2004 DACIA SUPERNOVA Repair Manual

CV JH3 - 05021
MANUAL GEARBOX
21 - 17
SECONDARY SHAFT
SECONDARY SHAFT DISMOUNTING
Dismounting of the secondary shaft is performed starting from the 4 th step.
Dismount the elements, in the following order:
1. - the support washer
2. - gear IV pinion
3. - synchronizing ring
4. - synchronizer for gear III and IV
5. - stopping ring
6. - grooved washer
7. - synchronizing ring
8. - pinion of gear III
9. - grooved washer
10. - stopping ring
11 . - grooved washer
12. - step pinion II
13. - grooved washer
14. - stopping ring
15. - synchronizer ring
16. - synchronizer for steps I and II
17. - synchronizing ring
18. - step I pinion.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 18
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 pre – oiled. Take into consideration that synchroniser hubs are matched with the sliding.
It is recommended to mark the positions of the sliding compared to the hubs.
The stopping rings shall be replaced after every dismounting.
Reassembling of the secondary shaft shall be performing the dismounting operations in the
reverse order. The stopping rings
are replaced after each dismounting.
Fo r mounting and dismounting the stopping rings, a pair of safety pincers to keep t he ends
apart, and, on the opposite side, a pair of flat tipped pincers to prevent the stopping ring breaking,
are to be used.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 19
R
EPLACEMENT 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 i ts 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 crimped by means of a mandrel (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 behind t he bearing will be damaged, being necessary its replacement with a
n ew one ( t his is ensuring the inner oiling of the secondary shaft).
:-
C.V. 552
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 20
The differential of the
JH3050 gearbox is the simple type (with two satellite s 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 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 with a hammer 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 the grooves.
GEARBOX DISMOUNTING
DIFFE RENTIAL
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CV JH3 - 05021
MANUAL GEARBOX
21 - 21
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 c oncave washer ( 6).
The crown of the speedometer ( 8) is dismount from the outside of the differential frame.
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.
REMOUNTING THE DIFFERENTIAL
5
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 22
DIFFERENTIAL BEARI NGS REPLACEMENT
DISMOUNTING
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.
DISMOUNTING
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
pressing on the outer ring of the bearing
Remount the bearing maintaining safety.
7
C.V. 1059
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 23
DIFFERENTIAL ASSEMBLY MOUNTING IN 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 C.V. 945 device and the A protector.
Mount the oiled protector A, on the planetary pinion and position the oiled seal ( C) by means
of the B device.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 24
The internal control
axles must not show any deformations or wear on the milling for locking
ball, and their sliding on bearings must be done make freely, without excessive clearance.
The contact surfaces of the forks with collar of the rocking must not show either deformations or
wear. Ensuring of the control forks axle is performed by means of the balls and springs located in
the holes made in the mechanisms crankcase.
The locking of the control axles is done by means of some cylindrical rolls mounted inside the
clutch–differential crankcase.
GEARBOX DISMOUNTING
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