gearbox RENAULT TWINGO RS 2009 2.G Chasiss Workshop Manual

31A-43
FRONT AXLE COMPONENTS
Front axle subframe: Removal - Refitting
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the universal joint cover (1) (do not keep).
aSet the wheels straight ahead.
aFit a flywheel immobiliser.
aRemove the bolt (2) from the universal joint (do not
keep).
aTilt the universal joint on the steering box to detach it
from the pinion. Special tooling required
Tav. 476Ball joint extractor.
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
flywheel immobiliser
Tightening torquesm
rear subframe bolts105 Nm
front subframe bolts62 Nm
front end cross member
bolts21 Nm
acoustic tie-rod bolts21 Nm
acoustic tie-rod bolts90 Nm
subframe tie-rod bolts21 Nm
subframe tie-rod nuts62 Nm
gear lever arm nut28 Nm
nuts of the lower arm
ball joints62 N.m
bolts of the lower ball
joints62 N.m
nuts of the track rod
ends37 N.m
universal joint bolt24 Nm
119544
Note:
Do not pull the intermediate shaft out.

31A-45
FRONT AXLE COMPONENTS
Front axle subframe: Removal - Refitting
31A
aRemove:
-the track rod ends using the (Tav. 476) (6) ,
-the lower arm ball joints.
aRemove the rubber protector (7) from the gear lever
arm.aRemove the nut (8) from the gear lever arm.
aRemove the gear lever arm from the gearbox con-
trol.
aRemove:
-the heat shield under the gear lever,
-the gearbox control lever arm.
aRemove:
-the subframe tie-rod nuts (9) ,
119345
JB1
119408
119407
119210

31A-48
FRONT AXLE COMPONENTS
Front axle subframe: Removal - Refitting
31A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the speed selection cable guide on the sub-
frame.
aRefit:
-the front driveshaft lower arms (see 31A, Front
axle components, Front driveshaft lower arm:
Removal - Refitting, page 31A-33) ,
-the front anti-roll bar (see 31A, Front axle compo-
nents, Front anti-roll bar: Removal - Refitting,
page 31A-52) ,
-the steering box (see 36A, Steering assembly,
Steering box: Removal - Refitting, page 36A-1) .
aRefit the « subframe - front driveshaft lower arm -
steering box - front anti-roll bar » assembly with the
(Mot. 1390).
aTighten to torque:
-the rear subframe bolts (105 Nm) (20) ,
-the front subframe bolts (62 Nm) (22) ,
-the front end cross member bolts (21 Nm) (21) .aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the acoustic tie rods.
aTighten to torque:
-the acoustic tie-rod bolts (21 Nm) (23) ,
-the acoustic tie-rod bolts (90 Nm) (24) .
aRefit the sub-frame tie-rods.
aTighten to torque:
-the subframe tie-rod bolts (21 Nm),
-the subframe tie-rod nuts (62 Nm).
aCheck the position of the gear selection cables in the
guide.
aFit the gearbox control gear lever arm.
aTorque tighten the gear lever arm nut (28 Nm).
aFit the gear lever arm rubber protector. K9K
Note:
Be careful with the guide of the lower or upper
radiator when fitting the subframe. There is a risk
of the radiator guides breaking.
119336
119335
K9K
JB1

33A-37
REAR AXLE COMPONENTS
Complete rear axle system: Removal - Refitting
33A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
aRelease the parking brake.
aFit the pedal press on the brake pedal to limit the
amount of brake fluid running out.
aRemove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Removal
aRemove:
-the heat shield clips (1) ,
-the heat shield.
aUndo the adjusting screw (2) of the parking brake
compensator.
aRemove the parking brake compensator brake ca-
bles. Special tooling required
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
pedal press
safety strap(s)
Tightening torquesm
rear axle bearing bolts62 Nm
brake hose lower unions17 Nm
119435
119436

37A-14
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
JB1 or JH1 or JH3 or JR5, and LEFT-HAND DRIVE
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove the gearbox computer (see Sequential
gearbox converter: Removal - Refitting) (21B,
Sequential gearbox).
aRemove the battery tray (see Battery tray: Remov-
al - Refitting) (80A, Battery).
aRemove the petrol injection computer (see Petrol
injection computer: Removal - Refitting) (17B,
Petrol injection).
aRemove the diesel injection computer (see Diesel
injection computer: Removal - Refitting) (13B,
Diesel injection).
aRemove:
-the injection computer mounting bolts (1) ,
-the engine harness bracket nut (2) ,
-the injection computer mounting,
-the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) . Tightening torquesm
brake servo nuts25 Nm
JH1
D4F or D7F or K4M
K9K
122323
122322

37A-18
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
JB1 or JH1 or JH3 or JR5, and LEFT-HAND DRIVE
37A
aRefit the battery tray (see Battery tray: Removal -
Refitting) (80A, Battery).
aRefit the gearbox computer (see Sequential gear-
box converter: Removal - Refitting) (21B, Se-
quential gearbox).
aRefit the battery (see Battery: Removal - Refitting)
(80A, Battery). JH1

37A-27
MECHANICAL COMPONENT CONTROLS
Pedal assembly: List and location of components
37A
I - LIST OF COMPONENTS
The pedal assembly consists of:
-an accelerator pedal (see 37A, Mechanical compo-
nent controls, Accelerator pedal: Removal - Refit-
ting, page 37A-29)
-a brake pedal switch (see 37A, Mechanical compo-
nent controls, Brake pedal switch: Removal - Re-
fitting, page 37A-42)
-a brake pedal (see 37A, Mechanical component
controls, Brake pedal: Removal - Refitting, page
37A-31)
-a brake - clutch pedal assembly (see 37A, Mechani-
cal component controls, Brake pedal: Removal -
Refitting, page 37A-31)
-a clutch pedal switch (see 37A, Mechanical compo-
nent controls, Clutch pedal switch: Removal - Re-
fitting, page 37A-52) II - LOCATION OF COMPONENTS
Accelerator pedal
Brake pedal switch 5-SPEED MANUAL SEQUENTIAL GEARBOX
5-SPEED MANUAL GEARBOX
CRUISE CONTROL
119134
121350

37A-28
MECHANICAL COMPONENT CONTROLS
Pedal assembly: List and location of components
37A
Brake pedal
Brake - clutch pedal assemblyClutch pedal switch 5-SPEED MANUAL SEQUENTIAL GEARBOX
122227
5-SPEED MANUAL GEARBOX
123905
CRUISE CONTROL
121349

37A-31
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
RIGHT-HAND DRIVE, and 5-SPEED MANUAL GEARBOX
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the dashboard lower trim (1) ,
-the brake pedal switch (see 37A, Mechanical
component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-42) .
aRemove the accelerator pedal (see 37A, Mechani-
cal component controls, Accelerator pedal: Re-
moval - Refitting, page 37A-29) .aRemove the clutch pedal switch (see ) .
aRemove the dashboard side face (2) .
aDisconnect the airbag inhibitor switch connector (3) . Equipment required
heat str ipper
Tightening torquesm
bolts of the « brake -
clutch pedal assembly » 21 N.m
123870
JB1
CRUISE CONTROL
123870
123871

37A-32
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
RIGHT-HAND DRIVE, and 5-SPEED MANUAL GEARBOX
37A
aRemove:
-the clutch master cylinder rod (4) ,
-the nuts (5) from the clutch master cylinder sup-
port,
-the clutch master cylinder support (6) ,
-the connecting clip (7) between the outlet pipe and
the clutch master cylinder,
-the clutch master cylinder (8) .aRemove the dashboard bolts (9) .
aMove the dashboard away slightly.
II - REMOVAL OPERATION FOR THE ALUMINIUM
PEDAL PADS
aHeat the pedal pad with a heat stripper to a maxi-
mum temperature of 80˚C.
aRemove the pad using a pair of pliers.
aClean the residue of adhesive on the pedal (see
Tools for stripping very thick soft mastic: Use) . JH3 or JR5
123904
123871
EQUIPMENT LEVEL SPORT