ABS RENAULT KANGOO 1997 KC / 1.G Transmission Workshop Manual

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

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
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

DRIVESHAFTS
Front driveshafts
NOTE : certain righthand driveshafts are fitted
with vibration absorbers; if the thermoplastic gai-
ter is damaged replace the whole driveshaft .
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 into 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
Righthand
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 (RC 462 joint) (see method previously
described).
29-6