2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20 - Alfa - 166 - eLearn

3315390 - 2110B34 4 speed gearbox gears, shafts and bearings - replace following operation 2110b20

- 2110B26 manual gearbox (six speed) with differential - dismantle and rebuild wash and check parts - replace synchronizers and internal parts if necessary . 1. Remove the layshaft front bearing outer race (1a) using the tools (1b) and (1c).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.655.000

	Name	Country
1c	Counter weight	1.840.206.001

1. Remove the main shaft front bearing outer race (1a) using the tool (1b).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.655.000

1. Remove the gear control rod bushes (1a) from the bell housing using the tool (1b).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.654.000

1. Remove the gear control rod bushes (1a) and the plugs (1b) from the gearbox casing using tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.654.000

1. Remove the gear engagement safety casing (1a) using a special extractor (1b).

1. Remove the gear selector shaft guide bush (1a) using a suitable tool (1b).

Apply sealant to a new gear selector shaft guide bush.

	Type	Component	Name	Qty.
-	Sealant	GEAR SELECTOR SHAFT GUIDE BUSHES	Loctite 270	-

1. Fit the new gear selector shaft guide bush (1a) using a suitable fitting tool (1b).

Apply sealant to a new gear engagement safety casing.

	Type	Component	Name	Qty.
-	Sealant	GEAR ENGAGEMENT SAFETY ROD	Loctite 270	-

1. Fit the new gear engagement safety casing (1a) using a suitable tool (1b).

Apply sealant to the new gear control rod bushes.

	Type	Component	Name	Qty.
-	Sealant	GEAR CONTROL ROD HOUSING BUSHES	Loctite 270	-

1. Fit the new gear control rod bushes (1a) in the gearbox casing using tool (1b) A.

	Name	Country
1b	Tool for Extracting/Fitting	1.870.654.000

Apply sealant to the new plugs for the gear control rods.

	Type	Component	Name	Qty.
-	Sealant	PLUGS FOR GEAR CONTROL RODS	Loctite 270	-

1. Fit the new plugs for the gear control rods (1a) using a suitable fitting tool (1b).

Apply sealant to the new gear control rod bushes.

	Type	Component	Name	Qty.
-	Sealant	GEAR CONTROL ROD HOUSING BUSHES	Loctite 270	-

1. Fit the new gear control rod bushes (1a) on the bell housing using the tool (1b).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.654.000

1. Fit the main shaft front bearing outer race (1a) using a hydraulic press and tools (1b) and (1c).

	Name	Country
1b	Fitting tool	1.870.656.000

	Name	Country
1c	Grip	1.821.171.000

1. Fit the layshaft front bearing outer race (1a) using a hydraulic press and tools (1b) and (1c).

	Name	Country
1b	Fitting tool	1.870.656.000

	Name	Country
1c	Grip	1.821.171.000

- 2110B26 manual gearbox (six speed) with differential - dismantle and rebuild wash and check parts - replace synchronizers and internal parts if necessary . 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	Support	1.871.001.014

1. Undo the bolts (1a), extract the retaining clip (1b) and remove the coaxial clutch operating cylinder (1c) complete with oil pipe.2. Extract the hydraulic clutch fluid duct from the lower part of the gearbox.3. Undo the inner bolt (3a) fixing the clutch casing (3b) to the gearbox casing.

Rotate the gearbox casing through 180 degrees on the overhaul stand.1. Undo the outer bolts fixing the clutch casing to the gearbox casing.2. Separate the gearbox casing from the clutch casing cutting the sealant using the special tool.

	Name	Country
2	Blade	1.870.718.000

3. Remove the gearbox casing (3a) from the clutch casing (3b).

1. Extract the main shaft (A) (1a) and first layshaft (B) (1b) assemblies at the same time complete with 1st-2nd and 5th-6th speed selector forks.

Keep the units assembled until they are placed on the workbench.

For quick identification, each control shaft has a corresponding letter: main shaft (A), first layshaft (B) and second layshaft (C), as illustrated.

1. Extract the layshaft (C) upwards complete with 3rd-4th speed and Reverse selector forks.2. Remove the differential assembly.

1. Take the gearbox casing support tool (1a) and place the pins (1b) marked with the letter (A) by the letters (A) on the plate (1c).

The pin position identification letters are on the support tool plate; position (A) is used for the gearbox casing support, positions (B) and (C) are used for the clutch casing support.

	Name	Country
1a	Gearbox casing/clutch casing support	1.870.897.700

2. Place the gearbox casing (2a) on the support tool, positioning it as illustrated, then secure it using the nuts (2b).

1. Remove the gearbox casing oil channel.2. Remove the lubrication ducts by the main and layshafts using pliers.

The lubrication ducts are destroyed during the removal operation so new components must be used when refitting.

3. Remove the main and layshaft rear bearing outer track using a USAG 468/2 type bridge and USAG 468/7 extractor or similar tools.

To facilitate the recognition of each shaft housing, the housing for the main shaft is identified by the letter (A), the housing for the first layshaft by the letter (B) and the housing for the second layshaft by the letter (C). The removal operation is the same for all three rear bearing outer races.

4. Remove the main shaft scraper ring (A), the first layshaft scraper ring (B) and the second layshaft scraper ring (C).

1. Remove the manget for collecting any impurities in the transmission fluid from the clutch casing. 2. Remove the main and layshaft front bearings outer race using a USAG 468/2 type bridge and USAG 468/7 extractor or similar tools.

Proceed with dismantling the main shaft (A), following the instructions given below.1. Position the main shaft (A) (1a) in a vice fitted with protective jaws, then undo the bolt (1b) retaining the 4th speed drive gear (1c) and the 6th speed drive gear (1d).

1. Place the reaction plates on the press support surface and fit the main shaft (A) by the 4th speed drive gear.

	Name	Country
1	Half-plate	1.860.837.000

2. Using the press fitted with a reaction pin (2a), remove the rear bearing (2b), 6th speed drive gear (2c), 4th speed drive gear (2d) and spacer (2e).

Support the main shaft (A) underneath during this operation.

	Name	Country
2a	Reaction pin	1.870.899.100

1. Remove the 3rd and 5th speed drive gear (1a) using a hydraulic press, the plates (1b) and the reaction pin (1c).

Support the main shaft (A) underneath during this operation.

	Name	Country
1b	Half-plate	1.860.837.000

	Name	Country
1c	Reaction pin	1.870.899.100

1. Fit the extracting half-rings (1a) in the housing in the extactor (1b); position the tools assembled in this way on the main shaft (A) front bearing and lock them using the nuts (1c).

	Name	Country
1a	Extractor half-rings	1.870.899.200

	Name	Country
1b	Extractor	1.870.845.100

2. Position the main shaft (A) complete with extraction tools on the press support surface, then extract the front bearing.

Support the main shaft (A) underneath during this operation.

Proceed with dismantling the layshaft (B), following the instructions given below.1. Remove the 1st and 2nd speed selector fork (1a) and 5th and 6th speed selector fork from the layshaft (B).

1. Position the reaction plates on the press support surface and fit the layshaft (B) by the 6th speed driven gear.

	Name	Country
1	Half-plate	1.860.837.000

2. Using the press fitted with a reaction pin (2a), remove the rear bearing (2b), the 6th speed driven gear (2c) and the needle bearing (2d).

Support the layshaft (B) underneath during this operation.

	Name	Country
2a	Reaction pin	1.870.899.100

1. Remove the 6th speed synchronizer ring set.2. Remove the 5th-6th speed engagement sliding sleeve.3. Remove the pre-synchronizer mountings.

1. Remove the circlip retaining the 5th-6th speed sliding sleeve hub using suitable pliers.

When refitting, replace the circplip.

1. Remove the 5th-6th speed sliding sleeve hub (1a), the 5th speed synchronizer ring set (1b), the 5th speed driven gear (1c) using a hydraulic press and the plates (1e) and the reaction pin (1f).

	Name	Country
1e	Half-plates	1.870.899.400

	Name	Country
1f	Reaction pin	1.870.899.100

2. Remove the needle bearing.

Support the layshaft (B) underneath during this operation.

1. Lift up the retaining ring (1a), then remove the thrust washers (1b) retaining the 2nd speed driven gear, releasing them from the housings (1c) on the layshaft (B). 2. Remove the 2nd speed driven gear (2a), the needle bearing (2b), the and the 2nd speed synchronizer rings (2c).3. Remove the 1st-2nd speed engagement sliding sleeve.4. Remove the pre-synchronizer mountings.

1. Remove the circlip retaining the 1st-2nd speed sliding sleeve hub using suitable pliers.

When refitting, replace the circplip.

1. Remove the 1st-2nd speed sliding sleeve hub (1a), the 1st speed synchronizer ring set (1b), the upper roller bearing (1c) for the 1st speed driven gear, the 1st speed driven gear (1d) using a hydraulic press and the plates (1e) and the reaction pin (1f).

	Name	Country
1e	Half-plate	1.860.837.000

	Name	Country
1f	Reaction pin	1.870.899.100

2. Remove the 1st speed driven gear lower roller bearing.

Support the layshaft (B) underneath during this operation.

1. Fit the extracting half-rings (1a) in the housing in the extractor (1b); position the tools assembled in this way on the layshaft (B) front bearing and lock them using the nuts (1c).

	Name	Country
1a	Extractor half-rings	1.870.899.600

	Name	Country
1b	Extractor	1.870.845.100

2. Position the layshaft (B) complete with extraction tools on the press support surface, then proceed with extracting the front bearing.

Support the layshaft (B) underneath during this operation.

Proceed with dismantling the layshaft (C), following the instructions given below.1. Remove the 3rd-4th speed selector fork (1a) and Reverse selector fork (1b) from the layshaft (C).

1. Position the reaction plates on the press support surface and fit them on the layshaft (C) by the 4th speed driven gear.

	Name	Country
1	Half-plates	1.870.899.400

2. Using the press fitted with a reaction pin (2a) remove the rear bearing (2b), the 4th speed driven gear (2c) and the needle bearing (2d).

Support the main shaft (A) underneath during this operation.

	Name	Country
2a	Reaction pin	1.870.899.100

1. Remove the 4th speed synchronizer ring set.2. Remove the 3rd-4th speed engagement sliding sleeve. 3. Remove the pre-synchronizer mountings.

1. Remove the hub circlip for the 3rd and 4th speed sliding sleeve using suitable pliers.

When refitting, replace the circplip.

1. Remove the hub for the 3rd and 4th speed sliding sleeve (1a), the 3rd speed synchronizer ring set (1b), the 3rd speed driven gear (1c), using a hydraulic press, the plates (1d) and the reaction pin (1e).

	Name	Country
1d	Half-plate	1.860.837.000

	Name	Country
1e	Reaction pin	1.870.899.100

2. Remove the needle bearing.

Support the layshaft (C) underneath during this operation.

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); position the tools assembled in this way on the spacer between the 3rd-4th speed and Reverse gears and lock them using the nuts (1c).

	Name	Country
1a	Extractor half-rings	1.870.899.700

	Name	Country
1b	Extractor	1.870.845.100

2. Position the layshaft (C), complete with extraction tools, on the press support surface, then proceed with extracting the spacer between the 3rd-4th speed and Reverse gears (2a) using the reaction pin (2b).

Support the layshaft (C) underneath during this operation.

	Name	Country
2b	Reaction pin	1.870.899.100

1. Remove the Reverse engagement sliding sleeve.2. Remove the pre-synchronizer mountings.

1. Remove the circlip retaining the Reverse sliding sleeve hub using suitable pliers.

When refitting, replace the circplip.

1. Remove the Reverse sliding sleeve hub (1a), the Reverse synchronizer ring set (1b), the Reverse driven gear (1c) using a hydraulic press, the plates (1d) and the reaction pin (1e).

	Name	Country
1d	Half-plate	1.860.837.000

	Name	Country
1e	Reaction pin	1.870.899.100

2. Remove the needle bearing.

Support the layshaft (C) underneath during this operation.

1. Remove the spacer under the Reverse driven gear.

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); position the tools assembled in this way on the layshaft (C) front bearing and lock them using the nuts (1c).

	Name	Country
1a	Extractor half-rings	1.870.899.500

	Name	Country
1b	Extractor	1.870.845.100

2. Position the layshaft (C) complete with extraction tools on the press support surface, then proceed with extracting the front bearing.

Support the layshaft (C) underneath during this operation.

When working on the differential, proceed as described below.1. Remove the rear differential bearing outer race using a USAG 468/2 type bridge and USAG 468/7 extractor or similar tools. 2. Remove the differential scraper ring underneath.