Renault Twingo Clio User Manual

Workshop Repair Manual

Manual gearbox

Type Range

JH1 Twingo

Clio

JH3 Clio

Laguna II

JR5 Laguna II

77 11 299 962

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

MARCH 2001

All copyrights reserved by Renault.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

Contents

Page

MANUAL GEARBOX

Section and tightening torques (in daNm) 21-1 Tightening torques (in daNm) 21-3 Gears 21-4 Consumables 21-5 Capacity - Lubricants 21-5 Parts to be systematically replaced 21-5 Special tooling 21-6 Repairing the gearbox 21-7

MANUAL GEARBOX

Section and tightening torques (in daNm)

21-1

121

MANUAL GEARBOX

Section and tightening torques (in daNm)

JH GEARBOX

A2.5

B2.5

D19

MANUAL GEARBOX

Section and tightening torques (in daNm)

21-2

JR GEARBOX

A2.5

B13

C2.5

E19

MANUAL GEARBOX

Tightening torques in daNm

21-3

Tightening torques in daNm

Description Torque in daNm

Gearbox edge bolt 2.5

Secondary shaft bolt 7

Primary shaft nut 19

Rear cover bolt 2.5

Reverse gear switch 2.5

Clutch slave cylinder bolt 2.1

Control shaft bolt 2

Catch bolt 0.5

Speed sensor bolt for sequential gearbox 1

MANUAL GEARBOX

Ratios

21-4

Ratios

JH GEARBOX

JR GEARBOX

Index Type

Reverse

gear

Final drive

Speedometer

JH1-002 Twingo 11/37 22/41 28/37 30/29 41/31 11/39 15/56 21/20

JH1-003 Twingo 11/37 22/41 28/37 30/29 39/32 11/39 15/58 21/20

JH1-007 Twingo 11/37 22/41 28/37 34/35 39/32 11/39 15/61 21/19

JH3-005 Laguna 2 11/37 22/41 28/37 34/35 39/32 11/39 14/59 None

Index Type

Reverse

gear

Final drive

Speedometer

JR5-003 Laguna 2 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None

JR5-008 Laguna 2 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None

JR5-009 Laguna 2 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None

JR5-012 Laguna 2 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None

MANUAL GEARBOX

Consumables

21-5

Consumables

Capacities - Lubricants

Parts to be systematically replaced

After they have been replaced: – lip seals, – O-rings, – stop rings, – roll pins, – secondary shaft and differential nuts, – gear supporting rings, – primary and secondary shaft bearing circlips.

Type Packaging Parts Stores No. Unit

Molykote BR2 1 kg tin 77 00 421 145 Sunwheel splines

Loctite 518 24 ml syringe 77 01 421 162

Housing assembling faces

Switch threading

Loctite FRENBLOC 24 cc bottle 77 01 394 071

Fixed gear and 5

gear hub

Primary shaft nut

Secondary shaft bolt

Capacity in litres Grade

JH 2.8 TRJ 75W80W

JR 2.5 TRJ 75W80W

MANUAL GEARBOX

Special tooling

21-6

Special tooling

B. Vi. 22-01 Bearing extractor tool

B. Vi. 31-01 Set of punches for roll pins

B. Vi. 945 Sunwheel oil seal gasket inserting tool (JH)

B. Vi. 946 Sunwheel circlip replacer

B. Vi. 949 Selector fork roll pin rem/ref tool

B. Vi. 1000 5

speed gear extractor shell

B. Vi. 1057 Differential locking tool

B. Vi. 1058 Sunwheel oil seal gasket inserting tool (JR)

B. Vi. 1059 Differential bearing bushes fitting kit

B. Vi. 1161 Steel plate to attach DTI gauge + pre-load adjust shims

B. Vi. 1165 Secondary shaft bearing on clutch housing extractor tool

B. Vi. 1170 Extractor for 5

speed hub gear

B. Vi. 1527 Primary and secondary shaft adjustment plate

B. Vi. 1570 Tool for fitting ball indentation

B. Vi. 1576 Mandrel for fitting bearings in the mechanism housing (JH)

B. Vi. 1581 Gearbox mounting on Desvil post

B. Vi. 1601 Mandrel for fitting primary shaft guide bearing

MANUAL GEARBOX

Repairing the gearbox

21-7

Repairing the gearbox

REMOVAL

Fit support plate B. Vi. 1581 on a Desvil shoe.

Fit the gearbox on the B. Vi. 1581 support.

Remove: – the clutch slave cylinder, – the bolts located inside the housing,

– the rear housing. This must be removed along the

horizontal axis of the gearbox because it has a lubrication spline which is located in the primary shaft bore.

Select 1

gear using the gear lever and 5th gear by

sliding the 5

gear fork along its shaft.

Remove the secondary shaft bolt and the primary shaft nut.

Removing and handling the parts must be carried out on a workbench with a knockproof cover (thick rubber or plastic).

19825

19826

19825-1

19824

MANUAL GEARBOX

Repairing the gearbox

21-8

Drive in the 5th gear fork pin using B. Vi. 31-01.

Remove the 5

gear fork and the sliding gear.

Extract the 5

gear hub using tool B. Vi. 1170.

Position the sliding gear of tool B. Vi. 1170 as if to select 5

gear and rotate it so as to position the splines of the sliding gear opposite those of the hub and withdraw the assembly.

Remove the 5

fixed gear using tools B. Vi. 22-01 and

B. Vi. 1000.

Remove the outer bolts from the mechanism housing.

(Remove the speed sensor (B) for sequential gearbox JH1).

19823

MANUAL GEARBOX

Repairing the gearbox

21-9

It is advisable to place two magnets or to close off the openings (C) to retrieve the locking balls and springs for shafts 1/2 and 3/4.

Remove the reverse gear shaft (A).

Remove the reverse gear switch (B).

Carry out an outwards stress test on the control shaft.

Lift and remove the mechanism housing.

Rotate the reverse gear shaft assembly to the left and remove the reverse/5

gear fork shaft.

Gently lift the primary shaft and remove the reverse gear shaft assembly.

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