Ball joint, gear linage and Clutch cable clip XANTIA 1.9td

[Stickyfinger]

As known I have "popped a ball joint" in the gear link rod system...

I have taken (enhanced) this photo...........Airbox on the left/fuse box to the right

Not sure of the connections etc atm.....I cannot get access to any diagrams as my links to the are broken.

OK, found another parts site:

Am I correct in thinking I am looking at the (Part No C ) the main gearbox, gear change Shaft/Arm..... if so what rod attaches to that and am I correct in assuming I see the internals of the rods ball joint still attached to its head ??

[mickthemaverick]

As I don't know which setup you have Roger here are all the relevant diagrams I could find for a 1.9TD. Hopefully one 0f them might help:

XANTIA - 0290 01 335605 - GEAR CHANGE CONTROL BINACLE SIDE.pdf

Copied from Servicebox backup

(150.13 KiB) Downloaded 57 times

XANTIA - 0290 01 335601 - GEAR CHANGE CONTROL BINACLE SIDE.pdf

Copied from Servicebox backup

(193.74 KiB) Downloaded 47 times

XANTIA - 0290 01 335125 - SPINDLES FORKS GEAR CHANGE CONTROL INT.pdf

Copied from Servicebox backup

(184.91 KiB) Downloaded 55 times

XANTIA - 0290 01 335103C - SPINDLES FORKS GEAR CHANGE CONTROL INT.pdf

Copied from Servicebox backup

(174.33 KiB) Downloaded 59 times

XANTIA - 0290 01 335103 - SPINDLES FORKS GEAR CHANGE CONTROL INT.pdf

Copied from Servicebox backup

(199.04 KiB) Downloaded 52 times

XANTIA - 0290 01 335101 - SPINDLES FORKS GEAR CHANGE CONTROL INT.pdf

Copied from Servicebox backup

(203.55 KiB) Downloaded 61 times

[Stickyfinger]

XANTIA - 0290 01 335103 - SPINDLES FORKS GEAR CHANGE CONTROL INT.pdf

Thanks Mick, that confirms the (internet) info I have......

Control rods ordered.....it is No 11 that has failed at part C end as I thought (shown grey'd out) .
Access via engine bay with airbox removed.

[Stickyfinger]

These arrived today....

[CitroJim]

Ohh nice! Adjustable ones You'll be able to turn your gearchange into a short-shift and pretend you're a rally driver

[Stickyfinger]

Ohhh GREAT.........There is an error with the supplied rod (one of), TWO HOURS of trying to get it to fit by feel (the ball joint is hard to see tucked behind the engine block....ARRRRGGGGG

As supplied this NEW long rod (like the small rods) has a Large head-Large ball joint and a Small head-Small ball joint......

BUT, there always is !!!
Both OEM small rods are Small head-small ball/Large head-large ball

The OEM Long rod is however a Large head/large ball & small head/Large ball ! No wonder I could not "pop" it on like the others !!!

Lucky, the small end/Large ball joint on the original LONG rod was in OK condition and was the adjustable end.....so I cut the small head/small ball joint off the new rod, cut an M6 thread onto the shaft and screwed on the old small end head/Large joint.

Onto the clutch clip next. I found a compleat undamaged metal clip under the dash sound deadening, it just fell out/no bits of plastic however.....so either the fitting is broken (the plastic cable carrier) or the clip just "fell out" because it has at some point been changed and fitted incorrectly (from below is incorrect I read)

[CitroJim]

This is so often the problem with a lot of the 'new production' spares stock for the older cars... Close but no coconut...

At least you got round it

All the best with the clip

[Stickyfinger]

Onto the Clutch cable clip..... NOT A JOB if you are 6ft4in !!

Seat out........

Bolt in the "impossible to remove" orientation........interestingly Citroen show the "impossible to do unless the care is stripped" orientation of said axle through bolt

So, how to remove it ??..... well I took a Reciprocating hacksaw blade and clamped it into a Stanley knife handle.....
working upside down, fun job, NOT !....arm lacking blood.

Bolt head removed.............

Peddle removed...........

Remains of the clip below (Jim thinks it is the original clip)

The whole "nose" of the clip is missing

[Stickyfinger]

New Gear selection rods in place.....

[mickthemaverick]

Looking good!

[Stickyfinger]

Looking good!

Easy bit Mick.....inside the car, on my 6ft4in back, spades for hands, sore neck ect ect------------trying to grab the cable/attach carrier, side on metal lock clip etc......now that is the hard bit, still struggling with that........... NO SPACE for people designed like me !.

[mickthemaverick]

Well we know someone who would fit in there much easier!!

[RichardW]

ISTR that it's easiest to put both parts of the clip on the pedal, then push it onto the cable till it clicks home, and then worry about getting the pedal on. But it was nearly 20 years ago....

[RichardW]

Only 19 years apparently https://www.frenchcarforum.co.uk/forum/ ... ng#p136237

[Stickyfinger]

Given up.....so far I have spent 5 hours trying and not got anywhere near success....not even a sniff at it

Not much (even steering racks) has ever defeated me/team, but I this it is 100% not possible for me to get my hand (hand, two hands = no chance) in there to even touch the plastic carrier let alone getting the metal clip in it. I "hooked" the cable into the plastic carrier... I tried with long nose pliers etc etc

Should the metal retaining clip be fully --Pre-Installed-- over the plastic cable carrier, the peddle installed THEN push the cable from the engine bay to force the "bullet head" past the retaining clip "wings" until it Clicks in place ??

I also seem to have dislodged a plastic tube (??) that the cable runs through the bulkhead. This is now loose !

Note I have NOT installed the metal retaining clip over the plastic carrier......is this my error,??, eg thinking the metal clip should be applied after ??


So the only thing left to do is take the car off the road, remove the dash and do it like that.....dash out needs doing as the heater matrix needs replacing but I had hoped to do that in the summer.