wheel FIAT PUNTO 1995 176 / 1.G Repair Manual

Manual transmission 7A*3
3,8 Unscrew the nut and disconnect the gear selector rod from the lever on the transmission unscrew the locknut and adjusting nut from the end of the clutch cable and disconnect the cable from the transmission. Recover the damper block. On models with a hydraulically operated clutch, unscrew the mounting bolts, release the slave cylinder pushrod from the re&ase arm on the transmission, then position the cylinder to one side.
7 Unscrew and remove the reverse gear Inhibiting device from the transmission. Tie the cable to one side out of the way. 8 Unscrew the nut and disconnect the gear selector rod from the lever on the transmission (see illustration). 9 Pull out the clip then disconnect the gear engagement cable from the control lever and release the cable from the mounting bracket (see illustrations). 10 Unscrew and remove the two upper transmisslon-to-englne mounting bolts. Unscrew the single bolt securing the starter motor to the transmission. 11 Remove the air cleaner and air ducting with reference to Chapter 4A or 4B. This Is necessary In order to fit the engine hoist 12 On 5-speed transmissions, trace the wiring back from the electronic speedometer sensor and disconnect the connector located on the left-hand side of the engine (see illustration). 13 On 6-speed transmissions, unscrew the knurled nut and disconnect the speedometer cable from the top of the final drive housing. 14 Support the weight of the engine using a hoist attached to the engine lifting eyes, or alternatively use a trolley jack and block of wood beneath Ihe engine. 15 Unscrew the Lambda/oxygen sensor from the exhaust downpipe and position It In a safe place to prevent damage. 16 Unscrew the nuts securing the downpipe to the exhaust manifold, then lower It and support on an axle stand. Recover the gasket. 17 Unbolt the support bracket from the engine and transmission. Recover the spacer plate. 18 Unbolt and remove the transmission lower cover, 19 Unscrew the remaining starter motor mounting bolts and support tho starter motor to one side. 20 Loosen and remove the clips securing the left- and right-hand driveshaft gaiters to the transmission output shafts.
3.9a Remove the clip to release the gear engagement cable 21 Unscrew and remove the boils securing the left-hand swivel hub assembly to the front suspension strut, then separate the components and support the swivel hub on an axle stand. 22 Move the swivel hub assembly outwards and disconnect the inner end of the dnveshaft from the transmission output shaft. Support the shaft away from the transmission to prevent damage to the garters. 23 Working beneath the vehicle, unscrew the botts securing the rear engine mounting to the underbody then unscrew the bolts securing the mounting to the transmission and withdraw the mounting assembly from under the vehicle. 24 Unscrew the bolts securing the left-hand engine/transmission mounting to Ihe body then unscrew the bolts from the transmission and remove the mounting. 25 Support the woight of the transmission on a trolley jack then unscrew the remaining nut and bolt from the belihousing and pull the transmission away from the engine. Lower it and remove from under the vehicle. A Warning: Support the trans-mission to ensure that it remains steady on the jack head. Keep the transmission levet until the Input shaft Is fully withdrawn from the clutch friction plate. Refitting
26 Refitting is a reversal of the removal procedure, but note the following points. a) Apply a smear of high-melting-point grease to the clutch friction plate splines; take care to avoid contaminating the friction surfaces.
3.12 Electronic speedometer sensor fitted to 5-speed transmissions
3.9b Removing the gear engagement cable from the mounting bracket b) Tighten all bolts to Ihe specified torque. c) Fit new clips to secure the driveshaft gaiters to the transmission output shafts. d) Adjust the clutch cable (where applicable) as described In Chapter 6.
Diesel models
Removal 27 Seloct a solid, level surface to park the vehicle upon. Give yourself enough space to move around it easily. Apply the handbrake then jack up the front of tho vehicle and support on axlo stands (see Jacking and vehicle support). Remove both front wheels. 28 Unbolt the relay support then remove the batlery and mounting tray as described in Chapter 5A. 29 On models with a cable operated clutch, unscrew the locknut and adjusting nut from the end of the clutch cable and disconnect the cable from the transmission. Recover the damper block. On models with a hydraulically operated clutch, unscrew the mounting botts. release the slave cylinder pushrod from the release arm on the transmission, then position the cylinder to one side, 30 Unscrew the nut and disconnect the gear selector rod from the lever on the transmission. 31 Disconnect the gear engagement cable from the control lever then slide out the clip and release the cable from the mounting bracket. 32 Unbolt the electronic rev counter sensor from the upper rear of the belihousing and position it to one side (see illustration).
3.32 Electronic rev counter sensor located in the upper rear of the belihousing

7B«1
Chapter 7 Part B:
Automatic transmission
Contents
Accelerator pedal micro-switch(es) - checking and adjustment II Automatic transmission filter and fluid change See Chapter 1A Automatic transmission fluid level check See Weekly checks Automatic transmission • overhaul 12 Automatic transmission • removal and refining 2 Bectro-magnetic clutch - removal, inspection and refitting 3 BectrO'fnagnetic clutch brushes- removal, inspection and refitting . 4
Electronic control unit - removal and refitting 5 Gear selector cable - adjustment 6 Gear selector cable - removal and refitting 9 General information 1 Kickdown cable - adjustment 7 Kickdown cable - removal and refitting 6 Transmission oil pump - removal and refitting 10
Degrees of difficulty

Easy,
suitable for novice
with
ittle experience ^
Party
easy,
suitable for beginner
with
^r someexperienoe ^
Faiily
difficult,
^ suitable
for
competent
DIY mechanic
^

Difficult, suitable
for fe, experienced DIY >8J mechanic
Verydfficult, ^
suitable
for
expert DIY
or professional ^
Specifications
General Type Ratios (at transmission): Lowest Highest Final drive
Torque wrench settings Esnh cable Control unit Sectro-magnetic clutch to flywheel Transmission-to-engine bolt/nut ..
ECVT (Electronic Continuously Variable Transmission)
2.503 0.497 4.647:1
Nm Ibftt 14 10 5 4 34 25 85 63
1 Genera) information
I The automatic transmission fitted is designated ECVT (Electronic Continuously Variable Transmission). The main components
01
the transmission are an electro-magnetic dutch, a variable-ratio coupling, a final drive/ differential unit, and the associated control mechanisms (see illustrations overleaf) 2 The variable-ratio coupling consists of two pulleys and a flexible metal drivebelt. The effective diameter of the two pulleys can be varied to provide different transmission ratios between them. 3 During normal driving, the transmission automatically selects the ratio giving the best
compromise between economy and speed. When the driver depresses the accelerator pedal to the floor, a kickdown effect is provided, and the transmission selects a lower ratio for improved acceleration. 4 The gear selector control resembles that fitted to conventional automatic transmissions. The control positions are as follows: P (Parking) The transmission is mech-anically locked by the engage-ment of a pawl with a toothed segment on the driven pulley. R (Reverse) Reverse gean's engaged, N (Neutral) The transmission is In neutral. D (Drive) Normal driving position. Trans-mission ratio is varied automat-ically to suit prevailing speed and load.
L (Low) Prevents the transmission
moving into high ratios. Provides maximum acceleration end maximum engine braking. 5 The engine can only be started In positions P and N. A warning buzzer sounds If the selector is in any position other than P when the ignition is switched off or when the driver's door is opened. 6 The electro-magnetic clutch consists of a driving element boiled to the engine flywheel, and a driven element spiined to the transmission Input shaft. The degree of coupling between the (wo elements Is determined by the intensity of a magnetic field generated by a current passing through windings in the driven element. The magnetic field acts on a layer of metallic powder between the driving and driven elements. When no magnetic field is present, the powder is loose and the two elements are effectively

7B*2 Automatic transmission
disconnected. As the magnetic field increases, the powder sticks together, and the coupling between Ihe elements becomes Increasingly rigid. 7 Selection of reverse, neutral and forward gears is by the movement of a sliding sleeve on a hub keyed to the drive pulley shaft. In forward gear, the sleeve engages with the gear on the end of the input shaft, which is then locked to the drive pulley shaft. When reverse is selected, the sleeve engages with reverse driven gear, which is in constant mesh with an idler gear driven by transfer gears from the input shaft gear. In neutral, the sleeve Is in an intermediate position, and the
two shafts are not connected. 8 Tho drive pulley and driven pulley both consist of fixed and moving halves. The movement of ihe drive pulley halves is controlled hydraulically, while the driven pulley halves move under the influence of a spring and the tension exerted by the drivebeit. As the drive pulley opens, the driven pulley closes, and vice-versa. In this way, the transmission ratio between the two pulleys can be varied. The ratios are continuously variable between preset limits; the difference between the lowest and highest ratios available is approximately 5:1. 9 Hydraulic pressure is generated by a gear-
type pump Inside the transmission. The punp driveshaft runs inside the Input and drive pulley shafts, and Is splined to the centred the engine flywheel. This means that hydreulc pressure is only generated when the engine is running, which is why a car with this type ot transmission cannot be push- or tow-started 10 Application of hydrautic pressure to the pulley halves is via a control unit, which receives information on accelerator pedal position, transmission selector lever position, transmission ratio currently in use, and drive pulley speed. From this information, the control unit determines whether, and in which direction, lo change the pulley ratios.
1.1 a Cutaway view of the ECVT (electronic continuously variable transmission) 7 Electromagnetic dutch 3 Drive pulley 5 Metal drivebeit 7 Hydraulic controt unit 2 Gear selector sleeve A Dnven pulley 6 Final drive reduction gears

Automatic transmission 7B*3
11 When reverse gear Is selected, the control unit keeps the transmission In tow ratio, if this were not the case, it would, In theory, be possible to drive as fast In reverse as in forward gear. 12 An electronic control unit supplies the current to energise the clutch. The control unit receives signals concerning engine speed, road speed, accelerator pedal position, and gear selector position, Sensors include the following. a) Engine rpm sensor (from the Injection/ignition control unit) b) Accelerator pedal switch
c) Throttle valve position sensor d) Selector lever position sensor e) Vehicle speed sensor f) Coolant temperature sensor g) Air conditioning sensor h) Brake switch I) Torque signal
13 The final drive/differential unit Is conventional. Drive from the driven pulley is transmitted to the differential by an Intermediate reduction gear. 14 The ECVT incorporates a warning light which illuminates when a fault occurs.
Precautions 1$ Observe the following precautions to avoid damage to the automatic transmission: a) Do not attempt to start the engine by pushing or towing the car. b) If the car has to be towed for recovery, the distance must not exceed 12 miles (20
km),
and the speed must not exceed
19
mph
(30 kph).
If these conditions cannot be met, or If transmission damage is suspected, only tow the car with the front wheels clear of the ground. c) Only engage P or R when the vehicle is stationary.
1.1b Electromagnetic f Coil 2 Signal from vehicle speed sensor 3 Transmission 4 Electromagnetic powder 5 Drive shaft (driven by crankshaft) $ Transmission input shaft 7 Electromagnetic clutch housing 8 ECVT control unit
clutch control system 9 Accelerator pedal micro switch 10 Throttle
vafve
opening position potentiometer 11 Multifunction switch 12 Ignition switch
13
Air conditioning
signal
14 Engine PPM
signal
15 Accelerator pedal 16 Coolant temperature signal 17 Injection/ignition control unit 18 8attery
1.1c Hydraulic control system 3 Injection/ignition control unit 4 Air conditioner sensor
signal
6 Coolant temperature signal 7 Clutch signal 8 Engine RPM
signal
9 ECVT warning light 10 Selector lever position 11 Accelerator
pedal
switch/throttle
valve
potentiometer/torque signal 12 Brake switch 13
ECVT
control unit 14 Signal from vehicle speed sensor
15
Accelerator pedal position switch
16 Pulley ratio 17 Input shaft RPM 18 Primary oil pressure
19
Primary pulley 20 Electromagnetic clutch 21 Pressure regulating solenoid valve 22 Oil pressure control valve 23 Secondary oil pressure 24 Slip ring 25 Drive from engine 26 Oil pump 27 Vehicle speed sensor 28 Secondary pulley 29 Belt and pulley 30 Drive to drlveshafts

7B*4 Automatic transmission
2 Automatic transmission - ^ removal and refitting St
Removal 1 Select a solid, level surface to park the vehicle upon. Give yourself enough space to move around it easily. Apply the handbrake then jack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both front wheels, 2 Remove the battery and mounting tray as described In Chapter 5A. 3 Remove the air cleaner and air inlet duct as described In Chapter 4A. 4 Disconnect the kickdown cable at the sector on the throttle housing and detach It from the mounting on the camshaft cover. Also release the cable from the support on the left-hand end of the cylinder head. 5 Disconnect the wiring connectors on the transmission. 6 Disconnect the fluid inlet and outlet Unas from the heat exchanger on top of the transmission. 7 Pull the fluid level dipstick from Its tube on the front of the transmission and tape over the top of the tube to prevent dirt entry. 8 Unscrew and remove the retaining pin and disconnect the speed selector cable from the top of the transmission. 9 Unscrew the upper bolt securing the starter motor to the transmission. 10 Unscrew the upper bolts securing the transmission to the engine. 11 Support the weight of the engine using a hoist attached to the engine lifting eyes, or alternatively UBO a trolley jack and block of wood beneath the engine, 12 Remove the screws and remove the front wheel arch liner from under the left-hand wheel arch. 13 Unscrew the nut securing the earth cablo to the transmission. 14 Using a punch drive out the roll pins securing both driveshafts to the final drive output shafts. 15 Unscrew and remove the bolts securing the left-hand swivel hub assembly to the front suspension strut, then separate the components and support the swivel hub on an axle stand. 16 Move the swivel hub assembly outwards and slide the inner end of the driveshaft from the splines on the transmission output shaft. Support the shaft away from the transmission to prevent damage to the gaiters. 17 Unscrew the lambdafoxygen sensor from the exhaust downpipe and position it In a safe place to prevent damage. 18 Unscrew ihe nuts securing the downpipe to Ihe exhaust manifold, then lower It and suppon on an axle stand. Recover the gasket. 19 Unscrew the knurled nut and disconnect the speedometer cable from the top of the final drive housing.
3-2 Locking the flywheel when removing the electromagnetic clutch 20 Unscrew the remaining bolt securing the staner motor to the transmission 21 Unbolt and remove Ihe lower flywheel cover from the transmission. 22 Working beneath the vehicle, unscrew the bolts securing the rear engine mounting to the underbody then unscrew the bolts securing the mounting lo the transmission and withdraw the mounting assembly from under the vehicle. 23 Unscrew the bolts securing the left-hand engine/transmission mounting to the body thon unscrew the bolts from the transmission and remove the mounting. 24 Support the weight of the transmission on a trolley jack then unscrew the remaining nut and bolt from the bellhouslng and pull the transmission away from the engine. Lower it and remove from under the vehicle.

A


Warning: Support the transmission to ensure that It remains steady on the Jack head. Keep the transmission level until the Input shaft and pump shaft are fully withdrawn from the electromagnetic clutch housing.
Refitting 25 Refitting is a reversal of the removal procedure, but note the following points. a} Apply a smear of high-melting-point grease to the splines of the transmission input shaft and oil pump driveshaft.
3.6 Checking the resistance of the clutch windings 1 Slip rings
0) Tighten all nuts and bolts to the
specified
torque, where given, c) Renew both driveshaft roll pins.
3 Electro-magnetic clutch • & removal, inspection 5. and refitting ^
Removal 1 Remove Ihe transmission as described n Section 2. 2 Turn the flywheel so that two of the lour mounting bolts are accessible, Hold tha flywheel stationary then unscrew Ihe tvrt bolts. To hold the flywheel, Insert a wida bladed screwdriver In the ring gear teeth or alternatively use a piece of angle iron against one of the retaining bolts temporarily Inserted in the cylinder block (see illustration). 3 Turn the crankshaft half a turn and unscrew the remaining bolts, then withdraw the electromagnetic clutch.
Inspection 4 Turn the driven element by means of tha slip rings, and check that the bearing is not noisy or rough. 5 Inspect the slip rings for burning or other damage. Clean them if necessary using fid and a clean rag. 6 Check the resistance of the clutch windings, using an ohmmetor connected across the slip rings (see Illustration). The resistance at 20*0 should be 2 to 4 ohms. 7 Check the Insulation of the windings, using an ohmmeter connected between either sip ring and the body of the clutch (see illustration). Resistance should be Infinity. 8 If the clutch fails any of the foregoing checks, renew it. Apart from the brush gear, Individual spares are not available.
Refitting 9 Refitting is a reversal of removal but tighten all bolts to the specified torque.
windings

7B*6 Automatic transmission
Gear selector cable -adjustment
1 Remove the battery and tray as described In Chapter 5A for access to the transmission. 2 Disconnect the selector cable from the lever on Ihe transmission. 3 Move the selector fever inside the vehicle to the N (Neutral) position, then move the lever on the transmission to Its central (Neutral) position. Locate the cable end over the lever. If the cable end fitting does not line up exactly with the hole In Ihe lever, loosen the adjustment nut and reposition the end fitting. 4 With the adjustment correct reconnect tha cable to the lever, then move the selector lever to the P (Park) position. Check that the lever on the transmission has also moved to the P position. 6 Refit the battery and tray as described in Chapter 5A. 6 Road test the vehicle, and check for correct operation in all selector lever positions.
9 Gear selector cable -removal and refitting at
7 Inside the vehicle disconnect the selector cable from the bottom of the selector lever (hen remove it from the support bracket, a Withdraw the cable into the engine compartment, and remove it.
Refitting 9 Refitting is a reversal of removal, but adjust the cable as described in Section 8. 10 Check that It is only possible to start the engine in positions P and N. Reposition the selector lever switch If necessary. 11 Road test the vehicle, and check for correct operation In ell selector lever positions.
10 Transmission oil pump - & mnvtiifll rAtiMlitA removal a/id refitting
Removal 1 Using an Allen key. unscrew the screw and remove the selector lever knob from the lever. 2 Remove the oddment tray and the ashtray. 3 Remove the screws and withdraw the centre console and selector mechanism cover. 4 Unscrew the mounting screws, slightly lift the centre console, then disconnect the wiring and remove the console, 5 Remove the battery and tray as described in Chapter 5A for access to the transmission, 6 Disconnect the selector cable from the lever on the transmission.
Removal 1 Apply the handbrake, then lack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the left-hand wheel. 2 Unscrew the screws and remove the wheel arch liner. 3 Working through the left-hand wheel arch, remove Ihe three bolts which secure the oil pump. 4 Attach a slide hammer to the oil pump, using the two tapped holes provided. Withdraw the pump using the slide hammer. Be prepared for some oil spillage. Recover the gasket end O-ring (see illustrations). 5 If the pump is defective, it must be renewed; no spares are available.
Refitting 6 Before refitting Ihe oil pump, clean Ihe mating surfaces of the transmission and pump. 7 Rt the oil pump, U9ing a new gasket and a new O-ring. Secure the pump with the three bolts.
8 Refit the wheel arch liner, then refit tto wheel and lower the vehicle to the ground. 9 Check the transmission fluid level » described earlier in this Section, and top-upif necessary.
11 Accelerator pedal & mfcro-Bwftcb(es) -checking
and
adjustment ^
1 Correct adjustment of the micro-awtlch which senses the accelerator pedal position s essential for correct operation of the clutch.
A
quick check can be made by listening for the switch clicking as the accelerator a depressed. For an accurate check, proceed as follows. 2 Disconnect Ihe mlcroswitch wiring connector (nside the vehicle. Connect a continuity tester across the terminals of the switch, located at the top of (he pedal box (see Illustration}. 3 Remove the air cleaner and air ducting as described in Chapter 4A. 4 With the accelerator pedal releassd, th« switch must be closed (zero resistance). Slowty depress the pedal, and check that the switch opens when the throttle valve on the throttle housing is 30° open. This will occur when the pedal has travelled between 3 and 7 mm. Adjust the switch position if necessary. 5 If the switch is permanently open or permanently closed, and adjustment makes no difference, renew ft. 6 Remake the original wiring connections on completion,
12 Automatic transmission -overhaul
Apart from the operations described earlier in this Section, transmission overhaul should be entrusted to a Rat dealer or transmission specialist.
10.4a Using a slide hammer to remove the oil pump from the transmission 10.4b Automatic transmission oil pump O-dng (1), housing (2) and gasket (3) 11.2 Continuity tester connected ecross the accelerator pedal micro-switch

6*172

Chapter 8
Driveshafts
Contents
Oriveshaft gaiter check See Chapter 1A or 1B General information 1 Oriveshaft overhaul and rubber gaiter renewal 3 intermediate driveshaft - removal and refitting 4 Driveshafts - removal and refitting 2
Degrees of difficulty

Easy,
suitable for ^ novtoewithittle experience ^
Fatly
easy,
suitable for beginner with
some experience
^

Fairty
difficult, suitable
tor
competent OtYmechanlc

Difficult,
suitable for experienced DIY mechanic ^
Veiydfficult, ^
suitable
for
expert DIY
or professional ^
Specifications
General Type
Lubrication lubricant type
Torque wrench settings Driveshaft nut* All models except turbo diesel (M22 plain) Turbo diesel (M24 with staking and captive washer) Roadwheel bolts Suspension strut-to-hub carrier bolts Track-rod balljolnt-to-hub carrier 'Use a new nut.
Unequal-length, solid steel shafts, splined to Inner and outer constant velocity joints. Intermediate shaft with support bearing on turbo diesel models with equal length driveshafts.
Fiat specification grease, supplied with gaiter repair kit
Nm Ibfft
240 177 280 207 85 63 70 52 40 30
1 General information
Power is transmitted from the differential to
Ihe
roadwheels by the driveshafts. via inboard and outboard constant velocity (CV) joints (we illustrations). An intermediate drive shaft, with its own support bearing is fitted between the gearbox output and right-hand drive shafts on turbo desei models (see Illustration overleaf). This layout has the effect of equalising driveshaft angles at sll suspension positions and reduces tfveshaft flexing, which improves directional stability, particularly under acceleration. The outer Rzeppa type CV joints allow smooth transmission of drive to the wheels at all steering and suspension angles. Drive Is transmitted by means of a number of radially static steel balls that run In grooves between
the two halves of the joint. The type of inboard CV joint fitted is model dependant. Those fitted to all except the turbo diesel models are of the plunge-cup type; drive is transmitted across the joint by means of three rollers, mounted on the driveshaft in a tripod arrangement, that are radially static but are free to slide in the grooved plunge cup.
The inboard CV joints fitted to turbo diesel models are of the Rzeppa type, similar to those at the outboard end of the driveshaft. On the right-hand driveshafl, the joint is bolted directly to the end of the intermediate driveshaft flange. On the left-hand driveshaft, the joint is bolted to the transmission output shaft flange.
1.1a Cross section of driveshaft - petrol and non-turbo diesel models A Transmission side B Roadwheef side

8*2 Driveshafts
f Outboard CV joint 3 Driveshaft 6 Flange 2 Gaiter clip A Garter 6 Inboard CV ioint
1.2 Intermediate driveshaft • turbo diesel models 1 Bearing flange 3 Washer S Retaining plate 2 Bearing A Circllp
2.S Extracting the driveshaft from the hub (arrowed) from the CV joint at the carrier transmission
The joints are protected by rubber g&itcrs and are packed with grease, to orovktt permanent lubrication. If wear Is detected in the joint. It can be detached from lii» driveshaft and renewed. Normally, the CV joints do not require additional lubrication, unless they havo been overhauled or lfi» rubber gaiters have been damaged, allotting the greasa to become contaminated. Rater
to
Chapter 1A or 1B for guidance In checking the condition of the driveshaft gaiters. Bolh driveshafts are splined at their outer ends, to accept the wheel hubs, ond ate threaded so that the hubs can be fastened to the driveshafts by means of a large, staked nut.
2 Driveshafts -removal and refitting & ^
Note: A balljoint separator tool will b» required for this operation. A new drivestnf, nut and tmck-rod end nut should be used
on
refitting. In addition, new lower arm
baHj&ot
nuts should be used. Removal 1 Chock the rear wheels, apply the handbrake, then jack up the front of tha vehicle and support on axle stands (see Jacking and vehicle support). Remove th« appropriate roadwheel(6). 2 The front hub must be held stationary
m
order to loosen the driveshaft nut. Ideally, M hub should be held by a suitable tool bolted Into placo using two of the roadwheel nuts, Alternatively, havo an assistant firmly apply the brake pedal to prevent the hub from rotating. Using e socket and extension bar, slacken and remove the driveshaft nut. Recover the washer (where fitted).

A


Warning: The nut Is extremely tight. Discard the nut - a new
one
must be used on refitting. 3 Remove the locking clip and extract the brake caliper hydraulic hose (and where applicable, the brake pad wear indicator cable) from the bracket on the base of the suspension strut. 4 With reference to Chapter 10, Section 3. unbolt the base of the suspension strut from Ihe top of the hub carrier. 5 Temporarily refit the driveshaft nut to the end of the driveshaft, to prevent damage to the driveshaft threads, then using a solt-faced mallet, carefully tap the driveshaft from the hub carrier (see illustration). If the shaft is a tight fit, a suitable hub puller can be used to force the end of the shaft from the hub. Support tha end of the driveshaft • do not allow the end o the driveshaft to hang down as this svill strain the joint components and gaiters. 6 Proceed as follows, according to which driveshaft is to be removed. All models except turbo diesels 7 Remove the driveshaft gaiter clip from the CV joint at the transmission (see Illustration)

Driveshafts 8*3
2.9 On turbo diesel models, unscrew the driveshaft Allen bolts (right-hand driveshaft shown) 2.13 Fitting a new driveshaft nut
then pull the driveshaft away from the plunge cup. Position a container underneath the joint to catch any grease that may escape fdnveshaft grease becomes liquid with use). 6 Remove the driveshaft from under the vehicle. Cover the open plunge cup on the vehicle to prevent the ingress of dirt: use a plastic bag secured with elastic bands. Turbo diesel models 9 Unscrew the six Allen bolts securing the inboard end of the driveshaft to the inter-mediate shaft flange (right hand driveshaft) or gearbox output shaft flange (left hand drive-shaft flange) (see Illustration). Recover tho reinforcement plates (where fitted). 10 Remove the driveshaft from under the vehicle. Cover the exposed flange at the gearbox/intermediate shaft, to prevent the ingress of dirt; use a plastic bag secured with elastic bands. 11 Loosely refit one of the strut lower mounting bolts, to support the hub carrier whilst the driveshaft is out of the vehicle.
Befitting 12 After removing the temporarily-fitted bolt torn the strut mounting, pivot the hub carrier away from the vehicle and push the splined end of the driveshaft Into the hub.
13 Fit a new driveshaft nut, but do not fully tighten it at this point (see illustration). 14 Support the driveshatt with one hand and push the hub carrier back towards the vehicle. All models except turbo diesels 15 Re-engage the tripod at the inboard end of the driveshaft with the plunge cup at the gearbox. Slide the gaiter into position over the joint and briefly lift the lip of the gaiter to expel any air trapped inside. Ensure that the gaiter is seated squarely over the universal joint, then fit a new clip around the centre of the joint to secure it in place. Turbo diesel models 16 Align the inboard end of the driveshaft joint with the intermediate shaft flange. Refit the six driveshaft bolts and tighten them securely. All models 17 Refit the suspension strut-to-hub carrier bolts and tighten them to the correct torque * refer to Chapter 10 for details. 18 Refit the brake caliper hydraulic hose (and where applicable, the brake pad wear indicator cable) to the bracket on the base of the suspension strut. 19 Refit the roadwheel and bolts. 20 Lower the vehicle to the ground and tighten the driveshaft nut to the specified
torque. Stake the rim of the nut into the machined recess in the end of the driveshaft. using a hammer and punch (see illustrations). 21 Tighten the wheel bolts to the specified torque and refit the wheel trim/centre cap.
3 Driveshaft overhaul and rubber gaiter renewal
1 Remove the driveshaft from the vehicle as described In Section 2. 2 Unfasten the remainder of the rubber gaiter securing clips. Slide the gaiters towards the centre of the shaft, away from Ihe joints. Wipe off the majority of the old grease with a rag. Outboard CV joint - removal
All models except turbo diesels 3 Mark the relationship between the joint and the driveshaft using a scriber or a dab of paint. Using pair of circlip pliers, expand the circlip that holds the driveshaft m place and withdraw the shaft from the CV joint. Note that the circlip is captive in tho joint, and need not be removed, unless it appears damaged or worn (see illustration overleaf).
2.20a Tighten the driveshaft nut to the specified torque (roadwheel removed for clarity) 2.20b Stake the rim ot the nut Into the recess in the driveshaft 2.20c Recess machined into end of the driveshaft

Driveshafts 8*5
4.4 Unbolt the Intermediate shaft from the 4.5a Withdraw the intermediate shaft from support bracket the transmission 4.5b Recover the dust seal
4 Unbolt the intermediate shaft from the support bracket (see Illustration). 5 Attach a slide hammer to the intermediate shaft flange and draw the splined end of the shaft out of the transmission. Take care to avoid damaging the oil seal. Recover the dust seal (see illustrations).
Refitting 6 Before installing the driveshaft, examine the oil seal in the transmission for signs of
damage or deterioration and, if necessary, renew it (it is advisable to renew the seal as a matter of course). 7 Thoroughly- clean the intermediate shaft splines and the aperture In the transmission. Fit a new dust seal to the shaft, then apply a thin film of grease to the oil seal lips, and to the intermediate shaft splines and shoulders. 8 Push the shaft squarely into the trans-mission, taking care to avoid damaging the oil
9 Line up the intermediate shaft bearing with the suppori bracket, then insert the bolls and tighten them securely. 10 Refit the right-hand driveshaft as described in Section 2, then refit the road-wheel and lower the vehicle to the ground. Tighten the roadwheel bolts to the specified torque. 11 On completion refill the transmission with the specified quantity and grade of oil. as described in Chapter 1B.
8