1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD - Lancia - MUSA - eLearn

184000788 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD

1. Open the cover (1a), loosen the nuts and disconnect the electrical connections (1b) from the starter motor.

	Description	Connector
1b	Starter motor	A20

2. Undo the bolts (2a) and remove the starter motor (2b).

Undo the bolts and remove the plate between the gearbox and engine.1. Undo the fastenings (1a) and remove the manual gearbox and differential (1b).

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.001

2. Undo the clutch tray fixing bolts, loosening them a little at a time, diagonally until the diaphragm spring is discharged.3. Remove the clutch tray.Remove the clutch plate.

1. Place the clutch plate and the clutch tray (1a) in their housing using the tool (1b) for centering.

When fitting the clutch plate the correct position is shown by the words "engine side" and "gearbox side".

Handle the clutch plate carefully. Do not touch the surfaces of the friction linings with your hands.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch tray.

	Description	Code
1b	Clutch locating tool	1.875.086.000

Tighten the clutch fixing bolts by hand.2. Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.8

3. Remove the flywheel lock.

	Description	Code
3	Counter-torque	1.860.846.001

Place the manual gearbox-differential unit in its housing and secure it tightening the bolts and the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M12	(Engine crankcase side) 7.2 - 8.8

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX/DIFFERENTIAL	M12	(Engine crankcase side) 7.2 - 8.8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M10	(Crankcase sump side) 5.0 - 6.1

Place the plate in position between the gearbox and engine and secure it using the bolts.Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	2.4 ÷ 3.0

Connect the electrical connections to the starter motor and secure them using the nut.Close the cover.