2004 DACIA SOLENZA Repair Manual

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 5
Ratio s
GEAR STEPI II III IV V R.D.
NR. OF TEETH 41/11 43/21 39/28 35/34 31/39 39/11
RATIO 3.727 2.048 1.393 1.029 0.795 3.545
GB INDEX VEHICLE MAIN MILEAGE TRANSMISSION GEARING
JH3-051 SOLENZA 15/56 21/19
A
CAPACITY , LUBRICANTS
O il used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 6
TYPEUSE
LOCTITE 518Crankcas es as s embling
Thread of reverse driving contact
LOCTITE FRENBLOCSecondary shaft screw
Ingredients
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 7
A
Oil used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
Capacity, lubricants
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 8
The following parts are to be replaced, if they have been dismounted:
- oil seal rings;
- fastening rings;
- elastic pins;
- primary shaft nut;
- the bushing under the pinion of the 5 – th gear;
- the outer safety devices of the bearings of the primary and the secondary shafts;
- the t ore gaskets.
P arts that are replaced after each dismonting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 9
Necessary special tools
SERVICEDENOMINATION DACIA
CO DE ITEM NUMBER
C.V. 22 - 01 Bearings extractor b ody 1002 2164 01
C.V. 945 Chuck for mounting the planetary pinion oil ring 1002 0945 00
C.V. 946 Chuck for safety mounting 1002 0946 00
C.V.551 Device for mounting/dismounting bearings of the mechanism casing 1002 0551 00
C.V. 949 Device for mounting/dismounting the elastic pins 1002 0949 00
C.V.1000 Extractor for the fixed pinion of the 5 th gear from the secondary shaft 1002 1000 00
C.V. 1059 Bushing kit for mounting/dismounting the differential bearings 1002 1059 00
C.V. 1170 Hub extractor of the 5 th gear 1002 117000
C.V. 1175 Screw for mounting the fixed pinion 5 th gear 1002 117500
C.V.552 Extractor of the secondary shaft bearing from th e
clutch – differential crankcase. 1002 0552 00
C.V.31 – 01 Set of punches for elastic pins dismounting/ remounting 1002 2594 01
C.V. 1162 Chuck for replacing control bearing bushings 1002 116200
C.V. 553 Device for di smounting/remounting the clutch shaft
bearing 1002 0553 00
C.V. 554 Bushing for depressing the differential assembly 1002 0554 00
C.V. 560 Set of punches for dismounting/remounting blocking pin of the reverse driving shaft. 1002 0560 00
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 10
Gearbox dismounting
2 1
ATTENTION !
Th
e dismounting and checking of the parts must be done on a surface coated with rub-
be r or soft plastic.
Before taking apart the gearbox from the vehicle, drain the oil from the gearbox.
DISMOUNTIN G
Dismount :
- clutch re lease fork ( 1) ;
- pressure bearing ( 2) ;
- the screws located inside the c lutch
crankcase.
Dismount the cap attachment screws.
The back c ap of the gearbox is extracted
so that its setting surface should is remaining
parallel to the c onjoined surface of the gear-
box, because this cap is containing an oiling
groove situated in the cylinder bore of the pri-
mary shaft. Engage the
1-st gear with the control lever
and the 5-th gear by manually shifting of the 5-
th gear fork. Dismount the primary shaft nut and the sec-
ondary shaft screw.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 11
C.V. 1170
C.V. 22-01
C.V. 1000
Dismount the elastic pin of the 5 th gear,
by means of the C.V. 31 – 01 mandrel.
Dismount the fork and the sliding collar of
the 5 th gear. The hub of the 5 th gear synchronizer i s
extracted by means of the C.V. 1170 extrac-
tor.
Dismount the synchronizer ring of the 5 –
th gear, the inner bushing of the pinion, t he
pinion and its supporting washer. Dismount
the fixed pinion of the 5 th gear
by means of the C.V. 1000 extractor and the
body extractor C.V. 22 -01 .
The gearbox is set in the neutral point, then
the 3-d gear is e ngaged.
Di smount the external screws fixing the
mechanisms crankcase
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 12
A
C.V. 949
Dismount the reverse driving contact (A).
In order to recover the balls and the lock-
ing springs of the 1-2 and 3-4 shafts, two
magnets placed in the C orifices are used.
Pull the control shaft towards exterior and
s eparate the crankcases
Dismount the reverse driving control shaft
and the 5-th gear. Remove the pin of the
3-4 fork by means
of the C.V. 949 device and dismount the 3-4
shaft and fork assembly .
Gearbox dismounting
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