2004 DACIA SUPERNOVA clutch

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 - 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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MECHAN ICAL ELEMENTS CONTROL
37
BRAKE PUMP
Close the connection pipe between the brake fluid reservoir and clutch transmitter cylinder
by means of the MOT 453 device. Disconnect the battery.
Drain the brake fluid reservoir.
Disconnect the connection pipe between the brake fluid reservoir and clutch transmitter
cylinder.
Dismount the brake fluid reservoir off the brake pump (avoiding fluid leakage).
Dismou nt :
- the rigid pipe screws from the brake pump and mark their position;
- the two attachment nuts of the brake pump on the servobrake .
DISMOUNTING
37 - 3
TIGHTENING MOMENTS (daNm)
Rigid pipe connection 1,5
Nut attachment P.C. with servobrake 1,3
I.C.P. (pressure drop indicator) 2
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MECHAN ICAL ELEMENTS CONTROL
37
MASTER VAC 7 SERVO M ECHANISM
The ” Master-Vac 7” servobrake is a brake booster with the objective of reducing the driver
effort on the brake pedal.
AT TENT ION
The servobrake cannot be repaired.
The only items of the servobrake which are to be replaced are the air filter and the retainer
valve.
DISMOUNTING
Close the pipe between the brake fluid reservoir and the clutch transmitter cylinder by means
of the MOT 453 device.
Drain the liquid out of the reservoir.
Disconnect from the reservoir the feeding pipe of the clutch transmitter cylinder. SERVOBRAKE
OBSERVAT ION
In case one circuit is damaged, the pedal stroke shall be longer, the braking being
done only by the circuit still working.
37 - 6
T I GHTENING MOME NTS (daNm)
Brake pump nut on servobrake 1,3
Servobrake attachment nut on the cowl panel 2,0
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MECHAN ICAL ELEMENTS CONTROL
37
The working principle of this control is similar to the one of a brake control, having the same
wo rking fluid : SA E J 1703 DOT 4.
TRANSMITTER CYLINDER REPLACEMENT
DISMOUNTING
Disconnect the battery.
Drain the clutch control hydraulic circuit ; for this purpose, open the purging connection and
connect to this a transparent hose for draining. Dismou nt :
- dashboard lower pa rt ;
- the feeding pipe 1 with brake fluid from the reservoir;
- the hydraulic pipe of the transmitter cylinder 2.
Detach the cylinder rod from the control pedal bolt (dismounting effort : min 5 daNm ).
Di smount the transmitter cylinder 3 as follows: by means of 24 mm wrench, rotate the
transmitter cylinder from the right to the left aprox. 45 ° and extract the cylinder ( dismounting
moment : min 0.2 daNm ).
37 - 19
CLUTCH HYDRAULIC CONTROL
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MECHAN ICAL ELEMENTS CONTROL
37CLUTCH HYDRAULIC CONTROL
37 - 20
REMOUNTING
Perform the dismounting
operations in the reverse order ;
-tr ansmitter cylinder mounting moment on the support – max 0.5 daNm
- cylinder rod mounting moment on the pedal bolt – max. 5.0 daN
Refill the brake fluid reservoir and purge the clutch control circuit by means of the purging
connection. Adjust the level in the brake fluid reservoir.
At t ent i on
When remounting the feeding pipe at the brake fluid reservoir and at the
transmitter cylinder, observe the positioning markings.
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MECHAN ICAL ELEMENTS CONTROL
37
HYDRAULIC RECEIVER REPLACEMENT
This operation shall be performed after dismounting of the engine-gearbox assembly and after
disconnecting of the engine from the gearbox.
DISM OUNTING
Dismount the two attachment screws and dismount the hydraulic receiver.
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten the screws at the required moment of 2.1 daNm.
PHYDRAULIC CIRCUIT PURGING
1. CIRCUIT REFILLING
Check if the clutch pedal is in the “up” position, maintain it by hand if necessary.
Fill the reservoir with brake fluid.
Remove the protection cap of the purging connection 1.
Connect a transparent hose a t the purging connection to recover the brake fluid.
Retrieve the clip 2 (do not definitely remove it in order to limit the movement of the feeding
pipe).
37 - 21
CLUTCH HYDRAULIC CONTROL
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MECHAN ICAL ELEMENTS CONTROL
37
Retrieve the feeding pipe (towards the arrow) to enable the fluid passing through the connection 1.
Bleed a little bit of fluid.
Close the purging connection (move the feeding pipe in reverse way).
2. FINAL PURGING OF THE CIRCUIT
a) Slowly push the clutch pedal to maximum position and keep it pushed.
W ait aprox. 10 seconds then open the purging connection.
b) Close the purging connection, release the clutch pedal, and slowly lift it by hand to
the upper position ( if the pedal does not come back itself in this position ).
Repeat the operations a and b till bubbles are not coming our through the purging.
connection, then repeat five more times these operations in order to be sure about a good circuit
pur ging.
These repeated purging allow “ the c leaning “ of the circuit from the air bubbles eventually
remained in the circuit after the circuit filling and purging.
An air bubble as little may be, remained in the circuit, may lead to operating deficiencies such
as: defective clutch pedal return or gears change noise being able to lead to a wrong diagnosis or
an inopportune replacement of a part of the clutch circuit.
CLUTCH HYDRAULIC CONTROL
37 - 22
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