Gearbox input shaft seal RENAULT TWINGO 2009 2.G Transmission Workshop Manual

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

20A-11
CLUTCH
Clutch thrust bearing: Removal - Refitting
JB1
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
aRemove the clutch thrust bearing (1) by tilting the
fork at (A) .aRemove the fork (2) by pulling it towards the inside
of the clutch housing.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aCheck that there are no leaks from the input shaft,
replace the guide tube if necessary (see 21A, Man-
ual gearbox, Input shaft lip seal: Removal - Refit-
ting, page 21A-41) .
aCoat the walls of the guide tube and the fork pads
with BR2+ GREASE.
107917
107914

21A-5
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
(40) Synchroniser r ing
(41) Retaining washer
(42) Input shaft nut
141102
(79) Clutch control fork
(80) Fork pivot ball joint
(81) Pivot gaiter
(82) Assembled reverse gear shaft
(83) Bear ing ring
(84) Assembled 1-2 fork shaft claw
(85) Assembled 3-4 fork shaft claw
(86) Reverse gear guide
(87) Assembled 5th gear fork shaft
(88) Lip seal
(89) Gaiter
(90) Tie-bar
(91) Gaiter
(92) Shaft lever and finger assembly
(93) Thickness washer
(94) 5th gear kickdown point
(95) Gaiter (96) Ball joint bearing shell
(97) Lock ring
(98) Retur n spring

21A-10
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
(35) Synchromesh r ing
(36) Washer
(37) Input shaft nut
101393
(38) Differential seal
(39) Bear ing
(40) Differential
(41) Tachometer sprocket (if fitted to
the vehicle)
(42) Satellite
(43) Sunwheel
(44) Axis
(45) Shaft retaining spr ing
(46) Fr iction cover
101390
(47) Selector shaft
(48) Gear shift catch
(49) Reverse gear brake fork and
shaft
(50) Fifth gear fork and shaft
(51) Pin
(52) Reverse gear shaft
(53) Third-four th gear fork and shaft
(54) Ring
(55) Lock shaft
(56) First-second gear fork and shaft
(57) Retaining locating ball car tridge
(58) Selector shaft bolt
(59) Reverse gear fork shaft bolt

21A-34
MANUAL GEARBOX
Manual gearbox: Repair
JB1
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION.
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aCheck the shafts (see Manual gearbox: Check) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the manual gearbox selector shaft (see Manual
gearbox selector shaft: Removal - Refitting) .
REFITTING
I - REFITTING PREPARATION OPERATION
aClean all the removed parts (see Manual gearbox:
Precautions for the repair) .
aReplace worn or damaged parts.
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the synchroniser hub springs,
-the removed bearings,
-the selector shaft rings,
-the spy seals,
-the hydraulic clutch thrust bearing (if equipped),
-the magnet.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) .
aRefit:
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) , IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .

21A-36
MANUAL GEARBOX
Manual gearbox: Repair
JH1 or JH3 or JR5
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) .aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) to clean all of the
removed parts.
aCheck (see Manual gearbox: Check) :
-the pinions (teeth, claws, friction cone, inner wall),
-the synchroniser hubs,
-the synchroniser rings,
-the bearings.
aReplace worn or damaged parts.
REFITTING
I - REFITTING PREPARATION OPERATION
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the selector rod hub springs,
-the hydraulic clutch slave cylinder (if fitted),
-the magnet,
-the selector shaft rings,
-the lock ring of the differential,
-the differential retaining nut.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) . IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .

21A-41
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting
JB1
21A
Detailed view of the Bvi tool components. 1445
aThe gearbox must be removed.
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
aPosition the gearbox on the mounting (1) adjusting
the adjustable support (2) .
aGently remove the guide tube with a press using the
(Bvi. 1828).
aDegrease the guide tube. Special tooling required
Bvi. 1828Snap r ivet and pressure plate
for removal and refitting of the
guide tube (JH1 gearbo x)
Note:
The lip seal and the primary shaft bearing are built
into the thr ust pad guide tube.
It is lubricated via an aperture into the housing
bore.
99057
(1) tightening clamp
(2) sleeve
(3) Sender
(4) key
(5) split ring
98934
98936

21A-42
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting
JB1
21A
aPlace the tightening clamp (3) onto the tube.
aLock the tightening clamp using the spanner (4) .
aTighten the nut firmly (5) .
aPosition the sleeve (6) and the split ring (7) .
aTurn the upper nut (8) .
aGently extract the guide tube.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aPosition the new guide tube on the clutch housing.
aGently remove the guide tube with a press and the
(Bvi. 1828).
II - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24)
(MR 411, 21A, Manual gearbox).
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
98937
98938
98939
98935-1

21A-43
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting
JH1 or JH3 or JR5
21A
aReplace the lip seal after having opened the gear-
box (see Clutch housing bearing: Removal - Re-
fitting) (Technical Note 6029A, 21A, Manual
gearbox).

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.