B2CG85K1 - 307 BE4R GEARBOX

REMOVAL - REFITTING GEARBOX

1 - SPECIAL TOOLS

SPECIAL TOOLS REQUIRED .

[1] Power train support crossmember (-).0009 .

2 - REMOVAL

WARNING : the gearbox is removed from under the vehicle .

Remove :

• the air cleaner bracket
• the air inlet hose
• the battery style cover
• the battery
• the battery container

Disconnect, unclip and move aside the electrical harnesses which are connected to the gearbox .

Remove the engine speed sensor (1) .

Uncouple :

• the engagement link (2) (USING THE TOOL [26])
• the reaction link (3) (USING THE TOOL [27])

Remove :

• the bolts (4)
• the nut (5)
• the gear lever connecting rods (6) support

Remove :

• THE WIPER ARMS
• the scuttle grille (7)

Position the power train support cross member [1] .

WARNING : position the contact points at (A) .

Hook the crossmember [1] or the engine lifting hook .

Remove :

• the gearbox shaft nut (8) and its washer
• the mounting bolts (9)
• the flexible mounting (10)
• the bolts (11)
• the gearbox shaft bracket (12)
• THE GEARBOX SHAFT (13) AND ITS WASHER USING TOOL [30]

Lift and support the vehicle with front wheels suspended .

Remove :

• the front wheels
• the engine undershield
• the front left mud shield

Drain the gearbox .

Remove the drive shafts .

IMPERATIVE : uncouple the exhaust line to avoid destroying the hose; this cannot withstand the torsion, traction or bending stresses caused by the removal of one of the power train supports .

WARNING : do not open the hydraulic circuit .

Remove the clutch slave cylinder (14) by means of the bolts (15) .

Remove the starter and harness support (16) mounting bolts (17) .

Move aside the assembly without disconnecting them .

Remove :

• the bolt (18)
• the bolt (19)
• the movement limiter (20)

Remove :

• the nuts (21)
• the bolts (22)
• the lower mounting bolts (23)
• the impactor (24)

Lower the power train slightly using the threaded rod of the crossmember [1] .

Attach a crane to the gearbox with the hook .

Remove The gearbox upper mounting bolts (25) .

WARNING : protect the radiator using a piece of cardboard when the gearbox is lowered .

Remove the gearbox .

Remove the stop (26) and fork (27) assembly .

3 - REFITTING

Check the condition of the ball joint shell bearing (28) .

If incorrect : Replace the clutch fork .

LIGHTLY COAT WITH G12 GREASE : The fingers of the fork (29) .

Position the stop (26), with the lugs (30) on the fork arms (29) .

LIGHTLY COAT WITH G12 GREASE : The bearing guide tube (31) .

WARNING : do not grease the input shaft splines .

Refit the fork (27) + stop (26) assembly .

Move the stop (26) in order to check that the lugs (30) are positioned behind the fork arms (29) .

IMPERATIVE : the stop should move with the fork .

Always renew :

• THE FINAL DRIVE OUTPUT OIL SEALS, USING DRIFTS [28] - [29]
• the extension o-ring
• self-locking nuts
• the spring washers

WARNING : ensure that the gearbox locating pins are fitted .

Fill the space between the oil seal lips with grease .

WARNING : do not trap the electrical harnesses when refitting the gearbox .

Attach the gearbox to the engine .

Fit the upper securing bolts (25) .

Tightening torque 5.5 da.Nm .

Clean the threads of the gearbox shaft ; COAT WITH E3 GREASE .

Fit :

• the gear level connecting rods support ; couple the connecting rods (2) - (3)
• the bolts (4) : 1.9 da.Nm
• the nut (5) : 1.3 da.Nm
• the starter
• the harness bracket (17)

Refit the slave cylinder (14) .

Tighten the bolts (15) to 2 daN.m .

Fit :

• the impactor (24)
• the nuts (21)
• the bolts (22)
• the gearbox lower mounting bolts (23)

Fit :

• the movement limiter (20)
• the bolt (19) : 4 da.Nm
• the bolt (18) : 5.5 da.Nm

Fit :

• the gearbox pin (13) and its washer : USING THE TOOL [30]
• the gearbox shaft bracket (12)
• the bolts (11)
• the flexible mounting (10)
• the mounting bolts (9) (without tighterning)
• the gearbox shaft nut (8) and its washer

WARNING : centralise the power train before tightening the flexible mounting securing bolts .

Tighten :

• the bolts (9) : 3.0 da.Nm
• the nut (8) : 6.5 da.Nm

Proceed in the reverse order to removal .

Refit the drive shafts .

Fill the gearbox to the correct level .

Initialise the various ECUs .

4 - TIGHTENING TORQUES

The gearbox shaft (14) : 5.0 da.Nm .

The mounting bolts (10) : 3.0 da.Nm .

The gearbox shaft nut (9) : 6.5 da.Nm .

Securing bolt(s) (12) for the battery tray bracket : 2.0 da.Nm .

Clutch slave cylinder securing bolt(s) (15) : 2 da.Nm .

The nuts (21) : 4.0 da.Nm .

The bolts (22) : 4 da.Nm .

The gearbox lower mounting bolts (23) : 5.5 da.Nm .

The gearbox upper mounting bolts (25) : 5.5 da.Nm .

Starter securing bolt : 3.5 da.Nm .

The bolts (4) : 1.9 da.Nm .

The nut (5) : 1.3 da.Nm .