clutch 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

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

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
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
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