2004 DACIA SUPERNOVA gearbox

DRIVE SHAFTS
29BELLOWS-BEARING ASSEMBLYTO THE GEARBOX
Usi ng a pre ss, e xt ract t he assembl ed
tripod, sustained it on an e xtractor, FACOM
U 53 G type, protecting the tripod clogs.
Before extra cting, mark the position of
the trip od compar ed to the t ransm issio n
shaft end.
Dismount the bellows - deflector beari ng
in the same manner l ike t ripod dismounting.
REMOUNTING
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 +/- 0.2 mm between the
b ackside of the bearing and the shaft
extremity. This value is obtained by means
of the PF 1331 device, when mounting, its
extremity is at the level of the shaft .
IMPORTANT
In order to avoid the deformation of the bearing, which includes a sealing gasket (annular
oil seal), the pre ssing effort must be constant (do not hammer).
29 - 05Left
transmi ssion
GPF 13
31
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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
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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
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DRIVE SHAFTS
29BELLOWS TO GEARBOX
Using a press, extract the assembled tripod, sustain it on an extractor type FACOM U
53 G, protecting the clogs of the tri pod.
REMOUNTING
Grease the transmission shaft to help the protection bellows putting back (positionin g
of the smallest diameter of the bellows on the transmission shaft).
The tripod is fixe d an d mo unted in the posi tion mark ed on dis mount ing.
Thr ee po in ts of crim pin g ar e mad e at 12 0 ° C by met al he ad ing of the tran sm iss ion
shaft grooves .
Distribute the grease prescribed quantity in the bellows and in the tulip casing .
Correctly position the bellows in the tulip-casing place.
A non-cutting, round-headed rod is introduced between the bellows and the tulip casing
to dose the air amount contained insid e the bellows. Len gthen or co mp re ss the bel l ows un ti l va lu e A = 19 0 mm is obt ained (t he va lue
between the extremity of the bellows and the extremity of the tulip casing) then from this
position extract the rod and remount the collars.
29 - 14
Right
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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
DISMOUNTING
The dismounting of the gears changing lever shall be performed after dismounting the central
case . Dismount under the vehicle the control lever.
Dismount under the vehicle the four attachment screws of the central case.
Dismount the assembly composed of control case and gears control lever. THE GEARS CONTROL
REMOUNTING
Perform the dismounting operations in the reverse order.
Tighten at the required moment :
- the control case attachment screws 1.2 daNm
- the control bar connection screw with the GB connecting rod 2.7 daNm
- the connection screw of the control bar with t he control lever 1.2 daNm
Grease the parts of the joint composed of control bar and GB connecting rod with MOLYKOTE
33M grease.
Introduce in the protection bellows aprox. 10 ml of grease.
NOTE
The tightening of the connection screw of the control bar with the control
lever shall be performed aft er adjustment of t he gearbox control.
37 - 23
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MECHAN ICAL ELEMENTS CONTROL
37
GEARS CONTROL ADJUSTMENT
This is to be performed after mounting the engine-gearbox assembly and the assembly lever-
control case every time when : - dismounting of the engine-gearbox a ssembly, t he c ontrol ba r or the assembly lever-
control case;
- establishin g of failures such as: gear change impossibility or unexpected gear uncoupling,
gear blocking.
For the gear control adjustment the CV 550 device i s to be used;
M ount the CV 550 device on the assembly lever- control c ase;
A ttach the control bar to the control lever end;
Place the gear lever in the device seat and fix it in this position by means of the device handle;
Tighten the attachment screw 1 of the bar to the lever at the required moment of 1.2 daNm;
Dismount the CV 550 device from the control box.
Check the gears coupling. THE GEARS CONTROL
37 - 24
SPECIAL TOOLS
CV 550 Linkage adjusting device
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