2004 DACIA SOLENZA oil

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 5
Ratio s
GEAR STEPI II III IV V R.D.
NR. OF TEETH 41/11 43/21 39/28 35/34 31/39 39/11
RATIO 3.727 2.048 1.393 1.029 0.795 3.545
GB INDEX VEHICLE MAIN MILEAGE TRANSMISSION GEARING
JH3-051 SOLENZA 15/56 21/19
A
CAPACITY , LUBRICANTS
O il used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 7
A
Oil used : Dacia Extragear 75 W – 80 W; API GL5
The oil quantity needed for the gearbox operation is 3.5 liters.
The oiling of the gearbox parts is done by splash lubrication
Checking of the oil level is done through the filling plug A.
A
Capacity, lubricants
vnx.su

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 8
The following parts are to be replaced, if they have been dismounted:
- oil seal rings;
- fastening rings;
- elastic pins;
- primary shaft nut;
- the bushing under the pinion of the 5 – th gear;
- the outer safety devices of the bearings of the primary and the secondary shafts;
- the t ore gaskets.
P arts that are replaced after each dismonting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 9
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 - 10
Gearbox dismounting
2 1
ATTENTION !
Th
e dismounting and checking of the parts must be done on a surface coated with rub-
be r or soft plastic.
Before taking apart the gearbox from the vehicle, drain the oil from the gearbox.
DISMOUNTIN G
Dismount :
- clutch re lease fork ( 1) ;
- pressure bearing ( 2) ;
- the screws located inside the c lutch
crankcase.
Dismount the cap attachment screws.
The back c ap of the gearbox is extracted
so that its setting surface should is remaining
parallel to the c onjoined surface of the gear-
box, because this cap is containing an oiling
groove situated in the cylinder bore of the pri-
mary shaft. Engage the
1-st gear with the control lever
and the 5-th gear by manually shifting of the 5-
th gear fork. Dismount the primary shaft nut and the sec-
ondary shaft screw.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 14
SHAFTS
THE PRIMARY
SHAFT
.
The primary shaft shall not be repaired and is not adjustable.
The shaft has a groove ( B) for oiling the 5-th gear free pinion.
Clean the oiling – groove of the 5 th gear
The oil seal ring in front of the shaft and the bearing cams are in direct contact with the shaft.
Check the condition of the shaft surface in the operation area ( A) of the oil seal; ring , and if
this shows ridges or irregularities, it will be replaced.
R EPLACING THE BEARINGS OF THE PRIMARY SHAFT
The bearings of the primary shaft are freely mounted on it
There are two types of bearings: - a cylindrical one with balls, pressed into the mechanism crankcase;
- a cylindrical one with rolls, pressed into the clutch-differential crankcase, together with
the clutch shaft oil seal ring.
The bearings replacement is to be done only with identical bearings with the original
ones.
G earbox dismounting
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 18
Gearbox dismounting
The stopping rings are to be replaced after each dismounting.
For mounting and dismounting the stopping rings, a pair of safety pincers to keep the ends
apart, and, on the opposite side, a pair of flat tipped pincers to prevent the stopping ring
breaking, are to be used.
SECONDARY SHAFT REASSEMBLING
Before reassembling the secondary shaft, perform the parts checking, as follows: -the pinions and claws tooth must not show chips or excessive wear;
- ensure that working surfaces of the shafts and the inner parts of the pinions do not show
traces of gripping or abnormal wear. When reassemblin g, clean the oiling grooves made in the secondary shaft and all its component
parts are to be pre – oi led. Take into consideration that synchroniser hubs are matched with the slidings.
It is recommended to mark the positions of the sliding compared to the hubs.
The stopping rings are to be replaced after every dismounting.
Reassembling of the secondary shaft shall be done by performing the dismounting operations
in the reverse order.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 19
Gearbox dismounting
C.V. 552
REPLACEMENT OF THE SECONDARY SHAFT BEARINGS
The secondary shaft bearing from the mechanisms crankcase i s identical to the one from the
primary shaft so that its dismounting and remounting are performed in the same way as for the
primary shaft.
Bearing dismounting and mounting in the clutch crankcase is performed by means of the C.V.
522 device.
The bearing is set by means of a mandre l
(puncher) in four equidistant points on a 55 mm
diameter. X = 0,9 ÷ 1,3 mm.
NOTE:
When dismounting the bearing from the clutch-diffe rential crankcase, the deflector
located be hind the be aring will be damaged, being necessary its replacement wi th a
n ew one (this i s ensuring the inside oiling of t he secondary shaft).
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