drain bolt RENAULT TWINGO 2009 2.G Transmission User Guide

21B-40
SEQUENTIAL GEARBOX
Sequential gearbox: Removal - Refitting
D4F, and JH1
21B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the catalytic converter (see Catalytic converter:
Removal - Refitting) ,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
aDrain:
-the cooling system (see Cooling system: Drain-
ing - Refilling) (MR 411, 19A, Cooling),
-the sequential gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling,
page 21A-2) .
aDrain the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (MR 411, 62A, Air conditioning).
aRemove:
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (MR
411, 10A, Engine and peripherals),
-the hub-carrier - driveshaft assembly (see ) (MR
411, 31A, Front axle components),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging),
-the crankshaft position sensor (see Crankshaft
position sensor: Removal - Refitting) (MR 411,
17B, Petrol injection). Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
workshop hoist
load balancer
roller-type stud removal tool
Tightening torquesm
sequential gearbox
studs7 Nm
sequential gearbox bolts44 Nm
sequential gearbox nuts44 Nm
flywheel protection plate
bolts (18)44 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
AIR CONDITIONING or CLIMATE CONTROL

21B-46
SEQUENTIAL GEARBOX
Sequential gearbox: Removal - Refitting
D4F, and JH1
21B
aRefit the « cooling radiator - cooling radiator hose -
air conditioning condenser » assembly to the front
axle sub-frame.
aConnect the cooling radiator bottom hose to the
coolant pump inlet pipe.
aRefit the cooling radiator bottom hose clip using the
(Mot. 1448).
aRefit:
-the air conditioning condenser inlet pipe,
-the air conditioning condenser inlet pipe bolt.
aRefit the sequential gearbox earth cable bolt.
aConnect the reverse gear switch connector.
aClip the wiring harness to the motor-driven fan as-
sembly.
aConnect:
-the motor-driven fan assembly resistor unit con-
nector,
-the motor-driven fan assembly connector.
aConnect the cooling radiator top hose to the water
chamber.
aRefit the cooling radiator top hose clip using the
(Mot. 1448).
aRefit:
-the engine speed and position sensor (see Crank-
shaft position sensor: Removal - Refitting) (MR
411, 17B, Petrol injection),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging),
-the hub-carrier - driveshaft assembly (see ) (MR
411, 31A, Front axle components),
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (MR
411, 10A, Engine and peripherals).aFill the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (MR 411, 62A, Air conditioning).
aRefill:
-the sequential gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling,
page 21A-2) ,
-the cooling system (see Cooling system: Drain-
ing - Refilling) (MR 411, 19A, Cooling).
aRefit:
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the catalytic converter (see Catalytic converter:
Removal - Refitting) ,
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery). AIR CONDITIONING or CLIMATE CONTROL
AIR CONDITIONING or CLIMATE CONTROL
AIR CONDITIONING or CLIMATE CONTROL

29A-2
DRIVESHAFTS
Front left-hand driveshaft: Removal - Refitting
JB1 or JH1
29A
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.
aDrain the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove the front left-hand wheel (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the wiring from the wheel speed sensor (1) .
aRemove:
-the hub nut (2) by immobilising the hub using the
tool (Rou. 604-01),
-the track rod end nut (3) ,
-the track rod end from the stub axle carrier using
the (Tav. 476),
-the shock absorber base bolts (4) . Special tooling required
Rou. 604-01Hub locking tool.
Tav. 476Ball joint extractor.
Tightening torquesm
the flange mounting
bolts21 Nm
shock absorber base
bolts105 N.m
track rod end nut37 Nm
hub nut280 N.m
WARNING
In order to prevent irreversible damage to the front
hub bear ing:
-Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
-Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
130488

29A-4
DRIVESHAFTS
Front left-hand driveshaft: Removal - Refitting
JB1 or JH1
29A
aThe seal (gearbox side) is made by pushing the gai-
ter lip (9) into its housing on the gearbox, moving the
flange (8) .
Wipe oil from:
-the flange (8) ,
-between the flange and the gaiter,
-the seal lip (9) ,
-the face of the lip on the gearbox.
Refit the driveshaft on the gearbox side (this opera-
tion requires two people):
-Person 1:
•position the driveshaft at the differential input,
•fit the flange (8) on the gaiter (7) ,
•fit the driveshaft into the gearbox whilst keeping
the flange (8) on the gaiter,
•push the flange (8) to insert the gaiter lip (9) in its
housing (do not pinch the gaiter (7) ).
-Person 2:
•tighten the 3 flange mounting bolts (8) but do not
tighten fully (the flange should still be loose).
-Person 1:
•keep the driveshaft as horizontal as possible (with
respect to the differential).
-Person 2:
•torque tighten the flange mounting bolts (21
Nm).
aFit the front left-hand driveshaft into the stub axle
carrier.
aRefit the bolts to the shock absorber base.
aTorque tighten the shock absorber base bolts(105 N.m).
aPosition the track rod.
Torque tighten the track rod end nut (37 Nm).
aRefit the hub nut.
aTorque tighten the hub nut (280 N.m ) using the tool
(Rou. 604-01).
aClip on the wheel speed sensor wiring harness.
II - FINAL OPERATION.
aRefit the front left-hand wheel (see Wheel: Removal
- Refitting) (35A, Wheels and tyres).
aFill the gearbox (see 21A, Manual gearbox, Manu-
al gearbox oils: Draining - Filling, page 21A-2) .
aRefit the engine undertray. WARNING
To ensure a correct seal when refi tting a gaiter to
a gearbox:
-the flange (8) must be fitted to the gaiter (7)
(see figure 107922) in order to support the seal
lip (9) and to fit it correctly into its holder on the
gearbox.
Note:
The driveshaft must fit freely into the stub-axle
carrier until it protrudes enough for the hub nut to
be fitted.

29A-5
DRIVESHAFTS
Front left-hand driveshaft: Removal - Refitting
JH3 or JR5
29A
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.
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aDrain the gearbox (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip:
-the wheel speed sensor wiring (1) ,
-the brake hose (2) .
aRemove:
-the hub nut (3) by immobilising the hub using the
tool (Rou. 604-01),
-the track rod end nut (4) ,
-the shock absorber base bolts (5) . Special tooling required
Rou. 604-01Hub locking tool.
Emb. 880Pin extractor tool.
Tav. 1813Extraction claw for clip
secured type driveshafts
Tightening torquesm
shock absorber base
bolts105 N.m
track rod end nut37 N.m
hub nut280 N.m
WARNING
In order to prevent irreversible damage to the front
hub bear ing:
-Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
-Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
132032

29A-7
DRIVESHAFTS
Front left-hand driveshaft: Removal - Refitting
JH3 or JR5
29A
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the differential output seal (see 21A,
Manual gearbox, Differential output seal: Re-
moval - Refitting, page 21A-38) .
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the front left-hand driveshaft into the gearbox as
horizontally as possible.
aFit the front left-hand driveshaft into the stub axle
carrier.
aRefit the bolts to the shock absorber base.
aTorque tighten the shock absorber base bolts
(105 N.m).
aPosition the track rod.
aTorque tighten the track rod end nut (37 N.m).
aRefit the hub nut.
aTorque tighten the hub nut (280 N.m) using the tool
(Rou. 604-01).
aRefit the left-hand tie-rod.
aRefit the lower nut for the left-hand anti-roll bar tie-
rod.
aClip:
-the brake hose,
-the wheel speed sensor wiring.
III - FINAL OPERATION
aTop up the gearbox (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the engine undertray.Note:
The driveshaft must fit freely into the stub-axle
carrier until it protrudes enough for the hub nut to
be fitted.

29A-10
DRIVESHAFTS
Front right-hand driveshaft: Removal - Refitting
JH3 or JR5
29A
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,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aDrain the gearbox (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip:
-the wheel speed sensor wiring (1) ,
-the brake hose (2) .
aRemove:
-the hub nut (3) by immobilising the hub using the
tool (Rou. 604-01),
-the track rod end nut (4) ,
-the track rod end from the stub axle carrier using
the (Tav. 476),
-the shock absorber base bolts (5) . Special tooling required
Rou. 604-01Hub locking tool.
Tav. 476Ball joint extractor.
Tightening torquesm
relay bearing bolt21 N.m
shock absorber base
bolts105 N.m
track rod end nut37 N.m
hub nut280 N.m
WARNING
In order to prevent irreversible damage to the front
hub bear ing:
-Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
-Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
132027

29A-13
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting
JH3 or JR5
29A
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.
aDrain the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel driveshaft (see 29A,
Driveshafts, Front right-hand driveshaft: Re-
moval - Refitting, page 29A-8) .
aExtract the deflector using a press and an extractor.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the rubber ring (1) of the relay bearing (2) .
aExtract the relay shaft bearing (2) using a press and
an extractor.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Relay shaft bearing.
parts always to be replaced: relay bearing rub-
ber ring.
aClean and degrease the bore of the relay bearing
with SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products).
aLubricate the mating face of the driveshaft receiving
the deflector and the relay shaft bearing.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit a new relay shaft bearing to the relay shaft.
aFit the bearing to the end using a tube, so that it
rests on the inner bush of the bearing.
aRefit a new rubber ring for the relay bearing.
III - FINAL OPERATION
aFit a new deflector to the relay shaft.
aFit the deflector to the end using a tube, so that it
rests on the surface of the deflector.
aClean and grease the bearing hole into which the
bearing will be inserted.
aRefit:
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) ,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aFill up the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit the engine undertray.
100642
Note:
Do not scratch the mating face of the lip seal on
the relay shaft (3) .