gearbox DACIA SUPERNOVA 2004 Manual PDF

DRIVE SHAFTS
29BELLOWS TO GEARBOX
Using a press, extract the assembled tripod, sustain it on an extractor type FACOM U
53 G, protecting the clogs of the tri pod.
REMOUNTING
Grease the transmission shaft to help the protection bellows putting back (positionin g
of the smallest diameter of the bellows on the transmission shaft).
The tripod is fixe d an d mo unted in the posi tion mark ed on dis mount ing.
Thr ee po in ts of crim pin g ar e mad e at 12 0 ° C by met al he ad ing of the tran sm iss ion
shaft grooves .
Distribute the grease prescribed quantity in the bellows and in the tulip casing .
Correctly position the bellows in the tulip-casing place.
A non-cutting, round-headed rod is introduced between the bellows and the tulip casing
to dose the air amount contained insid e the bellows. Len gthen or co mp re ss the bel l ows un ti l va lu e A = 19 0 mm is obt ained (t he va lue
between the extremity of the bellows and the extremity of the tulip casing) then from this
position extract the rod and remount the collars.
29 - 14
Right
transmissi on
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MECHAN ICAL ELEMENTS CONTROL
37
HYDRAULIC RECEIVER REPLACEMENT
This operation shall be performed after dismounting of the engine-gearbox assembly and after
disconnecting of the engine from the gearbox.
DISM OUNTING
Dismount the two attachment screws and dismount the hydraulic receiver.
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten the screws at the required moment of 2.1 daNm.
PHYDRAULIC CIRCUIT PURGING
1. CIRCUIT REFILLING
Check if the clutch pedal is in the “up” position, maintain it by hand if necessary.
Fill the reservoir with brake fluid.
Remove the protection cap of the purging connection 1.
Connect a transparent hose a t the purging connection to recover the brake fluid.
Retrieve the clip 2 (do not definitely remove it in order to limit the movement of the feeding
pipe).
37 - 21
CLUTCH HYDRAULIC CONTROL
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MECHAN ICAL ELEMENTS CONTROL
37
DISMOUNTING
The dismounting of the gears changing lever shall be performed after dismounting the central
case . Dismount under the vehicle the control lever.
Dismount under the vehicle the four attachment screws of the central case.
Dismount the assembly composed of control case and gears control lever. THE GEARS CONTROL
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten at the required moment :
- the control case attachment screws 1.2 daNm
- the control bar connection screw with the GB connecting rod 2.7 daNm
- the connection screw of the control bar with t he control lever 1.2 daNm
Grease the parts of the joint composed of control bar and GB connecting rod with MOLYKOTE
33M grease.
Introduce in the protection bellows aprox. 10 ml of grease.
NOTE
The tightening of the connection screw of the control bar with the control
lever shall be performed aft er adjustment of t he gearbox control.
37 - 23
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MECHAN ICAL ELEMENTS CONTROL
37
GEARS CONTROL ADJUSTMENT
This is to be performed after mounting the engine-gearbox assembly and the assembly lever-
control case every time when : - dismounting of the engine-gearbox a ssembly, t he c ontrol ba r or the assembly lever-
control case;
- establishin g of failures such as: gear change impossibility or unexpected gear uncoupling,
gear blocking.
For the gear control adjustment the CV 550 device i s to be used;
M ount the CV 550 device on the assembly lever- control c ase;
A ttach the control bar to the control lever end;
Place the gear lever in the device seat and fix it in this position by means of the device handle;
Tighten the attachment screw 1 of the bar to the lever at the required moment of 1.2 daNm;
Dismount the CV 550 device from the control box.
Check the gears coupling. THE GEARS CONTROL
37 - 24
SPECIAL TOOLS
CV 550 Linkage adjusting device
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LOWER INTERNAL ACCESSORIES
57
57 - 4
DISMOUNTING
Remove from the central console the attachment
frame (13) of the gearbox lever bellows by
detaching it from clips. Loosen the attachment screws (8) of the central console (12) from the climate control group.
Dismount the two metal screws (14) and the fast nuts (15) of the central console attachment,
in the lower part, on the control box of the gearbox lever. Loosen the screws (9 ) and the attachment nuts (1 0) of the central console, on the upper side,
on the dashboard. Dismount the climate control assembly from the central console.
Disconnect from the electric cigarette lighter, the wires from the dashboard wiring.
Disconnect the radio equipment.
Remove the central console.
REMOUNTING
Perform in the reverse order the dismounting operations, when mounting the central console,
engage the gearbox lever in different gears.
CENTRAL CONSOLE
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83
INSTRUMENT PANEL
DISMOUNTING
Disconnecting battery.
Dismounting flexible shaft( speedometer cable) from the gearbox.
Dismounting control cable from the recyclin g flap.
Dismounting steering wheel and the steering wheel casing.
Dismountin g dashboard lower fairing.
Dismountin g documents compartment.
Disconnect documents compartment lamp.
Dismountin g central console.
Dismounting flaps control cables from the climate control unit.
Discon necting: cigarette lighter, climate control lighting, ashtray lighting, climate control switch .
Dismounting headlamps adjustment control from the dashboard.
Dismounting dashboard from the windscreen lower cross bar.
Disconnecting flexible shaft (speedometer cable) from the instrument panel.
Disconnecting air conducting ducts to aerators.
Disconnecting front wiring from the instrument panel and from the dashboard wiring.
Dismounting instrument panel attachmen t clamps from the dashboard.
Dismountin g clamps from the instrument panel.
Mounting clamps on the new instrument panel.
Mounting instrument panel with clamps on dashboard.
Connecting flexible shaft to the instrument panel.
Connecting front wiring to the instrument panel and to the dashboard wiring.
Positioning and fixing air conducting ducts.
IN
STRUMENT PANEL REPLACEMENT
83-5
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83
INSTRUMENT PANEL
Positioning and fixing flaps control cables to the climate control unit.
Connecting dashboard wirin g to: cigarette lighter, climate contro l lighting, climate control switch,
ashtray lighting.
Connecting documents compartment lamp.
Mounting documents compartment.
Mounting central console.
Mounting dashboard lower fairing.
Mounting steering wheel casing and steering wheel.
Mounting flexible shaft to the gearbox.
Mounting control cable to the recycling flap.
Connecting battery.
Functional tests.
REMOUNTING
Perform the dismounting operations in the reverse order.
83-6
IN
STRUMENT PANEL REPLACEMENT
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83
INSTRUMENT PANEL
NOTE
Dismounting / re m ounting of t he spe e do c abl e, m ay be pe rform e d onl y aft e r
dismounting the instrument panel from the dashboard.
DISM OUNTING
Disconnect the battery;
Dismount the dashboard lower fairing;
Disconnect the RPM sensor connector;
Dismount the speedo cable from the gearbox;
Dismount the speedo cable from instrument panel back part, by detaching it from clips, pushing
in the direction of the A and B arrows, then extract it acting in t he direction of C arrow. Remove the speedo cable under the dashboard.
REMOUNTING
Perform the dismounting operations in the reverse order.
83-7
DISMOUNTING / REMOUNTING SPEEDOMETER CABLE ( FLEXIBLE SHAFT )
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