differential DACIA SUPERNOVA 2004 Repair Manual

CV JH3 - 05021
MANUAL GEARBOX
21 - 6
PARTICULARITIES
The gears grid is similar to that of the gearboxes previously mounted on the DACIA
SupeRNova vehicles, the only difference being the reverse driving, which is located on the right
s ide and backwards.
The synchronizers are BORG – WARNER type.
The synchronizing hub – sliding collar, and the synchronizing hub – shaft assemblies are com-
posed of matching parts . The synchronizing hubs are freely mounted on the secondary shaft and are maintained axially
through safety devices of the ring type. The cylindrical moment of the differential is not adjustable.
The differential assembly is supported on the gearbox crankcases by means of the bearings.
The primary and secondary shafts support at the clutch side is done by means of roll – bear-
ings, which get into direct contact with the shaft (the bearings do not have inner ring, its purpose
being taken over by the shafts). The reverse driving pinion is delivered mounted on the shaft. PARTICULARITIES
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CV JH3 - 05021
MANUAL GEARBOX
21 - 7
TYPEUSE
Molykote “BR 2” Grooves of the differential planetary pinion
Crankcase assembling
Loctite 518 Thread of reverse driving contact
Grooves of fixed pinion of 5 Th gear
Grooves of 5 Th gear hub
Loctite FRENBLOC Primary shaft nut
Secondary shaft screw
INGREDIENTS
IN
GREDIENTS
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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 - 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 - 16
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
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
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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
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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
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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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