RENAULT KANGOO 1997 KC / 1.G Transmission User Guide

MECHANICAL GEARBOX
Consumables
21
TYPEPACKAGING
Loctite 518
LOCTITE FRENBLOC
(locking and sealing
resin)
24 ml syringe
100 g tube
24 cc bottle
PART NUMBER
77 01 404 452
77 01 394 071
COMPONENT
77 01 421 162Housing assembling faces
Threaded plugs and switches
Bearing plugs
Ends of roll pins on driveshafts
Primary and secondary shaft nuts
Fixed gear and 5th gear hub
Rear differential lock drive stud
Splines of the right - hand sunwheel
Fork pivot
Thrust bearing guide
Fork pads
MOLYKOTE BR277 01 421 1451 kg tinClutch
Parts to be systematically replaced
After they have been removed :
- the lip seals,
- the O-ring seals,
- the clutch thrust bearing guide tubes,
- the secondary and differential shaft nuts,
- the speedometer drive gear and its shaft,
- the speedometer ring gear,
- the roll pins,
- the gear supporting rings.
RHODORSEAL 5661
Eg : CAF 4/60 THIXO
21-4

MANUAL GEARBOX
Gearbox (removal - refitting)
21
SPECIAL TOOLING REQUIRED
B. Vi. 31-01Set of punches
Mot. 1040-01Engine sub-frame carrier
T. Av. 476Ball joint extractor
Brake calliper bolt 4
Driveshaft gaiter bolt 2.5
Lower ball joint nut 5.5
Shock absorber base bolt 18
Engine tie-bar bolt 6.5
Gearbox edge and starter motor bolt 4.5
Suspended mounting bolt on gearbox 4
Wheel bolts 9
Track rod end nut 4
TIGHTENING TORQUES (In daN.m)
REMOVAL
Place the vehicle onto a two post lift.
Disconnect the battery.
Remove :
- the engine cover,
- the battery.
Disconnect the connectors on:
- the injection computer (petrol version),
- the preheating unit (diesel version),
_ the diesel fuel filter (diesel version),
- the impact sensor.
Remove the air filter sleeve.
13083S
EQUIPMENT REQUIRED
Engine support tool
Component jack
Remove the bolts (A) of the battery protective
screen.
13088R
21-5

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Remove :
- the two mounting bolts (B),
13119R
Disconnect the clutch cable.
Remove :
- the upper bolts at the gearbox edge and on
the starter motor (slacken the bolt (D) as far
as possible)
- the earth strap bolts on the gearbox,
- the two bolts of the
TDC sensor.
13097-2R
- the front wheels,
- the oil collector under the gearbox.
On the right-hand side of the vehicle, remove the
driveshaft pins using tool B. Vi. 31-01.
91755-1R2
Remove on both sides :
- the brake callipers and attach them together
- the mudguards,
- the track rod ends (T. Av. 476),
- the shock absorber base bolts,
- the sub-frame side member tie-rods (A),
- the stub axle carrier-driveshaft by disconnec-
ting it from the lower ball joint


99070R1
21-6

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Ensure that the rollers of the left driveshaft can-
not be removed by hand. If they can, check if any
of the needles have fallen into the gearbox.
Disconnect and remove the starter motor.
Disconnect:
- the reversing light connector,
- the speedometer connector and remove the
gearbox sensor.
Remove :
- the exhaust downpipe,
- the entire gear control lever by removing the
bolt (E) and the three bolts of the heat shield
for access to the base of the gear lever
- the engine tie-bar bolt,
- the rear support on the gearbox.
12993-1R2
Remove the engine-gearbox tie-rod.
To aid the removal of the steering box, fit, if ne-
cessary, a shim, in order to tilt the engine for-
ward.
Remove the steering box and secure it.
Fit the engine support and take the weight of
the engine and transmission assembly.
Positioning on F8Q engine
13120S
13121S
21-7

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Positioning on petrol engines
13122S
Remove the three mounting bolts for the support
on the gearbox.
Remove the engine sub-frame by slackening the
four mounting bolts.
Fit the component jack under the gearbox wi-
thout lifting it.
Separate the gearbox from the engine having re-
moved the nut (E) and the engine-gearbox moun-
ting stud.
98755R1
85812-1R
12924R
Lower the engine as far as possible.
Remove :
- the last gearbox edge bolt at the top,
- the bumper.
Fit the sub-frame support (Mot. 1040-01) and lo-
wer the vehicle.
21-8

MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
REFITTING
Coat the walls of the guide tube and the fork pads
with
MOLIKOTE BR2 grease.
Place the fork onto the slots of the clutch thrust
bearing.
Assemble the gearbox on the engine taking care
not to alter the height of the engine.
Ensure the presence and correct positioning of
the engine- gearbox centering rings .
The presence of the stud (C) aids assembly.
86308R2
Refit:
- the engine sub-frame,
- the steering,
- the exhaust downpipe,
- the engine tie-bar.
SPECIAL NOTE FOR THE E7J ENGINE
Refit the exhaust downpipe before the right-
hand driveshaft.
Refit the other components by proceeding in the
reverse order to removal.
21-9

DRIVESHAFTS
General
29
SPECIFICATION
NOTE : the replacement of the NYLSTOP nut with the ENKO driveshaft nut means that the splines of the
stub axles must no longer be coated with
Loctite SCELBLOC.
Vehicle type Engines
GearboxesDriveshaft seal
Left Right
F8Q JB1
D7F JB1
E7J
JB1 / JB3
FC0X
KC0XGE 86 + GI 69GE 86 + RC 462
CONSUMABLES
Type Quantity Component concerned
RHODORSEAL 5661Coat Gearbox side driveshaft roll pin
MOBIL K 575 GS180 g GE 86
ELF GMPT89 or
MOBIL CVJ 825 BLACK STAR110 cm3RC 462
29-1

DRIVESHAFTS
Front driveshafts
REFITTING
Left side :
Fit the driveshaft as horizontally as possible.
Right side :
Coat the splines of the joint on the gearbox side
with
MOLYKOTE BR2 grease.
Fit the driveshaft and check its positioning : an-
gled pin B. Vi. 31-01.
Fit two new roll pins : B. Vi. 31-01. Seal the roll pin
holes using
RHODORSEAL 5661.
On both sides :
Fit the driveshaft stub axle into the hub, it should
go in easily.
Refitting is the reverse of removal. Observe the
tightening torques.
Top up the gearbox oil.
Press the brake pedal several times in order to
bring the piston into contact with the pads.
29
REMOVAL
Vehicle on a two post lift.
Drain the gearbox.
Remove :
- the brake assembly (suspend it from the
chassis),
- the driveshaft nut : tool Rou. 604-01.
Left side :
Remove the three bolts on the gearbox.
Right side :
Remove the roll pin : tool B. Vi. 31-01.
On both sides :
Remove :
- The track rod end nut and extract the shaft :
tool T. Av. 476,
- the upper bolt of the shock absorber base.
Push back the driveshaft : tool T. Av. 1050-02.
Remove the lower bolt of the shock absorber
base and extract the driveshaft.
99544R
SPECIAL TOOLING REQUIRED
B. Vi. 31-01Roll pin punch
Rou. 604-01Hub locking tool
T. Av. 476Ball joint extractor
T. Av. 1050-02Driveshaft extractor
Driveshaft nut 28
Mounting bolt of gaiter on gearbox. 2.5
Wheel bolts 9
Shock absorber base nuts 18
Brake caliper mounting bolts 10
Track rod end nut 3.7
TIGHTENING TORQUES (in daN.m)
29-2

DRIVESHAFTS
Front driveshafts
REFITTING
For its correct positioning on the shaft, the
bearing must be pressed on to obtain a distance
of L = 118 ± 0.2 mm between the rear part of
the bearing and the end of the shaft.
This measurement is obtained using the tool T.
Av. 1331 when its extremity is level with the
shaft.
29
REPLACEMENT OF THE GAITER ON THE GEARBOX
SIDE
GI 69 JOINT
1 Spider
2 Rubber gaiter
3 Bearing guide
4 Retainer
5 Deflector
6 Circlip
7 Driveshaft
85884-1R1
Lefthand
driveshaft
SPECIAL TOOLING REQUIRED
T. Av. 1168 CAILLAU clip pliers
T. Av. 1256 OETIKER crimping pliers
T. Av. 1331 Tool for holding driveshaft bearing gai-
ter in position
DI2935R
REMOVAL
Remove the circlip.
On the press, remove the spider using an
extractor.
NOTE : mark the position of the spider before
extracting it.
Remove the gaiter and deflector - bearing
assembly in the same way as for the spider.
NOTE : in order to avoid deformation of the bea-
ring with a lip seal, and therefore any risk of lea-
kage, do not press it on using a hammer, but using
a press, in order to apply progressive pressure.
The driveshaft is held in the press using the slot
(G) with an extractor.
Replace the spider in the position marked on
removal and refit the retaining circlip.
29-3

DRIVESHAFTS
Front driveshafts
Remove the gaiter and replace with a new one.
Divide the recommended dose of grease
between the gaiter and the stub axle bowl.
NOTE : it is imperative to respect the volume of
grease prescribed in the consumables section.
Position the two beads of the gaiter in the
grooves of the stub axle bowl.
Set the quantity of air in the gaiter.
Fit and tighten the clips.
29
REPLACEMENT OF THE GAITER ON THE WHEEL
SIDE
GE 86 JOINT
1 Stub axle bowl
2 Retaining star
3 Spider
4 Yoke shaft
5 Thermoplastic gaiter
6 Clips
7 Spring
8 Pushrod
9 Shim
10 ABS target
Lefthand
driveshaft
DI2934R
REMOVAL
Join together the two clips (6) taking care not to
damage the grooves of the stub axle bowl.
Remove as much grease as possible.
For the replacement of the thermoplastic gaiter,
it will be necessary to remove the parts on the
gearbox side (GI 69 joint) (see method previously
described).
29-4