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 349 of 2492
MANUAL GEARBOX
Differential output seal
- the two mounting bolts (A) of the brake assem-
bly.
Secure the caliper to the suspension spring to pre-
vent 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 sun-
wheel.
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).
METHOD
Put the oiled protector (A) onto the sunwheel and
position the oiled seal (C) with the tool (B).
90149R1
86031S
86095R
86122R
2.7 daN.m
21-24
Page 350 of 2492
MANUAL GEARBOX
Differential output seal
Continue in the same way but using tool B.Vi.
1058 and protector (A) of B.Vi. 945.
21
Fit new roll pins and seal the ends with
RHODORSEAL 5661 (Eg. CAF 4/60 THIXO).
Tighten the nuts and bolts to the recommended
torques.
Refit the brake caliper and coat the bolts with
Loctite FRENBLOC.
Fill the gearbox with oil.
Fit the O-ring to the sunwheel and coat the splines
with grease N° 20.
Position the driveshaft with respect to the sun-
wheel.
Pivot the stub-axle carrier, engaging the drives-
haft into the sunwheel using pin B.Vi. 31-01 to
align the holes.
92111R
74937-3S
21-25
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 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 388 of 2492
DRIVESHAFTS
Driveshafts
29
With the vehicle on its wheels, remove the card-
board protectors by tearing them in accordance
with the diagram. On both sides
Position the brake calipers, coat the bolts with
Loctite FRENBLOC and tighten to the correct tor-
que.
Lower the vehicle back down onto its wheels.
91693R
91631S
91633S
91632R
And never use a sharp object which might "da-
mage" the gaiter.
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.
29-8
Page 1521 of 2492
SIDE DOOR MECHANISMS
Front door window mechanism
51
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
Secure the motor and engage the toothed wheel.
Connect the motor and operate the window
mechanism.
Position the stop (1) at the marks and tighten it.
Refit the window mechanism - window assembly.
The tightening torque for all of the bolts is 8 N.m.
AA A A
DD D D
JJ J J
UU U U
SS S S
TT T T
MM M M
EE E E
NN N N
TT T T
See section 54.
51-3