DACIA SOLENZA 2004 Repair Manual

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 31
Replacement of the planetary
sealing gasket (on the vehicle)
Position and mount the planetary transmission on the planetary pinion.
Perform the dismounting operations in the reverse order
Tighten at the required moment the screws and the nuts.
Perform the oil filling of the gearbox.
Check the gearbox sealing.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 32
Replacement of the 5-th gear synchroniserand pinion (on the vehicle
)
1
NECESSARY SPECIAL TOOLS
C. V. 22 – 01 Bearings extractor body
C. V. 31 - 01 Mandrels set for elastic pins
C. V. 1000 Extractor for the 5-th gear fix pinion C.V.
1 170 Extractor for the 5-th gear hub.
C. V. 1 175 Screw for mounting the 5-th gear fix pinion
Tightening moments (daNm)
Primary shaft nut 19
S econdary shaft screw 7
Wheel attachment screws 7.5
Back cap attachment screws 2.5
Oil draining plug 2.5
DISMOUNTIN G
Place the vehicle on a two columns
elevator.
Dismount the front left wheel.
Drain the oil off the gearbox.
Disconnect the connector of the reverse
driving contact. Dismount the cross-tie rod (1).
Dismount the attachment screws of the
back cap. Re m ove t he ba c k c a p on t he ge a rbox
horizontal axle direction, because the cap is
provided with an oiling groove ( A), which is
penetrating into the primary shaft.
Engage the 1-st gear.
Dismount the elastic pin of the 5-th gear fork
by means of the m andrel C.V. 31 – 01.
Engage the 5-th gear by hand.
Dismo unt :
- the nut from the primary shaft and t he
screws from the secondary shaft. - the 5-th gear fork and sliding collar.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 33
Replacement of the 5-th gear synchroniserand pinion (on the vehicle
)
C.V. 1170 C.V. 1000
C.V.
22-01
C.V. 1175
C.V. 31-01
Bring the gearbox in the neutral position.
Extract the synchroniser hub by means of the
extractor C.V. 1170.
Dismount the 5-th gear assembly
Dismount the 5-th gear fix pinion by means of
the extractor C.V. 1000 and the body extractor
C.V. 22 - 01.
REMOU NT I NG
Mount on the secondary shaft the 5-th gear
fix pinion by means of the C.V. 1175 device
Dismount the C.V. 1175 device.
A pply three drops of Loctite
FRENBLOC on t he scre w thread of the
secondary shaft. Mount the secondary shaft screw.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 34
Replacement of the 5-th gear synchroniserand pinion (on the vehicle
)
C.V. 31-01
Mount on t he pri m a ry sha ft , i n t he
following sequence: - the support washer (with the l arger side
towards the pinion ) - the bushing under the pinion;
- the free 5 th pinion equipped with its
synchroni ser ring ;
- the fork together with the 5-th gear sliding
collar;
- the primary shaft nut.
Engage t he 1-st gear with the ge ar l ever
and the 5-th gear by sliding the 5-th gear fork
on its axle. Tighten at the required moment:
- the primary shaft nut: 19 daNm;
- the secondary shaft screw: 7 daNm.
Mount the pin of the 5-th gear fork by
means the CV 31 01 device.
The pin slot must be oriented towards the
back cap. Bring the gearbox in the neutral position
and check the engagement of all speed gears. M
ount a new tore 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 gr o ove.
Tighten the back cap screws at the re quired
moment of 2,5 daNm .
Mount the reverse driving contact connector.
Check the correct gears shifting.
Perform the filling with oil of the gearbox .
Check the gearbox sealing.
M ount the two cross-tie rods.
Mount the right front wheel.
T ighten the screws and the nuts at the required
moment.
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TRANSM ISSION
29
29 - 1
Front transversal transmission
DISMOUNTING - THE SIDE TO W HEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Dismount the wheels.
Dismount the screws that attach the brake disk assembly on the steering knuckle.
U nscrew the transmission nut by means of the RO 604 – 01 device.
Dismou nt :
- the nut of the steering ball joint;
- steering ball j oint from the steering knuckle, by means of the PF 476 extractor;
- the attachment screws of the steering knuckle on the shock absorber end. SPECIAL TOOLS
RO 604-01 Hub immobilizing device
PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
T ransmission nut 28
S crew for fixing the bellows lid on the gearbox 2,5
Wheels attachment screw 7,5
Screws, nuts for fixing the stee ring knuckle on the shock absorber 10,5
S crew for fi xing the caliper on the steering knuckle 6,5
Nut for steering ball joint 4
Push the transmission in the steering knuckle and incline the latter.
Dismount the transmission, the wheel side.
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TRANSM ISSION
29
29 - 2
DISMOUNTING – THE SIDE TO THE GEARBOX
The right side
Due to t he solution assumed by the manufa cture r, the t ransmission j oint (the t ulip of the
transmission) with the t ransmission shaft of the gearbox shall be pe rformed only by m ea the
grooves.
The di smounting of the transmission, the side t o the gearbox, shall be pe rformed by a xial
displacement - extract the transmission tulip from the transmission shaft.
The left side
Drain the oil of the gearbox.
Dismou nt :
- the three screws for fixing the bellows – lid assembly on the gearbox;
- the transmission, the side to the gearbox.
F ront transversal transmission
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TRANSM ISSION
29
29 - 3
Front transversal transmission
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the transmission GI joint in the gearbox (the transmission position as horizontally as
possible).
Mount the three attachment screws of the bellows l id on the gearbox.
The right side
Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox
with transmission oil.
Engage t he tra nsmission GI joint (t he tulip) on the transmission shaft of the ge arbox (the
transmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter, so that
threaded area of the steering knuckle is allowin g to remounting the transmission nut.
Perform then the dismounting operations in the reverse order.
Observe the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Press several times the brake pedal to enable caliper piston coming in contact with the brake
pads.
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TRANSM ISSION
29
29 - 4
Bellows - Bearing assembly
to th e gearbox
THE JOINT TO THE GEARBOX - GI
SPECIAL TOOLS
Bearing mounting chuck on the shaft PF 1331
1. Tripod assembled
2. Bellows
3. bearing
4. bellows attachmen t lid
5. deflector
6. blocking ring
7. transmission shaft
DISMOUNTIN G
It is forbidden to use thinner for components
parts cleaning.
Dismount the blocking ring from the groove
made on the transmission shaft, using a special
pincers for these types of rings.
Left
transmission
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TRANSM ISSION
29
29 - 5
Bellows - Bearing assembly
to th e gearbox
Using a press, extract the assembled tripod,
sustained it on an extractor, FACOM U 53 G
type, protecting the tripod clogs.
Before extracting, mark the position of the
tripod compared to the transmission shaft end.
Dismount the bellows - deflector bearing in
the same manner like tripod dismounting .
REMOU NT I NG
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 ± 0.2 mm between the
backside of the bearing and the shaft extremity.
This value is obtained by means of the PF 1331
device, when mounting, its extremity is at the
level of the shaft.
IMP ORTANT:
In order to avoid the deformation of the bearing, which includes a sealing gasket
(annular oil seal), the pressing effort must be constant (do not hammer).
Left
transmi ssion
GPF
1331
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TRANSM ISSION
29
29 - 6
Bellows - Bearing assembly
to the gearbox
Maintaining the transmission on the press, on both sides, shall be ensured on the G groove
made on shaft, by means of a device t ype FACOM U 53 G, ( the flat side towards bellows) in
order to avoid the deflector damages on the wheel side. The pressing effort of the bearing on the transmission shaft ahas the value of = 100 – 700
daN. Press again the assembled tripod on the transmission shaft observing the marks made when
depressing. The press effort of the tripod assembly on the grooved area of the shaft end, shall be between
60 – 600 daN. Remount the blocking ring (Zeger lock) in the groove made on the transmiss ion shaft.
Left
transmi ssion
G
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