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. . - 7055B54 under-engine guard - 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. . - 7055B10 Front BUMPER - R.R. . Remove the front light clusters (refer to op. 5540B16 FRONT LIGHT CLUSTER with direction indicator (one), left or right - R.R. ). 1. Unscrew the retaining bolts and release the lock secured to the front beam.

1. Disconnect control cable (1a) from lock (1b).

Release the electrical wiring from the front beam.1. Unscrew the retaining bolts to remove the front beam.

- 1088E11 fans with single engine duct - r+r . 1. Unscrew the retaining bolts (1a) and remove the lower radiator - condenser guard (1b).

- 1048A48 throttle heater sleeve - r r . - 1048A10 air cleaner filtering element - replace . - 1092G10 single engine belt r r . Unscrew the retaining bolts and remove the power steering pump pulley1. Disconnect the earth lead from the gearbox casing.

	Name	Connector
1	Battery earth	C1

- 1008C10 power unit upper reaction link r r . 1. Disconnect the gear engagement/selector cables.2. Undo the bolts (2a) and move the mounting bracket (2b), complete with gear selector/engagement cables.

Remove the starter motor heat shield protection.1. Disconnect the electrical connections from the starter motor.

	Name	Connector
1	Starter' motor	A20

2. Undo the bolts (2a) and remove the starter motor (2b).

1. Unscrew the fastenings securing bracket (1a) to the gearbox and take off together with clutch actuator cylinder (1b).

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

	Name	Connector
1	Reversing lights switch	I20

- 1076B52 exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r . 1. Release power steering fluid hoses (1a) from fastenings (1b).

1. Unscrew the bolts securing the right drive shaft to the intermediate shaft flange.

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. Unscrew the bolts securing the left drive shaft to the flange on the differential inner drive shaft.

1. Support the engine by means of a chain using tools (1a), (1b) and (1c).

	Name	Country
1a	Support mountings	1.870.650.000

	Name	Country
1b	Crossmember	1.820.581.000

	Name	Country
1c	Mount	1.820.226.000

1. Undo the nuts (1a) and disconnect the steering rod arms (1b).2. Undo nuts (2a) and disconnect the lower wishbone from the wheel knuckle using tool (2b).

	Name	Country
2b	Extractor	1.821.169.000

Carry out the same procedure on the right side.

Tilt the wheel hubs forward as far as possible to move the drive shafts away from the differential.1. Unscrew the bolts securing the retaining flange and remove the intermediate shaft.

1. Undo the bolts and remove the lower engine flywheel protection.

Disconnect the electrical connection for the rpm sensor.

	Name	Connector
-	Rpm sensor	K46

1. Unscrew the retaining bolt and remove the rpm sensor.

1. Unscrew all the upper engine-gearbox bolts apart from the hexagonal-headed socket bolt on the lower side near the intermediate shaft flange on the gear casing.

- 1008A42 gear box left rigid mount - r r . 1. Fit the tools (1a) and (1b) on a hydraulic jack, and fix it to the gearbox differential.

	Name	Country
1a	Mount	1.870.644.001

	Name	Country
1b	Mount	1.870.644.000

- 1008A44 rear rigid mount - r r . 1. Unscrew the hexagonal-headed socket bolt on the lower side near the intermediate shaft flange on the gear casing.

After lowering the engine slightly, move it simultaneously toward the front of the car to prevent it fouling against the body. Withdraw the gearbox and remove from the engine bay by lowering the hydraulic jack. - 1810A24 clutch - r + r with gearbox removed .

Refitting ( Removing

) - 1810A24 clutch - r + r with gearbox removed . 1. Lift up the tapered seal (1a) for the clutch release bearing until the spring (1b) is covered.2. Fit the clutch release bearing (2a) on the main shaft and match it with the clutch release fork (2b).

Apply Molycote PG 21 grease to:- mating surfaces between the mainshaft sealing cover and thrust bearing;- both thrust bearing control fork pin levers.

Replace the gearbox and differential in its housing using the hydraulic jack and special tool.

	Name	Country
-	Mount	1.870.644.001

	Name	Country
-	Mount	1.870.644.000

Tighten the bolts fixing the gearbox and differential to the engine to the recommended torque.

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

Fit the intermediate shaft and ensure it fits properly into the differential. Then tighten the retaining bolts to torque.

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

Fit the starter motor and tighten the bolts to the required torque. Then connect the connections.

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

Act on the gear control lever to engage the clutch release bearing in the clutch.Undo the bolts and separate the supporting tool from the gearbox, then replace it after having removed it from the hydraulic jack.Position a hydraulic jack under the gearbox. - 1008A44 rear rigid mount - r r . - 1008A42 gear box left rigid mount - r r . Fit the rpm sensor and wiring.Fit the flywheel protective casing and tighten the bolts.Connect the upper wishbone to the wheel knuckle and secure by tightening the nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT SUSPENSION LOWER LEVER	M14	(Front steering knuckle side) 8.6 - 9.5

Connect the steering rods arms and secure by tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE LINK BALL JOINTS	M10	(Wheel damper side) 2.9 - 3.6

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	M10	(Diff. int./ intermediate. driveshaft.) side 5.0 ÷ 6.1

Secure the power steering pump oil pipe. - 1076B50 exhaust pipe attachment to engine - r + r . Connect the electrical connection for the reversing lights switch.Secure the bracket and clutch actuator cylinder to the gearbox.Connect the gear engagement/selector cables.Position the gear lever in neutral and move it completely towards the right.1. Loosen the adjustment nut for the gear selector/engagement unit.2. Fit the tool under the gear engagement cable attachment ball.

	Name	Country
2	Spacer	1.860.974.000

3. Connect the gear selector/engagement cables.Tighten the adjustment nut.Remove the spacer.

- 1008C10 power unit upper reaction link r r . Connect the earth lead to the gear casing.Fit the power steering pump pulley. - 1092G10 single engine belt r r . - 1048A10 air cleaner filtering element - replace . - 1048A48 throttle heater sleeve - r r . Fit the lower radiator guard. - 1088E11 fans with single engine duct - r+r . Connect the engine wiring connections.Fit the front beam and tighten the bolts.Secure the wiring to the front beam.Connect the bonnet lock control cable.Position the catch and do up the retaining bolts. Refit the front light clusters (refer to op. 5540B16 FRONT LIGHT CLUSTER with direction indicator (one), left or right - R.R. ). - 7055B10 Front BUMPER - 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 . - 7055B54 under-engine guard - r r . - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . - 5530B10 battery - r+r .