2004 DACIA SOLENZA gearbox

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DISMOUNTING – THE SIDE TO THE GEARBOX
The right side
Due to t he solution assumed by the manufa cture r, the t ransmission j oint (the t ulip of the
transmission) with the t ransmission shaft of the gearbox shall be pe rformed only by m ea the
grooves.
The di smounting of the transmission, the side t o the gearbox, shall be pe rformed by a xial
displacement - extract the transmission tulip from the transmission shaft.
The left side
Drain the oil of the gearbox.
Dismou nt :
- the three screws for fixing the bellows – lid assembly on the gearbox;
- the transmission, the side to the gearbox.
F ront transversal transmission
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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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Bellows - Bearing assembly
to th e gearbox
THE JOINT TO THE GEARBOX - GI
SPECIAL TOOLS
Bearing mounting chuck on the shaft PF 1331
1. Tripod assembled
2. Bellows
3. bearing
4. bellows attachmen t lid
5. deflector
6. blocking ring
7. transmission shaft
DISMOUNTIN G
It is forbidden to use thinner for components
parts cleaning.
Dismount the blocking ring from the groove
made on the transmission shaft, using a special
pincers for these types of rings.
Left
transmission
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Bellows - Bearing assembly
to th e gearbox
Using a press, extract the assembled tripod,
sustained it on an extractor, FACOM U 53 G
type, protecting the tripod clogs.
Before extracting, mark the position of the
tripod compared to the transmission shaft end.
Dismount the bellows - deflector bearing in
the same manner like tripod dismounting .
REMOU NT I NG
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 ± 0.2 mm between the
backside of the bearing and the shaft extremity.
This value is obtained by means of the PF 1331
device, when mounting, its extremity is at the
level of the shaft.
IMP ORTANT:
In order to avoid the deformation of the bearing, which includes a sealing gasket
(annular oil seal), the pressing effort must be constant (do not hammer).
Left
transmi ssion
GPF
1331
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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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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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Cut the bellows.
Remove maximum of grease.
NOTE :
The t ulip not being equipped with a
ho o d ha ving re tainin g wings,
dismounting is to be performed without
forcing.
It is avoided th e cams exit from the
trunnions (tripod a rms) because the rol l-
needles and the cams are paired and must be
not reversed. Never use thinner to wash the component
parts.
Dismount the blocking ring.
Bellows to gearbox
Right
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Bellows to gearbox
Using a press, extract the assembled tripod, sustain it on an extractor type FACOM U 53 G,
protecting the clogs of the tripod.
R EMOU NT I NG
Grease the transmission shaft to help the protection bellows putting back (positioning of the
smallest diameter of the bellows on the transmission shaft).
The tripod is fixed and mounted in the position marked on dismounting.
Three poi nts of crimping are made at 120 ° C by metal he ading of t he t ransmission shaft
grooves.
Distribute the grease prescribed quantity in the bellows and in the tulip casing.
Correctly position the bellows in the tulip-casing place.
A non-cutting, round-headed rod is introduced between the bellows and the tulip casing to
dose the air amount contained inside the bellows. Lengthen or compress the bellows until value A = 190 mm is obtained (the value between
the extremity of the bellows and the extremity of the tulip casing) then from this position extract
the rod and remount the collars.
Right
transmissi on
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