DACIA SOLENZA 2004 Repair Manual

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 21
Gearbox dismounting
5
The stopping safety device (A) is extracted, by means of a pincers from the differential
crankcase (press on clutch crankcase in order to release the safety ring).
The differential assembly is dismounted using a press, by means of a bushing C.V. 554 (the
bushing is pressing on the differential crankcase).
Di smount the spacer washer (5) and the elastic concave washer (6).
The crown of the speedometer (8) is dismounted from the outside of the differential casing.
REMOU NT ING THE DIFFERENTIA L
Remounting of the differential assembly is performed in the reverse order of the dismounting
operations, only this time the spacer that is mounted between the lateral surface of the crown
and the support bearing, shall be positioned with the concave side towards the crown.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 22
Gearbox dismounting
C.V. 1059
7
DIFFERENTIAL BEARINGS REPLACEMENT
DISMOUNTIN G
In order to extract the big bearing (7), of the differential from the clutch-differential crankcase,
a profiled metallic strap is used, which is pressed by means of an extension, at a press. In order to dismount the other bearing (10), first extract the safety (9), then press with a press
on the bearing by means of a sleeve with the outer diameter of 50 mm, towards the inside of the
clutch-differential crankcase.
R EMOU NT I NG
In case of the bearing (7), its cage C must
be oriented towards the opposite side of the
differential crown. In order to press this bearing into the clutch
crankcase, the C.V. 1059 device is used,
which is pressing on the outer ring of the bear-
ing.
When remounting the other bearing ( 10),
its cage C must be oriented towards the op-
posite side of the differential crown. For pressing, the 65 mm diameter sleeve
of the C.V.1059 device is used, which is
pressed on the outer ring of the bearing Remount the bearing maintaining safety.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 23
Gearbox dismounting
MOUNTING OF THE DIFFERENTIAL ASSEMBLY I N THE CLUTCH CRANKCASE
The differential assembly is pressed into the crankcase, then the stopping safety device (3)
is mounted on the planetary shaft by means of the C.V. 946 device.
Rotate the differential assembly and check the speedometer pinion rotation.
Remounting of the ( C) planetary oil seal ring is performed after this has been oiled, by means
of the CV 945 device and the ( A) protector.
Mount the oiled protector ( A), on the planetary pinion and position the oil seal ( C) by means
of the ( B) device.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 24
INTERNAL CONTROLS
MÎ
1-2
3-4
5
The internal control axles must not show any deformations or wear on the milling for locking
balls, and their sliding on bearings must be done freely, without excessive clearance.
The contact surfaces of the forks with collar of the rocking must not show either deformations
nor wear. Ensuring of the control forks axles is performed by means of the balls and springs placed in
the holes made in the mechanisms crankcase.
The locking of the control axles is done by means of some cylindrical rolls mounted inside
the clutch–differential crankcase.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 25
CONTROL AXLE DISMOUNTING
This operation is to be performed after crank-
cases separation.
The control axle is provided with a blocking
element “LOCTOU” –(A) attached on the
crankcase. The sealing is ensured by m eans of the tore
gasket (B).
Remove the elastic pin of the selection lever
(C), then dismount the a ttachment screws, and
retrieve the control axle assembly .
In order to replace the bearing bushing of the control axle, the CV 1162 device, or a tube with
the outer diameter 16.5 mm are to be used. Before mounting the bushing shall be oiled.
CONTROL AXLE REMOUNTING
When remounting the control axle, replace the selection finger pin with a new one.
Remounting is done by performing the dismounting operations in the reverse order, after all
parts have been oiled with oil. Tighten all attachment screws of the control axle assembly at the required moment of
2 daNm.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 26
CRA
NKCASES ASSEMBLING
A
B
The assemb ling surfaces must be flat (small
imperfections can be eliminated by means of
a thin file). Place the axle and 1-2 fork, assembled,
on the 1-2 sliding collar of the secondary shaft.
The two shafts (primary a nd secondary)
are taken together with the fork and 1-2 axle
and positioned at the same time into the clutch
– differential crankcase.
The crown and the secondary shaft are
rotated until t he end of the secondary shaft
fits into the bearing.
Mount the blocking roll of the shaft ˚ (A).With the
1 – 2 axle in fre e position, the fol -
lowing are mounted:
-synchronizing assembly 3 – 4 together
w ith the a xle and t he 3 – 4 fork;
- mount the pin of the fork 3 – 4 by means
of the CV 949 device.
M ount the blocking roll of the 5 th gear axle
(B).
After that, mount the followin gs:
- the control axle for the 5 –th gear and
reverse driving (A);
- the axle and the reverse driving pinion
assembly (B), by easy lifting the primary shaft.
Gearbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 27
Mount the elastic pin for reverse driving axle
attachment by means of the C.V. 560 mandrel.
Ensure the correct positioning of the two cen-
tering bushings and of the magnet.
Mount the springs and the locking balls 1-2
and 3-4 in the mechanisms crankcase, then the
false axes A w ith a 13-mm diameter are i ntro-
duced.
Check the positioning of the 5 th gear oiling
collector and of the aerating connection. Additionally, ensure (check) if the aeratin g t ube
is not damaged or clogged. Apply a continuos layer of
LOCTITE
518 on the gasket surface between the clutch
crankcase and the mechanism crankcase.
Engage the 3 -d gear.
M ount the spring and the 5 th gear lock-
ing ball into the crankcase of the mechanism.
Compress the locking ball and mount the
mechanisms crankcase.
Mount the attachmen t screws and tighten
them at the required moment of 2,5 daNm ,
after rotating the primary shaft, i n order t o
ensure o correct bearings setting. Retrieve the false axes.
REMARK :
The tightening at the requi red mo-
ment of al l the screws must be done i n
no mo re tha n 30 mi nutes a fter the
mounting of t he mechanisms crankcase,
b ecause of the polymerization of
LOCTITE 518.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 28
C.V. 1175
C.V. 31-01
Mount the 5-th gear fix pinion on the sec-
ondary shaft by means of the C.V. 1175 de-
vice. Dismount the C.V. 1175 device and mount
the secondary shaft screw, oiled with 3 drops
of LOCTITE FRENBLOC.
Remount on the primary shaft, observing
the following sequence :
- the support washers (with the larger side
towards the pinion ) - the bushing under the pinion;
- the fre e 5 th pinion equipped with its
synchroni ser ring ;
- the 5-th gear hub equipped with its spring
- the fork together with the 5 th sliding
collar. Engage the 1-st gear with the gear lever and
the 5 th gear by sliding the 5-th gear fork on its
axle. Mount the nut and the screw and tighten them
at the required moment: - primary shaft nut : 19 daNm;
- secondary shaft screw : 7 daNm.
Mount the pin of the 5 th gear fork by means
the CV 31 01 device.
Gearb ox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 29
Observe the mounting direction, the pin slot must be oriented towards the back cap.
Bring the gearbox in the neutral position
M ount a new gasket to ensure the back cap sealing.
Mount the back cap with the A groove in the primary shaft, and the oiling collector in the B
oil collecting groove, and tighten the screws at the required moment of 2,5 daNm .
Check the correct gears shifting.
Mount the reverse driving connector.
Mount the clutch control fork and the pressure bearing.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 30
Replacement of the planetary
sealing gasket (on the vehicle)
SDV-uri SPECIALE NECESARE
C. V. 945 Mandrin montare garniturã etanºare planetarã
TIGHTENING MOMENTS (d aNm)
Shoc k absorber attachment
nut on steering knuckle 7.5
Wheel attachment screws 7.5
Oil draining plug 2.5
1
DISMOUNTIN G
Place the vehicle on a two-columns
elevator.
Dismount the right front wheel.
Drain the oil off the gearbox.
Dismou nt :
- the wheel protector
- the shock absorber attachment nuts
(1) on steering knuckle.
REMOUNTING
Lubricate with oil the new sealing gasket.
Mount the sealing gasket by means of the
C.V. 945 device.
M ount the protector (A) lubricated with
oil, on the planetary shaft and position the
gasket (C) by means of the device (B).
Rock the steering knuckle and disconnect
the planetary transmission from the gearbox.Remove
the “O” ring off the planetary shaft,
then, by means of a pins mandrel and a
hammer,
is gently hit in order to make it pivoting in its place.
Remove the sealing gasket by means of a
pliers, taking c are not t o damage the planetary
pinion grooves.
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