Workshop Repair Manual

Manual gearbox Type JC7 Range Scnic RX4

Reduction gearing section For the gearbox section refer to the JB - JC manual

77 11 298 942

FEBRUARY 2001
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 introduced 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.

RENAULT 2001

Contents
Page

21 MANUAL GEARBOX
Identification Gears Section and tightening torques (in daNm) Tightening torques (in daNm) Special tooling Repairing the reduction gearing 21-1 21-1 21-3 21-4 21-5 21-6

MANUAL GEARBOX 121 Identification

21

Marking (1), on the gearbox casing, indicates: A B C D Gearbox type Gearbox index Fabrication number Factory of manufacture

Ratios
Reverse gear 11/39 11/39 Reduction gearing 15/41 15/41

Index JC7-000 JC7-001

Type J64 (F4R) J64 (F9Q)

1st 11/41 11/41

2 nd 21/43 21/43

3rd 28/39 28/37

4th 31/34 35/34

5 th 37/33 39/31

Final drive 15/61 15/61

Tachometer 22/18 22/18

21-1

MANUAL GEARBOX Capacities - Lubricants

CAPACITY (in litres)

21

5-speed gearbox JC7 3.3

Viscosity grade

TRX 75W 80W

CHECKING THE LEVEL

Fill up to the level of the hole

21-2

MANUAL GEARBOX Section and tightening torques (in daNm)

MANUAL GEARBOX JC7 (tightening torques in daNm)

21

A B C D E

16 7 3.5 3.5 15
20036

21-3

MANUAL GEARBOX Tightening torques (in danm)

21

Description Bolt joining the gearbox casing to the clutch casing Body (point of resistance of 5th) Rear cover bolt Drain plug Reversing light switch Left driveshaft gaiter mounting bolt Joining the gearbox to the cylinder casing

Torque in daNm 2.5 2 2.5 2.5 2.5 2.5 5

21-4

MANUAL GEARBOX Special tooling

21

B. Vi. 1161 B. Vi. 1389 B. Vi. 1419 B. Vi. 1554 B. Vi. 1556 B. Vi. 1581 B. Vi. 1582

Steel plate to attach DTI gauge + pre-load adjust shims Rules for measurements on automatic gearbox Bearing positioning tool Reduction gearing repair kit Tool for supporting the intake flange Gearbox support plate Input shaft support plate

RECOMMENDED TOOLING General purpose puller pliers 42 (example: U 49M + U49D8 Facom) Swivel head DESVIL stand Torque testing wrench

21-5

MANUAL GEARBOX Repairing the reduction gearing

DISMANTLING THE REDUCTION GEARING Fit the B. Vi. 1581 support plate on a DESVIL stand. Fit the gearbox on the B. Vi. 1581 support. REMOVING BEARINGS

21

Remove the bearings using an antisticking pin.

NOTE: the gearbox differential must be removed (refer to the JB-JC manual for removing/refitting) before any operation can be carried out on the reduction gearing.

On the inside, it is necessary to break the bearing cage in order to position the jaws of the antisticking pin on the bearing flange base.

Remove: the reduction gearing shaft (A), the cover (B). Remove the reduction gearing.

21-6

MANUAL GEARBOX Repairing the reduction gearing

RE-FITTING THE BEARINGS Fit the bearings as far as the thrust bearing on the casing using index tool D from the B. Vi. 1554 kit. Cover side Fit onto B. Vi. 1582.

21

REMOVING BEARING RETAINERS Remove the retainers using a 42 extractor and an inertia extractor. WARNING: take care not to mix the pre-stressed setting shims. Gearbox housing side

REFITTING THE RETAINERS After refitting the original prestressed shim, refit the housing side retainer to the press using tools C-F from the B. Vi. 1554 kit and the B. Vi. 1419 rod.

WARNING: the shim and the cover side retainer must be refitted after their pre-stress value has been determined.

21-7

MANUAL GEARBOX Repairing the reduction gearing

SETTING THE REDUCTION GEARING PRE-STRESS Housing side: dimension X Position the reduction gearing in the housing and fit the retainer, cover side, on its bearing. Fit tool G from the B. Vi. 1554 kit on the bearing retainer. Pass the cable inside the reduction gearing and attach a 20 kg weight Cover side: dimension X'

21

Measure between the cover plane (A) and the mating face of the pre-stressing shim (B) using B. Vi. 1389 and calculate the difference to determine dimension X'. Remember to subtract the thickness of the rule. Measuring on the cover plane:

19260 19258

Measuring on the shim mating face:

Measure between the housing plane and the top of the retainer using B. Vi. 1389 (dimension X). Remember to subtract the thickness of the rule.

19261

19259

21-8

MANUAL GEARBOX Repairing the reduction gearing

Measure the difference between the two dimensions (X and X') and add 0.09 mm to this amount to determine the thickness of the pre-stressing shim.

21

Fit the cover with a new O-ring and tighten the bolts to a torque of 3.5 daNm.

Example: X 14.65 X' 12.97 Value for pre-stressing shim 14.65 - 12.97 = 1.68 (+0.09) = 1.77

Select the shim closest to 1.77 from the kit. Fit the shim and the retainer using tool C-F from the B. Vi. 1554 kit.

19263

19262

21-9

MANUAL GEARBOX Repairing the reduction gearing

REPLACING THE INPUT SHAFT BEARINGS Measure the distance between the end of the shaft and the conical spacer shim (A), before removing the shaft on the casing. Then read the thickness of this shim (A).

21

Remove: the clamp and the input shaft using the press,

the bearing using an antistick pin.

19264

Fit the assembly on B. Vi. 1582 and remove the prestressing nut using B. Vi. 1556.

21-10

MANUAL GEARBOX Repairing the reduction gearing

Refit the bearing using the B tool from the B. Vi. 1554 kit.

21

Refit the retainers using tools A and C-F from the B. Vi. 1554 kit.

Remove the interior retainers using a roll pin punch.

21-11

MANUAL GEARBOX Repairing the reduction gearing

NOTE: the bearings are pre-stressed by deformation of the spacer (A). A new spacer must be fitted and use tool D from the B. Vi. 1554 kit to fit a small bearing to leave a slight play (B) so that the spacer is not deformed prematurely.

21

Fit the lip seal using tool E from the B. Vi. 1554 kit.

19266

18560

Fit the shaft in the casing, with a new pre-stressing spacer, and fit the small bearing using the press and tool D from the B. Vi. 1554 kit.

19265

21-12

MANUAL GEARBOX Repairing the reduction gearing

Partly fit the inlet clamp (so that there is always a slight play between the bearing and the pre-stressing spacer).

21

Check the bearings' pre-stress using a torque tester (A).

The inlet shaft must turn under a torque of 1.15 Nm. If the torque value is incorrect, gradually tighten the nut to obtain the correct pre-stress setting. WARNING: never loosen the nut: if pre-stressing is too high, repeat the removal operation to replace the pre-stress spacer.

19267

Fit the assembly on B. Vi. 1582. Tighten the nut to approximately 26 daNm using B. Vi. 1556.

21-13

MANUAL GEARBOX Repairing the reduction gearing

CHECKING THE CONIC DISTANCE Measure between the end of the shaft and the conical spacer shim (as during removal).

21

Fit the assembly on the gearbox with a new O-ring and tighten the bolts to a torque of 3.5 daNm.

19264

Calculate the difference between these two values (before removal and after refitting). Increase the shim if the value is higher. Decrease the shim if the value is higher. Example (in mm): Value of original shim 2.10

Before removal 56.80

After refitting 56.90

Difference + 0.10

Value of new conic distance shim: 2.10 + 0.10 = 2.20 Select from the kit the shim closest to 2.20.

21-14

MANUAL GEARBOX Repairing the reduction gearing

Check play of teeth: Fit a bolt (V) in one of the inlet shaft flange holes. Fit a dial gauge using the plate from B. Vi. 1161 so that the probe is in contact with one of the bolt flats. Measure the play by gently swivelling the inlet shaft. Measure this play four times, turning the inlet shaft about ten times, and moving the bolt (V) into another hole in the flange. Average it. The play must be between 0.15 and 0.25 mm.

21

If the play is not correct, reduce or increase the shims which are behind the reduction gearing bearing retainers. To reduce the play, decrease the shim thickness on the side opposite the ring and transfer this to the ring side (to retain the same bearing pre-stress). To increase the play, do the reverse.

21-15