2004 DACIA SOLENZA tow

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 28
C.V. 1175
C.V. 31-01
Mount the 5-th gear fix pinion on the sec-
ondary shaft by means of the C.V. 1175 de-
vice. Dismount the C.V. 1175 device and mount
the secondary shaft screw, oiled with 3 drops
of LOCTITE FRENBLOC.
Remount on the primary shaft, observing
the following sequence :
- the support washers (with the larger side
towards the pinion ) - the bushing under the pinion;
- the fre e 5 th pinion equipped with its
synchroni ser ring ;
- the 5-th gear hub equipped with its spring
- the fork together with the 5 th sliding
collar. Engage the 1-st gear with the gear lever and
the 5 th gear by sliding the 5-th gear fork on its
axle. Mount the nut and the screw and tighten them
at the required moment: - primary shaft nut : 19 daNm;
- secondary shaft screw : 7 daNm.
Mount the pin of the 5 th gear fork by means
the CV 31 01 device.
Gearb ox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 29
Observe the mounting direction, the pin slot must be oriented towards the back cap.
Bring the gearbox in the neutral position
M ount a new 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 groove, and tighten the screws at the required moment of 2,5 daNm .
Check the correct gears shifting.
Mount the reverse driving connector.
Mount the clutch control fork and the pressure bearing.
G earbox dismounting
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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 - 6
Bellows - Bearing assembly
to the gearbox
Maintaining the transmission on the press, on both sides, shall be ensured on the G groove
made on shaft, by means of a device t ype FACOM U 53 G, ( the flat side towards bellows) in
order to avoid the deflector damages on the wheel side. The pressing effort of the bearing on the transmission shaft ahas the value of = 100 – 700
daN. Press again the assembled tripod on the transmission shaft observing the marks made when
depressing. The press effort of the tripod assembly on the grooved area of the shaft end, shall be between
60 – 600 daN. Remount the blocking ring (Zeger lock) in the groove made on the transmiss ion shaft.
Left
transmi ssion
G
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TRANSM ISSION
29
29 - 7
Bellows to wheel
JOINT TOWARDS WHEEL
1. Steering knuckle casing ass.
2. Retainer star
3. Tripod to the wheel
4. Tulip shaft
5. Maintai ning collars
6. Rubber protection bellow SPECIAL TOOLS
GE 86 joint bellows replacement device PF 537-04
DISMOUNTIN G
Dismount the two maintaining collars off
the bellows by means of two rods, locally
manufactured (see the drawing)
Cut and remove the damaged bellows.
Remove as much grease as possible.
Mark one of the groove routes of the shaft
subject to its working corresponding clog by
marking w ith a centre punch on casing outer
conse quently on the shaft.
Detach th e connection be twe en the
transmission shaft and the steering knuckle
casing, lift ing one by one the arms of the
reta ining star from the three stamps performed
on the petals of the shaft tulip.
WHEN DISMOUN TIN G, DO N OT
DEFORM THE ARMS OF THE RETAINING
STAR
Retrieve the head and the spring from the
tripod to wheel.
Left
transmi ssion
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TRANSM ISSION
29
29 - 12
Bellows to gearbox
JOINT TOWARDS GEARBOX - GI
1. Tu lip
2. Tripod
3. Blocking ring
4. Rubber bellows
5. Maintai ning collars
DISMOUNTIN G
Cut the maintaining collar.
Cut by means of a saw the existent collar,
taking care not to scratch the tulip in the mounting
area with the bellows.
Right
transmissi on
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TRANSM ISSION
29
29 - 15
Bellows to wheel
JOINT TOWARDS THE WHEEL – GE
1. Steering knuckle casing assembled
2. Retaining star.
3. Tripod to wheel
4. Tulip shaft
5. Maintainin g collars
6. Protection rubber bellows
DISMOUNTIN G
Dismount the two m aintaining collars using two rod s locally produced (see the method
previously described for dismounting the joint GE, left transmission) .
Cut and remove the damaged bellows.
T ake out maximum of grease.
In order to replace the joint GE protection bellows, it is necessary to dismount/remount the
GI joint parts (see the method previously described).
R EMOU NT I NG
Grease the rod of transmiss ion shaft with grease.
Introduce the protection bellows of the GE joint.
Distribute the prescribed dosage of grease for GE joint.
Position the bellows beads in the grooves of the steering knuckle casing, consequently on the
transmission shaft tube and mount the collars (see the method described at mounting GE joint
bellows, left transmission) .
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GENERAL
30 - 16
30
The influence of angles
The influence of different angles over the road behavior, stability and abnormal wear preventing
of the vehicles tires.
CAMBER
The exit from the tolerance field of the left or right wheel camber, may have as result:
- tires external or internal edge wear (excessive positive or negative camber);
- steerin g is deviating towards the camber angle is more pronounced (asymmetry ), a deviation
from the trajectory is taking place, which must be corrected by means of the steering wheel (the
pronounced wear on the tire in question is occurring);
CASTER
A larger difference of 1° between the right side caster and left side, may have as result:
- a deviation from the trajectory, which must be corrected by means of the steering wheel, the
abnormal tires wear (the pronounced wear on the tire in question is occurring), tough steering,
instability when turning.
PA R ALLELISM
This adjustment has little importance over the vehicle road behavior.
Anyhow, note the followings:
-a prominent closing may lead to tires external edges wear.
-a prominent opening may lead to tires interior edges wear.
DIMENSIONS UNDER CARRIAGE BODY
These are especially influencing the different angles of the steering geometry.
A vehicle, which has run a large amount of km, it will have under the carriage body, dimension s
smaller than a new vehicle. This is the reason why some vehicle manufacturers, are prescribing, when the checking is
done with empty vehicle, different under carriage body dimensions and their respective places
where these values must be taken. Other vehicle manufacturers are recommending the suspension
compression by means of special (specific) tools or loading repartition in different places.
These different procedures (as performing ways) have as final purpose, the cancellation of the
vehicle suspension lowering, which has driven an important number of Km, compared with its
initial condition.
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