B2CG1GK1 - 406D9 BE4 GEARBOX

REMOVAL - REFITTING GEARBOX

1 - SPECIAL TOOLS

[1] Tool for unclipping 13 dia. ball joints (-).0216-G2 .

[2] Fitting drift for final drive right-hand output oil seal (-).0317-U .

[3] Fitting drift for final drive left-hand output oil seal (-).0317-T .

[4] Socket for the removal of the gearbox shaft (-).0317-AB .

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

[6] Clutch plate centralising mandrel (-).0214 .

2 - REMOVAL

WARNING : the gearbox is removed from under the vehicle .

Disconnect the battery .

Remove the pipe and the air cleaner housing .

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

Move aside the clutch slave cylinder without opening the circuit .

WARNING : do not press the clutch pedal (risk of clutch slave cylinder breakage) .

Remove :

• engine speed sensor (1)

Remove the 3 starter securing bolts .

Move aside the starter without disconnecting it .

Uncouple :

• the selector rod (2) ; using the tool [1]
• engagement rod (3) ; using the tool [1]

Remove the 2 bolts (4) .

Position the crossmember [5] and its brackets .

WARNING : position the contact points at (A) .

Hook the crossmember [5] or the engine lifting hook .

Remove :

• the gearbox shaft nut (5) and its washer
• the mounting bolts (6)
• the gearbox flexible mounting (7)
• the spacer
• the gearbox shaft (8) and its washer using tool [4]

Lift and support the vehicle with front wheels suspended .

Remove :

• the shield under the power train
• the front wheels
• the front left mud shield

Drain the gearbox .

IMPERATIVE : remove : the exhaust pipe .

remove the drive shafts .

Remove :

• the bolt (9)
• the bolt (10)
• the movement limiter (11)

Remove :

• the bolt (12)
• the mounting and the speedometer take-off gear (13)
• the bolts (14)
• the final drive extension (15)

Retrieve :

• the speedometer drive gear (16)
• the O-ring (17)

Remove the nut (18) .

Move aside : The gearbox control plate (19) .

Remove : The gearbox lower mounting bolts (20) .

Lower the power train slightly using the threaded rod of the crossmember [5] .

Attach a crane to the gearbox with the hook .

Remove :

• the gearbox upper mounting bolts (21)
• the gearbox

Remove the stop (22) and fork (23) assembly .

3 - REFITTING

Check the condition of the ball joint shell bearing (24) .

If incorrect : Replace the clutch fork .

Coat lightly with MOLYKOTE BR2 PLUS grease, The fingers of the fork (25) .

Position the stop (22), with the lugs (26) on the fork arms (25) .

Coat lightly with MOLYKOTE BR2 PLUS grease, The bearing guide tube (27) .

WARNING : do not grease the input shaft splines .

Refit the fork (23) + stop (22) assembly .

Move the stop (22) in order to check that the lugs (26) are positioned behind the fork arms (25) .

IMPERATIVE : the stop should move with the fork .

Always renew :

• the final drive output oil seals, using drifts [2]-[3]
• 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 (21) .

Tightening torque 5,5 da.Nm .

Clean the threads of the gearbox shaft (8), and coat with threadlock LOCTITE .

Fit the gearbox shaft (8) and its washer ; Using the tool [4] .

Tighten the shaft (8) to 5 da.Nm .

Fit :

• the spacer
• the gearbox flexible mounting (7)
• the gearbox shaft nut (5) and its washer
• the mounting bolts (6) (without tightening)

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

Tighten :

• the nut (5) : 6,5 da.Nm
• the bolts (6) : 3 da.Nm

Tighten the bolts (20) to 5,5 daN.m .

Position : The gearbox control plate (19) .

Tighten the nut (18) to 1,5 da.Nm .

Tighten the 2 bolts (4) to 2 da.Nm. .

Position the clutch slave cylinder (28) .

Tighten the bolts (29) to 2 daN.m .

Fit :

• the O-ring (17)
• the speedometer drive gear (16)
• the final drive extension (15)
• the bolts (14) (tightening torque 1,5 da.Nm)
• the mounting and the speedometer take-off gear (13)
• the bolt (12)

Fit :

• the movement limiter (11)
• the bolt (10) (tightening torque 8,5 da.Nm)
• the bolt (9) (tightening torque 4,5 da.Nm)

Proceed in the reverse order to removal .

IMPERATIVE : always renew : the exhaust clip .

Fill the gearbox to the correct level (Add new oil) .

Initialise the various ECUs .

4 - TIGHTENING TORQUE(S)

The gearbox shaft (8) : 5 da.Nm .

The mounting bolts (6) : 3 da.Nm .

The gearbox shaft nut (5) : 6,5 da.Nm .

Clutch slave cylinder securing bolt(s) (29) : 2 da.Nm .

The bolt (9) of the movement limiter to 4,5 da.Nm. .

The bolt (10) of the movement limiter to 8,5 da.Nm. .

Differential extension fastener (14) : 1,5 da.Nm .

The gearbox lower mounting bolts (20) : 5,5 da.Nm .

The gearbox upper mounting bolts (21) : 5,5 da.Nm .

Starter securing bolt : 3,5 da.Nm .

Drive shaft bearing nut : 1,35 da.Nm .

Drive shaft nut : 32,5 da.Nm .

The wheel bolts to 9 da.Nm .