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This is Citroen's procedure for a 2.0 petrol 138 bhp manual gearbox:

 

2. Removal
Place the vehicle on a 2 column lift.
Drain manual gearboxes only.
Remove the wheels.
 
 
Fit the tool [0606-AY / 6310-T] which is like a long bar that bolts to the wheel hub to hold to stop it turning as the hub nut is undone.
CAUTION : Never brake to loosen transmission nut because this is likely to shear the screws fastening the brake disc.
Take down :
  • The hub nut pin (1)
  • The hub nut steel cage (2)
  • The drive shaft hub nut
  • Remove the tool [0606-AY / 6310-T]
 
 
Unclip :
  • The wheel sensor harness (at "b") ; Move aside the harness
  • The brake wear warning lamp harness (at "a") ; Move aside the harness
Take down :
  • The steering track rod ball joint nut (4)
  • The strut lower nuts (7)
  • The brake hose to strut bolt (6)
Move aside the brake hose (3).
Uncouple the steering ball joint .
Remove strut lower bolts (5).
 
2.1. Right hand drive shaft
 
 
Loosen bearing thrust plate bolts (8).
Tilt the bearing thrust plate (9).
 
2.2. Removal (continued)
Move the strut towards the outside.
Detach the drive shaft from the hub.
Remove the drive shaft.
 
3. Refitting
CAUTION : Observe the tightening torque values.
 
 
Tightening torques : hub nut 345 Nm, drive shaft bearing 20 Nm.
CAUTION : Always fit new Nylstop nuts.
Check :
  • The absence of play in the driveshaft joints
  • The condition of the gaiters
  • The condition of the bush bearing
Overhaul the driveshafts (if necessary).
 
 
Always replace the ring seals ; Using tools [0332-B] / [0317-U] / [0346-S] and [0332-A] / [0317-T] / [0346-R].
Apply grease to the space between the oil seal lips.
Grease the outer cage of the right-hand driveshaft bearing.
CAUTION : Take care not to damage the gearbox output shaft seal lips when replacing the drive shafts.
 
Reinstall the driveshaft.
3.1. Right hand drive shaft
Relocate : The bearing thrust plate (9).
Retighten screws (8).
3.2. Refitting (continued)
CAUTION : Always fit new Nylstop nuts.
Reposition : The suspension unit.
Fit :
  • The screws (5)
  • The nuts (7)
Couple up the steering ball-joint.
Put the brake hose (3) in place.
Fit :
  • The bolt (6)
  • The nut (4)
  • The brake wear warning lamp harness (at "a")
  • The wheel sensor harness (at "b")
Fit :
  • The tool [0606-AY / 6310-T]
  • The drive shaft nut
  • The steel cage (2)
  • The pin 1
Remove the tool [0606-AY / 6310-T].
Fit the wheels.
 
Tighten the wheel bolts
 
4. Refilling : Gearbox
The gearboxes are lubricated for life (Without routine inspection).
After the gearbox has been drained, it is filled by means of a breather on top of the gearbox.
Grades of oil used : TOTAL LUNARIA S, ELFRIMA, TEXACO CAPELLA, CASTROL ICEMATIC 299, SHELL CLAVUS OIL, MOBIL GARGOYLE ARCTIC 300 : ESSO 75W80 EZL 848 or TOTAL 75W80 H 6965.
Oil capacity of the ML6C gearbox : 2,6 litres.
Oil capacity of the BE4 gearbox : 1,9 litres.
Oil capacity of the ML5C gearbox : 2,1 litres.
N.B. : If topping up is required this is carried out by draining the gearbox and filling it with the correct quantity of oil for its capacity.
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