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

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
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

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
Slightly lubricate the driveshaft in order to facili-
tate the fitting of the gaiter (position the smaller
diameter of the gaiter in the groove of the drives-
haft).
Replace the spider in the position marked on
removal and replace the locking spring ring.
Make three crimping points at 120° by forcing
back the metal of the splines on the driveshaft.
Fit the yoke sleeve onto the spider.
Divide the dose of grease between the gaiter and
the yoke sleeve.
Position the gaiter correctly on its grooves.
Introduce a blunt rod with a rounded edge bet-
ween the gaiter and the yoke sleeve, in order to
measure the quantity of air contained inside the-
joint.
Lengthen or shorten the joint until you obtain the
measurement A = 190 mm (measurement taken
between the end of the joint and the face of the
smaller diameter of the yoke sleeve).
In this position, remove the rod.
29
REPLACEMENT OF THE GAITER ON THE GEARBOX
SIDE
RC 462 JOINT
1 Yoke sleeve
2 Spider
3 Locking spring ring
4 Gaiter
5 Clips
Lefthand
driveshaft
DI2933R
REMOVAL
Cut the two clips (5) taking care not to damage
the groove of the yoke sleeve.
Remove as much grease as possible.
Remove the yoke sleeve
Remove the locking spring ring
IMPORTANT: never use solvent for cleaning the
components.
On the press, extract the spider by using a
releasing type extractor .
NOTE : mark the position of the spider before
extracting it.
90392R1
Refit the clips using the recommended tooling.
29-5