RENAULT KANGOO 1997 KC / 1.G Transmission Workshop Manual

Transmission
CLUTCH
MANUAL GEARBOX
DRIVESHAFTS
Renault 1997
77 11 194 244JULY 1997Edition Anglaise
"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."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
C
FC0A - FC0C - FC0D - FC0E - KC0A - KC0C - KC0D - KC0E

EXPLODED VIEW
PRF2000

21-1
21-2
21-3
21-4
21-4
21-5
Contents
Page
Transmission
CLUTCH
Mechanism- Disc
Flywheel20
20-1
20-4
ENSEMBLE MOTEUR ET BAS
Identification
Ratios
Capacities-Lubricants
Consumables
Parts to be systematically replaced
Gearbox (Removal-Refitting)MANUAL GEARBOX21
29-1
29-2General
Front driveshaft
DRIVESHAFTS29

CLUTCH
Mechanism - Disc
20
Cable-controlled dry-operating single disc clutch.
Constant pressure clutch thrust bearing.
Vehicle
TypeEngine
TypeMechanism Disc
F/K C0A
F/K C0CD7F
E7J
180 CP330026 splinesGA : Grey Silver
D = 181.5 mm VR : Violet Red
E = 6.7 mm
F/K C0D
F/K C0EF8Q
200 CPOV 325026 splinesRR : Red Ruby
D = 242 mm GB : Grey Blue
E = 6.8 mm
85873S
76906R
85873S
76906R 90693R9 90693R8
20-1

CLUTCH
Mechanism - Disc
REFITTING
Clean the splines of the clutch shaft and refit the
assembly without lubricant.
Fit the disc (with the offset on the hub on the
gearbox side).
Centre using the tool supplied in the kit.
20
REMOVAL
Fit the locking sector tool Mot. 582 or
Mot. 582-01.
Remove the mounting bolts from the mechanism
and remove the friction plate.
Check and replace any faulty parts.
99055R
SPECIAL TOOLING REQUIRED
Mot. 582
or Locking tool
Mot. 582-01
Mechanism mounting bolt 2
TIGHTENING TORQUES (in daN.m)
REPLACEMENT (after removal of the gearbox)
95414S
Tighten progressively in a star pattern, then tigh-
tenthe mounting bolts to the correct torque.
Remove the locking sector tool Mot. 582 or
Mot. 582-01.
Coat with
MOLYKOTE BR2 grease:
- the guide tube,
- the fork pads.
20-2

CLUTCH
Mechanism - Disc
20
After refitting the gearbox, place the cable onto
the clutch fork, reset the notched sector and
check that the play compensation is in working or-
der.
Check the travel of the clutch.
The travel of the fork must be:
X = 27.4 to 30.7 mm
97758-1R
NOTE : in the case of any intervention not requi-
ring the removal of the gearbox or after the fit-
ting of the gearbox,
DO NOT LIFT the fork, as it
would risk releasing itself from the slot (A) of the
clutch thrust bearing.
99054R
20-3

CLUTCH
Flywheel
20
REMOVAL
After removing the friction plate, remove the
mounting bolts of the flywheel (must not be
re-used).
Regrinding of the friction face is not permitted.
REFITTING
Clean the threads of the mounting bolts of the fly-
wheel on the crankshaft.
Remove the grease from the bearing face of the
flywheel on the crankshaft.
Refit the flywheel by immobilising it with tool
Mot. 582 or Mot. 582-01.
NOTE: the flywheel mounting bolts are to be sys-
tematically replaced.
SPECIAL TOOLING REQUIRED
Mot. 582
or Locking tool
Mot. 582-01
Flywheel bolt 2 + 60°
TIGHTENING TORQUES (In daN.m)
REPLACEMENT of the flywheel
20-4

MANUAL GEARBOX
Identification
All KANGOO vehicles are fitted with JB type gearboxes.
The Workshop Repair Manual "
B.V. JB. JC" deals with the complete repair of this component.
IDENTIFICATION PLATE
At A : the gearbox type
At B : the gearbox suffix
At C : the fabrication number
At D : the factory of manufacture
At E : a slot if the gearbox is assembled with an E
type engine
At F : the letter preceding all fabrication numbers
greater than 999999
21
X
000JB0BA
E
DCX0 0000
87227G
F
21-1

MANUAL GEARBOX
Ratios
21
906
175F/K C0D55
16
JB1
5thVehicleSuffixDifferential
ratio4th3rdSpeedometer
gear1st2ndReverse
gear
19
21171
172
173
174
59
14
35
34
32
39
33
37
39
28
39
1126
57
16
41
11
43
21
168
169F/K C0C59
14
JB3
5thVehicleSuffixDifferential
ratio4th3rdSpeedometer
gear1st2ndReverse
gear
19
21
35
34
32
39
43
21
39
28
39
112614
11
F/K C0A
F/K C0E
31
39
169 for vehicles fitted with Air Conditioning.
21-2

MANUAL GEARBOX
Capacities - Lubricants
CAPACITY (in litres)
21
CHECKING THE LEVEL
Filling is by overflow
5 gear box
JB13.4
JB33.4
Viscosity grade
TRX 75W 80W
92081S
21-3