Manual service Renault Scenic 2 Trans Misie

© Renault 2004

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 322 042 JUNE 2003 Edition Anglaise

X84, and J84

2 Transmission

20A CLUTCH

21A MANUAL GEARBOX

23A AUTOMATIC GEARBOX

29A DRIVESHAFTS

Scénic II - Section 2

Contents

Scénic II - Section 2ContentsPage

20A CLUTCH

Identification 20A-1

Mechanism / Plate 20A-3

Clutch thrust bearing 20A-7

Flywheel 20A-9

21A MANUAL GEARBOX

Gears 21A-1

Lubricants 21A-2

Consumables 21A-4

Parts to be replaced systematically 21A-5

Manual gearbox: Removal - Refitting 21A-6

Differential output seal 21A-22


Gears 23A-1

Lubricants 23A-2

Consumables 23A-3

Parts to be replaced systematically 23A-4

Changing the oil 23A-5

Filling - Levels 23A-7

Checking the converter setting point 23A-10

Line pressure measurement 23A-11

Hydraulic distributor 23A-12

Automatic gearbox: Removal - Refitting 23A-17

Drive plate 23A-26

Differential output gasket 23A-28

Converter seal 23A-30

Multifunction switch 23A-31

Computer 23A-33

Speed sensor 23A-35

Flow regulation solenoid valve 23A-36

Solenoid valves: Removal 23A-38

Gearbox connector 23A-39

29A DRIVESHAFTS

Identification 29A-1

Consumables 29A-2

Front left-hand driveshaft 29A-3

Front right-hand driveshaft 29A-4


20A-1

CLUTCHIdentification 20A

Mechanism

Plate

Plate external diameter: 200 mm

Plate thickness: 6.9 mm

Number of splines: 26

Colour of springs (1) and (2): Grey

Mechanism

Plate




K4J or K4M

102143

102142

2

1

K9K

102143

102142

3

4

20A-2

CLUTCHIdentification 20A

Colour of springs (3): Red and Black

Colour of springs (4): Grey

Mechanism

Plate




F4R or F9Q

22428

22429

20A-3

CLUTCHMechanism / Plate

F4R or F9Q

20A

REMOVALRemove the gearbox (Section Manual gearbox, Ma-nual gearbox: Removal - Refitting, page 21A-6).

Lock the engine using tool (Mot. 1677)(1) .

Remove the mechanism mounting bolts.

Remove the friction plate.

Replace any faulty parts.

REFITTING

EMB. 1604

Secure the base of tool (Emb. 1604) in a vice.

Special tooling required

Mot. 1677 Flywheel locking tool(F engines)

Emb. 1604 Clutch compressiontool for rearming theadjustment system

Emb. 1518 Set of clutch plate cen-tring mandrels

Tightening torquesm

mechanism mountingbolts

1.2 daNm

16180

1

19919

Note:

For mechanisms with automatic take-up, com-press the clutch mechanism using tool (Emb.1604).

20754

20A-4


F4R or F9Q

20A

Mount the mechanism on the base, then fit the thrustball bearing (1) and the nut (2).

Tighten the nut (2) fully.

Insert the circlip pliers at (3).

Compress the springs (4).

Loosen the nut (2) completely (springs compressed).

Release the mechanism.

20755

20756

1

2

20757

20759

3

4

20A-5


F4R or F9Q

20A

Remove the mechanism from the base (checkingthat the springs are properly compressed).

Mount the plate (small hub diameter (5) on flywheelside).

CENTRING

Centre the clutch plate using tool (Emb. 1518).

Refit the mechanism on the flywheel.

Gradually torque tighten the mechanism mountingbolts (1.2 daNm).

20758

WARNING

Clean the clutch shaft splines and refit theassembly without lubricant.

Degrease the friction face of the flywheel.

102695

5

22695

20A-6


K4J or K4M or K9K, and 722 or 728

20A

REMOVALRemove the gearbox (Section Manual gearbox, Ma-nual gearbox: Removal - Refitting, page 21A-6).

Lock the engine using tool (Mot. 582-01)(1).

Remove the mechanism mounting bolts.

Remove the friction plate.

Replace any faulty parts.

REFITTING

Clean the clutch shaft splines.

Refit the assembly without lubricant.

Mount the clutch plate.

Centre the clutch plate using tool (Emb. 1518).

Screw into place gradually in a radial pattern.

Torque tighten the mechanism mounting bolts (2daNm).

Remove tool (Mot. 582-01).


Mot. 582-01 Flywheel locking tool(K engines)

Emb. 1518 Set of clutch plate cen-tring mandrels

Tightening torquesm

mechanism mountingbolts

2 daNm

16180

1

95414

20A-7

CLUTCHClutch thrust bearing 20A

REMOVAL

Remove:

- the gearbox (Section Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-6),

- the two hydraulic union bolts (1),

- the hydraulic union,

- the two clutch thrust bearing - clutch housing moun-ting bolts (2) ,

- the clutch thrust bearing.

Remove:


- the hydraulic union clip (1),

- the hydraulic union,

- the two clutch thrust bearing - clutch housing moun-ting bolts (2),

- the clutch thrust bearing.

REFITTING

Proceed in the reverse order to removal.

Torque tighten:

- the hydraulic union mounting bolts (0.9 daNm),

- the clutch thrust bearing - clutch housingmounting bolts (2.1 daNm).

Tightening torquesm

hydraulic union moun-ting bolts

0.9 daNm

clutch thrust bearing -clutch housing moun-ting bolts

2.1 daNm

JH3 or JR5

18439

1

2

ND0

101223

JH3 or JR5

1

2

20A-8

CLUTCHClutch thrust bearing 20A

Torque tighten the clutch thrust bearing - clutchhousing mounting bolts (2.1 daNm).

Bleed the clutch control ( Mechanical element con-trolsSection).

ND0

WARNING

To avoid damaging the clutch slave cylinder, donot lubricate the clutch shaft.

Never operate the system while the slave cylinderis removed.

Note:

Always replace the hydraulic union.

20A-9

CLUTCHFlywheel 20A

REMOVAL

Remove:


- the clutch mechanism (Section Clutch, Mechanism/ Plate, page 20A-3).

Lock the engine using tool (Mot. 582-01)(8).

Remove:

- the flywheel mounting bolts,

- the flywheel,

- the tool (Mot. 582-01).(8)

Lock the engine using tool (Mot. 1677)(9).

Remove:

- the engine flywheel mounting bolts,

- the flywheel,

- the tool (Mot. 1677)(9).

REFITTINGClean the threads for the flywheel mounting bolts onthe crankshaft.

Degrease the bearing face of the flywheel on thecrankshaft.

Check the condition of the flywheel.




Tightening torquesm

flywheel mounting bolts 6.5 daNm

K4J or K4M or K9K

22698

8

F4R or F9Q

22698

Note:

The engine flywheel is of the double damperflywheel type.

9

20A-10

CLUTCHFlywheel 20A

Refit the spacer (11) observing the direction of fittingof the chamfer on the flywheel side.

Always replace the mounting bolts with new ones.

Coat the new bolts of the flywheel with LOCTITEFRENETANCH.

Tighten in the correct order and to the correct torquevalue the flywheel mounting bolts (6.5 daNm).

K9K

23325

101356

WARNING

Do not remove the flywheel drive plate mountingbolts (10).

1010101010

11

23326

7

6

5

4

2

3

1

21A-1

MANUAL GEARBOXGears 21A

JH3

Suffix 105 106 137 142 143 144

Differentialratio

14/59 14/63 14/59 15/61 15/61 15/61

First 11/41 11/41 11/41 11/41 11/41 11/41

Second 21/43 21/43 21/43 21/43 21/43 21/43

Third 28/39 28/39 28/39 28/39 28/39 28/39

Fourth 31/34 34/35 31/34 31/34 31/34 31/34

Fifth 37/33 39/32 37/33 37/33 37/33 37/33

Reverse 11/39 11/39 11/39 11/39 11/39 11/39

JR5

Suffix 103 104 110 125

Differential ratio 15/58 15/61 15/58 14/63

First 11/41 11/41 11/41 11/41

Second 21/43 21/43 21/43 21/43

Third 28/37 28/39 28/37 26/37

Fourth 35/34 31/34 35/34 35/34

Fifth 41/31 37/33 41/31 39/32

Reverse 11/39 11/39 11/39 11/39

ND0

Suffix 002 013 015

Differential ratio 15/58 14/57 16/70

First 12/41 14/49 14/49

Second 19/35 18/35 18/35

Third 31/39 28/39 28/39

Fourth 38/36 36/38 36/38

Fifth 45/33 42/34 52/45

Sixth 48/29 49/33 56/41

Reverse 12/38 14/46 14/46

21A-2

MANUAL GEARBOXLubricants

JH3 or JR5 or ND0, and LONG CHASSIS or STANDARD CHASSIS

21ACapacity (in litres)

I - QUALITY, VISCOSITY

TRANSELF TRJ 75 W80 to be ordered from ELF.

TRANSELF TRT 75 W80 to be ordered from ELF.

TRANSELF TRJ 75 W80 to be ordered from ELF.

II - LEVEL CHECK IN THE EVENT OF LEAKAGE

Fill up to the level of the aperture.

JR5 2.5

JH3 2.8

ND0 2.1

STANDARD CHASSIS

JH3 or JR5, and LONG CHASSIS

ND0, and LONG CHASSIS

92081

JH3 or JR5

18749

(1) Drain plug

(2) Filler plug

2176

2

1

5

21A-3

MANUAL GEARBOXLubricants

JH3 or JR5 or ND0, and LONG CHASSIS or STANDARD CHASSIS

21A

ND0

101532

(3) Drain plug

(4) Filler plug

101221

5

5

WARNING

Removing the breather valve (5) to fill the gearboxwith oil is prohibited.

21A-4

MANUAL GEARBOXConsumables 21A

JH3 or JR5 or ND0

Type Packaging Part no. Component

MOLYKOTE BR2 1 kg can 77 01 421 145 Splines

LOCTITE 518 24 ml syringe 77 01 421 162 JH/JR housing assembly faces

LOCTITE 5970 300 ml syringe 77 11 219 705 NDO housing assembly faces

RHODORSEAL 5661 100 g tube 77 01 404 452 Threaded plugs and switches

21A-5

MANUAL GEARBOXParts to be replaced systematically 21A

Replace the following parts after removal:

- the lip seals,

- the O-rings.

21A-6

MANUAL GEARBOXManual gearbox: Removal - Refitting

K4J, and 730 – K4M, and 782 – K9K, and 722 or 728

21AREMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negative ter-minal.

Remove the cowl grille ( Wiping / WashingSection).

Remove:

- the two air filter access panel mounting bolts (1),

- the air filter access panel,

- the plenum chamber partition mounting bolt (2).

Remove:

- the plenum chamber partition mounting bolts (3),

- the plenum chamber partition,

- the plenum chamber,

- the engine undertray.

Drain the gearbox.

Remove:

- the front wheels,

- the engine covers,


Rou. 604-01 Hub locking tool

Tav. 476 Ball joint extractor

Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps

Equipment required

jack

Tightening torquesm

wheel bolts 13 daNm

driveshaft nut 28 daNm

lower ball joint nut 6.2 daNm

track rod end nut 3.7 daNm

anti-roll bar ball joint nut 4.4 daNm

side panel mountingbolts

2.1 daNm

gearbox edge and star-ter bolts

4.4 daNm

engine tie-bar bolts onthe engine

10.5 daNm

engine tie-bar bolts onthe sub-frame

10.5 daNm

gearbox suspendedmounting bolts

6.2 daNm

suspended mountingnut on the rubber pad

18 daNm

cooling radiator crossmember front mountingbolts

10.5 daNm

gearbox drain plug (2.5 daNm)

gearbox filler plug 0.3 daNm

battery cover mountingbolts

0.4 daNm

104343

104246

2

1

33

21A-7



21A- the battery,

- the battery mounting,

- the injection computer with its support,

- the air flowmeter.

- the air inlet pipe.

Remove the electrical harness mountings.

Unclip the gear control cables from the gearbox.

Disconnect:

- the ABS sensor wiring,

- the discharge bulb adjustment sensor wiring (if fit-ted on vehicle).

Remove the wheel arch liners.

I - LEFT-HAND SIDE OF VEHICLE

Remove:

- the hub nut using tool (Rou. 604-01),

- the track rod end using tool (Tav. 476),

- the anti-roll bar ball joint,

- the lower ball joint.

Release the stub axle carrier from the driveshaft.

Remove the left-hand driveshaft.

101821

104086

102129

21A-8



21AII - RIGHT-HAND SIDE OF VEHICLE

Remove:





- the relay bearing bracket.


Remove the right-hand driveshaft.

Attach the cooling radiator assembly to the uppercross member using rope.

Remove the side stiffeners.

Remove the cooling radiator cross member.

101819

101212

102009

21A-9



21A

Remove the catalytic converter support from theclutch housing.

Remove the engine tie-bar.

Disconnect the reversing connector.

Disconnect the TDC sensor.

106199

102115

106204

106200

21A-10



21A

Disconnect:

- the starter (4),

- the diesel fuel pressure sensor (5).

Disconnect the earth strap from the gearbox.

Disconnect the oil level sensor.

Remove:

- the starter mounting bolts (6),

- the starter.

Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.

106205

106203

5

4

106201

14853

66

21A-11



21A

Disconnect the hydraulic union by removing the clip(7).

Set up the engine support tool (Mot. 1453).

Remove the gearbox support rubber pad.

Remove:

- the three gearbox support bolts,

- the gearbox support.

101701

102449

7

106195

106194

21A-12



21A

Remove the gearbox edge upper bolts.

Set up the jack under the gearbox

Remove:

- the gearbox edge lower bolts,

- the gearbox.

106193

21A-13



21AREFITTING

Check that the engine-gearbox centring rings are inplace and correctly positioned.


Torque tighten:

- the wheel bolts (13 daNm),

- the driveshaft nut (28 daNm),

- the lower ball joint nut (6.2 daNm),

- the track rod end nut (3.7 daNm),

- the anti-roll bar ball joint nut (4.4 daNm),

- the side panel mounting bolts (2.1 daNm),

- the gearbox edge and starter bolts (4.4 daNm),

- the engine tie-bar bolts on the engine (10.5daNm),

- the engine tie-bar bolts on the sub-frame (10.5daNm),

- the gearbox suspended mounting bolts (6.2daNm),

- the suspended mounting nut on the rubber pad(18 daNm),

- the cooling radiator cross member front moun-ting bolts (10.5 daNm),

- the gearbox drain plug ((2.5 daNm)),

- the gearbox filler plug (0.3 daNm).

Top up the gearbox oil.

Torque tighten the battery cover mounting bolts(0.4 daNm).

WARNING

Do not coat:

- the gearbox output shaft with grease to avoiddamaging the clutch slave cylinder,

- the clutch shaft splines.

Note:

To avoid any risk of leakage, the hydraulic unionmust always be replaced after the clutch mecha-nism is replaced.

WARNING

Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:

- Add brake fluid to the reservoir.

- Bleed the hydraulic circuit ( Mechanical ele-ment controlsSection).

- Top up the brake fluid level.

WARNING

Connect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

21A-14


F4R, and 770 – F9Q, and 812

21A

REMOVALPut the vehicle on a two-post lift.


Remove the scuttle panel grille (see MR 371 Bo-dywork, 55A, Exterior Protection, Scuttle PanelGrille).

Remove:

- the two air filter access panel mounting bolts(1),

- the air filter access panel,

- the plenum chamber partition mounting bolt(2).





Equipment required

jack

Tightening torquesm

driveshaft nut 280 N.m

lower ball joint nut 62 N.m

track rod end nut (37 N.m)

ball joint nut from theanti-roll bar

44 N.m

side panel mountingbolts

21 N.m

gearbox edge and star-ter motor bolts

44 N.m

engine tie-bar bolts tothe engine

180 N.m

engine tie-bar bolts onthe sub-frame

105 N.m

gearbox suspendedmounting bolt

44 N.m

suspended mountingnut on the support

180 N.m

steering shaft yokemounting bolt

21 N.m

cooling radiator crossmember front mountingbolts

105 N.m

cooling radiator crossmember rear mountingbolts

21 N.m

subframe cross-membermounting bolts

62 N.m

subframe rear mountingbolts

140 N.m

subframe tie-rod moun-ting bolts

105 N.m

gearbox drain plug 25 N.m

gearbox filler plug 3 N.m

wheel mounting bolts 130 Nm


4 N.m

104343

Tightening torquesm

2

1

21A-15


F4R, and 770 – F9Q, and 812

21A

Remove:

- the plenum chamber partition mounting bolts(3),

- the plenum chamber,


Drain the gearbox.

Remove:

- the front wheels,

- the engine covers,

- the battery,

- the battery mounting,

- the injection computer with its support,

- the air flowmeter.

- the air inlet pipe.

Remove the electrical harness mountings.

Unclip the gear control cables from the gearbox.

104246

33

101821

104085

21A-16


F4R, and 770 – F9Q, and 812

21A

Disconnect the heat exchanger - turbocharger air pi-pe.

Remove the air filter hose.

Disconnect:

- the ABS sensor wiring,

- the discharge bulb adjustment sensor wiring har-nesses (if fitted).

Remove the wheel arch liners.

I - LEFT-HAND SIDE OF THE VEHICLE

Remove:


- the track rod end using tool(Tav. 476),



Remove the stub-axle carrier from the driveshaft.

Remove the driveshaft.

F9Q

102244

102129

21A-17


F4R, and 770 – F9Q, and 812

21AII - RIGHT-HAND SIDE OF THE VEHICLE

Remove:





- the relay bearing bracket.

Remove the stub-axle carrier from the driveshaft.



Remove the side stiffeners.

Remove:

- the cooling radiator cross member.

- the catalytic converter support from the clutch hou-sing,

- the starter mounting bolts,

- the starter motor.

101819

101212

102009

21A-18


F4R, and 770 – F9Q, and 812

21A

Remove the engine upper tie-bar.

Remove the engine lower tie-bar.

Remove the steering shaft fork.

Remove the sub-frame angle bracket (4).

102452

102312

101354

101208

4

21A-19


F4R, and 770 – F9Q, and 812

21A

Strap the sub-frame to the jack.

Remove the sub-frame.

101209

21A-20


F4R, and 770 – F9Q, and 812

21A

Disconnect:

- the reversing connector,

- the TDC sensor.

Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.

Disconnect the hydraulic union by removing theclip(5).

Set up the engine support tool (Mot. 1453).

Remove:

- the gearbox support rubber pad,

- the gearbox suspended mounting,

- the gearbox edge upper bolts.

Position jack underneath the gearbox.

Remove:


- the gearbox.

102485

101701

5

102449

102112

21A-21


F4R, and 770 – F9Q, and 812

21AREFITTING

Check that the engine / gearbox centering rings arein place and correctly positioned.


Always replace the steering shaft yoke stud after re-moval.

Tighten to torque:

- the driveshaft nut (280 N.m),

- thelower ball joint nut (62 N.m),

- the track rod end nut ((37 N.m)),

- theball joint nut from the anti-roll bar (44 N.m),

- the side panel mounting bolts (21 N.m),

- the gearbox edge and starter motor bolts (44N.m),

- the engine tie-bar bolts to the engine (180 N.m),

- the engine tie-bar bolts on the sub-frame (105N.m),

- the gearbox suspended mounting bolt (44 N.m),

- thesuspended mounting nut on the support(180 N.m),

- the steering shaft yoke mounting bolt (21 N.m),

- the cooling radiator cross member front moun-ting bolts (105 N.m),

- the cooling radiator cross member rear moun-ting bolts (21 N.m),

- the subframe cross-member mounting bolts (62N.m),

- the subframe rear mounting bolts (140 N.m),

- the subframe tie-rod mounting bolts (105 N.m),

- the gearbox drain plug (25 N.m),

- the gearbox filler plug (3 N.m),

- the wheel mounting bolts (130 Nm).


Connect the battery, starting with the positive termi-nal.

Torque tighten the battery cover mounting bolts (4N.m).

WARNING

Do not coat:

- the gearbox output shaft with grease, to avoiddamaging the clutch slave cylinder,

- the clutch shaft splines.

Note:

To avoid leaks, the hydraulic union must alwaysbe replaced after the clutch mechanism is repla-ced.

WARNING

To refit the sub-frame (see 31A, Front LiftingComponents, Axle sub-frame).

WARNING

Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:

- Add brake fluid to the reservoir.

- Bleed the circuit (see 37A, Mechanical Com-ponent Controls, Clutch Circuit: Bleeding).

- Top up the brake fluid level.

WARNING

Carry out the necessary programming (see 80A,Battery: Remove and Refit).

21A-22

MANUAL GEARBOXDifferential output seal

JH3 or JR5

21A

REMOVAL

Put the vehicle on a two-post lift.

Disconnect the battery starting with the negative ter-minal.

Remove the engine undertray.

Drain the gearbox.

Remove:

- the wheel,

- the wheel arch liner,

- the hub nut,

- the track rod end,



Disconnect:

- the wheel speed sensor connector,

- the xenon headlight adjustment sensor wiring har-nesses (if fitted).

Remove the relay bearing bracket.


REPLACING THE SEAL

Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.

Remove the seal with pliers, taking care not to dama-ge the splines of the sunwheel.


Bvi. 1666 Differential seal fittingtool

Tightening torquesm

wheel bolts 13 daNm




hub nut 28 daNm

relay bearing bracket nut 2.1 daNm

engine - engine tie-barbolts

10.5 daNm

sub-frame - engine tie-bar bolts

10.5 daNm


0.4 daNm

102129

101819

21A-23


JH3 or JR5

21AREFITTING

Oil the seal.

Insert the seal onto the splined part of the sunwheel.

Refit the seal using the tool (Bvi. 1666), with themarking A on the right-hand side and marking B onthe left-hand side.

Position the driveshaft in relation to the sunwheel.

To refit, proceed in the reverse order of removal.

Tighten to torque:





- the hub nut (28 daNm),

- the relay bearing bracket nut (2.1 daNm),

- the engine - engine tie-bar bolts (10.5 daNm),

- the sub-frame - engine tie-bar bolts (10.5 daNm).


Torque-tighten the battery cover mounting bolts(0.4 daNm).

21503

WARNING


21A-24


ND0

21A

REMOVAL

Put the vehicle on a two-post lift.



Drain the gearbox.

Remove:

- the wheel,

- the wheel arch liner,

- the hub nut,

- the track rod end,



Disconnect:

- the wheel speed sensor connector,

- the xenon headlight adjustment sensor wiring har-nesses (if fitted).



REPLACING THE SEAL

Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.

Remove the dislodged seal with pliers, taking carenot to damage the sunwheel splines.


Bvi. 1689 Differential oil seal fit-ting tool

Tightening torquesm

wheel bolts 13 daNm




hub nut 28 daNm

relay bearing bracket nut 2.1 daNm

engine - engine tie-barbolts

18 daNm

sub-frame - engine tie-bar bolts

10.5 daNm


0.4 daNm

102129

101819

21A-25


ND0

21AREFITTING

Oil the seal before inserting it onto the splined part ofthe sunwheel.

Refit the seal using the tool (Bvi. 1689), with themarking A on the right-hand side and marking B onthe left-hand side.

Position the driveshaft in relation to the sunwheel.

To refit, proceed in the reverse order of removal.

Tighten to torque:






- the relay bearing bracket nut (2.1 daNm),

- the engine - engine tie-bar bolts (18 daNm),

- the sub-frame - engine tie-bar bolts (10.5 daNm).


Torque-tighten the battery cover mounting bolts(0.4 daNm).

102260

WARNING


23A-1

AUTOMATIC GEARBOXGears

DP0

23A

DP0

Suffix 056 057 059 061

Step-down 52/67 52/67 52/67 52/67

Final drive 20/73 20/73 20/73 23/70

23A-2

AUTOMATIC GEARBOXLubricants

DP0

23AThe DP0 automatic gearbox is greased for life anddoes not require any maintenance: It is only necessaryto top up the level in the event of a slight leak.

I - OIL SPECIFIED:

ELF RENAULT MATIC D3 SYN (can be ordered fromELF) DEXRON III standard

II - CAPACITY IN LITRES

Total volume: 6 litres.

23A-3

AUTOMATIC GEARBOXConsumables

DP0

23A

Description Component concerned

Grease

MOLYKOTE BR2

Converter centring fitting

LOCTITE FREN-BLOC

Flywheel mounting bolt

23A-4

AUTOMATIC GEARBOXParts to be replaced systematically

DP0

23AThe following parts must be replaced after being remo-ved:

- self-locking nuts,

- the seals,

- rubber seals,

- converter bolts.

23A-5

AUTOMATIC GEARBOXChanging the oil

DP0

23A

The engine oil change and topping-up plugs haveevolved.

The top-up and bleeding checking procedures arethe same for both fittings.

It is preferable to change the automatic transmissionoil when it is warm (60˚C maximum), in order to re-move as many impurities as possible.

Mount the vehicle on a lift.


former assembly

The cap has two functions:

- the topping-up plug (1),

- the overflow pipe (2).

Remove the assembly (1) and (2) to carry out thecomplete gearbox oil change.

Remove only the cap (1) for topping-up.

Tightening torquesm

old assembly topping-upcap

25 N.m

old assembly overflowpipe

35 N.m

new assembly topping-up cap

35 N.m

new assembly overflowpipe

9 N.m

WARNING

For both assemblies, when changing engine oil ortopping up, the control lever must be in Parkingpo-sition.

2316

2

1

23A-6

AUTOMATIC GEARBOXChanging the oil

DP0

23ANew assembly

Remove:

- the cap again (3).

- the overflow pipe (4)using an Allen key (5) with dia-meter of 8mm

Let the oil flow.

Refit the new overflow pipe.

Tighten to torque:

- the old assembly topping-up cap (25 N.m)

- the old assembly overflow pipe (35 N.m)

- the new assembly topping-up cap (35 N.m)

- the new assembly overflow pipe (9 N.m)

Carry out filling and top up of the gearbox oil (see23A, Gearbox, Filling - Top up).

107912

Note:

Always replace the overflow pipe (4) each time itis removed.

5

4

3

23A-7

AUTOMATIC GEARBOXFilling - Levels

DP0

23A

I - FILLING

Fill through the hole (1).

Use a funnel with a 15/100 filter to prevent impuritiesfrom entering the system.

II - FILLING PROCEDURE

Park the vehicle on level ground.


Disconnect the computer connectors.

Remove the battery tray mounting bolts(2).

Remove:

- the battery tray,

- the computer mounting.

Remove the turbocharger pressure regulation sole-noid valve (if fitted on the vehicle).

Remove the gearbox control(3).

Equipment required

Diagnostic tool

Tightening torquesm

plug 35 N.m

WARNING

It is essential to shift the control lever to the Parkingposition.

103407

1

101822

110245

222

3

23A-8


DP0

23A

Unclip the lever cable on the gearbox:

- clip the gearbox control at (A),

- pull the pin at (B),

- raise the gearbox control at (C).

Fill the automatic transmission with 3.5 litres of newoil.

Proceed in the reverse order to removal

Connect the battery, starting with the positive termi-nal.

Run the engine at idle speed.

Connect the Diagnostic tool ( CLIP ).

Establish dialogue with the automatic transmissioncomputer.

Monitor the gearbox oil temperature parameter.

Once a temperature of 60˚C +/- 1 is reached, openthe level-setting plug.

Former assembly

Open the plug again (4).

New assembly

Open the plug again (5).

101743

WARNING

carry out the necessary programming (see 80A,Battery: Remove and Refit)

B

A

C

A

2316

107912

4

5

23A-9


DP0

23A

Position a container, if the oil does not flow out or the quantity collected is below 0.1 litre.

- switch the engine off,

- add 0.5 litre of oil,

- let the automatic transmission cool to 50˚C,

- run the engine at idle speed,

- connect the Diagnostic tool ( CLIP ).

- establish dialogue with the automatic transmissioncomputer,

- monitor the automatic gearbox oil temperature pa-rameter.

- when the temperature reaches 60˚C ±±±± 1 open thetop-up plug,

- position a container.

Repeat these operations until more than 0.1 litre ofoil is obtained in the container.

Refit the plug again.

Torque tighten the plug (35 N.m).

III - LEVEL CHECKING PROCEDURE OUTSIDE FILLING OPERATIONS

Park the vehicle on level ground.

Fill the automatic transmission with 0.5 litre of newoil.

Run the engine at idle speed.

Connect theDiagnostic tool (CLIP).

Establish dialogue with the automatic transmissioncomputer.

Monitor the gearbox oil temperature parameter.

Once a temperature of 60˚C +/- 1 is reached, openthe level-setting plug.

If the oil does not flow out or the quantity collected is below 0.1 litre:

- switch the engine off,

- add 0.5 litre of oil,

- let the automatic transmission cool to 50˚C,

- run the engine at idle speed,

- connect the Diagnostic tool ( CLIP ).

- establish dialogue with the automatic transmissioncomputer,

- monitor the automatic gearbox oil temperature pa-rameter.

- when the temperature reaches 60˚C ±±±± 1, open thetop-up plug,

- position a container.

Repeat these operations until more than 0.1 litre ofoil is obtained in the container.

Enter the oil change date using the commandCF074« Enter the gearbox oil change date »usingthe Diagnostic tool (CLIP).

13792

Note:

The level must be checked following the methoddescribed below:

Note:

When the oil is replaced, the electronic oil ageingcounter must be reset (inside the computer).

23A-10

AUTOMATIC GEARBOXChecking the converter setting point

DP0

23A


Lift the vehicle until the wheels are raised off theground by a few centimetres.

Connect the Diagnostic tool (« CLIP »).

Establish dialogue with the automatic transmissioncomputer,

Monitor the automatic gearbox oil temperature para-meter.

Carry out the check at an oil temperature of between60˚C and 80˚C.

Start the engine and put the lever in D.

Monitor the engine speed parameter:

Establish dialogue with the computer.

Accelerate fully keeping the brakes applied.

The front wheels should not rotate.

The engine speed must be stablised at 2700 ±±±±150rpm.

The engine speed should stabilise at 2500 ±±±±150rpm.

A setting point outside the tolerance requires theconverter to be replaced.

Equipment required

Diagnostic tool

WARNING

- The full load position must not be held for morethan 5 seconds. Beyond this, there is a highrisk of destroying the converter or the automatictransmission.

- Once the measurement has been taken,release the accelerator and keep the brakes onuntil the engine speed stabilises to idle speed(there is a risk of damaging the automatic trans-mission if this is not complied with).

K4M

F4R

Note:

A setting point which is too low may be linked to alack of engine power.

23A-11

AUTOMATIC GEARBOXLine pressure measurement

DP0

23A

Some fault finding procedures on the automatic gear-box involve taking the line pressure using a pressuregauge.

The pressure measurement tapping is located close tothe pressure sensor.

Remove the bolt (1) to take the line pressure.

Remove the pressure tapping union (466-06) fromthe kit (Bvi. 1215-01) (Workshop Repair Manual372 « Fault finding »).


Bvi. 1215-01 Automatic transmis-sion oil pressuregauge kit

103420

1

23A-12

AUTOMATIC GEARBOXHydraulic distributor

DP0

23A

REMOVALMount the vehicle on a two post lift.

Remove the engine covers.



Drain the automatic transmission through plug (1).

Remove:

- the wheels,

- the air intake sleeve,

- the wheel arch liner.


Bvi. 1462 Ball plate adjustingscrew

Equipment required

Diagnostic tool

Tightening torquesm

distributor mountingbolts

0.75 daNm

ball detent plate bracketmounting bolt (12)

0.9 daNm

ball detent plate moun-ting bolt

0.8 daNm

cover mounting bolts 1 daNm

rechargeable battery 4 daNm

reinforcement platemounting bolts

2.1 daNm


0.4 daNm

13792

1

23A-13


DP0

23A

Move the electric wiring harness aside:

- from the battery (2),

- from the battery tray (3),

- from the injection computer (4).

Remove:

- the battery,

- the computer,

- the battery mounting.

Remove the electric wiring harness (5) on the sidestiffener.

Remove:

- the bolts (6) on the side stiffener plate,

- the side stiffener.

Remove the four retaining bolts (7) on the hydraulicdistributor cover (be careful as oil may run out).

101821

3

2

4

3

103412

14783

5

6666

7777

23A-14


DP0

23A

Remove the seven mounting bolts on the hydraulicdistributor.

Disconnect the solenoid valve connectors.

Remove the hydraulic distributor.

REFITTING

Fit the distributor and centre it using bolts (4) and (5).

Refit the other bolts.

Tighten to torque and in the correct order the distri-butor mounting bolts (0.75 daNm).

ADJUSTING THE BALL DETENT PLATE

Hold the multifunction switch lever in the end position(first selected) using a plastic clip and a bolt in themechanism housing.

13788

13789

14782

23A-15


DP0

23A

Remove the bolts (8).

Position the ball detent plate by placing the roller (9)in the hollow (11) of the sector (10) corresponding tothe first gear selected position.

Position the ball detent plate bracket mounting bolt(12) but do not tighten it.

Position the tool (Bvi. 1462) in place and fit the bolt(8).

Screw the tool in fully whilst holding the ball detentplate.

Tighten to torque the ball detent plate bracketmounting bolt (12) (0.9 daNm).

Remove the tool (Bvi. 1462).

Remove the ball detent plate mounting bolt (8).

Tighten to torque the ball detent plate mountingbolt (0.8 daNm).

When replacing the oil distributor, the auto-adaptivesmust be reset using command RZ005: « Eraseauto-adaptives » and the oil age counter of the

13788-1

2318

109 8

10

11

14785

12

23A-16


DP0

23Aautomatic transmission computer must be resetusing the Diagnostic tool, use command CF074:« Enter date of gearbox oil change ».

After using command RZ005, it is important to carryout a test drive performing all gear changes, both upand down, several times in order to store the new va-lues.

Torque tighten:

- the cover mounting bolts (1 daNm),

- the rechargeable battery (4 daNm),

- the reinforcement plate mounting bolts (2.1daNm).



Fill the gearbox.

WARNING


23A-17

AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting

K4M, and 761 – F4R, and 771

23A

REMOVAL




Remove the cowl grille ( Wiping / WashingSection).

Remove:

- the two air filter access panel mounting bolts (1),





Bvi. 1531 Inertia wheel centringtool for automatictransmission converter

Equipment required

jack

Tightening torquesm

wheel bolts 13 daNm

brake calliper guide pinbolts

0.7 daNm



engine tie-bar on thesub-frame

10.5 daNm

gearbox edge and star-ter bolts

4.4 daNm

gearbox suspendedmounting nut

4.4 daNm


converter - starter platemounting nut

3.7 daNm

modular connector sup-port bolts

2 daNm

engine speed sensormounting bolts

1 daNm

engine tie-bar bolts on Fengine

18 daNm

engine tie-bar bolts on Kengine

10.5 daNm

suspended mountingnut on the rubber pad

18 daNm


0.4 daNm

101821

104343

Tightening torquesm

21

23A-18


K4M, and 761 – F4R, and 771

23A- the air filter access panel,

- the plenum chamber partition mounting bolt (2).

Remove:

- the plenum chamber partition mounting bolts (3),

- the plenum chamber partition,


- the battery,

- the battery tray,

- the injection computer and its support,

- the air inlet pipe,

- the electrical harness mountings.

Remove:

- the multifunction switch cable ball joint (4),

- the multifunction switch cable wiring loom (5) by re-leasing the sheath stop,

- the electrical harness mountings.

Disconnect:

- the engine speed sensor,

- the connector (6) by releasing the connector slide.

Remove the modular connector support plate moun-ting bolts (7).

104246

33

103409

WARNINGProtect the connector by sliding it into a water-proof plastic bag.

777

65

4

23A-19


K4M, and 761 – F4R, and 771

23A

Remove the engine speed sensor.

Remove the engine speed sensor.

Fit the hose clamps.

Disconnect the heat exchanger.

Unclip the gearbox wiring harness.

Remove:

- the two starter bolts (8),


Drain the gearbox.

Remove:

- the wheels,

- the wheel arch liners.

Disconnect:

- the ABS system sensor wiring,

- the discharge bulb beam adjustment sensor wiring(if fitted on vehicle).

K4M

103753

F4R

103420

103423

Note:

The discharge bulb beam adjustment sensor isfitted onto the left-hand lower wishbone.

88

23A-20


K4M, and 761 – F4R, and 771

23AI - LEFT-HAND SIDE OF VEHICLE

Remove:



- the anti-roll bar ball joint using tool (Tav. 476),



Remove the left-hand driveshaft.

Remove:

- the clip (10) from the gearbox computer wiring har-ness,

- the side stiffener (9).

Open the gearbox computer wiring harness moun-ting bracket (11).

Disconnect the gearbox computer connector (12).

102129

103412

103413

9

10

11

12

23A-21


K4M, and 761 – F4R, and 771

23AII - RIGHT-HAND SIDE OF VEHICLE

Remove:



- the anti-roll bar ball joint using tool (Tav. 476),




Remove the right-hand driveshaft.


Remove the side stiffener.

102129

103418

101212

23A-22


K4M, and 761 – F4R, and 771

23A

Remove the cooling radiator lower cross member.

Remove:

- the exhaust mounting nuts (13),

- the engine tie-bar.

Remove:

- the lower engine - manifold strut,

- the starter mounting bolt (15),

- the starter,

- the three converter nuts.

102009

103421

13131414

103418

Note:

The converter nuts are accessed by removing thestar ter. Rotate the crankshaft clockwise to accessthe three starter plate - converter connecting nutsand remove them.

15

23A-23


K4M, and 761 – F4R, and 771

23A

Remove the gearbox upper edge studs (16).

Open the cover (13).

Remove the cover (14).

Set up tool (Mot. 1453).

Remove the gearbox support rubber pad.

Fit the jack tool beneath the gearbox.

Remove:


- the studs,

- the converter - starter plate bolts,

- the automatic transmission,

Attach the converter with string to stop it being deta-ched.

REFITTING

103423

102449

1616

14

13

13790

WARNING

- Do not reuse the converter mounting nuts or theinertia flywheel nuts if they have been removed:always use new nuts.

- Check that the centring rings are in place.

23A-24


K4M, and 761 – F4R, and 771

23A

Refit the inertia flywheel on the converter using tool(Bvi. 1531);.


When refitting the automatic transmission on the en-gine, make sure that the converter is properly enga-ged on the input shaft pin.

16361

WARNING

Check that the centring dowels are in place.

23A-25


K4M, and 761 – F4R, and 771

23A

The distance between the base of the threading (17)and the engine mating face (18) should be 17 mm.

Torque tighten:


- the brake calliper guide pin bolts (0.7 daNm),



- the engine tie-bar on the sub-frame (10.5 daNm),

- the gearbox edge and starter bolts (4.4 daNm),

- the gearbox suspended mounting nut (4.4daNm),


- the converter - starter plate mounting nut (3.7daNm),

- the modular connector support bolts (2 daNm),

- the engine speed sensor mounting bolts (1daNm),

- the engine tie-bar bolts on F engine (18 daNm),

- the engine tie-bar bolts on K engine (10.5daNm),

- the suspended mounting nut on the rubber pad(18 daNm).

Fill up the automatic transmission and check the le-vel (Section Automatic gearbox, Filling - Levels,page 23A-7).

When changing the oil, the auto-adaptives must bereset using command RZ005: « Clear auto-

adaptives » and the automatic transmission compu-ter oil ageing counter must be reset using commandCF074: « Enter date of gearbox oil change ».

After using command RZ005, it is important to carryout a test drive using all the gear ratio shifts, both upand down, several times in order to store the new va-lues.


13790

17

18

WARNINGConnect the battery; carry out the necessary pro-gramming (Section Electrical equipment).

23A-26

AUTOMATIC GEARBOXDrive plate

K4M, and 761 – F4R, and 771

23A

This operation can be performed after the automatictransmission has been removed.

REMOVAL

Position the tool (Mot. 1677) to immobilise the startermotor ring gear.

Position the tool (Mot. 582-01).

Remove:

- the bolts (1),

- the drive plate,

- the tool (Mot. 1677).

REFITTING

Check that the drive plate is not damaged (warpingtolerance 0.2 mm on the external diameter).

Fit the drive plate, ensuring it is correctly positionedin relation to the centring pin (2).

Tighten the bolts on the drive plate.




Equipment required

Diagnostic tool

Tightening torquesm

drive plate bolts (Fengine)

4.5 daNm + 50˚+/- 5

drive plate bolts (Kengine)

5.5 daNm + 50˚+/- 5


0.4 daNm

F4R

103245

1

2

11

1 11

1

2

K4M

103752

Note:

- Systematically replace the drive plate bolts.

- Apply LOCTITE FRENBLOC to the boltthreads.

1

11

1

23A-27

AUTOMATIC GEARBOXDrive plate

K4M, and 761 – F4R, and 771

23A

Angular and torque tighten the drive plate bolts (Fengine) (4.5 daNm + 50˚ +/- 5) locking the startermotor ring gear using tool (Mot. 1677).

Angular and torque tighten the drive plate bolts (Kengine) (5.5 daNm + 50˚ +/- 5) locking the startermotor ring gear using tool (Mot. 582-01).


Connect the Diagnostic tool to check conformity.


F4R

K4M

WARNING


23A-28

AUTOMATIC GEARBOXDifferential output gasket

DP0

23A

REMOVALThis operation is performed after removing the cor-responding driveshaft ( DriveshaftsSection).


Remove the battery cover.



Drain the automatic transmission through the plug(1).

Remove the faulty differential output seal using ascrewdriver or a hook, taking care not to scratch thecontact faces.


Bvi. 1459 Right-hand transmis-sion output seal fittingtool

Bvi. 1460 Left-hand transmissionoutput seal fitting tool

Tightening torquesm

wheel bolts 13 daNm


bolts for mountingengine tie-bar on thesub-frame

10.5 daNm

engine tie-bar bolts on Kengine

10.5 daNm

engine tie-bar bolts on Fengine

18 daNm


hub nut 28 daNm


0.4 daNm

13791

WARNING

Do not drop the seal spring into the automatictransmission.

1

23A-29

AUTOMATIC GEARBOXDifferential output gasket

DP0

23AREFITTING

Fit the seal using tool (Bvi. 1459) or tool (Bvi. 1460).

Guide the assembly until the tool is resting on theautomatic transmission casing.


Torque tighten:



- the bolts for mounting engine tie-bar on thesub-frame (10.5 daNm),

- the engine tie-bar bolts on K engine (10.5daNm),

- the engine tie-bar bolts on F engine (18 daNm),


- the hub nut (28 daNm).

Fill the automatic transmission and check the level(Section Automatic gearbox, Filling - Levels, page23A-7).


WARNING


23A-30

AUTOMATIC GEARBOXConverter seal

DP0

23A

REMOVAL

This operation is carried out after the automatictransmission and converter have been removed.

Remove the converter by withdrawing it as far aspossible without deviating from the shaft.

Using tool (Mot. 587), remove the seal, taking carenot to scratch the contact faces.

REFITTING

Refit:

- the new pre-lubricated seal to the end, using tool(Bvi. 1457),

- the converter.

The distance between the base of the thread (1) andthe face of the engine coupling (2) must measure 17mm.



Mot. 587 Seal extractor

Bvi. 1457 Converter l ip sealassembly

WARNINGThe converter contains a large amount of oil,which may spill when it is being removed.

WARNING

- Work as cleanly as possible to prevent foreignbodies penetrating the system.

- Oil all the contact faces.

13790

1

2

23A-31

AUTOMATIC GEARBOXMultifunction switch

DP0

23A

REMOVAL

Set to neutral « N ».


Remove:


- the battery,

- the battery tray,

- the injection computer and its support,

- the air filter box,

- the electric wiring harness mountings.

Disconnect:


- the control cable from the sheath stop (2) on themodular connector support.

Remove the lever and the two multifunction switchmounting bolts (3).

Disconnect the modular connector (4) by releasingthe connector slide mechanism.

Remove the three modular connector support platemounting bolts (5).

Remove the two modular connector plate mountingbolts.

Remove the green connector (6) from the multifunc-tion switch (12-track).

Tightening torquesm

selector lever nut 1 daNm

mult i funct ion switchmounting bolts

1 daNm


0.4 daNm

101821

103409

13785

1

5

4

3

2

3

55

6

23A-32

AUTOMATIC GEARBOXMultifunction switch

DP0

23AREFITTING

Set the multifunction switch to neutral « N ».

Adjust the multifunction switch.


Tighten to torque the selector lever nut (1 daNm).

Check that the system and gear selection are wor-king correctly.

ADJUSTING THE MULTIFUNCTION SWITCH

With the selector shaft in neutral, place two electricterminals on the position control tabs.

Set the multimeter to the « ohmmeter » position.

Turn the multifunction switch by hand until the elec-trical contact is closed (resistance at contact termi-nals: 0 Ω).

Tighten to torque the multifunction switch moun-ting bolts (1 daNm).

Check that the system and gear selection are wor-king correctly.

Tighten to torque the battery cover mounting bolts(0.4 daNm).

103411

WARNING

After tightening, the electrical contact must beclosed 0 Ω.

WARNING


23A-33

AUTOMATIC GEARBOXComputer

DP0

23A

The computer is located behind the left-hand wheelarch.




Remove the front bumper.

Disconnect the computer connector (1).

Remove the resonator (2).

Remove:

- the two computer mounting nuts (3),

- the computer (4).

REFITTING

To refit, proceed in the reverse order to removal.

Tighten to torque the battery cover mounting bolts(0.4 daNm)

REPLACING THE COMPUTER

Use the following procedure.

Read the oil ageing value from the memory of thecomputer being replaced using parameter PR133:« Oil ageing counter » and note down the value.

Replace the computer.

Tightening torquesm


0.4 daNm

103414

2

1

103415

WARNING


Note:

When the automatic gearbox computer is repla-ced, it is necessary to enter the age of the auto-matic gearbox oil stored in the memory of thecomputer to be replaced in the memory of thenew computer.

4

33

23A-34

AUTOMATIC GEARBOXComputer

DP0

23ACall up the oil ageing value in the memory of the newcomputer using command CF320: « Oil ageingcounter report ».

Confirm entry using the « Oil ageing counter » para-meter.

Enter the after-sales operation date using commandCF320 « Enter after-sales operation date ».

Carry out a road test so that the new computer storesthe programming.

23A-35

AUTOMATIC GEARBOXSpeed sensor

DP0

23A

REMOVAL





Disconnect the connector (1).

Remove the output speed sensor (2).

REFITTING


Tighten to torque the output speed sensor moun-ting bolt (1 daNm).


Tightening torquesm

output speed sensormounting bolt

1 daNm


0.4 daNm

Note:

The speed sensor can be removed without drai-ning or removing the automatic transmission.

103417

Note:

When replacing a sensor, always remove thegearbox connector (Section Automatic gearbox,Gearbox connector, page 23A-39).

WARNING

Protect the connector by sliding it into a water-proof plastic bag.

1

13786-1

WARNING


2

23A-36

AUTOMATIC GEARBOXFlow regulation solenoid valve

DP0

23A




Remove:

- the two solenoid valve bolts (1),

- radiator flow control solenoid valve (2).

REFITTING


Tightening torquesm

radiator flow controlsolenoid valve moun-ting bolt

1 daNm


0.4 daNm

Note:

The radiator flow control solenoid valve can beremoved without draining or removing the auto-matic gearbox.

103434

13786-1

1

2

1

23A-37

AUTOMATIC GEARBOXFlow regulation solenoid valve

DP0

23ATighten to torque the radiator flow control sole-noid valve mounting bolt (1 daNm).


WARNING


23A-38

AUTOMATIC GEARBOXSolenoid valves: Removal

DP0

23A

REMOVAL

WARNING

Work as cleanly as possible to prevent foreignbodies from entering the system.

13787

(1) Modulating solenoid valve

(2) « Lock up » solenoid valve (con-verter by-pass)

(3) Sequence solenoid valve 4






Note:

This operation can be performed after thehydraulic distributor has been removed.

876543

2 1

23A-39

AUTOMATIC GEARBOXGearbox connector

DP0

23AConnector numbering



Select neutral « N »


Remove:

- the air intake duct,

- the battery,

Tightening torquesm


0.4 daNm

13785

(1) Green connector (multifunctionswitch)

(2) Yellow connector (electrohydrau-lic interface)

(3) Green connector (line pressure)

(4) Yellow connector (turbine speed)

(5) Blue connector (radiator flowcontrol solenoid valve)

Note:

These connectors may be removed separately fromthe gearbox connector when certain componentsare replaced.

2

543

1

103248

101821

2

5

4

3

1

23A-40

AUTOMATIC GEARBOXGearbox connector

DP0

23A- the battery tray,

- the injection computer and its mounting,

- the air filter unit,

- the wiring harness mountings.

Disconnect:


- the wiring harness (7) from the multifunction switchcable by loosening the sleeve stop,

- the unit connector (8) by releasing the slider on theconnector.

Remove:

- the three mounting bolts (9) from the unit connectorsupport plate,

- the two unit connector mounting bolts,

- the connector of the colour indicated on the gear-box connector.

Follow the five wiring harnesses connected to thegearbox connector.

Remove the five wiring harnesses.

These wiring harnesses are either connected tocomponents directly or via a connector. If they areconnected to a component directly, the componentshould also be removed.

REFITTING


Tighten to torque the battery cover mounting bolts(0.4 daNm)

103409

7

9

8

99

WARNING


29A-1

DRIVESHAFTSIdentification 29A

MECHANICAL GEARBOX DRIVESHAFTS JR5 - JH3 - ND0 - DP0

102209

Vehicle type Engines Gearbox

Drive joint

Left-hand transmission Right-hand transmission

Wheel end Gearboxside

Wheel end Gearboxside

JM0U - JM1N -JM05

F4R 770 ND0 015 EBJ 95 TJ 92 EBJ 95 TJ 92

JM0U - JM1N -JM1M - JM05

F4R 771 DP0 056 EBJ 92 RC 463 EBJ 92 RC 462

JM0U - JM05 F4R 771 DP0 059 EBJ 92 RC 463 EBJ 92 RC 462

JM0W F4R 776 ND0 013 EBJ 95 TJ 92 EBJ 95 TJ 92

JM0G - JM1G -JM12

F9Q 812 ND0 002 EBJ 95 TJ 92 EBJ 95 TJ 92

JM0B - JM0H -JM1A

K4J 730 JH3 106 AC 2000i Gi 2000i AC 2000i Gi 2001

JM0C - JM0J -JM1B

K4M 782 JR5 104 AC 2000i Gi 2000i AC 2000i Gi 2001

JM0C - JM0J -JM1B

K4M 782 JR5 125 AC 2000i Gi 2000i AC 2000i Gi 2001

JM0C - JM1B -JMOJ

K4M 761 DP0 057 BJ 87 RC 463 BJ 87 RC 462

JMOF K9K 722 JR5 103 BJ 87 RC 465 BJ 87 RC 462

JM13 - JMO2 K9K 728 JR5 110 EBJ 92 RC 465 EBJ 92 RC 462

JM13 - JMO2 K9K 728 JR5 131 EBJ 92 RC 465 EBJ 92 RC 462

29A-2

DRIVESHAFTSConsumables 29A

Component concerned Type of product Quantity

Gearbox side seal splines MOLYKOTE BR2 grease Coat

Brake calliper bolt FRENBLOC cement Coat

RC 462 seal

MOBIL CVJ 825 Black Star or MOBIL EXF 57C grease

110 cm3

RC 463 seal 110 cm3

RC 465 seal 110 cm3

EBJ 82 seal 70 cm 3

EBJ 92 seal 105 cm3

EBJ 95 seal 110 cm3

TJ 92 seal 135 cm3

29A-3

DRIVESHAFTSFront left-hand driveshaft 29A

REMOVAL

I - WHEEL END


Remove:

- the left front wheel,

- the hub nut using tool (Rou. 604-01).

Disconnect the wheel speed sensor.

Remove:

- the track rod end nut (1),

- the stub axle carrier ball joint using tool (Tav. 476),

- the anti-roll bar upper nut (2),

- the lower ball joint stud (3).

Push back the driveshaft from the stub axle carrierby swinging round the stub axle carrier.

Remove the driveshaft (wheel end).

II - GEARBOX SIDE

Drain the gearbox (see 21A, Manual gearbox).

Remove the driveshaft (gearbox side).

REPLACEMENT

With the protector in place, coat the splines of thegearbox side seal with MOLYKOTE BR2.

Position and insert the driveshaft into the axle su-nwheel.

Insert the stub-axle into the hub.

The driveshaft must go in freely until it protrudesenough for the hub nut to be mounted.


Torque tighten:





- the anti-roll bar nut (4.4 daNm),

- the driveshaft bearing bolts (4.4 daNm),

Fill the gearbox with oil (see 21A, Manual gearbox).




Tightening torquesm

wheel bolts 13 daNm

hub nut 28 daNm



anti-roll bar nut 4.4 daNm

driveshaft bearing bolts 4.4 daNm

101213

1

3

2

JH3 or JR5 or ND0

Note:

Check the condition of the contact surfaces of thelip seal.

Systematically replace the differential outlet lipseal (see 21A, Manual gearbox, differentialoutlet seal).

29A-4

DRIVESHAFTSFront right-hand driveshaft 29A

REMOVAL

I - WHEEL END


Remove:

- the front right wheel,

- the hub nut using tool (Rou. 604-01).

Disconnect the wheel speed sensor.

Remove:

- the track rod end nut (1),

- the stub axle carrier ball joint using tool (Tav. 476),

- the anti-roll bar upper nut (2),

- the lower ball joint stud (3).

Push back the driveshaft from the stub axle carrierby swinging round the stub axle carrier.

Remove the driveshaft (wheel end).

II - GEARBOX SIDE

Drain the gearbox.

Remove both the driveshaft bearing bolts (4).

Remove the driveshaft (gearbox side).

REPLACEMENT

Clean and grease the bearing hole housing the bea-ring.




Tightening torquesm

wheel bolts 13 daNm

hub nut 28 daNm



anti-roll bar nut 4.4 daNm

driveshaft bearing bolts 4.4 daNm

101213

3

21

JH3 or JR5 or ND0

101819

Note:

If the bearing is seized in the relay bearing, itmust be replaced.

Note:

- Replace the O-ring at the base of the relay shaftbearing if it is damaged.

- Check the condition of the contact surfaces ofthe lip seal.

- Systematically replace the differential outlet lipseal (see 21A, Manual gearbox).

4

29A-5

DRIVESHAFTSFront right-hand driveshaft 29A

With the protector in place, coat the splines of thegearbox side seal with MOLYKOTE BR2.

Position and insert the driveshaft into the axle su-nwheel.

Insert the stub-axle into the hub.

The driveshaft must go in freely until it protrudesenough for the hub nut to be mounted.


Torque tighten:





- the anti-roll bar nut (4.4 daNm),

- the driveshaft bearing bolts (4.4 daNm),

Fill the gearbox with oil (see 21A, Manual gearbox).

REMOVING THE RELAY SHAFT BEARING

Remove the whole driveshaft.

Remove the bearing using a press.

Take care not to score the contact surface of the lipseal on the relay shaft.

REFITTING

Lubricate the contact surface of the shaft into whichthe bearing is inserted.

Insert the new bearing.

Fit the bearing to the end using a tube, so that it restson the inner bearing race.

Clean and grease the bearing hole housing the bea-ring.

Refit the driveshaft.

100642

Documents

Manual service Renault Scenic 2 Trans Misie