2004 DACIA SOLENZA lock

19
19 - 16
COOLING - EXHAUST - TANK
FILLING CAP
Fuel tank
The fuel tank is having a filling cap, sealed-type, with key. The filling cap for unleaded fuel has
a filler whole incompatible with a c lassical filling gun (lead has a negative effect upon the de-
pollution system : oxygen sensor and catalyst).
In case of vehicle overturning, the anti-overturning valve is getting blocked, avoiding in this
wa y, the petrol leakage towards the carbon can.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 3
Tightening moments in daNm
TIGHTENING MOMENTS (daNm)
A ttachment screws of the mechanism crankcase on the
clutch – differential case 2.5
S econdary shaft screw 7
Primary shaft nut 19
Back cap fixing screws 2.5
Oil draining plug 2.5
R everse driving contact 2.5
S crews for fixing the bellows assembly – left transmission cap assembly 2.5
Screws for fixing gearbox on engine case (M10 – 90) 4.4
Screws for fixing gearbox on engine case (M10 – 35) 2.1
Nuts for fixing gearbox on engine 4.4
LOCTOU blocking element fixing screw 0.5
S crews for fixing RPM sensor on the clutch case 0.8
S crews for fixing the control axle assembly 2
S crews for fixing clutch cable support 4.8
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CV JH3 - 05121
MECHANICAL GEARBOX
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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 - 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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CV JH3 - 05121
MECHANICAL GEARBOX
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A
B
C.V. 560
Dismount the attachment elastic pin of the re-
verse driving shaft, by means of the mandrel C.V.
560. Di
smount the secondary shaft assembly to-
gether with the a xle and 1-2 fork.
Place vertically the secondary shaft, with the
pinion of the 1-st gear downwards, so that the
other pinions will not fall down. Recover t he locking pins (A) and (B) of the
control axles. Remove the primary shaft together with
the reverse driving shaft and pinion.
Gearbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
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INTERNAL CONTROLS
MÎ
1-2
3-4
5
The internal control axles must not show any deformations or wear on the milling for locking
balls, and their sliding on bearings must be done freely, without excessive clearance.
The contact surfaces of the forks with collar of the rocking must not show either deformations
nor wear. Ensuring of the control forks axles is performed by means of the balls and springs placed 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.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
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CONTROL AXLE DISMOUNTING
This operation is to be performed after crank-
cases separation.
The control axle is provided with a blocking
element “LOCTOU” –(A) attached on the
crankcase. The sealing is ensured by m eans of the tore
gasket (B).
Remove the elastic pin of the selection lever
(C), then dismount the a ttachment screws, and
retrieve the control axle assembly .
In order to replace the bearing bushing of the control axle, the CV 1162 device, or a tube with
the outer diameter 16.5 mm are to be used. Before mounting the bushing shall be oiled.
CONTROL 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. Tighten all attachment screws of the control axle assembly at the required moment of
2 daNm.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
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CRA
NKCASES ASSEMBLING
A
B
The assemb ling surfaces must be flat (small
imperfections can be eliminated by means of
a thin file). Place the axle and 1-2 fork, assembled,
on the 1-2 sliding collar of the secondary shaft.
The two shafts (primary a nd secondary)
are taken together with the fork and 1-2 axle
and positioned at the same time into the clutch
– differential crankcase.
The crown and the secondary shaft are
rotated until t he end of the secondary shaft
fits into the bearing.
Mount the blocking roll of the shaft ˚ (A).With the
1 – 2 axle in fre e position, the fol -
lowing are mounted:
-synchronizing assembly 3 – 4 together
w ith the a xle and t he 3 – 4 fork;
- mount the pin of the fork 3 – 4 by means
of the CV 949 device.
M ount the blocking roll of the 5 th gear axle
(B).
After that, mount the followin gs:
- the control axle for the 5 –th gear and
reverse driving (A);
- the axle and the reverse driving pinion
assembly (B), by easy lifting the primary shaft.
Gearbox dismounting
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