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Laguna Gearbox Manual
Laguna Gearbox Manual
CLUTCH
MANUAL GEARBOX
AUTOMATIC TRANSMISSION
DRIVESHAFTS
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 2000
Driveshaft
Contents
Page Page
29 DRIVESHAFTS
23 AUTOMATIC TRANSMISSION
Exploded view 29-1
Identification 23-1 General 29-2
Gears 23-2 Front driveshaft 29-3
Use 23-3 Gaiter - wheel side 29-7
Consumables 23-4 Gaiter - gearbox side 29-10
Parts to be systematically replaced 23-4
Oil 23-5
Oil change 23-6
CLUTCH 120
Identification 20
VEHICLE ENGINE
MECHANISM PLATE
TYPE MODEL
26 splines B = Blue
D = 215 mm V = Green
E = 6.8 mm GB = Grey Blue
BG0A K4M
BG0B F4P
21 splines
BG0G F9Q
D = 228 mm
228-7900
E = 8.4 mm
20-1
CLUTCH
Exploded view 20
20-2
CLUTCH
F4P - K4M
ENGINES Mechanism - Plate 20
REPLACEMENT
This operation is carried out after the gearbox has been separated from the engine.
REFITTING
TIGHTENING TORQUE (in daN.m)
Precautions which must be followed when repairing
Mechanism mounting bolt 2
the clutch:
16180R
20-3
CLUTCH
F4P - K4M
ENGINES Mechanism - Plate 20
ALIGNMENT
20-4
CLUTCH
F9Q ENGINE
Mechanism - Plate 20
SPECIAL TOOLING REQUIRED
Mot. 582-01 Immobilising tool
Emb. 1604 Self adjusting tool for compressing
the clutch mechanism
REMOVAL
REFITTING
20-5
CLUTCH
F9Q ENGINE
Mechanism - Plate 20
Compress the three springs along the direction shown ALIGNMENT
below.
Use the plastic centring tool found in the clutch kit.
Insert the plate (offset (A) from the hub on the flywheel
side).
20-6
CLUTCH
F4P - K4M
ENGINES Thrust bearing 20
REPLACEMENT
REMOVAL
Remove:
– the bleed screw (screw A),
– the thrust bearing (screw B).
REFITTING
Refit:
– the end stop,
– the bleed screw.
20-7
CLUTCH
F9Q ENGINE
Thrust bearing 20
REPLACEMENT
REMOVAL
Remove:
– the bleed screw (screw A),
– the thrust bearing (screw B).
REFITTING
Refit:
– the end stop,
– the bleed screw.
20-8
CLUTCH
F4P - K4M
ENGINES Flywheel 20
REPLACEMENT
This operation is carried out after the gearbox has been separated from the engine and after the clutch has been
removed.
REFITTING
TIGHTENING TORQUE (in daN.m)
Clean the threads of the flywheel mounting bolts on
Flywheel bolt 4
the crankshaft.
20-9
CLUTCH
Clutch shaft bearing 20
REPLACEMENT
REMOVAL
REFITTING
20-10
121
MANUAL GEARBOX
Gears 21
JR5
Differential Reverse
Suffix Type 1st 2nd 3rd 4 th 5 th
ratio gear
15 11 22 28 34 39
003 BGOH
61 37 41 37 35 32 11
15 11 21 28 31 37 39
008 BGOB
58 41 43 39 34 33
JH3
Differential Reverse
Suffix Type 1st 2 nd 3 rd 4 th 5 th
ratio gear
14 11 22 28 34 39 11
005 BGOA
59 37 41 37 35 32 39
PK6
Differential Reverse
Suffix Type 1st 2nd 3 rd 4 th 5 th 6th
ratio gear
19 11 19 31 41 41 47 27
001 BGOG
64 43 40 43 40 31 30 47
21-1
MANUAL GEARBOX
Lubricants 21
CAPACITY (in litres) JR5/JH3
JR5 2.5
JH3 2.8
PK6 2.2
VISCOSITY GRADE
JR5/JH3
PK6
21-2
MANUAL GEARBOX
Lubricants 21
PK6
3 Drain plug
4 Filler plug
5 Oil quantity
6 Gearbox model
21-3
MANUAL GEARBOX
Consumables 21
JR/JH
PART
TYPE PACKAGING COMPONENT
NUMBER
RHODORSEAL 5661 100 g tube 77 01 404 452 Threaded plugs and switches
21-4
MANUAL GEARBOX
Special features 21
GEAR SELECTOR GRID WARNING: it is FORBIDDEN to remove the
breather valve (D) when filling with oil.
PK6
To select reverse gear, lift the collar (A) and move the
lever.
JH3/JR5
21-5
MANUAL GEARBOX
F4P - K4M
ENGINES Removal - Refitting 21
SPECIAL TOOLING REQUIRED
B. Vi. 1531 Tool for centring flywheel
Mot. 1453 Tool for securing engine
T. Av.476 Ball joint extractor
EQUIPMENT REQUIRED
Component jack
REMOVAL
Remove:
– the front wheels,
– the engine covers,
– the battery,
– the fuse box,
– the battery mounting.
Remove:
– the air resonator housing, – the engine undertray,
– the TDC sensor, – the left wheel arch liners,
21-6
MANUAL GEARBOX
F4P - K4M
ENGINES Removal - Refitting 21
Left-hand side of the vehicle: – the driveshaft.
Remove:
– the track rod end using tool T. Av. 476,
– the upper mounting bolt (3) of the shock absorber
base.
21-7
MANUAL GEARBOX
F4P - K4M
ENGINES Removal - Refitting 21
Remove the mounting from the intermediate bearing.
21-8
MANUAL GEARBOX
F4P - K4M
ENGINES Removal - Refitting 21
Remove: – the exhaust - gearbox strut,
– the power assisted steering hose mountings, – the torque reaction arm,
– the wiring on the gearbox,
– the left hand body tie-rods on the side member,
18 749
18 673-1
21-9
MANUAL GEARBOX
F4P - K4M
ENGINES Removal - Refitting 21
Remove the starter mountings. Position the component actuator.
Remove:
– the lower mountings of the gearbox.
– the gearbox.
REFITTING
WARNING:
Do not coat the clutch shaft splines.
18 676
Remove:
– the gearbox mounting,
– the upper mountings of the gearbox.
21-10
MANUAL GEARBOX
F9Q engine
Removal - Refitting 21
SPECIAL TOOLING REQUIRED
Mot. 1453 Tool for securing engine
T. Av.476 Ball joint extractor
B. Vi. 1531 Tool for centring flywheel
EQUIPMENT REQUIRED
Component jack
REMOVAL:
Remove:
– the front wheels,
– the engine covers,
– the battery (1),
– the fuse box (2),
– the battery tray (3).
Remove:
– the air hose on the flowmeter,
– the air housing and the flowmeter (4). 18 655
21-11
MANUAL GEARBOX
F9Q ENGINE
Removal - Refitting 21
– the reversing connector, Remove:
– the track rod ends (A) using tool T. Av. 476,
– the shock absorber base mountings (C).
18 655
Remove: Remove:
– the right and left wheel arch liners, – the driveshaft mountings on the gearbox,
– the brake calipers, securing them to the suspension – the driveshaft.
spring to protect the hose,
– the ABS sensors, Take care to protect the gaiters.
– the lower ball joints using a cut-down Allen key if the
nut cannot be slackened.
18 661
X = 25 mm
21-12
MANUAL GEARBOX
F9Q ENGINE
Removal - Refitting 21
Right-hand side of the vehicle: Disconnect the clutch slave cylinder (2).
Remove:
– the intermediate bearing from the bottom of the
engine (A),
– the driveshaft,
– the gearbox / exhaust stay (B),
Remove:
– the air filter to turbocharger pipe,
– the starter mountings.
18 657
18980
18704
21-13
MANUAL GEARBOX
F9Q ENGINE
Removal - Refitting 21
Attach the wiring harnesses and the hydraulic hoses to
facilitate removal of the gearbox.
18 676
18 656
Remove:
– the gearbox mounting, Refit the gearbox support tightening the mounting
– the upper mountings of the gearbox, bolts in the correct order.
– the air and water hose support.
Remove:
– the lower mountings of the gearbox.
– the gearbox.
REFITTING
IMPORTANT:
Ensure the brake pipes are correctly secured to the
shock absorber bases.
21-14
MANUAL GEARBOX
5th gear pinions on vehicle 21
SPECIAL TOOLING REQUIRED
B. Vi. 22-01 Extractor
B. Vi. 31-01 Set of punches for extracting and fitting
∅ 5 mm spring pins
B. Vi. 1000 5thgear fixed pinion extractor
B. Vi. 1170 5thgear hub extractor
B. Vi. 1175 Bolt for fitting 5thgear fixed pinion
REMOVAL
Remove:
– the wheel arch cover,
– the tie-rod (1).
18 673-1
21-15
MANUAL GEARBOX
5th gear pinions on vehicle 21
Place a wooden block between the 5 th gear fork and On the primary shaft:
the drive pinion to act as a support then remove the
pin from the fork using tool B. Vi. 31-01. Remove the 5th gear fork and the sliding gear.
19326 Position the sliding gear of tool B. Vi. 1170 in the same
way as when selecting 5th gear and rotate it so as to
NOTE: To remove and refit the pin, engage a gear position the splines of the sliding gear opposite those
(3rd or 4th). of the hub.
Do not pull the pin of the 5 th gear fork outwards as the
gear shift prohibitor may move, thus preventing it from
being refitted.
21-16
MANUAL GEARBOX
5th gear pinions on vehicle 21
Place the housing of the tool on the sliding gear, and On the secondary shaft:
rotate it until it stops, then extract the hub.
Using tools B. Vi. 22-01 and B. Vi. 1000,
21-17
MANUAL GEARBOX
5th gear pinions on vehicle 21
On the primary shaft: Put three drops of Loctite FRENBLOC
– onto the primary shaft nut (27) and tighten it to a
Refit in order (21) (shoulder opposite the bearing) (22), torque of 16 daN.m.
(23), (24) and (8).
Place a wooden block between the 5 th gear fork and
Fit the fork on the sliding gear (26) fitted with (25). the drive pinion to act as a support then refit a new 5th
gear fork pin using tool B. Vi. 31-01 using the correct
Put three drops of Loctite FRENBLOC on the hub and assembly order with the slot along the axis of the
replace the hub-sliding gear and fork assembly. shafts.
19326
Select 1 st gear using the gear lever and 5th gear on the
gearbox by sliding the 5 th gear fork along its pin.
21-18
MANUAL GEARBOX
5th gear pinions on vehicle 21
Put the gearbox in neutral and check that all gears can Fill the gearbox with oil.
be selected.
Check the rear housing is sealed when the engine is
If any problems occur, check that reverse gear is not running.
engaged.
Refit:
Fit a new O-ring to ensure the rear housing is sealed. – the power steering hose mounting,
– the tie-rod (1),
Fit the rear housing by inserting the tube (A) into the
primary shaft.
18 673-1
21-19
121
MANUAL GEARBOX
JH3
Clutch shaft lip seal 21
REPLACEMENT
The lip seal is replaced after the gearbox has been opened.
21-20
MANUAL GEARBOX
JR5 / PR6
Clutch shaft lip seal 21
REPLACEMENT
This operation is carried out after the gearbox has been separated from the engine.
REMOVAL REFITTING
Using a ∅ 2.5 mm drill bit, drill a hole in the seal. Fit a new seal along with its protector using tool
B. Vi. 1236-01.
WARNING: DO NOT SCRATCH THE SHAFT OR
THE SEAL SURFACE.
21-21
121
MANUAL GEARBOX
Differential output seal 21
SPECIAL TOOLING REQUIRED
B. Vi. 945 Mandrel for fitting differential seal
for JH gearbox
B. Vi. 1058 Mandrel for fitting differential seal
for JR gearbox
B. Vi. 1235 Mandrel for fitting differential seal
for PK gearbox
Remove:
– the wheel arch liners,
– the front right wheel,
– the upper bolt (3) of the shock absorber base and
slacken the lower bolt (4),
– the ABS sensor.
18 704
21-22
MANUAL GEARBOX
JH / JR
Differential output seal 21
REPLACING THE SEAL
Tap the base of the lip seal using a drift and a small
hammer to pivot it in its housing.
The seal is fitted with tool: Tighten the nuts, bolts and studs to the recommended
– B. Vi. 945 for JH gearboxes, torques.
– B. Vi. 1058 for JR gearboxes,
Fill the gearbox.
Oil the tool before inserting it into the splined part of
the sunwheel.
Fit the lip seal then the O-ring and coat the splines with
MOLYKOTE BR2 grease.
21-23
MANUAL GEARBOX
PK
Differential output seal 21
REPLACING THE SEAL
Tap the base of the lip seal using a drift and a small
hammer to pivot it in its housing.
21-24
123
AUTOMATIC TRANSMISSION
Identification 23
SU1 DP0
B Year of manufacture.
23-1
AUTOMATIC TRANSMISSION
Gears 23
DP0
Step- Final Reverse
Suffix Type Engine 1st 2 nd 3rd 4th
down drive gear
SU1
Final Reverse
Suffix Type Engine Step-down 1st 2nd 3rd 4 th 5 th
drive gear
57 26
002 BG0D L7X 731 4.685 2.942 1.923 1.301 1 3.177
56 59
23-2
AUTOMATIC TRANSMISSION
DP0 / SU1
Use 23
SPECIFICATIONS TOWING
23-3
AUTOMATIC TRANSMISSION
Consumables 23
DP0
SU1
23-4
AUTOMATIC TRANSMISSION
Oil 23
DP0
The DP0 automatic transmission is greased for life and does not require any maintenance.
Specific oil:
ELF RENAULTMATIC D3 SYN (to be ordered from ELF) Standard DEXRON III.
Capacity in litres
Mechanism
Total volume 6
SU1
The oil level should be checked every 6000 miles (10 000 km) in case there is a slight oil leak.
Capacity in litres
Mechanism
Total volume* 7.6
23-5
AUTOMATIC TRANSMISSION
DP0
Oil change 23
Special notes:
TIGHTENING TORQUES (in daN.m)
The plug has two functions:
Drain plug 2.5 – draining through the plug (A),
Filler spout 3.5 – filling through the spout (B).
DRAINING
23-6
AUTOMATIC TRANSMISSION
SU1
Oil change 23
DRAINING
23-7
AUTOMATIC TRANSMISSION
DP0
Filling - Levels 23
FILLING
Use a funnel with a 15/100 filter to prevent impurities PROCEDURE FOR CHECKING THE LEVEL
from entering the system. OUTSIDE FILLING OPERATIONS
1 - Park the vehicle on level ground. 1 - Park the vehicle on level ground.
2 - Fill the automatic transmission with 3.5 litres of 2 - Fill the automatic transmission with 0.5 litres of
new oil. new oil.
3 - Run the engine at idling speed. 3 - Run the engine at idling speed.
4 - Connect the diagnostic tool and set up a dialogue Perform operations 4, 5 and 6 described previously.
with the automatic transmission computer.
If oil does not flow out or if the quantity retrieved is less
5 - Monitor the transmission oil temperature than 0.1 litre: switch off the engine, add 0.5 litre, allow
parameter. the transmission to cool down to 50˚C then repeat
operations 3-4-5-6.
6 - When a temperature of 60˚C ± 1˚C is reached,
open the top-up plug.
IMPORTANT: you must reset the oil wear electronic
7 - Position a container to retrieve at least 0.1 litre of counter (integrated within the computer) when the
excess oil and wait until the oil flows out drop by oil is changed. Enter the date of the oil change
drop. using the "Write date of gearbox oil change"
command (NXR).
23-8
AUTOMATIC TRANSMISSION
SU1
Filling - Levels 23
The gearbox is filled through the pipe (D). NOTE: the dipstick has a reading at 40°C, this can
only be used for checking and topping up the oil when
the engine is running. It is essential to confirm this
using the diagnostic tool.
23-9
AUTOMATIC TRANSMISSION
Checking the setting point of the converter 23
Put the vehicle on a 2 post lift.
Lift the vehicle until the wheels are raised off the
ground by a few centimetres.
23-10
123 AUTOMATIC TRANSMISSION
DP0
Hydraulic distributor 23
SPECIAL TOOLING REQUIRED
REMOVAL
23-11
AUTOMATIC TRANSMISSION
DP0
Hydraulic distributor 23
– the four mounting bolts (A) of the hydraulic distributor Disconnect the solenoid valve connectors and remove
cover (be careful as oil may run out). the hydraulic distributor.
23-12
AUTOMATIC TRANSMISSION
DP0
Hydraulic distributor 23
REFITTING
23-13
AUTOMATIC TRANSMISSION
SU1
Hydraulic distributor 23
Remove:
TIGHTENING TORQUES (in daN.m) – the battery,
– the fuse box,
Cover mounting bolt 1.2 – the automatic transmission computer,
Distributor mounting bolts 1 – the battery mounting.
REMOVAL
Release:
– the injection computer,
– the injection computer tray.
23-14
AUTOMATIC TRANSMISSION
SU1
Hydraulic distributor 23
Disconnect the harness (1). Disconnect and separate the bulkhead (G).
Remove: Remove:
– the wiring channel support (2) and release it, – the six mounting bolts (5) of the hydraulic distributor,
– the engine undertray,
– the dipstick (3),
23-15
AUTOMATIC TRANSMISSION
SU1
Hydraulic distributor 23
– the distributor by tilting it slightly in order to release REFITTING
the control (H) from the automatic transmission
selector, Clean the seal faces on the automatic transmission,
taking care not to damage the surface.
23-16
AUTOMATIC TRANSMISSION
SU1
Hydraulic distributor 23
Clean the surfaces of the automatic transmission
housing.
23-17
AUTOMATIC TRANSMISSION
DP0
Removal - Refitting 23
SPECIAL TOOLING REQUIRED
Mot. 1453 Tool for securing engine
T. Av. 476 Ball joint extractor
EQUIPMENT REQUIRED
Component actuator
REMOVAL
Remove:
– the front wheels,
– the style cover.
23-18
AUTOMATIC TRANSMISSION
DP0
Removal - Refitting 23
Remove the injection computer and its support.
Disconnect:
– the MFS (Multifunction Switch) cable ball joint (1),
– the MFS cable (2) by releasing the sleeve stop.
Remove:
– the TDC sensor,
– the engine undertray,
– the wheel arches,
– the left and right driveshafts,
– the starter motor,
– the engine tie-bar.
Disconnect:
– the modular connector (3) by releasing the connector
collar,
– the speed sensor connector.
23-19
AUTOMATIC TRANSMISSION
DP0
Removal - Refitting 23
– the left hand tie-rods and the transverse tie-rod (1), Fit the engine support tool (Mot. 1453).
– the bolts (2) of the aluminium side member.
Remove:
– the upper gearbox edge bolts and studs,
– the gearbox mounting.
Unfasten the harnesses.
Tilt the engine / automatic transmission assembly as
Remove the mounting bolt from the power steering low down as possible.
hose support (3).
IMPORTANT: Be careful not to damage the air
conditioning compressor.
23-20
AUTOMATIC TRANSMISSION
DP0
Removal - Refitting 23
Secure the converter with rope to prevent it from being
released.
REFITTING
23-21
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
SPECIAL TOOLING REQUIRED
REMOVAL
Remove:
– the front wheels,
– the style cover.
– the battery (A),
– the fuse box (B),
– the automatic transmission computer,
– the battery tray (C),
– the wiring harness from the battery support,
– the air hose on the flowmeter,
– the air housing and the flowmeter (D).
23-22
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
Disconnect: Fit the hose clamps and disconnect the water
– the ball joint (1) from the multifunction switch cable, exchanger.
– the cable (2) of the multifunction switch by releasing
the sleeve stop Unfasten the harness from the gearbox.
Disconnect:
– the input speed sensor connector (3)
– the input speed sensor connector (4).
23-23
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
Remove the sub-frame (see section 31). Remove:
– the inlet manifold,
Release the automatic transmission harness (1).
18668
19117
23-24
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
Move the lifting lug (A) from the timing side of the front
cylinder head to the flywheel side of the rear cylinder
head.
19168
Remove:
– the upper gearbox edge bolts and studs,
19117 – the gearbox mounting.
– Tilt the engine / automatic transmission assembly as
Fit the engine support tool (Mot. 1453). low down as possible.
23-25
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
REFITTING
Special notes:
19232
23-26
AUTOMATIC TRANSMISSION
SU1
Removal - Refitting 23
NOTE: when refitting the driveshafts, ensure that they
are inserted straight so as not to damage the
differential seals.
23-27
AUTOMATIC TRANSMISSION
Drive plate 23
SPECIAL TOOLING REQUIRED
REFITTING
TIGHTENING TORQUE (in daN.m and/or ˚)
Fit the drive plate, ensuring it is correctly positioned in
Drive plate bolt 4.5 + 50° ± 5° relation to the centring pin (3).
Remove:
– the ten bolts (V), TIGHTEN ALL THE BOLTS, NUTS AND
– the drive plate. STUDS TO THE RECOMMENDED TORQUE.
23-28
AUTOMATIC TRANSMISSION
Differential output seal 23
SPECIAL TOOLING REQUIRED
B. Vi. 1400-02 Tool for fitting SU1 automatic transmission seals
B. Vi. 1459 Tool for fitting right hand automatic transmission
seals on DP0
B. Vi. 1460 Tool for fitting left hand automatic transmission
seals on DP0
SU1
TIGHTENING TORQUES (in daN.m)
The oil is drained using suction via the dipstick
Brake caliper column bolt 0.7
pipe (D).
Lower ball joint nut 11
Shock absorber base bolt 18
Wheel bolts 10.5
Track rod end nut 3.7
Drain plug 2.2
REMOVAL
DP0
23-29
AUTOMATIC TRANSMISSION
Differential output seal 23
REFITTING
23-30
AUTOMATIC TRANSMISSION
DP0
Converter seal 23
SPECIAL TOOLING REQUIRED
REMOVAL
Using tool Mot. 587, remove the seal, taking care not
to scratch the contact surfaces.
REFITTING
Insert the new seal (oiled) fully using tool B. Vi. 1457.
23-31
AUTOMATIC TRANSMISSION
SU1
Converter seal 23
SPECIAL TOOLING REQUIRED
Remove:
– the converter,
– the sealing ring (A) using tool B. Vi. 465, with the ring
marked 1, by inserting it straight and then turning it
through approximately half a turn and extracting the
seal by progressively tightening the extractor bolt.
23-32
AUTOMATIC TRANSMISSION
SU1
Selector shaft seal 23
REFITTING
SPECIAL TOOLING REQUIRED
Refit the seal (lubricated with automatic transmission
B. Vi. 1401 Guide tube oil).
REMOVAL
23-33
AUTOMATIC TRANSMISSION
DP0
Line pressure tapping 23
23-34
AUTOMATIC TRANSMISSION
DP0
Multifunction switch 23
Disconnect the modular connector (4) by releasing the
TIGHTENING TORQUES (in daN.m) slide mechanism of the connector.
REMOVAL
Remove the air filter unit and the air flow sensor.
Disconnect:
– the MFS (Multifunction Switch) cable ball joint (1),
– the MFS cable (2) by releasing the sleeve stop.
Remove the lever and the two mounting bolts (3) of the
multifunction switch.
REFITTING
23-35
AUTOMATIC TRANSMISSION
DP0
Multifunction switch 23
ADJUSTMENT
23-36
AUTOMATIC TRANSMISSION
SU1
Multifunction switch 23
SPECIAL TOOLING REQUIRED
REMOVAL
Remove:
– the style cover,
– the battery (A),
Unclip and disconnect the wiring (D).
– the fuse box (B),
– the automatic transmission computer,
– the battery tray (C),
– the wiring harness from the battery support.
23-37
AUTOMATIC TRANSMISSION
SU1
Multifunction switch 23
Remove: Remove the two bolts (4) and release the multifunction
– the control cable, switch.
REFITTING
23-38
AUTOMATIC TRANSMISSION
SU1
Multifunction switch 23
ADJUSTMENT Remove:
– the control cable,
Shift the lever to N.
Remove:
– the style cover,
– the battery (A),
– the fuse box (B),
– the automatic transmission computer,
– the battery tray (C),
– the wiring harness from the battery support.
23-39
AUTOMATIC TRANSMISSION
SU1
Multifunction switch 23
Slacken both bolts (4). REFITTING
Modify the slot (A) using a file to line it up with the mark
(M) engraved on the multifunction switch.
23-40
AUTOMATIC TRANSMISSION
Computer 23
LOCATION
23-41
AUTOMATIC TRANSMISSION
Computer 23
REPLACING THE COMPUTER
Programming procedure for the accelerator pedal full load and no load positions.
When replacing the automatic transmission computer, the Full Load and No Load positions of the accelerator pedal
must be programmed by applying the following procedure:
– Shift the selector lever to P or N and keep the engine switched off.
CLIP:
NXR:
The automatic transmission oil ageing value from the computer to be replaced must be entered in the new computer
when the automatic transmission computer is replaced. Use the following procedure:
CLIP:
NXR:
– From the memory of the computer to be replaced, read the oil ageing value using the "Read oil counter" command.
– Replace the computer.
– Enter the oil ageing value in the memory of the new computer using the "Write oil counter" command.
– Check that it has been entered using the "Read oil counter" command.
23-42
AUTOMATIC TRANSMISSION
DP0
Sensors 23
Special note on REMOVING:
TIGHTENING TORQUES (in daN.m)
When replacing a sensor, always remove the modular
Input speed sensor mounting bolt 1 connector (see section on "Removal - Refitting
Output speed sensor mounting bolt 1 automatic transmission").
23-43
AUTOMATIC TRANSMISSION
SU1
Input speed sensor 23
Clean the area around the sensor to prevent dirt from
TIGHTENING TORQUE (in daN.m) entering the automatic transmission.
Input sensor mounting bolt 0.55 Unclip the speed sensor (D) and remove it.
REMOVAL
Remove:
– the style cover,
– the battery (A),
– the fuse box (B),
– the automatic transmission computer,
– the battery tray (C),
– the wiring harness from the battery support.
REFITTING
Remove the injection computer and its support.
Oil the O-ring of the speed sensor.
23-44
AUTOMATIC TRANSMISSION
SU1
Output speed sensor 23
TIGHTENING TORQUE (in daN.m)
REMOVAL
REFITTING
23-45
AUTOMATIC TRANSMISSION
SU1
Wiring (bulkhead) 23
Remove the injection computer and its support.
TIGHTENING TORQUE (in daN.m)
REMOVAL
Remove:
– the battery,
– the fuse box, Remove the mounting bolt from the power steering
– the automatic transmission computer, hose support (1).
– the battery mounting.
23-46
AUTOMATIC TRANSMISSION
SU1
Wiring (bulkhead) 23
Disconnect the harness (1). Disconnect and separate the gland (A).
Remove:
– the wiring channel support (2) and release it,
– the dipstick (3),
23-47
AUTOMATIC TRANSMISSION
DP0
Solenoid valves 23
Removal of the solenoid values is performed after
removal of the hydraulic distributor (see relevant
section).
23-48
AUTOMATIC TRANSMISSION
SU1
Solenoid valves 23
TIGHTENING TORQUES (in daN.m)
REMOVAL REFITTING
This operation is performed after having removed the Refit in the reverse order to removal and tighten to the
distributor housing (see relevant section). correct torque.
There is no specific procedure for removing the Check that the wiring is correctly inserted in the clips.
solenoid valves and it is the same for all:
Special notes:
S1 = sequence solenoid valve.
S2 = sequence solenoid valve. Put Vaseline on the solenoid valve seals for better
S3 = converter lock-up solenoid valve. positioning.
Remove:
Fill the automatic transmission with oil,
– the socket (D),
following the instructions (see relevant section)
– the bolt (1),
and remove the solenoid valve.
23-49
AUTOMATIC TRANSMISSION
DP0
Modular connector 23
TRACK NUMBERING
23-50
129
DRIVESHAFTS
Exploded view 29
DRIVESHAFT - JR / JH / PK GEARBOX
PLANCHE PR 29.011.0
PLANCHE PR 29.021.0
29-1
129
DRIVESHAFTS
General 29
SPECIFICATIONS
Driveshaft seal
29-2
DRIVESHAFTS
Front driveshaft 29
SPECIAL TOOLING REQUIRED
Remove:
– the front wheels,
18613
– the hub nut,
19184
29-3
DRIVESHAFTS
Front driveshaft 29
REMOVAL - GEARBOX SIDE Left side:
Remove: Remove:
– the two mounting bolts of the intermediate support, – the three mounting bolts of the gaiter on the gearbox,
97359R
95315S
29-4
DRIVESHAFTS
Front driveshaft 29
REPLACEMENT With the protector in place, coat the splines of the seal,
on the gearbox side, with MOLYKOTE BR2 grease.
Left side:
Position the driveshaft in relation to the sunwheel and
Remove the plastic protector from the bearing gaiter insert it.
and insert the driveshaft as horizontally as possible.
On both sides:
DI2908
95241R
29-5
DRIVESHAFTS
Front driveshaft 29
Lengthen or shorten the joint until the measurement RELAY SHAFT BEARING
A = 156 ± 1 mm is obtained (measurement taken
between the end of the gaiter and the machined face REPLACEMENT
of the larger diameter of the yoke).
Remove the whole driveshaft.
Fit the large clip and tighten it using OETIKER pliers,
part number 1090 (see gaiter on gearbox side - seal Extract the bearing using a press, by pressing on a
RC 491). FACOM U53T type separating tool or similar.
Fit the tool for immobilising the hub Take care not to scratch the contact surface of the lip
Rou. 604-01 and tighten the driveshaft nut to the seal on the relay shaft.
correct torque.
Press the brake pedal several times in order to Lubricate the section of the shaft into which the
bring the piston into contact with the brake shoes. bearing is inserted.
29-6
DRIVESHAFTS
Gaiter - wheel side 29
SPECIAL TOOLING REQUIRED
78616R
REFITTING
Insert the ball joint (1) fitted with a new stop ring onto
the splines of the shaft down to the segment of the
shaft channel (B).
90319R
REMOVAL
Cut the clips and the gaiter along its whole length.
Separate the stop ring (7) and at the same time, hit the
front side of the ball hub (5) several times with a
mallet.
78615R2
29-7
DRIVESHAFTS
Gaiter - wheel side 29
Distribute the quantity of grease in the gaiter and the Use pliers T. Av. 1168.
stub axle bowl.
90319R
CAILLAU clips
93040S
DI2910
NOTE: CAILLAU clips cannot be reused.
29-8
DRIVESHAFTS
Gaiter - wheel side 29
OETIKER CLIP
96048S
Put the linkage (A) on the lower notch and close the pliers fully. The pre-crimped clip slides onto the gaiter and can
be positioned.
POSITION 2 - Crimping
Put the linkage (A) on the upper notch and close the pliers fully.
29-9
DRIVESHAFTS
PK / JR / JH
DP0 / SU1 Gaiter - gearbox side 29
Joint on right hand driveshaft - PK / JR / JH / DPO / SU1 gearboxes
1 Driveshaft yoke Saw the existing large clip, taking care not to damage
2 Spider the channel of the yoke.
3 Rubber gaiter
4 Retaining clip
5 Driveshaft
93034S1
REMOVAL
Cut the gaiter.
Cut the retaining clip.
92045S
93036S1
29-10
DRIVESHAFTS
PK / JR / JH
DP0 / SU1 Gaiter - gearbox side 29
(Joint on right hand driveshaft) Using a press, extract the spider by pressing on a
FACOM U53T type separating tool.
89145S
92048-2R
90387S
29-11
DRIVESHAFTS
PK / JR / JH
DP0 / SU1 Gaiter - gearbox side 29
Insert the spider onto the splined shaft.
DI2908
90389S
92052R
29-12
DRIVESHAFTS
PK / JR / JH
DP0 / SU1 Gaiter - gearbox side 29
To obtain OETIKER pliers, order directly from the
supplier.
SUPPLIER
OETIKER
9 Rue Jean Moulin 77340
PONTAULT-COMBAULT FRANCE
PART NUMBER
88601R
Manual pliers 1090 for fitting OETIKER clips
– the large clip until it clicks, using OETIKER pliers, without nibs or lugs
part number 1090,
29-13
DRIVESHAFTS
PK / JR / JH
Gaiter - gearbox side 29
DI2915
90387S
90388S
29-14
DRIVESHAFTS
PK / JR / JH
Gaiter - gearbox side 29
Remove the gaiter and bearing assembly in the same This distance is obtained using tool T. Av. 1244 or
way as for the spider. T. Av. 944 when its end is level with the shaft.
85933S 85884-1R1
86197S
29-15
DRIVESHAFTS
PK / JR / JH
Gaiter - gearbox side 29
In addition, the driveshaft should be secured on the
press at the channel using a FACOM U53T type tool to
avoid damaging the seal on the wheel side.
86198R
Insert the spider onto the splined shaft and replace the
retaining circlip (depending on assembly).
29-16
DRIVESHAFTS
DP0 / SU1
Gaiter - gearbox side 29
With a pair of pliers, lift each end of the retaining
Joint on left hand driveshaft - DP0 and SU1
plate (C), then remove the yoke.
gearboxes.
74655R
Cut the crimped clip and the gaiter along its whole
length.
90387S
75936-1S1
29-17
DRIVESHAFTS
DP0 / SU1
Gaiter - gearbox side 29
Using a press, extract the spider by using a releasing Position the retaining circlip or crimp at three points at
type extractor. 120° by folding the metal of the splines down onto the
driveshaft.
90388S
REFITTING
90391S
Lubricate the driveshaft and slide on the new clip and
gaiter.
Insert a 2.5 mm thick shim (made in accordance with
Insert the spider onto the splined shaft. the diagram) between the retaining plate and the yoke.
90389S
29-18
DRIVESHAFTS
DP0 / SU1
Gaiter - gearbox side 29
With a copper hammer, carefully return the plate to its Insert a smooth rod with a rounded end between the
initial position, then remove the shim (B). gaiter and the yoke to distribute the air inside the joint.
74867R
98823R1
88601R
29-19