component jack . 106086 Remove the sub-frame mounting bolts (8) .Refitting B84 or C84. and F4R.

the TDC sensor.MANUAL GEARBOX Manual gearbox: Removal . . .the gearbox mounting studs. .the gearbox support rubber pad. .Refitting B84 or C84.the gearbox. 102419 Remove: . . 1453) . and F4R.the reversing connector.the gearbox suspended mounting. 102513 Disconnect the clutch slave cylinder by removing the clip (9) . 102485 Disconnect: . Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe. 21A-43 .the gearbox edge upper bolts.the gearbox edge lower bolts. Remove: . Position the component jack underneath the gearbox. and 774 21A 102449 Set up the engine support tool (Mot.

the gearbox bell housing bolts ( 44 Nm ) . .the radiator cross member front mounting bolts ( 105 Nm ) . . 21A-44 .the gearbox drain plug ( 35 Nm ) . 80A. . .the bolts securing the lower engine tie-bar onto the engine ( 180 Nm ) . . to avoid damaging the clutch slave cylinder. Refit the sub-frame (see 31A.Refitting ). .the radiator cross member rear mounting bolts ( 21 Nm ) . WARNING It is essential that the hydraulic clutch circuit is bled in accordance with the following instructions: .the starter motor mounting bolts ( 38 Nm ) . and F4R.top up the brake fluid level. . Tighten to torque: . Connect the battery (see MR 364. WARNING Do not coat: .the side panel mounting bolts ( 21 Nm ) .the wheel bolts ( 130 Nm ) . Front axle component.Refitting ). .add brake fluid to the reservoir.gearbox locating rings (10) are present and correctly positioned. . Top up the gearbox oil. Proceed in the reverse order to removal.bleed the circuit (see 37A. .the bolts securing the engine tie-bar onto the sub-frame ( 105 Nm ) .the bolts securing the strut onto the sub-frame stiffener ( 62 Nm ) . .the gearbox output shaft with grease.the bolts securing the upper engine tie-bar onto the engine ( 105 Nm ) . the clutch slave o cylinder must always be replaced after a clutch mechanism is replaced. and 774 21A REFITTING . . 106087 Check that the engine .Refitting B84 or C84. Note: T prevent any risk of leaks.the steering shaft yoke mounting bolt ( 21 Nm ) .the sub-frame bracket mounting bolts ( 62 Nm ) .the nut securing the suspended mounting on the rubber pad ( 62 Nm ) . . Sub-frame: Removal . . Battery: Removal . . Mechanical components controls ).the sub-frame tie-rod mounting bolts ( 105 Nm ) . Battery.the bolts securing the suspended mounting onto the gearbox ( 62 Nm ) .MANUAL GEARBOX Manual gearbox: Removal . .

unless the precautions in the « Towing » section have been taken). the damage that this may cause cannot be stressed highly enough. The vehicle only has drive when the engine is running.): see the vehicle Owner's Manual.e. 23A . 13786 I . when going down a hill). Consequently. in exceptional circumstances. it is essential to comply with the following instructions: .AUTOMATIC GEARBOX Identification DP0 Identification engraving on the automatic transmission. if this is impossible. This function is performed by a « mini clutch » located on the converter. Nonetheless.SPECIFICATIONS Weight: 154 lbs (70 kg) . Vehicles fitted with DP0 automatic transmissions use systems called « Shift lock » and « Lock up » . The « Lock up » is controlled by the automatic transmission computer. As the automatic transmission is lubricated under pressure. caravan.e. WARNING Towing weight (trailer. Note: For repair operations when the battery is faulty. and to avoid serious damage. etc.never allow the vehicle to coast with the ignition switched off (i. It is therefore impossible to start the engine of a vehicle with an automatic transmission by pushing the vehicle.never push the vehicle (i. The purpose of the « Shift lock » function is to prevent the gear selector lever from being moved without the brake pedal being simultaneously depressed. lubrication is only provided when the engine is running. to get to a petrol station.TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. II . 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. 23A-1 . the vehicle may be towed at low speed (maximum 12 mph (20 km/h)) over a maximum distance of 18 miles (30 km) (lever in N position). boat.

000 0.499 1.000 0.177 054 BMOU/ CMOU 2.724 1.710 52 / 67 21 / 73 3.710 52 / 67 21 / 73 3.710 52 / 67 21 / 73 3.724 1.000 0.177 049 BMOU/ CMOU 2.710 52 / 67 20 / 73 3.724 1.000 0.724 1.177 050 BMOC/ CMOC 2.499 1.000 0.499 1.710 52 / 67 21 / 73 3.177 23A-2 .499 1.724 1.499 1.AUTOMATIC GEARBOX Gears DP0 23A Reduction Final drive Vehicle Engine Gearbox Automatic Gearbox suffix 046 BMOC/ CMOC K4M 761 DP0 047 050 049 BMOU/ CMOU F4R 771 DP0 052 054 52 / 67 52 / 67 52 / 67 52 / 67 20 / 73 21 / 73 21 / 73 20 / 70 DP0 Suffix Vehicle First Second Third Fourth Reduction Final drive Reverse gear 046 BMOC/ CMOC 2.499 1.177 052 BMOU/ CMOU 2.724 1.177 047 BMOC/ CMOC 2.710 52 / 67 21 / 73 3.000 0.

CAPACITY IN LITRES Total volume: 6 litres . I . 23A 23A-3 .OIL SPECIFIED: ELF RENAULT MATIC D3 SYN (can be ordered from ELF ) DEXRON III standard II .AUTOMATIC GEARBOX Lubricants DP0 The DP0 automatic gearbox is greased for life and does not require any maintenance: It is only necessary to top up the level in the event of a slight leak.

AUTOMATIC GEARBOX Consumables DP0 23A Description Grease M O L Y KOTE BR2 LOCTITE FRENBLOC Component concerned Centring tool Brake calliper mounting bolt 23A-4 .

Remove the engine undertray. The level check and bleeding procedure is the same for both assemblies.overflow pipe (2) . . The cap has two functions: . when changing engine oil or topping up. Remove only the cap (1) for topping-up.level-setting plug (1) . Remove the assembly (1) and (2) to carry out the complete gearbox oil change. The engine oil change and topping-up caps have evolved.AUTOMATIC GEARBOX Changing the oil DP0 Former assembly Tightening torquesm level-setting plug (old assembly) overflow assembly) pipe (old 25 Nm 35 Nm 23A 2 level-setting plug (new assembly) overflow pipe (new assembly) 35 Nm 9 Nm 1 2316 WARNING For both assemblies. the control lever must be in the Parking position. 23A-5 . Position the vehicle on a lift. Bleed the automatic gearbox when the oil is warm ( 60˚C maximum ) in order to remove as many impurities as possible.

AUTOMATIC GEARBOX Changing the oil
DP0 New assembly

23A

4 5

3

107912

Remove: - the level-setting cap (3) , - overflow pipe (4) using an Allen key (5) with diameter of 8 mm. Let the oil flow. Note: Always replace the overflow pipe each time it is removed. Refit the new overflow pipe. Tighten to torque: - the level-setting plug (old assembly) ( 25 Nm ) - the overflow pipe (old assembly) ( 35 Nm ) - the level-setting plug (new assembly) ( 35 Nm ) - the overflow pipe (new assembly) ( 9 Nm ) Fill up the gearbox and check the level (see 23A, Automatic gearbox, Filling - Levels ).

23A-6

AUTOMATIC GEARBOX Filling - Levels
DP0

23A

Equipment required diagnostic tool

Tightening torquesm level-setting plug 35 Nm

2

WARNING It is essential to shift the selector lever to the Park position. I - FILLING

101822

Disconnect the computer connectors. Remove: - the battery tray mounting bolts (2) , - the battery tray, - the computer mounting.

1

Remove the turbocharging pressure regulation solenoid valve (if fitted in the vehicle).

103407

Fill through the hole (1) . Use a funnel with a 15/100 filter to prevent impurities from entering the system. II - FILLING PROCEDURE Park the vehicle on level ground. Disconnect the battery, starting with the negative terminal.

3

110245

Remove gearbox control (3) .

23A-7

AUTOMATIC GEARBOX Filling - Levels
DP0 former assembly

23A

B

A

C A

4
2316

Open the cap again (4) . New assembly
101743

Unclip the gearbox lever cable: - clip the gearbox control at (a) , - pull the pin at (B) , - raise the gearbox control at (C) . Fill the automatic transmission with 3.5 litres of new oil. Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Remove and Refit ). Run the engine at idle speed. Connect the diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer. Monitor the gearbox oil temperature parameter. Once a temperature of 60˚C +/- 1 is reached, open the level-setting plug. Open the cap again (5) .
107912

5

23A-8

the electronic oil ageing counter must be reset (inside the computer).Once a temperature of 60˚C +/.AUTOMATIC GEARBOX Filling . Enter the oil change date using the CF074 Enter gearbox oil change date command on the diagnostic tool ( CLIP ).LEVEL CHECKING PROCEDURE OUTSIDE FILLING OPERATIONS Note: The level must be checked following the procedure described below: Park the vehicle on level ground.monitor the automatic gearbox oil temperature parameter.Levels DP0 23A III .let the automatic transmission cool to 50˚C . Fill the automatic transmission with 0.add 0.5 litre of new oil. .add 0. . If the oil does not flow out or the quantity collected is below 0. open the level-setting plug.switch off the engine.once a temperature of 60˚C ± 1 is obtained.1 is reached.run the engine at idle speed. . . .1 litre of oil is obtained in the container. 23A-9 .1 litre : . Repeat these operations until more than 0. . Run the engine at idle speed. . Repeat these operations until more than 0. open the level-setting plug. open the level-setting plug.monitor the automatic gearbox oil temperature parameter. Refit the cap again. . .connect the diagnostic tool ( CLIP ). . Establish dialogue with the automatic transmission computer. Tighten to torque the level-setting plug ( 35 Nm ) .Switch off the engine. Note: When the oil is replaced.1 litre .establish dialogue with the automatic transmission computer.5 litre of oil.position a container. .run the engine at idle speed. Once a temperature of 60˚C +/.5 litre of oil.connect diagnostic tool ( CLIP ).1 is reached. Connect diagnostic tool ( CLIP ). 13792 Use a container if the oil does not flow out or the volume collected is less than 0.1 litre of oil is obtained in the container. . Monitor the gearbox oil temperature parameter.establish dialogue with the automatic transmission computer. .position a container. .let the automatic transmission cool to 50˚C . . . .

the seals. .converter bolts. . .AUTOMATIC GEARBOX Parts to be replaced systematically DP0 The following parts must be replaced after being removed: . 23A 23A-10 .self-locking nuts.rubber seals.

Monitor the engine speed parameter: Establish dialogue with the computer. Note: A setting point which is too low may be linked to a lack of engine power. Lift the vehicle until the wheels are raised off the ground by a few centimetres.The full load position must not be held for more than 5 seconds . The front wheels should not rotate. Connect the diagnostic tool ( « CLIP » ). A setting point outside the tolerance requires the converter to be replaced. Start the engine and put the lever in D. . Monitor the automatic gearbox oil temperature parameter. Establish dialogue with the automatic transmission computer. The check should be done at an oil temperature of between 60˚C and 80˚C . there is a high risk of destroying the converter or the automatic gearbox. Accelerate fully keeping the brakes applied.AUTOMATIC GEARBOX Checking the converter setting point DP0 23A Equipment required diagnostic tool Put the vehicle on a two-post lift. F4R The engine speed should stabilise at 2500 rpm . Beyond this. 23A-11 . K4M The engine speed should stabilise at 2700 rpm +/150 . WARNING .Once the measurement has been taken. release the accelerator and keep the brakes on until the engine speed stabilises to idle speed (there is a risk of damaging the automatic gearbox if this is not complied with).

1 103420 Remove the bolt (1) to take the line pressure.AUTOMATIC GEARBOX Line pressure measurement DP0 Special tooling required Bvi. 1215-01) and place it in position ( Workshop Repair Manual 366 « Fault finding » ). Remove the pressure tapping union (466-06) from the kit (Bvi. 23A-12 . (in a kit). 23A Some fault finding procedures on the automatic gearbox involve taking the line pressure using a pressure gauge. 1215-01 Automatic transmission oil pressure gauge kit. The pressure measurement tapping is located close to the pressure sensor. 25 bar pressure gauge.

8 daNm 1 daNm 4 daNm 2. Remove the engine undertray.9 daNm 0.1 daNm 0.the air intake duct. REMOVAL Put the vehicle on a two-post lift.4 daNm Remove: . 13792 Drain the automatic gearbox using the plug (1) . Equipment required diagnostic tool 23A Tightening torquesm distributor mounting bolts ball detent plate bracket mounting bolt (12) ball detent plate mounting bolt cover mounting bolts rechargeable battery reinforcement plate mounting bolts battery cover 0. 23A-13 .the wheels.AUTOMATIC GEARBOX Hydraulic distributor: Removal .Refitting DP0 Special tooling required Bvi. 1462 Ball plate adjusting screw.75 daNm 1 0. Remove the battery cover Disconnect the battery starting with the negative terminal. . Remove the engine covers.

AUTOMATIC GEARBOX Hydraulic distributor: Removal . .from the battery tray (3) . .Refitting DP0 23A 4 2 6 5 3 101821 103412 Release the electrical harness: . .the battery.the battery mounting. . 7 14783 Remove the four retaining bolts (7) on the hydraulic distributor cover (be careful as oil may run out).the bolts (6) on the side reinforcement plate.from the injection computer (4) .the computer.from the battery (2) . . 23A-14 .the side reinforcement. Remove: . Remove: . Remove the electrical harness (5) on the side reinforcement.

23A-15 . ADJUSTING THE BALL DETENT PLATE 14782 Hold the multifunction lever switch in the end position (1st selected) using a plastic clip and a bolt in the mechanism housing. Disconnect the solenoid valve connectors. Tighten to torque and in the correct order the distributor mounting bolts ( 0. Refit the other bolts.75 daNm ) .AUTOMATIC GEARBOX Hydraulic distributor: Removal .Refitting DP0 23A REFITTING 13788 Remove the seven mounting bolts on the hydraulic distributor. 13789 Fit the distributor and centre it using bolts (4) and (5). Remove the hydraulic distributor.

Position the ball detent plate by placing the roller (9) in the hollow (11) of the sector (10) corresponding to the 1st gear selected position. Position the tool (Bvi.9 daNm ) . 1462) in place and fit the bolt (8) . 23A-16 .8 daNm ) .Refitting DP0 23A 10 9 8 12 13788-1 14785 Position the ball detent plate bracket mounting bolt (12) but do not tighten it. Screw the tool in fully whilst holding the ball detent plate.AUTOMATIC GEARBOX Hydraulic distributor: Removal . Tighten to torque the ball detent plate mounting bolt ( 0. the auto-adaptives must be reset using command RZ005: « Erase auto-adaptives » and the oil age counter of the Remove the bolt (8) . 10 11 2318 Remove the tool (Bvi. Tighten to torque the ball detent plate bracket mounting bolt (12) ( 0. 1462) . Remove the ball detent plate mounting bolt (8) . When replacing the oil distributor.

After using command RZ005 . To refit. use command CF074: « Enter date of gearbox oil change » .the cover mounting bolts ( 1 daNm ) .AUTOMATIC GEARBOX Hydraulic distributor: Removal . .Refitting DP0 automatic gearbox computer must be reset using the diagnostic tool .1 daNm ) . carry out the necessary programming ( (see 80A. Torque tighten the battery cover ( 0. Tighten to torque: .the reinforcement plate mounting bolts ( 2. WARNING Connect the battery. proceed in the reverse order to removal.4 daNm ) . it is important to carry out a test drive performing all gear changes. both up and down. several times in order to store the new values. Battery) ).the rechargeable battery ( 4 daNm ) . 23A 23A-17 . .

5 daNm 4.Refitting F4R or K4M. 1531 WARNING Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel: .4 daNm Special notes for vehicles fitted with a driver's airbag Bvi. .2 daNm REMOVAL Put the vehicle on a two-post lift.7 daNm 6.4 daNm 6.starter plate mounting nut modular connector support bolts engine speed sensor mounting bolts engine tie-bar bolts on K engines engine tie-bar bolts on F engines 11 daNm 0.AUTOMATIC GEARBOX Automatic gearbox: Removal . Tool for centring the torque converter for the automatic transmission converter. 604-01 Tav. In this case. Equipment required component jack 23A 18 daNm Tightening torquesm nut securing the suspended mounting on the rubber pad battery cover 0. and DP0 Special tooling required Rou.5 daNm 18 daNm 23A-18 . Multiple-adjusting engine mounting support with retaining straps.signals) ). 6. Ball joint extractor. it is necessary to remove the steering wheel to apply the centring procedure ( (see 84A.2 daNm 3.7 daNm 3. the steering wheel must be immobilised with the wheels straight for the duration of the operation using a steering wheel locking tool. Remove the engine covers. Tightening torquesm wheel bolts brake calliper guide pin bolts track rod end nut lower ball joint nut engine tie-bar bolts on the sub-frame gearbox bell housing and starter bolts nut securing the suspended mounting on the gearbox track rod end nut converter .Before the steering column and the steering rack are uncoupled.7 daNm 2 daNm 1 daNm 10. 476 Mot. Controls . only qualified personnel who have received training may carry out the operation. 1453 Hub locking tool.If there is any doubt about the correct alignment of the rotary switch.2 daNm 10.

. . Remove the mounting bolts (4) from the modular connector support plate. Remove: .the air inlet sleeve.the wiring harness mountings.the connector (3) by removing the connector slide. . Disconnect: .the electic wiring harness mountings.Refitting F4R or K4M.the air inlet pipe.the wiring harness (2) for the multifunction switch cable by removing the sleeve stop. . WARNING Protect the connector by sliding it into a waterproof plastic bag. .the multifunction switch cable ball joint (1) using the tool.the battery tray. Remove: . starting with the negative terminal.AUTOMATIC GEARBOX Automatic gearbox: Removal . 23A-19 .the engine speed sensor. . .the injection computer and its support.the battery. . and DP0 23A 3 2 4 1 101821 103409 Disconnect the battery.

103423 Remove: .the wheels. 23A-20 .AUTOMATIC GEARBOX Automatic gearbox: Removal .the ABS system sensor wiring. 103420 Remove the engine speed sensor. and DP0 23A K4M 5 103753 Remove the engine speed sensor. . Unclip the wiring harness from the gearbox. Fit the hose clamps. Note: The discharge bulb beam adjustment sensor is fitted onto the left-hand lower wishbone. Drain the gearbox.the wheel arch liners. F4R . Disconnect the heat exchanger. Disconnect: .the two bolts (5) from the starter. Remove: .the discharge bulb beam adjustment sensor wiring (if fitted to the vehicle).the engine undertray. .Refitting F4R or K4M.

the clip (7) from the gearbox computer wiring harness.the xenon bulb sensor linkage (if fitted to the vehicle).the lower ball joint. 476) . Release the stub axle carrier from the driveshaft. . Remove the left-hand driveshaft. and DP0 I . . 476) .the anti-roll bar ball joint using the (Tav. 604-01) . 23A-21 .the side reinforcement (6) Remove: . .LEFT-HAND SIDE OF THE VEHICLE 23A 7 6 103412 102129 Remove: . . Disconnect the gearbox computer connector (9) . .AUTOMATIC GEARBOX Automatic gearbox: Removal .the hub nut using the (Rou. 8 9 103413 Open the retaining bracket (8) on the gearbox computer wiring harness.Refitting F4R or K4M.the track rod end using the (Tav.

23A-22 .the lower ball joint. 101212 Remove the side stiffener. Release the stub axle carrier from the driveshaft. and DP0 II . .RIGHT-HAND SIDE OF THE VEHICLE 23A 103418 102129 Remove the relay bearing bracket. 604-01) .the hub nut using the (Rou. Remove: . .the track rod end using the (Tav. 476) .Refitting F4R or K4M. . Attach the cooling radiator assembly to the upper cross member using rope.AUTOMATIC GEARBOX Automatic gearbox: Removal . Remove the right-hand driveshaft. 476) .the anti-roll bar ball joint using the (Tav.

.the engine tie-bar.Refitting F4R or K4M.the exhaust mounting nuts. and DP0 23A F4R 102009 Remove the radiator lower cross member.the engine tie-bar.AUTOMATIC GEARBOX Automatic gearbox: Removal . K4M 11 10 103421 Remove: .the exhaust mounting nuts (10) . 10 103749 Remove: . 23A-23 . .

the gearbox edge lower bolts.the three converter nuts. 23A-24 . .the automatic transmission. . 1453) .AUTOMATIC GEARBOX Automatic gearbox: Removal .converter connecting nuts and remove them.the gearbox mounting studs. Note: The nuts on the converter can be accessed by removing the starter motor.the starter. Fit the component jack tool beneath the gearbox. Strap the bonnet down. Rotate the crankshaft clockwise to access the three starter plate .the starter mounting bolt (11) . . and DP0 23A 12 11 103418 103423 Remove: . Fit the (Mot. 13 14 102449 Open the cover (13) .the lower engine/manifold strut. . Remove the gearbox support rubber pad. . Remove: . Remove the upper studs (12) around the edge of the gearbox.Refitting F4R or K4M. Remove the cover (14) .

Do not reuse the converter mounting nuts or the inertia flywheel nuts if they have been removed: always use new nuts. .Check that the centring rings are in place. Refit the flywheel nuts on the converter using the (Bvi. and DP0 23A 13790 16361 Secure the converter with string to prevent it being dislodged. REFITTING WARNING . 1531) . 23A-25 .AUTOMATIC GEARBOX Automatic gearbox: Removal .Refitting F4R or K4M.

AUTOMATIC GEARBOX Automatic gearbox: Removal .the brake calliper guide pin bolts ( 0. .the nut securing the suspended mounting on the rubber pad ( 18 daNm ) . both up and down.2 daNm ) .the track rod end nut ( 3. Fill up the automatic transmission and check the level (see 23A.the gearbox bell housing and starter bolts ( 4. .the engine tie-bar bolts on the sub-frame ( 10. Filling . WARNING Check that the centring dowels are in place. . When changing the oil. . .starter plate mounting nut ( 3.the modular connector support bolts ( 2 daNm ) . make sure that the converter is properly engaged on the input shaft pin. .4 daNm ) .the converter .the engine tie-bar bolts on K engines ( 10.the engine speed sensor mounting bolts ( 1 daNm ) . proceed in the reverse order to removal.5 daNm ) . .7 daNm ) . .the lower ball joint nut ( 6. Tighten to torque the battery cover ( 0. . .the track rod end nut ( 6. After using command RZ005 .2 daNm ) . and DP0 To refit. carry out the necessary programming ( (see 80A.7 daNm ) . page 23A-7) . Automatic gearbox.2 daNm ) . .5 daNm ) .Levels. When refitting the automatic transmission on the engine.4 daNm ) .Refitting F4R or K4M. Tighten to torque: .the wheel bolts ( 11 daNm ) . it is important to carry out a test drive performing all gear changes.the nut securing the suspended mounting on the gearbox ( 6. Battery) ). the auto-adaptives must be reset using command RZ005: «Clear autoadaptives » and the automatic transmission com- 23A-26 . . several times in order to store the new values. 23A puter oil ageing counter must be reset using command CF074: « Enter date of gearbox oil change » . WARNING Connect the battery. .7 daNm ) .the engine tie-bar bolts on F engines ( 18 daNm ).

Battery: Removal . Move the turbocharging pressure regulator solenoid valve to one side. Unpick the wiring harness.Refitting ).Refitting K9K.the computer and its mounting. Disconnect the battery (see 80A.the battery tray. Battery. Battery. Disconnect: . Additional winder nut on engine lift support Mot.the air flowmeter connector.the battery (see 80A.REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A. Lifting equipment. . 1453-01 Tightening torquesm gearbox edge upper mounting bolts converter mounting nuts nuts securing the exhaust pipe onto the catalytic converter half sub-frame front mounting bolts half sub-frame rear mounting bolts front wheel bolts 44 Nm 101822 25 Nm 21 Nm Disconnect the computer connectors (1) . . 1453 Multiple-adjusting engine mounting support with retaining straps. REMOVAL I . Battery: Removal Refitting ). . Equipment required safety belt component jack 23A Mot. Remove the engine covers. Remove: 165 Nm 21 Nm 110 Nm . .the battery tray mounting bolts (2) . Underbody lift ).AUTOMATIC GEARBOX Automatic gearbox: Removal . 23A-27 .the air inlet sleeve.the air duct between the air filter unit and the turbocharger on the air unit. and DP0 Special tooling required Mot. 1453. Remove: .

23A-28 .the air filter unit. and DP0 23A 112657 104553 Move the air filter unit upstream air duct retaining tabs (3) slightly to one side. . Remove: .AUTOMATIC GEARBOX Automatic gearbox: Removal .Refitting K9K.the air filter unit upstream air duct.

not to crush the cooling hoses. . Note: 103409 When fitting the safety strap.the starter (see 16A. Remove: . 55A.AUTOMATIC GEARBOX Automatic gearbox: Removal . Remove the modular connector support plate.the right-hand and left-hand wheel arch liners. . . .the flywheel sensor connector. Exterior protection.the front wheels.the engine undertray. Disconnect the hoses (7) Move the hoses to one side.not to strap up the half sub-frame. Bodywork.the modular connector support plate mounting bolts (6) . Starter: Removal . Fit a set of 2 hose clamps onto the exchanger hoses 23A-29 . Front bumper: Removal Refitting ). . Fit the cooling assembly to the upper cross member using the safety belt .the multifunction switch control (5) . and DP0 (7) .Refitting ). Remove: 23A .the front bumper (see MR 365. . .the modular connector (4) by releasing the connector slide. Starting-charging. 101743 Disconnect: .Refitting K9K. take care: .

110247 Remove the mounting bolt (8) from the earth on the gearbox. 23A-30 . Move the earth harness (9) to one side. Front right-hand driveshaft: Removal .the torque converter mounting nuts on the flywheel through the starter opening.OPERATION FOR REMOVAL OF PART CONCERNED Remove: .the left-hand driveshaft (see 29A.AUTOMATIC GEARBOX Automatic gearbox: Removal .Refitting K9K.the gearbox upper mounting bolts. Remove: . Driveshafts. .the reinforcement mounting bolts. . . . 101212 110249 103412 Unclip the wiring harness.the side reinforcements. Remove .the half sub-frame.the right-hand driveshaft (see 29A. Front left-hand driveshaft: Removal .Refitting ).Refitting ). and DP0 23A II . Driveshafts. .the gearbox mounting nut (10) .

the mounting bolts and nuts from the catalytic converter reinforcing bracket .the scuttle panel grille (see MR 365. 1453-01) . 110253 Remove .AUTOMATIC GEARBOX Automatic gearbox: Removal . Remove .the gearbox mounting stud (11) . Fit the component jack tool beneath the gearbox.the gearbox mounting nut (12) then the mounting stud (13) . Exterior protection. 1453) fitted with the (Mot.Refitting ).the gearbox. Scuttle panel grille: Removal . .the gearbox lower mounting bolts (14) . and DP0 . Rear suspended mounting: Removal .Refitting K9K.Refitting ). . Bodywork. . Engine suspension. . 110230 Secure the converter to prevent it being dislodged. .the rear suspended mounting (see 19D.the catalytic converter reinforcing bracket.the nuts mounting the exhaust pipe on the catalytic converter. 23A-31 . 23A 102449 Fit the (Mot.

WARNING Check that the centring dowels (15) are in place.the starter (see 16A. Bodywork.the air filter unit upstream air duct. Engine mounting. . Starter: Removal .the modular connector plate mounting bolts.the gearbox upper mounting bolts.Refitting ). .the catalytic converter reinforcing bracket. .the gearbox earth strap mounting bolt.the flywheel sensor connector. . .the rear suspended engine mounting (see 19D. and DP0 23A REFITTING I .the modular connector support plate.the engine management computer and its support.PREPARATION BEFORE REFITTING OPERATION . Connect: II . Exterior protection. Starting-charging.the gearbox rear mounting nut. .the multifunction switch control.the air flowmeter connector. .Refitting K9K.the mounting bolts and nuts to the catalytic converter reinforcing bracket 23A-32 . . . Rear suspended engine mounting: Removal .the gearbox rear mounting stud. Note: Do not reuse the converter mounting nuts or the inertia flywheel nuts if they have been removed: always use new nuts. . . .the exchanger hoses. 1453) fitted with the (Mot. . . III . . Battery: Removal Refitting ).the gearbox front mounting stud.REFITTING OPERATION FOR PART CONCERNED Refit the gearbox Refit: . Remove the (Mot.the battery (see 80A. 145301) . . . Tighten to torque the converter mounting nuts ( 25 Nm ) .Refitting ). .the gearbox front mounting nut. Fit the wiring harness into its housing Refit: . 110230 .the engine management computer connectors.FINAL OPERATION Refit: . . .Refitting ).the gearbox lower mounting bolts. .the battery tray mounting bolts. . Battery.the gearbox suspended engine mounting.the air inlet sleeve.the scuttle panel grille (see MR 365.the battery tray.the earth strap on the gearbox. . Scuttle panel grille: Removal . Refit the gearbox upper mounting bolts Tighten to torque the gearbox edge upper mounting bolts ( 44 Nm ) Refit the converter mounting nuts through the starter opening.AUTOMATIC GEARBOX Automatic gearbox: Removal .the modular connector. .the air filter unit.

the left-hand driveshaft (see 29A. Exterior protection.the half sub-frame rear mounting nuts. Tighten to torque the nuts securing the exhaust pipe onto the catalytic converter ( 21 Nm ) Refit: . Tighten to torque: . 23A 23A-33 . Driveshafts. Battery.the half sub-frame front mounting bolts.the right-hand driveshaft (see 29A. Tighten to torque the front wheel bolts ( 110 Nm ) Connect the battery (see 80A. Driveshafts.the front bumper (see MR 365. . Bodywork.Refitting ). .the right-hand and left-hand wheel arch liners. Automatic transmission oil: Draining-refilling ). Remove the retaining belt from the cooling assembly.the half sub-frame rear mounting bolts ( 21 Nm ). Battery: Removal .the front wheel bolts. Front left-hand driveshaft: Removal . Refit: . Front right-hand driveshaft: Removal . Automatic transmission.the half sub-frame.the exhaust pipe mounting nuts to the catalytic converter. . 55A. .the front wheels. .Refitting ). Refit the engine covers. Front bumper: Removal Refitting ).Refitting K9K. .the half sub-frame front mounting bolts ( 165 Nm ) .AUTOMATIC GEARBOX Automatic gearbox: Removal . .the engine undertray.Refitting ). Check the gearbox oil level (see 23A. and DP0 . Refit the side reinforcements. . .

1677 Mot. 582-01 Flywheel locking tool.2 mm on the external diameter).the tool (Mot. 103752 REMOVAL F4R Position the tool (Mot. 2 1 1 Fit the drive plate. Tighten the bolts on the drive plate. . 1677) to immobilise the starter motor ring gear. 23A-34 . Remove: . ensuring it is correctly positioned in relation to the centring pins (2) . Flywheel locking tool. 1 1 2 . Equipment required diagnostic tool 23A 1 Tightening torquesm drive plate bolts (F4R engine) then tighten to torque drive plate bolts (K4M engine) then tighten to torque 4. 582-01) . 103245 Position tool (Mot. Note: Apply LOCTITE FRENBLOC to the bolt threads. 1677) or (Mot.5 daNm + 50˚ ± 5 1 1 5.the bolts (1) .AUTOMATIC GEARBOX Drive plate: Removal .5 daNm + 50˚ ± 5 1 This operation can be performed after the automatic gearbox has been removed. 582-01) REFITTING Check that the drive plate is not damaged (warping tolerance 0.the drive plate. and DP0 Special tooling required K4M Mot.Refitting F4R or K4M.

and DP0 23A F4R Angular tighten the drive plate bolts (F4R engine) then tighten to torque ( 4. To refit.5 daNm + 50˚ ± 5 ) locking the starter motor ring gear using tool (Mot. WARNING Connect the battery. carry out the necessary programming ( (see 80A. Connect the diagnostic tool for the conformity check. K4M Angular tighten the drive plate bolts (K4M engine) then tighten to torque ( 5. 58201) . 23A-35 .5 daNm + 50˚ ± 5 ) locking the starter motor ring gear using tool (Mot. 1677) . proceed in the reverse order to removal.AUTOMATIC GEARBOX Drive plate: Removal . Battery) ).Refitting F4R or K4M.

Remove the faulty differential output seal using a screwdriver or a hook. WARNING Do not drop the spring of the seal into the automatic gearbox.2 daNm 10. Remove the battery cover. Fitting left-hand transmission output seal.7 daNm (28 daNm) 0.5 daNm 13791 1 18 daNm 3. 1460 Tightening torquesm wheel bolts lower ball joint nut engine tie-bar mounting bolts on the sub-frame engine tie-bar bolts on the K engine engine tie-bar bolts on the F engine track rod end nut hub nut battery cover (11 daNm) 6. Remove the engine undertray. Section 2 ). 23A-36 .Refitting DP0 Special tooling required Bvi.AUTOMATIC GEARBOX Differential output seal: Removal . taking care not to scratch the contact faces. 23A Bvi. 1459 Fitting right-hand transmission output seal.5 daNm 10. REMOVAL This operation takes place after the relevant driveshaft has been removed (see Workshop Repair Manual 364.4 daNm Drain the automatic gearbox through plug (1) . Put the vehicle on a two-post lift. Disconnect the battery starting with the negative terminal.

WARNING Connect the battery. .5 daNm ) .the engine tie-bar bolts on the F engine ( 18 daNm ) . Filling .the engine tie-bar mounting bolts on the subframe ( 10.the hub nut ( (28 daNm) ) . . . Automatic gearbox. 1460) on the left-hand and righthand sides.the wheel bolts ( (11 daNm) ) .the engine tie-bar bolts on the K engine ( 10.7 daNm ) . proceed in the reverse order of removal. page 23A-7) . Battery) ). Fill the automatic gearbox and check the level (see 23A.5 daNm ) . . carry out the necessary programming ( (see 80A.Refitting DP0 23A REFITTING The seal should be fitted using either tool (Bvi. Tighten to torque: . .Levels. To refit.the lower ball joint nut ( 6. Torque-tighten the battery cover ( 0. 1459) or tool (Bvi.AUTOMATIC GEARBOX Differential output seal: Removal .2 daNm ) . .4 daNm ) . Guide the assembly until the tool is in contact with the automatic gearbox housing. 23A-37 .the track rod end nut ( 3.

587) . 23A-38 .Oil all the contact faces. To refit. taking care not to scratch the contact faces.AUTOMATIC GEARBOX Converter seal: Removal . 587 Bvi. remove the seal. 1457) . 23A REMOVAL This operation is performed after the automatic gearbox and converter have been removed. .Refitting DP0 Special tooling required Mot.Work as cleanly as possible to prevent foreign bodies from entering the system. Using the tool (Mot. 1457 Oil seal extractor Fitting converter lip seal. Position the new prelubricated seal as far as the stop using the tool (Bvi. Remove the converter by withdrawing it as far as possible without deviating from the course of the shaft. proceed in the reverse order of removal. Check that the converter is correctly positioned. REFITTING WARNING . WARNING The converter contains a large amount of oil which may escape when it is being removed.

Remove: .4 daNm) 2 5 1 REMOVAL Select neutral « N » 3 103409 Disconnect: . .the multifunction switch cable ball joint (1) .the wiring harness mountings.the battery tray.the control cable from the sleeve stop (2) on the modular connector support. 13785 6 Remove the two modular connector mounting plate bolts. 23A-39 . . .the air intake duct. . Remove the lever and the two multifunction switch mounting bolts (3) . Remove the three modular connector support plate mounting bolts (5) . .the battery.the air filter unit. 101821 Disconnect the battery starting with the negative terminal. Remove the green connector (6) on the multifunction switch (12-track).AUTOMATIC GEARBOX Multifunction switch: Removal .Refitting DP0 23A 4 Tightening torquesm selector lever nut to torque multifunction switch mounting bolts to torque battery cover bolts to torque (1 daNm) (1 daNm) (0. Disconnect the modular connector (4) by releasing the slide mechanism on the connector. .the injection computer and its mounting.

proceed in the reverse order to removal.4 daNm) ) . Turn the multifunction switch by hand until the switch is closed (resistance at contact terminals: 0 Ω ). Tighten the multifunction switch mounting bolts to torque ( (1 daNm) ) . To refit. WARNING Connect the battery. Adjust the multifunction switch. ADJUSTING THE MULTIFUNCTION SWITCH With the gearbox selector shaft in neutral.AUTOMATIC GEARBOX Multifunction switch: Removal . 23A-40 . WARNING After tightening.Refitting DP0 23A REFITTING Set the multifunction switch to neutral « N » . the electrical switch must be closed ( 0 Ω ). Tighten the battery cover bolts to torque ( (0. 103411 Switch the multimeter to the « ohmmeter » position. place two electric terminals on the position control tabs. Battery) ). carry out the necessary programming ( (see 80A. Check that the system and gears are working. Tighten the selector lever nut to torque ( (1 daNm) ). Check that the system and gears are working.

Remove the engine covers.the two computer mounting nuts (3) . proceed in the reverse order to removal. REPLACING THE COMPUTER Disconnect the computer connector (1) . . Battery) ). 23A-41 . Remove the resonator (2) .4 daNm) ) . REMOVAL Put the vehicle on a two-post lift.Refitting DP0 23A Tightening torquesm battery cover to torque (0. Replace the computer. 1 WARNING Connect the battery. Remove the front bumper.the computer (4) . Note: When the automatic gearbox computer is replaced. carry out the necessary programming ( (see 80A.4 daNm) 4 The computer is located behind the left-hand wheel arch. Use the following procedure. Disconnect the battery starting with the negative terminal. 3 103415 Remove: . Read the oil ageing value from the memory of the computer being replaced using parameter PR133: « Oil ageing counter » and note down the value. REFITTING To refit.AUTOMATIC GEARBOX Automatic transmission computer: Removal . 103414 2 Tighten the battery cover to torque ( (0. the age of the automatic gearbox oil stored in the memory of the computer to be replaced must be entered in the memory of the new computer.

23A 23A-42 . Enter the after-sales operation date using command CF320 « Enter after-sales operation date » .Refitting DP0 Call up the oil ageing value in the memory of the new computer using command CF320: «Oil ageing counter report » . Confirm entry using the « Oil ageing counter » parameter.AUTOMATIC GEARBOX Automatic transmission computer: Removal . Carry out a road test so that the new computer stores the programming.

Remove the engine covers. Automatic gearbox. page 23A-48) .AUTOMATIC GEARBOX Speed sensor: Removal . Disconnect the battery starting with the negative terminal.INPUT SPEED SENSOR Tightening torquesm output speed sensor mounting bolt input speed sensor mounting bolt battery cover bolts 1 daNm 1 daNm 0. 103416 1 1 103419 Remove the connector (1) from the gearbox connector support plate. always remove the gearbox connector (see 23A.4 daNm 23A REMOVAL Put the vehicle on a two-post lift. A utomatic transmission connector: Removal . When replacing a sensor. Note: The speed sensors can be removed without draining or removing the automatic gearbox.Refitting.Refitting DP0 I . 23A-43 . Remove the engine undertray.

. 103417 Disconnect the connector (3) . Torque-tighten the battery cover bolts ( 0. WARNING Protect the connector by sliding it into a waterproof plastic bag.OUTPUT SPEED SENSOR Remove the output speed sensor (4) . WARNING Protect the connector by sliding it into a waterproof plastic bag. carry out the necessary programming ( (see 80A.4 daNm ). Battery) ).Refitting DP0 23A 2 13786-1 4 103420 Remove the input speed sensor (2) .AUTOMATIC GEARBOX Speed sensor: Removal . 23A-44 . II . Tighten to torque: .the input speed sensor mounting bolt ( 1 daNm ) WARNING 3 Connect the battery. proceed in the reverse order of removal. REFITTING To refit.the output speed sensor mounting bolt ( 1 daNm ) .

103434 2 1 13786-1 Remove: . 23A-45 . REFITTING To refit. Note: The radiator flow control solenoid valve can be removed without draining or removing the automatic gearbox.AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal . Remove the engine covers. .the two solenoid valve bolts (1) .4 daNm REMOVAL Put the vehicle on a two-post lift. proceed in the reverse order to removal.Refitting DP0 23A Tightening torquesm radiator flow control solenoid valve mounting bolt battery cover bolts to a torque of 1 daNm 0. Disconnect the battery starting with the negative terminal.radiator flow control solenoid valve (2) .

23A 23A-46 . Tighten the battery cover bolts to a torque of ( 0.AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal .4 daNm ) . WARNING Connect the battery. carry out the necessary programming ( (see 80A.Refitting DP0 Tighten to torque the radiator flow control solenoid valve mounting bolt ( 1 daNm ) . Battery) ).

23A-47 .AUTOMATIC GEARBOX Solenoid valves: Removal DP0 23A WARNING Work as cleanly as possible to prevent foreign bodies from entering the system. REMOVAL 2 1 3 4 5 6 7 8 13787 (1) (2) (3) (4) (5) (6) (7) (8) Modulating solenoid valve « Lock up » solenoid valve (converter by-pass) Sequence solenoid valve 4 Sequence solenoid valve 3 Sequence solenoid valve 1 Sequence solenoid valve 2 Sequence solenoid valve 6 Sequence solenoid valve 5 Note: This operation can be performed after the hydraulic distributor has been removed.

Refitting DP0 Connector numbering Tightening torquesm battery cover bolts to a torque of 0. 23A-48 . . Remove the engine covers.AUTOMATIC GEARBOX Automatic transmission connector: Removal . Select neutral « N » Green connector (line pressure) Yellow connector (turbine speed) Blue connector (radiator flow control solenoid valve) Note: These connectors may be removed separately from the gearbox connector when certain components are replaced. Remove: .the air intake duct.the battery. 101821 Disconnect the battery starting with the negative terminal.4 daNm 23A 1 2 1 3 5 2 4 3 4 5 13785 103248 (1) (2) (3) (4) (5) Green connector (multifunction switch) Yellow connector hydraulic interface) (electro- REMOVAL Put the vehicle on a two-post lift.

WARNING Connect the battery.the injection computer and its mounting. .4 daNm ) . Remove: . . the component should also be removed. 7 8 9 6 103409 Disconnect: .Refitting DP0 . These wiring harnesses are either connected to components directly or via a connector. Battery) ). . Remove the five wiring harnesses.the two unit connector mounting bolts. If they are connected to a component directly.the unit connector (8) by releasing the slide valve on the connector. Follow the five wiring harnesses connected to the gearbox connector. carry out the necessary programming ( (see 80A.the connector in the colour that appears on the gearbox connector.the wiring harness mountings. 23A-49 . Tighten the battery cover bolts to a torque of ( 0. 23A REFITTING To refit. .AUTOMATIC GEARBOX Automatic transmission connector: Removal . proceed in the reverse order to removal. .the wiring harness (7) from the multifunction switch cable by loosening the sleeve stop. .the ball joint (6) from the multifunction switch cable.the battery tray. .the three mounting bolts (9) from the unit connector support plate.the air filter unit.

DP0 29A 102209 Driveshaft seal Vehicle type Engine Gearbox Left-hand driveshaft Wheel end XM0B XM0H XM1A XM08 XM0C XM0J XM1B K4M 760 JH3 142 K4J 732 JH3 105 K4J 730 JH3 105 EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 Gearbox end RC 465 RC 465 RC 465 RC 465 RC 465 RC 465 RC 465 Right-hand driveshaft Wheel end EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 EBJ 82 Gearbox end RC 462 RC 462 RC 462 RC 462 RC 462 RC 462 RC 462 29A-1 .DRIVESHAFTS Identification DRIVESHAFTS FOR MANUAL GEARBOXES JR JH .ND .

DRIVESHAFTS Identification Driveshaft seal Vehicle type Engine Gearbox Left-hand driveshaft Wheel end DP0 46 DP0 47 DP0 50 DP0 46 K4M 761 XM0J DP0 47 DP0 50 DP0 46 XM1B DP0 47 DP0 50 ND0 004 XM0U ND0 014 ND0 016 ND0 014 XM05 XM1M XM1N ND0 016 EBJ 95 TJ 92 EBJ 95 F4R 770 ND0 016 ND0 016 ND0 014 EBJ 95 EBJ 95 EBJ 95 TJ 92 TJ 92 TJ 92 EBJ 95 EBJ 95 EBJ 95 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 EBJ 95 EBJ 95 EBJ 95 EBJ 95 Gearbox end RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 TJ 92 TJ 92 TJ 92 TJ 92 29A Right-hand driveshaft Wheel end BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 BJ 87 EBJ 95 EBJ 95 EBJ 95 EBJ 95 Gearbox end RC AR RC AR RC AR RC AR RC AR RC AR RC AR 462 462 462 462 462 462 462 XM0C RC 462 RC 462 TJ 92 AR TJ 92 AR TJ 92 AR TJ 92 AR TJ 92 AR TJ 92 AR TJ 92 AR TJ 92 AR 29A-2 .

DRIVESHAFTS Identification
Driveshaft seal Vehicle type Engine Gearbox Left-hand driveshaft Wheel end DP0 049 DP0 052 DP0 54 DP0 049 DP0 052 DP0 054 DP0 052 DP0 053 DP0 054 DP0 052 XM1N DP0 054 XM0W XM0F XM02 K9K 728 XM013 XM02 XM0G F9Q 800 XM1G XM00 F9Q 808 ND0 008 ND0 001 EBJ 95 EBJ 95 TJ 92 TJ 92 EBJ 95 EBJ 95 K9K 729 DP0 051 JR5 108 EBJ 92 BJ 87 EBJ 95 RC 465 RC 463 TJ 92 EBJ 92 BJ 87 EBJ 95 F4R 776 K9K 722 ND0 009 JR5 102 EBJ 92 EBJ 95 EBJ 82 EBJ 92 RC 463 TJ 92 RC 465 RC 465 EBJ 92 EBJ 95 EBJ 82 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 Gearbox end RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463 RC 463

29A
Right-hand driveshaft Wheel end EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 EBJ 92 Gearbox end RC AR RC AR RC AR RC AR RC AR RC AR RC AR RC AR RC AR RC AR RC AR 462 462 462 462 462 462 462 462 462 462 462

XM0U

XM05 F4R 771

XM1M

TJ 92 AR RC 462 RC AR RC AR RC AR TJ 92 TJ 92 TJ 92 AR 465 465 462

29A-3

DRIVESHAFTS Consumables

29A
Quantity Coat Coat 110 cm 3 110 cm 3 110 cm 3

Component concerned Gearbox side seal splines Brake calliper bolt RC 462 seal RC 463 seal RC 465 seal EBJ 82 seal EBJ 92 seal EBJ 95 seal TJ 92 seal

Type of product MOLYKOTE BR2 grease FRENBLOC cement

MOBIL CVJ 825 Black Star or MOBIL EXF 57C grease

70 cm 3 105 cm 3 110 cm 3 135 cm 3

29A-4

DRIVESHAFTS Front left-hand wheel driveshaft: Removal - Refitting
Special tooling required Rou. 604-01 Tav. 476 Hub locking tool. Ball joint extractor.

29A

Push the driveshaft away from the stub axle carrier by pivoting the stub axle carrier. Remove the driveshaft (wheel end). II - GEARBOX END Drain the gearbox( (see Gearbox) .

Tightening torquesm wheel bolts hub nut track rod end nut lower ball joint nut anti-roll bar nut driveshaft bearing bolts 11 daNm

Remove the driveshaft (gearbox end).

REPLACEMENT
28 daNm 3.7 daNm 6.2 daNm 4.4 daNm 4.4 daNm Note: Check the condition of the contact surfaces of the lip seal. Always replace the differential output lip seal (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-16) . With the protector in place, coat the splines of the gearbox end seal with MOLYKOTE BR2 . Position and insert the driveshaft into the final drive sunwheel. Insert the stub-axle into the hub. The driveshaft must go in freely until it protrudes enough for the hub nut to be mounted. To refit, proceed in the reverse order to removal. Tighten to torque: - the wheel bolts ( 11 daNm ) , - the hub nut ( 28 daNm ) , - the track rod end nut ( 3.7 daNm ) ,

REMOVAL
I - WHEEL END Put the vehicle on a two-post lift. Remove the xenon bulb sensor linkage (if fitted to the vehicle). Remove: - the front left-hand wheel, - the hub nut using the (Rou. 604-01) . Disconnect the wheel speed sensor.

1

2

- the lower ball joint nut ( 6.2 daNm ) , - the anti-roll bar nut ( 4.4 daNm ) , - the driveshaft bearing bolts ( 4.4 daNm ) , Fill and check the gearbox oil level( (see Gearbox) .

3

101213

Remove: - the track rod end nut (1) , - the stub axle carrier ball joint using the (Tav. 476) , - the upper nut of the anti-roll bar (2) , - the lower ball joint stud (3) .

29A-5

.the anti-roll bar tie-rod upper nut (3) . 105893 Remove the lower linkage nut (4) .the hub nut (1) using the (Rou. .DRIVESHAFTS Front left-hand wheel driveshaft: Removal . 29A Tightening torquesm shock absorber turret bolts pivot support bolts lower linkage nut brake calliper bolts anti-roll bar return tierod ball joint nut track rod end nut driveshaft nut wheel mounting bolts 21 Nm 72 Nm 100 Nm 170 Nm 44 Nm 37 Nm 280 Nm 130 Nm Remove: . .WHEEL END Position the vehicle on a two-post lift (see 02A.the engine undertray. 604-01 Hub locking tool. and 774 Special tooling required Rou. Disconnect the wheel speed sensor. I . 604-01) .the front left-hand wheel. Lifting equipment. 105891 REMOVAL Drain the gearbox.Refitting B84 or C84. 29A-6 . Remove: . and F4R.the track rod end nut (2) . Vehicle: Towing and lifting ).

Remove the sub-frame reinforcement bar. 106245 Remove the pivot (7) from its support (6) using a hammer.Refitting B84 or C84. Remove the seal (9) . 29A-7 .DRIVESHAFTS Front left-hand wheel driveshaft: Removal . Relax the driveshaft by raising the lift by 50 cm . Remove the plastic rivets from the flap. Remove the pivot support bolts (5) . and 774 29A 106114 101210 Compress the driveshaft by approximately 10 cm . Extract the lower linkage ball joint. Cut the flap at (8) . 101211 Remove the shock absorber turret bolts (10) . and F4R.

29A-8 . until it is in far enough for the hub nut to be fitted. lubricate the gearbox side seal grooves with MOLYKOTE BR2 grease. Insert the stub-axle into the hub. With the protector in place. shock absorber and pivot assembly. The differential output lip seal must always be replaced. 106642 Remove the driveshaft (gearbox end). Position and insert the driveshaft into the final drive sunwheel. Extract the hub driveshaft.DRIVESHAFTS Front left-hand wheel driveshaft: Removal .GEARBOX END 29A 106126 In place of bolt (11) . Proceed in the reverse order to removal. and F4R. 106641 Remove the spring. and 774 II . REFITTING Note: Check the condition of the lip seal contact surfaces. Remove the turret bolts (12) . screw in an M8x30 bolt by letting the head extrude by 20 mm . The driveshaft should go in freely.Refitting B84 or C84.

the shock absorber turret bolts ( 21 Nm ) . Battery: Removal . Connect the battery (see MR364. . Tighten to torque: . . . and F4R. .the anti-roll bar return tie-rod ball joint nut ( 44 Nm ) .the brake calliper bolts ( 170 Nm ) .the track rod end nut ( 37 Nm ) . . 29A-9 .the pivot support bolts ( 72 Nm ) .Refitting B84 or C84. Note: It is essential to initialise the xenon bulb system. Fill and check the gearbox oil level. .Refitting ).DRIVESHAFTS Front left-hand wheel driveshaft: Removal .the wheel mounting bolts ( 130 Nm ) .the driveshaft nut ( 280 Nm ) . 80A.the lower linkage nut ( 100 Nm ) . Battery. . and 774 29A 101211 Position the indexing (13) in its housing.

476) . 604-01) .the upper nut from the anti-roll bar (2) . 476 Hub locking tool. 2 1 3 101213 Remove: .DRIVESHAFTS Front right-hand wheel driveshaft: Removal .Refitting .the front right-hand wheel.the lower ball joint bolt (3) . Remove: .the stub axle carrier ball joint using the (Tav. M9R. Disconnect the wheel speed sensor. Push the driveshaft away from the stub axle carrier by pivoting the stub axle carrier. .WHEEL END Put the vehicle on a two-post lift.GEARBOX END Tightening torquesm driveshaft bearing bolts d riveshaft mounting bolt bearing 44 Nm Drain the gearbox. . and 700 21 Nm 37 Nm 62 Nm 44 Nm 280 Nm 110 Nm track rod end nut lower ball joint nut anti-roll bar nut hub nut wheel bolts REMOVAL I . . Move the driveshaft bearing bracket to one side. II . Ball joint extractor. 29A-10 . 29A Special tooling required Rou.the hub nut using the (Rou.the track rod end nut (1) . 114927 Remove the driveshaft bearing mounting bolt (4) . 604-01 Tav. Remove the driveshaft (wheel end).

.Refitting) . .Check the condition of the contact surfaces of the lip seal. 100642 Remove: . Remove the bearing using a press.the track rod end nut ( 37 Nm ) . The driveshaft should go in freely. With the protector in place. Tighten to torque: .Replace the O-ring at the base of the relay shaft bearing if it is damaged.Refitting 29A Proceed in the reverse order to removal. Remove the driveshaft (gearbox end). Position and insert the driveshaft into the final drive sunwheel. it must be replaced( (see Relay shaft bearing: Removal . . Tighten to torque the driveshaft bearing mounting bolt ( 21 Nm ) . until it is in far enough for the hub nut to be fitted. 29A-11 . Manual gearbox.the complete driveshaft.the anti-roll bar nut ( 44 Nm ) . 101819 Remove both the driveshaft bearing bolts (5) .Refitting. .The differential output lip seal must always be replaced (see 21A. REMOVING THE RELAY SHAFT BEARING REFITTING Clean and grease the bearing hole into which the bearing will be inserted.the lock ring (6) .the lower ball joint nut ( 62 Nm ) . . Fill and check the gearbox oil level( (see Gearbox) . Note: . page 21A-16) . and 700 Fit the driveshaft bearing bracket.DRIVESHAFTS Front right-hand wheel driveshaft: Removal . Insert the stub-axle into the hub. Differential output seal: Removal . Tighten to torque the driveshaft bearing bolts ( 44 Nm ) .the hub nut ( 280 Nm ) . Note: If the bearing is seized in the relay bearing. . coat the splines of the seal on the gearbox side with MOLYKOTE BR2 .the wheel bolts ( 110 Nm ) . Take care not to score the contact surface of the lip seal on the relay shaft. . M9R.

Refit the driveshaft. Refit the new lock ring. so that it rests on the inner bearing race. 29A 29A-12 . Clean and grease the bearing hole into which the bearing will be inserted. Fit the bearing to the end using a tube.Refitting REFITTING Lubricate the contact surface of the shaft into which the bearing is inserted. Insert the new bearing.DRIVESHAFTS Front right-hand wheel driveshaft: Removal .

DRIVESHAFTS Front right-hand wheel driveshaft: Removal . . Disconnect the wheel speed sensor. 105893 Remove the lower linkage nut (4) .the hub nut (1) using (Rou. 29A-13 . Vehicle: Towing and lifting ). REMOVAL Drain the gearbox. 604-01 Hub locking tool. 29A Tightening torquesm relay bearing bracket mounting bolts shock absorber turret bolts pivot support bolts lower linkage nut brake calliper bolts anti-roll bar return tierod ball joint nut track rod end nut driveshaft nut wheel mounting bolts 44 Nm 21 Nm 72 Nm 100 Nm 170 Nm 44 Nm 105891 37 Nm 280 Nm 130 Nm Remove: . I .the engine undertray.the front left-hand wheel.the anti-roll bar tie-rod upper nut (3) . . and F4R.the track rod end nut (2) . and 774 Special tooling required Rou.Refitting B84 or C84. 604-01) . . Remove: . Lifting equipment.WHEEL END Position the vehicle on a two-post lift (see 02A.

101211 Remove the shock absorber turret bolts (10) . and 774 29A 106114 101210 Compress the driveshaft approximately 10 cm . Remove the sub-frame reinforcement bar. Cut the flap at (8) . Relax the driveshaft by raising the lift by 50 cm . Remove the pivot support bolts (5) . Extract the lower linkage ball joint. 106245 Remove the pivot (7) from its support (6) using a hammer. Remove the seal (9) .DRIVESHAFTS Front right-hand wheel driveshaft: Removal .Refitting B84 or C84. 29A-14 . and F4R. Remove the plastic rivets from the flap.

Remove the driveshaft (gearbox end). and 774 II . shock absorber and pivot assembly.GEARBOX END 29A 106126 In place of bolt (11) . it must be replaced. screw in an M8x30 bolt. Note: If the bearing is seized in the relay bearing. 106641 106642 Remove the spring. Extract the hub driveshaft. Remove the turret bolts (12) .Refitting B84 or C84. 106093 Remove the relay bearing bracket mounting bolts (13) . 29A-15 . letting the head extrude by 20 mm .DRIVESHAFTS Front right-hand wheel driveshaft: Removal . and F4R.

I .the pivot support bolts ( 72 Nm ) . The driveshaft should go in freely.REFITTING Lubricate the contact surface of the shaft into which the bearing is inserted. 100642 Remove the complete driveshaft. Position and insert the driveshaft into the final drive sunwheel. and 774 29A REFITTING Clean and grease the relay bearing hole into which the bearing is inserted. Proceed in the reverse order to removal. 29A-16 . Battery. 80A.the wheel mounting bolts ( 130 Nm ) . . .the track rod end nut ( 37 Nm ) . . Note: It is essential to initialise the xenon bulb system.REMOVING THE RELAY SHAFT BEARING Note: The relay bearing bracket must be refitted with the driveshaft. The differential output lip seal must always be replaced.the anti-roll bar return tie-rod ball joint nut ( 44 Nm ) .the shock absorber turret bolts ( 21 Nm ) .DRIVESHAFTS Front right-hand wheel driveshaft: Removal . Tighten to torque: .the lower linkage nut ( 100 Nm ) . Insert the new bearing.the driveshaft nut ( 280 Nm ) . until it is in far enough for the hub nut to be fitted. Remove the bearing with the press. II . . Fill and check the gearbox oil level. Connect the battery (see MR364. With the protector in place. Note: Replace the relay shaft bearing O-ring if it has deteriorated. grease the gearbox side seal grooves with MOLYKOTE BR2 grease. Insert the stub-axle into the hub. Position the bearing as far as the stop using a tube supported by the inner bearing race. Refit the driveshaft.the relay bearing bracket mounting bolts ( 44 Nm ) .Refitting B84 or C84. Check the condition of the lip seal contact surfaces. 101211 Position the indexing (14) in its housing.Refitting ).the brake calliper bolts ( 170 Nm ) . Take care not to score the contact surface of the lip seal on the relay shaft. Battery: Removal . . . . and F4R.

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