2110A16 MECHANICAL GEAR WITH DIFFERENTIAL - R.R. FOR 4X4 VERSIONS - Fiat - PANDA - eLearn

169001511 - 2110A16 MECHANICAL GEAR WITH DIFFERENTIAL - R.R. FOR 4X4 VERSIONS

) Op. 5530B10 BATTERY - R+R Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R. Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE Op. 1048A21 FILTER INPUT SLEEVE - R R1. Prise up the gear selection and engagement cable swivel heads.2. Unscrew bolts (2a) and move aside bracket (2b) supporting the gear selection and engagement cables.

1. Disconnect the reversing sensor electrical connection.

	Description	Connector
1	Reversing lights switch	I020

1. Unscrew the bolts and remove the exhaust manifold heat shield.

1. Unscrew nut (1a) and disconnect clutch cable (1b) from thrust bearing control lever (1c).

Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R1. Unscrew bolts (1a) and remove the under-engine guard (1b).

1. Unscrew bolts (1a) and remove the under-engine guard left bracket (1b).

Obtain a container suitable for collecting the transmission fluid.1. Undo the plug and drain the transmission fluid

1. Undo the bolts fixing the brake caliper.2. Remove clip (2a) securing the brake fluid pipe (2b).3. Move the brake caliper outside the working area and secure to ensure operations can be carried out in complete safety.Proceed in the same way on both sides of the vehicle.

1. Undo the nut.2. Fit the tool to release the steering heads.

	Description	Code	Function
2	Extractor	1.871.000.700	Head extraction

3. Release the steering heads from the wheel hub.4. Undo bolts (4a) and release front hub axle (4b) from shock absorber (4c).5. Unscrew bolt (5a) and disconnect ABS sensor (5b).- Proceed in the same way on both sides of the vehicle.

1. Prise the half-axle out if its seat on the front differential.Proceed in the same way on both sides of the vehicle.

1. Undo bolt (1a) securing wheel hub (1b) to wishbone head (1c).2. Remove the half-axle assembly and wheel hub.Proceed in the same way on both sides of the vehicle.

1. Unscrew the nut securing the metal collar securing the exhaust pipe.2. Disconnect the exhaust pipe rubber mounts.3. Remove the exhaust pipe assembly.

1. Undo screws (1a) and bolt (1b) and remove bracket (1c) joining the gearbox and power unit.

1. Undo bolt (1a) and release bracket (1b).2. Undo bolt (2a) and remove bracket (2b).

1. Unscrew bolts (1a) and remove the engine flywheel guard (1b).

1. Undo the bolts securing the propeller shaft front coupling to the idler unit.

1. Undo nuts (1a) and remove front propeller shaft safety bracket (1b).

1. Undo nuts (1a) and remove central guard (1b) protecting the propeller shaft universal joint.

1. Unscrew the bolts securing the central propeller shaft mount.

1. Release the front part of the propeller shaft.

1. Unscrew screws (1a) and bolt (1b) and remove the lower reaction link (1c).

1. Unscrew nut (1a) and release swivel head (1b) from stabiliser bar (1c).Proceed in the same way on both sides of the vehicle.

1. Unscrew the bolts securing the steering box to the suspension beam.

1. Position an appropropriate hydraulic lift to support the front suspension beam.2. Undo the bolts fixing the front suspension beam.3. With the aid of a second operator, move the hydraulic lift and remove the front suspension beam.

1. Unscrew the starter motor bolt.

Lower the vehicle.Open the protective cover.Unscrew the nut and disconnect the starter motor electrical wiring.

	Description	Connector
-	Starter motor	A020A

	Description	Connector
-	Starter motor	A020B

	Description	Connector
-	Starter motor	A020C

1. Unscrew the starter motor bolt and remove.

Op. 7055A42 FRONT GRILLE - R+R1. Undo bolts (1a) and move aside catch (1b).2. Fit tool (2a) complete with mounting blocks (2b).

	Description	Code	Function
2b	Support mounts	1.870.650.000	-

	Description	Code	Function
2a	Crossmember	1.870.595.000	Power unit mount

3. Fit tools (3a) and (3b), then connect them to the tool fitted previously.

	Description	Code	Function
3a	Crossmember	1.860.851.003	Engine mount

	Description	Code	Function
3b	Vertical support	1.871.001.300	Engine mount

Anchor the engine using support hooks and brackets/chains, taking the greatest care to find the engine balance point to prevent it tipping over in any way.

1. Unscrew the upper gearbox bolts.

1. Unscrew the bolt and nuts (1a) and remove flexible block (1b).2. Undo bolt (2a) and remove bracket (2b) joining the gearbox and mount.

1. Disconnect the reversing sensor switch electrical connection.

	Description	Connector
1	Reversing lights switch	I020

2. Undo nut (2a) and disconnect the earth lead on the gearbox (2b).

	Description	Connector
2b	Battery earth on engine	C002

1. Unscrew bolts (1a) and remove rigid power unit mount (1b).

1. Position a hydraulic lift (1a) with plate (1b) and brackets (1c) to support removal of the gearbox.

	Description	Code	Function
1b	Support plate	1.870.856.000	Gearbox support

	Description	Code	Function
1c	Brackets	1.870.847.000	Support

1. Unscrew bolt (1a) and nut (1b) securing the gearbox.

1. Lower the assembly, taking care not to damage any interfering parts, remove the gearbox-differential assembly (1b).

Refitting ( Removing

) Position the gearbox and differential assembly in the engine compartment fastened to the tools used for removal and fit in its seat, taking care not to damage the adjacent components.Centre the gearbox-differential unit on the locating pins and secure by tightening the nut and lower bolts.

To aid location of the pins on the engine and gear shaft on the clutch driven plate, swing the gearbox/differential unit slightly from side to side.

	Value daNm	Fastening	Component	Ø
-	8	Bolt	(lower gearbox)	M12x1.25

	Value daNm	Fastening	Component	Ø
-	8	Nut	(lower gearbox)	M12x1.25

Remove the tools and the hydraulic lift positioned previously when handling the gearbox during removal.

	Description	Code	Function
-	Support plate	1.870.856.000	Gearbox support

	Description	Code	Function
-	Brackets	1.870.847.000	Support

Tighten the upper bolts securing the gearbox to the crankcase.

	Value daNm	Fastening	Component	Ø
-	8	Bolt	(upper gearbox)	M12x1.25

Fit the gearbox side rigid power unit mount.Tighten the mount bolts to the gearbox in accordance with the specified torque setting.

	Value daNm	Fastening	Component	Ø
-	5	Bolt	Gearbox side	M10x1.25

Fit the bracket joning the gearbox and mount in its seat and tighten the bolt to torque.

	Value daNm	Fastening	Component	Ø
-	2.5	Bolt	-	M8

Fit the gearbox side flexible block in its seat.Tighten the bolt securing the rigid mount to the gearbox side flexible block and tighten to the specified torque.

	Value daNm	Fastening	Component	Ø
-	8	Bolt	Flexible block side	M12 X 1.25

Tighten the nuts securing the flexible block to the body to torque.

	Value daNm	Fastening	Component	Ø
-	5	Nut	Body side	M10 X 1.25

Remove the power unit bracket fitted previously.Remove the power unit support tools fitted previously.

	Description	Code	Function
-	Crossmember	1.870.595.000	Power unit support

	Description	Code	Function
-	Support blocks	1.870.650.000	-

	Description	Code	Function
-	Crossmember	1.860.851.003	Engine mount

	Description	Code	Function
-	Vertical support	1.871.001.300	Engine mount

Position the bonnet lid catch in its seat and tighten the bolts. Op. 7055A42 FRONT GRILLE - R+RConnect the reversing sensor electrical connection.

	Description	Connector
-	Reversing lights switch	I020

Connect the earth lead to the gearbox and tighten the nut.

	Description	Connector
-	Battery earth on engine	C002

Fit the starter motor in its seat and tighten the bolts to torque.

	Value daNm	Fastening	Component	Ø
-	2.7	Bolt	-	M8

Connect the electrical wiring to the starter motor and tighten the nut.

	Description	Connector
-	Starter motor	A020A

	Description	Connector
-	Starter motor	A020B

	Description	Connector
-	Starter motor	A020C

Tighten the bolts securing the beam to the body to the specified torque.

	Value daNm	Fastening	Component	Ø
-	8	Bolt	-	M12X1.25

Remove the hydraulic jack.Tighten the bolts securing the steering box to the suspension beam to the specified torque.

	Value daNm	Fastening	Component	Ø
-	6.5	Bolt	-	M12X1.25

Proceed in the same way on both sides of the vehicle.Tighten the nut securing the stabiliser bar to the swivel head to torque.

	Value daNm	Fastening	Component	Ø
-	5	Nut	-	M10X1.25

Position the lower reaction link in its seat and tighten the bolt securing it to the gearbox to torque.

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