Manual Transmission (F Series Engine) — removal and installation (Renault Clio 1)

Note: This chapter describes the removal of the transmission without the engine, which remains in the vehicle. If you have a sufficiently powerful lifting mechanism at hand, it is recommended to remove the power unit assembly (it's much easier) as described in Section 2F, and then separate them on the workbench. Where present (see text), new right-hand drive shaft to differential axle pinion retaining pins and suitable sealant will be required during installation.

Removal

1. The gearbox is removed from the engine compartment upwards. The block is heavy and suitable lifting equipment is required.

2. Apply the handbrake, then jack up the front of the car and place it on axle stands. Remove both front wheels.

3. Remove the battery (see Section 5A) and the air filter assembly (Section 4B or 4C).

4. Remove the hood as described in Section 11.

5. Remove the plastic cover from the base of the gearbox. Place a suitable container under the transmission, then remove the drain and filler plugs and allow the oil to drain (see illustrations).











Once all the oil has drained, clean and install the drain plug, tightening it securely.

6. Remove the nut securing the left tie rod end to the steering arm, then use a special puller to release the ball joint pin. On models equipped with ABS, disconnect the system sensor from the steering knuckle (see illustration).





7. Working in the engine compartment, unscrew the three bolts securing the left drive shaft inner CV joint boot to the gearbox (see illustration).



8. Remove the left brake caliper from the steering knuckle as described in Section 9 (see illustration).





Do not disconnect the hydraulic hose from the caliper. Tie the caliper to the suspension spring, being careful not to stretch the brake hose.

9. Loosen and remove the pinch bolt securing the front lower ball joint to the base of the left steering knuckle (see illustration).



10. Support the steering knuckle/drive shaft with a jack. Remove the two bolts and separate the steering knuckle from the base of the suspension strut and from the lower ball joint (see illustrations).







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11. Remove the left drive shaft assembly with the steering knuckle from the transmission. Make sure the CV joint tripod components remain in the operating position on the end of the shaft, otherwise they may fall into the transmission.

12. On the right drive shaft, push out the cylindrical pins (where available) using a 5 mm diameter punch.

Note: On some late models the roll pins on the inner end of the drive shaft are not used - ignore references to removing and installing the pins on such vehicles.

13. Loosen up (but don't take it off) lower bolt securing the right steering knuckle to the base of the suspension strut. Loosen and remove the top bolt, then tilt the steering knuckle and disconnect the drive shaft from the differential axle pinion shaft.

14. Cut the plastic tie and slide off the rubber boot, then disconnect the gear shift rod from the lever on the transmission by unscrewing the nut and removing the bolt (see illustrations).









Remove the bushing from the lever. Do not separate the shift rod from the clamp, otherwise you will have to adjust the position of the lever during installation.

15. Remove the protective cover of the inner panel of the front left wing (where necessary, drill out rivets) (see illustrations).







16. On F3P engines, loosen the powertrain tie rod bracket mounting bolts and remove the bracket (see illustration).



On F7P engines (with 16 valves) such a bracket is missing.

17. Unscrew the transmission-to-engine mounting nut located near the right output shaft of the gearbox (see illustration).



18. Squeeze the plastic clip and unhook the speedometer drive cable from the transmission, near the rear suspension (see illustration).





19. Separate the clutch cable from the gearbox (see Section 6).

20. Disconnect the wiring harness ground from the gearbox housing and from the cylinder block. Remove the wiring harness retainers and ground strap from the transmission and its brackets where applicable (see illustrations).







21. Disconnect the wiring connector from the reverse light switch on the transmission housing (see illustration).



22. See illustration 7.24 and loosen (but don't take it off) bolt A, then remove bolts B of the rear suspension support bar.



Move the bar down (see illustration).



23. Drain the cooling system and remove the radiator (see sections 1 and 3). On 16-valve F7P engines, it is necessary to detach the crossmember from the front part of the body.

24. Disconnect the upper radiator hose from the engine.

25. Remove the distributor cap.

26. Remove the ignition module (see Section 5C) and the engine speed sensor, where available (Section 4B or 4C).

27. Where applicable, disconnect the wiring harness from the ABS unit and from the gearbox bracket (see illustration).



28. Disconnect the wiring going to the engine in the plastic box located on the left side of the engine compartment.

29. Disconnect the wiring from the starter and (where necessary) from the oxygen sensor. Detach the wiring harness bracket from the rear of the cylinder block and route it through the starter cover. Remove the starter (see Section 5A) and pass the wiring harness going to the engine through the hole in the clutch housing (see illustration).



30. Loosen up (but don't take it off) the bolt securing the rear suspension bracket to the gearbox and rotate the suspension downwards.

31. Attach a suitable winch to the engine and lift it slightly. Alternatively, support the engine with a jack and then use a winch to remove the transmission.

32. Disconnect the lower radiator hose from the cylinder block pipe.

33. On models with ABS, remove the ABS unit bracket from the right fender inner panel. Remove the topmost nut securing the transmission bracket to the left suspension strut. Move the ABS unit to the side and tie it to the adjacent components, being careful not to deform the hydraulic lines (see illustrations).





34. Support the transmission.

35. Remove the remaining nuts and bolts securing the battery tray/transmission bracket to the body. Remove the bolts securing the bracket to the gearbox and remove the hanger (see illustration).



36. Remove the short tie rod from the left side of the engine subframe (see illustration).



37. Remove the air intake duct from the left front corner of the engine compartment.

38. Loosen up (but don't take it off) lower front bumper mounting bolt on the left side.

39. Loosen up (but don't take it off) two left nuts of the sub-engine frame and lower the frame as far as its bolts allow (see illustration).



This will provide the extra space needed to remove the transmission.

40. Loosen and remove all bolts and nuts securing the transmission to the engine, noting the location of the washers (see illustrations).





41. Separate the transmission from the engine by sliding its rear cover between the engine subframe and the front fender side panel. To remove the clutch housing from the engine mounting pins, carefully use a wide screwdriver. Do not allow the gearbox to hang on the input shaft.

42. Move the transmission to the left as far as possible and remove the clutch (see Section 6). This is necessary to create additional space for removing the transmission from the engine compartment.

43. Rotate the transmission forward to release the final drive. Lift the gearbox out of the engine compartment with the clutch housing facing up. If using a winch, attach it to the clutch housing mounting bolt holes (see illustration).

Installation

44. Perform installation in reverse order, paying attention to the following:

• Before installing the transmission onto the engine, place a piece of wood or similar spacer between the end of the clutch release fork and the cable housing bracket on the transmission case to hold the fork in the released position. This will prevent the release bearing from slipping off the end of the clutch release fork during installation.
• Make sure all mounting pins are in the working position.
• Apply a small amount of high temperature grease to the gearbox input shaft grooves. Measure the amount of grease very carefully, otherwise it may contaminate the clutch friction disc.
• Make sure the starter centering sleeve is installed correctly. See Section 5A, if necessary.
• Where present, use new roll pins when installing the right-hand drive shaft and apply a suitable sealant to the ends of the roll pins.
• Install and tighten the brake caliper mounting bolts (see Section 9).
• Where necessary, check the engine mount adjustment dimensions (see Section 2).
• Fill the gearbox with oil and check its level as described in Section 1.
• Tighten all nuts and bolts to the specified torque Specifications.
• Fill the cooling system (see Section 1).