Transmission

Transmission CLUTCH MANUAL GEARBOX DRIVESHAFTS

XL0B - XL0C 77 11 303 342

MAY 2001

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared.

EDITION ANGLAISE All copyrights reserved by Renault.

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."

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

Transmission Contents Page

20 CLUTCH Identification Mechanism - Plate Thrust bearing Flywheel Clutch shaft bearing

20-1 20-2 20-4 20-5 20-6

21 MANUAL GEARBOX Ratios Lubricants Consumables Parts always to be replaced Special features Removal - refitting Clutch shaft lip seal Differential output seal

21-1 21-2 21-3 21-3 21-4 21-5 21-12 21-13

29 DRIVESHAFTS Exploded view Front transverse driveshaft

29-1 29-2

CLUTCH 120 Identification

VEHICLE TYPE

ENGINE TYPE

MECHANISM

PLATE 21 splines D = 240 mm E = 7.1 mm

XL0B XL0C

20

F9Q

215 CPOE 4400

20-1

CLUTCH Mechanism - Plate

F9Q ENGINE

20

REPLACEMENT This operation is carried out after the gearbox has been separated from the engine. SPECIAL TOOLING REQUIRED Mot.

582 - 01

Immobilising tool

REFITTING

TIGHTENING TORQUE (in daNm) Mechanism mounting bolt

Precautions which must be followed when repairing the clutch:

2

Degrease the friction face of the flywheel.

REMOVAL

Insert the plate (hub shoulder (A) on the flywheel side).

Fit immobilising tool Mot. 582-01. Remove the mechanism mounting bolts and remove it along with the plate. Check and replace any faulty parts.

20-2

F9Q ENGINE

CLUTCH Mechanism - Plate ALIGNMENT Use the plastic centring tool found in the clutch kit.

Tighten progressively in a star pattern, then tighten the mounting bolts to the correct torque. Remove immobilising tool Mot. 582-01.

20-3

20

CLUTCH Thrust bearing

F9Q ENGINE

REPLACEMENT This operation is carried out after the gearbox has been separated from the engine. REMOVAL Remove: – the bleed screw (screw A), – the thrust bearing (bolts B).

REFITTING Refit: – the thrust bearing, – the bleed screw. Ensure the thrust bearing slides correctly.

20-4

20

CLUTCH Flywheel

F9Q ENGINE

20

REPLACEMENT This operation is carried out after the gearbox has been separated from the engine and after the clutch has been removed. SPECIAL TOOLING REQUIRED Mot.

582 - 01

Immobilising tool

REFITTING

TIGHTENING TORQUE (in daNm) Flywheel bolt

Clean the threads of the flywheel mounting bolts on the crankshaft.

6

Degrease the bearing face of the flywheel on the crankshaft.

REMOVAL Fit immobilising tool Mot. 582-01.

Bond the flywheel bolts using Loctite FRENETANCH and tighten them to the recommended torque.

Loosening the flywheel mounting bolts is forbidden. Replace the flywheel if it has been damaged.

20-5

F9Q ENGINE

CLUTCH Clutch shaft bearing REPLACEMENT This operation is carried out after the gearbox has been separated and after the clutch and flywheel have been removed. EQUIPMENT REQUIRED Bearing puller REMOVAL Use a general purpose puller to remove the bearing.

REFITTING Fit the new bearing. This is supplied greased so do not clean the external diameter. Coat the external diameter of the bearing with Loctite FRENBLOC. Fit the bearing with a tube pressing on the outer cage.

20-6

20

MANUAL GEARBOX 121 Ratios

21

PK 5 GEARBOX

Suffix

Vehicle/engine

Differential ratio

1

2

3

4

5

Reverse gear

PK5-011

Trafic/F9Q

16/67

11/51

17/38

31/43

41/40

41/31

27/47

PK 6 GEARBOX

Suffix

Vehicle/engine

Differential ratio

1

2

3

4

5

6

Reverse gear

PK6-008

Trafic/F9Q

17/67

11/51

19/40

31/40

41/37

41/29

47/30

27/47

21-1

MANUAL GEARBOX Lubricants

21

CAPACITY (in litres) PK5 PK6

2.35 2.35

VISCOSITY GRADE TRANSELF TRX 75 W80W

OIL CHANGE FREQUENCY No oil change

19201

5 Oil volume 6 Gearbox type

20712

1 Drain plug 2 Filler plug

21-2

MANUAL GEARBOX Consumables

21

PK5/PK6 Type

Packaging

Part no.

Unit

MOLYKOTE BR2

1 kg tin

77 01 421 145

Right-hand sunwheel splines

RHODORSEAL 5661

100 g tube

77 01 404 452

Threaded plugs and switches

Parts always to be replaced

If they have been removed: – the lip seals, – the O-rings.

21-3

MANUAL GEARBOX Special features

21

WARNING: it is FORBIDDEN to remove the breather valve (D) to fill the gearbox with oil.

GEAR SELECTION GATES PK6

18682

To select reverse gear, lift the collar (A) and shift the lever. 20715

DI2118

PK5

21-4

MANUAL GEARBOX Removal - Refitting

21

SPECIAL TOOLING REQUIRED Mot. 1453

Engine mounting support

T. Av. 476

Ball joint extractor

B. BVi. 1531

Tool for centring flywheel EQUIPMENT REQUIRED

Hydraulic jack

TIGHTENING TORQUES (in daNm) Wheel bolt Brake caliper column bolt Steering ball joint nut Lower ball joint nut Shock absorber base bolt Driveshaft nut Suspended mounting bolt to body Suspended mounting bolt to gearbox Sub-frame front mounting bolt Sub-frame rear mounting bolt Rear sub-frame tie bar mounting bolt Engine tie bar bolt to sub-frame Engine tie bar bolt to engine Starter motor bolt Bolts around the gearbox Filler plug Drain plug

21-5

14.2 3.5 3.7 10.5 18 28 4.4 8.5 10.5 12 10.5 18 10.5 4.4 4.4 0.4 2.2

MANUAL GEARBOX Removal - Refitting

21

– the preheating unit, without separating the two hoses to free the lifting bracket on the flywheel side, – the expansion bottle from its mounting (without touching the hoses) keeping it secure but mobile.

REMOVAL Put the vehicle on a two-post lift. Disconnect the battery. Open the bonnet and remove: – the particle filter housing (A), – the plenum chamber (B),

20716

20677

Use a syringe to drain the brake fluid reservoir down to the union where the clutch master cylinder pipes connect to it.

– the air-air exchanger hoses,

Disconnect: – hoses (E) and (F), – connectors (G), (H) and (I).

20342-1

20303

21-6

MANUAL GEARBOX Removal - Refitting Disengage the air inlet pipe from its filter.

21

Unclip the two electric wiring harnesses from their gearbox mounting (C).

Disconnect the clutch slave cylinder pipe (1). Unclip the breather pipe (2).

20717

Attach the two electric wiring harnesses to make it easier to remove the gearbox.

20456

Remove: – the upper soundproofing from the gearbox (be careful not to disengage the air duct), – the reverse gear connector (A), – the gear control cables (B).

21-7

MANUAL GEARBOX Removal - Refitting

21

Drain the gearbox.

Remove: – the front wheels, – the engine undertray protections (front and centre), – the gearbox soundproofing housings (inner and rear sections).

Remove: – the wheel arch liner left and right side protectors, – the brake calipers, securing them to the suspension spring to protect the hose, – the wheel sensor wires (for vehicles with ABS), Left-hand side of the vehicle Remove: – the driveshaft mountings on the gearbox,

20457-1

Disconnect the fan. Disconnect the radiator cross member bolt (A), tilt the assembly towards the front, and attach it so that you can remove the gearbox soundproofing housing (front section). Leave the radiator/ventilator assembly on the cross member during the operation.

20710

– the lower ball joints using a cut-down Allen key if the nut cannot be slackened.

NOTE: this operation is for vehicles fitted with air conditioning (for the front soundproofing housing).

18661 20535

X = 25 mm

21-8

MANUAL GEARBOX Removal - Refitting Remove: – the track rod ends using tool T. Av. 476, – the shock absorber base mountings (C), – the driveshaft.

21

Right-hand side of the vehicle Remove: – the two bearing bolts (A), – the intermediate bearing on the motor arm.

20710 20711

– – – – –

Take care to protect the gaiters.

the lower ball joint, the steering ball joint, the shock absorber base mountings, the driveshaft, the torque reaction arm,

20713

– the TDC sensor.

21-9

MANUAL GEARBOX Removal - Refitting Remove the sub-frame with its lower arms.

21

Remove: – the expansion chamber (bolt A) and attach it, – the tachometer connections (B), – the electrical harness earth from the catalytic converter metal support,

Unscrew the rear bolts on the two sub-frame stiffener bars. Remove: – the lower nuts on the anti-roll bar return tie-rod, – the heat shield on the steering rack, – the steering rack mounting bolts on the sub-frame. Position the hydraulic jack under the sub-frame. Remove: – the two front sub-frame mounting bolts, – the two rear sub-frame mounting bolts. Turn the two sub-frame stiffener bars towards the outside. Lower the sub-frame, arm and anti-roll bar assembly whilst turning the anti-roll bar to make sure it does not hook on to the steering rack.

20722

– – – – –

20713

21-10

the catalytic converter metal support (C), the starter electrical connections, the starter mountings, the starter motor (slide it back and secure it), the turbocharger outlet air duct (D).

MANUAL GEARBOX Removal - Refitting

21

Attach the two electric wiring harnesses to make it easier to remove the gearbox. Fit the bonnet strap. Fit the engine support Mot. 1453 using tool Mot. 1453-01.

18596

Refit the gearbox mounting (see the information on suspended engine mounting in section 19).

20720

Remove: – the nut (A), – the two bolts for the rubber mounting (B), – the rubber mounting, – the upper mountings of the gearbox, – the gearbox mounting. Tilt the engine and transmission assembly. Detach the gearbox mounting hydraulic pipes. Remove the gearbox mounting. Position the hydraulic jack. Proceed in the reverse order to removal to complete the operation.

Remove: – the lower mountings of the gearbox. – the gearbox.

Refill: – the gearbox (full volume), – the brake fluid reservoir.

REFITTING If the clutch has been removed, refer to section 20. Ensure that the engine/gearbox centring dowels are fitted.

Bleed the clutch system.

IMPORTANT: attach the brake pipes to the shock absorber base correctly.

IMPORTANT: do not grease the clutch shaft splines. Separate the wiring harnesses and remove the harness centring pin from the gearbox.

21-11

PK5/PK6

MANUAL GEARBOX Clutch shaft lip seal

21

REPLACEMENT This operation is carried out after the gearbox has been separated from the engine.

SPECIAL TOOLING REQUIRED B. Vi. 1236

Primary shaft oil seal fitting tool

REMOVAL

REFITTING

Drill a hole in the seal with a 2.5 mm diameter drill.

Fit a new seal along with its protector using tool B. Vi. 1236.

WARNING: DO NOT SCRATCH THE SHAFT OR THE SEAL BEARING SURFACE. Screw a screw into the seal and extract the seal using a pair of pliers.

Remove the protector. Refit the guide tube. 20714

21-12

MANUAL GEARBOX Differential output seal

21

CONSUMABLES Loctite FRENBLOC Brake caliper mounting bolt MOLYKOTE BR 2 Right-hand sunwheel splines

Remove the flange from the intermediate bearing. TIGHTENING TORQUES (in daNm) Shock absorber base mounting bolts

18

Wheel bolt

14.2

Remove the engine undertray. Drain the gearbox. Remove: – the wheel arch liner side protectors, – the front right wheel, – the upper bolt (3) of the shock absorber base and slacken the lower bolt (4), – the ABS sensor.

20711

Tilt the stub-axle carrier and disconnect the driveshaft (take care not to damage the gaiters during this operation - see section 29).

20583-1

21-13

MANUAL GEARBOX Differential output seal

21

REPLACING THE SEAL Remove the O-ring from the sunwheel. Tap the base of the lip seal using a drift and a small hammer to pivot it in its housing. When the seal is dislodged, remove it with pliers taking care not to damage the splines of the sunwheel.

Position the driveshaft in relation to the sunwheel. Pivot the stub-axle whilst inserting the driveshaft into the sunwheel. The seal is refitted with tool B. Vi 1235.

Tighten the nuts, bolts and studs to the recommended torques.

Oil the tool before inserting it into the splined part of the sunwheel.

Fill the gearbox.

Fit the lip seal then the O-ring and coat the splines with MOLYKOTE BR2 grease.

21-14

DRIVESHAFTS 129 Exploded view PK GEARBOX DRIVESHAFT

29-1

29

DRIVESHAFTS Front transverse driveshaft

29

SPECIAL TOOLING REQUIRED T. Av. 476

Ball joint extractor

TIGHTENING TORQUES (in daNm) Lower shock absorber bolt Track rod end nut

18 3.7

Hub nut

28

Wheel bolts

14.2

Mounting bolt on gearbox

4.4

Mounting bolt on intermediate support

4.4

Stud on gearbox

0.8

REMOVAL - WHEEL SIDE Put the vehicle on a two-post lift. Remove: – the wheel hubcap, – the hub nut, – the front wheels,

Push the driveshaft back into the stub-axle carrier, whilst tilting the stub-axle carrier.

– the track rod end nut (B), – the shock absorber lower mounting bolts (C).

29-2

DRIVESHAFTS Front transverse driveshaft

29

REMOVAL - GEARBOX SIDE

Left-hand side

Right-hand side

Drain the gearbox.

Remove: – the two mounting bolts (A) of the intermediate support,

Remove: – the three mounting bolts of the gaiter on the gearbox,

– the driveshaft on the gearbox side. – the driveshaft on the gearbox side.

29-3

DRIVESHAFTS Front transverse driveshaft

29

NOTE: it is recommended that the differential output seal is automatically replaced.

REFITTING Left-hand side

With the protector in place, coat the splines of the seal, on the gearbox side, with MOLYKOTE BR 2.

Remove the plastic protector from the driveshaft bearing gaiter as horizontally as possible.

Position the driveshaft and insert it. The driveshaft should enter freely until the thread protrudes allowing the stub-axle nut to be fitted. Proceed in the reverse order to removal.

The driveshaft should enter freely until the thread protrudes allowing the stub-axle nut to be fitted. Right-hand side Clean the bore of the bearing into which the bearing is inserted. Check the condition of the contact surface of the lip seal on the relay shaft.

29-4