Berlingo Clutch
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Thread: Berlingo Clutch

  1. #1
    Tadpole
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    Default Berlingo Clutch

    Hi all. New to your forum. Unfortunate circumstances have led us to your forum.
    We recently purchased a 2012 Berlingo 1.6 HDI at auction. Looked like a good vehicle at the time but unfortunately our expectations have fallen short. Has 95000km on clock.
    Our 5 speed manual gearbox appears to be behaving more like a CVT. Clutch slippage.
    We have no citroen or Peugeot dealers locally.
    I have obtained 2 local quotes both being around $2.5k. One indicated it would have a dual mass flywheel but all the trawling of forums indicates that it should be a solid mass. Cheap EBAY clutch kits for solid flywheels start around $350.
    I am trying to decide whether to do the job myself to save $2k or start getting quotes for labour only and supply the parts.
    I have not done a front wheel drive before and don't have a hoist. I don't particularly feel like crawling under the car with a bung shoulder down here in cold wintery Gippsland but if I can't get a more reasonable quote I will have too.
    I have watched a utube on an older petrol berlingo from the UK. Mechanic by the name of Williams did a sterling job in the piss pouring rain. Looks quite a bit more involved than the rear wheel drives I have done in the past.
    Just wondering if any of you have a step by step - blow by blow description to get my head around before deciding one way or another would be very much appreciated.
    Any other tips also appreciated.
    Thanks in advance.

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  2. #2
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    If you post the VIN, some here will know which type of flywheel is fitted.

    I'd also suggest you contact EAI in Melbourne, with the VIN to hand, to get a price for the clutch kit. They could look up the flywheel also.

    You don't need a hoist, but something to lift the front for access, and support for the engine when the gearbox mounting is removed. I do have a manual, but it's in French. I'll look around to see if I have an English one.

  3. #3
    1000+ Posts dmccurtayne's Avatar
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    Itís a basic job only problem is there is one bell housing bolt that goes from the engine side to the gearbox and depending on the exhaust you need to remove the exhaust down pipe to get it out


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  4. #4
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    Vf7 7e9hec cj668181
    Appears to be a hydraulic operated clutch - not one of those auto adjusting cables.
    We contacted our nearest Melbourne Citroen dealer today but their only parts interpreter is on leave.
    Cheers

  5. #5
    1000+ Posts dmccurtayne's Avatar
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    IMG_1559906675.162938.jpg IMG_1559906690.264069.jpg


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  6. #6
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    Did you contact EAI index ? There may be a significant price difference.

    The thing that makes FWD more involved is the suspension to shift, 2 drive shafts, and stuff fitted on top of the box mount and in the way. Once removed the clutch job is similar to RWD. Berlingo transmissions are quite conventional.

  7. #7
    1000+ Posts dmccurtayne's Avatar
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    Shit form from the dealer Iím a tech jeez my 13 year old could have looked that up anyway the flywheel shown on your car is a single some bongos had a dual but not yours I would just do a clutch kit.


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  8. #8
    1000+ Posts dmccurtayne's Avatar
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    https://rover.ebay.com/rover/0/0/0?m...2F173295237893
    Donít forget that bolt I mentioned


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  9. #9
    Tadpole
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    Trying to get a list of how to do this together.
    Is the B9 same as the older model as far as suspension set up https://www.youtube.com/watch?v=DW_NxTUZOBM

    or more like a c5? https://www.youtube.com/watch?v=b5B2MWMbCrA


    I have started to compile a list for disassembly
    Please feel free to correct/adjust as appropriate
    and again thanks for your valuable input.

    Position vehicle
    Chock rear wheels
    Disconnect and remove battery
    Remove battery tray
    Remove engine plastics
    Disconnect plugs, cables and earth, tie cables out of the way.
    Loosen wheel bolts
    Jack vehicle up and place front on stands
    Remove wheels – place under vehicle
    Remove plastics in wheel wells
    Remove plastics from beneath motor gearbox
    Drain oil from gearbox – replace and tighten sump plug
    Undo left wishbone ball joint and separate.
    Remove left drive shaft inner cv from gearbox. Plug hole with clean cloth
    Remove left hub nut from outer axle. Using brass or plastic rod knock axle shaft through and remove left drive shaft
    Undo right wishbone ball joint and separate.
    Remove right hub nut from outer axle. Using brass or plastic rod knock axle shaft through
    Undo Right drive shaft centre bearing mount
    Remove right drive shaft inner cv from gearbox, remove right drive shaft plug hole with clean cloth.
    Remove lower gearbox support mount or remove left sub frame assembly (not sure which
    Start undoing gearbox motor bolts and nuts from starter motor and work to front leaving some in place to support weight. Studs can be removed using Torx socket on tip.
    Bolt where exhaust is – bend heatshield to allow
    Remove clutch slave cylinder and tie out the way
    Support engine with trolley jack
    Remove top gearbox support
    Undo top engine to gearbox bolts
    Using second jack to support gearbox remove lower stud/bolts and slide out the way to access or remove.

  10. #10
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    I'm sorry that these are close to unreadable, but it's the price to pay for AF's very severe limit on attachment size.
    p1.jpg p2a.jpg

  11. #11
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    What is the trick to removing the plug on the top of the gearbox?
    Is it a pinch type plug - do I use right angle pliers to pinch it before pulling out or does it have a clip and use a screw driver down side to release?
    Or do you just pull it straight out?
    Cheers
    Last edited by Tritium; 20th June 2019 at 04:27 PM.

  12. #12
    1000+ Posts dmccurtayne's Avatar
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    I assume your talking about the reverse light switch you lift the tab up at the front of the plug and it will pull out


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  13. #13
    1000+ Posts dmccurtayne's Avatar
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    IMG_1561008942.872476.jpg


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  14. #14
    1000+ Posts dmccurtayne's Avatar
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    Do you have someone with a bit a experience to help you or are you going it alone


    Garage C5 X7 3008 XTE
    Gone but not forgotten 206 GTI 180 306 XR SED 405 MI16 x2 xzara VTS 406 SV 206 XT Berlingo 2011 (best car ever) 306 HDI 307 XSE HDI touring
    Fix it right the first time

  15. #15
    Tadpole
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    Going it alone.

    Pulled up for the day needing a 36mm socket to remove the driveshafts.

    Not sure on gear selector. Unbolt from gearbox or just disconnect cables and leave it attached...?

  16. #16
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    The big drive shaft nuts need real force. If you don't have a breaker bar, or a rattle gun, you'll need some way to extend your socket drive, like a steel pipe. The easiest one man way to hold the hub while you muscle away at the nut is to refit a couple of wheel bolts and jam them to the ground with a suitable bar. I reckon getting out the drive shafts is the hardest part.
    Last edited by seasink; 20th June 2019 at 09:21 PM.

  17. #17
    Tadpole
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    I have a 3/4 rattle gun but will have to slip drive shaft back into gear box. Got a little bit ahead of myself there.
    Cheers.
    Just waiting for shops to open then drive into town for socket.

  18. #18
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    Shafts have been removed.
    Does the starter motor have 2 or 3 bolts.
    So far the top starter motor bolt has been the most difficult/painful for me.
    Still not sure on selector. Can I just pry the cups off the balls or is there another way?

  19. #19
    Tadpole
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    Appears the gear linkages pop off with a little effort.
    The third starter bolt screws in from the gear box side.

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