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.