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MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Position the driveshaft with respect to the sun-
wheel, 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.IMPORTANT
Fit the bolt (V) and the starter motor centring do-
wel (D) correctly :
E and K engines
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. E and K
engines
86070R3
Reconnect the speedo cable, ensuring that the clip
is the correct way round.
92108-1S
74937-4S
Tighten all nuts and bolts to the recommended
torques.
Fill the gearbox with oil.
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Page 338 of 2492
MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
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.
Disconnect:
- the wires from the starter motor,
- the reversing light switch,
- the speedo cable.
Remove the engine/gearbox mounting nut. F
engine
98749R1
Remove the 2 bolts (H) from the engine-gearbox
tie-rod.
98902R
Slacken the 2 mounting bolts (C) on the engine
from the engine-gearbox tie-rod.
85812-1R
85966R1
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Page 339 of 2492
MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Remove :
- the air filter sleeve,
- the tie-rod from the shock absorber turret,
- the clutch cable. Slacken but do not remove bolt (B) then remove
mounting bolt (C) from the suspended engine
mounting rod.F
engine
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
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MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Remove the heat shield. Remove the upper mounting assembly on the
gearbox end .F
engine
Remove :
- the bolts around the gearbox,
- the starter motor,
- the connectors linked to the gearbox.
Remove the exhaust downpipe.
98827S
98865R2
Remove gear lever return spring.
Move and secure the gear lever towards the rear.
99309S1
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Page 341 of 2492

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Remove the steering box mounting bolts.F
engine
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
98836R1
97390-1R1
Remove the horn.
From above:
Secure the cooling assembly to the upper cross
member.
Remove the upper mounting bolt from the bum-
per then the bolts located in the wheel arches. Release the steering box and the steering column
(be careful not to damage the clip (C)).
ATTENTION :
to prevent any damage being done to the rota-
ting switch under the steering wheel, please fol-
low 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 under-
take this work.
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MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
F
engine
86308R2
86415S
Position the sub-frame support trolley and lower
the vehicle.
Remove the sub-frame by loosening the 4 moun-
ting bolts.
Be careful not to forget to remove the power as-
sisted steering pipe mounting from the sub-
frame.
Under the vehicle :
- position the component jack under the gearbox
without lifting it,
- release the gearbox and the engine by remo-
ving the studs (C).
98755R1
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 re-
moval operations in reverse.
REFITTING
Coat the sides of the guide tube and the fork pads
with
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 engine-
gearbox are present and are in the correct posi-
tion.
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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.
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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