B2CG74K1 - 406D9 4HP20 AUTOMATIC GEARBOX
REMOVAL - REFITTING GEARBOX
1 - SPECIAL TOOLS
 Workshop hoist .
 Shackles (Quantity 2) .
 Lifting chain (-).0102-M .
 Positioning pin for automatic gearbox (-).0336-A2 .
 Converter support pin (-).0336-E2 .
 ball joint extractor (-).0336-G .
 hose clamp (-).1512 (Quantity 2) .
 Gearbox mounting shaft removal/refitting socket (-).0338-P .
 Pliers for cooling circuit spring clips (-).0165 .
 Power train support crossmember (-).0009 .
 Retaining clip DW12 (-).0336-R .
 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 .
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  .
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  .
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 .
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) .
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 .
Position the crossmember  and its brackets (406) .
Hook the crossmember  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  .
Method valid only for EW12 engine(s) .
Position the converter retaining pin .
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 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 :
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  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  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  and the automatic gearbox lining up of parts pin  .
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 ) .
Tighten, The pin (14) to 5 daNm .
WARNING : centralise the power train before tightening the flexible mounting securing bolts .
IMPERATIVE : strictly follow the fastening and routes of the various harnesses and pipes .
Proceed in the reverse order to removal .
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  .
Reinitialisation of auto-adaptation functions, Automatic gearbox, DIAG 2000, Select the menu, Replacement parts, 4HP20 gearbox .