1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD - Alfa - 156 - eLearn

3237440 - 1004D10 power unit (manual gearbox), removed, remove and re-build

) Undo the plug and drain the transmission fluid.

Recover the fluid in a suitable container.

Disconnect the electrical connections from the starter motor.

	Name	Connector
-	Starter' motor	A20

Undo the fixing bolts and remove the starter motor.Undo the fixing bolts and remove the intermediate driveshaft.Undo the fastenings and remove the manual gearbox and differential.Fit the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

Undo the bolts and remove the clutch cover complete with thrust bearing.Remove the clutch disc.Remove the thrust bearing from the clutch cover using the tool.

	Name	Country
-	Extractor	1.821.215.000

Reassembling ( Dismantling

) Place the clutch disc and the clutch drip tray back in its housing using the centering tool.

	Name	Country
-	Centering	1.820.124.000

Tighten the bolts fixing the clutch cover to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.5 ÷ 3.1

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

Lift up the plastic tapered seal for the thrust bearing until the spring is covered.Place the thrust bearing in its housing on the main shaft and attach it to the fork bearing.Place the manual gearbox and differential unit back in its housing and secure it tightening the nuts and bolts to the recommended torque.

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

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

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

Act on the gear control lever to engage the clutch release bearing in the clutch.Place the starter motor back in its housing and tighten the fixing bolts to the recommended torque.

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

Fit the intermediate driveshaft in its housing and press fit it into the housing on the differential.Tighten the bolts fixing the intermediate driveshaft to the support.Connect the electrical connections to the starter motor. Refill the manual gearbox and differential - 0010T40 change manual gearbox oil .