Page 345 of 2492
MANUAL GEARBOX
5th gear on the vehicle
21
Release and remove the primary shaft nut and the
secondary shaft bolt (65).
Put the gearbox in neutral. 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.
93912-1R
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
On the primary shaft :
Remove the 5th gear fork and the sliding gear, ta-
king care not to pull the 5th gear pin outwards.
Extract the synchro hub using tool B.Vi. 1170.
93190S1
21-20
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MANUAL GEARBOX
5th gear on the vehicle
21
On the secondary shaft:
Remove the shouldered washer (64).
PRG21.1
Extract the fixed gear using B.Vi. 28-01 fitted with
its claws B.Vi. 1007.
88575R
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
Loctite FRENBLOC to the hub and
replace the sliding gear hub and fork assembly.
Fit the synchro ring bosses in the lugs on the hub.
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
Loctite FRENBLOC:
- 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
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 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
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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
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MANUAL GEARBOX
Speedometer drive gear
REPLACEMENT
1st case :
Only the speedo gear or the pin is damaged.
REMOVAL
The gearbox does not have to be completely dis-
mantled.
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 hou-
sing.
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.
21
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.
88577S
86053S
Correct Incorrect
21-26
Page 352 of 2492
AUTOMATIC TRANSMISSION
Section view
23
TYPE AD4 AUTOMATIC TRANSMISSION
DI2302
23-1