125001237 - 2110A11 MANUAL GEARBOX WITH DIFFERENTIAL - R R FOR VERSIONS WITH HYDRAULIC SELECTION (Smart gearbox)

Removing ( Refitting )

• Position the vehicle on a lift.
•     Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R
•     Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R.
•     Op. 5530B10 BATTERY - R+R
•     Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R.
•     Op. 4450B02 LEFT FRONT WHEEL R R
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 7055B54 UNDER-ENGINE GUARD - R R
•     Op. 2127C40 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH - R R

• 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

3. Disonnect the electrical connection to the electro-hydraulic selection gearbox input shaft speed sensor.

	Description	Connector
3	Gearbox output speed sensor	See K78 TRANSMISSION OUTPUT SPEED SENSOR

• Undo both upper starter motor bolts.
•     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE
•     Op. 4450B04 RIGHT FRONT WHEEL R R
•     Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY
•     Op. 5040A26 COMPRESSOR MOUNT - R R
•     Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R
•     Op. 1080B62 CATALYTIC CONVERTER - R + R

• Fit the tool to support the power unit safely on the crankcase as shown in the figure.

	Description	Code
1	Bracket	1.860.625.000

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

• Fit the tool complete with mountings blocks.

	Description	Code
-	Crossmember	1.820.581.000

	Description	Code
-	Support mountings	1.870.650.000

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

	Description	Code
-	Crossmember	1.860.851.003

	Description	Code
-	Vertical support	1.870.748.000

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

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

The bolts fixing the front driveshafts, intermediate driveshaft/differential internal driveshaft, have been treated with eslok; they should therefore be replaced each time they are removed.

• Remove the safety plates.

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

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

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

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

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

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

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

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

• Undo nuts (1a) and disconnect the front stabiliser bar joints (1b).

• Loosen the bolts securing the front anti-roll bar to the front suspension crossmember.

• Unscrew the power steering box bolts from the front suspension crossmember.
• Undo the bolts securing the lower wishbones to the forks.
• Unscrew the bolts securing the lower wishbones to the front suspension crossmember.

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

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

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

• 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

• Unscrew the bolt securing the gearbox end power unit rigid mount to the flexible block.
• Undo the bolts (2a), (2b) securing the power unit gearbox side rigid support to the gearbox.
• Remove the gearbox side rigid power unit support.

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

• 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.

• Tighten gearbox bolts (1a) and (1b) to the specified torque.

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

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

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

	Fastening	Component	Ø	Value (daNm)
1b	Bolt	GEARBOX SIDE RIGID SUPPORT FOR POWER UNIT	M10	(Gearbox side) 4.5 - 5.5 daNm

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	GEARBOX SIDE RIGID MOUNT	M10	(Gearbox side) 4.5 - 5.5 daNm

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	Bolt	GEARBOX SIDE RIGID MOUNT		(Flexible mounting side)

• 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

• 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	Bolt	INTERMEDIATE DRIVE SHAFT		(Mount side)

• 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	Bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Body side) 10.8 - 13.2 daNm

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	Bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Body side) 10.8 - 13.2 daNm

	Fastening	Component	Ø	Value (daNm)
2b	Bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Body side) 8.1 - 9.9 daNm

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 - 3.9, daNm

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 daNm

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

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

• 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, daNm

• 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	(Stabiliser bar side) 4.5 - 5.5 daNm

• Remove the hydraulic jack and the tool used to support the front suspension crossmember.

• 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 daNm

• Tighten the gear lever mount bolts.
• Refit the shims and tighten the front gear lever mount nuts.

• 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	POWER UNIT INTERM. FLEXIBLE MOUNTING BLOCKS	M8	(Front suspension crossmember side) 3.2 - 3.9 daNm

• 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	Bolt	POWER UNIT REAR RIGID MOUNT	M12	(Gearbox side) 7.2 - 8.0 daNm

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	POWER UNIT REAR RIGID MOUNT	M12	(Engine crankcase side) 6.8 - 8.3 daNm

	Fastening	Component	Ø	Value (daNm)
1d	Bolt	POWER UNIT REAR RIGID MOUNT		(Flexible mounting side)

• 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 SUPPORT REINFORCEMENT LINKS	M12	7.2 - 8.8, daNm

	Fastening	Component	Ø	Value (daNm)
1C	Nut	POWER UNIT REAR RIGID MOUNT REINFORCEMENT LINK

• 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, daNm

	Fastening	Component	Ø	Value (daNm)
1c	Nut	EXHAUST PIPE RIGID MOUNT	M8	2.3 - 2.8, daNm

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	(Front silencer side) 2.3 ÷ 2.8, daNm

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

• 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/inner differential shaft side) 3.6 - 4.4 daNm

• Tighten the upper bolts securing the gearbox to the specified torque

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

• Remove the tools used for supporting the power unit safely.
•     Op. 1080B62 CATALYTIC CONVERTER - R + R
•     Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R
•     Op. 5040A26 COMPRESSOR MOUNT - R R
•     Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY
•     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 daNm

• Connect the electrical connection to the electro-hydraulic selection gearbox input shaft speed sensor.
• Connect the electrical connection to the reversing light switch.
• Connect the battery earth lead and tighten the nut.
•     Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY
•     Op. 2127C40 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH - R R
•     Op. 0010T47 HYDRAULIC SYSTEM FLUID FOR GEARBOX WITH HYDRAULIC SELECTION CHECK LEVEL AND TOP UP IF NECESSARY
•     Op. 0010T48 HYDRAULIC SYSTEM FOR GEARBOX WITH HYDRAULIC SELECTION BLEED AIR
•     Op. 7055B54 UNDER-ENGINE GUARD - R R
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 4450B02 LEFT FRONT WHEEL R R
•     Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R.
•     Op. 5530B10 BATTERY - R+R
•     Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R.
•     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE
•     Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R
• Remove the vehicle from the lift.