Table of Contents
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Workshop Repair Manual
77 11 299 962
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."
Type
JH1
JH3
JR5
Laguna II
Laguna II
MARCH 2001
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
© RENAULT 2001
Range
Twingo
Clio
Clio
EDITION ANGLAISE
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Table of Contents
Related Manuals for Renault Twingo Clio
Summary of Contents for Renault Twingo Clio
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Page 1: Manual Gearbox
Copying or translating, in part or in full, of this document or use of the service part The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault. in the production of the various component units and accessories from which his vehicles are constructed."... - Page 2 Contents Page MANUAL GEARBOX Section and tightening torques (in daNm) 21-1 Tightening torques (in daNm) 21-3 Gears 21-4 Consumables 21-5 Capacity - Lubricants 21-5 Parts to be systematically replaced 21-5 Special tooling 21-6 Repairing the gearbox 21-7...
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Page 3: Section And Tightening Torques (In Danm)
MANUAL GEARBOX MANUAL GEARBOX Section and tightening torques (in daNm) Section and tightening torques (in daNm) JH GEARBOX 21-1... - Page 4 MANUAL GEARBOX Section and tightening torques (in daNm) JR GEARBOX 21-2...
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Page 5: Tightening Torques (In Danm)
MANUAL GEARBOX Tightening torques in daNm Tightening torques in daNm Description Torque in daNm Gearbox edge bolt Secondary shaft bolt Primary shaft nut Rear cover bolt Reverse gear switch Clutch slave cylinder bolt Control shaft bolt Catch bolt Speed sensor bolt for sequential gearbox 21-3... - Page 6 MANUAL GEARBOX Ratios Ratios JH GEARBOX Reverse Final Index Type Speedometer gear drive JH1-002 Twingo 11/37 22/41 28/37 30/29 41/31 11/39 15/56 21/20 JH1-003 Twingo 11/37 22/41 28/37 30/29 39/32 11/39 15/58 21/20 JH1-007 Twingo 11/37 22/41 28/37 34/35 39/32 11/39 15/61 21/19...
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Page 7: Primary Shaft Nut
MANUAL GEARBOX Consumables Consumables Type Packaging Parts Stores No. Unit Molykote BR2 1 kg tin 77 00 421 145 Sunwheel splines Housing assembling faces Loctite 518 24 ml syringe 77 01 421 162 Switch threading Fixed gear and 5 gear hub Loctite FRENBLOC 24 cc bottle 77 01 394 071... -
Page 8: Special Tooling
MANUAL GEARBOX Special tooling Special tooling B. Vi. 22-01 Bearing extractor tool B. Vi. 31-01 Set of punches for roll pins B. Vi. 945 Sunwheel oil seal gasket inserting tool (JH) B. Vi. 946 Sunwheel circlip replacer B. Vi. 949 Selector fork roll pin rem/ref tool B. -
Page 9: Repairing The Gearbox
MANUAL GEARBOX Repairing the gearbox Repairing the gearbox – the rear housing. This must be removed along the Removing and handling the parts must be carried horizontal axis of the gearbox because it has a out on a workbench with a knockproof cover lubrication spline which is located in the primary shaft (thick rubber or plastic). - Page 10 MANUAL GEARBOX Repairing the gearbox Drive in the 5 gear fork pin using B. Vi. 31-01. Remove the 5 fixed gear using tools B. Vi. 22-01 and B. Vi. 1000. Remove the 5 gear fork and the sliding gear. 19823 Remove the outer bolts from the mechanism housing.
- Page 11 MANUAL GEARBOX Repairing the gearbox It is advisable to place two magnets or to close off the Rotate the reverse gear shaft assembly to the left and openings (C) to retrieve the locking balls and springs remove the reverse/5 gear fork shaft. for shafts 1/2 and 3/4.
- Page 12 MANUAL GEARBOX Repairing the gearbox Take the pin out of the 3/4 gear fork using B. Vi. 949 and remove the shaft and 3/4 gear fork assembly. At the same time, remove the primary and secondary shaft assembly with the shaft and the 1/2 gear fork. 21-10...
- Page 13 MANUAL GEARBOX Repairing the gearbox Remember to retrieve the inhibiting pegs (A) and (B). 21-11...
- Page 14 MANUAL GEARBOX Repairing the gearbox JH SECONDARY SHAFT 21-12...
- Page 15 MANUAL GEARBOX Repairing the gearbox Removing the sprocket Put the secondary shaft in a vice fitted with a clamping jaw and remove the sprocket assembly. Use circlip pliers on one side and flat-nosed pliers on the other when removing and refitting stop rings. Checking parts The sprocket teeth and the claws should not be chipped or excessively worn.
- Page 16 MANUAL GEARBOX Repairing the gearbox REPLACING THE BEARINGS IN THE MECHANISM Fit the bearings using tool B. Vi. 1576. HOUSING Knock the tool with the bearing using a small hammer. Separate the circlips with circlip pliers and drive the bearing inside the housing using tool B. Vi. 1576. 19821 19821 REFITTING...
- Page 17 MANUAL GEARBOX Repairing the gearbox Remove the primary shaft bearing guide using a 38 ∅ Replacing the bearings on the clutch housing tube. Cut the base of the plastic hollow needle located at the centre of the bearing. Fit tool B. Vi. 1165 and extract the bearing. 19819 Refit the bearing guide using tool B.
- Page 18 MANUAL GEARBOX Repairing the gearbox JR SECONDARY SHAFT 21-16...
- Page 19 MANUAL GEARBOX Repairing the gearbox Removing the sprocket Checking parts The 2 , and 4 gear supporting rings are fitted The sprocket teeth and the claws should not be tightened. They will be systematically replaced during chipped or excessively worn. refitting.
- Page 20 MANUAL GEARBOX Repairing the gearbox Refitting the sprocket NOTE: the 1/2 gear has dual-cone synchronisation, bring the notches of the synchro rings together with A heating plate with a setting of 150°C should be used those on the hubs and gears. for refitting.
- Page 21 MANUAL GEARBOX Repairing the gearbox REPLACING THE BEARINGS ON THE PRIMARY Extract the secondary shaft bearing cone using an SHAFT anti-sticking pin. Remove the bearings on the press using the anti- sticking pin. Refit the cone on the press. Refit the bearings on the press using a 25 ∅ tube. Drive out the bearings cups on the housing side of the mechanism using a 55 mm diameter tube.
- Page 22 MANUAL GEARBOX Repairing the gearbox Refit the bearings cups on the housing side of the Refit the bearing using tool B. Vi. 1167. mechanism using a 60 mm diameter tube. 19814 19815 Drive out the primary shaft bearing cup using a 38 ∅ extractor.
- Page 23 MANUAL GEARBOX Repairing the gearbox SETTING THE PRE-TENSIONING OF THE A A Rotate the secondary shaft several times to fit the SECONDARY SHAFT BEARINGS bearings. NOTE: this operation is only carried out when B B Set the dial gauge to zero. replacing the bearings.
- Page 24 MANUAL GEARBOX Repairing the gearbox SETTING THE CLEARANCE OF THE PRIMARY A A Rotate the primary shaft several times to fit the SHAFT BEARINGS bearings. NOTE: this operation is only carried out when B B Set the dial gauge to zero. replacing the bearings.
- Page 25 MANUAL GEARBOX Repairing the gearbox REMOVING THE DIFFERENTIAL REPLACING THE BEARINGS Remove the O-ring. Crownwheel side Tap the lip seal using a drift and a small hammer to Insert a small bar into the casing and place it flat on pivot it.
- Page 26 MANUAL GEARBOX Repairing the gearbox Sunwheel side Refit the differential in the housing. Remove the bearing retaining circlip (A). Fit a wooden shim under the crownwheel. On the press, move the bearing towards the inside of Fit the circlip (B) on the head (1) of tool B. Vi. 946 and the housing using a 50 mm diameter tube.
- Page 27 MANUAL GEARBOX Repairing the gearbox REMOVING THE DIFFERENTIAL Remove the unit mounting nut. Remove the O-ring. Tap the lip seal using a drift and a small hammer to pivot it. Remove the seal, taking care not to damage the splines of the sunwheel. 19811 Retrieve the bearing pre-tensioning setting shim (A).
- Page 28 MANUAL GEARBOX Repairing the gearbox REPLACING THE BEARINGS REPLACING THE RACES REMOVAL REMOVAL Lift and remove the bearings using an anti-sticking pin. Drive out the bearing races using a tube inserted in the housing. REFITTING Fit the bearing races until they touch the housing shoulder using tool B.
- Page 29 MANUAL GEARBOX Repairing the gearbox Refit the differential in the housing, with the bearing The differential must rotate under a load of between: lightly oiled. – 0.5 and 2 daNm for reused bearings, – 1.6 and 3.2 daNm for new bearings. Fit the sunwheel side bearing, the pre-tensioning setting washer and the nut.
- Page 30 MANUAL GEARBOX Repairing the gearbox CONTROL SHAFT JH1 control shaft A prevention valve is fitted on the housing (A) of the control shaft. An O-ring (B) ensures that it is sealed tightly. After removing the pin from the selector finger (C), remove the mounting bolts and remove the control unit.
- Page 31 MANUAL GEARBOX Repairing the gearbox REFIT THE SHAFTS Gently lift the 3/4 hub and fit the 3/4 gear fork and shaft. Fit the primary and secondary shafts with the 1/2 gear fork at the same time. Pin the fork using tool B. Vi. 949. 19809 Fit the 1/2 gear shaft locking peg (A).
- Page 32 MANUAL GEARBOX Repairing the gearbox Fit the 1/2 and 3/4 locking springs and balls in the Fit the 5 gear shaft (A) and the reverse gear shaft (B) mechanism housing and press them down using tool by gently lifting the primary shaft. B.
- Page 33 MANUAL GEARBOX Repairing the gearbox Apply a line of Loctite 518 to the gasket face. On the secondary shaft: Engage 3 gear. Put three drops of Loctite Frenbloc on the splines of the fixed gear and fit it using tool B. Vi. 1175. Introduce the housing while guiding the control shaft into 3 gear, fit the locking spring and ball as the 5...
- Page 34 MANUAL GEARBOX Repairing the gearbox Refit and pin the 5 gear fork. Put the gearbox back in neutral. Fit a new O-ring. Fit the rear cover and tighten the bolts to torque (2.5 daNm). 19825 19823 Fit the reverse gear switch. Select 1 gear using the gear lever and 5 gear by...
- Page 35 MANUAL GEARBOX Repairing the gearbox Fit the clutch shaft seal gasket using tool B. Vi. 1601 for JR gearbox. 19805 Refit the clutch slave cylinder and tighten the bolts to a torque of 2.1 daNm. 19826 21-33...
- Page 36 MANUAL GEARBOX Repairing the gearbox Refit the differential outlet seal gasket using tool JR GEARBOX B. Vi. 945 for the JH gearbox and B. Vi. 1058 for the JR gearbox. Fit the B. Vi. 945 shield (A) on the sunwheel and position the oiled seal gasket with tool B.