gearbox

manual

Having removed :
  • Gearbox.
Adjust :
  • Control cable of the gearbox.
Hub locking tool Br :
  • Tool ref.: 0606-AY/6310-T.
Tool to extract the ball joint Rt :
  • Tool ref.: 0622/9509-T.
Tool to extract the ball joint Rt2 :
  • Tool ref.: 0709/1892-T.
Gearshift lever position tool Pv :
  • Tool ref.: 0346.AA.
Locking pin Pi :
  • Tool ref.: 0346.AB.

accessibility

Disconnect the negative battery terminal.

Remove :
  • The front wheels.
  • The motor's lower protecting cover (if pertinent).
Drain :
  • The gearbox.
Remove :
  • The front/left wheel arch.
  • The fuses cover.
Put aside :
  • The motor compartment fuse box.
Remove :
  • The air intake ducts.
  • The fastening screw A1 ( according to the versions ).
  • The battery and its tray.
Put aside :
  • The wiring harnesses.

accessibility

Disconnect :
  • The control A cables on the gearbox.
Put aside :
  • The bracket B ( gearbox outer cable ).
Extract :
  • The clamp C.
Disconnect :
  • The hose D.
  • The connector E.

Release the hose G.

Unclip the wiring harness H1.

Remove :
  • The fastening H2 screws.
Put aside :
  • The electrical waterpump.
Remove :
  • The earth cable H3.
  • The fastenings H4.
  • The threaded rod H5.
Put aside :
  • The bracket H6.

left side

Remove :
With the tool Br :
  • The hub nut J (tightening torque C4 II = 305 N.m C4 Picasso II = 285 N.m DS4 / DS5 = 312 N.m).
Extract :
With the tool Rt2 :
  • The steering ball joint.
Remove :
  • The nut L (tightening torque C4 II = 42 N.m C4 Picasso II = 65 N.m DS4 / DS5 = 42 N.m).
Extract :
With the tool Rt :
  • The lower ball joint.
Remove :
  • The drive shaft, front left.

right side

Remove :
With the tool Br :
  • The hub nut J (tightening torque C4 II = 305 N.m C4 Picasso II = 285 N.m DS4 / DS5 = 312 N.m).
Remove :
  • The nuts K.
  • The maintaining plate.
Extract :
With the tool Rt2 :
  • The steering ball joint.
Remove :
  • The nut L (tightening torque C4 II = 42 N.m C4 Picasso II = 65 N.m DS4 / DS5 = 42 N.m).
Extract :
With the tool Rt :
  • The lower ball joint.
Remove :
  • The drive shaft, front right.

accessibility

Remove :
  • The cross-member N1 (tightening torque 65 N.m).
Put aside :
  • The cross-member N2.
Remove :
  • The cross-member N3 (tightening torque 51 N.m).
  • The stiffener N4 (tightening torque 18 N.m).

accessibility

Remove :
  • The escape line clamp M (at the level of the flexible hose).
  • The lower torque rod.
  • The front subframe.
  • The heat shield.
  • The nut N1.
  • The threaded rod N2.
  • The fastening screw N3 (tightening torque 55 N.m).
  • The fastening P1 screws (tightening torque 20 N.m).
Put aside :
  • The starter.
Remove :
  • The lower fastening screws P2.
  • The threaded rod P3.

component removal

Place a rolling jack under the motor with a wooden wedge (do not support the motor directly on the oil pan).

Remove :
  • The nut Q (tightening torque 65 N.m).
  • The fastening R screws (tightening torque 30 N.m).
  • The rubber S buffer(s).
  • The fastening T screws (tightening torque 25 N.m).
  • The gearbox bracket U.

Keep the gearbox in position with a workshop lift.

Remove :
  • The fastening V1 screws (tightening torque 60 N.m).
  • The gearbox bracket V2.
  • The upper fastening screws V3 (tightening torque 55 N.m).
  • The threaded rod W.
  • The gearbox.

clutch release bearing removal

Remove :
  • The gearbox.
  • The fastening Z screws.
  • The clutch release bearing.
To avoid any risk of leakage :
  • After substituting the clutch mechanism.
Replace imperatively :
  • The clutch release bearing.
  • The output seal of the differential of the gearbox X2.

reassembly

Check there are no leaks :
  • At the level of the crankshaft seal.
Check :
  • The lack of any impact or scratch on the flywheel .
  • The degree of wear of the flywheel.
  • The condition of the starter's crown.
  • The clutch diaphragm.

Check that the centering rings (on motor side and on gearbox side) are in good condition and proper position.

Clean :
  • The output gearbox shaft.
Lubricate :
  • The output gearbox shaft.
Replace imperatively :
  • The slave cylinder of the clutch ( the clutch release bearing ).

Proceed reversing the order of the removal.

Fill-up the gearbox.

Bleed the clutch fluid circuit.

Adjust :
  • Control cable of the gearbox.

cables adjustment

Remove :
  • The air feeding duct.
  • The center console.
  • The shift knob 1.
  • The boot 2 of the gearshift lever.
  • The sound proofing cover 3.
Pull :
  • The locking 4.
  • The locking 5.
Put back :
  • The boot 2 of the gearshift lever.
  • The shift knob 1.

Put the tool Pv in place.

Watch the correct setting of 6.

Put the tool Pi in place.

Press on :
  • The locking 4.
  • The locking 5.

Remove the locking device Pv Pi.

Proceed reversing the order of the removal.




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