RENAULT MEGANE SCENIC 1995 Service Repair Manual

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Remove the steering box mounting bolts.F
engine
98868-1R
Remove the mounting bolts of the power assisted
steering pipes from the sub-frame.
Secure the steering box to the side members.
Special notes for vehicles fitted with driver’s
AIRBAG
98836R1
97390-1R1
Remove the horn.
From above:
Secure the cooling assembly to the upper cross
member.
Remove the upper mounting bolt from the bum-
per then the bolts located in the wheel arches. Release the steering box and the steering column
(be careful not to damage the clip (C)).
ATTENTION :
to prevent any damage being done to the rota-
ting switch under the steering wheel, please fol-
low these instructions :
- before releasing the steering column and the
rack, the steering wheel MUST be immobilised,
wheels straight, using the "steering wheel
locking" tool throughout the duration of the
repair,
- any doubts regarding the correct centring of
the rotating switch means that the steering
wheel has to be removed so as to apply the
centring method as described in chapter 88
"AIR-BAG".
REMINDER: in this case, only qualified personnel
who have received specific training may under-
take this work.
21-16

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
F
engine
86308R2
86415S
Position the sub-frame support trolley and lower
the vehicle.
Remove the sub-frame by loosening the 4 moun-
ting bolts.
Be careful not to forget to remove the power as-
sisted steering pipe mounting from the sub-
frame.
Under the vehicle :
- position the component jack under the gearbox
without lifting it,
- release the gearbox and the engine by remo-
ving the studs (C).
98755R1
Refit:
- the assembled support,
- the sub-frame,
- the steering.
Refit:
- the heat screen,
- the exhaust downpipe,
- the suspended engine mounting bar.
Refit the other components by carrying out the re-
moval operations in reverse.
REFITTING
Coat the sides of the guide tube and the fork pads
with
MOLYKOTE BR2 grease.
Position the fork on the notches of the clutch
thrust pad.
Offer the gearbox up using the component jack.
Connect the engine to the gearbox.
Check that the dowels for centring the engine-
gearbox are present and are in the correct posi-
tion.
21-17

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Position the driveshaft with respect to the sun-
wheel, pivot the stub-axle carrier, engaging the
driveshaft into the sunwheel using the shouldered
pin B.Vi. 31-01 in order to align the holes. F engine
A chamfer on the leading edge of the sunwheel
facilitates makes it easier to fit new roll pins.
Seal the ends
(RHODORSEAL 5661).
Fill with fluids.
Fit the caliper mounting bolts with Loctite
FRENBLOC and tighten to the correct torque.
Press the brake pedal several times to bring the
pistons back into contact with the brake pads. F
engine
86070-1R1
Check the adjustments of the upper mountings
(refer to chapter 10).
Ensure that the movement limiter is mounted the
correct way round: the nuts should be fitted on
the exhaust pipe side.
92661S
74937-4S
Tighten all nuts and bolts to the recommended
torques.
Fill the gearbox with oil.
21-18

MANUAL GEARBOX
5th gear on the vehicle
REMOVAL
Put the vehicle on a 2 post lift.
Remove the front left hand wheel.
Remove the protection from the wheel arch.
Remove the sub-frame-side member tie-rod.
Remove the engine undertray.
Drain the gearbox
The rear housing must be removed along the hori-
zontal axis of the gearbox since it contains a lubri-
cation nozzle (A) which enters the primary shaft.Position:
- a draining container under the rear housing
and remove the housing,
- a wooden block between the 5th gear fork
and the drive pinion to absorb the backlash;
then remove the pin from the fork using
B.Vi.
31.01.
SPECIAL NOTE
Do not pull the 5th gear fork pin outwards since
the locking ball will fall into the gearbox, for safe-
ty, engage a gear (3rd or 4th).
Removing the pin can be made easier by slightly
bending the pin of toolB.Vi. 31.01 in order to
prevent the gearbox being lifted.
TIGHTENING TORQUES (In daN.m)CONSUMABLES
SPECIAL TOOLING REQUIRED
B.Vi.28-01 Extractor body
B.Vi.31-01 Set of pins for extracting and
fitting 5 mm diameter roll pins
B.Vi.1003 5th gear hub extractor
B.Vi.1007 Claws for B.Vi. 28-01
21
87180R85979R
Loctite FRENBLOC :
Primary shaft nut
Secondary shaft bolt
5th fixed gear
5th gear hubPrimary shaft nut 13.5
Secondary shaft bolt 6.3
21-19

MANUAL GEARBOX
5th gear on the vehicle
21
Release and remove the primary shaft nut and the
secondary shaft bolt (65).
Put the gearbox in neutral. Lock the gearbox by putting the gear lever in 1st
gear and the gearbox in 5th gear by sliding the
5th gear fork inwards along its shaft.
93912-1R
Position the sliding gear of tool B.Vi. 1170 as if to
change into 5th gear and turn it so that the
splines of the sliding gear are opposite the splines
of the hub .
Extract the 5th gear assembly.
86045S
On the primary shaft :
Remove the 5th gear fork and the sliding gear, ta-
king care not to pull the 5th gear pin outwards.
Extract the synchro hub using tool B.Vi. 1170.
93190S1
21-20

MANUAL GEARBOX
5th gear on the vehicle
21
On the secondary shaft:
Remove the shouldered washer (64).
PRG21.1
Extract the fixed gear using B.Vi. 28-01 fitted with
its claws B.Vi. 1007.
88575R
REFITTING
On the secondary shaft:
Apply 3 drops of
Loctite FRENBLOC to the splines
of the fixed gear.
Fit the shouldered washer (64).
On the primary shaft :
Refit in the correct order (21) (shoulder facing the
ring (22), (23), (24) and (8)).
Put the fork on the sliding gear (26) fitted with
(25).
Apply 3 drops of
Loctite FRENBLOC to the hub and
replace the sliding gear hub and fork assembly.
Fit the synchro ring bosses in the lugs on the hub.
86045R1
Put the gear lever in 1st gear and the gearbox in
5th gear by sliding the 5th gear fork on its shaft.
Apply 3 drops of
Loctite FRENBLOC:
- to the primary shaft nut (27) and tighten it to
a torque of 13.5 daN.m,
- on bolt
(65) and tighten it to a torque of 6.3
daN.m to fit the fixed gear securely.
21-21

MANUAL GEARBOX
5th gear on the vehicle
21
Put a wooden block between the 5th gear fork
and the drive gear to take the backlash and refit a
new pin into the 5th gear fork using B.Vi. 31-01
complying with the assembly direction, the split
should be pointing towards the rear housing.
90498-1S
85979R1
Fit a new O-ring to ensure that the rear housing is
sealed.
Return the gearbox to neutral and check that all
gears can be engaged.
If any problems occur, check that reverse gear is
not engaged.Fit the rear housing by engaging nozzle (A) into
the primary shaft.
Tighten the mounting bolts to a torque of 2.4
daN.m.
87180R
Fill the gearbox with oil.
Check that the rear housing does not leak when
the engine is running.
21-22

MANUAL GEARBOX
Differential output seal
REMOVAL
Remove the engine undertray.
Drain the gearbox.
Put the front of the side being worked on on axle
stands.
Remove the wheel.
Extract the driveshaft pins using tool B.Vi. 31-01.Remove :
- the track rod end (tool T.Av. 476),
TIGHTENING TORQUES (in daN.m)
Brake caliper mounting bolt 2.7
Shock absorber base mounting bolts 17
Track rod end 3.5
Wheel bolts 9
CONSUMABLES
SPECIAL TOOLING REQUIRED
Loctite FRENBLOC :
Brake caliper mounting bolt
RHODORSEAL 5661 (Eg. CAF 4/60 THIXO) :
Ends of driveshaft pins
MOLYKOTE BR2 :
Right hand sunwheel splines
21
B.Vi.31-01 Set of pins
T.Av.476 Ball joint extractor
B.Vi.945 Mandrel for fitting differential seals
B.Vi.1058 Mandrel for fitting differential seals
(JB3 tapered bearings)
91755R
85965R
21-23

MANUAL GEARBOX
Differential output seal
- the two mounting bolts (A) of the brake assem-
bly.
Secure the caliper to the suspension spring to pre-
vent the pipe being damaged.
Slacken the lower bolt (3) from the base of the
shock absorber and remove the upper bolt (4).
Tilt the stub-axle carrier and release the driveshaft
(take care not to "damage" the gaiters during this
operation).
Remove the O-ring from the sunwheel.
Tap the base of the lip seal using a pin extractor
and a small hammer in order to extract it from its
housing .
When the seal is released, remove it using pliers
taking care not to damage the splines of the sun-
wheel.
21
REFITTING
1. JB1 - JB3 gearboxes
The seal is refitted using tool B.Vi. 945 comprising:
- a seal protector (A),
- a tool for positioning the seal (B).
METHOD
Put the oiled protector (A) onto the sunwheel and
position the oiled seal (C) with the tool (B).
90149R1
86031S
86095R
86122R
2.7 daN.m
21-24

MANUAL GEARBOX
Differential output seal
Continue in the same way but using tool B.Vi.
1058 and protector (A) of B.Vi. 945.
21
Fit new roll pins and seal the ends with
RHODORSEAL 5661 (Eg. CAF 4/60 THIXO).
Tighten the nuts and bolts to the recommended
torques.
Refit the brake caliper and coat the bolts with
Loctite FRENBLOC.
Fill the gearbox with oil.
Fit the O-ring to the sunwheel and coat the splines
with grease N° 20.
Position the driveshaft with respect to the sun-
wheel.
Pivot the stub-axle carrier, engaging the drives-
haft into the sunwheel using pin B.Vi. 31-01 to
align the holes.
92111R
74937-3S
21-25