AUTOMATIC GEARBOX: REMOVAL - REFITTING

Note, one or more warnings are present in this procedure

Equipment required

Diagnostic tool

component jack

safety strap(s)

indelible pencil

parts always to be replaced:

Differential output seal

WARNING

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and
operation recommendations before carrying out any repair:

Automatic gearbox: Precautions for the repair ,

Vehicle: Precautions for the repair .

REMOVAL

1. REMOVAL PREPARATION OPERATION

Position the vehicle on a two-post liftVehicle: Towing and lifting .

Remove:

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 the engine cover,

the batteryBattery: Removal - Refitting ,

the battery trayBattery tray: Removal - Refitting .

Remove (see 12A, Fuel mixture, Air inlet assembly: Exploded view) :

the air filter unit air inlet pipe,

the air filter unit.

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Unclip the battery wiring channel(1 ) from the left-hand suspended engine mounting.

Move the battery wiring channel away from the left-hand suspended engine mounting.

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Unclip:

the gear control cable(2) from the selector ball joint using an open-jawed spanner,

the gear control cable(3) from the support.

Move the gear control cable to one side.

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Remove:

the engine undertray,

the crankshaft position sensor(see Crankshaft position sensor: Removal - Refitting) .

Unclip the following from the automatic gearbox:

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the engine wiring channel(4) ,

the breather pipe from the gearbox(5) .

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Remove the lower bolt(6 ) of the engine wiring.

Note:

Do not touch the metal contacts of the computer - an electrostatic discharge can
damage the shift drum actuator motors.

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Disconnect the connector(7 ) from the gearbox computer.

Move the engine wiring away from the gearbox.

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 Note:

Before removing the earth terminal, mark its position using an indelible pencilby
drawing a line on the earth terminal and on the gearbox casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing
could result in damage to the earth terminal or earth wiring.

Remove the earth cable bolt(8 ) from the gearbox.

Remove:

the front wheelsFront hub carrier assembly: Exploded view ,

the front section of the front wheel arch linersExterior body front trim assembly: Exploded view ,

the starter(see 16A, Starting - Charging, Starter: Removal - Refitting) .

Drain the automatic gearbox oilAutomatic gearbox oil: Draining - Filling .

Remove:

the front left-hand driveshaftFront hub carrier assembly: Exploded view ,

the front right-hand driveshaftFront hub carrier assembly: Exploded view ,

the front bumperFront bumper assembly: Exploded view ,

the radiator mounting cross member,

the front axle subframeFront axle assembly: Exploded view .

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 Remove the left-hand suspended engine mountingEngine-gearbox unit support assembly: Exploded view .

2. REMOVAL OPERATION

Remove the gearbox bell housing bolts.

Fit a component jackunder the gearbox.

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 Note:

Correctly position the component jackunder the gearbox to facilitate the removal.

Remove:

the gearbox nuts,

the gearbox studs.

Using a safety strap(s), strap the gearbox on the component jack.

Remove the gearbox.

Note:

This operation requires two people due to the weight of the gearbox.

REFITTING

1. REFITTING PREPARATION OPERATION

Clean:

all the removed partsVehicle: Parts and consumables for the repair ,

the joint face of the automatic gearbox and engine casingsVehicle: Parts and consumables for the repair
.

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parts always to be replaced: Differential output seal .

CAUTION
Failure to observe the following procedure may damage the system connecting the
clutch to the flywheel of the automatic gearbox.

Check for the presence of centring dowels on the gearbox casing.

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Position the stud (9 ) on the gearbox.

Correctly position the gearbox on the component jack.

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Move aside the engine wiring.

Note:

Correctly position the gearbox using a component jackso that the gearbox bearing face
is exactly parallel to the engine bearing face, and the flywheel splines(10 ) and the
clutch pressure plate splines(11 ) are aligned.

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2. REFITTING OPERATION

Refit the gearbox using a component jack.

Note:

This operation requires two people due to the weight of the gearbox.

Note:

If the flywheel splines and the clutch pressure plate splines do not fit together, turn
the clutch pressure plate or the flywheel slightly.

Note:

Check for perfect contact between the bearing face of the gearbox and the engine.

Torque tighten:

the gearbox studs7 N.m,

the gearbox nuts44 N.m,

the gearbox bolts44 N.m.

Remove the safety strap(s)from the gearbox.

3. FINAL OPERATION

Refit the left-hand suspended engine mountingEngine-gearbox unit support assembly: Exploded view .

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Clip the rail protector drain pipe onto the gearbox.

Refit:

the front axle subframeFront axle assembly: Exploded view ,

the radiator mounting cross member,

the front bumperFront bumper assembly: Exploded view ,

new differential output sealsDifferential output seal: Removal - Refitting ,

the front right-hand driveshaftFront hub carrier assembly: Exploded view ,

the front left-hand driveshaftFront hub carrier assembly: Exploded view .

Fill the automatic gearboxAutomatic gearbox oil: Draining - Filling .

Refit:

the starter(see 16A, Starting - Charging, Starter: Removal - Refitting) ,

the front section of the front wheel arch linersExterior body front trim assembly: Exploded view ,

the front wheelsFront hub carrier assembly: Exploded view .

Note:

Refit the earth terminal at the mark made by the indelible marker on the gearbox
casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing
could result in damage to the earth terminal or earth wiring

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Torque tighten the gearbox earth cable bolt24 N.m.

Position the engine wiring on the gearbox.

Connect the gearbox computer connector.

Refit the engine wiring bolts onto the gearbox.

Clip the following onto the gearbox:

the breather pipe on the gearbox,

the engine harness channel.

Refit:

the crankshaft position sensor(see Crankshaft position sensor: Removal - Refitting) ,

the engine undertray.

Fit the gear control cable.

Clip:

the gear control cable on the support,

the gear control cable on the selector ball joint,

the battery wiring channel on the left-hand suspended engine mounting.

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 Adjust the gear control unit.Gear control unit: Adjustment

Refit the air filter unit(see 12A, Fuel mixture, Air inlet assembly: Exploded view) .

Refit:

the battery trayBattery tray: Removal - Refitting ,

the batteryBattery: Removal - Refitting ,

the engine cover.

Apply the After repair procedure using the Diagnostic toolDiagnostic tool : Use :
-Computer concerned by the After repair procedure:

"Automatic gearbox computer" .

Repair-12x07x01-01x37-1-57-1.xml

XSL version : 3.02 du 22/07/11

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