light RENAULT TWINGO RS 2009 2.G Transmission Workshop Manual

20A-3
CLUTCH
Clutch: Specifications
D4F – D7F – K9K – K4M
20A
Number of grooves: 26
Colour of springs (3) : Red and Black
Colour of springs (4) : Grey
Pressure plate
Pressure plate part no.: 215 CPOE 4350
Drive platePlate outer diameter: 215 mm
Plate thickness: 6.9 mm
Number of grooves: 26
Spring colour (5) : Moss green
Spring colour (6) : Light blue
Spring colour (7) : Green
Spring colour (8) : Capri blue K4M
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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.
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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.
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29A-16
DRIVESHAFTS
Front driveshaft gaiter, wheel side: Removal - Refitting
JB1 or JH1 or JH3 or JR5
29A
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the small securing clip (6) onto the driveshaft.
aLightly lubricate the driveshaft using the grease sup-
plied with the gaiter to facilitate its fitting.
aRefit the gaiter (7) onto the driveshaft.
aInsert the gaiter lip into the groove of the driveshaft.
aRefit the locking spring ring (8) .
aSpread the quantity of grease around the gaiter and
the stub axle bowl.aRefit the stub axle bowl (9) to the driveshaft by tap-
ping on the stub axle bowl using a brass drift until the
locking spring ring clicks into place behind the hub
bearing.
aFit the lip of the driveshaft gaiter into the groove on
the stub axle bowl.
aFit the small securing clip on the driveshaft gaiter.
aRefit the big securing clip on the driveshaft gaiter.
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Note:
Chec k that the gaiter lip is correctly positioned in
the g roove of the driveshaft.

29A-20
DRIVESHAFTS
Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting
JB1 or JH1 or JH3 or JR5
29A
aRemove the lock ring (4) .
aRemove:
-the spider (5) using a separator and a press,
-the driveshaft gaiter from the driveshaft.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace:
-the cup,
-the cup spring,
-the driveshaft gaiter,
-the stop ring,
-the big securing clip,
-the small securing clip.
aUsing a parts washer, clean the driveshaft, the spi-
der and the yoke sleeve.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the small securing clip (6) onto the driveshaft.
aLightly lubricate the driveshaft using the grease sup-
plied with the gaiter to facilitate its fitting.
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Note:
Mark the position of the spider before extracting
it.
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29A-25
DRIVESHAFTS
Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting
JH3 or JR5
29A
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Front left-hand
driveshaft gaiter, gearbox side.
aparts always to be replaced: gearbox side front
driveshaft seal locking ring.
aAlways replace:
-the cup,
-the cup spring,
-the big securing clip,
-the small securing clip.
aUse a parts washer to clean the driveshaft, the spi-
der and the driveshaft yoke sleeve.
II - REFITTING OPERATION
aFit the small tightening clip (2) to the driveshaft.
aLightly lubricate the driveshaft using the GREASE
supplied with the gaiter to facilitate its fitting.aRefit the gaiter (3) onto the driveshaft.
aInsert the gaiter lip into the groove of the driveshaft.
aRefit:
-the spider (6) in the position marked during remov-
al,
-a new lock ring using circlip pliers.
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