Gearbox Citroen XSARA 2005 1.G Repair Manual

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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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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
The gear selection and engagement cables have noadjustment.
Gear controls.
(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
B2CP3ZOD
C4
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
Length A (mm)
Gear engagement control cable643 ± 2
Length B (mm)
Gear selection control cable670 ± 2
NOTE:The gear engagement cable has a black colouridentification
on the sleeve stop at «a».
B2CP3Z1CB2CP3Z2C
C4
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
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.
B2CP3Z3D
C4
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
(1)Gear control lever
(2)Gear engagement control cable (*)
(3) Gear selection control cable (*)
(4)Gear selection ball-joint Ø 10 mm
(5)Gear engagement ball-jointØ 10 mm
(6)Flexible insulating grommet through the bulkhead
(*) = These two cables cannot be separated.
B2CP3BWD
XSARA - XSARA PICASSO
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GEARBOX
TRANSMISSION
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: 9607-T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the ball-joints on the gearbox lever.
Lock the cable lengths with the ball-joint locking keys.
WARNING: Do not use any tool to unclip the ball-joints.
To unlock the ball-joint, press at the centre «a», then pull the ball-joint upwards.
NOTE:Changing an individual ball-joint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3BXC
B2CP3BYC
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1]Tool for positioning the gear lever: 9607-T
Adjustments.
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 ball-joint keys at «a».
Place the gear selection and control levers on neutral.
Lock the cable lengths with the ball-joint 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 - WJY - 8HX - 8HZ - 9HZ - 9HY - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3C6CB2CP3C0C
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GEARBOX
TRANSMISSION
ML6 GEARBOX CONTROLS
Engine: RHR
Gear controls.
(1)Gear engagement ball-joint Ø 10 mm
(2)Gear selection ball-joint Ø 10 mm
(3)Gear engagement control cable
(4)Gear control lever
(5)Gear selection control cable
(6)Reverse gear unlocking cable
(7)O-ring seal
(8)Reverse gear unlocking device
B2CP3ZPD
C4
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
B2CP3ZQD
Adjustment NO
Length A (mm)
Gear engagement control cable723 ± 2
Adjustment YES at «b»
Length B (mm)
Gear selection control cable674 ± 2
NOTE:In order to differentiate the two gear control cables when they
have been removed, the gear engagement cable has a black colour
identification on the sleeve stop at «a».
Adjustment of the gear selection control cable
C4
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GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
Peform the following operations simultaneously:
- Move the cylinder «f»in the direction of the arrow «e».
- Pull the locking key «c»in the direction of the arrow «d».
Check that the gear lever (18)is in the mid position on the control housing (17).
Couple the ball-joint (19).
Press on the locking key «c».
IMPERATIVE: Check that all the gears engage.
B2CP3ZWD
Adjustment of the gear selection control cable
C4
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