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

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

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 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. 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.

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.

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 main and layshaft rear bearing circlips.

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

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

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

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

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

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 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.

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

When refitting, replace the circplip.

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.

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.

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. 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).

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

	Name	Country
1b	Fitting tool	1.860.945.000

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

	Name	Country
1b	Drift	1.870.448.000

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

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 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 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

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

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.

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. 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. 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. 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

	Name	Country
1a	Support	1.895.655.000

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

	Name	Country
1c	Fitting tool	1.875.016.000

Fit the differential flange and fix it tightening the bolts to torque. 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