DACIA SOLENZA 2004 Repair Manual

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 11
C.V. 1170
C.V. 22-01
C.V. 1000
Dismount the elastic pin of the 5 th gear,
by means of the C.V. 31 – 01 mandrel.
Dismount the fork and the sliding collar of
the 5 th gear. The hub of the 5 th gear synchronizer i s
extracted by means of the C.V. 1170 extrac-
tor.
Dismount the synchronizer ring of the 5 –
th gear, the inner bushing of the pinion, t he
pinion and its supporting washer. Dismount
the fixed pinion of the 5 th gear
by means of the C.V. 1000 extractor and the
body extractor C.V. 22 -01 .
The gearbox is set in the neutral point, then
the 3-d gear is e ngaged.
Di smount the external screws fixing the
mechanisms crankcase
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 12
A
C.V. 949
Dismount the reverse driving contact (A).
In order to recover the balls and the lock-
ing springs of the 1-2 and 3-4 shafts, two
magnets placed in the C orifices are used.
Pull the control shaft towards exterior and
s eparate the crankcases
Dismount the reverse driving control shaft
and the 5-th gear. Remove the pin of the
3-4 fork by means
of the C.V. 949 device and dismount the 3-4
shaft and fork assembly .
Gearbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 13
A
B
C.V. 560
Dismount the attachment elastic pin of the re-
verse driving shaft, by means of the mandrel C.V.
560. Di
smount the secondary shaft assembly to-
gether with the a xle and 1-2 fork.
Place vertically the secondary shaft, with the
pinion of the 1-st gear downwards, so that the
other pinions will not fall down. Recover t he locking pins (A) and (B) of the
control axles. Remove the primary shaft together with
the reverse driving shaft and pinion.
Gearbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 14
SHAFTS
THE PRIMARY
SHAFT
.
The primary shaft shall not be repaired and is not adjustable.
The shaft has a groove ( B) for oiling the 5-th gear free pinion.
Clean the oiling – groove of the 5 th gear
The oil seal ring in front of the shaft and the bearing cams are in direct contact with the shaft.
Check the condition of the shaft surface in the operation area ( A) of the oil seal; ring , and if
this shows ridges or irregularities, it will be replaced.
R EPLACING THE BEARINGS OF THE PRIMARY SHAFT
The bearings of the primary shaft are freely mounted on it
There are two types of bearings: - a cylindrical one with balls, pressed into the mechanism crankcase;
- a cylindrical one with rolls, pressed into the clutch-differential crankcase, together with
the clutch shaft oil seal ring.
The bearings replacement is to be done only with identical bearings with the original
ones.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 15
Gearbox dismounting
C.V. 551
BEARING DISMOUNTING OFF THE MECHANISMS CRANKCASE
The safety ring of the bearing (the holding ring) is enlarged by means of a pair of safety pincers,
then the bearing is extracted from the crankcase by hammering towards the inside of the mecha-
nisms crankcase, by means of the C.V. 551 device.
BEARING REMOUNTING OF THE MECHANISMS CRANKCASE
Replace the safety of the bearings with a new one, then this one is introduced into its groove in
the mechanisms crankcase, so that its position is observed a s compared t o the c rankcase (the
safety shows a shoulder). The bearing is pressed from the exterior of the mechanisms crankcase towards the inside of it,
until the safety fits into the groove carved on the outer ring of the bearing. Mounting of the bearing is performed by means of the C.V. 551 device.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 16
Gearbox dismounting
C.V. 553
BEARING DISMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANKCASE
Dismount the clutch shaft bearing towards the clutch opposite direction, by means of the
C. V. 553 device.
Ensure that device is well fixed upon depressing the bearing.
BEARING REMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANKCASE
The remounting shall be performed using the same C.V. 553 device, the mounting direction of
the bearing being towards the clutch.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 17
Gearbox dismounting
SECONDARY SHAFT
SECONDARY SHAFT DISMOUNTING
Dismounting of the secondary shaft is performed starting from the 4 th gear.
Dismount the elements, in the following order:
1. – the support washer
2. – gear IV pinion
3. – synchronizing ring;
4. – synchronizer for gears III and IV;
5. – stopping ring;
6. – grooved washer;
7. – synchronizing ring;
8. – pinion of gear III;
9. – grooved washer;
10. – stopping ring;
11 . – grooved washer;
12. – gear pinion II;
13. – grooved washer;
14. – stopping ring ;
15. – synchronizer ring;
16. – synchronizer for gears I and II;
17. – synchronizing ring;
18. – gear I pinion.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 18
Gearbox dismounting
The stopping rings are to be replaced after each dismounting.
For mounting and dismounting the stopping rings, a pair of safety pincers to keep the ends
apart, and, on the opposite side, a pair of flat tipped pincers to prevent the stopping ring
breaking, are to be used.
SECONDARY SHAFT REASSEMBLING
Before reassembling the secondary shaft, perform the parts checking, as follows: -the pinions and claws tooth must not show chips or excessive wear;
- ensure that working surfaces of the shafts and the inner parts of the pinions do not show
traces of gripping or abnormal wear. When reassemblin g, clean the oiling grooves made in the secondary shaft and all its component
parts are to be pre – oi led. Take into consideration that synchroniser hubs are matched with the slidings.
It is recommended to mark the positions of the sliding compared to the hubs.
The stopping rings are to be replaced after every dismounting.
Reassembling of the secondary shaft shall be done by performing the dismounting operations
in the reverse order.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 19
Gearbox dismounting
C.V. 552
REPLACEMENT OF THE SECONDARY SHAFT BEARINGS
The secondary shaft bearing from the mechanisms crankcase i s identical to the one from the
primary shaft so that its dismounting and remounting are performed in the same way as for the
primary shaft.
Bearing dismounting and mounting in the clutch crankcase is performed by means of the C.V.
522 device.
The bearing is set by means of a mandre l
(puncher) in four equidistant points on a 55 mm
diameter. X = 0,9 ÷ 1,3 mm.
NOTE:
When dismounting the bearing from the clutch-diffe rential crankcase, the deflector
located be hind the be aring will be damaged, being necessary its replacement wi th a
n ew one (this i s ensuring the inside oiling of t he secondary shaft).
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 20
DIFFERENTIAL
The differential of the
JH3-051 gearbox is the simple type (with two satellites and two planetary
wheels, one of which making a common body with the tulip of the planetary transmission).
This differential is supported in the clutch – differential crankcase by means of two cylindrical
bearings equipped with balls of various sizes.
The two bearings are pressed in the clutch – differential crankcase.
The crown of the main transmission is assembled by hooping, on the differential crankcase.
DIFFERENTIAL DISMOUNTING
This operation is to be performed after separating the crankcases.
The zero ring (1) is removed from the right planetary shaft, then by means of a pins extractor
and a hammer, the sealing gasket (2) is gently hit in order to make it pivoting.
The oil seal ring is carefully pulled along the grooved part of the planetary pinion in order not
to deteriorate t he grooves.
G earbox dismounting
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