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23A Automatic Gearbox

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23A- 1 AUTOMATIC GEARBOX General DP0 23A Identification engraving on the automatic gearbox. I - SPECIFICATIONS Weight: 70 kg. Vehicles fitted with the DP0 automatic gearboxes use systems called « Shift lock » and « Lock up ». The purpose of the « Shift lock » function is to prevent the gear selector lever from being moved without the brake pedal being simultaneously depressed. The purpose of « Lock up » or converter bypass is to connect the automatic gearbox directly to the engine. This function is performed by a « mini clutch » located on the converter. « Lock up » is controlled by the automatic gearbox. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. Consequently, and to avoid serious damage, it is essential to comply with the following instructions: - never allow the vehicle to coast with the ignition swit- ched off (i.e. when going down a hill); the damage that this may cause cannot be stressed highly enough, - never push the vehicle (i.e.: to get to a petrol station, unless the precautions in the « Towing » section have been taken). The vehicle only has drive when the engine is running. It is therefore impossible to start the engine of a vehicle with an automatic gearbox by pushing the vehicle. II - TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. Nonetheless, if this is impossible, in exceptional cir- cumstances, the vehicle may be towed at low speed (maximum 12 mph (20 km/h) over a maximum distan- ce of 18 miles (30 km) (lever in N position). 13786 Note: For repair operations when the battery is faulty, refer to the notice on board the vehicle. WARNING Towing weight (towing a caravan, boat, etc.): - the load being towed must be less than or equal to 950 kg for a DP0 gearbox. - failure to comply with this maximum load will, on a 7% gradient, result in the maximum engine oil and automatic gearbox oil temperature being excee- ded, causing damage to the engine.
Transcript
Page 1: 23A Automatic Gearbox

23A-1

AUTOMATIC GEARBOXGeneral

DP0

23AIdentification engraving on the automatic gearbox.

I - SPECIFICATIONS

Weight: 70 kg.

Vehicles fitted with the DP0 automatic gearboxes usesystems called « Shift lock » and « Lock up ».

The purpose of the « Shift lock » function is to preventthe gear selector lever from being moved without thebrake pedal being simultaneously depressed.

The purpose of « Lock up » or converter bypass is toconnect the automatic gearbox directly to the engine.This function is performed by a « mini clutch » locatedon the converter.

« Lock up » is controlled by the automatic gearbox.

As the automatic gearbox is lubricated under pressure,lubrication is only provided when the engine is running.

Consequently, and to avoid serious damage, it is essential to comply with the following instructions:

- never allow the vehicle to coast with the ignition swit-ched off (i.e. when going down a hill); the damage thatthis may cause cannot be stressed highly enough,

- never push the vehicle (i.e.: to get to a petrol station,unless the precautions in the « Towing » section havebeen taken).

The vehicle only has drive when the engine is running.It is therefore impossible to start the engine of a vehiclewith an automatic gearbox by pushing the vehicle.

II - TOWING

The vehicle should preferably be towed in all cases ona tow truck or with the front wheels raised.

Nonetheless, if this is impossible, in exceptional cir-cumstances, the vehicle may be towed at low speed(maximum 12 mph (20 km/h) over a maximum distan-ce of 18 miles (30 km) (lever in N position).

13786

Note:

For repair operations when the battery is faulty, referto the notice on board the vehicle.

WARNING

Towing weight (towing a caravan, boat, etc.):

- the load being towed must be less than or equal to950 kg for a DP0 gearbox.

- failure to comply with this maximum load will, on a7% gradient, result in the maximum engine oil andautomatic gearbox oil temperature being excee-ded, causing damage to the engine.

Page 2: 23A Automatic Gearbox

23A-2

AUTOMATIC GEARBOXRatios

DP0

23A

Vehicle Engine Gearboxes

Automatic

Gearbox suffix Step-down Final drive

CMOC K4M 761 DP0 047 52 : 67 21 : 73

CMOU F4R 771 DP0 049 52 : 67 21 : 73

Page 3: 23A Automatic Gearbox

23A-3

AUTOMATIC GEARBOXConsumables

DP0

23A

Description Component concerned

Grease

MOLYKOTE BR2

Centring tool

LOCTITE FREN-BLOC

Brake calliper mounting bolt

Page 4: 23A Automatic Gearbox

23A-4

AUTOMATIC GEARBOXParts to be replaced systematically

DP0

23AThe following parts must be replaced after being remo-ved:

- self-locking nuts,

- the seals,

- rubber seals,

- converter bolts.

Page 5: 23A Automatic Gearbox

23A-5

AUTOMATIC GEARBOXOil

DP0

23AThe DP0 automatic gearbox is greased for life anddoes not require any maintenance: It is only necessaryto top up the level in the event of a slight leak.

I - OIL SPECIFIED:

ELF RENAULT MATIC D3 SYN (can be ordered fromELF) DEXRON III standard

II - CAPACITY IN LITRES

Total volume: 6 litres.

Page 6: 23A Automatic Gearbox

23A-6

AUTOMATIC GEARBOXDrain the automatic gearbox oil.

DP0

23A

It is preferable to change the automatic gearbox oilwhen it is warm (60˚C maximum), in order to removeas many impurities as possible.

Put the vehicle on a lift.

Remove the engine undertray.

Drain the oil by removing the plug (1).

SPECIAL FEATURES

The plug has two functions:

- the drain plug (2.5 daNm)(1),

- the top up spillway (3.5 daNm)(2).

Tightening torquesm

drain plug 2.5 daNm

top up spillway 3.5 daNm

103406

Note:

As a precaution, it is recommended that thevolume of oil collected during the oil change (totalor partial) be measured to find out the volume ofoil which must be replaced, to prevent filling tothe wrong level.

12316

1

2

Page 7: 23A Automatic Gearbox

23A-7

AUTOMATIC GEARBOXFilling and topping up

DP0

23A

I - FILLING

Fill through the hole (1).

Use a funnel with a 15/100 filter to prevent impuritiesfrom entering the system.

II - FILLING PROCEDURE

Park the vehicle on level ground.

Fill the automatic gearbox with 3.5 litres of new oil.

Run the engine at idling speed.

Connect the Diagnostic tool (« CLIP »).

Establish dialogue with the automatic transmissioncomputer,

Monitor the transmission oil temperature parameter.

Once a temperature of 60˚C +/- 1 is reached, openthe level-setting plug.

Position a container to collect at least 0.1 litre of ex-cess oil and wait until the oil flows out drop by drop.

Close the filler cap.

III - LEVEL CHECKING PROCEDURE OUTSIDE FILLING OPERATIONS

Park the vehicle on level ground.

Fill the automatic gearbox with 0.5 litres of new oil.

Run the engine at idling speed.

Connect the Diagnostic tool (« CLIP »).

Establish dialogue with the automatic transmissioncomputer,

Monitor the transmission oil temperature parameter.

Once a temperature of 60˚C +/- 1 is reached, openthe level-setting plug.

If the oil does not flow out or the quantity collected isbelow 0.1 litre: stop the engine, add 0.5 litre, let theautomatic gearbox to cool to 50˚C, then carry out thefollowing operations.

Run the engine at idling speed.

Connect the Diagnostic tool (« CLIP »).

Establish dialogue with the automatic transmissioncomputer,

Essential equipment

Diagnostic tool

103407

113792

Note:

The level must be checked following the methoddescribed below:

Page 8: 23A Automatic Gearbox

23A-8

AUTOMATIC GEARBOXFilling and topping up

DP0

23A Monitor the transmission oil temperature parameter.

Once a temperature of 60˚C +/- 1 is reached, openthe level-setting plug.

Enter the oil change date using the CF074 Entergearbox oil change date command on the Dia-gnostic tool (« CLIP »).

Note:

When the oil is replaced, the electronic oil ageingcounter must be reset (inside the computer).

Page 9: 23A Automatic Gearbox

23A-9

AUTOMATIC GEARBOXChecking the setting point of the converter

DP0

23A

Put the vehicle on a two-post lift.

Lift the vehicle until the wheels are raised off theground by a few centimetres.

Connect the Diagnostic tool (« CLIP »).

Establish dialogue with the automatic transmissioncomputer,

Monitor the automatic gearbox oil temperature para-meter.

The check should be done at an oil temperature ofbetween 60˚C and 80˚C.

Start the engine and put the lever in D.

Monitor the engine speed parameter:

Establish dialogue with the computer.

Accelerate fully keeping the brakes applied.

The front wheels should not rotate.

The engine speed should stabilise at 2700 rpm +/-150.

The engine speed should stabilise2500 rpm.

A setting point outside the tolerance requires theconverter to be replaced.

Essential equipment

Diagnostic tool

WARNING

- The full load position must not be held for morethan 5 seconds. Beyond this, there is a highrisk of destroying the converter or the automaticgearbox.

- Once the measurement has been taken,release the accelerator and keep the brakes onuntil the engine speed stabilises to idle speed(there is a risk of damaging the automatic gear-box if this is not complied with).

K4M

F4R

Note:

A setting point which is too low may be linked to alack of engine power.

Page 10: 23A Automatic Gearbox

23A-10

AUTOMATIC GEARBOXHydraulic distributor

DP0

23A

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Remove the engine undertray.

Drain the automatic gearbox using the plug (1).

Remove:

- the wheels,

- the air intake duct.

Disconnect the electrical harness:

- from the battery (2),

- from the battery tray (3),

- from the injection computer (4).

Remove:

- the battery,

- the computer,

- the battery mounting.

Essential special tooling

Bvi. 1462 Ball plate adjustingscrew

Essential equipment

Diagnostic tool

Tightening torquesm

distributor mountingbolts

0.75 daNm

ball detent plate bracketmounting bolt (12)

0.9 daNm

ball detent plate moun-ting bolt

0.8 daNm

cover mounting bolts 1 daNm

rechargeable battery 4 daNm

reinforcement platemounting bolts

2.1 daNm

13792

1

101821

3

2

4

Page 11: 23A Automatic Gearbox

23A-11

AUTOMATIC GEARBOXHydraulic distributor

DP0

23A

Remove the electrical harness (5) on the side rein-forcement.

Remove:

- the bolts (6) on the side reinforcement plate,

- the side reinforcement.

Remove the four retaining bolts (7) on the hydraulicdistributor cover (be careful as oil may run out).

Remove the seven mounting bolts on the hydraulicdistributor.

Disconnect the solenoid valve connectors.

Remove the hydraulic distributor.

REFITTING

Fit the distributor and centre it using bolts (4) and (5).

Refit the other bolts.

Tighten to torque and in the correct order the distri-butor mounting bolts (0.75 daNm).

103412

14783

566

77

13788

13789

Page 12: 23A Automatic Gearbox

23A-12

AUTOMATIC GEARBOXHydraulic distributor

DP0

23AADJUSTING THE BALL DETENT PLATE

Hold the multifunction lever switch in the end position(1st selected) using a plastic clip and a bolt in themechanism housing.

Remove the bolt (8).

Position the ball detent plate by placing the roller (9)in the hollow (11) of the sector (10) corresponding tothe 1st gear selected position.

Position the ball detent plate bracket mounting bolt(12) but do not tighten it.

Position the tool (Bvi. 1462) in place and fit the bolt(8).

Screw the tool in fully whilst holding the ball detentplate.

Tighten to torque the ball detent plate bracketmounting bolt (12) (0.9 daNm).

Remove the tool (Bvi. 1462).

Remove the ball detent plate mounting bolt (8).

14782

13788-1

10

98

2318

14785

1011

12

Page 13: 23A Automatic Gearbox

23A-13

AUTOMATIC GEARBOXHydraulic distributor

DP0

23A Tighten to torque the ball detent plate mounting

bolt (0.8 daNm).

When replacing the oil distributor, the auto-adaptivesmust be reset using command RZ005: « Eraseauto-adaptives » and the oil age counter of theautomatic gearbox computer must be reset using theDiagnostic tool, use command CF074: « Enterdate of gearbox oil change ».

After using command RZ005, it is important to carryout a test drive performing all gear changes, both upand down, several times in order to store the new va-lues.

Tighten to torque:

- the cover mounting bolts (1 daNm),

- the rechargeable battery (4 daNm),

- the reinforcement plate mounting bolts (2.1daNm).

To refit, proceed in the reverse order of removal.

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 14: 23A Automatic Gearbox

23A-14

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23ASpecial notes for vehicles fitted with a driver's airbag

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Remove:

- the air intake duct,

- the battery,

- the battery tray,

- the injection computer and its mounting,

- the air intake pipe,

- the wiring harness mountings.

Essential special tooling

Rou. 604-01 Hub locking tool

Tav. 476 Ball joint extractor

Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps

Bvi. 1531 Inertia wheel centr ingtool for automatictransmission converter

Essential equipment

Jack

Tightening torquesm

wheel bolts 11 daNm

brake calliper columnbolts

0.7 daNm

track rod end nut 3.7 daNm

track rod end nut 6.2 daNm

engine tie-bar on thesub-frame

10.5 daNm

gearbox edge bolt andstarter motor

4.4 daNm

suspension mountingnut on the gearbox

4.4 daNm

track rod end nut 6.2 daNm

converter mounting nuton the drive plate

3.7 daNm

modular connectormounting bolts

2 daNm

engine speed sensormounting bolts

1 daNm

engine tie-bar bolts onthe K Engine

10.5 daNm

engine tie-bar bolts onthe F Engine

18 daNm

suspension mountingnut on the rubber pad

18 daNm

WARNING

Observe the following instructions to avoiddamaging the rotary switch beneath the steeringwheel:

- Before the steering column and the steering rackare uncoupled, the steering wheel must be immo-bilised with the wheels straight for the duration ofthe operation using a steering wheel locking tool.

- If there is any doubt about the correct alignment ofthe rotary switch, it is necessary to remove thesteering wheel to apply the centring method ( Con-trols - signalsSection). In this case, only qualifiedpersonnel who have received training may carryout the operation.

101821

Page 15: 23A Automatic Gearbox

23A-15

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A

Remove:

- the multifunction switch cable ball joint (1) using thetool,

- the wiring harness (2) for the multifunction switchcable by removing the sleeve stop,

- the wiring harness mountings.

Disconnect:

- the engine speed sensor,

- the connector (3) by removing the connector slide.

Remove the mounting bolts (4) from the modularconnector support plate.

Remove the engine speed sensor.

Remove the engine speed sensor.

Fit the hose clamps.

Disconnect the radiator.

Unclip the gearbox wiring harness.

103409

WARNINGProtect the connector by sliding it into a water-proof plastic bag.

1

2 3

44

K4M

103753

F4R

103420

Page 16: 23A Automatic Gearbox

23A-16

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A

Remove:

- the two bolts (5) from the starter,

- the engine undertray.

Drain the gearbox.

Remove:

- the wheels,

- the wheel arch liners,

Disconnect:

- the ABS system sensor wiring,

- the xenon headlight adjustment sensor wiring har-nesses (if fitted).

I -LEFT-HAND SIDE OF THE VEHICLE

Remove:

- the hub nut using the tool (Rou. 604-01),

- the track rod end using the tool (Tav. 476),

- the anti-roll bar ball joint using the tool (Tav. 476),

- the lower ball joint.

Remove the stub-axle carrier from the driveshaft.

Remove the left-hand driveshaft.

103423

Note:

The xenon headlight adjustment sensor is fittedonto the left-hand lower wishbone.

5

102129

103412

6

7

Page 17: 23A Automatic Gearbox

23A-17

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A Remove:

- the clip (7) from the gearbox computer wiring har-ness,

- the side reinforcement (6)

Open the retaining bracket (8) on the gearbox com-puter wiring harness.

Disconnect the gearbox computer connector (9).

II - RIGHT-HAND SIDE OF THE VEHICLE

Remove:

- the hub nut using the tool (Rou. 604-01),

- the track rod end using the tool (Tav. 476),

- the anti-roll bar ball joint using the tool (Tav. 476),

- the lower ball joint.

Remove the relay bearing bracket.

Remove the stub-axle carrier from the driveshaft.

Remove the right-hand driveshaft.

Attach the cooling radiator assembly to the uppercross member using rope.

Remove the side reinforcement.

103413

102129

8

9

103418

101212

Page 18: 23A Automatic Gearbox

23A-18

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A

Remove the radiator lower cross member.

Remove:

- the exhaust mounting nuts.

- the engine tie-bar.

Remove:

- the exhaust mounting nuts (10),

- the engine tie-bar.

Remove:

- the lower engine/manifold bracket,

- the starter mounting bolt (11),

102009

K4M

103749

1010

F4R

103421

103418

101011

11

Page 19: 23A Automatic Gearbox

23A-19

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A- the starter motor,

- the three nuts on the converter.

Remove the upper studs (12) around the edge of thegearbox.

Strap the bonnet down.

Open the cover (13).

Remove the cover (14).

Fit the tool (Mot. 1453).

Remove the gearbox support pad.

Fit the Jack tool beneath the gearbox.

Remove:

- the lower gearbox edge bolts,

- the studs,

- the automatic gearbox,

Attach the converter with a piece of string to stop itbeing knocked out of place.

REFITTING

Note:

The nuts on the converter can be accessed byremoving the starter motor. Rotate the crankshaftclockwise to access the three drive plate / con-verter connecting nuts and remove them.

103423

102449

12

1413

13790

WARNING

- Do not re-use the converter mounting nuts orthe inertia flywheel nuts if they have been remo-ved: always use new nuts.

- Check for the presence of the centring rings.

Page 20: 23A Automatic Gearbox

23A-20

AUTOMATIC GEARBOXGearbox: Removing / Refitting

DP0

23A

Refit the flywheel nuts on the converter using the tool(Bvi. 1531).

To refit, proceed in the reverse order to removal.

When refitting the automatic gearbox to the engine,make sure that the converter is perfectly positionedon the axis of the input shaft (the end of the studs islevel with the gasket face).

Tighten to torque:

- the wheel bolts (11 daNm),

- the brake calliper column bolts (0.7 daNm),

- the track rod end nut (3.7 daNm),

- the track rod end nut (6.2 daNm),

- the engine tie-bar on the sub-frame (10.5 daNm),

- the gearbox edge bolt and starter motor (4.4daNm),

- the suspension mounting nut on the gearbox(4.4 daNm),

- the track rod end nut (6.2 daNm),

- the converter mounting nut on the drive plate(3.7 daNm),

- the modular connector mounting bolts (2daNm),

- the engine speed sensor mounting bolts (1daNm),

- the engine tie-bar bolts on the K Engine (10.5daNm),

- the engine tie-bar bolts on the F Engine (18daNm),

- the suspension mounting nut on the rubber pad(18 daNm).

Fill the automatic gearbox and check the level (Sec-tion Automatic gearbox, Filling and topping up, page23A-7).

When the oil is replaced, the auto-adaptives must bereset using command RZ005: « Clear auto-adaptives » and the automatic gearbox oil ageingcounter must be reset using command CF074:« Enter date of gearbox oil change ».

After using command RZ005, it is important to carryout a test drive performing all gear changes, both upand down, several times in order to store the new va-lues.

16361

WARNING

Check that the centring pins are present.

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 21: 23A Automatic Gearbox

23A-21

AUTOMATIC GEARBOXStarter plate

DP0

23A

This operation can be performed after the automaticgearbox has been removed.

REMOVAL

Position the tool (Mot.1677) to immobilise the startermotor ring gear.

Position the tool (Mot. 582-01).

Remove:

- the bolts (1),

- the drive plate,

- the (Mot.1677) or (Mot. 582-01) tool.

REFITTING

Check that the drive plate is not damaged (warpingtolerance 0.2 mm on the external diameter).

Fit the drive plate, ensuring it is correctly positionedin relation to the centring pin (2).

Tighten the bolts on the drive plate.

Angular tighten to torque the drive plate bolts (4.5daNm + 50˚ +/- 5) by immobilising the starter motorring gear using the tool (Mot.1677).

Essential special tooling

Mot.1677 Flywheel locking tool(F engines)

Mot. 582-01 Flywheel locking tool(K engines)

Essential equipment

Diagnostic tool

Tightening torquesm

drive plate bolts 4.5 daNm + 50˚+/- 5

drive plate bolts 5.5 daNm

F4R

103245

11

1

1

1

22

K4M

103752

Note:

Apply LOCTITE FRENBLOC to the bolt threads.

F4R

1

1

1

1

Page 22: 23A Automatic Gearbox

23A-22

AUTOMATIC GEARBOXStarter plate

DP0

23A

Angular tighten to torque the drive plate bolts (5.5daNm) by immobilising the starter motor ring gearusing the tool (Mot. 582-01).

To refit, proceed in the reverse order of removal.

Connect the Diagnostic tool for the conformitycheck.

K4M

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 23: 23A Automatic Gearbox

23A-23

AUTOMATIC GEARBOXDifferential output gasket

DP0

23A

REMOVAL

This operation takes place after the relevant drives-haft is removed (see Workshop Repair Manual364, Section 2).

Put the vehicle on a two-post lift.

Remove the battery cover

Disconnect the battery.

Remove the engine undertray.

Drain the automatic transmission through plug (1).

Remove the faulty differential output seal using ascrewdriver or a hook, taking care not to scratch thecontact surfaces.

REFITTING

The seal should be fitted using either tool (Bvi. 1459)or tool (Bvi. 1460).

Guide the assembly until the tool is touching theautomatic gearbox housing.

To refit, proceed in the reverse order to removal.

Tighten to torque:

- the wheel bolts (11 daNm),

- the lower ball joint nut (6.2 daNm),

- the torque reaction mounting bolts on the sub-frame (10.5 daNm),

- the engine tie-bar bolts to the K engine (10.5daNm),

- the engine tie-bar bolts to the F engine (18daNm),

- the track rod end nut (3.7 daNm),

- the hub nut (28 daNm).

Essential special tooling

Bvi. 1459 Right-hand driveshaftoutput seal assembly

Bvi. 1460 Left-hand driveshaftoutput seal assembly

Tightening torquesm

wheel bolts 11 daNm

lower ball joint nut 6.2 daNm

torque reaction moun-ting bolts on the sub-frame

10.5 daNm

engine tie-bar bolts tothe K engine

10.5 daNm

engine tie-bar bolts tothe F engine

18 daNm

track rod end nut 3.7 daNm

hub nut 28 daNm

13791

WARNING

Do not drop the spring of the seal into the auto-matic gearbox.

1

Page 24: 23A Automatic Gearbox

23A-24

AUTOMATIC GEARBOXDifferential output gasket

DP0

23A Fill the automatic gearbox and check the level (Sec-

tion Automatic gearbox, Filling and topping up, page23A-7).

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 25: 23A Automatic Gearbox

23A-25

AUTOMATIC GEARBOXConverter seal

DP0

23A

REMOVAL

This operation is performed after the automatic gear-box and converter have been removed.

Remove the converter by withdrawing it as far aspossible without deviating from the course of theshaft.

Using the tool (Mot. 587), remove the seal, takingcare not to scratch the contact surfaces.

REFITTING

Position the new prelubricated seal as far as the stopusing the tool (Bvi. 1457).

Check that the converter is correctly positioned.

To refit, proceed in the reverse order to removal.

Essential special tooling

Mot. 587 Seal extractor

Bvi. 1457 Converter l ip sealassembly

WARNINGThe converter contains a large amount of oilwhich may escape when it is being removed.

WARNING

- Work as cleanly as possible to prevent foreignbodies from entering the system.

- Oil all the contact surfaces.

Page 26: 23A Automatic Gearbox

23A-26

AUTOMATIC GEARBOXLine pressure tapping

DP0

23A

Some fault finding procedures on the automatic gear-box involve taking the line pressure using a pressuregauge.

The pressure measurement tapping is located close tothe pressure sensor.

Remove the bolt (1) to take the line pressure.

Remove the pressure tapping union (466-06) fromthe kit (Bvi. 1215-01) and place it in position (Works-hop Repair Manual 366 « Fault finding »).

Essential special tooling

Bvi. 1215-01 Automatic transmis-sion oil pressuregauge kit

103420

1

Page 27: 23A Automatic Gearbox

23A-27

AUTOMATIC GEARBOXMultifunction switch

DP0

23A

REMOVAL

Set to neutral « N ».

Disconnect the battery.

Remove:

- the air intake duct,

- the battery,

- the battery tray,

- the injection computer and its mounting,

- the air filter unit,

- the wiring harness mountings.

Disconnect:

- the multifunction switch cable ball joint (1),

- the control cable from the sleeve stop (2) on themodular connector support.

Remove the lever and the two multifunction switchmounting bolts (3).

Disconnect the modular connector (4) by releasingthe slide mechanism on the connector.

Remove the three modular connector support platemounting bolts (5).

Remove the two modular connector mounting platebolts .

Remove the green connector (6) on the multifunctionswitch (12-track).

Tightening torquesm

selector lever nut 1 daNm

mult i funct ion switchmounting bolts

1 daNm

101821

103409

13785

1

55

4

3

2

6

Page 28: 23A Automatic Gearbox

23A-28

AUTOMATIC GEARBOXMultifunction switch

DP0

23AREFITTING

Place the multifunction switch in neutral « N ».

Adjust the multifunction switch.

To refit, proceed in the reverse order of removal.

Tighten to torque the selector lever nut (1 daNm).

Check that the system and gears are working.

ADJUSTING THE MULTIFUNCTION SWITCH

With the gearbox selector shaft in neutral, place twoelectric terminals on the pressure control tabs.

Switch the multimeter to the « ohmmeter » position.

Turn the multifunction switch by hand until the switchis closed (resistance at contact terminals: 0 Ω).

Tighten to torque the multifunction switch moun-ting bolts (1 daNm).

Check that the system and gears are working.

103411

WARNING

After tightening, the switch must be closed.

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 29: 23A Automatic Gearbox

23A-29

AUTOMATIC GEARBOXComputer

DP0

23AThe computer is located behind the left-hand wheelarch.

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Remove the front bumper.

Disconnect the computer connector.

Remove:

- the resonator (1),

- the four computer mounting nuts (2),

- the computer (3).

REFITTING

To refit, proceed in the reverse order of removal.

REPLACING THE COMPUTER

Use the following procedure.

Read the oil ageing value from the memory of thecomputer being replaced using parameter PR133:« Oil ageing counter » and note down the value.

Replace the computer.

Call up the oil ageing value in the memory of the newcomputer using command CF320: « Oil ageingcounter report ».

103415

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

1

2

3

Note:

When the automatic gearbox computer is repla-ced, it is necessary to enter the age of the auto-matic gearbox oil stored in the memory of thecomputer to be replaced in the memory of thenew computer.

Page 30: 23A Automatic Gearbox

23A-30

AUTOMATIC GEARBOXInput speed sensor

DP0

23A

REMOVAL

Remove the engine covers.

Disconnect the battery.

Remove the connector (1) from the gearbox connec-tor support plate.

Remove the input speed sensor (2).

REFITTING

To refit, proceed in the reverse order to removal.

Tightening torquesm

input speed sensormounting bolt

1 daNm

Note:

The speed sensor can be removed without drai-ning or removing the automatic gearbox.

103416

Note:

When replacing a sensor, always remove thegearbox connector (Section Automatic gearbox,Gearbox connector, page 23A-35).

103419

13786-1

WARNING

Protect the connector by sliding it into a water-proof plastic bag.

1

2

Page 31: 23A Automatic Gearbox

23A-31

AUTOMATIC GEARBOXInput speed sensor

DP0

23A Tighten to torque the input speed sensor moun-

ting bolt (1 daNm).

WARNINGConnect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

Page 32: 23A Automatic Gearbox

23A-32

AUTOMATIC GEARBOXOutput speed sensor

DP0

23A

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Disconnect the connector (1).

Remove the engine undertray.

Remove the output speed sensor (2).

REFITTING

To refit, proceed in the reverse order to removal.

Tighten to torque the output speed sensor moun-ting bolt (1 daNm).

Tightening torquesm

output speed sensormounting bolt

1 daNm

Note:

The speed sensor can be removed without drai-ning or removing the automatic gearbox.

103417

1

103420

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

2

Page 33: 23A Automatic Gearbox

23A-33

AUTOMATIC GEARBOXFlow regulation solenoid valve

DP0

23A

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Remove:

- the two solenoid valve bolts (1),

- radiator flow control solenoid valve (2).

REFITTING

To refit, proceed in the reverse order to removal.

Tighten to torque the radiator flow control sole-noid valve mounting bolt (1 daNm).

Tightening torquesm

radiator flow controlsolenoid valve moun-ting bolt

1 daNm

Note:

The radiator flow control solenoid valve can beremoved without draining or removing the auto-matic gearbox.

103434

13786-1

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

1

2

Page 34: 23A Automatic Gearbox

23A-34

AUTOMATIC GEARBOXSolenoid valves

DP0

23A

REMOVAL

WARNING

Work as cleanly as possible to prevent foreignbodies from entering the system.

13787

(1) Modulating solenoid valve

(2) « Lock up » solenoid valve (con-verter lock-up)

(3) Sequence solenoid valve 4

(4) Sequence solenoid valve 3

(5) Sequence solenoid valve 1

(6) Sequence solenoid valve 2

(7) Sequence solenoid valve 6

(8) Sequence solenoid valve 5

Note:

This operation can be performed after thehydraulic distributor has been removed.

12

3 4 5 6 7 8

Page 35: 23A Automatic Gearbox

23A-35

AUTOMATIC GEARBOXGearbox connector

DP0

23AConnector numbering

REMOVAL

Put the vehicle on a two-post lift.

Remove the engine covers.

Select neutral « N »

Disconnect the battery.

Remove:

- the air intake duct,

- the battery,

13785

(1) Green connector (multifunctionswitch)

(2) Yellow connector (electrohydrau-lic interface)

(3) Green connector (line pressure)

(4) Yellow connector (turbine speed)

(5) Blue connector (radiator flowcontrol solenoid valve)

Note:

These connectors may be removed separately fromthe gearbox connector when certain componentsare replaced.

2

543

1

103248

101821

2

5

4

3

1

Page 36: 23A Automatic Gearbox

23A-36

AUTOMATIC GEARBOXGearbox connector

DP0

23A- the battery tray,

- the injection computer and its mounting,

- the air filter unit,

- the wiring harness mountings.

Disconnect:

- the ball joint (6) from the multifunction switch cable,

- the wiring harness (7) from the multifunction switchcable by loosening the sleeve stop,

- the unit connector (8) by releasing the slide valveon the connector.

Remove:

- the three mounting bolts (9) from the unit connectorsupport plate,

- the two unit connector mounting bolts,

- the connector in the colour that appears on thegearbox connector.

Follow the five wiring harnesses connected to thegearbox connector.

Remove the five wiring harnesses.

These wiring harnesses are either connected tocomponents directly or via a connector. If they areconnected to a component directly, the componentshould also be removed.

REFITTING

To refit, proceed in the reverse order to removal.

103409

6

7 8

99

WARNINGConnect the battery; carry out the necessary pro-gramming (Section Electrical equipment).


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