Workshop Repair ManualManual gearboxType RangeJH1 TwingoClioJH3 ClioLaguna IIJR5 Laguna II77 11 299 962"The repair methods given by the manufactu
MANUAL GEARBOXRepairing the gearbox2121-8Drive in the 5th gear fork pin using B. Vi. 31-01.Remove the 5th gear fork and the sliding gear.Extract the 5
MANUAL GEARBOXRepairing the gearbox2121-9It is advisable to place two magnets or to close off the openings (C) to retrieve the locking balls and sprin
MANUAL GEARBOXRepairing the gearbox2121-10Take the pin out of the 3/4 gear fork using B. Vi. 949 and remove the shaft and 3/4 gear fork assembly.At th
MANUAL GEARBOXRepairing the gearbox2121-11Remember to retrieve the inhibiting pegs (A) and (B).
MANUAL GEARBOXRepairing the gearbox2121-12JH SECONDARY SHAFT
MANUAL GEARBOXRepairing the gearbox2121-13Removing the sprocketPut the secondary shaft in a vice fitted with a clamping jaw and remove the sprocket as
MANUAL GEARBOXRepairing the gearbox2121-14JHREPLACING THE BEARINGS IN THE MECHANISM HOUSINGSeparate the circlips with circlip pliers and drive the bea
MANUAL GEARBOXRepairing the gearbox21JHReplacing the bearings on the clutch housingCut the base of the plastic hollow needle located at the centre of
MANUAL GEARBOXRepairing the gearbox2121-16JR SECONDARY SHAFT
MANUAL GEARBOXRepairing the gearbox2121-17Removing the sprocketThe 2nd, 3rd, and 4th gear supporting rings are fitted tightened. They will be systemat
ContentsPage21 MANUAL GEARBOXSection and tightening torques (in daNm) 21-1Tightening torques (in daNm) 21-3Gears 21-4Consumables 21-5Capacity -
MANUAL GEARBOXRepairing the gearbox2121-18JRRefitting the sprocketA heating plate with a setting of 150°C should be used for refitting.Place the new r
MANUAL GEARBOXRepairing the gearbox2121-19JRREPLACING THE BEARINGS ON THE PRIMARY SHAFTRemove the bearings on the press using the anti-sticking pin.Re
MANUAL GEARBOXRepairing the gearbox2121-20JRRefit the bearings cups on the housing side of the mechanism using a 60 mm diameter tube.REPLACING THE BEA
MANUAL GEARBOXRepairing the gearbox2121-21JRSETTING THE PRE-TENSIONING OF THE SECONDARY SHAFT BEARINGSNOTE: this operation is only carried out when re
MANUAL GEARBOXRepairing the gearbox2121-22JRSETTING THE CLEARANCE OF THE PRIMARY SHAFT BEARINGSNOTE: this operation is only carried out when replacing
MANUAL GEARBOXRepairing the gearbox2121-23JHREMOVING THE DIFFERENTIALRemove the O-ring.Tap the lip seal using a drift and a small hammer to pivot it.R
MANUAL GEARBOXRepairing the gearbox2121-24JHSunwheel sideRemove the bearing retaining circlip (A).On the press, move the bearing towards the inside of
MANUAL GEARBOXRepairing the gearbox2121-25JRREMOVING THE DIFFERENTIALRemove the O-ring.Tap the lip seal using a drift and a small hammer to pivot it.R
MANUAL GEARBOXRepairing the gearbox2121-26JRREPLACING THE BEARINGSREMOVALLift and remove the bearings using an anti-sticking pin.REFITTINGPlace a smal
MANUAL GEARBOXRepairing the gearbox2121-27JRRefit the differential in the housing, with the bearing lightly oiled.Fit the sunwheel side bearing, the p
MANUAL GEARBOXSection and tightening torques (in daNm)2121-1121MANUAL GEARBOX Section and tightening torques (in daNm)JH GEARBOXA2.5B2.5C7D19
MANUAL GEARBOXRepairing the gearbox2121-28CONTROL SHAFTA prevention valve is fitted on the housing (A) of the control shaft.An O-ring (B) ensures that
MANUAL GEARBOXRepairing the gearbox2121-29REFIT THE SHAFTSFit the primary and secondary shafts with the 1/2 gear fork at the same time.Fit the 1/2 gea
MANUAL GEARBOXRepairing the gearbox2121-30Fit the 5th gear shaft (A) and the reverse gear shaft (B) by gently lifting the primary shaft.Check the posi
MANUAL GEARBOXRepairing the gearbox2121-31Apply a line of Loctite 518 to the gasket face.Engage 3rd gear.Introduce the housing while guiding the contr
MANUAL GEARBOXRepairing the gearbox2121-32Refit and pin the 5th gear fork.Select 1st gear using the gear lever and 5th gear by sliding the 5th gear fo
MANUAL GEARBOXRepairing the gearbox2121-33Fit the clutch shaft seal gasket using tool B. Vi. 1601 for JR gearbox.Refit the clutch slave cylinder and t
MANUAL GEARBOXRepairing the gearbox21A21-34Refit the differential outlet seal gasket using tool B. Vi. 945 for the JH gearbox and B. Vi. 1058 for the
MANUAL GEARBOXSection and tightening torques (in daNm)2121-2JR GEARBOXA2.5B13C2.5D7E19
MANUAL GEARBOXTightening torques in daNm2121-3Tightening torques in daNmDescription Torque in daNmGearbox edge bolt 2.5Secondary shaft bolt 7Primary s
MANUAL GEARBOXRatios2121-4RatiosJH GEARBOXJR GEARBOXIndex Type1st2nd3rd4th5thReverse gearFinal driveSpeedometerJH1-002 Twingo 11/37 22/41 28/37 30/29
MANUAL GEARBOXConsumables2121-5ConsumablesCapacities - LubricantsParts to be systematically replacedAfter they have been replaced:– lip seals,– O-ring
MANUAL GEARBOXSpecial tooling2121-6Special toolingB. Vi. 22-01 Bearing extractor toolB. Vi. 31-01 Set of punches for roll pinsB. Vi. 945 Sunwheel oil
MANUAL GEARBOXRepairing the gearbox2121-7Repairing the gearboxREMOVALFit support plate B. Vi. 1581 on a Desvil shoe.Fit the gearbox on the B. Vi. 1581
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