Citroen C5 2000 (DC/DE) / 1.G Owner's Manual

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CLUTCH
GEARBOX
DRIVESHAFTS
ML/5 GEARBOX SPECIFICATION
Engines : XFX – RHZ – 4HX
B2CP3CQD
[1] Gear lever positioning tool 8605-T.
(1) Gear engagement ball-joint Ø 10 mm.
(2) Gear control lever
(3) Gear engagement control cable.
(4) Gear selection control cable.
(5) Gear selection ball-joint Ø 10 mm.

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CLUTCH
GEARBOX
DRIVESHAFTS
ML/5 GEARBOX SPECIFICATION
Engines : XFX – RHZ – 4HX
Gear selection control cable. Gear engagement control cable.
B2CP3CRDB2CP3CSD
Left hand drive Right hand drive Left hand drive Right hand drive
Length A 750 ± 3 mm Length C 771 ± 3 mm
Length B 1012 ± 7.5 mm Length D 1094 ± 7.5 mm
Note : See adjustment page 190.

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CLUTCH
GEARBOX
DRIVESHAFTS
ML/5 GEARBOX SPECIFICATION
Engines : XFX – RHZ – 4HX
B2CP3CTDB2CP3BYC
Adjustments.
WARNING : Control cables should be adjusted each time the gearbox is
removed or cables changed.
WARNING : Do not use oil to detach the ball-joints.
To release the ball-joint, press at the centre«a»then pull the ball-joint upwards.
Ball-joints alone can be changed by removing the unlocking key with the aid of two
thin screwdrivers, unclip at «b».

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CLUTCH
GEARBOX
DRIVESHAFTS
ML/5 GEARBOX CONTROLS
Engines : XFX – RHZ – 4HX
Tools.
[1]Tool for positioning the gearbox control lever8605-T Tool kit 9040-T
Adjustments.
Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
Adjustment principles :
- Lock the gear lever in neutral position, using tool [1].
- Position the gearbox in neutral.
- Anchor the ball-joints on the gearbox levers.
- Lock the cable lengths with the ball-joint locking keys.
Inside the vehicle.
- Remove the central console (See corresponding operation).
- Remove the plastic blank at(a).
- Insert tool [1]fully and rotate a quarter turn to lock the gear control lever.
- At neutral.
B2CP3E7C

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CLUTCH
GEARBOX
DRIVESHAFTS
ML/5 GEARBOX CONTROLS
Engines : XFX – RHZ – 4HX
Adjustments (continued)
Under the bonnet.
- Remove the air filter assembly.
- Unlock the gear engagement and selection cable ball-joint(b).
- Make sure the gear levers (engagement and selection) are in neutral position.
- Lock the cable lengths with the ball-joint locking keys.
- Remove the tool [1].
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 not :
- Repeat the adjustment.
- Refit the console and the air filter assembly.
B2CP3EBC

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CLUTCH
GEARBOX
DRIVESHAFTS
4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION
Engines : XFX - 4HX
B2CP3CYD
Identification.
(1) Identification plate
(riveted on the casing).
(a) Serial no.
(b)ZF number.
(last digits taken into account)
(c) Type of automatic gearbox.
(d)Component reference.
Oil quality and quantity
(See chapter, page 19).

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CLUTCH
GEARBOX
DRIVESHAFTS
4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION
Engines : XFX - 4HX
Tightening torques m.daN.
Gearbox exterior.
(2) Oil channel union fixing Exteror fixing of2.5 ± 0.5
(3) Exterior fixing of converter cover on clutch housing 2.3 ± 0.5
(4) Speedometer take-off aperture plug1 ± 0.1
(5)Steel casing fixing0.6 ± 0.1
(6) Converter fixing on engine6 ± 1
(7) Interior fixing of converter cover on clutch housing2.3 ± 0.5
(8) Torx fixing of converter cover on clutch housing2.3 ± 0.5
Drain plug4.5 ± 0.8
Heat exchanger fixing3.5 ± 0.5
Selector lever position switch fixing1 ± 0.2
Converter cover fixing on engine cover(XFX engine) 6.5 ± 1
Converter cover fixing on engine cover(4HX engine) 5.8 ± 1
B2CP3CZCB2CP24BCB2CP24CC

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CLUTCH
GEARBOX
DRIVESHAFTS
4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION
Engines : XFX - 4HX
Tightening torques m.daN.
Gearbox interior.
(9) Input speed sensor fixing0.8 ± 0.1
(10) Hydraulic block fixing (Large head)0.8 ± 0.1
(11) Output speed sensor fixing1 ± 0.2
B2CP24DCB2CP24EC

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RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)
Engines : 6FZ - RFN - RHZ - XFX - 4HX
Towing
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised :
IMPERATIVE : - Put gear lever in position «N».
- Do not add any oil.
AL4 gearbox
- Do not exceed 50 km/h (30mph) over a distance of 50 km (30 m).
4 HP 20 gearbox
- Do not exceed 70 km/h (45mph) over a distance of 100 km (60 m).
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it;
(impossible with an automatic gearbox).
Lubrication
The automatic gearbox is only lubricated when the engine is running.Removing - refitting. (Automatic gearbox).
WARNING : Never place the gearbox on its lower casing
(risk of deforming the tray and damaging the hydraulic valve block).
Never use the connections as handles for raising, turning, holding or
pushing the gearbox.
ESSENTIAL :
- Fit the converter retaining peg while the gearbox is removed.
- Fit the centring peg to locate the gearbox on the engine:
(remove the converter retaining peg just before locating)
WARNING :With the emergency programme selected, an impact is
felt when changing from ‘‘P’’‘‘R’’or ‘‘N’’‘‘R’’.
Precautions to be taken
CLUTCH
GEARBOX
DRIVESHAFTS

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RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)
Engines : 6FZ - RFN - RHZ
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox
CLUTCH
GEARBOX
DRIVESHAFTS
If a gearbox malfunction occurs, there are two possible configurations
depending on the seriousness of the fault :
- Gearbox in back-up mode with a replacement programme of
(the fault values are taken in substitution).
- Gearbox in back-up mode with an emergency programme
(3rd hydraulic).
WARNING : In the emergency programme, an impact is felt when
changing P/R, N/RandN/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms..
Oil quality – Oil level.
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 quality.
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 de codes défauts.
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).