Transmission

CLUTCH

MANUAL GEARBOX

DRIVESHAFTS

FC0A - FC0C - FC0D - FC0E - KC0A - KC0C - KC0D - KC0E

77 11 194 244
"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."

JULY 1997
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

Renault 1997

EXPLODED VIEW

PRF2000

Transmission
Contents

Page

20 CLUTCH
Mechanism- Disc Flywheel 20-1 20-4

MANUAL GEARBOX 21 ENSEMBLE MOTEUR ET BAS Identification Ratios Capacities-Lubricants Consumables Parts to be systematically replaced Gearbox (Removal-Refitting) 21-1 21-2 21-3 21-4 21-4 21-5

29 DRIVESHAFTS
General Front driveshaft 29-1 29-2

CLUTCH Mechanism - Disc

20
Disc GA : Grey Silver VR : Violet Red

Vehicle Type

Engine Type

Mechanism 26 splines D = 181.5 mm E = 6.7 mm

F/K C0A F/K C0C

D7F E7J

85873S

180 CP3300

90693R8

76906R

26 splines D = 242 mm E = 6.8 mm

RR : Red Ruby GB : Grey Blue

F/K C0D F/K C0E

F8Q

85873S

200 CPOV 3250 Cable-controlled dry-operating single disc clutch. Constant pressure clutch thrust bearing.

90693R9

76906R

20-1

CLUTCH Mechanism - Disc

REPLACEMENT (after removal of the gearbox)
SPECIAL TOOLING REQUIRED

20

Mot. 582 or Mot. 582-01

Locking tool

TIGHTENING TORQUES (in daN.m)

REFITTING

Mechanism mounting bolt

REMOVAL

Clean the splines of the clutch shaft and refit the assembly without lubricant. Fit the disc (with the offset on the hub on the gearbox side). Centre using the tool supplied in the kit.

Fit the locking sector tool Mot. 582 or Mot. 582-01. Remove the mounting bolts from the mechanism and remove the friction plate. Check and replace any faulty parts.

95414S

Tighten progressively in a star pattern, then tightenthe mounting bolts to the correct torque.
99055R

Remove the locking sector tool Mot. 582 or Mot. 582-01. Coat with MOLYKOTE BR2 - the guide tube, - the fork pads. grease:

20-2

CLUTCH Mechanism - Disc

After refitting the gearbox, place the cable onto the clutch fork, reset the notched sector and check that the play compensation is in working order. Check the travel of the clutch. The travel of the fork must be: X = 27.4 to 30.7 mm

20

NOTE : in the case of any intervention not requi-

ring the removal of the gearbox or after the fitting of the gearbox, DO NOT LIFT the fork, as it would risk releasing itself from the slot (A) of the clutch thrust bearing.

99054R

97758-1R

20-3

CLUTCH Flywheel
REPLACEMENT of the flywheel SPECIAL TOOLING REQUIRED

20

Mot. 582 or Mot. 582-01

Locking tool

TIGHTENING TORQUES (In daN.m)

Flywheel bolt
REMOVAL

2 + 60

After removing the friction plate, remove the mounting bolts of the flywheel (must not be re-used). Regrinding of the friction face is not permitted.
REFITTING

Clean the threads of the mounting bolts of the flywheel on the crankshaft. Remove the grease from the bearing face of the flywheel on the crankshaft. Refit the flywheel by immobilising it with tool Mot. 582 or Mot. 582-01.
NOTE: the flywheel mounting bolts are to be sys-

tematically replaced.

20-4

MANUAL GEARBOX Identification

All KANGOO vehicles are fitted with
JB

21

type gearboxes.

The Workshop Repair Manual "B.V. JB. JC " deals with the complete repair of this component.

87227G

IDENTIFICATION PLATE

At A At B At C At D At E At F

: : : : :

the gearbox type the gearbox suffix the fabrication number the factory of manufacture a slot if the gearbox is assembled with an E type engine : the letter preceding all fabrication numbers greater than 999999

A D E

J B0 0 0 0 X X0 0 0 0 0
F

B C

21-1

MANUAL GEARBOX Ratios

21
3rd 4th 5th 39 31 Reverse gear

JB1
Suffix 906 175 171 172 173 174 Vehicle
F/K C0D

Differential ratio 16 55 14 59 16 57

Speedometer gear

1st

2nd

F/K C0A

21 19

11 41

21 43

28 39

34 35

39 32 37 33

11 39

26

F/K C0E

JB3
Suffix 168 169 Vehicle
F/K C0C

Differential ratio 14 59

Speedometer gear

1st 11 14

2nd 21 43

3rd 28 39

4th 34 35

5th 39 32

Reverse gear 11 39 26

21 19

169 for vehicles fitted with Air Conditioning.

21-2

MANUAL GEARBOX Capacities - Lubricants

CAPACITY (in litres)

21

5 gear box JB1 JB3 3.4 3.4

Viscosity grade

TRX 75W 80W

CHECKING THE LEVEL

92081S

Filling is by overflow

21-3

MECHANICAL GEARBOX Consumables

21
COMPONENT

TYPE

PACKAGING

PART NUMBER

Splines of the right - hand sunwheel

MOLYKOTE BR2

1 kg tin

77 01 421 145

Fork pivot Thrust bearing guide Fork pads

Clutch

Loctite 518
RHODORSEAL 5661 Eg : CAF 4/60 THIXO LOCTITE FRENBLOC

24 ml syringe

77 01 421 162

Housing assembling faces Threaded plugs and switches Bearing plugs Ends of roll pins on driveshafts Primary and secondary shaft nuts Fixed gear and 5th gear hub Rear differential lock drive stud

100 g tube

77 01 404 452

(locking and sealing resin)

24 cc bottle

77 01 394 071

Parts to be systematically replaced

After they have been removed : - the lip seals, - the O-ring seals, - the clutch thrust bearing guide tubes, - the secondary and differential shaft nuts, - the speedometer drive gear and its shaft, - the speedometer ring gear, - the roll pins, - the gear supporting rings.

21-4

MANUAL GEARBOX Gearbox (removal - refitting)

SPECIAL TOOLING REQUIRED

21

B. Vi. 31-01 Mot. 1040-01 T. Av. 476

Set of punches Engine sub-frame carrier Ball joint extractor

EQUIPMENT REQUIRED

Engine support tool Component jack

TIGHTENING TORQUES (In daN.m)

Brake calliper bolt Driveshaft gaiter bolt Lower ball joint nut Shock absorber base bolt Engine tie-bar bolt Gearbox edge and starter motor bolt Suspended mounting bolt on gearbox Wheel bolts Track rod end nut
REMOVAL

4 2.5 5.5 18 6.5 4.5 4 9 4

Place the vehicle onto a two post lift. Disconnect the battery. Remove : - the engine cover, - the battery. Disconnect the connectors on: - the injection computer (petrol version), - the preheating unit (diesel version), _ the diesel fuel filter (diesel version), - the impact sensor. Remove the air filter sleeve.
13083S

Remove the bolts (A) of the battery protective screen.

13088R

21-5

MANUAL GEARBOX Gearbox (Removal - Refitting)

Remove : - the two mounting bolts (B),

21

On the right-hand side of the vehicle, remove the driveshaft pins using tool B. Vi. 31-01.

13119R

91755-1R2

Disconnect the clutch cable. Remove : - the upper bolts at the gearbox edge and on the starter motor (slacken the bolt (D) as far as possible) - the earth strap bolts on the gearbox, - the two bolts of the TDC sensor.

Remove on both sides : - the brake callipers and attach them together - the mudguards, - the track rod ends (T. Av. 476), - the shock absorber base bolts, - the sub-frame side member tie-rods (A), - the stub axle carrier-driveshaft by disconnecting it from the lower ball joint

13097-2R

99070R1

the front wheels, the oil collector under the gearbox.

21-6

MANUAL GEARBOX Gearbox (Removal - Refitting)

Ensure that the rollers of the left driveshaft cannot be removed by hand. If they can, check if any of the needles have fallen into the gearbox. Disconnect and remove the starter motor. Disconnect: - the reversing light connector, - the speedometer connector and remove the gearbox sensor. Remove : - the exhaust downpipe, - the entire gear control lever by removing the bolt (E) and the three bolts of the heat shield for access to the base of the gear lever the engine tie-bar bolt, the rear support on the gearbox. Remove the steering box and secure it.

21

13120S

Fit the engine support and take the weight of the engine and transmission assembly. Positioning on F8Q engine

12993-1R2

Remove the engine-gearbox tie-rod. To aid the removal of the steering box, fit, if necessary, a shim, in order to tilt the engine forward.

13121S

21-7

MANUAL GEARBOX Gearbox (Removal - Refitting)

Positioning on petrol engines

21

Fit the sub-frame support (Mot. 1040-01) and lower the vehicle.

13122S

Remove the three mounting bolts for the support on the gearbox.

98755R1

Remove the engine sub-frame by slackening the four mounting bolts. Fit the component jack under the gearbox without lifting it. Separate the gearbox from the engine having removed the nut (E) and the engine-gearbox mounting stud.

12924R

Lower the engine as far as possible. Remove : - the last gearbox edge bolt at the top, - the bumper.
85812-1R

21-8

MANUAL GEARBOX Gearbox (Removal - Refitting)

REFITTING

21

Coat the walls of the guide tube and the fork pads with MOLIKOTE BR2 grease. Place the fork onto the slots of the clutch thrust bearing. Assemble the gearbox on the engine taking care not to alter the height of the engine. Ensure the presence and correct positioning of the engine- gearbox centering rings . The presence of the stud (C) aids assembly.

86308R2

Refit: - the engine sub-frame, - the steering, - the exhaust downpipe, - the engine tie-bar.
SPECIAL NOTE FOR THE E7J ENGINE

Refit the exhaust downpipe before the righthand driveshaft. Refit the other components by proceeding in the reverse order to removal.

21-9

DRIVESHAFTS General
SPECIFICATION

29
Driveshaft seal

Vehicle type

Engines

Gearboxes JB1 JB1

JB1 / JB3

Left

Right

F8Q FC0X KC0X D7F E7J

GE 86 + GI 69

GE 86 + RC 462

CONSUMABLES

Type

Quantity

Component concerned

RHODORSEAL 5661

Coat

Gearbox side driveshaft roll pin

MOBIL K 575 GS

180 g

GE 86

ELF GMPT89 or MOBIL CVJ 825 BLACK STAR

110 cm3

RC 462

NOTE : the replacement of the NYLSTOP nut with the ENKO stub axles must no longer be coated with Loctite SCELBLOC.

driveshaft nut means that the splines of the

29-1

DRIVESHAFTS Front driveshafts

SPECIAL TOOLING REQUIRED

29

B. Vi. Rou. T. Av. T. Av.

31-01 604-01 476 1050-02

Roll pin punch Hub locking tool Ball joint extractor Driveshaft extractor

TIGHTENING TORQUES (in daN.m)

Driveshaft nut Mounting bolt of gaiter on gearbox. Wheel bolts Shock absorber base nuts Brake caliper mounting bolts Track rod end nut
REMOVAL

28 2.5 9 18 10 3.7

Vehicle on a two post lift. Drain the gearbox. Remove : - the brake assembly (suspend it from the chassis), - the driveshaft nut : tool Rou. 604-01. Left side : Remove the three bolts on the gearbox. Right side : Remove the roll pin : tool B. Vi. 31-01. On both sides : Remove : - The track rod end nut and extract the shaft : tool T. Av. 476, - the upper bolt of the shock absorber base. Push back the driveshaft : tool T. Av. 1050-02. Remove the lower bolt of the shock absorber base and extract the driveshaft.

99544R

REFITTING

Left side : Fit the driveshaft as horizontally as possible. Right side : Coat the splines of the joint on the gearbox side with MOLYKOTE BR2 grease. Fit the driveshaft and check its positioning : angled pin B. Vi. 31-01. Fit two new roll pins : B. Vi. 31-01. Seal the roll pin holes using RHODORSEAL 5661. On both sides : Fit the driveshaft stub axle into the hub, it should go in easily. Refitting is the reverse of removal. Observe the tightening torques. Top up the gearbox oil. Press the brake pedal several times in order to bring the piston into contact with the pads.

29-2

Lefthand driveshaft

DRIVESHAFTS Front driveshafts

SPECIAL TOOLING REQUIRED

29

T. Av. 1168 T. Av. 1256 T. Av. 1331

CAILLAU clip pliers

OETIKER crimping pliers Tool for holding driveshaft bearing gaiter in position

REPLACEMENT OF THE GAITER ON THE GEARBOX SIDE GI 69 JOINT

REFITTING

1 2 3 4 5 6 7

Spider Rubber gaiter Bearing guide Retainer Deflector Circlip Driveshaft

For its correct positioning on the shaft, the bearing must be pressed on to obtain a distance of L = 118 0.2 mm between the rear part of the bearing and the end of the shaft. This measurement is obtained using the tool T. Av. 1331 when its extremity is level with the shaft.

85884-1R1 DI2935R

NOTE : in order to avoid deformation of the bea-

REMOVAL

Remove the circlip. On the press, remove the spider using an extractor.
NOTE : mark the position of the spider before

ring with a lip seal, and therefore any risk of leakage, do not press it on using a hammer, but using a press, in order to apply progressive pressure. The driveshaft is held in the press using the slot (G) with an extractor. Replace the spider in the position marked on removal and refit the retaining circlip.

extracting it. Remove the gaiter and deflector - bearing assembly in the same way as for the spider.

29-3

Lefthand driveshaft

DRIVESHAFTS Front driveshafts

29

REPLACEMENT OF THE GAITER ON THE WHEEL SIDE GE 86 JOINT

Remove the gaiter and replace with a new one. Divide the recommended dose of grease between the gaiter and the stub axle bowl.
NOTE : it is imperative to respect the volume of

1 2 3 4 5 6 7 8 9 10

Stub axle bowl Retaining star Spider Yoke shaft Thermoplastic gaiter Clips Spring Pushrod Shim ABS target

grease prescribed in the consumables section. Position the two beads of the gaiter in the grooves of the stub axle bowl. Set the quantity of air in the gaiter. Fit and tighten the clips.

DI2934R

REMOVAL

Join together the two clips (6) taking care not to damage the grooves of the stub axle bowl. Remove as much grease as possible. For the replacement of the thermoplastic gaiter, it will be necessary to remove the parts on the gearbox side (GI 69 joint) (see method previously described).

29-4

Lefthand driveshaft

DRIVESHAFTS Front driveshafts

REFITTING

29

REPLACEMENT OF THE GAITER ON THE GEARBOX SIDE RC 462 JOINT

1 2 3 4 5

Yoke sleeve Spider Locking spring ring Gaiter Clips

Slightly lubricate the driveshaft in order to facilitate the fitting of the gaiter (position the smaller diameter of the gaiter in the groove of the driveshaft). Replace the spider in the position marked on removal and replace the locking spring ring. Make three crimping points at 120 by forcing back the metal of the splines on the driveshaft. Fit the yoke sleeve onto the spider. Divide the dose of grease between the gaiter and the yoke sleeve. Position the gaiter correctly on its grooves. Introduce a blunt rod with a rounded edge between the gaiter and the yoke sleeve, in order to measure the quantity of air contained inside thejoint. Lengthen or shorten the joint until you obtain the measurement A = 190 mm (measurement taken between the end of the joint and the face of the smaller diameter of the yoke sleeve).
DI2933R

In this position, remove the rod.

REMOVAL

Cut the two clips (5) taking care not to damage the groove of the yoke sleeve. Remove as much grease as possible. Remove the yoke sleeve Remove the locking spring ring
IMPORTANT: never use solvent for cleaning the

components. On the press, extract the spider by using a releasing type extractor .
NOTE : mark the position of the spider before

90392R1

extracting it.

Refit the clips using the recommended tooling.

29-5

Righthand driveshaft

DRIVESHAFTS Front driveshafts

NOTE :

29

REPLACEMENT OF THE GAITER ON THE WHEEL SIDE GE 86 JOINT

certain righthand driveshafts are fitted with vibration absorbers; if the thermoplastic gaiter is damaged replace the whole driveshaft . Remove the gaiter and replace with a new one.

1 2 3 4 5 6 7 8 9 10

Stub axle bowl Retaining star Spider Yoke shaft Thermoplastic gaiter Clips Spring Pushrod Shim ABS target

Divide the recommended dose of grease between the gaiter and the stub axle bowl.
NOTE :

it is imperative to respect the volume of grease prescribed in the consumables section.

Position the two beads of the gaiter into the grooves of the stub axle bowl.

Set the quantity of air in the gaiter.

Fit and tighten the clips.

DI2934R

REMOVAL

Join together the two clips (6) taking care not to damage the grooves of the stub axle bowl.

Remove as much grease as possible.

For the replacement of the thermoplastic gaiter, it will be necessary to remove the parts on the gearbox side (RC 462 joint) (see method previously described).

29-6