2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Alfa - 156 - eLearn

3237924 - 2110A10 manual gearbox and differential - r + r

) Position the vehicle on the ramp. - 5530B10 battery - r+r . - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . - 4450B12 front or rear wheels (two) - r+r . - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . - 7055B54 under-engine guard - r r . Drain the oil from the gearbox1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Disconnect the intake air temperature sensor.

	Name	Connector
2	Air temperature sensor	K42

3. Remove the air intake sleeve.

- 5530B34 lead between terminal and starter motor - r+r . - 1048A28 vacuum air circuit resonator pipe - r+r . - 1048A10 air cleaner filtering element - replace . - 1088E10 radiator cooling fan - r + r . - 1008C10 power unit upper reaction link r r . Drain the fluid from the brake and clutch hydraulic circuit.1. Fully remove the fork from the actuator body and withdraw the pipe from its housing.2. Disconnect the battery earth lead from the gearbox bell housing.

	Name	Connector
2	Battery earth	C1

1. Disconnect the gear control and engagement cables (BOWDEN system) from the support and rod idler.

1. Undo the upper bolts securing the gearbox bell housing to the engine.Unscrew the starter motor upper bolts.

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

- 7055B10 Front BUMPER - R.R. . 1. Position both brackets to support the engine during gearbox removal.2. Fit the engine support beam complete with mounting blocks.

	Name	Country
2	Crossmember	1.820.581.000

3. Fit the engine mounting tool and connect to the brackets fitted previously using the links. Then put the engine under slight tension.

	Name	Country
3	Mount	1.820.226.000

- 1076B50 exhaust pipe attachment to engine - r + r . 1. Unscrew bolts (1a), recover the three washers (1b) and disconnect the left front drive shaft (1c).Repeat the operation for the right driveshaft.

The bolts securing the front half shafts, intermediate half shaft/differential inner half shaft side, have been treated with Eslok type locking compound; therefore every time they are removed they must be replaced.

1. Undo the bolt at the top end of the suspension and remove from its seat using the appropriate tool.

	Name	Country
1	Head extractor	1.847.035.000

Release the brake pipes and ABS sensor cables from their brackets. Then roll the wheel hubs as far forward as possible to move the drive shafts away from the differential.

Undo the bolts securing the intermediate drive shaft to the engine mount, release from the gearbox and move away from the working area before securing in place.Disconnect the electrical connections from the starter motor.

	Name	Connector
-	Starter' motor	A20

Undo the remaining bolts fixing the manual gearbox and differential.Remove the lower gearbox guard.1. Fit the gearbox-differential unit removal tool to a hydraulic jack and secure to the gearbox at the points shown in the figure.

	Name	Country
1	Support	1.860.859.000

- 1008A42 gear box left rigid mount - r r . - 1008A44 rear rigid mount - r r . 1. Undo the lower fastenings securing the gearbox to the engine.

Manoeuvre the hydraulic jack in order to withdraw the gearbox from the locating pins. Then remove from the engine bay by slowly lowering the hydraulic jack.

Refitting ( Removing

) Place the gearbox in its housing using the hydraulic jack and the gearbox-differential support tool.

Take care not to damage the sleeve on the coaxial clutch control actuator.

Secure the gearbox to the engine by tightening the bolts and nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M10	5.0 ÷ 6.1

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12	7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12	7.2 ÷ 8.8

- 1008A44 rear rigid mount - r r . - 1008A42 gear box left rigid mount - r r . Remove the gearbox-differential removal/refitting tool and the hydraulic jack.

	Name	Country
-	Support	1.860.859.000

Refit the lower gearbox guard.Replace the starter motor in its housing and fix it tightening the lower bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 ÷ 3.0

Connect the electrical connections to the starter motor.Refit the intermediate drive shaft in its seating and secure to the mounting bracket on the engine by tightening its bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.5 ÷ 2.8

Refit the left and right half shafts and tighten the new bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Diff. int./ intermediate. shaft.) driveshaft side 3.6 ÷ 4.4

Connect the upper strut head (right and left side). - 1076B50 exhaust pipe attachment to engine - r + r . Tighten the upper starter motor fastenings to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 ÷ 3.0

Connect the gear control and engagement cables to the support and rod idler.Connect the clutch hydraulic system pipe to the actuator casing as follows:

Ensure the housing on the actuator body, the O-ring and the pipe connector are absolutely clean and undamaged.

Wet the O-ring with brake fluid to make it easier to insert the pipe. Do not use detergents or mineral lubricants incompatible with the brake fluid materials.

1. Position the flexible fork as shown in the figure (without pushing fully home).Push the pipe fully home in the actuator.Push the fork fully home to lock the pipe in place.

Remove the engine support tools during gearbox removal.

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Mount	1.820.226.000

- 7055B10 Front BUMPER - R.R. . Connect the reversing light switch and battery earth lead to the gearbox bell housing. - 1008C10 power unit upper reaction link r r . - 1088E10 radiator cooling fan - r + r . - 1048A10 air cleaner filtering element - replace . - 1048A28 vacuum air circuit resonator pipe - r+r . - 1820B08 Clutch release HYDRAULIC SYSTEM - Bleeding air and restoring level . - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . - 5530B10 battery - r+r . - 5530B34 lead between terminal and starter motor - r+r . Refit the air intake sleeve, flow meter, air flow meter connection and intake air temperature sensor. - 7055B54 under-engine guard - r r . - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . - 4450B12 front or rear wheels (two) - r+r . Connect the battery negative terminal.