User manual RENAULT GEARBOXES WORKSHOP REPAIR MANUAL

[. . . ] Workshop Repair Manual Manual gearboxes Vehicle JB0 Renault 5 Extra Renault 9 Renault 11 Renault 19 Renault 21 Clio Twingo Laguna Mégane X X X X X X X X X JB1 X X X X X X JB2 Type JB3 X X X X X X X X X X X X X JB4 X X X X X X X X JB5 X JC5 This document cancels and replaces JB Gearbox manual part number 77 11 093 922 and JC5 Gearbox manual part number 77 11 092 186 and technical notes n° 1978, 2127, 2229A, 2284A, 2383A, 2457A. 77 11 192 787 FEBRUARY 1997 All copyrights reserved by Renault. Edition Anglaise "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 by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". 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. C Renault 1997 Contents Pages MANUAL GEARBOX 21 ENSEMBLE MOTEUR ET BAS Section view Identification Cross section - tightening torques Gears Capacity - Lubricants Special points Modifications Consumables Parts which must always be changed Special tools Gearbox repair Shafts Differential Internal controls Lubrication channel Reverse gear shaft Reverse gear brake Speedometer Thrust pad guide tube Assembling the housings Exploded view parts directory Exploded views 21-1 21-2 21-3 21-8 21-28 21-29 21-30 21-32 21-32 21-33 21-37 21-44 21-62 21-76 21-79 21-80 21-81 21-84 21-89 21-97 21-107 21-108 MANUAL GEARBOX Section view 21 JB0 JB2 JB4 DI2101 JB1 JB3 JB5 JC5 DI2102 21-1 MANUAL GEARBOX Identification 21 DI2117-2 DI2117-1 1st assembly 2nd assembly A A TYPE XXX - XX D B E J B0 0 0 0 X X0 0 0 0 0 G B C 000000 90775 C F A At A At B At C : : : Gearbox type. Production number. D J B0 A A 0 0 0 X 0000000 : : : : : : : B C 90 775 At A At B At C At D At E At F At G Gearbox type. Letter preceding production numbers greater than 999 999. Following saturation of the production numbering system on the identification plate of JB and JC gearboxes, a new numbering system will be in force for numbers greater than 999 999 (at C). [. . . ] Note: The adjustments must be carried out shaft by shaft without the differential. The thickness of the setting washer "F" determines the pre-load of the output shaft bearings. 93259R1 21-60 JC gearbox MANUAL GEARBOX Shafts Fit the dial gauge with its magnetic base. 21 Adjusting the pre-load of the output shaft bearings - Clutch housing without the differential and without the input shaft. - Position the output shaft in the clutch housing with the bearings and the 1. 60 mm pre-setting washer B. 1161 or equivalent on the the driveshaft mountings. A) Turn the output shaft by several revolutions to position the bearings. Calculate the average of the values read. Calculating the value of the pre-load setting washer Specified value + pre-setting washer value + average of values read on the dial gauge = value of the pre-load setting washer. Example : (Values in mm) 0. 26 + 0. 49 + 1. 60 = 2. 35 Specified Average value of values read Pre-setting washer value Pre-load setting washer value Note: A set of setting washers of thickness 2. 15 mm to 2. 43 mm rising in steps of 0, 04 mm is supplied as a replacement part. 92952R 21-61 MANUAL GEARBOX Differential 21 DIFFERENTIAL (FITTING TO BALL BEARINGS) DI2137 21-62 MANUAL GEARBOX Differential DIFFERENTIAL (DIFFERENT ASSEMBLIES) GEARBOX WITHOUT BEAD GEARBOX WITH BEAD 21 DI2138 DI2139 IN-PRODUCTION SOLUTON 1st assembly with circlip 40 thickness: 1. 75 2nd assembly with circlip 40 thickness: 1. 75 3rd assembly with circlip 40 thickness: 2. 5 4th assembly with circlip 40 thickness: 2. 5 DI2140 DI2141 DI2142 DI2143 REPAIR SOLUTION (if the bearing is changed) DI2144 DI2145 21-63 MANUAL GEARBOX Differential DIFFERENTIAL (FITTING TO BALL BEARINGS) REMOVAL 21 The differential is extracted by pushing on the sun wheel (52) using a press. Turn the assembly over. This operation is carried out after separating the housings. Strike the lip seal using a pin extractor and a small hammer in order to tilt it. Remove the seal taking care not to damage the splines on the sun wheel. Tighten the housing (45) in a vice with soft jaws. Extract the tripod sun gear (48) and remove the planet gear shaft (49). JB4-JB5 Remove the pin (74) and remove the planet gear shaft (49). Retrieve the sleeve (73) and remove (50 and 51) attaching the washers to their respective planet gears. If necessary, remove the speedometer crown wheel, the speedometer shaft and the gear. NOTE: these parts must always be changed once they have been removed. 86031S CHECKING PARTS: Using a press: - place a board under the crown wheel to support it, - push the clutch housing and the differential to free the circlips (40) and extract it. Check the condition of: - the teeth, - the bearing surfaces, - the washers (of the planet gears), - the grooves, - the housing. 21-64 MANUAL GEARBOX Differential DIFFERENTIAL CHANGING BEARINGS 21 Shouldered sun gear end bearing REMOVAL Crown wheel end bearing REMOVAL Pass a flat bar inside the gearbox and place it flat on the bearing. Press on the press using a lengthened tube and extract the bearing. Remove the circlips (66) retaining the bearing (65) in its seat, then, using a press, remove the bearing towards the inside of the housing using a 50 diameter sleeve. 85705R2 REFITTING The bearing housing (C) must be directed to the end opposite the crown wheel. Use a 65 diameter sleeve pressing on the bearing outer housing (65). 85705S1 REFITTING The bearing housing (C) must be directed to the end opposite the crown wheel. 1 059, with the load on the bearing outer ring. 85705R3 Change the bearing retaining circlips. 86317-1R 21-65 MANUAL GEARBOX Differential DIFFERENTIAL REFITTING - Special point REFITTING 21 Refit: JB - 1st Assembly - 1st assembly: (44) then (43) and (41). - 4th assembly and repair solutions: (44) then (43) and (41). NOTE: in all cases direct (44) as below. DI2146 JB - 2nd Assembly 85798R Replace the differential in the clutch and differential housing. Using a press: - place a wooden shim under the crown wheel, DI2147 It is essential to fit a new pin (74) (tool B. Ensure that it is clipped correctly. - ensure that the thickness of the circlips corresponds to the width of the groove, - fit the circlips (40) onto the tapered guide (1) of tool B. 946 on the tapered guide (1) and push using the press until the circlips are positioned in its groove. 946, - turn the assembly and check the rotation of the speedometer gear. 21-66 MANUAL GEARBOX Differential DIFFERENTIAL 21 The seal is refitted using tool B. 945 made up of: - a seal protector (A), - a tool for fitting the seal (B). 86095R Fit the protector (A) coated with oil to the sun wheel and position the seal (C) coated with oil using tool (B). 86123R 86122R NOTE: the lip seal can be changed on the vehicle with the gearbox in place. 21-67 MANUAL GEARBOX Differential DIFFERENTIAL (FITTING ON CONE-SHAPED BEARINGS) 21 DI2148 Differential bearings with tapered rollers fitting in an O configuration 93227S3 21-68 MANUAL GEARBOX Differential DIFFERENTIAL REMOVAL 21 Remove the gearbox mounting nut. This operation is carried out after separating the housings. Strike the lip seal using a pin extractor and a small hammer in order to tilt it. [. . . ] Example: gearbox engine centring pin. 93064R Also, ensure that the pipe is not damaged or blocked. 93065R2 21-99 MANUAL GEARBOX Assembling the housings Pull the control shaft towards the outside in order to place the gear engagement finger in the 5th gear shaft claw. 21 Lift the reverse gear shaft passing a hook into the opening in the housing. 93230R Apply Loctite 518 to the mating surface between the clutch housing and the mechanism housing. Align the shafts and the fork shafts, then fit the mechanism housing in place. Fit the mounting bolts. 93228S Fit the locking ball, its spring and the retaining Uclip (59). DI2162 Tighten the peripheral bolts to the specified torque after turning the input shaft to ensure correct final coupling of the cones on the tapered rollers. Note: All of the bolts must be tightened to the specified torque within thirty minutes of fitting the mechanism housing due to the polymerisation of the Loctite 518. 92962R1 21-100 MANUAL GEARBOX Assembling the housings ON THE OUTPUT SHAFT 21 4-speed gearbox: change the threaded thrust pad. 4-speed gearbox: Fit the output shaft washer and the circlip using tool B. [. . . ]