3026024 - 2110B20 manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary

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

NameCountry
1bMount1.820.146.000
2. Undo the bolts (2a) and remove the rear cover (2b).
1. Remove the left internal differential driveshaft (1a) using tools (1b) and (1c).

NameCountry
1bFlange1.820.229.000

NameCountry
1cCounter weight1.821.161.000
Replace the retaining clip (1d).
Engage any gear using the gear selector/engagement lever.1. Undo the 5th speed selector fork bolt.Engage 5th speed pressing the selector fork on the main shaft.
The simultaneous engagement of two gears will result in the gearbox shafts locking.
2. Remove the staking and loosen the ring nuts for the main and layshafts.
1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed selector fork complete with 5th speed sliding sleeve.3. Remove the flange (3a) and the hub for the 5th speed sliding sleeve (3b).4. Remove the pre-synchronizer mountings.5. Remove the 5th speed synchronizer ring.6. Remove the seal.7. Remove the 5th speed drive gear.8. Remove the needle bearing for the 5th speed drive gear.9. Remove the 5th speed drive gear bush.10. Remove the spacer.11. Remove the 5th speed driven gear.12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.
1. Lock the sleeve (1a) in the vice, with the protective plates fitted then, use a brass drift (1b), alternately on the two ends of the selector fork (1c) until it is released from the sleeve.
Take care not to damage the tapered part of the sleeve and the ends of the selector fork with the drift.
1. Remove the main and layshaft rear bearing circlips.
1. Undo the plugs for positioning the gear control rods.2. Undo the bolt fixing the Reverse gear shaft.3. Undo the reversing lights switch.
1. Undo the bolts (1a) and remove the differential flange (1b), complete with oil seal (1c), O-Ring (1d) and scraper ring (1e).
1. Undo the bolts fixing the gearbox casing to the bell housing.2. Position the gear selector/engagement lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.
1. Undo the bolts (1a) and remove the Reverse gear selector fork mounting bracket (1b).2. Undo the 3rd-4th speed selector fork bolt. 3. Lift the 3rd-4th speed selector fork (3a) slightly and remove the Reverse gear transfer gear (3b).
1. Undo the bolt on the 1st-2nd speed selector fork (1a).2. Remove the 1st-2nd control rod (2a) together with the selector fork (2b).
If the rod offers resistance to being withdrawn, move the other rods (3a) and (4a) to shift the pawls (5) and (3b).
3. Remove the 3rd-4th speed control rod (3a)..
Work carefully to avoid the pawl (3b) accidentally falling out.
4. Simultaneously remove the 5th-Reverse control rod (4a) and the 3rd-4th speed selector fork (4b).5. Remove the two gear engagement safety pawls.
1. Remove the main shaft and layshaft assemblies simultaneously.2. Remove the differential assembly.3. Remove the layshaft front bearing.4. Remove the magnet.
1. Remove the engine side oil seal for the bell housing.
1. On the gear box, undo the gear selector bolt.2. Remove the pin (2a) using a suitable drift and remove the gear selector (2b).
Separate the gearbox casing from the support tool and place it on a special workbench.PROCEED WITH DISMANTLING THE LAYSHAFT, FOLLOWING THE INSTRUCTIONS GIVEN BELOW.1. Remove the rear bearing (1a), the 4th speed driven gear (1b) and the spacer between 3rd and 4th speeds (1c) using a hydraulic press, a plate (1d) and the half-rings (1e).

NameCountry
1dPlate1.820.047.002

NameCountry
1eHalf-rings1.870.675.000
Lower the sleeve for 1st-2nd and Reverse.1. Remove the 3rd speed driven gear (1a) and the 2nd speed driven gear (1b) using a hydraulic press, the plate (1c) and the half rings (1d).

NameCountry
1cPlate1.820.047.002

NameCountry
1dHalf-rings1.870.676.000
1. Remove the 2nd speed synchronizer ring set.2. Remove the needle bearing for the 2nd speed driven gear.3. Remove the sliding sleeve for 1st - 2nd and Reverse gears.4. Remove the pre-synchronizer mountings.
1. Remove the 1st-2nd speed and Reverse hub circlip using suitable pliers.
When refitting, replace the circplip.
1. Remove the 1st, 2nd and Reverse gear sliding sleeve hub (1a), the 1st speed synchronizer ring set (1b), the 1st speed driven gear (1c) using a hydraulic press, the plate (1d) and the half rings (1e).

NameCountry
1dPlate1.820.047.002

NameCountry
1eHalf-rings1.870.676.000
2. Remove the needle bearing.
The layshaft front bearing inner race should not be refaced; if necessary, replace it together with the layshaft.
PROCEED WITH DISMANTLING THE MAIN SHAFT, FOLLOWING THE INSTRUCTIONS GIVEN BELOW.1. Remove the rear bearing (1a), the shim (1b), the 4th speed drive gear (1c), the needle bearing for the 4th speed drive gear (1d), the bush for the 4th speed drive gear (1e), the 3rd and 4th speed sliding sleeve (1f), the pre-synchronizer mountings (1g) for the 3rd and 4th speed sliding sleeve, the 4th speed synchronizer (1h), the hub for the 3rd and 4th speed sliding sleeve (1i), the 3rd speed synchronizer (1l) and the 3rd speed drive gear (1m) using a hydraulic press, the plate (1n) and the half-rings (1o).

NameCountry
1nPlate1.820.024.000

NameCountry
1oHalf-rings1.820.017.000
2. Remove the needle bearing for the 3rd speed drive gear.
1. Remove the main shaft front bearing (1a) using a hydraulic press and the half-plates (1b).

NameCountry
1bHalf-plates1.820.022.000
Proceed with washing and checking the condition of all the components.PROCEED WITH THE REASSEMBLY OF THE MAIN SHAFT, FOLLOWING THE INSTRUCTIONS GIVEN BELOW.1. Place the 3rd speed drive gear needle bearing back in its seating.2. Place the 3rd speed drive gear back in its housing.3. Place the 3rd speed synchronizer back in its housing.4. Place the 3rd and 4th speed sliding sleeve hub back in its housing.5. Place the 3rd and 4th speed sliding sleeve back in its housing.6. Place the pre-synchronizer mountings on the sliding sleeve hub back in their housings.7. Place the 4th speed synchronizer back in its housing.
1. Place the bush for the 4th speed drive gear (1a), the roller bearing for the 4th speed drive gear (1b) and the 4th speed drive gear (1c) back in their housings using a hydraulic press and the half-plates (1d).

NameCountry
1dHalf-plates1.820.022.000
1. Place the shim back in its housing.2. Place the rear bearing (2a) back in its housing usig a hydraulic press, the fitting tool (2b) and the half-plates (2c).

NameCountry
2bFitting tool1.870.659.000

NameCountry
2cHalf-plates1.820.022.000
1. Place the main shaft front bearing (1a) back in its housing using a hydraulic press, the fitting tool (1b) and the half-plates (1c).

NameCountry
1bFitting tool1.870.659.000

NameCountry
1cHalf-plates1.820.022.000
PROCEED WITH THE REASSEMBLY OF THE LAYSHAFT, FOLLOWING THE INSTRUCTIONS GIVEN BELOW.1. Place the 5th speed driven gear needle bearing back in its seating.2. Place the 5th speed driven gear back in its seating.3. Place the three rings of the 1st speed synchronizer (3a) back in their seatings, matching up the couplings (3b).
1. Place the 1st and 2nd speed sliding sleeve hub (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c). Match up the couplings (1d).

NameCountry
1bHalf-plates1.820.022.000

NameCountry
1cTool for Extracting/Fitting1.821.092.000
Fit a new 1st and 2nd speed sliding sleeve hub circlip.1. Place the 1st - 2nd and Reverse sliding sleeve back in its housing.2. Place the pre-synchronizer mountings back in their housings on the 1st - 2nd and Reverse sliding sleeve hub.3. Place the 2nd speed driven gear needle bearing back in its housing.4. Place the three rings of the 2nd speed synchronizer (4a) back in their seatings, matching up the couplings (4b) and (4c).5. Place the 2nd speed driven gear back in its housing.
1. Place the 3rd speed driven gear (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

NameCountry
1bHalf-plates1.820.022.000

NameCountry
1cTool for Extracting/Fitting1.870.658.000
1. Place the bush back in its housing.2. Place the 4th speed driven gear (2a) back in its housing using a hydraulic press, the half-plates (2b) and the fitting tool (2c).

NameCountry
2bHalf-plates1.820.022.000

NameCountry
2cFitting tool1.870.659.000
1. Place the rear bearing (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

NameCountry
1bHalf-plates1.820.022.000

NameCountry
1cFitting tool1.870.659.000
1. Fit the gear selector (1a) and fix it with the pin (1b) and bolt (1c), in its seating in the gear box.
1. Place a new engine side oil (1a) for the bell housing back in its housing using tools (1b) and (1c).

NameCountry
1bGrip1.821.171.000

NameCountry
1cFitting tool1.821.225.000
1. Place the magnet back in its housing.2. Place the layshaft front bearing back in its housing.3. Place the differential assembly back in its housing.4. Simultaneously place the main and layshaft assemblies back in their housings.
1. Place the gear engagement safety pawls back in their housings.2. Place the Reverse idler gear back in its housing.
Make sure that the gear engagement teeth are facing downwards.
3. Place the 5th and Reverse control rod back in its housing.4. Place the 3rd - 4th speed selector fork (4a) and the control rod (4b) back in their housings.
Position the safety pawl (4c) in the rod before fitting it in the housing.
5. Place the 1st - 2nd speed control rod (5a) complete with selector fork (5b) back in its housing.6. Tighten the bolts for the 1st-2nd speed (6a) and 3rd-4th speed selector forks (6b) to the recommended torque.

FasteningComponentØValue(daNm)
6aBolt1st - 2nd speed selector forkM61.6 ÷ 2.0

FasteningComponentØValue(daNm)
6bBolt3rd - 4th speed selector forkM61.6 ÷ 2.0
7. Place the Reverse selector fork mounting bracket (6a) back in its housing and secure it tightening the bolts (6b) to the recommended torque.

FasteningComponentØValue(daNm)
7bBoltReverse selector fork mounting bracketM60.9 ÷ 1.1
Position all the gear selector forks in neutral.Apply the recommended sealant to the contact surfaces between the bell housing and the gearbox casing.

TypeComponentNameQty.
-SealantGEARBOX SEALS/GASKETSLoctite 573-
Place the gearbox casing on the bell housing back in its housing.
Kepp the gear selector/engagement lever upwards and check that the gear selector engages with the 3rd - 4th speed selector fork.
Tighten the bolts fixing the gearbox casing to torque.

FasteningComponentØValue(daNm)
-BoltGEARBOX GEAR CASINGM82.3 ÷ 2.8
Place the reversing switch back in its housing and tighten it.Tighten the bolt fixing the Reverse shaft to the recommended torque.

FasteningComponentØValue(daNm)
-BoltReverse shaftM83.1 ÷ 3.7
Tighten the plugs for positioning the gear control rods.Place the main and layshaft rear bearing circlips back in their housings.
To facilitate the fitting of the circlips, place them with their openings at the front.
Apply the recommended sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.

TypeComponentNameQty.
-SealantGEARBOX SEALS/GASKETSLoctite 573-
Fit the main and layshaft rear bearing retaining plate and fix it tightening the bolt to torque.

FasteningComponentØValue(daNm)
-BoltGEARBOX REAR COVER SPACERM82.3 ÷ 2.8
1. Position the 5th speed sliding sleeve in the vice with the protective plates fitted.2. Position the selector fork so that the tapered end is in the same position as that of the sleeve, resting it against the side of the sleeve with the smaller diameter. Fit the selector fork manually, exerting the necessary pressure, until it is completely engaged on the sleeve.
When the fitting is complete, check that the sleeve can rotate freely inside the selector fork.
1. Place the 5th speed driven gear back in its seating.2. Place the spacer back in its housing.3. Place the 5th speed drive gear bush back in its seating.4. Place the 5th speed drive gear needle bearing back in its seating.5. Place the 5th speed drive gear back in its seating.6. Place the seal back in its housing.
Take care to fit the teeth on the seal correctly in the special groove.
7. Place the 5the speed synchronizer ring back in its seating.8. Place the flange (8a) and the hub for the 5th speed sliding sleeve (8b) back in their housings.9. Place the pre-synchronizer mountings back in their housings.10. Place the 5th speed selector fork complete with 5th speed sliding sleeve back in its housing.11. Tighten the new main shaft and layshaft ring nuts to the specified torque.

FasteningComponentØValue(daNm)
11Ring nutGEAR SHAFTSM2010.6 ÷ 13.0
12. Tighten the 5th speed selector fork bolt to the specified torque.

FasteningComponentØValue(daNm)
12Bolt5thª speed selector forkM61.6 ÷ 2.0
Apply the recommended sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.

TypeComponentNameQty.
-SealantGEARBOX SEALS/GASKETSLoctite 573-
1. Place the rear cover (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltGEARBOX REAR COVERM82.3 ÷ 2.8
Using a suitable drift, tighten the differential rear bearing outer race.1. Position the tool, complete with dial gauge, on the surface of the differential and z