Jr5 RENAULT TWINGO RS 2009 2.G Transmission User Guide

21A-20
MANUAL GEARBOX
Manual gearbox: Specifications
JH1 or JH3 or JR5
21A
JH3-060 11/41 21/43 28/39 34/35 39/31 11/39 14/59 22/18
JH3-061 11/41 21/43 28/39 34/35 39/31 11/39 14/61 22/18
JH3-062 11/41 21/43 28/39 34/35 39/31 11/39 14/61 22/18
JH3-063 11/41 21/43 28/39 34/35 39/32 11/39 14/61 22/18
JH3-064 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18
JH3-065 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18
JH3-066 11/41 21/43 28/29 34/35 39/31 11/39 14/63 22/18
JH3-067 11/37 22/41 28/37 34/35 39/32 11/39 14/63 22/18
JH3-068 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18
JH3-071 11/41 21/43 28/37 30/29 39/31 11/39 14/63 22/18
JH3-072 11/41 21/43 28/37 34/35 39/32 11/39 14/59 22/18
JH3-105 11/41 21/43 28/39 31/34 37/33 11/39 14/59 None
JH3-106 11/41 21/43 28/39 34/35 39/32 11/39 14/63 None
JH3-128 11/41 21/43 28/39 34/35 39/32 11/39 14/61 None
JH3-129 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-131 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None
JH3-132 11/37 22/41 28/37 30/29 42/41 11/39 15/58 None
JH3-137 11/41 21/43 28/39 31/34 37/33 11/39 14/59 None
JH3-141 11/37 22/41 28/37 30/29 42/41 11/39 15/58 None
JH3-142 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-143 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-144 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-145 11/37 22/41 28/37 30/29 42/31 11/39 16/57 None
JH3-150 11/37 22/41 28/37 30/29 42/41 11/39 15/58 None
JH3-154 11/41 21/43 28/39 31/34 37/33 11/39 16/61 None
JH3-155 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None
JH3-156
JH3-160 11/41 22/41 28/37 30/29 42/31 11/39 15/58 22/18
JH3-166 11/41 21/43 28/37 30/29 42/31 11/39 16/55 None
JH3-169 11/41 21/43 28/39 34/35 39/31 11/39 14/59 None Suffi x First Second Third Fourth Fifth Reverse
gearFinal
driveTacho
meter

21A-21
MANUAL GEARBOX
Manual gearbox: Specifications
JH1 or JH3 or JR5
21A
JH3-170 11/41 21/43 28/39 34/35 39/32 11/39 14/63 None
JH3-171 11/37 22/41 28/37 34/35 39/31 11/39 15/61 None
JH3-172 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-173 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-174 11/37 22/41 28/37 30/29 42/31 11/39 15/68 None
JH3-175 11/37 22/41 28/37 30/29 42/31 11/39 15/68 None
JH3-176 11/41 21/43 28/39 34/35 39/32 11/39 14/61 None
JH3-177 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None
JH3-179 11/41 21/43 28/39 31/34 37/33 11/39 15/68 None
JH3-183 11/41 21/43 28/39 34/35 39/32 11/39 14/59 None
JH3-184 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None
JH3-185 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None
JH3-186 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None
JH3-187 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None
JH3-189 11/37 22/41 28/37 30/29 42/31 11/39 15/56 None
JH3-190 11/37 22/41 28/37 30/29 42/31 11/39 15/56 None
JH3-193 11/41 21/43 28/37 30/29 42/31 11/39 16/55 None
JH3-199 11/41 21/43 28/39 34/35 39/32 11/39 14/59 None
JH3-309 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None
JH3-312 11/41 21/43 28/37 30/29 42/31 11/39 16/57 None
JH3-313 11/41 21/43 28/37 30/29 42/31 11/39 16/57 None
JH3-315 11/41 21/43 28/37 30/29 42/31 11/39 16/57 None
JH3-321 11/41 21/43 28/39 34/35 39/31 11/39 14/59 22/18
JR5 manual gearbox
JR5-003 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None
JR5-004 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None
JR5-008 11/41 21/43 29/39 31/34 37/33 11/39 15/58 None
JR5-015 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None
JR5-016 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None
JR5-017 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None Suffi x First Second Third Fourth Fifth Reverse
gearFinal
driveTacho
meter

21A-22
MANUAL GEARBOX
Manual gearbox: Specifications
JH1 or JH3 or JR5
21A
JR5-018 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None
JR5-113 11/41 21/43 28/37 35/34 41/31 11/39 16/57 None
JR5-116 11/41 21/43 28/37 35/34 41/31 11/39 16/55 21/19
JR5-124 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None
JR5-126 11/37 21/41 28/37 35/34 42/31 11/39 15/58 21/19
JR5-144 11/37 21/41 28/37 35/34 42/31 11/39 15/58 21/18
JR5-145 11/41 21/43 28/37 35/34 41/31 11/39 16/55 21/19
JR5-147 11/41 21/43 28/37 35/34 42/31 11/39 15/58 22/18
JR5-149 11/41 21/43 28/39 31/34 42/31 11/39 15/58 22/18
JR5-151 11/41 21/43 28/37 35/34 39/31 11/39 14/63 22/18
JR5-152 11/41 21/43 28/37 35/34 39/32 11/39 14/63 None
JR5-156 11/41 21/43 28/37 35/34 39/32 11/39 15/58 None
JR5-158 11/41 21/43 28/37 35/34 42/31 11/39 15/61 22/18
JR5-165 11/41 21/43 28/37 35/34 42/31 11/39 14/69 22/18
JR5-166 11/41 21/43 28/37 35/34 42/31 11/39 16/57 22/18
JR5-168 11/41 21/43 28/37 35/34 41/31 11/39 14/69 None
JR5-169 11/41 21/43 28/37 35/34 42/31 11/39 14/73 22/18
JR5-170 11/41 21/43 28/37 35/34 42/31 11/39 14/69 22/18
JR5-171 11/41 21/43 28/37 35/34 39/32 11/39 14/63 None
JR5-172 11/41 21/43 28/39 31/34 37/33 11/39 14/63 22/18
JR5-173 11/41 21/43 28/37 35/34 39/32 11/39 14/61 None
JR5-175 11/41 21/43 28/37 34/35 39/32 11/39 15/56 None
JR5-176 11/41 22/41 28/37 35/34 42/31 11/39 15/56 None
JR5-183 11/41 21/43 28/37 35/34 39/32 11/39 14/59 None
JR5-184 11/41 21/43 28/37 35/34 39/32 11/39 15/58 None
JR5-185 11/41 21/43 28/37 35/34 41/31 11/39 17/56 None
JR5-187 11/41 21/43 28/37 35/34 39/32 11/39 14/69 None
JR5-189 11/41 21/43 28/37 35/34 41/31 11/39 14/59 None
JR5-193 11/41 21/43 28/37 35/34 41/31 11/39 1756 None
JR5-301 11/41 21/43 28/37 35/34 41/31 11/39 15/56 None Suffi x First Second Third Fourth Fifth Reverse
gearFinal
driveTacho
meter

21A-23
MANUAL GEARBOX
Manual gearbox: Specifications
JH1 or JH3 or JR5
21A
JR5-302 11/41 21/43 28/37 35/34 41/31 11/39 14/69 None
JR5-308 11/41 21/43 28/37 31/29 45/31 11/39 18/57 None Suffi x First Second Third Fourth Fifth Reverse
gearFinal
driveTacho
meter

21A-24
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
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 - Refitting)
(80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery).
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment).
aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.aUnclip:
-the clutch hydraulic control pipe on the gearbox (1)
,
-the union (2) on the hydraulic tappet slave cylinder,
-the gearbox breather.
aRemove:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
lower gearbox bolts44 N.m
gearbox nuts and bolts44 N.m
gearbox upper bolts44 N.m
121410

21A-25
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
aLoosen the bolt (3) and the nut (4) on the upstream
strut of the catalytic converter on the gearbox.
aRemove:
-the bolt (5) from the upstream strut of the catalytic
converter on the catalytic converter,
-the upstream strut of the catalytic converter by slid-
ing it upwards,
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging).
aFit the (Mot. 1453) :
-positioning it on the front wing opening stops and
on the headlight brackets,
-using the two engine lifting eyes to avoid the
« engine - gearbox » assembly tilting too much,
-making sure the tool is strapped to the vehicle.aRemove:
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting),
-the subframe (see Front axle subframe: Removal
- Refitting) (31A, Front axle components).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the gearbox controls by pressing on the ca-
ble end pieces (6) .
aRemove the earth strap bolt.
aRemove the upper gearbox bell housing bolts.
aDisconnect:
-the speed and position sensor connector,
-the reverse gear switch connector.
aRemove:
-the lower gearbox bell housing bolts,
-the gearbox nuts,
-the gearbox studs.
aFit a component jack under the gearbox.
aRemove:
-the lower gearbox bell housing bolts,
-the gearbox.
106199
121415
108265

21A-26
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the gearbox using a component jack,
-the gearbox stud nuts,
-the gearbox lower bolts.
aTorque tighten:
-the lower gearbox bolts (44 N.m),
-the gearbox nuts and bolts (44 N.m).
aRefit the upper gearbox bolts.
aTorque tighten the gearbox upper bolts (44 N.m).
aRefit the earth strap bolt on the gearbox.
aConnect:
-the reverse gear switch connector,
-the speed and position sensor connector.
aClip the gearbox controls into place.
II - FINAL OPERATION
aRefit:
-the subframe (see Front axle subframe: Removal
- Refitting) (31A, Front axle components),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
aRemove the tool (Mot. 1453).
aRefit:
-the upstream strut of the catalytic converter by slid-
ing it upwards,
-the catalytic converter upstream strut bolt on the
catalytic converter.
aTighten the bolt and nut on the upstream strut of the
catalytic converter on the gearbox.
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aClip:
-the union onto the hydraulic tappet slave cylinder,
-the hydraulic clutch control pipe,
-the gearbox breather.
aBleed the clutch (see Clutch circuit: Bleed) (37A,
Mechanical component controls).
aRefit the engine management computer mounting
fitted with the engine management computer.
aFit the engine management computer wiring har-
ness.
aRefit the engine management computer wiring har-
ness nut on the engine management computer
mounting.
aFit the engine management computer mounting.
aRefit:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aConnect the engine management computer connec-
tors.
aRefit:
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
aFill up the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit:
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).

21A-30
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
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 battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (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 differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the “engine - gearbox” assembly from
theusing a workshop hoist.
aDisconnect the TDC sensor connector (1) . Equipment required
workshop hoist
Tightening torquesm
manual gearbox nuts
and bolts44 N.m
earth strap bolt on the
gearbox44 N.m
support bolts for the
suspended engine
mounting on the gear-
box62 N.m
132319

21A-31
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aRemove:
-the suspended engine mounting support bolts (2)
on the gearbox,
-the suspended engine mounting support (3) on the
gearbox.
aDisconnect the connector (4) from the reverse gear
switch.
aUnclip the reverse gear switch at (5) .aRemove the bolt (6) from the earth strap on the gear-
box.
aRemove the bolts (7) from the engine wiring harness
channel.
aMove aside the engine wiring.
aRemove the starter (see Starter: Removal - Refit-
ting) (16A, Starting - Charging).
144799
144798132321
132318

21A-32
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aRemove:
-the bolts (8) and the nuts (9) from the manual gear-
box,
-the manual gearbox.
REFITTING
I - REFITTING PREPARATION OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the manual gearbox.
aTorque tighten the manual gearbox nuts and bolts
(44 N.m).
132325
132324132326
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.
WARNING
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
WARNING
Do not grease the clutch shaft splines.