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

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

) Position the power unit on a suitable workbench.1. Disconnect and remove the electrical wiring from the power unit.2. Undo the bolts (2a) and remove the intermediate shaft (2b).3. Undo the bolts (3a) and remove the starter motor (3b).

1. Undo the fixings and remove the gearbox-differential unit from the engine.2. Undo the bolts (2a) and remove the clutch drip tray (2b).3. Remove the clutch disc.

1. Remove the clutch release bearing (1a) from the clutch cover using the tool (1b).

	Name	Country
-	Extractor	1.821.215.000

Reassembling ( Dismantling

) Fit the clutch disc and clutch cover, centring them using the tool.

	Name	Country
-	Centering	1.820.124.000

Tighten the clutch cover bolts to the specified torques.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.6 - 3.0

1. Lift up the plastic tapered seal (1a) for the thrust bearing until the spring (1b) is covered.2. Fit the thrust bearing (2a) on the main shaft and attach it to the fork bearing (2b).

Fit the gearbox-differential unit and fix it tightening the nuts and bolts to the recommended torque.

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

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

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

When fitting the gearbox, the main shaft must be inserted gradually into the clutch driven plate hub, to avoid abrupt axial thrusts and/or forcing of the disc.

Act on the clutch control lever to engage the thrust bearing in the clutch cover.Fit the starter motor and fix it tightening the bolts to the recommended torque.

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

Fit the intermediate shaft and fix it tightening the bolts to the recommended torque.

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

Place the electrical wiring in its housing and connect it.