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 the removal Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.Proceed with the removal Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R..Proceed with the removal Op. 5530B10 BATTERY - R+R.Proceed with the removal Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..1. Remove retainer (1a), press clips (1b) and disconnect the gear engagement cable (1c).2. Press the clips (2a) and disconnect the gear selector cable (2b).3. Unscrew bolts (3a) and move aside bracket (3b) complete with gear selection and engagement cables.

1. Move the protective cover away.2. Remove the cap from the bleed valve.3. Connect the recovery device (pipe and reservoir) to the bleed valve on the clutch hydraulic actuator.4. Raise the retaining clip (4a) until the first click is heard and remove pipe (4b) by a sufficient amount to uncover the bleed hole.Leave the hydraulic clutch system to drain completely.Lift up the spring completely and disconnect the pipe from the hydraulic clutch control actuator.

Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.1. Undo the plug and drain the gearbox transmission fluid.

Collect the transmission fluid in a suitable container.

1. Undo the nut (1a) and disconnect the earth lead (1b).

	Description	Connector
1b	Battery earth	See C1 BATTERY EARTH

2. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
2	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH

Undo both upper starter motor bolts.Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the removal Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with the removal Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY.Proceed with the removal Op. 5040A26 COMPRESSOR MOUNT - R R.Proceed with the removal Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R.Proceed with the removal Op. 1080B62 CATALYTIC CONVERTER - R + R.1. Fit the tool to support the power unit in safety to the crankcase as shown in the figure.

	Description	Code
1	Support	1.860.625.000

1. Fit an appropriate bracket to support the power unit on the intake manifold in safety.

Fit the tool complete with mountings support blocks.

	Description	Code
-	Crossmember	1.820.581.000

	Description	Code
-	Support mountings	1.870.650.000

Fit the tools and connect them to the brackets fitted previously using links.

	Description	Code
-	Crossmember	1.860.851.003

	Description	Code
-	Vertical support	1.870.748.000

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

1. Undo the bolts (1a) and disconnect the flanges for the driveshaft constant velocity joints (1b).Remove the safety plates.

1. Undo the bolt fixing the rigid pipe mounting collar for the exhaust pipe between the catalytic converter and the silencer to the bracket.2. Loosen the collar (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b).3. Remove the seal.

1. Undo the bolt (1a) and the nut (1b) and remove the exhaust pipe mounting (1c).

1. Undo the bolts (1a) and remove the heat shield (1b).2. Undo the nuts (2a) and remove the flexible mounting heat shield (2b).

1. Undo the bolt (1a) and the nut (1b) and remove the reinforcement link (1c).

1. Undo the bolts (1a) and remove the rigid power unit rear support (1b).

1. Undo the bolts (1a) and remove the flexible mounting for the power unit rear support (1b).

1. Undo the front gearlever mounting bolts.2. Remove the shims.3. Loosen the rear bolts (3a) and unscrew the remaining gearlever mounting bolts (3b).

1. Undo the remaining bolt (1a) and remove the starter motor (1b).

1. Support the front suspension crossmember using a hydraulic jack with a mount.

1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b).

Loosen the bolts securing the front anti-roll bar to the front suspension crossmember.1. Unscrew the power steering box bolts from the front suspension crossmember.2. Undo the bolts securing the lower wishbones to the forks.3. Unscrew the bolts securing the lower wishbones to the front suspension crossmember.

1. Undo the remaining rear bolts fixing the front suspension crossmember to the bodyshell.2. Undo the bolts fixing the front suspension crossmember to the bodyshell.

1. Lower the hydraulic jack and remove the front suspension crossmember complete with stabiliser bar.

1. Undo the bolts (1a) and remove the intermediate driveshaft (1b) from the differential.

1. Fit tool (1a) on a hydraulic jack (1b) and secure it to the gearbox with bolts (1c).

	Description	Code
1a	Support	1.860.859.000

1. Unscrew the bolt securing the gearbox end power unit rigid mount to the flexible block.2. Undo the bolts fixing the rigid power unit support, gearbox side to the gearbox.3. Remove the gearbox side rigid power unit support.

1. Undo the remaining bolts fixing the manual gearbox and differential unit.

1. Remove the gearbox by moving it away firstly from the engine and then lowering it using the hydraulic jack.

Refitting ( Removing

) Place the gearbox and differential back in its housing using the hydraulic jack and the support tool.1. Tighten gearbox bolts (1a) and (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M12	(Engine crankcase side) 7.2 - 8.8

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M10	(Crankcase sump side) 5.0 - 6.1

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

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

Unscrew the bolts and separate the support tool from the gearbox, then replace after withdrawing from the hydraulic jack.

	Description	Code
-	Support	1.860.859.000

1. Place the intermediate driveshaft (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

Refit the front suspension beam with stabiliser bar using the hydraulic jack.1. Tighten the front suspension crossmember side screws to the body to the specified torque.

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

2. Tighten the bolts (2a) and (2b) fixing the front suspension crossmember to the bodyshell to the recommended torque.

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

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

1. Tighten the bolts fixing the lower wishbones to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	LOWER FRONT TRACK CONTROL ARMS	M10	(Front suspension crossmember side) 7.1 - 7.9

2. Tighten the lower wishbone bolts to the forks to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	LOWER FRONT TRACK CONTROL ARMS	M12	(Fork side) 10.8 - 13.2

3. Tighten the bolts fixing the power assisted steering box to the front 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

Tighten the bolts fixing the front stabiliser bar to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT ANTI-ROLL BAR	M8	(Front suspension crossmember side) 3.6 - 4.4

1. Connect joints (1a) to the front stabiliser bara nd secure by tightening nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	(Anti-roll bar side) 4.5 - 5.5

Remove the hydraulic jack and the tool used to support the front suspension crossmember.1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 - 3.0

Tighten the gear lever mount bolts.Refit the shims and tighten the front gear lever mount nuts.1. Place the power unit rear support flexible mounting block (1a) in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 3.2 - 3.9

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

	Fastening	Component	Ø	Value(daNm)
1b	Nut	RIGID REAR SUPPORT POWER UNIT	M12	(Gearbox side) 7.2 - 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID REAR SUPPORT POWER UNIT	M12	(Crankcase sump side) 6.8 - 8.3

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

1. Place the reinforcement rod (1a) in its housing and fasten it tightening the bolt (1b) and the nut (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT REAR RIGID UPPER REINFORCEMENT LINK	M12

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

Place the heat shield for the flexible mounting back in its housing and fasten it using the nuts.Place the heat shield back in its housing and secure it using the bolts.1. Place the exhaust pipe mounting (1a) in its housing and fasten it tightening the bolt (1b) and the nut (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXHAUST PIPE RIGID MOUNT	M8	2.3 ÷ 2.8

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST PIPE RIGID MOUNT	M8

1. Place the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (1a) complete with gasket (1b) back in its housing and secure it to the front exhaust silencer tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID EXHAUST PIPE	M8

2. Tighten the bolt fixing the rigid pipe mounting collar for the exhaust pipe between the catalytic converter and the silencer to the bracket.

1. Connect the driveshaft constant velocity joint flanges and tighten the new bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	DRIVESHAFT COMPLETE WITH JOINTS	M8	(Intermediate driveshaft/differential internal shaft side) 3.6 - 4.4

1. Tighten the upper bolts securing the gearbox to the specified torque.

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

Remove the tools used for supporting the power unit safely.Proceed with the refitting Op. 1080B62 CATALYTIC CONVERTER - R + R.Proceed with the refitting Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R.Proceed with the refitting Op. 5040A26 COMPRESSOR MOUNT - R R.Proceed with the refitting Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY.Proceed with the refitting Op. 4450B04 RIGHT FRONT WHEEL R R.Tighten the remaining starter motor bolts to the specified torque.

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

Connect the electrical connection to the reversing light switch.Connect the battery earth lead and tighten the nut.Refill the gearbox/differential with the specified oil Op. 0010T40 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Fit the pipe fully home in its seat on the hydraulic clutch actuator and secure with the retaining clip.Place the cap in its housing on the bleed valve.Place the protective cover in its housing.Refit the bracket with gear selection and engagement cables and secure with bolts.Connect the gear selector cable.Connect the gear engagement cable and secure with the retainer.Proceed with the refitting Op. 0010T64 BRAKE AND OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY.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. 1048A59 PIPE from flow meter to throttle casing hose - R.R..Proceed with the refitting Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the refitting Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.Remove the vehicle from the lift.