2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD - Alfa - 156 - eLearn

3237963 - 2110D10 differential inner case - r + r with manual gearbox removed - includes gearbox dismantle and rebuild

) 1. Release the gearbox and differential (1a) from the hydraulic jack (1b) and the tool (1c) used for removing-refitting it from the vehicle.

	Name	Country
1c	Supports	1.820.623.000

1. Undo the bolts (1a) and remove the coaxial clutch operating cylinder (1b).

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

Two operators are needed for this operation.

	Name	Country
1b	Mount	1.820.146.000

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 internal differential driveshaft (2a) using tools (2b) and (2c).

	Name	Country
2b	Flange	1.820.229.000

	Name	Country
2c	Counter weight	1.821.161.000

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

The simultaneous enagement of two gears will result in the gearbox shafts locking.

1. Undo the 5 ^th speed selector fork bolt. 2. Remove the staking and loosen the ring nuts for the main and layshafts. Place the 5 ^th speed selector fork 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 5 ^th speed synchronizer roller and spring retaining flange. 4. Remove the 5 ^th speed selector fork. 5. Remove the 5 ^th speed sliding sleeve. 6. Remove the springs (6a) and rollers (6b) for the 5 ^th speed hub. 7. Remove the 5 ^th speed sliding sleeve hub. 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 5 ^th speed drive gear bush. 12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.

1. Remove the main and layshaft rear bearing circlips.

Undo the bolt fixing the Reverse gear shaft.Undo the bolts and remove the differential flange complete with oil seals, O-Rings and scraper ring.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. Remove the differential internal housing.

Reassembling ( Dismantling

) Fit the differential internal housingPosition 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.

Kepp 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 fixing the gearbox casing to torque.

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

Tighten the reverse shaft bolt to torque.

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

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	Main and layshaft rear bearing retaining plate....	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. Fit the springs (7a) and rollers (7b) for the 5 ^th speed sliding sleeve hub.

To avoid losing the synchronizer springs and rollers, place the sliding sleeve in neutral.

8. Fit the 5 ^th speed selector fork. 9. Fit the 5 ^th speed synchronizer spring and roller 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)
-	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)
-	Bolt	5thª speed selector fork	M6	1.5 - 1.9

Apply sealant to the contact surfaces between the main and layshaft rear bearing 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).

Place the gearbox side differential flange complete with a new oil seal back in its housing and secure it using the bolts.1. Position the tool, complete with dial gauge, on the surface of the engine side differential and zero the dial gauge with a pre-loading of 1 mm.

	Name	Country
1	Dial gauge mounting	1.820.085.000

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

	Name	Country
1	Dial gauge mounting	1.820.085.000

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

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

1. Place in the housing the adjustment shim or shims for pre-loading the differential bearings, of the size calculated or the next size up.Place the differential flange complete with new oil seal back in its housing and secure it using the bolts.

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

Two operators are needed for this operation.

	Name	Country
-	Mount	1.820.146.000

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
-	Supports	1.820.623.000