Transmission AD4

Transmission
CLUTCH
MANUAL GEARBOXES
AUTOMATIC TRANSMISSION
DRIVESHAFTS
77 11 190 841
NOVEMBER 1996
All copyrights reserved by Renault.
Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed".
Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.
Renault S.A. 1988
EXPLODED VIEW
PRD2013
Transmission
Contents
Pages
Pages
20 CLUTCH
Identification Side views Exploded view Consumables Mechanism - Clutch plate Thrust pad - Fork 20-1 20-4 20-4 20-5 20-6 20-10
23 AUTOMATIC TRANSMISSION
AD4 automatic transmission Exploded view Use Identification Gear ratios Gear change thresholds Consumables Parts which must be changed automatically Oil Oil drain intervals Oil draining Filling - Levels Oil pressure Changing the strainer Hydraulic distributor Automatic transmission (Removal Refitting) Full-load validation Load potentiometer Computer (119) Line pressure sensor (8) Multifunction switch (485) Vehicle speed sensor (250) Solenoid valve Engine torque reduction Special features 23-23 23-24 23-25 23-26 23-27 23-29 23-29 23-29 23-30 23-31 23-32 23-33 23-34 23-36 23-41 23-57 23-58 23-60 23-61 23-62 23-63 23-64 23-65 23-66
21 MANUAL GEARBOXES
Identification Gear ratios Capacities - Lubricants Special features Consumables Parts which must be changed automatically Gearbox (Removal - Refitting) 5th gear linkage in situ Differential output seal Speedometer drive 21-1 21-2 21-5 21-7 21-8 21-8 21-9 21-23 21-29 21-32
23 AUTOMATIC TRANSMISSION
MB automatic transmission Exploded view Use Identification Gear ratios Gear change thresholds Consumables Parts which must be changed automatically Oil Draining - Filling - Levels Checking and adjusting the potentiometer Oil pressure Strainer Automatic transmission (Removal Refitting) 23-1 23-2 23-3 23-4 23-5 23-6 23-6 23-7 23-8 23-11 23-13 23-15
29 DRIVESHAFTS
Consumables Driveshafts Gaiter at wheel end Gaiter at gearbox end Gaiter - bearing assembly 29-1 29-2 29-9 29-19 29-26
CLUTCH Identification
20
Plate
ENGINE TYPE
Mechanism
C1G C1J C2J C3J E6J B = White GB= Blue grey V = Green
85873S 90693R 76906R
180 CP 3300
26 splines E = 7.7 mm D = 181.5 mm
F2N F3N
76907S 90693R1 76906R
2000 CP 4000
26 splines M= 6 pale pink springs E = 7.7 mm D = 200 mm
20-1
ENGINE TYPE
20
CLUTCH PLATE
MECHANISM
F7P
76907S
93813R
76906R
200 CP 4400
26 splines D = 200 mm E = 7.7 mm
R = 4 red springs J = 4 yellow springs
Special feature: 2 additional springs on the hub.
F8Q
76907S
90693G1
76906R
200 CPV 3500
R = Red J = Yellow V = Green
20-2
ENGINE TYPE
20
CLUTCH PLATE
MECHANISM
Special feature: 2 additional springs on the hub.
F8Q Turbo
76907S
90693-2G2
76906R
200 CPV 4400
J = 4 yellow springs G = 4 grey springs
20-3
CLUTCH Side view

Single plate, dry, clutch, cable operated. Diaphragm spring clutch plate. Clutch plate with rubber hub. Self-centring, guided, ball type thrust pad in constant contact. Automatic wear take-up mechanism.
20
DI2001
Exploded view
PRD2012
20-4
CLUTCH Consumables
20
Unit Right hand sunwheel splines Shaft splines Fork pivot Release bearing guide Fork pads
Type
Pack size
MOLYKOTE BR2
1 kg tin
Clutch
RHODORSEAL 5661 LOCTITE 518
100 g tube 24 ml syringe
Ends of driveshaft roll pins. Housing assembly faces.
20-5
CLUTCH Mechanism - Clutch plate

ALL TYPES IMPORTANT PRECAUTIONS WHICH MUST BE FOLLOWED WHEN REPAIRING THE CLUTCH
20
In order to improve the sliding of the clutch plates, their hubs are nickel-plated. Clean the clutch shaft splines and refit the assembly without any lubricant. Special features of "diesel" clutch plates These are fitted with a damping pre-hub which is most efficient when its internal units are dry.
20-6
CLUTCH Mechanism - clutch plate

CHANGING
20
This operation is carried out after the gearbox has been removed.
ESSENTIAL SPECIAL TOOLS
Mot. 582 Locking sector Plus the tools required to remove the gearbox
TIGHTENING TORQUES (in daN.m)
REFITTING
7 mm diameter unit securing bolts for 180 mm diameter clutch 8 mm diameter unit securing bolts for 200 mm diameter clutch
Degrease the flywheel mounting face. 1.8 2.5 Use the plastic locating device supplied in the kit to fit the plate.
REMOVAL
Fit locking sector Mot. 582. Remove the mounting bolts from the mechanism and remove the unit and the clutch plate. Check and change the faulty parts.
94135S
92170R
20-7
20
74413R
Gradually screw up then torque tighten the bolts securing the mechanism. Remove locking sector Mot. 582. Coat the bore of the thrust pad, guide tube and clutch shaft splines with grease MOLYKOTE BR2 .
20-8
20
94235S
REMOVAL
F engines Degrease the crankshaft bore which receives the centring bush. Coat the external diameter of the bushing with Loctite FRENBLOC. Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore. Observe the direction of fitting of the bush and check that it is fitted correctly. C and E engines The centring bush will not be used for these engines.
20-9
CLUTCH Thrust pad - fork

CHANGING
20
Ensure that the assembly slides properly.

NOTE: when carrying out operations which do not
This operation is carried out when the gearbox has been removed.
REMOVAL
require removal of the gearbox or after fitting the gearbox, DO NOT RAISE the fork as there is a risk of it lifting out of catch (A) on the thrust pad.
Remove: - the thrust pad by tilting the fork, - the rubber protector, and pull the fork towards the inside of the clutch casing.
REFITTING
Check the extent of fork travel. It should be: X = 17 to 18 mm
Coat the walls of the guide tube and the fork pads with grease MOLYKOTE BR2. Fit the fork and refit the rubber protector. Fit the thrust pad on the guide tube, placing catch (A) in the fork.
91830R1 90300G1
After refitting the gearbox, re-set the toothed quadrant and check that the wear take-up mechanism operates correctly.
20-10
MANUAL GEARBOXES Identification
21
Gearbox type JB JC
Repair manual which deals with the gearbox concerned

B.V. JB B.V. JC
87227G
An identification plate on the clutch housing shows: At A At B At C At D At E : : : : : the gearbox type the gearbox suffix the fabrication number the production factory a notch is used when the gearbox has been assembled with a C or E type engine.
A D E
J B0 0 0 0 X 000000
90775
B C
TWO-COLOUR MARKING JB0 - JB1 - JB3 - JC5
Two-thirds of the surface are painted with a colour which is peculiar to each gearbox type, enabling the gearbox to be matched with the driveshaft. The remaining one-third of the surface is painted with a specific colour according to the gearbox suffix.
JB4 - JB5
Two-colour marking (green and pink) in the form of two bands of equal width.
21-1
MANUAL GEARBOXES Gear ratios
21
3rd 4th Reverse
JB0
Index Vehicle B531 - B532 - B537 C531 - C532 L531 - L532 - L537 B534 L53H B530 - C530 - L530 S530
B53W - C53W
Final drive set 16 57 15 56 15 58 15 61
Speedo drive set
1st
2nd
017
019 023 035
21 19
11 41
21 43
28 37
31 28
11 39
26
L53W
JB4
Index 000 006 Vehicle B530 - C530 - L530 S530 - C531 B531 - L531 B53P - C53P - L53P Final drive set 15 58 16 57 Speedo drive set 21 19 1st 2nd 3rd 4th Reverse
11 41
19 39
25 33
31 28
11 39
26
JB1
Index 023 Vehicle B532 - C532 - L532 B535 - C535 - L535 B530 - C530 - L530 S530 - B537 - C537 L537 - S537 - B53A
C53A - B53G
Final drive set 15 58 15 61 15 58 15 61 16 57 14 63 15 61
Speedo drive set
1st
2nd
3rd
4th
5th
Reverse
025
21 19
11 43
21 43
28 37
30 29
39 31
11 39
26
027 029 034 047
B53H L53H L53G B531 - C531 - L531 B53W - C53W L53W B530 - C530 - L530 S530 - B535 - C535 L535 - S535 - B537 C537 - L537 - B53A
C53A - L53A
21 19
11 41
21 43
28 37
30 29
39 31
11 39
26
070
21 19
11 45
21 43
28 37
30 29
39 31
11 39
26
21-2
21
3rd 4th 5th Reverse
JB3
Index 059 Vehicle B533 - C533 - L533 D53C B533 - C533 - L533 B53C - C53C - L53C D53C
B53M - C53M
Final drive set
Speedo drive set
1st
2nd
027
15 61
21 19
11 34
22 41
28 37
30 29
41 31
11 39
26
062
353A - 453A - 553A 853A B53C - D53C - L53C B53Y - D53Y - L53Y B538 - C538 - L538 B53F - C53F - L53F
S53C - S53D
094
095
353C - 453C - 553C 853C - 353D - 453D 553D - 453H - 553H B538 - C538 - L538
S53C - S53D
14 59
21 19
11 34
22 41
28 37
30 29
41 31
11 39
26
037
B538 - C538 - L538 B53C - C53C - D53C L53C - B53F - C53F L53F - B53Y - L53Y B53D - C53D - L53D B53D - C53D - L53D B533 - L533 - B53B C53B - L53B - B53I C53I - L53I - B53J C53J - L53J - S53J B533 353A - 453A - 553A 853A - B53Y - C53Y
D53Y - L53Y
071 083
15 61
21 19
11 34
22 41
28 37
34 35
34 28
11 39
26
060
16 57 15 58
21 19
11 41
22 43
28 37
30 29
39 31
11 39
26
061
067
047
B53B B53Y - C53Y - L53Y
16 55
21 19
11 41
21 43
28 37
30 29
39 31
11 39
26
21-3
21
3rd 4th 5th Reverse
JB3
Index 017 051 L532 B539 - C539 - B53D C53D - D53D - L53D B539 - C539 - L539 B53D - C53D D53D - L53D
Vehicle
Final drive set
Speedo drive set
1st
2nd
15 61
21 19
11 34
19 35
25 33
30 29
33 25
11 39
26
044
031 053
B533 - B536 - L536 B53D - C53D - L53D B532 - B533 - L533 C534 - L534 - S534 B53B - C53B - L53B B53C - L53C - B53E C53E - B53I - C53I L53I - B53J - C53J L53J - S53J
15 58 15 61
21 19 21 19
11 34 11 34
21 43 22 41
28 37 28 37
30 29 34 35
39 31 34 28
11 39 11 39
26 26
028
16 57
21 19
11 41
21 43
28 37
30 29
39 31
11 39
26
JB5
Index 006 000 Vehicle B531 - C531 - L531 B53P - C53P - L53P B530 - C530 - L530 S530 Final drive set 16 57 15 61 Speedo drive set 21 19 21 19 1st 11 41 11 41 2nd 19 39 19 39 3rd 25 33 25 33 4th 30 29 30 29 5th 34 27 34 27 Reverse 11 39 11 39 26 26
JC5
Index Vehicle B532 - C532 - L532 B53K - L53K - S53K B53T - C53T - L53T B53Z Final drive set 17 56 Speedo drive set 21 19 1st 11 41 2nd 21 43 3rd 28 37 4th 35 34 5th 41 31 Reverse 11 39
002
26
21-4
MANUAL GEARBOXES Capacities - Lubricants

CAPACITY (in litres)
21
Plug (B) with dipstick
4-speed gearbox JB0 JB2 JB4 3.25 2.75
5-speed gearbox JB1 JB3 JB5 JC5 3.40 2.90 3.10
CHECKING THE LEVEL
There are two ways of checking the level. Plug (A) without dipstick
DI2123
Wipe the dipstick section. Refit the plug, without screwing it up, with the dipstick pointing downwards. Remove the plug, the level should be on the boss (2).
OIL VISCOSITY GRADE
Tranself TRX 75/80 W
92081R
Fill to the level of the opening.
21-5
MANUAL GEARBOXES Lubricants

Precautions (TRX and TRZ oils)
21
"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in order to prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and result in seizure of the gearbox or of the final drive. STORAGE AND USE
Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of materials or water. In particular: Storing oil cans The cans must be stored: - sheltered from bad weather (rain, snow, outside splashes), - in a dry area (avoid storing in the vicinity of a washing area), - tightly sealed. Storing units (gearbox or final drive) When storing a gearbox or final drive which has not been drained, close the air inlets. Store the unit in a dry area. Using the oil The oil cans must be resealed each time they have been used. In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil into a larger container. When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil. The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time. Washing under pressure (of the vehicle or of a unit) Close the gearbox and final drive breather. If the gearbox is removed, correctly close all of the openings to prevent the entry of water.
21-6
MANUAL GEARBOXES Special features

The gearboxes of the following types: JB0 4 forward gears JB4 1 reverse JB2 JB1 JB3 JB5 JC5
21
5 forward gears 1 reverse
are fitted with BORG-WARNER synchronisers.
GEAR CHANGE PATTERN
R 1 3 5 2 4
To select reverse, raise ring (A) and move the lever.
DI2118
21-7
MANUAL GEARBOXES Consumables
21
UNIT
TYPE
PACK SIZE
MOLYKOTE BR2
1 kg sachet
Clutch fork pivot Thrust pad guide tube bore Clutch shaft splines Right hand sun wheel splines Housing joint faces 5th speed fixed gear 5th speed synchroniser hub Primary shaft nut Secondary shaft bolt Ends of roll pins on driveshafts Screw threads on switches
Loctite 518
24 ml syringe
LOCTITE FRENBLOC
24 cc bottle
RHODORSEAL 5661
100 g tube
Parts which must be changed automatically
When they have been removed: - the lip seals, - the O-rings, - the thrust pad guide tubes, - the secondary shaft and differential nuts, - the speedometer gear and its shaft, - the speedometer crown wheel, - the roll pins, - the bushes under the gears.
21-8
C engines
MANUAL GEARBOXES Gearbox (Removal - Refitting)
21
B.Vi. 31-01 T.Av. 476
Set of pin punches Ball joint extractor
MATERIALS Loctite FRENBLOC
Brake caliper securing bolts

RHODORSEAL 5661
Ends of pins on driveshafts

MOLYKOTE "BR2"
Clutch shaft and sun wheel splines
85965R
Brake caliper securing bolts Shock absorber lower securing bolts Steering ball joint nut Nut holding key on stub axle carrier Mounting securing bolts Wheel bolts Left hand driveshaft gaiter securing bolt
10 11 3.5 5.5 4 to 5 8 2.5
- the three bolts holding the driveshaft gaiter, - the two bolts securing the brake caliper and secure the caliper to the suspension spring so as to avoid stretching the hose, - the protective casing (side).
REMOVAL
The gearbox can be removed alone. Place the vehicle on a two post lift. Disconnect the battery. Remove the front wheels.
On the left hand side of the vehicle Remove: - the steering tie rod ball joint using tool T.Av. 476.
92122R2
21-9
C engines

On the right hand side of the vehicle Remove the driveshaft roll pins using tool B.Vi. 31-01
21
Remove: - the two bolts (2) securing the base of the shock absorber, - the nut and key (1),
90130R2
91755R
- the driveshaft - stub axle carrier assembly from the lower ball joint,
Slacken lower bolt (3) on the base of the shock absorber and remove upper bolt (4).
90311S
91758R4
Check that the driveshaft rollers do not come out manually. If they do, on reassembly, check that the needle bearings have not fallen into the gearbox.
Tilt the stub axle carrier and uncouple the driveshaft.
21-10
C engines
21
Under the vehicle, remove bolt (H) from the engine - gearbox tierod.
Disconnect: - the starter leads, - the connector on the reversing light switch. On vehicles fitted with power assisted steering, remove the two clamps securing the power assisted steering pipes to the gearbox. Remove: - the air filter unit and its mounting,
92028R2
Slacken: - the two mounting bolts on the engine, - the clutch protection plate, - the gear lever.
92031S
- the integral electronic ignition (A.E.I.) sensor, - the bolts from around the gearbox and from the starter.
85966R
21-11
C engines
21
Disconnect: - the clutch cable,
Lift the engine using a tool specific to this purpose (example: desvil 300B).
89204S 92110S
- the speedometer pin and cable.
Petrol engines - all types Remove: - the front mounting, - the earthing braid.
92108-1R1
92112R
21-12
C engines
21
Remove the three bolts securing the rear centre mounting and move it back as far as possible.
92108R1 92903S
NOTE: to make it easier to remove the bolts, raise the gearbox slightly with a component jack. Uncouple the gearbox from the engine, sliding the 5th speed housing between the vehicle sidemember and the engine cradle. Raise the engine. Turn the gearbox to the front slightly so as to free the final drive section then remove the gearbox from the vehicle. After uncoupling the gearbox from the engine, attach it to a workshop crane securing the eyes in place of two bolts around the gearbox.
21-13
E engines
21
REMOVAL
Remove the idle speed regulation valve mounting. Disconnect the starter and oil pressure sensor wires.
The gearbox is removed alone. Remove the radiator after first draining the cooling system. To detach the wiring, disconnect the connectors on: - the ignition power module, - the throttle housing,
92904R
Disconnect the two side bolts which secure the engine - gearbox tierod, starter end torx bolt (T). using a suitable spanner.
92817S
the idle speed regulation valve.
92904R1
92826S
21-14
E engines
21
Disconnect the fan motor and thermal switch connectors. Unfasten the radiator mountings and move it to the right hand side (without removing any of the hoses or pipes), protecting the sides with cardboard. Remove studs (A) and (B) using a nut and lock-nut, using an angled spanner and a ball joint ratchet.
After uncoupling the gearbox from the engine, attach it to a workshop crane securing the eyes in place of two bolts around the gearbox.
92903S
86308R1
21-15
F engines
21
The gearbox cannot be removed alone. The engine - gearbox assembly must be removed first (refer to section 10) and then uncoupled.
Uncouple the gear lever at the gearbox outlet lever after detaching the protective gaiter.
Bolt which secures the pendulum mounting system to the gearbox Nuts and bolts which secure the clutch housing to the engine Bolt which secures the clutch protector Drain plug Filler plug Bolt which secures the left hand driveshaft
3.5 5 2.5 1.8 0.15 2.5
Removal (Special points) Speedometer cable mounting. Pinch the tabs (arrows) and remove the cable.
85966R
Remove the starter plate.
98865R2
93902S
21-16
F engines
21
Disconnect the starter leads. From the lower section, remove: - nut (E) which secures the engine - gearbox,
After uncoupling the gearbox from the engine, attach it to a workshop crane securing the eyes in place of two bolts around the gearbox.
85812-1R
the tierod - clutch protector assembly.

92903S1
Place the engine on a stand. Remove the bolts from around the gearbox and from the starter. Vehicles fitted with power assisted steering, remove the two clamps (C) which secure the power assisted steering pipe.
92028R3
21-17
F engines
21
REFITTING
Ensure that the engine - gearbox locating rings are present and correctly positioned: - at A : gearbox assembled with a C or E type engine, - at B : gearbox assembled with an F type engine.
90300G1 86415R
Fit the thrust pad to the guide tube placing catch (A) in the fork, ensure that it slides correctly.
Do not raise the fork since there is a risk of it lifting out of catch (A) on the thrust pad. To prevent this, immobilise the thrust pad - fork assembly by inserting a tube (example: tool El. 1382) between the fork and the sheath end on the housing to prevent any movement of the thrust pad while the gearbox is fitted. Coat the walls of the guide tube and the fork pads with MOLYKOTE BR2 grease .
21-18
F engines

Fit the gearbox in place.
21
92903R1
Assemble the engine - gearbox. Ensure that the locating rings are fitted correctly in their locations. Refit studs (A) and (B) in the same way as on removal. These studs and the bolts around the gearbox are used for alignment and centring. Fit the fork and refit the rubber protector.
21-19
All types
21
WARNING: fit bolt (V) and starter locating pin (D)
correctly.
Reconnect the speedometer cable ensuring that the pin is in the correct position (C and E type engines).
C and E type engines
92108-1S
Speedometer cable mounting. Pinch the tabs (arrows) and remove the cable (F type engine).
86070R3
F type engine
93909S
86070-1R1
21-20
All types
21
Position the driveshaft in relation to the sun wheel, pivot the stub axle carrier engaging the driveshaft in the sun wheel using the angled drift B. Vi. 31-01 to align the holes.
91830R1
Pull the cable at the clutch fork on the gearbox. The cable should have at least 2 cm of slack.
74937-4S
There is an inlet chamfer on the sun wheel to make it easier to fit new roll pins. Seal the ends of the pins (RHODORSEAL 5661 ). After refitting the engine - gearbox assembly to the vehicle, check the extent of the fork travel. It should be: X = 17 to 18 mm
89204S
These checks enable the correct operation of the clutch automatic wear take-up system to be verified.
21-21
F engines

Check the setting of the upper mountings (refer to section 10). Ensure that the engine movement limiter is fitted the correct way: the nuts should be fitted at the exhaust pipe end.
21
92661S
Fill the cooling system. All types Fit the brake caliper mounting bolts with Loctite FRENBLOC and torque tighten them. Press on the brake pedal several times to bring the pistons into contact with the brake pads.
Tighten the bolts and nuts to the specified torque. Fill the gearbox.
21-22
MANUAL GEARBOXES 5th speed linkage in situ
21
ESSENTIAL SPECIAL TOOLS B.Vi. B.Vi. B.Vi. B.Vi. B.Vi.
28-01 31-01 1003 1007 1175
Extractor body Drifts for fitting roll pins 5th speed hub extractor Jaws for B.Vi. 28-01, 02, 03 5th speed fixed gear mounting bolt
Primary shaft nut Secondary shaft nut
13.5 7
MATERIALS Loctite FRENBLOC :
Primary shaft nut Secondary shaft bolt 5th speed fixed gear 5th speed hub
REMOVAL
Remove the front left hand wheel. Remove the side housing. Drain the gearbox. The rear housing must be removed horizontally as it has a lubricating duct (A) which goes into the primary shaft.
87180R
21-23

Fit: - a drainage tray under the rear housing and remove it, - a wooden block between the 5th speed fork and the leading gear to act as a counter-force; then remove the fork roll pin using tool B.Vi. 31-01. It is easier to remove the roll pin if the drift of tool B.Vi 31-01 is bent slightly to avoid having to raise the gearbox.
21
DI2122
Select 5th gear by sliding the fork on its shaft and 1st gear with the gear lever.
85979R
NOTE:
Do not pull the 5th speed fork shaft outwards as there is a risk that the prohibiting lock may move and prevent refitting of the shaft. As a safety measure, engage a gear (3rd or 4th) when removing - refitting the roll pin.
85966R2
Slacken and remove the primary shaft nut and secondary shaft bolt. Return the gearbox to neutral.
21-24

On the primary shaft: Remove the 5th speed fork and the slide gear. Extract the synchroniser hub using tool B.Vi. 1170.
21
Fit the rounded housing of the tool on the slide gear, turn it as far as possible and then extract the hub.
93190R
93237R
Fit the slide gear of tool B.Vi. 1170 as for selecting 5th gear and turn it so as to position the splines of the slide gear and the hub opposite each other.
Remove the 5th gear assembly.
86045R2
93189S
21-25

On the secondary shaft: Remove shouldered washer (64).
REFITTING
21
On the secondary shaft: Put three drops of Loctite FRENBLOC on the fixed gear splines. Fit the fixed gear using tool B. Vi. 1175 and shouldered washer (64).
PRG21.1
Remove the fixed gear using tool B.Vi. 28-01-0203 fitted with its jaws B.Vi. 1007.
93462R
Remove tool B. Vi. 1175.
88575R
21-26

On the primary shaft: Refit parts (21) (shoulder facing bearing (22), (23), (24) and (8)) in order. Fit the fork on slide gear (26) fitted with part (25). Put three drops of Loctite FRENBLOC on the hub and refit the slide gear - hub assembly and fork. Fit the bosses on the synchro ring in the notches on the hub. On the secondary shaft: Fit shouldered washer (64).
21
PRG21.1
Put three drops of Loctite FRENBLOC: - on nut (27) of the primary shaft and torque tighten it to 13.5 daN.m, - on bolt (65) and torque tighten it to 7 daN.m .
86045R1
Select 1st gear at the gear lever and 5th gear at the gearbox, sliding the 5th speed fork on its shaft.
21-27

Place a wooden block between the 5th speed fork and the primary gear as a counter-force and fit a new roll pin in the 5th speed fork using tool B.Vi. 31-01 ensuring that it is fitted the correct way round, with the slot in the centreline of the shafts.
21
Fit a new O-ring seal to ensure that the rear housing is leaktight. Fit the rear housing engaging duct (A) in the primary shaft and the lubricating channel in oil inlet rail (B) and torque tighten the bolts to 2.5 daN.m.
90498-1S
87180R6
Fill the gearbox with oil.
85979R1
Return the gearbox to neutral and check that all of the gears can be selected. If there are any difficulties, ensure that reverse gear is not engaged.
21-28
MANUAL GEARBOXES Differential output seal
21
ESSENTIAL SPECIAL TOOLS B.Vi. T.Av. B.Vi. B.Vi.
31-01 476 945 1058
Drifts for fitting roll pins Ball joint extractor Plug for fitting the differential seal Plug for fitting the differential seal
Brake caliper securing bolts Shock absorber lower securing bolts Steering ball joint Wheel bolts
10 11 3.5 8
MATERIALS Loctite FRENBLOC :
Brake caliper securing bolts

RHODORSEAL 5661 :
Ends of driveshaft roll pins

MOLYKOTE BR2 :
Splines on right hand sun wheel
91755R
Remove: - the steering ball joint (tool T.Av. 476),
REMOVAL
Remove the protective casing from under the engine. Drain the gearbox. Place the front of the vehicle on stands on the side in question. Remove the wheel. Knock out the driveshaft roll pins using tool B.Vi. 31-01.
85965R
21-29

- the two bolts (A) securing the brake assembly.
21
86031S
REFITTING
Grease protector (A) of B. Vi. 945 and fit it on the sun wheel. Position the greased seal using B. Vi. 1058.
90149R1
Fix the brake caliper to the suspension spring in order to avoid stretching the hose. Slacken lower bolt (3) on the shock absorber base and remove upper bolt (4). Tilt the stub axle carrier and uncouple the driveshaft (take care not to damage the gaiters during this operation). Remove the O-ring seal from the sun wheel. Knock the base of the lip seal using a pin drift and a small hammer so that it turns in its housing. When the seal has been loosened, take it out using a pair of pliers, taking care not to damage the sun wheel splines.
92111R
21-30

Fit the O-ring seal on the sun wheel and coat the splines with grease MOLYKOTE BR2. Position the driveshaft in relation to the sun wheel. Turn the stub axle carrier engaging the driveshaft in the sun wheel using drift B.Vi. 31-01 in order to align the holes.
21
Fit new roll pins and seal the ends (RHODORSEAL 5661).
Tighten the bolts and nuts to the recommended torque. Fit the brake caliper in place and coat the bolts with Loctite FRENBLOC. Fill the gearbox.
74937-3S
21-31
MANUAL GEARBOXES Speedometer drive

CHANGING REFITTING
21
1st possibility: Only the speedometer drive or shaft is damaged.
Refit the new speedometer drive using pliers with a long, flat nose. The drive gear and its shaft are refitted by hand. The shaft must be positioned correctly in relation to the locating notches on the drive gear, owing to the elasticity of the shaft lips.
REMOVAL
It is not necessary to dismantle the entire gearbox. Uncouple the left hand driveshaft. Remove the spider sun wheel. Turn the differential by hand so that the speedometer drive gear can be reached. Unclip the shaft, pulling it vertically using long nosed pliers. Using the same pliers, remove the drive gear from its location.
CORRECT
INCORRECT
86053S
Ensure that it is properly clipped in place. Refit the spider sun wheel. 2nd possibility: The speedometer drive gear and crown wheel are damaged.
88577S
The gearbox must be removed and the final drive dismantled.
21-32
MB AUTOMATIC TRANSMISSION Exploded view
23
DI2325
23-1
MB AUTOMATIC TRANSMISSION Use

DRIVING
23
The automatic transmission is greased under pressure and therefore only while the engine is running. Consequently, in order to avoid serious damage, the following recommendations must be followed: - never drive with the ignition switched off (on a downwards slope, for example), the danger of such a practice cannot be emphasised enough. - never push the vehicle (for example: to reach a petrol station), except in the situation where the precautions stated in the section below on "Towing" are observed. Furthermore, the vehicle can only be driven if the engine is running. It is therefore impossible to start the engine of an automatic transmission vehicle by pushing it.
TOWING
The front of the vehicle should be lifted. However, if this is not possible, the vehicle may, in exceptional circumstances, be towed with four wheels on the ground under the following conditions: 1. Add an additional two litres of automatic transmission oil ELF RENAULTMATIC D2 or MOBIL ATF 220. Only tow the vehicle at a speed of less than 20 mph (30 km/h) over a distance of less than 30 miles (50 km) (lever in"N")
2.
DO NOT FORGET TO REMOVE THE EXCESS OIL AFTER TOWING.
23-2
MB AUTOMATIC TRANSMISSION Identification
23
OIL
COMPUTER
VEHICLE
AUTO TRANS TYPE
ENGINE
STEP DOWN GEAR RATIO
FINAL DRIVE RATIO
SPEEDOMETER DRIVE RATIO
PRESSURE*
B53A C53A L53A B537 C537 L537 B53B C53B L53B
MB1
E7J
29/24
15/58
21/19
4.40.1
138
MB1
E6J
29/24
15/58
21/19
4.40.1
138
MB3
F3N
29/24
16/57
21/19
4.40.1
132
(*) On the road, with the lever in 2nd at 50 mph (80 km/h). Converter drive plate: Maximum permissible run-out: 0.3 mm Tightening torque: - Bolt for securing to the crankshaft: 6.5 daN.m - Bolt for securing to the converter: 2.5 daN.m
23-3
MB AUTOMATIC TRANSMISSION Gear ratios

For vehicle types B53A - C53A - L53A - B537 - C537 - L537
23
3rd 1 0.828 3.199 32.343 Reverse 2 1.655 6.399 16.171
Gear ratios Gear reduction Gear reduction +step down Gear reduction + stepdown + final drive Speed in km/h for 1000 rpm *
1st 2.5 2.069 7.999 12.937
2nd 1.5 1.241 4.799 21.562
For vehicle types B53B - C53B - L53B
Gear ratios Gear reduction Gear reduction + stepdown Gear reduction + stepdown + final drive Speed in km/h for 1000 rpm *
1st 2.5 2.069 7.370 14.042
2nd 1.5 1.241 4.422 23.403
3rd 1 0.828 2.948 35.105
Reverse 2 1.655 5.896 17.552
* For vehicles fitted with 165/70 R13 tyres.
23-4
MB AUTOMATIC TRANSMISSION Gear change thresholds

Gear change thresholds in km/h for vehicle types B53B - C53B - L53B 1 2 23 72 72 2 3 40 118 118 3 2 27 102 102
23
2 1 15 63 63
POSITION OF FOOT
No-load (PL) Full-load (PF) Kickdown
Gear change thresholds in km/h for vehicle types B537 - C537 - L537 - B53A - C53A - L53A 1 2 23 62 67 2 3 46 102 109 3 2 26 74 94 2 1 13 40 54
POSITION OF FOOT
No-load (PL) Full-load (PF) Kickdown
No-load (PL) Foot off accelerator pedal Full-load (PF) Accelerator pedal fully depressed
NOTE: The kickdown switch is incorporated in the computer via the load potentiometer. In the event of a
fault refer to workshop repair manual T.A. M.
23-5
MB AUTOMATIC TRANSMISSION Consumables
23
DESCRIPTION
COMPONENT CONCERNED
RHODORSEAL 5661
Sealing of the driveshaft roll pins - Sun wheel splines
Grease MOLYKOTE BR2
- Converter locating device

Loctite FRENBLOC
Brake caliper securing bolt

Parts which must be changed once they have been removed: - the roll pins, - the self-locking nuts, - the copper seals.
Oil
The MB automatic transmission is a gearbox which has only one level and one grade of oil (converter, final drive, mechanical section).
GRADE (for example) : ELF RENAULTMATIC D2.
If this is not available, use (example) : - MOBIL ATF 220D - TOTAL DEXRON
CAPACITY IN LITRES :
Theoretical total: 4.5 litres After draining: 2 litres
23-6
MB AUTOMATIC TRANSMISSION Draining - Filling - Levels

DRAINING - FILLING
23
Start the engine and wait one or two minutes for the converter and cooler to fill up. The oil is at an ambient temperature of 20C. Pull out the dipstick while the engine is running. The level should not be below mark (1) MINIMUM WHEN COLD (risk of damage) and should not exceed mark (2) MAXIMUM WHEN COLD (risk of damage).
Draining must be carried out when cold, dipstick and plug (A) removed. Change the strainer.
Never exceed the "MAXIMUM WHEN COLD"
level.
WARNING
Too much oil results in: - overheating of the oil, - leaks. Too little oil results in: - damage to the mechanisms.
93609R
Refit the plug together with a new seal. Fill with the recommended oil via the dipstick tube. Use a funnel fitted with a 15/100 filter in order to prevent the entry of impurities. Run the engine at idle speed. Check the level and top up if necessary.
CHECKING THE OIL LEVEL WHEN COLD
With the vehicle empty, place it on a even, horizontal surface. Position the selector lever in "PARK" (P).
CHECK THE LEVEL WHEN COLD. 1. MINIMUM WHEN COLD 2. MAXIMUM WHEN COLD
85935R
23-7
MB AUTOMATIC TRANSMISSION Checking and adjusting the potentiometer

1st METHOD
23
B.Vi. 958
Checking unit
ADVICE
With the vehicle stationary and the ignition off, check that the accelerator cable is adjusted correctly. Disconnect the 3-way connector (10) for the wiring which connects the computer to the potentiometer.
85651-1R
CHECKING
Press the accelerator pedal down fully

CORRECT
Indicator light 9
INCORRECT or maladjusted
93698R
Connect the potentiometer connector (10) to the B.Vi. 958 connector (16). Supply the B.Vi. 958 from the battery. Reversing switch "I2" on "Y".
Slightly slacken the two bolts (V) which secure the potentiometer. Keep the throttle fully open via the accelerator pedal and slowly turn the potentiometer to illuminate indicator light (9) and retighten the two bolts (V) If indicator light (9) cannot be illuminated by this adjustment, check its wiring and if the potentiometer is faulty, change it. Whenever the potentiometer is changed or removed, adjust it. NOTE: if the carburettor is cleaned, dismantle the load potentiometer or avoid splashing cleaning fluid on it.
23-8

2nd METHOD
ESSENTIAL SPECIAL TOOLS XR25
23
ADVICE
With the vehicle stationary and the ignition off, check that the accelerator cable is adjusted correctly. Disconnect the 3-way connector (10) of the wiring which connects the computer to the potentiometer.
93607R
Connect: - the round plugs to the battery (red on "+", black on "-"), - the three-way connector (16) to the potentiometer connector (10).
93608R
Connect the XR25, the three-way extension lead and the two round plugs.
23-9
23
93606S
On the XR25 keypad, press key "V" then "1"; Reading the numerical values on the display: At full-load, the display should show a value between "0" and "3"; ignore any "-" signs which may be displayed to the right of the value. For the adjustment procedure, refer to workshop repair manual MR T.A. M or the previous page.
23-10
MB AUTOMATIC TRANSMISSION Oil pressure
23
B.Vi. 466-06 B.Vi. 466-07
Adaptor Oil pressure gauge
CHECKING
ADJUSTING
Meauring conditions Ensure: - that the normal operating temperature is 80 C, - that the accelerator cable is adjusted correctly. Connect oil pressure gauge B.Vi. 466-07 to adapter B.Vi. 466-06 at (A).
Remove the stop (1) and turn the capsule. By screwing in the capsule, the pressure in increased and vice versa.
88967G 88990R
Measuring Place the selector lever in 2nd. Accelerate fully and apply the brake at the same time to stabilise the speed at 50 mph (80 km/h). The pressure should be 4.4 0.1 bars
85393S
NOTE: 2 notches = approximately 0.08 bar.
23-11
MB AUTOMATIC TRANSMISSION Oil pressure

To make this operation easier, a tool can be made: A = 8/30 mm diameter washer, thickness 1.5 mm B = 6 mm round rod
23
88862R1
23-12
MB AUTOMATIC TRANSMISSION Strainer

The strainer should be changed every 36,000 or 40,000 miles (50,000 km) depending on servicing programme applicable and when any significant work is carried out on the mechanism.
CHANGING
23
Lift the engine - gearbox assembly to a dimension of approximately 135 mm.
Drain the automatic transmission. Remove the gearbox silent block nut (A).
93605R
88170R
Place a lifting device under the gearbox at (B).
85546R
23-13
MB AUTOMATIC TRANSMISSION Strainer

Remove the sump and the strainer fitted with its seal. Clean the sump and its magnets and refit them (so that the grooved surface is fitted against the panel).
23
93618S
Fit the new strainer fitted and its seal and torque tighten to 0.9 daN.m. Refit the sump and fill with oil.
23-14
MB AUTOMATIC TRANSMISSION Automatic transmission (Removal - Refitting)
23
Removal of the MB type automatic transmission requires the removal of the engine - automatic transmission assembly.
Mot. 453-01 Mot. 582 Mot. 878 B.Vi. 31-01 B.Vi. 465 T.Av. 476
Hose clamps Converter locking sector Engine lifting eyes and chain Drifts for fitting roll pins Tool for replacing the torque converter seal Ball joint extractor
Brake caliper securing bolts Shock absorber base securing bolts Steering ball joint Lower ball joint nut Driveshaft gaiter securing bolts Wheel bolts Oil cooler bolts Converter drive plate bolts Bolts around the automatic transmission mounting
10 11 3.5 6 2.5 8 4 2.5 4
Remove: - the cooling system radiator and the expansion bottle, Special point for the E engine Remove : - the integral electronic ignition (A.E.I.), - hot air tube (A) then the air filter complete,
Depending on specification, remove the selfcontained air bag in order to eliminate any risk of triggering it (refer to the first generation air bag manual). Removal of the assembly does present any special points, however observe the points below:
REMOVAL
Place the vehicle on a two post lift. Disconnect the battery. Drain: - the cooling system (lower radiator flexible hose), - the automatic transmission oil.
DI2326
the bar between the shock absorber turrets, the front wheels.
23-15

Special point for the F3N engine Remove: - the ignition power module, -
23
the power assisted steering hose securing plate (1).
93601R 93603S
the air filter complete, the absolute pressure sensor and its mounting,
Fit clamps Mot. 453-01 to the steering pump reservoir hoses and then remove the steering pump reservoir pipes and the front wheels.
93602S
23-16

Remove (all types) : On the left hand side of the vehicle the brake caliper bolt (A) and attach it to the body,
BENDIX series IV
23
the steering ball joint using extractor tool T.Av. 476,
85965-1R
90149R
the three driveshaft gaiter securing bolts,
GIRLING
85678R
91758R
23-17

the lower ball joint and shock absorber base bolts, the transmission - stub axle carrier assembly, taking care to protect the spider. -
23
the upper bolt (1) and slacken the lower bolt (2).
90311S
90259R
On the right hand side of the vehicle: It is not necessary to remove the brake caliper. Extract: - the driveshaft roll pin using drift tool B.Vi. 31-01,
Tilt the stub axle carrier and uncouple the driveshaft. Disconnect the hoses for the heater matrix on the coolant pump and the automatic transmission oil cooler, the fuel circuit hoses and the brake servo braking vacuum hoses.
93710R
23-18

Remove (all types) : - the electrical connectors, the injection computer connector,
23
93598S
the oxygen sensor (1): this is located on the exhaust manifold upstream of the clamp which connects the primary down-pipe.
92056S
the earthing braids.
Special point for the F3N engine Disconnect: - the three hoses (A) (it is advisable to mark them before disconnecting them),
89091R
93600R
23-19

Remove: - the earthing braids (engine and automatic transmission), - the following cables: accelerator cable, rev counter cable, gear selection cable at attachment points (A) and (B). Figure 2
23
DI2327
the front and rear rubber mounting nuts (E).
93604R
Remove : the computer retaining strap, the exhaust clamp (for F3N engine figure 1) the exhaust pipe (for E engine figure 2),
92108R
Figure 1
91128S
23-20

Attach tool Mot. 878 to the engine lifting eyes. Lift the engine - automatic transmission assembly and remove bolts (E). Remove the engine - automatic transmission assembly from the engine compartment.
23
Fit torque converter tool B.Vi. 465 and uncouple the automatic transmission from the engine.
86724R
REFITTING (Special points)

93599S
Remove: - the starter motor, - the converter protective plate. Fit locking sector tool Mot. 852 and remove the bolts for the drive plate on the converter.
Lower the engine - automatic transmission assembly, align it using the front rubber mountings and secure the two bolts for the rear rubber mountings. Torque tighten the bolts and nuts. Fit the brake caliper securing bolts with adhesive (Loctite FRENBLOC) and torque tighten them. Press the brake pedal several times to bring the pistons into contact with the brake pads. Apply RHODORSEAL 5661 to the driveshaft roll pin holes. Adjust the accelerator and choke cables.
86511R
23-21
23
Carry out the following: - fill the automatic transmission, - fill and bleed the cooling system (refer to subsection 19), - fill and bleed the power-assisted steering pump circuit, - retighten the exhaust flange.
85915-1S
To ensure correct sealing, do not forget to fit the O-ring seals (T) on each side of the oil cooler. Gradually tighten the bolts to a torque of 4 daN.m.
92323R
NOTE: the exhaust down-pipe flanges are fitted
with spacers (1) which determine the tension of the springs. Tighten until the spacers are in contact. Start the engine and check that the assembly is perfectly sealed.
89010R
23-22
AD4 AUTOMATIC TRANSMISSION Exploded view
23
DI2302
23-23
AD4 AUTOMATIC TRANSMISSION Operation

DRIVING
23
The automatic transmission is greased under pressure and therefore only while the engine is running. Consequently, in order to avoid serious damage, the following recommendations must be followed: - never drive with the ignition switched off (on a downwards slope, for example), the danger of such a practice cannot be emphasised enough. - never push the vehicle (for example: to reach a petrol station), unless the precautions described in the "Towing" section below are taken. Moreover, the vehicle canonly be driven if the engine is running. It is therefore impossible to start the engine of an automatic transmission vehicle by pushing it.
TOWING
It is always preferable to tow the vehicle on a flat bed trailer or with the front wheels lifted. However, if this is not possible, the vehicle may, in exceptional circumstances, be towed under the following conditions: 1rear wheels lifted by 15 cm or all four wheels on the ground (without adding any oil to the mechanism), Only tow the vehicle at a speed of less than 25 mph (40 km/h) over a distance of less than 15 miles (25 km) (lever in"N")
2.
23-24
AD4 AUTOMATIC TRANSMISSION Identification
23
COMPUTER
VEHICLE
AUTO TRANS TYPE
ENGINE
CONVERTER
STEP DOWN RATIO
FINAL DRIVE RATIO
SPEEDOMETER RATIO
B533 C533 L533 B536 L536 B53C C53C D53C L53C 353F 453F 553F 853F B53V C53V D53V L53V B53Y C53Y D53Y L53Y D53Y D53V
AD4 001
F2N 721 F2N 727 F2N 725
227 D AA
69/77
17/64
18/16
100
AD4 001
227 D AA
69/77
17/64
18/16
103
AD4 004
F3N 743
227 D AA
69/77
17/64
18/16
101
AD4 014
F3P 765
227 D AA
69/77
17/64
18/16
108
AD4 004
F3P 705 F3P 707 F3P 705 F3P 707 F3P 765
227 D AA
69/77
17/64
18/16
103
AD4 004 AD4 014
227 D AA
69/77 69/77
17/64 17/64
18/16 18/16
111 118 115 122 103 111 118 100 122
227 D AA
B53Y B533 353H 453H
AD4 014 AD4 001 AD4 014
F3P 705 F3P 765 F3P 682
227 D AA
77/71 77/71 69/77
17/64 17/64 19/65
18/16 18/16 18/16
227 D AA 227 D AA
* For identification using the XR25 refer to the FAULT-FINDING section.
23-25
AD4 AUTOMATIC TRANSMISSION Gear ratios

For vehicle types X533, X536, X53C, X53F, X53V, X53Y, 053H
23
4th 0.68 2.85 37.04 Reverse 2.11 8.86 11.90
Gear ratio Gear reduction Overall reduction Speed in km/h for 1000 rpm with 1.76 tyres
1st 2.71 11.40 9.26
2nd 1.55 6.51 16.20
3rd 1 4.20 25.13
23-26
AD4 AUTOMATIC TRANSMISSION Gear change thresholds

AUTO TRANS TYPE
ACCELER-ATOR
23
3 3 B
51 112 133 48 46 85 30 43 78 30 52 78 55 120 70 85 61 132 36 68 93 40 79 6 21 48 32 75 68 81 12 20 45 14 36 26 40 15 30 83 38 10 30
1 A
2 2 B
20 46 48
3 3 B
40 83 88
4 4 B
70 130
2 2 B
31 68 26 41 10 28
1 B
10 30 45
VEHICLE
POSITION
A
35 76
A
60 120
A
46 103 130
No-load X533 AD4 000 AD4 001 Full-load

Kickdown
17 41
136 39 79 56 100 126 40 80 60 117 60 120 135 70 128
No-load X536 AD4 001 Full-load

Kickdown
16 41 48 17 36 42 18 40 50 10 45 53
20 44
35 68 86
81 117 47 103
103 130 50 112
41
No-load X53C AD4 004 Full-load

Kickdown
20 42 44
35 70 80 40
131 62 87 122 65 140 50
130
No-load X53Y AD4 004 Full-load

Kickdown
47
75 90
108
144 47 95 69 138 75 152 55
135
X53F X53H X53V
No-load AD4 014 Full-load

Kickdown
20 51
45 85 98
114
157
149
23-27
AD4 AUTOMATIC TRANSMISSION Gear change thresholds

The figures shown in the table are average theoretical values of gear change speeds in km/h tolerances = 10 %. No-load (PL) : Accelerator pedal released. Full-load (PF) : Accelerator pedal fully pressed. Kickdown : Kickdown (changing to a lower gear).
23
A : Lower gear change thresholds. The gears change to lower gear ratio. Switch (1) is not operated and the EXC warning light is extinguished. B : Higher gear change thresholds. The gears change to a higher gear ratio. Switch (1) is operated and the EXC warning light is illuminated.
91115-1R
23-28
AD4 AUTOMATIC TRANSMISSION Consumables
23
DESCRIPTION
COMPONENT CONCERNED
RHODORSEAL 5661
Sealing of the driveshaft roll pins Sun wheel splines
Grease MOLYKOTE BR2
Converter locating device

Loctite FRENBLOC
Brake caliper securing bolt

Parts which must be changed once they have been removed: - the roll pins, - the self-locking nuts, - the copper seals.
Oil
The AD4 automatic transmission is a gearbox which has two grades of oil and two levels.
MECHANICAL SECTION : ELF RENAULTMATIC D2 (D20104).
If this is not available, use: - MOBIL ATF 220 D (D 20104 or D 21412). - TEXAMATIC 4011.
FINAL DRIVE: TRANSELF TRX 80W.
23-29
AD4 AUTOMATIC TRANSMISSION Oil drain intervals

For draining of the mechanical section, refer to the warranty and servicing booklet for the vehicle. The oil level must be checked every 10,000 miles (15,000 km) in case there is a slight oil leak. The final drive is not drained; it is filled for life. The level can be topped up if there is a slight leak.
23
Oil capacity
TOTAL volume MECHANICAL SECTION FINAL DRIVE
Volume after draining 3.5 litres -
5.7 litres 1 litre
NOTE : If the automatic transmission is changed, only carry out the level checking operation, as the
transmission is supplied filled by the Parts Department.
23-30
AD4 AUTOMATIC TRANSMISSION Oil drain

ESSENTIAL SPECIAL TOOLS B.Vi. 1213
23
M.S. 1019-10
DRAINING
Automatic transmission drain plug spanner XR25 Final drive: The final drive is filled and topped up via plug (C) by filling with oil until it overflows.
Mechanical section : There are two plugs on the mechanical section cover : A : Oil level top-up plug. B : Oil drain plug (triangular imprint on it). The unit is drained by removing plug (B).
94882R
Reminder: The final drive is not drained, it is filled for life.

94882R2
23-31
AD4 AUTOMATIC TRANSMISSION Filling - Levels

FILLING - LEVELS
23
Filling is via tube (D).
1 - The vehicle must be on a four post lift and the transmission at ambient temperature. 2 - Switch on the engine with the selector lever in park. 3 - Connect the XR25 and enter: D 0 4 then # 0 4
4 - Lift the vehicle and run the engine until a temperature of 60 C is reached 5 - When the required temperature has been reached, with the engine running, open the oil top-up plug; allow the excess oil to flow out for approximately 20 seconds (this excess should exceed 0.1 litres). Refit the plug. 6 - If the volume of oil recovered is less than 0.1 litres, the level is not correct, repeat the operation.
94845R1
In this case, add 1 litre of the recommended oil and leave the automatic transmission to cool before carrying out the operations which follow.
Use a funnel fitted with a 15/100 filter to prevent the entry of impurities. The level is MUST be checked in accordance with the procedure described below: Before carrying out this procedure: - if the gearbox has been drained, fill it with 3.5 litres of oil, - if the gearbox is simply to be checked, 0.5 litres of the recommended oil must be added.
23-32
AD4 AUTOMATIC TRANSMISSION Filling - Levels

ELECTRONIC FAULT WARNING LIGHT MESSAGE
23
When the ignition is switched on, with the vehicle stationary and the engine stopped, in position P or N, the warning light illuminates. When the starter is operated, the warning light remains illuminated. When the key is released, with the ignition on and the engine running, the warning light extinguishes approximately 3 seconds after starting the engine.
Operation with no fault
When the vehicle is stationary with the engine running or when driving, the warning light is permanently illuminated. When the vehicle is moving the warning light illuminates and extinguishes with no operation of the ignition key. When the vehicle is moving, the warning light illuminates briefly.
Fault present
Oil temperature <- 20C or >+140C
When the vehicle is moving or stationary, the warning light flashes with a frequency of approximately 1 flash per second. In this case, reduce the performance requirement by reducing the acceleration.
Oil pressure
The transmission is fitted with an oil pressure socket. Connect tool B.Vi. 1215 for checking the automatic transmission pressure sensor only. The oil pressure cannot be adjusted. Its value is determined by the computer.
94845-1R
23-33
AD4 AUTOMATIC TRANSMISSION Changing the strainer

This filters the oil and assures correct operation of the automatic transmission. For models with ABS
23
Remove: - the nut (C) which secures the ABS electropump assembly to the silent block.
Strainer securing bolts Casing securing bolts Bolts securing the rubber mounting to the sidemember Rear mounting securing bolts Wheel bolts
0.50 +0.1 0 1 0.1 2 6.5 9
REMOVAL
94933R
Place the vehicle on a two post lift and fit the tilting prevention claws to the pads (see Technical Note 1168). Drain the automatic transmission (mechanical section; triangular imprint on the drain plug). Remove: - the expansion bottle, - the air filter, - the two upper rubber mount bolts (A) and slacken the other two (B), without removing them.
the front left hand wheel and remove the plastic deflector in the wheel arch (to enable the two automatic transmission sump rear securing bolts to be extracted later).
Using the component jack, lift the automatic transmission.
94933-1R
94887S
23-34
AD4 AUTOMATIC TRANSMISSION Changing the strainer

Remove - the automatic transmission sump, - the strainer and its seal (bolts 1).
23
94933-1S
On models with ABS Refit the nut (C) which secures the ABS electropump assembly to the silent block.
92084R
Before refitting, clean the sump and its magnet. Check the condition of the sump seal and the drain and top-up plugs.
REFITTING
Fit the new strainer and its seal. Torque tighten the bolts to 0.5 +0.1 0 daN.m.
94933R
Fit the sump and torque tighten the bolts to 10.1 daN.m. Lower the transmission and remove the component jack. Refit the transmission rubber mounting bolts.
Refit: - the plastic deflector in the front left hand wheel arch, - the front left hand wheel, - the air filter, - the expansion bottle. Fill with oil and check the level.
23-35
AD4 AUTOMATIC TRANSMISSION Hydraulic distributor

23
the selector lever (2) to enable the lever to travel beyond the "Park" position.
Casing securing bolts Strainer securing bolts Distributor securing bolts
1 0.1 0.50 0.50 +0.1 0 +0.1 0
Removal This operation is carried out with the selector lever in position "P" (Park). Drain the transmission. Remove: - the sump (refer to the section on "Changing the strainer"), - the strainer (bolts 1),
94845-2R
This excess travel is necessary to release the drive for the manual valve control sector.
94840R
the gear selector lever cable,
94841R
23-36

Disconnect the sealed connector cable by pressing on the locking ring. -
23
the selector from the manual valve (4) by detaching first at (A) and then at (B).
Extract the hydraulic distributor manual valve.
94925S
Remove: - the sealed connector after removing bolt (3),
94848R
Remove the 16 bolts which secure the hydraulic distributor. Bolts (X) remain in place and secure the closing plate to the distributor.
94848-1R
94841-1R
23-37

Push the selector lever to the stop and disconnect the hydraulic distributor by releasing the modulating solenoid valve from the casing.
REFITTING
23
Ensure that the F1 supply tube (8), the modulating solenoid valve filter (7), and the system inserts (6) are present.
91724R 94852R1
Ensure that the inserts (6) and the filter (7) remain in place in the hydraulic circuit of the casing. Engage the hydraulic distributor. Push the gear selector lever to the stop taking care to correctly engage the modulating solenoid valve in the casing.
94852R2
23-38
23
Fit the manual valve and the selector (4) by first engaging section (A) and then section (B).
91724R
Fit the 16 bolts securing the distributor to the casing and torque tighten them to 0.5 daN.m in the order shown.
91350R4
Refit the sealed connector with its O-ring seal and bolt (3).
94841-1R1
94848-1R
23-39

Fit a new strainer and a new seal. Torque tighten to 0.5 +0.1 0 daN.m.
23
94845-2R
Refit the control cable. Fill with oil and check the level.
94840R
NOTE:
Fit the sump (check that the seals are in good condition and that the magnet is present). Torque tighten bolts (1) to 1 +0.1 daN.m. 0
Whenever the hydraulic distributor is changed or removed, change the modulating solenoid valve filter, the strainer and its seal.
Refit the automatic transmission (refer to the section on "Changing the strainer"). Reconnect the sealed connector. Refit the gear selector lever (2).
23-40
AD4 AUTOMATIC TRANSMISSION Automatic transmission (Removal - Refitting)
23
Mot. 453-01 Hose clamps Mot. 582 Locking sector Mot. 1202 Hose clamp grips
Shock absorber securing bolts Transmission securing bolts Wheel bolts Bolts securing the automatic transmission to the engine Bolt securing the rubber mounting to the sidemember Steering ball joint Rear mounting securing bolts Oil cooler bolts Converter drive plate bolts
11 3.5 9
2 3.5 6.5 2.5 1.5
IN ORDER TO REMOVE THE AUTOMATIC TRANSMISSION, THE ENGINE - AUTOMATIC TRANSMISSION ASSEMBLY MUST BE REMOVED.
Depending on equipment level, remove the selfcontained air bag in order to eliminate any risk of triggering (refer to the first generation air bag manual). Place the vehicle on a two post lift.
REMOVAL
Disconnect the battery. Drain: - the automatic transmission (only if it is to be changed), - the cooling system. Remove: - the bonnet, - the air filter and its mounting, - the antipercolation air duct., - the bar (if fitted).
23-41
23
94948R
Disconnect the accelerator cable (2) from the carburettor after disconnecting the kickdown switch connector (1).
Carburation system
94932R
23-42

Injection system
23
94927S 94930R
Disconnect: - the choke cable (depending on type), - the speedometer cable after unscrewing it from the automatic transmission, -
the earthing braids (engine and automatic transmission), the AEI (integral electronic ignition) or, the MPA (ignition power module) and the oxygen sensor connector (depending on vehicle type).
94834-1S
the engine wiring harness connectors in the box on the left hand wheel arch and the automatic transmission computer connectors,
94929S
23-43

Remove the following pipes: fuel pipe, vacuum pipe on the brake servo, (Depending on vehicle type) remove the pipes for the automatic transmission accelerated idle solenoid valves (2) and the power-assisted steering (3),
23
Remove: - the 35-way injection computer connector (5), - the purge canister solenoid valve supply connector (6), - the engine harness connection connector (7),
94931R
94928-1R
bleed canister (A), bleed canister solenoid valve(B).
(all types) the following hoses: radiator, heater, power assisted steering pump reservoir after fitting tool Mot. 453-01.
94928R
23-44

the oil cooler,
23
86511R
Remove: - the starter motor heat shield, - the starter motor,
94835S
the bolts securing the automatic transmission to the engine.
Remove the transmission from the engine taking care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the engine, check the presence of the centring pins on the block. Grease the device which locates the converter in the crankshaft with Molykote "BR2" . Fit the automatic transmission to the engine and torque tighten the securing bolts to 4 daN.m .
94890S
Fit the nuts which secure the drive plate to the converter using Loctite FRENBLOC and torque tighten them to 1.5 daN.m. Refit: - the oil cooler and torque tighten the bolts to 2.5 daN.m, - the starter motor and the heat shield, - the converter protective plate. Refit the engine - automatic transmission assembly in the engine compartment. Refit in the reverse order to removal.
23-45

Remove: - the power assisted steering reservoir, - the power assisted steering high pressure pipe (detach it from the retaining plate underneath the vehicle),
23
1st type assembly: Hexagonal socket-type screws. (For removal and refitting it is advisable to use, for example, socket FACOM J 235 and the 6 mm hexagonal male adaptor). 2nd type assembly: 12-sided socket-type screws. (For removal and refitting it is advisable to use, for example, 12-sided male socket FACOM SV. 8L).
Right hand side
94949S
the gear selector lever, the radiator, the exhaust clamp

94838-2S
Left hand side
91128S
the front wheels, the 6 bolts which secure the driveshafts to the sun wheel outlet flanges.
94837S
23-46

On each side of the vehicle remove: - the steering ball joint using extractor tool T. Av. 476,
23
Remove : - the driveshafts on the side, - the engine - automatic transmission rubber mountings. Fit the load positioner to the engine - automatic transmission assembly. Remove the assembly from the engine compartment.
85965-1R
the upper bolt (1) and slacken the lower bolt (2) for the shock absorber base.
91131S
90259R
23-47

Remove the converter protective plate.
REFITTING
23
Special points: Before refitting the driveshafts, fill the sun wheel outlet flanges with Molykote "BR2" grease .
94885S
Fit locking sector tool Mot. 582 and remove the three nuts which secure the drive plate to the converter.
94890-2S
IMPORTANT:
When refitting the accelerator cable, adjust it correctly as this is important to ensure correct operation of the kickdown switch. Carry out the following operations: - fill and bleed the cooling system, - top up the power assisted steering, - top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load potentiometer travel.
23-48
ABS version
23
On vehicles fitted with ABS, the automatic transmission is removed after removing the engine-gearbox drive assembly.
Mot. 1040-01
Dummy engine cradle for removing - refitting the enginegearbox drive assembly Hose clamps
REMOVAL
Mot.
453-01
Front engine sub-frame mounting bolts Rear engine sub-frame mounting bolts Upper shock absorber mounting bolts Brake caliper securing bolts Steering universal joint securing bolt Wheel bolts Driveshaft mounting bolts Shock absorber base mounting bolts Steering ball joint Bolts securing the automatic transmission to the engine Oil cooler bolts Converter drive plate bolts
4 8.5 2.5 10 3 9 3.5 11 3.5
Disconnect the battery. Remove the bumper at (A).
4 2.5 15
92054R
Place the vehicle on a two post lift. Depending on equipment level, remove the selfcontained air bag in order to eliminate any risk of triggering (refer to the 1st generation air bagmanual).
92058R
23-49
ABS version

Remove: - the interior wheel arch trim,
23
92057R
the air filter and its mounting.
Remove the separating bar and the antipercolation pipes (if fitted).
94948S
23-50
ABS version
23
Disconnect: - the accelerator cable from the carburettor after disconnecting connector (1) from the kickdown switch (2).
94927S 94932R
the choke cable (depending on type of carburation), the speedometer cable after unscrewing it from the automatic transmission, -
the earthing braids (engine and automatic transmission), the integral electronic ignition (AEI) and remove it, the following pipes : fuel pipes, vacuum pipes on the brake servo, remove the pipes for the automatic transmission accelerated idle solenoid valves (2) and the power-assisted steering (3),
94834-1S
the engine wiring harness connectors in the box on the left hand wheel arch and the automatic transmission computer connectors, radiator hoses, heater pipes.
94931R1
23-51
ABS version

-
23
Remove (depending on vehicle type) : - the air filter and its mounting, - the antipercolation air duct. Disconnect: - the accelerator cable from the throttle housing after disconnecting connector (1) for the kickdown switch (2),
the engine wiring harness connectors in the box on the left hand wheel arch and the automatic transmission computer connectors,
94927S
94930R
the speedometer cable after unscrewing it from the automatic transmission,
the 35-way injection computer connector (5), the bleed canister solenoid valve supply connector (6), the engine wiring harness connection connector (7).
94834-1S
94928-1R
23-52
ABS version
23
Disconnect the oxygen sensor connector. Remove: - the earthing braids (motor and automatic transmission), - the ignition power module (MPA), - the following pipes : fuel pipes, vacuum pipes on the brake servo, bleed canister (A), bleed canister solenoid valve (B).
92059S
Fit tool Mot. 1040-01.
94928R
radiator hoses, heater pipes.
ALL TYPES
Unhook: - the power assisted steering reservoir, - the gear selector lever cable. Refit: - the radiator, - the brake calipers and attach them to the vehicle body, - the tie rods connecting the sub-frame to the body, - the primary exhaust down-pipe, - the cam bolt for the universal joint.
92061S
Lower the vehicle to the ground.
23-53
ABS version

With the fan assembly removed.
23
Remove: - the upper shock absorber bolts,
92382S 92114R
Separate the engine - automatic transmission assembly from the engine sub-frame. the bolt securing the rubber mounting to the automatic transmission, Remove the converter protective plate.
94933-2R
the four engine sub-frame mounting bolts.

94885S
Lift the body and remove the engine-gearbox drive assembly.
Fit locking sector tool Mot. 582 and remove the three nuts which secure the drive plate to the converter.
23-54
ABS version
23
86511R
94835S
Remove: - the starter motor heat shield, - the starter motor,
the bolts securing the automatic transmission to the engine.
Separate the transmission from the engine taking care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the engine, check the presence of the locating pins on the block. Grease the device which locates the converter in the crankshaft with Molykote "BR2" . Fit the automatic transmission to the engine and torque tighten the securing bolts to 4 daN.m . Fit the nuts which secure the drive plate to the converter using Loctite FRENBLOC and torque tighten them to 1.5 daN.m. Refit: - the oil cooler and torque tighten the bolts to 2.5 daN.m, - the starter motor and the heat shield, - the converter protective plate. Refit the engine - automatic transmission assembly to the engine sub-frame. Refit in reverse order to removal.
94890S
the oil cooler,
23-55
ABS version
23
Special points Before refitting the driveshafts, fill the sun wheel outlet flanges with Molykote "BR2" grease .
Position the upper mountings in the appropriate drilled hole. A = Manual steering B = Power assisted steering
94890-2S
92114-1R
The alignment of the body with the engine subframe is made easier by using threaded rods which are approximately 100 mm long.
IMPORTANT
When refitting the accelerator cable, adjust it correctly as this is important to ensure correct operation of the kickdown switch. Carry out the following operations: - fill and bleed the cooling system (refer to section 19), - top up the power assisted steering, - top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load potentiometer travel.
85742S
Tighten the brake caliper securing bolts to a torque of 10 daN.m.
23-56
AD4 AUTOMATIC TRANSMISSION Full-load validation

Connect the XR25 to the vehicle diagnostic socket. The diagnostic socket (1) is located in the passenger compartment, under the dashboard, in the relay and fuse compartment.
23
0 4
Switch on the ignition without starting the engine. Enter the "A" transmission code on the keypad: D
On the bargraph displays only bargraphs 1 - 3 - 4 5 - 6 - 11 remain illuminated either on the right or on the left hand side. Validate the full-load position by pressing the accelerator pedal for 5 seconds. Bargraph 2 illuminates. Bargraph 6 extinguishes. When the accelerator pedal is released, only bargraphs 1 - 3 - 4- 5 - 11 should remain illuminated. VERY IMPORTANT: switch off the ignition. Switch the ignition on again and enter the "A" transmission code to check whether the validation has been carried out. (Repeat the operation if necessary).
92827R
Switch off the ignition and disconnect the XR25. WARNING: If the full-load is validated incorrectly, this may cause: - permanent illumination of the warning light, - gear change difficulties, - incorrect gear change thresholds, - difficulties in the operation of the kickdown function, - uncomfortable driving conditions.
Place the selector in position S4.
92655R1
23-57
AD4 AUTOMATIC TRANSMISSION Load potentiometer

Connect the XR25 to the vehicle diagnostic socket (located under the dashboard, in the relay and fuse compartment). Switch on the ignition without starting the engine. Enter the "A" transmission code on the keypad: D 0 4 Slacken the idle screw fully until the flap is completely closed.
23
The computer number is displayed. Example :
Computer identification number
4-speed auto trans
Enter on the keypad
90034
The potentiometer setting value in % appears on the central display. Slacken the potentiometer securing bolts (V). Example :
ADJUSTMENT
According to type (carburation)

THE LOAD POTENTIOMETER IS SPECIFIC TO THIS ENGINE AS IT HAS A LONGER TRACK. THEREFORE IT IS NOT INTERCHANGEABLE WITH ANOTHER TYPE OF POTENTIOMETER.
VERY IMPORTANT: Is is essential that the potentiometer adjustment procedure described below is applied.
94922R
Rotate the potentiometer body until a value is obtained on the central display of between 89.7 and 92.1 %.
23-58
AD4 AUTOMATIC TRANSMISSION Load potentiometer

Retighten securing bolts (1). (If adjustment is not possible, check the feed). Readjust the idle speed to 80050 rpm with the selector lever in neutral. Then erase the memory and programme the "Full-load" value. Depending on vehicle type (Injection) Slacken the potentiometer securing bolts (V).
23
94915R
With the accelerator cable at rest, rotate the potentiometer body until a value is obtained on the central display of between 89.7 and 92.1 %. Retighten the securing bolts (V). (If adjustment is not possible, check the feed). Then erase the memory and programme the "Full-load" value.
23-59
AD4 AUTOMATIC TRANSMISSION Computer (119)
23
94926R
When the computer is changed or the memory is erased, do not forget to carry out a full-load validation.
23-60
AD4 AUTOMATIC TRANSMISSION Line pressure sensor (8)
23
94884R
The sensor is secured to the automatic transmission casing by two bolts. It is directly accessible from underneath the vehicle, after removing the protective sleeve. After changing it, do not forget to erase the memory and carry out a full-load validation.
23-61
AD4 AUTOMATIC TRANSMISSION Multifunction switch (485)
23
94837-1R
The switch is secured to the automatic transmission casing. It is accessible from above or underneath the vehicle, after removing the securing plate and the earth wire (A). After changing it, do not forget to erase the memory and carry out a full-load validation.
23-62
AD4 AUTOMATIC TRANSMISSION Vehicle speed sensor (250)
23
94845-3R1
The speed sensor is secured to the top of the automatic transmission. It is accessible after removing: - the expansion bottle, - the rubber mounting bracket. After changing it, do not forget to erase the memory and carry out a full-load validation.
23-63
AD4 AUTOMATIC TRANSMISSION Solenoid valves
23
Solenoid valve securing bolts Distributor plate securing bolts Hydraulic distributor bolts
0.9 0.5 0.5
0.1 0.1 +0.1 0
The sequence and modulating solenoid valves and the temperature sensor can only changed after removal of the hydraulic distributor. Remove: - bolts (A) which secure the distributor closing plate(B), - the bolts securing the sequence solenoid valves (C) and modulating solenoid valve bolt (D). Remove the solenoid valve - sensor assembly from the distributor.
91367R
Refitting the assembly does not present any particular difficulties. proceed in reverse order to removal. Retighten the bolts to the recommended torque (very important).
NOTE:
Each sequence solenoid valve is fitted to its own mounting. Check to make sure that they are fitted to the correct mounting.
23-64
AD4 AUTOMATIC TRANSMISSION Engine torque reduction

The purpose of engine torque reduction during gear changes is: 1) to ensure smooth gear change,
23
2) to reduce the theoretical load of the hydraulic slave cylinders which are operated during gear changes, 3) to relieve the mechanical units. The torque is reduced by action on the point of advance. The torque reduction signal is supplied by the automatic transmission computer to the injection computer. Throughout the duration of the gear change, the point of advance is moved back by 35.
CHECKING THE CONNECTION BETWEEN THE AUTOMATIC TRANSMISSION COMPUTER AND THE INJECTION COMPUTER
Condition Gear change pattern selector in position "EXC". Automatic transmission in 3rd. With the vehicle at approximately 35 mph (60km/h) in 2nd, change from 2nd 3rd under light throttle.
Selection on the XR25 Enter D03 # 51
Display on the XR25
Note Brief change to zero on the checking equipment display.
23-65
AD4 AUTOMATIC TRANSMISSION Special features

KICKDOWN FUNCTION ADJUSTING THE CABLE
23
In order to trigger the kickdown switch on the AD4 automatic transmission, two pieces of information are required. 1st piece of information Accelerator pedal fully depressed to obtain load potentiometer information (value less than 6%). The value displayed on the XR25 at # 12 ). 2nd piece of information The kickdown switch fitted to the accelerator cable detects excess accelerator pedal travel which, when it compresses, creates an earth connection to the automatic transmission computer.
Connect the XR25 to the diagnostic socket on the vehicle. Place the selector in position S4.
92655R1
Switch on the ignition without starting the engine. Enter the "A" transmission code D04 on the keypad and read # 22 .
94932S1
This methods enables the kickdown function to be used at higher engine speeds. In order for the accelerator cable over travel to be fully effective, check to make sure that the accelerator cable is correctly adjusted.
23-66
AD4 AUTOMATIC TRANSMISSION Special features
23
NOTES
TEST CONDITIONS
DISPLAY ON THE XR25
Accelerator pedal released (No-load) (PL)
If value 1 is not displayed, check the electrical connection on the kickdown switch.
Accelerator pedal pressed (Full-load) (PF)
If value 0 is not displayed at Full-load, check the adjustment of the accelerator cable.
23-67
DRIVESHAFTS Consumables
29
COMPONENT CONCERNED
TYPE Loctite SCELBLOC RHODORSEAL 5661 MOLYKOTE BR2 FRENBLOC MOBIL CVJ 825
QUANTITY
Coating Coating Coating Coating 320 g 140 g 160 g 130 g
Stub axle splines Pins on driveshaft at gearbox end Splines on coupling at gearbox end Brake caliper bolt Joint GE 86 Joint AC 1700 Joint RC 490 Joint GI 62
Black Star or
MOBIL EXF 57C
Allocation of seals on the vehicle
JOINTS
Right hand driveshaft X X X X
Left hand driveshaft X X
Wheel end
Gearbox end
GE 86 AC 1700 RC 490 GI 62 GI 69
X X X X
29-1
DRIVESHAFTS Driveshafts
29
Rou. 604 -01 T.Av. 476 T.Av. 1050-02 B.Vi. 31-01
Hub locking tool Ball joint extractor Hub extractor Pin drift
TIGHTENING TORQUES(en daN.m)
On the left hand side 25 2.5 9 17 10 3.5 Drain the gearbox. Remove the three bolts.
Driveshaft nut Bolts securing gaiter to gearbox Wheel bolts Nuts securing bottom of shock absorber Brake caliper securing bolts Steering ball joint nuts
REMOVAL
Remove: - the brake assembly (suspend it from the chassis so as not to damage the brake hose), - the driveshaft nut using tool Rou. 604-01.
85678R
On the right hand side Remove the rollpin using tool B.Vi. 31-01.
85876-1R
91755R
29-2
On both sides: Remove: - the steering ball joint nut using tool T.Av. 476,
29
Remove the lower bolt securing the bottom of the shock absorber and take out the driveshaft.
91691S 85965-1R
the upper bolt securing the bottom of the shock absorber.
Take care not to damage the gaiters during this operation.
These vehicles have bonded driveshafts which, therefore, must be pushed back using tool T.Av. 1050-02.
REFITTING
NOTE: The Parts Department now supplies driveshafts equipped with protectors and supplied with fitting instructions which MUST be followed to ensure correct assembly with the highest degree of QUALITY. The slightest knock on the gaiters will damage them sooner or later and lead to destruction of the driveshaft.
91750R1
29-3
DRIVESHAFTS Driveshafts ESSENTIAL FITTING INSTRUCTIONS
29
DI2905
29-4
Never remove the cardboard protectors until the very end of the refitting operation.
29
On the left hand side Remove the plastic protector from the gaiter and engage the driveshaft keeping it as horizontal as possible.
91630R
85677S
Never use a sharp instrument as this could damage the gaiters.
91629R
29-5
On the right hand side With the protector fitted, smear the driveshaft splines at the gearbox end with MOLYKOTE BR2 grease. Position the driveshaft in relation to the sun wheel and insert it. Check its position using the angled drift from tool B.Vi. 31-01. Fit two new rollpins using tool B.Vi. 31-01. Seal the pin holes using RHODOSEAL 5661.
NOTE: the inlet chamfers on the sun wheels make it easier to fit new rollpins.
29
On both sides Coat the stub axle splines with Loctite SCELBLOC.
91749S
Engage the driveshaft stub axle in the hub.
91691R 74937-4S
29-6
On the left hand side
29
Clean the area where the gaiter bears against the gearbox, re-fasten the gaiter and the plate. Keep the gaiter as horizontal as possible and torque tighten the three bolts.
91691-1S
Re-secure: - the two bolts for the bottom of the shock absorber to the stub able carrier and torque tighten them, - the steering ball joint and torque tighten its nut. Torque tighten the driveshaft nut using tool Rou. 604-01.
85678R
85876-1R
29-7
On both sides Fit the brake calipers, coat the bolts with Loctite FRENBLOC and torque tighten them. Put the vehicle back on its wheels.
29
With the vehicle on its wheels, remove the cardboard protectors, tearing them as shown in the diagram.
91693R
91633S
Never use a sharp instrument as this could damage the gaiter.
91631S
91632R
Press on the brake pedal several times so that the piston makes contact with the shoes. If the left hand driveshaft is being changed, top up the oil in the gearbox.
29-8
Joint GE 86
DRIVESHAFTS Gaiter at wheel end
29
T. Av. T. Av. T. Av.
537 -02 GE 86 expander 1168 CAILLAU click collar tool 1256 OETIKER collar crimping tool
1 2 3 4 5 6 7
Bell-shaped stub axle Retaining star plate Spider Shaft yoke Retaining collar Rubber gaiter Retaining collar
DISMANTLING
Remove the existing collars taking care not to damage the grooves in the bell-shaped stub axle.
88578R
88638S
29-9
Joint GE 86

REASSEMBLING
29
Remove as much grease as possible. Free the bell-shaped stub axle from the driveshaft by raising the star plate arms (2) one by one.
Expander tool TAv. 537-02 must be used when refitting the GE 86 gaiter.
74650R
DO NOT TWIST THE STAR PLATE ARMS.
78411R
Retain the thrust ball, spring and shim under the ball joint (B). NOTE: the thickness of the shim under the ball joint is adapted to the original clearance. This shim must be retained and reused on reassembly.
Hold the driveshaft at a convenient angle in a vice fitted with soft jaws. Fit the expander on the end of the yoke (if it will not fit, deburr the inside of the cylindrical section of the tool with emery cloth).
88579R 78408-1R
Remove all traces of grease.
29-10
Joint GE 86
29
It is essential to make sure that there are no sharp edges on yoke (A) (deburr lightly with emery cloth if necessary). Carefully and generously lubricate the following with clean engine oil: - the whole expander (stems and centre), - inside the gaiter and in particular the neck. Place a thumb over the bottom hole, pour some oil into the gaiter and spread it round the inside.
Wrap a piece of clean rag round one hand and grip the gaiter so that the first fold will stretch when it is slid on.
Incorrect
Correct
80040
78409G
Lean against the edge of the vice.

80158S
Place one hand over the other and pull taking care that the first fold does not double back. Pull the gaiter as close as possible to the cylindrical section of the expander and then let it return halfway. Repeat this operation several times (maximum 5 times ) to make the rubber of the gaiter more pliable (relubricate the stems during the operation if necessary).
Slip the gaiter over the end of the expander.
78410S
29-11
Joint GE 86
29
When the gaiter slides more freely, with one continuous pull, fit the gaiter on the cylindrical section of the expander.
Insert the driveshaft yoke in the bell-shaped stub axle. Tilt the shaft to fit one arm of the retaining star plate in a slot in the yoke and press in to locate it correctly.
78412-2S
Fit the spring and thrust ball in the spider. Move the roller cages towards the centre. Position retaining star plate (2) so that each arm is central between each spider trunnion.
74653S
74652R
29-12
Joint GE 86
29
The other two arms may be fitted easily by using, for example, a screwdriver with the tip ground as shown A = 5 mm B = 3 mm Ensure that each arm of the retaining star plate is located in its slot. Tilt the shaft in the plane of one of the star plate arms and the ball joint will be freed under the action of the spring.
88668S
74697R
Insert the shim under the top of the ball joint (the shim should not project above the top of the ball joint).
29-13
Joint GE 86
29
Check the operation of the spider coupling by hand. No tight spots should be apparent. Distribute the sachet of grease evenly between the gaiter and the bell-shaped stub axle. NOTE: make sure that you use the amount of grease specified in the "Consumables" section. Position the gaiter lips in their grooves in the stub axle and driveshaft.
88601R
Correct
Incorrect
88578S 88639R
Insert a smooth round-edged piece of rod between the gaiter and the stub axle to restrict the amount of air inside. Fit the collars and tighten them using tool T. Av. 1034.
29-14
Joint AC 1700
29
T. Av. T. Av.
1168 1256
CAILLAU click collar tool OETIKER collar crimping tool
A driveshaft can be partially repaired at the wheel end: - a coupling change, - a gaiter change.
6-BALL COUPLING AT THE WHEEL END
1 2 3 4 5 6 7 A
Bell-shaped stub axle Balls Ball cage Retaining ring Driveshaft Gaiter Ball hub ABS crown wheel (option)
REASSEMBLING
78616R
Slide onto the shaft: - the small collar, - gaiter (3). Slide the ball coupling (1) complete with retaining ring (new) onto the shaft splines until the retaining ring locates in the shaft groove (B).
98824R
DISMANTLING
Cut the clip and gaiter all the way along. Remove as much grease as possible. Spread retaining ring (7) and tap the exposed face of ball hub (5) at the same time. Separate the coupling from the shaft.
78615R2
29-15
Joint AC 1700

Spread the sachet of grease round inside the gaiter and the bell-shaped stub axle. NOTE: it is essential to use the amount of grease specified in the "Consumables" section. Position the lips of the gaiter in the grooves in the bell-shaped stub axle (1) and the driveshaft (2).
29
98824R
Fit the collars and tighten them using the tool which corresponds to the type of collars supplied in the kit (click CAILLAU or OETIKER).
29-16
Joints AC 1700 and GE 86
29
OETIKER COLLAR
T.Av. 1256
OETIKER collar crimping tool
96048S
POSITION 1 - Pre-crimping and positioning of the collar
DI2901
Fit connecting rod (A) in the lower notch and close the tool fully. The pre-crimped collar slides onto the gaiter and can be positioned.
POSITION 2 - Crimping
DI2902
Fit connecting rod (A) in the upper notch and close the tool fully.
29-17
Joints AC 1700 and GE 86
29
CAILLAU CLICK COLLAR
T.Av. 1168
CAILLAU click collar tool
DI2903
93039R
93040S
NOTE: CAILLAU click type collars cannot be re-used.
29-18
Joint RC 490
DRIVESHAFTS Gaiter at gearbox end
29
T.Av. 1034
Driveshaft collar crimping tool
1 2 3 4 5 6 7
Yoke Spider Metal cover Rubber gaiter Retaining collar Driveshaft Metal insert
Cut the retaining collar and gaiter along its entire length.
92045S
Remove as much grease as possible.

92303R
Remove the metal cover.
DISMANTLING
Uncrimp the three points on the cover using pliers.
92046S
92044S
29-19
Joint RC 490
DRIVESHAFT Gaiter at gearbox end
29
Remove the yoke.
Never use thinners to clean the component parts. On the press, extract the spider, using a stripping extractor for support.
89145S
NOTE: as the yoke is not fitted with an antiseparation pate, it can be removed without force. Do not remove the roller cages from their respective trunnions since the cages and rollers are matched and must never be mixed. Remove the circlips (depending on vehicle model).
REASSEMBLY
90388S
Grease the driveshaft and slide on: - the new retaining collar, - rubber gaiter (4) with metal insert (7) and metal cover (3).
90387S
92048-1R
29-20
Joint RC 490
29
Fit the spider onto the splined shaft.
Spread the contents of the sachet of grease inside the gaiter and the yoke. NOTE: it is essential to use the amount of grease specified in the "Consumables" section. Position: - the gaiter and its metal insert in the metal cover, - the metal cover, sliding it on until the guide plate is flush with the yoke. In this position, crimp three points in the locations provided for this on the guide plate.
90389S
Refit the retaining circlips or make 3 crimping points 120 apart, pushing back the metal on the driveshaft splines.
92050S
Insert a smooth rod with a rounded end between the gaiter and the shaft to restrict the amount of air inside.
90391S
Grease the yoke and engage it on the spider assembly.
29-21
Joint RC 490
29
92051R
88601R
Lengthen or shorten the coupling until dimension A = 156 1 mm is obtained (distance measured between the end of the gaiter and the matched face, with largest diameter, of the yoke). In this position, remove the rod. Fit the collar on the gaiter and tighten it using tool T.Av. 1034.
92052R
29-22
Joint GI 62
29
1 2 3 4 5 6 7
Yoke Spider Metal cover Retaining spring Rubber gaiter Retaining collar Driveshaft
Using a pair of pliers, raise each end of the antiseparation plate (C), then remove the yoke.
88648R
74655R
DISMANTLING
Cut the crimped collar and the gaiter along its entire length. Remove as much grease as possible.
Do not remove the roller cages from their respective trunnions since the cages and rollers are matched and must never be mixed. Never use thinners to clean the component parts. Remove the circlips depending on the type of assembly.
75936-1S1
90387S
29-23
Joint GI 62
DRIVESHAFTS gaiter at gearbox end
29
Extract the spider in a press, using a stripping extractor for support.
Refit the retaining circlips or make 3 crimping points 120 apart, pushing back the metal on the driveshaft splines. NOTE: it is essential to use the amount of grease specified in the "Consumables" section.
90388S
REASSEMBLING
Lubricate the driveshaft and slide on the new retaining clip and gaiter. Fit the spider onto the splined shaft.
90391S
Insert a 2.5 mm wedge (B), made as shown in the sketch, between the anti-separation plate and yoke.
90389S
75434-1R
29-24
Joint GI 62
29
Carefully tap the anti-separation plate into its original position with a bronze drift, then remove wedge (B).
Insert a smooth round-ended piece of rod between the gaiter and yoke so as to restrict the amount of air retained inside the coupling. Lengthen or shorten the coupling to obtain dimension A = 153,5 1 mm (dimension measured between the gaiter end face and the largest diameter machined face on the yoke).
74867R
Locate the gaiter lips in the groove on the driveshaft and on the metal cover.
90390R
In this position, remove the rod and fit the retaining collar. Tighten it using tool T. Av. 1034.
75434-1S
88601R
29-25
Joint GI 69
DRIVESHAFTS Gaiter - bearing assembly
29
T.Av. 944
Mandrel for fitting bearing to shaft
REMOVAL
Never use thinners for cleaning component parts. Remove the circlip depending on the type of assembly.
90388S
Remove the gaiter and bearing assembly in the same way as the spider.
90387S
Remove the spider, on the press, using an extractor for support.
85933S
29-26
Joint GI 69
29
REFITTING
For it to be in its correct position on the shaft, the bearing must be inserted until dimension L = 148,5 mm is obtained between the front section of the bearing and the end of the shaft. This dimension is obtained when the end of tool T.Av. 944 is flush with the end of the shaft.
86197S
85884-1R1
The bearing is fitted with a lip seal. To avoid distortion and consequent leakage, it must never be driven in with a hammer. Fit it on the press so as to apply a gradual pressure.
29-27
Joint GI 69

Furthermore, secure the driveshaft on the press via its groove (G) using an extractor to avoid damaging the coupling at the wheel end.
29
86198R
Refit the spider on the splined shafts and refit the retaining clrclips (depending on the type of assembly).
29-28

Transmission AD4

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Transmission AD4

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Transmission

Renault S.A. 1988

26 splines E = 7.7 mm D = 181.5 mm

26 splines M= 6 pale pink springs E = 7.7 mm D = 200 mm

26 splines D = 200 mm E = 7.7 mm

R = 4 red springs J = 4 yellow springs

Special feature: 2 additional springs on the hub.

200 CPV 3500

26 splines D = 200 mm E = 7.7 mm

R = Red J = Yellow V = Green

Special feature: 2 additional springs on the hub.

200 CPV 4400

26 splines D = 200 mm E = 7.7 mm

J = 4 yellow springs G = 4 grey springs

CLUTCH Side view

RHODORSEAL 5661 LOCTITE 518

100 g tube 24 ml syringe

Ends of driveshaft roll pins. Housing assembly faces.

CLUTCH Mechanism - Clutch plate

CLUTCH Mechanism - clutch plate

ESSENTIAL SPECIAL TOOLS

TIGHTENING TORQUES (in daN.m)

CLUTCH Mechanism - clutch plate

CLUTCH Mechanism - clutch plate

CLUTCH Thrust pad - fork

Ensure that the assembly slides properly.

Check the extent of fork travel. It should be: X = 17 to 18 mm

MANUAL GEARBOXES Identification

Repair manual which deals with the gearbox concerned

TWO-COLOUR MARKING JB0 - JB1 - JB3 - JC5

MANUAL GEARBOXES Gear ratios

Final drive set 16 57 15 56 15 58 15 61

Speedo drive set

019 023 035

Final drive set 15 58 15 61 15 58 15 61 16 57 14 63 15 61

Speedo drive set

027 029 034 047

MANUAL GEARBOXES Gear ratios

Final drive set

Speedo drive set

B53B B53Y - C53Y - L53Y

MANUAL GEARBOXES Gear ratios

Final drive set

Speedo drive set

MANUAL GEARBOXES Capacities - Lubricants

4-speed gearbox JB0 JB2 JB4 3.25 2.75

5-speed gearbox JB1 JB3 JB5 JC5 3.40 2.90 3.10

CHECKING THE LEVEL

OIL VISCOSITY GRADE

Tranself TRX 75/80 W

Fill to the level of the opening.

MANUAL GEARBOXES Lubricants

MANUAL GEARBOXES Special features

5 forward gears 1 reverse

are fitted with BORG-WARNER synchronisers.

GEAR CHANGE PATTERN

MANUAL GEARBOXES Consumables

Parts which must be changed automatically

MANUAL GEARBOXES Gearbox (Removal - Refitting)

ESSENTIAL SPECIAL TOOLS

B.Vi. 31-01 T.Av. 476

Set of pin punches Ball joint extractor