Repair of manual transmission (Renault Laguna 2)

Attention! Be sure to disassemble and place parts on a surface with a shock-resistant coating (rubber or thick layer of plastic).

Removal

Install the mounting plate (B.VL.1581) onto the stand (Desvil).

Install the gearbox onto the mounting plate (B.VL1581).



Remove the clutch release slave cylinder.

Unscrew the bolts located inside the crankcase.



Remove the rear cover strictly along the horizontal axis of the box, as it includes a capsule with grease located in the hole of the primary shaft.





Engage first gear with the gear shift lever and fifth gear by sliding its fork along the rod.



Remove the secondary shaft bolt and the primary shaft nut.

Using a core (B.Vi.31-01), knock out the fifth gear fork pin.



Remove the fifth gear fork and clutch.

Remove the fifth gear hub using the tool (B.VL1170).



Set the toothed coupling of the device (B.VU170) to the position of the engaged fifth gear, turning it so as to align the splines of the toothed coupling and the hub, and remove the device together with the hub.



Remove the fixed fifth gear pinion using tools (B.VJ.22-01 and B.Vi.1000).



Remove the outer transmission case bolts.

Remove the speed sensor B (for semi-automatic gearbox JH1).



It is recommended to install two magnets or cover the holes C in order not to lose the balls and springs that fix the 1/2 and 3/4 rods.





Remove the reverse rod A and reverse contactor B.



Press the shift rod outward.

Disconnect and remove the gearbox housing.

Turn the reverse gear shaft assembly to the left and remove the reverse/fifth gear shift fork rod.



Raise the input shaft slightly and remove the reverse gear shaft assembly.



Disconnect the 3/4 fork pins using the tool (B.VL949) and remove the 3/4 fork and stem assembly.



At the same time, remove the primary and secondary shaft assembly with the rod and 1/2 fork.



Remove locking pins A and B.

Removal gears

Clamp the secondary shaft in a vice with jaws, then remove all gears.

When removing and installing snap rings, use snap ring pliers on one end and circlip pliers on the other.

Checking the details

The teeth of gears and couplings should not be too worn or have nicks.

Also, make sure that there are no signs of friction or excessive wear on the shaft surfaces and the inner surfaces of the gears.

It is recommended to mark the position of the gear couplings relative to the hubs.

Installing a group of gears

Perform installation in the reverse order of removal.

The retaining rings must be replaced regularly.

Replacing bearings in the gearbox housing

Spread the snap rings with suitable pliers and press the bearing into the crankcase using the tool (B.Vi.1576).

Installation

Install new snap rings into their seats.

Note: There are two types of snap rings: primary shaft A and secondary shaft B.

Install the bearings using the tool (B.VL1576).



Insert the bearing fixture using a hammer.

Replacing bearings on the clutch housing side

Cut off the plastic capsule located in the center of the bearing at the base.

Install the tool (B.Vi.1165) and remove the bearing.

Installing bearings from the clutch housing side

Install the deflector and then press the bearing in, aligning it with the inside of the crankcase.

Caulk the bearing with a chisel.



Remove the input shaft centering bearing using a 38 mm diameter bushing.





Install the centering bearing using the tool (B.Vi.1601).

Removal gears

The bushings under the 2nd, 3rd and 4th gears are installed with tension. They must be systematically replaced during assembly.

Using a press, remove the "ring, hub and third gear" assembly. Support yourself with the third gear clutch teeth.



Using a press, remove the assembly "1st and 2nd gear bushings and pinions. hub, toothed clutch". Lean on the first gear pinion.

Checking the details

The teeth of the gears and couplings must not be too worn and must not have any nicks.

Also, make sure that there are no signs of friction or excessive wear on the shaft surfaces and the inner surfaces of the gears.

It is recommended to mark the position of the gear couplings relative to the hubs.

Installing a group of gears

For assembly, it is necessary to use a heating plate with a mode of 150°C.

Place the new bushings on a cold heating plate. Warm them up for 15 minutes with the thermostat set to 150°C.

Installation of bushings

Remove the bushing from the heating plate with pliers and install it on the shaft using a bushing with an internal diameter of 33 mm. Push it until it rests against the hub.

Note: The 1/2 gear synchronizer is a double cone type; align the projections of the synchronizer rings with the grooves of the hubs and gears.

Replacing the primary shaft bearings

Press out the bearings using a puller.



Press the bearings in using a 25mm diameter bushing.



Remove the secondary shaft bearing cone using a puller.



Press the cone into place.

Push the outer bearing races out from the crankcase side using a 55 mm diameter bushing.



Install the outer bearing rings from the crankcase side using a 60 mm diameter bushing.

Replacing the bearing on the clutch housing side

Cut off the plastic capsule located in the center of the bearing at the base.

Install the tool (B.Vi.1165) and remove the bearing.



Install the bearing using the tool (B.Vi.1167).



Push out the outer race of the input shaft bearing from the clutch housing side using a 38 mm diameter puller.

Press the bearing ring in using a 46mm diameter bushing.



Adjusting the secondary shaft bearing pre-tension

Note: Adjust only if bearings are replaced.

Install the secondary shaft into the clutch housing with bearings and ring for preliminary adjustment (B.Vi. 1161) or a similar ring with a thickness of 1.60 mm (large outside diameter).

Install the crankcase.

Install and tighten the box connector bolts.

Install the pointer type indicator bracket plate (B.VL1161) (or similar) on the tripod body mounts.

Install special bushing (VL/I527) A and bolt C.



Install a pointer type indicator with a magnetic support.



Rotate the secondary shaft several times to seat the bearings.

Set the indicator scale to zero.

Using two screwdrivers as levers, pull up on the secondary shaft.

Read the readings on the pointer type indicator.

Repeat these operations several times in the same sequence.

Determine the average value of the obtained values.

Calculate the thickness of the pre-tension adjustment ring using the following calculation formula:

prescribed value + thickness of pre-tensioning ring + average value of dial indicator readings = thickness of pre-tensioning ring.

Example (values in mm):

prescribed value 0.26 + thickness of the ring for preliminary adjustment 0.49 + average value of the readings of the pointer-type indicator 1.60 = 2.35.

Note: A set of adjustment rings with a thickness of 2.15-2.43 mm with a pitch of 0.04 mm is supplied as a replacement.

Adjusting the axial clearance of the secondary shaft bearings

Note: Adjust only if bearings are replaced.

Install the primary shaft together with the bearings and the preliminary adjustment ring (B.Vi.1161) with a thickness of 0.62 mm (small outside diameter).

Install the differential housing, install and tighten the gearbox connector bolts and the pointer indicator bracket plate (B.Vi.1161) onto the tripod housing mounts.
Install:

• bushing (B.Vi.1527) A;
• support ring B;
• gear ring C;
• nut tightened to end D.

Install a pointer type indicator with a magnetic support.

Rotate the input shaft several times to seat the bearings.

Set the indicator scale to zero.

Using two screwdrivers as levers, pull up on the input shaft.

Read the readings on the pointer type indicator.



Repeat these operations several times in the same sequence.

Determine the average value of the obtained values.

Calculate the thickness for the pre-tension adjustment ring using the following calculation formula:

thickness of the ring for preliminary adjustment + average value of the readings of the pointer-type indicator - 0.02 (this value must be subtracted to ensure a minimum gap) = thickness of the adjustment ring.

Example (values in mm):

- thickness of the ring for preliminary adjustment 0.62 + average value of the readings of the pointer-type indicator 0.50-0.02 (this value must be subtracted to ensure a minimum gap) = thickness of the adjustment ring 1.10.

Note: A set of adjustment rings with a thickness of 0.86-1.30 mm with a pitch of 0.04 mm is supplied as a replacement.