differential RENAULT TWINGO RS 2009 2.G Transmission Workshop Manual

TWINGO - Chapitre 2
Contents
Pages
TWINGO - Chapitre 2ContentsPages
20A CLUTCH
Clutch: Precautions for the
repair 20A-1
Clutch: Specifications 20A-2
Pressure plate - Disc:
Removal - Refitting 20A-4
Clutch thrust bearing:
Removal - Refitting 20A-9
21A MANUAL GEARBOX
Manual gearbox oil:
Specifications 21A-1
Manual gearbox oils:
Draining - Filling 21A-2
Manual gearbox: List and
location of components 21A-4
Manual gearbox:
Identifi cation 21A-12
Manual gearbox:
Specifications 21A-14
Manual gearbox: Removal -
Refitting 21A-24
Manual gearbox: Repair 21A-34
Differential output seal:
Removal - Refitting 21A-38
Input shaft lip seal: Removal
- Refitting 21A-41
Reverse gear switch:
Removal - Refitting 21A-44
21B SEQUENTIAL GEARBOX
Sequential gearbox:
Precautions for the repair 21B-1
Sequential gearbox: List and
location of components 21B-2
Sequential gearbox oil:
Draining - Filling 21B-3
Pressure accumulator:
Removal - Refitting 21B-5
Pump assembly reservoir:
Removal - Refitting 21B-9
Electro-hydraulic unit:
Removal - Refitting 21B-11
Pump assembly: Removal -
Refitting 21B-18
Solenoid valves: Removal -
Refitting 21B-21
Engagement sensor :
Removal - Refitting 21B-27
Actuator module: Removal -
Refitting 21B-28
Gear selection sensor :
Removal - Refitting 21B-31 21A MANUAL GEARBOX

21A-7
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
141101
(114) O-r ing
(115) Lip seal
(116) Lock r ing
(117) Ball bear ing
(118) Lock r ing
(119) Lip seal
(120) Differential line tightening nut
(121) Adjusting shim
(122) Roller bearing
(123) Tachometer control ring
(124) Tachometer control pinion
(125) Tachometer pinion shaft
(126) Locking pin
(127) Ball bear ing
(128) Washer
(129) Spring washer
(130) Assembled differential mecha-
nism
(131) Hollow sun wheel (132) Thrust w asher
(133) Stop washer

21A-10
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
(35) Synchromesh r ing
(36) Washer
(37) Input shaft nut
101393
(38) Differential seal
(39) Bear ing
(40) Differential
(41) Tachometer sprocket (if fitted to
the vehicle)
(42) Satellite
(43) Sunwheel
(44) Axis
(45) Shaft retaining spr ing
(46) Fr iction cover
101390
(47) Selector shaft
(48) Gear shift catch
(49) Reverse gear brake fork and
shaft
(50) Fifth gear fork and shaft
(51) Pin
(52) Reverse gear shaft
(53) Third-four th gear fork and shaft
(54) Ring
(55) Lock shaft
(56) First-second gear fork and shaft
(57) Retaining locating ball car tridge
(58) Selector shaft bolt
(59) Reverse gear fork shaft bolt

21A-30
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) ,
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the “engine - gearbox” assembly from
theusing a workshop hoist.
aDisconnect the TDC sensor connector (1) . Equipment required
workshop hoist
Tightening torquesm
manual gearbox nuts
and bolts44 N.m
earth strap bolt on the
gearbox44 N.m
support bolts for the
suspended engine
mounting on the gear-
box62 N.m
132319

21A-33
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aFit the engine wiring.
aRefit:
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),
-the bolts of the engine wiring channel,
-the earth strap bolt on the gearbox.
aTorque tighten the earth strap bolt on the gearbox
(44 N.m).
aConnect the reverse gear switch connector.
aClip on the reverse gear switch.
aRefit the suspended engine mounting support on the
gearbox.
aTorque tighten the support bolts for the suspend-
ed engine mounting on the gearbox (62 N.m).
aConnect the TDC sensor connector.
aRefit the engine - gearbox assembly on the.
III - FINAL OPERATION
aRefit:
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefill:
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).
aRefit the engine undertray.

21A-34
MANUAL GEARBOX
Manual gearbox: Repair
JB1
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION.
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aCheck the shafts (see Manual gearbox: Check) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the manual gearbox selector shaft (see Manual
gearbox selector shaft: Removal - Refitting) .
REFITTING
I - REFITTING PREPARATION OPERATION
aClean all the removed parts (see Manual gearbox:
Precautions for the repair) .
aReplace worn or damaged parts.
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the synchroniser hub springs,
-the removed bearings,
-the selector shaft rings,
-the spy seals,
-the hydraulic clutch thrust bearing (if equipped),
-the magnet.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) .
aRefit:
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) , IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .

21A-36
MANUAL GEARBOX
Manual gearbox: Repair
JH1 or JH3 or JR5
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) .aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) to clean all of the
removed parts.
aCheck (see Manual gearbox: Check) :
-the pinions (teeth, claws, friction cone, inner wall),
-the synchroniser hubs,
-the synchroniser rings,
-the bearings.
aReplace worn or damaged parts.
REFITTING
I - REFITTING PREPARATION OPERATION
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the selector rod hub springs,
-the hydraulic clutch slave cylinder (if fitted),
-the magnet,
-the selector shaft rings,
-the lock ring of the differential,
-the differential retaining nut.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) . IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .

21A-37
MANUAL GEARBOX
Manual gearbox: Repair
JH1 or JH3 or JR5
21A
III - REMOVAL OPERATION
aRefit:
-the differential (see Manual gearbox differential:
Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) .
aAdjust the shafts (see Gearbox shaft: Adjustment)
if replacing a shaft or housing.
aRefit:
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) .
IV - FINAL OPERATION
aRemove the gearbox from the component support
(see Gearbox support equipment: Use) .
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .

21A-38
MANUAL GEARBOX
Differential output seal: Removal - Refitting
JB1 or JH1 or JH3 or JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel driveshaft (see 29A,
Driveshafts, Front right-hand driveshaft: Re-
moval - Refitting, page 29A-8) .
aDrain the gearbox (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the wheel on the side concerned (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres),
-the front wheel driveshaft for the side in question
(see 29A, Driveshafts, Front left-hand drive-
shaft: Removal - Refitting, page 29A-2) or (see
29A, Driveshafts, Front right-hand driveshaft:
Removal - Refitting, page 29A-8) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aTap the base of the differential output seal using a
roll pin punch and a small hammer to rotate it in its
housing.
aRemove the differential output seal using pliers, tak-
ing care not to damage the splines on the sunwheel. Special tooling required
Bvi. 945Mandrel for fitting the sun-
wheel seal.
Bvi. 1666Tool for fitting differential
seals .
Equipment required
roll pin punch
JB1 or JH1
JH3 or JR5
JB1 or JH1
86031

21A-39
MANUAL GEARBOX
Differential output seal: Removal - Refitting
JB1 or JH1 or JH3 or JR5
21A
aTap the base of the differential output seal using a
roll pin punch and a small hammer to detach it and
rotate it in its housing.
aRemove the differential output seal using a large
screwdriver, taking care not to damage the differen-
tial housing.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aThe differential output seal (3) is refitted using the
(Bvi. 945) consisting of:
-a seal protector (1) ,
-a mandrel (2) for fitting the differential output seal
(3) .
aLubricate the external surface of the seal protector.
aFit:
-the seal protector (1) onto the sunwheel,
-the differential output seal (3) onto the seal protec-
tor (1) .
aTap the mandrel (2) with a copper hammer to fully
seat the differential output seal (3) . JH3 or JR5
109147
JB1 or JH1
18150
86122