Transmission 2009-2015 Renault Fluence

CLUTCH
Clutch: Specifications 20A

K4M or K9K
K9K, and 838

K4M, and 838
108795
132330
102142
102142 Plate outer diameter: 216 mm
Plate external diameter: 200 mm
Plate thickness: 7 mm
Plate thickness: 6.9 mm
Number of grooves: 26
20A-1
CLUTCH
Clutch: Specifications 20A
K4M or K9K
K9K, and 842
123819
123820
Plate outer diameter: 225 mm
Plate thickness: 6.9 mm
20A-2
CLUTCH
Pressure plate - Disc: Removal - Refitting 20A
JH3 or JR5 or TL4
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
clutch pressure plate 12 N.m JH3 or JR5

bolts
clutch pressure plate 15 N.m

bolts
IMPORTANT
To avoid all risk of damage to the systems, apply

the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair:
- (see Clutch: Precautions for the repair) ,
- (see Vehicle: Precautions for the repair) (01D,
Mechanical introduction).
Note:
When fitting the clutch plate, the "RENAULT part
134558
number" should be visible when the plate is in posi-
tion. a Lock the flywheel using tool (1) .
a Remove:
REMOVAL - the bolts (2) from the « mechanism - disc » assem-

bly,
I - REMOVAL PREPARATION OPERATION - the « pressure plate - disc » assembly.
a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).
a Remove the manual gearbox (see 21A, Manual
gearbox, Manual gearbox: Removal - Refitting,
page 21A-5) .
20A-3
CLUTCH
JH3 or JR5 or TL4
II - REFITTING OPERATION FOR PART
CONCERNED
K9K, and TL4
134217 132331
a Lock the flywheel using tool (4) . a Fit the clutch plate, with the face (6) to the clutch
a Remove: pressure plate end.
- the bolts (3) from the « mechanism - disc » assem-
bly,
JH3 or JR5
- the « pressure plate - disc » assembly.
REFITTING
I - REFITTING PREPARATION OPERATION

a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
- the flywheel friction face,
- the clutch shaft splines.
WARNING
Do not grease the clutch shaft splines.
134557
a Centre the clutch plate using the (7) .
20A-4
CLUTCH
JH3 or JR5 or TL4
K9K, and TL4
134219
a Centre the clutch plate using the (8) .
a Refit the clutch mechanism.
TL4
a Torque tighten the clutch pressure plate bolts (12

N.m) gradually in a radial pattern.
JH3 or JR5
a Torque tighten the clutch pressure plate bolts (15

N.m) gradually in a radial pattern.
a Remove theand.
III - FINAL OPERATION
a Refit the manual gearbox (see 21A, Manual gear-

box, Manual gearbox: Removal - Refitting, page
21A-5) .
20A-5
CLUTCH
Clutch thrust bearing: Removal - Refitting 20A
JH3 or JR5 or TL4
REFITTING
Tightening torquesm
clutch thrust bearing 21 N.m
bolts a parts always to be replaced: Clutch thrust bear-
ing (12,03,01,04).
REMOVAL Note:
To obtain optimum bleeding, pre-fill the clutch
I - REMOVAL PREPARATION OPERATION thrust bearing when refitting the thrust bearing.
a Remove the manual gearbox (see 21A, Manual CONCERNED
gearbox, Manual gearbox: Removal - Refitting,
a Refit a new clutch thrust bearing.
page 21A-5) .
a Torque tighten the clutch thrust bearing bolts (21
N.m).
CONCERNED
a Refit the manual gearbox (see 21A, Manual gear-
box, Manual gearbox: Removal - Refitting, page
21A-5) .
134625
a Remove:
- the bolts (1) from the clutch thrust bearing,
- the clutch thrust bearing.
20A-6
MANUAL GEARBOX
Manual gearbox oils: Draining - Filling 21A
JH3 or JR5
Special tooling required
Mot. 1018 8 mm square engine drain

plug spanner.
Equipment required
oil recovery tray
torque wrench
oil change end piece with an 8 mm square drive
Tightening torquesm
drain plug 25 N.m
Gearbox type Capacity (litres)
JH3 2.7 136474

a Remove the drain plug (1) using the (Mot. 1018).
JR5 2.4
a Let the oil run into the oil recovery tray.
I - PARTS AND CONSUMABLES FOR THE REPAIR

a Part for repair:
- the manual gearbox drain plug seal.
a Consumables for repair:
- Manual gearbox oil (see Manual gearbox oil:
Specifications) (Technical Note 6012A, 04A, Lu-
bricants).
II - DRAINING OPERATION
a Remove:
- the engine undertray bolts,
- the engine undertray.
a Position the oil recovery tray under the gearbox.
113764
a Refit a new seal on the drain plug with the groove (2)
facing the plug.
a Refit the drain plug fitted with its new seal.
a Torque tighten the drain plug (25 N.m) using a
torque wrench fitted with a oil change end piece
with an 8 mm square drive.
21A-1
MANUAL GEARBOX
JH3 or JR5
III - FILLING
135244
a Undo the filler cap (3) .
92081
a Fill the gearbox using a syringe containing recom-
mended oil (see Manual gearbox oil: Specifica-
tions) (04A, Lubricants) until the oil overflows out of
the filler cap hole.
a Refit the filler cap.
a Wipe any oil run-off with a cloth.
a Remove the oil recovery tray.
a Refit the engine undertray.
21A-2
MANUAL GEARBOX
TL4
Mot. 1018 8 mm square engine drain

plug spanner.
Equipment required
oil recovery tray
torque wrench
oil change end piece with an 8 mm square drive
Tightening torquesm
drain plug 24 N.m
CAPACITY
Gearbox type Capacity (litres) 136488
TL4 1.9 a Remove the drain plug (1) using the (Mot. 1018).
a Let the oil flow out of the gearbox in the oil recovery
I - PARTS AND CONSUMABLES FOR THE REPAIR tray.
a Part for repair:
- the manual gearbox drain plug seal.
a Consumables for repair:
- Gearbox oil (see Manual gearbox oil: Specifica-
tions) (Technical Note 6012A, 04A, Lubricants).
II - DRAINING OPERATION
a Remove:
a Position the oil recovery tray under the gearbox.
113764
a Refit a new seal on the drain plug with the groove (2)
facing the plug.
a Refit the drain plug fitted with its new seal.
a Torque tighten the drain plug (24 N.m) using a

torque wrench fitted with a oil change end piece
with an 8 mm square drive.
21A-3
MANUAL GEARBOX
TL4
III - FILLING
136503
a Undo the filler cap (3) .
92081
a Fill the gearbox using a syringe containing recom-
mended oil (see Manual gearbox oil: Specifica-
tions) (04A, Lubricants) until the oil overflows out of
the filler cap hole.
a Refit the filler cap.
a Wipe any oil run-off with a cloth.
a Remove the oil recovery tray.
21A-4
MANUAL GEARBOX
Manual gearbox: Removal - Refitting 21A
K4M, and JH3
- the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Equipment required
Washing),
safety strap(s) - the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
indelible pencil
- the scoop under the scuttle panel grille (see Scoop
component jack under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
- the battery (see Battery: Removal - Refitting)
Tightening torquesm (80A, Battery),
- the battery tray (see Battery tray: Removal - Re-
stud on the engine 7 N.m
fitting) (80A, Battery),
stud on the gearbox 7 N.m - the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture).
manual gearbox nuts 44 N.m
a Loosen the clip on the throttle valve air inlet pipe.
manual gearbox lower 44 N.m
a Disconnect the air outlet pipe from the air filter unit.
bolts
a Remove the air outlet pipe from the air filter box.
manual gearbox earth 24 N.m
cable bolt
manual gearbox upper 44 N.m

bolts
left-hand suspended 62 N.m

engine mounting cover
bolts on the manual
gearbox
left-hand suspended 62 N.m

engine mounting rubber
pad mounting bolt
air filter unit air inlet pipe 6 N.m

clip
IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
REMOVAL
I - REMOVAL PREPARATION OPERATION

a Remove:
- the engine cover,
21A-5
MANUAL GEARBOX
K4M, and JH3
134553 136542
a Fit the toolon the hydraulic clutch supply pipe at the

outlet of the brake fluid reservoir.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
a Remove the hydraulic clutch pipe (see Clutch cir-

cuit: Removal - Refitting) (37A, Mechanical com-
ponent controls).
a Disconnect the reverse gear switch connector.
a Remove:
- the manual gearbox breather pipe,
- the front wheels (see Wheel: Removal - Refitting)

(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
109149 Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
a Unclip:
- the gear selector cables on the manual gearbox by
pushing at (1) , - the engine undertray,
- the control cables by pushing at (2) . - the front bumper (see Front bumper: Removal -
a Move the manual gearbox selector cables aside. Refitting) (55A, Exterior protection).
a Drain the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling, page
21A-1) .
a Remove:
- the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),
21A-6
MANUAL GEARBOX
K4M, and JH3
- the lower engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine mount-
ing),
- the crankshaft position sensor (see Crankshaft
position sensor: Removal - Refitting) (17B,
Petrol injection),
- the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
- the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
- the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-25) ,
- the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(31A, Front axle components),
- the front axle subframe (see Front axle subframe: 135947
Removal - Refitting) (31A, Front axle compo- a Unclip the battery wiring channel at (3) .
nents).
a Move aside the battery wiring channel.
135935
134554
a Fit thefitted with thewith a safety strap(s).
a Remove the bolt (4) of the rubber pad mounting from
the left-hand suspended engine mounting on the
manual gearbox.
a Slightly lower the manual gearbox.
21A-7
MANUAL GEARBOX
K4M, and JH3
CONCERNED
134548
a
134554
a Remove: Note:
- the bolts (5) of the left-hand suspended engine Before removing the earth terminal, mark its
mounting rubber pad cover on the manual gearbox, position using a indelible pencil by drawing a
line on the earth terminal and on the gearbox
- the left-hand suspended engine mounting cover on casing.
the manual gearbox.
When reassembling, improper positioning of the
earth terminal on the gearbox casing could result
in damage to the earth terminal or ear th cable.
a Remove the manual gearbox earth cable bolt (7) .

a Remove the earth cable from the manual gearbox.
135243
a Remove the manual gearbox upper bolts (6) .
21A-8
MANUAL GEARBOX
K4M, and JH3
134555 134549
a Fit:
- theto a component jack,
- theand the component jack under the manual
gearbox.
a Tighten the rod anti-clockwise to avoid tilting the
manual gearbox.
134548
a Remove:
- the manual gearbox nuts (9) and (10) ,
- the manual gearbox using the component jack
and.
a When replacing the manual gearbox, remove the re-
134543 verse gear switch (see 21A, Manual gearbox, Re-
verse gear switch: Removal - Refitting, page
a Remove the lower bolts (8) from the manual gear-
21A-37) .
box.
21A-9
MANUAL GEARBOX
K4M, and JH3
REFITTING a Refit the left-hand suspended engine mounting cov-

er on the manual gearbox.
I - REFITTING PREPARATION OPERATION a Torque tighten the left-hand suspended engine

mounting cover bolts on the manual gearbox (62
a N.m).
Note:
If a stud loosens during this operation, coat it III - FINAL OPERATION
with FRENETANCHE.
a Bring into contact the left-hand suspended engine
Torque tighten: mounting cover on the left-hand suspended engine
mounting rubber pad using the toolfitted with the
- the stud on the engine (7 N.m),
tool.
- the stud on the gearbox (7 N.m).
a Refit the bolt of the left-hand suspended engine
mounting rubber pad mounting on the manual gear-
Replacing the manual gearbox box.
a Refit the reverse gear switch (see 21A, Manual a Torque tighten the left-hand suspended engine
gearbox, Reverse gear switch: Removal - Refit- mounting rubber pad mounting bolt (62 N.m).
ting, page 21A-37) . a Fit the battery wiring channel.
a Clip on the battery wiring channel.
Note:
a Remove the toolfitted with the toolusing the safety
To fit the toolon the new manual gearbox, follow
strap(s).
the same steps as for the removal operation.
a Refit:
a Fit the new manual gearbox on the.
- the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
II - REFITTING OPERATION FOR PART nents),
CONCERNED
a Ensure that the « engine - gearbox » centring rings mounting cross member: Removal - Refitting)
are in place and correctly positioned. (31A, Front axle components),
a Fit the manual gearbox using the component jack - the new differential output seals (see 21A, Manual
and the. gearbox, Differential output seal: Removal - Re-
a Refit the manual gearbox nuts. fitting, page 21A-25) ,
a Torque tighten the manual gearbox nuts (44 N.m). - the front right-hand driveshaft (see 29A, Drive-
a Remove the tool:
- the manual gearbox,
- from the component jack. shafts, Front left-hand driveshaft: Removal -
a Refit the manual gearbox lower bolts.
a Torque tighten the manual gearbox lower bolts - the crankshaft position sensor (see Crankshaft
(44 N.m). position sensor: Removal - Refitting) (17B,
Petrol injection),
a It is essential to refit the earth cable respecting the
marks made during disassembly. - the lower engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine mount-
a Refit the earth cable bolt on the manual gearbox. ing),
a Torque tighten the manual gearbox earth cable - the starter (see Starter: Removal - Refitting)
bolt (24 N.m). (16A, Starting - Charging).
a Refit the manual gearbox upper bolts.
a Fill the manual gearbox (see 21A, Manual gearbox,
a Torque tighten the manual gearbox upper bolts Manual gearbox oils: Draining - Filling, page
(44 N.m). 21A-1) .
21A-10
MANUAL GEARBOX
K4M, and JH3
a Refit:
- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),
- the engine undertray,

Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the hydraulic clutch pipe (see Clutch circuit: Re-

moval - Refitting) (37A, Mechanical component
controls),
a Remove the toolfrom the hydraulic clutch supply

pipe at the outlet of the brake fluid reservoir.
a Bleed the hydraulic clutch circuit (see Clutch cir-
cuit: Bleed) (37A, Mechanical component controls).
a Fit the manual gearbox gear selector cables.

a Clip on the manual gearbox gear selector cables.
a Adjust the manual gearbox gear selector cables

(see Mechanical gear control cable: Adjustment)
(37A, Mechanical component controls).
a Connect the reverse gear switch connector.
a Refit the air outlet pipe onto the air filter unit.
a Connect the air outlet pipe of the air filter unit.
a Torque tighten the air filter unit air inlet pipe clip
(6 N.m).
a Refit:
- the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),


(80A, Battery),
- the scoop under the scuttle panel grille (see Scoop

under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),
- the windscreen wiper arms (see Windscreen wip-

er arm: Removal - Refitting) (85A, Wiping -
Washing),
- the engine cover.
21A-11
MANUAL GEARBOX
K9K, and TL4
Equipment required
indelible pencil
component jack
Tightening torquesm
manual gearbox bolts 44 N.m
manual gearbox earth 24 N.m

cable bolt
REMOVAL

135508
a Disconnect the connector (1) from the turbocharging
pressure regulation solenoid valve.
a Remove:
a Move aside the turbocharging pressure regulation
- the engine cover, solenoid valve wiring.
(80A, Battery),
fitting) (80A, Battery).
a Remove the air filter unit (see Air filter unit: Re-
moval - Refitting) (12A, Fuel mixture).
135506
a Unclip the battery wiring channel (2) from the left-
hand suspended engine mounting.
a Move the battery wiring channel away from the left-
21A-12
MANUAL GEARBOX
K9K, and TL4
134484 134224
a Unclip: a Unclip the following from the manual gearbox:
- the gear control cables (3) from the selector ball - the engine wiring channel (5) ,
joints using an open-jawed spanner,
- the manual gearbox breather pipe (6) .
- the gear control cables (4) from their support,
a Move aside the manual gear selector cables.
a Disconnect the reverse gear switch connector.
a Remove:
- the hydraulic clutch control pipe (see Clutch cir-
ponent controls).
Petrol injection).
21A-13
MANUAL GEARBOX
K9K, and TL4
nents).
K9K, and 832 or 842
134214
a
Note:
Before removing the earth terminal, mark its
position using a indelible pencil by drawing a
casing.
in damage to the earth terminal or earth wiring.
a Remove the earth cable bolt (7) from the manual

gearbox.
a Remove: 134216
- the starter (see Starter: Removal - Refitting) a Remove:

(16A, Starting - Charging), - the catalytic converter downstream strut bolts (9) ,
- the front wheels (see Wheel: Removal - Refitting) - the nut (1 0) from the catalytic converter down-
(35A, Wheels and tyres), stream strut,
- the front section of the front wheel arch liners (see - the catalytic converter downstream strut.
(55A, Exterior protection).
box, Manual gearbox oils: Draining - Filling, page a Unclip the rail protector drain pipe from the manual
21A-1) . gearbox.
a Remove: a Remove the left-hand suspended engine mounting
(see Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
CONCERNED
Refitting, page 29A-8) , a Remove the manual gearbox bell housing bolts.
21A-14
MANUAL GEARBOX
K9K, and TL4
tilting the manual gearbox.
a Remove:
- the nuts from the manual gearbox,
- the manual gearbox using the component jack and
the,
- the clutch thrust bearing (see 20A, Clutch, Clutch
thrust bearing: Removal - Refitting, page 20A-6)
.
REFITTING

a parts always to be replaced: Clutch thrust bear-
ing (12,03,01,04).
WARNING
116711
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
WARNING
Do not grease the clutch shaft splines.
a Check that the centring dowelsare in place.
116713
a Fit:
- theto a component jack,
- the component jack fitted with theunder the me-
chanical gearbox,
- the bracket (12) using the nuts (13) ,
- the support (14) ,
- the pin (15) ,
- the rod (16) using the bracket (17) and the bolt (18)
.
a Tighten the rod (16) anti-clockwise in order to avoid
21A-15
MANUAL GEARBOX
K9K, and TL4
If replacing the manual gearbox
K9K, and 832 or 842

a Refit:
- the catalytic converter downstream strut,
- the catalytic converter downstream strut bolts,
- the catalytic converter downstream strut nut.

a Refit:
nents),
116712 (31A, Front axle components),
a - the front bumper (see Front bumper: Removal -
Note:
- new differential output seals (see 21A, Manual
To fit the tool onto the new manual gearbox, fol- gearbox, Differential output seal: Removal - Re-
low the same steps as for the removal operation. fitting, page 21A-25) ,
a Fit the new manual gearbox on the component jack - the front left-hand driveshaft (see 29A, Drive-
fitted with the. shafts, Front left-hand driveshaft: Removal -
II - REFITTING OPERATION FOR PART - the front right-hand wheel driveshaft (see 29A,
CONCERNED Driveshafts, Front right-hand driveshaft: Re-
moval - Refitting, page 29A-8) .
a Refit:
a Fill up the manual gearbox (see 21A, Manual gear-
- a new clutch thrust bearing (see 20A, Clutch, box, Manual gearbox oils: Draining - Filling, page
Clutch thrust bearing: Removal - Refitting, page 21A-1) .
20A-6) ,
a Refit:
- the manual gearbox using the component jack
and. - the front section of the front wheel arch liners (see
a Remove the component jack fitted with thefrom the (55A, Exterior protection),
manual gearbox.
a Torque tighten: (35A, Wheels and tyres),
- the manual gearbox nuts (44 N.m), - the starter (see Starter: Removal - Refitting)
- the manual gearbox bolts (44 N.m). (16A, Starting - Charging).
III - FINAL OPERATION Note:

a Refit the left-hand suspended engine mounting (see Refit the earth terminal, aligning the indelible
Left-hand suspended engine mounting: Remov- marks on the gearbox casing.
al - Refitting) (19D, Engine mounting). When reassembling, improper positioning of the
a Clip the rail protector drain pipe onto the manual earth terminal on the gearbox casing could result
gearbox. in damage to the earth terminal or ear th wiring.
21A-16
MANUAL GEARBOX
K9K, and TL4
a Torque tighten the manual gearbox earth cable
bolt (24 N.m).
a Clip the following on the manual gearbox:
- the engine harness channel.
a Refit:
Petrol injection),
ponent controls).
a Fit the manual gear selector cables.
a Clip:
- the gear selector cables onto their mounting,
- the gear selector cables onto the gear selector ball
joints.
a Fit the battery wiring channel on the left-hand sus-
pended engine mounting.
a Fit the turbocharging pressure regulation solenoid
valve wiring.
a Connect the turbocharging pressure regulation sole-
noid valve connector.
a Refit the air filter unit (see Air filter unit: Removal -
Refitting) (12A, Fuel mixture).
a Refit:
(80A, Battery),
- the engine cover.
21A-17
MANUAL GEARBOX
K9K, and TL4
21A-18
MANUAL GEARBOX
K9K, and JR5
Equipment required
indelible pencil
component jack
Tightening torquesm
reverse gear switch 23 N.m
manual gearbox studs 6.5 N.m
manual gearbox lower 44 N.m

bolts
manual gearbox upper 44 N.m

bolts
manual gearbox earth 24 N.m 135508

cable bolt a Disconnect the connector from the turbocharging
pressure regulation solenoid valve (1) .
a Move aside the turbocharging pressure regulation
REMOVAL solenoid valve wiring.

a Remove:
- the engine cover,
(80A, Battery),
a Remove the air filter unit (see Air filter unit: Re-
moval - Refitting) (12A, Fuel mixture).
135415
a Unclip the battery wiring channel from the left-hand
suspended engine mounting (2) .
a Remove the battery wiring channel from the left-
21A-19
MANUAL GEARBOX
K9K, and JR5
ponent controls).
Petrol injection).
135416
136633
a Unclip the following from the manual gearbox:
- the engine wiring channel (10) ,
- the manual gearbox breather pipe (11) .
109149
a Unclip the manual gear selector cables by:

- unclipping the anchoring ball joints (3) from the
manual gear selector,
- pinching the manual gear selector at (A) ,
- lifting the manual gear selector (4) from the manual
gear selector mounting.
a Move aside the manual gear selector cables.
a Remove:
21A-20
MANUAL GEARBOX
K9K, and JR5
nents).
135846
a
Note:
Before removing the earth terminal, mark its
position using a indelible pencil by drawing a
casing.
in damage to the earth terminal or earth wiring.
135848
a Remove the earth cable bolt (12) from the manual
gearbox. a Disconnect the connector (13) from the reverse gear
switch.
a Remove:
a Unclip the reverse gear switch wiring from the man-
- the starter (see Starter: Removal - Refitting) ual gearbox at (14) .
(16A, Starting - Charging),
(55A, Exterior protection).
21A-1) .
a Remove:
21A-21
MANUAL GEARBOX
K9K, and JR5
CONCERNED
K9K, and 830 or 838
135850
135851
a Remove the manual gearbox upper bolts (18) .
a Remove:
- the catalytic converter downstream strut bolts (15) ,
- the nut (16) from the catalytic converter down-
stream strut,
- the catalytic converter downstream strut.
a Remove the left-hand suspended engine mounting

(see Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
134555
a Fit a component jack (19) beneath the manual
gearbox.
21A-22
MANUAL GEARBOX
K9K, and JR5
a Refit the reverse gear switch on the new manual
gearbox.
a Torque tighten the reverse gear switch (23 N.m)
using the.

CONCERNED
a Refit a new clutch thrust bearing (see 20A, Clutch,
Clutch thrust bearing: Removal - Refitting, page
20A-6) .
a Fit the new manual gearbox using the component
jack.
a Refit the manual gearbox studs.
a Torque tighten the manual gearbox studs (6.5
N.m).
a Refit the manual gearbox nuts.
a Torque tighten the manual gearbox nuts (44 N.m).
135852
a Refit the manual gearbox lower bolts.
a Remove:
a Torque tighten the manual gearbox lower bolts
- the lower bolts (20) from the manual gearbox, (44 N.m).
- the nuts from the manual gearbox, a Remove the component jack from the manual
- the manual gearbox using the component jack, gearbox.
- the manual gearbox studs, a Refit the manual gearbox upper bolts.
- the clutch thrust bearing (see 20A, Clutch, Clutch a Torque tighten the manual gearbox upper bolts
thrust bearing: Removal - Refitting, page 20A-6) (44 N.m).
.
REFITTING a Refit the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Remov-
al - Refitting) (19D, Engine mounting).
a parts always to be replaced: Clutch thrust bear-
K9K, and 830 or 838
ing (12,03,01,04).
a Refit:
WARNING - the catalytic converter downstream strut,

To avoid damaging the slave cylinder, do not coat - the catalytic converter downstream strut bolts,
the gearbox output shaft with grease.
- the catalytic converter downstream strut nut.
WARNING
Do not grease the clutch shaft splines. a Clip the reverse gear switch wiring on the manual
gearbox.
a Check that there are centring rings in place on the
new manual gearbox. a Connect the reverse gear switch connector.
a Refit:
Replacing the manual gearbox
a When replacing the manual gearbox, remove the re- Removal - Refitting) (31A, Front axle compo-
verse gear switch from the gearbox using the tool. nents),
21A-23
MANUAL GEARBOX
K9K, and JR5
- the radiator mounting cross member (see Radiator a Refit the engine undertray.
a Fit the manual gear selector cables.
a Clip the manual gear selector cables:
Refitting) (55A, Exterior protection), - on the sheath stop,
- new differential output seals (see 21A, Manual - on the anchoring ball joints.
a Fit the battery wiring channel on the left-hand sus-
pended engine mounting.
- the front left-hand driveshaft (see 29A, Drive- a Fit the turbocharging pressure regulation solenoid
shafts, Front left-hand driveshaft: Removal - valve wiring.
a Connect the turbocharging pressure regulation sole-
- the front right-hand wheel driveshaft (see 29A, noid valve connector.
Driveshafts, Front right-hand driveshaft: Re-
moval - Refitting, page 29A-8) . a Refit the air filter unit (see Air filter unit: Removal -
Refitting) (12A, Fuel mixture).
box, Manual gearbox oils: Draining - Filling, page a Refit:
21A-1) . - the battery tray (see Battery tray: Removal - Re-
a Refit: fitting) (80A, Battery),
- the front section of the front wheel arch liners (see - the battery (see Battery: Removal - Refitting)
Front wheel arch liner: Removal - Refitting) (80A, Battery),
(55A, Exterior protection), - the engine cover.
- the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging).
Note:
Refit the earth terminal, at the mark made by the
indelible pencil on the gearbox casing.
earth terminal on the gearbox housing could
result in damage to the earth terminal or earth
cable.
a Torque tighten the manual gearbox earth cable

bolt (24 N.m).
a Clip the following on the manual gearbox:
- the engine harness channel.
a Refit:
Petrol injection),
ponent controls).
21A-24
MANUAL GEARBOX
Differential output seal: Removal - Refitting 21A
JH3 or JR5
CONCERNED
Equipment required
roll pin punch Right-hand differential output seal
REMOVAL

a Remove:
21A-1) .
1 - When replacing the differential output seal on

the left-hand side
a Remove: 125563
- the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres), Left-hand differential output seal
Refitting, page 29A-2) .

the right-hand side
a Remove:
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front right-hand wheel driveshaft (see 29A,
125569
a Tap the base of the differential output seal using a
roll pin punch and a small hammer to detach it and
rotate it in its housing.
a Remove the seal with a screwdriver, taking care not
to damage the differential housing.
21A-25
MANUAL GEARBOX
JH3 or JR5
REFITTING

a parts always to be replaced: Differential output
seal (12,01,05,10).
21A-26
MANUAL GEARBOX
JH3 or JR5
II - REFITTING OPERATION FOR PART Refitting the left-hand side differential output seal.
CONCERNED
103191
Refitting the right-hand side differential output seal

125562
a Refit a new differential output seal using the tool (1)

composed of:
- a mandrel (2) for the right-hand side,
- a mandrel (3) for the left-hand side.
a Lubricate the internal surface of the differential out-

put seal.
a Fit:
- a differential output seal on the gearbox,
- the mandrel (2) or (3) of the toolon the new differ-

ential output seal.
a Tap the tool (1) with a copper hammer to fit the new
125570
differential output seal fully.

the left-hand side
a Refit:


Refitting) (35A, Wheels and tyres).
21A-27
MANUAL GEARBOX
JH3 or JR5
the right-hand side
a Refit:

21A-1) .
21A-28
MANUAL GEARBOX
TL4
CONCERNED
Equipment required
roll pin punch Left-hand differential output seal
REMOVAL

a Remove:
21A-1) .

the left-hand side
a Remove: 125894
Refitting) (35A, Wheels and tyres), Right-hand differential output seal
Refitting, page 29A-2) .

the right-hand side
a Remove:
- the front right-hand wheel driveshaft (see 29A,
125896
a Tap the base of the lip seal using a roll pin punch
and a small hammer to release it and make it turn in
its housing.
a Remove the lip seal using a large screwdriver, tak-
ing care not to damage the differential housing.
21A-29
MANUAL GEARBOX
TL4
REFITTING

a parts always to be replaced: Differential output
seal (12,01,05,10).
21A-30
MANUAL GEARBOX
TL4
II - REFITTING OPERATION FOR PART Refitting the left-hand side differential output seal.
CONCERNED
116923
Refitting the right-hand side differential output seal

125893
a The new differential output seal is refitted using the
tool (1) consisting of:
- a mandrel (2) for the right-hand side,
- a mandrel (3) for the left-hand side.
a Oil the internal surface of the new differential output
seal.
a Fit:
- the new differential output seal on the gearbox,
- the mandrel (2) or (3) of the toolon the new differ-
ential output seal.
a Tap the tool (1) with a copper hammer to fit the new
differential output seal fully.

125895
1 - Refitting the left-hand driveshaft

a Refit:
2 - Refitting the right-hand driveshaft

a Refit:
21A-31
MANUAL GEARBOX
TL4
3 - Final operation
a Fill the manual gearbox oil and check the level (see
21A, Manual gearbox, Manual gearbox oils:
Draining - Filling, page 21A-1) .
21A-32
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting 21A
JH3 or JR5
Bvi. 1828
IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
Note:
The lip seal and the primary shaft bearing are built
into the thrust bearing guide tube.
Bvi. 1445
122820
(6) Snap rivet

(7) Pressure plate
a The thrust pad guide tube is removed using theand.
Note:
The gauge (5) is not used for the JH gearbox.
REMOVAL
99057 I - REMOVAL PREPARATION OPERATION

(1) Tightening clamp Towing and lifting) (02A, Lifting equipment).
(2) Sleeve
a Remove:
(3) Split ring
- the manual gearbox (see 21A, Manual gearbox,
(4) Key Manual gearbox: Removal - Refitting, page 21A-
(5) Sender 5) ,
- the clutch thrust bearing (see 20A, Clutch, Clutch
thrust bearing: Removal - Refitting, page 20A-6)
.
21A-33
MANUAL GEARBOX
JH3 or JR5
CONCERNED
122822
a In order, fit the following on the guide tube:
- the pressure plate (7) of the,
- the tightening clamp (1) of the.
a Immobilise the tightening clamp using the key (4) of
the.
98934
a Tighten the nut firmly.
a Position the manual gearbox on the support.
a Adjust the adjustable support if necessary.
122823
a Position the sleeve (2) and the split ring in place (3)
122821 with the.
a Gently remove the guide tube with a press using the a Gently remove the guide tube by moving the upper
snap rivet (6) , section (A) of theon the guide tube nut (8) .
end.
a Degrease the guide tube.
21A-34
MANUAL GEARBOX
JH3 or JR5
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
122821
a Refit the new guide tube with a press until the snap
rivet is flush (6) on thewith the housing, on the guide
tube section side (B) .
II - FINAL OPERATION
a Refit:
- a new clutch thrust bearing (see 20A, Clutch,
Clutch thrust bearing: Removal - Refitting, page
20A-6) ,
Manual gearbox: Removal - Refitting, page 21A-
5) .
21A-35
MANUAL GEARBOX
TL4
REMOVAL REFITTING

a
Towing and lifting) (02A, Lifting equipment). Note:
When refitting the input shaft lip seal, take care
a Remove:
not to damage either the shaft or the contact sur-
face of the lip seal.
5) ,
CONCERNED
- the hydraulic clutch release bearing (see 20A,
Clutch, Clutch thrust bearing: Removal - Refit-
ting, page 20A-6) .

CONCERNED
18061
a Fit a new input shaft lip seal, fitted with its protector,
using the (2) .
a Remove the protector from the new input shaft lip
seal.
a Insert theand tap it gently with a rubber mallet to en-
sure it is inserted fully.

a Refit:
123822 - a new hydraulic clutch release bearing (see 20A,
Clutch, Clutch thrust bearing: Removal - Refit-
a ting, page 20A-6) ,
Note: - the manual gearbox (see 21A, Manual gearbox,
Do not drill too deeply as this risks damaging the
deflector positioned behind the input shaft lip 5) .
seal.
a Drill a hole in the input shaft lip seal (1) using a 2.5
mm drill bit.
a Fit a bolt in the input shaft lip seal (1) .
a Remove the input shaft lip seal (1) with a pair of pli-
ers.
21A-36
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting 21A
JH3 or JR5
REFITTING
Bvi. 1934 Socket for removing/refitting I - REFITTING OPERATION FOR PART

reverse gear switch CONCERNED
a Apply some SILICONE ADHESIVE SEALANT (see
Vehicle: Parts and consumables for the repair)
Tightening torquesm (04B, Consumables - Products) to the threading of
the reverse gear switch.
reverse gear switch 23 N.m
a Refit the reverse gear switch using the (Bvi. 1934).
a Torque tighten the reverse gear switch (23 N.m).
REMOVAL a Connect the reverse gear switch connector.
I - REMOVAL PREPARATION OPERATION II - FINAL OPERATION

a Position the vehicle on a two-post lift (see Vehicle: a Fill the gearbox (see 21A, Manual gearbox, Manu-
Towing and lifting) (02A, Lifting equipment). al gearbox oils: Draining - Filling, page 21A-1) .
a Remove the engine undertray.

CONCERNED
135848
a Disconnect the connector (1) from the reverse gear

switch.
a Remove the reverse gear switch using the tool (Bvi.

1934).
Note:
Seal the housing of the reverse gear switch while
replacing the part.
21A-37
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting 21A
TL4
II - FINAL OPERATION
Tightening torquesm a Refit:

reverse gear switch 23 N.m fitting) (80A, Battery),
REMOVAL (80A, Battery).

a Remove:
(80A, Battery),

CONCERNED
134484
a Disconnect the connector (1) from the reverse gear
switch.
a Remove the reverse gear switch using the tool.
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
a Refit the reverse gear switch.
a Torque tighten the reverse gear switch (23 N.m)
using the tool.
21A-38
DRIVESHAFTS
Driveshaft: Precautions for the repair 29A
GENERAL RECOMMENDATIONS
1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).
2 - Instructions to be followed during the operation
WARNING
In order to prevent irreversible damage to the front

hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
Lubricate the base of the driveshaft bearing with BR2 +

GREASE (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to prevent
the bearing from sticking.
Always replace the differential output seals every time
a driveshaft is removed.
Check for oil leaks from the gearbox. An oil leak can
damage a driveshaft.
29A-1
DRIVESHAFTS
Front left-hand driveshaft: Removal - Refitting 29A
TL4
CONCERNED
Tightening torquesm
shock absorber base 180 N.m

bolts
track rod end nut 37 N.m
hub nut 280 N.m
bolt of the brake hose 8 N.m

and wheel speed sensor
wiring support
WARNING

hub bearing:
ground when the driveshaft has been loosened or 134508
removed. a Unclip:
- the wheel speed sensor wiring at (1) ,

REMOVAL
- the front brake hose at (2) .

a Remove:
21A-1) .
134507
a Remove:
- the bolt (3) of the brake hose and wheel speed sen-
sor wiring support,
- the brake hose and wheel speed sensor wiring

support,
29A-2
DRIVESHAFTS
TL4
- the nut (4) from the hub, immobilising the hub using a Remove the left-hand side differential output seal
the, (see 21A, Manual gearbox, Differential output
seal: Removal - Refitting, page 21A-25) .
- the nut (5) from the track rod end,
- the track rod end from the hub carrier using the
tool,
REFITTING
- the shock absorber base studs (6) .

a parts always to be replaced: Front wheel hub nut
(13,02,03,20).

CONCERNED
a Refit a new left-hand differential output seal (see
21A, Manual gearbox, Differential output seal:
Removal - Refitting, page 21A-25) .
Note:
When removing, if there is threadlock on the
splines of the universal joint and the universal
joint nut, apply threadlock to the splines of the
universal joint and the universal joint nut when
refitting.
a Fit the front left-hand driveshaft into the gearbox as

horizontally as possible.
134502
a Insert the front left-hand driveshaft into the hub car-
a Push back the front left-hand driveshaft from the rier.
stub axle carrier using the assembled toolsand.
Note:
The driveshaft must fit freely into the stub-axle
carrier until it protrudes enough for the hub nut to
be fitted.
a Refit the shock absorber base bolts

a Torque tighten the shock absorber base bolts
(180 N.m).
a Position the track rod.
a Torque tighten the track rod end nut (37 N.m).
a Refit a new hub nut.
a Torque tighten the hub nut (280 N.m) while immo-
bilising the hub using tool.
a Refit:
support,
134501
- the bolt of the brake hose and wheel speed sensor
a Detach the front left-hand driveshaft on the gearbox wiring support.
side using the toolfitted with the tool.
a Torque tighten the bolt of the brake hose and
a Remove the front left-hand driveshaft. wheel speed sensor wiring support (8 N.m).
29A-3
DRIVESHAFTS
TL4
a Clip:
- the wheel speed sensor wiring,
- the brake hose.

21A-1) .
a Refit:
29A-4
DRIVESHAFTS
JH3 or JR5
CONCERNED
Tightening torquesm

bolts
hub nut 280 N.m
brake hose retaining N.m

bracket bolt8
WARNING

hub bearing:
134508
removed.
a Unclip the wiring from the wheel speed sensor at (1)
.
REMOVAL a Remove the bolt (2) from the brake hose retaining
bracket.
I - REMOVAL PREPARATION OPERATION a Move aside the brake hose retaining bracket.
a Remove:
21A-1) .
29A-5
DRIVESHAFTS
JH3 or JR5
134507 134501
a Remove: a Extract the front left-hand driveshaft from the manu-

- the hub nut (3) by immobilising the hub using the al gearbox using the toolfitted with the tool.
tool,
a Remove:
- the track rod end nut (4) .
- the front left-hand driveshaft.
a Detach the track rod end using the.
- the left-hand differential output seal (see 21A,
a Remove the shocker absorber base bolts (5) . Manual gearbox, Differential output seal: Re-
REFITTING

(13,02,03,20).

CONCERNED
a Refit a left-hand differential output seal (see 21A,

Manual gearbox, Differential output seal: Re-
Note:
134502
a Push back the front left-hand driveshaft (6) from the splines of the universal joint and the universal
stub axle carrier (7) and. joint nut, apply threadlock to the splines of the
a Remove the front left-hand driveshaft, on the wheel universal joint and the universal joint nut when
side. refitting.
29A-6
DRIVESHAFTS
JH3 or JR5
a Insert the front left-hand driveshaft into the gearbox,
moving it straight in horizontally until it clips.
Note:
Pull on the driveshaft slightly to verify that it is
properly clipped into the gearbox.
a Insert the front left-hand driveshaft into the stub axle

carrier.
Note:
be fitted.
a Refit the shock absorber base bolts.

(180 N.m).
a Fit the retaining bracket of the brake hose.
a Refit the bolt of the brake hose retaining bracket.
a Torque tighten the brake hose retaining bracket
bolt8 (N.m).
a Clip on the wheel speed sensor wiring harness.

21A-1) .
a Refit:
29A-7
DRIVESHAFTS
Front right-hand driveshaft: Removal - Refitting 29A
TL4
CONCERNED
Tightening torquesm
relay bearing bolt 21 N.m

bolts
hub nut 280 N.m
wheel speed sensor 8 N.m

support bolt
WARNING

hub bearing:
- Do not place the vehicle with its wheels on the 134506
a Unclip:
removed.
- the wheel speed sensor wiring at (1) ,
REMOVAL - the brake hose at (2)

a Remove:
21A-1) .
134505
a Remove:
- the bolt (3) of the brake hose and wheel speed sen-
sor wiring support,

support,
29A-8
DRIVESHAFTS
TL4
- the nut (4) from the hub, immobilising the hub using - the right-hand differential output seal (see 21A,
the, Manual gearbox, Differential output seal: Re-
- the nut (5) from the track rod end,
- the track rod end from the hub carrier using the
tool, REFITTING
- the shock absorber base studs (6) .

(13,02,03,20).
a parts always to be replaced: relay bearing brack-

et bolt (13,01,01,11).
Note:
Always replace the relay bearing self-threading
bolt with a classic tapered-end bolt or a cylindri-
cal-pilot bolt every time the right-hand driveshaft
is removed (except if the entire relay bearing is
replaced, in which case it is supplied with a self-
threading bolt).
a Clean and grease the driveshaft relay bearing bore

into which the bearing is inserted with BR2+
GREASE (see Vehicle: Parts and consumables
134503 for the repair) (04B, Consumables - Products).
a Remove the driveshaft relay bearing bolt (7) .

CONCERNED
a Refit the new right-hand differential output seal (see

Note:
refitting.
a Fit the front right-hand driveshaft into the gearbox as

horizontally as possible.
a Refit:
134504
- the front right-hand driveshaft into the relay bear-
a Push back the front right-hand driveshaft from the ing,
stub axle carrier using the assembled toolsand.
- a new relay bearing bolt.
a Remove:
- the front right-hand driveshaft, a Torque tighten the relay bearing bolt (21 N.m).
29A-9
DRIVESHAFTS
TL4
a Insert the front right-hand driveshaft into the hub car-
rier.
Note:
The driveshaft must fit freely into the hub carrier
until it protrudes enough for the hub nut to be fit-
ted.

(180 N.m).
a Refit:
support,
- the bolt of the brake hose and wheel speed sensor
wiring support.
a Torque tighten the wheel speed sensor support
bolt (8 N.m).
a Clip:
- the wheel speed sensor wiring,
- the brake hose.

21A-1) .
a Refit:
29A-10
DRIVESHAFTS
JH3 or JR5
CONCERNED
Tightening torquesm
relay bearing bolt 21 N.m

bolts
hub nut 280 N.m
brake hose retaining N.m

bracket bolt8
WARNING

hub bearing:
- Do not place the vehicle with its wheels on the 134506
ground when the driveshaft has been loosened or a Unclip the wiring from the wheel speed sensor at (1)
removed. .
a Remove the bolt (2) from the brake hose retaining
bracket.
REMOVAL
a Move aside the brake hose retaining bracket.
a Remove:
21A-1) .
29A-11
DRIVESHAFTS
JH3 or JR5
134505 134504
a Push back the front right-hand driveshaft (7) from
a Remove:
the stub axle carrier (8) using the assembled tool-
sand.
- the hub nut (3) by immobilising the hub using the
tool, a Remove:
- the front right-hand driveshaft from the gearbox,
- the track rod end nut (4) .
- the front right-hand driveshaft.
a Detach the track rod end using the.
- the right-hand differential output seal (see 21A,
a Remove the shocker absorber base bolts (5) .
REFITTING

(13,02,03,20).
a parts always to be replaced: relay bearing brack-
et bolt (13,01,01,11).
a Clean and grease the relay bearing hole on the front
right-hand driveshaft into which the bearing is insert-
ed with BR2 + GREASE (see Vehicle: Parts and
consumables for the repair) (04B, Consumables -
Products).
134682
a Remove the bolt (6) from the front right-hand drive-

shaft relay bearing.
29A-12
DRIVESHAFTS
JH3 or JR5
II - REFITTING OPERATION FOR PART - the engine undertray.
CONCERNED
a Refit a new right-hand differential output seal (see
Note:
refitting.
a Position and fit the front right-hand driveshaft into

the gearbox.
a Refit the front right-hand driveshaft in the relay bear-
ing equipped with a new bolt.
a Torque tighten the relay bearing bolt (21 N.m).
a Insert the front right-hand driveshaft into the stub
axle carrier.
Note:
be fitted.

(180 N.m).
a Fit the retaining bracket of the brake hose.
a Refit the brake hose retaining bracket.
a Torque tighten the brake hose retaining bracket
bolt8 (N.m).
a Clip on the wheel speed sensor wiring harness.

21A-1) .
a Refit:
29A-13
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting 29A
JH3 or JR5
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: a parts always to be replaced: Relay shaft bearing
Towing and lifting) (02A, Lifting equipment). (13,01,01,07).
a parts always to be replaced: relay bearing rub-
a Remove: ber ring (13,01,01,10).
- the engine undertray bolts, a Using SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products), clean and degrease the relay
a Drain the gearbox (see 21A, Manual gearbox, bearing bore.
Manual gearbox oils: Draining - Filling, page a Lubricate the relay shaft mating face into which the
21A-1) . relay shaft bearing is inserted.
a Remove:
- the front right-hand wheel (see Wheel: Removal - CONCERNED
a Fit a new bearing on the relay shaft.
shafts, Front right-hand driveshaft: Removal - a Fit the relay shaft bearing until it is fully inserted us-
Refitting, page 29A-8) , ing a tube so that it rests on the relay shaft inner
bearing ring.
- the differential output seal (see 21A, Manual gear-
a Refit a new lock ring.
box, Differential output seal: Removal - Refit-
ting, page 21A-25) .
II - OPERATION FOR REMOVAL OF PART a Refit:

CONCERNED - the differential output seal (see 21A, Manual gear-
ting, page 21A-25) ,
a Fill the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-1) .
100642
a Remove the lock ring (1) from the relay shaft bearing
(2) .
Note:
Do not scratch the contact surface of the lip seal
on the relay shaft (3) .
a Extract the relay shaft bearing (2) using a press and

an extractor.
29A-14
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting 29A
TL4
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: a parts always to be replaced: Relay shaft bearing
Towing and lifting) (02A, Lifting equipment). (13,01,01,07).
a Remove: parts always to be replaced: relay bearing rub-

ber ring (13,01,01,10).
a Clean and degrease the bore of the relay bearing
- the engine undertray. with SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
a Drain the gearbox (see 21A, Manual gearbox, ables - Products).
21A-1) or (see Automatic gearbox oil: Draining - a Lubricate the relay shaft mating face into which the
Filling) . bearing is inserted.
a Remove:
- the front right-hand wheel (see Wheel: Removal - CONCERNED
Refitting) (35A, Wheels and tyres), a Fit a new bearing on the relay shaft.
- the front right-hand driveshaft (see 29A, Drive- a Fit the bearing to the end using a tube, so that it
shafts, Front right-hand driveshaft: Removal - rests on the inner bearing race.
a Refit a new lock ring.
- the right-hand differential output seal (see 21A,
moval - Refitting, page 21A-25) . III - FINAL OPERATION
a Refit:
II - OPERATION FOR REMOVAL OF PART - a new right-hand differential output seal (see 21A,
CONCERNED Manual gearbox, Differential output seal: Re-
moval - Refitting, page 21A-25) ,
a Fill up the gearbox (see 21A, Manual gearbox,
21A-1) or (see Automatic gearbox oil: Draining -
Filling) .
100642
a Remove the lock ring (1) from the relay shaft bearing
(2) .
Note:
Do not scratch the contact surface of the lip seal
on the relay shaft (3) .
a Extract the relay shaft bearing (2) using a press and

an extractor.
29A-15
DRIVESHAFTS
Front driveshaft gaiter, wheel side: Removal - Refitting 29A
JH3 or JR5 or TL4
a Drain the gearbox (see 21A, Manual gearbox,
Equipment required
steel inertia hammer Filling) .
a Remove:
roll pin punch
- the wheel on the side concerned (see Wheel: Re-
parts washer moval - Refitting) (35A, Wheels and tyres),
- the wheel driveshaft on the side concerned (see
29A, Driveshafts, Front right-hand driveshaft:
Removal - Refitting, page 29A-8) or (see 29A,
Driveshafts, Front left-hand driveshaft: Remov-
al - Refitting, page 29A-2) ,
- the differential output seal on the side concerned
(see 21A, Manual gearbox, Differential output
seal: Removal - Refitting, page 21A-25) .
109634
(1) Big securing clip

(2) Small securing clip
(3) Driveshaft gaiter
(4) Ball hub
(5) Stub axle bowl
(6) Ball race
(7) Driveshaft
(8) Balls
(9) Lock ring
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
REMOVAL

a Remove:
29A-16
DRIVESHAFTS
JH3 or JR5 or TL4
CONCERNED
128077
a Using a steel inertia hammer and a roll pin punch,

hit the ball hub (12) a few times to detach the stub
axle bowl (13) from the driveshaft.
93034
128411
a Remove the lock ring (14) .
REFITTING
128415
a Cut the big securing clip (10) and the small securing
clip (11) using cutting pliers or a metal saw, taking a parts always to be replaced: Front driveshaft
care not to damage the stub axle bowl and the drive- gaiter, wheel side (13,01,03,05).
shaft. a parts always to be replaced: wheel side front
driveshaft seal locking ring (13,01,01,09).
a Push back the gaiter to release the stub axle bowl.
a Always replace:
a Cut off the driveshaft gaiter. - the small securing clip,
a Remove as much grease as possible. - the big securing clip.
29A-17
DRIVESHAFTS
JH3 or JR5 or TL4
a Using a parts washer, clean the driveshaft and the a Spread the quantity of grease around the gaiter and
stub axle bowl. the stub axle bowl.

CONCERNED
109768
a Refit the stub axle bowl (18) to the driveshaft by tap-
ping the stub axle bowl using a brass drift until the
128412
lock ring clicks into place behind the ball hub.
a Fit the small securing clip (15) onto the driveshaft. a Fit the lip of the driveshaft gaiter into the groove on
the stub axle bowl.
a Lightly lubricate the driveshaft using the grease sup-
plied with the gaiter to facilitate its fitting.
Note:
Check that the gaiter lip is correctly positioned in
the groove of the driveshaft.
a Fit the small securing clip on the driveshaft gaiter.

a Refit the big securing clip on the driveshaft gaiter.
128416
a Refit the gaiter (16) onto the driveshaft.

a Insert the gaiter lip into the groove of the driveshaft.
a Refit the lock ring (17) .
29A-18
DRIVESHAFTS
JH3 or JR5 or TL4
Clic clip - the wheel driveshaft on the side concerned (see
29A, Driveshafts, Front right-hand driveshaft:
Removal - Refitting, page 29A-8) or (see 29A,
Driveshafts, Front left-hand driveshaft: Remov-
al - Refitting, page 29A-2) ,
- the wheel on the side concerned (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres),
Filling) .
115197
Clip with profile end
115196
a Tighten the clips using the tool (19) for clic clips or
the tool (20) for profile end clips.

a Refit:
- the differential output seal on the side concerned
(see 21A, Manual gearbox, Differential output
seal: Removal - Refitting, page 21A-25) ,
29A-19
DRIVESHAFTS
Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting 29A
JH3 or JR5 or TL4
a Remove:
Equipment required - the front right-hand wheel (see Wheel: Removal -
parts washer
109767
(1) Deflector
(2) Driveshaft
(3) Ball bearing
(4) Driveshaft yoke sleeve
(5) Spider
(9) Lock ring
IMPORTANT
tion.
REMOVAL

a Remove
a Drain the gearbox (see 21A, Manual gearbox,
Filling) .
29A-20
DRIVESHAFTS
JH3 or JR5 or TL4
CONCERNED
128793
a Remove the driveshaft yoke sleeve (12) .
128487
Note:
- since the driveshaft yoke sleeve does not have
a stop tab, it can be removed without being
forced,
- do not remove the rollers from their respective
bushings as the rollers and needles are
matched and should never be interchanged.
a Remove as much grease as possible from inside the

yoke sleeve.
Note:
Never use thinner to remove grease.
128486
clip (11) using cutting pliers or a metal saw, taking
care not to damage the yoke sleeve or the drive-
shaft.
a Push back the driveshaft gaiter to release the drive-
shaft yoke sleeve.
29A-21
DRIVESHAFTS
JH3 or JR5 or TL4
REFITTING

a parts always to be replaced: Front right-hand
driveshaft gaiter, gearbox side (13,01,03,03).
a parts always to be replaced: gearbox side front
a Always replace:
- the big securing clip,
- the small securing clip.
a Use a parts washer to clean the driveshaft, the spi-
der and the driveshaft yoke sleeve.

CONCERNED
109409
a Remove the lock ring (13) using circlip pliers.
128412
a Fit the small tightening clip (16) to the driveshaft.
plied with the gaiter to facilitate its fitting.
127992
Note:
Mark the position of the spider before extracting
it.
a Remove the spider (14) using a press and a releas-

ing type extractor.
a Remove the driveshaft gaiter (15) from the drive-

shaft.
29A-22
DRIVESHAFTS
JH3 or JR5 or TL4
128409 109409
a Refit the gaiter (17) onto the driveshaft. a Fit a new lock ring (19) using circlip pliers.
128488
127992 a Divide the quantity of grease between the driveshaft
a Refit the spider (18) in the position marked during re- gaiter and the yoke sleeve.
moval.
a Engage the yoke sleeve (20) on the tripod (21) .
a Position the driveshaft gaiter lip into the groove of

the yoke sleeve.
Note:
29A-23
DRIVESHAFTS
JH3 or JR5 or TL4
a Fit the small securing clip on the driveshaft gaiter. III - FINAL OPERATION
a Refit the big securing clip on the driveshaft gaiter. a Refit:
- a new differential output seal (see 21A, Manual
Clic clip gearbox, Differential output seal: Removal - Re-
Filling) .
115197
Clip with profile end
115196
29A-24
DRIVESHAFTS
Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting 29A
JH3 or JR5 or TL4
Equipment required a Drain the gearbox (see 21A, Manual gearbox,
parts washer 21A-1) or (see Automatic gearbox oil: Draining -
Filling) .
a Remove:
109401

(4) Driveshaft yoke sleeve
(5) Lock ring
(6) Spider
(7) Cup
(8) Cup spring
(9) Deflector
(10) Driveshaft
IMPORTANT
tion.
REMOVAL

a Remove:
29A-25
DRIVESHAFTS
JH3 or JR5 or TL4
CONCERNED
109408
a Remove the driveshaft yoke sleeve (13) .
128413
Note:
- since the driveshaft yoke sleeve does not have
a stop tab, it can be removed without being
forced,
- do not remove the rollers from their respective
bushings as the rollers and needles are
matched and should never be interchanged.
a Remove as much grease as possible from inside the

driveshaft yoke sleeve.
Note:
Never use thinner to remove grease.
128414
clip (12) using cutting pliers or a metal saw, taking
care not to damage the yoke sleeve or the drive-
shaft.
a Push back the driveshaft gaiter to release the drive-
shaft yoke sleeve.
29A-26
DRIVESHAFTS
JH3 or JR5 or TL4
- the cup equipped with the cup spring.
REFITTING
a parts always to be replaced: Front left-hand

driveshaft gaiter, gearbox side (13,01,03,04).
a parts always to be replaced: gearbox side front

a Always replace:
- the cup,
- the cup spring,
- the big securing clip,

109409
a Remove the lock ring (14) using circlip pliers. - the small securing clip.
a Use a parts washer to clean the driveshaft, the spi-

der and the driveshaft yoke sleeve.

CONCERNED
127992
Note:
Mark the position of the spider before extracting
it.
128412
a Remove the spider (15) using a press and a releas-
ing type extractor. a Fit the small securing clip (16) onto the driveshaft.
a Remove:
- the gaiter from the driveshaft, plied with the gaiter to facilitate its fitting.
29A-27
DRIVESHAFTS
JH3 or JR5 or TL4
128409 109409
a Refit the gaiter (17) onto the driveshaft. a Fit a new lock ring (19) using circlip pliers.
128410
127992 a Refit:
a Refit the spider (18) in the position marked during re- - the cup (20) onto the cup spring (21) ,
moval.
- the cup spring equipped with the cup into the drive-
shaft yoke sleeve (22) .
29A-28
DRIVESHAFTS
JH3 or JR5 or TL4
Clic clip
109408 115197
a Divide the quantity of grease between the driveshaft
gaiter and the yoke sleeve. Clip with profile end
a Engage the yoke sleeve (23) on the tripod (24) .
a Position the driveshaft gaiter lip into the groove of
the yoke sleeve.
Note:
a Fit the small securing clip on the driveshaft gaiter.

a Refit the big securing clip on the driveshaft gaiter.
115196

a Refit:
- a new differential output seal (see 21A, Manual
29A-29
DRIVESHAFTS
JH3 or JR5 or TL4
Filling) .
29A-30

Transmission 2009-2015 Renault Fluence

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CLUTCH

Clutch: Specifications 20A

K9K, and 838

K9K, and 842

clutch pressure plate 12 N.m JH3 or JR5

clutch pressure plate 15 N.m

To avoid all risk of damage to the systems, apply

REMOVAL - the bolts (2) from the « mechanism - disc » assem-

I - REMOVAL PREPARATION OPERATION - the « pressure plate - disc » assembly.

a Position the vehicle on a two-post lift (see Vehicle:

I - REFITTING PREPARATION OPERATION

a Centre the clutch plate using the (7) .

K9K, and TL4

a Centre the clutch plate using the (8) .

a Refit the clutch mechanism.

a Torque tighten the clutch pressure plate bolts (12

a Torque tighten the clutch pressure plate bolts (15

III - FINAL OPERATION

a Refit the manual gearbox (see 21A, Manual gear-

Special tooling required

Mot. 1018 8 mm square engine drain

oil recovery tray

oil change end piece with an 8 mm square drive

drain plug 25 N.m

Gearbox type Capacity (litres)

JH3 2.7 136474

I - PARTS AND CONSUMABLES FOR THE REPAIR

Special tooling required

Mot. 1018 8 mm square engine drain

oil recovery tray

oil change end piece with an 8 mm square drive

drain plug 24 N.m

Gearbox type Capacity (litres) 136488

a Refit the drain plug fitted with its new seal.

a Torque tighten the drain plug (24 N.m) using a

manual gearbox upper 44 N.m

left-hand suspended 62 N.m

left-hand suspended 62 N.m

air filter unit air inlet pipe 6 N.m

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:

- the engine cover,

a Fit the toolon the hydraulic clutch supply pipe at the

a Remove the hydraulic clutch pipe (see Clutch cir-

- the front wheels (see Wheel: Removal - Refitting)

a Remove the manual gearbox earth cable bolt (7) .

REFITTING a Refit the left-hand suspended engine mounting cov-

I - REFITTING PREPARATION OPERATION a Torque tighten the left-hand suspended engine

- the front bumper (see Front bumper: Removal -

- the engine undertray,

- the front section of the front wheel arch liners (see

- the front wheels (see Wheel: Removal - Refitting)

- the manual gearbox breather pipe,

- the hydraulic clutch pipe (see Clutch circuit: Re-

a Remove the toolfrom the hydraulic clutch supply

a Fit the manual gearbox gear selector cables.

a Adjust the manual gearbox gear selector cables

a Connect the reverse gear switch connector.

a Connect the air outlet pipe of the air filter unit.