Transmission CLUTCH MANUAL GEARBOX

Transmission

CLUTCH

MANUAL GEARBOX

AUTOMATIC TRANSMISSION

DRIVESHAFTS

BA0A - BA0E - BA0F - BA0G - BA0L - BA0U

77 11 176 221

SEPTEMBER 1995

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."

All copyrights reserved by the Regie Nationale des Usines Renault.

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of the

Regie Nationale des Usines Renault.

C Régie Nationale des Usines Renault S.A. 1995

EXPLODED VIEW

PRG20.1

Transmission

Contents

20 CLUTCH

Identification

Section views

Exploded views

Consumables

Fault finding

Mechanism - Plate

Thrust pad - Fork

21 MANUAL GEARBOX

Identification

Ratios

Capacity -Lubricants

Special notes

Consumables

Parts to be systematically replaced

Fault finding

Gearbox (Removal - Refitting)

5th gear on the vehicle

Differential output seal

Speedometer drive gear

21-1

21-2

21-3

21-4

21-5

21-5

21-6

21-9

21-19

21-23

21-26

20-1

20-3

20-3

20-4

20-5

20-13

20-14

Page Page

23 AUTOMATIC TRANSMISSION

Section view

Use

Identification

Gear ratios

Gear change thresholds

Consumables

Parts to be systematically replaced

Oil

Oil change frequencies

Fault warning light

Draining

Filling - levels

Oil pressure

Hydraulic distributor

Automatic transmission (Removal -

Refitting)

Differential output seal

Wiring

Wiring diagram

Checking the "timing point" on the converter

23-6

23-6

23-7

23-8

23-8

23-9

23-1

23-2

23-3

23-3

23-4

23-5

23-5

23-5

23-15

23-20

23-23

23-27

23-29

29 DRIVESHAFTS

Consumables

Driveshafts

Front transverse driveshafts

Gaiter on wheel end

Gaiter on gearbox end

Bearing gaiter

29-1

29-2

29-9

29-10

29-17

29-24

ENGINE

TYPE

MECHANISM

CLUTCH

Identification

PLATE

20

E7J

180 DST 3050

85873S 90693R4

26 splines

E = 8.5 mm

D = 181.5 mm

BC

= White

BU

= Blue

R

= Red

N

= Black

76906R

E7J

180 CP 3300

85873S 90693R3

26 splines

E = 8.3 mm

D = 181.5 mm

V

= Green

G

= Grey blue

B

= White

76906R

20-1

ENGINE

TYPE

MECHANISM

CLUTCH

Identification

PLATE

20

K7M

200 HR 4000

85873S 90693R5

26 splines

D = 200 mm

E = 8.3 mm

R

= Light pink

76906R

F8Q

200 HRV 3100

85873S 90693R6

26 splines

D = 200 mm

E = 8.3 mm

R

= Red

V

= Green

J

= Yellow

76906R

20-2

CLUTCH

Section views

Dry operating cable controlled monodisc clutch.

Clutch plate with diaphragm.

Rubber hub mounted clutch plate.

Self-centring guided and constant pressure thrust pad.

Automatic wear adjustment.

20

DI2001

Exploded view

20-3

PRD2004

Type

MOLYKOTE BR2

LOCTITE 518

CLUTCH

Consumables

20

Packaging

1 kg tin

24 ml syringe

Part number

77 01 421 145

77 01 421 162

Component

Splines of the right hand sunwheel

Fork pivot

Thrust pad guide

Fork pads

CLUTCH

Housing assembly surfaces

20-4

CLUTCH

Fault finding

20

KEY

Fault found

Check

Operations to be carried out

The clutch is slipping :

when stopped, handbrake on, at 2000 to

3000 rpm, impossible to stall the engine when letting the clutch in,

with 4th or 5th gear engaged, the engine seems to race.

Check the travel of the fork (1)

INCORRECT

Check the clearance

CORRECT

INCORRECT

INCORRECT

Check the condition of the cable and the anti-noise rubber washer (2)

CORRECT

Replace the faulty parts

CORRECT

Check the condition of the pedal and the assistance spring (*)

INCORRECT

Check the automatic adjustment device

INCORRECT

Repair the automatic adjustment device

CORRECT

CORRECT

INCORRECT

Check the condition of the fork

CORRECT


Replace the fork

Check the condition of the pins and support points

OILY

Check the condition of the clutch

Replace the clutch and repair the leak

WORN

Replace the clutch

(*)

Depending on version

(1)

See "Removal - Refitting" chapter

20-5

(2)

Grommet placed on the end of the clutch cable on the gearbox end

CLUTCH

Fault finding

The gearbox clunks.

Clutch pedal fully pressed down :

- vehicle stationary,

- engine running.

INCORRECT

INCORRECT

Toothed sector jammed or spring broken

Check the automatic adjustment system

CORRECT

INCORRECT

Check the condition of the cable and the antinoise rubber washer

(1)

CORRECT


CORRECT

INCORRECT

Check the condition of the pedal

CORRECT

20

CORRECT

Clutch stuck

Free the clutch

Rare case, may occur after the vehicle has been stopped for a long time

(several months)


Clutch operation

INCORRECT

Replace the clutch fork or check that it is correctly positioned


(1)

Grommet placed on the end of the clutch cable on the gearbox end

20-6

CLUTCH

Fault finding

The gearbox clunks in 1st or reverse gear only when cold:

- vehicle stationary,

- engine running.

Check the grade of the gearbox oil

INCORRECT CORRECT

Change the oil

Check the internal parts of the gearbox

20

20-7

CLUTCH

Fault finding

The gears are difficult to engage :

- vehicle moving.

Check the travel of the fork (1)

20

INCORRECT

Check the clearance

CORRECT

Check the gearbox control lever

INCORRECT

Check the automatic adjustment device

CORRECT INCORRECT



CORRECT INCORRECT


CORRECT



INCORRECT CORRECT


CORRECT

Check the condition of the pedal and the assistance spring (*)

INCORRECT

INCORRECT


CORRECT


(*)


(1)


Replace the fork


(2)

Grommet positioned on the end of the clutch cable on the gearbox end

20-8

INCORRECT


CORRECT

Check the clutch control

CLUTCH

Fault finding

Impossible to change gear

Check the condition of the gear control lever

INCORRECT


20

CORRECT

CORRECT



INCORRECT


20-9

CLUTCH

Fault finding

Juddering

20

Check the travel of the fork(1)

CORRECT

INCORREC

Check the clearance

INCORRECT

Check the condition of the gearbox mountings

CORRECT

INCORRECT

Check the automatic clearance device

CORRECT INCORRECT



CORRECT

Change the clutch plate and repair the leak

Change the mountings, check the engine mountings are tight and check that the gearbox is properly mounted on the engine

INCORREC


CORRECT


CORRECT

Check the condition of the pedal and assistance spring (*)

INCORRECT

INCORRECT


CORRECT


(*)


(1)


Replace the fork


(2)

Grommet positioned on the end of the clutch cable on the gearbox side.

20-10

INCORRECT


CLUTCH

Fault finding

Pedal is stiff

CORRECT

Check the clutch control and cable routing

Check the condition of the pedal and assistance spring (*)

CORRECT

Check the condition of the clutch and that the thrust pad slides freely

(*)


INCORRECT

Repair the faulty parts

20

20-11

CLUTCH

Fault finding

The clutch pedal clunks

The clutch pedal goes to the floor

20

Whistling when letting the clutch out

Clutch thrust pad seized

Replace the thrust pad

Grease the clutch pedal pin

Check the toothed sector

INCORRECT CORRECT

Pedal pin worn

Replace the clutch pedal pin and bearings

INCORRECT CORRECT

Toothed sector broken


Check the cable

INCORRECT CORRECT

Replace the cable

Check the fork, the thrust pad and the clutch

20-12

CLUTCH

Mechanism - Plate

REPLACEMENT

This operation is performed after the gearbox has been removed.

SPECIAL TOOLING REQUIRED

Mot.

582 Locking piece

Plus the tooling for removing the gearbox

TIGHTENING TORQUES (in daN.m)

Diameter 7mm mechanism bolt for

160 and 180 diameter clutch

Diameter 8mm mechanism bolt for

diameter 215 clutch

1.8

2.25

REMOVAL

Fit:

the locking piece Mot. 582,

the centring device (to prevent the friction plate falling out).

Remove the mounting bolts from the mechanism and remove the mechanism and the clutch plate.

Check and replace any faulty parts.

20

REFITTING

Degrease the mounting face of the flywheel.

Position the plate (hub offset fitted on the gearbox end).

Centre it using the tool supplied in the replacement kit.

99055R

20-13

95414S

Progressively tighten in a star arrangement, then lock the mechanism mounting bolts at the correct torque.

Remove the locking piece Mot. 582.

Coat with

MOLYKOTE BR2

grease:

the guide tube,

the fork pads.

CLUTCH

Thrust pad - Fork

REPLACING

This operation is performed after the gearbox has been removed.

REMOVAL

Pull out:

the thrust pad by tilting the fork,

the rubber protector and pull the fork towards the inside of the clutch housing.

REFITTING

Coat the sides of the guide tube and the fork pads with

MOLYKOTE BR2

.

Position the fork and replace the rubber protector.

Put the thrust pad on the guide tube by placing the lugs (A) into the fork.

20

99054R

Ensure that it slides freely.

NOTE :

when performing an operation which does not require the gearbox to be removed or after fitting the gearbox,

DO NOT LIFT

the fork since the lug (A) may be removed from the thrust pad.

20-14

CLUTCH

Thrust pad Fork

After the gearbox has been refitted, position the cable on the clutch fork, reset the toothed sector and check that the play compensation device works.

Check the clutch travel.

The fork travel should be:

X = 27.4

to 30.7 mm

20

97758-1R

20-15

MANUAL GEARBOX

Identification

B64

vehicles are fitted with JB or JC type gearboxes

MR "B.V. JB" and MR "B.V. JC" cover the complete repair process for these components.

21

NEW IDENTIFICATION PLATE

At A : the gearbox type

At B : the gearbox suffix

At C : the fabrication number

At D : the factory of manufacture

At E : a notch when the gearbox is assembled with an E engine

At F : the letter preceding fabrication numbers greater than 999999

87227G

A

D

E

X

J B0 0 0 0

X0 0 0 0 0

B

C

F

21-1

Suffix

54

95

129

68

119 120

123 124

Vehicle

BA0E

BA0U

BA0A

BA0L

BA0F

MANUAL GEARBOX

Ratios

21

Step down

15

61

15

56

15

58

Speedo gear

JB1

1 st

11

41

21

19

11

37

2 nd

3 rd

21

43

22

41

28

37

4 th

30

29

5 th

Reverse

39

31

11

39

26

Gearbox

Suffix

AC

95

X

JB1

119

X

123

X

Suffix

106

Vehicle

BA0G

Step down

15

61

Speedo gear

21

19

JB3

1 st

11

34

2 nd

22

41

3 rd

28

37

4 th

30

29

5 th

42

31

Reverse

11

39

26

Suffix

35

25

Vehicle

BA09

BA0H

Step down

17

56

15

61

Speedo gear

21

19

21

18

JC5

1 st

11

41

11

37

2 nd

21

43

22

41

3 rd

28

37

4 th

35

34

34

35

5 th

41

31

39

32

Reverse

11

39

26

21-2

CAPACITY

(in litres)

MANUAL GEARBOX

Capacity - Lubricants

JB1

5-speed gearbox

3.4

JB3

JC5

3.4

3.1

Viscosity - Grade

TRX 75W 80W

CHECKING THE LEVEL

21

92081S

Fill up to the level of the aperture.

21-3

MANUAL GEARBOX

Special notes

Gearboxes:

JB1 5 forward gears

JB3

JC5 1 reverse gear are fitted with BORG-WARNER synchros.

Special notes on the JB3 gearbox

The JC5 gearbox differs from the

JB3

gearbox in the following ways :

- wider teeth on the gears in 1st, 2nd, 3rd and

4th,

- rings under the gears in 2nd, 3rd and 4th,

- offset dog gears on the idle gears in 1st, 2nd and 4th,

- a new 65.5 mm diameter 1st and 2nd synchro,

- the use of tapered bearings on the primary and secondary shafts,

- a guide tube with a double seal on the housing and clutch shaft which can be removed without opening the gearbox,

- mechanism and clutch housing reinforced ,

- wider torque teeth on the final drive .

GEAR LAYOUT

R 1 3 5

21

2 4

B.V. JB - JC

To engage reverse gear, lift the locking ring (A) and move the lever.

DI2118

21-4

MANUAL GEARBOX

Consumables

JB and JC

TYPE

MOLYKOTE BR2

Loctite 518

RHODORSEAL 5661

Eg : CAF 4/60 THIXO

LOCTITE FRENBLOC

(locking and sealing resin)

PACKAGING

1 kg tin

24 ml syringe

100 g tube

24 cc bottle

PART NUMBER

77 01 421 145

COMPONENT

Clutch shaft splines

Fork pivot

Thrust pad guide

Fork pads

Clutch

77 01 421 162

77 01 404 452

Housing assembly faces

Threaded plugs and switches

Bearing plugs

Ends of roll pins on driveshafts

77 01 394 071

Primary and secondary shaft nuts

5th gear fixed gear and hub

Differential lock drive stud

21

Parts to be systematically replaced

When they have been removed:

- lip seals,

- O rings

- thrust pad guide tubes,

- secondary shaft and differential nuts,

- speedo gear and its pin,

- speedo crown wheel,

- roll pins,

- rings under the gears.

21-5

Grinding noise when engaging a gear

Remove the gearbox

MANUAL GEARBOX

Diagnostic

21

Clunking when each gear is engaged

(after checking clutch)

Remove the gearbox

Check the synchro and the synchro spring of the faulty gear

Correct

Impossible to engage gears

(after checking the clutch)

Check the adjustment of the selection linkage

Incorrect

Adjust the linkage

Condition of the parts of the linkage

Check the synchros and the synchro hubs

Correct

Incorrect

Remove the gearbox

Check the gearbox locking system


Adjust the linkage

KEY

Operations to be carried out

Check

21-6

MANUAL GEARBOX

Diagnostic

Abnormal noises when driving

• Stop the vehicle

• Engine running

• Gear lever in neutral

21

The noise stops

No

Clutch fully depressed

Amount of clearance

The noise stops

Correct Incorrect

Correct

Yes

Check driveshafts

Oil level

Incorrect Yes

Check the toothed sector of the clutch pedal and the cable

Yes

Remove the gearbox and repair it

The noise stops

No

Correct

Check wheel bearings

Incorrect

Replace the driveshafts

Check the thrust pad, cable and plate

Remove the gearbox and repair it

Replace the wheel bearings


21-7

Look for the noise in the engine

No

Look for the noise in the engine

MANUAL GEARBOX

Diagnostic

Gears jump out

Correct

Check engine and gearbox mountings

Incorrect

21

Correct

Adjust the linkage

Tighten the bolts or replace the mountings

Incorrect

Gear sticking

Adjust the control

Correct

Incorrect

Remove the gearbox

Check the locking system of the hubs and sliding gears


Adjust the linkage

Correct

Check the parts forming the control

Incorrect

Adjust the gearbox control

Remove the gearbox and check:

- the locking balls

- the forks

- the locking plungers

21-8


Adjust the linkage

All engines

MANUAL GEARBOX

Gearbox (Removal - Refitting)

21

B.Vi. 31-01

T.Av. 476


Set of pins

Ball joint extractor


Bolts of the rear linkage of the suspended engine mountings (tie-bar) 6

Bolts for securing battery mounting on body 2

Driveshaft gaiter mounting bolt

Gearbox mounting bolt

2.4

3.5

Gearbox control rod bolt

Shock absorber base bolt

Track rod end nut

Stub-axle key nut

2.8

17

3.5

6

Support mounting bolts

Wheel bolts

Caliper guide bolts

4.5

9

2.7

REMOVAL

- Put the vehicle on a two post lift.

- Disconnect the battery.

- Remove the front wheels.

- Remove the engine undertray.

- Drain the gearbox.

LEFT HAND SIDE OF THE VEHICLE:

Remove:

- the wheel arch (protection),

- the track rod end using tool T.Av. 476.

Remove:

- the two mounting bolts from the caliper by securing the caliper to the suspension spring to avoid stretching the pipe,

- the three mounting bolts of the driveshaft gaiter.

92122R2

85965R

21-9

All engines

MANUAL GEARBOX


Remove :

- the bolt (1),

- the 2 mounting bolts (2) from the base of the shock absorber,

21

RIGHT HAND SIDE OF THE VEHICLE:

Remove the driveshaft pins using tool B.Vi. 31-01

90130R2

- the stub-axle carrier driveshaft assembly by releasing the lower ball joint,

- the sub-frame-side member tie rod (A).

91755-1R2

Remove the bolts from the base of the shock absorber.

99070R1

Check that the driveshaft rollers cannot be removed by hand. If this is the case, when refitting, check that the needles have not fallen into the gearbox.

21-10

98712R1

Tilt the stub-axle carrier and release the driveshaft.

Remove the stub-axle carrier driveshaft assembly by releasing the lower ball joint.

Remove and secure the brake caliper.

Remove the mudguard.

Remove the sub-frame body tie rod.

E and K engines

MANUAL GEARBOX


Special notes for E7J - K7M engines

Remove the engine/gearbox assembly from above

(see Workshop Repair Manual Chap. 10).

Once the engine and transmission assembly is suitably clear, remove the bolts from around the gearbox.

Release the gearbox from the engine by removing the pin (C).

21

REFITTING


MOLYKOTE BR2

grease.

Position the fork on the notches of the clutch thrust pad.

Connect the engine to the gearbox.

Check that the rings (C) for centring the enginegearbox are present and are in the correct position.

86308R2

86415R2

Refit:

- the heat shield,

- the exhaust downpipe.

Refit the other components by carrying out the removal operations in reverse (see Workshop Repair

Manual Chapter 10).

21-11

E and K engines

MANUAL GEARBOX


IMPORTANT

Fit the bolt (V) and the starter motor centring dowel (D) correctly :

E and K engines

21

Position the driveshaft with respect to the sunwheel, pivot the stub-axle carrier and engage the driveshaft into the sunwheel using the shouldered pin B.Vi. 31-01 in order to align the holes.

86070R3

Reconnect the speedo cable, ensuring that the clip is the correct way round.

74937-4S

A chamfer on the leading edge of the sunwheel makes it easier to fit new roll pins.

Seal the ends

(RHODORSEAL 5661).

Fill with fluids.

Fit the caliper mounting bolts with Loctite

FRENBLOC

and tighten to the correct torque.

Press the brake pedal several times to bring the pistons back into contact with the brake pads.

92108-1S

Tighten all nuts and bolts to the recommended torques.

Fill the gearbox with oil.

21-12

F engine

MANUAL GEARBOX


Remove gear control, bolt (F).

Special notes for the F engine

Under the vehicle, remove the 2 mounting bolts

(B) from the power assisted steering pipe clamps.

21

98749R1

Remove the 2 bolts (H) from the engine-gearbox tie-rod.

85966R1

Disconnect:

- the wires from the starter motor,

- the reversing light switch,

- the speedo cable.

Remove the engine/gearbox mounting nut.

Slacken the 2 mounting bolts (C) on the engine from the engine-gearbox tie-rod.

98902R

85812-1R

21-13

F engine

MANUAL GEARBOX


Slacken but do not remove bolt (B) then remove mounting bolt (C) from the suspended engine mounting rod.

Remove :

- the air filter sleeve,

- the tie-rod from the shock absorber turret,

- the clutch cable.

21

99309R

Remove the rear mounting.

Remove shock absorber actuator (on version F8Q).

Remove :

- the expansion bottle,

- the air filter mounting.

Release the wiring.

89204S

Position the engine support tool and take the weight of the engine and transmission assembly.

98750S

99213S

21-14

F engine

MANUAL GEARBOX


Remove the upper mounting assembly on the gearbox end .

Remove the heat shield.

21

99309S1

Remove :

- the bolts around the gearbox,

- the starter motor,

- the connectors linked to the gearbox.

Remove the exhaust downpipe.

98827S

Remove gear lever return spring.

Move and secure the gear lever towards the rear.

98865R2

21-15

F engine

MANUAL GEARBOX


Remove the steering box mounting bolts.

21

Release the steering box and the steering column

(be careful not to damage the clip (C)).

98868-1R

Remove the mounting bolts of the power assisted steering pipes from the sub-frame.

Secure the steering box to the side members.

Special notes for vehicles fitted with driver’s

AIRBAG

ATTENTION : to prevent any damage being done to the rotating switch under the steering wheel, please follow these instructions :

- before releasing the steering column and the rack, the steering wheel MUST be immobilised, wheels straight, using the "steering wheel locking" tool throughout the duration of the repair,

- any doubts regarding the correct centring of the rotating switch means that the steering wheel has to be removed so as to apply the centring method as described in chapter 88

"AIR-BAG".

REMINDER: in this case, only qualified personnel who have received specific training may undertake this work.

97390-1R1

Remove the horn.

From above:

Secure the cooling assembly to the upper cross member.

Remove the upper mounting bolt from the bumper then the bolts located in the wheel arches.

98836R1

21-16

F engine

MANUAL GEARBOX


Position the sub-frame support trolley and lower the vehicle.

21

REFITTING


MOLYKOTE BR2

grease.

Position the fork on the notches of the clutch thrust pad.

Offer the gearbox up using the component jack.

Connect the engine to the gearbox.

Check that the dowels for centring the enginegearbox are present and are in the correct position.

98755R1

Remove the sub-frame by loosening the 4 mounting bolts.

Be careful not to forget to remove the power assisted steering pipe mounting from the subframe.

Under the vehicle :

- position the component jack under the gearbox without lifting it,

- release the gearbox and the engine by removing the studs (C).

86415S

Refit:

- the assembled support,

- the sub-frame,

- the steering.

Refit:

- the heat screen,

- the exhaust downpipe,

- the suspended engine mounting bar.

Refit the other components by carrying out the removal operations in reverse.

86308R2

21-17

F engine

F engine

MANUAL GEARBOX


21

Position the driveshaft with respect to the sunwheel, pivot the stub-axle carrier, engaging the driveshaft into the sunwheel using the shouldered pin B.Vi. 31-01 in order to align the holes.

86070-1R1

Check the adjustments of the upper mountings

(refer to chapter 10).

Ensure that the movement limiter is mounted the correct way round: the nuts should be fitted on the exhaust pipe side.

74937-4S

A chamfer on the leading edge of the sunwheel facilitates makes it easier to fit new roll pins.

Seal the ends

(RHODORSEAL 5661).

Fill with fluids.

Fit the caliper mounting bolts with Loctite

FRENBLOC



92661S

Tighten all nuts and bolts to the recommended torques.


21-18

MANUAL GEARBOX

5th gear on the vehicle

21

B.Vi.

B.Vi.

28-01

31-01

B.Vi.

B.Vi.

1003

1007


Extractor body

Set of pins for extracting and fitting 5 mm diameter roll pins

5th gear hub extractor

Claws for B.Vi. 28-01

TIGHTENING TORQUES (In daN.m)

Primary shaft nut

Secondary shaft bolt

REMOVAL

Put the vehicle on a 2 post lift.

Remove the front left hand wheel.

Remove the protection from the wheel arch.

Remove the sub-frame-side member tie-rod.

Remove the engine undertray.

13.5

6.3

Drain the gearbox

The rear housing must be removed along the horizontal axis of the gearbox since it contains a lubrication nozzle (A) which enters the primary shaft.

CONSUMABLES

Loctite FRENBLOC :

Primary shaft nut

Secondary shaft bolt

5th fixed gear

5th gear hub

Position:

a draining container under the rear housing and remove the housing,

a wooden block between the 5th gear fork and the drive pinion to absorb the backlash; then remove the pin from the fork using

B.Vi.

31.01

.

SPECIAL NOTE

Do not pull the 5th gear fork pin outwards since the locking ball will fall into the gearbox, for safety, engage a gear (3rd or 4th).

Removing the pin can be made easier by slightly bending the pin of tool B.Vi. 31.01 in order to prevent the gearbox being lifted.

87180R

21-19

85979R

MANUAL GEARBOX


Lock the gearbox by putting the gear lever in 1st gear and the gearbox in 5th gear by sliding the

5th gear fork inwards along its shaft.

21

On the primary shaft :

Remove the 5th gear fork and the sliding gear, taking care not to pull the 5th gear pin outwards.

Extract the synchro hub using tool B.Vi. 1170.

93912-1R

Release and remove the primary shaft nut and the secondary shaft bolt (65).

Put the gearbox in neutral.

93190S1

Position the sliding gear of tool B.Vi. 1170 as if to change into 5th gear and turn it so that the splines of the sliding gear are opposite the splines of the hub .

Extract the 5th gear assembly.

86045S

21-20

On the secondary shaft:

Remove the shouldered washer (64).

MANUAL GEARBOX


PRG21.1

Extract the fixed gear using B.Vi. 28-01 fitted with its claws B.Vi. 1007.

21

REFITTING

On the secondary shaft:

Apply 3 drops of

Loctite FRENBLOC

to the splines of the fixed gear.

Fit the shouldered washer (64).

On the primary shaft

:

Refit in the correct order (21) (shoulder facing the ring (22), (23), (24) and (8)).

Put the fork on the sliding gear (26) fitted with

(25).

Apply 3 drops of


to the hub and replace the sliding gear hub and fork assembly.

Fit the synchro ring bosses in the lugs on the hub.

88575R 86045R1

Put the gear lever in 1st gear and the gearbox in

5th gear by sliding the 5th gear fork on its shaft.

Apply 3 drops of


:

to the primary shaft nut (27) and tighten it to a torque of 13.5 daN.m,

on bolt (65) and tighten it to a torque of 6.3

daN.m

to fit the fixed gear securely.

21-21

MANUAL GEARBOX


Put a wooden block between the 5th gear fork and the drive gear to take the backlash and refit a new pin into the 5th gear fork using B.Vi. 31-01 complying with the assembly direction, the split should be pointing towards the rear housing.

21

Fit the rear housing by engaging nozzle (A) into the primary shaft.

Tighten the mounting bolts to a torque of 2.4

daN.m

.

90498-1S


Check that the rear housing does not leak when the engine is running.

87180R

85979R1

Fit a new O-ring to ensure that the rear housing is sealed.

Return the gearbox to neutral and check that all gears can be engaged.

If any problems occur, check that reverse gear is not engaged.

21-22

MANUAL GEARBOX

Differential output seal

B.Vi.

T.Av.

B.Vi.

B.Vi.

31-01

476

945

1058


Set of pins


Mandrel for fitting differential seals

Mandrel for fitting differential seals

(JB3 tapered bearings)


Brake caliper mounting bolt

Shock absorber base mounting bolts

Track rod end

Wheel bolts

2.7

17

3.5

9

REMOVAL

Remove the engine undertray.

Drain the gearbox.

Put the front of the side being worked on on axle stands.

Remove the wheel.

Extract the driveshaft pins using tool B.Vi. 31-01.

CONSUMABLES

Loctite FRENBLOC :

Brake caliper mounting bolt

RHODORSEAL 5661 (Eg.

CAF 4/60 THIXO) :

Ends of driveshaft pins

MOLYKOTE BR2 :

Right hand sunwheel splines

Remove :

the track rod end (tool T.Av. 476),

21

85965R

91755R

21-23

MANUAL GEARBOX


- the two mounting bolts (A) of the brake assembly.

21

REFITTING

1.

JB1 - JB3 gearboxes

The seal is refitted using tool B.Vi. 945 comprising:

- a seal protector (A),

- a tool for positioning the seal (B).

2.7 daN.m

90149R1

Secure the caliper to the suspension spring to prevent the pipe being damaged.

Slacken the lower bolt (3) from the base of the shock absorber and remove the upper bolt (4).

Tilt the stub-axle carrier and release the driveshaft

(take care not to "damage" the gaiters during this operation).

Remove the O-ring from the sunwheel.

Tap the base of the lip seal using a pin extractor and a small hammer in order to extract it from its housing .

When the seal is released, remove it using pliers taking care not to damage the splines of the sunwheel.

86095R

METHOD

Put the oiled protector (A) onto the sunwheel and position the oiled seal (C) with the tool (B).

86031S

21-24

86122R

MANUAL GEARBOX


Continue in the same way but using tool

B.Vi.

1058

and protector (A) of B.Vi. 945.

Fit new roll pins and seal the ends with

RHODORSEAL 5661 (Eg.

CAF 4/60 THIXO).

21

Tighten the nuts and bolts to the recommended torques.

Refit the brake caliper and coat the bolts with

Loctite FRENBLOC.


92111R

Fit the O-ring to the sunwheel and coat the splines with grease N

°

20.

Position the driveshaft with respect to the sunwheel.

Pivot the stub-axle carrier, engaging the driveshaft into the sunwheel using pin B.Vi. 31-01 to align the holes.

74937-3S

21-25

MANUAL GEARBOX

Speedometer drive gear

REPLACEMENT

1 st

case :

Only the speedo gear or the pin is damaged.

REMOVAL

The gearbox does not have to be completely dismantled.

Release the left hand driveshaft.

Remove the sunwheel spider.

Rotate the differential by hand so that the speedo gear is accessible.

Unclip the pin by pulling it vertically using a pair of long nose pliers.

Using these pliers, remove the gear from its housing.

Correct Incorrect

21

REFITTING

Refit a new speedo gear using a pair of flat nose pliers.

The gear and its pin should be refitted by hand.

The pin must be correctly positioned with respect to the key lugs on the gear due to the elasticity of the lips of the pin.

88577S

86053S

Ensure that it is correctly clipped in.

Refit the sunwheel spider.

2nd case :

The speedo gear and crown wheel are damaged

The gearbox has to be removed and the final drive has to be dismantled.

21-26


Section view

TYPE AD4 AUTOMATIC TRANSMISSION

23

23-1

DI2302


Use

DRIVING

The automatic transmission is lubricated under pressure and therefore this only occurs if the engine is running.

As a result, and with the risk of serious damage, the following instructions must be complied with:

- never drive with the ignition off (going downhill for example), we cannot stress enough how dangerous this practice is.

- never push a vehicle (eg. : to reach a petrol pump), except by following the instructions in the "Towing" paragraph.

In addition, the vehicle is only driven if the engine is running. It is therefore impossible to start the engine of a vehicle with automatic transmission by pushing it.

TOWING

In all cases, it is preferable to tow the vehicle on a trailer or with the front wheels off the ground.

However, if this is not possible, the vehicle can be towed at a speed below 25 mph (40 km/ h

and over a maximum distance of 30 miles (50 km) (lever in N).

23

23-2


Identification

23

VEHICLE

TRANS-

MISSION

TYPE

ENGINE CONVERTER

STEP

DOWN

BA0 AD4 013 K7M 227

*

For identifying with the

XR25

test kit, see MR

TA.A

.

69/77

RATIO

19/65

SPEEDO

ELECTRONIC

UNIT*

22/20 114

Gear

Gear reduction

Overall reduction

Speed in km/h at 1000 rpm. with

1.76 m tyres

1st

2.71

10.35

10.19

Gear ratios

2nd

1.55

5.92

17.83

3rd

1

3.82

27.66

4th

0.68

2,6

40.79

Reverse

2.11

8.06

13.11

23-3


Gear change thresholds

23

VEHICLES

BA0

TRANS-

MISSION TYPE

ACCELER-

ATOR

POSITION

1 2 2 3 3 4 4 3 3 2 2 1

A B A B A B A B A B A B

AD4

PL

PF

RC

16 20 40 46 64 73

41 49

52

76

96

95 126

158

149

50 59 32 34 7 15

107 127 65 81 28 32

146 90 48

The figures given in the table represent the average theoretical speed values for changing gear in km/h

tolerances =

±

10 %.

PL

: No load.

PF

: Full load.

RC

: Kickdown (changing to a lower gear).

A

: Gear change thresholds are set lower down. Gears change at a lower speed. Switch (1) is not activated and the warning light EXC is extinguished.

B

: Gear change thresholds are set higher up. Gears change at a higher speed. Switch (1) is activated and the warning light

EXC

is illuminated.

23-4

98597R

DESCRIPTION

RHODORSEAL 5661

(Eg : CAF 4/60 THIXO)

MOLYKOTE BR2 grease



Consumables

COMPONENT AFFECTED

Seals the driveshaft pins

- Sunwheel splines

- Converter centrer

Brake caliper mounting bolt

Parts to be systematically replaced

Parts to be replaced after they have been removed :

- roll pin,

- lock nuts,

- copper seals.

Oil

AD4

automatic transmission uses two grades of oil and has two levels.

MECHANISM :

ELF RENAULTMATIC D2

(D20104).

In emergency, use:

- MOBIL ATF 220 D (D 20104 or D 21412).

-

TEXAMATIC 4011.

FINAL DRIVE:

TRANSELF TRX 75W 80W.

23-5

23


Oil change frequencies

23

The mechanism is drained during the major service.

The oil level must be checked every 10000 miles (15 000 km) in case there is a slight oil leak.

The final drive is never drained ;

it is filled for life.

The strainer is no longer replaced (NT 2261A).

Only the level may change due to a slight leak.

Oil capacity

MECHANISM

FINAL DRIVE

TOTAL volume

5.7 l

1 l

NOTE : if the automatic transmission is replaced, only check the oil level since the transmission is supplied by the Parts Department full of oil.

Fault warning light

MESSAGE FROM THE ELECTRONIC FAULT

WARNING LIGHT

Normal operation :

• The warning light is not illuminated during normal operation whether the vehicle is being started, engine running or when the vehicle is stationary.

Presence of a fault :

• Vehicle stopped, engine running, or when driving, warning light permanently illuminated

• Vehicle moving, warning light illuminates and extinguishes without action at the ignition key.

• Vehicle moving, warning light illuminates briefly.

Oil temperature < - 20

°

C or > + 140

°

C

• Vehicle moving or stationary, warning light flashes at a rate of approximately 1 flash per

second,

in this case, reduce the performance requirement by moderating acceleration.

23-6


Draining

B.Vi.

1213


MS 1019-10

Automatic transmission drain spanner

XR25 test kit

DRAINING

Mechanism :

Mechanism sump with two plugs:

A

: Top-up plug.

B

: Drain plug (triangular socket).

Draining is performed by removing plug (B).

Final drive:

Filling and topping up are performed through plug (C) which overflows when the level is exceeded.

23

94882R

Reminder:

The final drive is never drained, it is filled for life.

94882R2

23-7


Filling - Levels

23

FILLING - TOPPING UP

Filling is performed though tube (D).

94845R1

Use a funnel fitted with a 15/100 filter so as to prevent any impurities entering.

The level

MUST

be checked in accordance with the following method:

Before starting:

- if the gearbox has been drained, fill it with 3.5

litres

of oil,

- if you are simply checking the level, you must add 0.5 litre of the recommended type of oil.

1 -

Vehicle on a 4 post lift, transmission at ambient temperature.

2 -

Start the engine with the selector lever in the

Park position.

3 -

Connect the

XR25

test kit and enter:

D 1 4

then

#

0 4

4 -

Raise the vehicle and allow the engine to run until it reaches a temperature of 60

°

C

.

5 -

When the desired temperature has been reached, open the top-up plug; allow the excess

oil to overflow

(must be more than 0.1 litre) for approximately 20 seconds. Replace the plug

6 -

If the volume of oil which flowed out is less than 0.1 litre, the level is not correct. Repeat the operation.

In this case, add 1 litre of the recommended oil and allow the transmission to cool down between successive operations.

Oil pressure

The transmission is fitted with an oil pressure take-off. Connect the B.Vi. 1215 to check the automatic transmission pressure sensor only.

The oil pressure cannot be altered.

Its value is determined by the electronic computer.

94845-1R

23-8


Hydraulic Distributor

TIGHTENING TORQUES (In daN.m)

Strainer mounting bolts

Sump mounting bolts

Mounting bolts for engine mounting dampers on side member

Rear support mounting bolts

Wheel bolts

Strainer mounting bolts

Distributor mounting bolts

0.5

1

2

6.5

9

0.5

0.5

23

For versions with ABS

Remove the mounting nut (C) from the ABS electro-pump assembly on the rubber mounting.

REMOVAL

Put the vehicle on a 2 post lift.

Put the lever in the "P" (Park) position.

Drain the automatic transmission (mechanismsection; drain plug with triangular socket).

Remove:

- the expansion bottle,

- the air filter,

- the two upper bolts (A) of the engine mounting damper and slacken the other two (B), without removing them.

94933R

Remove the front left hand wheel and remove the plastic shield from the wheel arch (in order to be able to remove the two rear mounting bolts of the automatic transmission sump at a later stage).

Using the component jack, raise the automatic transmission.

94933-1R 94887S

23-9



Remove:

- the sump from the automatic transmission,

- the strainer and its seal (bolt 1),

23

This extra travel is required to release the drive from the control sector of the manual valve.

92084R

- the gear control cable from the selector (2) so that the lever can be moved past the "Park" position.

94841R

Disconnect the sealed connector cable by pressing on the locking ring.

99586R

94925S

23-10



Remove the sealed connector after having removed the bolt (3).

23

Remove the 16 mounting bolts from the hydraulic distributor. The bolts marked (

* )

remain in place and secure the distributor closing plate.

94848-1R

Remove the manual valve selector (4) by firstly releasing at (A) and then at (B).

Extract the manual valve from the hydraulic distributor.

94841-1R2

Push the gear control selector in fully and release the hydraulic distributor by releasing the modulating solenoid valve from the sump (5).

94848R

23-11

91724R



Ensure that the inserts (6) and the filter (7) have stayed in position in the sump’s hydraulic circuit.

23

94852R2

REFITTING

Ensure that the supply tube F1 (8), the modulating solenoid valve filter (7), and the circuit inserts (6) are in place.

91724R

Replace the 16 bolts for mounting the distributor onto the sump and tighten them to a torque of

0.5

daN.m. in accordance with the order shown.

94841-1R1

94852R1

Engage the hydraulic distributor.

Push the gear control selector in fully taking care to engage the modulating solenoid valve into the sump (5) correctly.

23-12



Refit the manual valve and the selector (4) by engaging firstly part (A) and then part (B).

Fit a new strainer and new seal.

Tighten to a torque of 0.5 daN.m.

23

91350R4

Refit the sealed connector fitted with its O-ring and bolt (3).

Replace the sump (Ensure that the seals are not damaged and check that the magnet is present).

Tighten the bolts to a torque of 1

daN.m.

94840R

Refit the automatic transmission.

Replace the bolts of the transmission mounting dampers.

94848-1R

94933-1S

Reconnect the sealed connector.

Refit the gear selector.

23-13



On versions with ABS

Refit the mounting nut (C) from the ABS electropump unit on the rubber mounting.

23

94933R

Refit:

- the plastic shield in the front left wheel arch,

- the front left hand wheel,

- the air filter,

- the expansion bottle.

Fill with oil and check the level.

NOTE :every time the hydraulic distributor is replaced or removed, replace the modulating solenoid valve filter, the strainer and its seal.

23-14

K7M

ENGINE


Automatic transmission (Removal - Refitting)

REMOVING FROM UNDERNEATH


Mot. 1040-01

Dummy cradle for removingrefitting the engine and

Mot. 1202

transmission assembly

Hose clamp pliers

Mot. 1311-06

Tool for removing fuel pipes


- the left and right hand mudguards,

Sub-frame front mounting bolts

Sub-frame rear mounting bolts

Shock absorber upper cup mounting bolts

Wheel bolts

Brake caliper mounting bolts

Steering universal joint mounting bolt

Nut for mounting rubber engine mounting onto front left side-member mounting

6

11

3

9

3.5

3.5

4.5

23

Put the vehicle on a two post lift.

Disconnect the battery.

Drain:

- the cooling circuit through the lower radiator hose (radiator end),

- the engine if necessary.

Remove:

- the front wheels,

98710S

- the sub-frame-body tie-rods,

- the brake calipers and secure them to the body,

- the front bumper,

PRG23.1

23-15

K7M

ENGINE



- the heat shield from the exhaust manifold,

- the catalytic converter (disconnect the oxygen sensor) and secure the exhaust pipe to the body,

- the horn,

- the acoustic tie-rod between the shock absorber turrets,

- the air filter,

- the earth strap,

- the absolute pressure sensor,

- the expansion bottle and secure it to the engine.

Disconnect:

- the accelerator cable as well as the kickdown switch connector,

- the brake servo pipe,

- the relay plate and the electrical connectors from the engine connection unit,

23

Disconnect:

- the injection supply wire located in the scuttle panel as well as the starter motor supply,

- the fuel inlet and outlet hoses using Mot. 1311-

06

, unclip them from their support,

99461R

- the heating pipes on the thermostat.

Unclip the radiator and move it away by securing it to the engine.

98756R

- the connector from the automatic transmission computer,

- the canister pipe.

Remove the battery mounting bracket.

23-16

K7M

ENGINE



Remove:

- the automatic transmission selector control,

- the nut and eccentric bolt (4) (remove it using the pin extractor) from the steering shaft yoke after having pushed back the protector.

23

Remove the nut (A), then, using a copper hammer, hit the stud in the left hand suspended mounting in order to remove it.

97390-1S

SPECIAL NOTES FOR VEHICLES FITTED WITH

DRIVER’S AIRBAG

ATTENTION

: to prevent any damage being done to the rotating switch under the steering wheel, please follow these instructions :

Before releasing the steering column and the rack, the steering wheel MUST be immobilised, wheels straight, using the "steering wheel locking" tool throughout the duration of the repair. Any doubts regarding the correct centring of the rotating switch means that the steering wheel has to be removed so as to apply the centring method as described in chapter 88 "AIR-

BAG".

REMINDER

: in this case, only qualified personnel who have received specific training may undertake this work.

Put a wedge between the automatic transmission and the front left hand sub-frame.

PREPARING TOOL MOT. 1040-01

Position the roller pin in the lower holes (G).

It is then secured to the sub-frame using the Tpieces (I).

PRG23.2

92442R

23-17

K7M

ENGINE



Secure Mot. 1040-01 under the sub-frame.

23

Extract the engine and transmission assembly by lifting the body.

Secure the spring-shock absorber assembly with rope.

98755R

Lower the final drive until the tool touches the ground.

Remove:

- the shock absorber upper mounting bolts,

- the sub-frame mounting bolts.

99588S

Separate the engine and transmission assembly from the sub-frame by removing:

- the upper radiator hose,

- the power assisted steering reservoir and the pump,

- the power assisted steering pipe mounting on the automatic transmission.

Unclip the wiring loom from the sub-frame.

Position the lifting tool.

Remove:

- the right hand mounting,

- the engine tie-bar.

Release the driveshafts.

PRG23.3

23-18

K7M

ENGINE



Lift the engine from the sub-frame.

Separate the gearbox from the engine by :

- removing the starter motor,

- removing the bolts from the automatic transmission sump.

Remove:

- the hoses on the exchanger,

91131S

23

- the converter bolts

- the bolts around the gearbox and the TDC sensor.

Separate the automatic transmission from the engine.

REFITTING (special notes)

Refit the converter by positioning it with respect to the mounting bolts.

Tighten the bolts around the automatic transmission.

Refitting is the reverse of removal.

Aligning the engine sub-frame with the body will be made easier by positioning two approximately

100 mm

long threaded rods in the two front subframe-body mountings.

Tighten the sub-frame front mounting bolts to a torque of 6 daN.m. and to a torque of 11 daN.m at the rear.

Tighten all nuts and bolts to the recommended torque.

Fit the caliper mounting bolts using Loctite

FRENBLOC and tighten them to the correct torque.


Fill:

- the cooling circuit and purge it (see chapter 19),

- the engine with oil if necessary.

NOTE :

check that the steering shaft yoke spacer is in place when refitting.

99586R2

23-19



1) REPLACING A LEFT OR RIGHT HAND LIP SEAL

23

PRG23.4

REMOVAL

Using a screwdriver, remove the protective shield

(A).

B. Vi. 1322


Tool for fitting differential output seals

Using a screwdriver, remove the seal taking care not to damage the differential bolt as well as the output shaft.

97725R

The shield is fitted tight.

23-20

97746S



REFITTING

The lip seal (oiled) is positioned using tool

B.Vi.

1322

(this determines the correct position of the seal).

23

2)

REPLACING THE O-RING

The principle is the same on both sides, but only

one side must be removed at a time

.

B. Vi. 1323


Tool for fitting differential output seals

Special notes:

The is no flange on the driveshaft outputs, but instead a simple splined end piece protected by a shield.

95791-5R

Refit the protective heat shield in the opposite order to removal using a 45 mm diameter socket.

97746-1S

23-21



REMOVAL

Drain the final drive and remove the shield, as explained in paragraph 1.

Locate the position of the nut (F) with respect to the sump by putting a mark on one of the teeth and on the face of the sump.

Remove bolt (D) and the locking plate (E) from the nut using tool B.Vi. 1323, remove the nut, counting the number of turns it takes.

23

Replace the O-ring on the nut, cleaning the seat properly and lubricating the new seal with final drive oil.

95791-2R

95791-6R

REFITTING

Refit the nut, turning the same number of turns as when it was removed.

Align the marks made on the nut and the sump.

Replace the bolt (D) and the locking plate (E).

Refit the shield after having replaced the lip seal if necessary (see paragraph 1).

Fill the final drive with oil.

23-22


Wiring

The new generation of A4.2 automatic transmission is fitted with monoblock wiring which means that many of the intermediate connectors are no longer required. As a result, the method for repairing sensors or switches is different.

23

1 - 55 track connector on the automatic transmission computer

2 - Oil pressure sensor

3 - Electro-hydraulic interface (sealed connector)

4 - Inter engine unit connection

5 - Injection/diagnostic connector

6 - Pressure sensor connector

7 - Speed sensor

8 - Multifunction switch

23-23

PRG23.5


Wiring

REPAIRING COMPONENTS

Most of the components comprising the monoblock wiring are not directly interchangeable.

Only the pressure sensor can be replaced without having to cut the cable.

REPAIRING THE MULTIFUNCTION SWITCH

23

If one of the insulations or one of the continuities is not assured, replace the multifunction switch and refer to note 8074 for the repair procedure.

Refer to notes 8074 and 8075 for repairing the speed sensor and using the locally made lifting plate.

99613S4

Initially, this is checked with the 55 track connector using the bornier Sus. 1228 and the table below.

If this checking procedure highlights a fault, section the cable 15 cm from the switch and check between the section and the 55 track connector.

See the wiring diagram and table below.

NOTE:

remember to distribute the connection joints.

99585S

LEVER POSITION

P/N

R

D

3

2

1

ASSURED CONTINUITIES

Terminal 44 / Earth

Terminal 27 / Terminal 46

None

Terminal 51 / Earth

Terminals 51 and 52 / Earth

Terminal 52 / Earth

ASSURED INSULATIONS



Terminals 44, 51 and 52 /

Earth

Terminals 44, 51 and 52 /

Earth




Terminal 44 / Earth




23-24


Wiring

Removing the wiring assembly is specific to the

AD4 A4.2.

23

REMOVAL


Disconnect the battery.

Remove the front left hand wheel.

From the wheel arch:

Remove:

- the earth wire from the multifunction sensor,

- the multifunction sensor mounting bolt (A).

99613S

Fit the engine support tool with the support bracket on the left hand side.

99182S

99586R1

On the vehicle:

- position the lifting plate (tool made locally as described on the next page).

98750R1

Remove the engine torque traction link on the gearbox side.

Remove the speed sensor (mounting bolt (B)).

Remove gear selector control ball joint (C).

Remove all the wiring assembly, taking note of its position and mountings so that is refitted correctly.

Disconnect the 52 track connector and the connector in the inter engine unit.

23-25


Wiring

REFITTING

Replace the wiring without securing it.

Refit:

- the speed sensor,

- the multifunction sensor.

Refit the mounting on the gearbox side.

Remove the engine support tool.

Reconnect all the components.

Secure the wiring using its clips.

LIFTING PLATE

23

99613S1

Disconnect the connectors from the pressure sensor and the diagnostic/injection socket.

Disconnect the sealed connector switch.

Remove the wiring.

99613S2

There are two possible solutions for manufacturing this plate.

99585R

1)

By modifying the existing plate on the E7J engine (air filter support plate mounted onto the cylinder head).

2)

By having it manufactured locally

Parts list: - 1 plate of thickness 4 or

5 mm in semi-hard steel,

-

2 HEX M8

×

20 bolts (collar bolts).

23-26


Wiring diagram

104 - Ignition switch

119 - Automatic transmission computer

120 - Injection computer

129 - ECO/PERF selector switch

160 - Stop switch

163 - Starter motor

225 - Diagnostic socket

247 - Double headlight relay

250 - Speed sensor

303 - Automatic transmission selector lighting

319 - Air conditioning control panel

535 - ECO/PERF selector switch warning light

569 - 4 speed automatic transmission kickdown

597 - Engine fuse box

645 - Passenger compartment connection unit

754 - Electrical/hydraulic interface

779 - Automatic transmission multifunction switch

780 - Automatic transmission turbine or vehicle speed sensor

781 - Line pressure sensor

R22 - Engine/automatic transmission

R34 - Engine/dashboard

MH - Engine electric earth

MJ - Front right pillar electric earth

23

23-27


Wiring diagram

23

23-28

98463S


Checking the "timing point" on the converter


Lift the vehicle until the wheels are a few centimetres off the ground.

Connect the

XR25

.

Put the

ISO

switch on S8.

Enter the A4.2 transmission code :

D 1 4

then #06 to display the engine speed.

Accelerate fully with the brake fully on.

The engine speed should stabilise to :

- K7M engine: 2430 rpm.

If this value is not correct, replace the converter.

A timing point which is more than 200 rpm. below the specified value requires the automatic transmission to be replaced.

NOTE :

for all diagnostic questions, refer to MR

TA.A, "General".

23

23-29

TYPE

Loctite SCELBLOC

RHODORSEAL 5661

(example : CAF 4/60 THIXO)

MOLYKOTE BR2

FRENBLOC

MOBIL CVJ 825

Black Star or

MOBIL EXF 57C

DRIVESHAFTS

Consumables

QUANTITY

Coating

Coating

Coating

Coating

320 g

140 g

160 g

130 g

COMPONENT CONCERNED

Stub axle splines

Driveshaft roll pins on gearbox end

Seal splines on gearbox end

Brake caliper bolt

GE 86 seal

AC 1700 seal

RC 490 seal

GI 62 seal

29

Allocation of seals on vehicles

SEALS

GE 86

AC 1700

RC 490

GI 62

GI 69

Right hand driveshaft

X

X

X

X

Left hand driveshaft

X

X

X

Wheel

end

X

X

Gearbox

end

X

X

X

29-1

DRIVESHAFTS

Driveshafts


Rou. 604 -01

T.Av. 476

T.Av. 602

T.Av. 1050-01

B.Vi. 31-01

Hub immobiliser


Driveshaft puller

Hub extractor

Roll pin punch


Driveshaft nut

Gaiter mounting bolt on gearbox

Wheel bolt

Shock absorber base nut

Brake caliper mounting bolt

Track rod end nuts

25

2.5

9

17

10

3.5

Left hand side

Drain the gearbox.

Remove the three bolts

REMOVAL

Remove:

the brake assembly (suspend it from the chassis so as not to damage the brake pipe),

the driveshaft nut: tool Rou. 604-01.

85678R1

Right hand side

Remove the pin: tool B.Vi. 31-01.

29

94338-1R 91755R

29-2

On both sides

Remove:

the track rod end nut : tool T.Av. 476,

DRIVESHAFTS

Driveshafts

29

Remove the lower mounting bolt on the shock absorber base and extract the driveshaft

85965-1R

the upper mounting bolt of the shock absorber base.

These vehicles are fitted with bonded driveshafts.

They therefore have to be pushed back using tool

T.Av. 1050-01.

96353S

Take care not to "damage" the gaiters during this operation.

REFITTING

NOTE : the Parts Department now supplies driveshafts fitted with protectors and accompanied with assembly instructions. These instructions must be complied with in order to ensure correct assembly of maximum QUALITY, given that the slightest knock to these gaiters will result in the rubber splitting in time and will lead to the driveshaft being destroyed.

94421-3R

29-3

TRANSMISSION

Driveshafts

COMPULSORY ASSEMBLY INSTRUCTIONS

29

29-4

DI2905

DRIVESHAFTS

Driveshafts

Never remove the cardboard protectors before the driveshaft is fitted onto the vehicle.

29

Left hand side

Remove the plastic protector from the bearing gaiter and engage the driveshaft as horizontally as possible.

91630R

Never use a sharp object which might "damage" the gaiter.

85677S

91629R

29-5

DRIVESHAFTS

Driveshafts

Right hand side

With the protector in place, coat the splines of the seal on the gearbox side with

MOLYKOTE BR2

grease.

Position the driveshaft with respect to the sunwheel and engage it.

Check its position with the angled pin of tool

B.Vi.

31-01.

Fit two new roll pins : tool B.Vi. 31-01. Seal the pin holes with

RHODOSEAL 5661 (eg. : CAF 4/60

THIXO).

NOTE :

chamfers on the leading edges of the sunwheels make it easier to fit new roll pins.

On both sides

Coat the splines of the stub axle with Loctite

SCELBLOC.

29

91749S

Insert the driveshaft stub axle into the hub.

It should enter freely until the thread shows allowing the stub axle nut to be fitted.

If any problems arise, use tool T. Av. 602.

74937-4S

96353R

29-6

DRIVESHAFTS

Driveshafts

29

On the left hand side

Clean the face of the gaiter on the gearbox, refit the gaiter and the plate.

Position the gaiter as horizontally as possible and tighten the three bolts to the correct torque.

96353-1S1

Refit:

the two bolts at the base of the shock absorber on the stub axle carrier and tighten them to the correct torque,

the track rod end, tighten the nut to the correct torque.

Tighten the driveshaft nut to the correct torque: tool Rou. 604-01.

85678R1

85876-1R

29-7

On both sides

Position the brake calipers, coat the bolts with



Lower the vehicle back down onto its wheels.

DRIVESHAFTS

Driveshafts

29

With the vehicle on its wheels, remove the cardboard protectors by tearing them in accordance with the diagram.

91693R 91633S

And never use a sharp object which might "damage" the gaiter.

91631S

29-8

91632R

Press the brake pedal several times to bring the piston back into contact with the linings.

If the left hand driveshaft has been replaced, refill the gearbox with oil.

DRIVESHAFTS

Front transverse driveshafts

ABS TARGET

ABS targets cannot be removed (sintered steel).

The Parts Department supplies replacement machined driveshafts fitted with ABS targets.

29

29-9

GE 86 seal

6

7

A

1

2

Stub axle cup

Spider

3 and 5 Retaining clips

4 Yoke shaft

Thermoplastic gaiter

Retaining star

ABS ring (option)

TRANSMISSION

Gaiter on wheel end


T. Av.

1256

T. Av.

1168

Pliers for crimping OETIKER clips

Pliers for CAILLAU clips

29

REMOVAL

Remove the gaiter from the gearbox side, referring to the method below.

Unclip the small clip using tool T. Av. 1168.

98825R

93033R

29-10

GE 86 seal

DRIVESHAFTS


Saw the existing large clip taking care not to damage the channel of the stub axle cup.

REFITTING

Empty the content of the grease sachet into the gaiter and into the stub axle cup.

29

Cut the gaiter

93034S 93035S

NOTE : the amount of grease, given in the

"Consumables" chapter must be complied with.

Push the gaiter and insert it correctly into the channel of the stub axle cup and then into the tube channel.

Remove as much grease as possible.

93036S

29-11

93037S

GE 86 seal

DRIVESHAFTS


29

Position the ends of the gaiter.

93038S

92305R1

Work the seal by hand to check that both ends are correctly positioned and to expel the air.

Fit the clips and tighten them with the tool corresponding to the type of clips supplied in the kit

(CAILLAU or OETIKER).

29-12

AC 1700 seal

DRIVESHAFTS


29


T. Av.

1256

T. Av.

1168



A driveshaft can be partially repaired on the wheel side:

replacing the seal,

replacing the gaiter.

CONSTANT VELOCITY JOINT ON THE WHEEL END

5

6

7

A

3

4

1

2

Stub axle cup

Balls

Ball cage

Locking ring

Driveshaft

Gaiter

Ball hub

ABS ring (option)

78616R

REFITTING

Put onto the shaft:

the small collar,

the gaiter (3).

Insert the ball seal (1) fitted with its locking ring

(new) on the splines of the shaft until it presses up against the shaft grooved section (B).

98824R

REMOVAL

Cut the clips and the gaiter along the whole length.

Remove as much grease as possible

Move the locking ring (7) and simultaneously tap the front face of the ball hub several times with a mallet (5).

Then separate the seal from the driveshaft.

78615R2

29-13

AC 1700 seal

TRANSMISSION


Empty the contents of the grease sachet into the gaiter and into the stub axle cup.



Insert the lips of the gaiter into the channels of the cup (1) and the driveshaft (5).

29

98824R

Fit the clips and tighten them with the tool corresponding to the type of clips supplied in the kit

(CAILLAU or OETIKER).

29-14

AC 1700 and GE 86 seals

CAILLAU CLIP

DRIVESHAFTS


T.Av. 1168



29

DI2903

NOTE : CAILLAU

clips cannot be reused.

93039R 93040S

29-15

AC 1700 and GE 86 seals

OETIKER CLIPS

DRIVESHAFTS


T.Av. 1256



29

96048S

POSITION 1

- Precrimping and positioning the clip

Put the connecting bar (A) in the lower notch and close the pliers fully. The precrimped clip slides onto the gaiter and can be positioned.

DI2901

POSITION 2

- Crimping

DI2902

Put the connecting bar (A) in the upper notch and close the pliers fully.

29-16

RC 490 seal

DRIVESHAFTS

Gaiter on gearbox end

SEAL ON RIGHT HAND DRIVESHAFT

T.Av. 1034


Pliers for crimping driveshaft clips

1 Yoke

2 Spider

3 Metal retaining cover

4 Rubber gaiter

5 Retaining clip

6 Driveshaft

7 Metal insert

Cut the retaining clip and the gaiter along its whole length.

29

REMOVAL

Unclip the three points of the metal cover with the pliers.

92303R

Remove as much grease as possible

Ease off the metal retaining cover.

92045S

92046S

92044S

29-17

RC 490 seal

Remove the yoke.

DRIVESHAFTS


29

Never using thinners for cleaning these components.

With a press, extract the triaxe component by using a

FACOM U53G

type extractor tool.

NOTE : as the yoke does not have a stop tab, it can be removed without using force.

Do not remove the rollers from their respective journals since the rollers and the needles match each other and should never be interchanged.

Remove the circlips (depending on the model).

89145S

90388S

REFITTING

Lubricate the driveshaft and slide on:

a new retaining clip,

the rubber gaiter (4) with the metal insert (7) and the metal retaining cover (3).

90387S

29-18

92048-1R

RC 490 seal

DRIVESHAFTS


Refit the triaxe component onto the splined shaft.

29

Distribute the quantity of grease into the gaiter and yoke.



Position:

the gaiter and its metal insert into the metal retaining cover,

the metal retaining cover by sliding it up until it touches the guide plate on the yoke.

In this position, form three crimps in the holes designed for this purpose on the guide plate.

90389S

Replace the retaining circlips or make three crimping points at 120

°

by pressing the metal from the splines onto the driveshaft.

Insert a blunt rod with a rounded end between the gaiter and the shaft in order to expel the air inside the seal.

92050S

Grease the yoke and engage it onto the triaxe component.

90391S

29-19

RC 490 seal

DRIVESHAFTS


29

92051R

Extend or shorten the seal until it reaches a length of A = 156

±

1 mm

(dimension between the end of the gaiter and the machined face of the largest part of the yoke).

In this position, remove the rod

Fit the clip onto the gaiter and tighten it using tool T.Av. 1034.

88601R

92052R

29-20

GI 62 seal

6

7

4

5

1 and 3 Retaining clips

2 Rubber gaiter

Yoke

Spider

Metal cover

Driveshaft

DRIVESHAFTS


Using pliers, remove each end of the retainer plate (C), then remove the yoke.

29

REMOVAL

Cut the crimped clip and the gaiter along its whole length.

Remove as much grease as possible.

98823R 74655R

Do not remove the rollers from their respective journals since the rollers and the needles match each other and should never be interchanged.

Never use thinners to clean these components.

Depending on the assembly, remove the circlips

75936-1S1

29-21

90387S

GI 62 seal

DRIVESHAFTS


With a press, extract the triaxe component by using an extractor tool.

29

Replace the retaining circlips or make three crimping points at 120

°

by pressing the metal from the splines onto the driveshaft.



90388S

REFITTING

Lubricate the driveshaft and slide on the new ring and gaiter.

Refit the triaxe component on the splined shaft.

90391S

Put a shim (B) of thickness 2.5 mm, manufactured according to the following diagram, between the retainer plate and the yoke.

90389S

29-22

74867R1

GI 62 seal

DRIVESHAFTS


With a copper hammer, carefully put the plate into its original position, then remove the shim (B).

29

Insert a blunt rod with a rounded end between the gaiter and the shaft in order to expel the air inside the seal.

Extend or shorten the seal until it reaches a length of A = 153

±

1 mm

(dimension between the end of the gaiter and the machined face of the largest part of the yoke).

74867R

Position the lips of the gaiter in the grooves of the driveshaft and on the metal cover.

90390R

In this position, remove the rod and fit the retaining clip.

Tighten it with tool T. Av. 1034.

98823R1

88601R

29-23

GI 69 seal

DRIVESHAFTS

Bearing gaiter

T.Av. 944


Mandrel for fitting bearing onto shaft

REMOVAL

Never use thinners to clean these components.

Depending on the assembly, remove the circlips

29

With a press, extract the triaxe component by using a

FACOM U53T

type extractor tool.

90387S

Remove the gaiter and bearing assembly in the same way as the triaxe component.

90388S

85933S

29-24

GI 69 seal

DRIVESHAFTS

Bearing gaiter

REFITTING

To be in the correct position on the shaft, the bearing must be fitted so as to obtain a dimension L between the front part of the bearing and the end of the shaft.

L = 118

±

0.2 mm (JB1 gearbox)

L = 123.2

±

0.2 mm (JB3 gearbox)

This dimension is obtained using tool T.Av. 944 when its end is level with the shaft.

29

86197S

85884-1R1

To avoid damaging the bearing which contains a lip seal, therefore to avoid the risk of leaks, do not fit the bearing using a hammer but instead use a press which provides progressive pressure.

29-25

GI 69 seal

DRIVESHAFTS

Bearing gaiter

In addition, the driveshaft is held in place on the press by channel (G) with a

FACOM U53T

type tool to avoid damaging the seal on the wheel side.

29

86198R

Fit the triaxe component onto the splined shaft and refit the retaining circlips (depending on assembly).

29-26

Transmission CLUTCH MANUAL GEARBOX

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Scenic 2 Transmission & Gearbox