184001122 - 2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY

Removing ( Refitting ) 1. Remove the hydraulic jack (1a) and the support tools (1b) and (1c) used for the removing-refitting operations from the gearbox and differential.

NameCountry
1bMount1.870.689.000

NameCountry
1cGearbox mount1.860.873.000
1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).
Two operators are needed for this operation.

NameCountry
-Rotating stand1.871.000.000

NameCountry
1bSupport1.871.001.014
1. Undo the bolts (1a) and remove the gearbox rear cover (1b).
Use a drier to facilitate the removal of the sealant.
2. Remove the differential output shafts with external three lobe joints.
Engage any gear using the gear selector/engagement lever.1. Undo the stud (1a) and the fixing bolts (1b), then remove the gear engagement unit cover (1c).
1. Undo the 5 th speed selector fork (1b) bolt (1a).Engage 5 th speed pressing the selector fork on the main shaft.
The simultaneous engagement of two gears will cause the gearbox shafts to lock.
2. Remove the staking from the main and layshaft ring nuts using a suitable drift.3. Loosen the main and layshaft ring nuts.Place the selector fork for 5 th speed in neutral.
Positioning the selector fork for 5 th speed in neutral is necessary to prevent the synchronizer rollers from being lost.
1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5 th speed driven gear (2a) using the tool (2b).

NameCountry
2bExtractor1.840.005.400
1. Remove the roller and spring retaining flange for the 5 th speed synchronizer.2. Remove the 5 th speed engagement fork.3. Remove the 5 th speed engagement sleeve.4. Remove the springs and rollers for the 5 th speed hub.
1. Remove the hub for the 5 th speed sliding sleeve (1a), the 5 th speed synchronizer (1b) and the 5 th speed drive gear (1c), using the tool (1d).

NameCountry
1dExtractor1.840.005.400
1. Remove the bush for the 5 th speed drive gear (1a) using the tool (1b).

NameCountry
1bExtractor1.845.057.000
1. Undo the bolts (1a) and remove the rear bearing retaining plate (1b).
1. Remove the rear bearing circlips.
To facilitate the fitting of the circlips, place them with their openings at the front.
2. Undo the reverse idler gear shaft bolt.
1. Undo the bolts (1a) and remove the gearbox casing (1b).2. Undo the bolts (2a) and remove the support and reverse gear lever and fork (2b).
1. Undo the bolt (1a) and release the gear engagement fork guide rod (1b).2. Remove the 3 rd -4 th speed engagement fork.3. Remove the reverse gear engagement fork control lever.4. Remove the 5 th speed selector fork control lever.5. Remove the 1 st -2 nd speed engagement fork.
1. Remove the reverse idler gear.2. Remove the main shaft assembly.3. Remove the layshaft assembly.
1. Undo the bolts (1a) and remove the differential casing cover (1b) complete with gasket (1c) and oil seal (1d).
The gasket and the seal should always be replaced.
1. Undo the bolt (1a) and remove the speedometer idler gear (1b).
1. Undo the bolts (1a) and remove the manual gearbox and differential support (1b) complete with oil seal.2. Remove the magnet.3. Remove the differential bearing pre-loading scraper ring.4. Remove the differential assembly.5. Remove the differential bearing outer races.
1. Remove the clutch thrust bearing outer linkage circlip.2. Remove the outer linkage (2a) and the bush (2b) for the clutch thrust bearing.
1. Remove the inner linkage (1a) and the bush (1b) for the clutch thrust bearing.
Replace the inner and outer bushes each time the clearance for the thrust bearing control shaft is excessive.
1. Remove the staking and, using a universal extractor (1a), remove the main shaft oil seal (1b) from the manual gearbox and engine support.
Proceed with dismantling the layshaft.1. Remove the bearing circlip.2. Remove the rear bearing (2a) and the 4 th speed driven gear (2b) using the tools (2c), (2d) and (2e).

NameCountry
2cExtractor1.840.005.002

NameCountry
2dClamps1.840.005.301

NameCountry
2eExtractor1.842.133.000
3. Remove the spacer between the 3 rd and 4 th speed driven gears.
1. Remove the 3 rd speed driven gear (1a) and the 2 nd speed driven gear (1b) using the tools (1c) and (1d).

NameCountry
1cExtractor1.840.005.002

NameCountry
1dClamps1.840.005.303
2. Remove the 2 nd speed synchronizer ring (2a) and the 1 st and 2 nd speed sliding sleeve (2b).Keep the pre-synchronizer mountings for the 1 st and 2 nd speed hub.
1. Remove the hub circlip.2. Remove the 1 st speed driven gear (2a), the 1 st speed synchronizer ring (2b) and the hub for the 1 st and 2 nd speed sliding sleeve (2c) using the tools (2d) and (2e).

NameCountry
2dExtractor1.840.005.002

NameCountry
2eClamps1.840.005.306
For the removal of the layshaft front bearing, see    Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
Proceed with the dismantling of the main shaft.1. Remove the rear bearing (1a) and the 4 th speed drive gear (1b) using the tools (1c) and (1d).

NameCountry
1cExtractor1.840.005.200

NameCountry
1dClamps1.840.005.103
2. Remove the 4 th speed synchronizer ring (2a) and the 3 rd and 4 th speed sliding sleeve (2b).3. Keep the springs (3a) and the rollers (3b) for the 3 rd and 4 th speed hub.
1. Remove the hub circlip for the 3 rd and 4 th speed sliding sleeve.2. Remove the hub for the 3 rd and 4 th speed sliding sleeve (2a), the 3 rd speed synchronizer (2b), the 3 rd speed drive gear (2c), using the tools (2d) and (2e).

NameCountry
2dExtractor1.840.005.001

NameCountry
2eClamps1.840.005.303
Refitting ( Removing ) Proceed with washing and checking the condition of all the components.Proceed with the reassembly of the main shaft, following the instructions given below.Lubricate the parts concerned using transmission fluid before fitting.1. Fit the 3 rd speed drive gear (1a) and the 3 rd speed synchronizer (1b).2. Fit the 3 rd and 4 th speed sliding sleeve hub (2a) using the tool (2b).

NameCountry
2bDrift1.870.152.000
1. Fit the springs on the 3 rd and 4 th speed sliding sleeve hub.2. Fit the 3 rd and 4 th speed sliding sleeve.
The references on the sleeve should coincide with the springs.
3. Fit the rollers between the springs and the notches in the 3 rd and 4 th speed sliding sleeve.4. Fit the 4 th speed synchronizer ring.Place the 3 rd and 4 th speed sliding sleeve in neutral to prevent losing the springs and rollers.5. Fit the 4 th speed drive gear.
1. Fit the rear bearing (1a) on the main shaft using the tool (1b).

NameCountry
1bDrift1.870.631.000
Proceed with the reassembly of the layshaft, following the instructions given below.Lubricate the parts concerned using transmission fluid before fitting.1. Fit the 1 st speed driven gear.2. Fit the 1 st speed synchronizer ring.3. Fit the 1 st and 2 nd speed sliding sleeve hub (3a) using the tool (3b).

NameCountry
3bDrift1.870.152.000
4. Fit the 1 st and 2 nd speed sliding sleeve hub circlip.
1. Fit the 1 st and 2 nd speed sliding sleeve.2. Fit the pre-synchronizer mountings in the notches in the 1 st and 2 nd speed sliding sleeve.3. Fit the 2 nd speed synchronizer ring. Position the 1 st and 2 nd speed sliding sleeve in neutral.4. Fit the 2 nd speed driven gear.5. Fit the 3 rd speed driven gear (5a) using the tool (5b).

NameCountry
5bDrift1.870.152.000
1. Fit the spacer between the 3 rd and 4 th speed driven gears.2. Fit the 4 th speed driven gear (2a) using the tool (2b).

NameCountry
2bDrift1.870.631.000
3. Fit the rear bearing (3a) using the tool (3b).

NameCountry
1bDrift1.870.631.000
4. Fit the rear bearing circlip on the layshaft.
1. Fit the main shaft oil seal (1a) on the manual gearbox/engine support using the fitting tool (1b) together with the drift (1c).

NameCountry
1bFitting tool1.870.796.000

NameCountry
1bGrip1.870.007.000
1. Fit the clutch thrust bearing linkage inner bush (1a) using the tool (1b).

NameCountry
1bFitting tool1.870.633.000
1. Fit the inner linkage (1a), the outer bush (1b) and the outer linkage (1c) for the clutch thrust bearing.2. Fit the clutch thrust bearing outer linkage circlip.
1. Fit the complete differential (1a) and differential bearing outer races (1b).2. Fit the magnet.Apply the recommended sealant to the contact surfaces between the differential support and the gearbox casing.

TypeComponentNameQty.
-SealantGEARBOX DIFFERENTIAL MOUNTLOCTITE 573-
3. Fit the manual gearbox differential casing support (3a), then tighten the bolts (3b) to the recommended torque.

FasteningComponentØValue(daNm)
3bBoltGEARBOX DIFFERENTIAL MOUNTM82

FasteningComponentØValue(daNm)
3bBoltGEARBOX DIFFERENTIAL MOUNTM103.5
1. Fit the speedometer idler gear (1a) and tighten the bolt (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltGEARSM60.5
1. Fit the layshaft assembly.2. Fit the main shaft assembly.3. Fit the reverse idler gear (3a) inserting the pin (3b) in the special housing in the casing.
1. Fit the 3 rd - 4 th speed engagement fork.2. Fit the 1 st - 2 nd speed engagement fork.3. Fit the 5 th speed engagement fork bracket.4. Fit the reverse gear engagement fork bracket.5. Fit the gear engagement fork guide rod in its housing.6. Tighten the bolt for the 5 th speed engagement fork bracket to the recommended torque.

FasteningComponentØValue(daNm)
6Bolt5thª speed selector forkM61.2
1. Fit the reverse gear engagement lever and fork support (1a) and tighten the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltGEARBOX INTERNAL LINKAGEM81.5
2. Apply the recommended sealant to the contact surfaces between the gearbox casing and the bellhousing.

TypeComponentNameQty.
-SealantGEARBOX GEAR CASINGLOCTITE 573-
3. Fit the gearbox casing (3a) and secure it tightening the bolts (3b) to the recommended torque.

FasteningComponentØValue(daNm)
3bBoltGEARBOX GEAR CASINGM8(Support side) 2
1. Tighten the reverse idler gear shaft bolt to the recommended torque.

FasteningComponentØValue(daNm)
1BoltREVERSE IDLERM82.6
2. Fit the rear bearing circlips.
To facilitate the fitting of the circlips, place them with their openings at the front.
1. Fit the rear bearing retaining plate (1a) and secure it tightening the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltMain and layshaft rear bearing retaining plate....M82
1. Fit the bush (1a) for the 5 th speed drive gear using the tool (1b).

NameCountry
1bDrift1.870.631.000
1. Fit the 5 th speed drive gear.2. Fit the 5 th speed synchronizer oil seal.3. Using the tool (3a), fit the hub for the 5 th speed sliding sleeve hub (3b) with the splining for the oil facing towards the gear.

NameCountry
3aDrift1.870.631.000
1. Fit the springs on the 5 th speed sliding sleeve hub.2. Fit the 5 th speed sliding sleeve.
The notches in the sleeve should be aligned with the springs.
3. Fit the 5 th speed engagement fork.4. Fit the rollers between the springs and the notches for the 5 th speed sliding sleeve.5. Fit the 5 th speed synchronizer roller and spring retaining plate.Place the 5 th speed sliding sleeve in neutral to prevent losing the springs and rollers.
1. Fit the 5 th speed driven gear (1a) on the layshaft using the tool (1b).

NameCountry
1bDrift1.870.631.000
Fit the ring nuts for the main and layshafts without tightening them.
1. Apply the recommended sealant to the contact surfaces between the gearbox casing and the gear engagement assembly cover.

TypeComponentNameQty.
1SealantM/D GEARBOX SPEED ENGAGEMENT UNIT COVERLOCTITE 573-
2. Fit the gear engagement assembly cover (2a) and tighten the bolts (2b) the recommended torque.

FasteningComponentØValue(daNm)
2bBoltM/D GEARBOX SPEED ENGAGEMENT UNIT COVERM62
Engage any gear using the gear selector/engagement lever.Engage 5 th speed by pressing the main shaft selector fork.
The simultaneous engagement of two gears will cause the gearbox shafts to lock.
1. Tighten the 5 th speed selector fork bolt to torque.

FasteningComponentØValue(daNm)
1Bolt5thª speed selector forkM61.2
2. Tighten the ring nuts securing the main and layshaft gears to torque.

FasteningComponentØValue(daNm)
2Ring nutGEAR SHAFTSM2011.8
1. Stake the ring nuts (1a) securing the main and layshaft 5 th speed gear using the tools (1b) and (1c).

NameCountry
1bPair of heads1.874.140.005

NameCountry
1bPliers1.874.140.001
1. Apply the recommended sealant to the contact surfaces between the gearbox rear cover and the gearbox casing.

TypeComponentNameQty.
1SealantGEARBOX REAR COVERLOCTITE 573-
2. Fit the gearbox rear cover (2a) and secure it tightening the bolts (2b) to the recommended torque.

FasteningComponentØValue(daNm)
2bBoltGEARBOX REAR COVERM60.5
1. Position the tool (1a), complete with dial gauge (1b), on the differential flange support surface then position the pointer in contact with the conical roller bearing outer race.

NameCountry
1aSupport1.895.655.000
Zero the dial gauge with a pre-loading of 1 mm.
1. Position the tool (1a), complete with dial gauge on the differential flange (1b), as illustrated and measure the difference.

NameCountry
1aSupport1.895.655.000
Calculate the size of the adjustment ring for pre-loading the differential bearings adding 0.12 mm to the difference measured.
0.12 mm corresponds to the interference for bedding in and the pre-loading of the differential bearings.
1. Place the differential bearing pre-loading adjustment shim of the size calculated or the next size up in the housing.
1. Fit the oil seal (1b) on the differential cover (1a) using the tools (1c) and (1d).

NameCountry
1cFitting tool1.870.629.000

NameCountry
1dGrip1.870.007.000
2. Fit the gasket on the differential cover.
The oil seal and the gasket should always be replaced.
1. Fit the differential cover (1a) and tighten the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltMAN G/BOX DIFF SEALING FLANGE/SM82
1. Fit the gearbox casing differential support oil seal (1a) using the tools (1b) and (1c).
The oil seal should always be replaced.

NameCountry
1bFitting tool1.870.630.000

NameCountry
1cGrip1.870.007.000
Fit the differential output shafts and outer three lobe joints.Undo the fixings and remove the gearbox and differential from the tool.
Two operators are needed for this operation.

NameCountry
-Support1.871.001.014
Remove the support tool for the overhaul stand and place it back on the board.Position the gearbox and differential on the tools used for the removal.

NameCountry
-Mount1.870.689.000

NameCountry
-Gearbox mount1.860.873.000