DACIA SUPERNOVA 2004 Repair Manual

CV JH3 - 05021
MANUAL GEARBOX
21 - 19
R
EPLACEMENT 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 i ts 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 crimped by means of a mandrel (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 behind t he bearing will be damaged, being necessary its replacement with a
n ew one ( t his is ensuring the inner oiling of the secondary shaft).
:-
C.V. 552
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 20
The differential of the
JH3050 gearbox is the simple type (with two satellite s 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 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 with a hammer 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 the grooves.
GEARBOX DISMOUNTING
DIFFE RENTIAL
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CV JH3 - 05021
MANUAL GEARBOX
21 - 21
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 c oncave washer ( 6).
The crown of the speedometer ( 8) is dismount from the outside of the differential frame.
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.
REMOUNTING THE DIFFERENTIAL
5
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 22
DIFFERENTIAL BEARI NGS REPLACEMENT
DISMOUNTING
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.
DISMOUNTING
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
pressing on the outer ring of the bearing
Remount the bearing maintaining safety.
7
C.V. 1059
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 23
DIFFERENTIAL ASSEMBLY MOUNTING IN 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 C.V. 945 device and the A protector.
Mount the oiled protector A, on the planetary pinion and position the oiled seal ( C) by means
of the B device.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 24
The internal control
axles must not show any deformations or wear on the milling for locking
ball, and their sliding on bearings must be done make freely, without excessive clearance.
The contact surfaces of the forks with collar of the rocking must not show either deformations or
wear. Ensuring of the control forks axle is performed by means of the balls and springs located 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.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 25
CO
NTROL 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.
CONTROL AXL E DISMOUNTING
This operation is to be perform ed af ter
crankcases separation. The control axle is provided with a stopping
flap LOCTOU – (A) attached on the crankcase.
The sealing is ensured by means of the gasket ( B).
Remove the elastic pin of the selection finger
(C), then dismount the attachment screws, a nd
retrieve the control axle assembly .
In order to replace the gallery bearing bush-
ings of the c ontrol axle, the C.V. 1162 device,
or a tube with the outer diameter 16.5 mm are
to be used. Before mounting the bushings shall
be oiled.
GEARBOX DISMOUNTING
INTERNAL CONTROLS
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CV JH3 - 05021
MANUAL GEARBOX
21 - 26
The assembling surfaces must be flat (small
imperfections can be eliminated by means of a thin
file). Place the a xle and 1-2 fork assembled on the 1-
2 sliding collar of the secondary shaft.
The two shafts (primary and secondary) are taken
together with the fork and 1-2 axle and positioned
at the same time into the clutch – differential crank-
case.
The c rown and the secondary shaft are rotated
until the end of the secondary shaft fits into the bear-
ing.
Mounting the blocking roll of the shaft ˚ (A).
With the 1 – 2 axle in free position, the following
are mounted:
- synchronizing a ssembly 3 – 4 together axle
and 3 – 4 fork;
- mount the for pin 3 – 4 by means of the CV
949 device. Mount the blocking roll of the 5 th step axle ( B).
A
B
GEARBOX DISMOUNTING
CRANCKASE ASSEMBLING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 27
Check the positioning of t he
5 th gear oi ling
collector and of the aerating connection.
Additionally , ensure (check) if the aerating tube is
not damaged or clogged. Apply a layer of LOCTITE 518 on the ga sket
su rface between the clutch crankcase and the
mechanism crankcase. Engage the 3 -d gear step.
M ount the spring and the 5 th gear step locking
ball into the crankcase of the mechanism.
Press the locking ball and mount the mechanisms
crankcase. Ensure the correct positionin g of the two
centering bushings and of the magnet Mount the springs and the locking balls 1-2 and
3-4 in t he m echanisms crankcase, t hen the false
axes A with a 13 mm diameter a re introduced.
Than mount the followings:
- the c ontrol a xle for t he 5 gear a nd reverse
driving (A);
- the axle a nd the reverse driving pinion (B)
assembly , by easy lifting the primary shaft.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
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REMARK :
The tightening at t he required moment of al l t he screws must be done i n no
more than 30 minutes after the mounting of the mechanisms crankcase, because of the
polymerization of LOCTITE 518.
Mount the a ttachment screws and tighten them at a 2,5 daNm moment, after rotating the
primary shaft in order to ensure o correct bearings setting.
Retrieve the false axes.
Mount the locking pin of the reverse driving pinion (A).
GEARBOX DISMOUNTING
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