2016 Dacia Sandero Stepway Service and Repair Manual

2012-2016 DACIA SANDERO SERVICE AND REPAIR MANUAL

- 1 - 5TH GEAR HOUSING: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required oil recovery tray parts always to be replaced: 5th gear housing seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: Manual gearbox: Precautions for the repair , Vehicle: Precautions for the repair (01D, Mechanical introduction). REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift Vehicle: Towing and lifting (02A, Lifting equipment). Remove: the engine undertray bolts, the engine undertray, the front left-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front left-hand arch side liner(see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection). Remove Front axle assembly: Exploded view : the tie-rod bolt, the tie rod nut, the tie rod. Drain the gearbox (see 21A, Manual gearbox , Manual gearbox oils: Draining - Filling ) .

- 2 - Unclip the wiring(1) of the reverse gear switch on the 5th gear housing. Disconnect the connector(2) from the reverse gear switch. 2. REMOVAL OPERATION Fit an oil recovery tray under the 5th gear housing.

- 3 - Remove: the bolts( 3) of the 5th gear housing, the 5th gear housing, the seal of the 5th gear housing. REFITTING 1. REFITTING PREPARATION OPERATION

- 4 - parts always to be replaced: 5th gear housing seal . CAUTION Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. CAUTION To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). Use surface cleaner(see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean and degrease the joint face of: the 5th gear housing, the mechanism housing. 2. REFITTING OPERATION Proceed in the reverse order to removal. Torque tighten the 5th gear housing bolts 25 N.m . Fill and check the gearbox oil level (see 21A, Manual gearbox , Manual gearbox oils: Draining - Filling ) . Repair-12x01x03x01-01x37-1-6-1.xml XSL version : 3.02 du 22/07/11

- 1 - ABS BODYWORK COMPONENT: PREPARATION AND PAINT RANGE Note, one or more warnings are present in this procedure WARNING Always wear protective gear (gloves, goggles and breathing masks). Use extra ventilation source. Note: Before using the products, consult the manufacturer's technical sheet. Note: Never apply pre-treatment primer or primer filler on this type of material. 1. PRE PRIMED PARTS

- 2 - Steps Description Special notes 1 Wipe / blow 2 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 3 Sand P400 - P500 dry / P400 - P800 with water 4 Wipe / blow 5 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 6 Blow / rub with the abrasive finishing pad 7 Apply the finishing paint 2. REPAIRED PARTS

- 3 - Steps Description Special notes 1 Wipe / blow 2 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 3 Sand the defect P240 dry / orbital sander (mid speed) 4 Wipe / blow 5 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 6 Apply and sand polyester mastic if necessary Plastic material bodywork component: Repair (50A, General information) 7 Wipe / blow 8 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 9 Smooth Grey adhesive pad soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products) 10 Wipe / blow 11 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth

- 4 - 12 Apply a bi component primer Vehicle: Parts and consumables for the repair (04B, Consumables - Products) 13 Remove solvent / dry 14 Sand P400 - P500 dry / P400 - P800 with water 15 Wipe / blow 16 Degrease Lint-free cloth soaked in antistatic thinner Vehicle: Parts and consumables for the repair (04B, Consumables - Products). Wipe with a dry lint-free cloth 17 Blow / rub with an adhesive pad 18 Apply the finishing paint Repair-40x01x45x09-02x65-1-1-1.xml XSL version : 3.02 du 22/07/11

- 1 - ABS

2016 Dacia Sandero Stepway Service and Repair Manual

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