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

125001236 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

) Position the vehicle on a lift.Proceed with removal - 1016A10 SOUNDPROOFING COVER - R&R. .Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal Op. 1088D24 RIGID PIPE FOR COOLANT INLET TO WATER PUMP - R + R.Proceed with the removal Op. 5530B10 BATTERY - R+R.Proceed with the removal Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the removal Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.1. Loosen the bands (1a) and remove the air supply hose between the turbocharger and the heat exchanger (1b).2. Undo the nut (2a) and disconnect the earth lead (2b) from the power unit gearbox side rigid support.

	Description	Connector
2b	Battery earth	See C1 BATTERY EARTH

1. Undo the bolts (1a) and remove the lower heat shield (1b) for the exhaust pipe.

1. Undo the nuts (1a) and remove the upper heat shield (1b) for the exhaust pipe.

1. Disconnect the rapid connector for the front fuel supply pipe, fuel filter side.2. Disconnect the rapid connector for the fuel return pipe to the fuel return manifold pipe, fuel filter side.3. Disconnect the rapid connector for the fuel supply pipe to the pressure pump, fuel filter side.

Collect the fuel that comes out in a suitable container.

4. Disconnect the electrical connection from the fuel temperature sensor.

	Description	Connector
4	Fuel temperature sensor and heating resistance	See K100A FUEL HEATING RESISTANCE AND TEMPERATURE SENSOR ( CONNECTORS )

5. Disconnect the electrical connection from the fuel preheating device.

	Description	Connector
5	Fuel temperature sensor and heating resistance	See K100B FUEL HEATING RESISTANCE AND TEMPERATURE SENSOR ( CONNECTORS )

1. Undo the nuts (1a), lift up the fuel filter as necessary and disconnect the electrical connection from the water in the fuel filter sensor (1b).

	Description	Connector
1b	Water in diesel filter sensor	See K31 WATER IN DIESEL FILTER SENSOR

2. Remove the fuel filter.

Proceed with the removal Op. 1076B70 EXHAUST PIPE BETWEEN PRE-CATALYTIC CONVERTER AND CATALYTIC CONVERTER - R R.Proceed with the removal Op. 5520B10 STARTER MOTOR - R+R.Remove the protective cap from the bleed valve on the clutch operating cyliner.Connect the recovery device (pipe and reservoir) to the bleed valve on the operating cylinder.Loosen the bleed valveOperate the clutch pedal until the brake/clutch reservoir is drained.1. Undo the connector (1a) and disconnect the pipe from the vibration damper to the clutch operating cylinder (1b), operating cylinder side.2. Remove the circlip (2a) and release the operating cylinder (2b) from the mounting.3. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
3	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH

1. Disconnect the gear selector and engagement cables.2. Undo the fastenings and move the mounting bracket aside complete with gear selection and engagement cables.

1. Undo the nuts (1a) and move front bonnet catch (1b) aside without disconnecting the bonnet opening cable.

1. Fit bracket (1a) on the exhaust manifold and secure with nut (1b).2. Fit bracket (2a) to the crankcase sump and secure with bolt (2b).3. Fit the tool (3a) complete with support blocks (3b).

	Description	Code
3a	Crossmember	1.820.581.000

	Description	Code
3b	Support mountings	1.870.650.000

4. Fit the tools (4a) and (4b), then connect them to the brackets fitted previously using links (4c).

	Description	Code
4a	Crossmember	1.860.851.003

	Description	Code
4b	Vertical support	1.870.748.000

1. Undo the upper bolts fixing the manual gearbox and differential unit to the engine.

Proceed with the removal Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with the removal Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the removal Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the removal Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R.Proceed with the removal Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R..1. Loosen the collars securing the driveshaft gaiters to the intermediate driveshaft/inner differential driveshaft.

1. Undo the nuts securing the front suspension lower wishbones to the struts.2. Loosen the bolts securing the front shock absorber forks to the lower wishbones.3. Disconnect the front suspension lower wishbones from the steering knuckles using the tool.

	Description	Code
3	Extractor	1.821.169.000

1. Undo the nuts (1a) and disconnect the front suspension stabiliser bar (1b) from the front shock absorber forks.

1. Undo the nut securing the power unit rigid rear support to the flexible mounting.2. Undo the bolts (2a) and remove the power unit rear support (2b).

1. Undo the bolts fixing the catalytic converter to the exhaust pipe rigid pipe.2. Remove the catalytic converter (2a) after having released it from the flexible mountings (2b).Remove the gasket.

1. Undo front bolts (1a) and nuts (1b) securing the gearlever mount.2. Recover the shims.3. Loosen the rear bolts fixing the gear lever support.4. Lower the gear lever mount as far as necessary.

1. Support the front suspension crossmember using a hydraulic jack (1a) fitted with a suitable flange (1b).2. Undo the bolts fixing the steering box to the front suspension crossmember.3. Undo the rear bolts fixing the front suspension crossmember to the bodyshell.4. Undo the bolts fixing the front suspension crossmember to the bodyshell.

1. Undo the bolt (1a) and release the power steering system pipe mounting bracket (1b) from the front suspension crossmember.

1. Lower the hydraulic jack slowly and remove the front suspension crossmember (1a) complete with lower track control arms (1b) and anti-roll bar (1c).

1. Undo the drain plugs and drain the transmission fluid completely.

Collect the transmission fluid in a suitable container.

1. Undo the bolts (1a) and remove the intermediate driveshaft (1b).2. Remove the dust cover.

1. Undo the bolts (1a) and remove the flywheel guard (1b).2. Undo the bolts fixing the manual gearbox-differential unit to the crankcase sump.3. Loosen the nut fixing the gearbox-differential unit to the engine block.

1. Unscrew the bolt securing the power unit rigid mount to the flexible block.2. Undo the bolts (2a) and remove the power unit gearbox side rigid support (2b).

1. Position the tool (1a) for supporting the gearbox and secure it using the bolts (1b) to the openings in the gearbox and using the bolt (1c) to the gearbox bracket (1d).

	Description	Code
1a	Support	1.870.826.000

2. Position a hydraulic jack underneath the tool supporting the gearbox.

1. Undo the remaining fastenings securing the manual gearbox and differential to the engine.2. Retract the hydraulic jack and remove the manual gearbox and differential from its housing.

Check that the gearbox is properly balanced on the hydraulic jack.

Proceed with the removal Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED.

Refitting ( Removing

) Proceed with the refitting Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED.1. Lift up the tapered seal (1a) for the thrust bearing until the spring (1b) is covered.2. Fit the thrust bearing (2a) on the main shaft and match it with the fork pin (2b).

Place the manual gearbox and differential back in its housing using the hydraulic jack and support tool and secure it to the engine block using the lower bolt without tightening it.Remove the tool supporting the manual gearbox and differential and the hydraulic jack.

	Description	Code
-	Support	1.870.826.000

1. Place the power unit gearbox side rigid support (1a) in its housing and secure it to the gearbox tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Manual gearbox/differential side) 4.5 - 5.5

2. Tighten the bolt securing the power unit gearbox side rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

Tighten the bolts and the nut fixing the gearbox-differential unit to the engine block to the recommended torque.

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

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

Tighten the bolts fixing the manual gearbox-differential unit to the crankcase sump to the specified torque.

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

Use the clutch lever to engage the thrust bearing in the clutch.Place the flywheel guard in its housing and secure it using the bolts.1. Refit the intermediate driveshaft (1a) complete with dust cover (1b) in its housing and secure it tightening the bolts (1c) to the recommended torque.

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

1. Clean the gearbox-differential fluid drain plugs (1a) and (1b) and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Drain plug	GEAR CASING PADS	M18	(Differential side) 1.6 - 2.6

	Fastening	Component	Ø	Value(daNm)
1b	Drain plug	GEAR CASING PADS	M22	(Manual gearbox/differential union mount side) 3.0 ÷4.8

Place the front suspension crossmember back in its housing complete with lower track control arms and anti-roll bar using a hydraulic jack fitted with a suitable support tool.1. Tighten the side bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 - 13.2

2. Tighten the rear bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 - 13.2

	Fastening	Component	Ø	Value(daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 - 9.9

3. Tighten the bolts fixing the power steering box to the rear suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.7 - 14.3

Remove the hydraulic jack fitted with a suitable support tool from the front suspension crossmember.

Secure the power assisted steering system pipes mounting bracket to the front suspension crossmember and tighten the bolt.Place the manual gearbox control lever support back in its housing and secure it using the bolts and nuts.1. Place the catalytic converter (1a) back in its housing complete with gasket and secure it to the flexible mountings (1b).2. Tighten the bolts fixing the catalytic converter to the exhaust pipe rigid pipe to the recommended torque .

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CATALYTIC CONVERTER (ONE)	M8	(Rigid pipe side) 2.3 - 2.8

1. Place the power unit rigid rear support (1a) in its housing and secure it to the differential tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	RIGID REAR SUPPORT POWER UNIT	M12	(Manual gearbox/differential side) 6.8 - 8.3

2. Tighten the nut securing the power unit side rigid rear support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

1. Connect the front suspension anti-roll bar joints (1a) to the front shock absorber forks and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	(front shock absorber fork side) 4.1 ÷ 5.0

1. Connect the front suspension lower wishbones to the struts and secure by tightening the nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	LOWER FRONT TRACK CONTROL ARMS	M14	(Strut side) 8.1 - 9.9

2. Tighten the bolts securing the front shock absorber forks to the lower wishbones.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Lower wishbone side) 10.8 ÷ 13.2

Tighten the collars securing the driveshaft gaiters to the intermediate driveshaft/inner differential driveshaft.Proceed with the refitting Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R..Proceed with the refitting Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R.Proceed with the refitting Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the refitting Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the refitting Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Remove the tools used for supporting the power unit safely.

	Description	Code
-	Crossmember	1.820.581.000

	Description	Code
-	Support mountings	1.870.650.000

	Description	Code
-	Crossmember	1.860.851.003

	Description	Code
-	Vertical support	1.870.748.000

Refit the front bonnet catch and secure with nuts.Place the mounting bracket in position complete with gear selection and engagement cables.Connect the gear selector and engagement cables.1. Connect the electrical connection to the reversing light switch.2. Place the clutch operating cylinder (2a) in position on the support and secure it using ghe seal (2b).3. Connect the pipe from the vibration damper to the operating cylinder (3a), operating cylinder side and tighten the connector (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	-	-	-	-

Proceed with the refitting Op. 5520B10 STARTER MOTOR - R+R.Proceed with the refitting Op. 1076B70 EXHAUST PIPE BETWEEN PRE-CATALYTIC CONVERTER AND CATALYTIC CONVERTER - R R.Connect the electrical connection to the water in the fuel filter sensor, then place the fuel filter back in its housing and secure it using the nuts.Connect the electrical connection to the fuel preheating device.Connect the electrical connection to the fuel temperature sensor.Connect the rapid connector for the fuel supply pipe to the pressure pump, fuel filter side.Connect the rapid connector for the fuel return pipe to the fuel return manifold pipe, fuel filter side.Connect the rapid connector for the front fuel supply pipe, fuel filter side.Place the upper heat shield in its housing, then secure it using the nuts.Place the lower exhaust pipe heat shield in its housing and secure it using the bolts.Connect the earth lead to the power unit gearbox side rigid support and tighten the nut.Place the air supply hose between the turbocharger and the heat exchanger in position and tighten the bands.Proceed with the refitting Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.Proceed with the refitting Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR.Proceed with the refitting Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting Op. 5530B10 BATTERY - R+R.Proceed with the refitting Op. 1088D24 RIGID PIPE FOR COOLANT INLET TO WATER PUMP - R + R.Refill the engine cooling system Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Refit the manual gearbox with differential Op. 0010T40 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with refitting - 1016A10 SOUNDPROOFING COVER - R&R. .Remove the vehicle from the lift.