2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD - Lancia - Ypsilon - eLearn

2429777 - 2110D10 differential inner case - r + r with manual gearbox removed - includes gearbox dismantle and rebuild

) 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

1. 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 5th speed selector fork to the main shaft.Engage 5th speed pressing the selector fork onto 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.Position the selector fork for 5th speed in neutral.

Positioning the selector fork for 5th speed in neutral is necessary to prevent losing the synchronizer rollers.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed driven gear.3. Remove the 5th speed synchronizer rollers and springs retaining flange.4. Remove the 5th speed selector fork.5. Remove the 5th speed sliding sleeve.6. Remove the pre-synchronizer mountings.7. Remove the 5th speed sliding sleeve hub.8. Remove the 5th speed synchronizer ring.9. Remove the 5th speed drive gear.10. Remove the needle bearing for the 5th speed drive gear. 11. Remove the 5th speed drive gear bush. 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 5th 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 5th speed synchronizer being longer.

Dismantling new 5th 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. Place the gear selector lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.

1. Remove the differential assembly.

Reassembling ( Dismantling

) 1. Fit the 5th speed drive gear bush.2. Fit the needle bearing for the 5th speed drive gear.3. Fit the 5th speed drive gear.4. Fit the 5th speed synchronizer gear.5. Fit the 5th speed sliding sleeve hub.6. Fit the 5th speed sliding sleeve.7. Place the pre-synchronizer mountings back in their housings.8. Fit the 5th speed control fork.9. Fit the 5th speed synchronizer ring spring and roller retaining flange.10. Fit the 5th 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 5th speed selector fork bolt to torque.

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

Reassembly of new 5th 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 it is fitted, 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