GEARBOX

CONTENTS PAGE

GEARBOX MAINTENANCE D3

GENERAL : 8209 D4

LUBRICATION CIRCUIT D6

RANGE CHANGE UNIT D7

LONGITUDINAL SECTION D8

GENERAL : 9 S 109 D9

LUBRICATION CIRCUIT D11

RANGE CHANGE UNIT D12

LONGITUDINAL SECTION D13

AIR CIRCUIT AND CONTACTORS D14

GENERAL : 16 S 151 D15

MAINTENANCE D17

RANGE CHANGE UNIT D19

LONGITUDINAL SECTION D20

MAIN SHAFT D21

FRONT SPLITTER D22

AIR CIRCUIT AND CONTACTORS D23

CONTROL D24

SERVICES CIRCUIT D25

TRANSFER BOX V6 1600-2000 D27

MAINTENANCE D28

VERSION WITH LONGITUDINAL DIFFERENTIAL D29

RENAULT V.I. D1 502 CEPTEC

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RENAULT V.I. D2 502 CEPTEC
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 MAINTENANCE LUBRICATION

You should comply with

these recommendations !

INTERNATIONAL STANDARDS
Select lubricants according to operating temperature.

Operating
Oil Mil.l API
temperature

SAE 30 2104 E CE / SF -20°C to +30°C

SAE 40 2104 E CE / SF -10°C to +40°C

SAE 80 W 90 2105 GL4 -10°C to +30°C

RENAULT V.I. recommends Huiles Renault Diesel

Select lubricants according to operating temperature.

Oil Operating temperature

MV 4 R 25 W 40 -10°C to +40°C

EP 80 W 90 -25°C to +30°C

SUPER EPX 80 W 90 -25°C to +50°C

NOTE
For very heavy duty applications, use an oil corresponding to RENAULT V.I. standard 03-
80-4003 (SUPER EPX 80 W 90).

MAINTENANCE
- First oil change at Technical Inspection (10 000 km or 6 months)
- Oil change : between 60 000 and 90 000 kms*
- Clean breather at each oil change

* 16 S 151 gearbox + NMV 221 = oil change between 40 000 and 50 000 kms

RENAULT V.I. D3 502 CEPTEC

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 GENERAL
8209

What are the specifications

of this gearbox ?

8 2 09

9 forward speeds
4 + 4 synchromesh + 1 crawler and reverse

Technical evolution reference

Admissible torque = 800 Lb / Ft

(1100 Nm)

Version A

R / AR C/L 1 2 3 4 5 6 7 8

13.21 12.64 8.81 6.55 4.77 3.55 2.48 1.85 1.34 1

Weight = 165 kg

RENAULT V.I. D4 502 CEPTEC

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 GENERAL
8209
IDENTIFICATION

Here is an example of
the identification plate

y 08023 100 Specification

FS 8209 A Model
E 635001 Serial number
9401 Date of manufacture
5010243068 Customer

Specification : EATON references defining the overall

gearbox specifications.

Model : FS: "FULL SYNCHROMESH"

8209 : Gearbox designation
A: Version (reduction ratios)

Serial number : Letter identifying factory of manufacture

Examples : E : AYCLIFF (Great Britain)
M : MANCHESTER
N : ST NAZAIRE

Customer : RENAULT V.I. reference

RENAULT V.I. D5 502 CEPTEC

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 RENAULT V.I.

SCHEMATIC
To engine cooling circuit
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Sealing plug

LUBRICATION CIRCUIT
for deviation
D6
REFER TO WORKSHOP MANUAL

ATTENTION !
Filter Artics and 4x4 units
Pressure control valve are fitted with heat
exchangers.
The oil pump is driven by the countershaft

Version without exchanger : a duct connects the pump outlet to the main shaft circuit
Version with exchanger : a sealing plug and 2 drillings divert oil from the pump to the
exchanger
NOTE : if the exchanger is deleted without a bypass being fitted, oil will no longer flow to
502

8209
the main shaft
CEPTEC

Oil capacity : 8.5 litres (Power take-off : 1 litre).

 RANGE CHANGE UNIT
8209

REDUCTION RATIO : 3.55 / 1

1 : Ring gear integral with synchronizer sliding gear

ring

2 : Sun gear integral with gearbox output shaft

3 : Planet gears

4 : Planet carrier integral with range change output

shaft

Oil the synchronizer assembly

when fitting

Synchronizer - ring gear assembly in detail

RENAULT V.I. D7 502 CEPTEC

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 RENAULT V.I.

Attention : smear all

threadings with
LT 648

+ LT 270 55
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LONGITUDINAL SECTION
37 650
D8
REFER TO WORKSHOP MANUAL

73

74

Magnet to hold filings,

stuck on with scotch
Preload for new bearings: 0.07 to 0.12 mm 44 grip 1300
Preload for used bearings : 0,05 mm Oil filter (cleaned with acetone
plug before sticking)
502

8209
CEPTEC

LT 518 on
joint faces
 GENERAL
9 S 109

9 S 109

Input torque *
1100 Nm

Synchronmesh

9 forward speeds
4 + 4 synchromesh + 1 crawler and reverse

Version with overdrive

R/AR C/L 1 2 3 4 5 6 7 8

9.44 10.24 6.57 4.78 3.53 2.61 1.86 1.35 1 0.74

* : version homologated by ZF at 1220 Nm

RENAULT V.I. D9 502 CEPTEC

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 GENERAL
9 S 109

IDENTIFICATION

Here is an example of
the identification plate

1 2

3 4

6 7

10 11

8 9

1 - Medium range model

2 - Type
3 - Parts list N°
4 - Serial N°
5 - Renault V.I. identification
6 - Lowest and highest gear ratios
7 - Tachometer specification (6 pulses per turn)
8 - Oil capacity
9 - Number of ZF lubricant table
10 - Type of power take-off
11 - Power take-off ratio

Note : The serial number is also stamped on the housing.

RENAULT V.I. D10 502 CEPTEC

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 LUBRICATION CIRCUIT
9 S 109

The oil pump is driven

by the countershaft

Drain :
- Via plugs 2 and 3

Top up :
- Via plug 1

Oil capacity :
9 S 109 : 8 litres

Power take-off : 1 litre

RENAULT V.I. D11 502 CEPTEC

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 RANGE CHANGE UNIT
9 S 109
REDUCTION RATIO : 3.53 / 1

Oil the synchronizer

assembly when fitting

Ring assembly
integral with synchro hub

Direct drive side

Reduction side

RENAULT V.I. D12 502 CEPTEC

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 180

25

RENAULT V.I.
60
Bearing preload
main shaft and
layshaft
0.18 to 0.30 mm.

180

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LT 241

D13
25

160 M18 x 1.5

Circlips end
clearance 49 LT 241
= 0 to 0.1 mm.
TRANSVERSAL SECTION

Tightening

REFER TO WORKSHOP MANUAL

torques are given
in Nm

502
9 S 109

CEPTEC
 AIR CIRCUIT AND
CONTACT SWITCHES
9 S 109

Now for a look at

the air circuit !

5
1

4
*

2
1 - Range change control valve

2 - Range change control cylinder

3 - Reverse information contact switch

4 - Range change position information contact switch

(not used by RENAULT V.I.)

5 - Neutral contact switch

* Air pressure supply to ancillary services

Depending on assembly, the supply connection can be
placed on the opposite side on the range change control
valve

RENAULT V.I. D14 502 CEPTEC

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 GENERAL
16 S 151

16 S 151 Type of housing

(aluminium)

Input torque
1700 Nm*

Synchromesh

16 gears (8x2)

* : version homologated
by ZF at 1750 Nm

OLD RATIOS

R/AR 1 2 3 4 5 6 7 8

L/PV 13.12 13.74 9.55 6.78 4.57 3.01 2.09 1.49 1

H/GV 10.98 11.51 7.99 5.68 3.82 2.52 1.75 1.24 0.84

NEW RATIOS

R/AR 1 2 3 4 5 6 7 8

L/PV 12.92 13.8 9.49 6.53 4.57 3.02 2.08 1.43 1

H/GV 10.8 11.54 7.93 5.46 3.82 2.53 1.74 1.20 0.84

RENAULT V.I. D15 502 CEPTEC

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 GENERAL
16 S 151
IDENTIFICATION

Here is an example of
the identification plate

1 2

3 4

6 7

8 9

10 11

1 - Heavy range high tonnage model

2 - Type
3 - Parts list N°
4 - Serial N°
5 - Renault V.I. identification
6 - Lowest and highest gear ratios
7 - Tachometer specification (6 pulses per turn)
8 - Type of power take-off
9 - Power take-off ratio
10 - Oil capacity
11 - Number of ZF lubricant table

Note : The serial number is also stamped on the housing.

RENAULT V.I. D16 502 CEPTEC

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 MAINTENANCE
16 S 151

TO DRAIN
- Via plugs 1

TO FILL - TOP UP
- Fill with oil via orifice 2 .
- With vehicle static, let
the engine run for 5 mn.
- Stop and leave to rest for
5 mn.
- Top up via orifice 2

OIL CAPACITY:
Oil change : 8 litres (approx.)
Housing dry : 11 litres (approx.)
Power take-off : 1 litre (approx.)

The oil pump is driven

by the countershaft

Drawbar units are fitted with heat exchangers

RENAULT V.I. D17 502 CEPTEC

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 MAINTENANCE
VERSION WITH PTO NMV 221
16 S 151

MAINTENANCE
- First oil change : at Technical Inspection
(10 000 km or 6 months)
- Change every 40/45000 km
- Clean breather 10 at each change

TO DRAIN
- Via plugs 1 .

TO CHANGE OIL FILTER (at each oil change)

- Remove cover 6 .
- Change filter 8 .
- Oil O rings 7 and 9 .
- Tighten the cover screw 5 : 25 Nm.

TO FILL - TOP UP
- Fill with oil via orifice 2 .
- Pour in 2 litres via orifice 3 .
- With vehicle static, let the engine run for 5 mn.
- Stop and leave to rest for 5 mn.
- Top up via orifice 2 .

OIL CAPACITY:
Oil change : 11 litres (approx.)
Housing dry : 13 litres (approx.)
10 breather

RENAULT V.I. D18 502 CEPTEC

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 RANGE CHANGE UNIT
16 S 151

Epicyclic gears with helicoidal toothing.

Reduction ratio : 4.58/1

The end of the

output shaft is the
sun gear

Reduction side
Direct drive side

250 150

LT 241

RENAULT V.I. D19 502 CEPTEC

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 RENAULT V.I.

46
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LONGITUDINAL SECTION
LT 262
D20
REFER TO WORKSHOP MANUAL

End clearance of main shaft

and layshaft bearings
0.0 to 0.1 mm

49
49

16 S 151
502

*120
60 Nm: version epicyclic gear train with spur toothing
CEPTEC

Nm: version with epicyclic gear train with helicoidal toothing (standard equipment on KERAX)
 LAYSHAFT
16 S 151

SYNCHRO CLEARANCE ADJUSTMENT

Version with epicyclic gear train with helicoidal toothing

- Select thickness of shim 1 to obtain a dimension between +0.07 and -0.08 mm in relation to the
shoulder of the shaft.

- Select thickness of shim 2 to obtain 4.6 - 0.4 mm.

RENAULT V.I. D21 502 CEPTEC

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 FRONT SPLITTER
16 S 151

FORK ADJUSTMENT

Put splitter control cylinder in place and hold

in position with tool N° 2399.

Engage sliding gear 4 on Low Range side

(downwards).

Adjust position of fork 3 by manoeuvring

the screws 2 so that the pads are centred
in the sliding gear.

Version with NMV :

there is no bearing 1
so the shaft has to be
kept centred.

RENAULT V.I. D22 502 CEPTEC

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 AIR CIRCUIT AND
CONTACT SWITCHES
16 S 151

Now for a look

at the air circuit !

Feed via splitter

control valve on
the clutch slave
cylinder

1 - Range change control valve

2 - Range change control cylinder
3 - Reverse information contact switch
4 - Range change position information contact switch, location varies depending
on version (not used by RENAULT V.I.)
5 - Neutral information contact switch
6 - Splitter position information contact switch
7- Splitter control pneumatic distributor
8- 4th gear contact switch (not used by RENAULT V.I.)

* Air pressure supply to services

Depending on assembly, the supply connection can be
placed on the opposite side on the range change control valve.
RENAULT V.I. D23 502 CEPTEC
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 CONTROL
16 S 151

Cab
stabilised

Longitudinal adjustment :
190 mm by ball joint 1
Measured with operator on
step (cab empty)

Dashboard

LH door
handle

If necessary, reverse
the position of the ball joint
in the link rod 2
see inset for correct
assembly Transversal
adjustment :
Neutral 3-4 647 mm by link
position
rod 2

Lever position 3 :
- inclination 9°
Up to CAM 27 HV

- inclination 0°
after CAM 27 HV

RENAULT V.I. D24 502 CEPTEC

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 SERVICES CIRCUIT

RENAULT V.I. D25 502 CEPTEC

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RENAULT V.I. D26 502 CEPTEC
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 TRANSFER BOX

GENERAL

This is the
identification

V : DISTRIBUTOR (Verteiler)

G : GEARBOX (Getriebe)

1600 : Torque at input 18 000 Nm

2000 : Torque at input 25 000 Nm

REDUCTION

High range (road work) : 0.89

Low range (off road) : 1.536

RENAULT V.I. D27 502 CEPTEC

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 MAINTENANCE

INTERNATIONAL STANDARDS

Follow the Operating

Oil MIL.L API
recommendations ! temperature

SAE 80 W 90 2105 D GL 5 - 25°C to + 40° C

RENAULT V.I. Recommends Huiles Renault Diesel

Oil Operating temperature

HD 80 W 90 - 25° C to + 40° C

MAINTENANCE
First oil change : at Technical Inspection
(10 000 km or 6 months)
Change : every 60000 km

Drain via plugs 1 and 3

Fill with oil via orifice 4 until oil flows at orifice 2
Check and top up via orifice 2
5 breather

OIL CAPACITY

Transfer box ........................................................................... VG 1600

7121.752 ........................................................................................ 6.5 l
7121.784 ........................................................................................ 7.1 l

Transfer box ........................................................................... VG 2000

7121.754 ........................................................................................ 7.1 l
7121.792 ........................................................................................ 6.5 l
7121.803 ........................................................................................... 9 l
7121.831 ........................................................................................ 8.4 l

All versions are fitted with heat exchangers

RENAULT V.I. D28 502 CEPTEC

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 VERSION WITH LONGITUDINAL
DIFFERENTIAL
VG 1600
ADJUSTMENTS AND TIGHTENING TORQUES
VG 2000

Shaft
adjustment

Adjustment shim :
clearance 0.06 to 0.12

1080

LT 242
Adjustment shim clea-
rance : 0.4 to 0.6

1080

LT 242

Adjustment shims :
Adjustment shim : preload 0 to 0.05
clearance 0.02 to 0.08

30 90° 195

RENAULT V.I. D29 502 CEPTEC

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RENAULT V.I. D30 502 CEPTEC
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