clutch 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-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-6
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
141103
(99) Suppor t bracket
(100) Gaiter
(101) Clutch protection component
(102) Clutch guide tube
(103) Clutch housing
(104) Oil collector
(105) Oil supply channel
(106) Filler plug
(107) Mechanism housing
(108) 5th gear cover seal
(109) Breather vent body
(110) Breather pipe
(111) Union
(112) Breather
(113) 5th gear cover

21A-11
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
101391
(60) Mechanism housing
(61) Filler plug
(62) Spacer
(63) Oil channel
(64) Breather pipe
(65) Reverse gear sensor
(66) O-r ing
(67) Fifth gear housing
(68) Gearbox bell housing bolt
(69) Fifth gear housing bolt
101392
(70) Clutch housing
(71) Drain plug
(72) Magnet
(73) Hydraulic clutch release bearing
(74) Hydraulic clutch release bear-
ing bolt

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-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).