Page 317 of 2492
CLUTCH
Fault finding
20
The gearbox clunks in 1st or
reverse gear only when
cold:
- vehicle stationary,
- engine running.
Check the grade
of the
gearbox oil
INCORRECT
Change the oilCheck the internal
parts of the gearbox
CORRECT
20-7
Page 332 of 2492
MANUAL GEARBOX
Diagnostic
21
Abnormal noises when driving
• Stop the vehicle
• Engine running
• Gear lever in neutral
Check
driveshafts
Check
wheel
bearingsReplace the
driveshafts
Replace the
wheel bearings
CorrectIncorrect
CorrectIncorrect
The noise
stops
Yes
Check the thrust
pad, cable and
plate
Replace the faulty
parts
The noise
stops
Look for the
noise in the
engine
Amount
of clearance
Check the toothed
sector of the clutch
pedal and the
cable
Oil level
YesNo
CorrectIncorrect
No
Look for the noise in
the engine
Remove the gearbox
and repair it
The noise
stops
Yes
No
Clutch fully depressed
Remove the
gearbox and
repair it
21-7
Page 343 of 2492
MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Position the driveshaft with respect to the sun-
wheel, 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. F engine
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 and tighten to the correct torque.
Press the brake pedal several times to bring the
pistons back into contact with the brake pads. F
engine
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.
92661S
74937-4S
Tighten all nuts and bolts to the recommended
torques.
Fill the gearbox with oil.
21-18
Page 347 of 2492
MANUAL GEARBOX
5th gear on the vehicle
21
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.
90498-1S
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.Fit the rear housing by engaging nozzle (A) into
the primary shaft.
Tighten the mounting bolts to a torque of 2.4
daN.m.
87180R
Fill the gearbox with oil.
Check that the rear housing does not leak when
the engine is running.
21-22
Page 357 of 2492

AUTOMATIC TRANSMISSION
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
NOTE :if the automatic transmission is replaced, only check the oil level since the transmission is supplied by
the Parts Department full of oil.
TOTAL volume
MECHANISM
5.7 l
FINAL DRIVE1 l
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
Page 359 of 2492

Oil pressure
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 am-
bient temperature.
2-Start the engine with the selector lever in the
Park position.
3-Connect the
XR25 test kit and enter:
D14then
#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 rea-
ched, 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.
AUTOMATIC TRANSMISSION
Filling - Levels
23
FILLING - TOPPING UP
Filling is performed though tube (D).
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:
94845R1
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 compu-
ter.
94845-1R
23-8
Page 365 of 2492
AUTOMATIC TRANSMISSION
Hydraulic Distributor
23
On versions with ABS
Refit the mounting nut
(C) from the ABS electro-
pump unit on the rubber mounting.
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 re-
placed or removed, replace the modulating sole-
noid valve filter, the strainer and its seal.
23-14
Page 370 of 2492

AUTOMATIC TRANSMISSION
Automatic transmission (Removal - Refitting)
23
K7M
ENGINE
Separate the gearbox from the engine by :
- removing the starter motor,
- removing the bolts from the automatic trans-
mission sump.
Remove:
- the hoses on the exchanger, Lift the engine from the sub-frame.
91131S
- the converter bolts
- the bolts around the gearbox and the TDC sen-
sor.
Separate the automatic transmission from the en-
gine.
REFITTING (special notes)
Refit the converter by positioning it with respect
to the mounting bolts.
Tighten the bolts around the automatic transmis-
sion.
Refitting is the reverse of removal.
Aligning the engine sub-frame with the body will
be made easier by positioning two approximately
100 mmlong threaded rods in the two front sub-
frame-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 re-
commended torque.
Fit the caliper mounting bolts using Loctite
FRENBLOC and tighten them to the correct tor-
que.
Press the brake pedal several times to bring the
pistons back into contact with the brake pads.
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