RENAULT TWINGO RS 2009 2.G Transmission User Guide

20A-8
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
aRefill:
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).
aRefit:
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the engine undertray.

20A-9
CLUTCH
Clutch thrust bearing: Removal - Refitting
JH3 or JR5
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 gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting, page 21A-24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the clutch thrust bearing bolts (1) .aRemove the clutch thrust bearing (2) .
REFITTING
I - REFITTING PREPARATION OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the clutch thrust bearing. Tightening torquesm
clutch thrust bearing
bolts (JH3)21 N.m
clutch thrust bearing
bolts (JR5)25 N.m
Note:
The clutch thrust bear ing cannot be separated from
the clutch slave cylinder.
108796
108797
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
WARNING
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
WARNING
Never operate the system when the slave cylin-
der is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the sla ve cylinder stop will be ejected.
Note:
To obtain optimum bleeding, pre-fill the clutch
thrust bearing when refitting the thrust bearing.

20A-10
CLUTCH
Clutch thrust bearing: Removal - Refitting
JH3 or JR5
20A
aTorque tighten the clutch thrust bearing bolts
(JH3) (21 N.m).
aTorque tighten the clutch thrust bearing bolts
(JR5) (25 N.m).
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .
aBleed the clutch control (see Clutch circuit: Bleed)
(37A, Mechanical component controls).
aRefit the engine undertray. JH3
JR5

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

20A-12
CLUTCH
Clutch thrust bearing: Removal - Refitting
JB1
20A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the fork.
aRefit:
-the fork,
-the stop on the guide tube, placing the hooks (3)
into the fork.
aEnsure that it slides correctly.
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .aAfter refitting the gearbox, check the travel (X) of the
fork.
This must be:
-D4F engine: x = 29.5 mm ±± ± ±
0.5,
-D7F engine: x = 29.5 mm ±± ± ±
0.5.
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
107916
Note:
During operations where the gearbox does not
have to be removed or refitted, do not lift the fork
because this may cause the hooks to come out
(3) of the thrust bearing.
91830

21A-1
MANUAL GEARBOX
Manual gearbox oil: Specifications
5-SPEED MANUAL GEARBOX
21A
I - GEARBOX TYPE/OIL TYPE CORRELATIONS:
Component identification:
The third character X corresponds to the figure written
on the identification plate and therefore covers the en-
tire manual gearbox range.
II - STANDARDS AND PART NUMBERS OF THE
VARIOUS RECOMMENDED OILS:III - IDENTIFICATION OF OIL FOR STANDARD
EXCHANGE PK1 GEARBOXES: GEARBOX TYPE TYPE OF OIL FOR
GEARBOX
JBX
JCX
JRX
JHX
NDX
TLXTRANSELF TRJ
75W80
or
TRANSELF NFJ
75W80
PKX
PFX
VMX
NEX
NGX
N0X
UNXTRANSELF TRX
75W80
or
TRANSELF NFP
75W80
ZFX T RANSELF LD
75W80
DESIGNATION STANDARDPART NUM-
BER
TRANSELF
TRX 75W80
or
TRANSELF
NFP 75W80APIGL4,
MIL-L-2105
C or D77 11 143 534
(5 litres)TRANSELF
TRJ 75W80
or
TRANSELF
NFJ 75W80APIGL4,
MIL-L-2105
C or DMay be
ordered from
ELF
TRANSELF
LD 75W80APIGL4,
MIL-L-2105May be
ordered from
ELF
Note:
For standard exchange PK1 gearboxes, the oil type
(TRZ or TRP) is shown on a label.
These two oils are replaced by TRX 75W80 or NFP
75W80.

21A-2
MANUAL GEARBOX
Manual gearbox oils: Draining - Filling
JB1 or JH3 or JR5
21A
DRAINING
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the engine undertray.
aFit a oil recovery tray under the gearbox.
aRemove the drain plug (1) .
aLet the oil run into the oil recovery tray.
FILLING
aparts always to be replaced: mechanism hous-
ing drain plug seal.aRefit a new seal on the drain plug with the groove (2)
facing the plug.
aRefit the drain plug fitted with its new seal.
aRemove the filler cap (3) . Equipment required
oil recovery tray
Gearbox Capacity (l)
JB1 3.4
JH3 2.8
JR5 2.3
18749
113764
18749

21A-3
MANUAL GEARBOX
Manual gearbox oils: Draining - Filling
JB1 or JH3 or JR5
21A
aFill with the recommended oil to the level (4) of the
opening (see 21A, Manual gearbox, Manual gear-
box oil: Specifications, page 21A-1) (Technical
Note 6012A, 04A, Lubricants).
aRefit the filler cap.
aWipe any oil run-off with a cloth.
aRemove the oil recovery tray.
aRefit the engine undertray.
92081

21A-4
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
101388
(1) Oil defl ector
(2) Output shaft bear ing
(3) Output shaft
(4) First idle gear
(5) Synchroniser r ing
(6) First-second synchroniser hub
(7) Synchroniser r ing
(8) Lock r ing
(9) Splined w asher
(10) Second idle gear
(11) Splined w asher
(12) Lock r ing
(13) Splined w asher
(14) Third idle gear
(15) Synchroniser r ing
(16) Splined w asher
(17) Lock r ing
(18) Third-four th synchroniser hub
(19) Synchroniser r ing
(20) Four th idle gear (21) Lock washer
(22) Bear ing retaining clips on mech-
anism housing
(23) Output shaft bear ing
(24) Fifth fi xed gear
(25) Output shaft bolt
(26) Input shaft bear ing
(27) Primar y shaft
(28) Bear ing retaining clips on mech-
anism housing
(29) Input shaft bear ing
(30) Lock washer
(31) Ring under fifth idle gear
(32) Fifth idle gear
(33) Synchroniser r ing
(34) Synchroniser spring
(35) Fifth gear synchroniser hub
(36) Synchroniser spring
(37) Friction cone
(38) Retaining washer
(39) Input shaft nut

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