125000867 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD

Removing ( Refitting )

• Work with the power unit positioned on a suitable support with a hydraulic hoist for support as a safety measure.

• Undo the drain plug and drain the transmission fluid.

Collect the transmission fluid in a suitable container.

• Undo the bolt (1a) and the nut (1b) and remove the reinforcement rod (1c).
• Undo the bolts (2a) and the nut (2b) and remove the power unit rigid rear support (2c).

• Undo the bolts (1a) and remove the intermediate driveshaft (1b).
• Remove the dust cover.

• Open the cover (1a), loosen the nuts (1b) and (1c) and disconnect the electrical connections (1d) from the starter motor.

	Description	Connector
1d	Starter motor	See A020 Starter motor

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

• Undo the bolts fixing the manual gearbox-differential unit to the crankcase sump.
• Undo the lower bolt fixing the manual gearbox and differential unit to the engine block.

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

• Separate the manual gearbox-differential unit from the engine.

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.161.001

2. Undo the bolts (2a) and remove the cluth tray (2b) and the clutch plate (2c). Refitting ( Removing ) 1. Place the clutch plate (1a) and the clutch tray (1b) in their housing using the tool (1c) for centering.

	Description	Code
1c	Centering	1.870.447.001

2. Tighten the bolts securing the clutch tray to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.5 - 3.1

3. Remove the flywheel lock.

	Description	Code
3	Counter-torque	1.860.161.001

• Place the manual gearbox and differential back in its housing.

• Tighten the upper bolts fixing the gearbox-differential unit to the engine block to the recommended torque.

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

1. Tighten the lower bolt fixing the gearbox-differential unit to the engine block to the recommended torque.

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

2. Tighten the bolts fixing the manual gearbox-differential unit to the crankcase sump to the specified torque.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M10	(Engine crankcase side) 5.0 - 6.0

• 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 ASSEMBLY	M8	(Gearbox side) 2.4 - 3.0

• Connect the starter motor electrical connections and secure them using the nuts, then close the cover.

• Refit the intermediate driveshaft (1a) complete with dust cover (1b) in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	FRONT INTERMEDIATE DRIVESHAFT	M8	(Mount side) 2.3 - 2.8

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

	Fastening	Component	Ø	Value (daNm)
1b	Bolt	POWER UNIT REAR RIGID MOUNT	M12	(Gearbox side) 6.8 - 8.3

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

	Fastening	Component	Ø	Value (daNm)
1d	Nut	POWER UNIT REAR RIGID MOUNT	M12	(Gearbox side) 7.2 - 8.8

2. Place the reinforcement rod (2a) in its housing and secure it by tightening the bolt (2b) and the nut (2c) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2b	Bolt	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD	M12	(Power unit rigid rear support side) 6.8 - 8.3

	Fastening	Component	Ø	Value (daNm)
2c	Nut	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD	M12	(Engine crankcase side) 2.7 - 3.4

• Tighten the manual gearbox and differential oil drain plug to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1	Plug	GEAR CASING PADS	M22	2.9 ÷ 4.3

• When the refitting of the power unit is complete:
•     Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY