B2CG74K1 - 406D9 4HP20 AUTOMATIC GEARBOX

REMOVAL - REFITTING GEARBOX

1 - SPECIAL TOOLS

[1] Workshop hoist .

[2] Shackles (Quantity 2) .

[3] Lifting chain (-).0102-M .

[4] Positioning pin for automatic gearbox (-).0336-A2 .

[5] Converter support pin (-).0336-E2 .

[6] ball joint extractor (-).0336-G .

[7] hose clamp (-).1512 (Quantity 2) .

[8] Gearbox mounting shaft removal/refitting socket (-).0338-P .

[9] Pliers for cooling circuit spring clips (-).0165 .

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

[11] Retaining clip DW12 (-).0336-R .

[12] Retaining clip EW12 (-).0336-Q .

2 - REMOVAL

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) .

NOTE : the gearbox is removed from under the vehicle .

WARNING : the 4HP20 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) .

Disconnect the battery .

Remove :

• the air cleaner
• the air inlet hose
• the battery
• the battery container
• variable damping electronic actuators (according to specification)
• inlet manifold (only on ES9J4 - ES9J4S engines)

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

Unclip the multifunction switch connector (1) .

Unclip the selection control cable (2) using the tool [6] .

Detach the cable (2) from the bracket (3) .

Move aside The cable (2) .

Disconnect the connector (4) .

Disconnect the earth socket on the automatic gearbox .

Protect the connector (4) on the automatic gearbox .

Fit the hose clamps [5] .

Remove the hoses (5) from the heat exchanger .

WARNING : protect the heat exchanger outlets on the gearbox .

Remove the support (6) .

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 .

Suspend the steering rack from the exhaust manifold .

Remove :

• ENGINE SUB FRAME
• THE DRIVE SHAFTS

Disconnect : The engine speed sensor connector (7) .

Disconnect the speedometer drive connector .

Unclamp the pipe (8) .

Remove the starter .

This procedure is valid only for engine(s) (ES9J4) .

Move aside the power steering pipe (9) .

Remove the closer panel (10) .

Remove the 3 bolts securing the converter (11) by turning the crankshaft .

This procedure is valid only for engine(s) (EW) .

This procedure is valid only for engine(s) (XU) .

Remove :

• the 3 nuts (11) - (17)

This procedure is valid only for engine(s) DW .

Move aside the power steering pipe (14) .

Remove the air supply pipe (1a) .

Remove the 3 bolts securing the converter (16) by turning the crankshaft .

Remove :

• the lower gearbox/engine assembly bolts

Position the crossmember [10] and its brackets (406) .

Hook the crossmember [10] or the engine lifting hook .

ES9J4 ENGINE ES9J4S ENGINE

Method valid only for ES9J4 - ES9J4S engine(s) .

Remove : The automatic gearbox engine speed sensor .

Position the converter support pin [5] .

EW12J4 ENGINE

Method valid only for EW12 engine(s) .

Position the converter retaining pin .

ALL MODELS

NOTE : the gearbox must only be attached by the sling hook next to the heat exchanger .

WARNING : the gearbox weighs approximately 90 kg .

Using the workshop crane, attach the automatic gearbox by its sling hook .

Remove :

• the shaft nut (12) and its washer
• the flexible mounting (13)
• the spacer
• the gearbox shaft (14) and its washer using tool (8)

Remove : The upper gearbox/engine assembly bolts .

Detach the gearbox .

Separate the gearbox .

Lower the gearbox carefully ensuring that no electrical harness will be damaged .

Precautions to be taken :

• do not place the gearbox on the bench without protection
• never use the connectors as a handle for lifting, turning, holding or pushing the gearbox

WARNING : be careful of the nose (15) and housing of the converter (16) during these operations .

3 - REFITTING

Position a new converter guide ring (17) .

Ensure that the ring (17) is present before lining up .

Check that the pins (18) are present .

Position one of the holes (19) as low as possible .

WARNING : take care not to damage the flywheel plate when the gearbox is refitted to the engine, do not trap the electrical harnesses when refitting the gearbox .

Offer up the gearbox .

Fit the centralising pin [4] to the converter .

Position the converter (Pin, Downward) (For ES9J4 - ES9J4S engine(s)) .

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

Method for XU10J4R - EW12 engine(s) .

IMPERATIVE : line up the positioning pin [4] with the drive plate and the opening (G) .

Line the gearbox up with the engine .

Fit the gearbox/engine securing bolts(Tighten to the specified torque : 5.2 da.Nm) .

Take out the converter retaining pin [5] and the automatic gearbox lining up of parts pin [4] .

Fit : The speed sensor .

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

Fit : The converter securing nuts (11) .

Pre-tightening : 2 da.Nm .

Tightening torque to 6 da.Nm .

Fit the gearbox shaft (14) and its washer (Using the tool [8]) .

Tighten, The pin (14) to 5 daNm .

Fit :

• the spacer
• the gearbox flexible mounting (13)
• the gearbox shaft nut (12) and its washer
• the mounting bolts (20) (without tightening)

Detach :

• the crossmember and its brackets
• the workshop crane

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

Tighten :

• the nut (12) to 6.5 da.Nm + LOCTITE FRENETANCH
• the bolts (20) to 3 da.Nm

IMPERATIVE : strictly follow the fastening and routes of the various harnesses and pipes .

Proceed in the reverse order to removal .

Tighten :

• the drive shaft nuts to 32.5 da.Nm.
• the wheel bolts to 9 daN.m.

CHECK THE GEARBOX LEVEL .

BLEED THE COOLING SYSTEM .

Bleed the power steering circuit (For ES9J4S - ES9J4 engine(s)) .

WARNING : use appropriate bolts for securing .

Remove the centralising pin [4] .

Reinitialisation of auto-adaptation functions, Automatic gearbox, DIAG 2000, Select the menu, Replacement parts, 4HP20 gearbox .