Tài liệu sửa chữa xe ô tô Renault 19 (Repair Manual) - P2

Tài liệu sửa chữa xe ô tô Renault 19 (Repair Manual) Chassis, Heating and ventilation, Sheet metal work, Sealing and Soundproofing, Trim and Upholstery

PRD2013

Contents

Pages

23-2323-2423-2523-2623-2723-2923-2923-2923-3023-3123-3223-3323-3423-3623-4123-5723-5823-6023-6123-6223-6323-6423-6523-66

AD4 automatic transmission

Exploded viewUse

IdentificationGear ratiosGear change thresholdsConsumables

Parts which must be changedautomatically

OilOil drain intervalsOil drainingFilling - LevelsOil pressureChanging the strainerHydraulic distributorAutomatic transmission (Removal -Refitting)

Full-load validationLoad potentiometerComputer (119)Line pressure sensor (8)Multifunction switch (485)Vehicle speed sensor (250)Solenoid valve

Engine torque reductionSpecial features

Mechanism - Clutch plate

Thrust pad - Fork

20

20-120-420-420-520-620-10

Gearbox (Removal - Refitting)

5th gear linkage in situ

Differential output seal

Turbo

TYPE

76906R 90693-2G2

Single plate, dry, clutch, cable operated

Diaphragm spring clutch plate

Clutch plate with rubber hub

Self-centring, guided, ball type thrust pad in

constant contact.

Automatic wear take-up mechanism

Exploded view

MOLYKOTE BR2 1 kg tin

Right hand sunwheel splinesShaft splines

Fork pivotRelease bearing guideFork pads

Clutch

Mechanism - Clutch plate 20

ALL TYPES

IMPORTANT PRECAUTIONS WHICH MUST BE

FOLLOWED WHEN REPAIRING THE CLUTCH

In order to improve the sliding of the clutch

plates, their hubs are nickel-plated

Clean the clutch shaft splines and refit the

assem-bly without any lubricant.

Special features of "diesel" clutch plates

These are fitted with a damping pre-hub which is

most efficient when its internal units are dry

Degrease the flywheel mounting face

Use the plastic locating device supplied in the kit

to fit the plate

REMOVAL

Fit locking sector Mot 582.

Remove the mounting bolts from the mechanism

and remove the unit and the clutch plate

Check and change the faulty parts

92170R

This operation is carried out after the gearbox has been removed.

ESSENTIAL SPECIAL TOOLS

Plus the tools required to remove the gearbox

TIGHTENING TORQUES (in daN.m)

7 mm diameter unit securing bolts

8 mm diameter unit securing bolts

94135S

Mechanism - clutch plate 20

Gradually screw up then torque tighten the bolts

securing the mechanism

Remove locking sector Mot 582.

Coat the bore of the thrust pad, guide tube and

clutch shaft splines with grease MOLYKOTE BR2

74413R

F engines

Degrease the crankshaft bore which receives the centring bush

Coat the external diameter of the bushing with Loctite FRENBLOC

Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore.

Observe the direction of fitting of the bush and check that it is fitted correctly

94235S

Thrust pad - fork

Ensure that the assembly slides properly

NOTE: when carrying out operations which do notrequire removal of the gearbox or after fitting thegearbox, DO NOT RAISE the fork as there is a risk

of it lifting out of catch (A) on the thrust pad

20

CHANGING

This operation is carried out when the gearbox

has been removed.

REMOVAL

Remove:

- the thrust pad by tilting the fork,

- the rubber protector, and pull the fork

to-wards the inside of the clutch casing

REFITTING

Coat the walls of the guide tube and the fork pads

with grease MOLYKOTE BR2

Fit the fork and refit the rubber protector

Fit the thrust pad on the guide tube, placing catch

(A) in the fork.

An identification plate on the clutch housing shows:

At A : the gearbox type

At B : the gearbox suffix

At C : the fabrication number

At D : the production factory

At E : a notch is used when the gearbox has been

assembled with a C or E type engine

5716

5615

5815

6115

19

21

28

3143

6115

5815

6115

Speedo

5815

11

2611

Final drive set

Speedo

1126

39

1126

39

1126

39

1126

39

1126

Final drive set

353A - 453A - 553A

853A - B53Y - C53Y

22

37

2834

11

6115

22

37

2834

22

37

2834

11

5914

5716

22

37

2841

11

5815

21

37

2841

11

1126

39

1126

19

33

2534

21

37

2841

1157

16

39

112658

21

37

2834

11

39

112661

22

37

2834

6115

19

21

29

3039

11

Final drive set

Speedo

2734

2734

Speedo

Final drive set

Speedo

CHECKING THE LEVEL

Fill to the level of the opening

There are two ways of checking the level

Plug (A) without dipstick Wipe the dipstick section.

Refit the plug, without screwing it up, with thedipstick pointing downwards

Remove the plug, the level should be on the boss(2)

DI2123

OIL VISCOSITY GRADE Tranself TRX 75/80 W

Lubricants 21

Precautions (TRX and TRZ oils)

"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in order

to prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and result

in seizure of the gearbox or of the final drive

STORAGE AND USE

Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of rials or water

mate-In particular:

Storing oil cans

The cans must be stored:

- sheltered from bad weather (rain, snow, outside splashes),

- in a dry area (avoid storing in the vicinity of a washing area),

- tightly sealed

Storing units (gearbox or final drive)

When storing a gearbox or final drive which has not been drained, close the air inlets

Store the unit in a dry area

Using the oil

The oil cans must be resealed each time they have been used

In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil into

a larger container

When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil

The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time

Washing under pressure (of the vehicle or of a unit)

Close the gearbox and final drive breather

If the gearbox is removed, correctly close all of the openings to prevent the entry of water

GEAR CHANGE PATTERN

are fitted with BORG-WARNER synchronisers

To select reverse, raise ring (A) and move the

Consumables 21

Parts which must be changed automatically

When they have been removed:

- the lip seals,

- the O-rings,

- the thrust pad guide tubes,

- the secondary shaft and differential nuts,

- the speedometer gear and its shaft,

- the speedometer crown wheel,

- the roll pins,

- the bushes under the gears

Clutch fork pivotThrust pad guide tube boreClutch shaft splines

Right hand sun wheel splines

Loctite 518 24 ml syringe Housing joint faces

LOCTITE FRENBLOC 24 cc bottle

5th speed fixed gear5th speed synchroniser hubPrimary shaft nut

Secondary shaft bolt

RHODORSEAL 5661 100 g tube Ends of roll pins on driveshafts

Screw threads on switches

REMOVAL

The gearbox can be removed alone

Place the vehicle on a two post lift

Disconnect the battery

Remove the front wheels

On the left hand side of the vehicle

Remove:

- the steering tie rod ball joint using tool

B.Vi 31-01 Set of pin punches T.Av 476 Ball joint extractor

Shock absorber lower securing bolts 11

Nut holding key on stub axle carrier 5.5

Mounting securing bolts 4 to 5

Left hand driveshaft gaiter securing bolt 2.5

TIGHTENING TORQUES (in daN.m) 85965R

- the three bolts holding the driveshaft gaiter,

- the two bolts securing the brake caliper and cure the caliper to the suspension spring so as

se-to avoid stretching the hose,

- the protective casing (side)

Gearbox (Removal - Refitting)

- the driveshaft - stub axle carrier assembly from

the lower ball joint,

21engines

On the right hand side of the vehicle

Remove the driveshaft roll pins using tool

- the nut and key (1),

Slacken lower bolt (3) on the base of the shock sorber and remove upper bolt (4)

ab-91755R

- the two mounting bolts on the engine,

- the clutch protection plate,

- the gear lever

92028R2

- the connector on the reversing light switch

On vehicles fitted with power assisted steering,remove the two clamps securing the powerassisted steering pipes to the gearbox

Remove:

- the air filter unit and its mounting,

- the integral electronic ignition (A.E.I.) sensor,

- the bolts from around the gearbox and fromthe starter

92031S

85966R

Gearbox (Removal - Refitting) 21

Lift the engine using a tool specific to this purpose(example: desvil 300B)

- the front mounting,

- the earthing braid

engines

- the speedometer pin and cable

92108-1R1

mounting and move it back as far as possible.

92108R1

NOTE: to make it easier to remove the bolts, raise

the gearbox slightly with a component jack.

Uncouple the gearbox from the engine, sliding

the 5th speed housing between the vehicle

side-member and the engine cradle

Raise the engine

Turn the gearbox to the front slightly so as to free

the final drive section then remove the gearbox

from the vehicle

After uncoupling the gearbox from the engine,

attach it to a workshop crane securing the eyes in

place of two bolts around the gearbox

92903S

Gearbox (Removal - Refitting) 21

Remove the idle speed regulation valve ting

moun-Disconnect the starter and oil pressure sensorwires

REMOVAL

The gearbox is removed alone

Remove the radiator after first draining the

co-oling system

To detach the wiring, disconnect the connectors

on:

- the ignition power module,

- the throttle housing,

Disconnect the two side bolts which secure the gine - gearbox tierod, starter end torx bolt (T).using a suitable spanner

en-engines

92817S

- the idle speed regulation valve

92904R

attach it to a workshop crane securing the eyes inplace of two bolts around the gearbox

connectors

Unfasten the radiator mountings and move it to

the right hand side (without removing any of the

hoses or pipes), protecting the sides with

card-board

Remove studs (A) and (B) using a nut and lock-nut,

using an angled spanner and a ball joint ratchet

92903S

86308R1

Gearbox (Removal - Refitting) 21

Uncouple the gear lever at the gearbox outlet ver after detaching the protective gaiter

le-engines

The gearbox cannot be removed alone The

en-gine - gearbox assembly must be removed first

(re-fer to section 10) and then uncoupled

85966R

98865R2

Remove the starter plate

Bolt which secures the pendulum

mounting system to the gearbox 3.5

Nuts and bolts which secure the clutch

Bolt which secures the clutch

TIGHTENING TORQUES (in daN.m)

Removal (Special points)

Speedometer cable mounting Pinch the tabs

(ar-rows) and remove the cable

93902S

From the lower section, remove:

- nut (E) which secures the engine - gearbox,

85812-1R

- the tierod - clutch protector assembly

Place the engine on a stand

Remove the bolts from around the gearbox and

from the starter

Vehicles fitted with power assisted steering,

re-move the two clamps (C) which secure the power

assisted steering pipe

92903S1

attach it to a workshop crane securing the eyes inplace of two bolts around the gearbox

Gearbox (Removal - Refitting) 21engines

90300G1

REFITTING

Ensure that the engine - gearbox locating rings

are present and correctly positioned:

- at A : gearbox assembled with a C or E type

engine,

- at B : gearbox assembled with an F type

en-gine

Fit the thrust pad to the guide tube placing catch

(A) in the fork, ensure that it slides correctly

86415R

Do not raise the fork since there is a risk of it ting out of catch (A) on the thrust pad To preventthis, immobilise the thrust pad - fork assembly by

lif-inserting a tube (example: tool Elé 1382)

bet-ween the fork and the sheath end on the housing

to prevent any movement of the thrust pad whilethe gearbox is fitted

Coat the walls of the guide tube and the fork padswith MOLYKOTE BR2 grease

Assemble the engine - gearbox

Ensure that the locating rings are fitted correctly

in their locations

Refit studs (A) and (B) in the same way as on val These studs and the bolts around the gearboxare used for alignment and centring

remo-Fit the fork and refit the rubber protector

Gearbox (Removal - Refitting)

Speedometer cable mounting Pinch the tabs rows) and remove the cable (F type engine)

93909S

Pull the cable at the clutch fork on the gearbox.

The cable should have at least 2 cm of slack.

wheel, pivot the stub axle carrier engaging the

driveshaft in the sun wheel using the angled drift

B Vi 31-01 to align the holes.

91830R1

74937-4S

There is an inlet chamfer on the sun wheel to

make it easier to fit new roll pins

Seal the ends of the pins (RHODORSEAL 5661)

After refitting the engine - gearbox assembly to

the vehicle, check the extent of the fork travel

It should be: X = 17 to 18 mm

89204S

These checks enable the correct operation of the

Gearbox (Removal - Refitting) 21

Check the setting of the upper mountings (refer

to section 10)

Ensure that the engine movement limiter is fittedthe correct way: the nuts should be fitted at theexhaust pipe end

engines

92661S

Fill the cooling system

All types Fit the brake caliper mounting bolts with Loctite FRENBLOC and torque tighten them

Press on the brake pedal several times to bring thepistons into contact with the brake pads

Tighten the bolts and nuts to the specified torque

Fill the gearbox

TIGHTENING TORQUES (in daN.m)

MATERIALS

B.Vi. 28-01 Extractor body B.Vi. 31-01 Drifts for fitting roll pins B.Vi. 1003 5th speed hub extractor B.Vi. 1007 Jaws for B.Vi 28-01, 02, 03 B.Vi. 1175 5th speed fixed gear mounting bolt

87180R

Loctite FRENBLOC :

Primary shaft nut

Secondary shaft bolt

5th speed fixed gear

5th speed hub

REMOVAL

Remove the front left hand wheel

Remove the side housing

Drain the gearbox

The rear housing must be removed horizontally as

it has a lubricating duct (A) which goes into the

primary shaft

5th speed linkage in situ 21

Select 5th gear by sliding the fork on its shaft and1st gear with the gear lever

- a wooden block between the 5th speed fork

and the leading gear to act as a counter-force;

then remove the fork roll pin using tool B.Vi.

31-01.

It is easier to remove the roll pin if the drift of tool

B.Vi 31-01 is bent slightly to avoid having to raise

the gearbox

85979R

NOTE:

Do not pull the 5th speed fork shaft outwards as

there is a risk that the prohibiting lock may move

and prevent refitting of the shaft As a safety

measure, engage a gear (3rd or 4th) when

remo-ving - refitting the roll pin

Slacken and remove the primary shaft nut andsecondary shaft bolt

Return the gearbox to neutral

Fit the slide gear of tool B.Vi 1170 as for selecting

5th gear and turn it so as to position the splines of

the slide gear and the hub opposite each other

Remove the 5th speed fork and the slide gear

Extract the synchroniser hub using tool B.Vi 1170.

5th speed linkage in situ 21

On the secondary shaft:

Remove shouldered washer (64)

PRG21.1

Remove the fixed gear using tool B.Vi

28-01-02-03 fitted with its jaws B.Vi 1007.

88575R

REFITTING

On the secondary shaft:

Put three drops of Loctite FRENBLOC on the fixedgear splines

Fit the fixed gear using tool B Vi 1175 and

shoul-dered washer (64)

93462R

Remove tool B Vi 1175.

Fit shouldered washer (64).

PRG21.1

Refit parts (21) (shoulder facing bearing (22), (23),

(24) and (8)) in order

Fit the fork on slide gear (26) fitted with part (25)

Put three drops of Loctite FRENBLOC on the hub

and refit the slide gear - hub assembly and fork

Fit the bosses on the synchro ring in the notches

on the hub

86045R1

Select 1st gear at the gear lever and 5th gear at

the gearbox, sliding the 5th speed fork on its

shaft

Put three drops of Loctite FRENBLOC:

- on nut (27) of the primary shaft and torque

tighten it to 13.5 daN.m,

- on bolt (65)and torque tighten it to 7 daN.m