2110C15 SUPPORT FOR GEARBOX LINKING TO THE ENGINE AND REAR DRIVE TRANSFER CASE - R.R. WITH THE GEARBOX DETACHED (SUV) - Fiat - PANDA - eLearn

169001522 - 2110C15 SUPPORT FOR GEARBOX LINKING TO THE ENGINE AND REAR DRIVE TRANSFER CASE - R.R. WITH THE GEARBOX DETACHED (SUV)

) 1. Position the gearbox-rear drive idler casing (1a) on the special support stand (1b) securing it to the mounting bracket (1c).

	Description	Code	Function
1b	Stand	1.871.001.014	Gearbox support

	Description	Code	Function
1c	Bracket	1.871.001.000	Gearbox support

1. Undo the bolts fixing the rear transmission assembly.

1. Remove the rear transmission assembly (1a) and the two adjustment shims (1b).

Dismantling rear transmission assembly.1. Place the tool (1a) in a vice and secure it to the flange (1b) tightening the fixing bolts (1c) in order to prevent the rotation of the pinion during the dismantling of the retaining nut.

	Description	Code	Function
1a	Counter-torque	1.871.004.800	Counter-torque

2. Undo the nut fixing the bevel pinion to the flange.

1. Position the rear transmission assembly (1a) in the press on the tool (1b), remove the bevel pinion (1c) and remove the flange (1d).

	Description	Code	Function
1b	Plate	1.846.017.000	Flange support

During this operation, support the bevel pinion from underneath.

1. Remove the oil seal (1a) using leverage, remove the front conical bearing inner race (1b) from the housing in the bevel pinion support (1c).

1. Fit the extraction half-rings (1a) in the housing in the plates (1b), position the tools created in this way on the rear conical bearing inner race (1c) and secure them by tightening the fixing nuts.

	Description	Code	Function
1a	Reaction plate	1.870.845.000	Reaction plate

	Description	Code	Function
1b	Reaction plate	1.870.845.000	Reaction plate

2. Position the bevel pinion (2a) complete with extraction tools on the support surface of the press, then proceed with extracting the rear conical bearing inner race and the spacer (2b).

During this operation, support the bevel pinion from underneath.

1. Fit the expansion extractor (1a) on the bevel pinion support (1b).2. Check that the extractor is correctly positioned on the edge of the bearing outer race.

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and remove the rear conical bearing outer race (1c) using the extractor.

	Description	Code	Function
1b	Plate	1.846.017.000	Support

Remove the extractor and position it in the bevel pinion support for the removal of the second bearing outer race.1. Fit the expansion extractor (1a) on the bevel pinion support (1b).2. Check that the extractor is correctly positioned on the edge of the bearing outer race.

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and remove the front conical bearing outer race (1c) using the extractor.

	Description	Code	Function
1b	Plate	1.846.017.000	Support

1. Prise up and remove the differential side joints.

1. Undo the fixing bolts (1a) and, using the special tool (1b), cut the bead of sealant and remove the inspection cover (1c).

	Description	Code	Function
1b	Blade	1.870.718.000	Cutting the sealant

1. Undo the fixing bolts (1a) and, using the special tool (1b), cut the bead of sealant and remove the inspection cover (1c).

	Description	Code	Function
1b	Blade	1.870.718.000	Cutting the sealant

1. Undo the fixing bolts (1a) and remove the gear selector and engagement assembly (1b).

1. Undo the retaining bolts.2. Cut the bead of sealant using the special tool.

	Description	Code	Function
2	Blade	1.870.718.000	Cutting the sealant

3. Remove the fifth speed gears protective cover.

1. Undo the fixing nuts (1a) and the bolt (1b).2. Remove the fifth speed gears.

1. Undo the fixing bolts (1a) and remove the retaining cover (1b).

1. Remove the two seger seals.

1. Undo the reverse shaft fixing bolt.2. Undo the fixing bolts (2a) and remove the gearbox casing (2b).

1. Undo the fixing bolts (1a) and remove the shaft, synchronizer and selector assembly (1b).

use a wrench with an extension to uncrew/tighten unaccessible bolts.

1. Undo the fixing bolts (1a) and remove the oil seal cover (1b).2. Undo the fixing bolts (2a) and remove the rear drive idler assembly (2b).

Dismantling rear drive idler assembly.1. Position the rear drive idler assembly (1a) on the special tool (1b) and secure it using the special retaining levers (1c).

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

2. The hexagonal profile of the support (2a) should match with the hexagonal housing (2b) for the straight spur gear.

1. Position the support for the rear drive idler assembly casing.

	Description	Code	Function
1	Rear drive idler casing support kit	1.871.005.500	Support

2. Undo the nut fixing the ring gear, using a power unscrewer.

The nut should always be replaced every time it is removed.

1. Position the rear drive idler assembly (1a) complete with support tool (1b) on the press.

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

2. Remove the ring gear (2a), the scraper rings (2b), the front conical bearing inner race (2c), the spacer (2d) and the straight spur gear (2e).

	Description	Code	Function
1a	Reaction plate	1.870.845.000	Reaction plate

	Description	Code	Function
1b	Reaction plate	1.870.845.000	Reaction plate

2. Position the straight spur gear complete with extraction tools on the support surface of the press, then proceed with extracting the rear taper bearing inner race.

During this operation, support the straight spur gear from underneath.

1. Position the special expansion extractor (1a) and remove the conical bearing front outer race (1b) from the housing in the rear drive idler assembly casing.

1. Position the special expansion extractor (1a) and remove the conical bearing rear outer race (1b) from the housing in the rear drive idler assembly casing working on the actual extractor.

1. Remove the differential assembly, bearings and outer races.Remove the remaining oil seal.2. Remove the spacer.

Refitting ( Removing

) Remove the gearbox/engine support from the special stand and the mounting bracket.

	Description	Code	Function
-	Stand	1.871.001.014	Gearbox support

	Description	Code	Function
-	Bracket	1.871.001.000	Gearbox support

Fit the NEW gearbox/engine support on the special stand and the mounting bracket.

	Description	Code	Function
-	Stand	1.871.001.014	Gearbox support

	Description	Code	Function
-	Bracket	1.871.001.000	Gearbox support

Each time one of the following two components has to be replaced: gearbox/engine support or rear drive idler assembly casing, BOTH COMPONENTS MUST BE REPLACED and consequently all the clearances and shims checked.

1. Fit the differential assembly, bearings and outer races in place on the NEW gearbox/engine support.2. Fit the old spacer.

If bolts bear the code 8.8 on their heads, replace with 10.9 bolts, the new bolts are pretreated with locking compound. If removing/refitting the same bolt (10.9), it is obligatory to apply a new layer of locking compound.

use a wrench with an extension to uncrew/tighten inaccessible bolts.

1. Fit the NEW casing (1a) for the rear driver idler assembly in position on the gearbox/engine support and tighten the fixing bolts (1b) to torque.

	Value daNm	Fastening	Component	Ø
1b	5 ± 0.3	Bolt		-

2. Fit the oil seal cover (2a) using the special fitting tool and tighten the fixing bolts (2b) to torque.

	Description	Code	Function
-	Fitting tool	1.871.005.900	Fitting oil seal

	Value daNm	Fastening	Component	Ø
2b	3 ± 0.3	Bolt	10.9	-

1. Fit the special tool and measuring the rolling torque for the differential unit to determine the total thickness of the spacer.

To determine the size of the spacer it is advisable to start the check using the old spacer and, if necessary, increasing or decreasing the size to produce the correct rolling torque. The shims available go from a minimum of 1.75 mm to a maximum of 3.00 mm.

	Subject	Value
-	Differential unit rolling torque (daNm)	0 - 0.30

The rolling torque figure is measured after having completed ten revolutions of the differential ring gear.

Undo the fixing bolts and remove the oil seal cover.Undo the fixing bolts and remove the rear drive idler casing.Remove the differential unit, space and outer taper roller bearing races.1. Position the bevel pinion support (1a) in the press on the special tool (1b) and fit the rear conical bearing outer race in place using the special fitting tool (1c).

	Description	Code	Function
1b	Plate	1.846.017.000	Support

	Description	Code	Function
1c	Fitting tool	1.871.004.200	Fit the bearing outer races

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and fit the front conical bearing outer race in place using the special fitting tool (1c).

	Description	Code	Function
1b	Plate	1.846.017.000	Support

	Description	Code	Function
1c	Fitting tool	1.871.004.200	Fit the bearing outer races

In order to establish the correct height for the bevel pinion bearing pre-loading spacer, proceed as described below.1. Position the dial gauge on a bench.

	Description	Code	Function
1	Dial gauge	1.871.005.300	Measurement

2. Position the dial gauge on the reference bench. In this position, set the gauge to zero.

1. Position the calibrated sample pin (50 mm theoretical) on the reference bench.

	Description	Code	Function
1	Template	1.871.005.200	-

2. Take the measurements shown in figures A, B, C, D on the plane indicated for the calibrated sample pin using the dial gauge reset previously.

Take the arithmetic mean of the four measured values (A,B,C,D)The value obtained corresponds to the height of the calibrated sample pin to be inserted in the following equation (in the example used in the equation, a theoretical value of 50 mm was used for the calibrated sample pin, which could have a tolerance of ± 0.01mm)1. Position tool (1a) on the tool reference surface (1b).

	Description	Code	Function
1a	Dial gauge	1.871.005.300	Measurement

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

2. Position the dial gauge pointer at the level of the tool on which the rear conical bearing inner race is fitted. Zero the measuring equipment in this position.

1. Fit the rear conical bearing inner race (1a) in the special tool (1b).

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

1. Fit the support (1a) for the bevel pinion complete with conical bearing outer races and the inner race for the front conical bearing (1b) in position on the special tool (1c).

	Description	Code	Function
1c	Template	1.871.005.200	Measuring thickness

1. Position the tool (1a) (calibrated sample pin) and tighten the fixing nut (1b) to torque.

	Description	Code	Function
1a	Template	1.871.005.200	Measuring thickness

	Value daNm	Fastening	Component	Ø
1b	1.0 - 1.1	Nut	-	-

Turn the bevel pinion mount and check or settle the taper roller bearings.

1. Take the measurements shown in figures A, B, C, D on the plane indicated for the calibrated sample pin using the dial gauge reset previously.

Take the arithmetical average of the four values measured (A, B, C, D) and subtract 50 mm (corresponding to the theoretical height of the sample pin) from this average figure:(Average A, B, C, D) - 50 mm = RThe value R obtained corresponds to the distance between the outer planes of the inner races for the two conical bearings.Subtract 39.68 (19.84 x 2) (corresponding to the total height of the two conical bearings) from value R:R -39.68 mm = XcThe value Xc obtained corresponds to the distance between the inner planes of the inner races for the two conical bearings.Apply the following formula to the result obtained for Xc to obtain the value Sc corresponding to the thickness of the spacer to be used.Sc = ( Xc -0.01 mm ) ± 0.025 mmThe value 0.01 corresponds to the pre-loading for the two taper bearings.

The spacers available vary from a minimum of 23.10 mm to a maximum of 23.80 mm in increments of 0.05 mm.

Remove the support for the bevel pinion from the measuring equipment.

	Description	Code	Function
-	Template	1.871.005.200	Measuring thickness

1. Fit the expansion extractor (1a) on the bevel pinion support (1b).2. Check that the extractor is correctly positioned on the edge of the rear conical bearing outer race.

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and remove the rear conical bearing outer race (1c) using the extractor.

	Description	Code	Function
1b	Plate	1.846.017.000	Support

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and remove the front conical bearing outer race (1c) using the extractor.

	Description	Code	Function
1b	Plate	1.846.017.000	Support

1. Fit the outer race (1b) for the front conical bearing on the rear drive idler casing supported by the tool (1c) using the special fitting tool (1a).

	Description	Code	Function
1a	Fitting tool	1.871.004.200	Tool for fitting bearing outer races

	Description	Code	Function
1c	Rear drive idler casing support kit	1.871.005.500	Support

Remove the rear drive idler casing from the support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

1. Fit the reaction tool (1b) on the special support tool (1a).

	Description	Code	Function
1a	Rear drive idler casing support kit	1.871.005.500	Support

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

Position the rear drive idler casing on the special support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

1. Fit the outer race (1b) for the rear conical bearing in place using the special fitting tool (1a).

	Description	Code	Function
1a	Fitting tool	1.871.004.200	Tool for fitting bearing outer races

Remove the rear drive idler casing from the special support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

In order to establish the correct height for the bevel pinion bearing pre-loading spacer, proceed as described below.1. Place the dial gauge (1a) in the zero position on the plane for the conical bearing and the tool (1b).

	Description	Code	Function
1a	Dial gauge	1.871.005.300	Measurement

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

2. Position the dial gauge pointer at the level of the tool on which the rear conical bearing inner race is fitted. Zero the measuring equipment in this position.

1. Fit the conical bearing inner race (1a) in the special tool (1b).

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

1. Fit the rear drive idler assembly casing (1a) and the conical bearing (1b) in position on the special tool (1c).

	Description	Code	Function
1c	Template	1.871.005.200	Measuring thickness

Turn the rear drive idler casing, checking or settling the taper bearings.

1. Position the tool (1a) and tighten the fixing nut (1b) to torque.

	Description	Code	Function
1a	Template	1.871.005.200	Measuring thickness

	Value daNm	Fastening	Component	Ø
1b	1.0 - 1.1	Nut	-	-

1. Take the measurements shown in figures A, B, C, D on the plane indicated using the dial gauge reset previously.

Use the value obtained previously for the height of the calibrated sample pin (in the example in the following equation, a theoretical value of 50mm has been used for the calibrated sample pin, which may have a manufacturing tolerance of ± 0.01mm)Take the arithmetical average of the four values measured (A, B, C, D) and subtract 50 mm (corresponding to the theoretical height of the sample pin) from this average figure:(Average A, B, C, D) - 50 mm = RThe value R obtained corresponds to the distance between the outer planes of the inner races for the two conical bearings.Subtract 39.68 (19.84 x 2) (corresponding to the total height of the two conical bearings) from value R:R -39.68 mm = XcThe value Xc obtained corresponds to the distance between the inner planes of the inner races for the two conical bearings.Apply the following formula to the result obtained for Xc to obtain the value Sc corresponding to the thickness of the spacer to be used.Sc = ( Xc -0.01 mm ) ± 0.025 mmThe value 0.01 corresponds to the pre-loading for the two taper bearings.

The spacers available vary from a minimum of 23.10 mm to a maximum of 23.80 mm in increments of 0.05 mm.

Remove the rear drive idler casing from the measuring equipment.

	Description	Code	Function
-	Template	1.871.005.200	Measuring thickness

Proceed with determining the thickness of the shims placed underneath the straight spur gear ring gear.1. Fit the front conical bearing inner race (1a) and the dummy straight spur gear (1b) in place in the rear drive idler casing.

	Description	Code	Function
1b	Dummy straight spur gear	1.871.005.600	Measurement

1. Fit the spacer (1a) and the rear conical bearing inner race (1b) on the dummy straight spur gear (1c).

	Description	Code	Function
1c	Dummy straight spur gear	1.871.005.600	Measurement

Turn the dummy straight spur gear mount and check or settle the taper roller bearings.

1. Fit the spacer (1a) and tighten the fixing nut (1b) so that it is in contact with the dummy straight spur gear (1c).

	Description	Code	Function
1a	Dummy straight spur gear spacer	1.871.005.600	Measurement

	Description	Code	Function
1c	Dummy straight spur gear	1.871.005.600	Measurement

1. Position the tool (1a) on the bevel pinion support (1b).

	Description	Code	Function
1a	Gauge	1.871.005.700	Measurement

Position the rear drive idler casing on the special support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

1. Fit the support for the bevel pinion (1a) in place in the rear drive idler casing and tighten the fixing bolts (1b) so that they are in contact.

1. Using a feeler gauge, measure the distance between the dummy straight spur gear and the gauge in order to determine the size of the two spacers to be placed underneath the ring gear.

Make a note of the value (x) measured.

1. After the measurement has been taken, determine the total size S of the cylindrical pinion ring gear scraper rings following the instructions given below. The distance of 50 mm corresponds to the theoretical distance between the ring gear and the centre of rotation of the bevel pinion. This theoretical distance has been reconstructed by inserting the dummy straight spur gear .

1. From the markings on the back of the ring gear, detect the value (C) corresponding to the actual distance between the ring gear and the centre of rotation of the bevel pinion. The marking (B) should be used to determine the size of the shims to be placed underneath the bevel pinion support casing. The marking (A) corresponds to the ring gear identification number, the same number should be stamped on the bevel pinion because the two components should be matched; if one component is replaced, the other component with the same number also has to be replaced.

Determine the value VP, corresponding to the difference between the actual distance between the ring gear and the centre of rotation of the bevel pinion (determined from the marking on the ring gear) with the theoretical distance between the ring gear and the centre of rotation of the bevel pinion (50 mm).In this case:VP = 50.11 mm - 50 mmVP = 0.11

The value VP can be either positive or negative

Calculate the thickness S of both straight spur gear ring gear shims using the following equation:S = [ X + (VP)] ± 0.04S = total thickness of both scraper rings to be obtained (mm)X = value measured using feeler gauge (mm)VP = deviation between nominal value of sample pin and stamping on ring gear (mm)0.04 = tolerance (mm)Example of numerical calculation with positive VP.Let us suppose that the following figures have been obtained:X = 0.73 mm (feeler gauge reading)VP = 0.11 mmS = [0.73 + 0.11] ± 0.04 mm = 0.80 - 0.88 mmThe spacers available as spares vary from a minimum of 0.30 mm to a maximum of 0.55 mm in increments of 0.05 mm.To produce a total thickness of 0.85 mm (average of the values calculated) use one 0.30 mm shim and one 0.55 mm one.Example of numerical calculation with negative VP.Let us assume that the stamping on the ring gear is 49.97 mm. In this case, VP would be negative:VP = 49.97 mm - 50 mmVP = -0.03 mmGoing back to the previous example, we obtain:X = 0.73 mm (feeler gauge reading)VP = -0.03 mmS = [0.73 + (-0.03)] ± 0.04 mm = 0.66 - 0.74 mmTo produce a total thickness of 0.70 mm (average of the values calculated) use two 0.35 mm shims.Remove the tools fitted previously on the rear drive idler casing.1. Position the expansion extractor (1a) and remove the front conical bearing outer race (1b).

1. Position the expansion extractor (1a) and remove the rear conical bearing outer race (1b).

Proceed with determining the thickness of the scraper rings for the bevel pinion support.1. Position the tool on the rear drive idler casing, secure with the reaction bracket and tighten the bolt.

	Description	Code	Function
1	Gauge	1.871.004.600	Measurement

1. Fit the rear conical bearing inner race (1a) in position on the dummy bevel pinion (1b).

	Description	Code	Function
1b	Dummy bevel pinion	1.871.004.700	Measurement

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and fit the rear conical bearing outer race in place using the special fitting tool (1c).

	Description	Code	Function
1b	Plate	1.846.017.000	Support

	Description	Code	Function
1c	Fitting tool	1.871.004.200	Fit the bearing outer races

1. Position the bevel pinion support (1a) in the press on the special tool (1b) and fit the front conical bearing outer race in place using the special fitting tool (1c).

	Description	Code	Function
1b	Plate	1.846.017.000	Support

	Description	Code	Function
1c	Fitting tool	1.871.004.200	Fit the bearing outer races

1. Fit the spacer (1a) selected previously and the support for the bevel pinion (1b) in position on the dummy bevel pinion.

1. Fit the front conical bearing inner race (1a) and the flange (1b) in position on the dummy bevel pinion.

Turn the dummy bevel pinion and check or settle the taper roller bearings.

1. Tighten the fixing nut (1a) bringing in contact with the flange (1b).

1. Position the component (1a) without shims on the rear drive idler casing and tighten the fixing bolts (1b) until they are in contact.

1. Using a feeler gauge, measure the distance between the dummy bevel pinion and the gauge in order to determine the size of the spacers for the bevel pinion support.

Make a note of the value (x) measured.

1. After the measurement has been taken, determine the total size S of the bevel pinion support scraper rings following the instructions given below. The distance of 73 mm corresponds to the theoretical distance between the ring gear for the bevel pinion and the centre of rotation of the straight spur gear . This theoretical distance has been reconstructed by inserting the dummy bevel pinion.

1. From the markings on the back of the ring gear, detect the value (B) corresponding to the actual distance between the ring gear and the centre of rotation of the cylindrical pinion. The marking (C) has been used to determine the size of the scraper rings to be placed underneath the straight spur gear ring gear. The marking (A) corresponds to the ring gear identification number, the same number should be stamped on the bevel pinion because the two components should be matched; if one component is replaced, the other component with the same number also has to be replaced.

Determine the value VP, corresponding to the difference between the actual distance between the bevel pinion ring gear and the centre of rotation of the straight spur gear (determined from the marking on the ring gear) with the theoretical distance between the bevel pinion ring gear and the centre of rotation of the straight spur gear (73 mm).In this case:VP = 73.05 mm -73 mmVP = 0.05

The value VP can be either positive or negative.

Calculate the thickness S of both bevel pinion shims using the following equation:S = [ 3 - X + (VP)] ± 0.04S = total thickness of both scraper rings to be obtained (mm)3 = reference constant (mm)X = value measured using feeler gauge (mm)VP = deviation between nominal value of sample pin and stamping on ring gear (mm)0.04 = tolerance (mm)Example of numerical calculation with positive VP.Let us suppose that the following figures have been obtained:X = 1.06 mm (feeler gauge reading)VP = 0.05 mmS = [3 - 1.06 + (0.05)] ± 0.04 mm = 1.95 - 2.03 mmThe spacers available as spares vary from a minimum of 0.70 mm to a maximum of 1.25 mm in increments of 0.05 mm.To produce a total thickness of 2.00 mm (average of the values calculated) use two 1.00 mm shims.Example of numerical calculation with negative VP.Let us assume that the stamping on the ring gear is 72.98 mm. In this case, VP would be negative:VP = 72.98 mm -73 mmVP = -0.02 mmGoing back to the previous example, we obtain:X = 1.06 mm (feeler gauge reading)VP = -0.02 mmS = [3 - 1.06 + (- 0.02)] ± 0.04 mm = 1.88 - 1.96 mmTo produce a total thickness of 1.90 mm (average of the values calculated) use one 1.20 mm shim and one 0.70 mm one.Remove the tools fitted previously on the rear drive idler casing.1. Fit the outer race (1b) for the front conical bearing in place using the special fitting tool (1a).

	Description	Code	Function
1a	Fitting tool	1.871.004.200	Tool for fitting bearing outer races

Remove the rear drive idler casing from the support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

1. Fit the reaction tool (1b) on the special support tool (1a).

	Description	Code	Function
1a	Rear drive idler casing support kit	1.871.005.500	Support

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

Position the rear drive idler casing on the special support tool.

	Description	Code	Function
-	Rear drive idler casing support kit	1.871.005.500	Support

1. Fit the outer race (1b) for the rear conical bearing in place using the special fitting tool (1a).

	Description	Code	Function
1a	Fitting tool	1.871.004.200	Tool for fitting bearing outer races

1. On the press using a special fitting tool (1a), fit the inner race for the rear conical bearing (1b) on the straight spur gear (1c).

	Description	Code	Function
1a	Fitting tool	1.871.004.400	Bearing fitting tool

1. Positino the straight spur gear (1a) on the special support tool (1b).

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

The hexagonal profile of the support should match with the hexagonal housing for the straight spur gear.

1. Position the rear drive idler casing (1a) on the special support tool (1b) and secure it using the special retaining levers.

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

2. Fit the spacer (2a), having calculated the size previously, and the inner race of taper earing (2b) in position on the straight spur gear (2c).

1. Fit the two scraper rings selected previously to the straight spur gear.

1. Fit ring gear (1a) and pretighten nut (1b), checking or settling the taper bearings, tighten nut (1b) to torque.

Always replace the fixing nut.

	Value daNm	Fastening	Component	Ø
1b	Pretorque1.5 - 2.5	Nut	-	-

	Value daNm	Fastening	Component	Ø
1b	Torque26.5 ± 1.5	Nut	-	-

1. Fit the inner race for the rear conical bearing (1a) on the bevel pinion (1b) on the press using the special fitting tool (1c).

	Description	Code	Function
1c	Fitting tool	1.871.004.400	Bearing fitting tool

1. Fit the support for the bevel pinion (1b) in place and the spacer (1b) selected previously.

1. Fit the inner race for the front conical bearing in place on the bevel pinion support.

1. Fit the oil seal on the bevel pinion support.

Turn the bevel pinion and check or settle the taper roller bearings.

1. Fit the flange on the bevel pinion support.2. Fit the special reaction tool (2a) and tighten the fixing nut (2b) to torque.

Always replace the fixing nut.

	Description	Code	Function
2a	Counter-torque	1.871.004.800	Counter-torque

	Value daNm	Fastening	Component	Ø
2b	26.5 ± 1.5	Nut	-	-

Remove the reaction tool from the flange.

	Description	Code	Function
-	Counter-torque	1.871.004.800	Counter-torque

1. Fit the two adjustment shims (1a) selected previously and the flange (1b) in position.2. Tighten the flange bolts crosswise to the specified torque.

	Value daNm	Fastening	Component	Ø
2	2.5 ± 0.3	Bolt	-	-

1. Position the rear drive idler assembly (1a) on the special tool (1b) and secure it using the special retaining levers (1c).

	Description	Code	Function
1b	Rear drive idler casing support kit	1.871.005.500	Support

2. The hexagonal profile of the support (2a) should match with the hexagonal housing (2b) for the straight spur gear .

1. Fit bracket (1a) and secure with bolt (1b) to the rear drive unit casing.2. Using the special dial gauge (2a) carry out the measurement on the ring gear at the point indicated (3b), moving the ring gear by hand, measure the clearance between it and the bevel pinion making sure that the value measured corresponds to the figures given.

	Subject	Value
-	Clearance between ring gear and bevel pinion (mm)	0.15 ± 0.04

If the value measured for the clearance between the bevel pinion and the ring gear differs from the figures given, the overhaul must be repeated.

Clean both inspection covers and the contact surfaces thoroughly using the appropriate product.

	Description	Qty.	Component	Type	Classification
-	Loctite Activator	-	-	7063	-

Reapply the sealant strip.

	Description	Qty.	Component	Type	Classification
-	Loctite	-	-	5970	Sealant

Fit both inspection covers in place.Tighten the bolts fixing the two inspection covers crosswise to torque.

	Value daNm	Fastening	Component	Ø
-	1.55 ± 0.15	Bolt	10.9	-

Clean the contact surfaces using an appropriate product.

	Description	Qty.	Component	Type	Classification
-	Loctite Activator	-	-	7063	-

Renew the bead of sealant in the area where the rear drive idler casing and the gearbox casing are matched.

	Description	Qty.	Component	Type	Classification
-	Loctite	-	-	5970	Sealant

Fit the rear drive idler casing on the gearbox casing and tighten the fixing bolts to torque.

	Value daNm	Fastening	Component	Ø
-	5 ± 0.3	Bolt	-	-

Fit the scraper ring obtained previously in place.1. Fit a new left oil seal (1a) using the special fitting tool (1b).

	Description	Code	Function
1b	Fitting tool	1.871.005.900	Fitting oil seal

Renew the thread-locking agent on the oil seal cover fixing bolts.2. Tighten the cover bolts crosswise to the specified torque.

	Value daNm	Fastening	Component	Ø
2	3 ± 0.3	Bolt	10.9	-

3. Fit the right side oil seal using the special fitting tool.

	Description	Code	Function
3	Fitting tool	1.871.005.900	Fitting oil seal

Place the shafts, synchronizer and selector assembly in position and tighten the fixing bolts to torque.

	Value daNm	Fastening	Component	Ø
-	1.5 ± 0.15	Bolt	-	M8

Fit the gearbox casing and secure it tightening the bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	3 ± 0.3	Bolt	Join support side	M8 - 10.9

Tighten the reverse idler gear shaft bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	2.6 ± 0.26	Bolt	-	M8

Fit the rear bearing circlips.

To facilitate the fitting of the rear bearing circlips, position them with the openings at the front.

Fit the rear bearing retaining plate and secure it tightening the bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	2 ± 0.2	Bolt	-	M8

1. Fit the 5th speed drive gear.2. Fit the 5th speed synchronizer oil seal.3. Using the tool (3a), fit the hub for the 5th speed engagement sliding sleeve (3b) with the splining for the oil facing the gear.

	Description	Code	Function
3a	Fitting tool	1.870.631.000	Sliding sleeve hub fitting

1. Fit the springs on the hub for the 5th speed engagement sliding sleeve.2. Fit the 5th speed engagement sliding sleeve.

The notches in the sleeve should correspond with the springs.

3. Fit the 5th speed engagement fork.4. Fit the rollers between the springs and the notches for the 5th speed engagement sliding sleeve.5. Fit the 5th speed synchronizer roller and spring retaining plate.Place the 5th speed sliding sleeve in neutral to prevent the springs and rollers from being lost.

1. Fit the 5th speed driven gear (1a) on the layshaft using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.631.000	5th speed driven gear fitting

Fit the ring nuts on the main and layshafts without tightening them.

Clean the contact surfaces thoroughly.

	Description	Qty.	Component	Type	Classification
-	Loctite Activator	-	-	7063	-

Apply the recommended sealant to the contact surfaces between the gearbox casing and the gear engagement assembly cover.

	Description	Qty.	Component	Type	Classification
-	Loctite	-	-	510	Sealant

Fit the gear engagement assembly cover and tighten the bolts crosswise to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	2 ± 0.2	Bolt	-	M8

Engage any gear using the gear selection/engagement lever.Engage 5th speed by pressing the main shaft control fork.

If two gears are engaged simultaneously the gear shafts will lock.

Tighten the 5th speed control fork bolt to torque.

	Value daNm	Fastening	Component	Ø
-	1.2 ± 0.12	Bolt	-	M6

Tighten the ring nuts securing the main and layshaft gears to torque.

	Value daNm	Fastening	Component	Ø
-	11.8 ± 1.2	Ring nut	-	M20

1. Stake the ring nuts (1a) securing the main and layshaft 5th speed gear using the tools (1b) and (1c).

	Description	Code	Function
1b	Pair of tools	1.874.140.005	Staking ring nuts

	Description	Code	Function
1b	Caliper	1.874.140.001	Staking ring nuts

Clean the contact surfaces thoroughly.

	Description	Qty.	Component	Type	Classification
-	Loctite Activator	-	-	7063	-

Apply the recommended sealant to the contact surfaces between the gearbox rear cover and the gearbox casing.

	Description	Qty.	Component	Type	Classification
-	Loctite	-	-	5970	Sealant

Fit the gearbox rear cover and secure it tightening the bolts crosswise to the recommended torque.

	Value daNm	Fastening	Component	Ø
-	0.5 ± 0.05	Bolt	-	M6

Fit the two differential joints in position.Remove the gearbox-rear drive idler casing assembly from the support stand releasing it from the mounting bracket.

	Description	Code	Function
-	Stand	1.871.001.014	Gearbox support

	Description	Code	Function
-	Bracket	1.871.001.000	Gearbox support