Renault Scenic 2 Transmission & Gearbox User manual

"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."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use

of the spare parts reference numbering system, are prohibited without the prior written

consent 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

23A AUTOMATIC GEARBOX

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

23A AUTOMATIC GEARBOX

20A-1

CLUTCH

Identification

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

Plate external diameter: 215 mm

Plate thickness: 6.8 mm

Number of splines: 26

K4J or K4M

102143

102142

2

1

K9K

102143

102142

3

4

20A-2

CLUTCH

Identification

20A

Colour of springs (3): Red and Black

Colour of springs (4): Grey

Mechanism

Plate

Plate external diameter: 239 mm

Plate thickness: 7.8 mm

Number of splines: 21

F4R or F9Q

22428

22429

20A-3

CLUTCH

Mechanism / Plate

F4R or F9Q

20A

REMOVAL

Remove 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 compression

tool for rearming the

adjustment system

Emb. 1518 Set of clutch plate cen-

tring mandrels

Tightening torquesm

mechanism mounting

bolts

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

CLUTCH

Mechanism / Plate

F4R or F9Q

20A

Mount the mechanism on the base, then fit the thrust

ball 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

CLUTCH

Mechanism / Plate

F4R or F9Q

20A

Remove the mechanism from the base (checking

that the springs are properly compressed).

Mount the plate (small hub diameter (5) on flywheel

side).

CENTRING

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

Refit the mechanism on the flywheel.

Gradually torque tighten the mechanism mounting

bolts (1.2 daNm).

20758

WARNING

Clean the clutch shaft splines and reﬁt the

assembly without lubricant.

Degrease the friction face of the ﬂywheel.

102695

5

22695

20A-6

CLUTCH

Mechanism / Plate

K4J or K4M or K9K, and 722 or 728

20A

REMOVAL

Remove 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 (2

daNm).

Remove tool (Mot. 582-01).

Special tooling required

Mot. 582-01 Flywheel locking tool

(K engines)

Emb. 1518 Set of clutch plate cen-

tring mandrels

Tightening torquesm

mechanism mounting

bolts

2 daNm

16180

1

95414

20A-7

CLUTCH

Clutch thrust bearing

20A

REMOVAL

Remove:

-the gearbox (Section Manual gearbox, Manual

gearbox: 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 gearbox (Section Manual gearbox, Manual

gearbox: Removal - Refitting, page 21A-6),

- 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 housing

mounting 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

CLUTCH

Clutch thrust bearing

20A

Torque tighten the clutch thrust bearing - clutch

housing mounting bolts (2.1 daNm).

Bleed the clutch control ( Mechanical element con-

trolsSection).

ND0

WARNING

To avoid damaging the clutch slave cylinder, do

not lubricate the clutch shaft.

Never operate the system while the slave cylinder

is removed.

Note:

Always replace the hydraulic union.

20A-9

CLUTCH

Flywheel

20A

REMOVAL

Remove:

-the gearbox (Section Manual gearbox, Manual

gearbox: Removal - Refitting, page 21A-6),

-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).

REFITTING

Clean the threads for the flywheel mounting bolts on

the crankshaft.

Degrease the bearing face of the flywheel on the

crankshaft.

Check the condition of the flywheel.

Special tooling required

Mot. 582-01 Flywheel locking tool

(K engines)

Mot. 1677 Flywheel locking tool

(F engines)

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 damper

ﬂywheel type.

9

20A-10

CLUTCH

Flywheel

20A

Refit the spacer (11) observing the direction of fitting

of the chamfer on the flywheel side.

Always replace the mounting bolts with new ones.

Coat the new bolts of the flywheel with LOCTITE

FRENETANCH.

Tighten in the correct order and to the correct torque

value the flywheel mounting bolts (6.5 daNm).

K9K

23325

101356

WARNING

Do not remove the ﬂywheel drive plate mounting

bolts (10).

1010101010

11

23326

7

6

5

4

2

3

1

21A-1

MANUAL GEARBOX

Gears

21A

JH3

Sufﬁx 105 106 137 142 143 144

Differential

ratio

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 GEARBOX

Lubricants

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

21A

Capacity (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 GEARBOX

Lubricants

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

21A

ND0

101532

(3)Drain plug

(4) Filler plug

101221

5

WARNING

Removing the breather valve (5) to ﬁll the gearbox

with oil is prohibited.

21A-4

MANUAL GEARBOX

Consumables

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 GEARBOX

Parts to be replaced systematically

21A

Replace the following parts after removal:

- the lip seals,

- the O-rings.

21A-6

MANUAL GEARBOX

Manual gearbox: Removal - Refitting

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

21A

REMOVAL

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,

Special tooling required

Rou. 604-01 Hub locking tool

Tav. 476 Ball joint extractor

Mot. 1453 Multiple-adjusting

engine mounting sup-

port with retaining

straps

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 mounting

bolts

2.1 daNm

gearbox edge and star-

ter bolts

4.4 daNm

engine tie-bar bolts on

the engine

10.5 daNm

engine tie-bar bolts on

the sub-frame

10.5 daNm

gearbox suspended

mounting bolts

6.2 daNm

suspended mounting

nut on the rubber pad

18 daNm

cooling radiator cross

member front mounting

bolts

10.5 daNm

gearbox drain plug (2.5 daNm)

gearbox ﬁller plug 0.3 daNm

battery cover mounting

bolts

0.4 daNm

104343

104246

2

1

33

21A-7

MANUAL GEARBOX

Manual gearbox: Removal - Refitting

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

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

MANUAL GEARBOX

Manual gearbox: Removal - Refitting

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

21A

II - RIGHT-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.

-the relay bearing bracket.

Release the stub axle carrier from the driveshaft.

Remove the right-hand driveshaft.

Attach the cooling radiator assembly to the upper

cross member using rope.

Remove the side stiffeners.

Remove the cooling radiator cross member.

101819

101212

102009

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Renault Scenic 2 Transmission & Gearbox User manual

Renault Scenic 2 Transmission & Gearbox User manual

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