2009 RENAULT TWINGO towing

21A-38
MANUAL GEARBOX
Differential output seal: Removal - Refitting
JB1 or JH1 or JH3 or JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel driveshaft (see 29A,
Driveshafts, Front right-hand driveshaft: Re-
moval - Refitting, page 29A-8) .
aDrain the gearbox (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the wheel on the side concerned (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres),
-the front wheel driveshaft for the side in question
(see 29A, Driveshafts, Front left-hand drive-
shaft: Removal - Refitting, page 29A-2) or (see
29A, Driveshafts, Front right-hand driveshaft:
Removal - Refitting, page 29A-8) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aTap the base of the differential output seal using a
roll pin punch and a small hammer to rotate it in its
housing.
aRemove the differential output seal using pliers, tak-
ing care not to damage the splines on the sunwheel. Special tooling required
Bvi. 945Mandrel for fitting the sun-
wheel seal.
Bvi. 1666Tool for fitting differential
seals .
Equipment required
roll pin punch
JB1 or JH1
JH3 or JR5
JB1 or JH1
86031

21A-41
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting
JB1
21A
Detailed view of the Bvi tool components. 1445
aThe gearbox must be removed.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the gearbox on the mounting (1) adjusting
the adjustable support (2) .
aGently remove the guide tube with a press using the
(Bvi. 1828).
aDegrease the guide tube. Special tooling required
Bvi. 1828Snap r ivet and pressure plate
for removal and refitting of the
guide tube (JH1 gearbo x)
Note:
The lip seal and the primary shaft bearing are built
into the thr ust pad guide tube.
It is lubricated via an aperture into the housing
bore.
99057
(1) tightening clamp
(2) sleeve
(3) Sender
(4) key
(5) split ring
98934
98936

21A-44
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting
JB1 or JH1 or JH3 or JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aRemove the engine undertray.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the connector (1) from the reverse gear
switch.aRemove the reverse gear switch using the tool (Bvi.
1934) (2) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aApply some SILICONE ADHESIVE SEALANT (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the threading of
the reverse gear switch.
aRefit the reverse gear switch using the (Bvi. 1934).
aTorque tighten the reverse gear switch (23 N.m).
aConnect the reverse gear switch connector.
II - FINAL OPERATION
aFill the gearbox (see 21A, Manual gearbox, Manu-
al gearbox oils: Draining - Filling, page 21A-2) .
aRefit the engine undertray.
aRefit:
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection), Special tooling required
Bvi. 1934Socket for removing/refitting
reverse gear switch
Tightening torquesm
reverse gear switch23 N.m
132082
144801
Note:
Seal the housing of the reverse gear switch while
replacing the par t.

21B-3
SEQUENTIAL GEARBOX
Sequential gearbox oil: Draining - Filling
JH1
21B
Oil capacity
DRAINING
I - DRAINING PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray.
II - DRAINING OPERATION
aFit a oil recovery tray under the gearbox.aRemove:
-the gearbox drain plug (1) using the tool (Mot.
1018),
-the drain plug seal.
aLet the oil run into the oil recovery tray.
FILLING
I - FILLING PREPARATION OPERATION
aAlways replace the manual gearbox drain plug seal. Special tooling required
Mot. 10188 mm square engine drain
plug spanner.
Equipment required
oil recovery tray
Tightening torquesm
drain plug25 N.m
Gearbox type Oil capacity (in litres)
JH1 2.8
JA32.8
JA52.5
18749

21B-9
SEQUENTIAL GEARBOX
Pump assembly reservoir: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection).
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) ,
aPosition the (Ms. 583)
aSeparate
-the pump assembly from the electro-hydraulic unit
(see 21B, Sequential gearbox, Pump assembly:
Removal - Refitting, page 21B-18) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the (Ms. 583) (1) from the low pressure
hose (2) .
aDrain the pump assembly reservoir.
aRemove:
-the bolts (3) from the pump assembly reservoir,
-the electric pump unit tank.
aIn the event of replacement, remove:
-the clip (4) from the low pressure hose (2) ,
-the low pressure hose (2) . Special tooling required
Ms. 583Pipe clamps .
Equipment required
Diagnostic tool
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
Note:
To discharge the accumulator and deactivate the
pump assembly pump, (see Fault finding -
Replacement of components) (MR 413, 21B,
Sequential gearbox).
122173

21B-11
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection).
aDetach from the petrol injection computer mounting:
-the cooling hose,
-the sequential gearbox computer wiring harness,
-the petrol injection computer wiring harness,
-the battery wiring harness. Special tooling required
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
Diagnostic tool
Tightening torquesm
left-hand suspended
engine mounting bolts21 N.m
left-hand suspended
engine mounting rubber
pad bolts62 N.m
left-hand suspended
engine mounting rubber
pad nut105 N.m
Note:
When replacing the electric pump assembly, always
replace the control relay.
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.

21B-18
SEQUENTIAL GEARBOX
Pump assembly: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the supply connector from the pump as-
sembly pump.
aDetach the pump assembly pump supply connector
from the electro-hydraulic unit connector mounting. Special tooling required
Ms. 583Pipe clamps .
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pipe
unions14 N.m
Note:
When replacing the electric pump assembly, always
replace the control relay.
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
Note:
To discharge the accumulator and deactivate the
pump assembly pump, (see Fault finding -
Replacement of components) (21B, Sequential
gearbox).

21B-21
SEQUENTIAL GEARBOX
Solenoid valves: Removal - Refitting
D4F, and JH1
21B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection).
aDetach from the petrol injection computer mounting:
-the cooling hose,
-the sequential gearbox computer wiring harness,
-the petrol injection computer wiring harness,
-the battery wiring harness.
aRemove:
-the petrol injection computer mounting nut (1) , Special tooling required
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
Diagnostic tool
Tightening torquesm
left-hand suspended
engine mounting bolts21 N.m
left-hand suspended
engine mounting rubber
pad bolts62 N.m
left-hand suspended
engine mounting rubber
pad nut105 N.m
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
Note:
To discharge the accumulator and deactivate the
pump assembly pump, (see Fault finding -
Replacement of components) (MR 413, 21B,
Sequential gearbox).
122323
122322