oil RENAULT TWINGO RS 2009 2.G Transmission Workshop Manual

TWINGO - Chapitre 2
Contents
Pages
TWINGO - Chapitre 2ContentsPages
20A CLUTCH
Clutch: Precautions for the
repair 20A-1
Clutch: Specifications 20A-2
Pressure plate - Disc:
Removal - Refitting 20A-4
Clutch thrust bearing:
Removal - Refitting 20A-9
21A MANUAL GEARBOX
Manual gearbox oil:
Specifications 21A-1
Manual gearbox oils:
Draining - Filling 21A-2
Manual gearbox: List and
location of components 21A-4
Manual gearbox:
Identifi cation 21A-12
Manual gearbox:
Specifications 21A-14
Manual gearbox: Removal -
Refitting 21A-24
Manual gearbox: Repair 21A-34
Differential output seal:
Removal - Refitting 21A-38
Input shaft lip seal: Removal
- Refitting 21A-41
Reverse gear switch:
Removal - Refitting 21A-44
21B SEQUENTIAL GEARBOX
Sequential gearbox:
Precautions for the repair 21B-1
Sequential gearbox: List and
location of components 21B-2
Sequential gearbox oil:
Draining - Filling 21B-3
Pressure accumulator:
Removal - Refitting 21B-5
Pump assembly reservoir:
Removal - Refitting 21B-9
Electro-hydraulic unit:
Removal - Refitting 21B-11
Pump assembly: Removal -
Refitting 21B-18
Solenoid valves: Removal -
Refitting 21B-21
Engagement sensor :
Removal - Refitting 21B-27
Actuator module: Removal -
Refitting 21B-28
Gear selection sensor :
Removal - Refitting 21B-31 21A MANUAL GEARBOX

20A-6
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
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 battery (see Battery: Removal - Refitting)
(80A, Battery)
-the air filter box (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 engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the (Mot. 1677) (1) .
aRemove:
-the clutch pressure plate bolts (2) ,
-the clutch pressure plate,
-the clutch plate. Special tooling required
Mot. 1677Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts23 N.m
132329

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.

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-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-8
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
JH1 or JH3
101388
(1) Oil defl ector
(2) Bear ing
(3) Output shaft
(4) First gear pinion
(5) Synchromesh r ing
(6) First-second gear synchroniser
hub
(7) Spring
(8) Roller
(9) Lock r ing
(10) Splined w asher
(11) Second gear pinion
(12) Third gear pinion
(13) Third-four th gear synchroniser
hub
(14) Four th gear pinion
(15) Lock washer
(16) Retaining clips (17) Bear ing
(18) Fifth gear pinion
(19) Output shaft bolt
(20) Bear ing guide
(21) Primar y shaft
(22) Retaining clips
(23) Bear ing
(24) Lock washer
(25) Sprocket supporting ring
(26) Fifth gear pinion
(27) Synchromesh r ing
(28) Spring
(29) Synchroniser hub
(30) Spring
(31) Friction cone
(32) Synchromesh r ing
(33) Washer
(34) Input shaft nut

21A-9
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
JR5
101389
(1) Oil defl ector
(2) Bear ing
(3) Output shaft
(4) First gear pinion
(5) Synchromesh r ing
(6) Spring
(7) First-second gear synchroniser
hub
(8) Synchromesh r ing
(9) Sprocket supporting ring
(10) Second gear pinion
(11) Splined w asher
(12) Sprocket supporting ring
(13) Third gear pinion
(14) Synchromesh r ing
(15) Third-four th gear synchroniser
hub
(16) Synchromesh r ing (17) Sprocket supporting ring
(18) Four th gear pinion
(19) Adjustment washer
(20) Bear ing
(21) Fifth gear pinion
(22) Output shaft bolt
(23) Bear ing guide
(24) Primar y shaft
(25) Retaining clips
(26) Bear ing
(27) Lock washer
(28) Sprocket supporting ring
(29) Fifth gear pinion
(30) Synchromesh r ing
(31) Spring
(32) Synchroniser hub
(33) Spring
(34) Friction cone