2. Transmission AD4

77 11 190 841 NOVEMBER 1996 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".

All copyrights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority ofRenault.

C Renault S.A. 1988

Transmission

CLUTCH

MANUAL GEARBOXES

AUTOMATIC TRANSMISSION

DRIVESHAFTS

EXPLODED VIEW

PRD2013

21-121-221-521-721-8

21-821-9

21-2321-2921-32

Contents

Pages

23-2323-2423-2523-2623-2723-29

23-2923-2923-3023-3123-3223-3323-3423-36

23-4123-5723-5823-6023-6123-6223-6323-6423-6523-66

AD4 automatic transmissionExploded viewUseIdentificationGear ratiosGear change thresholdsConsumablesParts which must be changedautomaticallyOilOil drain intervalsOil drainingFilling - LevelsOil pressureChanging the strainerHydraulic distributorAutomatic transmission (Removal -Refitting)Full-load validationLoad potentiometerComputer (119)Line pressure sensor (8)Multifunction switch (485)Vehicle speed sensor (250)Solenoid valveEngine torque reductionSpecial features

AUTOMATIC TRANSMISSION23

Transmission

CLUTCH

IdentificationSide viewsExploded viewConsumablesMechanism - Clutch plateThrust pad - Fork

20

20-120-420-420-520-6

20-10

IdentificationGear ratiosCapacities - LubricantsSpecial featuresConsumablesParts which must be changedautomaticallyGearbox (Removal - Refitting)5th gear linkage in situDifferential output sealSpeedometer drive

MANUAL GEARBOXES21

29-129-229-9

29-1929-26

ConsumablesDriveshaftsGaiter at wheel endGaiter at gearbox endGaiter - bearing assembly

DRIVESHAFTS29

Pages

23-123-223-323-423-523-6

23-6

23-7

23-823-1123-13

23-15

MB automatic transmissionExploded viewUseIdentificationGear ratiosGear change thresholdsConsumablesParts which must be changedautomaticallyOilDraining - Filling - LevelsChecking and adjusting thepotentiometerOil pressureStrainerAutomatic transmission (Removal -Refitting)

AUTOMATIC TRANSMISSION23

76907S 90693R1

CLUTCHIdentification 20

ENGINE

TYPEMechanism Plate

180 CP 3300

F2N

F3N

B = WhiteGB= Blue greyV = Green

76906R90693R85873S

2000 CP 4000

C1G

C1J

C2J

C3J

E6J

26 splinesE = 7.7 mmD = 181.5 mm

76906R

26 splinesM = 6 pale pink springsE = 7.7 mmD = 200 mm

20-1

F8Q


ENGINETYPE

MECHANISM CLUTCH PLATE

200 CP 4400 R = 4 red springsJ = 4 yellow springs

76906R93813R76907S

F7P

26 splinesD = 200 mmE = 7.7 mm

76906R90693G1

200 CPV 3500 R = RedJ = YellowV = Green

76907S


Special feature: 2 additional springs on the hub.

20-2

F8Q

Turbo


ENGINETYPE

MECHANISM CLUTCH PLATE

76906R90693-2G2

200 CPV 4400 J = 4 yellow springsG = 4 grey springs

76907S


Special feature: 2 additional springs on the hub.

20-3

PRD2012

DI2001

CLUTCHSide view 20

Single plate, dry, clutch, cable operated.

Diaphragm spring clutch plate.

Clutch plate with rubber hub.

Self-centring, guided, ball type thrust pad inconstant contact.

Automatic wear take-up mechanism.

Exploded view

20-4

CLUTCHConsumables 20

Type Pack size Unit

MOLYKOTE BR2 1 kg tin

Right hand sunwheel splines

Shaft splinesFork pivotRelease bearing guideFork pads

RHODORSEAL 5661 100 g tube Ends of driveshaft roll pins.

LOCTITE 518 24 ml syringe Housing assembly faces.

Clutch

20-5

CLUTCHMechanism - Clutch plate 20

ALL TYPES

IMPORTANT PRECAUTIONS WHICH MUST BEFOLLOWED WHEN REPAIRING THE CLUTCH

In order to improve the sliding of the clutchplates, their hubs are nickel-plated.

Clean the clutch shaft splines and refit the assem-bly without any lubricant.

Special features of "diesel" clutch plates

These are fitted with a damping pre-hub which ismost efficient when its internal units are dry.

20-6

CLUTCHMechanism - clutch plate

REFITTING

Degrease the flywheel mounting face.

Use the plastic locating device supplied in the kitto fit the plate.

20

REMOVAL

Fit locking sector Mot. 582.

Remove the mounting bolts from the mechanismand remove the unit and the clutch plate.

Check and change the faulty parts.

92170R

CHANGING

This operation is carried out after the gearbox has been removed.

ESSENTIAL SPECIAL TOOLS

Mot. 582 Locking sector

Plus the tools required to remove the gearbox

TIGHTENING TORQUES (in daN.m)

7 mm diameter unit securing boltsfor 180 mm diameter clutch 1.88 mm diameter unit securing boltsfor 200 mm diameter clutch 2.5

94135S

20-7

CLUTCHMechanism - clutch plate 20

Gradually screw up then torque tighten the boltssecuring the mechanism.

Remove locking sector Mot. 582.

Coat the bore of the thrust pad, guide tube andclutch shaft splines with grease MOLYKOTE BR2 .

74413R

20-8

CLUTCHMechanism - clutch plate 20

REMOVAL

F engines

Degrease the crankshaft bore which receives the centring bush.

Coat the external diameter of the bushing with Loctite FRENBLOC.

Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore.

Observe the direction of fitting of the bush and check that it is fitted correctly.

C and E engines

The centring bush will not be used for these engines.

94235S

20-9

CLUTCHThrust pad - fork

Ensure that the assembly slides properly.

NOTE: when carrying out operations which do notrequire removal of the gearbox or after fitting thegearbox, DO NOT RAISE the fork as there is a riskof it lifting out of catch (A) on the thrust pad.

20CHANGING

This operation is carried out when the gearboxhas been removed.

REMOVAL

Remove:- the thrust pad by tilting the fork,- the rubber protector, and pull the fork to-

wards the inside of the clutch casing.

REFITTING

Coat the walls of the guide tube and the fork padswith grease MOLYKOTE BR2.

Fit the fork and refit the rubber protector.

Fit the thrust pad on the guide tube, placing catch(A) in the fork.

90300G1

Check the extent of fork travel.

It should be:X = 17 to 18 mm

91830R1

After refitting the gearbox, re-set the toothedquadrant and check that the wear take-up mecha-nism operates correctly.

20-10

MANUAL GEARBOXESIdentification

An identification plate on the clutch housing shows:

At A : the gearbox typeAt B : the gearbox suffixAt C : the fabrication numberAt D : the production factoryAt E : a notch is used when the gearbox has been

assembled with a C or E type engine.

21

87227G

Gearbox typeRepair manual which deals

with the gearbox concerned

JB B.V. JB

JC B.V. JC

X0 0 0J B0 BA

E

D C0 0 0 0 0 0

TWO-COLOUR MARKING

JB0 - JB1 - JB3 - JC5

Two-thirds of the surface are painted with a colour which is peculiar to each gearbox type, enabling the gear-box to be matched with the driveshaft.

The remaining one-third of the surface is painted with a specific colour according to the gearbox suffix.

JB4 - JB5

Two-colour marking (green and pink) in the form of two bands of equal width.

90775

21-1

MANUAL GEARBOXESGear ratios 21

JB0

Index Vehicle

017B531 - B532 - B537C531 - C532L531 - L532 - L537

019 B534L53H

023 B530 - C530 - L530S530

035 B53W - C53WL53W

Final driveset

Speedodrive set

1st 2nd 3rd 4th Reverse

5716

5615

5815

6115

1921

2831

4321

3728

3911

264111

JB1

Index Vehicle

023 B532 - C532 - L532B535 - C535 - L535

025

B530 - C530 - L530S530 - B537 - C537L537 - S537 - B53AC53A - B53G

027 B53HL53H

029 L53G

034 B531 - C531 - L531

047 B53W - C53W L53W

070

B530 - C530 - L530S530 - B535 - C535L535 - S535 - B537C537 - L537 - B53AC53A - L53A

5815

6115

5815

6115

1921

2930

3139

4321

3728

3911

264311

JB4

Index Vehicle

000 B530 - C530 - L530S530 - C531

006 B531 - L531B53P - C53P - L53P

Final driveset

Speedodrive set

1st 2nd 3rd 4th Reverse

5815

5716 19

212831

3919

3325

3911

264111

5716

6314

6115

1921

2930

3139

4321

3728

3911

264111

1921

2930

3139

4321

3728

3911

264511

Final driveset

Speedodrive set

1st 2nd 3rd 4th 5th Reverse

21-2

3911

26

3911

26

3911

26

3911

26

3911

26

Final driveset

Speedodrive set



JB3

Index Vehicle

059 B533 - C533 - L533D53C

027

B533 - C533 - L533B53C - C53C - L53CD53CB53M - C53M

062

353A - 453A - 553A853AB53C - D53C - L53CB53Y - D53Y - L53Y

094B538 - C538 - L538B53F - C53F - L53FS53C - S53D

095

353C - 453C - 553C853C - 353D - 453D553D - 453H - 553HB538 - C538 - L538S53C - S53D

037

B538 - C538 - L538B53C - C53C - D53CL53C - B53F - C53FL53F - B53Y - L53Y

071 B53D - C53D - L53D

083 B53D - C53D - L53D

060

B533 - L533 - B53BC53B - L53B - B53I -C53I - L53I - B53J -C53J - L53J - S53J

061 B533

067353A - 453A - 553A853A - B53Y - C53YD53Y - L53Y

047 B53BB53Y - C53Y - L53Y

6115

1921

2930

3141

4122

3728

3411

6115

1921

2930

3141

4122

3728

3411

1921

3534

2834

4122

3728

3411

5914

5716

1921

2930

3139

4322

3728

4111

5815

5516

1921

2930

3139

4321

3728

4111

21-3

3911

26

3911

26


JB3

Index Vehicle

017 L532

051 B539 - C539 - B53DC53D - D53D - L53D

044B539 - C539 - L539B53D - C53D -D53D - L53D

031 B533 - B536 - L536

053 B53D - C53D - L53D

028

B532 - B533 - L533C534 - L534 - S534B53B - C53B - L53BB53C - L53C - B53EC53E - B53I - C53I -L53I - B53J - C53J -L53J - S53J

6115

1921

2930

2533

3519

3325

3411

1921

2930

3139

4321

3728

4111

5716

3911

265815

1921

2930

3139

4321

3728

3411

3911

266115

1921

3534

2834

4122

3728

3411

JB5

Index Vehicle

006 B531 - C531 - L531B53P - C53P - L53P

000 B530 - C530 - L530S530

5716

6115

1921

2930

3919

3325

3911

264111

1921

2930

3919

3325

3911

264111

Final driveset

Speedodrive set


2734

2734

JC5

Index Vehicle

002

B532 - C532 - L532B53K - L53K - S53KB53T - C53T - L53TB53Z

5617

1921

3435

4321

3728

3911

264111

3141

Final driveset

Speedodrive set


Final driveset

Speedodrive set


21-4

MANUAL GEARBOXESCapacities - Lubricants

CAPACITY (in litres)

21

CHECKING THE LEVEL

Fill to the level of the opening.

92081R

4-speed gearbox

JB0JB2 3.25

5-speed gearbox

JB1JB3 3.40

JB4 2.75 JB5 2.90

JC5 3.10

There are two ways of checking the level.

Plug (A) without dipstickWipe the dipstick section.

Refit the plug, without screwing it up, with thedipstick pointing downwards.

Remove the plug, the level should be on the boss(2).

DI2123

Plug (B) with dipstick

OIL VISCOSITY GRADE

Tranself TRX 75/80 W

21-5

MANUAL GEARBOXESLubricants 21

Precautions (TRX and TRZ oils)

"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in orderto prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and resultin seizure of the gearbox or of the final drive.

STORAGE AND USE

Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of mate-rials or water.

In particular:

Storing oil cans

The cans must be stored:- sheltered from bad weather (rain, snow, outside splashes),- in a dry area (avoid storing in the vicinity of a washing area),- tightly sealed.

Storing units (gearbox or final drive)

When storing a gearbox or final drive which has not been drained, close the air inlets.

Store the unit in a dry area.

Using the oil

The oil cans must be resealed each time they have been used.

In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil intoa larger container.

When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil.

The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time.

Washing under pressure (of the vehicle or of a unit)

Close the gearbox and final drive breather.

If the gearbox is removed, correctly close all of the openings to prevent the entry of water.

21-6

MANUAL GEARBOXESSpecial features

GEAR CHANGE PATTERN

The gearboxes of the following types:JB0JB4JB2

JB1JB3 5 forward gearsJB5 1 reverseJC5

are fitted with BORG-WARNER synchronisers.

To select reverse, raise ring (A) and move the le-ver.

21

R 1 3 5

2 4

DI2118

4 forward gears1 reverse

21-7

MANUAL GEARBOXESConsumables 21

Parts which must be changed automatically

When they have been removed:- the lip seals,- the O-rings,- the thrust pad guide tubes,- the secondary shaft and differential nuts,- the speedometer gear and its shaft,- the speedometer crown wheel,- the roll pins,- the bushes under the gears.

TYPE PACK SIZE UNIT

MOLYKOTE BR2 1 kg sachet

Clutch fork pivotThrust pad guide tube boreClutch shaft splinesRight hand sun wheel splines

Loctite 518 24 ml syringe Housing joint faces

LOCTITE FRENBLOC 24 cc bottle

5th speed fixed gear5th speed synchroniser hubPrimary shaft nutSecondary shaft bolt

RHODORSEAL 5661 100 g tube Ends of roll pins on driveshaftsScrew threads on switches

21-8

MATERIALS

MANUAL GEARBOXESGearbox (Removal - Refitting)

REMOVAL

The gearbox can be removed alone.

Place the vehicle on a two post lift.

Disconnect the battery.

Remove the front wheels.

On the left hand side of the vehicle

Remove:- the steering tie rod ball joint using tool

T.Av. 476.


B.Vi. 31-01 Set of pin punches

T.Av. 476 Ball joint extractor

21

Brake caliper securing bolts 10Shock absorber lower securing bolts 11Steering ball joint nut 3.5Nut holding key on stub axle carrier 5.5Mounting securing bolts 4 to 5Wheel bolts 8Left hand driveshaft gaiter securing bolt 2.5


Cengines

85965R

- the three bolts holding the driveshaft gaiter,- the two bolts securing the brake caliper and se-

cure the caliper to the suspension spring so asto avoid stretching the hose,

- the protective casing (side).

92122R2

Loctite FRENBLOC

Brake caliper securing bolts RHODORSEAL 5661

Ends of pins on driveshaftsMOLYKOTE "BR2"

Clutch shaft and sun wheel splines

21-9


- the driveshaft - stub axle carrier assembly fromthe lower ball joint,

21Cengines

On the right hand side of the vehicle

Remove the driveshaft roll pins using toolB.Vi. 31-01

90130R2

Remove:- the two bolts (2) securing the base of the shock

absorber,- the nut and key (1),

Check that the driveshaft rollers do not come outmanually. If they do, on reassembly, check thatthe needle bearings have not fallen into the gear-box.

Slacken lower bolt (3) on the base of the shock ab-sorber and remove upper bolt (4).

91758R4

Tilt the stub axle carrier and uncouple the drives-haft.

90311S

91755R

21-10


Slacken:- the two mounting bolts on the engine,- the clutch protection plate,- the gear lever.

21Cengines

92028R2

Under the vehicle, remove bolt (H) from the en-gine - gearbox tierod.

Disconnect:- the starter leads,- the connector on the reversing light switch.

On vehicles fitted with power assisted steering,remove the two clamps securing the powerassisted steering pipes to the gearbox.

Remove:- the air filter unit and its mounting,

- the integral electronic ignition (A.E.I.) sensor,- the bolts from around the gearbox and from

the starter.

92031S

85966R

21-11

MANUAL GEARBOXESGearbox (Removal - Refitting) 21

Lift the engine using a tool specific to this purpose(example: desvil 300B).

89204S

Disconnect:- the clutch cable,

92110S

Petrol engines - all types

Remove:- the front mounting,- the earthing braid.

Cengines

- the speedometer pin and cable.

92108-1R1

92112R

21-12


Remove the three bolts securing the rear centremounting and move it back as far as possible.

92108R1

NOTE: to make it easier to remove the bolts, raisethe gearbox slightly with a component jack.

Uncouple the gearbox from the engine, slidingthe 5th speed housing between the vehicle side-member and the engine cradle.

Raise the engine.

Turn the gearbox to the front slightly so as to freethe final drive section then remove the gearboxfrom the vehicle.

After uncoupling the gearbox from the engine,attach it to a workshop crane securing the eyes inplace of two bolts around the gearbox.

92903S

Cengines

21-13


Remove the idle speed regulation valve moun-ting.

Disconnect the starter and oil pressure sensorwires.

REMOVAL

The gearbox is removed alone.

Remove the radiator after first draining the co-oling system.

To detach the wiring, disconnect the connectorson:- the ignition power module,- the throttle housing,

Disconnect the two side bolts which secure the en-gine - gearbox tierod, starter end torx bolt (T).using a suitable spanner.

Eengines

92817S

- the idle speed regulation valve.

92904R1

92826S

92904R

21-14



Disconnect the fan motor and thermal switchconnectors.

Unfasten the radiator mountings and move it tothe right hand side (without removing any of thehoses or pipes), protecting the sides with card-board.

Remove studs (A) and (B) using a nut and lock-nut,using an angled spanner and a ball joint ratchet.

Eengines

92903S

86308R1

21-15


Uncouple the gear lever at the gearbox outlet le-ver after detaching the protective gaiter.

Fengines

The gearbox cannot be removed alone. The en-gine - gearbox assembly must be removed first (re-fer to section 10) and then uncoupled.

85966R

98865R2

Remove the starter plate.

Bolt which secures the pendulummounting system to the gearbox 3.5Nuts and bolts which secure the clutchhousing to the engine 5Bolt which secures the clutchprotector 2.5Drain plug 1.8Filler plug 0.15Bolt which secures the left handdriveshaft 2.5


Removal (Special points)

Speedometer cable mounting. Pinch the tabs (ar-rows) and remove the cable.

93902S

21-16


Disconnect the starter leads.

From the lower section, remove:- nut (E) which secures the engine - gearbox,

Fengines

85812-1R

- the tierod - clutch protector assembly.

Place the engine on a stand.

Remove the bolts from around the gearbox andfrom the starter.

Vehicles fitted with power assisted steering, re-move the two clamps (C) which secure the powerassisted steering pipe.

92903S1


92028R3

21-17

MANUAL GEARBOXES

Gearbox (Removal - Refitting) 21Fengines

90300G1

REFITTING

Ensure that the engine - gearbox locating ringsare present and correctly positioned:- at A : gearbox assembled with a C or E type

engine,- at B : gearbox assembled with an F type en-

gine.

Fit the thrust pad to the guide tube placing catch(A) in the fork, ensure that it slides correctly.

86415R

Do not raise the fork since there is a risk of it lif-ting out of catch (A) on the thrust pad. To preventthis, immobilise the thrust pad - fork assembly byinserting a tube (example: tool Elé. 1382) bet-ween the fork and the sheath end on the housingto prevent any movement of the thrust pad whilethe gearbox is fitted.

Coat the walls of the guide tube and the fork padswith MOLYKOTE BR2 grease .

21-18


Fit the gearbox in place.

Fengines

92903R1

Assemble the engine - gearbox.

Ensure that the locating rings are fitted correctlyin their locations.

Refit studs (A) and (B) in the same way as on remo-val. These studs and the bolts around the gearboxare used for alignment and centring.

Fit the fork and refit the rubber protector.

21-19


Speedometer cable mounting. Pinch the tabs (ar-rows) and remove the cable (F type engine).

21WARNING: fit bolt (V) and starter locating pin (D)correctly.

92108-1S

All types

C and E type engines

86070R3

F type engine

86070-1R1

Reconnect the speedometer cable ensuring thatthe pin is in the correct position (C and E type en-gines).

93909S

21-20


Pull the cable at the clutch fork on the gearbox.

The cable should have at least 2 cm of slack.

21Position the driveshaft in relation to the sunwheel, pivot the stub axle carrier engaging thedriveshaft in the sun wheel using the angled driftB. Vi. 31-01 to align the holes.

91830R1

All types

74937-4S

There is an inlet chamfer on the sun wheel tomake it easier to fit new roll pins.

Seal the ends of the pins (RHODORSEAL 5661).

After refitting the engine - gearbox assembly tothe vehicle, check the extent of the fork travel.

It should be: X = 17 to 18 mm

89204S

These checks enable the correct operation of theclutch automatic wear take-up system to be veri-fied.

21-21


Check the setting of the upper mountings (referto section 10).

Ensure that the engine movement limiter is fittedthe correct way: the nuts should be fitted at theexhaust pipe end.

Fengines

92661S

Fill the cooling system.

All types

Fit the brake caliper mounting bolts with LoctiteFRENBLOC and torque tighten them.

Press on the brake pedal several times to bring thepistons into contact with the brake pads.

Tighten the bolts and nuts to the specified torque.

Fill the gearbox.

21-22

MANUAL GEARBOXES5th speed linkage in situ


MATERIALS


B.Vi. 28-01 Extractor body

B.Vi. 31-01 Drifts for fitting roll pins

B.Vi. 1003 5th speed hub extractor

B.Vi. 1007 Jaws for B.Vi. 28-01, 02, 03

B.Vi. 1175 5th speed fixed gear mounting bolt

21

87180R

Loctite FRENBLOC :Primary shaft nutSecondary shaft bolt5th speed fixed gear5th speed hub

Primary shaft nut 13.5Secondary shaft nut 7

REMOVAL

Remove the front left hand wheel.

Remove the side housing.

Drain the gearbox.

The rear housing must be removed horizontally asit has a lubricating duct (A) which goes into theprimary shaft.

21-23

MANUAL GEARBOXES5th speed linkage in situ 21

Select 5th gear by sliding the fork on its shaft and1st gear with the gear lever.

85966R2

DI2122

Fit:- a drainage tray under the rear housing and re-

move it,- a wooden block between the 5th speed fork

and the leading gear to act as a counter-force;then remove the fork roll pin using tool B.Vi.31-01.

It is easier to remove the roll pin if the drift of toolB.Vi 31-01 is bent slightly to avoid having to raisethe gearbox.

85979R

NOTE:Do not pull the 5th speed fork shaft outwards asthere is a risk that the prohibiting lock may moveand prevent refitting of the shaft. As a safetymeasure, engage a gear (3rd or 4th) when remo-ving - refitting the roll pin.

Slacken and remove the primary shaft nut andsecondary shaft bolt.

Return the gearbox to neutral.

21-24


Fit the slide gear of tool B.Vi. 1170 as for selecting5th gear and turn it so as to position the splines ofthe slide gear and the hub opposite each other.

On the primary shaft:

Remove the 5th speed fork and the slide gear.

Extract the synchroniser hub using tool B.Vi. 1170.

93190R

93189S

Fit the rounded housing of the tool on the slidegear, turn it as far as possible and then extract thehub.

93237R

86045R2

Remove the 5th gear assembly.

21-25


On the secondary shaft:

Remove shouldered washer (64).

PRG21.1

Remove the fixed gear using tool B.Vi. 28-01-02-03 fitted with its jaws B.Vi. 1007.

88575R

REFITTING


Put three drops of Loctite FRENBLOC on the fixedgear splines.

Fit the fixed gear using tool B. Vi. 1175 and shoul-dered washer (64).

93462R

Remove tool B. Vi. 1175.

21-26



Fit shouldered washer (64).

PRG21.1

On the primary shaft:

Refit parts (21) (shoulder facing bearing (22), (23),(24) and (8)) in order.

Fit the fork on slide gear (26) fitted with part (25).

Put three drops of Loctite FRENBLOC on the huband refit the slide gear - hub assembly and fork.

Fit the bosses on the synchro ring in the notcheson the hub.

86045R1

Select 1st gear at the gear lever and 5th gear atthe gearbox, sliding the 5th speed fork on itsshaft.

Put three drops of Loctite FRENBLOC:- on nut (27) of the primary shaft and torque

tighten it to 13.5 daN.m,- on bolt (65) and torque tighten it to 7 daN.m .

21-27


Place a wooden block between the 5th speed forkand the primary gear as a counter-force and fit anew roll pin in the 5th speed fork using tool B.Vi.31-01 ensuring that it is fitted the correct wayround, with the slot in the centreline of the shafts.

90498-1S

85979R1

Return the gearbox to neutral and check that allof the gears can be selected.

If there are any difficulties, ensure that reversegear is not engaged.

Fit a new O-ring seal to ensure that the rear hou-sing is leaktight.

Fit the rear housing engaging duct (A) in the pri-mary shaft and the lubricating channel in oil inletrail (B) and torque tighten the bolts to 2.5 daN.m.

87180R6

Fill the gearbox with oil.

21-28

MANUAL GEARBOXESDifferential output seal

REMOVAL

Remove the protective casing from under the en-gine.

Drain the gearbox.

Place the front of the vehicle on stands on the sidein question.

Remove the wheel.

Knock out the driveshaft roll pins using tool B.Vi.31-01.

Remove:- the steering ball joint (tool T.Av. 476),


Brake caliper securing bolts 10

Shock absorber lower securing bolts 11

Steering ball joint 3.5

Wheel bolts 8

MATERIALS


Loctite FRENBLOC :

Brake caliper securing boltsRHODORSEAL 5661 :

Ends of driveshaft roll pinsMOLYKOTE BR2 :

Splines on right hand sun wheel

21



B.Vi. 945 Plug for fitting the differential seal

B.Vi. 1058 Plug for fitting the differential seal

91755R

85965R

21-29

MANUAL GEARBOXESDifferential output seal

- the two bolts (A) securing the brake assembly.

Fix the brake caliper to the suspension spring inorder to avoid stretching the hose.

Slacken lower bolt (3) on the shock absorber baseand remove upper bolt (4).

Tilt the stub axle carrier and uncouple the drives-haft (take care not to damage the gaiters duringthis operation).

Remove the O-ring seal from the sun wheel.

Knock the base of the lip seal using a pin drift anda small hammer so that it turns in its housing.

When the seal has been loosened, take it outusing a pair of pliers, taking care not to damagethe sun wheel splines.

21

90149R1

86031S

REFITTING

Grease protector (A) of B. Vi. 945 and fit it on thesun wheel. Position the greased seal using B. Vi.1058.

92111R

21-30

MANUAL GEARBOXESDifferential output seal 21

Fit new roll pins and seal the ends (RHODORSEAL5661).

Tighten the bolts and nuts to the recommendedtorque.

Fit the brake caliper in place and coat the boltswith Loctite FRENBLOC.

Fill the gearbox.

Fit the O-ring seal on the sun wheel and coat thesplines with grease MOLYKOTE BR2.

Position the driveshaft in relation to the sunwheel.

Turn the stub axle carrier engaging the driveshaftin the sun wheel using drift B.Vi. 31-01 in order toalign the holes.

74937-3S

21-31

MANUAL GEARBOXESSpeedometer drive

CHANGING

1st possibility:Only the speedometer drive or shaft is damaged.

REMOVAL

It is not necessary to dismantle the entire gearbox.

Uncouple the left hand driveshaft.

Remove the spider sun wheel.

Turn the differential by hand so that the speedo-meter drive gear can be reached.

Unclip the shaft, pulling it vertically using long no-sed pliers.

Using the same pliers, remove the drive gear fromits location.

REFITTING

Refit the new speedometer drive using pliers witha long, flat nose.

The drive gear and its shaft are refitted by hand.The shaft must be positioned correctly in relationto the locating notches on the drive gear, owingto the elasticity of the shaft lips.

21

Ensure that it is properly clipped in place.

Refit the spider sun wheel.

2nd possibility:The speedometer drive gear and crown wheel aredamaged.

The gearbox must be removed and the final drivedismantled.

88577S

86053S

CORRECT INCORRECT

21-32

MB AUTOMATIC TRANSMISSIONExploded view 23

DI2325

23-1

MB AUTOMATIC TRANSMISSIONUse 23

DRIVING

The automatic transmission is greased under pres-sure and therefore only while the engine is run-ning.

Consequently, in order to avoid serious damage,the following recommendations must be follo-wed:

- never drive with the ignition switched off (on adownwards slope, for example), the danger ofsuch a practice cannot be emphasised enough.

- never push the vehicle (for example: to reach apetrol station), except in the situation wherethe precautions stated in the section below on"Towing" are observed.

Furthermore, the vehicle can only be driven if theengine is running. It is therefore impossible tostart the engine of an automatic transmission ve-hicle by pushing it.

TOWING

The front of the vehicle should be lifted. However,if this is not possible, the vehicle may, in exceptio-nal circumstances, be towed with four wheels onthe ground under the following conditions:

1. Add an additional two litres of automatictransmission oil ELF RENAULTMATIC D2 orMOBIL ATF 220.

2. Only tow the vehicle at a speed of less than20 mph (30 km/h) over a distance of less than30 miles (50 km) (lever in"N")

DO NOT FORGET TO REMOVE THE EXCESS OILAFTER TOWING.

23-2

MB AUTOMATIC TRANSMISSIONIdentification 23

(*) On the road, with the lever in 2nd at 50 mph (80 km/h).

Converter drive plate:

• Maximum permissible run-out: 0.3 mm

• Tightening torque:- Bolt for securing to the crankshaft: 6.5 daN.m- Bolt for securing to the converter: 2.5 daN.m

VEHICLEAUTOTRANSTYPE

ENGINE

STEPDOWNGEARRATIO

FINALDRIVERATIO

SPEEDOMETERDRIVE RATIO

OILPRESSURE*

COMPUTER

B53AC53AL53A

MB1 E7J 29/24 15/58 21/19 4.4±0.1 138

B537C537L537

MB1 E6J 29/24 15/58 21/19 4.4±0.1 138

B53BC53BL53B

MB3 F3N 29/24 16/57 21/19 4.4±0.1 132

23-3

MB AUTOMATIC TRANSMISSIONGear ratios 23

For vehicle types B53A - C53A - L53A - B537 - C537 - L537

Gear ratios 1st 2nd 3rd Reverse

Gear reduction 2.5 1.5 1 2

Gear reduction +step down 2.069 1.241 0.828 1.655

Gear reduction + stepdown + final drive 7.999 4.799 3.199 6.399

Speed in km/h for 1000 rpm * 12.937 21.562 32.343 16.171

* For vehicles fitted with 165/70 R13 tyres.

For vehicle types B53B - C53B - L53B

Gear ratios 1st 2nd 3rd Reverse

Gear reduction 2.5 1.5 1 2

Gear reduction + stepdown 2.069 1.241 0.828 1.655

Gear reduction + stepdown + final drive 7.370 4.422 2.948 5.896

Speed in km/h for 1000 rpm * 14.042 23.403 35.105 17.552

23-4

MB AUTOMATIC TRANSMISSIONGear change thresholds 23

No-load (PL) Foot off accelerator pedalFull-load (PF) Accelerator pedal fully depressed

NOTE: The kickdown switch is incorporated in the computer via the load potentiometer. In the event of afault refer to workshop repair manual T.A. M.

POSITION OF FOOT 1 → 2 2 → 3 3 → 2 2 → 1

No-load (PL) 23 40 27 15

Full-load (PF) 72 118 102 63

Kickdown 72 118 102 63

Gear change thresholds in km/h for vehicle types B53B - C53B - L53B

POSITION OF FOOT 1 → 2 2 → 3 3 → 2 2 → 1

No-load (PL) 23 46 26 13

Full-load (PF) 62 102 74 40

Kickdown 67 109 94 54

Gear change thresholds in km/h for vehicle types B537 - C537 - L537 - B53A - C53A - L53A

23-5

MB AUTOMATIC TRANSMISSIONConsumables 23

DESCRIPTION COMPONENT CONCERNED

RHODORSEAL 5661 Sealing of the driveshaft roll pins

Grease MOLYKOTE BR2- Sun wheel splines

- Converter locating device

Loctite FRENBLOC Brake caliper securing bolt


Parts which must be changed once they have beenremoved:

- the roll pins,- the self-locking nuts,- the copper seals.

Oil

The MB automatic transmission is a gearbox which has only one level and one grade of oil (converter, finaldrive, mechanical section).

GRADE (for example) : ELF RENAULTMATIC D2.

If this is not available, use (example) :

- MOBIL ATF 220D- TOTAL DEXRON

CAPACITY IN LITRES :Theoretical total: 4.5 litresAfter draining: 2 litres

23-6

MB AUTOMATIC TRANSMISSIONDraining - Filling - Levels 23

85935R

CHECK THE LEVEL WHEN COLD.1. MINIMUM WHEN COLD2. MAXIMUM WHEN COLD

DRAINING - FILLING

Draining must be carried out when cold, dipstickand plug (A) removed.

Change the strainer.

93609R

Refit the plug together with a new seal.

Fill with the recommended oil via the dipsticktube.

Use a funnel fitted with a 15/100 filter in order toprevent the entry of impurities.

Run the engine at idle speed.

Check the level and top up if necessary.

Start the engine and wait one or two minutes forthe converter and cooler to fill up.

The oil is at an ambient temperature of 20°C.

Pull out the dipstick while the engine is running.

The level should not be below mark (1) MINIMUMWHEN COLD (risk of damage) and should not ex-ceed mark (2) MAXIMUM WHEN COLD (risk of da-mage).

Never exceed the "MAXIMUM WHEN COLD"level.

WARNING

Too much oil results in:- overheating of the oil,- leaks.

Too little oil results in:- damage to the mechanisms.

CHECKING THE OIL LEVEL WHEN COLD

With the vehicle empty, place it on a even, hori-zontal surface.

Position the selector lever in "PARK" (P).

23-7

MB AUTOMATIC TRANSMISSIONChecking and adjusting the potentiometer 23

93698R

1st METHOD


B.Vi. 958 Checking unit

ADVICE

With the vehicle stationary and the ignition off,check that the accelerator cable is adjusted cor-rectly.

Disconnect the 3-way connector (10) for the wi-ring which connects the computer to the poten-tiometer.

Connect the potentiometer connector (10) to theB.Vi. 958 connector (16).

Supply the B.Vi. 958 from the battery.

Reversing switch "I2" on "Y".

85651-1R

Press the accelerator pedal downfully

Indicatorlight 9

CORRECT

INCORRECT or maladjusted

Slightly slacken the two bolts (V) which secure thepotentiometer.

Keep the throttle fully open via the acceleratorpedal and slowly turn the potentiometer to illumi-nate indicator light (9) and retighten the twobolts (V)

If indicator light (9) cannot be illuminated by thisadjustment, check its wiring and if the potentio-meter is faulty, change it.

Whenever the potentiometer is changed or remo-ved, adjust it.

NOTE: if the carburettor is cleaned, dismantle the load potentiometer or avoid splashing clea-ning fluid on it.

*

CHECKING

23-8


93608R

Connect:- the round plugs to the battery (red on "+",

black on "-"),- the three-way connector (16) to the

potentiometer connector (10).

2nd METHOD


XR25

ADVICE

With the vehicle stationary and the ignition off,check that the accelerator cable is adjusted cor-rectly.

Disconnect the 3-way connector (10) of the wiringwhich connects the computer to the potentiome-ter.

Connect the XR25, the three-way extension leadand the two round plugs.

93607R

23-9


93606S

On the XR25 keypad, press key "V" then "1";

Reading the numerical values on the display:

At full-load, the display should show a value bet-ween "0" and "3"; ignore any "-" signs whichmay be displayed to the right of the value.

For the adjustment procedure, refer to workshoprepair manual MR T.A. M or the previous page.

23-10

MB AUTOMATIC TRANSMISSIONOil pressure 23

88990R

ADJUSTING

Remove the stop (1) and turn the capsule. By scre-wing in the capsule, the pressure in increased andvice versa.

CHECKING

Meauring conditions

Ensure:- that the normal operating temperature is

80° C,- that the accelerator cable is adjusted correctly.

Connect oil pressure gauge B.Vi. 466-07 toadapter B.Vi. 466-06 at (A).


B.Vi. 466-06 Adaptor

B.Vi. 466-07 Oil pressure gauge

Measuring

Place the selector lever in 2nd.

Accelerate fully and apply the brake at the sametime to stabilise the speed at 50 mph (80 km/h).

The pressure should be 4.4 ± 0.1 bars

88967G

85393S

NOTE: 2 notches = approximately 0.08 bar.

23-11

MB AUTOMATIC TRANSMISSIONOil pressure 23

88862R1

To make this operation easier, a tool can be made:

A = 8/30 mm diameter washer, thickness 1.5 mmB = 6 mm round rod

23-12

MB AUTOMATIC TRANSMISSIONStrainer 23

88170R

The strainer should be changed every 36,000 or40,000 miles (50,000 km) depending on servicingprogramme applicable and when any significantwork is carried out on the mechanism.

CHANGING

Drain the automatic transmission.

Remove the gearbox silent block nut (A).

93605R

Place a lifting device under the gearbox at (B).

85546R

Lift the engine - gearbox assembly to a dimensionof approximately 135 mm.

23-13

MB AUTOMATIC TRANSMISSIONStrainer 23

93618S

Remove the sump and the strainer fitted with itsseal.

Clean the sump and its magnets and refit them (sothat the grooved surface is fitted against thepanel).

Fit the new strainer fitted and its seal and torquetighten to 0.9 daN.m.

Refit the sump and fill with oil.

23-14

MB AUTOMATIC TRANSMISSIONAutomatic transmission (Removal - Refitting) 23

DI2326

Remove:- the cooling system radiator and the expansion

bottle,

Special point for the E engine

Remove :- the integral electronic ignition (A.E.I.),- hot air tube (A) then the air filter complete,

Depending on specification, remove the self-contained air bag in order to eliminate any risk oftriggering it (refer to the first generation air bagmanual).

Removal of the assembly does present any specialpoints, however observe the points below:

REMOVAL



Drain:- the cooling system (lower radiator flexible

hose),- the automatic transmission oil.

Removal of the MB type automatic transmission requires the removal of the engine - automatic transmissionassembly.

Mot. 453-01 Hose clamps

Mot. 582 Converter locking sector

Mot. 878 Engine lifting eyes and chain


B.Vi. 465 Tool for replacing the torque

converter seal



Brake caliper securing bolts 10Shock absorber base securing bolts 11Steering ball joint 3.5Lower ball joint nut 6Driveshaft gaiter securing bolts 2.5Wheel bolts 8Oil cooler bolts 4Converter drive plate bolts 2.5Bolts around the automatic transmission mounting 4


- the bar between the shock absorber turrets,- the front wheels.

23-15


93601R

- the power assisted steering hose securingplate (1).

Special point for the F3N engine

Remove:- the ignition power module,

93603S

- the air filter complete,- the absolute pressure sensor and its moun-

ting,

93602S

Fit clamps Mot. 453-01 to the steering pump re-servoir hoses and then remove the steering pumpreservoir pipes and the front wheels.

23-16


85965-1R

- the three driveshaft gaiter securing bolts,

Remove (all types) :

On the left hand side of the vehicle

- the brake caliper bolt (A) and attach it to thebody,

90149R

BENDIX series IV

GIRLING

91758R

- the steering ball joint using extractor toolT.Av. 476,

85678R

23-17


90259R

- the upper bolt (1) and slacken the lower bolt(2).

- the lower ball joint and shock absorber basebolts,

- the transmission - stub axle carrier assembly,taking care to protect the spider.

90311S

On the right hand side of the vehicle:

It is not necessary to remove the brake caliper.

Extract:- the driveshaft roll pin using drift tool

B.Vi. 31-01,

93710R

Tilt the stub axle carrier and uncouple the drives-haft.

Disconnect the hoses for the heater matrix on thecoolant pump and the automatic transmission oilcooler, the fuel circuit hoses and the brake servobraking vacuum hoses.

23-18

MB AUTOMATIC TRANSMISSION

Automatic transmission (Removal - Refitting) 23

92056S

- the oxygen sensor (1): this is located on theexhaust manifold upstream of the clampwhich connects the primary down-pipe.

Special point for the F3N engine

Disconnect:- the three hoses (A) (it is advisable to mark

them before disconnecting them),

93600R

- the injection computer connector,

93598S

Remove (all types) :- the electrical connectors,

89091R

- the earthing braids.

23-19


DI2327

- the front and rear rubber mounting nuts (E).

Remove:- the earthing braids (engine and automatic

transmission),- the following cables:

• accelerator cable,• rev counter cable,• gear selection cable at attachment points

(A) and (B).

93604R

Remove :- the computer retaining strap,- the exhaust clamp (for F3N engine figure 1)- the exhaust pipe (for E engine figure 2),

Figure 1

91128S

Figure 2

92108R

23-20

MB AUTOMATIC TRANSMISSIONAutomatic transmission (Removal - Refitting)

Fit torque converter tool B.Vi. 465 and uncouplethe automatic transmission from the engine.

Attach tool Mot. 878 to the engine lifting eyes.

Lift the engine - automatic transmission assemblyand remove bolts (E).

Remove the engine - automatic transmission as-sembly from the engine compartment.

23

86724R

93599S

Remove:- the starter motor,- the converter protective plate.

Fit locking sector tool Mot. 852 and remove thebolts for the drive plate on the converter.

86511R

REFITTING (Special points)

Lower the engine - automatic transmission assem-bly, align it using the front rubber mountings andsecure the two bolts for the rear rubber moun-tings.

Torque tighten the bolts and nuts.

Press the brake pedal several times to bring thepistons into contact with the brake pads.Apply RHODORSEAL 5661 to the driveshaft rollpin holes.

Adjust the accelerator and choke cables.

Fit the brake caliper securing bolts withadhesive (Loctite FRENBLOC) and torquetighten them.

23-21

MB AUTOMATIC TRANSMISSIONAutomatic transmission (Removal - Refitting)

NOTE: the exhaust down-pipe flanges are fittedwith spacers (1) which determine the tension ofthe springs.

Tighten until the spacers are in contact.

Start the engine and check that the assembly isperfectly sealed.

To ensure correct sealing, do not forget to fit theO-ring seals (T) on each side of the oil cooler.

Gradually tighten the bolts to a torque of 4 daN.m.

23

92323R

85915-1S

89010R

Carry out the following:- fill the automatic transmission,- fill and bleed the cooling system (refer to sub-

section 19),- fill and bleed the power-assisted steering

pump circuit,- retighten the exhaust flange.

23-22

AD4 AUTOMATIC TRANSMISSIONExploded view 23

DI2302

23-23

AD4 AUTOMATIC TRANSMISSIONOperation 23

DRIVING

The automatic transmission is greased under pres-sure and therefore only while the engine is run-ning.

Consequently, in order to avoid serious damage,the following recommendations must be follo-wed:

- never drive with the ignition switched off (on adownwards slope, for example), the danger ofsuch a practice cannot be emphasised enough.

- never push the vehicle (for example: to reach apetrol station), unless the precautions descri-bed in the "Towing" section below are taken.

Moreover, the vehicle canonly be driven if the en-gine is running. It is therefore impossible to startthe engine of an automatic transmission vehicleby pushing it.

TOWING

It is always preferable to tow the vehicle on a flatbed trailer or with the front wheels lifted.However, if this is not possible, the vehicle may, inexceptional circumstances, be towed under thefollowing conditions:

1 - rear wheels lifted by 15 cm or all four wheelson the ground (without adding any oil to themechanism),

2. Only tow the vehicle at a speed of less than25 mph (40 km/h) over a distance of less than15 miles (25 km) (lever in"N")

23-24

AD4 AUTOMATIC TRANSMISSIONIdentification 23

* For identification using the XR25 refer to the FAULT-FINDING section.

VEHICLEAUTOTRANSTYPE

ENGINE CONVERTERSTEP

DOWNRATIO

FINALDRIVERATIO

SPEEDOMETERRATIO

COMPUTER

B533C533L533

AD4 001 F2N 721F2N 727 227 D AA 69/77 17/64 18/16 100

B536L536 AD4 001 F2N 725 227 D AA 69/77 17/64 18/16 103

B53CC53CD53CL53C

AD4 004 F3N 743 227 D AA 69/77 17/64 18/16 101

353F453F553F853FB53VC53VD53VL53V

AD4 014 F3P 765 227 D AA 69/77 17/64 18/16 108

B53YC53YD53YL53Y

AD4 004 F3P 705F3P 707 227 D AA 69/77 17/64 18/16 103

D53Y AD4 004 F3P 705F3P 707 227 D AA 69/77 17/64 18/16 111

118

D53V AD4 014 F3P 765 227 D AA 69/77 17/64 18/16 115122

B53Y AD4 014 F3P 705 227 D AA 77/71 17/64 18/16103111118

B533 AD4 001 F3P 765 227 D AA 77/71 17/64 18/16 100

353H453H AD4 014 F3P 682 227 D AA 69/77 19/65 18/16 122

23-25

AD4 AUTOMATIC TRANSMISSIONGear ratios 23

Gear ratio 1st 2nd 3rd 4th Reverse

Gear reduction 2.71 1.55 1 0.68 2.11

Overall reduction 11.40 6.51 4.20 2.85 8.86

Speed in km/h for 1000 rpm with1.76 tyres

9.26 16.20 25.13 37.04 11.90

For vehicle types X533, X536, X53C, X53F, X53V, X53Y, 053H

23-26

VEHICLE

AD4 AUTOMATIC TRANSMISSION

Gear change thresholds 231 2 2 3 3 4 4 3 3 2 2 1

A B A B A B A B A B A B

46 51No-load

ACCELER-ATOR

POSITION

AUTO

TRANS

TYPE

X533AD4 000

AD4 001

Full-load

Kickdown

41 46

48

76 83

88

120 130

136

103 112 46 68 26 30

17 20 35 40 60 70

85

31 10

130 133 41 45

No-load

X536 AD4 001 Full-load

Kickdown

41 44

48

68 79

86

100 120 81 103

16 20 35 39 56 60 30 10

117 130 38 41

48

43 28

126 135 78 83

No-load

X53C AD4 004 Full-load

Kickdown

36 42 70 80

80

117 128 103 112

17 20 35 40 60 70 30 10

78 81

47 50

52 68 26 30

42 44 131 130 40

No-load

X53Y AD4 004 Full-load

Kickdown

40 47 75 87

90

122 140 108 120

62 65 3250 55

70 75 20 30

144 135 45

18 40 12 15

50 85

No-loadX53FX53HX53V

AD4 014 Full-load

Kickdown

45 51 85 95

98

138 152 114 132

69 75 55 61

68 79 21 36

157 149 48

6 14

53 93

10 20 45 47 36 40

23-27

AD4 AUTOMATIC TRANSMISSIONGear change thresholds 23

The figures shown in the table are average theoretical values of gear change speeds in km/h tolerances = ± 10 %.

No-load (PL) : Accelerator pedal released.Full-load (PF) : Accelerator pedal fully pressed.Kickdown : Kickdown (changing to a lower gear).

A : Lower gear change thresholds. The gears change to lower gear ratio. Switch (1) is not operated and theEXC warning light is extinguished.

B : Higher gear change thresholds. The gears change to a higher gear ratio. Switch (1) is operated and theEXC warning light is illuminated.

91115-1R

23-28

AD4 AUTOMATIC TRANSMISSIONConsumables 23

Parts which must be changed once they have beenremoved:

- the roll pins,- the self-locking nuts,- the copper seals.

The AD4 automatic transmission is a gearbox which has two grades of oil and two levels.

MECHANICAL SECTION : ELF RENAULTMATIC D2 (D20104).

If this is not available, use:

- MOBIL ATF 220 D (D 20104 or D 21412).- TEXAMATIC 4011.

FINAL DRIVE: TRANSELF TRX 80W.

DESCRIPTION COMPONENT CONCERNED

RHODORSEAL 5661 Sealing of the driveshaft roll pins

Grease MOLYKOTE BR2Sun wheel splines

Converter locating device

Loctite FRENBLOC Brake caliper securing bolt


Oil

23-29

AD4 AUTOMATIC TRANSMISSIONOil drain intervals 23

For draining of the mechanical section, refer to the warranty and servicing booklet for the vehicle.

The oil level must be checked every 10,000 miles (15,000 km) in case there is a slight oil leak.

The final drive is not drained; it is filled for life.

The level can be topped up if there is a slight leak.

Oil capacity

NOTE : If the automatic transmission is changed, only carry out the level checking operation, as thetransmission is supplied filled by the Parts Department.

TOTAL volume Volume after draining

MECHANICALSECTION

5.7 litres 3.5 litres

FINAL DRIVE 1 litre -

23-30

AD4 AUTOMATIC TRANSMISSIONOil drain 23

DRAINING

Mechanical section :

There are two plugs on the mechanical sectioncover :

A : Oil level top-up plug.B : Oil drain plug (triangular imprint on it).

The unit is drained by removing plug (B).


B.Vi. 1213 Automatic transmission drainplug spanner

M.S. 1019-10 XR25

Final drive:

The final drive is filled and topped up via plug (C)by filling with oil until it overflows.

Reminder:The final drive is not drained, it is filled for life.

94882R2

94882R

23-31

1 - The vehicle must be on a four post lift and thetransmission at ambient temperature.

2 - Switch on the engine with the selector leverin park.

3 - Connect the XR25 and enter:

AD4 AUTOMATIC TRANSMISSIONFilling - Levels 23

FILLING - LEVELS

Filling is via tube (D).

Use a funnel fitted with a 15/100 filter to preventthe entry of impurities.

The level is MUST be checked in accordance withthe procedure described below:

Before carrying out this procedure:- if the gearbox has been drained, fill it with

3.5 litres of oil,- if the gearbox is simply to be checked, 0.5 litres

of the recommended oil must be added.

94845R1

D 0 4

4 - Lift the vehicle and run the engine until a tem-perature of 60 °C is reached

5 - When the required temperature has beenreached, with the engine running, open theoil top-up plug; allow the excess oil to flowout for approximately 20 seconds (this excessshould exceed 0.1 litres). Refit the plug.

6 - If the volume of oil recovered is less than 0.1litres, the level is not correct, repeat the ope-ration.

In this case, add 1 litre of the recommended oiland leave the automatic transmission to cool be-fore carrying out the operations which follow.

then # 0 4

23-32

Oil pressure

AD4 AUTOMATIC TRANSMISSIONFilling - Levels 23

The transmission is fitted with an oil pressuresocket. Connect tool B.Vi. 1215 for checking theautomatic transmission pressure sensor only.

The oil pressure cannot be adjusted.

Its value is determined by the computer.

94845-1R

ELECTRONIC FAULT WARNING LIGHT MESSAGE

Operation with no fault

- When the ignition is switched on, with the vehicle stationary and the enginestopped, in position P or N, the warning light illuminates.

- When the starter is operated, the warning light remains illuminated.

- When the key is released, with the ignition on and the engine running, thewarning light extinguishes approximately 3 seconds after starting the engine.

Fault present

- When the vehicle is stationary with the engine running or when driving, thewarning light is permanently illuminated.

- When the vehicle is moving the warning light illuminates and extinguisheswith no operation of the ignition key.

- When the vehicle is moving, the warning light illuminates briefly.

Oil temperature<- 20°C or >+140°C

- When the vehicle is moving or stationary, the warning light flashes with afrequency of approximately 1 flash per second. In this case, reduce theperformance requirement by reducing the acceleration.

23-33

AD4 AUTOMATIC TRANSMISSIONChanging the strainer

- the front left hand wheel and remove the pla-stic deflector in the wheel arch (to enable thetwo automatic transmission sump rear secu-ring bolts to be extracted later).

Using the component jack, lift the automatictransmission.

23This filters the oil and assures correct operation ofthe automatic transmission.

94933R


Strainer securing bolts 0.50Casing securing bolts 1 ± 0.1Bolts securing the rubbermounting to the sidemember 2Rear mounting securing bolts 6.5Wheel bolts 9

+0.1 0

REMOVAL

Place the vehicle on a two post lift and fit the til-ting prevention claws to the pads (see TechnicalNote 1168).

Drain the automatic transmission (mechanical sec-tion; triangular imprint on the drain plug).

Remove:- the expansion bottle,- the air filter,- the two upper rubber mount bolts (A) and

slacken the other two (B), without removingthem.

94933-1R

For models with ABS

Remove:- the nut (C) which secures the ABS electro-

pump assembly to the silent block.

94887S

23-34

AD4 AUTOMATIC TRANSMISSIONChanging the strainer

On models with ABS

Refit the nut (C) which secures the ABS electro-pump assembly to the silent block.

23Remove- the automatic transmission sump,- the strainer and its seal (bolts 1).

94933-1S

92084R

Before refitting, clean the sump and its magnet.

Check the condition of the sump seal and thedrain and top-up plugs.

REFITTING

Fit the new strainer and its seal.

Torque tighten the bolts to 0.5

Fit the sump and torque tighten the bolts to1±0.1 daN.m.

Lower the transmission and remove the compo-nent jack.

Refit the transmission rubber mounting bolts.

+0.1 0 daN.m.

Refit:- the plastic deflector in the front left hand

wheel arch,- the front left hand wheel,- the air filter,- the expansion bottle.

Fill with oil and check the level.

94933R

23-35

AD4 AUTOMATIC TRANSMISSIONHydraulic distributor 23


Casing securing bolts 1 ± 0.1

Strainer securing bolts 0.50

Distributor securing bolts 0.50

+0.1 0

+0.1 0

Removal

This operation is carried out with the selector le-ver in position "P" (Park).

Drain the transmission.

Remove:- the sump (refer to the section on "Changing

the strainer"),- the strainer (bolts 1),

94840R

- the gear selector lever cable,

- the selector lever (2) to enable the lever to tra-vel beyond the "Park" position.

94845-2R

This excess travel is necessary to release the drivefor the manual valve control sector.

94841R

23-36

AD4 AUTOMATIC TRANSMISSIONHydraulic distributor

- the selector from the manual valve (4) by de-taching first at (A) and then at (B).

Extract the hydraulic distributor manual valve.

23Disconnect the sealed connector cable by pressingon the locking ring.

94848R

94925S

Remove:- the sealed connector after removing bolt (3),

94848-1R

94841-1R

Remove the 16 bolts which secure the hydraulicdistributor. Bolts (X) remain in place and securethe closing plate to the distributor.

23-37

AD4 AUTOMATIC TRANSMISSIONHydraulic distributor

Engage the hydraulic distributor.

Push the gear selector lever to the stop takingcare to correctly engage the modulating solenoidvalve in the casing.

23Push the selector lever to the stop and disconnectthe hydraulic distributor by releasing the modula-ting solenoid valve from the casing.

94852R1

91724R

Ensure that the inserts (6) and the filter (7) remainin place in the hydraulic circuit of the casing.

94852R2

REFITTING

Ensure that the F1 supply tube (8), the modulatingsolenoid valve filter (7), and the system inserts (6)are present.

23-38


91724R

Fit the 16 bolts securing the distributor to the ca-sing and torque tighten them to 0.5 daN.m in theorder shown.

94841-1R1

Fit the manual valve and the selector (4) by firstengaging section (A) and then section (B).

91350R4

Refit the sealed connector with its O-ring seal andbolt (3).

94848-1R

23-39


Fit a new strainer and a new seal.

Torque tighten to 0.5

94840R

Fit the sump (check that the seals are in goodcondition and that the magnet is present).

Torque tighten bolts (1) to 1

Refit the automatic transmission (refer to thesection on "Changing the strainer").

Reconnect the sealed connector.

Refit the gear selector lever (2).

+0.1 0 daN.m.

94845-2R

Refit the control cable.

Fill with oil and check the level.

NOTE:Whenever the hydraulic distributor is changed orremoved, change the modulating solenoid valvefilter, the strainer and its seal.

+0.1 0 daN.m.

23-40

AD4 AUTOMATIC TRANSMISSIONAutomatic transmission (Removal - Refitting) 23


Mot. 453-01 Hose clampsMot. 582 Locking sectorMot. 1202 Hose clamp grips


Shock absorber securing bolts 11

Transmission securing bolts 3.5

Wheel bolts 9

Bolts securing the automatic

transmission to the engine 4

Bolt securing the rubber mounting to the

sidemember 2


Rear mounting securing bolts 6.5

Oil cooler bolts 2.5

Converter drive plate bolts 1.5

IN ORDER TO REMOVE THE AUTOMATICTRANSMISSION, THE ENGINE - AUTOMATICTRANSMISSION ASSEMBLY MUST BE REMOVED.

Depending on equipment level, remove the self-contained air bag in order to eliminate any risk oftriggering (refer to the first generation air bagmanual).


REMOVAL


Drain:- the automatic transmission (only if it is to be

changed),- the cooling system.

Remove:- the bonnet,- the air filter and its mounting,- the antipercolation air duct.,- the bar (if fitted).

23-41


94948R

Disconnect the accelerator cable (2) from the carburettor after dis-connecting the kickdown switch connector (1).

Carburation system

94932R

23-42

AD4 AUTOMATIC TRANSMISSIONAutomatic transmission (Removal - Refitting)

- the earthing braids (engine and automatictransmission),

- the AEI (integral electronic ignition) or,- the MPA (ignition power module) and the

oxygen sensor connector (depending on vehi-cle type).

23Injection system

94930R

Disconnect:- the choke cable (depending on type),- the speedometer cable after unscrewing it

from the automatic transmission,

94834-1S

- the engine wiring harness connectors in thebox on the left hand wheel arch and the auto-matic transmission computer connectors,

94927S

94929S

23-43


(all types)

- the following hoses:• radiator,• heater,• power assisted steering pump reservoir af-

ter fitting tool Mot. 453-01.

23Remove the following pipes:

• fuel pipe,• vacuum pipe on the brake servo,

(Depending on vehicle type)• remove the pipes for the automatic

transmission accelerated idle solenoid valves(2) and the power-assisted steering (3),

94928-1R94931R

• bleed canister (A),• bleed canister solenoid valve(B).

94928R

Remove:- the 35-way injection computer connector (5),- the purge canister solenoid valve supply

connector (6),- the engine harness connection connector (7),

23-44


Remove:- the starter motor heat shield,- the starter motor,

23- the oil cooler,

94835S

86511R

94890S

- the bolts securing the automatic transmissionto the engine.

Remove the transmission from the engine takingcare not to drop the converter.

REFITTING

Before refitting the automatic transmission to theengine, check the presence of the centring pins onthe block.

Grease the device which locates the converter inthe crankshaft with Molykote "BR2" .

Fit the automatic transmission to the engine andtorque tighten the securing bolts to 4 daN.m .

Fit the nuts which secure the drive plate to theconverter using Loctite FRENBLOC and torquetighten them to 1.5 daN.m.

Refit:- the oil cooler and torque tighten the bolts to

2.5 daN.m,- the starter motor and the heat shield,- the converter protective plate.

Refit the engine - automatic transmission assem-bly in the engine compartment.

Refit in the reverse order to removal.

23-45


Right hand side

23Remove:- the power assisted steering reservoir,- the power assisted steering high pressure pipe

(detach it from the retaining plate under-neath the vehicle),

94838-2S

94949S

- the gear selector lever,- the radiator,- the exhaust clamp

91128S

- the front wheels,- the 6 bolts which secure the driveshafts to the

sun wheel outlet flanges.

1st type assembly: Hexagonal socket-type screws.(For removal and refitting it is advisable to use, forexample, socket FACOM J 235 and the 6 mm hexa-gonal male adaptor).

2nd type assembly: 12-sided socket-type screws.(For removal and refitting it is advisable to use, forexample, 12-sided male socket FACOM SV. 8L).

Left hand side

94837S

23-46


On each side of the vehicle remove:- the steering ball joint using extractor tool

T. Av. 476,

91131S

85965-1R

- the upper bolt (1) and slacken the lower bolt(2) for the shock absorber base.

90259R

Remove :- the driveshafts on the side,- the engine - automatic transmission rubber

mountings.

Fit the load positioner to the engine - automatictransmission assembly.

Remove the assembly from the engine compart-ment.

23-47


REFITTING

Special points:

Before refitting the driveshafts, fill the sun wheeloutlet flanges with Molykote "BR2" grease .

23Remove the converter protective plate.

94890-2S

94885S

Fit locking sector tool Mot. 582 and remove thethree nuts which secure the drive plate to theconverter.

IMPORTANT:

When refitting the accelerator cable, adjust it cor-rectly as this is important to ensure correct opera-tion of the kickdown switch.

Carry out the following operations:- fill and bleed the cooling system,- top up the power assisted steering,- top up the automatic transmission.

VERY IMPORTANT: DO NOT FORGET TOVALIDATE THE FULL-LOAD POSITION in order toreprogramme the computer with the load poten-tiometer travel.

23-48


REMOVAL


Remove the bumper at (A).

On vehicles fitted with ABS, the automatic transmission is removed after removing the engine-gearboxdrive assembly.

92058R

ABS version


Mot. 1040-01 Dummy engine cradle forremoving - refitting the engine-gearbox drive assembly

Mot. 453-01 Hose clamps


Front engine sub-frame mounting bolts 4

Rear engine sub-frame mounting bolts 8.5

Upper shock absorber mounting bolts 2.5

Brake caliper securing bolts 10

Steering universal joint securing bolt 3

Wheel bolts 9

Driveshaft mounting bolts 3.5

Shock absorber base mounting bolts 11


Bolts securing the automatic

transmission to the engine 4

Oil cooler bolts 2.5

Converter drive plate bolts 15


Depending on equipment level, remove the self-contained air bag in order to eliminate any risk oftriggering (refer to the 1st generation air bagma-nual).

92054R

23-49


Remove:- the interior wheel arch trim,

94948S

ABS version

92057R

- the air filter and its mounting.

Remove the separating bar and the antipercola-tion pipes (if fitted).

23-50


- the earthing braids (engine and automatictransmission),

- the integral electronic ignition (AEI) and re-move it,

- the following pipes :• fuel pipes,• vacuum pipes on the brake servo,• remove the pipes for the automatic trans-

mission accelerated idle solenoid valves (2)and the power-assisted steering (3),

23Disconnect:- the accelerator cable from the carburettor af-

ter disconnecting connector (1) from the ki-ckdown switch (2).

94927S

ABS version

94932R

- the choke cable (depending on type of carbu-ration),

- the speedometer cable after unscrewing itfrom the automatic transmission,

94834-1S


94931R1

• radiator hoses,• heater pipes.

23-51


- the 35-way injection computer connector (5),- the bleed canister solenoid valve supply

connector (6),- the engine wiring harness connection connec-

tor (7).

23Remove (depending on vehicle type) :- the air filter and its mounting,- the antipercolation air duct.

Disconnect:- the accelerator cable from the throttle hou-

sing after disconnecting connector (1) for thekickdown switch (2),

94927S

ABS version

94930R

- the speedometer cable after unscrewing itfrom the automatic transmission,

94834-1S


94928-1R

23-52


Fit tool Mot. 1040-01.

23Disconnect the oxygen sensor connector.

Remove:- the earthing braids (motor and automatic

transmission),- the ignition power module (MPA),- the following pipes :

• fuel pipes,• vacuum pipes on the brake servo,• bleed canister (A),• bleed canister solenoid valve (B).

92059S

ABS version

94928R

• radiator hoses,• heater pipes.

ALL TYPES

Unhook:- the power assisted steering reservoir,- the gear selector lever cable.

Refit:- the radiator,- the brake calipers and attach them to the ve-

hicle body,- the tie rods connecting the sub-frame to the

body,- the primary exhaust down-pipe,- the cam bolt for the universal joint.

92061S

Lower the vehicle to the ground.

23-53


Separate the engine - automatic transmission as-sembly from the engine sub-frame.

Remove the converter protective plate.

23Remove:- the upper shock absorber bolts,

92382S

ABS version

92114R

- the bolt securing the rubber mounting to theautomatic transmission,

94933-2R

- the four engine sub-frame mounting bolts.

Lift the body and remove the engine-gearboxdrive assembly.

With the fan assembly removed.

94885S

Fit locking sector tool Mot. 582 and remove thethree nuts which secure the drive plate to theconverter.

23-54


- the bolts securing the automatic transmissionto the engine.

Separate the transmission from the engine takingcare not to drop the converter.

REFITTING

Before refitting the automatic transmission to theengine, check the presence of the locating pins onthe block.

Grease the device which locates the converter inthe crankshaft with Molykote "BR2" .

Fit the automatic transmission to the engine andtorque tighten the securing bolts to 4 daN.m .

Fit the nuts which secure the drive plate to theconverter using Loctite FRENBLOC and torquetighten them to 1.5 daN.m.

Refit:- the oil cooler and torque tighten the bolts to

2.5 daN.m,- the starter motor and the heat shield,- the converter protective plate.

Refit the engine - automatic transmission assem-bly to the engine sub-frame.

Refit in reverse order to removal.

23

Remove:- the starter motor heat shield,- the starter motor,

94835S

ABS version

86511R

94890S

- the oil cooler,

23-55


Position the upper mountings in the appropriatedrilled hole.A = Manual steeringB = Power assisted steering

23Special points

Before refitting the driveshafts, fill the sun wheeloutlet flanges with Molykote "BR2" grease .

92114-1R

ABS version

94890-2S

The alignment of the body with the engine sub-frame is made easier by using threaded rodswhich are approximately 100 mm long.

85742S

IMPORTANT

When refitting the accelerator cable, adjust it cor-rectly as this is important to ensure correct opera-tion of the kickdown switch.

Carry out the following operations:- fill and bleed the cooling system (refer to sec-

tion 19),- top up the power assisted steering,- top up the automatic transmission.

VERY IMPORTANT: DO NOT FORGET TOVALIDATE THE FULL-LOAD POSITION in order toreprogramme the computer with the load poten-tiometer travel.

Tighten the brake caliper securing bolts to a tor-que of 10 daN.m.

23-56

AD4 AUTOMATIC TRANSMISSIONFull-load validation

Switch on the ignition without starting the en-gine.Enter the "A" transmission code on the keypad:

Connect the XR25 to the vehicle diagnostic socket.

The diagnostic socket (1) is located in the passen-ger compartment, under the dashboard, in the re-lay and fuse compartment.

23

92827R

92655R1

Place the selector in position S4.

D 0 4

On the bargraph displays only bargraphs 1 - 3 - 4 -5 - 6 - 11 remain illuminated either on the right oron the left hand side.

Validate the full-load position by pressing the ac-celerator pedal for 5 seconds.

Bargraph 2 illuminates.Bargraph 6 extinguishes.

When the accelerator pedal is released, only bar-graphs 1 - 3 - 4- 5 - 11 should remain illuminated.

VERY IMPORTANT: switch off the ignition.

Switch the ignition on again and enter the "A"transmission code to check whether the validationhas been carried out.

(Repeat the operation if necessary).

Switch off the ignition and disconnect the XR25.

WARNING: If the full-load is validated incorrectly,this may cause:- permanent illumination of the warning light,- gear change difficulties,- incorrect gear change thresholds,- difficulties in the operation of the kickdown

function,- uncomfortable driving conditions.

23-57

AD4 AUTOMATIC TRANSMISSIONLoad potentiometer 23

Slacken the potentiometer securing bolts (V).

Connect the XR25 to the vehicle diagnostic socket(located under the dashboard, in the relay andfuse compartment).

Switch on the ignition without starting the en-gine.

Enter the "A" transmission code on the keypad:

D 0 4

The computer number is displayed.

Example :

Computeridentification

number4-speed

auto trans

Enter on the keypad # 0 2

The potentiometer setting value in % appears onthe central display.

Example :

ADJUSTMENT

According to type (carburation)

THE LOAD POTENTIOMETER IS SPECIFIC TO THISENGINE AS IT HAS A LONGER TRACK.

THEREFORE IT IS NOT INTERCHANGEABLE WITHANOTHER TYPE OF POTENTIOMETER.

VERY IMPORTANT: Is is essential that the poten-tiometer adjustment procedure described belowis applied.

Slacken the idle screw fully until the flap iscompletely closed.

94922R

Rotate the potentiometer body until a value is ob-tained on the central display of between 89.7 and92.1 %.

90034

23-58

AD4 AUTOMATIC TRANSMISSIONLoad potentiometer 23

94915R

With the accelerator cable at rest, rotate the po-tentiometer body until a value is obtained on thecentral display of between 89.7 and 92.1 %.

Retighten the securing bolts (V).(If adjustment is not possible, check the feed).

Then erase the memory and programme the"Full-load" value.

Retighten securing bolts (1).(If adjustment is not possible, check the feed).

Readjust the idle speed to 800±50 rpm with the se-lector lever in neutral.

Then erase the memory and programme the"Full-load" value.

Depending on vehicle type (Injection)

Slacken the potentiometer securing bolts (V).

23-59

AD4 AUTOMATIC TRANSMISSIONComputer (119) 23

94926R

When the computer is changed or the memory iserased, do not forget to carry out a full-load vali-dation.

23-60

AD4 AUTOMATIC TRANSMISSIONLine pressure sensor (8) 23

The sensor is secured to the automatic transmis-sion casing by two bolts.

It is directly accessible from underneath the vehi-cle, after removing the protective sleeve.

After changing it, do not forget to erase the me-mory and carry out a full-load validation.

94884R

23-61

AD4 AUTOMATIC TRANSMISSIONMultifunction switch (485) 23

94837-1R

The switch is secured to the automatic transmis-sion casing.

It is accessible from above or underneath the ve-hicle, after removing the securing plate and theearth wire (A).


23-62

AD4 AUTOMATIC TRANSMISSIONVehicle speed sensor (250) 23

94845-3R1

The speed sensor is secured to the top of the auto-matic transmission.

It is accessible after removing:- the expansion bottle,- the rubber mounting bracket.


23-63

AD4 AUTOMATIC TRANSMISSIONSolenoid valves 23

91367R

Refitting the assembly does not present any parti-cular difficulties. proceed in reverse order to re-moval.

Retighten the bolts to the recommended torque(very important).

NOTE:Each sequence solenoid valve is fitted to its ownmounting. Check to make sure that they arefitted to the correct mounting.

The sequence and modulating solenoid valves andthe temperature sensor can only changed after re-moval of the hydraulic distributor.

Remove:- bolts (A) which secure the distributor closing

plate(B),- the bolts securing the sequence solenoid

valves (C) and modulating solenoid valve bolt(D).

Remove the solenoid valve - sensor assembly fromthe distributor.

Solenoid valve securing bolts 0.9 ±0.1

Distributor plate securing bolts 0.5 ±0.1

Hydraulic distributor bolts 0.5


+0.1 0

23-64

AD4 AUTOMATIC TRANSMISSIONEngine torque reduction 23

The purpose of engine torque reduction during gear changes is:

1) to ensure smooth gear change,

2) to reduce the theoretical load of the hydraulic slave cylinders which are operated during gear changes,

3) to relieve the mechanical units.

The torque is reduced by action on the point of advance.

The torque reduction signal is supplied by the automatic transmission computer to the injection computer.Throughout the duration of the gear change, the point of advance is moved back by 35°.

CHECKING THE CONNECTION BETWEEN THE AUTOMATIC TRANSMISSION COMPUTER AND THE INJECTIONCOMPUTER

Condition Selection on the XR25Display onthe XR25

Note

Gear change pattern selectorin position "EXC".

Automatic transmission in 3rd.

With the vehicle atapproximately 35 mph(60km/h) in 2nd, change from2nd → 3rd under lightthrottle.

Enter D03 # 51 Brief change to zero onthe checking equipmentdisplay.

23-65

AD4 AUTOMATIC TRANSMISSIONSpecial features 23

92655R1

This methods enables the kickdown function to beused at higher engine speeds.

In order for the accelerator cable over travel to befully effective, check to make sure that the accele-rator cable is correctly adjusted.

KICKDOWN FUNCTION

In order to trigger the kickdown switch on theAD4 automatic transmission, two pieces of infor-mation are required.

1st piece of information

Accelerator pedal fully depressed to obtain loadpotentiometer information (value less than 6%).The value displayed on the XR25 at # 12 ).

2nd piece of information

The kickdown switch fitted to the accelerator ca-ble detects excess accelerator pedal travel which,when it compresses, creates an earth connectionto the automatic transmission computer.

94932S1

Switch on the ignition without starting the en-gine.

Enter the "A" transmission code D04 on the key-pad and read # 22 .

ADJUSTING THE CABLE

Connect the XR25 to the diagnostic socket on thevehicle.

Place the selector in position S4.

23-66

AD4 AUTOMATIC TRANSMISSIONSpecial features 23

TEST CONDITIONS DISPLAY ON THE XR25 NOTES

Accelerator pedal released(No-load) (PL)

If value 1 is not displayed, check the electricalconnection on the kickdown switch.

Accelerator pedal pressed(Full-load) (PF)

If value 0 is not displayed at Full-load, check theadjustment of the accelerator cable.

23-67

DRIVESHAFTSConsumables

Allocation of seals on the vehicle

29

TYPE QUANTITY COMPONENT CONCERNED

Loctite SCELBLOC Coating Stub axle splines

RHODORSEAL 5661 Coating Pins on driveshaft at gearbox end

MOLYKOTE BR2 Coating Splines on coupling at gearbox end

FRENBLOC Coating Brake caliper bolt

MOBIL CVJ 825

Black Star

or

MOBIL EXF 57C

320 g

140 g

160 g

130 g

Joint GE 86

Joint AC 1700

Joint RC 490

Joint GI 62

JOINTSRight handdriveshaft

Left handdriveshaft

Wheel end Gearboxend

GE 86 X X X

AC 1700 X X X

RC 490 X X

GI 62 X X

GI 69 X X

29-1

DRIVESHAFTSDriveshafts 29

85876-1R

REMOVAL

Remove:- the brake assembly (suspend it from the chas-

sis so as not to damage the brake hose),- the driveshaft nut using tool Rou. 604-01.


Rou. 604 -01 Hub locking tool


T.Av. 1050-02 Hub extractor

B.Vi. 31-01 Pin drift

Driveshaft nut 25Bolts securing gaiter to gearbox 2.5Wheel bolts 9Nuts securing bottom of shock absorber 17Brake caliper securing bolts 10Steering ball joint nuts 3.5

TIGHTENING TORQUES(en daN.m)

85678R

On the left hand side

Drain the gearbox.

Remove the three bolts.

91755R

On the right hand side

Remove the rollpin using tool B.Vi. 31-01.

29-2


91691S

Take care not to damage the gaiters during thisoperation.

REFITTING

On both sides:

Remove:- the steering ball joint nut using tool T.Av. 476,

85965-1R

- the upper bolt securing the bottom of theshock absorber.

These vehicles have bonded driveshafts which,therefore, must be pushed back using tool T.Av.1050-02.

91750R1

Remove the lower bolt securing the bottom of theshock absorber and take out the driveshaft.

NOTE: The Parts Department now supplies drives-hafts equipped with protectors and supplied withfitting instructions which MUST be followed toensure correct assembly with the highest degreeof QUALITY. The slightest knock on the gaiterswill damage them sooner or later and lead to des-truction of the driveshaft.

29-3


DI2905

ESSENTIAL FITTING INSTRUCTIONS

29-4


85677S

On the left hand sideRemove the plastic protector from the gaiter andengage the driveshaft keeping it as horizontal aspossible.

Never remove the cardboard protectors until thevery end of the refitting operation.

91630R

Never use a sharp instrument as this could da-mage the gaiters.

91629R

29-5


91749S

Engage the driveshaft stub axle in the hub.

On the right hand sideWith the protector fitted, smear the driveshaftsplines at the gearbox end with MOLYKOTE BR2grease.

Position the driveshaft in relation to the sunwheel and insert it.

Check its position using the angled drift from toolB.Vi. 31-01.

Fit two new rollpins using tool B.Vi. 31-01. Sealthe pin holes using RHODOSEAL 5661.

NOTE: the inlet chamfers on the sun wheels makeit easier to fit new rollpins.

74937-4S

On both sidesCoat the stub axle splines with Loctite SCELBLOC.

91691R

29-6


85876-1R

Re-secure:- the two bolts for the bottom of the shock

absorber to the stub able carrier and torquetighten them,

- the steering ball joint and torque tighten itsnut.

Torque tighten the driveshaft nut using tool Rou.604-01.

91691-1S

85678R

On the left hand side

Clean the area where the gaiter bears against thegearbox, re-fasten the gaiter and the plate.

Keep the gaiter as horizontal as possible and tor-que tighten the three bolts.

29-7


With the vehicle on its wheels, remove the card-board protectors, tearing them as shown in thediagram.

On both sides

Fit the brake calipers, coat the bolts with LoctiteFRENBLOC and torque tighten them.

Put the vehicle back on its wheels.

91693R

91631S

91633S

91632R

Never use a sharp instrument as this could da-mage the gaiter.

Press on the brake pedal several times so that thepiston makes contact with the shoes.

If the left hand driveshaft is being changed, topup the oil in the gearbox.

29-8

DRIVESHAFTS Gaiter at wheel end 29

88638S

Joint GE 86


T. Av. 537 -02 GE 86 expander

T. Av. 1168 CAILLAU click collar tool

T. Av. 1256 OETIKER collar crimping tool

1 Bell-shaped stub axle2 Retaining star plate3 Spider4 Shaft yoke5 Retaining collar6 Rubber gaiter7 Retaining collar

88578R

DISMANTLING

Remove the existing collars taking care not to da-mage the grooves in the bell-shaped stub axle.

29-9

DRIVESHAFTSGaiter at wheel end 29

78411R

Hold the driveshaft at a convenient angle in a vicefitted with soft jaws.

Fit the expander on the end of the yoke (if it willnot fit, deburr the inside of the cylindrical sectionof the tool with emery cloth).

Remove as much grease as possible.

Free the bell-shaped stub axle from the driveshaftby raising the star plate arms (2) one by one.

Joint GE 86

74650R

DO NOT TWIST THE STAR PLATE ARMS.

Retain the thrust ball, spring and shim under theball joint (B).

NOTE: the thickness of the shim under the balljoint is adapted to the original clearance.

This shim must be retained and reused on reas-sembly.

88579R

REASSEMBLING

Expander tool TAv. 537-02 must be used when re-fitting the GE 86 gaiter.

78408-1RRemove all traces of grease.

29-10

DRIVESHAFTS

Gaiter at wheel end 29Joint GE 86

78409G

It is essential to make sure that there are no sharpedges on yoke (A) (deburr lightly with emery clothif necessary).

Carefully and generously lubricate the followingwith clean engine oil:- the whole expander (stems and centre),- inside the gaiter and in particular the neck.

Place a thumb over the bottom hole, pour someoil into the gaiter and spread it round the inside.

80158S

Slip the gaiter over the end of the expander.

Wrap a piece of clean rag round one hand andgrip the gaiter so that the first fold will stretchwhen it is slid on.

78410S

80040

Incorrect Correct

Lean against the edge of the vice.

Place one hand over the other and pull takingcare that the first fold does not double back.

Pull the gaiter as close as possible to the cylindricalsection of the expander and then let it return half-way.

Repeat this operation several times (maximum 5times ) to make the rubber of the gaiter more plia-ble (relubricate the stems during the operation ifnecessary).

29-11

DRIVESHAFTSGaiter at wheel end 29Joint GE 86

74653S

When the gaiter slides more freely, with onecontinuous pull, fit the gaiter on the cylindricalsection of the expander.

Fit the spring and thrust ball in the spider.

Move the roller cages towards the centre.

Position retaining star plate (2) so that each arm iscentral between each spider trunnion.

Insert the driveshaft yoke in the bell-shaped stubaxle.

Tilt the shaft to fit one arm of the retaining starplate in a slot in the yoke and press in to locate itcorrectly.

74652R

78412-2S

29-12


88668S

The other two arms may be fitted easily by using,for example, a screwdriver with the tip ground asshown

A = 5 mm B = 3 mm

Ensure that each arm of the retaining star plate islocated in its slot.

Tilt the shaft in the plane of one of the star platearms and the ball joint will be freed under the ac-tion of the spring.

74697R

Insert the shim under the top of the ball joint (theshim should not project above the top of the balljoint).

29-13


88601R

Check the operation of the spider coupling byhand.

No tight spots should be apparent.

Distribute the sachet of grease evenly betweenthe gaiter and the bell-shaped stub axle.

NOTE: make sure that you use the amount ofgrease specified in the "Consumables" section.

Position the gaiter lips in their grooves in the stubaxle and driveshaft.

88578S

IncorrectCorrect

Insert a smooth round-edged piece of rod bet-ween the gaiter and the stub axle to restrict theamount of air inside.

Fit the collars and tighten them using tool T. Av.1034.

88639R

29-14


98824R

REASSEMBLING

Slide onto the shaft:- the small collar,- gaiter (3).

Slide the ball coupling (1) complete with retainingring (new) onto the shaft splines until the retai-ning ring locates in the shaft groove (B).

Joint AC 1700


T. Av. 1168 CAILLAU click collar tool

T. Av. 1256 OETIKER collar crimping tool

A driveshaft can be partially repaired at the wheelend:- a coupling change,- a gaiter change.

6-BALL COUPLING AT THE WHEEL END

1 Bell-shaped stub axle2 Balls3 Ball cage4 Retaining ring5 Driveshaft6 Gaiter7 Ball hubA ABS crown wheel (option)

DISMANTLING

Cut the clip and gaiter all the way along.


Spread retaining ring (7) and tap the exposedface of ball hub (5) at the same time.

Separate the coupling from the shaft.

78616R

78615R2

29-15


Spread the sachet of grease round inside the gai-ter and the bell-shaped stub axle.

NOTE: it is essential to use the amount of greasespecified in the "Consumables" section.

Position the lips of the gaiter in the grooves in thebell-shaped stub axle (1) and the driveshaft (2).

Joint AC 1700

98824R

Fit the collars and tighten them using the toolwhich corresponds to the type of collars suppliedin the kit (click CAILLAU or OETIKER).

29-16


96048S

OETIKER COLLAR

Joints AC 1700and GE 86


T.Av. 1256 OETIKER collar crimping tool

POSITION 1 - Pre-crimping and positioning of the collar

Fit connecting rod (A) in the upper notch and close the tool fully.

DI2901

Fit connecting rod (A) in the lower notch and close the tool fully. The pre-crimped collar slides onto the gaiterand can be positioned.

DI2902

POSITION 2 - Crimping

29-17


DI2903

NOTE: CAILLAU click type collars cannot be re-used.

CAILLAU CLICK COLLAR

Joints AC 1700and GE 86


T.Av. 1168 CAILLAU click collar tool

93039R 93040S

29-18

DRIVESHAFTSGaiter at gearbox end 29

92303R


Remove the metal cover.

1 Yoke2 Spider3 Metal cover4 Rubber gaiter5 Retaining collar6 Driveshaft7 Metal insert

Joint RC 490


T.Av. 1034 Driveshaft collar crimping

tool

92045S

DISMANTLING

Uncrimp the three points on the cover usingpliers.

92044S

Cut the retaining collar and gaiter along its entirelength.

92046S

29-19

DRIVESHAFTGaiter at gearbox end 29

90388S

REASSEMBLY

Grease the driveshaft and slide on:- the new retaining collar,- rubber gaiter (4) with metal insert (7) and me-

tal cover (3).

Remove the yoke.

Joint RC 490

89145S

NOTE: as the yoke is not fitted with an anti-separation pate, it can be removed without force.

Do not remove the roller cages from their respec-tive trunnions since the cages and rollers are mat-ched and must never be mixed.

Remove the circlips (depending on vehicle model).

90387S

Never use thinners to clean the component parts.

On the press, extract the spider, using a strippingextractor for support.

92048-1R

29-20


92050S

Spread the contents of the sachet of grease insidethe gaiter and the yoke.


Position:- the gaiter and its metal insert in the metal co-

ver,- the metal cover, sliding it on until the guide

plate is flush with the yoke.

In this position, crimp three points in the locationsprovided for this on the guide plate.

Fit the spider onto the splined shaft.

Joint RC 490

90389S

Refit the retaining circlips or make 3 crimpingpoints 120° apart, pushing back the metal on thedriveshaft splines.

90391S

Grease the yoke and engage it on the spider as-sembly.

Insert a smooth rod with a rounded end betweenthe gaiter and the shaft to restrict the amount ofair inside.

29-21


88601R

Lengthen or shorten the coupling until dimensionA = 156 ± 1 mm is obtained (distance measuredbetween the end of the gaiter and the matchedface, with largest diameter, of the yoke).

In this position, remove the rod.

Fit the collar on the gaiter and tighten it usingtool T.Av. 1034.

Joint RC 490

92051R

92052R

29-22

DRIVESHAFTSGaiter at gearbox end

Do not remove the roller cages from their respec-tive trunnions since the cages and rollers are mat-ched and must never be mixed.

Never use thinners to clean the component parts.

Remove the circlips depending on the type of as-sembly.

291 Yoke2 Spider3 Metal cover4 Retaining spring5 Rubber gaiter6 Retaining collar7 Driveshaft

90387S

Joint GI 62

88648R

DISMANTLING

Cut the crimped collar and the gaiter along its en-tire length.


75936-1S1

Using a pair of pliers, raise each end of the anti-separation plate (C), then remove the yoke.

74655R

29-23

DRIVESHAFTSgaiter at gearbox end

Insert a 2.5 mm wedge (B), made as shown in thesketch, between the anti-separation plate andyoke.

29Extract the spider in a press, using a stripping ex-tractor for support.

90391S

Joint GI 62

90388S

REASSEMBLING

Lubricate the driveshaft and slide on the new re-taining clip and gaiter.

Fit the spider onto the splined shaft.

90389S

Refit the retaining circlips or make 3 crimpingpoints 120° apart, pushing back the metal on thedriveshaft splines.


75434-1R

29-24

DRIVESHAFTSGaiter at gearbox end

Insert a smooth round-ended piece of rod bet-ween the gaiter and yoke so as to restrict theamount of air retained inside the coupling.

Lengthen or shorten the coupling to obtain di-mension A = 153,5 ± 1 mm (dimension measuredbetween the gaiter end face and the largest dia-meter machined face on the yoke).

29Carefully tap the anti-separation plate into its ori-ginal position with a bronze drift, then removewedge (B).

90390R

Joint GI 62

74867R

Locate the gaiter lips in the groove on the drives-haft and on the metal cover.

75434-1S

88601R

In this position, remove the rod and fit the retai-ning collar.

Tighten it using tool T. Av. 1034.

29-25

DRIVESHAFTSGaiter - bearing assembly

Remove the gaiter and bearing assembly in thesame way as the spider.

29

REMOVAL

Never use thinners for cleaning component parts.

Remove the circlip depending on the type of as-sembly.

90388S

Joint GI 69


T.Av. 944 Mandrel for fitting bearing to

shaft

90387S

Remove the spider, on the press, using an extrac-tor for support.

85933S

29-26

DRIVESHAFTSGaiter - bearing assembly 29

REFITTING

For it to be in its correct position on the shaft, thebearing must be inserted until dimensionL = 148,5 mm is obtained between the front sec-tion of the bearing and the end of the shaft.

This dimension is obtained when the end of toolT.Av. 944 is flush with the end of the shaft.

86197S

Joint GI 69

85884-1R1

The bearing is fitted with a lip seal. To avoid dis-tortion and consequent leakage, it must never bedriven in with a hammer. Fit it on the press so asto apply a gradual pressure.

29-27

DRIVESHAFTSGaiter - bearing assembly 29

86198R

Joint GI 69

Furthermore, secure the driveshaft on the pressvia its groove (G) using an extractor to avoid da-maging the coupling at the wheel end.

Refit the spider on the splined shafts and refit theretaining clrclips (depending on the type of as-sembly).

29-28

Documents

2. Transmission AD4