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