125001236 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting ) Position the vehicle on a lift.Proceed with the removal 5530B10 BATTERIA - S.R..Proceed with the removal 5530B52 SUPPORTO/CESTELLO batteria - S.R..1. Disconnect the earth lead from the power unit gearbox side rigid support.

	Description	Connector
1	Earth on engine	C40A

2. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
2	Reversing lights switch	I20

1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	K41

Release the electrical wiring for the air flow meter from the fastening on the air intake hose.2. Disconnect the oil vapour recirculation pipe from the air intake hose.3. Disconnect the air intake hose from the throttle casing.

• Remove the air filter assembly and intake hose complete with air flow meter after having released it from the resonator unit.

1. Move the rubber protection aside to access the coupling for the clutch hydraulic actuator pipe.2. Completely release the flexible clip retaining the pipe to the actuator body.3. Disconnect the flexible pipe from the vibration damper to the clutch hydraulic actuator, hydraulic actuator side.

Collect the clutch fluid that comes out in a suitable container, then seal the pipe and place it at the side.

4. Undo the nuts and move the clutch hydraulic circuit vibration damper complete with pipe sideways. 1. Disconnect the gear selector and engagement cables.

To disconnect the gear selection cable, press the release tabs shown in the figure and withdraw the cable.

2. Remove the retaining plates (2a) and release the gear selector and engagement cables rom the mounting bracket (2b).

• Undo the nuts (1a) and move front bonnet catch (1b) aside without disconnecting the bonnet opening cable.

• Fit two brackes to the engine to support the power unit safely as shown in the figure.

1. Fit the tool (1a) complete with support mountings (1b).

	Description	Code
1a	Crossmember	1.820.581.000

	Description	Code
1b	Support mountings	1.870.650.000

2. Fit the tools (2a) and (2b), then connect them to the brackets fitted previously using the links (2c).

	Description	Code
2a	Crossmember	1.860.851.003

	Description	Code
2b	Vertical support	1.870.748.000

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

•     Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R
•     Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R
•     Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R.
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD ON BULKHEAD - R+R

• Undo the bolts fixing the driveshafts to the internal differntial driveshaft/intermediate driveshaft.

• Undo the nuts securing the front suspension lower wishbones to the struts.
• Loosen the bolts securing the front shock absorber forks to the lower wishbones.
• Use the tool to disconnect the front suspension lower wishbones from the struts.

	Description	Code
3	Extractor	1.821.169.000

• Undo the nuts (1a) and disconnect the front suspension stabiliser bar (1b) from the front shock absorber forks.

•     Op. 1080B40 CATALYTIC PRE-CONVERTER - R R

• Undo the bolt (1a) and the nut (1b) and remove the reinforcement rod (1c).
• Undo the bolts fixing the power unit rigid rear support flexible mounting to the front suspension crossmember.
• Undo the bolts (3a) and the nut (3b), then remove the power unit rigid rear support (3c) complete with flexible mounting (3d).

• Undo front bolts (1a) and nuts (1b) securing the gearlever mount.
• Keep the shims.
• Loosen the rear bolts fixing the gear lever support.
• Lower the gearlever mount at the front as far as necessary.

• Position a hydraulic jack (1a) equipped with device (1b) to support the front suspension crossmember.

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

• Undo the bolt (1a) and release the power steering system pipe mounting bracket (1b) from the front suspension crossmember.

• Lower the hydraulic jack slowly and remove the front suspension crossmember (1a) complete with lower track control arms (1b) and anti-roll bar (1c).

• Undo the drain plug and drain the transmission fluid.

Collect the transmission fluid in a suitable container.

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

• Undo the bolts (1a) and move the starter motor (1b) away from the gearbox, then secure it.

• Undo the bolts (1a) and remove the flywheel guard (1b).
• Undo the bolts fixing the manual gearbox-differential unit to the crankcase sump.
• Loosen the bolt fixing the manual gearbox and differential unit to the engine block.

• Undo the two bolts fixing the gearbox casing to the engine support.
• Fit the tool (2a) on a hydraulic jack and secure it using the bolts removed previously and using bolt (2b).

	Description	Code
2a	Support	1.860.859.002

• Undo the bolts fixing the power unit gearbox side rigid support flexible mounting to the bodyshell.
• Undo the bolts (2a) and (2b), then remove the power unit gearbox side rigid support (2c) complete with flexible mounting (2d).

• Completely undo the bolt loosened previously fixing the manual gearbox-differential unit to the engine block.

• Lower the hydraulic jack and remove the manual gearbox and differential.

Refitting ( Removing )

• Place the manual gearbox and differential back in its housing using the hydraulic jack and support tool and secure it to the engine block using the lower bolt without tightening it.

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

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	GEARBOX SIDE RIGID SUPPORT FOR POWER UNIT	M10	(Manual gearbox/differential side) 4.5 - 5.5

	Fastening	Component	Ø	Value (daNm)
1d	Bolt	GEARBOX SIDE RIGID SUPPORT FOR POWER UNIT	M10	(Manual gearbox/differential side) 4.5 - 5.5

2. Tighten the bolts fixing the power unit gearbox side rigid support flexible mounting to the bodyshell.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(Bodyshell side) 3.2 - 3.9

• Unscrew the bolts and separate the support tool from the manual gearbox and differential, then replace after withdrawing from the hydraulic jack.

	Description	Code
-	Support	1.860.859.002

• Tighten the bolts fixing the gearbox casing to the engine support to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1	Bolt	GEARBOX GEAR CASING	M8	(Manual gearbox-differential to engine support side) 2.3 - 2.8

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 sump side) 5.0 - 6.0

• Place the flywheel guard in its housing and secure it using the bolts.

• 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

• 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		(Mount side)

• 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

• Use the hydraulic jack fitted with a support tool to replace the front suspension crossmember complete with lower wishbones and stabiliser bar.

• Tighten the side bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 - 13.2

2. Tighten the rear bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 - 13.2

	Fastening	Component	Ø	Value (daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 7.2 - 8.8

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

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

• Remove the hydraulic jack with support tool from the front suspension crossmember.
• Refit the power steering system pipe mounting bracket and secure to the front suspension crossmember using the bolt.
• Place the manual gearbox control lever support back in its housing and secure it using the bolts and nuts.

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

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

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

	Fastening	Component	Ø	Value (daNm)
1e	Nut	POWER UNIT REAR RIGID MOUNT	M12	(Gearbox side) 7.2 - 8.3

2. Tighten the bolts fixing the power unit rigid rear support flexible mounting to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	POWER UNIT INTERM. SUPPORT FLEXIBLE MOUNTING	M8	(Front suspension crossmember side) 3.2 - 3.9

3. Place the reinforcement rod (3a) in its housing and secure it by tightening the bolt (3b) and the nut (3c) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
3b	Bolt	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT LINK	M12	(Power unit rear rigid mount side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value (daNm)
3c	Nut	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT LINK	M8	(Engine crankcase side) 2.4

•     Op. 1080B40 CATALYTIC PRE-CONVERTER - R R

• Connect the front suspension stabiliser bar joints (1a) to the front shock absorber forks and secure by tightening nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value (daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M8	(front shock absorber fork side) 4.1 ÷ 5.0

1. Connect the front suspension lower wishbones to the struts and secure by tightening the nuts to the specified torque.

	Fastening	Component	Ø	Value (daNm)
1	Nut	LOWER FRONT TRACK CONTROL ARMS	M14	(Strut side) 8.6 - 9.5

2. Tighten the bolts securing the front shock absorber forks to the lower wishbones to the specified torque.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	FRONT SHOCK ABSORBER FORK TO WISHBONE	M12	(Lower wishbone side) 10.8 ÷ 13.2

• Tighten the bolts fixing the driveshafts to the internal differential driveshaft/intermediate driveshaft to the specified torque.

	Fastening	Component	Ø	Value (daNm)
1	Bolt	DRIVESHAFT	M8	(Internal differential driveshaft/intermediate driveshaft side) 3.5 ÷ 4.3

•     Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD ON BULKHEAD - R+R
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R.
•     Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R
•     Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R

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

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

• Remove the tools used for supporting the power unit safely.

	Description	Code
-	Crossmember	1.860.851.003

	Description	Code
-	Vertical support	1.870.748.000

	Description	Code
-	Crossmember	1.820.581.000

	Description	Code
-	Support mountings	1.870.650.000

• Refit the front bonnet catch and secure with nuts.
• Connect the gear selection and engagement cables and secure to the mounting bracket with the retaining plates.
• Place the clutch hydraulic circuit vibration damper in its housing and secure it using the nuts.

1. Position the flexible clip as illustrated, i.e. not fully fitted.

Make sure that the housing in the hydraulic actuator for the O-ring and the connector on the pipe is thoroughly clean and in good condition.Lubricate the O ring with brake fluid, if necessary, to facilitate the fitting of the pipe.Do not use detergents or mineral lubricants that are not compatible with the materials for the brake fluid.

2. Fully introduce the flexible pipe from the vibration damper to the clutch hydraulic actuator into the clutch hydraulic actuator.

• Insert the flexible clip completely to lock the pipe.
• Place the rubber protection back in its housing.

• Place the air filter assembly and intake hose complete with air flow meter in position and connect it to the resonator unit.
• Connect the air intake hose to the throttle casing.
• Connect the oil vapour recirculation pipe to the air intake hose.
• Connect the electrical connection to the air flow meter and secure the electrical wiring to the air intake hose using the band.
• Connect the electrical connection to the reversing light switch.
• Connect the earth lead to the power unit gearbox side rigid support.
•     Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R.
•     Op. 5530B10 BATTERY - R+R
•     Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY
•     Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR
• Remove the vehicle from the lift.