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 platform and secure it as appropriate.1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).

1. Open the cover (1a), undo the nut (1b) and disconnect the electrical connections from the starter motor (1c).

	Name	Connector
1c	Starter' motor	A20

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

1. Support the manual gearbox with differential using a hydraulic crane fitted with suitable chains.2. Undo the top bolts securing the manual gearbox with differential to the crankcase. 3. Loosen the nuts fixing the manual gearbox and differential to the crankcase.4. Undo the bolts fixing the crankcase sump to the manual gearbox with differential.5. Remove the manual gearbox and differential from the engine using the hydraulic crane.

IF TOOL 1.871.003.100 IS AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Undo the three bolts at 120 degrees securing the clutch cover.3. Fit the centring device (3a) and the rest of the tool (3b), tightening the bolts (3c) in the seats of the bolts removed previously.

	Name	Country
3	Tool for Extracting/Fitting	1.871.003.100

4. Rotate the handwheel on the tool until the pins (4a) come into contact with the disc (4b).5. Undo the remaining bolts securing the clutch cover.6. Unscrew the handwheel of the tool to discharge the clutch mechanism's diaphragm spring.Remove the tool.

	Name	Country
-	Tool for Extracting/Fitting	1.871.003.100

7. Remove the clutch cover.Remove the clutch disc.

IF TOOL 1.871.003.100 IS NOT AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Undo the clutch cover bolts by slackening them off a little at a time, in diagonal order, to discharge the diaphragm spring.3. Remove the clutch cover.Remove the clutch disc.

IF TOOL 1.871.003.100 IS AVAILABLE, REFIT THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the tool's centring device in the crankshaft.Refit the clutch disc in its seating.

When fitting the clutch disc, make sure it is orientated as indicated by the words 'engine side' or 'gearbox side'.

Handle the clutch disc carefully. Do not touch the friction surfaces with the hands.

2. Refit the clutch cover in its seating.

Clean the protective anti-corrosion products or detergents from the friction surfaces of the clutch cover.

3. Fit the remaining part of the tool (3a) for fitting the clutch unit, by tightening the bolts (3b).4. Turn the handwheel of the tool until the pins (4a) come into contact with the disc (4b).5. Manually tighten the thre free bolts for securing the clutch unit.6. Unscrew the handwheel of the tool to discharge the clutch mechanism's diaphragm spring.Remove the tool.

	Name	Country
-	Tool for Extracting/Fitting	1.871.003.100

Tighten by hand the remaining bolts securing the clutch unit.Gradually tighten, in diagonal order, the bolts securing the clutch unit until the recommended torque is reached.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.8

7. Remove the flywheel lock.

	Name	Country
7	Counter-torque	1.860.846.001

IF TOOL 1.871.003.100 IS NOT AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Place the clutch disc and the clutch cover (1a) back in its housing using the centring tool (1b).

When fitting the clutch disc, make sure the clutch is orientated as indicated by the words 'engine side' or 'gearbox side'.

Handle the clutch disc carefully. Do not touch the friction surfaces with your hands.

Clean the protective anti-corrosion products or detergents from the friction surface of the clutch cover.

	Name	Country
1b	Clutch centering	1.875.086.000

Manually tighten the clutch unit bolts.2. Gradually tighten, in diagonal order, the bolts securing the clutch unit until the recommended torque is reached.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.8

3. Remove the flywheel lock.

	Name	Country
3	Counter-torque	1.860.846.001

1. Place the manual gearbox with differential in its seating on the engine using the hydraulic crane.2. Tighten the bolts fixing the crankcase sump to the manual gearbox with differential to the recommended torque.

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

3. Tighten the nuts fixing the manual gearbox and differential to the crankcase to the recommended torque.

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

4. Tighten the top bolts securing the manual gearbox with differential to the crankcase to the specified torque.

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

5. Remove the hydraulic crane fitted with suitable chains used to support the manual gearbox with differential.

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	-	-	-	-

2. Connect the electrical connections (2a) to the starter motor, tighten the nut (2b) and close the protective cover (2c).

1. Refit the intermediate half shaft (1a) in its seating and tighten its bolts (1b) to the specified torque.

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