2004 Citroen XSARA PICASSO Switch

Downloaded from www.Manualslib.com manuals search engine 303
CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

Downloaded from www.Manualslib.com manuals search engine 307
CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
Features.
This gearbox:
has no adjustment.
has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.
Oil capacity : 2 ± 0,15 Litres.
Checking the oil level : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

Downloaded from www.Manualslib.com manuals search engine 308
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

Downloaded from www.Manualslib.com manuals search engine 309
CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Operations on electrical components.Do not disconnect:
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
When carrying out electrical checks: The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
Before disconnecting connector, check: The condition of the various contacts (for deformation, corrosion, etc).
The presence and the status of the mechanical unlocking.
Driving the vehicle.
IMPERATIVE:
Never move the vehicle with the ignition switched off.
Never push the vehicle to attempt to start it
(impossible with a piloted
manual gearbox).
Towing.
Conditions for towing.
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on theseriousness of the fault.
If a gear is engaged,the conditions for immobilisation of the
vehicle are:
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
In these conditions are met, you can lift the front of the vehicle to tow it.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it:
Engage «N», using a diagnostic tool.
Engage «N», without using a diagnostic tool.
Engines: HFX KFV NFU 8HX
C2

Downloaded from www.Manualslib.com manuals search engine 310
CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Engaging of «N», using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12.5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicle’s diagnostic socket.
From the diagnostic tool menus, select:
«DIAGNOSIS»
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N(neutral).
NOTE:The letter «N»should appear on the instrument panel.
If not, see the following solution:
Engaging of
«N», without using a diagnostic tool.
Engaging of «N», without using a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
NOTE:This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage b via the diagnostic toolhas failed.
Engines: HFX KFV NFU 8HX
C2

Downloaded from www.Manualslib.com manuals search engine 315
CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws):2,2 ±0,2
(27)
Gearbox input speed sensor(1 screw): 0,8 ± 0,2
(28)
Reverse gear switch(1 screw): 2,5 ± 0,5
(29)
Drain plug(1 screw): 3,3 ± 0,3
(30)
Level plug(1 screw): 3,3 ± 0,3
B2CP3SUD
C2

Downloaded from www.Manualslib.com manuals search engine 320
CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: 6FZ RFN RFS WJY 8HV 8HY 8HZ 9HZ 9HY RHY RHZ
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 screws): 1,25 ± 0,2
(24)
Clutch housing (13 screws): 1,3 ± 0,2
(25)
Primary shaft nut (1 screw):7,25 ± 0,5
(26)
Secondary shaft nut (1 screw): 6,5 ± 0,5
(27)
Yoke retaining screw (2 screws): 1,5 ± 0,2
(28)
Differential gearwheel screw (2 screws): 6,5 ± 0,5
Reverse gear switch (1 screw): 2,5 ± 0,3
(29)
Differential housing (4 screws): 5 ± 0,5
(30)
Breather pipe:1,7 ± 0,2
(31)
Rear housing cover screws (7 screws):1,25 ±0,2
(32)
Topup plug (1 screw):2,2 ±0,2
(33)
Differential housing screws (4 screws):1,25 ±0,2
(34)
Drain plug (1 screw):3,5 ±0,3
B2CP3BRD
C3 XSARA XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine 332
CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
Precautions to be taken.
Towing.
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised:
IMPERATIVE: Put gear lever in position «N».
Do not add any oil.
Do not exceed
30 mphover a distance of 30 milesof maximum.
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it
(impossible with an automatic gearbox).
NOTE:The automatic gearbox is only lubricated when the engine is
running.
Repairs on electrical components.
Do not disconnect:
The battery when the engine is running.
The ECU when the ignition is switched on.
Before reconnecting a switch,check: The condition of the various contacts (for deformation, corrosion etc).
The presence and condition of the mechanical locking.
When performing electrical checks: The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
C3 XSARA XSARA PICASSO