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

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

) Position the vehicle on the ramp. - 4450B12 front or rear wheels (two) - r+r - 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R.1. Unscrew the bolt on the fluid intake pipe to the slave cylinder.2. Remove circlip (2a), withdraw slave cylinder (2b) with pipe (2c) and move to one side.3. Undo bolts (3a) and remove slave cylinder mount (3b).

1. Disconnect the electrical connection from the reversing lights switch.2. Remove the reversing light switch.

	Name	Connector
2	Reversing lights switch	I20

1. Disconnect the gear selector/engagement cables.2. Undo bolts (2a) and remove mounting bracket (2b) complete with gear selector/engagement cables.3. Undo bolts (3a) and remove gear selector and engagement unit (3b).

1. Disconnect the oil vapour recirculation pipe from the separator.2. Undo nuts (2a) and move oil vapour separator (2b) away from the intake manifold.3. Remove the bracket.

Undo both upper starter motor bolts.Undo both upper gearbox bolts. - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B10 Front BUMPER - R.R.1. Unscrew the rear exhaust manifold and intake manifold nuts.2. Fit the tool and secure it using the previously removed nuts.

	Name	Country
2	Brackets	1.870.651.000

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

	Name	Country
1a	Crossmember	1.820.581.000

	Name	Country
1b	Support mountings	1.870.650.000

2. Fit the tool and connect to the brackets fitted previously using the links.

Fit a wooden spacer between the mount and front beam.

	Name	Country
2	Mount	1.820.226.000

3. Undo bolts (3a) and disconnect left driveshaft (3b) from the differential.

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.

Raise the car.1. Undo the plugs and drain the manual gearbox and differential.2. Remove the sleeve joining the turbocharger to the air-air heat exchanger.3. Undo nuts (3a) and remove the brackets and air conditioning lines (3b) from the lower radiator beam.

- 1076B50 exhaust pipe attachment to engine - r + r1. Position a hydraulic jack under the differential.2. Undo bolts (2a) and remove rear power unit mount assembly (2b).3. Remove the rigid exhaust pipe support.Lower the hydraulic jack slowly and remove.

- 1008B20 power unit intermediate mount flexible block - replace - 4410D13 front suspension beam - r r1. Undo bolts (1a) and remove protection (1b).2. Undo lower bolt (2a) and move starter motor (2b) away from the gearbox.3. Undo bolts (3a) and move differential flange (3b) and thrust washer (3c) away from the gearbox.

1. Unscrew bolts (1a) and nuts (1b) securing the gearbox to the engine.2. Undo nut (2a) and disconnect earth lead (2b).Position a hydraulic jack under the gearbox.3. Undo bolts (3a) and remove gearbox side rigid power unit mount (3b).Remove the hydraulic jack from under the gearbox.

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

	Name	Country
1a	Mount	1.870.644.001

	Name	Country
1b	Mount	1.870.644.000

Undo the remaining fastenings and remove the gearbox and differential. Firstly move the unit away from the engine and then lower using the jack.

- 1810A24 clutch - r + r with gearbox removed

Refitting ( Removing

) - 1810A24 clutch - r + r with gearbox removed1. 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 tool. Secure by tightening the bolts to torque.

	Name	Country
-	Mount	1.870.644.001

	Name	Country
-	Mount	1.870.644.000

	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 refitting the gearbox, the main shaft should be fitted gradually in the driven disc hub in order to prevent sharp axial thrusts and/or forcing the actual disc.

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.1. Fit rigid power unit mount (1a) and secure by tightening bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	4.2 - 5.1

Remove the hydraulic jack from under the gearbox.2. Connect earth lead (2a) to the gearbox and secure using nut (2b).

1. Secure flange (1a) with thrust washer (1b) to the differential by tightening bolts (1c) to torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MAN G/BOX DIFF SEALING FLANGE/S	M8	2.1 - 2.6

2. Fit starter motor (2a) to the gearbox and secure by tightening lower bolt (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	STARTER MOTOR	M8	(Manual gearbox side) 2.4 ÷ 3.0

3. Fit protection (3a) and securing with bolts (3b).

- 4410D13 front suspension beam - r r - 1008B20 power unit intermediate mount flexible block - replace1. Position a hydraulic jack under the differential.2. Fit power unit rear mount (2a) complete with rigid exhaust pipe mount (2b) and secure by tightening bolts (2c) and (2d) to torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	POWER UNIT RIGID REAR MOUNT	M12	7.5 - 9.2

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT RIGID REAR MOUNT	M16	10.2 - 12.6

	Fastening	Component	Ø	Value(daNm)
2d	Bolt	INTERM RUBBER MOUNT	M8	2.7 - 3.4

Remove the hydraulic jack from under the differential.

- 1076B50 exhaust pipe attachment to engine - r + rSecure the air conditioning hose brackets to the lower radiator beam using nuts.Fit the turbocharger connection sleeve to the air-air heat exchanger.Tighten the manual gearbox and differential fluid drain plugs to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Plug	GEAR CASING PADS	M18	1.6 - 2.6

	Fastening	Component	Ø	Value(daNm)
-	Plug	GEAR CASING PADS	M22	3.0 - 4.8

Lower the vehicle.1. Connect the left driveshaft (1a) to the differential and fix it tightening the new bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	3.6 ÷ 4.4

Remove all power unit support tools and put away. - 7055B10 Front BUMPER - R.R. - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R.Tighten both upper starter motor bolts to torque.

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

Place the oil vapour separator back in its housing and secure it to the bracket using the nuts.Connect the oil vapour recirculation pipe to the separator.1. Fit the gear selector/engagement unit (1a) and fix it with the bolts (1b).2. Place the mounting bracket (2a) back in its housing complete with gear selector/engagement cables (2b) and fix it with the bolts.

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.

Fit the reversing light switch and tighten.

	Name	Connector
-	Reversing lights switch	I20

Connect the electrical connection to the reversing lights switch.Fit the slave cylinder mount and secure with bolts.Refit the slave cylinder and lines. Secure using a circlip.Tighten the bolt on the slave cylinder fuel intake pipe. - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 5530B10 battery - r+r - 4450B12 front or rear wheels (two) - r+rFill the gearbox and differential with oil.

	Type	Component	Name	Qty.
-	Oli [l]	MANUAL GEARBOX	Tutela ZC 75 SYNTH	2

Remove the car from the ramps.