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

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

) Position the vehicle on the ramp. Proceed with removal - 5530B10 battery - r+r . Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . 1. Disconnect the gear selector/engagement cables.2. Undo the nuts (2a) and release the bracket (2b) complete with gear selector/engagement cables.

1. Move the protective cover away.2. Remove the cap on the bleed valve.3. Connect the collection system (pipe and reservoir) to the bleed valve on the hydraulic clutch actuator.4. Lift retaining clip (4a) until the first click is heard and remove pipe (4b) sufficiently to uncover the bleed hole.Let the hydraulic clutch system drain completely.Lift up the clip completely and disconnect the pipe from the hydraulic clutch control actuator.

Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with removal - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with removal - 7055B54 under-engine guard - r r . Proceed with removal - 7055A43 central front grille - r r . Proceed with removal - 7055A41 RIGHT FRONT GRILLE - R.R. . Proceed with removal - 7055B10 Front BUMPER - R.R. . 1. Undo the drain plug and drain the gearbox-differential oil.

Collect the manual gearbox and differential oil in a suitable container.

1. Disconnect the battery earth lead from the gearbox.

	Name	Connector
1	Battery earth	C1

2. Disconnect the electrical connection from the reversing switch.

	Name	Connector
2	Reversing lights switch	I20

Undo both upper starter motor bolts.1. Remove the engine oil filler plug.2. Undo the bolts (2a) and remove the ignition coils cover (2b).Refit the engine oil filler plug.

Drain the air conditioner coolant circuit. - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling Proceed with removal - 5040A20 air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with removal - 5040A26 compressor mount - r r . Proceed with removal - 1076A48 catalytic converter heat shield - r r . Proceed with removal - 1080B62 catalytic converter - r + r . 1. Undo the bolts (1a) and remove the Lambda sensor electrical wiring mounting bracket (1b).

1. Fit the tool for safely supporting the power unit on the engine block in the position shown in the diagram.

	Name	Country
1	Mount	1.860.625.000

1. Fit a suitable bracket for safely supporting the power unit on the intake manifold.

1. Fit the tool (1a), complete with support mountings (1b).

	Name	Country
1a	Crossmember	1.820.581.000

	Name	Country
1b	Brackets	1.870.651.000

2. Fit the tool (2a) and connect it to the brackets fitted previously using the rods (2b).

	Name	Country
2a	Mount	1.820.226.000

1. Undo the upper manual gearbox and differential fixing bolts.

1. Undo the bolts (1a) and disconnect the flanges for the driveshaft constant velocity joints (1b).

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.

Remove the safety plates.

1. Undo the bolt securing the collar supporting the rigid exhaust pipe section between the catalytic converter and silencer to the relevant bracket.2. Undo the bolts (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b). 3. Remove the gasket.

1. Undo the bolt (1a) and the nut (1b) and remove the exhaust pipe (1c) support.

1. Undo the bolt (1a) and nut (1b) and remove the reinforcing link (1c).

1. Undo the bolts (1a) and remove the power unit rigid rear support (1b).

1. Undo the bolts (1a) and remove the flexible mounting for the power unit rear support (1b).

1. Undo the front nuts for the gear lever support.2. Remove the plates.3. Loosen the rear bolts (3a) and undo the remaining bolts (3b) for the gear lever support.

1. Undo the remaining bolt (1a) and move the starter motor (1b).

1. Support the front suspension crossmember using a hydraulic jack fitted with a suitable support.

1. Undo the nuts (1a) and disconnect the front anti-roll bar (1b) joints.

Loosen the bolts fixing the front anti-roll bar to the front suspension crossmember.1. Undo the bolts fixing the power assisted steering box to the front suspension crossmember.2. Undo the bolts fixing the lower track control arms to the forks.3. Undo the bolts fixing the lower track control arms to the front suspension crossmember.

1. Undo the remaining rear bolts fixing the front suspension crossmember to the bodyshell.2. Undo the side bolts fixing the front suspension crossmember to the bodyshell.

1. Lower the hydraulic jack and remove the front suspension crossmember complete with anti-roll bar.

1. Undo the bolts (1a) and release the intermediate driveshaft (1b) from the differential.

1. Fit the tool (1a) on a hydraulic jack (1b) and fix it to the gearbox using the bolts (1c).

	Name	Country
1a	Support	1.860.859.000

1. Undo the bolt fixing the gearbox side power unit rigid support to the flexible mounting.2. Undo the bolts (2a) and (2b) fixing the gearbox side power unit rigid support to the gearbox.3. Remove the gearbox side power unit rigid support.

1. Undo the remaining bolts fixing the manual gearbox and differential.

1. Remove the gearbox, moving it away firstly from the engine and then lowering it using the hydraulic jack.

Refitting ( Removing

) Place the gearbox back in its housing using the hydrauilc jack and support tool.1. Tighten the gearbox bolts (1a) and (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.1

1. Fit the gearbox side power unit rigid support (1a) and secure it to the gearbox by tightening the bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.5 ÷ 5.5

2. Tighten the bolt securing the gearbox side rigid power unit support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

Undo the bolts and separate the supporting tool from the gearbox, then replace it after having removed it from the hydraulic jack.1. Place the intermediate driveshaft (1a) in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.5 ÷ 2.8

Place the front suspension crossmember, complete with anti-roll bar, in its housing using the hydraulic jack.1. Tighten the side bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Tighten the rear bolts (2a) and (2b) securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2a	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
2b	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

1. Tighten the bolts securing the lower track control arms to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT SUSPENSION LOWER LEVER	M10	(Front suspension crossmember side) 7.1 ÷ 7.9

2. Tighten the bolts securing the lower track control arms to the forks to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT SUSPENSION LOWER LEVER	M12	(Selector forks side) 10.8 ÷ 13.2

3. Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.7 ÷ 14.3

Tighten the bolts securing the front anti-roll bar to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT ANTI-ROLL BAR	M8	(Front suspension crossmember side) 3.6 ÷ 4.4

1. Connect the joints (1a) to the front anti-roll bar and fix them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	(Anti-roll bar side) 4.5 ÷ 5.5

Remove the hydraulic jack and the tool used for supporting the front suspension crossmember.1. Place the starter motor (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 ÷ 3.0

Tighten the gear lever support bolts.Place the plates back in their housings and tighten the gear lever support front nuts.1. Place the flexible mounting for the power unit rear support (1a) back in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 3.2 ÷ 3.9

1. Refit the gearbox side power unit rear rigid support reinforcement (1a) in its seating and secure by tightening the bolts (1b), (1c) and (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Crankcase sump side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1d	-	-	-	-

1. Place the reinforcement rod (1a) back in its housing and secure it by tightening the bolt (1b) and the nut (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD....	M12	6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Nut	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD....	M12	5.0 ÷ 6.1

1. Fit the support for the exhaust pipe (1a) and secure by tightening bolt (1b) and nut (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXHAUST PIPE RIGID MOUNT	M8	2.3 ÷ 2.8

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST PIPE RIGID MOUNT	M12	6.8 ÷ 8.3

1. Place the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (1a) complete with gasket (1b) back in its housing and secure it to the front exhaust silencer by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	RIGID EXHAUST PIPE	M10	(Front silencer side) 5.9 ÷ 7.2

2. Tighten the bolt securing the collar supporting the rigid exhaust pipe section between catalytic converter and silencer to the relevant bracket.

1. Connect the flanges for the driveshaft constant velocity joints and tighten the new fixing bolts to the recommended torque.

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

1. Tighten the upper bolts fixing the gearbox to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX WITH ELECTRO-HYDRAULIC SELECTION...	M12	(Crankcase side) 7.2 ÷ 8.8

Remove the safety tools used for supporting the power unit.Place the Lambda sensor electrical wiring mounting bracket back in its housing and secure it using the bolts. Proceed with refitting - 1080B62 catalytic converter - r + r . Proceed with refitting - 1076A48 catalytic converter heat shield - r r . Proceed with refitting - 5040A26 compressor mount - r r . Proceed with refitting - 5040A20 air conditioner compressor - r+r - includes fluid level check and top up if necessary . Remove the engine oil filler plug.Place the ignition coils cover back in its housing and secure it using the bolts.Refit the engine oil filler plug.Tighten the remaining bolts securing the starter motor to the recommended torque.

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

Connect the electrical connection to the reversing switch.Connect the battery earth lead to the gearbox. Refill the gearbox/differential using the recommended fluid - 0010T40 change manual gearbox oil . Proceed with refitting - 7055B10 Front BUMPER - R.R. . Proceed with refitting - 7055A41 RIGHT FRONT GRILLE - R.R. . Proceed with refitting - 7055A43 central front grille - r r . Proceed with refitting - 7055B54 under-engine guard - r r . Proceed with refitting - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with refitting - 4450B12 front or rear wheels (two) - r+r . Fit the pipe fully home in its seat on the hydraulic clutch control actuator and secure with the retaining clip.Place the cap in its housing on the bleed valve. Place the protective cover back in its housing.Refit the bracket complete with gear selector/engagement cables and secure it using the nuts.Connect the gear selector/engagement cables. Proceed with refitting - 1820B08 Clutch release HYDRAULIC SYSTEM - Bleeding air and restoring level . Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting - 5530B10 battery - r+r . Fill the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling . Remove the car from the ramps.