2004 DACIA SUPERNOVA Repair Manual

CV JH3 - 05021
MANUAL GEARBOX
21 - 25
CO
NTROL AXLE REMOUNTING
When remounting the control axle, replace the selection finger pin with a new one.
Remounting is done by performing the dismounting operations in the reverse order, after all
parts have been oiled with oil.
CONTROL AXL E DISMOUNTING
This operation is to be perform ed af ter
crankcases separation. The control axle is provided with a stopping
flap LOCTOU – (A) attached on the crankcase.
The sealing is ensured by means of the gasket ( B).
Remove the elastic pin of the selection finger
(C), then dismount the attachment screws, a nd
retrieve the control axle assembly .
In order to replace the gallery bearing bush-
ings of the c ontrol axle, the C.V. 1162 device,
or a tube with the outer diameter 16.5 mm are
to be used. Before mounting the bushings shall
be oiled.
GEARBOX DISMOUNTING
INTERNAL CONTROLS
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CV JH3 - 05021
MANUAL GEARBOX
21 - 26
The assembling surfaces must be flat (small
imperfections can be eliminated by means of a thin
file). Place the a xle and 1-2 fork assembled on the 1-
2 sliding collar of the secondary shaft.
The two shafts (primary and secondary) are taken
together with the fork and 1-2 axle and positioned
at the same time into the clutch – differential crank-
case.
The c rown and the secondary shaft are rotated
until the end of the secondary shaft fits into the bear-
ing.
Mounting the blocking roll of the shaft ˚ (A).
With the 1 – 2 axle in free position, the following
are mounted:
- synchronizing a ssembly 3 – 4 together axle
and 3 – 4 fork;
- mount the for pin 3 – 4 by means of the CV
949 device. Mount the blocking roll of the 5 th step axle ( B).
A
B
GEARBOX DISMOUNTING
CRANCKASE ASSEMBLING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 27
Check the positioning of t he
5 th gear oi ling
collector and of the aerating connection.
Additionally , ensure (check) if the aerating tube is
not damaged or clogged. Apply a layer of LOCTITE 518 on the ga sket
su rface between the clutch crankcase and the
mechanism crankcase. Engage the 3 -d gear step.
M ount the spring and the 5 th gear step locking
ball into the crankcase of the mechanism.
Press the locking ball and mount the mechanisms
crankcase. Ensure the correct positionin g of the two
centering bushings and of the magnet Mount the springs and the locking balls 1-2 and
3-4 in t he m echanisms crankcase, t hen the false
axes A with a 13 mm diameter a re introduced.
Than mount the followings:
- the c ontrol a xle for t he 5 gear a nd reverse
driving (A);
- the axle a nd the reverse driving pinion (B)
assembly , by easy lifting the primary shaft.
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 28
REMARK :
The tightening at t he required moment of al l t he screws must be done i n no
more than 30 minutes after the mounting of the mechanisms crankcase, because of the
polymerization of LOCTITE 518.
Mount the a ttachment screws and tighten them at a 2,5 daNm moment, after rotating the
primary shaft in order to ensure o correct bearings setting.
Retrieve the false axes.
Mount the locking pin of the reverse driving pinion (A).
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 29
Three drops of
LOCTITE FRENBLOC
are a pplied on the grooves of the fi xed pinion
for the 5 th gear, then this is m ounted by means
of the C.V. 1175 device on the secondary shaft.
Di smount the C.V. 1175 device and mount
the secondary shaft screw oiled with 3 drops of
LOCTITE FRENBLOC.
On the primary shaft remount the following
sequence :
- the support washers (with the larger side
towards the pinion )
- the bushing under the pinion;
- the free 5 th pinion equipped with its
synchroni ser ring ;
- the 5-th gear step hub equipped with its
spring after the hub grooves have been oiled with
LOCTITE FRENBLOC; - the fork together with the 5 th sliding
collar.
Engage the 1-st gear with the gear lever and
the 5 th ge ar by sliding the 5-th gear step fork
on its axle.
Apply 3 drops of LOCTITE FRENBLOC
on the primary shaft nut.
Mount the nut and the screw and tighten them
at the required moment: - primary shaft nut : 19 daNm
- secondary shaft screw : 7 daNm
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
21 - 30
Mount the pin of the
5 th gear fork by means
the C.V. 31 01 device as for dismounting.
Observe the mounting direction, the pin slot
must be oriented towards the back c ap.
Bring the gearbox in the free position.
Mount a new gasket to ensure t he back cap
sealing. Mount the back cap with the A groove in the
primary shaft, and the oiling collector in the (B)
oil bringing groove, and tighten the screws at a
moment of 2,5 daNm .
Check the correct gears shifting.
Mount the reverse driving connector.
Mount the clutch control receiver cylinder and
tighten the screws at the required moment ( 2,1
daNm) .
GEARBOX DISMOUNTING
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DRIVE SHAFTS
29
FRONT TRANSVERSAL TRANSMISSION
DISMOUNTING - THE SIDE TO WHEEL
Loosen the left wheel screws.
Lift the vehicle on an elevator with two columns.
Di smount the wheels.
Di smount the scre ws that attach the brake disk assembly on the steering knuckle.
Un screw the transmission nut by means of the RO 604 – 01 device.
Di smount :
- the nut of t he steering ball joint;
- steering ball joint from the steering knuckle, by means of the PF 476 extractor; the
attachment screws of the steering knuckle on the shock absorber end. S
PECIAL TOOLS
- RO 604-01 Hub immobilizing device
- PF 476 Ball joint extractor
TIGHTENING MOMENTS (daN/m)
- Transmission nut 21\
- Screw for fixing the bellows lid on the gearbox 2,5
- Wheels attachment screw 7,5
- Screws, nuts for fixing the steerin g knuc kle on the shock absorber 7,5
- Screw for fixing the caliper on the steeri ng knuckle 6,5
- Nut for steering ball joint 4
Pu sh the transmission in the steering knuckle and incline the latter.
Di smount the transmission, the wheel side.
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DRIVE SHAFTS
29
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 transmission shaft of the gearbox shall be performed only by mea
the grooves.
The dismounting of the transmission, the side to t he gearbox, shall be performed by
axial displacement - extract the transmission tulip from the transmission shaft.
The left side
Drain the oil of the gearbox.
Di smount :
- the thre e screws for fixing the bellows – lid assembly on the gearbox;
- the tra nsmission, the side to the gearbox. FRONT TRANSVERSAL TRANSMISSION
29 - 2
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