Renault Koleos Service Repair Manual: Automatic gearbox: Removal - Refitting

6-SPEED AUTOMATIC GEARBOX

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove:
  • the air inlet sleeve
  • the battery
  • the battery tray
• Drain the refrigerant circuit using the refrigerant charging station
• Remove the engine undertray.
• Drain:
  • the cooling circuit
  • the automatic gearbox
• Remove:
  • the front wheels
  • the front wheel arch liners
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the particle filter
  • 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 using a string.
• Remove the transfer box.

• Remove:
  • the engine - gearbox assembly
  • the engine - gearbox assembly from the tool (Mot.1390) using a workshop hoist,
  • the starter

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the four nuts (1) from the torque converter by rotating the crankshaft clockwise.

• Remove:
  • the gearbox nuts (2) ,
  • the gearbox studs (3) .

• Remove the gearbox lower bolts (4) .

• Remove:
  • the gearbox side bolts (5) ,
  • the automatic gearbox.

• Remove:
  • the left-hand suspended engine mounting bolts (6) ,
  • the left-hand suspended engine mounting (7) ,
  • the earth strap bracket bolt (8) ,
  • the earth strap bracket (9) ,
  • the control cable bracket bolts (10) ,
  • the control cable bracket (11) .

• Secure the converter with string to prevent it from being dislodged.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the converter nuts.

• Check:
  • that the centring dowels are in place (12) ,
  • that the drive plate is not damaged (run-out tolerance of 0.2 mm on the outer diameter).

• Check that the converter is correctly coupled to the automatic gearbox using a rule and a straightedge.

  The distance (X) between the converter retaining bolt bead and the housing must be at least 20.4 mm.

• Refit:
  • the left-hand suspended engine mounting bracket on the automatic gearbox,
  • the left-hand suspended engine mounting bolts,
  • the earth strap bolt on the automatic transmission,
  • the earth strap bracket bolt,
  • the control cable bracket,
  • the control cable bracket bolts.
• Torque tighten:
  • the left-hand suspended engine mounting bolts (75 N.m),
  • the earth strap bracket bolt (25 N.m),
  • the control cable bracket bolts (14 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the automatic gearbox,
  • the gearbox side bolts,
  • the gearbox lower bolts,
  • the gearbox studs (3) ,
  • the gearbox nuts (2) .
• Torque tighten:
  • the gearbox side bolts (48 N.m),
  • the gearbox lower bolts (48 N.m),
  • the gearbox studs (20 N.m),
  • the gearbox nuts (48 Nm).
• Refit the new converter nuts by rotating the crankshaft clockwise.
• Torque tighten the converter nuts (57 N.m).

III - FINAL OPERATION.

• Refit:
  • the starter
  • the engine - gearbox assembly on the (Mot. 1390) using a workshop hoist,
  • the engine - gearbox assembly.

4X4 TRANSMISSION

• Refit:
  • the transfer box
  • the propshaft on the transfer box

• Refit:
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the front axle subframe
  • the particle filter
  • the rear suspended engine mounting
• Perform the following operations:
  • top up and bleed the cooling circuit
  • top up the oil in the automatic gearbox
  • top up the refrigerant circuit using the refrigerant charging station
• Refit:
  • the front wheel arch liners
  • the front wheels
  • the battery tray
  • the battery
  • the air inlet sleeve

FK0 or FK8

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove the engine undertray.
• Drain:
  • the cooling system
  • the automatic gearbox
• Remove:
  • the battery
  • the battery tray

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

• Remove the bolts (3) from the engine wiring harness channel.
• Remove the wiring harness channel (4) .

• Remove:
  • the oil level gauge (5) from the automatic gearbox,
  • the automatic gearbox oil charging pipe bolts (6) ,
  • the automatic gearbox oil charging pipe (7) ,
  • the O-ring from the automatic gearbox oil charging pipe.
• Disconnect:
  • the speed sensor connectors
  • the multifunction switch connector
  • the automatic gearbox control cable

• Unclip the automatic gearbox wiring clips (8) .
• Remove:
  • the front wheels
  • the front wheel arch liners

• Disconnect the automatic transmission connector (9) .
• Remove:
  • the earth strap bolt (10) ,
  • the automatic gearbox cooling hoses
  • the starter
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the rear suspended engine mounting
  • the front axle subframe
  • the connector pipe.

FK8

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

• Remove the engine wiring harness nuts (11) .
• Move the wiring harness to one side.

• Fit:
  • the lifting eye (12) ,
  • the lifting eye bolts (13) .
• Torque tighten the lifting eye bolts (28 N.m).

• Remove the hood seals (14) .

• Position the (Mot. 1453) (15) .

• Remove:
  • the bolts (16) from the battery tray bracket,
  • the battery tray bracket (17) .

• Remove in the following order:
  • the left-hand suspended engine mounting bolt A (18) ,
  • the left-hand suspended engine mounting bolt B (19) ,
  • the left-hand suspended engine mounting bolt C (20) ,
  • the left-hand suspended engine mounting bolt D (21) .

• Remove:
  • the converter cover bolts (22) ,
  • the converter cover (23) .

• Remove the four nuts (24) from the torque converter by rotating the crankshaft clockwise.
• Place the component jack underneath the gearbox.

• Remove:
  • the control cable bracket bolts (25) ,
  • the control cable bracket (26) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the gearbox mounting bolt A (27) ,
  • the gearbox mounting bolts B (28) ,
  • the gearbox mounting bolts C (29) ,
  • the gearbox mounting bolts D (30) ,
  • the automatic gearbox.

• Secure the converter with string to prevent it from being dislodged.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the converter nuts,
  • the O-ring.

• Check that the centring dowels (31) are in place.

• Check that torque converter is correctly coupled to the continuously variable gearbox using a rule and a straightedge. The distance (X) between the converter retaining bolt bead and the housing must be at least 14.4 mm.
• Refit:
  • the control cable bracket,
  • the control cable bracket bolts.
• Torque tighten the control cable bracket bolts (14 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the automatic gearbox,
  • the gearbox mounting bolts D,
  • the gearbox mounting bolts C,
  • the gearbox mounting bolts B,
  • the gearbox mounting bolt A,
• Torque tighten:
  • the gearbox mounting bolts D (60 N.m),
  • the gearbox mounting bolts C (43 N.m),
  • the gearbox mounting bolts B (75 N.m),
  • the gearbox mounting bolt A (35 N.m).

III - FINAL OPERATION.

• Refit the new converter nuts by rotating the crankshaft clockwise.
• Torque tighten the converter nuts (51 N.m).
• Refit:
  • the converter cover,
  • the converter cover bolts.
• Torque tighten the converter cover bolts (7 N.m).
• Refit and tighten to torque and in order:
  • the left-hand suspended engine mounting bolt D (50 N.m),
  • the left-hand suspended engine mounting bolt C (50 N.m),
  • the left-hand suspended engine mounting bolt B (50 N.m),
  • the left-hand suspended engine mounting bolt A (50 N.m).
• Remove:
  • the (Mot. 1453),
  • the lifting eye bolts,
  • the lifting eye.
• Refit:
  • the hood seals,
  • the engine wiring harness,
  • the engine wiring harness nuts.
• Torque tighten the engine wiring harness nuts (10 N.m).
• Refit:
  • the battery tray bracket,
  • the battery tray bracket bolts.
• Tighten to torque the battery tray bracket mounting bolts (28 N.m).
• Refit:
  • the automatic gearbox cooling hoses
  • the starter
  • the connector pipe
  • the front axle subframe
  • the rear suspended engine mounting
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the earth strap bolt.
• Torque tighten the earth strap bolt (25 N.m).

FK8

• Refit the transfer box.
• Refit the propshaft on the transfer box.

• Connect:
  • the automatic gearbox connector
  • the speed sensor connectors
  • the multifunction switch connector
  • the automatic gearbox control cable.
• Clip the automatic gearbox wiring clips.
• Refit:
  • the front wheel arch liners
  • the front wheels
• Refit:
  • the new O-ring on the automatic gearbox oil charging pipe,
  • the automatic gearbox oil charging pipe,
  • the automatic gearbox oil charging pipe bolts,
  • the oil level gauge on the automatic gearbox.
• Torque tighten the automatic gearbox oil charging pipe bolt (10 N.m).
• Refit:
  • the air filter box
  • the air resonator
  • the air inlet sleeve
  • the engine cover
  • the breather hose
  • the engine wiring harness channel
  • the engine wiring harness channel bolts.
• Torque tighten the wiring harness channel bolts (28 N.m).
• Refit:
  • the battery tray
  • the battery
• Refill:
  • the automatic gearbox oil
  • the cooling circuit
• Bleed the cooling circuit .
• Refit the engine undertray.