2752661 - 2110A11 manual gearbox with differential - r r for versions with hydraulic selection

Removing ( Refitting )  - 5530B10  battery - r+r - 5530B56  BATTERY DRIP TRAY COVER - R.R. - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 2127C40  hydraulic speed selection hydraulic actuator unit and clutch - r r1. Open the protective cover.2. Undo the fixing nut (2a) and disconnect the starter motor electrical wiring (2b).

NameConnector
2bStarter' motor A20A

NameConnector
2bStarter' motor A20B

NameConnector
2bStarter' motor A20C
3. Disconnect the electrical connection for the speedometer sensor.

NameConnector
3Speedometer sensor K84
4. Undo the bolts (4a) fixing the starter motor (4b) and remove it.
 - 1072C44  exhaust manifold heat shield on bulkhead - r+r - 7055A42  front grille - r+r1. Unscrew the retaining nut.2. Fit the tool for releasing the steering track rod ends.

NameCountry
2Extractor1.871.000.700
3. Release the steering track rod ends from the wheel hub.4. Undo the fixing bolts (4a) and release the front steering knuckle (4b) from the shock absorber (4c). Work in the same way on both sides of the vehicle.
Vehicle left side.1. Open the bands fastening the coupling boot.2. Release the driveshaft from the differential side joint.
Work in the same way for the right side of the vehicle as described above for the left side, carrying out the following operation first:1. Undo the fixing nut (1a) and the fixing bolts (1b) and move the wheel arch liner (1c) aside.
1. Undo the fixing bolts (1a) and remove the timing dust guard (1b).
 - 1024B54  engine flywheel protection r r - 1008C32  GEARBOX LOWER REACTION ROD ' -R.R.1. Undo the fixing bolts (1a) and move the lock (1b) aside.2. Fit the tool (2a), complete with support mountings (2b).

NameCountry
2aCrossmember1.870.595.000

NameCountry
2bSupport mountings1.870.650.000
3. Fit the tools (3a) and (3b), then connect them to the tool fitted previously.

NameCountry
3aCrossmember1.860.851.003

NameCountry
3bVertical support1.871.001.300
Secure the engine, using the special hooks and brackets/chains taking great care to ensure that the engine is properly balanced.
1. Undo the upper bolts securing the gearbox to the engine.
1. Undo the bolt fixing the gearbox side power unit rigid support flexible mounting.
1. Undo bolts (1a) securing engine mount (1b) to the gearbox and remove
1. Undo the fixing bolts (1a) and remove the clutch cable mounting bracket (1b).2. Using a special hydraulic lift (2a), position the gearbox support tools (2b).

NameCountry
2bGearbox mount1.860.873.000
1. Undo the remaining fixing bolts (1a) and the nut and lower the assembly taking care not to damage any interfering components, then remove the gearbox-differential assembly (1b).
Refitting ( Removing ) Position the gearbox and differential assembly fastened to the tools used for the removal in the engine compartment, and fit it in place taking care not to damage surrounding components. Centre the gearbox-differential unit on the centring pins and secure it, tightening the lower nut and bolts to torque.
To facilitate centring the pins on the engine and the gearbox shaft and the clutch driven plate, move the gearbox-differential unit slightly.

FasteningComponentØValue(daNm)
-BoltMANUAL GEARBOXM12 x 1.25(below gearbox) 8

FasteningComponentØValue(daNm)
-NutMANUAL GEARBOXM12 x 1.25(below gearbox) 8
Remove the tool positioned previously for manoeuvring the gearbox during the removal stage.

NameCountry
-Gearbox mount1.860.873.000
Tighten to torque the top bolts securing the gearbox to the engine block.

FasteningComponentØValue(daNm)
-BoltMANUAL GEARBOXM12 x 1.25(upper gearbox) 8
Fit the gearbox side power unit rigid support in place.Tighten the bolts fixing the support to the gearbox to the recommended torque.

FasteningComponentØValue(daNm)
-BoltPOWER UNIT GEAR BOX END RIGID MOUNTM10 x 1.25(Gearbox side) 5
 - 1008C32  GEARBOX LOWER REACTION ROD ' -R.R. - 1024B54  engine flywheel protection r rTighten the bolt fixing the rigid support to the gearbox side flexible mounting to torque.

FasteningComponentØValue(daNm)
-BoltPOWER UNIT GEAR BOX END RIGID MOUNTM12 x 1.25(Flexible block side) 8
Remove the power unit anchoring bracket fitted previously.Remove the tools supporting the power unit previously fitted.

NameCountry
-Crossmember1.870.595.000

NameCountry
-Support mountings1.870.650.000

NameCountry
-Crossmember1.860.851.003

NameCountry
-Vertical support1.871.001.300
Position the bonnet catch in its seating and tighten the fixing bolts.Work in the same way on both sides of the vehicle as illustrated below:Fit the driveshaft in place in the differential side joint.Refit the joint boot fastening band.Position the front hub steering knuckle in the housing in the shock absorber and tighten the fixing bolts to torque.

FasteningComponentØValue(daNm)
-NutFRONT HUB WITH BEARINGSM10 x 1.257.5
Fit the steering track rod ends in place and tighten the fixing nut to torque.

FasteningComponentØValue(daNm)
-NutADJUSTABLE STEERING LINKSM10 x 1.254
 - 7055A42  front grille - r+r - 1072C44  exhaust manifold heat shield on bulkhead - r+rConnect the electrical connection of the speedometer sensor.

NameConnector
-Speedometer sensor K84
Fit the starter motor in place and tighten the fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltSTARTER MOTORM82,7
Connect the electrical wiring to the starter motor and tighten the fixing nut.

NameConnector
-Starter' motor A20A

NameConnector
-Starter' motor A20B

NameConnector
-Starter' motor A20C
Fit the timing dust guard in place and tighten the fixing bolts.Fit the mounting bracket for the ball joints in place.

FasteningComponentØValue(daNm)
-BoltGEAR ENGAGEMENT ASSEMBLY CABLEM83
Fit the ball joints for the gear selection and engagement flexible cables in place. - 2127C40  hydraulic speed selection hydraulic actuator unit and clutch - r r - 0010T21  coolant check density and top up if necessary - 0010T47  hydraulic system fluid for gearbox with hydraulic selection check level and top up if necessary - 0010T48  hydraulic system for gearbox with hydraulic selection bleed air - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 5530B56  BATTERY DRIP TRAY COVER - R.R. - 5530B10  battery - r+rRemove the vehicle from the lift.