DACIA SOLENZA 2004 Repair Manual

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 1
Sectional view
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 2
Identification
A - type of gearbox
B – index of gearbox
C – manufacturer’s series
D – the code for the manufacturing
000 000
0 000000
A B
D
C
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 3
Tightening moments in daNm
TIGHTENING MOMENTS (daNm)
A ttachment screws of the mechanism crankcase on the
clutch – differential case 2.5
S econdary shaft screw 7
Primary shaft nut 19
Back cap fixing screws 2.5
Oil draining plug 2.5
R everse driving contact 2.5
S crews for fixing the bellows assembly – left transmission cap assembly 2.5
Screws for fixing gearbox on engine case (M10 – 90) 4.4
Screws for fixing gearbox on engine case (M10 – 35) 2.1
Nuts for fixing gearbox on engine 4.4
LOCTOU blocking element fixing screw 0.5
S crews for fixing RPM sensor on the clutch case 0.8
S crews for fixing the control axle assembly 2
S crews for fixing clutch cable support 4.8
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 4
Particurarities
12R 5
4 3
Gr ila de viteze este i denticã c u cea de la c utiile de viteze montate pe automobilele Dacia
SupeRNova.
To engage the reverse driving, the gearbox lever is brought in neutral position, then it is en-
gaged like in any other gear gear The synchronizers are BORG – WARNER type.
The synchronizing hub – sliding collar, and the synchronizing hub – shaft assemblies are com-
posed of matching parts .
The synchronizing hubs are freely mounted on the secondary shaft and axially maintained by
means of ring type safety devices. The cylindrical moment of the differential is not adjustable.
The differential assembly is supported on the gearbox crankcases by means of ball bearings.
The primary and secondary shafts support at the clutch side is done by means of roll – bear-
ings, which get into direct contact with the shaft (the bearings do not have inner ring, its purpose
being taken over by the shafts). The reverse driving pinion is delivered mounted on the shaft.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 5
Ratio s
GEAR STEPI II III IV V R.D.
NR. OF TEETH 41/11 43/21 39/28 35/34 31/39 39/11
RATIO 3.727 2.048 1.393 1.029 0.795 3.545
GB INDEX VEHICLE MAIN MILEAGE TRANSMISSION GEARING
JH3-051 SOLENZA 15/56 21/19
A
CAPACITY , LUBRICANTS
O il used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 6
TYPEUSE
LOCTITE 518Crankcas es as s embling
Thread of reverse driving contact
LOCTITE FRENBLOCSecondary shaft screw
Ingredients
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 7
A
Oil used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
Capacity, lubricants
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 8
The following parts are to be replaced, if they have been dismounted:
- oil seal rings;
- fastening rings;
- elastic pins;
- primary shaft nut;
- the bushing under the pinion of the 5 – th gear;
- the outer safety devices of the bearings of the primary and the secondary shafts;
- the t ore gaskets.
P arts that are replaced after each dismonting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 9
Necessary special tools
SERVICEDENOMINATION DACIA
CO DE ITEM NUMBER
C.V. 22 - 01 Bearings extractor b ody 1002 2164 01
C.V. 945 Chuck for mounting the planetary pinion oil ring 1002 0945 00
C.V. 946 Chuck for safety mounting 1002 0946 00
C.V.551 Device for mounting/dismounting bearings of the mechanism casing 1002 0551 00
C.V. 949 Device for mounting/dismounting the elastic pins 1002 0949 00
C.V.1000 Extractor for the fixed pinion of the 5 th gear from the secondary shaft 1002 1000 00
C.V. 1059 Bushing kit for mounting/dismounting the differential bearings 1002 1059 00
C.V. 1170 Hub extractor of the 5 th gear 1002 117000
C.V. 1175 Screw for mounting the fixed pinion 5 th gear 1002 117500
C.V.552 Extractor of the secondary shaft bearing from th e
clutch – differential crankcase. 1002 0552 00
C.V.31 – 01 Set of punches for elastic pins dismounting/ remounting 1002 2594 01
C.V. 1162 Chuck for replacing control bearing bushings 1002 116200
C.V. 553 Device for di smounting/remounting the clutch shaft
bearing 1002 0553 00
C.V. 554 Bushing for depressing the differential assembly 1002 0554 00
C.V. 560 Set of punches for dismounting/remounting blocking pin of the reverse driving shaft. 1002 0560 00
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 10
Gearbox dismounting
2 1
ATTENTION !
Th
e dismounting and checking of the parts must be done on a surface coated with rub-
be r or soft plastic.
Before taking apart the gearbox from the vehicle, drain the oil from the gearbox.
DISMOUNTIN G
Dismount :
- clutch re lease fork ( 1) ;
- pressure bearing ( 2) ;
- the screws located inside the c lutch
crankcase.
Dismount the cap attachment screws.
The back c ap of the gearbox is extracted
so that its setting surface should is remaining
parallel to the c onjoined surface of the gear-
box, because this cap is containing an oiling
groove situated in the cylinder bore of the pri-
mary shaft. Engage the
1-st gear with the control lever
and the 5-th gear by manually shifting of the 5-
th gear fork. Dismount the primary shaft nut and the sec-
ondary shaft screw.
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