oil DACIA SUPERNOVA 2004 Workshop 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 - 14
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 - 18
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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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 - 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 - 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 - 29
Three drops of
LOCTITE FRENBLOC
are a pplied on the grooves of the fi xed pinion
for the 5 th gear, then this is m ounted by means
of the C.V. 1175 device on the secondary shaft.
Di smount the C.V. 1175 device and mount
the secondary shaft screw oiled with 3 drops of
LOCTITE FRENBLOC.
On the primary shaft remount the following
sequence :
- the support washers (with the larger side
towards the pinion )
- the bushing under the pinion;
- the free 5 th pinion equipped with its
synchroni ser ring ;
- the 5-th gear step hub equipped with its
spring after the hub grooves have been oiled with
LOCTITE FRENBLOC; - the fork together with the 5 th sliding
collar.
Engage the 1-st gear with the gear lever and
the 5 th ge ar by sliding the 5-th gear step fork
on its axle.
Apply 3 drops of LOCTITE FRENBLOC
on the primary shaft nut.
Mount the nut and the screw and tighten them
at the required moment: - primary shaft nut : 19 daNm
- secondary shaft screw : 7 daNm
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 30
Mount the pin of the
5 th gear fork by means
the C.V. 31 01 device as for dismounting.
Observe the mounting direction, the pin slot
must be oriented towards the back c ap.
Bring the gearbox in the free position.
Mount a new gasket to ensure t he back cap
sealing. Mount the back cap with the A groove in the
primary shaft, and the oiling collector in the (B)
oil bringing groove, and tighten the screws at a
moment of 2,5 daNm .
Check the correct gears shifting.
Mount the reverse driving connector.
Mount the clutch control receiver cylinder and
tighten the screws at the required moment ( 2,1
daNm) .
GEARBOX DISMOUNTING
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