Berlingo EGS clutch

[Lighty]

I replaced one of these for the 1st time this week, and also a manual gearbox one, so got a good insight into the differences between the two. Both were late vehicles, the manual car had done 130000 miles, the EGS 99000.
This is not a description of how to do the job, just a few pictures & a general idea of the work involved.
On the EGS car, the subframe has to be removed, because the gearbox is much larger, so the job is much more time consuming.
1st on the EGS car, you need diagbox, to depressurise the system, this takes a few seconds once you have connected to the car & gone into the gearbox ecu. Then you can remove the battery& tray, driveshafts etc etc. When I remove the subframe, I leave it hanging on the antiroll bar links & just pull it back out of the way. This makes refitting much easier although it tends to be in the way a little more

[Lighty]

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Notice the subframe pulled back and the unsupported steering rack needs to fastened up on the N/S, by a cable tie .

[Lighty]

One of the hardest parts of the job is getting the starter motor bolts undone, particularly the centre one as it is a real stretch in it's position, I have a very short but top quality hardened 6mm Allen socket so as not to round off the bolt.

[Lighty]

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[Lighty]

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The wiring above the top of the gearbox needs to be moved safely out of the way, this contains some important wires, so great care should be taken with this part .some of the bell housing bolts are behind the plastic shroud.

[Lighty]

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A 2 feet long 3/8 extension helps to reach very arkward bolts once the gearbox is lowered from its mounts.

[Lighty]

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This is the last bolt to undo, it hits the dpf retaining bolt, so you have to gradually pull the gearbox away whilst undying the bolt 1 turn at a time, it takes quit a while and makes your arm ache. Putting it back in is way harder.

[Lighty]

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Gearbox on the floor, it's a large unit, I can lift this out on my own, but not put it back in without assistance.

[Lighty]

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Old & new electronic thrust bearing , this must be replaced & is quite expensive

[Lighty]

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Clutch now visible, close inspection shows the clutch fingers are very worn , this is the usual failure point.