C4 Grand Picasso EGS: Clutch replacement

[uzigon]

It has come time to replace the clutch assembly in my C4 Picasso (230,000 km). The winter wasn't kind to her, the clutch starting really wearing after having it stuck in a farm field and rocking the car back and forth between reverse and forward gear to break free - since then it had been grinding whenever building inertia, like stopping at roundabouts and hill starts. A few weeks ago we had part of our road wash out along a hilly section and the car has been struggling to climb ever since. Now the clutch appears to be slipping (strange rubbing/whirring noise from gearbox area) and cutting out. There is likely enough life left on the plate to get it to a shop but not back up the hill, which is about a 200 meter climb from the main road. I've been calling around and no shop within 50 km wants to do the work saying it is "more trouble than it's worth" which I can believe after researching about these vehicles and their piloted manual gearboxes.

Now I am capable and willing to take this job on myself, and since it's my only car I don't really have much choice in the matter if no one else will. I have most of the tools already apart from the diagnostics software to depressurise/re-pressurise, program the gear grid, etc, etc. I was hoping some guidance from the community might prove to be valuable.

Primary questions: What all do I need for EasyDiagnostics? Do I need the tool, the Diagbox software and the PSA license (which I priced at around 300 euros!) does this tool and software work with tablets or laptops? Windows 10? Linux? I've never need to use a computer so much to work on a car before owning a Citroen. LOL! And most importantly can I carry out the servicing and reprogramming using Diagbox? I have seen more reference to Lexia for carrying out this procedure.

Secondary line of questioning: What all should I replace while I am performing this job? I want to replace the DMF, clutch components, and the drop out cylinder. I seen mention of a "electronic clutch cylinder ECP" is this another part that I should have ready to install? I also plan to replace the fluid in the gearbox to maybe make it easier to remove, would this be a good idea or is it risky business if there aren't any complaints coming from the gears? And if so should I opt for a higher grade gear oil? (performance 75w-80 for larger gearboxes) due to the age of the gearbox.

I would not be considering doing this job if I didn't find such a supportive community. These cars are genuinely interesting for their quirkiness and stubbornness, and if I can keep this one running I think there is reward in that alone.

Cheers!

[uzigon]

I think I was able to answer most of my questions from above. This job has turned into a bit of nightmare. Nearly a month in, stranded up the country trying to simply remove the gearbox.

**SEIZED SUBFRAME BOLT**

Right now we are stuck trying to remove one of the subframe bolts. I have learned about these notorious captive bolts that are held with dainty pieces of sheet metal.

I am at the point where I can see enough of the bolt threads between the subframe and the chasis that I am tempted to cut it out. But what will I be able to do in order to refit the subframe?

Any advice before I get out the grinder?