184002551 - 2110B26 MANUAL GEARBOX (SIX SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD WASH AND CHECK PARTS - REPLACE SYNCHRONIZERS AND INTERNAL PARTS IF NECESSARY

Removing ( Refitting ) REMOVING AND FITTING THE 5TH AND 6TH GEAR- Arrange the gearbox on the rotary stand using the mount.
ToolNameOperationFunctionValidity
1871000000Cavalletto rotativo2110B26Revisione cambi1.4 16v
ToolNameOperationFunctionValidity
1871001014Supporto2110B26Revisione cambi1.4 16v
- Remove the rear cover.
- Straighten the staking of the 5th and 6th speed gear nut. Remove the 5th and 6th speed engagement fork nut and engage two speeds.
The simultaneous engagement of two gears results in the gearbox mainshafts locking; this operation is necessary in order to be able to release the ringnuts securing the gears.
- Unscrew the nut securing the 5th and 6th speed gears to the mainshaft.
- Unscrew the left-threaded bolt securing the 5th and 6th gears to the layshaft.
- Remove the layshaft rear bearing.
ToolNameOperationFunctionValidity
1840005308Staffe2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1840005001Estrattore2110B26Estrazione cuscinetto posteriore albero secondarioeEstrazione ingranaggi1.4 16v
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1842133000Estrattore2110B26Rimozione cuscinetto posteriore albero secondarioRimozione ingranaggi1.4 16v
- Remove the 6th speed gear from the layshaft.
- Unscrew the spacer for the 5th and 6th speed gears from the layshaft.
- Remove the 6th speed gear with its bush from the mainshaft. Then remove the 6th speed synchroniser ring.
ToolNameOperationFunctionValidity
1840005308Staffe2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1840005001Estrattore2110B26Estrazione cuscinetto posteriore albero secondarioeEstrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1842134000Estrattore2110B26Rimozione ingranaggi1.4 16v
- 6th speed synchroniser ring, 6th speed gear, bush
- Remove the presynchronisation blocks from the 5th and 6th speed hub.
- Remove the 5th and 6th speed engagement fork and sleeve.
- Remove the gear, the synchroniser ring and the 5th and 6th speed hub from the mainshaft.
ToolNameOperationFunctionValidity
1840005309Staffe2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1840005002Estrattore2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1842134000Estrattore2110B26Rimozione ingranaggi1.4 16v
- Remove the 5th speed gear bush from the mainshaft.
ToolNameOperationFunctionValidity
1840005309Staffe2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1840005002Estrattore2110B26Estrazione ingranaggi1.4 16v
- Remove the bolts securing the bearing retaining plate to the gear casing. This allows the mainshaft a slight amount of play to facilitate the next operation.
- Use the tool to prise up the 5th speed gear to allow the extractor to be correctly fitted.
ToolNameOperationFunctionValidity
1840005400Estrattore2110B26Estrazione ingranaggio1.4 16v
ToolNameOperationFunctionValidity
1842133000Estrattore2110B26Rimozione cuscinetto posteriore albero secondarioRimozione ingranaggi1.4 16v
- Remove the 5th speed gear from the layshaft.
ToolNameOperationFunctionValidity
1840005309Staffe2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1840005002Estrattore2110B26Estrazione ingranaggi1.4 16v
ToolNameOperationFunctionValidity
1842133000Estrattore2110B26Rimozione cuscinetto posteriore albero secondarioRimozione ingranaggi1.4 16v
Refitting ( Removing ) - Fit the bearing retaining plate to the gear casing and tighten the bolts to the specified torque.
ComponentFasteningØValue (daNm)Validity
Piastra ritegno cuscinetti scatola cambioViteM.........................1.4 16v
- Fit the 5th speed driven gear to the layshaft.
ToolNameOperationFunctionValidity
1870631000Battitoio2110B26Introduzione ingranaggi1.4 16v
- Fit the 5th speed gear bush to the mainshaft.
ToolNameOperationFunctionValidity
1870631000Battitoio2110B26Introduzione ingranaggi1.4 16v
- Fit the 5th speed drive gear to the layshaft.
- Fit the 5th speed drive gear synchroniser ring to the mainshaft.
- Fit the 5th and 6th speed sliding engagement sleeve hub.
ToolNameOperationFunctionValidity
1870631000Battitoio2110B26Introduzione ingranaggi1.4 16v
- Fit the 5th and 6th speed sliding engagement fork and sleeve.
Fit the sleeve so that the presynchronisation pad grooves are aligned with their seats.
- Fit new presynchronisation pads.
- Fit the 6th speed synchroniser ring to the mainshaft.
- Fit the 6th speed drive gear to the mainshaft.
- Fit the 6th speed drive gear bush.
ToolNameOperationFunctionValidity
1875088000Battitoio2110B26Introduzione ingranaggi1.4 16v
- Fit the spacer on the layshaft.
- Fit the 6th speed driven gear to the layshaft.
- Remove the layshaft rear bearing.
- Tighten the left-threaded bolt securing the driven gears to the layshaft to the specified torque.
ComponentFasteningØValue (daNm)Validity
Ingranaggi condotti albero secondarioViteM.......10.51.4 16v
- Tighten the nut fixing the gear to the mainshaft to the recommended torque.
ComponentFasteningØValue (daNm)Validity
Ingranaggio albero primarioDadoM.......11.51.4 16v
The nut must be staked and replaced whenever it requires removal.
- Remove the mainshaft rear bearing from its seat on the cover.
The bearing removal operation is destructive. The bearing must therefore always be replaced whenever it needs removing.
The operation can be carried out using commercially-available extractors.
- When refitting the oil locator (1), reference hole (2) must always be positioned as shown in the figure.
- Remove the mainshaft rear bearing (1) from its seat on the cover.