2429109 - 2110A10 manual gearbox and differential - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with removal  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with removal  - 1048A10  air cleaner filtering element - replace . 1. Loosen the collar and disconnect the engine oil vapour intake pipe from the tappet cover.2. Disconnect the engine oil vapour inlet pipe from the intake manifold.3. Loosen the band, disconnect the hose from the air filter to the intake manifold, intake manifold side and remove it. 1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe.2. Undo the nut (2a) and disconnect the battery earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	C1

3. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
3	Reversing lights switch	I20

1. Undo the bolts (1a) fixing the gear selector and engagement cables mounting bracket (1b).2. Press the release button (2a) and disconnect the gear selector cable (2b). 3. Disconnect the gear engagement cable.Move the gear selector and engagement cables, complete with mounting bracket, sideways. 1. Undo the plug and drain the manual gearbox and differential.

Collect the manual gearbox and differential oil in a suitable container.

1. Undo the nuts (1a) and disconnect the track rods (1b) from the steering knuckles usiing the tool (1c).

	Name	Country
1c	Extractor	1.871.000.700

2. Undo the bolts fixing the front hub steering knuckle to the front shock absorbers. 1. Loosen the bands (1a) and disconnect the driveshafts (1b ). Position a hydraulic jack under the gearbox.1. Undo the bolt (1a) and the bolt (1b) and remove the power unit lower reaction rod (1c).Remove the hydraulic jack from under the gearbox. 1. Undo the top bolts securing the manual gearbox with differential to the crankcase.2. Undo the front bolt fixing the starter motor. 1. Open the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) for the alternator.

	Name	Connector
1c	Starter' motor	A20

2. Undo the rear bolt (2a) and remove the starter motor (2b). 1. Undo the bolt fixing the lower radiator crossmember to the bodyshell.2. Fit the tool (2a) and secure it using the bolts (2b).

The above bolts are fitted in place of the bolt fixing the lower radiator crossmember to the bodyshell and in place of the bolt fixing the power unit lower reaction rod to the front suspension crossmember.

	Name	Country
2a	Crossmember	1.870.595.000

1. Undo the bolts fixing the power unit gearbox side rigid support to the flexible mounting. 1. Release the supply pipe from the master cylinder (1a) from the bands (1b) on the flexible mounting for the gearbox side rigid power unit support.2. Undo the bolt (2a) and remove the power unit gearbox side rigid engine mount (2b). 1. Loosen the bolt fixing the manual gearbox and differential to the crankcase.2. Undo the bolt fixing the engine flywheel protective cover to the manual gearbox and differential.3. Undo the bolts fixing the manual gearbox and differential to the crankcase sump.4. Undo the bolt fixing the manual gearbox and differential to the cylinder block/crankcase. 1. Fit the tool (1a) and hydraulic jack (1b) on the manual gearbox and differential.

	Name	Country
1a	Gearbox mount	1.860.873.000

2. Completely undo the bolt loosened previously fixing the manual gearbox and differential to the crankcase.3. Remove the manual gearbox with differential, first moving it away from the engine and then lowering it slowly with the hydraulic jack.

Take care not to damage the engine compartment components whilst removing the manual gearbox and differential.

Refitting ( Removing ) Place the manual gearbox and differential back in its housing using the hydrauilc jack and support tool.Temporarily secure the manual gearbox and differential to the crankcase using the bolt.Remove the manual gearbox and differential support tool and the hydraulic jack.

	Name	Country
-	Gearbox mount	1.860.873.000

1. Tighten the bolt fixing the manual gearbox and differential to the crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

2. Tighten the bolts fixing the manual gearbox and differential to the crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

3. Tighten the bolts fixing the manual gearbox and differential to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	-	-	-	-

4. Tighten the bolts fixing the engine flywheel protective cover to the manual gearbox and differential. 1. Refit the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.5 ÷ 5.5

2. Fasten the supply pipe from the master cylinder (2a) using the bands (2b) on the flexible mounting for the gearbox side rigid power unit support. 1. Undo the bolt fixing the gearbox side rigid power unit support to the flexbile block to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

Remove the safety tool used for supporting the power unit.

	Name	Country
-	Crossmember	1.870.595.000

Tighten the bolt securing the radiator bottom crossmember to the bodywork.1. Place the starter motor (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	2.4 ÷ 3.0

2. Connect the electrical connections (3a) to the starter motor, fix them using the nut (2b) and close protective cover (2c). 1. Refit the lower power unit reaction rod (1a) back in its seating, then secure it with the bolt (1b) and bolt (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	LOWER ROD ON ENGINE	M12	(Gearbox side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	LOWER ROD ON ENGINE	M12	(Front suspension crossmember side) 11.4 ÷ 12.6

Connect the driveshafts and tighten the bands.1. Tighten the front wheel hub fastening bolts to the front shock absorbers to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT HUB STEERING KNUCKLE.	M10	(Shock absorber side) 6.2 ÷ 6.8

2. Connect the steering rods (2a) to the front steering knuckles and tighten the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	ADJUSTABLE STEERING LINKS	M10	(Steering knuckle side) 3.6 ÷ 4.4

1. Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Drain plug	GEAR CASING PADS	M16	(Differential side) 1.6 ÷ 2.0

Place the gear selector and engagement cables, complete with mounting bracket, back in their housings.Connect the gear selector cable.Connect the gear engagement cable.Tighten the bolts fixing the gear selector and engagement mounting bracket.Connect the electrical connection to the reversing lights switch.Connect the earth lead and tighten the nut.Replace the clutch operating cylinder, then fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH SLAVE CYLINDER	M8	(Gearbox side) 1.6 ÷ 2.4

Place the hose from the air filter to the intake manifold back in its housing, connect it to the intake manifold and tighten the band.Connect the engine oil vapour inlet pipe to the intake manifold.Connect the engine oil vapour intake pipe to the tappet cover and tighten the band. Proceed with refitting  - 1048A10  air cleaner filtering element - replace . Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Refill the manual gearbox and differential  - 0010T41  MANUAL GEARBOX OIL - Check level and top up, if necessary . Remove the car from the ramps.