Renault Koleos Service Repair Manual: 2TR, and 6-SPEED MANUAL GEARBOX

Manual gearbox

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair .

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
IMPORTANT To prevent the vehicle from falling, lash it to the vehicle lift using a strap.
  • Remove the engine undertray.
  • Drain the manual gearbox.
  • Remove:
    • the battery
    • the battery tray

Manual gearbox

  • Unclip the breather hose clip (1) .
  • Remove:
    • the breather hose clip (2) ,
    • the breather hose (3) ,
    • the engine cover,
    • the air inlet sleeve ,
    • the air resonator,
    • the air filter box.

Manual gearbox

  • Remove:
    • the bolts (4) from the battery tray bracket,
    • the battery tray bracket (5) ,
    • the bolts (5) from the wiring harness channel.
  • Remove the wiring harness channel (7) .
  • Disconnect:
    • the selector cable
    • the gear lever cable

Manual gearbox

  • Disconnect:
    • the neutral switch (8) ,
    • the reverse gear switch (9) .
  • Unclip:
    • the clip (10) from the reverse gear switch wiring,
    • the gearbox wiring clips (11) .

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

  • Disconnect the 1st gear position switch (12) .
  • Unclip the clips from the 1st gear position switch wiring (13) .

 

  • Remove:
    • the front left-hand wheel
    • the front left-hand wheel arch liner
    • the front left-hand driveshaft
    • the front right-hand driveshaft
    • the intermediate pipe
    • the rear suspended engine mounting
    • the front axle subframe .

4X4 TRANSMISSION

  • Disconnect the propshaft from the transfer box.
  • Secure the propshaft to the control cable bracket using a strap.
  • Remove the transfer box.

Manual gearbox

  • Remove:
    • the earth strap bolt (14) ,
    • the clip (15) from the clutch pipe.
  • Disconnect:
    • the clutch control pipe (16) from the manual gearbox,
    • the clutch control pipe (16) from the clip (17) .
  • Drain the clutch oil.
  • Remove the starter.

Manual gearbox

  • Remove the engine wiring harness nuts (18) .
  • Move the engine wiring to one side.

Manual gearbox

  • Fit:
    • the lifting eye (19) ,
    • the lifting eye bolts (20) .
  • Torque tighten the lifting eye bolts (28 N.m).

Manual gearbox

  • Remove the hood seals (21) .

Manual gearbox

  • Fit the (Mot. 1453) (22) .
  • Remove the left-hand suspended engine mounting.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Manual gearbox

  • Remove:
    • the gearbox mounting bolt A (23) ,
    • the gearbox mounting bolts B (24) ,
    • the gearbox mounting bolt C (25) .

Manual gearbox

  • Remove:
    • the gearbox mounting bolt B (26) ,
    • the gearbox mounting bolts D (27) ,
    • the gearbox mounting bolts E (28) .
  • Fit the component jack underneath the manual gearbox.
  • Remove the manual gearbox.

III - FINAL OPERATION

  • Remove the clutch thrust bearing.

Manual gearbox

  • Remove:
    • the selector cable bracket bolts (29) ,
    • the selector cable bracket (30) ,
    • the gear lever cable bracket bolts (31) ,
    • the gear lever cable bracket (32) ,
    • the clutch pipe bracket bolt (33) ,
    • the clutch pipe bracket (34) .

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

Manual gearbox

  • Remove:
    • the switch wiring bolt (35) ,
    • the switch wiring bracket (36) .

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace the clutch thrust bearing.
  • Refit the clutch thrust bearing.

Manual gearbox

  • Check that the centring dowels (37) are in place.
  • Refit:
    • the clutch pipe bracket,
    • the clutch pipe bracket bolt,
    • the gear lever cable bracket,
    • the gear lever cable bracket bolts,
    • the selector cable bracket,
    • the selector cable bracket bolts,
    • the earth bracket,
    • the earth strap bolt.
  • Torque tighten:
    • the clutch pipe bracket bolt (14 N.m),
    • the gear lever cable bracket bolts (17 N.m), the selector cable bracket bolts (17 N.m), the earth strap bracket bolt (25 N.m).

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

  • Refit:
    • the switch wiring bracket,
    • the switch wiring bracket bolt.
  • Torque tighten the switch wiring bracket bolt14 (N.m).

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the manual gearbox,
    • the gearbox mounting bolt A,
    • the gearbox mounting bolt B,
    • the gearbox mounting bolt C,
    • the gearbox mounting bolt D,
    • the gearbox mounting bolt E.
  • Torque tighten:
    • the gearbox mounting bolt A (35 N.m),
    • the gearbox mounting bolt B (75 N.m),
    • the gearbox mounting bolt C (75 N.m),
    • the gearbox bolt D (43 N.m),
    • the gearbox bolt E (43 N.m).

III - FINAL OPERATION

  • Refit the left-hand suspended engine mounting.
  • Remove:
    • tool (Mot. 1453)
    • the lifting eye bolts,
    • the lifting eye.
  • Torque tighten the engine wiring harness nuts (10 N.m).
  • Refit the bonnet seals.

4X4 TRANSMISSION

  • Refit:
    • the transfer box
    • the propshaft

 

  • Refit:
    • the earth strap,
    • the earth strap bolt.
  • Torque tighten the earth strap bolt (14 N.m).
  • Refit:
    • the clutch control pipe,
    • the clutch control pipe clip,
    • the starter .
  • Connect:
    • the neutral switch,
    • the reverse gear position switch.
  • Clip:
    • the reverse gear position switch wiring clip,
    • the neutral switch wiring clips.

4X4 TRANSMISSION

  • Connect the 1st gear position switch.
  • Clip on the 1st gear position switch wiring clips.

 

  • Refit:
    • the intermediate pipe
    • the front left-hand driveshaft
    • the front right-hand driveshaft
    • the front axle subframe
    • the rear suspended engine mounting
  • Connect:
    • the selector cable
    • the gear lever cable
  • Refit:
    • the battery tray bracket,
    • the battery tray bracket bolts,
    • the wiring bracket,
    • the wiring bracket bolts.
  • Torque tighten:
    • the battery tray bracket bolts (28 N.m),
    • the wiring bracket bolts28 (N.m).
  • Refit:
    • the air filter box,
    • the air resonator,
    • the air inlet sleeve,
    • the engine cover,
    • the breather hose,
    • the breather hose clip.
  • Clip on the breather hose clip.
  • Refit:
    • the battery tray
    • the battery
  • Refill:
    • the brake fluid,
    • the manual gearbox with oil
  • Bleed the hydraulic clutch control .
  • Refit:
    • the front left-hand wheel arch liner
    • the front left-hand wheel
    • the engine undertray.
    M9R, and 6-SPEED MANUAL GEARBOX

    Reverse gear switch: Removal - Refitting

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