RENAULT TWINGO 2009 2.G Transmission Workshop Manual

© Renault s.a.s 2007 "The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are
constructed".All rights 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.
NOVEMBER 2009 EDITION ANGLAISE
X44
2Transmission
20ACLUTCH
21AMANUAL GEARBOX
21BSEQUENTIAL GEARBOX
29ADRIVESHAFTS

TWINGO - Chapitre 2
Contents
Pages
TWINGO - Chapitre 2ContentsPages
20A CLUTCH
Clutch: Precautions for the
repair 20A-1
Clutch: Specifications 20A-2
Pressure plate - Disc:
Removal - Refitting 20A-4
Clutch thrust bearing:
Removal - Refitting 20A-9
21A MANUAL GEARBOX
Manual gearbox oil:
Specifications 21A-1
Manual gearbox oils:
Draining - Filling 21A-2
Manual gearbox: List and
location of components 21A-4
Manual gearbox:
Identifi cation 21A-12
Manual gearbox:
Specifications 21A-14
Manual gearbox: Removal -
Refitting 21A-24
Manual gearbox: Repair 21A-34
Differential output seal:
Removal - Refitting 21A-38
Input shaft lip seal: Removal
- Refitting 21A-41
Reverse gear switch:
Removal - Refitting 21A-44
21B SEQUENTIAL GEARBOX
Sequential gearbox:
Precautions for the repair 21B-1
Sequential gearbox: List and
location of components 21B-2
Sequential gearbox oil:
Draining - Filling 21B-3
Pressure accumulator:
Removal - Refitting 21B-5
Pump assembly reservoir:
Removal - Refitting 21B-9
Electro-hydraulic unit:
Removal - Refitting 21B-11
Pump assembly: Removal -
Refitting 21B-18
Solenoid valves: Removal -
Refitting 21B-21
Engagement sensor :
Removal - Refitting 21B-27
Actuator module: Removal -
Refitting 21B-28
Gear selection sensor :
Removal - Refitting 21B-31 21A MANUAL GEARBOX

Contents
Clutch position sensor :
Removal - Refitting 21B-34
Solenoid valve assembly
pressure sensor: Removal -
Refitting 21B-36
Sequential gearbox engine
speed sensor: Removal -
Refitting 21B-38
Sequential gearbox:
Removal - Refitting 21B-40
Sequential gearbox
converter: Removal -
Refitting 21B-47
Sequential gearbox gear
lever: Removal - Refitting 21B-48
29A DRIVESHAFTS
Driveshaft: Precautions for
the repair 29A-1
Front left-hand driveshaft:
Removal - Refitting 29A-2
Front right-hand driveshaft:
Removal - Refitting 29A-8
Relay shaft bearing:
Removal - Refitting 29A-13
Front driveshaft gaiter, wheel
side: Removal - Refitting 29A-14
Front right-hand driveshaft
gaiter, gearbox side:
Removal - Refitting 29A-18
Front left-hand driveshaft
gaiter, gearbox side:
Removal - Refitting 29A-23 21B SEQUENTIAL GEARBOX

20A-1
CLUTCH
Clutch: Precautions for the repair
20A
Before removing the clutch, check:
-The direction of fitting for the clutch plate.
Before refitting the clutch, check:
-The flywheel friction track (no scratches or blue
stains),
-The crankshaft bearing (no sticking),
-The engine and gearbox seals (replace if necessary),
-The sliding action of the clutch plate on the output
shaft,
-The guide of the thrust bearing and clutch fork (no
wear or scratches).
During refitting:
Check the direction of the clutch plate.
Centre the clutch plate using the (Emb. 1518) or (Emb.
1780).
Gradually torque tighten the clutch pressure plate
bolts.
After refitting, check:
-The clutch play (for a cable operated vehicle),
-Bleeding of the hydraulic circuit (for vehicles with hy-
draulic controls).Special tooling required
Emb. 1518Set of clutch plate centr ing
mandrels
Emb. 1780Set of clutch plate centr ing
mandrels.
WARNING
To prevent the clutch from juddering or slipping, do
not grease the output shaft or the clutch plate hub.

20A-2
CLUTCH
Clutch: Specifications
D4F – D7F – K9K – K4M
20A
Pressure plate
Pressure plate part no.: 180 CPOE 3300
Drive plate
Plate external diameter: 181.5 mm
Plate thickness: 6.7 mm
Number of grooves: 26
Colour of springs (1) : GreyColour of springs (2) : Black
Pressure plate
Pressure plate part no.: 215 CPOVK 4400
Drive plate
Plate outer diameter: 215 mm
Plate thickness: 6.9 mm D4F – D7F
102143
105680
K9K
108795
102142

20A-3
CLUTCH
Clutch: Specifications
D4F – D7F – K9K – K4M
20A
Number of grooves: 26
Colour of springs (3) : Red and Black
Colour of springs (4) : Grey
Pressure plate
Pressure plate part no.: 215 CPOE 4350
Drive platePlate outer diameter: 215 mm
Plate thickness: 6.9 mm
Number of grooves: 26
Spring colour (5) : Moss green
Spring colour (6) : Light blue
Spring colour (7) : Green
Spring colour (8) : Capri blue K4M
132330
132331

20A-4
CLUTCH
Pressure plate - Disc: Removal - Refitting
D4F – D7F – K9K
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLock the engine using tool (Mot. 582-01) (1) .
aRemove:
-the pressure plate bolts (2) ,
-the pressure plate and friction plate.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aDegrease the flywheel friction face.
aClean the clutch shaft splines. Special tooling required
Mot. 582-01Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts (D4F and D7F
engines)20 Nm
clutch pressure plate
bolts (K9K engine)15 Nm
108799

20A-5
CLUTCH
Pressure plate - Disc: Removal - Refitting
D4F – D7F – K9K
20A
II - REFITTING OPERATION FOR PART
CONCERNED
aPosition the clutch plate, face (3) against the fly-
wheel, face (4) against the clutch pressure plate.
aPosition the clutch driven plate.aCentre the clutch plate using tool (Emb. 1780) (5) .
aRefit:
-the clutch pressure plate,
-the clutch pressure plate bolts by gradually tighten-
ing them in a radial pattern.
aTorque tighten the clutch pressure plate bolts
(D4F and D7F engines) (20 Nm).
aTorque tighten the clutch pressure plate bolts
(K9K engine) (15 Nm).
aRemove the (Emb. 1780) and (Mot. 582-01).
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery). K9K
118975
D4F – D7F
108798
D4F – D7F
K9K

20A-6
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the (Mot. 1677) (1) .
aRemove:
-the clutch pressure plate bolts (2) ,
-the clutch pressure plate,
-the clutch plate. Special tooling required
Mot. 1677Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts23 N.m
132329

20A-7
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel friction face,
-the clutch shaft splines.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the clutch plate, with the face (3) to the clutch
pressure plate end.aCentre the clutch plate using the (Emb. 1780) (4) .
aRefit:
-the clutch pressure plate,
-the clutch pressure plate bolts by gradually tighten-
ing them in a radial pattern.
aTorque tighten the clutch pressure plate bolts (23
N.m).
aRemove the (Emb. 1780) and (Mot. 1677).
III - FINAL OPERATION.
aRefit:
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) ,
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting). WARNING
Do not grease the clutch shaft splines.
132331
132332