Manual gearbox: Removal - Refitting

F4R or F9Q

Essential special tools
Rou. 604-01	Hub holder
Tav. 476	Ball joint extractor
Mot. 1453	Multi-adjustable engine mounting bracket, with retaining straps

Essential equipment

steering wheel lock

component spring compressor

Tightening torques
wheel mounting bolts	11 daN.m
driveshaft nut	28 daN.m
lower ball joint nut	6.2 daN.m
steering ball joint nut	3.7 daN.m
stabilizer bar ball joint nut	4.4 daN.m
side cheek mounting bolts	2.1 daN.m
gearbox bellhousing and starter bolts	4.4 daN.m
engine torque rod bolt	18 daN.m
subframe torque rod bolt	10.5 daN.m
gearbox pendulum mount bolt	6.2 daN.m
pendulum mount nut on bump stop	18 daN.m
steering clevis bolt	2.1 daN.m
front radiator crossmember mounting bolts	10.5 daN.m
rear radiator crossmember mounting bolt	2.1 daN.m
subframe crossmember mounting bolt	6.2 daN.m
rear subframe mounting bolt	14 daN.m
subframe brace mounting bolts	10.5 daN.m
gearbox drain plug	2.5 daN.m
gearbox filler plug	0.3 daN.m
battery cover	0.4 daN.m

WARNING

To avoid any risk of damaging the clockspring, observe the following instructions:

• Be sure to immobilise the steering wheel, wheels straight, using the steering wheel lock for the entire duration of the operation, before disconnecting the steering column and the rack.
• Any doubt about the correct centring of the clockspring requires removing the steering wheel to apply the centring method described in the Controls - Signalling chapter.

In this case, only qualified personnel who have received training must carry out the work.

REMOVAL

• Position the vehicle on a two-post lift.
• Remove the battery cover.
• Disconnect the battery, starting with the negative terminal.
• Remove the undershield.
• Drain the gearbox oil.
• Remove:

• the front wheels,
• the engine covers,
• the battery,
• the battery tray,
• the injection ECU with its bracket,
• the air flow meter,
• the air intake hose.

• Remove the wiring harness mountings.
• Unclip the gear selector cables from the gearbox.

Note: Do not touch the spool valve.

F9Q

Disconnect the air duct between the intercooler and the turbocharger.

• Disconnect:

• the wheel anti-lock sensor wiring,
• the xenon headlamp levelling sensor wiring (if fitted).

• Remove the mudguards.

I - LEFT-HAND SIDE OF THE VEHICLE

• Remove:

• the hub nut, using tool (Rou. 604-01),
• the steering track rod end, using tool (Tav. 476),
• the anti-roll bar link ball joint,
• the lower ball joint.

• Release the hub carrier from the driveshaft.
• Remove the driveshaft.

II - RIGHT-HAND SIDE OF THE VEHICLE

• Remove:

• the hub nut, using tool (Rou. 604-01),
• the steering track rod end, using tool (Tav. 476),
• the anti-roll bar link ball joint,
• the lower ball joint,
• the intermediate bearing bracket.

• Release the hub carrier from the driveshaft.
• Remove the driveshaft.
• Tie all the cooling radiators to the upper cross member using ropes.

• Remove the side reinforcements.

• Remove the radiator cross member.
• Remove:

• the catalytic converter bracket on the clutch housing,
• the starter motor mounting bolts,
• the starter motor.

• Remove the upper torque strut.

• Remove the lower torque strut.

• Remove the steering yoke.

• Remove the subframe bracket.

• Remove the subframe.

• Disconnect:

• the reverse gear connector,
• the top dead centre sensor.

• Drain the brake fluid reservoir using a syringe down to the clutch slave cylinder hose connection.

• Disconnect the clutch release bearing by removing the clip (1).

• Fit the engine support tool (Mot. 1453).

• Remove:

• the gearbox support bush,
• the gearbox pendulum mount,
• the upper gearbox torque bolts.

• Fit the unit support jack under the gearbox.
• Remove:

• the lower gearbox torque bolts,
• the gearbox mounting studs,
• the gearbox.

INSTALLATION

WARNING

Do not grease:

• the gearbox output shaft with grease, to avoid damaging the clutch release bearing,
• the clutch shaft splines.

Note: To avoid any risk of leaks, always replace the clutch slave cylinder after replacing the clutch mechanism.

• Make sure the engine - gearbox centring dowels are present and correctly positioned.
• Refit in the reverse order of removal.
• Tighten to the following torques:

• wheel mounting bolts (11 daN.m),
• the driveshaft nut (28 daN.m),
• the lower ball joint nut (6.2 daN.m),
• the steering ball joint nut (3.7 daN.m),
• stabilizer bar ball joint nut (4.4 daN.m),
• the side plate mounting bolts (2.1 daN.m),
• the gearbox and starter motor torque bolts (4.4 daN.m),
• the torque strut bolts on the engine (18 daN.m),
• the torque strut bolts on the subframe (10.5 daN.m),
• the gearbox pendulum mount bolts (6.2 daN.m),
• the pendulum mount nut on the bush (18 daN.m),
• the steering yoke fixing bolt (2.1 daN.m),
• front radiator crossmember mounting bolts (10.5 daN.m),
• the rear radiator cross member mounting bolts (2.1 daN.m),
• the subframe cross member mounting bolts (6.2 daN.m),
• the rear subframe mounting bolts (14 daN.m),
• the subframe tie rod mounting bolts (10.5 daN.m),
• the gearbox drain plug (2.5 daN.m),
• the gearbox filler plug (0.3 daN.m).

• Check the gearbox oil level.

WARNING

The hydraulic clutch circuit must be bled, following these instructions:

• Add brake fluid to the reservoir.
• Bleed the circuit (see Mechanical Controls chapter).
• Top up the brake fluid level.

WARNING

Connect the battery; carry out the necessary relearn procedures (see Battery chapter).

• Torque the battery cover (0.4 daN.m).

K4J or K4M or K9K

Essential special tools
Rou. 604-01	Hub holder
Tav. 476	Ball joint extractor
Mot. 1453	Multi-adjustable engine mounting bracket, with retaining straps

Essential equipment

component spring compressor

Tightening torques
wheel mounting bolts	11 daN.m
driveshaft nut	28 daN.m
lower ball joint nut	6.2 daN.m
steering ball joint nut	3.7 daN.m
anti-roll bar link ball joint nut	4.4 daN.m
side cheek mounting bolts	2.1 daN.m
gearbox bellhousing and starter bolts	4.4 daN.m
engine torque rod bolt	10.5 daN.m
subframe torque rod bolt	10.5 daN.m
gearbox pendulum mount bolt	6.2 daN.m
pendulum mount nut on bump stop	18 daN.m
front radiator crossmember mounting bolts	10.5 daN.m
gearbox drain plug	2.5 daN.m
gearbox filler plug	0.3 daN.m
battery cover	0.4 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Remove the battery cover.
• Disconnect the battery, starting with the negative terminal.
• Remove the undershield.
• Drain the gearbox oil.
• Remove:

• the front wheels,
• the engine covers,
• the battery,
• the battery tray,
• the injection ECU with its bracket,
• the air flow meter,
• the air intake hose.

• Remove the wiring harness mountings.

• Unclip the gear selector cables from the gearbox

• Disconnect:

• the wheel anti-lock sensor wiring,
• the xenon headlamp levelling sensor wiring (if fitted).

• Remove the mudguards.

I - LEFT-HAND SIDE OF THE VEHICLE

• Remove:

• the hub nut, using tool (Rou. 604-01),
• the steering track rod end, using tool (Tav. 476),
• the anti-roll bar link ball joint,
• the lower ball joint.

• Release the hub carrier from the driveshaft.
• Remove the left-hand driveshaft.

II - RIGHT-HAND SIDE OF THE VEHICLE

• Remove:

• the hub nut, using tool (Rou. 604-01);,
• the steering track rod end, using tool (Tav. 476),
• the anti-roll bar link ball joint,
• the lower ball joint,
• the intermediate bearing bracket.

• Release the hub carrier from the driveshaft.
• Remove the right-hand driveshaft.
• Tie all the cooling radiators to the upper cross member using ropes.

• Remove the side reinforcements.

• Remove the radiator cross member.

• Remove:

• the catalytic converter bracket on the clutch housing,
• the starter motor mounting bolts,
• the starter motor.

• Remove the torque strut.
• Disconnect:

• the reverse gear connector,
• the top dead centre sensor.

• Drain the brake fluid reservoir using a syringe down to the clutch slave cylinder hose connection

• Disconnect the clutch release bearing by removing the clip (1).

• Fit the engine support tool (Mot. 1453).
• Remove:

• the gearbox support bush,
• the upper gearbox torque bolts.

• Fit the unit support jack under the gearbox.
• Remove:

• the lower gearbox torque bolts,
• the gearbox mounting studs,
• the gearbox.

INSTALLATION

WARNING

Do not grease:

• the gearbox output shaft with grease, to avoid damaging the clutch release bearing,
• the clutch shaft splines.

Note: To avoid any risk of leaks, always replace the clutch slave cylinder after replacing the clutch mechanism.

• Make sure the engine - gearbox centring dowels are present and correctly positioned.
• Refit in the reverse order of removal.
• Tighten to the following torques:

• wheel mounting bolts (11 daN.m),
• the driveshaft nut (28 daN.m),
• the lower ball joint nut (6.2 daN.m),
• the steering ball joint nut (3.7 daN.m),
• the anti-roll bar link ball joint nut (4.4 daN.m),
• the side plate mounting bolts (2.1 daN.m),
• the gearbox and starter motor torque bolts (4.4 daN.m),
• the torque strut bolts on the engine (10.5 daN.m),
• the torque strut bolts on the subframe (10.5 daN.m),
• the gearbox pendulum mount bolts (6.2 daN.m),
• the pendulum mount nut on the bush (18 daN.m),
• front radiator crossmember mounting bolts (10.5 daN.m),
• the gearbox drain plug (2.5 daN.m),
• the gearbox filler plug (0.3 daN.m).

Check the gearbox oil level.

WARNING

The hydraulic clutch circuit must be bled, following these instructions:

• Add brake fluid to the reservoir.
• Bleed the hydraulic circuit (see Mechanical Controls chapter).
• Top up the brake fluid level.

WARNING

Connect the battery; carry out the necessary relearn procedures (see Battery chapter).

• Torque the battery cover (0.4 daN.m).