DIY AL4 / DPO gearbox repair

AL4 / DPO Automatic Gearbox

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Peugeot 307 XS
2004, 2.0 16v, 90tkm

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Most part of this job is done from the upper side of the gearbox, so the vehicle doesn't have to be elevated much. A flat surface is needed to accurately top-up the gearbox oil level after the job, and two 2" wooden planks to drive the vehicle upon for access to the drain- / level- plug.
When changing the valves, the gearbox oil doesn't necessary have to be changed. Nor does the gearbox need to be drained. 1 ltr of oil should be sufficient to fill and top-up the gearbox, after the valve change.

Peugeot 307 :There is no need for coolant fluid draining, or radiator removal, only the Air-Cleaner assembly needs to be removed to gain access to the valve unit cover.
Renault Scenic :Thanks to information left in comments below, on the Scenic ( 2007 ) the front needs stripping down for access. Unfortunately i cannot say how much needs stripping down or does it require removal of the radiator.
Thanks for the comments. Much appreciated.

Preparations

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• Set the vehicle gearbox in P-position ( No Handbrake ).
• Remove the battery minus ( - ) terminal.
• Make sure the vehicle cannot move by using wedges.
• Locate and identify the Drain/Level plug TYPE.
  ( See text below ).

There are at least two different "plug's" and you want to be certain you open the right plug, depending on if you want to drain the gearbox or not. Read more about how to identify the plug further down. Jump from here.
On this particular Peugeot, in addition to changing the Main Pressure EVM and the Converter Lock-Up EVM, the oil was changed for two obvious reasons that can be seen in the picture where only the Level-plug has been opened. The gearbox is hugely overfilled and the oli is red, meaning it's NOT Mobil ATF LT 71141.

Gaining access

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For access to the Valve Unit Cover, the Air-Cleaner assembly needs to be removed.
Remove Air Filter upper cover and the air-filter. The lower half of the Air-Cleaner assembly is attached to the main frame and it might be necessary to open up the LH-side inner wheelhouse a little to gain access.
After releasing the lower half push it down, out of the way of the gearbox valve cover that is located just behind it. Release any clamps holding wiring or hoses and move them aside or hoses from the front side of the valve cover.

Changing the Valves

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It is very important to ensure that the area above and around the cover is clean, so that dirt or particles don't enter the gearbox when the cover is opened.
Remove the mounting bolts around the cover and carefully remove the valve unit cover.

!! Very Important !! 
Notice and mark up the position of the lever arm on the upper side of the valve body.
Also notice the position of the lever on the back side, and the slot it goes into. The position of this lever and slot is easy to get wrong when reassembling the unit.
Release the valve body and pull the upper side slightly towards you.
After removing the connecting wire the valve unit can be removed.
The rubber sealing rings shown in the picture are not needed if the valves are replaced with the new
Borg Warner type ( recommended ).

Original valve part no: 2574.10
Borg Warner valve part no: 2574.16

Reassembling

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Remove and replace the old valves with new and connect their wires. Also remove the rubber sealing if the new valve is delivered and fitted with the seal ( Borg Warner ).
When reinstalling the Valve Unit, make sure the levers are positioned correctly before attaching the valve body to the gearbox.
Perform an oil level check as describe further down.
After topping up and checking the oil level, the vehicle should be driveable without performing any software update. Although it is recommended to visit a dealer to get the latest / correct software for the gearbox.

For this vehicle the Parts was delivered to Sweden by:

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Eurocarcare Limited
Units 3 & 4 Beaufort Court
Mansfield Road
Derby
DE21 4FA

Location: UK

Link:  EuroCarCare Ltd




Oil level check / Top Up

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After reassembling everything the gearbox oil level should be checked and a top-up done. This is basically performed in the same regardless of plug type.
The important thing is to open and close the Level-Plug, not the Drain-Plug.

• Make sure the Level plug at the bottom is OPEN.
• Locate the Filler plug on the gearbox upper side and slowly top-up the gearbox until oil starts dripping from the level plug.
• CLOSE the level plug and add approximately 0.5 L oil into the gearbox.
• CLOSE Filler and Start plugs and start the engine. Let the engine idle until the gearbox oil is warm. If you have access to a thermometer, let the oil warm up to 58 - 68 degrees Celsius, otherwise just let the engine idle until the gearbox feels clearly warm.
• With the engine RUNNING, open the Level plug.

! ! C A U T I O N ! ! 
The oil may be HOT!

If the oil runs out in a trickle and then start dripping, the oil level is CORRECT.

If no oil runs out.
Close the Level plug and stop the engine.
After the oil has cooled, top-up with 0.5 L oil and close the plugs. Repeat level check.





Drain- / Level- Plug

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There are at least two different types of drain- / level- plugs on the AL4.
On one of the two different plugs, you can easily see and tell the difference between the filler and the drain plug, but as on this 307 you only see one plug.
The plug you see is actually the level-plug, and only after opening the level-plug the drain-plug comes visible.
The draining is done by taking out the level-pipe using an Allen-key.

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Update: 

This change of valves was carried out in April 2016.

Up to date ( November 2025 ), no gearbox problems have been noticed.

No gearbox related fault codes have been registered after the change to the new type of valves.

DISCLAIMER

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If you are inexperienced working on projects like those mentioned on this blog, especially but not limited to electrical or mechanical projects,please remember to read all safety precautions and use safety equipment. Also remember that during the work, it is very possible to cause more harm to the vehicle than it initially had. You might also void your vehicle insurance, create a hazardous condition, harm or even kill yourself or others. By using information given on these pages, you agree to do so on your own risk. In NO event shall the blog OWNER be responsible or liable for injuries to persons or damage to property, related to or resulting from, ANY information published on this blog. The information on this blog is published “As Is” and appear without expressed, implied or promised warranties of ANY kind. In particular the Blog Owner makes no warranties as to the accuracy, quality, completeness or applicability of the information provided.