2004 DACIA SOLENZA oil

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 32
Replacement of the 5-th gear synchroniserand pinion (on the vehicle
)
1
NECESSARY SPECIAL TOOLS
C. V. 22 – 01 Bearings extractor body
C. V. 31 - 01 Mandrels set for elastic pins
C. V. 1000 Extractor for the 5-th gear fix pinion C.V.
1 170 Extractor for the 5-th gear hub.
C. V. 1 175 Screw for mounting the 5-th gear fix pinion
Tightening moments (daNm)
Primary shaft nut 19
S econdary shaft screw 7
Wheel attachment screws 7.5
Back cap attachment screws 2.5
Oil draining plug 2.5
DISMOUNTIN G
Place the vehicle on a two columns
elevator.
Dismount the front left wheel.
Drain the oil off the gearbox.
Disconnect the connector of the reverse
driving contact. Dismount the cross-tie rod (1).
Dismount the attachment screws of the
back cap. Re m ove t he ba c k c a p on t he ge a rbox
horizontal axle direction, because the cap is
provided with an oiling groove ( A), which is
penetrating into the primary shaft.
Engage the 1-st gear.
Dismount the elastic pin of the 5-th gear fork
by means of the m andrel C.V. 31 – 01.
Engage the 5-th gear by hand.
Dismo unt :
- the nut from the primary shaft and t he
screws from the secondary shaft. - the 5-th gear fork and sliding collar.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 34
Replacement of the 5-th gear synchroniserand pinion (on the vehicle
)
C.V. 31-01
Mount on t he pri m a ry sha ft , i n t he
following sequence: - the support washer (with the l arger side
towards the pinion ) - the bushing under the pinion;
- the free 5 th pinion equipped with its
synchroni ser ring ;
- the fork together with the 5-th gear sliding
collar;
- the primary shaft nut.
Engage t he 1-st gear with the ge ar l ever
and the 5-th gear by sliding the 5-th gear fork
on its axle. Tighten at the required moment:
- the primary shaft nut: 19 daNm;
- the secondary shaft screw: 7 daNm.
Mount the pin of the 5-th gear fork by
means the CV 31 01 device.
The pin slot must be oriented towards the
back cap. Bring the gearbox in the neutral position
and check the engagement of all speed gears. M
ount a new tore gasket to ensure the back
cap sealing. Mount the back cap with the ( A) groove in
the primary shaft, and the oiling collector in the
(B) oil collecting gr o ove.
Tighten the back cap screws at the re quired
moment of 2,5 daNm .
Mount the reverse driving contact connector.
Check the correct gears shifting.
Perform the filling with oil of the gearbox .
Check the gearbox sealing.
M ount the two cross-tie rods.
Mount the right front wheel.
T ighten the screws and the nuts at the required
moment.
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TRANSM ISSION
29
29 - 2
DISMOUNTING – THE SIDE TO THE GEARBOX
The right side
Due to t he solution assumed by the manufa cture r, the t ransmission j oint (the t ulip of the
transmission) with the t ransmission shaft of the gearbox shall be pe rformed only by m ea the
grooves.
The di smounting of the transmission, the side t o the gearbox, shall be pe rformed by a xial
displacement - extract the transmission tulip from the transmission shaft.
The left side
Drain the oil of the gearbox.
Dismou nt :
- the three screws for fixing the bellows – lid assembly on the gearbox;
- the transmission, the side to the gearbox.
F ront transversal transmission
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TRANSM ISSION
29
29 - 3
Front transversal transmission
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the transmission GI joint in the gearbox (the transmission position as horizontally as
possible).
Mount the three attachment screws of the bellows l id on the gearbox.
The right side
Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox
with transmission oil.
Engage t he tra nsmission GI joint (t he tulip) on the transmission shaft of the ge arbox (the
transmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter, so that
threaded area of the steering knuckle is allowin g to remounting the transmission nut.
Perform then the dismounting operations in the reverse order.
Observe the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Press several times the brake pedal to enable caliper piston coming in contact with the brake
pads.
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TRANSM ISSION
29
29 - 5
Bellows - Bearing assembly
to th e gearbox
Using a press, extract the assembled tripod,
sustained it on an extractor, FACOM U 53 G
type, protecting the tripod clogs.
Before extracting, mark the position of the
tripod compared to the transmission shaft end.
Dismount the bellows - deflector bearing in
the same manner like tripod dismounting .
REMOU NT I NG
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 ± 0.2 mm between the
backside of the bearing and the shaft extremity.
This value is obtained by means of the PF 1331
device, when mounting, its extremity is at the
level of the shaft.
IMP ORTANT:
In order to avoid the deformation of the bearing, which includes a sealing gasket
(annular oil seal), the pressing effort must be constant (do not hammer).
Left
transmi ssion
GPF
1331
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TRANSM ISSION
29
29 - 8
Bellows to wheel
REMOUNTING
The mounting of the new bellows is to be
performed by means of the PF 573 – 04 device.
Catch the inclined transmission in a vice with
soft jaws in order to avoid the shaft damaging.
Engage the PF 537 – 04 device over the tulip
of the transmission shaft.
O bturate the small e xtremity of the bellows
and, abundantly grease with automatic
transmission oil or ELF CARDREXA RNT 2
grease: - the all outer surface of the PF 537 – 04
device, - the inner part of the bellows, especially its
smaller diameter part (this operation is performed
for slipping help).
Left
transmi ssion
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FRONT AX LES ELEMENTS
31
31 - 10
Brake caliper
DISMOUNTIN G
Loosen the front wheel attachment screws.
Lift the vehicle by means of a two-column
elevator Dismount the wheel.
Drain the brake fluid from the reservoir
Remove the locks and the caliper wedges.
Un screw the rigid duct screw from the
brake flexible hose and detach the caliper
assembly.
REMARK :
If it is necessary to dismount the
cali per fork, di sm ount the at tachm ent
sc rews on the caliper fork.
When remounting the fork, replace the
Grower washers, tighten the screws to the
r equired moment of 6.5 daNm then seal
them with FIXAMED R 58.
RE PAI R ING
Dismount the protection gasket.
Extract the piston using a wooden wedge and
a compressed air source.
Remove the sealing gasket from its seat in the
caliper groove by means of a blade. Clean with alcohol the parts, replace t he
damaged ones, mounting being performed in the
dismounting reverse order, after previously all
parts have been oiled with brake fluid.
REMARK :
Before remounting on the fork, check the
sealing of t he assembled caliper.
TIGHTENING MOMENTS (d aNm)
Wheel screws 7.5
Rigid duct on fr ont flexible screw 1.5
Purging screw 1
Flexible hose - caliper 1.7
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FRONT AX LES ELEMENTS
31
31 - 17
Shock absorber, Spring
TIGHTENING MOMENTS (d aNm)
Shock absorber rod nut 6
Shock absorber lower attachment nut 10.5
Shock absorber upper attachment screws 2
The shock absorbers are stored in horizontal
position. In these conditions, it is possible that
s hock absorbe rs working vert ically, to get
depressed.
Therefore, before mounting on the vehicle, it
is necessary to perform the shock absorbers
pressing, by alternatively shifting the shock
absorber rod (upwards a nd downwards), the
shock absorber being in vertical position. S
HOCK ABSORBER
1. Upper attachment nut
2. Lower attachment screw
3. Filtering block
4. Upper plate
5. Shock buffer
6. Lower plate
7. Axial bearing
The coil diameter of the front axle spring is Ø 13,1+ 0,0 8 mm.
REMARK :
Make sure that springs of every axle have the same characteristics.- 0
3
4
5
6
7
2 1
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