2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY - Lancia - Ypsilon - eLearn

2429772 - 2110B20 manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary

) 1. Remove the hydraulic jack (1a) and the support tools (1b) and (1c) used for the removing-refitting operations from the gearbox and differential.

	Name	Country
1b	Mount	1.870.689.000

	Name	Country
1c	Gearbox mount	1.860.873.000

Dismantling ( Reassembling

) Release the gearbox and differential from the support tool used for the removal-refitting from the vehicle.

	Name	Country
-	Gearbox mount	1.860.873.000

Fit the gearbox and differential (1a) on the overhaul stand (1b) using the tool (1c).

Two operators are needed for this operation.

	Name	Country
1b	Rotating stand	1.871.000.000

	Name	Country
1c	Support	1.871.001.014

2. Undo the bolt (2a) and remove the speedometer idler gear (2b).3. Undo the bolts (3a) and remove the rear cover (3b).

1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).

Two operators are needed for this operation.

	Name	Country
-	Rotating stand	1.871.000.000

	Name	Country
1b	Support	1.871.001.014

1. Undo the bolts (1a) and remove the gear selector/engagement mounting bracket (1b).

1. Undo the bolts (1a) and remove the gearbox rear cover (1b).

Use a drier to facilitate the removal of the sealant.

2. Remove the differential output shafts with external three lobe joints.

1. Remove the left differential internal driveshaft (1a) using the tool composed of the brackets (1b) from the steering knuckle (1c) and the element (1d).

	Name	Country
1b	Brackets	1.840.005.308

	Name	Country
1c	Extractor	1.840.005.001

	Name	Country
1d	Counter weight	1.840.206.000

Engage any gear using the gear selector/engagement lever.1. Undo the stud (1a) and the fixing bolts (1b), then remove the gear engagement unit cover (1c).

Engage any gear using the gear selector/engagement lever.1. Undo the bolt fixing the 5 ^th speed selector fork to the main shaft. Engage 5 ^th speed pressing the selector fork on the main shaft.

The simultaneous engagement of two gears will cause the gearbox shafts to lock.

2. Remove the staking and loosen the ring nuts for the main and layshafts. Place the selector fork for 5 ^th speed in neutral.

Positioning the selector fork for 5 ^th speed in neutral is necessary to prevent the synchronizer rollers from being lost.

1. Undo the 5 ^th speed selector fork (1b) bolt (1a). Engage 5 ^th speed pressing the selector fork on the main shaft.

The simultaneous engagement of two gears will cause the gearbox shafts to lock.

2. Remove the staking from the main and layshaft ring nuts using a suitable drift.3. Loosen the main and layshaft ring nuts. Place the selector fork for 5 ^th speed in neutral.

Positioning the selector fork for 5 ^th speed in neutral is necessary to prevent the synchronizer rollers from being lost.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5 ^th speed driven gear. 3. Remove the roller and spring retaining flange for the 5 ^th speed synchronizer. 4. Remove the 5 ^th speed selector fork. 5. Remove the 5 ^th speed sliding sleeve. 6. Remove the pre-synchronizer mountings.7. Remove the hub for the 5 ^th speed sliding sleeve. 8. Remove the 5 ^th speed synchronizer ring. 9. Remove the 5 ^th speed drive gear. 10. Remove the needle bearing for the 5 ^th speed drive gear. 11. Remove the bush for the 5 ^th speed drive gear. 12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5 ^th speed driven gear (2a) using the tool (2b).

	Name	Country
2b	Extractor	1.840.005.400

Starting from the month of June 1998, a new selector fork for engaging 5 ^th speed has been adopted on C510-C513 type gearboxes which replaces the selector fork fitted previously. The new selector fork (no. 46549946) should be fitted on gearboxes where it is already used (production from 6/98), but it is interchangeable with the previous selector fork (fitted on gearboxes produced before 6/98). The previous selector fork (which should only be fitted on gearboxes produced before 6/98) is available from the Parts Division until stocks run out.

1. The new selector fork (1a) differs from the previous one (1b) through the different conformation with the two ends (1c) which partly wrap around the hub for the 5 ^th speed synchronizer being longer.

1. Remove the roller and spring retaining flange for the 5 ^th speed synchronizer. 2. Remove the 5 ^th speed engagement fork. 3. Remove the 5 ^th speed engagement sleeve. 4. Remove the springs and rollers for the 5 ^th speed hub.

Dismantling new 5 ^th speed engagement fork. 1. Lock the hose (1a) in a vice, fitting protective plates then, use a brass drift (1b) alternately on the two ends of the selector fork (1c) until it is released from the hub.

take care not to damage the tapered part of the sleeve and the ends of the selector fork with the drift.

1. Remove the hub for the 5 ^th speed sliding sleeve (1a), the 5 ^th speed synchronizer (1b) and the 5 ^th speed drive gear (1c), using the tool (1d).

	Name	Country
1d	Extractor	1.840.005.400

1. Remove the main and layshaft rear bearing circlips.

1. Remove the bush for the 5 ^th speed drive gear (1a) using the tool (1b).

	Name	Country
1b	Extractor	1.845.057.000

1. Undo the plugs for positioning the gear control rods.2. Undo the Reverse shaft fixing bolt.3. Undo the reversing lights switch.

1. Undo the bolts (1a) and remove the rear bearing retaining plate (1b).

1. Undo the fixing bolt and remove the differential flange (1a), complete with O-Ring (1b), oil seal (1c) and scraper ring (1d).

1. Remove the rear bearing circlips.

To facilitate the fitting of the circlips, place them with their openings at the front.

2. Undo the reverse idler gear shaft bolt.

1. Undo the fixing bolts and remove the differential flange (1a), complete with O-Ring (1b) and adjustment shim (1c).

1. Undo the bolts (1a) and remove the gearbox casing (1b).2. Undo the bolts (2a) and remove the support and reverse gear lever and fork (2b).

1. Undo the bolts fixing the gearbox casing to the bell housing.2. Position the gear selector/engagement lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.

1. Undo the bolt (1a) and release the gear engagement fork guide rod (1b).2. Remove the 3 ^rd -4 ^th speed engagement fork. 3. Remove the reverse gear engagement fork control lever.4. Remove the 5 ^th speed selector fork control lever. 5. Remove the 1 ^st -2 ^nd speed engagement fork.

1. Undo the bolts (1a) and remove the Reverse gear selector fork mounting bracket (1b).2. Undo the 3 ^rd -4 ^th speed selector fork bolt. 3. Undo the bolt for the 1 ^st -2 ^nd speed selector fork.

1. Remove the reverse idler gear.2. Remove the main shaft assembly.3. Remove the layshaft assembly.

1. Remove the 1 ^st -2 ^nd control rod (1a) together with the selector fork (1b).

If the rod offers resistance to being withdrawn, move the other rods (2a) and (3a) to shift the pawls (4) and (2b).

2. Remove the 3 ^rd -4 ^th speed control rod (2a).

Work carefully to avoid the pawl (2b) accidentally falling out.

3. Simultaneously remove the 5 ^th -Reverse control rod (3a) and the 3 ^rd -4 ^th speed selector fork (3b). 4. Remove the two gear engagement safety pawls.

1. Undo the bolts (1a) and remove the differential casing cover (1b) complete with gasket (1c) and oil seal (1d).

The gasket and the seal should always be replaced.

1. Remove the main shaft and layshaft assemblies simultaneously.2. Remove the Reverse idler gear.3. Remove the layshaft front bearing.4. Remove the differential assembly.5. Remove the magnet.

1. Undo the bolt (1a) and remove the speedometer idler gear (1b).

1. Remove the engine side oil seal for the bell housing.

1. Undo the bolts (1a) and remove the manual gearbox and differential support (1b) complete with oil seal.2. Remove the magnet.3. Remove the differential bearing pre-loading scraper ring.4. Remove the differential assembly.5. Remove the differential bearing outer races.

1. Undo the gear selector bolt.2. Remove the pin (2a) using a suitable drift and remove the gear selector (2b).

1. Remove the clutch thrust bearing outer linkage circlip.2. Remove the outer linkage (2a) and the bush (2b) for the clutch thrust bearing.

1. Undo the bolts (1a) and remove the gear selector/engagement lever (1b).

1. Remove the inner linkage (1a) and the bush (1b) for the clutch thrust bearing.

Replace the inner and outer bushes each time the clearance for the thrust bearing control shaft is excessive.

Proceed with dismantling the layshaft, following the instructions given below.1. Remove the rear bearing (1a), the 4 ^th speed driven gear (1b) and the spacer between 3 ^rd and 4 ^th speeds (1c) using tools (1d) and (1e).

	Name	Country
1d	Extractor	1.840.005.002

	Name	Country
1e	Clamps	1.840.005.303

1. Remove the 3 ^rd speed driven gear (1a) and the 2 ^nd speed driven gear (1b) using tools (1c) and (1d).

	Name	Country
1c	Extractor	1.840.005.002

	Name	Country
1d	Clamps	1.840.005.306

1. Remove the staking and, using a universal extractor (1a), remove the main shaft oil seal (1b) from the manual gearbox and engine support.

1. Remove the 2 ^nd speed dual cone synchronizer ring set. 2. Remove the needle bearing for the 2 ^nd speed driven gear. 3. Remove the sliding sleeve for 1 ^st - 2 ^nd and Reverse gears. 4. Remove the pre-synchronizer mountings.

Proceed with dismantling the layshaft.1. Remove the bearing circlip.2. Remove the rear bearing (2a) and the 4 ^th speed driven gear (2b) using the tools (2c), (2d) and (2e).

	Name	Country
2c	Extractor	1.840.005.002

	Name	Country
2d	Clamps	1.840.005.301

	Name	Country
2e	Extractor	1.842.133.000

3. Remove the spacer between the 3 ^rd and 4 ^th speed driven gears.

1. Remove the 1 ^st -2 ^nd speed and Reverse hub circlip using suitable pliers.

When refitting, replace the circplip.

1. Remove the 3 ^rd speed driven gear (1a) and the 2 ^nd speed driven gear (1b) using the tools (1c) and (1d).

	Name	Country
1c	Extractor	1.840.005.002

	Name	Country
1d	Clamps	1.840.005.303

2. Remove the 2 ^nd speed synchronizer ring (2a) and the 1 ^st and 2 ^nd speed sliding sleeve (2b). Keep the pre-synchronizer mountings for the 1 ^st and 2 ^nd speed hub.

1. Remove the 1 ^st -2 ^nd speed and Reverse sliding sleeve hub (1a), the 1 ^st speed synchronizer ring set (1b) and the 1 ^st speed driven gear (1c) using tools (1d) and (1e).

	Name	Country
1d	Extractor	1.840.005.002

	Name	Country
1e	Clamps	1.840.005.306

2. Remove the needle bearing.

The layshaft front bearing inner race should not be refaced; if necessary, replace it together with the layshaft.

1. Remove the hub circlip.2. Remove the 1 ^st speed driven gear (2a), the 1 ^st speed synchronizer ring (2b) and the hub for the 1 ^st and 2 ^nd speed sliding sleeve (2c) using the tools (2d) and (2e).

	Name	Country
2d	Extractor	1.840.005.002

	Name	Country
2e	Clamps	1.840.005.306

For the removal of the layshaft front bearing, see - 2110B32 manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers, inner controls, gears, shafts and bearings

Proceed with dismantling the main shaft, following the instructions given below.1. Remove the rear bearing (1a), the shim (1b), the 4 ^th speed drive gear (1c), the needle bearing for the 4 ^th speed drive gear (1d), the bush for the 4 ^th speed drive gear (1e), the 3 ^rd and 4 ^th speed sliding sleeve (1f), the pre-synchronizer mountings (1g) for the 3 ^rd and 4 ^th speed sliding sleeve, the 4 ^th speed synchronizer (1h), the hub for the 3 ^rd and 4 ^th speed sliding sleeve (1i), the 3 ^rd speed synchronizer (1l) and the 3 ^rd speed drive gear (1m) using tools (1n) and (1o).

	Name	Country
1n	Extractor	1.840.005.002

	Name	Country
1o	Clamps	1.840.005.306

2. Remove the needle bearing for the 3 ^rd speed drive gear.

Proceed with the dismantling of the main shaft.1. Remove the rear bearing (1a) and the 4 ^th speed drive gear (1b) using the tools (1c) and (1d).

	Name	Country
1c	Extractor	1.840.005.200

	Name	Country
1d	Clamps	1.840.005.103

2. Remove the 4 ^th speed synchronizer ring (2a) and the 3 ^rd and 4 ^th speed sliding sleeve (2b). 3. Keep the springs (3a) and the rollers (3b) for the 3 ^rd and 4 ^th speed hub.

Reassembling ( Dismantling

) Proceed with washing and checking the condition of all the components.Proceed with the reassembly of the main shaft, following the instructions given below.1. Fit the needle bearing for the 3 ^rd speed drive gear. 2. Fit the 3 ^rd speed drive gear. 3. Fit the 3 ^rd speed synchronizer ring. 4. Fit the 3 ^rd and 4 ^th speed sliding sleeve hub. 5. Fit the 3 ^rd and 4 ^th speed sliding sleeve. 6. Place the pre-synchronizer mountings on the sliding sleeve hub back in their housings.7. Fit the 4 ^th speed synchronizer ring.

1. Remove the hub circlip for the 3 ^rd and 4 ^th speed sliding sleeve. 2. Remove the hub for the 3 ^rd and 4 ^th speed sliding sleeve (2a), the 3 ^rd speed synchronizer (2b), the 3 ^rd speed drive gear (2c), using the tools (2d) and (2e).

	Name	Country
2d	Extractor	1.840.005.001

	Name	Country
2e	Clamps	1.840.005.303

1. Fit the 4 ^th speed drive gear bush (1a), using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

2. Fit the roller bearing for the 4 ^th speed drive gear (2a) and the 4 ^th speed drive gear (2b).

Reassembling ( Dismantling

) Proceed with washing and checking the condition of all the components.Proceed with the reassembly of the main shaft, following the instructions given below.Lubricate the parts concerned using transmission fluid before fitting.1. Fit the 3 ^rd speed drive gear (1a) and the 3 ^rd speed synchronizer (1b). 2. Fit the 3 ^rd and 4 ^th speed sliding sleeve hub (2a) using the tool (2b).

	Name	Country
2b	Drift	1.870.152.000

1. Fit the rear bearing (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

1. Fit the springs on the 3 ^rd and 4 ^th speed sliding sleeve hub. 2. Fit the 3 ^rd and 4 ^th speed sliding sleeve.

The references on the sleeve should coincide with the springs.

3. Fit the rollers between the springs and the notches in the 3 ^rd and 4 ^th speed sliding sleeve. 4. Fit the 4 ^th speed synchronizer ring. Place the 3 ^rd and 4 ^th speed sliding sleeve in neutral to prevent losing the springs and rollers. 5. Fit the 4 ^th speed drive gear.

Proceed with the reassembly of the layshaft, following the instructions given below.1. Fit the needle bearing for the 1 ^st speed driven gear. 2. Fit the 1 ^st speed driven gear. 3. Fit the three rings for the 1 ^st speed synchronizer rings (3a) matching the couplings (3b).

1. Fit the rear bearing (1a) on the main shaft using the tool (1b).

	Name	Country
1b	Drift	1.870.631.000

1. Fit the 1 ^st and 2 ^nd speed sliding sleeve hub (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

Proceed with the reassembly of the layshaft, following the instructions given below.Lubricate the parts concerned using transmission fluid before fitting.1. Fit the 1 ^st speed driven gear. 2. Fit the 1 ^st speed synchronizer ring. 3. Fit the 1 ^st and 2 ^nd speed sliding sleeve hub (3a) using the tool (3b).

	Name	Country
3b	Drift	1.870.152.000

4. Fit the 1 ^st and 2 ^nd speed sliding sleeve hub circlip.

Fit a new 1 ^st and 2 ^nd speed sliding sleeve hub circlip. 1. Fit the 1 ^st - 2 ^nd and reverse sliding sleeve. 2. Place the pre-synchronizer mountings back in their housings on the 1 ^st - 2 ^nd and Reverse sliding sleeve hub. 3. Fit the needle bearing for the 2 ^nd speed driven gear. 4. Fit the three rings for the 2 ^nd speed synchronizer (4a) matching the couplings (4b) and (4c). 5. Fit the 2 ^nd speed driven gear.

1. Fit the 1 ^st and 2 ^nd speed sliding sleeve. 2. Fit the pre-synchronizer mountings in the notches in the 1 ^st and 2 ^nd speed sliding sleeve. 3. Fit the 2 ^nd speed synchronizer ring. Position the 1 ^st and 2 ^nd speed sliding sleeve in neutral. 4. Fit the 2 ^nd speed driven gear. 5. Fit the 3 ^rd speed driven gear (5a) using the tool (5b).

	Name	Country
5b	Drift	1.870.152.000

1. Fit the 3 ^rd speed driven gear (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.465.000

1. Fit the spacer between the 3 ^rd and 4 ^th speed driven gears. 2. Fit the 4 ^th speed driven gear (2a) using the tool (2b).

	Name	Country
2b	Drift	1.870.631.000

3. Fit the rear bearing (3a) using the tool (3b).

	Name	Country
1b	Drift	1.870.631.000

4. Fit the rear bearing circlip on the layshaft.

1. Fit the spacer between the 3 ^rd speed driven gear and the 4 ^th speed driven gear. 2. Fit the 4 ^th speed driven gear (2a) using the tool (2b).

	Name	Country
2b	Fitting tool	1.870.465.000

1. Fit the main shaft oil seal (1a) on the manual gearbox/engine support using the fitting tool (1b) together with the drift (1c).

	Name	Country
1b	Fitting tool	1.870.796.000

	Name	Country
1b	Grip	1.870.007.000

1. Fit the rear bearing (1a) using the tool (1b).

	Name	Country
1b	Drift	1.870.448.000

1. Fit the clutch thrust bearing linkage inner bush (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.633.000

1. Fit the gear selector/engagement lever (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEAR ENGAGMENT SELECTOR LEVER	M8	2.1 - 2.6

1. Fit the inner linkage (1a), the outer bush (1b) and the outer linkage (1c) for the clutch thrust bearing.2. Fit the clutch thrust bearing outer linkage circlip.

1. Fit the gear selector (1a) and fix it with the pin (1b) and bolt (1c).

1. Fit the complete differential (1a) and differential bearing outer races (1b).2. Fit the magnet.Apply the recommended sealant to the contact surfaces between the differential support and the gearbox casing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX DIFFERENTIAL MOUNT	LOCTITE 573	-

3. Fit the manual gearbox differential casing support (3a), then tighten the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	GEARBOX DIFFERENTIAL MOUNT	M8	2

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	GEARBOX DIFFERENTIAL MOUNT	M10	3.5

1. Fit a new engine side oil seal (1a) for the bell housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.875.016.000

1. Fit the speedometer idler gear (1a) and tighten the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARS	M6	0.5

1. Fit the magnet.2. Fit the layshaft front bearing.3. Fit the differential assembly.4. Fit the Reverse idler gear.

Make sure that the gear engagement teeth are facing downwards.

5. Fit the main shaft and layshaft assemblies simultaneously.Fit the gear engagement safety pawls using a suitable drift.

1. Fit the layshaft assembly.2. Fit the main shaft assembly.3. Fit the reverse idler gear (3a) inserting the pin (3b) in the special housing in the casing.

1. Fit the 5 ^th speed and Reverse control rod. 2. Fit the 3 ^rd - 4 ^th speed selector fork (2a) and the control rod (2b).

Position the safety pawl in the rod before fitting it in the housing.

3. Fit the 1 ^st - 2 ^nd speed control rod (3a), complete with selector fork (3b).

To facilitate the fitting, move the 1 ^st - 2 ^nd speed selector forks (5a) in the direction shown by the arrow.

4. Tighten the bolts for the 1 ^st -2 ^nd speed (4a) and 3 ^rd -4 ^th speed selector forks (4b) to torque.

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	1st - 2nd speed selector fork	M6	1.5 - 1.9

	Fastening	Component	Ø	Value(daNm)
4b	Bolt	3rd - 4th speed selector fork	M6	1.5 - 1.9

5. Fit the Reverse selector fork mounting bracket (5a) and fix it tightening the bolts (5b) to torque.

	Fastening	Component	Ø	Value(daNm)
5b	Bolt	Reverse selector fork mounting bracket	M6	8.5 - 1.1

1. Fit the 3 ^rd - 4 ^th speed engagement fork. 2. Fit the 1 ^st - 2 ^nd speed engagement fork. 3. Fit the 5 ^th speed engagement fork bracket. 4. Fit the reverse gear engagement fork bracket. 5. Fit the gear engagement fork guide rod in its housing.6. Tighten the bolt for the 5 ^th speed engagement fork bracket to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
6	Bolt	5thª speed selector fork	M6	1.2

Position all the gear selector forks in neutral.Apply sealant to the contact surfaces between the bell housing and the gearbox casing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the gearbox casing on the bell housing.

Keep the gear selector/engagement lever upwards and check that the gear selector engages with the 3 ^rd - 4 ^th speed selector fork.

Tighten the bolts for the gearbox casing to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	2.1 - 2.6

Fit the gear control rod positioning plugs.Tighten the reverse shaft bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REVERSE IDLER	M8	2.9 - 3.6

Fit the reversing lights switch.Fit the main and layshaft rear bearing circlips.

To facilitate the fitting of the circlips, place them with their openings at the front.

Apply sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the main and layshaft rear bearing retaining plate and fix it tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER SPACER	M8	2.1 - 2.6

1. Fit the 5 ^th speed drive gear bush. 2. Fit the needle bearing for the 5 ^th speed drive gear. 3. Fit the 5 ^th speed drive gear. 4. Fit the 5 ^th speed synchronizer gear. 5. Fit the 5 ^th speed sliding sleeve hub. 6. Fit the 5 ^th speed sliding sleeve. 7. Place the pre-synchronizer mountings back in their housings.8. Fit the 5 ^th speed selector fork. 9. Fit the 5 ^th speed synchronizer springs and rollers retaining flange. 10. Fit the 5 ^th speed driven gear. 11. Tighten the new ring nuts for the main and layshafts to torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	10 - 12.4

12. Tighten the bolt for the 5 ^th speed selector fork to torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	GEARBOX INTERNAL CONTROLS	M6	1.5 - 1.9

1. Fit the reverse gear engagement lever and fork support (1a) and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX INTERNAL LINKAGE	M8	1.5

2. Apply the recommended sealant to the contact surfaces between the gearbox casing and the bellhousing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX GEAR CASING	LOCTITE 573	-

3. Fit the gearbox casing (3a) and secure it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	GEARBOX GEAR CASING	M8	(Support side) 2

Reassembly of new 5 ^th speed selector fork. 1. Lock the sleeve in the vice, with protective plates fitted;2. Position the selector fork so that the tapered end is in the same direction as that of the sleeve, resting it against the side of the sleeve with the smaller diameter; fit the selector fork manually, exerting the necessary pressure, until it is completely engaged in the hub.

1. Tighten the reverse idler gear shaft bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	REVERSE IDLER	M8	2.6

2. Fit the rear bearing circlips.

To facilitate the fitting of the circlips, place them with their openings at the front.

When the fitting is complete, check that the sleeve can rotate freely inside the selector fork.

Apply sealant to the contact surfaces between the main and layshaft rear bearings retaining plate and the rear cover.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

1. Fit the rear cover (1a) and fix it tightening the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX REAR COVER	M8	2.1 ÷ 2.6

2. Fit the speedometer idler gear (2a) and fix it using the bolt (2b).

1. Fit the rear bearing retaining plate (1a) and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	Main and layshaft rear bearing retaining plate....	M8	2

1. Position the tool (1a), complete with dial gauge on the differential flange (1b), and measure distance 'H' (flange height).

	Name	Country
1a	Support	1.895.655.000

1. Fit the bush (1a) for the 5 ^th speed drive gear using the tool (1b).

	Name	Country
1b	Drift	1.870.631.000

1. Position the tool (1a), complete with dial gauge on the differential flange (1b), and measure distance 'H' (flange height).

	Name	Country
1a	Support	1.895.655.000

1. Fit the 5 ^th speed drive gear. 2. Fit the 5 ^th speed synchronizer oil seal. 3. Using the tool (3a), fit the hub for the 5 ^th speed sliding sleeve hub (3b) with the splining for the oil facing towards the gear.

	Name	Country
3a	Drift	1.870.631.000

1. Position the tool (1a), complete with dial gauge, on the differential flange support surface (1b), and measure distance 'P' (depth between differential flange support plate and bearing (1c) outer race).

	Name	Country
1a	Support	1.895.655.000

1. Fit the springs on the 5 ^th speed sliding sleeve hub. 2. Fit the 5 ^th speed sliding sleeve.

The notches in the sleeve should be aligned with the springs.

3. Fit the 5 ^th speed engagement fork. 4. Fit the rollers between the springs and the notches for the 5 ^th speed sliding sleeve. 5. Fit the 5 ^th speed synchronizer roller and spring retaining plate. Place the 5 ^th speed sliding sleeve in neutral to prevent losing the springs and rollers.

	Name	Country
1a	Support	1.895.655.000

1. Fit the 5 ^th speed driven gear (1a) on the layshaft using the tool (1b).

	Name	Country
1b	Drift	1.870.631.000

Fit the ring nuts for the main and layshafts without tightening them.

Calculate the thickness 'S' of the scraper ring for the differential bearing pre-loading using the followign formula: S = P - H + 0.12

0.12 corresponds to the interference for bedding in and the pre-loading of the differential bearings. After having determined the exact value of the scraper ring, try and achieve the closest possible value to that obtained using the rings available as spares. If the value obtained does not correspond to the thickness of one or more adjustment shims available, fit the shim(s) giving the closest value which is immediately higher.

1. Place the scraper ring(s) for the differential bearing pre-loading in its/their housing.

1. Apply the recommended sealant to the contact surfaces between the gearbox casing and the gear engagement assembly cover.

	Type	Component	Name	Qty.
1	Sealant	M/D GEARBOX SPEED ENGAGEMENT UNIT COVER	LOCTITE 573	-

2. Fit the gear engagement assembly cover (2a) and tighten the bolts (2b) the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	M/D GEARBOX SPEED ENGAGEMENT UNIT COVER	M6	2

1. Fit a new oil seal (1a) on the differential flange (1b) using the tool (1c).

	Name	Country
1c	Fitting tool	1.875.016.000

Engage any gear using the gear selector/engagement lever. Engage 5 ^th speed by pressing the main shaft selector fork.

The simultaneous engagement of two gears will cause the gearbox shafts to lock.

1. Tighten the 5 ^th speed selector fork bolt to torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	5thª speed selector fork	M6	1.2

2. Tighten the ring nuts securing the main and layshaft gears to torque.

	Fastening	Component	Ø	Value(daNm)
2	Ring nut	GEAR SHAFTS	M20	11.8

Fit the differential flange and fix it tightening the bolts to torque. 1. Stake the ring nuts (1a) securing the main and layshaft 5 ^th speed gear using the tools (1b) and (1c).

	Name	Country
1b	Pair of heads	1.874.140.005

	Name	Country
1b	Pliers	1.874.140.001

Fit the left differential internal driveshaft.Fit the gear selector/engagement mounting bracket and fix it using the bolts.Undo the fixings and remove the gearbox and differential from the support tool.

Two operators are needed for this operation.

	Name	Country
1c	Support	1.871.001.014

Remove the tool supporting the overhaul stand and put it back.Position the gearbox and differential on the tool used for the removing-refitting from the vehicle.

	Name	Country
-	Gearbox mount	1.860.873.000

1. Apply the recommended sealant to the contact surfaces between the gearbox rear cover and the gearbox casing.

	Type	Component	Name	Qty.
1	Sealant	GEARBOX REAR COVER	LOCTITE 573	-

2. Fit the gearbox rear cover (2a) and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	GEARBOX REAR COVER	M6	0.5

1. Position the tool (1a), complete with dial gauge (1b), on the differential flange support surface then position the pointer in contact with the conical roller bearing outer race.

	Name	Country
1a	Support	1.895.655.000

Zero the dial gauge with a pre-loading of 1 mm.

1. Position the tool (1a), complete with dial gauge on the differential flange (1b) as illustrated and measure the difference.

	Name	Country
1a	Support	1.895.655.000

Calculate the size of the adjustment ring for pre-loading the differential bearings adding 0.12 mm to the difference measured.

0.12 mm corresponds to the interference for bedding in and the pre-loading of the differential bearings.

1. Place the differential bearing pre-loading adjustment shim of the size calculated or the next size up in the housing.

1. Fit the oil seal (1b) on the differential cover (1a) using the tools (1c) and (1d).

	Name	Country
1c	Fitting tool	1.870.629.000

	Name	Country
1d	Grip	1.870.007.000

2. Fit the gasket on the differential cover.

The oil seal and the gasket should always be replaced.

1. Fit the differential cover (1a) and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MAN G/BOX DIFF SEALING FLANGE/S	M8	2

1. Fit the gearbox casing differential support oil seal (1a) using the tools (1b) and (1c).

The oil seal should always be replaced.

	Name	Country
1b	Fitting tool	1.870.630.000

	Name	Country
1c	Grip	1.870.007.000

Fit the differential output shafts and outer three lobe joints. Undo the fixings and remove the gearbox and differential from the tool.

Two operators are needed for this operation.

	Name	Country
-	Support	1.871.001.014

Remove the support tool for the overhaul stand and place it back on the board.Position the gearbox and differential on the tools used for the removal.

	Name	Country
-	Mount	1.870.689.000

	Name	Country
-	Gearbox mount	1.860.873.000