3239109 - 2110C34 spacer and rear cover - r + r with gearbox removed

Removing ( Refitting ) 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 bolts (2a) and remove the rear cover (2b). 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. Position 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 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. Refitting ( Removing ) Apply Loctite 573 sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.Fit the main and layshaft rear bearing retaining plate and secure by tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER SPACER	M8	(Gearbox casing side) 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 main shaft and layshaft ring nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	10.0 ÷ 12.4

12. Tighten the 5 ^th speed selector fork bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	5TH SPEED SELECTOR FORK	M6	1.5 ÷ 1.9

Apply Loctite 573 sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.1. Fit the rear cover (1a) and secure by tightening the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX REAR COVER	M8	2.1 ÷ 2.6

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.