2010B42 5TH SPEED GEARS OF MANUAL GEARBOX WITH DIFFERENTIAL - R+R WITH GEARBOX REMOVED - Alfa - 156 - eLearn

3239108 - 2010B42 5th speed gears of manual gearbox with differential - r+r with gearbox removed

) 1. Undo the bolts (1a) and remove the rear cover (1b).

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.

Refitting ( Removing

) Fit the 5 ^th speed drive gear bush. Fit the needle bearing for the 5 ^th speed drive gear. Fit the 5 ^th speed drive gear. Fit the 5 ^th speed synchronizer gear. Fit the 5 ^th speed sliding sleeve hub. Fit the 5 ^th speed sliding sleeve. Fit the srpings and rollers in the 5 ^th speed slding sleeve hub.

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

Fit the 5 ^th speed selector fork. Fit the 5 ^th speed synchronizer spring and roller retaining flange. Fit the 5 ^th speed driven gear. 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

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	-

Fit the rear cover and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER	M8	2.1 - 2.6