Page 344 of 2492

MANUAL GEARBOX
5th gear on the vehicle
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.
Drain the gearbox
The rear housing must be removed along the hori-
zontal axis of the gearbox since it contains a lubri-
cation nozzle (A) which enters the primary shaft.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 safe-
ty, engage a gear (3rd or 4th).
Removing the pin can be made easier by slightly
bending the pin of toolB.Vi. 31.01 in order to
prevent the gearbox being lifted.
TIGHTENING TORQUES (In daN.m)CONSUMABLES
SPECIAL TOOLING REQUIRED
B.Vi.28-01 Extractor body
B.Vi.31-01 Set of pins for extracting and
fitting 5 mm diameter roll pins
B.Vi.1003 5th gear hub extractor
B.Vi.1007 Claws for B.Vi. 28-01
21
87180R85979R
Loctite FRENBLOC :
Primary shaft nut
Secondary shaft bolt
5th fixed gear
5th gear hubPrimary shaft nut 13.5
Secondary shaft bolt 6.3
21-19
Page 348 of 2492
MANUAL GEARBOX
Differential output seal
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.Remove :
- the track rod end (tool T.Av. 476),
TIGHTENING TORQUES (in daN.m)
Brake caliper mounting bolt 2.7
Shock absorber base mounting bolts 17
Track rod end 3.5
Wheel bolts 9
CONSUMABLES
SPECIAL TOOLING REQUIRED
Loctite FRENBLOC :
Brake caliper mounting bolt
RHODORSEAL 5661 (Eg. CAF 4/60 THIXO) :
Ends of driveshaft pins
MOLYKOTE BR2 :
Right hand sunwheel splines
21
B.Vi.31-01 Set of pins
T.Av.476 Ball joint extractor
B.Vi.945 Mandrel for fitting differential seals
B.Vi.1058 Mandrel for fitting differential seals
(JB3 tapered bearings)
91755R
85965R
21-23
Page 360 of 2492

Strainer mounting bolts 0.5
Sump mounting bolts1
Mounting bolts for engine mounting
dampers on side member2
Rear support mounting bolts6.5
Wheel bolts9
Strainer mounting bolts0.5
Distributor mounting bolts0.5
AUTOMATIC TRANSMISSION
Hydraulic Distributor
23
REMOVAL
Put the vehicle on a 2 post lift.
Put the lever in the "P" (Park) position.
Drain the automatic transmission (mechanismsec-
tion;
drain plug with triangular socket).
Remove:
- the expansion bottle,
- the air filter,
- the two upper bolts (A) of the engine moun-
ting damper and slacken the other two (B), wi-
thout removing them.
TIGHTENING TORQUES (In daN.m)For versions with ABS
Remove the mounting nut (C) from the ABS
electro-pump assembly on the rubber mounting.
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
94933R
94887S
23-9
Page 366 of 2492
SPECIAL TOOLING REQUIRED
Mot. 1040-01Dummy cradle for removing-
refitting the engine and
transmission assembly
Mot. 1202Hose clamp pliers
Mot. 1311-06Tool for removing fuel pipes
TIGHTENING TORQUES (in daN.m)
Sub-frame front mounting bolts6
Sub-frame rear mounting bolts11
Shock absorber upper cup mounting bolts3
Wheel bolts9
Brake caliper mounting bolts3.5
Steering universal joint mounting bolt3.5
Nut for mounting rubber engine mounting
onto front left side-member mounting4.5
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,
AUTOMATIC TRANSMISSION
Automatic transmission (Removal - Refitting)
23
K7M
ENGINE
- the left and right hand mudguards,
98710S
- the sub-frame-body tie-rods,
- the brake calipers and secure them to the body,
- the front bumper,
REMOVING FROM UNDERNEATH
PRG23.1
23-15
Page 373 of 2492
AUTOMATIC TRANSMISSION
Differential output seal
23
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.
95791-2R
REMOVAL
Drain the final drive and remove the shield, as ex-
plained 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, coun-
ting the number of turns it takes.Replace the O-ring on the nut, cleaning the seat
properly and lubricating the new seal with final
drive oil.
95791-6R
23-22
Page 382 of 2492
DRIVESHAFTS
Driveshafts
29
94338-1R
REMOVAL
Remove:
- the brake assembly (suspend it from the chas-
sis so as not to damage the brake pipe),
- the driveshaft nut: tool Rou. 604-01.
SPECIAL TOOLING REQUIRED
Rou. 604 -01 Hub immobiliser
T.Av. 476 Ball joint extractor
T.Av. 602 Driveshaft puller
T.Av. 1050-01 Hub extractor
B.Vi. 31-01 Roll pin punch
Driveshaft nut 25
Gaiter mounting bolt on gearbox 2.5
Wheel bolt 9
Shock absorber base nut 17
Brake caliper mounting bolt 10
Track rod end nuts 3.5
TIGHTENING TORQUES (in daN.m)
85678R1
Left hand side
Drain the gearbox.
Remove the three bolts
91755R
Right hand side
Remove the pin: tool B.Vi. 31-01.
29-2
Page 1538 of 2492

MECHANISMS OF OPENINGS OTHER THAN SIDE DOORS
Hydraulic system reservoir
52
PRE5205
RR R R
EE E E
MM M M
OO O O
VV V V
AA A A
LL L L
RR R R
EE E E
FF F F
II I I
TT T T
TT T T
II I I
NN N N
GG G G
Coat the O-ring with hydraulic oil.
Fit the seal in the oil reservoir groove.
Position the reservoir on the pump.
Tighten the bolts (2) to a torque of 7 N.m.
II I I
MM M M
PP P P
OO O O
RR R R
TT T T
AA A A
NN N N
TT T T
:: : :
the hood must be closed when the
hydraulic system is filled.
Fill the reservoir with
EE E E
SS S S
SS S S
OO O O
UU U U
NN N N
II I I
VV V V
II I I
SS S S
JJ J J
22 2 2
66 6 6 oil (capaci-
ty 0.75 l).
The oil level must be between the MINIMUM and
MAXIMUM marks.
The hydraulic system is of the "AUTOMATIC
BLEED" type. The oil level
MM M M
UU U U
SS S S
TT T T
be checked with
the hood open, hood cover closed.
Check the oil level and top up if necessary.
Switch on the ignition, apply the handbrake.
Operate the hood switch.
Open and close the hood several times.
The bleeding process is completed when move-
ment is regular and without jolts with a constant
level of pump noise. Remove:
- the filler bolt (1) and drain,
- the reservoir mounting bolts (2).
12297-1R
52-16
Page:
< prev 1-8 9-16 17-24