2004 DACIA SOLENZA check oil

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 23
Gearbox dismounting
MOUNTING OF THE DIFFERENTIAL ASSEMBLY I N THE CLUTCH CRANKCASE
The differential assembly is pressed into the crankcase, then the stopping safety device (3)
is mounted on the planetary shaft by means of the C.V. 946 device.
Rotate the differential assembly and check the speedometer pinion rotation.
Remounting of the ( C) planetary oil seal ring is performed after this has been oiled, by means
of the CV 945 device and the ( A) protector.
Mount the oiled protector ( A), on the planetary pinion and position the oil seal ( C) by means
of the ( B) device.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 27
Mount the elastic pin for reverse driving axle
attachment by means of the C.V. 560 mandrel.
Ensure the correct positioning of the two cen-
tering bushings and of the magnet.
Mount the springs and the locking balls 1-2
and 3-4 in the mechanisms crankcase, then the
false axes A w ith a 13-mm diameter are i ntro-
duced.
Check the positioning of the 5 th gear oiling
collector and of the aerating connection. Additionally, ensure (check) if the aeratin g t ube
is not damaged or clogged. Apply a continuos layer of
LOCTITE
518 on the gasket surface between the clutch
crankcase and the mechanism crankcase.
Engage the 3 -d gear.
M ount the spring and the 5 th gear lock-
ing ball into the crankcase of the mechanism.
Compress the locking ball and mount the
mechanisms crankcase.
Mount the attachmen t screws and tighten
them at the required moment of 2,5 daNm ,
after rotating the primary shaft, i n order t o
ensure o correct bearings setting. Retrieve the false axes.
REMARK :
The tightening at the requi red mo-
ment of al l the screws must be done i n
no mo re tha n 30 mi nutes a fter the
mounting of t he mechanisms crankcase,
b ecause of the polymerization of
LOCTITE 518.
G earbox 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 - 31
Replacement of the planetary
sealing gasket (on the vehicle)
Position and mount the planetary transmission on the planetary pinion.
Perform the dismounting operations in the reverse order
Tighten at the required moment the screws and the nuts.
Perform the oil filling of the gearbox.
Check the gearbox sealing.
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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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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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36
STEERING ASSEMBLY
36 - 2
St eering connecting rods
REMOU NT I NG
At each dismounting, it is OBLIGATORY the replacement of the limiter washer( 1) as well
as of the safety washer ( 2).
M ount in the rack : j oint body ( 3), not before positioning the safety washer ( 2), the limiter
w asher (1) and oiling the t hreaded pa rt ( 4) of the j oint body with FIXAMED R 58-C.S.1/82
(not excessively).
After tightening to t he required m oment of the axial ball joint on the rack, bend the safety
w asher over one of the cuts made on the joint body.
By means of the DIR 1306 , lock up the rack in regard to t he steering box casing.
Tighten to the required moment of 5 daNm, the joint body in the rack by means of the
DIR 505 wrench.
M ount the funnel ball joint in the steering knuckle arm, then tighten the nut to the required
moment of 4 daNm.
P osition the steering at the middle point ( wheels being in straight line position) in order to
balance the air from bellows. Mount the bellows in its c hannel from the steering box casing and secure it using a clip.
CHECKING
S lightly tighten by hand one of the bellows in order to check the other one inflation, in this
way, the good air circulation inside the steering box is checked. Check the steering geometry and adjust the parallelism if necessary.
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36
STEERING ASSEMBLY
36 - 10
R
EMARK :
It is forbidden to dismount from the power
st eering box the pipes between the rotary
valve and the steering box.
Whe n dismounti ng, the high and low
p ressure pipes are to be positioned with the
connection screws downward oriented, i n
order to avoid contaminants penetration.
R EMOU NT I NG
Mount :
-steering box
-s teering rods ball j oints in t he steeri ng
knuckle arms; - exhaust
-anti-rocking steering rod;
- cardan joint in the position marke d at
dismounting;
-high and low pressure pipes (remove
MOT 453 pliers), ob serving t he re qui re d
tightening moments; -piping attachment collars;
- wheels;
- battery.
Refill the circuit with oil ( full reservoir).
With stopped engine, easy a ct upon the
steering wheel in both directions, so that rack
is performing a complete double stroke.
Repeat the operation with started engine
(oil pump operatin g), then fill up to the MAXI
mark, the oil level in the reservoir.
Check and eventually adjust the
parallelism.
Pow er steering box
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