125001249 - 2110C34 SPACER AND REAR COVER - R + R WITH GEARBOX REMOVED

Removing ( Refitting ) 1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).

Two operators are needed for this operation.

	Name	Country
1b	Mount	1.820.146.000

2. Undo the bolts (2a) and remove the rear cover (2b). Engage 5^thspeed pressing the selector fork on the main shaft.Engage any gear using the gear selector/engagement lever.

The simultaneous engagement of two gears will cause the gearbox shafts to lock.

1. Undo the 5^thspeed selector fork bolt.2. Remove the staking and loosen the ring nuts for the main and layshafts.Position the selector fork for 5^thspeed in neutral.

Positioning the selector fork for 5 th speed in neutral is necessary to prevent the synchronizer rollers from being lost.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5^thspeed driven gear.3. Remove the roller and spring retaining flange for the 5^thspeed synchronizer.4. Remove the 5^thspeed selector fork.5. Remove the 5^thspeed sliding sleeve.6. Remove the springs (6a) and rollers (6b) for the 5^thspeed hub.7. Remove the hub for the 5^thspeed sliding sleeve.8. Remove the 5^thspeed synchronizer ring.9. Remove the 5^thspeed drive gear.10. Remove the needle bearing for the 5^thspeed drive gear.11. Remove the 5^thspeed drive gear bush.12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings. Refitting ( Removing ) Apply Loctite 573 sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.Fit the main and layshaft rear bearing retaining plate and secure by tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER SPACER	M8	(Gearbox casing side) 2.1 ÷ 2.6

1. Fit the 5^thspeed drive gear bush.2. Fit the needle bearing for the 5^thspeed drive gear.3. Fit the 5^thspeed drive gear.4. Fit the 5^thspeed synchronizer gear.5. Fit the 5^thspeed sliding sleeve hub.6. Fit the 5^thspeed sliding sleeve.7. Fit the springs (7a) and the rollers (7b) for the 5^thspeed sliding sleeve hub.

To avoid losing the synchronizer springs and rollers, place the sliding sleeve in neutral.

8. Fit the 5^thspeed selector fork.9. Fit the 5^thspeed synchronizer springs and rollers retaining flange.10. Fit the 5^thspeed driven gear.11. Tighten the new main shaft and layshaft ring nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	10.0 ÷ 12.4

12. Tighten the 5^thspeed selector fork bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	5TH SPEED SELECTOR FORK	M6	1.5 ÷ 1.9

Apply Loctite 573 sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.1. Fit the rear cover (1a) and secure by tightening the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX REAR COVER	M8	2.1 ÷ 2.6

Undo the fixings and remove the gearbox and differential from the tool.

Two operators are needed for this operation.

	Name	Country
-	Mount	1.820.146.000

Remove the tool supporting the overhaul stand and put it back.