B2CG1CK1 - 607 ML5T GEARBOX

REMOVAL - REFITTING ML5T GEARBOX

1 - SPECIAL TOOLS

[1] Tool for unclipping 10 dia. ball joints (-).0216-G1 .

[2] Clutch stop clipping tool (-).0216-K .

[3] fitting drift for final drive left-hand output oil seal (-).0332-A .

[4] fitting drift for final drive right-hand output oil seal (-).0332-B .

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

2 - REMOVAL

NOTE : the gearbox is removed from under the vehicle .

Remove the upper style covers (1) and (2) .

Disconnect the battery .

Remove the air filter assembly plus sleeve (3) .

With a clean syringe empty the brake fluid bottle .

Undo the accelerator cable .

Remove the accelerator control bracket housing (4) .

Using the tool [1], unclip the gear control ball joints for gear selection (5) and gear changing (6) .

Empty the hydraulic circuit (clutch hydraulic control) with the bleed screw (7) .

Move aside the clip (8), Without removing .

Move aside the pipe .

Release the clutch slave cylinder (9) on the hydraulic control (by pressing in the direction of the arrow (A) and releasing in the direction of the arrow (B), anti-clockwise .

WARNING : do not use any tools to unfasten the cylinder .

Disconnect, The connector (10) to the reverse gear switch .

Remove :

• the earth lead (11)
• the starter fixing bolts (12)

Move aside the starter without disconnecting it .

Remove the engine speed sensor (13) .

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

Remove the wheels .

Remove the right and left mud guards .

Remove the shields under the power train .

Drain, The gearbox .

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Remove the air conduit (15) .

Unclip the power steering pipe (14) .

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drain the power steering circuit .

Disconnect the power steering pipe (14) from the valve (16) .

Blank the connectors on the pipe (14) and the valve (16) .

Unclamp the power steering pipe (14) and let it hang down .

ALL MODELS

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

Remove :

• the sub-frame
• the right-hand drive shaft

Disengage the left-hand drive shaft .

Remove the control cable clips from the gearbox .

Position the crossmember [5] and its brackets .

WARNING : position the contact points at (C) .

Remove :

• the gearbox shaft nut (17)
• the 3 bolts (18) from the gearbox shaft

Remove :

• the lower bolts (19) securing the gearbox on the engine

Hook a hoist on the gearbox .

Remove :

• {{o60519}} les vis de fixation superieures de la boite sur le moteur
• the gearbox

3 - REFITTING

Always renew :

• the O ring (20) of the bearing stop plate (21)
• the final gear outlet lip seal (22) using the tool [3]
• self-locking nuts
• the spring washers

Always renew, The final gear outlet lip seal (23) using the tool [4] .

WARNING : ensure that the gearbox locating pins are fitted .

Coat lightly with MOLYKOTE BR2 PLUS grease :

• the release bearing guide sleeve
• the fingers of the fork

Coat with grease the gap between the lips of the final drive outlet seal .

Clean the bolt threads .

On refitting, the stop must be on its guide and positioned by the declutching fork .

The stop is clipped to the mechanism after the gearbox has been assembled on the engine .

Refit the clutch .

Attach the gearbox to the engine, Tighten the bolts (19) to 6 daN.m .

Reclip the clutch stop :

• insert the tool [2] in the oblong hole in the clutch fork
• rotate the tool [2] by 90 °
• pull, using the handle, to clip the stop
• check that it is correctly clipped by pushing the tool (the stop should not fall back)

Proceed in the reverse order to removal .

WARNING : on refitting the hydraulic cable, check that the rod is correctly positioned, do not forget to refit the toothed washers between the steering rack and the sub-frame .

Fill the gearbox: 1.850 litre(s) .

4 - TIGHTENING TORQUE(S)

Bolt which secures the gearbox to the engine: 6 da.Nm .

Bolt which secures the gearbox mounting: 4.5 da.Nm .

Bolt which secures the flexible mounting to its bracket: 3 da.Nm .

Gearbox mounting shaft nut: 6.5 da.Nm .

Starter securing bolt: 3.5 da.Nm .

Closer plate securing bolt: 2 da.Nm .

Drive shaft bearing fastenings: 1.75 da.Nm .

Bolt(s) (24) securing the sub-frame to the body to 6.5 daNm .

Bolt(s) (25) securing the sub-frame to the body to 12.8 daNm .

Bolt(s) (26) securing the sub-frame to the body to 10 daNm .

Steering housing nuts (28): 8 da.Nm .

Reaction link rod bolts (29): 5 da.Nm .

{{O97551}} vis (34) de tirants de berceau: 5 da.Nm .

Wishbone ball joint nut (31): 4 da.Nm .

Nut (32) for securing the rod to the stabiliser bar: 3.5 da.Nm .

Wheels: 9 da.Nm .

Drive shaft nut (33): 32.5 da.Nm .