2004 DACIA SOLENZA differential

CV JH3 - 05121
MECHANICAL GEARBOX
21 - 3
Tightening moments in daNm
TIGHTENING MOMENTS (daNm)
A ttachment screws of the mechanism crankcase on the
clutch – differential case 2.5
S econdary shaft screw 7
Primary shaft nut 19
Back cap fixing screws 2.5
Oil draining plug 2.5
R everse driving contact 2.5
S crews for fixing the bellows assembly – left transmission cap assembly 2.5
Screws for fixing gearbox on engine case (M10 – 90) 4.4
Screws for fixing gearbox on engine case (M10 – 35) 2.1
Nuts for fixing gearbox on engine 4.4
LOCTOU blocking element fixing screw 0.5
S crews for fixing RPM sensor on the clutch case 0.8
S crews for fixing the control axle assembly 2
S crews for fixing clutch cable support 4.8
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 4
Particurarities
12R 5
4 3
Gr ila de viteze este i denticã c u cea de la c utiile de viteze montate pe automobilele Dacia
SupeRNova.
To engage the reverse driving, the gearbox lever is brought in neutral position, then it is en-
gaged like in any other gear gear The synchronizers are BORG – WARNER type.
The synchronizing hub – sliding collar, and the synchronizing hub – shaft assemblies are com-
posed of matching parts .
The synchronizing hubs are freely mounted on the secondary shaft and axially maintained by
means of ring type safety devices. The cylindrical moment of the differential is not adjustable.
The differential assembly is supported on the gearbox crankcases by means of ball bearings.
The primary and secondary shafts support at the clutch side is done by means of roll – bear-
ings, which get into direct contact with the shaft (the bearings do not have inner ring, its purpose
being taken over by the shafts). The reverse driving pinion is delivered mounted on the shaft.
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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 - 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 - 16
Gearbox dismounting
C.V. 553
BEARING DISMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANKCASE
Dismount the clutch shaft bearing towards the clutch opposite direction, by means of the
C. V. 553 device.
Ensure that device is well fixed upon depressing the bearing.
BEARING REMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANKCASE
The remounting shall be performed using the same C.V. 553 device, the mounting direction of
the bearing being towards the clutch.
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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 - 21
Gearbox dismounting
5
The stopping safety device (A) is extracted, by means of a pincers from the differential
crankcase (press on clutch crankcase in order to release the safety ring).
The differential assembly is dismounted using a press, by means of a bushing C.V. 554 (the
bushing is pressing on the differential crankcase).
Di smount the spacer washer (5) and the elastic concave washer (6).
The crown of the speedometer (8) is dismounted from the outside of the differential casing.
REMOU NT ING THE DIFFERENTIA L
Remounting of the differential assembly is performed in the reverse order of the dismounting
operations, only this time the spacer that is mounted between the lateral surface of the crown
and the support bearing, shall be positioned with the concave side towards the crown.
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CV JH3 - 05121
MECHANICAL GEARBOX
21 - 22
Gearbox dismounting
C.V. 1059
7
DIFFERENTIAL BEARINGS REPLACEMENT
DISMOUNTIN G
In order to extract the big bearing (7), of the differential from the clutch-differential crankcase,
a profiled metallic strap is used, which is pressed by means of an extension, at a press. In order to dismount the other bearing (10), first extract the safety (9), then press with a press
on the bearing by means of a sleeve with the outer diameter of 50 mm, towards the inside of the
clutch-differential crankcase.
R EMOU NT I NG
In case of the bearing (7), its cage C must
be oriented towards the opposite side of the
differential crown. In order to press this bearing into the clutch
crankcase, the C.V. 1059 device is used,
which is pressing on the outer ring of the bear-
ing.
When remounting the other bearing ( 10),
its cage C must be oriented towards the op-
posite side of the differential crown. For pressing, the 65 mm diameter sleeve
of the C.V.1059 device is used, which is
pressed on the outer ring of the bearing Remount the bearing maintaining safety.
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