2004 DACIA SUPERNOVA tow

20
CLUTCH
The clutch disc is mounted with the A damping flange towards the gearbox
The clutch d isc is centered with the AMB 1518 centering device
The clutch mech anism is mounted;
Th e fixing screws are progressively put on the thread of the mechanism, then they are tight-
ened to the couple;
The MOT 582 fly wheel-stopping sector is taken off.
CLUTCH DISC MECHANISM
20 - 10
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CV JH3 - 05021
MANUAL GEARBOX
21 - 13
In order to recover t he balls and t he locking
s prings of the shafts, two magnets placed in the
C orifices are used.
Pull the control shaft towards exterior.
The crankcases are separated.
Rotate to the left the shaft – reverse driving
pinion assembly and dismount the control reverse
driving shaft velocity 5-th step. T
ake out the fork pin 3-4 by means of the
C.V. 949 device and dismount the a xle and
3-4 fork assembly. Simultaneously, dismount the primary shaft
and secondary shaft assembly with the axle
and 1-2 fork.
Place vertically the secondary shaft, with
the pinion of the 1 step downwards, so that
the other pinions will not fall. Recover the locking pi ns ( A) and ( B) of
the command axles.
GEARBOX DISMOUNTING
Easy lift the primary shaft and di smount the
shaft and reverse driving pinion assembly .
C.V. 1170
C.V. 94 9
A
B
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CV JH3 - 05021
MANUAL GEARBOX
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BEARING DISMOUNTING OF THE MECHANISMS
CRANKCASE
The safety ring of the bearing (t he hol ding ri ng) i s widened by means of a pa ir of safety
pincers, then the bearing is extracted from the crankcase by hammering towards the inside of the
mechanisms crankcase, by means of the C.V. 551 device.
BEARING REMOUNTING OF THE MECHANISMS CRANKCASE
Replace the safety of the bearings with a new one, then it is introduced into its groove in the
mechanisms crankcase, so that i t keeps its position as c ompared t o the crankcase (the safety
shows a shoulder).
The bearing lying a t the outside of the c rankcase of the mechanism is pressed towards the
inside of it, until the safety fits into the groove carved on the outer ring of the bearing.
Mounting the bearing is performed by means of the C.V. 551 device.
C.V. 551
GEARBOX DISMOUNTING
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CV JH3 - 05021
MANUAL GEARBOX
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The roll bearing i n the c rankcase i s dismounted in t he opposite di rection to the clutch, by
means of the C.V. 553 device.
Ensure that device is well fixed upon depressing the bearing.
BEARING REMOUNTING FROM TH E CLUTCH – DIFFERENTIAL CRANK-
CASE
The remounting shall be performed using the same C.V. 553 device, the mounting directions
of the bearing being towards the clutch. BEARING DISMOUNTING FROM THE CLUTCH – DIFFERENTIAL CRANK-
CASE
C.V. 553
GEARBOX DISMOUNTING
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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
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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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MANUAL GEARBOX
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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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