User manual RENAULT GEARBOXES - WORKSHOP REPAIR MANUAL

Workshop Repair Manual Manual gearboxes Vehicle JB0 Renault 5 Extra Renault 9 Renault 11 Renault 19 Renault 21 Clio Twingo Laguna Mégane X X X X X X X X X JB1 X X X X X X JB2 Type JB3 X X X X X X X X X X X X X JB4 X X X X X X X X JB5 X JC5 This document cancels and replaces JB Gearbox manual part number 77 11 093 922 and JC5 Gearbox manual part number 77 11 092 186 and technical notes n° 1978, 2127, 2229A, 2284A, 2383A, 2457A. 77 11 192 787 FEBRUARY 1997 All copyrights reserved by Renault. Edition Anglaise "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 by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault. C Renault 1997 Contents Pages MANUAL GEARBOX 21 ENSEMBLE MOTEUR ET BAS Section view Identification Cross section - tightening torques Gears Capacity - Lubricants Special points Modifications Consumables Parts which must always be changed Special tools Gearbox repair Shafts Differential Internal controls Lubrication channel Reverse gear shaft Reverse gear brake Speedometer Thrust pad guide tube Assembling the housings Exploded view parts directory Exploded views 21-1 21-2 21-3 21-8 21-28 21-29 21-30 21-32 21-32 21-33 21-37 21-44 21-62 21-76 21-79 21-80 21-81 21-84 21-89 21-97 21-107 21-108 MANUAL GEARBOX Section view 21 JB0 JB2 JB4 DI2101 JB1 JB3 JB5 JC5 DI2102 21-1 MANUAL GEARBOX Identification 21 DI2117-2 DI2117-1 1st assembly 2nd assembly A A TYPE XXX - XX D B E J B0 0 0 0 X X0 0 0 0 0 G B C 000000 90775 C F A At A At B At C : : : Gearbox type. Gearbox suffix. Production number. D J B0 A A 0 0 0 X 0000000 : : : : : : : B C 90 775 At A At B At C At D At E At F At G Gearbox type. Gearbox suffix. Production number. Manufacturing factory. A notch if the gearbox is assembled with a C or E engine. Homologation letter. Letter preceding production numbers greater than 999 999. Following saturation of the production numbering system on the identification plate of JB and JC gearboxes, a new numbering system will be in force for numbers greater than 999 999 (at C). These will have a letter in place of the first number, (at G). 21-2 MANUAL GEARBOX Cross-section and Tightening torques (in daN.m) JB 4-speed manual gearbox - 1st assembly 21 85680R 21-3 MANUAL GEARBOX Cross-section and Tightening torques (in daN.m) JB 4-speed manual gearbox - 2nd assembly 21 88519R 21-4 MANUAL GEARBOX Cross-section and Tightening torques (in daN.m) 5-speed manual gearbox 21 90674R1 21-5 MANUAL GEARBOX Cross-section and Tightening torques (in daN.m) JC 5-speed manual gearbox 21 DI2126 21-6 MANUAL GEARBOX Tightening torques 21 Torque in daN.m 2.5 7 13.5 2 2.5 2.5 2.5 2.5 2.5 5 Tightening torques Description Bolt securing the mechanism housing to the clutch housing Output shaft bolt Input shaft nut Body (5th gear detent) Rear cover bolt Thrust pad guide tube bolt Drain plug Reversing lights switch Bolt securing the left-hand drive shaft bellows Bolt securing the gearbox to the cylinder block 21-7 MANUAL GEARBOX Gears These tables group together all of the gears available for JB gearboxes. JB0 gear table Gear A 1st 11 -39 11 -41 11 -41 2nd 16 -33 19 -39 21 -43 3rd 25 -33 25 -33 28 -37 4th 31 -28 31 -28 31 -28 21 Reverse 11 -- 26 39 11 -- 26 39 11 -- 26 39 B C Gearbox suffixes Vehicles L 421 - L 422 - L 425 B/C/S 371 B/C 372 C 37S L 422 Differential ratio 15 -58 14 -59 15 -58 14 -59 15 -58 19 -59 16 -57 15 -58 14 -63 Speedometer drive gear 21 -19 21 -19 21 -19 21 -19 21 -19 21 -20 21 -19 21 -19 21 -19 Gear 000 A 003 A 004 L 422 B/C 372 A 006 L 422 - L423 B 008 L422 B/C 372 B 009 B/C/S 404 B 010 F 404 L 421 - L 422 - L 423 L425 - L 426 B/C/S 371 B/C 372 - B/C 375 F 401 - F 40H F 400 B 011 B 014 B 21-8 MANUAL GEARBOX Rapports Gearbox suffixes Vehicles L 422 - L 423 B 372 - B 373 B/C 401 B/C/L 531 - B/C/L 532 B/C/L 537 - B/C/L 53P B/C/L 53R 21 Gear 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -20 21 -20 21 -20 21 -20 21 -19 21 -19 21 -19 21 -20 21 -19 B Differential ratio 14 -59 16 -57 15 -58 15 -56 14 -59 14 -63 15 -58 16 -57 15 -58 15 -58 17 -56 16 -55 16 -57 15 -58 16 -57 15 -61 15 -61 15 -61 Speedometer drive gear 016 017 C 018 F 401 B/C/L 53H B 019 K/S 480 B 372 - B 401 C 021 C 022 F 400 B/C 37S C 023 F 401 - F 40H B/C/L/S 530 C 024 F 404 C 025 F 401 B/C 400 F 401 - F 40T B/C/S 401 C 028 C 029 C 031 B/C/S 571 B/C 572 C 57A F 401 - F 404 - F 40H C 032 C 033 C 034 B/C 57N C 035 F 40F C 036 F 40F C 038 F 404 C 21-9 MANUAL GEARBOX Gears JB1 gear table Gear A 1st 11 -39 11 -41 11 -39 11 -41 11 -41 11 -41 11 -34 11 -41 11 -41 11 -37 11 -41 11 -37 11 -37 11 -41 11 -41 2nd 16 -33 16 -33 16 -33 19 -39 21 -43 22 -41 22 -41 21 -43 21 -43 22 -41 21 -43 22 -41 22 -41 21 -43 21 -43 3rd 25 -33 26 -33 25 -33 25 -33 28 -37 28 -37 28 -37 28 -37 28 -39 28 -37 28 -39 28 -37 28 -37 28 -37 28 -37 4th 31 -28 31 -28 31 -28 30 -29 30 -29 30 -29 30 -29 30 -39 34 -35 30 -39 34 -35 30 -29 30 -39 30 -29 30 -29 5th 33 -25 37 -27 37 -27 34 -27 39 -31 41 -31 39 -31 41 -31 34 -28 39 -31 39 -32 41 -31 39 -32 39 -32 41 -31 21 Reverse 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 11 -- 26 39 B C D E F G H I J K L M N O 21-10 MANUAL GEARBOX Gears Gearbox suffixes Vehicles L 421 - L 422 - L 423 B/C 371 - B/C 372 B/C 373 L 421 Differential ratio 14 -59 15 -58 15 -58 15 -58 14 -59 15 -58 14 -59 14 -59 Speedometer drive gear 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 ELECTRONIC SPEEDOMETER 21 Gear A 001 002 A 003 L 422 - L 423 L 421 - L 424 B/C/S 374 L 422 - L 423 B/C 372 - B 373 L 424 B/C 374 L 424 B/C 374 B/C 373 L 421 - L 422 - L 423 L 424 - L 42A - L 42C L 42R - L 42S B/C 371 - B/C 372 B/C/S 373 B/C 37A - B/C 37C B 004 C 005 A 006 C 007 C 008 A 009 15 -61 21 -19 D B 37R - B/S 37S 011 L 424 - B/C/S 374 F 401 - F 402 - F 407 F 40H B 373 15 -58 15 -61 17 -56 15 -58 16 -57 17 -56 14 -63 15 -58 21 -19 ELECTRONIC SPEEDOMETER E 012 E 013 B/C/S 404 L 424 B/C 374 L 424 B 374 L 422 - L 423 B/C 372 - B 373 B 374 L 423 B/C 373 B/C 402 L 424 B/C/S 374 F 404 21 -20 21 -19 21 -19 21 -19 21 -19 21 -19 E 014 E 015 E 016 D 018 D 019 D 21-11 MANUAL GEARBOX Gears Gearbox suffixes Vehicles Differential ratio 16 -57 15 -61 15 -61 15 -58 15 -57 Speedometer drive gear 21 -20 21 -19 21 -19 21 -19 21 -19 21 Gear D 020 B/C 404 021 F 404 D 022 B 402 F 401 - F 402 - F 407 F 40H - F 40M B/C/L 532 B/C 53 L 423 - L 424 - L 42A L 42C - L 42S B/C 373 - B/C 37A B 37C F 401 B/C/L/S 537 B/C/L/S 530 B/C/L/ 53A B/C/L 53R D 023 E 024 E 025 15 -61 21 -19 E 026 F 402 F 402 B/L 53H 15 -58 15 -58 17 -56 15 -61 15 -58 16 -57 15 -61 14 -63 16 -57 16 -55 21 -19 21 -19 21 -20 21 -19 21 -19 21 -20 21 -19 21 -19 21 -19 21 -20 D 027 E 028 B/C/S 404 B 402 B/C 480 K/S 480 B/C/L 53G E 029 E 030 F 404 L 424 B/C/S 374 B/C/S 404 E 031 E 032 F 404 L 423 B 373 B/C/L 531 B/C/L 53P E 033 E 034 E 035 B/C/S 401 B/C 403 B/C/S 407 B 40H E 21-12 MANUAL GEARBOX Gears Gearbox suffixes Vehicles B/C 400 F 401 F 40T C 402 B/C/S 40F 21 Gear 21 -20 21 -20 21 -20 21 -20 21 -20 21 -20 21 -20 21 -19 21 -19 21 -20 21 -19 21 -19 21 -20 21 -20 21 -19 21 -20 21 -20 21 -19 E Differential ratio 15 -61 17 -56 16 -57 14 -59 14 -59 15 -61 16 -57 15 -58 14 -59 14 -59 14 -63 14 -63 14 -63 14 -63 14 -59 15 -56 14 -59 15 -61 Speedometer drive gear 036 037 E 038 B/C 402 B/C 40F B/C/S 571 B/C 570 E 039 E 041 X 57 F 042 X 40 B/C/S 572 - B/C 573 F 043 B/C 57A - B/C 57B B/C 57J - B/C 57L B/C 57T E 044 F 401 - F 40H B/C 57N B/C 57P E 045 F 046 B/C/S 572 B/C/S 57A B/C/S 57R G 047 F 40F F 40A - F 40U F 40V - F 40Y F 40A E 048 E 049 E 050 F 40F E 051 F 407 E 052 C06 3 H 053 X 57 F 054 BA0 E E 21-13 MANUAL GEARBOX Gears Gearbox suffixes Vehicles Differential ratio 15 -56 15 -58 15 -56 15 -56 15 -58 15 -61 16 -57 15 -59 15 -58 15 -56 16 -57 15 -56 15 -56 15 -61 14 -63 15 -58 15 -61 17 -56 Speedometer drive gear 21 -20 21 -20 21 -20 21 -19 21 -20 21 -19 21 -20 21 -19 21 -19 21 -20 21 -20 21 -20 21 -19 21 -19 21 -18 21 -19 21 -19 21 -20 21 Gear H 057 X 06 X 06 with AC X 57 BA0 A - BA0 U 061 I 066 I 068 DA0 X 06 with AC X 53 - F 40 E 069 E 070 E 071 X 57 E 072 X 57 F 074 X 57 E 080 X 57 I 082 X 57 E 085 B/C 57 I 087 B/C 57 BA0 E SA0 E JA0 E BA0 DA0 F 40 E 095 E 097 K 099 E 100 E 104 X 57 E 21-14 MANUAL GEARBOX Gears Gearbox suffixes Vehicles Differential ratio 17 -56 15 -58 15 -58 15 -58 16 -57 16 -57 15 -58 15 -58 15 -58 15 -58 16 -61 15 -56 14 -63 17 -56 15 -56 15 -56 15 -56 15 -56 Speedometer drive gear 21 -20 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -19 21 -18 21 -20 21 -20 21 -20 21 -20 21 -20 21 Gear E 105 X 57 BA0 DA0 F 40 106 E 107 E 109 F 40 E 110 F 40 X 53 X 48 BA0 L BA0 F BA0 L BA0 F BA0 L BA0 P BA0 L BA0 F F 40 BA0 SA0 BA0 E JA0 E X 57 D 111 D 119 J 120 J 123 J 124 J 126