Xsara 2 Citroen XSARA 2004 1.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
Features.
This gearbox:
has no adjustment.
has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.
Oil capacity : 2 ± 0,15 Litres.
Checking the oil level : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
B2CP3BNCB2CP3BPD
(a) Marking zone (sequence and serial no.).(b) Location of identification label.
C3 XSARA XSARA PICASSO

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GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
(1)Drain plug.
(2)Filling and topup plug.
(3)Air vent.
NOTE:The air vent aperture can be used for filling.
Quality of oil.Refer to the manufacturer’s instructions.
Quantity of oil.Gearbox empty:1,9 Litres.
After draining:2 Litres.
B2CP3BLD
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
Description
(1)
Primary shaft.
(2)Clutch bearing guide.
(3)Gearbox casing.
(4)Clutch housing.
(5)Reverse idle.
(6)Drive gear (3rd gear).
(7)3rd / 4th gear synchroniser.
(8)Drive gear (4th gear).
(9)Drive gear (5th gear).
(10)5th gear synchroniser.
(11)Driven gear (5th gear).
(12)Driven gear (2nd / 4th gear).
(13) Driven gear (2nd gear).
(14)1st / 2nd gear synchroniser.
(15)Driven gear (1st gear).
(16)Secondary shaft.
(17)Differential gear.
(18)Satellite gears.
(19)Planet gears.
(20)Differential housing.
(21)Speedometer drive.
(22)Extension.
«d» Adjusting shims: 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
«c»Adjusting shims:1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
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BE4/5 GEARBOX
Engines: 6FZ RFN RFS WJY 8HV 8HY 8HZ 9HZ 9HY RHY RHZ
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 screws): 1,25 ± 0,2
(24)
Clutch housing (13 screws): 1,3 ± 0,2
(25)
Primary shaft nut (1 screw):7,25 ± 0,5
(26)
Secondary shaft nut (1 screw): 6,5 ± 0,5
(27)
Yoke retaining screw (2 screws): 1,5 ± 0,2
(28)
Differential gearwheel screw (2 screws): 6,5 ± 0,5
Reverse gear switch (1 screw): 2,5 ± 0,3
(29)
Differential housing (4 screws): 5 ± 0,5
(30)
Breather pipe:1,7 ± 0,2
(31)
Rear housing cover screws (7 screws):1,25 ±0,2
(32)
Topup plug (1 screw):2,2 ±0,2
(33)
Differential housing screws (4 screws):1,25 ±0,2
(34)
Drain plug (1 screw):3,5 ±0,3
B2CP3BRD
C3 XSARA XSARA PICASSO

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GEARBOX
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CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: KFW NFU 8HZ
1 Gear lever.2 Gear control bar.3 Engagement rod.4 Gear selection rod.5 Torque reaction rod.6 Gear engagement balljoint.7 Fixed point on gearbox.
Adjustment.The gear control assembly is not adjustable.
The rods do not have threaded ends.
Features.Grease the gear engagement balljoint.
WARNING:To secure the balljoints, set the
gearbox control to neutral.After fitting the gear
control assembly, check that all the gears will
engage without any
”tight spot”.
B2CP27WD
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
(1)Gear control lever.
(2) Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(4)
Gear selection balljoint Ø 10 mm.
(5) Gear engagement balljoint Ø 10 mm.
(6) Flexible insulating grommet through the bulkhead.
(*)= These two cables cannot be separated.
B2CP3BWD
XSARA XSARA PICASSO

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GEARBOX
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CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Principles of adjusting the gear controls.
WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are
removed.
Principles.
Lock the gear lever in neutral position, using tool:9607T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the balljoints on the gearbox lever.
Lock the cable lengths with the balljoint locking keys.
WARNING: Do not use any tool to unclip the balljoints.
To unlock the balljoint, press at the centre «a», then pull the balljoint upwards.
NOTE:Changing an individual balljoint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3BXCB2CP3BYC

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GEARBOX
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CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1] Tool for positioning the gear lever: 9607T.
Adjustements.
WARNING: Cables should be adjusted each
time the gearbox, gear controls or power unit
are removed.
Inside the vehicle:
Remove the trim under the gear lever.
Lock the gear lever in neutral position,
using tool
[1].
Under the bonnet: Remove the air filter assembly.
Unlock the balljoint keys at «a».
Place the gear selection and control levers on
neutral.
Lock the cable lengths with the balljoint locking
keys.
Checks.
Remove the tool [1].
Check that all the gears engage without
«tightness ».
Check that the gear lever moves identically
forwards and backwards and to right and left. If it
does not, repeat the adjustment.
Refit the trim under the gear lever.
Refit the air filter assembly.
Adjusting the gear controls Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3C6CB2CP3C0C

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GEARBOX
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RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
If a gearbox malfunction occurs, there are two possible
configurations depending on the seriousness of the fault:
Gearbox in backup mode with a replacement programme of
(the
fault values are taken in substitution).
Gearbox in backup mode with an emergency programme (3rd
hydraulic).WARNING:In the emergency programme, an impact is felt
when changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.Oil quality Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction
or the destruction of a clutch, the oil will overheat and become
contaminated with impurities: the oil is said to be
«burnt».
This is characterised by a black colour and the presence of an
unpleasant smell.
ESSENTIAL: The gearbox must be replaced.
Oil level (see corresponding operation).
An excessive oil level can result in the following consequences:
Excessive heating of the oil.
Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes
(engine and gearbox).
Absence of fault codes.Carry out parameter measures, actuator tests and a road test.
Presence of fault codes.Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
gearbox ECU parameters
(this is essential after an initialisation
of the ECU).
XSARA XSARA PICASSO
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox