Installation of shafts (Renault Megane 2)

Fig. 3.112. Installing the primary shaft and secondary shaft with a 1/2 fork

Install the primary shaft and secondary shaft with the 1/2 fork at the same time (fig. 3.112).

Fig. 3.113. Locking pin of rod 1/2 a and locking pin of rod of fifth gear B

Install the 1/2 A rod lock pin and the 5th gear rod lock pin B (fig. 3.113).

Raise the 3/4 hub slightly and install the 3/4 fork and stem.

Fig. 3.114. Installing pins into the fork using a device

Insert the pins into the fork using the tool (B.Vi.949) (fig. 3.114).

Fig. 3.115. Installing the fifth gear rod A and the reverse axle B

Install the fifth gear rod A and the reverse axle B. To do this, slightly raise the primary shaft (fig. 3.115).

Make sure that the following are positioned correctly:

centering bushings;
magnet;
adjusting rings for pre-tensioning bearings on the JR gearbox (fig. 3.116).

Fig. 3.116. Location of centering bushings, magnet, and adjusting rings for pre-tensioning bearings on a JR gearbox

Fig. 3.117. Installing springs and balls for locking 1/2 and 3/4 in the crankcase

Install the springs and balls for locking 1/2 and 3/4 into the crankcase and compress them using the device (B.Vi.1570) (fig. 3.117).

Apply Loctite 518 to the joint surface.

Set to third gear.

Position the crankcase with the control shaft in third gear and install the spring and ball to lock until the fifth gear rod appears.

Fig. 3.118. Squeezing the ball to lock

Compress the ball to lock and finish installing the crankcase (fig. 3.118).

Remove the device (B.Vi.1570).

Rotate the input shaft to ensure the bearings are correctly seated and tighten the tightening bolt to torque (25 Nm).

Fig. 3.119. Installing the reverse axle A

Install the reverse axle A in place (fig. 3.119).

Fig. 3.120. Installing a constant mesh gear on the secondary shaft

Apply three drops of Loctite Frenbloc to the splines of the constant mesh gear and install it using the tool (B.Vi.1175) (fig. 3.120).

On the primary shaft install:

support ring (with the larger side facing the gear);
bushing under the gear;
fifth gear parasitic gear equipped with a synchronizing ring;
fifth gear hub with spring (fig. 3.121).

Fig. 3.121. Assembly of primary shaft parts

Fig. 3.122. Installing the fifth gear fork pin

Using a core (B.Vi.31-01) install the fifth gear fork pin (fig. 3.122).

Fig. 3.123. Disengaging first and fifth gears

Engage first gear with the shift lever and fifth gear by sliding its fork along the rod (fig. 3.123).

Tighten the bolt and nut of the gears to the torque:

primary shaft nut - 25 Nm;
secondary shaft bolt - 160 Nm.

Set the gearbox to neutral.

Install a new O-ring.

Fig. 3.124. Installing the rear cover of the gearbox

Install the rear cover and tighten the bolts to 25 Nm (fig. 3.124).

Reinstall the reverse contactor.

Install the JH semi-automatic transmission speed sensor in place.

Fig. 3.125. Installing the clutch shaft sealing ring

Install the clutch shaft seal ring using the tool (B.Vi.1601) – for the JR gearbox (fig. 3.125).

Fig. 3.126. Installing the clutch release drive slave cylinder

Install the clutch release slave cylinder and tighten the bolts to 21 N·m (fig. 3.126).

Original publication on the website [renaultbook]

Install the differential output shaft seal using tool (B.Vi.945) for the JH gearbox and tool (B.Vi.1058) for the JR gearbox.