B2CG0IK1 - 406D9 AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING GEARBOX

1 - REMOVAL

The gearbox is removed from under the vehicle .

WARNING : the automatic gearbox is sealed for life; there is no need to drain the gearbox for this operation .

Place the vehicle on a two-post ramp (To make the operation easier) .

Before removing the sub-frame, position the steering column/steering wheel assembly (1) in the lowest and most rearwards position possible .

Press button (2) on the universal joint indexer (3) to immobilise the assembly (1) .

Remove the left hand drive shaft nut .

Raise the vehicle .

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 .

Clamp the steering unit to the bulkhead .

Remove :

• the sub-frame

Remove :

• the left hand drive shaft

Move aside the right hand drive shaft .

Remove :

• the nut (7)
• the connector (8)
• the bolts (9)
• the 3 nuts (10)
• the speed sensor

DIESEL DW

Remove :

• the turbo pipe (11)
• housing bottom closing plate

Remove the converter securing nuts by turning the crankshaft .

Remove the rod (12) .

Move aside the starter without disconnecting it .

Remove the impactor .

Remove :

• the bottom fastening bolts (gearbox to engine)

Lower the vehicle .

Disconnect the battery .

Remove :

• the air cleaner
• the exhaust expansion chamber
• the air ducts
• the battery cover
• the battery and its tray

Remove :

• the bolt (14)
• the ball joint connection (B) using the tool [6]
• the cable stop (15) by means of an electrician's screwdriver

position the tools [29] on the pipes (18) .

Remove :

• the bracket mounting (16)
• the pipes (18) ; using the tool [25]

Move aside the harnesses (19) .

Disconnect the interconnection (20) .

AL4 AUTOMATIC GEARBOX

Position : the tools [30] - [31] - [32] - [21] .

ALL MODELS

Remove :

• the gearbox shaft nut (20) and its washer
• the bolts (21)
• the flexible mounting (22)
• the bolt (23) using tool [16]

2 - REFITTING

Check the presence of the centralising bushes (25) .

locate the positioning pin [1] .

EW/DW ENGINE

Remove the tool [18] .

ALL MODELS

Smear MOLYCOTE BR2 grease on the converter nose ( At D) .

EW/DW ENGINE

Line up the positioning pin [1] with the drive plate and the opening (26) .

ALL MODELS

WARNING : when lining up the parts, do not distort the drive plate or the ring .

Refit the gearbox/engine upper mounting bolts (28) (Tightening torque 5.2 da.Nm) .

Remove the torque converter retaining tool .

Tighten the bolts (29) to 3.5 daN.m .

Remove the tool [1] using a rubber end-piece .

Fit :

• the engine/gearbox lower mounting bolts (30) (tightening torque 5.2 da.Nm)
• the converter securing nuts (27)

IMPERATIVE : fit new nuts : pre-tighten to 1 da.Nm ; tightening torque 3 da.Nm .

Ensure that there is no space remaining at the contact surfaces .

Coat with LOCTITE FRENETANCH ; The gearbox shaft (23) .

Fit the gearbox shaft (23) and its washer ; using the tool [16] .

Tighten the shaft (23) to 5 da.Nm ; Using the tool [16] .

Fit :

• the spacer (coat with PCAS SPAGRAM grease)
• the gearbox flexible mounting
• the gearbox shaft nut (20) and its washer
• the mounting bolts (21) (without tightening)

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

Tighten :

• the nut (20) to 6.5 da.Nm
• the bolts (21) to 3 da.Nm

Continue the fitting operations in the reverse order to removal .

Fit :

• the drive shafts
• the sub-frame

Check :

• the oil level in the gearbox
• the coolant level

NOTE : if changing the auto-adaptive gearbox, update the oil wear meter using the diagnostic equipment AL4 .

Reinitialisation of auto-adaptation functions ; Using the tool [DIAG 2000] .

Carry out accelerator pedal learning .