Citroen C4 2005 2.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: BE4/5 GEARBOX
Engines: RFN - RFK - 9HX - 9HY - 9HZ
Tightening torques (m.daN).
(12)Fork shaft stop screw: 1,5 ± 0,2
(13)Differential gearwheel fixing screw: 6 ± 0,5
(14)Bearing stop screw: 1,5 ± 0,2
(15)Secondary shaft nut: 6,5 ± 0,5
(16)Primary shaft nut: 7,3 ± 0,5
(17)Gear control support fixing screw: 1,5 ± 0,2
B2CP3ZZC
B2CP3ZYD
C4
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: BE4/5 GEARBOX
Engines: RFN - RFK - 9HX - 9HY - 9HZ
Tightening torques (m.daN).
(18)Stop guide screw: 1,25 ± 0,2
(19)Speedometer fixing screw: 1,5 ± 0,2
(20) Gearbox support shaft nut : 6,5 ± 0,6
(21)Nuts fixing rubber support: 3 ± 0,2
(22) Gearbox rubber support shaft: 5 ± 0,5
(23)Screw M10fixing the engine/gearbox housing support: 6 ± 0,5
(24) Screws M10fixing the engine/gearbox housing support: 3 ± 0,3
B2CP401C
B2CP400C
C4
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: BE4/5 GEARBOX
Engines: 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
T
ightening 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)Top-up 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
XSARA - XSARA PICASSO
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: ML6 GEARBOX
Engine: RHR
Tightening torques (m.daN).
(1)Primary shaft screw: 10 ± 1
(2)Bearing guide screw: 2 ± 0,2
(3) Differential gearwheel screw: 7,7 ± 0,3
(4)Secondary shaft screw: 13 ± 1,3
B2CP3ZLD
C4
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: ML6 GEARBOX
Engine: RHR
Tightening torques (m.daN).
(5)Reverse gear switch: 2,5 ± 0,5
(6)Level plug: 3 ± 0,2
(7)Drain plug: 3 ± 0,3
(8)Differential bearing stop plate screw: 3 ± 0,3
(9)Screw fixing gearbox housing / clutch housing: 3 ± 0,3
(10) 6thgear housing fixing screw: 2 ± 0,2
(11)Differential housing fixing
(screws M8): 1,8 ± 0,3
(12)Differential housing fixing
(screws M10): 4 ± 0,8
B2CP3ZMP
C4
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: ML6 GEARBOX
Engine: RHR
B2CP3ZNC
Tightening torques (m.daN).
(13)Screws/nuts fixing the gearbox support: 4,5 ± 0,4
(14)Screw fixing the rubber bush: 3 ± 0,3
(15) Nut fixing the gearbox casing: 6,5 ± 0,6
C4
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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: KFU - NFU
B2CP3ZCD
Gear controls
C4
The gear selection and engagement cables have no adjustment.
NOTE:The two gear control cables cannot be separated.
(1)Gear engagement ball-joint: Ø 10 mm
(2)Gear engagement control cable
(3)Gear control lever
(4)Gear selection control cable
(5)Gear selection ball-joint: Ø 10 mm
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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: KFU - NFU
Length A (mm)
Gear engagement control cable791,2 ± 2
Length B (mm)
Gear selection control cable791,2 ± 2
NOTE: The gear engagement cable has a black colouridentification on
the sleeve stop at«a».
Gear engagement and selection control cables
B2CP3ZDD
B2CP3ZEC
C4
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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: KFU - NFU
Features.
Unlocking a sleeve stop:
- Press on the tabs of the clip (6)at «b», using a flat screwdriver.
- Disengage the sleeve stops from their supports by pulling upwards.
B2CP3ZFD
C4
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: KFW - NFU - 8HX - 8HZ
(1)Gear lever
(2)Gear control bar
(3)Engagement rod
(4)Gear selection rod
(5)Torque reaction rod
(6)Gear engagement ball-joint
(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 ball-joint.
WARNING: To secure the ball-joints, 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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