DACIA SUPERNOVA 2004 Repair Manual

CV JH3 - 05021
MANUAL GEARBOX
21 - 9
N
ECESSARY SPECIAL TOOLS
C. V. 22-01 Bearings extractor body
C. V. 945 Chuck for mounting the right planetary pinion oil ring
C. V. 946 Chuck for safety mounting
C. V. 551 Device for mounting/dismounting bearings of mechanism casing
C. V. 949 Device for mounting and taking apart the elastic pins of the forks
C. V. 1000 Extractor for the fi xed pinion of the 5 th step of the secondary shaft
C. V. 1059 Bushing kit for mounting/dismounting the differential bearings
C. V. 1 170 Hub extractor of the 5 th step on the primary shaft
C. V. 1 175 Screw for mounting the fixed pinion 5 th step
C. V. 552 Device for e xtracti ng the bearing of the secondary shaft on the
clutch – differential crankcase.
C. V. 31-01 Set of punches for elastic pins F 5
C. V. 1 162 Chuck for replacing command axle bushings
C. V. 553 Device for dismounting – remounting the clutch shaft bearing
C. V. 554 Bushing for depressing the differential case assembly from the
differential crankcase.
SPECIAL TOOLS
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CV JH3 - 05021
MANUAL GEARBOX
21 - 10
OBSERVATION :
The dismounting and checking of t he spare parts must be done on a surface coated
with rubber or soft plastic. Before taking apart the gearbox from the vehicle, drain the oil from the gearbox.
DISMOUNTING
Dismou nt :
- hydraulic receiver cylinder;
- the screws locate inside the crankcase.
Dismounting the cap attachment screws.
Th e back cap of the gearbox is extracted so that its setting surface should stay parallel to the
c onjoined surface of the gearbox, because this cap contains an oiling groove situated in the cylinder
bore of the primary shaft.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 11
GEARBOX DISMOUNTING
Engage the 1-St gear with the control lever and the reverse driving by operating the 5-th gear
fork on its axle.
Dismount the primary shaft nut and the secondary shaft screw.
Dismount the fork and the sliding collar of the 5 th step.
Di
smount the elastic pin of the 5 th step, by means of the C.V. 3 – 01 mandrel.
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CV JH3 - 05021
MANUAL GEARBOX
21 - 12
Dismount
the fixed pinion of the 5 th gear
by means of the C.V. 1000 extra ctor a nd
the body e xtractor C.V. 22 -01.
The hub of the 5 th step synchronizer is
extracted by means of the C.V. 1170 extractor.
Dismount the synchronizer ring of the 5
step, the inner bushing of the pinion, the pinion
an d its supporting washer.
The gearbox is set in the dead point, then
engage the 3-d step.
Di smount the external screws fixing the
crankcase of the m echanisms and blocking
pin of the reverse driving pinion axle. Dismount the reverse driving contact ( B).
GEARBOX DISMOUNTING
C.V. 1170
C.V. 1000
C.V. 22 -01
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CV JH3 - 05021
MANUAL GEARBOX
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In order to recover t he balls and t he locking
s prings of the shafts, two magnets placed in the
C orifices are used.
Pull the control shaft towards exterior.
The crankcases are separated.
Rotate to the left the shaft – reverse driving
pinion assembly and dismount the control reverse
driving shaft velocity 5-th step. T
ake out the fork pin 3-4 by means of the
C.V. 949 device and dismount the a xle and
3-4 fork assembly. Simultaneously, dismount the primary shaft
and secondary shaft assembly with the axle
and 1-2 fork.
Place vertically the secondary shaft, with
the pinion of the 1 step downwards, so that
the other pinions will not fall. Recover the locking pi ns ( A) and ( B) of
the command axles.
GEARBOX DISMOUNTING
Easy lift the primary shaft and di smount the
shaft and reverse driving pinion assembly .
C.V. 1170
C.V. 94 9
A
B
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CV JH3 - 05021
MANUAL GEARBOX
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THE PRIMARY SHAFT
The primary shaft shall not be repaired and is not adjustable.
The shaft has a spry nozzle (B) which cannot be dismounted.
Clean the oiling – groove of the 5 th step
The oil seal ring in front of the shaft and the bearing cams are in direct contact with the shaft.
Check the state of the shaft in the opera tion area ( A) of the oil seal; ring, a nd if this shows
ridges or irregularities, it will be replaced.
REPLACING THE B EARINGS OF T HE 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 crankcase of the mechanism;
- a cylindrical one with rolls , pressed into the crankcase of the clutch-differential, together
with the clutch shaft oil seal ring.
T he bearings replacement is performed only with identical bearings with the original ones.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 15
BEARING DISMOUNTING OF THE MECHANISMS
CRANKCASE
The safety ring of the bearing (t he hol ding ri ng) i s widened by means of a pa ir of safety
pincers, then the bearing is extracted from the crankcase by hammering towards the inside of the
mechanisms 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 it is introduced into its groove in the
mechanisms crankcase, so that i t keeps its position as c ompared t o the crankcase (the safety
shows a shoulder).
The bearing lying a t the outside of the c rankcase of the mechanism is pressed towards the
inside of it, until the safety fits into the groove carved on the outer ring of the bearing.
Mounting the bearing is performed by means of the C.V. 551 device.
C.V. 551
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
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The roll bearing i n the c rankcase i s dismounted in t he opposite di rection to the clutch, by
means of the C.V. 553 device.
Ensure that device is well fixed upon depressing the bearing.
BEARING REMOUNTING FROM TH E CLUTCH – DIFFERENTIAL CRANK-
CASE
The remounting shall be performed using the same C.V. 553 device, the mounting directions
of the bearing being towards the clutch. BEARING DISMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANK-
CASE
C.V. 553
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
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SECONDARY SHAFT
SECONDARY SHAFT DISMOUNTING
Dismounting of the secondary shaft is performed starting from the 4 th step.
Dismount the elements, in the following order:
1. - the support washer
2. - gear IV pinion
3. - synchronizing ring
4. - synchronizer for gear 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. - step pinion II
13. - grooved washer
14. - stopping ring
15. - synchronizer ring
16. - synchronizer for steps I and II
17. - synchronizing ring
18. - step I pinion.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
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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 pre – oiled. Take into consideration that synchroniser hubs are matched with the sliding.
It is recommended to mark the positions of the sliding compared to the hubs.
The stopping rings shall be replaced after every dismounting.
Reassembling of the secondary shaft shall be performing the dismounting operations in the
reverse order. The stopping rings
are replaced after each dismounting.
Fo r mounting and dismounting the stopping rings, a pair of safety pincers to keep t he ends
apart, and, on the opposite side, a pair of flat tipped pincers to prevent the stopping ring breaking,
are to be used.
GEARBOX DISMOUNTING
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