Renault Megane 2 F4R 770 ND0 manual gearbox

Technical Note6034A X84, and ND0 ND0 manual gearbox

This Note cancels and replaces Technical Note 3663A

Edition 2

77 11 397 542

MAY 2009

"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."

Edition Anglaise

All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

© Renault s.a.s 2008

ND0 manual gearbox

ND0manual gearboxContentsPage

Contents Page

21A

MANUAL GEARBOX Manual gearbox: Precautions for repair Manual gearbox: Specifications Manual gearbox: List and location of components

21A

MANUAL GEARBOX

21A-1

Reverse gear shaft:Adjustment

21A-52

21A-3

Manual gearbox differential: Removal - Refitting

21A-54

21A-4

Manual gearbox differential bearing: Re Removal - Refitting

21A-57

Manual gearbox: Repair

21A-10

Manual gearbox: Check

21A-12

Gearbox support equipment: Use

21A-15

Mechanism cover: Removal Refitting

21A-16

Gearbox shaft: Removal Refitting

21A-21

Input shaft: Stripping Rebuilding

21A-29

Output shaft: Stripping Rebuilding

21A-34

Gearbox shaft: Adjustment

21A-40

Clutch housing bearing: Removal - Refitting

21A-43

Manual gearbox selector shaft: Removal - Refitting

21A-45

Selector fork shaft ring: Removal - Refitting

21A-47

Reverse gear shaft: Removal - Refitting

21A-49

ND0 manual gearbox

ND0manual gearboxContentsPage

Contents Page

21A

MANUAL GEARBOX Manual gearbox: Precautions for repair Manual gearbox: Specifications Manual gearbox: List and location of components

21A

MANUAL GEARBOX

21A-1

Reverse gear shaft:Adjustment

21A-52

21A-3

Manual gearbox differential: Removal - Refitting

21A-54

21A-4

Manual gearbox differential bearing: Re Removal - Refitting

21A-57

Manual gearbox: Repair

21A-10

Manual gearbox: Check

21A-12

Gearbox support equipment: Use

21A-15

Mechanism cover: Removal Refitting

21A-16

Gearbox shaft: Removal Refitting

21A-21

Input shaft: Stripping Rebuilding

21A-29

Output shaft: Stripping Rebuilding

21A-34

Gearbox shaft: Adjustment

21A-40

Clutch housing bearing: Removal - Refitting

21A-43

Manual gearbox selector shaft: Removal - Refitting

21A-45

Selector fork shaft ring: Removal - Refitting

21A-47

Reverse gear shaft: Removal - Refitting

21A-49

MANUAL GEARBOX Manual gearbox: Precautions for repair

21A

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

SAFETY WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid may cause damage to some components.

General information This method provides information which will allow you to: - acquire good knowledge of the component on which you will be working, - benefit from the best repair repair conditions, conditions,

Observe the chronological order of the steps: - remove remove the component, component,

- obtain optimum component component operation and meet customer requirements,

- clean the component component before repairing, repairing,

- optimise component component repair repair time. time.

- remove the part(s) concerned concerned

It is worth taking the time to read this method as you will gain time later on during the repairs.

- check the part(s) removed,

a - General recommendations

- perform the necessary necessary adjustments adjustments and/or settings settings so that the component operates correctly,

Observe basic principles of vehicle repair.

- replace faulty part(s) part(s) with new part(s), part(s),

- observe the the tightening tightening torques. torques.

The quality of repair depends first and foremost on the care exercised by the person in carrying it out. Note:

Carry out the operation on the component on a clean working area.

Ensure you use the correct type of bearing for the gearbox. There are three types of bearing for different gearbox suffixes (NTN - SNR - TIMKEN). They are not interchangeable.

To ensure good repair: - use the recommended recommended consumables consumables (see (see Vehicle: Parts and ingredients for the repairwork ) , - use the recommended recommended tools, tools, - observe the the tightening tightening torques, torques,

Note:

- observe the recommenda recommendations tions for parts that should always be replaced after removal, refitting or replacement operations,

Ensure sure that the parts removed match up and ensure that they are refitted in the correct order.

- clean and degrease degrease the sections sections to be bonded, to ensure they bond correctly.

b - Special tooling Use suitable tools which are in good condition (use of « multi-purpose » tools, such as adjustable pliers, etc., should be avoided wherever possible).

WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).

For good quality repairs and for working in safe conditions, use only special tooling. c - Safety Equipment risks:

WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

- The "Note" heading heading used in the description description of the method indicates that particular care should be taken for the operation described.

Use professional products and apply them with care, for example do not apply too much sealing paste to the sealing surface to prevent damaging the component.

- The "Important" "Important" heading used used in the description of the method indicates that there is a risk of damage to the component.

21A-1

MANUAL GEARBOX Manual gearbox: Precautions for repair 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX Working safely: - The "Warning" heading used in the description of the method indicates that particular care should be taken for the operation described and that there is a human risk, - use supports and adopt a correct posture when performing heavy work or raising loads, - check that the working area is clean and tidy during the operation, - use personal protection (gloves, goggles, work shoes, masks, skin protection, etc.), - do not use harmful products in unventilated rooms, - do not ingest any chemicals (brake fluid, coolant, etc.). Respecting the environment: - sort waste according to its particular qualities, - do not burn discarded products (tyres, etc.). d - Conclusion Respecting the recommended methods will guarantee the best performance and reliability of the component.

21A-2

21A

MANUAL GEARBOX Manual gearbox: Specifications

21A

I - IDENTIFICATION (1 )

Identification plate

(2 )

Etching

II - GEAR RATIOS

101222

Suffix

1st

2nd

3rd

4th

5th

6th

Final drive

Reverse gear

ND0-000

13/41

18/35

28/39

36/38

42/34

49/33

14/57

13/38

ND0-001

13/41

19/34

31/37

40/34

47/31

50/27

15/58

13/38

ND0-002

12/41

19/35

31/39

38/36

45/33

48/29

15/58

12/38

ND0-003

14/49

18/35

28/39

36/38

42/34

49/33

14/57

14/46

ND0-008

13/41

19/34

31/37

40/34

47/31

50/27

14/57

13/38

ND0-009

12/41

19/35

31/39

38/36

42/34

49/33

14/57

12/38

ND0-013

14/49

18/35

28/39

36/38

42/34

49/33

14/57

14/46

ND0-014

13/41

18/35

28/39

36/38

52/45

56/41

16/70

13/38

ND0-015

14/49

18/35

28/39

36/38

52/45

56/41

16/70

14/46

ND0-016

14/49

18/35

28/39

36/38

52/45

56/41

16/70

14/46

ND0-020

13/41

18/35

28/39

36/38

42/34

49/33

14/57

13/38

21A-3

MANUAL GEARBOX Manual gearbox: List and location of components

21A

117443

(1 )

Bearing

(2 )

Primary shaft

(3 )

Needle bearing

(4 )

Third gear pinion

(5 )

Synchroniser ring

(6 )

Synchroniser spring

(7 )

Rollers

(8 )

Third-fourth synchroniser hub

(9 )

Synchroniser spring

(10)

Synchroniser ring

(11)

Sprocket supporting ring

(12)

Needle bearing

(13)

Fourth gear pinion

(14)

Adjusting shim

(15)


(16)

Needle bearing

(17)

Fifth gear pinion

(18)

Synchroniser ring

(19)

Synchroniser spring

(20)

Rollers

21A-4

(21)

Fifth - sixth synchroniser hub

(22)

Synchroniser spring

(23)

Synchroniser ring

(24)

Sixth gear pinion

(25)

Needle bearing

(26)


(27)

Locking spring ring

(28)

Bearing

(29)

Oil deflector

(30)

Permanent shim

(31)

Retaining pin

(32)

Reverse gear shaft

(33)

Washer

(34)

Needle washer

(35)

Washer

(36)

Needle bearing

(37)

Reverse gear sprocket

(38)

Synchroniser ring

(39)

Washer

(40)

Needle washer

(41)

Washer

MANUAL GEARBOX Manual gearbox: List and location of components (42)

Needle bearing

(43)

Engagement clip

(44)

Synchroniser hub

(45)


(46)

Permanent shim

21A

102088

(47)

Oil deflector

(48)

Bearing

(49)

Output shaft

(50)


(51)

First gear pinion

(52)


(53)

Needle bearing

(54)

Triple-cone synchroniser rings

(55)

Synchronising spring

(56)

First-second synchroniser hub

(57)

Roller

(58)

Triple-cone synchroniser rings

(59)

Retaining shim

(60)

Bolt

(61)


21A-5

(62)

Needle bearing

(63)

Second gear pinion

(64)

Third gear pinion

(65)

Spacer

(66)

Adjusting shim

(67)

Fourth gear pinion

(68)

Fifth gear pinion

(69)

Spacer

(70)

Sixth gear pinion

(71)

Permanent shim

(72)

Bearing

(73)

Half shims

(74)

Closure washer

(75)

Locking spring ring

(76)

Bearing locking spring ring

(77)

Adjusting shim


21A

102087

(78)

First - second gear fork

(79)

Pin

(80)

First-second gear control lever

(81)

First-second gear fork shaft

(82)

Shaft ring

(83)

Exterior control

(84)

O-ring

(85)

Retaining ball

(86)

Spring

(87)

Bolt

(88)

Shaft ring

(89)

Third-fourth gear fork shaft

(90)

Internal lock shaft

(91)

Retaining clip

(92)

Third-fourth gear fork

(93)

Third-fourth gear control lever

(94)

Pin

(95)

Fifth-sixth gear control lever

(96)

Locking ball

(97)

Fifth-sixth gear fork shaft

21A-6

(98)

Fifth-sixth gear fork

(99)

Reverse gear selector fork shaft

(100)

Lock shaft

(101)

Spring

(102)

Bolt

(103)

Reverse gear lever

(104)

Bearing shell

(105)

Reverse switch support

(106)

Reverse gear fork

(107)

Reverse gear selector fork shaft

(108)

Selection locating ball

(109)

Stop lever

MANUAL GEARBOX Manual gearbox: List and location of components (110)

Bearing

(111)

Crownwheel

(112)

Differential

(113)

Crownwheel bolt

102090

102145

(114)

Clutch housing

(115)

Centring ring

(116)

Hydraulic tappet

(117)

Differential seal

21A-7

(118)

Sleeve stop

(119)

Magnet

(120)

Input shaft seal

21A


102146

(121)

Mechanism housing

(122)

Gearbox bell housing bolts

(123)

Oil neck

(124)

Reverse gear switch

(125)

Breather pipe

(126)

Neutral switch

(127)

Differential seal

(128)

Blanking cover

(129)

Drain plug

(130)

Blanking cover

(131)

Filler plug

21A-8

21A


21A

102892

The ND0 gearbox is equipped with several balls and retaining or lock shafts Note:

- (132) Lock shaft

The shafts of the third-fourth gear and of the fifthsixth gear are equipped with an internal tappet (136) .

- (133) Locking ball - (134) Locking balls - (135) Retaining balls

101143

21A-9

MANUAL GEARBOX Manual gearbox: Repair

- the clutch housing bearings (see 21A, Manual gearbox, Clutch housing bearing: Removal Refitting, page 21A-43) .

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1) .

REFITTING I - REFITTING PREPARATION OPERATION a

Clean all the removed parts (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1 ) .

a

Check (see 21A, Manual gearbox, Manual gearbox: Check, page 21A-12 ) :

REMOVAL I - REPAIR PREPARATION OPERATION a

Remove the gearbox (see Manual gearbox: Removal - Refitting) .

a

Position the gearbox on the component support (see 21A , Manual gearbox, Gearbox support equipment: Use, page 21A-15) .

- the shafts, - the pinions (teeth, claws, friction cone, inner wall), - the synchroniser hubs, - the synchroniser rings, - the bearings.

II - REMOVAL OPERATION a

21A

Remove: - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) ,

a

Replace worn or damaged parts.

a

Parts always to be replaced: - the fork shaft rings, - the seal of the gearbox selector shaft,

- the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) ,

- the input shaft seal, - the differential seals,

- the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) ,

- the stop ring of the output shaft,

- the differential (see 21 A , Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) .

- the pins,

- the blanking cover at the end of the output shaft,

- the hydraulic clutch thrust bearing.

II - REFITTING OPERATION III - REPAIR OPERATION a

a

a

Strip:

Refit:

- the input shaft (see 21A , Manual gearbox, Input shaft: Stripping - Rebuilding , page 21A-29 ) ,

- the bearings of the clutch housing (see 21A , Manual gearbox , Clutch housing bearing: Removal - Refitting , page 21A-43 ) ,

- the output shaft (see 21A , Manual gearbox, Output shaft: Stripping - Rebuilding, page 21A-34) .

- the mechanism housing bearing (see Pressure plate housing bearing: Removal - Refitting) ,

Remove:

- the fork shaft rings (see 21A , Manual gearbox, Selector fork shaft ring: Removal - Refitting , page 21A-47 ) ,

- the differential bearings (see 21A , Manual gearbox, Manual gearbox differential bearing: Removal - Refitting, page 21A-57 ) , - the fork shaft rings (see 21A , Manual gearbox, Selector fork shaft ring: Removal - Refitting , page 21A-47 ) ,

- the differential bearings (see 21A , Manual gearbox, Manual gearbox differential bearing: Removal - Refitting, page 21A-57 ) . a

- the mechanism housing bearing (see Pressure plate housing bearing: Removal - Refitting) ,

21A-10

Rebuild: - the output shaft (see 21A , Manual gearbox, Output shaft: Stripping - Rebuilding, page 21A-34) ,

MANUAL GEARBOX Manual gearbox: Repair - the input shaft (see 21A , Manual gearbox, Input shaft: Stripping - Rebuilding , page 21A-29 ) . a

Adjust: - the input shaft and the output shaft (see 21A , Manual gearbox, Gearbox shaft: Adjustment , page 21A-40 ) , - the reverse gear shaft (see 21A, Manual gearbox, Reverse gear shaft:Adjustment , page 21A-52) .

a

Refit: - the differential (see 21 A , Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gear lever (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal - Refitting , page 21A-45 ) .

III - FINAL OPERATION a

Remove the gearbox from the component support (see 2 1 A , Manual gearbox , Gearbox support equipment: Use, page 21A-15) .

a

Refit the gearbox (see Manual gearbox: Removal Refitting) .

21A-11

21A

MANUAL GEARBOX Manual gearbox: Check

21A

II - TEST OPERATION IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) .

1 - Gearing

I - PREPARATION OPERATION FOR CHECK Remove the gearbox (see Manual gearbox: Removal - Refitting ) . Position the gearbox on the component support (see 21A , Manual gearbox, Gearbox support equipment: Use , page 21A-15) . Remove: - the gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45 ) , - the mechanism housing (see 21A, Manual gearbox, Mechanism cover: Removal - Refitting , page 21A16) , - the gearbox shafts (see 2 1A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A-21 ) , - the reverse gear shaft (see 21A, Manual gearbox, Reverse gear shaft: Removal - Refitting , page 21A-49 ) , - the differential (see 21A , Manual gearbox, Manual gearbox differential: Removal - Refitting , page 21A-54 ) . Strip: - the input shaft (see 21 A , Manual gearbox , Input shaft: Stripping - Rebuilding , page 21A-29 ) ,

100413

When checking, make sure that you pay particular attention to the appearance of the teeth, especially that of the chamfers and claws. Check that: - the teeth (1 ) are not broken or chipped, - the dogs (2) are not broken, chipped or worn, - the friction cone (3 ) shows no sign of scratches or blue stains, - the inner wall (4 ) shows no sign of sticking or wear.

- the output shaft (see 21A, Manual gearbox, Output shaft: Stripping - Rebuilding , page 21A-34 ) . Before any checks, clean the parts concerned (see 21A , Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) .

21A-12

MANUAL GEARBOX Manual gearbox: Check 2 - Synchroniser hub

21A

To check that the synchroniser ring is working correctly, push the ring on the friction cone and rotate (7 ) : the ring should not turn. Otherwise, replace the synchroniser ring.

4 - Bearing

101896

Check: - the selector rod slides into the hub without any problem,

111681

- that the collets (5) are in good condition.

Make sure the bearings ( 8) are rotating properly.

3 - Synchroniser ring

If a bearing rotates unevenly or noisily, it must be replaced.

III - FINAL OPERATION Rebuild: - the output shaft (see 21A, Manual gearbox, Output shaft: Stripping - Rebuilding , page 21A-34 ) , - the input shaft (see 21A, Manual gearbox , Input shaft: Stripping - Rebuilding , page 21A-29 ) . Adjust: - the input shaft (see 21A, Manual gearbox, Gearbox shaft: Adjustment , page 21A-40) , - the output shaft (see 21A , Manual gearbox , Gearbox shaft: Adjustment , page 21A-40 ) , - the reverse gear shaft (see 21A, Manual gearbox, Reverse gear shaft:Adjustment , page 21A-52 ) . Refit: 100414

Check that the dog teeth (6 ) show no sign of wear or any fractures.

- the differential (see 21A , Manual gearbox, Manual gearbox differential: Removal - Refitting , page 21A-54 ) ,

21A-13

MANUAL GEARBOX Manual gearbox: Check - the reverse gear shaft (see 21A, Manual gearbox, Reverse gear shaft: Removal - Refitting , page 21A-49 ) , - the gearbox shafts (see 2 1A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A-21 ) , - the mechanism housing (see 21A, Manual gearbox, Mechanism cover: Removal - Refitting , page 21A16) , - the gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45 ) . Remove the gearbox from the component support (see 21A , Manual gearbox, Gearbox support equipment: Use , page 21A-15) . Refit the gearbox (see Manual gearbox: Removal Refitting) .

21A-14

21A

MANUAL GEARBOX Gearbox support equipment: Use

21A

Essential special tooling Bvi. 1417

Housing support.

Essential equipment component support workshop hoist

IMPORTANT To work work on the gearbox gearb ox in complete safety saf ety,, it is essential to use a component support. 117502

I - PREPARATION OPERATION FOR FITTING THE GEARBOX ON THE COMPONENT SUPPORT a


a

Fit the gearbox on the stand plate (engine face side against the plate) using the workshop hoist .

a

Using the bolts and nuts, attach the gearbox on the stand plate.

III - OPERATION FOR REMOVING THE GEARBOX FROM THE COMPONENT SUPPORT

II - OPERATION FOR FITTING THE GEARBOX ON THE COMPONENT SUPPORT

a

Remove: - the bolts and nuts nuts from the gearbox gearbox on the stand plate, - the gearbox from from the component component support using the workshop hoist , - the stand stand plate plate (Bvi. 1417) from the component support.

IV - FINAL OPERATION a

129890 a

Fit the gearbox stand plate (Bvi. 1417) (1 ) on a component support (2 ) using the bolts (3) .

21A-15


MANUAL GEARBOX Mechanism cover: Removal - Refitting

21A

II - OPERATION FOR REMOVAL OF PART CONCERNED

Tightening torques m bolts of the mechanism housing

65 N.m

mechanism bolts

housing

52 N.m

bolts of the fork shaft locating balls

15 N.m

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) .

REMOVAL 100937

I - REMOVAL PREPARATION OPERATION a

a

a

Remove the manual gearbox (see Manual gearbox: Removal - Refitting) .

a

Remove: - the blanking blanking cover cover cap cap (1 ) ,

Position the gearbox on the component support (see 21A 21 A , Manual gearbox , Gearbox support equipment: Use, page 21A-15) .

- the fork shaft locating locating balls (2) , - the me mechanism chanism housing housing bolts.

Remove: - the clutch thrust bearing (see Clutch thrust bearing: Removal - Refitting) , - the gearbox gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

100936 a

Separate the retaining locking ring ( 3) of the output shaft.

a

Remove the mechanism housing.

21A-16


21A

117440

129897 a

a

- the lock lock ring ring (9 ) ,

Note:

- the output output shaft permanent permanent shim,

The breather pipe ( 4 ) prevents removal of the funnel (5) . a

Remove:

- the differential differential output output seal (see Differential output seal: Removal - Refitting ) ,

Remove:

- the differential bearing housing housing (see 21A , Manual gearbox , Manual gearbox differential bearing: Removal - Refitting, page 21A-57 ) .

- the breather breather pipe (4) , - the two oil funnels funnels (5 ) and (6 ) by pulling them upwards,


Clean the joint faces of the mechanism housing using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products).

WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. a

100935 a

Remove the deflector (7) and the permanent shim (8) of the input shaft.

21A-17

Remove the residue using a plastic spatula.

MANUAL GEARBOX Mechanism cover: Removal - Refitting a

21A

Finish cleaning the joint faces using a GREY ABRASIVE PAD (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products).

WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). a

Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to clean: - the joint face of the mechanism housing and the clutch housing, - the mechanism housing.

a

Parts always to be replaced:

129960 a

- the fork shaft rings,

Refit: - the output shaft adjusting shim,

- the differential seals,

- the new lock ring (10) . a

- the locking ring of the output shaft,

Refit the deflector and the permanent shim at the end of the input shaft.

- the blanking cover at the end of the output shaft, - the pins, - the hydraulic clutch thrust bearing, - the seal of the gearbox selector shaft.

II - REFITTING OPERATION FOR PART CONCERNED a

When replacing a shaft or a housing, adjust: - the input shaft (see 21A , Manual gearbox , Gearbox shaft: Adjustment , page 21A-40) , - the output shaft (see 21A, Manual gearbox, Gearbox shaft: Adjustment , page 21A-40) , - the reverse gear shaft (see 21A, Manual gearbox, Reverse gear shaft:Adjustment , page 21A-52) .

a

117441 a

Refit: - the differential bearing housing (see Pressure plate housing bearing: Removal - Refitting ) , - the differential output seal (see Differential output seal: Removal - Refitting ) .

21A-18

Refit the oil neck (11) , making sure that the lug (12) is properly positioned in its housing.


117442 a

Refit:

139237 a

- the oil neck (13) by positioning the two lugs (14 ) and the centring pin (15) in their housings, - a new breather pipe in its housing ( 16) . a

21A

Widen the locking ring ( 17) at the level of the output shaft rear bearing in such a way that the locking ring comes into contact with the edge of the output shaft rear bearing.

Check that the centring dowels are in place.

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid may cause damage to some components. a

Apply a bead of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) all around the joint face of the mechanism housing.

a

Fit the mechanism housing.

102257 a

Use SEALING RESIN (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to coat the threading of the bolts ( 19) .

a

Tighten the mechanism housing bolts until contact is made.

a

Torque tighten: - the bolts of the mechanism housing (65 N.m) marked ( 19) ,

21A-19

MANUAL GEARBOX Mechanism cover: Removal - Refitting - the other mechanism housing bolts (52 N.m). a

Refit: - the fork shaft locating balls (4) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

a

Torque tighten the bolts of the fork shaft locating balls (15 N.m).

a

Position the gear lever in second gear in order to lift the output shaft and clip on the bearing.

a

Check that: - the locking ring (17) is in the bearing channel of the output shaft, - the permanent shim (18) rotates freely in its housing and is not secured.

a

Put the gear lever in neutral.

a

Refit: - a new blanking cover cap, - a new clutch thrust bearing (see Clutch thrust bearing: Removal - Refitting ) .



a

Refit the manual gearbox (see Manual gearbox: Removal - Refitting) .

21A-20

21A

MANUAL GEARBOX Gearbox shaft: Removal - Refitting

21A



Tool for removing/refitting Mecanindus pins for selector fork shafts

Bvi. 1683

Tool kit for repairing ND gearboxes.

Tightening torques m reverse switch bolts

15 N.m

locating ball bolts

15 N.m


100934 a

Remove: - the selector shaft ball mechanisms (1 ) (see 21A, Manual gearbox, Manual gearbox: List and location of components , page 21A-4)

REMOVAL I - REMOVAL PREPARATION OPERATION a


a


a

Remove:

- the switch (2) - the reverse gear control shaft and lever (3) . a

- the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) .

21A-21

Recover the two locking balls (or shafts) (see 21A, Manual gearbox , Manual gearbox: List and location of components , page 21A-4)


21A

a

Unpin the third-fourth gear control lever using the tool (Bvi. 949) (7) .

a

Remove the "third-fourth gear fork and shaft" assembly.

a

Recover the small tappet from inside the third-fourth gear shaft (see 21 A , Manual gearbox , Manual gearbox: List and location of components , page 21A-4 ) .

100932 a

Unpin the fifth-sixth gear fork using tool (Bvi. 949) (4) .

a

Remove: - the lock ring of the fifth/sixth gear control lever (5) , - Remove the "fifth-sixth gear shaft/fork" assembly.

a

Recover the small tappet from inside the fifth-sixth gear shaft and the two locking balls (see 21A , Manual gearbox, Manual gearbox: List and location of components , page 21A-4) .

100930 a

Unpin the first-second gear fork.

a

Remove: - the "first-second gear fork and shaft" assembly (8) , - the "reverse gear fork and shaft" assembly.

100931 a

Remove the lock ring from the third-fourth gear fork (6) .

21A-22


21A

100939

- the input shaft seal,

a

a

Note:

- the pins,

This operation requires two people.


Remove the "input shaft - output shaft - reverse gear" assembly (9) .

REFITTING



I - REFITTING PREPARATION OPERATION a

Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the shafts, - the shaft mating surfaces, - the differential, - the mechanism housing, - the clutch housing.

a

Parts always to be replaced: - the lock ring of the output shaft, - the differential seals,

21A-23

Adjust the input shaft or the output shaft (see 21A, Manual gearbox , Gearbox shaft: Adjustment, page 21A-40 ) when replacing a shaft or a housing.


100944 a

Refit a new input shaft seal using component G (10) of the tool (Bvi. 1683).

21A-24

21A


21A

100939 a

Note: This operation requires two people.

Note: Do not forget the permanent shim of the reverse gear assembly (11) . a

Refit the "input shaft - output shaft - reverse gear" assembly.

21A-25


21A

a

Pin the first-second gear fork.

a

Fit the lock shaft (13) (see 21A , Manual gearbox , Manual gearbox: List and location of components, page 21A-4) .

101144 a

Note: When refitting the shaft assembly, pay attention to the positioning of the reverse gear shaft.

100931 a

Rotation of the shaft is prevented using a pin (12 ) .

Fit the "third-fourth gear control lever and fork shaft" assembly. Note: Do not forget the small tappet inside the thirdfourth gear shaft (see 21A , Manual gearbox, Manual gearbox: List and location of components , page 21A-4) .

a

100930 a

Fit the "first-second gear control lever and fork shaft" assembly.

21A-26

Pin the third-fourth gear control lever using the tool (Bvi. 949) (14 ) and refit the locking spring ring (15) of the third-fourth gear fork.


21A

100932 a

Fit:

100933 a

Fit the reverse gear shaft and fork (18) .

- the two locking balls (see 21A , Manual gearbox, Manual gearbox: List and location of components , page 21A-4 ) , - the "fifth-sixth gear control lever and shaft - fork" assembly. Note: Do not forget the small tappet inside the fifthsixth gear shaft (see 21A , Manual gearbox, Manual gearbox: List and location of components, page 21A-4) . a

Pin the fifth-sixth gear fork using the tool (Bvi. 949) (16) and fit the locking ring (17) of the fifth-sixth gear fork.

101148 a

Note: Do not forget the bearing shell of the reverse gear switch lever (19) .

21A-27


100934 a

Fit: - the two locking balls (see 21A , Manual gearbox, Manual gearbox: List and location of components , page 21A-4 ) , - the reverse gear control lever and shaft (20) , - the switch (21) ,

a

Torque tighten the reverse switch bolts (15 N.m) .

a

The retaining balls (G) (see 21A, Manual gearbox, Manual gearbox: List and location of components, page 21A-4) : - (G1 ) = main shaft and large spring, - (G2 ) = small shaft and small spring.

a

Torque tighten the locating ball bolts (15 N.m) .


Refit: - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

a

Remove the gearbox from the component support (see 2 1 A , Manual gearbox , Gearbox support equipment: Use, page 21A-15 ) .

a


21A-28

21A

MANUAL GEARBOX Input shaft: Stripping - Rebuilding

21A




STRIPPING I - STRIPPING PREPARATION OPERATION a


a


a

Remove:

100059 a

Remove the bearing ( 1) using a press and an extractor (2 ) .

- the manual gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal - Refitting, page 21A-45 ) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) .

II - STRIPPING OPERATION FOR PART CONCERNED a

Note: The gear supporting rings are fitted tightly on the shafts, and the pressure required to remove them is approximately 3 to 5 tons, which means that high-quality equipment is needed (press and support).

100060 a

Remove: - the lock ring (3 ) , - the « rings - gears - hubs » assembly using a press, while applying pressure under the third gear pinion using component A (4 ) of the tool (Bvi. 1683) .

21A-29

MANUAL GEARBOX Input shaft: Stripping - Rebuilding REASSEMBLING

21A

II - REBUILDING OPERATION FOR PART CONCERNED

I - REBUILDING PREPARATION OPERATION a


a

Parts always to be replaced: - the lock ring on the input shaft, - the input shaft seal, - the differential seals, - the lock ring on the output shaft, - the blanking cover at the end of the output shaft, 100061

- the pins, - the hydraulic clutch thrust bearing. a

Check (see 21A, Manual gearbox, Manual gearbox: Check, page 21A-12 ) :

a

Fit the input shaft on component B (5 ) of the tool (Bvi. 1683).

a

Lubricate and position the needle bearing (6) and the third idle gear (7) equipped with its synchroniser ring.

a

Refit the third-fourth gear selector rod (8) using a press and component C of the tool (Bvi. 1683), (large hub offset on third gear side, selector rod offset on fourth gear side) .

a

Align and engage the notches on the ring with those on the hub.

a

Refit the gear supporting ring (9) using a press and component C of the tool (Bvi. 1683) positioning the lubrication holes at 90˚ in relation to those of the shaft.

a

Apply a final pressure of 2.5 tonnes.

- the input shaft, - the gears on the input shaft, - the input shaft bearings, - the input shaft selector rod hubs, - the input shaft synchroniser rings. a


21A-30

MANUAL GEARBOX Input shaft: Stripping - Rebuilding

21A

100062 a

Measure the distance (X1) between the bearing pressure face and the end of the ring in order to determine the thickness of the thrust washer. Given that the nominal value is 154.75 ± 0.05 mm, use the following procedure:

100063 a

Lubricate and position the needle bearing ( 10) and the fourth idle gear ( 11) equipped with its synchroniser ring.

a

Refit the thrust washer (12) then the gear supporting ring (13) using a press and component C of the tool (Bvi. 1683), positioning the lubrication holes at 90˚ in relation to those of the shaft.

a


Thrust washer = 154.75 - X1. Example:

X1 = 150.80 mm. Thrust washer= 154.75 - 150.80 = 3.95 mm . The difference between the shims is 0.06 mm ; use a shim from the set with the closest thickness to the calculated value. In this example: 3.96 mm shim.

100064 a

21A-31

Lubricate and position the needle bearing ( 14) and the fifth idle gear ( 15) equipped with its synchroniser ring.

MANUAL GEARBOX Input shaft: Stripping - Rebuilding a

Refit the fifth-sixth gear selector rod (16) using a press and component C of the tool (Bvi. 1683), (large hub offset on fifth gear side, selector rod offset on sixth gear side) .

a

Align and engage the notches on the ring with those on the hub.

21A

100060 a

Select and fit a locking ring ( 20) so that it just enters the groove.

100065 a

Fit the sixth gear pinion ( 17) equipped with its synchroniser ring.

a

Lubricate and position the needle bearing (18) .

a

Refit the gear supporting ring (19) using a press and component C of the tool (Bvi. 1683), positioning the lubrication holes at 90˚ in relation to those of the shaft.

a


117234 a

Note: Position the bearing with the dust seal at the top. a

Refit the bearing ( 21) using component C (22) of the tool (Bvi. 1683).

a

Refit: - the oil deflector. - the permanent shim.

21A-32

MANUAL GEARBOX Input shaft: Stripping - Rebuilding a

Adjust the input shaft (see 21A , Manual gearbox, Gearbox shaft: Adjustment , page 21A-40 ) if replacing a shaft or housing.


Refit: - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the manual gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal - Refitting, page 21A-45 ) .

a


a


21A-33

21A

MANUAL GEARBOX Output shaft: Stripping - Rebuilding

II - STRIPPING OPERATION FOR PART CONCERNED


21A


Essential equipment set of feeler gauges


STRIPPING I - STRIPPING PREPARATION OPERATION a

a

a


100066 a

Remove:


- the locking ring (1) ,

Remove:

- the two half shims (3 ) .

- the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) .

21A-34

- the closure washer (2 ) ,

Note: The gear supporting rings are fitted tightly on the shafts, and the pressure required to remove them is approximately 3 to 5 tonnes, using a good quality tool (press-support).


21A

REASSEMBLING I - REBUILDING PREPARATION OPERATION a


a

Parts always to be replaced: - the seal of the gearbox selector shaft, - the input shaft seal, - the differential seals, - the stop ring of the output shaft,

100068 a


Remove the fourth, fifth and sixth gear assembly with a press, applying pressure under the fourth gear with an extractor.

- the pins, - the hydraulic clutch thrust bearing. a

Check (see 21A, Manual gearbox, Manual gearbox: Check, page 21A-12 ) : - the output shaft, - the gears on the output shaft, - the selector rod hubs on the output shaft, - the synchroniser rings on the output shaft, - the bearings of the output shaft.

a

100069 a

Remove the gears - hubs assembly with a press, applying pressure under the reverse gear using component A (4) of the tool (Bvi. 1683).

21A-35



21A

II - REBUILDING OPERATION FOR PART CONCERNED

100071 100070 a

Refit the reverse gear (5 ) and the ring (6 ) using a press and component D of the tool (Bvi. 1683), positioning the lubrication holes at 90˚ in relation to those of the shaft.

a

Apply a final pressure of 2.5 tons.

a

Lubricate and position the needle bearing ( 7 ) and the first idle gear (8 ) with its synchroniser ring.

a

Refit the first-second gear selector rod (9 ) using a press and component C of the tool (Bvi. 1683),(large hub offset on second gear side, selector rod offset on first gear side).

a

Align and engage the notches on the synchroniser ring with those on the hub.

a

Refit the ring ( 10) using a press and component D of the tool (Bvi. 1683) , positioning the lubrication holes at 90˚ in relation to those of the shaft.

a

Apply a final pressure of 2.5 tons.

21A-36

MANUAL GEARBOX Output shaft: Stripping - Rebuilding a

21A

Given that the nominal value is 173.90 use the following procedure:

± 0.05

mm,

Permanent shim = 173.90 - X1 . Example:

X1 = 173.23 mm Permanent shim = 173.90 - 173.23 = 0.67 mm Given that shims vary by 0.08 mm, in this example it is necessary to use the 0.68 mm shim in the set.

100072 a

Lubricate and position the needle bearing ( 11) and the second idle gear (12) with its synchroniser ring.

a

Refit the third fixed gear (13) using a press an d component D of the tool (Bvi. 1683).

100074 a

Position the selected shim.

a

Refit the fourth ( 15) and fifth ( 16) fixed gear using a press and component D of the tool (Bvi. 1683).

a

Position the spacer ( 17) and the sixth fixed gear (18) .

100073 a

Position the spacer (14) .

a

Measure the distance (X1) between the end of the fixed gear of the shaft and the end of the spacer in order to determine the thickness of the permanent shim.

21A-37


100075 a

The output shaft end float must be 0.01 mm.

a

Measure the distance (X2) between the end of the shaft and the sixth gear, in order to determine the thickness of the shim (19) .

21A

100067 a

Determine the thickness of the half shims using a set of feeler gauges (21) .

Example:

X2 = 1.30 mm Shim (19) = 1.30 - 0.01 = 1.29 mm Given that shims vary by 0.08 mm, in this example it is necessary to use the 1.28 mm shim in the set. a

Refit the bearing (20) using component C of (Bvi. 1683) and a press.

100066 a

Refit: - the two half shims (22) , - the closure washer (23) , - the lock ring (24) .

21A-38

MANUAL GEARBOX Output shaft: Stripping - Rebuilding III - FINAL OPERATION a

Refit: - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

a


a


21A-39

21A

MANUAL GEARBOX Gearbox shaft: Adjustment - the stop ring of the output shaft,


21A


Steel plate to attach DTI gauge and 0.6 and 1.6 standard wrench.

- the pins, - the hydraulic clutch thrust bearing.

Essential equipment

II - INPUT SHAFT AXIAL CLEARANCE ADJUSTMENT

dial gauge

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) . I - ADJUSTMENT PREPARATION OPERATION a


a


a

Remove: - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) ,

100940 a


With the input shaft in place, note the distance (X1) between the end of the bearing and the joint face.

- the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the differential (see 21 A , Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) . a

Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the shafts, - the mating faces of the seals, - the shaft mating surfaces, - the clutch housing, - the mechanism housing.

a

Parts always to be replaced: 101151

- the seal of the gearbox selector shaft, - the input shaft seal,

a


21A-40

Measure the distance ( X2) between the mechanism housing joint face and the bearing face that takes the permanent shim.

MANUAL GEARBOX Gearbox shaft: Adjustment a

21A

Determine the thickness of the shim using the following procedure, accounting for the axial clearance between 0 and 0.06 mm.

Permanent shim = (X2 - X1) - axial clearance. Example:

X1 = 226.59 mm. X2 = 227.56 mm. Permanent shim = (227.56 - 226.59) = 0.97 mm . Given that shims vary by 0.04 mm, in this example, it is necessary to use the 0.96 mm shim in the set.

III - OUTPUT SHAFT AXIAL CLEARANCE ADJUSTMENT

101145 a

Check the distance between the bearing and the bearing face of the housing shim using a dial gauge ( 2) fitted to the (Bvi. 1161) (3) . To do this: Fit the dial gauge in place (test needle on the bearing), move away the locking spring ring with a screwdriver (4 ) while at the same time lifting the output shaft so that the bearing is fully engaged on the bearing face of the housing. Note the distance value (D). Determine the thickness of the permanent shim using the following procedure, taking account of the end float between 0 and 0.06mm.

Permanent shim = D - end float Example:

100936 a

D = 0.73 mm Given that shims vary by 0.04 mm, in this example, it is necessary to use the 0.72 mm shim in the set.

Note: This operation is to be carried out only if the housings are replaced. a

a


Fit: - the output shaft, - the mechanism housing (not equipped with the permanent shim) (see 21A, Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16) .

a

a

Remove:

Separate the locking spring ring (1) and complete the positioning procedure.

- the output shaft.

IV - FINAL OPERATION a

Fit the output shaft in order to clip it on using a screwdriver.

21A-41

Refit: - the differential (see 21A, Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) ,

MANUAL GEARBOX Gearbox shaft: Adjustment - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) . a


a


21A-42

21A

MANUAL GEARBOX Clutch housing bearing: Removal - Refitting



21A


1 - Differential bearing housing

Tightening torques m retaining bracket bolt

8 N.m




a


a

Remove:

100943 a

Remove the differential bearing housing using a roll pin punch.

2 - Output shaft bearing

- the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the differential (see 21 A , Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) .

129935 a

Remove: - the retaining bracket bolt (1) , - the retaining bracket,

21A-43

MANUAL GEARBOX Clutch housing bearing: Removal - Refitting

21A

2 - Differential bearing housing

- the output shaft bearing (2 ) , - the oil deflector (3 ) .


Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to clean: - the bearing mating faces in the clutch housing, - the clutch housing, - the mechanism housing, - the shafts, - the differential.

a

Parts always to be replaced: - the stop ring of the output shaft, 100945

- the differential seals, - the input shaft seal,

a

Refit the differential bearing housing using component E (4 ) of the tool (Bvi. 1683).

- the seal of the gearbox selector shaft, - the pins,

III - FINAL OPERATION

- the hydraulic clutch thrust bearing,

a

- the blanking cover at the end of the output shaft.

- the differential (see 21A, Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) ,

II - REFITTING OPERATION FOR PART CONCERNED

- the gearbox shafts (see 21 A, Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) ,

1 - Output shaft bearing a

- the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) .

Refit: - the oil deflector. - the output shaft bearing,

a

Remove the gearbox from the component support (see 21 A , Manual gearbox , Gearbox support equipment: Use, page 21A-15) .

a


- the retaining bracket, - the retaining bracket bolt. a

Refit:

Torque tighten the retaining bracket bolt (8 N.m) .

21A-44

MANUAL GEARBOX Manual gearbox selector shaft: Removal - Refitting

21A

II - REMOVAL OPERATION Tightening torques m 7 N.m

bolts of the selection control

30 N.m

reverse gear switch neutral switch

30 N.m.

selection locating ball

24 N.m

selection end stop lever

28 N.m

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) . 100937

REMOVAL

a

- the selection end stop lever (1) ,

I - REMOVAL PREPARATION OPERATION a

a

Remove:

- the selection locating ball (2) ,


- the neutral switch (3) ,


- the reverse gear switch (4) , - the bolts of the selection control assembly (5) , - the selection control assembly (6 ) .


Clean all the removed parts (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1 ) .

a

parts always to be replaced: Gear lever shaft seal (12,02,01,09) .

II - REFITTING OPERATION a

Refit: - the selection control assembly equipped with a new seal, - the bolts of the selection control assembly.

a

21A-45

Torque tighten the bolts of the selection control (7 N.m) .

MANUAL GEARBOX Manual gearbox selector shaft: Removal - Refitting a

Use SEALING RESIN (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to coat the threading of the reverse gear and neutral switches.

a

Refit: - the reverse gear switch, - the neutral switch.

a

Torque tighten: -the reverse gear switch (30 N.m) , -the neutral switch (30 N.m.)

a

Refit the selection locating ball.

a

Torque tighten the selection locating ball (24 N.m).

a

Refit the selection end stop lever.

a

Torque tighten the selection end stop lever (28 N.m).



a


21A-46

21A

MANUAL GEARBOX Selector fork shaft ring: Removal - Refitting



21A





a


a

102259 a

Remove: - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) ,

Use a 14mm diameter slide hammer puller ( 1) to remove the reverse gear and selector fork shaft rings.



Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the shafts, - the differential,


- the shaft mating surfaces, - the mating faces of the seals, - the mating faces of the rings, - the clutch housing, - the mechanism housing. a

Parts always to be replaced: - the seal of the selector shaft, - the fork shaft rings, - the differential seals, - the input shaft seal, - the stop ring of the output shaft, - the blanking cover at the end of the output shaft, - the pins, - the hydraulic clutch thrust bearing.

21A-47

MANUAL GEARBOX Selector fork shaft ring: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED

102258 a

Refit the reverse gear and selector fork shaft rings using component F of the tool (Bvi. 1683) (2) .


Refit: - the differential (see 21 A , Manual gearbox , Manual gearbox differential: Removal - Refitting , page 21A-54 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

a


a


21A-48

21A

MANUAL GEARBOX Reverse gear shaft: Removal - Refitting

21A

II - OPERATION FOR REMOVAL OF PART CONCERNED IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) .



a


a


129956 a

Remove: - the permanent shim (1) , - the reverse gear sprocket (2) ,

- the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) .

- the synchroniser hub ( 3) , - the engagement clips (4 ) , - the needle bearing cage (5) , - the stop needle bearing cage (6 ) , - the synchroniser ring ( 7) , - the reverse gear sprocket (8) , - the needle bearing cage (9) , - the stop needle bearing cage (10) , - the pin (11) from the reverse gear shaft (12) .


Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the reverse gear pinions and shaft, - the shafts, - the shaft mating surfaces, - the clutch housing, - the mechanism housing.

21A-49

MANUAL GEARBOX Reverse gear shaft: Removal - Refitting a

21A

Parts always to be replaced:

- the stop needle bearing cage (10) ,

- the engagement clips,

- the needle bearing cage (9) ,

- the seal of the gearbox selector shaft,

- the reverse gear sprocket (8) ,

- the input shaft seal,

- the synchroniser ring (7) ,


- the stop needle bearing cage (6) ,

- the stop ring of the output shaft,

- the needle bearing cage (5) ,


- the synchroniser hub (3) ,

- the pins,

- the reverse gear sprocket (2) ,


- the permanent shim (1) .


Check all of the removed parts (see 21A, Manual gearbox , Manual gearbox: Check , page 21A-12 ) .

a


a

Adjust the reverse gear shaft (see 21 A , Manual gearbox, Reverse gear shaft:Adjustment , page 21A-52) when replacing the shaft or a reverse gear intermediate pinion.

129942 a

Note: When refitting the shaft assembly, pay attention to the position of the reverse gear shaft. The anti-rotation mechanism of the shaft is retained by a pin ( 15) .

III - FINAL OPERATION 101146 a

a

a

When refitting, fit the new engagement clips ( 13) .

Refit:

Note:

- the gearbox shafts (see 21 A, Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) ,

Position the engagement clips (13) in the locations indicated by the mark etched on the tooth sides (14) .

- the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

Refit: - a new pin (11) ,

21A-50

MANUAL GEARBOX Reverse gear shaft: Removal - Refitting a


a


21A-51

21A

MANUAL GEARBOX Reverse gear shaft:Adjustment

21A

II - ADJUSTMENT OPERATION FOR THE AXIAL CLEARANCE OF THE REVERSE GEAR SHAFT IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 21A , Manual gearbox, Manual gearbox: Precautions for repair, page 21A-1 ) .

I - ADJUSTMENT PREPARATION OPERATION a


a


a

Remove: - the manual gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal - Refitting, page 21A-45 ) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) .

a

100941 a

Measure the distance (X1) between the end of the reverse gear pinion and the joint face with the reverse gear shaft in place.

a

Remove the reverse gear shaft.

Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the shafts, - the reverse gear pinions and shaft, - the shaft mating surfaces, - the clutch housing, - the mechanism housing.

a

Parts always to be replaced: - the input shaft seal, - the seal of the gearbox selector shaft, 101150

- the differential seals, a

- the stop ring of the output shaft, - the blanking cover at the end of the output shaft, - the pins, - the hydraulic clutch thrust bearing.

21A-52

Measure the distance ( X2) between the mechanism housing joint face and the bearing face that takes the permanent shim.

MANUAL GEARBOX Reverse gear shaft:Adjustment a

Determine the thickness of the shim using the following procedure, accounting for the axial clearance between 0.04 and 0.14 mm.

Permanent shim = (X2 - X1) - axial clearance Example:

X1 = 58.29 mm X2 = 60.60 mm Permanent shim = (60.60 - 58.29) - 0.04 = 2.27 mm Given that shims vary by 0.080 mm, in this example, it is necessary to use the 2.24 mm shim in the set.


Refit: - the gearbox shafts (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A21) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the manual gearbox selector shaft (see 21A , Manual gearbox, Manual gearbox selector shaft: Removal - Refitting, page 21A-45 ) .

a


a


21A-53

21A

MANUAL GEARBOX Manual gearbox differential: Removal - Refitting

21A

REMOVAL Tightening torques m differential crownwheel bolts

I - REMOVAL PREPARATION OPERATION 120 N.m


a

Remove the manual gearbox (see Manual gearbox: Removal - Refitting ) .

a

Position the gearbox on the component support (see 21A , Manual gearbox, Gearbox support equipment: Use , page 21A-15) .

a

Remove: - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) , - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) .


100939

Note:

- the « input shaft - output shaft - reverse gear » assembly (1) (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A-21 ) ,

This operation requires two people.

- the differential (2) .

a

a

Remove:

21A-54


21A


Refit: - the differential bearings (see 21A , Manual gearbox, Manual gearbox differential bearing: Removal - Refitting, page 21A-57 ) , - the differential unit on the differential crownwheel, - the bolts of the differential crownwheel.

a

Torque tighten the differential crownwheel bolts (120 N.m).

Adjusting the pretension of the differential bearings

139458 a

Remove: - the bolts (3 ) of the differential crownwheel, - the differential unit of the differential crownwheel, - the differential bearings (see 21A , Manual gearbox, Manual gearbox differential bearing: Removal - Refitting, page 21A-57 ) .


Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) :

a

Fit the differential.

- the shafts,

a

Measure the distance (X1) between the end of the bearing housing and the joint face.

a

Remove the differential.

100942

- the shaft mating surfaces, - the differential, - the mechanism housing, - the clutch housing. a

Parts always to be replaced: - the seal of the gearbox selector shaft, - the input shaft seal, - the differential seals, - the stop ring of the output shaft, - the blanking cover at the end of the output shaft, - the pins, - the hydraulic clutch thrust bearing.

21A-55


21A


Refit: - the mechanism housing (see 21A , Manual gearbox, Mechanism cover: Removal - Refitting , page 21A-16 ) , - the gearbox selector shaft (see 21A, Manual gearbox, Manual gearbox selector shaft: Removal Refitting, page 21A-45) .

a


a


101149 a

Measure the distance (X2) between the mechanism housing joint face and the bearing face that takes the permanent shim.

a

Determine the thickness of the permanent shim using the following procedure, accounting for a pretensioning determined by a value between 0.15 and 0.21 mm.

Permanent shim = (X2 - X1) + pretensioning Example:

X1 = 26.49 mm X2 = 26.98 mm Permanent shim = (26.98 - 26.49) + 0.18 = 0.67 mm Given that shims vary by 0.040 mm, in this example, it is necessary to use the 0.68 mm shim in the set.

Note: In some cases, two shims are required to obtain the correct pretensioning torque. Example: Calculated value 1.04 mm - shims available 0.48 + 0.56 = 1.04 mm a

Refit: - the differential, - the « input shaft - output shaft - reverse gear » assembly (see 21A , Manual gearbox, Gearbox shaft: Removal - Refitting , page 21A-21 ) .

21A-56

MANUAL GEARBOX Manual gearbox differential bearing: Removal - Refitting



21A





a


a


105554 a

Remove the differential bearings using a separator ( 1) .



Clean (see 21A, Manual gearbox, Manual gearbox: Precautions for repair , page 21A-1) : - the shafts, - the shaft mating surfaces,


- the mating faces of the seals, - the differential, - the mechanism housing, - the clutch housing. a

Parts always to be replaced: - the input shaft seal, - the differential seals, - the seal of the gearbox selector shaft, - the stop ring of the output shaft, - the blanking cover at the end of the output shaft, - the pins, - the hydraulic clutch thrust bearing.

21A-57

Renault Megane 2 F4R 770 ND0 manual gearbox

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