2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Alfa - 147 - eLearn

3025121 - 2110A10 manual gearbox and differential - r + r

) Position the vehicle on the ramp.Proceed with removal - 5530B10 battery - r+r .Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. .1. Disconnect the earth cable from the gearbox side rigid power unit mounting.

	Name	Connector
1	Earth on engine	C40A

2. Disconnect the electrical connection from the reversing switch.

	Name	Connector
2	Reversing lights switch	I20

1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

Release the electrical wiring for the air flow meter from the fastening on the air intake hose.2. Disconnect the oil vapour recovery pipe from the air intake hose.3. Disconnect the air intake hose from the throttle casing.

1. Remove the air filter assembly and intake duct complete with air flow meter after releasing it from the resonator unit.

1. Move the rubber protection, as necessary, to gain access to the hydraulic clutch actuator pipe coupling.2. Complete release the flexible spring retaining the pipe to the actuator casing.3. Disconnect the flexible pipe from the vibration damper to the hydraulic clutch actuator, hydraulic actuator side.

Collect the clutch fluid which comes out in a suitable container, then seal the pipe and place it to the side.

4. Undo the nuts (4a) and move the hydraulic clutch circuit vibration damper (4b), complete with pipe, to the side.

1. Disconnect the gear selector and engagement cables.

To disconnect the gear selector cables, press the release tabs shown in the diagram and move the cable backwards.

2. Remove the safety plates (2a) and release the gear selector and engagement cables from the mounting bracket (2b).

1. Undo nuts (1a) and move bonnet lid catch (1b) aside without disconnecting the bonnet opening cable.

1. Fit two brackets to the engine to support the power unit the power unit safely as shown in the figure.

1. Fit the tool (1a), complete with support mountings (1b).

	Name	Country
1a	Crossmember	1.820.581.000

	Name	Country
1b	Support mountings	1.870.650.000

2. Fit the tools (2a) and (2b), then connect them using links (2c) to the brackets fitted previously.

	Name	Country
2a	Crossmember	1.860.851.003

	Name	Country
2b	Vertical support	1.870.748.000

1. Undo the upper two bolts fixing the manual gearbox and differential to the engine.

Proceed with removal - 4450B12 front or rear wheels (two) - r+r .Proceed with removal - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. (Left side).Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r .1. Unscrew the bolts securing the drive shafts to the internal differential/drive shaft.

1. Undo the nut for the bolts securing the fronts suspension lower wishbones to the knuckles.2. Loosen the bolts fixing the front shock absorber forks to the lower track control arms.3. Use the tool to disconnect the front suspension lower wishbone from the steering knuckles.

	Name	Country
3	Extractor	1.821.169.000

1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b) from the front damper forks.

2. Undo the bolts securing the flexible block on the power unit rear rigid mounting to the front suspension crossmember.3. Undo the bolts (3a) and the nut (3b), then remove the power unit rigid rear support (3c), complete with flexible mounting (3d).

1. Undo bolts (1a) and nuts (1b) fixing the manual gear lever mounting.2. Recover the plates.3. Slacken the rear bolts fixing the manual gear lever mounting.4. Lower the gearlever mount as necessary.

1. Fit the tool (1a) on the hydraulic jack (1b) to support the front suspension frame.

	Name	Country
1a	Flange	1.860.978.000

1. Undo the bolts securing the power steering box to the front suspension crossmember.2. Undo the rear bolts fixing the front suspension crossmember to the bodyshell.3. Undo the side bolts fixing the front suspension crossmember to the bodyshell.

1. Undo the bolt (1a) and release the power assisted steering pipes mounting bracket (1b) from the front suspension crossmember.

1. Slowly lower the hydraulic jack and remove the front suspension crossmember (1a) complete with lower track control arms (1b) and anti-roll bar (1c).

1. Undo the drain plug and drain the manual gearbox-differential oil.

Collect the gearbox-differential oil in a suitable container.

1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).2. Remove the dust cover.

1. Undo the bolts (1a) and move the starter motor (1b) away from the gearbox, then secure it.

1. Undo the bolts (1a) and remove the engine flywheel protection (1b).2. Undo the bolts fixing the manual gearbox and differential to the crankcase sump.3. Loosen the bolt fixing the manual gearbox and differential to the crankcase.

1. Undo the two bolts fixing the gearbox casing to the bell housing.2. Fit the tool (2a) on a hydraulic jack and fix it using the bolts removed previously and bolt (2b).

	Name	Country
2a	Support	1.860.859.002

1. Undo the bolts fixing the gearbox side power unit rigid support to the bodyshell.2. Undo the bolts (2a) and (2b), then remove the gearbox side rigid power unit support (2c) complete with flexible mounting (2d).

Completely undo the bolt loosened previously fixing the manual gearbox and differential to the crankcase.1. Lower the hydraulic jack and remove the manual gearbox and differential.

Refitting ( Removing

) Place the manual gearbox and differential back in its housing using the hydraulic jack and the support tool and secure it using the lower bolt to the crankcase without tightening it. 1. Fit the gearbox side rigid power unit support (1a) complete with flexible mounting (1b) and secure by tightening bolts (1c) and (1d) to the recommeded torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Manual gearbox/differential side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Manual gearbox/differential side) 4.5 ÷ 5.5

2. Tighten the bolts fixing the power unit gearbox side rigid support flexible mounting to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(Bodyshell side) 3.2 ÷ 3.9

Undo the bolts and separate the supporting tool from the manual gearbox and differential, then replace it after having removed it from the hydraulic jack.

	Name	Country
-	Support	1.860.859.002

1. Tighten the bolts fixing the gearbox casing to the bell housing to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	GEARBOX GEAR CASING	M8	(Mechanical. gearbox.differential upper. side../..)2.3 ÷ 2.8

1. Tighten the bottom bolt securing the manual gearbox with differential to the crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

2. Tighten the bolts fixing the manual gearbox and differential to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.0

Place the engine flywheel protection back in its housing and secure it using the bolts.1. Place the starter motor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 ÷ 3.0

1. Place back in its housing the intermediate drive shaft (1a) complete with dust cover (1b) and secure it with its bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

1. Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Plug	GEAR CASING PADS	M22	2.9 ÷ 4.3

Use a hydraulic jack with mounting tool to refit the front suspension beam with lower wishbones and anti-roll bar.

	Name	Country
-	Flange	1.860.978.000

1. Tighten the side bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Tighten the rear bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 7.2 ÷ 8.8

3. Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.7 ÷ 14.3

Remove the hydraulic jack with mounting tool from the front suspension beam.Place the power assisted steering pipes mounting bracket back in its housing and secure it to the front suspension crossmember using the bolt.Refit the handbrake control mount and secure with bolts and nuts.1. Place the power unit rigid rear support (1a), complete with flexible mounting (1b) back in its housing and fasten it by tightening the bolts (1c) and (1d) and the nut (1e) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Crankcase sump side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1e	Nut	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 7.2 ÷ 8.8

2. Tighten the bolts fixing the power unit rigid rear support flexible mounting to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 3.2 ÷ 3.9

3. Place reinforcement link (3a) back in its housing and secure by tightening bolt (3b) and nut (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	(Power unit rear rigid mounting side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
3c	Nut	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M8	(Engine crankcase side) 2.4

1. Connect the front suspension anti-roll bar joints (1a) to the front shock absorber forks and secure them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M8	(Front shock absorber fork side.) 4.1 ÷ 5.0

1. Connect the front suspension lower wishbones to the knuckles and secure by tightening the nuts to the required torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	FRONT SUSPENSION LOWER LEVER	M14	(Steering knuckle side) 8.6 ÷ 9.5

2. Tighten the bolts securing the front damper forks to the lower wishbones to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Lower track control arm side) 10.8 ÷ 13.2

1. Tighten the bolts securing the drive shafts to the intermediate differential/drive shaft internal drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	DRIVESHAFT	M8	(Differential. internal. driveshaft./side..) 3.5 ÷ 4.3

Proceed with the refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+rProceed with the refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).Proceed with the refitting - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. (Left side).Proceed with refitting - 4450B12 front or rear wheels (two) - r+r .1. Tighten the upper two bolts fixing the manual gearbox and differential to the engine to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.860.851.003

	Name	Country
-	Vertical support	1.870.748.000

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Support mountings	1.870.650.000

Refit the bonnet lid catch and secure with nuts.Connect the gear selector and engagement cables and secure them to the mounting bracket using the safety plates.Place the hydraulic clutch circuit vibration damper back in its housing and secure it using the nuts.1. Position the flexible spring as illustrated in the diagram, i.e. not fully introduced.

Make sure that the housing on the hydraulic actuator for the O-Ring and the connector on the pipe are perfectly clean and intact.If necessary, lubricate the O-Ring with brake fluid to facilitate the subsequent fitting of the pipe.Do not use detergents or mineral lubricants incompatible with the brake fluid materials.

2. Fully introduce the flexible pipe from the vibration damper to the hydraulic clutch actuator, in the hydraulic clutch actuator.Fully insert the flexible spring so that the pipe is locked in place.Place the rubber protection back in its housing.

Place the air filter assembly and air intake duct complete with air flow meter back in its housing and connect it to the resonator unit.Connect the air intake hose to the throttle casing.Connect the oil vapour recirculation pipe to the air intake sleeve.Connect the electrical connection to the air flow meter and secure the electrical wiring with the band to the air intake duct.Connect the electrical connection to the reversing switch.Connect the earth cable to the gearbox side rigid power unit mounting.Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. .Proceed with refitting - 5530B10 battery - r+r .Refill the manual gearbox and differential - 2110A04 Manual gearbox and differential OIL - Check level and top up, if necessary .Bleed the air and top up the level in the hydraulic clutch system - 1820B08 Clutch release HYDRAULIC SYSTEM - Bleeding air and restoring level .Remove the car from the ramps.

It is not possible to remove/refit the manual gearbox with differential in the car. The power unit has to be removed/refitted and then the manual gearbox with differential has to be separated from the engine at the bench.