Transmission: Manual Gearbox

Transmission
21A MANUAL GEARBOX
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Fault finding - Customer complaints 21A - 1
Fault finding - Fault Finding Chart 21A - 2
Fault finding - Tests 21A - 8
SEPTEMBER 2005 EDITION ANGLAISE

"The repair procedures given by the manufacturer in this document are based on the All rights reserved by Renault s.a.s.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of
in the production of the various component units and accessories from which his Renault s.a.s.
vehicles are constructed."
© Renault s.a.s. 2005

121A
MANUAL GEARBOX
Fault finding - Customer complaints 21A
Consult Customer complaints only after carrying out a complete fault finding
NOTES
procedure using the diagnostic tool and carry out a conformity check.
CREAKING WHEN CHANGING GEAR ALP1
CREAKING WHEN CHANGING ANY GEAR ALP2
GEAR JAMMED ALP3
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GEARS CANNOT BE SELECTED ALP4
GEARS JUMPING ALP5
UNUSUAL NOISES WHEN DRIVING ALP6
21A-1
MANUAL GEARBOX
Fault finding - Fault Finding Chart 21A
ALP1 Creaking when changing gear
Consult the fault finding charts only after carrying out a complete fault finding
NOTES
Check the gearbox oil grade and level. OK Remove the gearbox:
– check the synchronisation of the
ratio in question (see Test 1),
NO
– check the sliding gear hub in
question (see Test 2),
– repair.
Check the oil level.
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Check that there are no oil leaks.
If there is a leak, locate the source of the leak and carry

out the necessary repairs.
21A-2
MANUAL GEARBOX
ALP2 Creaking when selecting any gear
NOTES
Check the clutch (see 20A, Fault finding - fault finding chart).
– check the synchronisation of the
ratio in question (see Test 1),
NO – check the sliding gear hub in
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question (see Test 2),
– repair.

21A-3
MANUAL GEARBOX
ALP3 Gear jammed
NOTES
Check the clutch.
Check the condition and adjustment of the gear selector as well as the area around it.
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Check the condition of the gearbox mountings.
Remove the gearbox:

– check the internal control,
– check the sliding gear hub (see Test 2),
– check the sprockets (see Test 3),
– repair.
21A-4
MANUAL GEARBOX
ALP4 Gears cannot be selected
NOTES
Check the clutch (see 20A, Fault finding - fault finding chart).
Check the condition and adjustment of the gear selector.
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– check the sliding gear hub in
NO question (see Test 1),
– repair.

21A-5
MANUAL GEARBOX
ALP5 Gears jumping
NOTES
Check the condition of the gearbox and engine mountings.
Check the condition and adjustment of the gear selector as well as the area around it.
Remove the gearbox:

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– check the sliding gear hubs (see Test 2),
– check the synchronisation (see Test 1),
– repair.
21A-6
MANUAL GEARBOX
ALP6 Unusual noises when driving
NOTES
Noise when stationary NO
YES
Declutch NO Check:
– the flywheel,
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– the clutch,
Does the noise stop? – the thrust bearing.
YES
– check the bearings
(see Test 14),
NO
– repair.

– check the bearings (see Test 4),
NO
– repair.

21A-7
MANUAL GEARBOX
Fault finding - Tests 21A
NOTES Only consult the tests after following the fault finding chart procedure.
CHECKING THE SYNCHRONISATION TEST 1
CHECKING THE SLIDING GEAR HUBS TEST 2
CHECKING THE SPROCKETS TEST 3
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CHECKING THE BEARINGS TEST 4
21A-8
MANUAL GEARBOX
TEST 1 Synchronisation inspection
Synchro ring:
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Check that the teeth of dog clutches (6) are not worn or broken.
To check the efficiency of the synchro ring, push the ring onto the friction cone and rotate the cone in the direction
of (7); the ring must not turn.
Otherwise, replace the synchroniser ring.
21A-9
MANUAL GEARBOX
TEST 2 Sliding gear hubs inspection
Sliding gear hub:
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Make sure the sliding gear turns smoothly on the hub.
Check that the pulleys and keys are in good condition (5).
21A-10
MANUAL GEARBOX
TEST 3 Sprocket inspection
Sprockets:
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The inspection focuses mainly on the appearance of the teeth, especially the dog clutches and chamfers.
Check that:
– the teeth are not broken or chipped (1),
– the dog clutches are not broken, chipped or worn (2),
– the friction cone is not scratched or is showing signs of bluing (3),
– the inside wall does not show signs of sticking or wear (4).
21A-11
MANUAL GEARBOX
TEST 4 Bearing inspection
Bearing:
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Check that the bearings rotate properly (8).
If they rotate unevenly or noisily, they must be replaced.
21A-12

Transmission: Manual Gearbox

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21A MANUAL GEARBOX

SEPTEMBER 2005 EDITION ANGLAISE

© Renault s.a.s. 2005

CREAKING WHEN CHANGING GEAR ALP1

CREAKING WHEN CHANGING ANY GEAR ALP2

GEAR JAMMED ALP3

GEARS JUMPING ALP5

UNUSUAL NOISES WHEN DRIVING ALP6

If there is a leak, locate the source of the leak and carry

Check that there are no oil leaks.

If there is a leak, locate the source of the leak and carry

Check the clutch.

Remove the gearbox:

Check the condition and adjustment of the gear selector.

Check the oil level.

Check that there are no oil leaks.

If there is a leak, locate the source of the leak and carry

Check the condition of the gearbox and engine mountings.

Remove the gearbox:

Noise when stationary NO

Check that there are no oil leaks.

If there is a leak, locate the source of the leak and carry

Check the oil level.

Check that there are no oil leaks.

If there is a leak, locate the source of the leak and carry

CHECKING THE SYNCHRONISATION TEST 1

CHECKING THE SLIDING GEAR HUBS TEST 2

CHECKING THE SPROCKETS TEST 3

Otherwise, replace the synchroniser ring.

Sliding gear hub:

If they rotate unevenly or noisily, they must be replaced.

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