Dacia Solenza (engine E7J). Manual - part 63

CV JH3 - 051

21

MECHANICAL GEARBOX

21 - 32

Replacement of the 5-th gear synchroniser

and pinion (on the vehicle

)

1

NECESSARY SPECIAL TOOLS

C.V. 22 – 01

Bearings extractor body

C.V. 31 - 01

Mandrels set for elastic pins

C.V. 1000

Extractor for the 5-th gear fix pinion C.V.

1170

Extractor for the 5-th gear hub.

C.V. 1175

Screw for mounting the 5-th gear fix pinion

Tightening moments (daNm)

Primary shaft nut

19

Secondary shaft screw

7

Wheel attachment screws

7.5

Back cap attachment screws

2.5

Oil draining plug

2.5

DISMOUNTING

Place the vehicle on a two columns

elevator.

Dismount the front left wheel.
Drain the oil off the gearbox.
Disconnect the connector of the reverse

driving contact.

Dismount the cross-tie rod (1).
Dismount the attachment screws of the

back cap.

Remove the back cap on the gearbox

horizontal axle direction, because the cap is
provided with an oiling groove (A), which is
penetrating into the primary shaft.

Engage the 1-st gear.
Dismount the elastic pin of the 5-th gear fork

by means of the mandrel C.V. 31 – 01.

Engage the 5-th gear by hand.
Dismount:

- the nut from the primary shaft and the

screws from the secondary shaft.

- the 5-th gear fork and sliding collar.

CV JH3 - 051

21

MECHANICAL GEARBOX

21 - 33

Replacement of the 5-th gear synchroniser

and pinion (on the vehicle

)

C.V. 1170

C.V. 1000

C.V.  22-01

C.V. 1175

C.V.  31-01

Bring the gearbox in the neutral position.
Extract the synchroniser hub by means of  the

extractor C.V. 1170.

Dismount the 5-th gear assembly
Dismount the 5-th gear fix pinion by means of

the extractor  C.V. 1000 and the  body extractor
C.V. 22 - 01.

REMOUNTING

Mount on the secondary shaft the 5-th gear

fix pinion by means of the C.V. 1175 device

Dismount the C.V. 1175 device.

Apply three drops of Loctite

FRENBLOC on the screw thread of  the
secondary shaft.

Mount the secondary shaft screw.

CV JH3 - 051

21

MECHANICAL GEARBOX

21 - 34

Replacement of the 5-th gear synchroniser

and pinion (on the vehicle

)

C.V.  31-01

Mount on the primary shaft, in the

following sequence:

- the support washer (with the larger side

towards the pinion )

- the bushing under the pinion;
- the free 5 th pinion equipped with its

synchroniser ring ;

- the fork together with the 5-th gear sliding

collar;

- the primary shaft nut.

Engage the  1-st gear with the gear lever

and the 5-th gear by sliding the 5-th gear fork
on its axle.

Tighten at the required moment:
- the primary shaft nut: 19 daNm;
- the secondary shaft screw: 7 daNm.
Mount the pin of the 5-th gear fork  by

means the CV 31 01 device.

The pin slot must be oriented towards the

back cap.

Bring the gearbox in the neutral position

and check the engagement of all speed gears.

Mount a new tore gasket to ensure the back

cap sealing.

Mount the back cap with the (A) groove in

the primary shaft, and the oiling collector in the
(B) oil collecting groove.

Tighten the back cap screws at the required

moment of  2,5 daNm .

Mount the reverse driving contact connector.

Check the correct gears shifting.
Perform the filling with oil of  the gearbox  .
Check the gearbox sealing.
Mount the two cross-tie rods.
Mount the right front wheel.
Tighten the screws and the nuts at the required

moment.

TRANSMISSION

29

29 - 1

Front transversal transmission

DISMOUNTING 

 -  THE SIDE TO WHEEL

Loosen the left wheel  screws.
Lift the vehicle on an elevator with two columns.
Dismount the wheels.
Dismount the screws that attach the brake disk assembly on the steering knuckle.
Unscrew the transmission nut by means of the RO 604 – 01 device.
Dismount :

- the nut of the 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.

SPECIAL TOOLS

RO 604-01

Hub immobilizing device

PF 476

Ball joint extractor

TIGHTENING MOMENTS (daN/m)

Transmission nut

28

Screw for fixing the bellows lid on the gearbox

2,5

Wheels attachment screw

7,5

Screws, nuts for fixing the steering knuckle on the shock absorber

10,5

Screw for fixing the caliper on the steering knuckle

6,5

Nut for steering ball joint

4

Push the transmission in the steering knuckle and incline the latter.
Dismount the transmission, the wheel side.