Renault Koleos Service Repair Manual: Transfer box: Removal - Refitting

M9R, and 4X4 TRANSMISSION

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

• Remove the engine undertray.

6-SPEED MANUAL GEARBOX

• Drain the gearbox oil (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-5)

6-SPEED AUTOMATIC GEARBOX

• Drain the gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Filling, page 23A-11)

• Remove:
  • the particle filter (see Particle filter: Removal - Refitting) (19B, Exhaust),
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (19D, Engine mounting).
  • the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle components).
• Uncouple the longitudinal driveshaft from the transfer box (see 29A, Driveshafts, Propshaft: Removal - Refitting, page 29A-12) (29A, Driveshafts).
• Secure the longitudinal driveshaft to the bracket of the control cable using a strap.

• Remove:
  • the catalytic converter bracket nut (1) ,
  • the catalytic converter bracket bolts (2) ,
  • the catalytic converter bracket (3) .

• Remove:
  • the catalytic converter insulation bolts (4) ,
  • the catalytic converter insulation (5) .

• Remove the bolts (6) from the turbocharger cooling pipe.
• Move aside the turbocharger cooling pipe.

• Remove:
  • the transfer box support bolts A (7) ,
  • the transfer box support bolts B (8) ,
  • the transfer box support (9) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the transfer box bolts (10) ,
  • the transfer box.

• Remove the O-ring (11) .

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the O-ring.

• Check that the centring dowel (12) is in position.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the transfer box,
  • the transfer box bolts.
• Torque tighten the transfer box bolts (44 N.m).

III - FINAL OPERATION.

• Refit:
  • the transfer box support.
  • the transfer box support bolts A,
  • the transfer box support bolts B,
• Torque tighten:
  • the transfer box mounting bolts A (48 N.m),
  • the transfer box mounting bolts (B50 N.m),
• Refit:
  • the turbocharger cooling pipe,
  • the turbocharger cooling pipe bolts.
• Torque tighten the turbocharger cooling pipe bolts (10 N.m).
• Refit:
  • the catalytic converter insulation.
  • the catalytic converter insulation bolts.
• Torque tighten the catalytic converter insulation bolts (6 N.m).
• Refit:
  • the catalytic converter bracket,
  • the catalytic converter bracket bolts,
  • the catalytic converter bracket nut.
• Torque tighten:
  • the catalytic converter bracket bolts (50 N.m),
  • the catalytic converter bracket nut (50 N.m).

6-SPEED MANUAL GEARBOX

• Remove the front left-hand splash guard (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).
• Fill the gearbox (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-5)
• Refit the front left-hand splash guard (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

6-SPEED AUTOMATIC GEARBOX

• Fill the gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Filling, page 23A- 11)

• Refit:
  • the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle components),
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (19D, Engine mounting),
  • the particle filter (see Particle filter: Removal - Refitting) (19B, Exhaust),
  • the engine undertray.

2TR, and 4X4 TRANSMISSION

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

• Remove the engine undertray.

6-SPEED MANUAL GEARBOX

• Drain the gearbox oil (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-5)

FK0 or FK8

• Drain the gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Filling, page 23A-11)

• Remove:
  • the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
  • the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal - Refitting, page 29A-4) ,
  • the connector pipe (see Intermediate pipe: Removal - Refitting) ,
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (19D, Engine mounting).
  • the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle components).
• Disconnect the longitudinal driveshaft from the transfer box (see 29A, Driveshafts, Propshaft: Removal - Refitting, page 29A-12) (29A, Driveshafts).
• Secure the longitudinal driveshaft to the bracket of the control cable using a strap.

• Remove:
  • the bolts (1) from the transfer box support,
  • the transfer box support (2) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the transfer box bolts (3) ,
  • the transfer box.

• Remove the O-ring (4) .

6-SPEED MANUAL GEARBOX

• Remove the right-hand differential output seal (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-7) (21A, Manual gearbox).

FK0 or FK8

• Remove the right-hand differential output seal (see Differential seal: Removal - Refitting) (23A, Automatic gearbox).

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the O-ring,
  • the differential output seal.

6-SPEED MANUAL GEARBOX

• Refit the right-hand differential output seal (see 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-7) (21A, Manual gearbox).

FK0 or FK8

• Refit the right-hand differential output seal (see Differential seal: Removal - Refitting) (23A, Automatic gearbox).

• Refit the new O-ring.

• Check that the centring dowel (5) is in position.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the transfer box,
  • the transfer box bolts.
• Torque tighten the transfer box bolts (44 N.m).

III - FINAL OPERATION.

• Refit:
  • the transfer box support.
  • the transfer box support bolts.
• Torque tighten the transfer box support bolts (48 N.m).
• Refit:
  • the longitudinal driveshaft to the transfer box (see 29A, Driveshafts, Propshaft: Removal - Refitting, page 29A-12) (29A, Driveshafts),
  • the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle components),
  • the connector pipe (see Intermediate pipe: Removal - Refitting) ,
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (19D, Engine mounting),
  • the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal - Refitting, page 29A-4) ,
  • the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres).

6-SPEED MANUAL GEARBOX

• Remove the front left-hand splash guard (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).
• Fill the gearbox (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-5) .
• Refit the front left-hand splash guard (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

FK0 or FK8

• Fill the gearbox (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Filling, page 23A- 11)