Workshop Repair Manual

Manual gearbox PF1

APPENDIX
This section deals with the repair of PF1 type gearboxes only and in no way cancels or replaces Technical Note 2859A. This section may however be used in the limited internal repair of PK1 (triple cone) gearboxes, for replacing: • all bearings on the shafts, • the synchro rings. The PK1 suffixes concerned are : 043 - 046 - 047 - 048 - 049 - 050 - 051 - 062 - 064 - 066 - 067 069 - 070 - 071.

Workshop Repair Manual
Manual gearbox
Gearbox Type PF1 Vehicle Range Master

77 11 201 959

OCTOBER 1998
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.

C

Renault 1998

Contents
Page

21 MANUAL GEARBOX
Identification Section view and torques (in daN.m) Ratios Special tooling Consumables Parts to be systematically replaced Gearbox repair Opening the gearbox Removing the gears Checking the parts Removing - refitting the bearings Removing the bearing outer cages in the mechanism housing Removing the bearing outer cages in the clutch housing Refitting the gears Refitting the bearing outer cages in the mechanism housing Refitting the bearing outer cages in the clutch housing Differential Internal controls Command module Refitting the shafts Closing the gearbox Clutch shaft lip seal 21-1 21-2 21-4 21-5 21-6 21-6

21-7 21-10 21-12 21-13 21-15 21-16 21-17 21-21 21-22 21-23 21-26 21-27 21-29 21-30 21-33

MANUAL GEARBOX Identification

21

B A

XXX A A XXX

C

15270S

At A At B At C

: : :

the gearbox type. the homologation letter. the gearbox suffix.

21-1

MANUAL GEARBOX Section view and torques (in daN.m)

21

DI2164

21-2

MANUAL GEARBOX Section view and torques (in daN.m)
TIGHTENING TORQUES (in daN.m)

21

Edge bolt Differential crown wheel Reverse gear switch Gear grid Guide finger 3/4 inverter bolt Guide tube

2.4 13 0.9 0.9 0.9 2.3 0.9

21-3

MANUAL GEARBOX Ratios
PF1 Suffix 000 011 017 004 012 018 002 013 019 003 014 020 Vehicle FD0A JD0E UD0E FD0E FD0E JD0E JD0A JD0B UD0C FD0C JD0F FD0C JD0B JD0F Differential ratio Speedo gear 1st 2nd 3rd 4th 5th

21
Reverse

17/82

24/18

11/51

17/42

21/32

39/43

39/34

10/41

16/67

24/19

11/51

17/42

21/32

39/43

39/34

10/41

17/82

24/18

11/43

19/42

31/40

41/37

41/29

11/40

16/67

24/19

11/43

19/42

31/40

41/37

41/29

11/40

21-4

MANUAL GEARBOX Special tooling

21

B. Vi. 28-01 B. Vi. 31-01 B. Vi. 1235 B. Vi. 1236 B. Vi. 1240 B. Vi. 1267 B. Vi. 1412 B. Vi. 1416 B. Vi. 1417 B. Vi. 1418 B. Vi. 1419 B. Vi. 1442 B. Vi. 1443 B. Vi. 1508 B. Vi. 1510E B. Vi. 1510F B. Vi. 1510H B. Vi. 1510J B. Vi. 1510A B. Vi. 1510C B. Vi. 1510G B. Vi. 1510K B. Vi. 1510B B. Vi. 1510I

Claw extractor Set of roll pin punches Tool for fitting differential output seal Tool for fitting primary shaft seal Tool for fitting differential output seal Tool for removing and fitting gear lever roll pins Tool for removing / refitting clutch fork shaft roll pin Fork for retaining counter pressure pins and shims Housing support and chassis Adjustable support for fitting bearing cages Tool for fitting bearing cages Reverse gear shaft extractor Tool for fitting reverse gear shaft Tool for removing large diameter differential bearing cage Tool for removing gears Tool for refitting gears Tool for fitting large diameter differential bearing cage Tool for fitting bearing cages (clutch side) Tool for fitting small diameter differential bearings Tool for fitting shaft seal Tool for refitting differential stop ring Tool for fitting differential bearings Tool for fitting module shaft seal Tool for fitting reverse gear shaft seal

Recommended tooling: 42 mm diameter extractor pliers, example " U49M + U49D8" ( FACOM).

21-5

MANUAL GEARBOX Consumables

21
Component Clutch thrust pad guide tube Immersion of all parts

Types Molykote "BR2" TRX 75W80W gearbox oil Rhodorseal
CAPACITY

Packaging 1 kg tin

Part No. 77 01 421 145

100 g tube

77 01 404 452

Housing

PF1 PK1
IMPORTANT:

2.1 (minimum mark) 2.6 (maximum mark) the level is not found by overflow, too much oil may impair the operation of the gearbox. a = 19 ± 0.5 mm b = 31 ± 0.5 mm c = 42 ± 0.5 mm SAFRANE J and Z engines : MAXIMUM level : Mark B MINIMUM level : Mark C

SAFRANE S and G engines, LAGUNA G, Z and L engines, ESPACE G and L engines, MASTER S engines : - MAXIMUM level : Mark A - MINIMUM level : Mark B Checking conditions: reference marker (D) on the bottom of the filling hole
11223R2

Parts to be systematically replaced
When they have been removed: - lip seals, - O rings, - bearing circlips, - sunwheel stop ring, - hub springs, - roll pins.

21-6

MANUAL GEARBOX Gearbox repair
OPENING THE GEARBOX

21
S engine

Fit support plate B. Vi. 1417 to a stand. With support B. Vi. 1417 horizontal, fit the gearbox with the engine side against the plate.

12600R

G engine
12608R

Strap the gearbox onto the plate according to the table below.

Gearbox assembled with engine type Z J S G

Hole used/ bolts required (the holes are marked on the tool)

Z1/36-30 J1/M10-80 S1/M8-30 G1/M10-55

Z2/M10-55 J2/M8-25 S2/M6-30 G2/M6-60
12599R

S3/M10-55

21-7

MANUAL GEARBOX Gearbox repair
Tilt the gearbox half a turn. From the clutch housing remove, : - the command module guide finger (A) to make removing the mechanism housing easier.
IMPORTANT: the seal sometimes remains in

21

the housing. the reverse gear shaft nut (B) and its washer.

13503R

Tilt the gearbox half a turn. Remove the bolts at the edge of the housings. Take hold of the housing as shown by the arrows in the diagram. Pivot the gear lever to release the command module fingers and remove the mechanism housing.

12707R1

Position tool B. Vi. 1442 aligning the pressure bolt with the reverse gear shaft.

12609R

21-8

MANUAL GEARBOX Gearbox repair
Remove the 3/4 inverter (B).

21

12597S

Remove the shaft and the fork.
12595-1R5

Push on the reverse gear shaft using tool B. Vi. 1442. Remove the shaft, the gear, its needle roller bearing cage and the friction washer. Remove tool B. Vi. 1442. Engage 4th gear. Remove the roll pin from the 3/4 fork. Apply counter pressure to the shaft to avoid damaging the ring in the clutch housing.

IMPORTANT: Do not separate the shaft and the fork as the shaft is not symmetrical.

Remove the short secondary shaft. With the help of a second person, simultaneously remove the three remaining lines with the shaft and command forks to avoid damaging the bearings on the clutch housing side.

21-9

MANUAL GEARBOX Gearbox repair
REMOVING THE GEARS

21

IMPORTANT: the rings are press fitted on the

shafts; the pressure required to remove them is approximately 10 to 15 tonnes ; good quality equipment is needed (press - support).

Long secondary shaft After removing the clip (A),

15272R

(place a cloth at the bottom of the tool to prevent the shaft falling down when extraction is complete).

15271R

use the press to remove the set of rings, gears, and hubs, taking the weight on the reverse gear sprocket using tool B. Vi. 1510E

21-10

MANUAL GEARBOX Gearbox repair
Short secondary shaft After removing the clip (A),

21

15274R

(place a cloth at the bottom of the tool to prevent the shaft falling down when extraction is complete).
15273R

use the press to remove the set of rings, gears, and hubs, taking the weight on the third gear sprocket using tool B. Vi. 1510E

21-11

MANUAL GEARBOX Gearbox repair
CHECKING THE PARTS

21

Check that the gear teeth and drive dogs are not chipped and are not excessively worn. Also check that the surfaces of the shaft and the inner walls of the gears show no signs of seizing or abnormal wear.
SLIDING GEAR HUBS

Not the position of the sliding gears in relation to the hubs.
BEARINGS

The bearings must be replaced as soon as they show signs of scratching, overheating or excessive wear.

PRE2301

21-12

MANUAL GEARBOX Gearbox repair
REMOVING - REFITTING THE BEARINGS

21

Refit the bearings using tool B. Vi. 1419.

Long secondary shaft

15277R 15275S

Short secondary shaft

15278R

15276S

Extract the bearings on the press using the releasing tool.

21-13

MANUAL GEARBOX Gearbox repair
Primary shaft Extract the bearings on the press using the releasing tool. Refit the bearings using tool B. Vi. 1510G.

21

15280R

15279S

21-14

MANUAL GEARBOX Gearbox repair
REMOVING THE OUTER BEARING CAGES IN THE MECHANISM HOUSING

21

Remove the large differential bearing outer cage using tool B. Vi. 1508.

Position the housing on chassis B. Vi. 1417 and secure it with three bolts. Remove the bearing outer cage for the long secondary shaft (ASL), the short secondary shaft (ASC) and the primary shaft (AP) using a 42 mm diameter extractor and an impact hammer.

15290R

NOTE : retain the pre-load adjusting shims under

the cages.
IMPORTANT: take care not to confuse the three

adjusting shims.
12596R1

13501S

21-15

MANUAL GEARBOX Gearbox repair
REMOVING THE OUTER BEARING CAGES IN THE CLUTCH HOUSING

21

On the press, using tool B. Vi. 1510K, remove the differential bearing cage with its shield.

Remove the bearing outer cage for the long secondary shaft (ASL), the short secondary shaft (ASC) and the primary shaft (AP) using a 42 mm diameter extractor and an impact hammer.

15281R

15292S

21-16

MANUAL GEARBOX Gearbox repair
REFITTING THE GEARS IMPORTANT: the replacement of parts such as :

21

- single or double rings, - hubs, requires the settings to be modified by comparison as described below.
OPERATION: measure the height of the original part (to be replaced) and of the new part (replacement).

Where the difference between the two parts exceeds 0.025 mm, the adjusting shim must be changed, making it thinner or thicker depending on whether the replacement part is larger or smaller than the original part. The formula in the table below gives an example of the value for the new shim (x) depending on the values for the original part and the replacement part.
CHANGING LONG SECONDARY SHAFT RINGS OR HUBS

Part Single ring Hub (1/2) Double ring Hub (5/Reverse) Shim

Dimension specified (mm)

Original part A B C D X

New part a b c d x = X ± (A-a) ± (B-b) ±(C-c) ± (D-d)

34.5 (± 0.025) 19.3 (± 0.025) 66 (± 0.025) 17.3 (± 0.025)

CHANGING SHORT SECONDARY SHAFT RINGS OR HUBS
Dimension specified (mm)

Part Single ring Hub (3/4) Shim

Original part A B X

New part a b x = X ± (A-a) ± (B-b)

34.5 (± 0.025) 17.3 (± 0.025)

Example : replacing a single ring on the short secondary shaft
Dimension specified (mm)

Part Single ring Hub(1/2) Shim

Original part A 34.505 B 17.304 X 1.680

New part a 34.533 b 17.304 x = X ± (A-a) ± (B-b) x = 1.680 ±(- 0.028) ±(0)

34.5 (± 0.025) 17.3 (± 0.025)

Result: X = 1.680 - 0.028 = 1.652 Shim thickness available: 1.600 to 1.880 in steps of 0.020 In this example, a shim of thickness 1.660 must be selected.

21-17

MANUAL GEARBOX Gearbox repair
REFITTING THE GEARS

21

Long secondary shaft Refit the reverse gear sprocket with its needle roller bearing cage and its synchro ring. Using tool B. Vi. 1510F, refit the revere gear/5th gear sliding gear hub (line up the notches on the hub with those on the synchro ring).

15283R

Refit the 2nd gear sprocket with its needle roller bearing cage and its synchro ring. On the press refit the sliding gear hub for 2nd/1st gears (line up the notches on the hub with those on the synchro ring).

15282R

Refit the 5th gear sprocket with its needle roller bearing cage and its synchro ring. On the press refit the double ring (apply a pressure of approximately 5 tonnes at the end of fitting).

15284R

21-18

MANUAL GEARBOX Gearbox repair
Refit the 1st gear sprocket with its needle roller bearing cage and its synchro ring. On the press refit the single ring (apply a pressure of approximately 5 tonnes at the end of fitting). Short secondary shaft

21

Refit the 3rd gear sprocket with its needle roller bearing cage and its synchro ring. Using tool B. Vi. 1510F, refit the 3rd / 4th gear sliding gear hub (line up the notches on the hub with those on the synchro ring).

15285R

Refit the bearing using tool B. Vi. 1419.
15287R

15286R

Select and fit a new circlip which just fits into the groove (it should not be free once fitted).

21-19

MANUAL GEARBOX Gearbox repair
Refit the 4th gear sprocket with its needle roller bearing cage and its synchro ring. On the press refit the ring (apply a pressure of approximately 5 tonnes at the end of fitting). Refit the bearing using tool B. Vi. 1419.

21

15289R

15288R

Select and fit a new circlip which just fits into the groove (it should not be free once fitted).

21-20

MANUAL GEARBOX Gearbox repair
REFITTING THE OUTER BEARING CAGES IN THE MECHANISM HOUSING

21

Refit the differential bearing cage using tool B. Vi. 1510H.

Position the housing on its chassis then on the press plate. Fit the adjustable support B. Vi. 1418, under the mechanism housing. Fit the adjusting shims for each line. Fit the outer bearing cages for the shafts using tool B. Vi. 1419.

15291R

12604R1

21-21

MANUAL GEARBOX Gearbox repair
REFITTING THE OUTER BEARING CAGES IN THE CLUTCH HOUSING

21

Position the housing on the press plate. Fit the adjustable support B. Vi. 1418 under the clutch housing for each line. Fit the outer bearing cages using tools B. Vi. 1510J and 1510B.

15293R

NOTE : remember to fit a new shield under the

small diameter differential cage.

21-22

MANUAL GEARBOX Gearbox repair
DIFFERENTIAL REMOVAL

21

Remove the locking ring from the spider sunwheel and remove the shim. Remove the spider sunwheel. Hold the unit in a vice with soft jaws and remove the crown wheel. Remove the planet wheels and the sunwheel, attaching the pressure washers to their respective planet wheels.
CHECKING THE PARTS

Check the condition: - of the gear teeth (crown wheel - planet wheels - sunwheel), - of the washers (planet wheels - sunwheel), - of the unit.

PRE2302

21-23

MANUAL GEARBOX Gearbox repair
Remove the large bearing using an extractor.

21

15294S

Remove the small bearing using an extractor.

15295S

21-24

MANUAL GEARBOX Gearbox repair
REFITTING

21

Refit the large bearing using tool B. Vi. 1510I.

Refitting is the reverse of removal. After cleaning and checking all the parts, lubricate them in turn before refitting. Systematically renew the locking ring. Tighten the crown wheel bolts to 13 daN.m. Refit the small bearing using tool B. Vi. 1510A.

15302R

15296R

21-25

MANUAL GEARBOX Gearbox repair
INTERNAL CONTROLS

21

PRE2303

21-26

MANUAL GEARBOX Gearbox repair
COMMAND MODULE REMOVAL

21

Remove the selector finger (C) (see previous diagram) by removing the roll pin. Remove the shaft (D) (see previous diagram) from above. Remove: - the reverse gear switch, - the circlip (E) and the ring (F) from the command module shaft.

Remove the command finger (A) by removing the roll pin using tool B. Vi. 1267.

15297R

Remove the sealing ring (B) using tool B. Vi. 28-01.

15299R

Push the module to release it and remove it upwards.

15298R

15300S

21-27

MANUAL GEARBOX Gearbox repair
REFITTING

21

Refitting of the module is the reverse of removal. Systematically renew the sealing ring using tool B. Vi. 1510C and the O rings on the shaft (D).

15301R

21-28

MANUAL GEARBOX Gearbox repair
REFITTING THE SHAFTS

21

The three shafts should be refitted with the help of a second person. Assemble the components on the bench before fitting them into the clutch housing. Refit: - the short secondary shaft into the clutch housing - the shaft and the fork. Fit the roll pins to the 3/4 fork using hollow tool B. Vi. 31-01. Apply a counter pressure to the shaft to avoid damaging the ring in the clutch housing.

Position tool B. Vi. 1443 at the bottom of the thread to immobilise the pulling cylinder in relation to the shaft. Fit the shaft, holding the body of the tool using a wrench.

13502R2

12597R

Refit the 3/4 inverter. Tighten the bolts to a torque of 2.3 daN.m. Fit: - the friction washer for the reverse gear pinion in the clutch housing, - the reverse gear pinion with its needle roller bearing cage. Position the reverse gear shaft. The flat should be perpendicular to a line through the centre of the primary shaft and the centre of the reverse gear shaft.

21-29

MANUAL GEARBOX Gearbox repair
CLOSING THE GEARBOX

21

Put the three forks and the command module in the neutral position. Align the selector fingers (1) with the prevention fingers (2).

Fit the magnet (C).
IMPORTANT: the seal should only be renewed if it

is deformed or cut. Check the centring dowels (D) are present.

12595-1R4

Fit the seal on the clutch housing. It is fitted dry.
NOTE : for gearboxes with no seal (new genera-

tion), apply a bead of silicon sealant coat the sealing face between the clutch and gearbox mechanism housings. Important: new generation housings are not compatible with old generation housings. Lubricate the ends of the shafts and the gearbox shafts to make fitting easier.
IMPORTANT: do not allow oil to get on the hou-

DI2166

sing seal.

21-30

MANUAL GEARBOX Gearbox repair
Position the retaining forks of tool B. Vi. 1416 under the 1/2/5/reverse and 3/4 shafts to prevent them from leaving the neutral position.

21

Offer up the housing while tilting the module as far as possible towards the outside using the gear engaging lever without taking it out of the neutral position (only a slight force required). Fit the housing on the stud. Keep the housing horizontal during assembly, aligning the second centring dowel with the corresponding hole in the mechanism housing. Move the gear engaging lever to engage the module fingers in the forks. Push the housing against the fork retaining tools. Remove the forks B. Vi. 1416. Complete the refitting of the housing.
CHECK: the selector lever (A) should move to

three positions.

12594R1

Fit a stud (A) (100 mm) into the hole with a dowel on the differential side to guide the mechanism housing. Lubricate the command module in the mechanism housing (bearings, gear change finger, etc.).

DI2167

Do not move the gear change lever (B).

12609R

21-31

MANUAL GEARBOX Gearbox repair
Fit the module guide finger (A) with its seal. Gently move the gear change lever to make refitting easier. Tighten the bolt to a torque of 0.9 daN.m.

21

12603R

Pretighten bolts (2) and (15) to 1 daN.m.

12707R

Remove the stud. Fit the bolts at the edge of the gearbox and hand tighten them. Tilt the gearbox a half turn. Fit the washer and a new nut to the reverse gear shaft. Tighten it to a torque of 13 daN.m. Turn the primary shaft through all six gears. Make a tool to do this from a clutch friction hub. Ensure that dimensions (C) and (D) allow the tool to fit through the centre of support B. Vi. 1417.

12602R

Turn the primary shaft through all six gears again. Torque tighten the bolts to 2.4 daN.m in the order shown above. Fit a new primary shaft seal using tool B. Vi. 1236.
IMPORTANT: in certain cases, the clutch fork roll pin must be removed. Refer to the corresponding section for this.

Refit a new differential output seal using tool B. Vi. 1235.

21-32

MANUAL GEARBOX Gearbox repair
CLUTCH SHAFT LIP SEAL REPLACEMENT

21

After removing the roll pins, tilt the fork and remove the guide tube.

This operation is carried out after removing the gearbox.
REMOVING THE ROLL PINS

Position: - tool B. Vi. 1412 to the clutch fork, tightening head (A) and progressively tighten the pushrod of the tool opposite the roll pin, - handle (C) and tighten wheel (B) to hold the tool during the extraction operation. Tighten head (A) until the roll pin is released.

12359R

REMOVAL

Using a 2.5 mm diameter drill, drill a hole in the seal.

IMPORTANT: TAKE CARE NOT TO SCRATCH THE SHAFT OR THE SEALING FACE

12358R

21-33

MANUAL GEARBOX Gearbox repair
Fit a bolt and remove the seal using pliers. Remove the protector. Refit: - the guide tube, - new roll pins.

21

Position the fork holes opposite those on the command shaft. Fit a roll pin, tapping it in gently using a mallet. Fit: - tool B. Vi. 1412 to the clutch fork, tightening head (A) and progressively tighten the pushrod of the tool opposite the roll pin, - handle (C) and tighten wheel (B) to hold the tool during the extraction operation. Tighten head (A) and progressively fit the roll pin.
NOTE : press the roll pin in until it is flush with the

fork.
95415-3S

Repeat the operation for the second roll pin.

REFITTING

Fit a new seal with its protector using tool B. Vi. 1236.

12358R 95415-4S

21-34

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