Renault Twingo Clio User's Manual
Contents
1. tube Drive out the bearings cups on the housing side of the mechanism using a 55 mm diameter tube 21 19 MANUAL GEARBOX Repairing the gearbox 1167 Refit the bearing using tool B Vi Refit the bearings cups on the housing side of the mechanism using a 60 mm diameter tube Drive out the primary shaft bearing cup using a 38 extractor REPLACING THE BEARING ON THE JR CLUTCH HOUSING Cut the base of the plastic hollow needle located at the centre of the bearing 1165 and extract the bearing B Vi Fit tool B Vi 1165 Refit this on the press using a 46 tube 21 20 MANUAL GEARBOX SETTING THE PRE TENSIONING OF THE SECONDARY SHAFT BEARINGS NOTE this operation is only carried out when replacing the bearings Clutch housing without differential and without primary shaft Fit the secondary shaft in the clutch housing with the bearings and the pre setting washer B Vi 1161 or equivalent of 1 60 mm large outer Fit the mechanism housing Fit and tighten to torque the box belt bolts Fit the dial gauge support plate B Vi 1161 or equivalent on the tripod basin mountings Fit the B Vi 1527 special spacer A the bolt C the dial gauge with its magnetic holder 21 21 Repairing the gearbox A A Rotate the secondary shaft several times to fit the bearings B B Set the dial gauge to zero C C Pull the secondary shaft upwards by m2. is reduced by 0 05 mm and vice versa 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 JH3 and JR5 control shaft 21 28 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 Fit the 5 gear shaft locking peg B 21 29 MANUAL GEARBOX Repairing the gearbox Fit the 1 2 and 3 4 locking springs and balls in the mechanism housing and press them down using tool B Vi 1570 Fit the 5 gear shaft A and the reverse gear shaft B by gently lifting the primary shaft B Vi 1570 ry ce Tamra B Check the positioning of the centring dowels the magnet the pre tension timing washers of the bearings on JR5 21 30 MANUAL GEARBOX Repairing the gearbox Apply a line of Loctite 518 to the gasket face On the secondary shaft Engage an 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 34 gear fit the locking spring and ball as the 5th g
3. 1059 VEE URUU UUU if The differential comes out when the sunwheel is pushed on the press 21 23 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 the head on the sunwheel Fit the tool 2 B Vi 946 on the head and push with the press until the circlip falls into place in its channel Remove tool B Vi 946 Refit the bearing using a 65 mm diameter tube The bearing race must be facing the opposite side to the crownwheel 86 096 1 SS705R3 Refit the bearing retaining circlip Rotate the assembly and check the rotation of the speedometer drive gear if fitted 21 24 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 Retrieve the bearing pre tensioning setting shim A Immobilise the differential unit crownwheel assembly using tool B Vi 1057 mounted on the housing 21JHO7 Remove the assembly by pressing on the sunwheel B Vi 1057 21 25 MANUAL GEARBOX REPLACING THE BEARINGS REMOV
4. 27 B Vi 1570 B Vi 1576 B Vi 1581 B Vi 1601 MANUAL GEARBOX Special tooling Mandrel for fitting bearings in the mechanism housing JH 21 6 MANUAL GEARBOX Repairing the gearbox the rear housing This must be removed along the horizontal axis of the gearbox because it has a lubrication spline which is located in the primary shaft bore Removing and handling the parts must be carried out on a workbench with a knockproof cover thick rubber or plastic REMOVAL Fit support plate B Vi 1581 on a Desvil shoe Fit the gearbox on the B Vi 1581 support Select 15t gear using the gear lever and 5 gear by sliding the 5 gear fork along its shaft Remove the secondary shaft bolt and the primary shaft nut Remove the clutch slave cylinder the bolts located inside the housing SK gii z mz 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 B Vi 22 01 B Vi 1000 a Game 4 if bye lt gt ks Remove the outer bolts from the mechanism housing Extract the 5 gear hub using tool B Vi 1170 Remove the speed sensor B for sequential gearbox Position the sliding gear of tool B Vi 1170 as if to JH1 select 5 gear and rotate it so as to position the splines of the sliding gear opposite those of t
5. AL Lift and remove the bearings using an anti sticking pin 90866S REFITTING Place a small board under the crownwheel to act as a support Fit the bearings as far as they will go in the housing using tool B Vi 1059 and a press Repairing the gearbox REPLACING THE RACES REMOVAL 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 Vi 1059 and a press Large Sey 1059 Small B Vi 1059 90591R MANUAL GEARBOX Refit the differential in the housing with the bearing lightly oiled Fit the sunwheel side bearing the pre tensioning setting washer and the nut As for disassembly immobilise the unit crownwheel assembly using tool B Vi 1057 Pre tighten to a torque of 1 to 2 daNm Remove tool B Vi 1057 and rotate the differential to fit the bearings Refit tool B Vi 1057 and tighten the nut to a torque of 13 daNm Remove tool B Vi 1057 and rotate the differential and check the pre tension 21 27 Repairing the gearbox The differential must rotate under a load of between 0 5 and 2 daNm for reused bearings 1 6 and 3 2 daNm for new bearings 906685 If the setting is not correct Determine the thickness of the timing washer bearing in mind that The pre tension increases by approximately 0 7 to 0 8 daNm when the timing washer thickness
6. RENAULT Workshop Repair Manual Manual gearbox Type Range JH1 Twingo Clio JH3 Clio Laguna Il JR5 Laguna Il 77 11 299 962 MARCH 2001 EDITION ANGLAISE The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault technical specifications current when it was prepared 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 RENAULT 2001 Contents 21 MANUAL GEARBOX Section and tightening torques in daNm Tightening torques in daNm Gears Consumables Capacity Lubricants Parts to be systematically replaced Special tooling Repairing the gearbox Page 21 1 21 3 21 4 21 5 21 5 21 5 21 6 21 7 MANUAL GEARBOX Section and tightening torques in daNm JH GEARBOX E a 19803 MANUAL GEARBOX Section and tightening torques in daNm JR GEARBOX Ex SS 19804 MANUAL GEARBOX Tightening torques 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 g
7. aft upwards by making a lever out of two screwdrivers D D Take a reading from the dial gauge Repeat the actions A to D several times Calculate the average of the readings Calculation of the value of the timing washer Value of the pre setting washer average of the readings on the dial gauge 0 02 value to subtract to guarantee a minimum clearance value of the timing washer Example Values in mm 0 62 0 50 0 02 1 10 Pre Average Value of rec Value of setting reading ommended timing value minimum washer clearance NOTE a set of timing washers of 0 86 mm to 1 30 mm from 0 04 mm to 0 04 mm thickness is supplied as replacement parts 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 the bearing Remove the seal taking care not to damage the Press on the press with a tube and extract the bearing splines of the sunwheel TT ele or hw Use the press to fit a small board under the crownwheel to act as a support Press on the clutch housing to release the circlip A and remove it REFITTING The bearing race C must be facing the opposite side to the crownwheel Drive the bearing home on the press using tool B Vi 1059 and resting on the outer ring of the bearing B Vi
8. aking a lever out of two screwdrivers D D Take a reading from the dial gauge Repeat the actions A to D several times Calculate the average of the readings Calculation of the value of the pre tensioning timing washer Prescribed value value of the pre setting washer average of the readings on the dial gauge value of the pre tensioning dial gauge washer Example Values in mm 0 26 0 49 1 60 2 35 Pre Average Pre setting Pre scribed reading washer tensioning value value timing washer value NOTE a set of timing washers of 2 15 mm to 2 43 mm from 0 04 mm to 0 04 mm thickness is supplied as replacement parts MANUAL GEARBOX SETTING THE CLEARANCE OF THE PRIMARY SHAFT BEARINGS NOTE this operation is only carried out when replacing the bearings Clutch housing without differential and without secondary shaft Fit the primary shaft with the bearings and the pre setting washer B Vi 1161 of 0 62 mm small outer Fit the mechanism housing fit and tighten to torque the box belt bolts the dial gauge support plate B Vi 1161 on the tripod basin mountings Fit the spacer B Vi 1527 A the support washer B the gear ring C the nut screwed right down D the dial gauge with its magnetic holder 21 22 Repairing the gearbox A A Rotate the primary shaft several times to fit the bearings B B Set the dial gauge to zero C C Pull the primary sh
9. ced during refitting With the press remove the ring hub 3 gear unit resting under the 3rd gear claw teeth With the press remove the rings 15t and 2 gears hub sliding shaft unit resting under the qst gear 944415 21 17 Checking parts The sprocket teeth and the claws should not be chipped or excessively worn Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls of the sprockets It is advisable to mark the position of the sliding shafts in relation to the hub 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 Place the new rings on the cold heating plate Heat them for 15 minutes with the thermostat at 150 C Proceed in the reverse order to removal Refit the rings Remove a ring from the heating plate using pliers and use a tube with an internal diameter of 33 mm to fit it on the shaft until it is resting on the hub 21 18 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 a Refit the cone on the press Refit the bearings on the press using a 25
10. ear shaft appears Press down the locking ball and finish fitting the housing On the primary shaft fit the support washer top side gear side the sprocket bush the 5 idle gear fitted with its synchro ring Remove tool B Vi 1570 the 5 gear hub fitted with its spring Tighten the peripheral bolt to a torque of 2 5 daNm after rotating the primary shaft to ensure correct alignment of the bearings Fit the reverse gear shaft A 21 31 MANUAL GEARBOX Repairing the gearbox Refit and pin the 5 gear fork aa we a A ea pt Wad re asl r Select 15t gear using the gear lever and 5 gear by sliding the 5 gear fork along its shaft Tighten the gear bolt and nut to torque Primary shaft nut 2 5 daNm Secondary shaft bolt 16 daNm UE 21 32 Put the gearbox back in neutral Fit a new O ring Fit the rear cover and tighten the bolts to torque 2 5 daNm Fit the reverse gear switch Fit the speed sensor for the JH1 sequential gearbox 21 MANUAL GEARBOX Repairing the gearbox Fit the clutch shaft seal gasket using tool B Vi 1601 for JR gearbox Refit the clutch slave cylinder and tighten the bolts to a 21 33 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 p
11. earbox 21 3 MANUAL GEARBOX Ratios JH GEARBOX Reverse Final st nd rd th th JH1 002 Twingo 11 37 22 41 28 37 30 29 41 31 11 39 15 56 21 20 JH1 003 11 37 22 41 28 37 30 29 39 32 11 39 15 58 21 20 JH1 007 11 37 22 41 28 37 34 35 39 32 11 39 15 61 21 19 JH3 005 11 37 22 41 28 37 34 35 39 32 11 39 14 59 JR GEARBOX Reverse Final st nd rd th th JR5 003 Laguna 2 11 37 22 41 28 37 34 35 39 32 11 39 15 61 None JR5 008 11 41 21 43 28 39 31 34 37 33 11 39 15 58 JR5 009 11 37 22 41 28 37 34 35 39 32 11 39 15 61 JR5 012 11 41 21 43 28 37 35 34 41 31 11 39 16 55 MANUAL GEARBOX Consumables Molykote BR2 1 kg tin 77 00 421 145 Sunwheel splines x 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 Primary shaft nut Secondary shaft bolt Capacities Lubricants Capacity in litres JH 2 8 TRJ 75W80W JR 2 5 TRJ 75W80W Parts to be systematically replaced After they have been replaced lip seals O rings stop rings roll pins secondary shaft and differential nuts gear supporting rings primary and secondary shaft bearing circlips 21 5 B Vi 22 01 B Vi 31 01 B Vi 945 B Vi 946 B Vi 949 B Vi 1000 B Vi 1057 B Vi 1058 B Vi 1059 B Vi 1161 B Vi 1165 B Vi 1170 B Vi 15
12. he hub and withdraw the assembly B Vi 1170 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 Remove the reverse gear shaft A Remove the reverse gear switch B Carry out an outwards stress test on the control shaft Gently lift the primary shaft and remove the reverse Lift and remove the mechanism housing gear shaft assembly 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 ul is 21 10 MANUAL GEARBOX Repairing the gearbox Remember to retrieve the inhibiting pegs A and B 21 11 MANUAL GEARBOX Repairing the gearbox JH SECONDARY SHAFT 21JH01 21 12 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 Also ensure that there are no signs of grating or abnor
13. mal wear on the surfaces of the shafts or the inner walls of the sprockets It is advisable to mark the position of the sliding shaft in relation to the hub Refitting the sprocket Proceed in the reverse order to removal The stop rings must be systematically replaced 21 13 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 REFITTING Place the new circlips in their respective housings NOTE the circlips have different shapes primary shaft circlip A secondary shaft circlip B 21 14 MANUAL GEARBOX Repairing the gearbox Replacing the bearings on the clutch housing Remove the primary shaft bearing guide using a 38 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 B Vi 1165 REFITTING Fit the deflector and the bearing on the press flush with the inner side of the housing Set the bearing with a mortise chisel 21 15 MANUAL GEARBOX Repairing the gearbox JR SECONDARY SHAFT 21JHO6 21 16 MANUAL GEARBOX Repairing the gearbox Removing the sprocket The 2 37 and 4 gear supporting rings are fitted tightened They will be systematically repla
14. osition the oiled seal gasket with tool B Vi 1058 JH GEARBOX Fit the oiled shield A on the sunwheel and position the oiled seal gasket C with the tool B 92111R B Vi 1 058 21 34
Download Pdf Manuals
Related Search