2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY - Alfa - 156 - eLearn

3239106 - 2110B20 manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary

) 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).2. 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.

1. Undo plugs (1a) and remove springs (1b) and balls (1c) for gear control rod positioning.2. Undo the bolt fixing the Reverse gear shaft.

Undo the bolts and remove the differential flanges complete with oil sealing rings, 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. Undo the bolts (1a) and remove the Reverse gear selector fork mounting bracket (1b).2. Remove the Reverse idler gear.

1. Undo the bolts securing the 1 ^st -2 ^nd (1a) and 3 ^rd -4 ^th speed (1b) selector forks. 2. Remove the 1st-2nd speed control rod (2a) together with the selector fork (2b) and 3rd-4th speed control rod (2c). 3. Simultaneously remove the 5th-Reverse control rod (3a) and the 3 ^rd -4 ^th speed selector fork (3b). 4. Remove the gear engagement safety pawls.

1. Remove the main shaft and layshaft assemblies simultaneously.2. Remove the differential assembly.3. Remove the main and layshaft front bearings.

1. Remove the magnet.2. 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 a hydraulic press, a plate (1d) and the half-rings (1e).

	Name	Country
1d	Plate	1.820.024.000

	Name	Country
1e	Half-rings	1.820.017.000

1. Remove the 3rd speed driven gear (1a) and the 2nd speed driven gear (1b) using a hydraulic press and half plate (1c).

	Name	Country
1c	Plate	1.820.019.000

1. Remove the sliding sleeve for 1 ^st - 2 ^nd and Reverse gears. 2. Remove the springs (2a) and the rollers (2b) for the 1s ^t -2 ^nd speed and Reverse sliding sleeve hub. 3. Remove the 2 ^nd speed synchronizer ring. 4. Remove the needle bearing for the 2 ^nd speed driven gear.

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 and reverse gear sliding sleeve hub (1a), the 1 ^st speed synchronizer (1b), the 1 ^st speed driven gear (1c) using a hydraulic press and the plate (1d).

	Name	Country
1d	Plate	1.820.024.000

2. Remove the needle bearing.

Proceed with dismantling the main shaft, following the instructions given below.1. Remove:the rear bearing (1a), the 4 ^th speed driven gear (1b), the needle bearing for the 4 ^th speed drive gear (1c), the bush for the 4 ^th speed drive gear (1d), 3rd and 4th speed sliding sleeve (1e), the springs (1f) and rollers (1g) for the 3r ^d and 4 ^th speed sliding sleeve hub, the 4 ^th speed synchronizer ring (1h), the 3 ^rd and 4 ^th speed sliding sleeve hub (1i), the 3 ^rd speed synchronizer ring (1l), 3 ^rd speed drive gear (1m), using a hydraulic press, plate (1n) and half-rings (1o).

	Name	Country
1n	Plate	1.820.024.000

	Name	Country
1o	Half-rings	1.820.017.000

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. Fit the springs (6a) and rollers (6b) in the sliding sleeve hub.To avoid losing the synchronizer springs and rollers, place the sliding sleeve in neutral.7. Fit the 4 ^th speed synchronizer ring.

1. Place the bush for the 4 ^th speed drive gear (1a), the roller bearing for the 4 ^th speed drive gear (1b) and the 4 ^th speed drive gear (1c) back in their housings using a hydraulic press and the half-plates (1d).

	Name	Country
1d	Half-plates	1.821.149.000

1. Fit the rear bearing (1a), using a hydraulic press, fitting tool (1b) and suitable half-plates (1c).

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 1 ^st speed synchronizer ring.

1. Place the 1 ^st and 2 ^nd speed sliding sleeve hub (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

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. Fit the springs (2a) and rollers (2b) in the hub for the 1st and 2nd and Reverse sliding sleeve. To avoid losing the synchronizer springs and rollers, place the sliding sleeve in neutral.3. Fit the needle bearing for the 2 ^nd speed driven gear. 4. Fit the 2 ^nd speed synchronizer ring. 5. Fit the 2 ^nd speed driven gear.

1. Fit the 3 ^rd speed driven gear (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

1. Place the 4 ^rd speed driven gear (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Fitting tool	1.821.050.000

1. Fit the rear bearing (1a), using a hydraulic press, the half plates (1b) and the fitting tool (1c).

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Tool for Extracting/Fitting	1.870.117.000

1. Fit the gear selector/engagement lever (1a) and fix it tightening the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	Gear selector/engagement 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 tools (1b) and (1c).

	Name	Country
1b	Grip	1.821.171.000

	Name	Country
1c	Fitting tool	1.821.225.000

1. Fit the magnet.2. Fit the main and layshaft front bearings.3. Fit the differential assembly.4. Fit the main shaft and layshaft assemblies simultaneously.5. Fit the gear engagement safety pawls (5a) using a drift (5b) and tool (5c).

	Name	Country
5c	Fitting tool	1.821.047.000

1. Fit the Reverse idler gear.

Make sure that the gear engagement teeth are facing downwards.

2. Fit the 5 ^th speed and Reverse control rod. 3. Fit the 3 ^rd - 4 ^th speed selector fork (3a) and the control rod (3b).

Position the safety pawl in the rod before fitting it in the housing.

4. Fit the 1 ^st - 2 ^nd speed control rod (4a), complete with selector fork (4b).

To facilitate the fitting, move the 1 ^st - 2 ^nd speed selector forks in the direction shown by the arrow.

5. Tighten the bolts for the 1 ^st -2 ^nd speed (5a) and 3 ^rd -4 ^th speed selector forks (5b) to torque.

	Fastening	Component	Ø	Value(daNm)
5a	Bolt	1st - 2nd speed selector fork	M6	1.5 - 1.9

	Fastening	Component	Ø	Value(daNm)
5b	Bolt	3rd - 4th speed selector fork	M6	1.5 - 1.9

6. Fit the Reverse selector fork mounting bracket (6a) and fix it tightening the bolts (6b) to torque.

	Fastening	Component	Ø	Value(daNm)
-	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. 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

Fit the gear control rod positioning balls and springs and tighten the plugs.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 secure it by 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 rings 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)
-	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 differential flange, gearbox side, complete with 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
1a	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, engine side, 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 control cylinder and tighten 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
-	Mount	1.820.623.001