2004 DACIA SUPERNOVA lock

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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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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DRIVE SHAFTS
29 BELLOWS –BEARING ASSEMBLY
TO THE GEARBOX
THE JOINT TO THE GEARBOX - GI
SPECIAL TOOLS
Bearing mounting chuck on the shaft PF 1331
1. Tripod assembled
2. Bellows
3. bearing
4. bellows attachment lid
5. deflector
6. blocking ri ng
7. transmission shaft
DISMOUNTING
It is forbidden to use t h inner for
components parts cleaning.
Dismo u nt the blocki n g r i ng fr om t he
groove made on the transmission shaft, using
a special pincers for these types of rings.
29 - 04
Left
transmission
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DRIVE SHAFTS
29BELLOWS-BEARING ASSEMBLYTO THE GEARBOX
M aintaining the transmission on the press, on both sides, shall be ensured on the G
groove made on shaft, by means of a device type FACOM U 53 G, ( the flat side towards
bellows) in order t o avoid the defl ector damages on the wheel side. The pressing effort of the beari ng on the tra nsmission shaft ahas the value of = 100 –
700 daN. Press again the assembled tripod on the tra nsmission shaft observing the marks made
when depressing. The pre ss effort of t he tripod assembly on t he groove d area of t he shaft end, shall be
between 60 – 600 daN. Remount the blocking ring (Zeger lock) in the groove made on the tra nsmission shaft.
29 - 6Left
transmi ssion
G
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DRIVE SHAFTS
29BELLOWS TO GEARBOX
JOINT TOWARDS GEARBOX - GI
1. Tulip
2. Tripod
3. Blocking ri ng
4. Rubber bellows
5. Maintaining collars
DISMOUNTING
Cut the maintaining collar.
Cut by means of a saw the existent collar,
taking c are not t o sc ratch t he t ulip in t he
mounting area with the bellows.
29 - 12
Right
transmissi on
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DRIVE SHAFTS
29
Cut the bellows.
Remove maximum of grease.
NOTE :
The t ulip not being equipped with a
ho o d ha ving re tainin g wings,
dismounting is to be performed without
forcing.
It is avoided th e cams exit from the
trunnions (tripod a rms) because the rol l-
needles and the cams are paired and must
be not reversed. Nev er u se th inner to wash the
component parts.
Dismount the blocking ri ng. BELLOWS TO GEARBOX
29 - 13
Right
transmissi on
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