2110E22 REAR DRIVE TRANSFER CASE - OVERHAUL WITH THE GEARBOX DETACHED (SUV) - Fiat - PANDA - eLearn

169001555 - 2110E22 REAR DRIVE TRANSFER CASE - OVERHAUL 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.2. Undo the nut fixing the bevel pinion to the flange.

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

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.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).

	Description	Code	Function
1a	Reaction plate	1.870.845.000	Reaction plate

	Description	Code	Function
1b	Reaction plate	1.870.845.000	Reaction plate

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
1a	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 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 cylindrical pinion.

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 cylindrical pinion (2e).

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.2. Position the cylindrical pinion complete with extraction tools on the support surface of the press, then proceed with extracting the rear conical bearing inner race.

	Description	Code	Function
1a	Reaction plate	1.870.845.000	Reaction plate

	Description	Code	Function
1b	Reaction plate	1.870.845.000	Reaction plate

During this operation, support the cylindrical pinion 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.

Refitting ( Removing

) 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 tools (1a) and (1b) on the surface of a gauge.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.

	Description	Code	Function
1a	Dial gauge	1.871.005.300	Measurement

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

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	-	-

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 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 39.068 (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 - 0.04 mm ) ± 0.013 mmThe value 0.04 corresponds to the pre-loading for the two conical 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 cylindrical 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).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.

	Description	Code	Function
1a	Dial gauge	1.871.005.300	Measurement

	Description	Code	Function
1b	Template	1.871.005.200	Measuring thickness

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

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.

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 cylindrical pinion ring gear.1. Fit the front conical bearing inner race (1a) and the dummy cylindrical pinion (1b) in place in the rear drive idler casing.

	Description	Code	Function
1b	Dummy cylindrical pinion	1.871.005.600	Measurement

1. Fit the spacer (1a) and the rear conical bearing inner race (1b) on the dummy cylindrical pinion (1c).

	Description	Code	Function
1b	Dummy cylindrical pinion	1.871.005.600	Measurement

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

	Description	Code	Function
1a	Dummy cylindrical pinion	1.871.005.600	Measurement

	Description	Code	Function
1c	Dummy cylindrical pinion	1.871.005.600	Measurement

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

	Description	Code	Function
1a	Gauge	1.871.004.600	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 cylindrical pinion 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 cylindrical pinion.

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 our case: VP = 50.11 mm - 50 mm VP = 0.11

The value VP can be either positive or negative

Determine the thickness S of the two scraper rings for the bevel pinion ring gear on the basis of the following formula: S = [ X + (VP) ] ± 0.04S = total thickness of two scraper rings required (mm) X = value measured using feeler gauge (mm) VP = difference between nominal value of sample pin and marking 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 mm S = [0.73 + 0.11] ± 0.04 mm = 0.80 ¸ 0.88 The sizes 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 obtain a total thickness of 0.85 mm (average of the values calculated) use a 0.30 mm shim and a 0.55 mm one.Example of numerical calculation with negative VP.Let us suppose that the marking on the ring gear is 49.97 mm; in this case a negative VP is produced: VP = 49.97 mm - 50 mm VP - - 0.03 mm - Going back to the previous example: X = 0.73 mm (feeler gauge reading) VP = - 0.03 mm S = [0.73 + (-0.03)] ± 0.04 mm = 0.66 ¸ 0.74 To 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.

	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.

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 cylindrical pinion. 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 cylindrical pinion 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 ring gear for the bevel pinion and the centre of rotation of the cylindrical pinion (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 cylindrical pinion (73 mm). In our case: VP = 73.05 mm - 73 mm VP = 0.05

The value VP can be either positive or negative.

Determine the thickness S of the scraper rings for the bevel pinion support on the basis of the following formula: S = [ 3 - X + (VP) ] ± 0.04 S = total thickness of scraper rings required (mm) 3 = reference constant (mm) X = value measured using feeler gauge (mm) VP = difference between nominal value of sample pin and marking 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 mm S = [3 - 1.06 + (0.05) ± 0.04 mm = 1.95 ¸ 2.03 The sizes 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 obtain 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 suppose that the marking on the ring gear is 72.98 mm; in this case a negative VP is produced: VP = 72.98 mm - 73 mm VP - -0.02 mm - Going back to the previous example: X = 1.06 mm (feeler gauge reading) VP = - 0.02 mm S = [3 - 1.06 + (-0.02)] ± 0.04 mm = 1.88 ¸ 1.96 To produce a total thickness of 1.90 mm (average of the values calculated), use a 1.20 mm shim and a 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 cylindrical pinion (1c).

	Description	Code	Function
1a	Fitting tool	1.871.004.400	Bearing fitting tool

1. Positino the cylindrical pinion (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 cylindrical pinion.

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 conical bearing (2b) in position on the cylindrical pinion (2c).

1. Fit the inner race for the front conical bearing (1a) and the two scraper rings (1b) selected previously on the cylindrical pinion.

1. Fit the ring gear (1a) and tighten the fixing nut (1b) to torque.

Always replace the fixing nut. The new nut should have been pre-treated with a thread-locking agent, if it has not, apply some.

	Value daNm	Fastening	Component	Ø
-	25	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.

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. The new nut should have been pre-treated with a thread-locking agent, if it has not, apply some.

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

	Value daNm	Fastening	Component	Ø
2b	25	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 fixing bolts to torque.

	Value daNm	Fastening	Component	Ø
2	2.7	Bolt	-	-

1. Position the assembly on a bench.2. Fit the reaction lever in place on the flange to prevent rotation.

	Description	Code	Function
2	Counter-torque	1.871.004.800	Counter-torque

3. Using the special dial gauge (3a) 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.

	Description	Code	Function
3a	Dial gauge	1.871.005.300	Measuring clearance

	Subject	Value
-	Clearance between ring gear and bevel pinion (mm)	0.15 - 0.20

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.

Fit the two inspection covers in place, renewing the bead of sealant.

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

Tighten the bolts fixing the two inspection covers to torque.

	Value daNm	Fastening	Component	Ø
-	0.85 - 1.0	Bolt	-	-

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	-	-	510	Sealant

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

	Value daNm	Fastening	Component	Ø
-	7	Bolt	-	-

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 fixing bolts to torque.

	Value daNm	Fastening	Component	Ø
-	2.5	Bolt	-	-

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