Transmission

CLUTCH

MANUAL GEARBOX

DRIVESHAFTS

BB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E

77 11 197 298 DECEMBER 1997 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
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 reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories Renault.
from which his vehicles are constructed."

C Renault 1997
EXPLODED VIEW

PRO20.2
 Transmission

Contents

Page

20 CLUTCH
Mechanism - Disc 20-1
Flywheel 20-4

21 MANUAL GEARBOX
Identification 21-1
Ratios 21-2
Capacity - Lubricants 21-3
Consumables 21-4
Parts to be systematically replaced 21-4
Gearbox (Removal - Refitting) 21-5

29 DRIVESHAFTS
General 29-1
Front driveshafts 29-2
 CLUTCH
Mechanism - Disc 20
Vehicle Engine
Mechanism Disc
type type

26 splines GA : Grey Silver

D = 181.5 mm VR : Violet Red
E = 6.7 mm

B/C B0A D7F

B/C B0C E7J

85873S

180 CP 3300 90693R8 76906R

26 splines V :Green
D = 200 mm RR : Red Ruby
E = 6.8 mm GB : Grey Blue

B/C B0E F8Q

85873S

200 CPOV 3250 90693R11 76906R

26 splines JS : Yellow Sand

D = 200 mm
E = 6.8 mm

B/C B0D K7M

85873S

200 CPO 3500 90693R12 76906R

Cable controlled, dry operating single disc clutch.

Thrust pad in constant contact.

20-1
 CLUTCH
Mechanism - Disc 20
REPLACEMENT (after removing the gearbox)

SPECIAL TOOLING REQUIRED

Mot. 582
or Locking sector
Mot. 582-01

TIGHTENING TORQUES (in daN.m) REFITTING

Mechanism mounting bolt 2 Clean the clutch shaft splines and refit the assem-
bly without lubricant.

Fit the disc into position (hub offset on gearbox

side).
REMOVAL
Centre using the tool in the replacement kit.
Fit the locking sector Mot. 582 or Mot. 582-01.

Remove the mechanism mounting bolts and re-

move the friction disc.

Check and replace any faulty parts.

95414S

Tighten progressively in a star pattern then lock

the mechanism mounting bolts to the correct tor-
que.
99055R2

Remove the locking sector Mot. 582 or

Mot. 582-01.

Coat with MOLYKOTE BR2 :

- the guide tube,
- the fork pads.

20-2
 CLUTCH
Mechanism - Disc 20
After refitting the gearbox, place the cable on the NOTE : during an operation which does not re-
clutch fork , reset the notched sector and check quire the gearbox to be removed or after fitting
the operation of the wear compensation system. the gearbox, DO NOT LIFT the fork as it may be-
come released from lug (A) on the thrust pad.
Check the clutch travel.

The fork travel should be :

X = 27.4 to 30.7 mm

99054R

97758-1R

20-3
 CLUTCH
Flywheel 20
REPLACING THE FLYWHEEL

SPECIAL TOOLING REQUIRED

Mot. 582
or Locking sector
Mot. 582-01

TIGHTENING TORQUES ( in daN.m )

Flywheel bolt 2 + 60°

REMOVAL

After removing the friction disc, remove the fly-

wheel mounting bolts (they cannot be re-used).

The friction face cannot be reground.

REFITTING

On the crankshaft, clean the flywheel mounting

bolt threaded holes.

Degrease the pressure face of the flywheel on the

crankshaft.

Refit the flywheel, locking it using Mot. 582 or

Mot. 582-01.

NOTE: the flywheel mounting bolts must be syste-

matically renewed.

20-4
 MANUAL GEARBOX
Identification 21
This type of vehicle is fitted with a JB type gearbox.

Workshop Repair Manual "B.V. JB. JC " deals with the complete repair of this component.

87227G

IDENTIFICATION PLATE

At A : gearbox type A J B0 0 0 0 B
At B : gearbox suffix
At C : fabrication number D X X0 0 0 0 0 C
At D : factory of manufacture E
At E : a notch when the gearbox is assembled with
an E engine
At F : letter preceding fabrication numbers grea- F
ter than 999999

21-1
 MANUAL GEARBOX
Ratios 21
JB1

Step down
Suffix Vehicle Speedo 1st 2nd 3rd 4th 5th Reverse

16
180
55 39
B/C B0E
16 31
905 (1)
57 34
15 35
183 B/C B0D
58 39
15 21 11 22 28 32 11
184 26
61 19 37 41 37 39
B/C B0A
15 30
909
58 29

15 39
185
61 31
34
B/C B0C
15 35
186 (1)
61

(1) Vehicle fitted with AC.

21-2
 MANUAL GEARBOX
Capacity - Lubricants 21
CAPACITY (in litres)

5 speed gearbox

JB1 3.4

Viscosity

TRX 75W 80W

CHECKING THE LEVEL

92081S

Fill up to the level of the opening.

21-3
 MANUAL GEARBOX
Consumables 21
TYPE PACKAGING PART NUMBER COMPONENT

Right hand sunwheel splines

Fork pivot
MOLYKOTE BR2 1 kg tin 77 01 421 145
Thrust pad guide Clutch
Fork pads control

LOCTITE 518 24 ml syringe 77 01 421 162 Housing assembly faces

Threaded plugs and switches

Bearing plugs
RHODORSEAL 5661 100 g tube 77 01 404 452
Ends of driveshaft roll pins

LOCTITE FRENBLOC Primary and secondary shaft nuts

(locking and sealing 24 cc bottle 77 01 394 071 Fixed gear and 5th gear hub
resin) Differential lock drive stud

Parts to be systematically replaced

Whenever they are removed:

- lip seals,
- O rings,
- thrust pad guide tubes,
- secondary and differential shaft nuts,
- speedo gear and shaft,
- speedo drive,
- roll pins,
- inner hubs.

21-4
 MANUAL GEARBOX
Gearbox (Removal - Refitting) 21
SPECIAL TOOLING REQUIRED

B. Vi. 31-01 Set of punches

Mot. 1040-01 Trolley for sub-frame
T. Av. 476 Ball joint extractor
EQUIPMENT REQUIRED

Engine support tool

Component jack

TIGHTENING TORQUES (in daN.m)

Brake caliper bolt 4

Driveshaft gaiter bolt 2.5
Lower ball joint nut 5.5
Shock absorber base bolt 18
Engine tie bar bolt 6.5
Bolt at edge of gearbox and starter 4.5
Suspended mounting bolt on gearbox 4
Wheel bolt 9
Track rod end nut 4

REMOVAL

Put the vehicle on a 2 post lift.

Remove the battery. 13083S

Disconnect the connectors on: Remove bolts (A) from the battery protective
- the injection computer (petrol version), shield.
- the preheating unit (diesel version),
- the fuel filter (diesel version),
- the impact sensor.

Remove the air filter sleeve.

13088R

21-5
 MANUAL GEARBOX
Gearbox (Removal - Refitting) 21
Remove the two mounting bolts (B). Right hand side of the vehicle, remove the drives-
haft roll pins using tool B. Vi. 31-01.

13119R
91755-1R2

Disconnect the clutch cable. On the right and left hand sides, remove:
- the brake calipers and attach them,
Remove: - the mudguards,
- the upper bolts at the edge of the gearbox - the track rod ends (T. Av. 476),
and starter motor (slacken bolt (D) as far as - the shock absorber base bolts,
possible), - the sub-frame- side member tie rods (A),
- the earth strap bolts on the gearbox, - the driveshaft - stub axle carrier assembly by
- the two TDC sensor bolts, releasing the lower ball joint.

13097-2R
99070R1

- the front wheels,

- the oil collector under the gearbox.

21-6
 MANUAL GEARBOX
Gearbox (Removal - Refitting) 21
Check that the rollers for the left hand driveshaft
do not come out by hand. If they do, check that
the needles have not fallen into the gearbox.

Disconnect and remove the starter motor.

Disconnect:
- the reversing light switch,
- the speedo connector and remove the final
drive sensor.

Remove:
- the exhaust downpipe,
- the complete gear control rod, removing bolt
(E) and the three bolts for the heat shield to
reach the base of the gear lever,
- the engine tie bar bolt,
- the rear gearbox mounting.

13120S

Remove the steering rack and attach it.

Fit the engine support tool and take the weight of

the engine and transmission assembly.

Positioning for F8Q engine

12993-1R2

Remove the engine - gearbox tie rod. 14279-1S

To make removing the steering rack easier, if ne-

cessary, fit a block to allow the engine to be tilted
forwards.

21-7
 MANUAL GEARBOX
Gearbox (Removal - Refitting) 21
Positioning for other engines Fit the trolley (Mot. 1040-01) to support the sub-
frame and lower the vehicle.

14278S

Remove the three mounting bolts for the support

on the gearbox.

98755R1

Remove the sub-frame by slackening the four

mounting bolts.

Fit the component jack under the gearbox wi-

thout lifting it.

Release the gearbox from the engine by removing

nut (E) and the engine - gearbox mounting stud.

12924R

Lower the engine as far as possible.

Remove:
- the last upper bolt at the edge of the gearbox,
- the shield/bumper.
85812-1R

21-8
 MANUAL GEARBOX
Gearbox (Removal - Refitting) 21
REFITTING

Coat the walls of the guide tube and the fork pads
with MOLYKOTE BR2 .

Fit the fork in the lugs on the clutch thrust pad.

Connect the gearbox to the engine, avoiding alte-

ring the height of the engine.

Ensure the engine - gearbox centring rings are

present and correctly positioned.

Stud (C) makes connecting the engine and gear-

box easier.

86308R2

Refit:
- the sub-frame,
- the steering,
- the exhaust downpipe,
- the engine tie bar.

SPECIAL NOTES FOR E7J ENGINES

Refit the exhaust downpipe before refitting the

right hand driveshaft.

Refitting is then the reverse of removal.

21-9
 DRIVESHAFTS
General 29
SPECIFICATIONS

Driveshaft joint
Engines Gearbox
Left Right

F8Q JB1

D7F
GE 86 + GI 69 GE 86 + RC 462
E7J JB1
K7M

CONSUMABLES

Type Quantity Component concerned

RHODORSEAL Coat Driveshaft roll pin, gearbox end

MOBIL OIL
180 g
55911L 611 GE 86
Part No. : 77 01 366 100
(supplied with the repair kit)

SHELL STAMINA 0233 grease

110 cm3 RC 462
(supplied with the repair kit)

NOTE : the ENKO driveshaft nut does not require the stub axle splines to be coated with Loctite SCELBLOC.

29-1
 DRIVESHAFTS
Front driveshafts 29
SPECIAL TOOLING REQUIRED

B. Vi. 31-01 Roll pin punch

Rou. 604-01 Hub locking tool
T. Av. 476 Ball joint extractor
T. Av. 1050-02 Driveshaft extractor

TIGHTENING TORQUES (in daN.m) On both sides

Driveshaft nut 28 Remove:

Gaiter mounting bolt on gearbox 2.5 - the track rod end nut and remove the pin
using tool T. Av. 476,
Wheel bolt 9
- the upper shock absorber base bolt.
Shock absorber base nut 18
Brake caliper mounting bolt 10 Push the driveshaft back using tool T. Av. 1050-02
Track rod end nut 3.7 (if necessary).

Remove the lower shock absorber base bolt and

REMOVAL remove the driveshaft.

Put the vehicle on a 2 post lift.

Drain the gearbox.

Remove:
- the brake assembly (suspend it from the
chassis),
- the driveshaft nut ; tool Rou. 604-01.

Left hand side

Remove the three bolts on the gearbox.

Right hand side

Remove the roll pin; tool B. Vi. 31-01.

99544R

29-2
 DRIVESHAFTS
Front driveshafts 29
REFITTING

Left hand side:

Fit the driveshaft as horizontally as possible.

Right hand side:

Coat the splines of the joint at the gearbox end

with MOLYKOTE BR2 .

Fit the driveshaft and check its position using the

elbow pin B. Vi. 31-01.

Fit two new roll pins : B. Vi. 31-01. Seal the roll pin
holes using RHODORSEAL 5661.

On both sides:

Fit the driveshaft stub axle into the hub; it should

enter easily.

Refitting is then the reverse of removal. Observe

the correct tightening torques.

Fill the gearbox with oil.

Press the brake pedal several times to bring the

piston into contact with the pads.

29-3
 DRIVESHAFTS
Left hand
driveshaft
Front driveshafts 29
SPECIAL TOOLING REQUIRED

T. Av. 1168 CAILLAU clip pliers

T. Av. 1256 OETIKER clip crimping pliers
T. Av. 1331 Tool for retaining the driveshaft bearing
gaiter in position

REPLACING THE GAITER, GEARBOX END REFITTING

GI 69 JOINT To be correctly positioned on the shaft, the

bearing must be pressed on to give dimension
1 Spider L = 118 ± 0.2 mm between the rear part of the
2 Rubber gaiter bearing and the end of the shaft.
3 Bearing guide
4 Retaining clip This dimension is obtained using tool T. Av. 1331
5 Shield when the end of the tool is level with the shaft.
6 Circlip
7 Driveshaft

85884-1R1

DI2935R
NOTE : to avoid damaging the bearing which has
a lip seal, which could cause leakage, do not press
REMOVAL it on using a mallet, but use the press to ensure
progressive pressure.
Remove the circlip.
The driveshaft is secured on the press by groove
On the press, remove the spider using an (G) using an extractor.
extractor.
Fit the spider into the position noted on removal
NOTE : note the position of the spider before and refit the retaining circlip.
removing it.

Remove the gaiter and bearing - shield assembly

in the same manner as for the spider.

29-4
 DRIVESHAFTS
Left hand
driveshaft
Front driveshafts 29
REPLACING THE GAITER, WHEEL END Remove the gaiter and replace it with a new one.

GE 86 JOINT Spread the recommended dose of grease in the

gaiter and the stub axle bowl.
1 Stub axle bowl
2 Retaining starplate NOTE : the volume of grease specified in the
3 Spider consumables section must be observed.
4 Shaft yoke
5 Thermoplastic gaiter Position the two gaiter rings in the grooves on the
6 Clips stub axle bowl.
7 Spring
8 Pushrod Adjust the amount of air in the gaiter.
9 Shim
10 ABS target Fit the clips and tighten them.

DI2934R

REMOVAL

Cut the two collars (6), taking care to avoid

damaging the grooves in the stub axle bowl.

Remove as much grease as possible.

To replace the thermoplastic gaiter, the parts at

the gearbox end must be removed(GI 69 joint)
(see method described previously).

29-5
 DRIVESHAFTS
Right hand
driveshaft
Front driveshafts 29
REPLACING THE GAITER, GEARBOX END REFITTING

RC 462 JOINT Slightly lubricate the driveshaft to make fitting

the gaiter easier (position the smaller diameter of
1 Yoke sleeve the gaiter on the driveshaft groove).
2 Spider
3 Locking spring ring Position the spider in the position noted on
4 Gaiter removal and fit the locking spring ring.
5 Clips
Crimp three points at 120° by folding over the
metal of the splines on the driveshaft.

Fit the yoke sleeve on the spider.

Spread the dose of grease in the gaiter and the

yoke sleeve.

Ensure the gaiter is correctly positioned in the

grooves.

Insert a rounded end rod between the gaiter and

the yoke sleeve to adjust the amount of air in the
joint.

Lengthen or shorten the joint to obtain dimension

A = 190 mm (dimension measured between the
end of the gaiter and the face of the smaller dia-
meter of the yoke sleeve).

DI2933R Remove the rod in this position.

REMOVAL

Cut the two collars (5), taking care to avoid

damaging the groove in the yoke sleeve.

Remove as much grease as possible.

Remove the yoke sleeve.

Remove the locking spring ring.

IMPORTANT: never use thinners to clean the

parts.

On the press, remove the spider, using a releasing 90392R1

type extractor.
Refit the clips using the recommended tooling.
NOTE : note the position of the spider before
removing it.

29-6
 DRIVESHAFTS
Right hand
driveshaft
Front driveshafts 29
REPLACING THE GAITER, WHEEL END NOTE : certain right hand driveshafts have a vibra-
tion damper. If the thermoplastic gaiter is dama-
GE 86 JOINT ged, replace the complete driveshaft.

1 Stub axle bowl Remove the gaiter and replace it with a new one.
2 Retaining starplate
3 Spider Spread the recommended dose of grease in the
4 Shaft yoke gaiter and the stub axle bowl.
5 Thermoplastic gaiter
6 Clips NOTE : the volume of grease specified in the
7 Spring consumables section must be observed.
8 Pushrod
9 Shim Position the two gaiter rings in the grooves on the
10 ABS target stub axle bowl.

Adjust the amount of air in the gaiter.

Fit the clips and tighten them.

DI2934R

REMOVAL

Cut the two collars (6), taking care to avoid

damaging the grooves in the stub axle bowl.

Remove as much grease as possible.

To replace the thermoplastic gaiter, the parts at

the gearbox end must be removed(RC 462 joint)
(see method described previously).

29-7