2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD - Alfa - GT - eLearn

125001254 - 2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD

) 1. Release the gearbox and differential (1a) from the hydraulic jack (1b) and the tool (1c) used for removing-refitting it from the vehicle.

	Name	Country
1c	Supports	1.820.623.000

1. Undo the bolts (1a) and remove the coaxial clutch operating cylinder (1b).

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 bolt (2a) and remove the speedometer idler gear (2b).3. Undo the bolts (3a) and remove the rear cover (3b).

1. Undo the bolts (1a) and remove the gear selector/engagement mounting bracket (1b).1. Remove the left internal differential driveshaft (2a) using tools (2b) and (2c).

	Name	Country
2b	Flange	1.820.229.000

	Name	Country
2c	Counter weight	1.821.161.000

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.Place 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 bush for the 5^thspeed drive gear.12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.

1. Remove the main and layshaft rear bearing circlips.

Undo the Reverse shaft fixing bolt.Undo the bolts and remove the differential flange complete with oil seals, O-Rings and scraper ring.1. Undo the bolts fixing the gearbox casing to the bell housing.2. Position the gear selector/engagement lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.

1. Remove the differential internal housing.

Refitting ( Removing

) Fit the differential internal housingPosition all the gear selector forks in neutral.Apply sealant to the contact surfaces between the bell housing and the gearbox casing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the gearbox casing on the bell housing.

Keep the gear selector/engagement lever upwards and check that the gear selector engages with the 3 ^rd - 4 ^th speed selector fork.

Tighten the bolts for the gearbox casing to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	2.1 - 2.6

Tighten the reverse shaft bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REVERSE IDLER	M8	2.9 - 3.6

Fit the main and layshaft rear bearing circlips.

To facilitate the fitting of the circlips, place them with their openings at the front.

Apply sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the main and layshaft rear bearing retaining plate and fix it tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	Main and layshaft rear bearing retaining plate....	M8	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 ring nuts for the main and layshafts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Ring nut	GEAR SHAFTS	M20	10 - 12.4

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	5thª speed selector fork	M6	1.5 - 1.9

Apply sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

1. Fit the rear cover (1a) and fix it tightening the bolts (1b) to torque.

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

2. Fit the speedometer idler gear (2a) and fix it using the bolt (2b).

Place the gearbox side differential flange complete with a new oil seal back in its housing and secure it using the bolts.1. Position the tool, complete with dial gauge, on the surface of the engine side differential and zero the dial gauge with a pre-loading of 1 mm.

	Name	Country
1	Dial gauge mounting	1.820.085.000

1. Position the tool (1a), complete with dial gauge, on the differential flange, engine side (1b) and measure the difference.

	Name	Country
1	Dial gauge mounting	1.820.085.000

Calculate the size of the adjustment shim for pre-loading the differential bearings adding 0.12 mm to the difference measured.

0.12 corresponds to the interference for bedding in and the pre-loading of the differential bearings.

1. Place in the housing the adjustment shim or shims for pre-loading the differential bearings, of the size calculated or the next size up.Place the differential flange complete with new oil seal back in its housing and secure it using the bolts.

Fit the gear selector/engagement mounting bracket and fix it using the bolts.Fit the left differential internal driveshaft.Fit the coaxial clutch operating cylinder and secure using the bolts.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.Position the gearbox and differential on the tool used for the removing-refitting from the vehicle.

	Name	Country
-	Supports	1.820.623.000