2004 DACIA SOLENZA wheel

20
CLUTCH
20 - 5
Clutch disk – Mechanism
TIGHTENING MOMENTS (daNm)
Clutch mechanism attachment screws 2
S. D. V. -uri necesare
MOT 582 Flywheel immobilizing sector
AMB 1518 Clutch centering device
A
REPLACEMENT
This opera tion is to be pe rformed after dismounting t he gearbox –engine a ssembly a nd
after t heir separation.
DISMOUNTING
M ount the i mmobilizing sector MOT
582. Dism ount the clutch mechanism
attachment screws.
Dismount the mechanism and the clutch
disk.
Perform a visual checking of :
- the wear of the engine flywheel and
of the mechanism plate; - t he c ondi t i on c r own t oo t hi ng for
starter; - the sealing at c rankshaft sealing gasket
level; - the wear of the pressure bearing guide
and of the control fork;
- the conditions of the clutch shaft grooves.
Replace the damaged part s and clean the
clutch shaft grooves.REMOUNTING
D egrease the friction surface of t he engine
flywheel.
Clean the grooves of the clutch shaft.
Check the disk sliding on the clutch shaft
Mo u n t the clutch disk (with hub
protuberance ( A) towards the engine
flywheel).
Center the clutch disk by means of the
centering device AMB 1518.
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CLUTCH
20
20 - 8
S
PECIAL TOOLS
MOT 582 Flywheel immobilizing sector
.
Engine flywheel
TI GHTENING MOMENTS (daNm)
Flywheel screws 5 ÷ 5,5
REPLACEMENT
This operation is to be performed after dismounting the clutch mechanism and the ge arbox.
DISMOUNTING
Mount the immobilizing sector MOT 582.
Di smount the fl ywheel attachment screws.
The screws are not to be re used.
Di smount the engine flywheel.
REMOUNTING
Clean the holes thread from the cra nkshaft by means of a dry gauze.
Degrease the flywheel seating surfaces on the crankshaft .
Mount the flywhe el with new scre ws (the scre ws thread shall be lubr icated with
LOCTITE FRENETANCH).
Tighten the screws to the required moment.
Dismount the immobilizing sector MOT 582
REMARK
The flywheel attachment screws are to be replaced aft er each dismounting.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 20
DIFFERENTIAL
The differential of the
JH3-051 gearbox is the simple type (with two satellites 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 to be 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 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 t he grooves.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 30
Replacement of the planetary
sealing gasket (on the vehicle)
SDV-uri SPECIALE NECESARE
C. V. 945 Mandrin montare garniturã etanºare planetarã
TIGHTENING MOMENTS (d aNm)
Shoc k absorber attachment
nut on steering knuckle 7.5
Wheel attachment screws 7.5
Oil draining plug 2.5
1
DISMOUNTIN G
Place the vehicle on a two-columns
elevator.
Dismount the right front wheel.
Drain the oil off the gearbox.
Dismou nt :
- the wheel protector
- the shock absorber attachment nuts
(1) on steering knuckle.
REMOUNTING
Lubricate with oil the new sealing gasket.
Mount the sealing gasket by means of the
C.V. 945 device.
M ount the protector (A) lubricated with
oil, on the planetary shaft and position the
gasket (C) by means of the device (B).
Rock the steering knuckle and disconnect
the planetary transmission from the gearbox.Remove
the “O” ring off the planetary shaft,
then, by means of a pins mandrel and a
hammer,
is gently hit in order to make it pivoting in its place.
Remove the sealing gasket by means of a
pliers, taking c are not t o damage the planetary
pinion grooves.
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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 - 1
Front transversal transmission
DISMOUNTING - THE SIDE TO W HEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Dismount the wheels.
Dismount the screws that attach the brake disk assembly on the steering knuckle.
U nscrew the transmission nut by means of the RO 604 – 01 device.
Dismou nt :
- the nut of the steering ball joint;
- steering ball j oint from the steering knuckle, by means of the PF 476 extractor;
- the attachment screws of the steering knuckle on the shock absorber end. SPECIAL TOOLS
RO 604-01 Hub immobilizing device
PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
T ransmission nut 28
S crew for fixing the bellows lid on the gearbox 2,5
Wheels attachment screw 7,5
Screws, nuts for fixing the stee ring knuckle on the shock absorber 10,5
S crew for fi xing the caliper on the steering knuckle 6,5
Nut for steering ball joint 4
Push the transmission in the steering knuckle and incline the latter.
Dismount the transmission, the wheel side.
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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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