clutch RENAULT TWINGO RS 2009 2.G Transmission Owner's Manual

21A-27
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove the air filter unit (see Air filter unit: Re-
moval - Refitting) (MR 411, 12A, Fuel mixture).
aRemove:
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 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 cable,
-the gearbox breather.
aRemove:
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior 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 ) (MR 411, 31A, Front
axle components),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
gearbox mountings44 Nm
D4F

21A-28
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
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) (MR 411, 19D, Engine mount-
ing),
-the subframe (see Front axle subframe: Removal
- Refitting) (MR 411, 31A, Front axle component).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the reverse gear switch connector.
aRemove:
-the earth strap bolt on the gearbox,
-the gearbox upper bolts,
-the engine speed and position sensor (see Crank-
shaft position sensor: Removal - Refitting) (MR
411, 17B, Petrol injection).
-the gearbox lower bolts,
-the flywheel protection plate bolts,
-the flywheel protection plate,
-the gearbox stud nuts,
-the gearbox using a component jack.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the gearbox using a component jack.
-the gearbox mountings.
aTorque tighten the gearbox mountings (44 Nm).
aRefit:
-the engine speed and position sensor (see Crank-
shaft position sensor: Removal - Refitting) (MR
411, 17B, Petrol injection),
-the earth strap bolt on the gearbox.
aConnect the reverse gear switch connector.
II - FINAL OPERATION.
aRefit:
-the subframe (see Front axle subframe: Removal
- Refitting) (MR 411, 31A, Front axle compo-
nents),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (MR 411, 19D, Engine mount-
ing).
aRemove the (Mot. 1453).
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (MR 411, 31A, Front
axle components),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres).
aClip:
-the clutch cable,
-the gearbox breather.
121415

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.

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-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).

21B-2
SEQUENTIAL GEARBOX
Sequential gearbox: List and location of components
D4F, and JH1
21B
122171
(1) Actuator module high pressure
supply pipe
(2) Clutch stay high pressure supply
pipe
(3) Reservoir retur n hose
(4) Engagement solenoid v alve 2
(5) Solenoid valve unit pressure
sensor
(6) Clutch position sensor
(7) Tank
122172
(8) Pump unit
(9) Actuator module
(10) Gear selection sensor
(11) Clutch solenoid valve
(12) Engagement solenoid valve 1
(13) Selection solenoid valve 3
(14) Selection solenoid valve 4
(15) Engagement sensor
122160
(16) Sequential gearbox speed sen-
sor

21B-13
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
aMark the positions:
-of the left-hand suspended engine mounting on the
body,
-of the rubber pad on the left-hand suspended en-
gine mounting.
aRemove:
-the left-hand suspended engine mounting rubber
pad nut (4) ,
-the left-hand suspended engine mounting rubber
pad bolts (5) ,
-the rubber pad from the left-hand suspended en-
gine mounting
aLower the sequential gearbox to access the left-
hand suspended engine mounting bolt on the body.
aRemove:
-the left-hand suspended engine mounting bolts (6)
,
-the left-hand suspended engine mounting.aRemove:
-the selector shaft cover bolt (7) ,
-the selector shaft cover (8) .
aDisconnect the connector (9) from the electro-hy-
draulic unit by moving the lock (10) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the clutch stay cable (11) from the clutch
fork.
120310122321
122168

21B-16
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
aIt is essential to replace the electro-hydraulic unit
seal.
aPlace the actuator module selector shaft in a raised
and locked position.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit:
-the new electro-hydraulic unit seal,
-the electro-hydraulic unit.
aRefit:
-the sequential gearbox lifting eye on the sequential
gearbox,
-the breather pipe on the sequential gearbox.
-the electro-hydraulic unit nuts,
-the electro-hydraulic unit bolts.
aConnect the sequential gearbox speed sensor con-
nector.
aAttach the breather pipe:
-to the cooling hose,
-to the sequential gearbox lifting eye.aPress on the selector shaft with a screwdriver to clip
the sequential gearbox selector shaft to the actuator
module.
aRefit the clutch stay cable to the clutch fork.
aConnect the electro-hydraulic unit connector by
moving the lock.
III - FINAL OPERATION
aRefit:
-the selector shaft cover,
-the selector shaft cover bolt.
aFit the left-hand suspended mounting on the body.
aFit the left-hand suspended engine mounting bolts
without tightening them.
aTorque tighten the left-hand suspended engine
mounting bolts (21 N.m).
aRaise the sequential gearbox to its original position.
aFit the left-hand suspended engine mounting rubber
pad.
aFit the left-hand suspended engine mounting rubber
pad bolts without tightening them.
aTorque tighten the left-hand suspended engine
mounting rubber pad bolts ( 62 N.m).
aFit the left-hand suspended engine mounting rubber
pad nut without tightening it.
aTorque tighten the left-hand suspended engine
mounting rubber pad nut (105 N.m ).
17970
17970