gearbox 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
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

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

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