125001285 - 2127C40 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH - R R (Smart gearbox)

Removing ( Refitting )

Do not reuse the fluid from the gear selection electro-hydraulic system circuit.

  • Disconnect the electrical connection for the hydraulic gear activation unit wiring.
DescriptionConnector
1Gearbox sensor coupling See D79 TRANSMISSION SENSOR JUNCTION
1. Loosen the band and disconnect the pipe from the electro-hydraulic selection activation hydraulic unit to the fluid reservoir, hydraulic unit side.2. Undo the connector (2a) and disconnect the pipe from the pump to the gearbox electro-hydraulic selection actuator hydraulic unit (2b), hydraulic unit side.
Collect the fluid from the circuit that comes out and should not be reused.
3. Disconnect the electrical connection from the gearbox output speed sensor.
DescriptionConnector
3Gearbox output speed sensor See K77 TRANSMISSION OUTPUT SPEED SENSOR
4. Disconnect the electrical connection from the reversing light switch.
DescriptionConnector
4Reversing lights switch See I20 REVERSING LIGHTS SWITCH

  • Release the clutch push rod cover.
  • Undo the locknut (2a) and fully tighten the clutch push rod (2b).
  • Retract the clutch push rod and insert the tool.
DescriptionCode
3Pin1.870.753.002
1. Remove the plug (1a) and fit the tool (1b) in the upper part of the gearbox control shaft housing to lock the selection linkage inside the hydraulic actuator unit.
The tool should be fully tightened and should not be removed in order to allow the hydraulic unit to be correctly fitted.
DescriptionCode
1bPin1.870.753.001
Undo the bolt shown (M6 x 110) fixing the electro-hydraulic gear selection hydraulic implementation unit and clutch.

  • Loosen the bolt securing the gearbox side power unit rigid support to the flexible mounting as necessary.

  • Remove the hydraulic jack.
This operation is necessary to unscrew the bolt fixing the hydraulic actuator unit to the gearbox control shaft.

  • Loosen the cap.
  • Undo the bolt (M8 x 16) fixing the hydraulic actuator unit to the gearbox control shaft.
The above bolt is the pre-treated type and it therefore cannot be reused when refitting.

  • Undo the remaining bolts (1a) (M6 x 110) and (1b) (M8 x 30) fixing the electro-hydraulic gear selection hydraulic implementation unit and clutch.
These bolts are the pre-treated type and therefore cannot be reused when refitting.

  • Remove the electro-hydraulic gear and clutch selection hydraulic actuator unit and the seal.
Refitting ( Removing )
All the procedures described below and, in particular, the fitting sequence for the hydraulic unit and the fastening of the gearbox control shaft bolt to the hydraulic actuator unit could adversely affect the correct operation of the system if they are not carried out properly.
Before fitting the hydraulic actuator unit on the gearbox, clean any impurities from the thread of the gearbox shaft and/or in the hydraulic actuator housing (by blowing).
Clean the threaded seat for the bolt fixing the gearbox control shaft to the hydraulic actuator unit making sure that there are shavings, grease, oil, lubricants, etc. whatsoever to ensure that the threaded seat is "dry" (this condition is vital to guarantee the non-slip effect of the bolt).

  • Check manually that the gearbox shaft slides freely in its housing and that there is grease at the end of the actual shaft; if necessary, renew it.
  • FITTING A NEW HYDRAULIC UNIT
1. Undo the cap (1a) on the new unit supplied by the Parts Dept. and make sure that the seal (1b) is present.2. Place the hydraulic unit back in its housing.
Make sure that the hydraulic actuator unit is in contact with the gearbox.
3. Undo the cap (3a) and remove the spacer pipe (3b) fitted by the Parts Dept. to lock the selection linkage inside the hydraulic unit during transit.
This operation should only be carried out after the hydraulic actuator unit has been fitted on the gearbox.
4. Fit the tool in place of the spacer pipe removed and tighten it fully.
DescriptionCode
4Pin1.870.753.001

  • FITTING THE HYDRAULIC UNIT REMOVED

  • Fit the seal checking that it is intact; if the same hydraulic unit is being refitted on a new gearbox, use the seal that was removed and not the one on the new gearbox.
  • Place the hydraulic actuator unit (2a) in position already complete with the tool (2b).
Make sure that the hydraulic actuator unit is in contact with the gearbox.

  • Proceed as described below for both the fitting of a new hydraulic unit and for refitting the same hydraulic unit as was removed.

  • Fit the new bolts (1a) (M6 x 110) and (1b) (M8 x 30) and tighten fully by hand.
1. Tighten a new bolt (M8 x 16) (n° 46545861) fixing the gearbox control shaft to the hydraulic actuator unit and tighten it to the recommended torque.
Always use a new bolt checking that the special treatment is present on the thread.
The bolt should be tightened in a single operation.
FasteningComponentØ  Value (daNm)
1BoltHYDRAULIC ACTUATOR UNITM8(Gearbox control shaft side) 2.7 - 3.3, daNm
2. Tighten the cap to the recommended torque.
FasteningComponentØ  Value (daNm)
2PlugCAP FOR BOLT SECURING GEARBOX CONTROL SHAFT TO HYDRAULIC ACTUATOR UNIT(Hydraulic actuator unit side) 1.3 - 1.7, daNm
1. Fit the new bolt (M6 x 110) tightening it fully by hand.2. Remove the tool
DescriptionCode
2Pin1.870.753.001
3. Fit the cap and tighten to the specified torque.
FasteningComponentØ  Value (daNm)
3PlugCAP FOR TOOL LOCKING HYDRAULIC UNIT SELECTION LINKAGE(Hydraulic actuator unit side) 5.0 - 6.0, daNm
Do not refit the spacer used for the transportation of the new hydraulic unit because it would impede its operation.

  • Tighten the bolts tightened previously (M6 x 110) and (M8 x 30) to the recommended torque.
FasteningComponentØ  Value (daNm)
-BoltHYDRAULIC ACTUATOR UNITM6(Gearbox side) 1.3 - 1.7, daNm
FasteningComponentØ  Value (daNm)
-BoltHYDRAULIC ACTUATOR UNITM8(Gearbox side) 1.3 - 1.7, daNm

  • Apply Tutela MRM2 grease to the clutch lever in the push rod housing.
1. Adjut the clutch control push rod (1a), zero the clearances by placing the push rod in contact with the lever (1b) and turn through three further revolutions towards the lever.2. Tighten the locknut the recommended torque.
FasteningComponentØ  Value (daNm)
2NutCLUTCH CONTROL PUSH ROD LOCKNUT0.5 - 0.7, daNm
3. Remove the tool (3a) locking the clutch control push rod travel and fit the cover (3b).
DescriptionCode
3aPin1.870.753.002

  • Tighten the bolt securing the power unit gearbox side rigid support to the flexible mounting to the recommended torque.
FasteningComponentØ  Value (daNm)
-BoltGEARBOX SIDE RIGID SUPPORT FOR POWER UNITM104.0 - 5.0, daNm
1. Connect the electrical connection to the reversing light switch.2. Connect the electrical connection to the gearbox output speed sensor.3. Connect the pipe from the electro-hydraulic selection gearbox hydraulic actuation unit (3a), hydraulic unit side and tighten the connector (3b) to the recommended torque.
Take care to prevent any impurities from entering the hydraulic circuit.
FasteningComponentØ  Value (daNm)
3bConnectorPIPE FROM PUMP/ACTUATOR UNIT(Actuator unit side) 1.8 - 2.2, daNm
4. Connect the pipe from the electro-hydraulic selection activation hydraulic unit to the fluid reservoir, hydraulic unit side.
Take care to prevent any impurities from entering the hydraulic circuit.

This operation is carried out with the bleed screw open which should be closed when the operation is completed.