Removal and installation of gearbox PK1 (Renault Espace III)

Removal

• When removing the box, it is necessary to use the Tav. 476 ball joint puller.
• Also, when removing the power unit, it is necessary to use the following equipment:

• Place the vehicle on a two-post lift.
• Disconnect the wires from the battery terminals and remove the battery.
• Remove the front wheels.
• Remove the engine sump guard and the left front wheel arch liner.
• Drain the transmission oil from the gearbox.
• Replace the drain plug with a new gasket.

On the right side of the car

• Remove the front right floating brake caliper bracket and secure it to the suspension spring to protect the brake hose from damage.
• Remove the two bolts securing the intermediate support of the drive shaft in the support bearing.
• Using the Tav. 476 puller, remove the steering rod end.
• Disconnect the wire from the brake pad wear sensor.
• Disconnect the wire from the wheel speed sensor.
• Loosen the lower mounting bolts of the shock absorber strut to the steering knuckle.
• Remove the wheel speed sensor if the vehicle is equipped with ABS.
• Loosen the lower ball joint tip nut as much as possible and press the tip out of the steering knuckle using an impact ball joint puller.
• Remove the drive shaft - steering knuckle - brake disc assembly. Do not damage the drive shaft corrugated boots

On the left side of the car

• Remove the brake caliper floating bracket and secure it to the suspension spring.
• Remove the three bolts securing the drive shaft corrugated boot.
• Using the Tav. 476 puller, remove the steering rod end.
• Disconnect the wire from the brake pad wear sensor.
• Disconnect the connector from the wheel speed sensor.
• Remove the bolts that secure the lower shock absorber strut to the steering knuckle.
• Disconnect the steering rod ends and lower ball joints from the steering knuckles.
• Remove the hub - drive shaft - steering knuckle - brake disc assembly.
• Disconnect the ground bus from the gearbox.
• Disconnect the crankshaft speed and position sensor connector located at the rear of the transmission.
• Remove the stopper and partially release the gear selector cable.
• Remove 2 bolts and disconnect the clutch slave cylinder from the gearbox.
• Remove the bolt (1, Fig. 6.24) fastenings of the jet rod and loosen the bolt (2).
• Disconnect the connector from the reverse light switch and remove the harness clamp from the transmission.

From below the car

• Disconnect the engine ground bus located near the oil filter cover.
• Loosen but do not remove the power steering line bracket mounting bolt and remove the lines from the brackets.
• To make it easier to access the starter mounting bolts, remove the crankshaft speed and position sensor.
• Remove the starter heat shield.

On top of the car

• Release the oil cooler without disconnecting the hoses from it and secure it to the engine.
• Install a self-made protective screen for the engine cooling system radiator (Fig. 6.25).

Fig. 6.25. Dimensions of the protective screen of the cooling system radiator

• Remove the air filter, the air duct located between the air filter and the turbocharger and the air filter mounting bracket.
• To facilitate access to the bolts securing the clutch housing to the engine block, remove the rigid tube located between the air-to-air heat exchanger and the intake manifold
• Remove the air duct located between the turbocharger and the air-to-air heat exchanger.
• Remove the three air cleaner bracket holders.
• Loosen the bolts securing the power steering tubes to the clutch housing, located behind the clutch release fork.
• Remove the shift cable retaining bracket and remove the cable end from the shift lever ball head.
• Route the control cable over the coolant hose to prevent it from twisting when disconnecting it from the transmission.

• Loosen the bolts securing the clutch housing to the engine cylinder block and the bolts securing the starter.
• Unload the engine mount by placing a support stand with a rubber pad under the oil pan.
• Loosen the bolt securing the left pendulum support to the cushion
• Remove the spring retainer and remove the gear selector cable.
• Place the jack underneath the transmission.
• Lower the power unit slightly to make it easier to remove the 4 bolts securing the left gearbox support (Fig. 6.26).

Fig. 6.26. Location of the bolts for fastening the left support of the gearbox

• Remove the remaining bolts securing the clutch housing to the engine block. All bolts are the same length.
• With an assistant, remove the gearbox from the vehicle.

Installation

• Make sure that the mounting bushings are present in the clutch housing sockets.
• First, install and tighten the left powertrain mount cap screw.
• Lubricate the end surface of the intermediate support bearing of the right drive shaft to prevent the parts from sticking until the next removal.
• Correctly secure the shift cable housing to the left air cleaner bracket holder. If the housing is not secured correctly, noise may occur when the vehicle is driven.
• Further installation is carried out in the reverse order of removal.
• Replace the brake caliper floating bracket guide pin mounting bolts and tighten them to the specified torque.
• Press the brake pedal several times to set the brake cylinder pistons to the working position.
• Tighten all nuts and bolts to the specified torque.
• Fill the gearbox with transmission oil.

Fig. 6.27. Gears of the RK1 gearbox

Fig. 6.28. Crankcases and gearshift mechanism of the RK1 gearbox: 1 - bearing guide sleeve; 2 - primary shaft seal of the gearbox; 3 - left drive shaft seal; 4 - speedometer drive; 5 - sealing ring; 6 - speedometer drive gear; 7 - transmission drain plug; 8 - transmission fluid fill/check plug; 9 - gear selector rod seal;10 - breather; 11 - dipstick for measuring engine oil level;12 - elastic protective coupling;13 - clutch release rod seal; 14 - gear shift lever; 15 - gear selector lever; 16 - base; 17 - Gear shift lever handle; 18 - gear shift cable;19 - gear selection cable; 20 - cable retainer

Fig. 6.29. Differential of the RK1 gearbox: 1 - axle gear; 2 - satellites; 3 - satellite support washers; 4 - satellite axis; 5 - adjusting washer; 6 - retaining ring