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1. Gear train housing bolts on spacer housing 2 5 Bolts coated with Loctite FRENETANCH 23 25 AUTOMATIC TRANSMISSION Cross section and tightening torques in daN m ML AUTOMATIC TRANSMISSION et DAN eZ Pre coated with Loctite FORMAJOINT 23 26 AUTOMATIC TRANSMISSION Strainer The strainer filters the oil and ensures that the automatic transmission operates correctly Tightening torques in daN m V Distributor bolt strainer bolt Sump bolts REMOVAL Drain the oil and remove sump for vehicles fitted with MB AUTO MATIC TRANSMISSION this must be raised up the strainer and its seal Before refitting clean the sump and its magnets and replace them as shown in the diagrams see following page REFITTING Refit the new strainer with its seal check the as sembly direction see diagram and tighten to a torque of 0 9 daN m the sump and refill with oil 23 27 AUTOMATIC TRANSMISSION Strainer Original fitment Second fitment check assembly direction MB MJ MB 88163 25 88163 55 With sump 88162 15 88162 35 Direction for fitting magnets ribbed side against plate 23 28 AUTOMATIC TRANSMISSION Strainer 3rd fitment except MB1 600 601 NOTE The deeper type of sump must be fitted with a modified strainer and dipstick see Dip stick conformity table No modifications have been made to the sump or the oil level on MB
2. Ensure that the circlips are correctly positioned in the bearing grooves Before coupling the separator housing to the step down casing check that the two location dowels B and C are present and fit the paper seal it must be fitted dry 88207R3 Refit thecirclip 9 with tool B Vi 902 01 keep the output shaft in position through the inspec tion cover the casing 26 fitted with its seal cap towards the bottom and its magnet See the relevant section for fitting the gear sec tion casing to the separator casing 88212R 23 106 0i Hi Q AUTOMATIC TRANSMISSION Exploded view DIAGRAM N 1 Mechanism housing Oil pump F2 piston F2 piston return cup Drive hub Needle thrust race F2 discs F1 piston support Circlip E1 E2 clutch Forward planet wheel carrier F1 piston F1 discs E2 bell housing Plastic washer thickness 1 5 Reverse planet wheel carrier Free wheel Needle thrust race Plastic washer thickness to be determined Circlip Park wheel Vacuum capsule Hydraulic distributor Park pawl Park pawl pivot pin Park pawl spring Park linkage Clip Quadrant Gear liner pin Strainer seal Strainer Quadrant ball Quadrant spring Sump gasket Needle thrust race Plastic washer thickness 1 5 Pump shaft Turbine shaft End float adjusting shim Washer Disc Undulated 1 1 1 1 Flat 4 5 3 4 Lined 3 4 3 4 23 107 oo
3. Original fitment The stop screw B is used to prevent the manually operated valve 14 slipping at the end of its tra vel 88168R Adjust stop screw B put selector quadrant in Park slacken the lock nut and bring screw B to wi thin 1 mm of the manually operated valve tighten the locknut 2nd fitment However the Parts Department supplies distribu tors with the 2nd fitment manually operated valve 14 extended by 14 mm This distributor must in all cases be fitted by removing stop screw B 88168 1R Refit the sump equipped with a perfect gasket Top up the oil and adjust the oil pressure AUTOMATIC TRANSMISSION Hydraulic distributor REMOVAL REFITTING 85526R Pressure limiting valve ball VLP Pressure limiting valve spring medium size VLP Pressure limiting valve VLP Pressure limiting valve seal VLP Sequence valve spring small VS Sequence valve SV Sequence valve SV No 1 selector valve VP1 Plungers 10 2 selector valve VP2 11 Pressure regulating valve VRP 12 Pressure regulating valve spring large size VRP 13 Cover plate 14 Manually operated valve VM 15 Hydraulic unit oo QI The plungers 9 are identical Valves 3 7 8 10 are symmetrical Valve 6 is not symmetrical 23 34 AUTOMATIC TRANSMISSION Hydraulic distributor Removal must be performed in a clean dust free location REMOVAL Re
4. Check the connections of the solenoid valves and the vehicle wiring on the computer 3DMXTT1 0 23 267 AUTOMATIC TRANSMISSION Fault finding aid Chart 47 No reverse gear when warm or bang when engaging reverse when reaccelerating fault check the condition of the engine and transmission assembly mounting pads Check and if necessary adjust the idle speed selector lever in position D After the operation does the fault persist If the warning light is operational and it remains extinguished when there is a e yes Check the condition of the seals for the piston and the piston mounting for F1 Replace any parts deemed to be faulty Chart 48 No 1st gear hold after operation on hydraulic distributor If the warning light is operational and it remains extinguished when there is a fault the fault is certainly due to the absence of the sequence valve spring in the hydraulic distributor reference mark VS Chart 49 Cannot change 2 3 in full load but can change in no load If the warning light is operational and it remains extinguished when there is a fault check the adjustment of the accelerator cable Also check the condition of the air filter 3DMXTT1 0 23 268 AUTOMATIC TRANSMISSION Fault finding aid Chart 50 Banging when changing gears If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace
5. Jt R2 23 187 On the keypad enter e o E The following will appear on the display EF T Validate the erasing request by pressing The following will appear on the display EE Two cases may arise from this point E e 1st CASE You have not fulfilled the conditions given pre viously The following will appear on the display 1 T then LJ nu Please follow the conditions given previously Repeat the whole erasing procedure AUTOMATIC TRANSMISSION Additional tests 2nd CASE You have complied with the previously given conditions The following will appear on the display then then 4 c The memory has been erased The only bargraphs illuminated should be 1RH 11 17RH You may continue your fault finding procedure 23 188 END OF TEST On the keypad enter ie 1 8 7 The following will appear on the display F The XR25 makes a noise The following will appear on the display Turn off the ignition You may disconnect the XR25 AUTOMATIC TRANSMISSION General THIS PART RELATES TO VEHICLES FITTED AS STANDARD WITH A NEW COMPUTER PRESENTATION This new generation computer has A vehicle speed sensor 1 A multifunction switch and an earth 5 Aconnector 11 making the connection bet ween the injection and automatic transmission computers on track A load information on track B torque redu
6. Vehicle stationary enter the code of the automa tic transmission The following will appear on the display Jt R2 23 203 On the keypad enter e o E The following will appear on the display Validate the erasing request by pressing The following will appear on the display Two cases may arise from this point e 1st CASE You have not fulfilled the conditions given pre viously The following will appear on the display Jt Re Please follow the conditions given previously then Repeat the whole procedure for erasing and for programming the no load and full load positions AUTOMATIC TRANSMISSION Additional tests 2nd CASE You have complied with the previously given conditions The following will appear on the display The memory has been erased The no load and full load positions must be vali dated Validate the full load position by pressing the ac celerator pedal fully down for five seconds Bargraph 10RH extinguishes Validate the no load position by releasing the ac celerator pedal Bargraph 10LH will extinguish The following will appear on the display then JER3 The only bargraphs illuminated should be 1RH 12RH 17RH 9RH for vehicles not fitted with a ki ckdown compensator 23 204 IMPORTANT Turn off the ignition Turn the ignition on again Enter the automatic transmission code Check that the no load full load positions have bee
7. theclearance at section J must be between 0 05 and 0 35 mm 73122R1 AUTOMATIC TRANSMISSION Gear section casing e BRAKES 7 13 Any lined discs showing signs of overheating blackening of lining on which the finish is poor or which are worn must be scrapped Scrap all steel discs that show signs of picking up or seizing e CLUTCH E1 E2 10 Clutch E1 E2 cannot be dismantled Clutch E2 has visible discs Using a set of shims check the clearance of clutch E2 85525S Maximum permissible clearance MB 3 5 mm MJ ML 4 1 mm If the clearance is not correct change E1 E2 and check the hydraulic distributor Clutch E1 is not visible but the clearance can be checked by moving ring C 85525 1R MB 3 mm MJ ML 3 5 mm Permissible movement 23 60 On E1 E2 check the condition of theturbine shaft retaining seal theinside of the bore accommodating the E2 BELL HOUSING 14 Check the condition of thepinion the two white metal faced bushes e CUP WITH PRESSED SPRING 4 Check that the springs and their crimped areas are in good condition e SEALS Systematically replace all removed seals e HYDRAULIC DISTRIBUTOR 23 The hydraulic distributor assembly can be re moved see Hydraulic distributor section If clutch E1 is burnt out change the hydraulic dis tributor e EPICYCLIC GEAR TRAIN 11 16 Check the condition of the teeth on all the gears Ensure
8. 1 2 1 E2 TYPE OF AT i Steel discs po Steel discs pura Steel discs Lined Steel discs Lin ed discs discs MJ ML 4 4 5 4 5 5 5 5 MB3 One undulated disc is fitted to each group of brakes and clutches 23 20 AUTOMATIC TRANSMISSION Operation of the transmission OPERATING COMPONENTS A Park wheel 23 21 23 DX ERI 00 4 FEKA R m f the t AUTOMATIC TRANSMISSION Operati x N e a a s m Oem mn gt 24 2 22 oon lt lt HO a lt amp A ERX 3 amas O 00 e cil mn m nn AUTOMATIC TRANSMISSION Cross section and tightening torques in daN m MB AUTOMATIC TRANSMISSION g 1h E Pv i vmm M LIT n k a i k 4 E 4 86293 1 Bolts coated with Loctite FRENETANCH 23 23 AUTOMATIC TRANSMISSION Cross section and tightening torques in daN m MJ AUTOMATIC TRANSMISSION Differential cover plate 2 85615R Bolts coated with Loctite FRENETANCH 23 24 AUTOMATIC TRANSMISSION Cross section and tightening torques in daN m ML AUTOMATIC TRANSMISSION m m j 1 DE LE TI PERT LI E ape He H n E 1 mar Ts mo ee 5 Bi d jn Ae d HAN Hu nn c A 5 Mn i a Em
9. In the full load position the bargraph of the left hand column must be aligned with the bargraph of the right hand column thus illuminating bar graphs 5RH and 5LH In the full load position a value between 0 and 3 should be read on the central display 0 being the optimum setting 23 143 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination FAULT FINDING CHART TO BE USED FROM THE BARGRAPHS Page ONE OF THE BARGRAPH INDICATES A FAULT Bargraph 0 RH extinguished or lack of communication with the computer 146 Bargraph 1 RH illuminated Solenoid valve faults 147 Bargraph 2 RH illuminated Faults on vehicle speed information 148 Bargraph 3 RH illuminated Load potentiometer fault 149 Bargraphs 4 5 RH illuminated Coherence fault between the lever position and the XR25 display 150 Bargraph 6 RH illuminated Operating check of the kickdown switch for vehicles with kickdown or starting authorisation check in P N for vehicles without kickdown 151 152 1DMXTTI1 0 23 144 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 0 RH EXTINGUISHED OR NO COMMUNICATION WITH THE COMPUTER Check that the battery voltage is gt 10 5 V Check that the fuse of the automatic transmission is not blown no After these checks does the fault persist yes Check the 2 track connector connecting the diagnostic socket and the computer is correctly connected If the vehicle does not hav
10. Qn DIAGRAM N 2 End float adjusting shim Spacer Cover plate bolt Cover plate Circlip Taper washer Ball bearing Thick washer Primary gear Snap ring Speedometer drive wheel Speedometer drive pinion Speedometer drive shaft Speedometer drive seal Spring ring Final drive pinion nut Taper bearing Spacer Secondary gear Final drive pinion O ring Lip seal Baffle Band ring Taper roller bearing Housing Sunwheels Long shaft Short shafts Planet wheels Hub Crown wheel Crown wheel bolt Torque converter seal Torque converter Shim for adjusting differential preload Output shaft Inspection cover Plate seal Spacer depending on version Needle bearing AUTOMATIC TRANSMISSION 0i Exploded view DIAGRAM 3 Circlip Ball bearing Step down gear on secondary shaft Roller bearing Secondary shaft Torque converter and differential casing Circlip Ball bearing Spring ring Spring ring Step down gear on primary shaft Circlip Output shaft Separator housing Differential housing Tail shafted sunwheel Planet wheel washers Planet wheels Planet wheel shaft Spider housing sunwheel Washer Stop ring Speedometer drive crown wheel Spring washer Circlip Ball bearing Circlip Lip seal O ring Converter Converter seal End float adjusting shim Differential bearing Needle bearing Speedometer drive pinion Speedometer driveshaft Speedometer s
11. Some vehicles may change abruptly from 2nd to 3rd gear and vice versa when driving particularly Tighten the distributor bolts to the correct torque slowly in town The oil pressure must be checked and adjusted if necessary see relevant section The distributor plate can be modified only on ve hicles fitted with MB1 automatic transmission and up until 1994 Special tooling 1drill bit diameter 2 5 mm drillbit diameter 1 1 mm 1 Reduce the dividing hole n 21 diameter 1 3 mm so that it becomes 1 1 mm Put the plate on a flat hard and clean surface Using a 3 or 4 mm punch and a copper ham mer restrict the diameter to 1 1 mm If necessary check the 1 1 mm again 2 Increase hole E2 n 11 diameter 1 7 mm to 2 5 mm DI2356 A Hole n 21 diameter 1 3 mm becomes 1 1 mm B Hole n 11 diameter 1 7 mm becomes 2 5 mm 23 36 AUTOMATIC TRANSMISSION Solenoid valves Tightening torques in daN m Distributor bolts Sump bolts Cover plate bolts retains solenoid valves REMOVAL The hydraulic distributor must be removed in or der to remove the solenoid valves see Hydraulic distributor section Slacken the two bolts until the solenoid valves can be released TAKE CARE not to lose the spring 12 Before refitting check that seal J is in perfect condition that O rings on the solenoid valves and the sealed connector are in perfect condition that the ball bearing
12. the pistons 12 3 thedrive hub 5 the oil pump 2 the pump shaft 38 the turbine shaft 39 86025R 23 57 AUTOMATIC TRANSMISSION Gear section casing JAA 86497G Blow compressed air into the oil cooler inlet and return pipes A and After cleaning lubricate the parts immediately with recommended oil 23 58 AUTOMATIC TRANSMISSION Gear section casing CHECKING e GEAR SECTION CASING 1 DI2361 Check that the following are in good condition the oil pump location see Oil pump the circlip grooves the seal faces for pistons F1 and F2 the face of the casing holding the hydraulic distributor thecoupling faces the seal faces of the sealed connector and in put shaft e OIL PUMP 2 Check the condition of the oil pump pinions The gear section casing pinions wheel assem bly is matched If one part has to be changed then the entire as sembly must be changed 23 50 e DRIVE HUB SEALING RINGS 5 Before removing the rings from the hub check that they rotate freely on the hub If they are seized CHANGE THE HUB RING ASSEMBLY Remove the rings and check the condition of the following on the hub thebottom of the three grooves in which the rings fit 73122R B CORRECT the white metal faced bush theface at the oil pump end On the rings check thering gap ends 3 they should fit to gether exactly 4
13. 12jnduro ada LY WAL ad Ay 8 ad Ay o otuaA VORPIYHUSPT apy Surpuyy neg UOneisusS Boneu 23 134 AUTOMATIC TRANSMISSION Vehicles concerned OET 108 E N 0sz Uzi ESF X 194 fIN ZTL L l tT 91 OET F98 00 ZZ 964 00 ZZ VSP X 094 ERN LCL Lal eel PEL P98 00 ZZ OT 6 Z 00 ZZ 9c EQN 164 Nd 9 X O9c 1 TUIN 464 CO 671 106 868 00 ZZ 009 ZEZ 00 ZZ EZEX 1 cCO LAIN 814 LEL 98 00 ZZ 468 ZEZ 00 ZZ ZO LAIN 814 4 X CF 1 00 LEN 8L fco LOS LN 494 cO 621 F98 00 ZZ OES EEZ 00 ZZ 4 X cr a nez onos Lawn ima saqunu EPIN CVIN oyu onomu ou ped ou ad ad 8 2d aprya ayo Surpuy pIO 23 135 AUTOMATIC TRANSMISSION Vehicles concerned 2 po PN posn aq 0 u apy Supu StI CFI Jaquunu WOHPIHUSp 6ET F98 00 ZZ SEL P98 00 ZZ EUN IFZ NEJ 8S8 00 8 00 00 Sa 174 Net LCL 98 00 ZZ 9ct 98 00 ZZ FIN ou ped amnduroo uoreiasuaS 97L SPL 00 ZZ EEZ 00 ZZ Ces CEL 00 ZZ ou ped 8 pjo 990D SOPS LZSX 9 5
14. 26 No vehicle drive in R D 2 and 1 when warm only the vehicle starts again after being stopped for a few minutes fault which can be repetitive If the warning light is operational and it remains extinguished when there is a fault the strainer is blocked and the automatic transmission is burnt out Repair the faulty components Refer to MR T A M 3DMXTT1 0 23 253 AUTOMATIC TRANSMISSION Fault finding aid Chart 27 Will not change into 2nd the engine speed increases in 1st above 31 mph 50 km h changes to 3rd after releasing pedal If the warning light is operational and it remains extinguished when there is a fault check the appearance of the oil Is it dirty ensure it has not been replaced since the fault appeared yes Y Seal for piston F2 or circlip loose Refer to the replacement instructions in MR T A M Remove the hydraulic distributor Is the ball for EL1 jammed open no Is valve VP1 jammed yes Brake F2 burnt out Refer to the replacement instructions in MR T A M Repair the hydraulic distributor or replace it 3DMXTT1 0 23 254 AUTOMATIC TRANSMISSION Fault finding aid Chart 28 The engine races when changing from 2 3 the automatic transmission seems to change to neutral no drive in reverse If the warning light is operational and it remains extinguished when there is a fault check the hydraulic distributor e em Check that valve VP2 slides
15. D of the computer If the fault persists replace the computer Erase the memory if an M 4 3 computer is fitted Vehicles with closed contact kickdown switch Presence of earth on track D of the computer Is there continuity between the 2 tracks of the yes Replace the kickdown switch kickdown switch in the No Load position Check ensure the insulation of the line between the track of the kickdown switch connector and track D of the computer If the fault persists replace the computer Erase the memory if an M 4 3 computer is fitted 1DMXTT1 0 23 150 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 6 RH ILLUMINATED cont Operating check of the kickdown switch for vehicles with kickdown or starting authorisation check in P N for vehicles without kickdown B Bargraph 6 extinguished in the Full Load position Vehicles with open contact kickdown switch Earth still present on track D of the computer Check the adjustment of the accelerator pedal Is there continuity between the 2 yes gt Replace the kickdown switch tracks of the kickdown switch in the Full Load position no Check ensure the insulation of the line between the kickdown switch connector and track D of the computer Vehicles with closed contact kickdown switch No earthing on track D of the computer Check the adjustment of the accelerator pedal no gt Replace the kickdown swi
16. J all distributors bolts except for bolt A When removing bolt A take care that the fol lowing do not fall the manually operated valve 14 the plate and two seals located under the hy draulic distributor Remove clip E from the sealed connector and re move the distributor solenoid valve assembly 85661R 85596R CHECKING Check that the sequence valves 6 and 7 slide freely at A using a small screwdriver and also make sure that the other valves slide freely TAKE CARE not to damage the parts 88864R REFITTING Fit clip E to the sealed connector and reconnect it Fit the manually operated valve 14 in the centre line of the toothed quadrant Place the vacuum capsule on the pressure regulat ing valve 11 Tighten bolts 2 and 6 on the distributor as far as they will go since they determine the position of the distributor when all the bolts have been tightened Using a torque wrench 0 3 to 2 daN m tighten the hydraulic distributor bolts to 0 9 daN m in the order given 88163R AUTOMATIC TRANSMISSION Hydraulic distributor 88163 2R After tightening bolts 1 and 2 fit the new strai ner fitting direction shown in diagram together with its seal 88163 4R After tightening bolts 1 to 6 fit the new strai ner fitting direction shown in diagram together with its seal After fitting check that the manually operated valve moves correctly
17. K Fit tool B Vi 715 and measure The clearance L is equal to the dimension of the tool H the dimension D measured between the L G E spacer 2 and the tool The thickness of the shim K is equal to Calculate dimension E K L 0 8 mm E M D Example H 120mm F 145 3 mm D 97 6 mm 145 3 120 25 3 mm E 120 97 6 22 4 mm Total end float 25 3 22 4 2 9 mm K 2 9 0 8 2 1 mm Thickness of shims available 0 25 0 7 1 1 1 7 2 3 mm In this case select a 2 3 mm thick shim which will 86135R give the clearance closest 0 8 mm Once the adjustment has been made set the mechanism in the Park position IMPORTANT The end float must also be adjusted when a ser vice exchange gear section casing is fitted B Vi 715 88984R 23 71 AUTOMATIC TRANSMISSION Gear section casing FITTING THE GEAR SECTION CASING TO THE FINAL DRIVE CASING Refit the spacer 2 except on MB the shim whose thickness has been pre viously determined Check that the two locating dowels are present and also check the condition of their seats 88951R1 Special feature ML Refit the sump and tighten the bolts to a torque of 0 6 daN m IMPORTANT The casing must fit perfectly if it does not this means that notches E of the plastic shim 19 are not in the correct place see page 126 Fit the oil pump driveshaft Depending on automatic transmission
18. MB 23 1 AUTOMATIC TRANSMISSION Diagram This diagram represents an automatic transmission Type MJ 23 2 AUTOMATIC TRANSMISSION Using DRIVING As the automatic transmission is lubricated under pressure lubrication only occurs if the engine is running Consequently the following instructions must be respected in order to avoid serious damage Never move the vehicle with the ignition off when going down a slope for example the danger of such a measure cannot be emphasised too greatly Never have the vehicle pushed for example in order to reach the next service station unless precautions taken in the Towing are fol lowed In addition the vehicle can only be driven if the engine is running It is therefore impossible to start the engine on a vehicle with automatic trans mission by pushing the vehicle TOWING The front of the vehicle must be raised however if this is impossible towing can be carried out in ex ceptional cases with the wheels on the ground in the following conditions 1 Add an additional 2 litres of oil to the auto matic transmission Elf Renaultmatic D2 or Mobil ATF 220 2 When towing do not exceed a speed of 25 mph 40 km h or a distance of 30 miles 50 km maximum lever in N Remember to drain off the excess oil at the end of the towing operation 23 3 AUTOMATIC TRANSMISSION Identification The identification plate indicates atA the type
19. The components must be removed and handled on a bench with a padded top rubber or thick plastic SEPARATING THE CASINGS 88951R Remove the converter ML Remove the pump drive shaft Remove the external bolts from the gear section casing and the two internal bolts which can be Remove the dipstick tube and its O ring MJ reached by removing the sump and strainer Separate the final drive casing from the gear sec tion casing Special notes MB Remove the bolts marked with an arrow and the external bolts from the gear section housing RE MEMBER TO REMOVE THE NUT AT THE LEFTHAND SUNWHEEL END 23 53 MB Leave shim K for adjusting the end float on the converter casing spacer casing assembly on the output shaft DI2336 AUTOMATIC TRANSMISSION Gear section casing Leave spacer E and shim K on the output shaft MJ DI2337 the sump the strainer and retrieve its seal J all the distributor bolts except bolt A 85744R 85596R1 When removing bolt A take care not to let the following drop the manually operated valve MV REMOVAL the plate and the two seals located under the distributor From the gear section remove AE park wheel 21 NOTE See the hydraulic distributor section for the park pawl 24 and it spring 26 complete instructions on removal the plastic washer 19 the needle thrust race 18 23 54 AUTOMATIC TRANSMISSION Gear
20. and in test conditions 23 183 AUTOMATIC TRANSMISSION Additional tests 1 2 Load potentiometer transformed load Value expressed in accelerator control in full load position PF lis For vehicles not fitted with kickdown compensators Value less than 6 25 full load on accelerator pedal for kickdown function For vehicles fitted with kickdown compensator Value less than 12 5 full load on accelerator pedal for kickdown function 4 Computer identification The identification number of the computer appears on the central display Example The identification number of an old generation computer is the same as the 4 identification number of the corresponding new generation computer NOTE All information displayed other than that described here cannot be used for fault finding the M automatic transmission 23 184 AUTOMATIC TRANSMISSION Additional tests ADJUSTING THE LOAD POTENTIOMETER at No Slacken the mounting bolts V of the potentio load meter Connect the XR25 Turn the selector to 58 iy Accelerator control at rest rotate the body of the potentiometer until a value of 89 1 is obtained on the display Switch on the ignition Retighten the mounting bolts V On the keypad enter the code of the automatic P tratismission If it is not possible to adjust the potentiometer check its drive Check that the trans
21. be fitted regardless of the original type of assembly DI2350 Check that the two locating dowels are on the se parator housing 14 86374R5 AUTOMATIC TRANSMISSION Final drive assembly MB Lubricate the seal and fit it on the separator hou sing 14 Tighten the bolts to a torque of 2 5 daN m See the relevant section for fitting the converter seal See the previous chapter for fitting the gear sec tion casing on the separator housing NOTE the separator housing 14 and the con verter and differential housing 6 are matched by their machining 85678R2 SPECIAL FEATURE There are two types of assembly for stud E secur ing the lefthand driveshaft gaiter Original fitment The stud is smooth it is essential to fit a driveshaft gaiter with a welded spacer Second fitment This is a shouldered stud it is essential to fit a driveshaft gaiter without a welded spacer In all cases fit the appropriate type of stud to the gaiter clamp on the vehicle 23 85 AUTOMATIC TRANSMISSION Final drive assembly MJ REMOVAL SPECIAL TOOLING REQUIRED Seal extractor Set of drifts for fitting 5 mm roll pins Drift for fitting 4 and 10 mm roll pins Tool for replacing converter seal Tool for replacing differential band ring Tool for replacing speedometer driveshaft seal Tool for fitting differential seal Tool for locking secondary gear Tool for measuring preload Tool for fitting ci
22. bolts to a torque of 2 5 daN m 23 76 AUTOMATIC TRANSMISSION Final drive assembly MB e Differential DI2363 Remove 23 or 37 38 39 Clamp the casing 15 in a vice fitted with soft jaws and remove parts 22 to 16 Attach the washers 17 to their respective planet wheels 18 CHECKING THE COMPONENTS Check the condition of the teeth the bearing locating areas the washers 17 the speedometer crown wheel 23 or the sensor ring 37 thesplines Speedometer drive pinion Remove the speedometer pinion driveshaft 36 using flat nose pliers Allow the speedometer pinion 35 to drop into the casing and remove it 23 77 AUTOMATIC TRANSMISSION Final drive assembly MB SEPARATOR HOUSING Remove circlips 1 and 7 the output shaft 13 fitted with the pinion gear 11 and the circlip 12 the secondary shaft 5 together with the pin ion 3 the bearings 2 and 8 separating spring rings 9 and 10 Secondary shaft 5 Mark the position of pinion 3 on 5 Extract the pinion 3 using the press DI2348 NOTE do not mark the bearing faces DI2347 Output shaft 13 Mark the position of pinion 11 on 13 Remove the circlip 12 and extract the pinion 11 using the press DI2349 CHECKING THE COMPONENTS Check the condition of the teeth the white metal faced bushes on 13 the splines the general condition of the casin
23. delayed Illuminated when the vehicle speed information supplied to the automatic 6 transmission computer is wrong or absent 23 180 AUTOMATIC TRANSMISSION Meaning of the bargraphs Illuminated when the circuit of solenoid valve No lis faulty On the keypad enter CI Led 9 The following will appear on the display either The circuit of solenoid valve N 1 is short circuited or The circuit of solenoid valve N 1 is broken Or The circuit of solenoid valve N 1 is operating correctly the bargraph should not be illuminated Illuminated when the circuit of solenoid valve N 2 is faulty Onthe keypad enter He s The following will appear on the display either The circuit of solenoid valve N 2 is short circuited or E The circuit of solenoid valve N 2 is broken or The circuit of solenoid valve N 2 is operating correctly the bargraph should not be illuminated 23 181 a c ED AUTOMATIC TRANSMISSION Meaning of the bargraphs Illuminated when the full load PF position is recognised by the automatic transmission computer Illuminated when the kickdown compensator supplies its information to the automatic transmission computer IMPORTANT This bargraph is always extinguished for automatic transmissions which do not have a kickdown compensator Illuminated when the gear selector lever is in the P or N position Starting is authorised The LH bar
24. fault Replace the vehicle speed sensor following the instructions given in MR T A M speed sensor section Does the fault persist yes Replace the computer and erase the memory Validate the no load and full load values for version E7 And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTTI 0 23 214 Check the presence and the condition of the feed AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 7 RH ILLUMINATED Air conditioning authorisation relay control circuit fault Enter 27 on the XR25 keypad What is displayed No fault fuse of the air conditioning relay After the no gt Success operation does the fault persist Measure the resistance of the coil yes of the AC relay terminals 1 and 2 Is the coil short circuited R 0 Q Measure the resistance of the coil of the relay terminals 1 and 2 Is the coil broken R yes Replace the relay Ensure the insulation of the line between terminal 2 of the relay base and track E of the automatic transmission computer 6 track connector Does the fault persist Check ensure the following continuities Between track E of the computer 6 track connector and terminal 2 of the relay base Between the relay fuse and terminal 1 of the relay base After the repair does the fault persist
25. from 2 3 Abnormal noises or vibrations Buzzing type noise in P and N when cold Metallic noise when idling from the converter housing Noise when operating the starter motor Drive plate keeps breaking Vibration at 37 50 mph 60 80 km h or humming on flat road Drive plate keeps breaking 23 228 Chart 2 Chart 1 Chart 47 Chart 3 Chart 8 Chart 14 Chart 27 Chart 4 Chart 7 Chart 7 Chart 5 Chart 7 Chart 7 Chart 31 Chart 32 Chart 33 Chart 34 Chart 39 Chart 34 3DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding aid B PROBLEM WITH ILLUMINATION OF THE FAULT WARNING LIGHT FAULT FINDING WITH THE XR25 see display and meaning of the bargraphs NO COMMUNICATION BETWEEN THE XR25 AND THE COMPUTER Chart 52 RANDOM GEAR CHANGES Chart 41 FAULT WARNING LIGHT ILLUMINATES AND EXTINGUISHES AT RANDOM Chart 40 GEAR CHANGING THRESHOLDS DELAYED AND WARNING LIGHT ILLUMINATES vehicles fitted with on board computer Chart 42 C FAULT WARNING LIGHT DOES NOT ILLUMINATE WHEN IGNITION TURNED ON Chart 53 3DMXTT1 0 23 229 AUTOMATIC TRANSMISSION Fault finding aid Chart 1 Slipping when starting for all forward gear lever selections without engine racing normal operation above 45 55 mph 70 80 km h in no load position no sensation when changing gear If the warning light is operational and it remains extinguished when there is a fault drain and remove the automatic transmission sump Is there a large n
26. instructions for replacement in MR T A M Check the hydraulic distributor sequence valves slide Is there absolutely no slip when correctly and clean it if necessary changing 2 3 Recheck your diagnosis Check the drive hub the condition of the quadrant rings and the condition of E2 Replace E2 and if its condition warrants it replace the drive hub Refer to the instructions for replacement in MR T A M 3DMXTT1 0 23 232 AUTOMATIC TRANSMISSION Fault finding aid Chart 4 Skidding with engine racing when starting in position D or 2 but not in 1 sometimes intermittently If the warning light is operational and it remains extinguished when there is a fault the freewheel is damaged Refer to the instructions for replacement in MR T A M 3DMXTT1 0 23 233 AUTOMATIC TRANSMISSION Fault finding aid Chart 5 Juddering in reverse If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Under the conditions where the fault appears adjust the idle speed to the maximum tolerance no Correct level lever in D Does the vehicle still show the fault Check the oil pressure in reverse gear when the AT
27. lever Parking difficult to engage lever in P Chart 18 Lever difficult to move or lever blocked Chart 37 Starting possible in N but not in P Chart 43 Abnormal noise or vibrations Buzzing type noise in P and N when cold Chart 31 Metallic noise when idling from the converter housing Chart 32 Noise when operating the starter motor Chart 33 Drive plate keeps breaking Chart 34 Oil leaks After replacing the computer Chart 35 Other cases Chart 36 No drive in forward or reverse gear No forward drive permanent E No drive with lever in D or 2 but drive in 1 only Chart 30 The vehicle does not move forward in D 2 and 1 but neutral park and reverse are correct Chart 20 No reverse drive permanent And the engine races when changing from 2 3 and the automatic transmission seems to change into neutral Chart 28 No engine braking in 1st gear hold normal operation of reversing lights Chart 29 Vehicle does not drive in forward gear or reverse gear Chart 44 Periodic absence of drive in forward gear and reverse gear Vehicle does not drive in R D 2 and 1 when warm only the vehicle starts again after being stopped for a few minutes fault which can be repetitive Chart 26 No reverse gear when warm or bang when engaging reverse when reaccelerating Chart 47 3DMXTT1 0 23 223 AUTOMATIC TRANSMISSION Fault finding aid A PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING cont with the knowledge that the warning light is working corr
28. move the potentiometer wire as far away as possible from the high voltage leads and check the computer earth After any repair does the fault persist yes no Check the routing and condition of the high voltage leads and move them as far away as possible from metal parts Refer to MR T A M computer section 3DMXTT1 0 23 240 AUTOMATIC TRANSMISSION Fault finding aid Chart 12 Random gear changes and hesitation except in 3rd If the warning light is operational and it remains extinguished when there is a fault check the computer earth Tightness of the earth wire of the multifunction switch on the housing or the wire on track E of the 6 track computer connector for the first versions 3DMXTT1 0 23 241 AUTOMATIC TRANSMISSION Fault finding aid Chart 13 Banging when changing gears in no load when changing lever from 2 to D If the warning light is operational and it remains extinguished when there is a fault check the oil level and top up if necessary no gt Does the fault persist Check the vacuum pipe pinched at mountings Is the pipe in good condition Repair After the operation does the fault persist Check the oil pressure at 37 mph 60 km h no load in 3rd no gear AT warm Is the value between 3 2 and 3 6 bars yes no Is the vacuum capsule holed If the banging is only present when changing 2 3 check the conformity of the hydraulic distributor plate Refer to t
29. no L Success Replace the relay and remove the computer 6 track connector Connect terminal E to earth on the wiring side and turn on the ignition no Recheck Does the relay work no yes Replace the computer and erase the memory Validate the full load and no load positions on version E7 yes Check the wiring on the computer 6 track connector and the wires After the operation no gt Success does the fault persist Replace the automatic transmission computer and erase the memory Validate the full load and no load positions on version E7 And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTT1 0 23 215 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 8 RH and or LH ILLUMINATED Solenoid pilot valve fault Bargraph 8 LH EL1 Before starting to work on a vehicle with a load potentiometer specific to the automatic transmission look for any short circuits between tracks B and C of the potentiometer This fault causes a drop in overall 5 volts feed voltage and a solenoid pilot valve fault to be memorised Enter 08 on the XR25 keypad What is displayed No fault Disconnect the connector on the sealed connector Check the 3 track connector of the solenoid pilot On the sealed connector side what is the resistance
30. recommended oil the planet wheels and their washers locking notch in the casing hole engage the planet wheel shaft fitted with the hub 31 depending on vehicle aligning the hole in the shaft with the one in the casing fit the roll pin push it down by approximately 5 mm inside the housing using drift B Vi 31 01 or B Vi 39 fit the other two planet wheels and insert 84511R their shafts depending on vehicle immerse the second sunwheel in the recom Check that the edges A of the band ring 24 are mended oil and fit it to the crown wheel correctly positioned in the differential casing assemble the crown wheel on the casing using groove new bolts which cannot be loosened Tighten the bolts to a torque of 2 planet wheels 9 to 11 daN m 4planetwheels 12 to 14 daN m 88164R If they are not move the band ring down slightly using a copper hammer If necessary accentuate the curve of the edge at A very slightly 23 91 AUTOMATIC TRANSMISSION Final drive assembly MJ When the bearings are refitted on the press take cover plate to the differential casing and care not to change them over since they do not tighten to a torque of 2 daN m have the same internal diameter The bearing with the larger diameter should be at the crown Attach a spring balance to the string and measure wheel end the load Differential with four plant wheels without roll pin Proceed in the same
31. seal on the cover plate side B A tool for fitting the seal on the opposite side to the cover plate A protective sleeve Oil sleeve C before us ing it V 23 42 Tool for fitting the differential oil seal B Vi 951 86104 1R Method Onthe cover plate side Fit the sleeve C to the sunwheel fit the seal to the sleeve and position the seal using tool A Onthe opposite side to the cover plate Follow the same method using tool B to position the seal 86066R AUTOMATIC TRANSMISSION Differential seal and lock nut ML REPLACEMENT SPECIAL TOOLING REQUIRED Castellated wrench for differential lock nut Castellated wrench for differential lock nut can be fitted to B Vi 645 Drain the final drive casing Disconnect the driveshaft at the final drive end Mark the position of the adjusting nut in relation to the casing Remove the lock plate Slacken the nut counting the number of turns us ing tools B Vi 805 and B Vi 645 80545R Replace the seal alone or the nut seal assembly Refit the nut fitted with a new lubricated O ring tightening it by the same number of turns as was needed to slacken it and making sure it is in line with the marks made during removal Refit the lock plate Reconnect the driveshaft Fill the final drive casing with oil 23 43 AUTOMATIC TRANSMISSION Converter As from 1985 on MB automatic transmissions the VERTO diameter 21
32. that all the gears in the forward and re verse gear trains turn freely and without excessive play on their shafts e FREE WHEEL 17 Check the condition of thecomponents of the free wheel spring roller body thesurface of the free wheel track 16 If any components are faulty the entire free wheel and the reverse gear train 16 must be re placed AUTOMATIC TRANSMISSION Gear section casing REASSEMBLY BRAKE F2 IMPORTANT there are several different ways of fitting the circlip In all cases fit circlip part num ber 77 04 002 420 identified by 88940R DI2342 A One undulating disc one flat disc and one li ned disc alternately Anew lubricated F1 piston support 8 Number of discs see identification A Outer pinion following mark made during dismantling chamfer facing downwards B depending on version Lubricate it and check X that it rotates freely in the casing B Grease or lubricate the seals C Centre the drive hub insert the bolts and tighten them progressively diameter 7 1 5 daN m diameter 6 0 6 daN m C Theoperating clearance should be between 1 5 and 2 1 mm 23 61 AUTOMATIC TRANSMISSION Gear section casing ADJUSTING BRAKE F2 CHECKING THE OPERATION This is adjusted using a spacer shim C which is Ensure that the piston is working properly by available in three size 0 5 1 and 2 and is placed blowing compressed air through hole T between the F1 pi
33. the automatic transmis sion 23 120 AUTOMATIC TRANSMISSION Multifunction switch b Replacing a multifunction switch with earth wire There is no earth wire E on the computer feed connector REMEMBER TO REFIT THE EARTH WIRE ON THE AUTOMATIC TRANSMISSION HOUSING see page 23 119 IN BOTH CASES G OPERATING DIAGRAM OF THE MULTIFUNCTION SWITCH 91617R The control pins are represented in the mid position position D at the lever 1 Starter motor authorisation Red 2 1st gear hold engine braking Salmon or orange 3 Barth tio gee taeda Brown 4 Reversing lights Grey 5 2nd gear hold engine braking Blue 6 Reversing lights Green A Control pins on mounting plate side 23 121 AUTOMATIC TRANSMISSION Speed sensor REPLACEMENT strip both wires by 5 mm puta seal on each wire This operation consists of cutting the wire linking crimp the connectors the computer to the speed sensor and replacing the sensor with a new one Before cutting the wire check the speed sensor Composition of the replacement kit 1 speed sensor fitted with a cable and a male connector 1 female connector 2male pins 2seals Method Remove the speed sensor from the automatic transmission and cut the wire to the same length as the replacement wire 86332R When fitting the wires in the connector ensure that the same colours are put opposite each other Fo
34. the shoulder at the final drive pinion end the spacer 18 recovered during dismantling see diagram for direction of fitting the inner bearing track ring 17 the new nut 16 23 93 AUTOMATIC TRANSMISSION Final drive assembly MJ FINAL DRIVE PINION PRELOAD The final drive pinion preload is adjusted without the differential in place It is obtained using spac er 18 Fit tool B Vi 955 to the final drive pinion nut 16 and attach a piece of string and a balance 86068R The final drive pinion should rotate under a load of between 2 and 3 5 daN m if the bearings are new and freely without play when the original bearings are refitted The preload is reduced by fitting a thicker shim 18 and vice versa Once the adjustment has been made tighten the nut 16 to a torque of 16 daN m and lock it 23 94 AUTOMATIC TRANSMISSION Final drive assembly MJ Fitting the output shaft 39 85851R4 In the final drive fit the needle bearing 43 on the press the spring ring 15 B Vi 953 Place pinion 9 in the final drive shoulder at con verter end At the same time thread onto the output shaft 39 the step down gear 9 and the speedometer drive wheel 11 with the notch towards the con verter Fit the half circlip 10 check that 11 is properly clipped in place On the output shaft 39 fit the washer 8 the bearing 7 with the groove opposite the conve
35. transmissions Strainers A with D or E 911985 With its sump and three magnets 88162 35 Strainer B with D or E DI2355 E With its sump and six magnets 936185 Direction for fitting magnets ribbed side against plate AUTOMATIC TRANSMISSION Strainer 88163 15 INCORRECT 881635 With its sump and 4 magnets 88162 25 As for the following transmissions e MJ3 761 762 800 and 801 for L483 L489 L48K L K 48A e MJ3016 116 126 for B29E B297 and B29B the sump has been modified Its depth has been increased by 6 mm and the drain plug moved 911955 This modification is connected with the replace ment of the strainer which has improved filtering ability 911965 91195 15 Direction for fitting magnets ribbed side against plate AUTOMATIC TRANSMISSION Strainer ML 88163 35 With its sump and four magnets 88162 45 Direction for fitting magnets ribbed side against plate 23 31 AUTOMATIC TRANSMISSION Hydraulic distributor The hydraulic distributor delivers or discharges oil to or from the clutches and brakes in accordance with the solenoid valve feed Tightening torques in daN m Distributor bolts Sump bolts Cover plate bolts REMOVAL Drain the oil and remove sump for vehicles fitted with type MB automatic transmission this must be raised up the strainer and recover its seal
36. valves on the computer between tracks C and B approximately 0 Q 25 t50 After checking repairing the wiring does the fault persist yes Disconnect the solenoid pilot valve wire and check the insulation between tracks C and B Is there inslation Disconnect the connector on the sealed connector On the sealed connector side is there a resistance of 25 5 between tracks C and B no Check the continuities on the solenoid pilot Replace the solenoid yes valve WILES pilot valves Are the continuities ensured no yes Replace the wire Replace the computer and erase the memory Validate the full load and no load values on version E7J And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTTI 0 23 216 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination Bargraph 8RH EL2 Before starting to work on a vehicle with a load potentiometer specific to the automatic transmission look for any short circuits between tracks B and C of the potentiometer This fault causes a drop in overall 5 volts feed voltage and a solenoid pilot valve fault to be memorised Enter 28 on the XR25 keypad What is displayed No fault Check the 3 track connector of the solenoid pilot Disconnect the connector on the sealed connector valves on the computer After checking On the sealed connec
37. when accelerating or no reverse gear when warm Chart 47 3DMXTT1 0 23 225 AUTOMATIC TRANSMISSION Fault finding aid A PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING cont with the knowledge that the warning light is working correctly cont PROBLEM LINKED TO THE GEARS Problem changing gears When changing from 2 3 or 3 2 Juddering in reverse and skidding when changing from 2 to 3 Slipping when changing from 2 3 only The engine races when changing from 2 3 and the automatic transmission seems to change to neutral no drive in reverse Cannot change 2 3 in full load but can change in no load Random gear changes Up to 60 75 mph 100 125 km h And hesitation except in 3rd Banging when changing gears In no load when changing lever from 2 to D The engine speed increases in 1st and 2nd changes above 37 mph 60 km h When pedal is released the A T seems to change to neutral and there is a bang when reaccelerating Banging when changing gears Slipping when changing gears When changing from 2 3 only In full load position When changing from 1 2 with lever in D or 2 Gear changing thresholds incorrect The engine speed increases in 1st and 2nd changes above 37 mph 60 km h When pedal is released the A T seems to change to neutral and there is a bang when reaccelerating Will not change into second the engine speed increases in 1st above 31 mph 50 km h changes to 3rd after releasing pedal Lack of one or s
38. with engaging delay Banging when changing gears In no load and when moving lever from 2 to D The engine speed increases in 1st and 2nd changes above 37 mph 60 km h When pedal is released the A T seems to change to neutral and there is a bang when reaccelerating 23 227 Page Chart 9 Chart 46 Chart 51 Chart 38 Chart 38 Chart 15 Chart 16 Chart 47 Chart 47 Chart 13 Chart 24 3DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding aid A PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING cont with the knowledge that the warning light is working correctly cont OTHER Slipping Slipping when starting In forward or reverse gear but operating normal above 12 5 mph 20 km h in forward gear For all forward gear lever selections without engine racing normal operation above 45 55 mph 70 80 km h in no load position no sensation when changing gear Slipping in reverse gear and no engine braking in Ist gear hold Slipping in reverse gear Slipping when changing gears When changing from 2 3 only In full load position When changing from 1 2 with lever in D or 2 Slipping Slipping with engine racing when starting In position D or 2 but not in 1 sometimes intermittently Lever in D and juddering in reverse Slipping when changing from 2 3 juddering in reverse Juddering Juddering in reverse Juddering in reverse and skidding when starting with lever in D Juddering in reverse and skidding when changing
39. yes Success Check the condition of the wiring on the injection computer side and the automatic transmission computer side If the wiring is not faulty check the engine speed information on the injection side After repair erase the computer memory and program the no load and full load values BARGRAPH 13 RH ILLUMINATED Air conditioning reduction requested BARGRAPH 17 RH and LH ILLUMINATED Dynamic test of solenoid pilot valves This test is used to display the electrical operation of the 2 solenoid pilot valves and may also confirm a hydraulic or mechanical problem 2DMXTT1 0 23 222 AUTOMATIC TRANSMISSION Fault finding aid LIST OF PROBLEMS TO BE USED AS A FUNCTION OF CUSTOMER COMPLAINTS PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING with the knowledge that the warning light is working correctly PROBLEM WHICH CAN BE NOTICED WITHOUT DRIVING Poor operation of the starter motor or reversing lights Reversing lights do not work But the starter motor works reverse gear correct Chart 22 And the starter motor does not work Chart 23 Starter motor does not work But the reversing lights work Chart 21 And the reversing lights do not work Chart 23 Starting possible in all selector lever positions Chart 25 Starting possible in position N but not in P Chart 43 Selector lever operating incoherence Starting possible in all selector lever positions Chart 25 Other cases of incorrect operation of the selector
40. 0 Dimension F Dimension between the bearing faces of the differential Dimension X Thickness of the shim to be placed between the bearing and the differential casing DI2365 Refit part 8 and parts 4 to 6 Ensure the pinion 5 is the correct way round REASSEMBLING THE TORQUE CONVERTER FINAL DRIVE CASING Lubricate the seal and push it on straight using tool B Vi 1402 B Vi 1404 11954R Replace the converter after having oiled the face of the seal 23 103 AUTOMATIC TRANSMISSION Final drive assembly ML Assemble the casing and the crown wheel using REASSEMBLING THE STEP DOWN CASING three bolts Refit Measure dimension F using a vernier with 90 mm slide gauge X E F Shims are available in thicknesses from 0 8 to 1 4 mm in 0 05 mm steps b Adjusting the differential bearing preload Ensure that the differential bearings are correctly positioned by rotating them in a clockwise direc tion Using tool B Vi 906 press on one tooth of the crown wheel to make the differential turn in a clockwise direction in the direction of D 88211R The value should be between 2 and 2 5 daN m 84445R1 If it is not slacken or tighten the differential us ing tool B Vi 645 and B Vi 805 02 the lubricated seal 23 using tool B Vi 465 position the pinion 22 and fit the final drive pinion 20 using the press thecirclip 21 with tool B Vi 902 01 23 104 AUTOMATIC T
41. 37 AUTOMATIC TRANSMISSION Fault finding aid Chart 9 Remains in 1st warning light extinguished If the warning light is operational and it remains extinguished when there is a fault warm up the automatic transmission and carry out the following road test Lever in 2nd gear hold start off under full load to reach a speed greater than no 43 mph 70 km h Does the transmission change to 2nd gear yes for vehicle with kickdown yes for vehicle without Repeat the previous road test lifting off switch kickdown switch the accelerator at 43 mph 70 km h and moving the selector lever from 2 to D Does the transmission change to 3rd gear Check the operation of the kickdown switch on the XR25 no yes or using BVI 958 Check the insulation of its line in relation to earth The kickdown function may be permanently active Does the fault persist Consult Chart 27 Replace the hydraulic distributor valves VP1 and VP2 are seized Check the potentiometer bridging plate is present and tightened to the correct torque if the plate is missing the potentiometer may be blocked and damaged when it is tightened Replace the potentiometer if the control is jammed 3DMXTT1 0 23 238 AUTOMATIC TRANSMISSION Fault finding aid Chart 10 3rd gear missing with racing of engine in 2nd reverse gear correct If the warning light is operational and it remains extinguished when there is a fault remove the hydraulic dist
42. 5 volts on track B C on Trafic of the potentiometer connector Adjust the potentiometer to 89 e Is bargraph 4 still illuminated yes Press gently on the pedal no Does the load vary regularly Replace the computer if the wiring is correct yes no Erase the memory In the full load position is there between 0 and 1 37 on 02 Replace and adjust the potentiometer yes Refer to MR T A M no yes Does the fault persist no Adjust the potentiometer to between hs 1 37 and 12 5 in the full load position for 89 in the no load position Refer to MR T A M Check the condition under the bonnet of the automatic Does the fault persist transmission wiring but also the high voltage wiring test with engine running After checking does the fault persist yes AES no Replace the computer Erase the memory 2DMXTT1 0 23 213 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 5 LH ILLUMINATED Injection potentiometer circuit fault The injection potentiometer fault information is transmitted by the injection computer to the automatic transmission computer the automatic transmission operates the with the emergency value Refer to the fault finding of the injection section then erase the memory of the automatic transmission computer and validate the no load and full load values BARGRAPH 6 LH ILLUMINATED Vehicle speed sensor
43. 6 converter has been replaced by a RENAULT diameter 227 converter Replacing the torque converter involves replacing the drive plate replacing the pump turbine and stator shafts The method for removing and refitting the torque converter and pump and turbine shafts on the automatic transmission is the same as the method described on the following page SPECIAL TOOLING REQUIRED B Vi 465 Tooling for replacing the converter seal REMOVAL CHECKING Remove the retaining bracket B Vi 465 Check the condition of converter centring device 1 at crank shaft and converter end diameter 16 MB diameter 40 MJ ML thesealing area 2 theconverter white metal bush 3 the free wheel 4 for MB1 thethree securing points or studs the ignition sensor target 5 85710 1R Pull the converter towards you and remove it 23 44 AUTOMATIC TRANSMISSION Converter NOTE 1 ONLY THE RECOMMENDED OIL MUST BE USED IN THE TORQUE CONVERTER 2 Ifthe oil contains particles from damaged clutches or brakes the oil will be black and smell burnt and no trace of swarf in the sump follow the instructions below for dis charging the oil from the converter ALLOW THE OIL TO DRAIN FROM THE CON VERTER FILL THE CONVERTER WITH CLEAN OIL ELF RENAULTMATIC D2 USING A TURBINE SHAFT ROTATE THE TURBINE TO MIX THE OIL AND LET IT DRAIN AFTER REFITTING THE AUTOMATIC TRANS MISSION TOP UP THE O
44. 73 C373 Switzerland Pedal Pedal position position The kickdown switch is integrated into the The kickdown switch is integrated into the computer computer B408 C408 1342 1352 1343 1353 1277 1279 Pedal position Pedal position The kickdown switch is integrated into the 105 computer L423 B373 C373 Pedal position Full load Full load 110 Kickdown 100 1363 Pedal position Pedal position Full load 65 70 The kickdown switch is integrated into the Kickdown 121 computer These values are given as an example 23 7 AUTOMATIC TRANSMISSION Gear change thresholds L48K L483 L489 L K 48A B C 373 573 Pedal position Pedal position Full load m 122 107 The kickdown switch is integrated into the computer L42 Pedal position Pedal position The kickdown switch is integrated into the computer B297 B29B B29E Pedal position Pedal position Full load 125 10 The kickdown switch is integrated into the 56 computer Txx1 Pedal position Pedal position These values are given as an example 23 8 AUTOMATIC TRANSMISSION Gear change thresholds 1343 1353 1363 B53B C53B L53B Pedal position Kickdown 120 101 Kickdown us 102 Pedal position The kickdown switch is integrated into the computer 1341 1351 DAI Pedal position Full load Fulloa
45. Attach the washers R to their respective planet wheels and recover the adjusting shim X Depending on type of assembly 23 89 AUTOMATIC TRANSMISSION Final drive assembly MJ Differential with 4 planet wheels with band ring Break the band ring 24 with a cold chisel and se parate the various parts Break the band ring 24 with a cold chisel and separate the various parts 85851R3 Differential with 4 planet wheels with roll pin and band ring DI2351 Remove the roll pin holding the planet wheel shaft using drifts B Vi 31 01 or B Vi 39 Attach the washers R to their respective planet wheels and recover the adjusting shim X Depending on type of assembly NOTE The speedometer sensor target C cannot be dismantled 72851R 23 90 AUTOMATIC TRANSMISSION Final drive assembly MJ REASSEMBLY Checking the parts Check the condition of the teeth the bearing faces the washers on the planet wheels the splines the casing REASSEMBLING THE DIFFERENTIAL Differential with 2 planet wheels and 4 planet BITS wheels and a roll pin The band ring 24 is refitted on the press using In the casing place tool B Vi 883 without the bearing fitted the bakelite washer with the oilway at the sunwheel end use a 1 96 mm thick shim If the mesh clearance of the sunwheel with the planet wheels is too large use the 2 02 mm thick shim asunwheel immerse it in the
46. C TRANSMISSION Computer REMOVAL REFITTING The computer controls the earthing of the sole noid pilot valve as a function of the peripheral in formation and checks that all the electrical com ponents of the automatic transmission are work ing correctly Before removing the computer and its speed sen sor and multifunction switch carefully note the routing of the wiring and disconnect the battery REMOVAL Remove from the automatic transmission the multifunction switch C and its earth wire H depending on version and its seal the speed sensor with its seal disconnect the connectors and that of the load potentiom eter depending on version Remove the computer 889525 23 117 AUTOMATIC TRANSMISSION Computer REFITTING Check for the presence of the O rings T on the speed sensor and the multifunction switch 85651 2 85651G On the automatic transmission refit the speed sensor the multifunction switch and the earth wire G depending on version at H NOTE vehicles which do not have an earth wire G on the multifunction switch have one on the 6 track connector of the computer MB 88705R1 various locations depending on version 23 118 MJ PT p E Tee Z HM N m 88706R 88704R Replace the wires in their ringed sleeve Reconnect the connectors depending on version Put the computer on its mounting using the strap AU
47. Clean the casing faces and coat them with Loctite FORMAJOINT paste and fit a special ex change paper seal Couple the gear section casing to the final drive casing lock one sunwheel of the differential Put a pin in hole A of the driveshaft roll pin and ro tate using small movements in order to engage the splines of the various shafts Tighten the bolts to a torque of 2 daN m 23 72 AUTOMATIC TRANSMISSION Final drive assembly MB SPECIAL TOOLING REQUIRED Mandrel for fitting sunwheel seal Mandrel for fitting stop ring to sunwheel Mandrel for fitting bearings in separator housing Tool for centring converter seal from kit B Vi 1400 01 TIGHTENING TORQUES in daN m oo from the conver Bolts 8 mm for assembling the gear section casing on the final drive casing Bolts 8 mm for assembling the converter and differential casing on the separator housing Bolts for mounting stator shaft REMOVAL The parts must be removed and handled ona bench with a padded top rubber or thick plastic e Separating the casings Remove m 86374R theconverter theoil pump driveshaft e Converter and differential casing Separate the final drive casing from the gear sec tion casing REMEMBER THE NUT AT THE LEFTHAND SUNWHEEL END Remove the O ring 29 from the sunwheel Tap the base of the lip seal 28 with a pin drift and a small mallet so that it turns in its seat Once the seal
48. IC TRANSMISSION Gear ratios For vehicles C06 peat oo om mew 2nd 3rd 4 8 3 2 2 Gear reduction stepdown 2 069 1 241 0 827 1 655 Speed in km h per 1000 rpm 12 52 20 87 31 31 15 656 Tyres 155 70 R 13 For vehicles F40 Tyres 155 R 13 23 12 AUTOMATIC TRANSMISSION Specifications REPLACEMENT INSTRUCTIONS Damaged brakes or clutch 1st possibility Repair the gear section and clean the final drive oil cooler converter and check the hydraulic dis tributor 2nd possibility Change the gear section alone Adjust the end float and the oil pressure setting Or change the entire automatic transmission service exchange or new transmission The cleaning method is given in the Torque converter section Bearing s which is are noisy but not broken Change the bearing s and the filter Bearing s or other mechanical component damaged If the damage is extensive change the automatic transmission service exchange or new transmis sion For a service exchange Return the worn transmission with the packaging in which the new part was delivered Parts to be replaced after removal roll pins Oand square section seals lip seals paper seals bearings if they have had to be removed cirdlps differential bank MJ speedometer drive shaft MB speedometer drive gears if they have had to be removed theentir
49. IL AND RUN THE EN GINE lever in Park FOR SEVERAL MINUTES DRAIN THE AUTOMATIC TRANSMISSION AND REPLACE THE STRAINER Refitting Rotate the oil pump shaft and turbine shaft by hand to check that they turn freely Oil the white metal bush and the seal joint face Fit the torque converter and the retaining bracket B Vi 465 Protect the seal joint face with a plastic cap whilst the converter is being handled 86149G 23 45 AUTOMATIC TRANSMISSION Drive plate ATTENTION Both the torque converter and the drive plate have a mark on them These marks should line up with each other If they do not line up the converter will be offset by 120 when mounted which means that the ignition tim ing point mark will be read at the wrong time MB diameter 216 converter 86348G Dab of paint on the converter Dab of paint and pointed section cut out of drive plate MB diameter 227 converter On MB automatic transmissions fitted with a 227 converter the converter and plate do not have to line up no ignition target and no TDC mark on the converter all types 85851G Dab of paint on the converter Dab of paint on the drive plate the TDC park A is on the plate 23 46 AUTOMATIC TRANSMISSION Drive plate CHECK that the locating dowels are present on the engine and starter Place a support fitted with a dial gauge on one thatthe ignition sensor target on the drive of the cylinder block moun
50. ING TORQUES daN m Remove the shim K and the spacer Bearing nut on final drive pinion circlips 1 and 9 Bolt securing separator casing to the bolts mounting the separator housing and step down casing separate it from the step down casing Bolt securing step down casing to bearings 2 and 10 by separating circlips 3 converter casing 11 REMOVAL SEPARATOR HOUSING 23 99 AUTOMATIC TRANSMISSION Final drive assembly ML STEP DOWN CASING Remove Remove thecirclip 21 84447 1R the casing 26 the mounting bolts and separate the step down casing from the final drive casing Remove the final drive pinion on the press 84506 1R the output shaft and its pinion the speedometer drive gear 18 and and its shaft 19 using a small screwdriver 88208R the speedometer drive seal using tool B Vi 905 02 if the seal is stuck remove it using an angled tool the step down shaft 12 using a tool through the inspection cover for leverage 88209R the needle bearing 7 using tool FACOM U40 and U51B or similar AUTOMATIC TRANSMISSION Final drive assembly ML the lip seal 23 using tool B Vi 465 Using an extractor extract the bearing 88208 1 844435 Dismantling the final drive pinion 20 Dismantling the step down drive shaft 12 Unlock the nut 24 and remove it using B Vi 903 Remove parts 12 t
51. OUT SWITCHING OFF NP IGNITION POTENTIOMETER DEPENDING ON VEHICLE 3mm MB MJ AUTOMATIC TRANSMISSIONS 45 EN Oaa 5 E O L3 TEST 2 IGNITION ON Ch FULL THROTTLE KICK DOWN OR STARTER AUTHOR IN P ORN im CORRECT INCORRECT FI21601 Bargraphs on a red background represent a fault Bargraphs on a white background represent a status 23 140 AUTOMATIC TRANSMISSION Meaning of the bargraphs DISPLAY and MEANING OF THE BARGRAPHS IMPORTANT The information given below is only valid for computers found in the Vehicles involved sec tion TEST 1 After a road test with the vehicle stationary ignition on and engine running 0 Illuminated with the ignition on when the communication between the automatic transmission computer and the XR25 is established Illuminated when the circuit of solenoid pilot valve N 1 or N 2 is faulty Illuminated when the vehicle speed information supplied to the automatic transmission computer is wrong or absent IP Illuminated when the load information received by the automatic transmission computer is incoherent or absent IMPORTANT Vehicles B297 B294 X40 Switzerland and X537 X53B X573 before 04 91 have no fault finding signal relating to the load potentiometer The bargraphs will never illuminate for these vehicles If the potentiometer circuit is broken the vehicle will remain in 1st gear If the potentiometer circuit is short cir
52. RANSMISSION Final drive assembly ML the needle bearing 7 on the press fitting di Before coupling the step down casing to the mension 37 mm converter final drive casing check that the loca ting dowel A is in position and coat the faces of the casings with Loctite FORMAJOINT 88209R1 the step down shaft 12 88208R2 theoutput shaft 8 IMPORTANT the two bolts under the stator shaft must be coated with Loctite FORMAJOINT REASSEMBLING THE SEPARATOR HOUSING Refit circlips 3 and 11 with the notches on the same side 88209 1R speedometer seal using tool B Vi 905 02 anew speedometer drive gear with its shaft Check that the speedometer drive clips cor rectly into its shaft 88207 1R 23 105 AUTOMATIC TRANSMISSION Final drive assembly ML the bearing 10 using tool B Vi 947 ATTENTION allbolts mounting the separator the bearing 2 inserting a piece of strap iron housing must be coated with Loctite so as to keep the circlip open FORMAJOINT before being fitted On the output shaft refit 8 B vi 947 washer 28 thecirclip 1 and bring it under groove C To position the circlip 1 in its groove use tool B Vi 959 fitthe washer D from the tool onto the circlip place the crescent piece E from the tool in groove C and tighten the three bolts V un til circlip 1 enters its groove Ensure that 1 is correctly positioned
53. RENAULT Workshop repair manual AUTOMATIC TRANSMISSION Type Range Renault 5 Extra 1 Renault 9 11 Renault 19 Clio Twingo MB3 Renault 5 Renault 9 11 Renault 19 MJ1 Renault 18 Renault Fuego Renault 18 MJ3 Renault Fuego Renault 20 Renault 21 Renault 25 L 1 Renault Trafic Cancels and replaces Workshop Manual M R T A M Part Number 77 11 088 275 and N T N 1275 1599 1769 1770 2061 77 11 193 528 Edition Anglaise The repair methods given by the manufacturer in this copyrights reserved by Renault document are based on the technical specifications sae eae i opying or translating in part or in full of this current when it was prepared SOR ES A use Te serine pat br A lefence The methods may be modified as a result of changes numbering system 15 forbidden without the prior introduced by the manufacturer in the Toductio of written authority of Renault the various cOmponent units and accessories from which his vehicles are Constructed RENAULT 1997 AUTOMATIC TRANSMISSION Diagram Using Identification Gear change thresholds Gear ratios Specifications Parts to be replaced after removal Consumables Maintenance Piston Identification Number of discs Transmission operation Cross section and tightening torques in daN m Strainer Hydraulic distributor Solenoid valves Speedo shaft seal MJ ML Speedo drive MB Speedo drive J Differential s
54. THE CONNECTION BETWEEN THE COMPUTER AND THE XR25 In order to be able to make the connection bet ween the computer and the XR25 you must have the adaptor wire 18 supplied with cassette N 12 Connect connector K to connector 9 of the computer Connect connectors B and C to the plus and mi nus terminals of the battery in order to feed the XR25 Connect connector H to the XR25 To adjust the load potentiometer connect connector L to connector 10 of the load poten tiometer Carry out the fault finding and to do this refer to the section on Using the XR25 DG7001 23 138 AUTOMATIC TRANSMISSION General USING THE XR25 The XR25 is essential for all faults on the automa tic transmission regardless of the origin of the problems It is fitted with a microprocessor which allows r access to all information supplied by the va rious sensors the fault messages supplied by the computer to be read NN After a road test with the vehicle stationary igni tion on and engine running connect the XR25 Enter the code of the automatic transmission le e 1 The following will appear on the display 926565 Turn the selector to S8 23 139 AUTOMATIC TRANSMISSION XR25 fiche N 1 x 58 D 0 1 read 3tA 0o SOLENOID VALVES OR WIRING TEST 1 SPEED SENSOR Cm CHECKS AFTER ROAD TEST WITH
55. TOMATIC TRANSMISSION Multifunction switch REPLACEMENT Computer side strip back 65 mm of protective sleeve This operation consists of cutting the wire con necting the computer to the multifunction switch and replacing the switch with a new one Before cutting the wire check the multifunction switch Composition of the replacement kit 1 multifunction switch with earth wire fitted with a cable and a male connector 1 female connector 6 male pins Method 86332R1 Remove the multifunction switch from the auto strip the wires over 5 mm matic transmission and cut the wire to the same puta seal J on each wire length as the replacement wire crimps the connectors 86332R2 86332S1 23 119 AUTOMATIC TRANSMISSION Multifunction switch When refitting the wires in the connector ensure FITTING the same colours wires are connected opposite each other Push back the connector lock piece a Replacing a multifunction switch without an earth wire with a multifunction switch with an earth wire 8633252 There are computers connected to multifunction switches by seven wires and in this case cut the 7th wire yellow or white level with the sleeve on the computer side 86377R CUT THE EARTH WIRE E LEVEL WITH THE COMPUTER FEED 6 TRACK CONNECTOR more than one earth must not be present 85651 1R5 Check the presence of the O ring T and fit the multifunction switch on
56. X O 0 620 LEN FCO LAIN NN LEAL 104 NC 00 LAW 104 93 ETO LAIN 102 93 PAUP HADIYAL E MN HT SVU S00 ITN ZINIV ABP H TOIJV3LI 10 EN SL Lal d c 8 aea CHE 202 wof aP HA Z6cH 1 ee ad Lv 23 136 AUTOMATIC TRANSMISSION General THIS PART DEALS WITH VEHICLES FITTED AS STANDARD WITH AN OLD GENERATION COMPUTER PRESENTATION The computer 13 has a system for self checking the electrical components which is shown by the fault war ning light 8 illuminating on the instrument panel The fault warning light 8 should illuminate when the ve hicle s ignition is turned on and should extinguish either when driving at more than 1 8 mph 3 km h or after 3 seconds depending on version If the fault warning light 8 illuminates when driving the vehicle DO NOT TURN OFF THE IGNITION in order to memorise the type of fault to be searched for and connect the XR 25 test kit NOTE it is normal for the fault warning light 8 to flash very slightly during normal operation 85651 1R3 1 Vehicle speed sensor 8 Fault warning light 2 Load potentiometer 9and14 Fault warning light connector and XR 3 Solenoid pilot valves 25 connection 4 7 Six track connector 10 and 11 Load potentiometer connector 5 Multifunction switch 13 Computer 6 and 12 Solenoid valve connector 23 137 AUTOMATIC TRANSMISSION General ESTABLISHING
57. adaptor leads This type of test can differentiate between an electrical problem and an hydraulic problem This lead is in serted between the sealed connector and the computer 88870R 1 Order sockets their plugs and their seals 1 Part No 77 01 996 008 Part No 77 01 997 016 x 3 Part No 77 01 999 021 x 6 2 Part No 77 01 996 003 77 01 997 017 x 3 3 Part No 77 03 097 244 77 03 097 255 x 3 Some 1 mm cross section wire in 3 lots of 3 metre lengths 2 Assemble the sockets and their wires as shown in the diagram and melt the end of the plug 2 at B in the same way as and C 23 163 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 FAULT FINDING OF THE HYDRAULIC FUNCTION cont 3 Assembly on vehicle Disconnect 8 and 12 and fit connector 1 to 8 and 2 to 12 Connect connector 3 to the B Vi 958 88871G 4 Test Put dial R of the B Vi 958 on Auto Carry out a road test and check that the solenoid valves operate correctly see page 23 22 Check that the gears change simultaneously as a function of the electrical command and if incorrect the hydraulic distribu tor is faulty 23 164 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 CHECKING ADJUSTING THE LOAD POTENTIOMETER Check that the accelerator cable and kickdown are correctly adjusted beforehand Vehicle stationary Ignition off Disconnect the three track connector 10 of the wiring conne
58. and it remains extinguished when there is a fault turn the ignition off and disconnect the 6 track computer connector Carry out a starting test Does the vehicle start The fault is due to a permanent earth on track C of The fault is due to a non conformity in the starter the 6 track connector on the computer side motor relay wiring Turn the ignition off and check the Shunt as for manual gearbox version in place of operation of the multifunction switch between the relay tracks C and E of the 6 track connector computer Insulation fault in relation to earth on the line side between track C on the 6 track connector and Lever in P N R 0 to 3000 Q track 2 on the starter motor relay base Lever in R D 2 1 R infinity Repair if necessary or a high value on vehicles without a kickdown switch Do you note these values on testing Recheck your Cut the multifunction switch cable as if a replacement were being made diagnosis With the switch still in position on the automatic transmission repeat the previous tests at the switch side between the brown and red wires Are the measurements still incorrect yes Replace the multifunction switch Replace the computer Erase the memory if M 4 3 Validate the no load and full load values for the E7 version And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 252 AUTOMATIC TRANSMISSION Fault finding aid Chart
59. aph 10 RH and or LH illuminated 223 Bargraph 11 RH extinguished lever in P and or N 224 Bargraph 12 RH illuminated engine running 224 Bargraph 13 RH illuminated 224 Bargraph 17 RH and LH illuminated 224 2DMXTT1 0 23 207 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 1 RH EXTINGUISHED OR NO COMMUNICATION WITH THE COMPUTER Check that the battery voltage is gt 10 5 V Check that the fuse of the automatic transmission is not blown no After these checks does the fault persist yes If the XR25 is connected directly to the diagnostic socket check that the 3 track connector is correctly connected between the diagnostic socket and the computer Check ensure the continuity of the line between the 3 track connector and the no Success diagnostic socket Check ensure that track 2 of the diagnostic socket is earthed and the presence of battery on track 6 After this operation does the fault persist yes Check the computer feed is correct Earth through wire on multifunction switch after ignition on track of the 6 no gt track connector on the wiring side After checking repairing does the fault persist yes Replace the computer if the fault persists after checking the wiring on the 6 track connector Erase the computer memory On E7J version erasing the memory requires the no load and full load values to be reprogrammed And vehicl
60. ar no bargraphs should be illuminated Illuminated when using the memory of the XR25 NOTE To determine faults refer to the Fault finding charts to be used from the bargraphs section 23 199 AUTOMATIC TRANSMISSION Additional tests READING THE VARIOUS Connect the XR25 to the diagnostic socket Put the selector on S8 Turn on the ignition Enter the specific automatic transmission code D 1 4 Then enter s followed by 2 figures in order to gain access to the various items of information sup plied by the computer lo 1 Gear engaged The following be read when the transmission is operating normally Lever Ignition on Vehicle position engine off moving R I rd I rd N O P D I rd I rd 2 rd 3 rd 2 1 2 1 2 2 2 1 I I I I Manoeuvre to be performed with care only when fault finding on the automatic transmission 2 Load potentiometer Value expressed in of accelerator control at rest H Value of 89 1 no load on accelerator pedal PL and in test conditions 23 200 AUTOMATIC TRANSMISSION Additional tests x o e Engine speed Value expressed in rpm 4 en It varies from 0 to 6000 approximately depending on version gt 1 2 Load potentiometer transformed load Value expressed in accelerator control in full load position PF Value less than 6 25 full load on accelerator pedal for kickdown func
61. aring using the press so that it is flush with the casing face 85704R A Crimping depth 0 9 to 1 3 mm Crimp the bearing using a cold chisel paying at tention to the crimping depth AUTOMATIC TRANSMISSION Final drive assembly MB Output bearing shaft 34 Fitting the differential in the casing NEVER USE THE CONVERTER CASING AS A SUP In all assemblies where washers 40 are required PORT see page 137 place them in front of the spring washer 24 and ensure 24 is the right way Fit a block C under the stator shaft round Offer up the needle bearing 34 and push it on using the press so that it is flush with the stator shaft face 44 mue n SN NS XX MAN INT MXYAX ah h m 85798R Electronic version Fit sensor wheel 37 and 39 38 88942R Speedometer drive gear 35 The drive gear and its shaft are refitted by hand The shaft must be correctly positioned in relation to the gear locating spigots owing to the elastic ity of the lips of the shaft Using a mallet ensure they are properly clipped in 86374R3 Place the differential in the converter and diffe rential casing and fit it on the press 860535 23 81 AUTOMATIC TRANSMISSION Final drive assembly MB On the press Seal 28 is refitted using tool B Vi 945 which consists of Place a wooden block under the crown wheel aseal protector A Ensure that the circl
62. ay from high voltage sources All high voltage cables should be properly connected well sleeved and should not 90624R be touching any metal objects A Vehicle wiring THE AUTOMATIC TRANSMISSION CONTROL MAY BE SUBJECT TO INTERFERENCE IF THIS IS NOT THE CASE 23 115 AUTOMATIC TRANSMISSION Kickdown Located at the end of the accelerator pedal travel CHECKING this earths a circuit of the computer which in cer tain cases changes down to a lower gear Disconnect the kickdown wire and connect a test bulb in its place connected to the battery feed Accelerate fully and the light should illuminate check the black earth wire adjust if necessary NOTE control units are used to check the kickdown without removing the wiring ADJUSTING The end stop K should move by 3 mm in the full load position Method draw a line T on the sleeve 3 mm from the kickdown cover in the full load position the line should line up with the edge of the cover If it does not move the sleeve stop clip or the stop device to obtain this result 76417R carry out the check using the light or control units The kickdown tends to be removed and incorpo check that the wire allows the idle end stop to rated into the end of travel of the load potentio be reached meter no wire at D on the 6 track connector It is adjusted by adjusting the load potentiometer see Fault finding section checking B Vi 958 23 116 AUTOMATI
63. chisel but only for metal shelled seals old fitment 119555 LEER For rubber encased seals new fitment 86457 1G Remove the sealing ring using tool B Vi 1405 with the ring marked 41 50 inserting it very Check the condition of the smooth part of the sta straight Then turn it through approximately one tor shaft at 1 revolution and extract the seal by progressively tightening the bolt of the extractor 23 49 AUTOMATIC TRANSMISSION Converter seal Refitting SPECIAL NOTES NOTE depending on when the MB automatic FIT A RUBBER ENCASED SEAL ONLY transmissions were manufactured the converter casing may or may not have grooves 2 and 3 Position the lip seal oiled using tool B Vi 1402 take care not to allow dirt to enter when fitting the seal B Vi 1402 11954R Refit the converter lubricating the face of the seal 86457 1R with automatic transmission oil If the casing does have grooves follow the in structions below remove the sharp edges of the grooves 2 and 3 at the bore after fitting the seal fill grooves 2 and 3 with Loctite SCELBLOC 23 50 AUTOMATIC TRANSMISSION Converter seal MJ automatic transmission Removal When the converter has been removed remove the seal use a tool without any mould seams so that the casing bore is not damaged Check the condition of the smooth part of the stator shaft at 1 Refitting Lightly grease the ne
64. ck 1341 1342 1351 1352 1362 Grey 1 1 001 No PAS CA L 225 mm 1341 1342 1351 1352 1362 Yellow 1 1 500 with PAS L 660 mm 501 1343 1353 1363 1277 1279 1 MJ3 301 29 297 29 L 243 mm 350 010 012 112 120 122 110 29 B29B 297 Blue 2 MJ3 015 L K 483 L K 48K L K 489 L 247 mm 016 115 116 125 126 800 801 B C 403 B C 408 B C 40 Green 2 MB3 All types L423 B C 373 L 243 mm MB1 000 001 002 003 007 L423 L426 Red 1 1 500 L 252 mm 501 502 503 C40J C403 B Red 2 MB1 500 L 243 mm 501 502 503 2 57 3 2 1 024 1 243 026 Orange 2 1 029 L 231mm F40 Violet 2 MB1 031 L 347 mm 038 L423 B C 373 DAI White 1 MB1 500 with air pre filter L 324 mm 501 502 503 23 17 AUTOMATIC TRANSMISSION Maintenance 1344 1354 Yellow 1 MJ3 200 L 240 mm 201 L K 48A Grey 2 MJ3 761 deeper sump L 247 mm 762 B Red 2 MB3 003 53B L 243 mm 005 L B Yellow 2 MB1 023 C 537 L 334 mm 027 L Light grey 2 MB1 033 L 338 mm C373 Green 2 MB1 001 011 019 L 243 mm 002 013 021 003 015 504 007 017 MB3 B373 1 MB1 500 L 252 mm 501 502 503 23 18 AUTOMATIC TRANSMISSION Maintenance 88860R Jj 91193R1 23 19 AUTOMATIC TRANSMISSION Identification Identification of pistons F1 F2 DI2331 DI2332 Number of discs
65. ck the reversing lights bulbs 44 3Q wiring D and earth 0 to 0 5 Q Press the accelerator pedal fully down Check the kickdown Check the adjustment and the operation of the accelerator cable Foot removed D and earth Check the wiring from accelerator pedal infinity 86377R3 Tf there is no wire at E the earth of the computer is in the multifunction switch see page 23 157 Tf there is no wire at D the kickdown is incorporated into the load potentiometer 23 167 AUTOMATIC TRANSMISSION Fault finding Checking the connectors CHECK WITH THE B Vi 958 Connect the B Vi 958 to the battery SIX TRACK CONNECTOR cont Connect the wiring P following the colours 86326R A Red B Blue TEST using a single wire on the tested component Voltmeter function Measuring points using the blue wire only Action on the vehicle B Vi 958 O70 O76 Tf not correct measuring point using red wire Battery voltage Fuse Condition of terminals oxidation Fuse No voltage present Wiring connection Continuity of wires 23 168 AUTOMATIC TRANSMISSION Fault finding Checking the connectors Multifunction switch Disconnect the 6 track connector and check on the computer side with an ohmmeter or the B Vi 958 zone B having disconnected the battery beforehand During the test check that the ignition is off and that the computer is isolated from the vehicle earth do
66. correctly and replace it if necessary After cleaning replacement does the fault persist yes Carry out a complete check of clutch E2 Refer to MR T A M 3DMXTT1 0 23 255 AUTOMATIC TRANSMISSION Fault finding aid Chart 29 No reverse gear or engine braking in 1st gear hold Reversing lights operate normally If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect FI ae gt Correct Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes Check the condition of the oil Is it dirty Check the hydraulic distributor sequence solenoid valve Does it slide normally Carry out a complete check of brake F1 and refer to MR T A M for instructions on replacement piston seal F1 piston mounting circlip Clean the hydraulic distributor and replace it if the fault persists 3DMXTT1 0 23 256 AUTOMATIC TRANSMISSION Fault finding aid Chart 30 No drive with lever in D and 2 but drive in 1 only If the warning light is operational and it remains extinguished when there is a fault the freewheel is damaged Refer to the instructions for replacement in MR T A M Chart 31 Buzzing type noise in P and N when cold If the warning light is operational and it remains ex
67. cting the automatic transmission computer to the carburettor Connect the three track connector 1 of the potentiometer to that of the B Vi 958 16 Connect the plugs 14 to the battery Dial I2 on Y 1 CHECKING THE ADJUSTMENT OF THE LOAD POTENTIOMETER I2 on Y Press accelerator LIGHT 9 down fully CORRECT INCORRECT or not adjusted L O 85651G1 2 ADJUSTING THE POTENTIOMETER Slacken the two potentiometer mounting bolts V slightly on the carburettor Keep the carburettor throttle valve fully open using the accelerator pedal and turn the potentiometer slightly to illuminate the light 9 Then retighten the bolts V in the position where 9 remains illuminated throttle valve still fully open If the warning light 9 does not illuminate check its wiring and the potentiometer Replace it if faulty Adjust the potentiometer after replacing or removing it IMPORTANT When washing a carburettor remove the load potentiometer 23 165 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 CHECKING ADJUSTING THE LOAD POTENTIOMETER cont 3 SPECIFIC CASE e Trafic ML 1 1344 1354 Same connection Same connection Dial I2 on X Adjust the angular position of the quadrant using the sleeve stops 1 on the potentiometer and in jection pump side so that the light 9 illuminates in the full load position Perform the test again in the full load position and readjust if necessary If ligh
68. ction in position N and P on track C engine speed information Asolenoid pilot valve connector 12 on track A solenoid valve 1 on track B solenoid valve 2 on track C solenoid valves positive feed A six track connector 4 on track A reversing lights feed on track B reversing lights on track C starting prohibition on track D kickdown information on track E air conditioning information on track F positive after ignition A three track connector 9A on track A instrument panel fault warning light on track B diagnostic connection on track C diagnostic connection 23 189 3 4and 7 5 6 and 12 Vehicle speed sensor Connection between injection and automatic transmission computer Solenoid valves Six track socket Multifunction switch and earth Solenoid valve connector General 23 190 8 9A and 14A 10 and 11 13 17 AUTOMATIC TRANSMISSION 85651 2R1 Fault warning light Warning light and diagnostic socket connector Intercomputer connector Computer Diagnostic socket AUTOMATIC TRANSMISSION General DEFECT MODES IN THE EVENT OF PROBLEMS If one of the peripheral transmission components or the feed 12V develops a fault the computer causes the warning light to illuminate and implements defect modes for the transmission which can vary depending on the faulty components Warning Memori Forward one light sed ars gears Comments illumi
69. cuited gear changes will be delayed 23 141 TEST N 2 Engine off ignition on vehicle with kickdown compensator vehicle without kickdown compensator AUTOMATIC TRANSMISSION Meaning of the bargraphs Bargraphs 4 and 5 represent the position of the gear selector lever as a function of the information supplied by the multifunction switch Selector in 1st gear hold Bargraphs 4RH and 5RH are illuminated Selector in 2nd gear hold Bargraph 4RH is illuminated bargraph 5RH is extinguished Selector in P R N D Bargraphs 4RH and 5RH are extinguished Illuminated when the kickdown supplies information to the automatic transmission computer There are two types of kickdown Opening kickdown Accelerator cable at rest and contacts closed Closing kickdown Accelerator cable at rest and contacts open Illuminated when the gear selector lever is in the P or N position Starting is authorised NOTE To determine a fault refer to the Fault finding charts to be used from the bargraphs section 23 142 AUTOMATIC TRANSMISSION Adjusting the load potentiometer Connect connector L of the adaptor lead 18 to connector 10 of the load potentiometer Do not enter the automatic transmission code On the keypad enter Iv 1 Adjustments are performed at full load On the upper part of the bargraphs the bargraph located in the left hand column is moving bargraph 5 RH is fixed
70. d Erase memory GOx at P N End test G134 P N h x illuminates in P N start author 12 Load pot load Iiiuminated Eng stopped converted Extinguished Eng running 94 Computer No gd e 14 SOLENOID CHECK CONTROL MODES G 15 llumin if sotenoid fed 01 SV test and AC relay then check status of TR BR BE bar 16 0 ST PN 2ND 3RD graph 1f extinguistied Evi EV2 EV1 EV2 EV1 EV2 CORRECT 17 Note Line SR is illuminated on vehicle without compensator d XR25 MEMORY 0 C3 Hs ANG FI21626 Bargraphs on a red background represent a fault Bargraphs on a white background represent a status 23 195 AUTOMATIC TRANSMISSION Meaning of the bargraphs DISPLAY AND MEANING OF THE BARGRAPHS IMPORTANT HEAT fiat I gt The information given below is only valid for computers given in the Vehicles concerned section 1 Illuminated when the computer no longer performs its function Illuminates when the ignition is turned on when the communication between the 1 automatic transmission and the XR25 is established 2 Illuminated when the computer cannot identify the position of the gear lever Illuminated when the connection transporting the load information from the 3 injection computer to the automatic transmission computer is faulty Illuminated when the load information received by the automatic transmission 4 computer is incoh
71. d 71 121 1344 1354 1277 DAD Pedal position Pallad amp 4 1 Full load The kickdown switch is integrated into the Kickdown 65 computer These values are given as an example 23 9 AUTOMATIC TRANSMISSION Gear change thresholds C06 Pedal position Kickdown 13 106 The kickdown switch is integrated into the computer The figures in the tables indicate the theoretical average gear change speeds actual time speed These figures may vary depending on the ac cepted tolerance limits on the component units and tyres fitted Noload Foot off accelerator pedal Full load Kickdown switch disconnected full throttle Kickdown Kickdown connected full throttle 23 10 AUTOMATIC TRANSMISSION Gear ratios For vehicles B53A C53A L53A B537 C537 L537 Gear reduction stepdown 2 069 1 241 0 828 1 655 Overall reduction 7 999 4 799 3 199 6 399 Speed in km h per 1000 rpm 12 937 21 562 32 343 16 171 For vehicles B53B C53B L53B Gear reduction stepdown 2 069 Overall reduction 7 370 Speed in km h per 1000 rpm 14 042 23 403 35 105 17 552 For vehicles fitted with 165 70 R13 tyres 2nd For vehicles B 573 C 573 1 5 1 Emm pa fe Gear reduction stepdown 2 069 1241 0 828 1 655 Overall reduction 7 370 4 422 2 948 5 896 Speed in km h per 1000 rpm 13 431 22 385 33 578 16 789 For vehicles fitted with 165 65 R13 tyres 23 11 AUTOMAT
72. d off the ignition replace the vehicle speed sensor Refer to the replacing instructions in MR T A M If the fault persists replace the computer Erase the computer memory if the new one is an M 4 3 1DMXTT1 0 23 147 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 3 RH ILLUMINATED Load potentiometer fault Check that the potentiometer is correctly connected to the harness and check the condition of the wiring Check the 5 volt feed to the potentiometer Is there a voltage of 4 5 0 5 volts on track B of the potentiometer connector C on the Trafic no yes Replace the computer if the wiring between Check adjust the load potentiometer refer the computer and the connector is not to MR T A M faulty After the repair does the fault persist Erase the memory if the new computer is an M 4 3 yes Change and adjust the potentiometer Refer to MR T A M Does the fault persist Check the condition under the bonnet of the automatic transmission wiring but also of the high voltage leads After the repair does the fault persist Replace the computer and erase the memory if fitting an M 4 3 computer 1DMXTT1 0 23 148 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 4 5 RH ILLUMINATED Coherence fault between the lever position and the XR25 display Ignition off disconnect the 6 track connector from the computer Is track C
73. d top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Adjust the idle speed lever in position D Is the vehicle still showing the fault ne Carry out a general check of the condition of the automatic transmission sealing of the piston of E1 sealing of the piston of E2 When cold If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary 3DMXTT1 0 23 244 AUTOMATIC TRANSMISSION Fault finding aid Chart 16 Banging when changing from position N to D 2 1 or R If the warning light is operational and it remains extinguished when there is a fault check and if necessary adjust the idle speed Also check the condition of no gt the engine and transmission assembly mounting pads and the condition of the driveshafts After the operation does the fault persist Check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Adjust the idle speed lever in position D Is the vehicle still showing the fault no d Connect pressure gauge BVI 466 07 and measure the
74. d when there is a fault check the operation of the kickdown switch Refer to MR T A M checking the connectors section no gt Correct Repair if necessary After the operation does the fault persist yes For 12 is the transformed load less than 12 5 for full load 6 25 for E7 your diagnosis yes no for all types except E7 no for E7 Recheck Is the throttle at the stop for full load Is the throttle at the stop for full load gt no Adjust the accelerator Adjust the accelerator yes control control Does the fault persist Does the fault persist vac yes no Adjust the load potentiometer Correct B Erase the computer memory no revalidate the full load and no load values Does the fault persist yes Check the load potentiometer from the injection side And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 271 AUTOMATIC TRANSMISSION Fault finding aid Chart 51 No kickdown at full load or kickdown threshold abnormal at full load cont Versions fitted with M4 3 type computer without kickdown switch If the warning light is operational and it remains extinguished when there is a fault for 12 is the transformed load less than 6 25 for full load no for all types except E7 no for E7J Is the throttle at the stop for full load yes Recheck Is the throttle at the
75. de of the automatic transmission on the keypad The following appears on the display f then Bie You should use fault finding fiche N 24 Turnon the ignition but do not start the en E AERAJ Turn the selector to S8 You should use fault finding fiche N 26 23 193 AUTOMATIC TRANSMISSION General MEMORY FUNCTION USING THE XR25 The memory function using the XR25 is used to store the values of the various parameters in the memory in order to read them one after the other and to check the coherence of them all Once XR25 gt computer communications have been established to obtain this function enter at the moment chosen by the user 23 194 AUTOMATIC TRANSMISSION Fiche XR25 N 26 3t 58 code D 1 4 read 3 83 i CODE PRESENT zm 2 iF ILLUMINATED LEVER POSITION INCORRECT 3 wa IF ILLUMINATED AT INJ COMP CONN DEF iF ILLUMINATED DATA RECEPTION DEFECT INJ METERING 5 IF ILLUMINATED INJ POTENTIOMETRE CIRC DEF 6 mE mu IF ILLUMINATED VEHICLE SPEED DEF IF ILLUMINATED SOL 8 o EVT t gt CIRCUIT DEF Eve 9 IE ILLUMINATES ACCELERATOR FULL ILLUMINATES E IF 10L R EXTING LOAD SEE NOTE IF ILLUMINATED VALIDATE ACCEL FULL LOAD RELEASE AFTER 10 C DISPLAYING APF BY KEY GO C3 If display 3 t A 2 see card no 24 ADDITIONAL CHECKS AUTOMATIC TRANSMISSION 6 sear engagea 02 Load no loa
76. delay Chart 15 Banging when changing from position N toD 2 1orR Chart 16 3DMXTT1 0 23 224 AUTOMATIC TRANSMISSION Fault finding aid A PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING cont with the knowledge that the warning light is working correctly cont PROBLEMS STARTING OR OPERATING THE VEHICLE cont In reverse gear No reverse drive No reverse drive permanent And the engine races when changing from 2 3 and the automatic transmission seems to change into neutral Chart 28 No engine braking in 1st gear hold normal operation of reversing lights Chart 29 Vehicle does not drive in forward gear or reverse gear Chart 44 Vehicle does not drive in R D 2 and 1 when warm only the vehicle starts again after being stopped for a few minutes fault which can be repetitive Chart 26 No reverse gear when warm or bang when engaging reverse when reaccelerating Chart 47 Juddering in reverse gear Juddering in reverse gear Chart 5 Juddering in reverse gear and skidding when starting with lever in D Chart 7 Juddering in reverse and skidding when changing from 2 to 3 Chart 7 Slipping in reverse gear Slipping in reverse gear Chart 3 Slipping in reverse gear and no engine braking in 1st gear hold Chart 47 Banging when starting or when engaging reverse gear Banging when starting in R with engaging delay Chart 47 Banging when engaging position N to D 2 1 or R Chart 16 Banging when engaging reverse gear
77. ds Illustration reference Description B Vi 28 01 00 01 227 301 Extractor with interchangeable jaws 7162551 68997 151 Set of 3 drifts for fitting 5 mm roll pins B Vi 31 01 00 01 259 401 y 00 01 322 500 Drift for fitting 4 and 10 mm roll pins 69001S1 2 Tool for replacing converter seal o gt Vi 465 00 00 046 500 Bracket for holding converter 70800S1 B Vi 1215 01 0000121501 Oil pressure checking kit 7630251 Castellated spanner for adjusting differential B Vi 645 00 00 064 500 play 77746S1 B Vi 715 Locally made tool in accordance with drawing on page 23 131 B Vi 805 00 00 080 500 Spanner for differential nut 8054552 23 127 AUTOMATIC TRANSMISSION Special tooling Methods Description reference Illustration B Vi 883 00 00 088 300 Tool for fitting differential band ring B Vi 902 01 00 00 090 201 Tool for fitting circlips B Vi 903 00 00 090 300 Ring spanner for final drive pinion nut Tool for replacing speedometer drive shaft B Vi 905 02 00 00 090 500 seal boxed set 00 00 090 600 Tool for measuring torque 8486351 00 00 094 500 Mandrel for fitting sunwheel seal 00 00 094 600 Mandrel for fitting spring ring on sunwheel Mandrel for fitting bearings in separator 00 00 094 700 i casing 860975 23 128 Illustration 86104 15 86424R 8613751 900285 AUTOMATIC TRANSMISSION Special to
78. e a diagnostic socket check the special wiring is correctly connected red terminal to battery black terminal to battery and green terminal to fault warning no Success light output Check the continuity of the line between the 2 track connector and track 7 of the diagnostic socket Check ensure that track 2 of the diagnostic socket is earthed and the presence of battery on track 6 After this operation does the fault persist yes Check the computer feed is correct Earth through wire on multifunction switch earth on track E of the 6 track connector on the first version no after ignition on track F of the 6 track connector on the wiring side After checking repairing does the fault persist Replace the computer if the fault persists after checking the wiring on the 6 track connector Erase the computer memory if an M4 3 computer is fitted 1DMXTT1 0 23 145 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 1 RH ILLUMINATED Fault on solenoid pilot valve s This solenoid pilot valve fault may be stored due to the drop in supply voltage 5 volts of the load potentiometer supplied by the automatic transmission computer In the event of a short circuit between tracks B and C of the load potentiometer the 1st fault considered by the computer will be a solenoid valve fault It is therefore necessary to test the circuit of the load potentiome
79. e free wheel if there is a problem the quadrants with the drive hub if they are seized in the hub Consumables LOCTITE FORMAJOINT LOCTITE FRENETANCH LOCTITE SCELBLOC Transmission oil ELF RENAULTMATIC D2 or MOBIL ATF 220 Final drive oil SAE 80 W or 75 W 50 ml bottle 24 ml bottle 24 ml bottle 23 13 Housing joint faces 1 drop on converter drive plate bolt at crankshaft end 1 drop on converter seal MB Immersion of all parts before assembly except those for ML final drive Immersion of final drive components ML AUTOMATIC TRANSMISSION Maintenance MB MJ automatic transmissions have a single oil level and a single oil grade for all sections converter final drive gear section ML type automatic transmission has two different oil levels and grades 1 Oil for MB MJ automatic transmission and for ML converter and gear section Grade ELF RENAULTMATIC D2 otherwise use MOBIL ATF 220 Capacity in litres approximately AT ML Theoretical total 5 After oil change 2 5 2 Oil for ML final drive section API GL5 Oil grade 4 or MIL L2105 B or C SAE 80 W Hot and temperate countries Viscosity SAE 75 W Cold countries Capacity in litres Final drive 0 8 23 14 AUTOMATIC TRANSMISSION Maintenance DRAIN REFILL ML MB and gear sections The oil must be drained when the engine is cold and with dipstick and plugs A removed Allow the oil to drain o
80. eal MB Differential seal MJ Differential seal and nut ML Converter Drive plate Stator shaft Converter seal Gear section casing Final drive assembly MB Final drive assembly MJ Final drive assembly ML Exploded view Exploded view of mechanisms Final drive exploded view MJ Final drive exploded view MB Computer and wiring Kickdown Computer Multifunction switch Speed sensor Oil pressure Vacuum capsule Special tooling Contents Page 23 1 23 3 Fault finding Introduction 23 4 Vehicles concerned 23 7 23 11 FICHEN 1 23 13 General 23 13 XR25 fiche 23 13 Meaning of the bargraphs 23 314 Adjusting the load potentiometer 23 20 Fault finding using bargraph 23 20 illumination 23 21 Fault finding Control unit B Vi 958 23 23 Fault finding Checking connectors 23 27 23 32 23 37 FICHE N 24 23 38 General 23 39 XR25 fiche 23 40 Meaning of the bargraphs 23 41 Additional checks 23 42 23 43 FICHE N 26 23 44 General 23 48 Meaning of the bargraphs 23 49 Additional checks 23 52 23 73 FICHES N 24 and 26 23 86 Fault finding using bargraph 23 98 illumination 23 109 23 110 23 111 23 112 23 116 23 117 23 119 23 122 23 124 23 126 23 127 Page 23 132 23 133 23 137 23 140 23 141 23 143 23 144 23 152 23 167 23 173 23 179 23 180 23 183 23 189 23 195 23 196 23 200 23 207 23 223 AUTOMATIC TRANSMISSION Diagram This diagram represents an automatic transmission Type
81. earing A is either mounted on a stator shaft which can be dismantled diameter 227 converter or which cannot be dismantled diameter 216 con verter 23 75 Stator shaft which can be dismantled Use tool FACOM U 40 U 50 bearing A and extract the 13 Stator shaft which cannot be dismantled ATTENTION this must only be removed in excep tional cases as the bearing is mounted in the sta tor shaft and press fitted onto the converter ca sing there is a risk of loosening the stator shaft if the following method is not followed Using tool FACOM U 40 U 50 dowel n 7 place the tool so that it is pressing on the stator shaft and extract the bearing A d AUTOMATIC TRANSMISSION Final drive assembly MB e Stator shaft IDENTIFICATION Stator shaft which can be dismantled Stator shaft which cannot be dismantled Assembly with Assembly with Renault diameter 227 converter Verto diameter 216 converter cS LOW E L m 9 A ERE EE ER 24 a OU 1 i il i Li i ram VATI Pump shaft length 324 mm Pump shaft length 334 mm Turbine shaft length 284 mm Turbine shaft length 294 mm Remove the bolts A and extract the shaft When refitting ensure that the paper seal B is fitted and that the O ring C is in good condition Tighten the
82. ears Earth feed RP Change to 3rd when fault appears Solenoid valves 1 RP Change to 3rd when fault appears and 2 Computer RP Change to 3rd when fault appears Vehicle speed RP Change to 3rd when fault appears Multifunction switch RP No longer recognises imposed gears Potentiometer RP The load is set to 50 All types except B297 B29E X40 Switzerland and X537 X53B X573 before 04 91 23 175 AUTOMATIC TRANSMISSION General SETTING UP THE CONNECTION BETWEEN THE COMPUTER AND THE XR25 To be able to make the connection between the computer and the XR25 you must have an adap tor lead 18 supplied with cassette N 12 Connect the connector F to the computer connector 9A Connect connectors B and C to the positive and negative terminals of the battery to feed the XR25 Connect the connector to the XR25 Carry out a fault finding procedure To do this re fer to the using the XR25 section 13 DG7002 23 176 AUTOMATIC TRANSMISSION General USING THE XR25 new generation computer fit ted to a vehicle in after sales The XR25 is essential for all faults on the automa tic transmission regardless of the origin of the faults It has a microprocessor which r provides access to all the information supplied by the various sensors Fault finding messages to be read supplied by the computer Ny the non read only memory of the comput
83. ectly cont PROBLEMS STARTING OR OPERATING THE VEHICLE In forward gears No forward drive No forward drive permanent No drive with lever in D or 2 but drive in 1 only Chart 30 The vehicle does not move forward in D 2 and 1 but neutral park and reverse are correct Chart 20 Vehicle does not drive in forward gear or reverse gear Chart 44 Vehicle does not drive in R D 2 and 1 when warm only the vehicle starts again after being stopped for a few minutes fault which can be repetitive Chart 26 No reverse gear when warm or bang when engaging reverse when reaccelerating Chart 47 Starting possible in all selector lever positions Chart 25 The vehicle moves forward or backwards in N The vehicle moves forwards or backwards with the lever in N and starter motor position and reversing lights offset Chart 17 The vehicle moves forwards or backwards with the lever in N P position operational starter motor action normal Chart 19 Slipping when starting In forward or reverse gear but operating normal above 12 5 mph 20 km h in forward gear Chart 2 For all forward gear lever selections without engine racing normal operation above 45 55 mph 70 80 km h in no load position no sensation when changing gear Chart 1 Skidding with engine racing when starting In position D or 2 but not in 1 sometimes intermittently Chart 4 Lever in D and juddering in reverse Chart 7 Banging when starting with lever in D 2 and 1 with engaging
84. ed disc one flat disc and one line disc should be fitted alternately 88963R IMPORTANT Take care not to mix the F2 and E2 discs PRE ASSEMBLY OF THE FREE WHEEL AND RE VERSE GEAR TRAIN CHECKING THAT THE ASSEMBLY IS CORRECT The dimension between the end of sunwheel P and the joint face must be 40 6 7 mm VED _ AU 2292 F 7 n DI2344 NOTE The components of the free wheel should only be dismantled in exceptional circumstances 88961 1R 23 64 AUTOMATIC TRANSMISSION Gear section casing IMPORTANT Circlip 20 part number 77 04 002 CHECKING THE OPERATION 420 must be fitted Ensure that the piston is working properly by blowing compressed air through hole 88963 2R A Offer up the assembly and rotate the reverse gear train so that the brake notches are in line with their locations The operating clearance for brake F1 should be between 0 8 and 2 7 mm for MB 1 1 and 3 1 mm for MJ ML 86069G Check that the piston moves backwards and for wards properly 860225 23 65 AUTOMATIC TRANSMISSION Gear section casing ADJUSTING THE REVERSE GEAR TRAIN The aim of the adjustment is to restrict the dis placement of the reverse gear train by determin ing the thickness of the plastic shim 19 The average clearance should be 0 4 mm The adjustment is made in two stages 1 At the gear section casing end Check that stop 18 is on the sunwheel and that there is
85. ensor target electronic ver sion Spacer electronic version Spring electronic version Adjusting washer 23 108 AUTOMATIC TRANSMISSION Exploded view gear mechanisms DIAGRAM 1 85525R1 23 109 23 AUTOMATIC TRANSMISSION Exploded view final drive MJ 2 DIAGRAM N Parts not on a differential with two planet wheels 23 110 AUTOMATIC TRANSMISSION Exploded view final drive MB DIAGRAM 3 86374 1R6 23 111 AUTOMATIC TRANSMISSION Computer and wiring Original fitment XR fiche N 1 85651 1R3 1 Vehicle speed sensor 8 Fault warning light 2 Load potentiometer 9and14 Fault warning light connector and XR25 3 Solenoid pilot valves connection 4and7 Sixtrack connector 10 and 11 Load potentiometer connector 5 Multifunction switch 13 Computer 6and12 Solenoid pilot valve connector 23 112 AUTOMATIC TRANSMISSION Computer and wiring 2nd fitment XR fiche N 24 4 and 7 5 6 and 12 8 Vehicle speed sensor Load potentiometer Solenoid pilot valves Six track connector Multifunction switch Solenoid pilot valve connector 85651 1R4 9and14 Fault warning light connector 9A Fault warning light connector and XR25 connection 10 and 11 Load potentiometer connector 13 Computer 15 and 16 Adaptor lead connector Fault warning light 23 113 AUTOMATIC TRANSMISSION Computer and wiring 2nd fitment XR fiche N 26 85651 2R1 1 Vehicle speed sensor 8 Fault wa
86. er to be erased Use fault finding fiche N 24 If you are in doubt the fault finding fiche to be used can be ascertained using the XR25 Connect the XR25 Enter the code of the automatic transmission on the keypad The following appears on the display f then Bie You should use fault finding fiche N 24 Turnon the ignition but do not start the en E JAERI Turn the selector to S8 You should use fault finding fiche N 26 23 177 AUTOMATIC TRANSMISSION General MEMORY FUNCTION USING THE XR25 The memory function using the XR25 is used to store the values of the various parameters in the memory in order to read them one after the other and to check the coherence of them all Once XR25 gt computer communications have been established to obtain this function enter at the moment chosen by the 0 23 178 Fiche n 24 7 AUTOMATIC TRANSMISSION Fiche n 24 Fiche XR25 N 4 code D 1 4 read 3rRe 2 mt ir ILLUMINATED CHECK LEVER POSITION 3 iF ILLUMINATED POT DEF op e G BIN iF ILLUMINATED VEHICLE SPEED DEF Bm o ILLUMINATED SOLVANE NM 9 Cam iiuweaTES FULL ACCELERATOR LOAD see nore Rel 10 if display 3 1 3 see card 0 26 ADDITIONAL CHECKS 9k AUTOMATIC TRANSMISSION 02 Load pot No 1621 LA Erase memory GOwx in P N Endoftest G13 lluminates in P N S
87. er to MR T A M Chart 35 Oil leaks after replacing the computer Replace or fit the O rings on the speed sensor and the multifunction switch 3DMXTT1 0 23 259 AUTOMATIC TRANSMISSION Fault finding aid Chart 36 Oil leak Wash the automatic transmission Top up the level and apply talc no Can the origin of the leak be detected yes What is the origin of the leak Replace the sunwheel seals Does the leak persist yes Fit seal Part Number 7700729392 after cleaning the casings Does the leak persist Leak from gear section final drive yes casing seal Leak from base of dipstick tube Replace the O ring s on the dipstick tube After the operation does the yes MJ type automatic transmission leak persist Replace the oil remembering to shake the can before pouring the oil in anti emulsion product at the bottom Replace the dipstick with an anti emulsion 5 type dipstick see MR T A M After the operation does the leak persist Leak from top of dipstick tube Leak from pressure measurement plug Seal this plug with adhesive loctite aj or replace the seal on the cylindrical plug yes oil on the sump no After the operation does the leak persist Ensure the O rings on the speed sensor and sealed connected are present Repair if the seals are missing 3DMXTT1 0 23 260 AUTOMATIC TRANSMISSION Fault finding aid Chart 37 Lever difficult
88. erent 5 Illuminated when the load potentiometer belonging to the injection is faulty 6 Illuminated when the vehicle speed information supplied to the automatic transmission computer is wrong or absent 23 196 AUTOMATIC TRANSMISSION Meaning of the bargraphs Illuminated when the control circuit of the air conditioning relay cut off is faulty On the key pad enter The following will appear on the display either E The control circuit is short circuited The control circuit is broken or The control circuit is operating correctly the bargraph should not be illuminated Illuminated when the circuit of solenoid valve No 115 faulty On the keypad enter le s The following will appear on the display either The circuit of solenoid valve N 1 is short circuited A L The circuit of solenoid valve N 1 is broken or The circuit of solenoid valve N 1 is operating correctly the bargraph should not be illuminated 23 197 1 gi mt 10 10 AUTOMATIC TRANSMISSION Meaning of the bargraphs Illuminated when the circuit of solenoid valve N 2 is faulty Onthe keypad enter The following will appear on the display either E The circuit of solenoid valve N 2 is short circuited L The circuit of solenoid valve N 2 is broken The circuit of solenoid valve N 2 is operating correctly the bargraph should not be illumi
89. es Between the engine electrical earth and a track of the kickdown switch connector Between the other track of the kickdown switch connector and track D of the computer Vehicles fitted with a closed contact kickdown switch Presence of earth on track D of the computer Is there continuity between the 2 tracks of the Replace the kickdown kickdown switch in the no load position yes gt switch no Check ensure the insulation of the line between the track of the kickdown switch connector and track D of the computer 2DMXTT1 0 23 218 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination 2 Bargraph 9 RH extinguished in full load position Vehicles fitted with an open contact kickdown switch Earth maintained on track D of the computer Check the adjustment of the accelerator pedal Replace the kickd Is there continuity between the 2 tracks of the yes gt E AE kickdown switch in the full load position nu no Check ensure the insulation of the line between the kickdown switch connector and track D of the computer Vehicles fitted with a closed contact kickdown switch Track D of the computer not earthed Check the adjustment of the accelerator pedal Check that the connector on the kickdown switch is f correctly connected n Replace the kickdown Is there continuity between the 2 tracks of the switch kickdown switch in the full load position yes C
90. es with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTT1 0 23 208 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 1 LH ILLUMINATED Replace the automatic transmission computer Erase the computer memory Program the no load and full load values on version E7 And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTT1 0 23 209 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 2 LH ILLUMINATED Electrical coherence fault on the lever position illuminated illuminated or flashing Ignition off disconnect the 6 track connector from the computer Is track C on the wiring side isolated from earth yes Ensure the isolation of the line between the starter motor relay and track C of the automatic transmission computer connector and that between track C and the injection computer for injection versions Erase the memory of the automatic transmission computer On version E7J program the no load and full load positions Does the fault reappear yes Check the multifunction switch on the 6 track connector computer side using a multimeter Refer to MR T A M checking the connectors section Are the checks correct no yes Replace the multifunction sw
91. eter connector 11 asolenoid valve connector 12 asix track connector 4 THE MAJOR DIFFERENCE visible from the outside allowing a new generation computer M 4 3 to be distinguished from an old generation computer M 4 2 is that the two track connector 9 has been replaced by a three track connector 9A This new connector means that communications can be set up between the computer and the XR25 To carry this out on the vehicle an adaptor lead part number 77 01 367 618 is required At its ends this lead has athree track connector 15 atwo track connector 16 23 173 AUTOMATIC TRANSMISSION General 85651 1R4 1 Vehicle speed sensor 9and14 Fault warning light connector 2 Load potentiometer 9A Fault warning light connector and 3 Solenoid pilot valves XR25 connection 4and7 Six track connector 10 and 11 Load potentiometer connector 5 Multifunction switch 13 Computer 6 and 12 Solenoid valve connector 15 and 16 Adaptor lead connector 8 Fault warning light 23 174 AUTOMATIC TRANSMISSION General DEFECT MODES IN THE EVENT OF PROBLEMS If one of the peripheral transmission components or the feed 12V develops a fault the computer causes the warning light to illuminate and implements defect modes for the transmission which can vary depending on the faulty components Warns Memori Forward light gears Comments illuminated gears possible 12V feed RP Change to 3rd when fault app
92. everal gears Will not change into second the engine speed increases in 1st above 31 mph 50 km h changes to 3rd after releasing pedal No drive in D and 2 but drive in 1 only Third missing with racing of engine in 2nd reverse gear correct No 1st gear after operation on distributor No 1st gear hold after operation on hydraulic distributor 23 226 The engine races in full load position when changing from 2 3 and 3 1 the automatic transmission seems to change into neutral Chart 6 Chart 7 Chart 8 Chart 28 Chart 49 Chart 11 Chart 12 Chart 13 Chart 24 Chart 50 Chart 8 Chart 14 Chart 27 Chart 24 Chart 27 Chart 27 Chart 30 Chart 10 Chart 45 Chart 48 3DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding aid A PROBLEMS WITHOUT THE FAULT WARNING LIGHT ILLUMINATING cont with the knowledge that the warning light is working correctly cont PROBLEMS LINKED TO THE GEARS cont The automatic transmission remains locked in one gear Remains in 1st Remains locked in 3rd No kickdown at full load or kickdown threshold abnormal at full load PROBLEM FOLLOWING SEVERE BRAKING OR A SHARP BEND Surging after braking Engine races after a bend OTHER Banging Banging when starting or when engaging Banging when starting with lever in D 2 1 Banging when engaging from position N to D 2 1 or R Banging when engaging reverse when accelerating or lack of reverse when warm Banging when starting in R
93. fitting the seal on the final drive ca sing end C Protective sleeve Grease the outside of sleeve C before using it 84886G Dipstick tube Fit a new O ring and refit the dipstick tube 23 96 AUTOMATIC TRANSMISSION Final drive assembly MJ Method Cover plate end Fit sleeve C to the sunwheel fit the seal to the sleeve and position the seal using tool A Final drive casing end Proceed in the same way but use tool B to fit the seal Fit the O rings to the sunwheels Refer to page 108 for assembling the torque con verter 34 Refer to page 130 for assembling the gear section to the final drive casing 23 97 AUTOMATIC TRANSMISSION Final drive assembly ML MATCHING PARTS The final drive pinion and crown wheel The final drive casing and the converter casing 846325 845775 sing DI2352 23 98 AUTOMATIC TRANSMISSION Final drive assembly ML SPECIAL TOOLING REQUIRED Tool for extracting interchangeable grids Tooling for replacing converter seal Castellated wrench for adjusting differential clearance Tool from kit B Vi 710 Spanner for differential nut TE Tool for fitting circlips Ring spanner for final drive pinion nut Tool for replacing speedometer drive shaft Tool for measuring torque Mandrel for fitting bearings in the housing Tool for fitting circlip to output shaft Tool for centring converter seal Shaft protecting end piece ARR TIGHTEN
94. formed load is correct at full load on 12 see reading the various sec The following will appear on the display tion dERe On the keypad enter 110 2 the display will appear the value in of the potentiometer setting Example 23 185 AUTOMATIC TRANSMISSION Additional tests COMMAND MODE On the keypad enter Command mode is used to test the operation of e lo 1 the solenoid valve statically The following will appear on the display Connect the XR25 Turn the selector to S8 RE Bargraphs 17RH and 17LH will illuminate when the components are tested Bargraph 13RH also il luminates ignore At the end of the test the XR25 makes a noise The following will appear on the display iy F PAP Turn on the ignition If faults have been detected bargraphs 8RH Engine not running vehicle stationary on the and or 8LH will illuminate keypad enter the code of the automatic transmis mm The following will appear on the display Jt R2 Locate the fault using the fault finding charts 23 186 AUTOMATIC TRANSMISSION Additional tests ERASING THE MEMORY Operation to be performed at the end of each fault finding procedure Connect the XR25 Turn the selector to S8 Turn on the ignition Put the gear selector in position N or P Vehicle stationary enter the code of the automa tic transmission The following will appear on the display
95. g AUTOMATIC TRANSMISSION Final drive assembly MB REASSEMBLY TORQUE CONVERTER AND DIFFERENTIAL CASING Fitting the differential and its bearings CROWN WHEEL WITHOUT SHOULDER CROWN WHEEL WITH SHOULDER SOLUTION DURING PRODUCTION Original fitment Second fitment Third fitment with circlip with circlip with circlip 25 1 75 25 2 5 25 2 5 14 15 5 With circlip 25 2 5 0 4 1 16 5 Differential There are no special points concerning refitting however the parts must be immersed in auto matic transmission oil Ensure that notch E on part 23 is in groove C on 15 except for electronic versions Check that the planet wheels rotate properly 86528R1 23 79 AUTOMATIC TRANSMISSION Final drive assembly MB REASSEMBLY 86374R2 Differential bearings Bearing 26 Offer up the bearing with bearing track ring C at the bottom end of the casing end opposite op erator Use a diameter 65 mm sleeve to press on the out er bearing track only 86231R Replace the circlip which holds the bearing Bearing 33 Offer up the bearing with bearing track ring C at the casing end end opposite operator 23 80 Press on the bearing with the press using a shoul dered bar or sleeve with a diameter of diameter 125 minimum and diameter 128 maximum to press on the outer bearing ring 86317 1R1 Shaft bearing Secondary shaft bearing 4 Fit the be
96. graph represents the electrical feed of solenoid valve N 1 The RH bargraph represents the electrical feed of solenoid valve N 2 When the vehicle is stationary and regardless of the position of the gear lever only the RH bargraph should be illuminated When in 1st or reverse gear only the RH bargraph should be illuminated When in 2nd gear the RH and LH bargraphs should be illuminated When in 3rd gear no bargraphs should be illuminated Illuminated when using the memory of the XR25 NOTE To determine faults refer to the Fault finding charts to be used from the bargraphs section 23 182 AUTOMATIC TRANSMISSION Additional tests READING THE VARIOUS Connect the XR25 to the diagnostic socket Put the selector on S8 Switch on the ignition Enter the specific automatic transmission code D 1 4 Then enter s followed by 2 figures in order to gain access to the various items of information sup plied by the computer lo 1 Gear engaged The following be read when the transmission is operating normally Lever Ignition on Vehicle position engine off moving R I rd I rd N O P D I rd I rd 2 rd 3 rd 2 1 2 1 2 2 2 1 I I I I Manoeuvre to be performed with care only when fault finding on the automatic transmission 2 Load potentiometer Value expressed in of accelerator control at rest H Value of 89 1 no load on accelerator pedal PL
97. h voltage connections are correct oxidation tightness on plugs coil distributor 3DMXTT1 0 23 264 AUTOMATIC TRANSMISSION Fault finding aid Chart 42 Gear changing thresholds delayed and warning light illuminates vehicles fitted with on board computer If the XR25 gives no information on the nature of the origin of the fault check that the potentiometer wire is not incorrectly connected in place of the on board computer wire Reconnect if necessary Chart 43 Starting possible in N but not in P If the warning light is operational and it remains extinguished when there is a fault adjust the control following the Workshop Repair Manual for the vehicle After the operation does the fault persist no yes Adjust again 3DMXTT1 0 23 265 AUTOMATIC TRANSMISSION Fault finding aid Chart 44 Vehicle does not drive in forward gear or reverse gear If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level engine running and top it no gt up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes Connect pressure gauge BVI 466 07 Is there any oil pressure when the engine is running Refer to MR T A M for values Add up to 2 litres of oil to the automatic transmis
98. he hydraulic distributor section of the Workshop Repair Manual yes i Replace the capsule Replace the hydraulic distributor and strainer Correct ne After replacement does the fault persist yes Replace clutches E1 and E2 3DMXTT1 0 23 242 AUTOMATIC TRANSMISSION Fault finding aid Chart 14 Slipping when changing gears in full load position If the warning light is operational and it remains extinguished when there is a fault check the condition of the oil Is it dirty and does it smell yes Check if it has already been changed since the fault appeared no Check the line pressure in 2nd gear hold full load Refer to MR T A M pressure section Is the value correct yes no Replace the strainer Adjust the pressure following the instructions in MR Does the fault persist T A M After adjustment does the fault persist no e yes yes Replace the hydraulic distributor After replacement does the fault persist Repair the automatic transmission Replace it if necessary 3DMXTT1 0 23 243 AUTOMATIC TRANSMISSION Fault finding aid Chart 15 Banging when starting with lever in D 2 1 with engaging delay When warm If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level an
99. he vehicle type the engine type the automatic transmission type the old generation computer reference the new generation computer refe rence 1st PART This involves an old generation computer M 4 2 fitted to the vehicle during production You must use fault finding fiche N 1 In this part you will find presentation of the layout of the computer on the vehicle a fault finding method to be carried out using the XR25 fault finding charts to be used with the bar graphs 23 132 2nd PART This involves a new generation computer M 4 3 fitted to the vehicle in after sales You must use fault finding fiche N 24 In this part you will find a presentation of the layout of the computer on the vehicle afault finding method to be carried out using the XR 25 fault finding charts to be used with the bar graphs They are common to the 2nd and 3rd part 3rd PART This involves a new generation computer M 4 3 fitted to the vehicle during production You must use fault finding fiche N 26 In this part you will find presentation of the layout of the computer on the vehicle afault finding method to be carried out using the XR 25 fault finding charts to be used with the bar graphs They are common to the 2nd and 3rd part The fault finding charts to be used as a function of the customer complaints are common to all three parts Each part of
100. heck ensure the following continuities Between a track of the kickdown switch connector and earth Between the other track of the kickdown switch connector and track D of the computer 2DMXTT1 0 23 219 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 9 LH EXTINGUISHED IN THE FULL LOAD POSITION If in addition to this bargraph bargraph 4 is also illuminated deal with bargraph 4 first Vehicle with kickdown switch Does bargraph 9 RH illuminate in the full load Deal with bargraph 9 position extinguished in the full load position Check the accelerator cable control Check the change in load on 12 and replace the automatic transmission potentiometer if necessary Kickdown function performed if RC 1 12 lt 12 5 Vehicle without kickdown switch Check the accelerator cable control Check the change in load on 12 and replace the automatic transmission potentiometer if necessary for versions fitted with it On versions E7 and D7F program the no load and full load values after having erased the computer memory Kickdown function performed if 12 lt 6 25 2DMXTT1 0 23 220 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 10 RH and or LH ILLUMINATED Program the no load and full load values only on version E7J Failure to program bargraph 10 remains illuminated after programming is normal if the val
101. hecking the connections on the 6 track connector On the E7J version erasing the memory means that the full load and no load values must be reprogrammed And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 274 AUTOMATIC TRANSMISSION Fault finding aid Chart 53 Warning light does not illuminate when ignition turned on Disconnect the 3 track MIC connector or the 2 track connector depending on computer version supplying the warning light and earth track A of the MIC connector or the warning light output on the 2 track connector Does the warning light illuminate when the ignition is turned on Replace the computer if the fault persists after Check the condition of the instrument panel checking the connections on the warning light fuse If the vehicle has a diagnostic socket connector and the computer earth check its condition and the presence of the shunt in the cover Check the warning light bulb and the continuity between the computer output and the warning light 3DMXTT1 0 23 275
102. ic transmission must be drained and re filled with clean oil and the strainer changed AUTOMATIC TRANSMISSION Differential seal MB REPLACEMENT SPECIAL TOOLING REQUIRED B Vi 945 Tool for fitting lip seal REMOVAL Remove the sunwheel O ring Strike the lip seal base with a pin punch and a light hammer to cause it to tilt in its location Once the seal is dislodged remove it with pliers taking care not to damage the sunwheel splines 860315 REFITTING The seal is fitted using tool B Vi 945 which con sists of aseal protector A a tool for fitting the seal 23 41 Method 86095R Put the greased protector A on the sunwheel and position the seal with the tool B 86122R1 AUTOMATIC TRANSMISSION Differential seal MJ REPLACEMENT SPECIAL TOOLING REQUIRED B Vi 951 TIGHTENING TORQUES in daN m Cover plate securing bolts REMOVAL Remove the sunwheel O rings and the differential cover plate securing bolts Using a mallet tap the right hand sunwheel to re move the cover plate During this operation take care not to allow the differential to drop Remove the two baffles and the two lip seals REFITTING Refit thetwo baffles the differential thecover plate fitted with a new O ring Tighten the cover plate bolts to the correct torque The lips seals are refitted using tool B Vi 951 which consists of A A tool for fitting the
103. id Chart 7 Skidding when starting lever in D juddering in reverse If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Check the condition of the drive hub the condition of the quadrant rings and E2 Replace any parts as necessary Refer to MR T A M 3DMXTT1 0 23 236 AUTOMATIC TRANSMISSION Fault finding aid Chart 8 Slipping when changing from 2 to 3 only If the warning light is operational and it remains extinguished when there is a fault connect pressure gauge BVI 466 07 and measure the line pressure in 2nd gear hold and full load Adjust the pressure if necessary no gt Correct Refer to MR T A M identification and pressure section After the operation does the fault persist yes Measure again for no load Is the pressure less than 3 8 bars Repair the vacuum circuit Pipe burnt holed Capsule holed Does the fault persist no Remove the hydraulic distributor Do valves 6 and 7 slide normally Refer to MR T A M distributor section Replace the hydraulic distributor and strainer After replacement does the Clutch E2 is damaged Replace it fault persist 3DMXTT1 0 23 2
104. ifunction switch Earth on track E of 6 track connector on first version no gt Correct after ignition feed on track F of the 6 track connector wiring side After checking repair does the fault persist yes Replace the computer if the fault persists after checking the connections on the 6 track connector Erase the computer memory if it is an M 4 3 computer 3DMXTT1 0 23 273 AUTOMATIC TRANSMISSION Fault finding aid Chart 52 No communication between the XR25 and the computer cont Versions with an M 4 3 computer Check that the battery voltage gt 10 5 V Check that the automatic transmission fuse has not blown no gt Correct After these checks does the fault persist yes If the XR25 is connected directly to the diagnostic socket check the 3 track MIC connector is correctly connected between the diagnostic socket and the computer Check ensure the continuity of the lines between the MIC 3 track connector and the diagnostic socket Check ensure the earth on track 2 of the diagnostic socket and the presence of battery feed on track 6 After this operation does the fault persist es y no Check the computer is correctly fed Earth via wire on multifunction switch after ignition feed on track F of the 6 track no gt Correct connector wiring side After checking repair does the fault persist yes Replace the computer if the fault persists after c
105. ion computer or automatic transmission load potentiometer fault A Vehicle without automatic transmission potentiometer Bargraph 4 illuminated Deal with Is bargraph 3 also illuminated ee Ala Turn the ignition off then on again 2 Is the fault confirmed Check the injection potentiometer on the injection side After repairing on the injection side erase the memory of the automatic transmission computer and program the no load and full load values Bargraph 4 flashing Erase the computer memory and program the no load and full load values Check the battery voltage too low a voltage may memorise a fault in the starting phase Check the condition under the bonnet of the automatic transmission wiring and also the high voltage wiring test with engine running 2DMXTT1 0 23 212 RANSMISSION 24 and 26 Fault finding using bargraph illumination B Vehicle with automatic transmission potentiometer Engine off and no load position is there 50 on no 12 yes Replace the computer and erase the memory yes Engine off and no load position is there 0 on 02 Is there between 87 5 and 98 5 End Turn the ignition off then on again Does the fault persist Check that the potentiometer is correctly connected to the harness the condition of the wiring Check the 5 volt feed of the potentiometer Is there a voltage of 4 5 0
106. ip is the correct thickness a tool used for fitting the seal B for the grooves see previous page Place circlip 25 on nose 1 of tool B Vi 946 then place the nose on the sunwheel Fittool 2 B Vi 946 onto nose 1 and push on the press until the circlip fits in its groove Remove tool B Vi 946 86095R Method Fit the greased protector A on the sunwheel and position the seal using tool B 86398R 86122R2 86123R1 23 82 AUTOMATIC TRANSMISSION Final drive assembly MB SEPARATOR HOUSING 86374R4 Shaft bearing bearings 2 and 8 using tool B Vi 947 bea ring 8 has a larger internal diameter than Bearings 2 and 8 bearing 2 so tool B Vi 947 must be centred Refit on the bearing circlips 3 and 11 with the notches on the same side 88207 1R Ensure that the circlips are correctly positioned in the bearing grooves 23 83 AUTOMATIC TRANSMISSION Final drive assembly MB Output shaft 13 On 13 fit pinion 11 aligning the mark on the shoulder on the opposite side to circlip 12 on the press so that it is flush with circlip 12 86498R Secondary shaft 5 On 5 fit pinion 3 with the mark on the shoulder at the outer end of the shaft 5 using the press 86498R1 Fit the shafts on the separator housing and fit cir clips 1 and 7 COUPLING THE SEPARATOR HOUSING TO THE CONVERTER AND DIFFERENTIAL CASING A seal must
107. is dislodged remove it with a pair of pliers taking care not to damage the sunwheel splines 86031R 88951R2 23 73 AUTOMATIC TRANSMISSION Final drive assembly MB On the press Place a piece of wood under the differential crown wheel to support it Place a spacer bar C between the casing and the press and push so that circlip 25 comes free and remove it Remove the differential on the press via the sun wheel with its washer or washers Differential bearing Extract the circlip holding the bearing in its seat then on the press remove bearing 26 with a di ameter 50 sleeve moving it towards the inside of the casing M i ES RE L 857054 23 74 Insert small bar inside the housing and place it flat against the bearing R On the press apply a load using an extension tube and extract the bearing R msi k 4 k e Bearing 4 on intermediate shaft 5 Bearing 4 is crimped in place in the casing 85705R5 Remove the crimping points using a small grinder or a sharp cold chisel Remove the inner track ring by destroying it and the bearing rollers 4 86374R1 AUTOMATIC TRANSMISSION Final drive assembly MB Extract the bearing using an extractor example FACOM U49 CLEANING Clean off the crimping burrs using abrasive paper Remove any dust using an air gun or a clean cloth e Needle bearing A on output shaft 13 B
108. is ensured check the operation Ignition on is there of the switch Battery feed on track A on the wiring side After the operation does the fault persist yes yes Check ensure continuity between track B of the 6 track connector and the reversing no lights After the operation does the fault persist yes Test the multifunction switch between tracks A and B on the 6 track connector computer side Recheck Lever in R 0 to 0 5 your Lever in P N D 2 1 R infinity diagnosis Do you note these values when testing Cut the multifunction switch cable as if a replacement were being made With the switch still in position on the automatic transmission repeat the previous tests at the switch side between the grey and green wires Are the measurements still incorrect Replace the multifunction switch Replace the computer Erase the memory if M 4 3 Validate the no load and full load values for the 7 version And vehicles where load information and TDC information is given by the injection computer 23 249 AUTOMATIC TRANSMISSION Fault finding aid Chart 23 The starter motor and the reversing lights do not work Check the connection of the 6 track connector on the computer and the condition of its connections 3DMXTT1 0 23 250 AUTOMATIC TRANSMISSION Fault finding aid Chart 24 The engine speed increases in 1st 2nd changes above 37 mph 60 km h When the pedal is released the AT
109. is warm Refer to MR T A M oil pressure section Is the pressure greater than 2 bars Leak from the quadrant rings Replace the drive hub and its quadrant rings Also check the oil pump Check the general condition of brake F1 and clutch E2 Carry out a check referring to MR T A M Check the hydraulic distributor sequence valves slide correctly and clean it if necessary 3DMXTT1 0 23 234 AUTOMATIC TRANSMISSION Fault finding aid Chart 6 The engine races in full load position when changing from 2 3 and 3 1 The automatic transmission seems to change into neutral If the warning light is operational and it remains extinguished when there is a fault connect pressure gauge BVI 466 07 and measure the line pressure in 2nd gear hold and full load Adjust the pressure if necessary gt Correct Refer to T A M identification and pressure section After the operation does the fault persist yes Drain then remove the sump Is there a swarf deposit at the bottom of the sump Check the strainer conforms and is correctly fitted Refer to MR T A M strainer section Remove the hydraulic distributor s this correct Do valves 6 and 7 slide normally Refer to MR T A M distributor section Replace the automatic transmission freewheel Replace the hydraulic distributor and strainer Repair and top up the level 3DMXTT1 0 23 235 AUTOMATIC TRANSMISSION Fault finding a
110. it carefully Chart 20 The vehicle does not move forward in D 2 and 1 but neutral park and reverse are correct If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Clutch E1 is burnt out or heavily damaged Refer to the instructions for replacement in MR T A M 3DMXTT1 0 23 247 AUTOMATIC TRANSMISSION Fault finding aid Chart 21 The starter motor does not work but the reversing lights work If the warning light is operational and it remains extinguished when there is a fault move the selector lever while operating the starter Does the vehicle start yes no Adjust the control according to the Workshop Disconnect the 6 track computer connector and check Repair Manual After the operation does the the condition of the connections fault persist In the starting phase is there Battery feed on track C 5 wiring side no yes ee j adjustment Ensure continuity between track C on the 6 track connector and the Turn the ignition off and check the operation of the multifunction ignition switch If there is switch between tracks C and E of the 6 track connector computer side continuity check the operation of Leve
111. itch Replace the computer and erase its memory On E7J version erasing the memory requires the no load and full load values to be reprogrammed And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTTI 0 23 210 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 3 LH ILLUMINATED Connection fault between the automatic transmission computer and the injection computer load information Check ensure the continuity and the isolation of the connection between track A of the automatic transmission computer connector and the injection computer connector track 22 for E7J engine track 41 for the D7F engine Does the fault persist after checking repairing yes Check the condition of the wiring on the injection computer side and the automatic transmission computer side IF the wiring is not faulty replace the automatic transmission computer and erase the memory M 4 3 On E7J version erasing the memory requires the no load and full load values to be reprogrammed And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTTI 0 23 211 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 4 LH ILLUMINATED Reception fault of the load information provided by the inject
112. l end piece aM M vora B Vi 466 06 NOTE 2notches approximately 0 08 bar 0 01 bar for X 06 Twingo 85393R2 23 124 AUTOMATIC TRANSMISSION Oil pressure ADJUSTING A tool can be made to make this operation easier 88862R A Washer diameter 8 30 thickness 1 5 mm B Bar diameter 6 mm V1 Viewonl1 Alter the length of the rod B depending on the usage 23 125 AUTOMATIC TRANSMISSION Vacuum capsule The vacuum capsule modulates the oil pressure as a function of engine load CHECKING Engine switched off Check the routing of the vacuum hose Connect the manual vacuum pump to the vacuum hose which has been disconnected from the inlet manifold already 77998 15 Needle Vacuum to be applied Drops 525 mbar or CORRECT INCORRECT 400 mmHg If this is not correct perform the check again di rectly on the capsule If correct replace the hose if incorrect replace the capsule Also ensure that the inlet manifold connector is in good condition 23 126 REMOVAL Secure the automatic transmission and remove the automatic transmission mounting if necessary Disconnect the hose remove the clip 2 and un screw the capsule 85393R1 REFITTING Grease or oil the capsule black rubber Tighten the capsule by 2 5 to 3 turns and fit the clip 2 CHECK THE OIL LEVEL AND ADJUST THE OIL PRES SURE see section on Oil pressure AUTOMATIC TRANSMISSION Special tooling Metho
113. ld down the connector lock piece 85651S On the computer side remove 40 mm of protective sleeve and scree ning 8633252 86332R3 23 122 AUTOMATIC TRANSMISSION Speed sensor Before refitting check for the presence of the O ring T 85651 2R2 23 123 AUTOMATIC TRANSMISSION Oil pressure Setting the oil pressure correctly ensures good quality gear changes and increases the life length of the automatic transmission mechanism part SPECIAL TOOLING REQUIRED B Vi 466 07 Oil pressure gauge CHECKING Connect pressure gauge B Vi 1215 01 before using the device reset the pressure gauge to ze The check is performed with the transmission ro warm 80 C and only during a road test the oil pressure varies with temperature Drive for a few miles in order to increase the oil to approximately 80 C Check the oil level of the automatic transmission Put the selector lever in the 2nd gear hold posi Ensure that the engine is correctly adjusted tion Identify the type of oil pressure plug 1 Accelerate fully and brake at the same time in or der to stabilise the speed to 50 mph 80 km h and read the value on the pressure gauge Distance across flats Refer to the value of pressure see section on Tooling to be used identification ADJUSTING Tapered end piece in B Vi 466 04 Remove the clip 2 and rotate the capsule The pressure is increased by tightening the capsule Cylindrica
114. line pressure in 2nd gear hold and full load Adjust the pressure if necessary no gt Refer to MR T A M identification and pressure section After the operation does the fault persist yes Repair the vacuum circuit Pipe burnt holed Capsule holed Does the fault persist Check all the components of the command and adjust it 3DMXTT1 0 23 245 AUTOMATIC TRANSMISSION Fault finding aid Chart 17 The vehicle moves forwards or backwards with the lever in N and the starter motor and reversing lights positions are offset If the warning light is operational and it remains extinguished when there is a fault the fault is due to the selection mechanism being offset Adjust the selector lever After repair does the fault persist yes no Check the complete command Chart 18 Parking difficult to engage lever in P Check the park system Adjust and repair if necessary as described in MR T A M gear section casing section 3DMXTT1 0 23 246 AUTOMATIC TRANSMISSION Fault finding aid Chart 19 The vehicle moves forwards lever in N position P operational Normal starter action If the warning light is operational and it remains extinguished when there is a fault and it is not a case of creeping when the oil is cold less than 60 C the clutches have been damaged also check the brakes Refer to the instructions for replacement in MR T A M Remember to clean the oil cooler circu
115. lip E to the sealed connector T and connect ADJUSTING THE END FLOAT it The end float is the operating clearance of the gear section of the automatic transmission The average clearance J must be 0 8 mm The end float is adjusted by shim K which is a ground shim 85661R1 Refit the hydraulic distributor and its two seals and plate Tighten the hydraulic distributor bolts to the correct torque in the order given see Hydraulic distributor section Fit a new strainer mh eea 85615R1 The adjustment is made in two stages 855965 Fit the sump and tighten the bolts to a torque of 0 6 daN m except on ML 23 69 AUTOMATIC TRANSMISSION Gear section casing 1 Gear section casing end The park wheel 21 must be fitted correctly With the notch in the plastic washer 19 in place Fit tool B Vi 715 and measure the dimension of the tool H the dimension F measured between the tool and the park wheel 21 Calculate dimension G G F H Lon VN D zx 7 er 86134R 2 Final drive housing end The shims must be removed and the paper seal in place Fit tool B Vi 715 and measure the dimension of the tool H the dimension D measured between the circlip and the tool Calculate dimension E 23 70 E H D 88984 1R AUTOMATIC TRANSMISSION Gear section casing Position the paper seal 3 Calculating the thickness of the shim
116. lot valves 1 Solenoid valves Checking the e Wiring solenoid valves Speed Speed sensor 2 e Speed sensor faulty Dotnet 3 Load potentiometer Adjusting the Wiring potentiometer VEHICLE STATIONARY IGNITION ON Light 2 and DIAG illuminate ignore them Selector lever position Light Light status Components which might be Correct After having 2nd gear hold 4and5 4 D 5 O adjusted the control if still 1st gear hold 4and5 4 5 faulty wash the Gear control f multifunction Wiring switch with soapy PRND 4and5 4 5 Multifunction switch thoroughly If still P N Check starter function faulty replace the C multifunction switch Kickdown Press accelerator fully down Adjust the Wiring kickdown i Extinguishes after 3 seconds on some versions Vehicle with kickdown incorporated into the computer 23 156 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 SPECIFIC FAULT FINDING I The fault warning light 8 on the instrument panel remains extinguished when the vehicle ignition is switched on Check the connection of the warning light and if correct connect the B Vi 958 A The DIAG light B Vi 958 check the warn ing light 8 on the instrument panel Action on the vehicle Turnon Warning light Warning light ignition 8 illuminates 8 is CORRECT extinguished INCORRECT Separate Check 14 fr
117. mbly of the automatic transmission earth strap to the chassis 2 The correct assembly and the condition of the terminal G of the earth wire on the automatic transmis sion housing 3 The continuity of the earth wire ohmmeter placed between the terminal G and point E of the connec tor on the computer Correct result 0 to 0 5 Q If incorrect replace the multifunction switch or the computer depending on where the wire is cut 23 159 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 II The DIAG ligh C and lights 1 to 6 extinguished on the B Vi 958 regardless of the lever position Vehicle behaviour remains in 3rd or random gear changes reverse normal and warning light illuminated normal or intermittently FAULT INCORRECT FEED VOLTAGE TO COMPUTER a Components which might be faulty 1 5 A or 2 A automatic transmission fuse on the relay plate broken oxidised poorly clipped in After ignition relay on relay plate 6 track connector of computer or vehicle wiring connectors poor contact wires poorly crimped or broken Barth wire oxidised incorrectly tightened painted Alternator or battery faulty 23 160 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 b Repairs TO DISPLAY A RETURN TO A NORMAL FEED VOLTAGE 1 Check the condition of the fuse and the fuse IMPORTANT holder the battery voltage and its wires earth On vehicles where the warning light extinguishes and after 3
118. motor check 15 Diagnostic socket 14 Unit feed RAZ Reset warning lights 1 to 6 TEST Test B Vi 958 DIAG Instrument panel warning light informa tion Depending on vehicle 16 Measuring connector ees NH o M oss IBI 5 2 DI2367 ZONE C used for automatic transmissions 4139 4141 and possibly MB MJ ML see pages 23 64 ZONE used for measuring the continuities of the solenoid valves and measuring the voltage multifunction switch all types of automatic transmission 7 8 Measuring lights P Measuring wiring P1 Measuring socket 23 153 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 INTERPRETATION OF THE AUTOMATIC TRANSMISSION WARNING LIGHT The computer 13 has a system for self checking the electrical components which is shown by the fault warn ing light 8 on the instrument panel The warning light 8 should illuminate when the vehicle s ignition is turned on a extinguish either after driving at more than 1 8 mph 3 km h or after 3 seconds depending on version If the fault warning light 8 illuminates whilst driving DO NOT TURN OFF THE IGNITION in order to store the type of fault to be searched for and connect the test kit B Vi 958 NOTE itis normal for the fault warning light 8 to flash very slightly during normal operation 85651 1R3 1 Speed sensor 12 Sealed connector socket 2 Load potentiometer 8 Fault warning light 3 Solenoid valves 9and14 Diag
119. move in succession the 2 bolts securing the cov er plate 13 Take care not to lose the spring 12 Remove the other components turning the man ually operated valve unit 14 over CLEANING Use White Spirit lint free wadding for wiping down compressed air blowing strongly into all ducts CHECKS If there are any scoring or wear marks on any of the valves the entire hydraulic distributor must be changed All valves should move freely and should not stick at any point The seal 4 and those on the solenoid pilot valves must be in perfect condition REFITTING Oil all parts and refit them as shown in the ex ploded diagram IMPORTANT Valve 6 with the biggest spigot must face to wards the small spring 5 23 35 85526R1 Secure plate 13 by its two bolts and fit the sole noid pilot valve with mark 1 at the same end as the pressure regulating valve 85660R Tighten the bolts securing the cover plate 13 progressively so that the last coil of the spring 12 is not jammed between the plate 13 and the unit 15 and tighten to a torque of 1 3 daN m IMPORTANT Ensure that the wiring mounting clips are secured correctly to the solenoid pilot valves and are in their original position Check that all valves move freely AUTOMATIC TRANSMISSION Hydraulic distributor HYDRAULIC DISTRIBUTOR PLATE 3 Perform the following Modification clean the plate replace the seals
120. n the accessories plate and the 6 track connector on the computer are correctly clipped in Repair if necessary and retest Does the fault persist yes Disconnect the 6 track connector and check for battery feed on track F of the 6 track connector Is this correct yes Recheck no Ensure after ignition feed on track F NOTE For E7 engines the fault may be caused by a break in TDC information Check using 06 if the engine speed information changes to 0 when the fault occurs Repair the wiring if necessary And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 263 AUTOMATIC TRANSMISSION Fault finding aid Chart 41 Random gear changes If the XR25 gives no information on the nature of the origin of the fault check the adjustment and tightness of the automatic transmission control After the operation does the fault persist yes no Check the condition of the high voltage ignition leads and their routing Replace the leads if necessary no gt Correct Does the fault persist yes Check that the kickdown switch wire is connected to the accelerator cable compensator i Correct Reconnect it if necessary After the operation does the fault persist yes Are the kickdown switch wires sufficiently far away form the high voltage leads Repair After the operation does the fault persist Check that all the hig
121. n validated Bargraphs 10RH and 10LH should be extinguished If this is not the case repeat the operation for erasing and for programming the no load and full load positions If the no load and full load positions cannot be validated refer to the Fault finding charts to be used from the bar graphs section IMPORTANT An incorrectly validated full load position may cause the warning light to be permanently illumina ted Anomalies when changing gears Incorrect gear changing thresholds Kickdown problems Uncomfortable driving AUTOMATIC TRANSMISSION Additional tests END OF TEST On the keypad enter ie 1 BIE The following will appear on the display Flin The XR25 makes a noise The following will appear on the display Turn off the ignition You may disconnect the XR25 23 205 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination FAULT FINDING CHARTS TO BE USED FROM THE BARGRAPHS Fault finding fiches N 24 and 26 Page Bargraph 1 RH extinguished or no communication with automatic transmission computer 210 Bargraph 1 LH illuminated 211 Bargraph 2 LH illuminated 212 Bargraph 3 LH illuminated 213 Bargraph 4 LH illuminated 214 Bargraph 5 LH illuminated 216 Bargraph 6 LH illuminated 216 Bargraph 7 RH illuminated 217 Bargraph 8 RH and or LH illuminated 218 Bargraph 9 RH illuminated 220 Bargraph 9 LH extinguished in full load position 222 Bargr
122. nated Illuminated when the full load PF position is recognised by the automatic transmission computer Illuminated when the kickdown compensator supplies its information to the automatic transmission computer IMPORTANT This bargraph is always illuminated for automatic transmissions which do not have a kickdown compensator Illuminated when the no load position PL is not validated see erasing the memory and programming the no load and full load positions section Illuminated when the full load position PF is not validated see erasing the memory and programming the no load and full load positions section 23 198 AUTOMATIC TRANSMISSION Meaning of the bargraphs Illuminated when the gear selector lever is in the P or N position Starting is authorised Illuminated when the engine is stopped If the bargraph is illuminated when the engine is running this means that the engine speed information is faulty or absent Illuminated when the air conditioning compressor clutch feed cut off is active The LH bargraph represents the electrical feed of solenoid valve N 1 The RH bargraph represents the electrical feed of solenoid valve N 2 When the vehicle is stationary and regardless of the position of the gear lever only the RH bargraph should be illuminated When in 1st or reverse gear only the RH bargraph should be illuminated When in 2nd gear the RH and LH bargraphs should be illuminated When in 3rd ge
123. nated 8 possible 12V feed RP Change to 3rd when fault appears Earth feed RP Change to 3rd when fault appears Solenoid valves 1 Change to 3rd when fault appears and 2 Computer RP Change to 3rd when fault appears Vehicle speed RP Change to 3rd when fault appears Multifunction switch RP No longer recognises imposed gears Potentiometer The load is set to 50 Engine speed 23 191 AUTOMATIC TRANSMISSION General SETTING UP THE CONNECTION BETWEEN THE COMPUTER AND THE XR25 The computer is connected to the diagnostic socket 17 through the connector 9A To establish the connection connect the XR25 to the diagnostic socket 17 Carry out a fault finding procedure To do this re fer to the using the XR25 section DG7003 19 Injection computer 23 192 AUTOMATIC TRANSMISSION General USING THE XR25 new generation computer fit ted to a vehicle in production The 25 is essential for all faults on the automa tic transmission regardless of the origin of the faults It has a microprocessor which r provides access to all the information supplied by the various sensors Fault finding messages to be read supplied by the computer Ny the non read only memory of the computer to be erased Use fault finding fiche N 26 If you are in doubt the fault finding fiche to be used can be ascertained using the XR25 Connect the XR25 Enter the co
124. nformation B Potentiometer feed C Earth If incorrect check the 6 Ignitionon C 2 earth 43V 0 5 track connector see page 23 167 85651R2 A Potentiometer information B Earth C Potentiometer feed 23 171 AUTOMATIC TRANSMISSION Fault finding Checking the connectors CHECKING THE SEALED CONNECTOR FITTED WITH SOLENOID VALVES AND SOLENOID VALVES ON THEIR OWN for the position of the solenoid pilot valves see page 23 37 86449G With the B Vi 958 connected to the battery Red wire of the B Vi 958 on C Result Blue wire of the B Vi 958 NN Fault finding 7 ofo ofo Short circuit Break or earthed Or with a multimeter ohmmeter function Measuring point Fault finding If0Q replace the wiring or the solenoid valves Between B and C 30 2 100 600 20 wrong connection Between A and C 30 OQ 10 0 replace the wiring or the solenoid valves If different to Between C and earth short circuit between earth and the solenoid valve coil replace the wiring or the solenoid valves 23 172 AUTOMATIC TRANSMISSION General THIS PART RELATES TO VEHICLES FITTED WITH THE NEW COMPUTER IN AFTER SALES PRESENTATION AND IDENTIFICATION Of the new computer Of the adaptor lead The new generation computer comes in the same format as the old generation computer It has avehicle speed sensor 1 amultifunction switch 5 and an earth wire aload potentiom
125. no plastic shim 19 Position tool B Vi 715 and measure DI2345 the dimension A between the tool and the planet wheel carrier 16 the dimension B between the stop 18 and the tool Calculate the dimension X X A B Wy VEA TER TTEA GEESE LPL i b e LL LL B Vi 15 PLA DONNEES 86133R 23 66 AUTOMATIC TRANSMISSION Gear section casing 2 On the park wheel 21 Measure the dimension C Ll AAAS Sa Calculate the thickness E of shim 19 The total clearance is equal to JT The thickness of the shim is equal to E JT 0 4 Example A 158 2 mm B 156 9mm C 13mm X A B 158 2 156 9 1 3 mm JT X C 1 3 1 3 2 6mm Shim thickness 2 6 0 4 2 2 mm Thickness of shims available 1 5 mm 2 2 6 3 2 In this case select the 2 mm shim which should give the clearance closest to 0 4 mm 23 67 86021R AUTOMATIC TRANSMISSION Gear section casing Fit plastic shim 19 whose thickness has already REFITTING been determined and park wheel 21 4 DI2346 Refit 34 33 29 30 simultaneously fitted with a new seal and its roll pin 27 and 28 85963 3R Fit park pawl 24 and its spring 26 on shaft 25 88953R NOTE to limit the movement of the park pawl 24 there is a shim which is placed between the park pawl and the gear section at C 23 68 AUTOMATIC TRANSMISSION Gear section casing Fit c
126. nostic socket 4and7 6 track socket 10 and 11 Load potentiometer socket 5 Multifunction switch 13 Computer 23 154 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 UTILISATION CONNECTION CONDITION ZONE A If the fault warning light on the instrument panel remains illuminated or illuminates during a test DO NOT TURN OFF THE IGNITION Intermittent illumination of the fault warning light The fault warning light remains extinguished when the ignition is turned on No gear imposed No kickdown or wrong gear change threshold Checking starter motor function depending on version 23 155 CONNECTION 1 Connect the plugs 14 to the battery 2 Checking the B Vi 958 Switch I1 to the TEST position lights 1 to 6 DIAG 7 8 9 and should be illuminated Otherwise the B Vi 958 is faulty Contact your After Sales Head Office for fur ther details 3 Release I1 and and switch it to RAZ only the DIAG and 6 lights should be illuminated 4 Release 11 only the 6 light is illuminated 5 Connect the diagnostic socket 15 to the con nector of the 9 automatic transmission com puter instrument panel warning light feed 86334R AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 GENERAL FAULT FINDING AFTER ROAD TEST VEHICLE STATIONARY IGNITION ON ENGINE RUNNING Light status Light Components which might be For repair see Checks number faulty section Correct Incorrect Pi
127. not touch the bodywork of the vehicle Light on B Vi 958 Selector lever position Correct value points correct multifunction Value not equal to or for vehicles with kickdown incorporated into the load computer AB P N D 2 1 infinity 88869R 23 169 AUTOMATIC TRANSMISSION Fault finding Checking the connectors CHECKING THE LOAD POTENTIOMETER with an ohmmeter Disconnect connector 10 from 11 and using an ohmmeter check Correct value Fault finding points If the measurements C B 4 1 are different the potentiometer is A B 25kQ 1 faulty or poorly adjusted see B Vi 958 Open the carburettor throttle slightly the ohmmeter BosR should never indicate an infinite resistance 86378R CHECKING THE THREE TRACK CONNECTOR 11 FEEDING THE POTENTIOMETER with a voltmeter INSTRUCTION Look at the carburettor on the po tentiometer mounting side 1st case Throttle opens in an anti clockwise direc tion except Trafic 88154R AUTOMATIC TRANSMISSION Fault finding Checking the connectors 2nd case Throttle opens in a clockwise direction Action on Measuring Correct Fault Trafic the vehicle points value finding If incorrect check the 6 Ignitionon B earth 43V 0 5 track connector see page 23 167 88979R Action on Measuring Correct Fault 85651R2 the vehicle points value finding A Potentiometer i
128. o 17 13 and 15 using the press DI2354 DI2353 23 101 AUTOMATIC TRANSMISSION Final drive assembly ML TORQUE CONVERTER FINAL DRIVE CASING 845775 See 222 for instructions on dismantling the final drive Dismantling the torque converter seal Remove the seal 27 using a chisel or an extractor 88210R1 ADJUSTING REASSEMBLY REASSEMBLING THE SHAFTS Final drive pinion 20 84632R1 Fit the bearing 25 using the press with the mark at the final drive pinion end Put three drops of Loctite SCELBLOC on the threads of the nut With the final drive pinion vertical tighten nut 24 and then tighten to a torque of 4 daN m us ing B Vi 903 Rotate the bearing by hand then tighten the nut to a torque of 22 daN m Step down drive shaft 12 13 14 15 16 17 DI2364 Refit parts 12 to 17 15 and 13 using the press Ensure pinion 13 is fitted the correct way round AUTOMATIC TRANSMISSION Final drive assembly ML Output shaft 8 NOTE check the condition of the O ring 28 on the stator shaft and oil it see next page Refitting see M R 222 and adjusting the final drive Before refitting lubricate all the parts a Adjusting the backlash Since the backlash cannot be measured once the transmission has been assembled it is adjusted when the differential bearings are fitted by mea suring the following dimensions 0 07 Dimension E Theoretical dimension 93 93
129. of automatic transmission the type suffix atC the fabrication number atD kthemanufacturing factory wm 863045 857105 12329 Oil Speedo Vehicle Final drive ratio drive pressure Computer A T in bar number 0 1 bar 600 B C 403 601 B C 40 MPI 602 603 B C 408 L 423 7 Switzer land d f Vehicle MJ3 1344 1354 1344 1354 oe 1277 1277 DAI J X57 B T B 573 C573 AUTOMATIC TRANSMISSION Identification Oil pressure in bar 0 1 bar Speedo Step down gear ratio drive ratio Final drive ratio The instrument panel warning light must be disconnected 23 5 No of planet wheels Computer number 297 MJ3 B 297 MJ3 B297 B29B with cruise control X57 B T B573 C573 031 038 024 026 029 030 AUTOMATIC TRANSMISSION Identification i il Step down gear ratio Speedo dive pressure lanet Computer Step down Differential step number j ratio wheels mechanisms down A 29 24 21 20 139 1 Sump 6 mm deeper felt gauze strainer with increased surface area leaktight dipstick with reduced level 2 Sump 6 mm deeper felt gauze strainer with increased surface area leaktight dipstick with reduced level Unidirectional differential output seals specific to right hand left hand sides 23 6 AUTOMATIC TRANSMISSION Gear change thresholds B403 C403 L423 B3
130. oling Methods reference B Vi 1400 01 Rou 15 01 M S 1019 10 00 00 095 100 Description Tool for fitting differential seal Locally made tool in accordance with drawing on page 23 131 00 00 095 500 00 00 095 800 00 00 095 900 00 00 140 001 00 01 331 601 00 00 101 910 23 129 Tool for measuring the preload in the final drive pinion bearings Test kit Tool for fitting the circlip on the output shaft Tool kit for working on automatic transmission Protective end piece for shaft with internal diameter of 16 mm XR25 test kit for checking microprocessor systems Illustration 7766951 AUTOMATIC TRANSMISSION Special tooling Methods Description reference Mot 587 00 00 058 700 Tool for extracting seals 23 130 AUTOMATIC TRANSMISSION Special tooling B Vi 715 11939R B Vi 952 11938R 23 131 AUTOMATIC TRANSMISSION Fault finding Introduction HOW TO USE THE DOCUMENT There are two types of computer fitted to T A M This document is divided into three parts To each part corresponds computer assembly on the vehicle a fault finding fiche HOW TO KNOW WHICH PART TO USE There are two possibilities e 1st possibility You can identify the type of assembly on the vehicle e 2nd possibility Refer to the vehicle tables in question see fol lowing pages they will give you the number of the fault finding fiche to use as a function of t
131. om 9 the and connect instrument 14 to panel fuse earth the wiring the light NOTE a 1344 or 1354 with a 5 100 250 008 computer must have the warning light 8 dis connected 85651R B The DIAG light Ghd lights 1 to 6 extin guished B Vi 958 Vehicle behaviour remains in 3rd or random gear changes may cause starter motor not to work reverse normal without light illumina ting AUR COMPUTER NOT EARTHED CORRECTLY 23 157 a Identification of the earth 1st version On the 6 track connector on track E through wire 86377R4 2nd version On the multifunction switch through wire G se cured to the automatic transmission G 85651 3R AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 b Checking 1st version Take the following measurement using an ohm meter oe Result Fault finding point E and earth 0 to 0 5 Q CORRECT OTHER INCORRECT See 1 Check the continuity of wire G the earths 86377R1 23 158 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 2nd version Disconnect the 6 track connector and isolate the computer from the vehicle earth do not let it touch the vehi cle bodywork Take the following measurement using an ohmmeter 86381G Measuring points Result Fault finding Between the battery terminal 0 to 0 5 Q CORRECT and point E on the computer OTHER INCORRECT connector See 1 2 3 1 The correct asse
132. on the wiring side isolated from earth Check the insulation of the line between the starter motor relay and track C of the automatic transmission yes computer connector and the insulation of the line between track C and the injection computer for injection versions Does the fault reappear no Success yes Check the multifunction switch on the 6 track connector on the computer side using a multimeter or BVI 958 Refer to MR T A M checking the connectors section Are the checks correct no Replace the multifunction switch 23 149 yes Replace the computer Erase the memory if the new one is an M 4 3 1DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 6 RH ILLUMINATED Operating check of the kickdown switch for vehicles with kickdown or starting authorisation check in P N for vehicles without kickdown 1 VEHICLES FITTED WITH A KICKDOWN SWITCH A Bargraph 6 illuminated on RH at no load Vehicles with open contact kickdown switch No earth on track D of the computer Check that the connector is correctly connected on the kickdown switch Is there continuity between the 2 tracks of the no Replace the kickdown switch switch in the No Load position Check ensure the following continuities Between the engine earth and one track of the kickdown switch connector Between the other track of the switch connector and track
133. rclip on output shaft Tool for fitting final drive pinion bearing track rings TIGHTENING TORQUES in daN m V Differential crown wheel bolts 12 to 14 Differential crown wheel bolts 9 to 11 2 planet wheels Differential cover plate bolts 2 Final drive pinion nuts 16 Inspection cover bolts 1 5 The parts must be removed and handled on a bench with a padded top rubber or thick plastic SEPARATING THE CASINGS Remove the converter the oil pump shaft Separate the final drive casing from the gear sec tion casing the O rings from the sunwheels 86137R shim s 1 and the spacer 2 thecirclip 5 and the washer 6 the differential cover plate DO NOT ALLOW THE DIFFERENTIAL TO FALL the differential 23 86 AUTOMATIC TRANSMISSION Final drive assembly MJ the inspection cover 40 and its seal 42 take care not to lose spacers 41 depending on version Break off notches A on 12 and recover them 85851R1 Pull on the speedometer driveshaft 13 Move the step down drive 9 back so as to release the half clip 10 then remove it Push the speedometer drive gear 11 back to wards the converter Open the spring ring 15 and simultaneously ex tract shaft 39 with bearing 7 Recover the speedometer drive wheel 11 and the drive pinion 9 23 87 85851R6 Extract the bearing 7 and the washer 8 from 39 Lock the final drive pinion 20
134. ributor Does valve VP2 slide normally Refer to MR T A M hydraulic distributor section yes no Replace the solenoid valves and strainer Replace the hydraulic distributor and strainer 3DMXTT1 0 23 239 AUTOMATIC TRANSMISSION Fault finding aid Chart 11 Random gear changes up to 60 75 mph 100 125 km h Vehicle with kickdown switch If the warning light is operational and it remains extinguished when there is a fault disconnect the kickdown switch wire Does the vehicle now behave normally Check the adjustment of Replace the cable Check the routing and the accelerator cable and adjust it condition of the kickdown Is it too tight After replacement switch wire burnt cut or in does the fault contact with vehicle earth persist Is this routing correct Adjust the accelerator cable After this adjustment does the fault persist Repair the wire no Correct no Does the yes fault persist Move the kickdown switch and potentiometer wire as far away as possible from the high voltage leads and check the computer earth After any repair does the fault persist yes Check the routing and condition of the high voltage leads and move them as far away as possible from metal parts Correct Refer to MR T A M computer section Recheck your diagnosis Vehicle without kickdown switch If the warning light is operational and it remains extinguished when there is a fault
135. rin P N R 0 to 3000 Q the switch Leverin R D 2 1 R infinity a high value on vehicles without a kickdown switch no Do you note these values on testing Cut the multifunction switch cable as if a replacement were being made With the switch still in position on the automatic transmission repeat the previous tests at the switch side between the brown and red wires Are the measurements still incorrect Replace the computer Erase the memory if M 4 3 yes Validate the no load and full load values for the E7J version Check the wiring and the condition of the starter relay Replace the multifunction switch Repair if necessary YES Does the fault persist P ry P no And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 248 AUTOMATIC TRANSMISSION Fault finding aid Chart 22 Reversing lights do not work but the starter motor works If the warning light is operational and it remains extinguished when there is a fault check the condition of the reversing lights bulbs and check the earth on the rear lights units Me After the operation does the fault persist no yes Turn the ignition off and ensure the Check the reversing lights fuse continuity between track A on the 6 track Disconnect the 6 track computer connector connector and the ignition switch and check the condition of the connections If continuity
136. rning light 2 Connection between injection compu 9A and 14A Fault warning light connector and dia ter and automatic transmission gnostic socket 3 Solenoid pilot valves 10 and 11 Intercomputer connector 4and7 Sixtrack connector 13 Computer 5 Multifunction switch and earth 17 Diagnostic socket 6and12 Solenoid pilot valve connector 23 114 AUTOMATIC TRANSMISSION Computer and wiring Wiring modification after replacing MB1 automa To install these computers on these vehicles the tic transmission connection wiring 1 has to be separated from the computer and the existing wiring on the A modification to the wiring on L42 B57 C37 vehicle used vehicles C2J engine up to year 1986 had led to the starter motor relay being moved from the In all cases the computer must remain on the relay plate into the engine compartment automatic transmission MB automatic transmissions are delivered by the Modification to the computer earth and conse Parts Department either as a replacement trans quences for fault finding see section on Fault mission or as a service replacement fitted with the finding B Vi 958 computer and the wiring on the vehicle for the starter prevention relay located in the engine compartment 906255 After refitting the transmission on the vehicle en sure that the wiring is correctly positioned and protected in the sheaths NOTE all wiring items of the automatic transmis sion should be at least 150 mm aw
137. rter and spread spring ring 15 apart the belleville washer 6 see diagram for di rection of fitting thecirclip 5 fitting it under groove C 86137R1 When fitting circlip 5 into its groove use tool B M f Vi 959 Fit the spacer 2 and the adjusting shim 1 fit the washer D from the tool onto the circlip place the crescent piece E from the tool in the groove G and tighten the three bolts V until the circlip 5 enters its groove Ensure that 5 is in the correct position 23 95 AUTOMATIC TRANSMISSION Final drive assembly MJ Speedometer drive pinion Differential and its seals Fit a new speedometer drive pinion 12 and its These are reassembled when the differential bear shaft 13 ing and final drive pinion preloads have been ad justed Fit the baffle 23 at the final drive and cover plate end When the final drive pinion is in place fit the final drive assembly and the cover plate fitted with its O ring Tighten the plate securing the bolts to a torque of 2 daN m Fitting the sunwheel seals The seals are refitted using the following tools 85851R5 B Vi 951 Check that 12 is properly clipped on 13 Refit the inspection cover 4 equipped with seal 42 and its spacers 41 depending on version Fit seal 14 on the speedometer drive pinion us ing tool B Vi 905 86104 1R A Tool for fitting the seal on the cover plate end B for
138. s move properly and that the solenoid valves are clean REFITTING Lubricate the solenoid valves and fit the solenoid pilot valve marked 1 on the regulating valve side see diagram Tighten the bolts securing the plate 13 progres sively so that the final coil of the spring 12 is not jammed between the plate 13 and the unit 15 and tighten to a torque of 1 3 daN m Fit the clip into the socket of the sealed connector and reconnect it Refit the hydraulic distributor see previous pages Top up the oil and adjust the oil pressure F Tr pr MET n z Car w eeta eek rra MTS 855965 85596G IMPORTANT if the solenoid valves are not fitted in the correct locations the vehicle will no longer have 1st gear AUTOMATIC TRANSMISSION Speedometer drive shaft seal MJ ML REPLACING SPECIAL TOOLING REQUIRED B Vi 905 02 Tool for removing and refitting speedometer drive shaft seal The speedometer drive shaft seal is replaced using Extract the seal by turning nut B and holding tool B Vi 905 which comprises tool A aseal extractor A fitted with a nut B a tool for positioning seals C athin spacer D spacer E is not used 84803R1 REFITTING Fit the seal on tool C making sure it is the correct way round and tap the end of the tool 84817R REMOVAL Disconnect the speedometer drive cable from the automatic transmission Fit the extracting tool A fit
139. seconds the vehicle warning light and the after ignition relay lights DIAG and 2 of B Vi 958 will extinguish the feed voltage on the six track connec after 3 seconds tor 7 and F ignition on The status of lights 1 to 6 must be in P or N 2 Check the following are correctly clipped in the fuse the six track connector 7 on the com puter and its wires the vehicle wiring connectors involved 86334 1R 6 illuminated for vehicles with integrated kickdown 23 161 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 SPECIFIC FAULT FINDING cont III If the instrument panel warning light illuminates intermittently when driving 1 Refer to section COMPUTER general instructions and check that the earths and feeds are in perfect con dition 2 Make two extension leads so as to be able to put the B Vi 958 in the passenger compartment 88867G Carry out a road test and determine the faulty component depending on the illumination of lights 1 to 6 IMPORTANT If lights 1 to 6 of B Vi 95 operate in a random fashion there is an interference problem NOTE it is normal for the DIAG light to flash very slightly during normal operation 23 162 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 FAULT FINDING ON THE HYDRAULIC FUNCTION In order to view the electrical operation of the solenoid valves part 4139 4141 of B Vi 958 zone C can be used after making some
140. section casing Remove clip A and pull on connector T thecirclip 20 and assembly 17 16 15 13 85661R DI2338 NOTE to remove the lever 30 put it in 1st gear hold opposite the Park position and extract roll pin G TAKE CARE NOT TO LOSE THE QUADRANT BALL AND SPRING DI2339 the piston 12 blowing compressed air through hole T see next page insert a small pipe into hole T and apply com pressed air DO NOT USE TOOLS TO RELEASE 12 23 55 AUTOMATIC TRANSMISSION Gear section casing the assembly E1 E2 10 using the turbine shaft 39 assembly 10 cannot be repaired 85525 2R 86069G DI2360 DI2359 23 56 AUTOMATIC TRANSMISSION Gear section casing 4 the piston 3 using tool B Vi 952 Mark the face chamfer A of the oil pump outer or a locally manufactured tool see Special pinion and remove 2 tooling section NOTE on some versions the faces are reversible DD341 DI2340 CLEANING Do not use trichloroethylene as this may splash on the seals and cause damage Do not use cloths which could leave fluff in the system white spirit or degreasing fluid except on the seals and lint free wadding for wiping off compressed air blowing hard in all holes feed ways and oil ways on the gear section casing 1 thefree wheel 17 forward gear train 11 thereverse gear train 16 the E2 bell housing 14
141. seems to change to neutral and there is a bang when reaccelerating Vehicle with kickdown switch If the warning light is operational and it remains extinguished when there is a fault connect the XR25 and check the operation of the kickdown switch Is the kickdown function active at times other than full load yes Check the load potentiometer sector rotates freely and check the bridging plate is present which prevents damage to the potentiometer when it is tightened Replace and adjust the potentiometer if necessary Validate the no load and full load values for the E7J version y no Check the routing and condition of the kickdown switch wire burnt cut or in contact with vehicle earth and repair if necessary Does the fault persist Replace the cable Vehicle without kickdown switch If the warning light is operational and it remains extinguished when there is a fault check the load potentiometer sector rotates freely and check the bridging plate is present which prevents damage to the potentiometer when it is tightened Replace and adjust the potentiometer if necessary Validate the no load and full load values for the E7J version And vehicles where load information and TDC information is given by the injection computer 23 251 3DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding aid Chart 25 Starting possible in all selector lever positions If the warning light is operational
142. sion Under these conditions can oil pressure be established Check the strainer seal is present and in good yes yes condition Check the strainer sealing surface is flat and the strainer is correctly positioned Replace any parts deemed to be faulty The pump shaft is broken or the splines of the shaft or the converter are damaged Replace the shaft or the converter and the strainer no Clean the hydraulic distributor Fill with oil and check the level Does the fault persist Put the selector lever in P and push the vehicle Does it move forward yes Check if the driveshafts are broken Replace the differential unit Repair or replace the automatic transmission 3DMXTT1 0 23 266 AUTOMATIC TRANSMISSION Fault finding aid Chart 45 No 1st gear after operation on distributor If the warning light is operational and it remains extinguished when there is a fault the solenoid pilot valves are incorrectly connected Only solenoid pilot valve EL1 has a reference mark to correspond with valve VP1 Chart 46 Automatic transmission remains locked in 3rd gear and warning light remains extinguished If the warning light is operational and it remains extinguished when there is a fault check the computer earth Multifunction switch earth wire mounted on automatic transmission housing or earth at terminal E on 6 track connector on 1st version After checking repair does the fault persist no yes
143. sion does not have to be removed and the final drive does not have to be dismantled AUTOMATIC TRANSMISSION Speedometer drive pinion J REPLACING Depending on the type of vehicle release or re move the steering mechanism to gain access to the inspection plate 40 Disconnect the speedometer cable 85851R REMOVAL Remove the cover plate 40 carefully do not drop spacers 41 if working on original fitment spacers 41 of the seal 42 using a mag net original fitment the seal 42 1st CASE Only the speedometer drive pinion 12 or the shaft 13 is damaged Pass a piece of 0 05 mm thick strap iron under the three notches A of the speedometer drive pinion 12 spreading them apart slightly with a screw driver Pull the speedometer drive shaft 13 with a pair of flat nose pliers do not let the strap iron fall in to the sump 23 40 87285R 2nd CASE The pinion 12 and the drive wheel 11 are damaged The automatic transmission must be removed Break off notches A from 12 and recover them 12 N DI2357 Pull the speedometer drive shaft 13 Remove the speedometer drive wheel 11 see page 145 REFITTING Special features Check the condition of 13 Replace 12 systematically Grease all parts before assembly Top up the oil level If particles of polyamide from the speedometer drive pinion or wheel are found in the oil the automat
144. ston support 8 and the discs of F2 7 DI2343 86069R1 Calculation example Check that the piston moves backwards and for clearance measured 3 6 mm wards properly select the 2 mm shim clearance after adjustment 3 6 2 1 6 When the assembly has been refitted with the shim check the clearance again Do not fit more than two shims If this clearance is not correct check the way the rings are stacked and the dimension of the piston refer to the Identification section 23 62 AUTOMATIC TRANSMISSION Gear section casing STRENGTHENED FORWARD GEAR TRAIN ON MB MJ TYPE AUTOMATIC TRANSMISSION There is a strengthened forward gear train with 3 planet wheels as well as an E1 E2 clutch assembly which can be identified by three roll pins A on the forward gear train and a distance of 27 mm between the crown wheel B and cup C of E1 on E1 E2 Original fitment not strengthened Second fitment strengthened 88708G All automatic transmissions of the MB MJ type before the 85 model may be fitted with the modified E1 E2 as sembly identified by a dimension of 27 mm However it is not possible to fit the strengthened forward gear train to an E1 E2 assembly which has not been modified 23 63 AUTOMATIC TRANSMISSION Gear section casing Clip the turbine shaft in the E1 E2 assembly and BRAKE F1 fit 88963 1R A Oil the seals and fit them progressively onto the piston B One undulat
145. stop for full load your diagnosis os Adjust the accelerator Adjust the accelerator yes control control Does the fault persist Does the fault persist yes no no yes Adjust the load potentiometer yes Erase the computer memory and no revalidate the full load and no load values Does the fault persist yes Check the load injection side And vehicles where load information and TDC information is given by the injection computer 3DMXTT1 0 23 272 AUTOMATIC TRANSMISSION Fault finding aid Chart 52 No communication between the XR25 and the computer Versions with an M 4 2 computer Check that the battery voltage gt 10 5 V Check that the automatic transmission fuse has not blown no gt Correct After these checks does the fault persist yes Check the connection of the 2 track connector making the connection between the diagnostic socket and the computer If the vehicle has no diagnostic socket check that the special wiring is correctly connected red plug to Battery black plug to Battery and green plug to warning light output Check ensure the continuity of the line between the 2 track connector and track 7 of the diagnostic socket Check ensure the earthing of track 2 of the diagnostic socket and the presence of Battery feed on track 6 After this operation does the fault persist yes no Check the computer is correctly fed Earth via wire on mult
146. t 9 does not illuminate during this adjust ment check its wiring and the potentiometer and replace if faulty A fault on the potentiometer leads to fixed gear changing thresholds Regardless of the position of the accelerator pe 85651R1 dal Press accelerator fully down LIGHT 9 INCORRECT or poorly adjusted mom ADJUSTING Slacken the two potentiometer mounting bolts V slightly Keep the carburettor throttle valve fully open us ing the accelerator pedal and turn the potentiom eter slightly to illuminate the light 9 Then retighten the two bolts V 87253R If the warning light 9 does not illuminate check its wiring and the potentiometer Replace it if faulty Adjust the potentiometer after replacing or re moving it 23 166 AUTOMATIC TRANSMISSION Fault finding Checking the connectors SIX TRACK CONNECTOR CHECK USING AN OHMMETER VOLTMETER Measuring point Operations to be performed if valu s and values are incorrect Measuring conditions F and earth Computer feed spas Check feed fuse wiring 12 2 V Ignition on x Reversing lights feed D n Check the fuse and the wiring Starter motor A C and earth Check the relay and the starter motor Starter motor authorisation feed n operating 12 2 V wiring Computere E and earth Check the wiring and the earthing on ot 0 to 0 5 Q the vehicle m LN Component checked heht bulbs and earth Che
147. tarter Tie 32 Load Pot Corr load n authorised SOL VALVE DYNAMIC TEST lliumin SV energised CONTROL MODES G 15 01 SV check status of bar graphs BR BL 16 1ST PNR 2ND 3RD CORRECT if off Evi EV2 EV1 EV EV EV2 i ote Line 9R remains exting for full load on veh without compensatar MS anc R Bargraphs on a red background represent a fault Bargraphs on a white background represent a status 23 179 FI21624 AUTOMATIC TRANSMISSION Meaning of the bargraphs DISPLAY AND MEANING OF THE BARGRAPHS IMPORTANT x The information given below is only valid for computers given in the Vehicles concerned section 1 Illuminated when the computer no longer performs its function Illuminates when the ignition is turned on when the communication between the automatic transmission computer and the XR25 is established Illuminated when the computer cannot identify the position of the gear lever Illuminated when the load information received by the automatic transmission computer is incoherent IMPORTANT Vehicles B297 B29E X40 Switzerland and X537 X53B and X573 before 04 91have no fault finding signal relating to the load potentiometer 4 The bargraph will never illuminate for these vehicles If the potentiometer circuit is broken the vehicle will remain in 1st gear If the potentiometer circuit is short circuited gear changes will be
148. tch Check that the connector is correctly connected on the kickdown switch Is there continuity between the 2 tracks of the kickdown switch in the Full load position yes Check ensure the following continuities Between a track of the kickdown switch connector and earth Between the other track of the kickdown switch connector and track D of the computer 2 VEHICLE NOT FITTED WITH A KICKDOWN SWITCH Bargraph 6 extinguished in P N position Check all components of the control and adjust Check the multifunction switch Refer to MR T A M checking the connectors section 23 151 1DMXTT1 0 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 THE TEST KIT B Vi 958 ONLY DETECTS FAULTS OF ELECTRICAL OR ELECTRONIC ORIGIN 86424R FEED TO COMPUTER SPEED SENSOR SOLENOID VALVES LOAD POTENTIOMETER MULTIFUNCTION SWITCH KICKDOWN SETTING LOAD POTENTIOMETER FEED VOLTAGE CONTINUITY OF SOLENOID VALVES MEASURE MENTS 23 152 AUTOMATIC TRANSMISSION Fault finding Test kit B Vi 958 DESCRIPTION OF THE KIT ZONE A used for checking transmissions of type MB MJ ML ZONE D used for checking adjusting the load potentiometer transmissions of type MJ ML Solenoid valves Speed sensor I2 Inverter Potentiometer 9 Adjusting light 1st gear hold Gear Feed light MB MJ ML 2nd gear hold lever F Fuse 3 15 A Kickdown or starter
149. ted with nut B and spacer D Screw in tool A for approximately 3 turns after the tool has made contact with the seal so that the screw thread 1 penetrates the rubber 84886R 23 38 AUTOMATIC TRANSMISSION Speedometer drive pinion MB REPLACING 1st CASE Only the speedometer drive pinion or shaft is damaged The automatic transmission must be removed but the final drive assembly does not have the be dis mantled Process as follows From the differential remove thecirclip 22 and the washer 21 thesunwheel 20 17 18 20 2122 86528R Pull the speedometer drive shaft using a pair of flat nose pliers Rotate the differential until the speedometer drive pinion can be seen inside it 885775 23 39 Loosen the pinion with a screwdriver and recover it Fit the new speedometer drive pinion using a pair of flat nose pliers The pinion and its drive shaft can be refitted by hand The drive shaft must be correctly positioned in relation to the pinion key notches due to the re silience of the lips of the shaft Use a mallet to ensure that it is properly clipped in place 860535 Reposition the drive shaft 19 in the differential and refit the sunwheel 20 washer 21 make sure that the notch is in the correct position and its circlip 22 Refit the automatic transmission 2nd CASE The speedometer drive pinion and wheel are damaged The automatic transmis
150. ter before searching for a possible solenoid pilot valve fault Disconnect the 3 track connector of the load potentiometer Turn the ignition off then on again Replace the load potentiometer if the solenoid pilot valve fault has disappeared and if the potentiometer fault is confirmed short circuit test using multimeter If however the fault persists apply the fault finding procedure associated to this solenoid pilot valve fault Check the 3 track connector of the solenoid pilot valves on the computer After checking the wiring replacing the connector does the fault persist no Disconnect the connector on the sealed connector On the sealed connector side is Ll ad Replace the solenoid valves there a resistance of 25 5 between tracks C and B and between tracks and C yes yes Disconnect the solenoid valve wiring and check the continuity on the wiring lines Is continuity ensured yes Disconnect the solenoid valve wiring and check the insulation of the lines with respect to earth as well as the insulation between the wiring lines Is the insulation ensured Replace the wire Replace the computer and erase the memory if an M 4 3 computer is fitted 1DMXTT1 0 23 146 AUTOMATIC TRANSMISSION Fault finding using bargraph illumination BARGRAPH 2 RH ILLUMINATED Fault on vehicle speed information After a road test if the warning light is still illuminated without having turne
151. the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist Connect pressure gauge BVI 466 07 and measure the line pressure in 2nd gear hold and full load Adjust the pressure if necessary Refer to MR T A M identification and pressure section 3DMXTT1 0 23 269 AUTOMATIC TRANSMISSION Fault finding aid Chart 51 No kickdown at full load or kickdown threshold abnormal at full load Versions fitted with M4 2 type computer with kickdown switch If the warning light is operational and it remains extinguished when there is a fault use the XR25 to check the operation of the kickdown switch Refer to MR T A M checking the connectors section Repair if necessary After the operation does the fault persist yes no Adjust the load potentiometer and adjust the accelerator control if the throttle is not at the stop for full load Versions fitted with M4 2 type computer without kickdown switch Adjust the load potentiometer and adjust the accelerator control if the throttle valve is not at the stop for full load 3DMXTT1 0 23 270 AUTOMATIC TRANSMISSION Fault finding aid Chart 51 No kickdown at full load or kickdown threshold abnormal at full load cont Versions fitted with M4 3 type computer with kickdown switch If the warning light is operational and it remains extinguishe
152. the document will be identified in the top left hand corner by the number of the fault finding fiche to be used AUTOMATIC TRANSMISSION Vehicles involved The following table will give you the number of the fault finding fiche to use as a function of the vehicle type the engine type the automatic transmission type the old generation computer reference the new generation computer refe rence IMPORTANT The identification number of an old generation computer is the same as the identification number of the corresponding new generation computer NOTE as part numbers may change you are advi sed to check the part numbers given in the parts catalogue of the vehicle involved when ordering 23 133 AUTOMATIC TRANSMISSION Vehicles concerned SET Aq 09 LAN 684 cO IEL 98 00 ZZ 666 LEL 00 ZZ ser Aq i 109 TAWN 684 cO Tc ICT F98 00 ZZ ces EELZ 00 ZZ ae e _ PC 201 ETI 98 00 ZZ 67S CEL 00 LL OEN 6 159 IN ISE CHN EIL wolf onov zaen TZE P98 00 ZZ 9P8 804 00 ZZ 100 94 IN9V ZSEI 100 T N 9cZ N9V TSE CLIN 184 9 TOE E N GIZ Y9f TOE E N ETZ of Loe SIN LIL w9f 01 IZE F98 00 ZZ TTS EEL 00 ZZ TOL ERN 104141 P98 00 ZZ c 9 LOL 00 ZZ 0 9 FET S98 00 ZZ TIZ 00 ZZ E N 114 ssi FSET PPETI F 12qumu F CIN pasn oq 0y u ou ped ou ped
153. ting holes plate is circular for a diameter 227 converter Take a reading at each converter mounting hole Compare the readings the permissible runout is 0 3 mm all types 0 5 mm C06 If the readings are above this figure the drive plate must be replaced 80115 1R1 ATTENTION The drive plate of a CO6 requires specific assem bly Refer to the relevant technical note 76985R Before refitting the automatic transmission check the condition of the locating spigot 1 in the crankshaft 23 47 AUTOMATIC TRANSMISSION Stator shaft The stator shaft can be removed from the conver ter housing To do this after opening the final drive housing remove the bolts A and extract the shaft When refitting ensure that the paper seal B is fitted and that the O ring C is in good condition Tighten the stator shaft mounting bolts to 2 5 daN m LI 4 4 P dp 89263R Length of pump shaft 324 mm Length of turbine shaft 284 mm 23 48 AUTOMATIC TRANSMISSION Converter seal SPECIAL TOOLING REQUIRED B Vi 1405 Tool for extracting converter seal from kit B Vi 1400 01 B Vi 1402 Tool for centring converter seal from kit B Vi 1400 01 B Vi 465 Tool for replacing converter seal MJ automatic transmission This operation is performed after the converter has been removed Removal Remove the seal using a
154. tinguished when there is a fault it often occurs following an oil change as not enough oil was refilled Check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level engine running and top it no Correct up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes Vibration of the pressure regulating valve Replace the plate and its seals on the hydraulic distributor Adjust the line pressure 3DMXTT1 0 23 257 AUTOMATIC TRANSMISSION Fault finding aid Chart 32 Metallic noise when idling from the converter housing If the warning light is operational and it remains extinguished when there is a fault the drive plate is split Refer to the instructions for replacement in MR T A M Chart 33 Noise when operating the starter motor If the warning light is operational and it remains extinguished when there is a fault check the tightness of the plate on the converter Check that the starter mounting bracket and the centring dowel are present Check that the converter housing has not split 3DMXTT1 0 23 258 AUTOMATIC TRANSMISSION Fault finding aid Chart 34 Drive plate keeps breaking If the warning light is operational and it remains extinguished when there is a fault the engine automatic transmission centring dowels were not refitted when the drive plate was replaced Ref
155. tion 2 le 9 4 Computer identification The identification number of the computer appears on the central display Example NOTE All information displayed other than that described here cannot be used for fault finding the M automatic transmission 23 201 AUTOMATIC TRANSMISSION Additional tests COMMAND MODE The following will appear on the display Command mode is used to statically test the ope ration of 4 4 the air conditioning compressor clutch cut off relay the solenoid valves On the keypad enter ie Te JE The following will appear on the display Connect the XR25 Turn the selector to S8 r mr Bargraphs 13RH 17RH and 17LH will illuminate when the components are tested At the end of the test the XR25 makes a noise JN The following will appear on the display MU then Turn on the ignition Engine not running vehicle stationary on the If faults have been detected bargraphs 7RH keypad enter the code of the automatic transmis and or 8RH and or 8LH will illuminate sion p 1 4 Locate the fault using the fault finding charts 23 202 AUTOMATIC TRANSMISSION Additional tests ERASING THE MEMORY AND PROGRAMMING THE NO LOAD FULL LOAD POSITIONS Operation to be performed at the end of each fault finding procedure Connect the XR25 Turn the selector to 58 J Turn on the ignition Put the gear selector in position N or P
156. to move or lever blocked Disconnect the control cable on the automatic transmission side Is the lever free to move yes no Repair the control Cable seized in sheath No spacer on the lever base shaft Remove the hydraulic distributor and check the manual valve Is it blocked yes Replace the hydraulic distributor Check the input shaft may be seized 3DMXTT1 0 23 261 AUTOMATIC TRANSMISSION Fault finding aid Chart 38 Engine races after a bend Surging after braking Check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Check the position of the strainer as shown in MR T A M strainer section Chart 39 Vibration at 37 50 mph 60 80 km h or humming on flat road Check the balancing and tyre inflation pressure of the wheels Replace the stepdown gears Refer to MR T A M 3DMXTT1 0 23 262 AUTOMATIC TRANSMISSION Fault finding aid Chart 40 Fault warning light illuminates and extinguishes at random If the XR25 gives no information on the nature of the origin of the fault check the automatic transmission fuse and its mounting Is this correct no Repair replace the faulty components After the operation does the fault persist Check the connector o
157. tor side what resistance is there repairing the wiring between tracks C and A does the fault ist See approximately 0 Q 25 t50 no Disconnect the solenoid pilot valve wire and check the insulation between tracks C and A Disconnect the connector on the sealed connector Is there inslation On the sealed connector side is there a resistance of 25 5 between tracks and A yes Check the continuities on the solenoid pilot valve wires Are the continuities ensured Replace the solenoid pilot valves no yes Replace the wire Replace the computer and erase the memory Validate the full load and no load values on version E7T And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTTI 0 23 217 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 9 RH ILLUMINATED Checking the operation of the kickdown switch 1 Bargraph 9 RH illuminated in no load position Versions with E7 and D7F engines have no kickdown switch Bargraph 9 RH always illuminated Vehicles fitted with an open contact kickdown switch No earth on track D of the computer Check that the connector is correctly connected to the kickdown switch Replace the kickdown Is there continuity between the 2 tracks of the switch no switch in the no load position Check ensure the following continuiti
158. ues programmed are not between 1 37 and 37 5 in the full load position and or greater than 60 in the no load position Validate the full load position by pressing on the accelerator pedal for 5 seconds ignition on bargraph 9 illuminates bargraph 10 RH extinguishes yes Release the accelerator pedal and wait for at least 5 seconds before switching off the ignition Is bargraph 10 extinguished Is bargraph 4 also illuminated yes Deal with bargraph 4 Is the throttle valve 100 open when the accelerator is pressed down fully Adjust the accelerator control Check the potentiometer on and validate the no load and the injection side full load values Validate the no load and full load values And vehicles with load information supplied by the injection computer Without load potentiometer specific to the automatic transmission 2DMXTT1 0 23 221 AUTOMATIC TRANSMISSION 24 and 26 Fault finding using bargraph illumination BARGRAPH 11 RH EXTINGUISHED IN P N Starting authorisation selector in position P N Check all control components and adjust them BARGRAPH 12 RH ILLUMINATED ENGINE RUNNING Engine speed information fault Check ensure the continuity and the insulation of the connection between track C of the automatic transmission computer connector and the injection computer connector track 12 for E7 engine track 48 for D7F engine After checking repairing does the fault persist
159. umber of particles at the bottom of the housing yes no Repair the automatic Check that the hydraulic distributor valves transmission slide correctly and that the ball of solenoid valve EL2 is not jammed Is there a fault yes Clean the hydraulic distributor and replace its seals or replace the solenoid pilot valves depending on the fault no Also replace the strainer and its seal Refit the transmission and fill it with oil to the correct level Recheck your diagnosis 3DMXTT1 0 23 230 AUTOMATIC TRANSMISSION Fault finding aid Chart 2 Slipping when starting in forward or reverse gear but operating normal above 12 5 mph 20 km h in forward gear If the warning light is operational and it remains extinguished when there is a fault the fault is due to the converter freewheel which is no longer engaging Replace the converter and check the condition of the ignition target 3DMXTT1 0 23 231 AUTOMATIC TRANSMISSION Fault finding aid Chart 3 Slipping in reverse gear If the warning light is operational and it remains extinguished when there is a fault check the conformity of the dipstick on the table in MR T A M Replace the dipstick if it is incorrect Check the oil level and top it up if necessary After checking replacing the dipstick and topping up the level does the fault persist yes no Is there engine braking in 1st H gear hold Brake 1 is faulty Refer to the
160. using tool B Vi 953 on the pinion 19 86138R Unlock nut 16 and remove it Remove the tool and knock out the output shaft 20 using a mallet recover bearing 17 spacer 18 and drive pinion 19 AUTOMATIC TRANSMISSION Final drive assembly MJ Remove From the final drive casing remove the final drive pinion outer bearing track rings the baffle 23 using a copper hammer theseal 22 using a diameter 41 mm sleeve the needle race 43 from the output shaft using an extractor such as a FACOM U40 U51B dowel n 7 85614 2R With a small lever release the outer track ring 25 and use tool Mot 587 to finish the opera speedometer drive seal with tool B Vi 905 tion theadjusting shim 38 From the differential cover plate 4 remove the baffle 23 theseal 22 the outer track ring 84803R 85851R2 23 88 AUTOMATIC TRANSMISSION Final drive assembly MJ DIFFERENTIAL Remove two of the bolts securing the crown wheel Extract the bearings on the crown wheel end and casing end using tool B Vi 28 01 fitted with jaws B Vi 48 or similar type of extractor 20 01 67145R RL mm ne 67144R Remove the bolts securing the crown wheel to the casing bolts cannot be reused Differential with 2 planet wheels Remove the roll pin holding the planet wheel shaft using drifts B Vi 31 01 or B Vi 39 72851R 77024R
161. ut for as long as possible Refit the plugs with new seals rnc es d 23 15 AUTOMATIC TRANSMISSION Maintenance The oil is refilled via the dipstick tube Fit plug C Use a funnel fitted with a 15 100 mesh filter to The oil is refilled through plug B and the oil trap any impurities in the oil should be level with the bottom of the aperture of plug B When the oil has been drained refill with the rec ommended oil CHECKING THE LEVEL gear section oil Start the engine and let it idle check the oil level The vehicle must be unladen and top up if necessary EXAMPLE MB The oil is at ambient temperature engine cold Place the vehicle on a flat horizontal surface Place the selector lever in Park P Start the engine and wait one or two minutes for the converter and cooler to fill with oil Remove the dipstick with the engine running The oil level must not be below the MIN COLD mark risk of damage or above the MAX COLD mark risk of damage 87297R 2 ML final drive B The oil must be drained with plugs B and C re A moved 85935R1 A Min cold B Max cold ATTENTION Too much oil will lead to the oil overheating abnormally leaks Too little oil will lead to the gear section being damaged 84495R 23 16 AUTOMATIC TRANSMISSION Maintenance CONFORMITY OF THE DIPSTICK IMPORTANT in order to ensure that the oil level is correct you must check the conformity of the dipsti
162. w seal and fit it on the cham fer To position it use tool B Vi 465 tapping lightly Refit the converter after having lubricated the seal face ML automatic transmission Removal When the converter has been removed remove the seal using a chisel or an extracting tool 88210R Check the condition of the smooth part of the sta tor shaft 1 Refitting Oil the seal and push it fully on using tool B Vi 1402 B Vi 1402 11954R Refit the converter after lubricating the seal face 23 51 AUTOMATIC TRANSMISSION Gear section casing NEEDLE THRUST RACES AND WASHERS Needle thrust race between the drive hub and E1 E2 30 x 48 x 3 60 Needle thrust race between E1 E2 and planet wheel carrier 32 x 48 x 3 60 Plastic washer between bell housing E2 and the planet Plastic washer between bell housing E2 and the planet Plastic washer between park whdg and planet wheel transmission Needle thrust races between park wheel and sunwheel Adjusting shim 0 to x unremovable DI2358 23 52 AUTOMATIC TRANSMISSION Gear section casing SPECIAL TOOLING REQUIRED B Vi 952 B Vi 715 Tool for removing F2 piston Tool from kit B Vi 710 TIGHTENING TORQUES in daN m Gear section casing mounting bolts 2 Sump bolts 0 6 Hydraulic distributor mounting bolts see tightening order 0 9 Oil pump hub mounting bolts Diameter7 1 5 Diameter 6 REMOVAL
163. way Do not fit washers or shims to the planet wheels ADJUSTING THE DIFFERENTIAL PRELOAD The differential preload readings are taken be fore the seal 22 and the final drive pinion are fit ted It is obtained using a shim 38 In the casing refit the shim 38 removed during dismantling the outer bearing track ring 25 Place a piece of string around the differential and 860675 fit it in place The differential should rotate under a load of bet On the cover plate 4 fit ween 3 and 6 daN m in the case of new bearings the outer bearing track ring and freely without play when the original bea rings are refitted By increasing the thickness of the shim 38 the preload increases and vice versa iy cates Remove the cover plate 4 and the differential PRET 85614 1R 23 92 AUTOMATIC TRANSMISSION Final drive assembly MJ REASSEMBLING THE FINAL DRIVE PINION Fit tool B Vi 953 and tighten the nut to a torque of 16 daN m see NOTE The final drive pinion outer bearing track rings are refitted using tool B Vi 961 85615R2 NOTE For some automatic transmissions the helical angle of the secondary pinion has been modified thus B Vi 953 must be ground to modify E 86142R Refit the inner bearing track ring to the final drive pinion 20 856155 Offer up the final drive pinion 2 to its location on the final drive casing and fit step down gear 19 with

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