2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY - Alfa - 147 - eLearn

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.

	Name	Country
1b	Mount	1.820.146.000

2. Undo the bolts (2a) and remove the rear cover (2b).

1. Remove the left internal differential driveshaft (1a) using tools (1b) and (1c).

	Name	Country
1b	Flange	1.820.229.000

	Name	Country
1c	Counter weight	1.821.161.000

Replace the retaining clip (1d).

Engage any gear using the gear selector/engagement lever.1. Undo the 5^th speed selector fork bolt.Engage 5^th 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 5^th speed selector fork complete with 5^th speed sliding sleeve.3. Remove the flange (3a) and the hub for the 5^th speed sliding sleeve (3b).4. Remove the pre-synchronizer mountings.5. Remove the 5^th speed synchronizer ring.6. Remove the seal.7. Remove the 5^th speed drive gear.8. Remove the needle bearing for the 5^th speed drive gear.9. Remove the 5^th speed drive gear bush.10. Remove the spacer.11. Remove the 5^th 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 3^rd-4^th speed selector fork bolt. 3. Lift the 3^rd-4^th speed selector fork (3a) slightly and remove the Reverse gear transfer gear (3b).

1. Undo the bolt on the 1^st-2^nd speed selector fork (1a).2. Remove the 1^st-2^nd 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 3^rd-4^th 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 3^rd-4^th 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 4^th speed driven gear (1b) and the spacer between 3^rd and 4^th speeds (1c) using a hydraulic press, a plate (1d) and the half-rings (1e).

	Name	Country
1d	Plate	1.820.047.002

	Name	Country
1e	Half-rings	1.870.675.000

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

	Name	Country
1c	Plate	1.820.047.002

	Name	Country
1d	Half-rings	1.870.676.000

1. Remove the 2^nd speed synchronizer ring set.2. Remove the needle bearing for the 2^nd speed driven gear.3. Remove the sliding sleeve for 1^st - 2^nd and Reverse gears.4. Remove the pre-synchronizer mountings.

1. Remove the 1^st-2^nd speed and Reverse hub circlip using suitable pliers.

When refitting, replace the circplip.

1. Remove the 1^st, 2^nd and Reverse gear sliding sleeve hub (1a), the 1^st speed synchronizer ring set (1b), the 1^st speed driven gear (1c) using a hydraulic press, the plate (1d) and the half rings (1e).

	Name	Country
1d	Plate	1.820.047.002

	Name	Country
1e	Half-rings	1.870.676.000

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 4^th speed drive gear (1c), the needle bearing for the 4^th speed drive gear (1d), the bush for the 4^th speed drive gear (1e), the 3^rd and 4^th speed sliding sleeve (1f), the pre-synchronizer mountings (1g) for the 3^rd and 4^th speed sliding sleeve, the 4^th speed synchronizer (1h), the hub for the 3^rd and 4^th speed sliding sleeve (1i), the 3^rd speed synchronizer (1l) and the 3^rd speed drive gear (1m) using a hydraulic press, the plate (1n) and the half-rings (1o).

	Name	Country
1n	Plate	1.820.024.000

	Name	Country
1o	Half-rings	1.820.017.000

2. Remove the needle bearing for the 3^rd speed drive gear.

1. Remove the main shaft front bearing (1a) using a hydraulic press and the half-plates (1b).

	Name	Country
1b	Half-plates	1.820.022.000

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 3^rd speed drive gear needle bearing back in its seating.2. Place the 3^rd speed drive gear back in its housing.3. Place the 3^rd speed synchronizer back in its housing.4. Place the 3^rd and 4^th speed sliding sleeve hub back in its housing.5. Place the 3^rd and 4^th 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 4^th speed synchronizer back in its housing.

1. Place the bush for the 4^th speed drive gear (1a), the roller bearing for the 4^th speed drive gear (1b) and the 4^th speed drive gear (1c) back in their housings using a hydraulic press and the half-plates (1d).

	Name	Country
1d	Half-plates	1.820.022.000

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).

	Name	Country
2b	Fitting tool	1.870.659.000

	Name	Country
2c	Half-plates	1.820.022.000

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).

	Name	Country
1b	Fitting tool	1.870.659.000

	Name	Country
1c	Half-plates	1.820.022.000

PROCEED WITH THE REASSEMBLY OF THE LAYSHAFT, FOLLOWING THE INSTRUCTIONS GIVEN BELOW.1. Place the 5^th speed driven gear needle bearing back in its seating.2. Place the 5^th speed driven gear back in its seating.3. Place the three rings of the 1^st speed synchronizer (3a) back in their seatings, matching up the couplings (3b).

1. Place the 1^st and 2^nd 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).

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Tool for Extracting/Fitting	1.821.092.000

Fit a new 1^st and 2^nd speed sliding sleeve hub circlip.1. Place the 1^st - 2^nd and Reverse sliding sleeve back in its housing.2. Place the pre-synchronizer mountings back in their housings on the 1^st - 2^nd and Reverse sliding sleeve hub.3. Place the 2^nd speed driven gear needle bearing back in its housing.4. Place the three rings of the 2^nd speed synchronizer (4a) back in their seatings, matching up the couplings (4b) and (4c).5. Place the 2^nd speed driven gear back in its housing.

1. Place the 3^rd speed driven gear (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Place the bush back in its housing.2. Place the 4^th speed driven gear (2a) back in its housing using a hydraulic press, the half-plates (2b) and the fitting tool (2c).

	Name	Country
2b	Half-plates	1.820.022.000

	Name	Country
2c	Fitting tool	1.870.659.000

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

	Name	Country
1b	Half-plates	1.820.022.000

	Name	Country
1c	Fitting tool	1.870.659.000

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).

	Name	Country
1b	Grip	1.821.171.000

	Name	Country
1c	Fitting tool	1.821.225.000

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 5^th and Reverse control rod back in its housing.4. Place the 3^rd - 4^th 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 1^st - 2^nd speed control rod (5a) complete with selector fork (5b) back in its housing.6. Tighten the bolts for the 1^st-2^nd speed (6a) and 3^rd-4^th speed selector forks (6b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
6a	Bolt	1st - 2nd speed selector fork	M6	1.6 ÷ 2.0

	Fastening	Component	Ø	Value(daNm)
6b	Bolt	3rd - 4th speed selector fork	M6	1.6 ÷ 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.

	Fastening	Component	Ø	Value(daNm)
7b	Bolt	Reverse selector fork mounting bracket	M6	0.9 ÷ 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.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 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 3^rd - 4^th speed selector fork.

Tighten the bolts fixing the gearbox casing to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	2.3 ÷ 2.8

Place the reversing switch back in its housing and tighten it.Tighten the bolt fixing the Reverse shaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	Reverse shaft	M8	3.1 ÷ 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.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the main and layshaft rear bearing retaining plate and fix it tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER SPACER	M8	2.3 ÷ 2.8

1. Position the 5^th 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 5^th speed driven gear back in its seating.2. Place the spacer back in its housing.3. Place the 5^th speed drive gear bush back in its seating.4. Place the 5^th speed drive gear needle bearing back in its seating.5. Place the 5^th 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 5^the speed synchronizer ring back in its seating.8. Place the flange (8a) and the hub for the 5^th speed sliding sleeve (8b) back in their housings.9. Place the pre-synchronizer mountings back in their housings.10. Place the 5^th speed selector fork complete with 5^th speed sliding sleeve back in its housing.11. Tighten the new main shaft and layshaft ring nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	10.6 ÷ 13.0

12. Tighten the 5^th speed selector fork bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	5thª speed selector fork	M6	1.6 ÷ 2.0

Apply the recommended sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

1. Place the rear cover (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX REAR COVER	M8	2.3 ÷ 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 zero the dial gauge on the bearing outer race with a pre-loading of 1 mm.

	Name	Country
1	Dial gauge mounting	1.820.085.000

1. Position the tool (1a), complete with dial gauge on the differential flange (1b), and measure the difference.

	Name	Country
1a	Dial gauge mounting	1.820.085.000

Calculate the size of the scraper 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.

Place in the housing the scraper ring or rings for pre-loading the differential bearings, of the size calculated or the next size up.1. Place a new oil seal (1a) on the differential flange using the tools (1b) and (1c).

	Name	Country
1b	Grip	1.821.171.000

	Name	Country
1c	Fitting tool	1.821.225.000

Place the differential flange complete with new oil seal back in its housing and secure it using the bolts.Place the left differential internal driveshaft back in its housing. Undo the fixings and remove the gearbox and differential from the tool.

Two operators are needed for this operation.

	Name	Country
-	Mount	1.820.146.000

Remove the tool supporting the overhaul stand and put it back.

Dismantling ( Reassembling

) 1. Release the gearbox and differential (1a) from the hydraulic jack (1b) and the tool (1c) used for removing-refitting it from the vehicle.

	Name	Country
1c	Mount	1.870.644.001

1. Fit the manual gearbox with differential (1a) to the overhaul stand using the tool (1b).

Two operators are needed for this operation.

	Name	Country
1b	Support	1.871.001.014

1. Remove the left internal differential driveshaft (1a) using tools (1b) and (1c).

	Name	Country
1b	Flange	1.847.017.004

	Name	Country
1c	Counter weight	1.840.206.001

1. Undo the bolts (1a) and remove the flanges on the differential (1b), complete with seals.2. Remove the adjustment shim.

1. Undo the bolts (1a) and remove the support for the differential internal housing (1b).2. Remove the differential.3. Remove the differential bearing outer races.4. Remove the magnet.

1. Remove the bolt for the Reverse gear shaft.2. Undo the bolts (2a) and remove the gearbox casing (2b).

The gearbox casing is sealed to the bell housing: release the two parts using a wooden or resin hammer.

1. Undo the bolts (1a) and (1b).2. Remove the 5^th speed control rod (2a) from the Reverse gear selector fork (2b) and the 5^th speed selector (2c).3. Remove the 5^th speed selector fork from the control rod.

1. At the same time, remove the main shaft, layshaft, reverse shaft and 1^st, 2^nd, 3^rd and 4^th speed selector fork assemblies.

Keep the units assembled until they are placed on the workbench.

Separate the selector forks from the rods.

1. Remove the clutch release bearing fork.2. Remove the outer non-slip bush.

1. Remove the inner non-slip bush (1a) using the tools (1b) and 1c).

	Name	Country
1b	Extractor	1.840.207.814

	Name	Country
1c	Counter weight	1.840.206.001

2. Undo the bolts (2a) and remove the main shaft cover (2b).

1. Remove the main shaft rear bearing outer race (1a) using the tools (1b) and (1c).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.655.000

	Name	Country
1c	Counter weight	1.840.206.001

2. Remove the main shaft scraper ring.3. Remove the lubrication duct.

1. Remove the layshaft rear bearing outer race (1a) using the tools (1b) and (1c).

	Name	Country
1b	Tool for Extracting/Fitting	1.870.655.000

	Name	Country
1c	Counter weight	1.840.206.001

2. Remove the layshaft scraper ring.

Proceed with dismantling the layshaft, following the instructions given below.1. Check, in three places, that the gap between the gear teeth and the synchronizer ring support surfaces are within the recommended values.

In order to carry out the measurement, keep the sliding sleeve raised using a screwdriver. If the figures do not correspond with the recommended values, during reassembly, the worn synchronizer should be replaced.

	Measurement		Value
1	Gear. teeth clearance and synchronizer ring support. surfaces. (mm)		>= 0.8

1. Remove the rear bearing (1a), the 5^th speed driven gear (1b), the 4^th speed driven gear (1c) and the spacer (1d) using a hydraulic press and the plate (1e) and the half-rings (1f) using a suitable drift (1g).

	Name	Country
1e	Plate	1.874.290.000

	Name	Country
1f	Half-rings	1.870.675.000

1. Remove the 3^rd speed driven gear (1a) and the 2^nd speed driven gear (1b) using a hydraulic press, the plate (1c) and the half rings (1d).

	Name	Country
1c	Plate	1.874.290.000

	Name	Country
1d	Half-rings	1.870.675.000

1. Remove the needle bearing for the 2^nd speed driven gear.2. Remove the 'triple cone' 2^nd speed synchronizer.3. Remove the 1^st and 2^nd speed and Reverse gear engagement sliding sleeve (3a) with the springs (3b) and rollers (3c).

1. Remove the circlip using pliers.

When refitting, replace the circplip.

1. Remove the 1^st, 2^nd and Reverse gear sliding sleeve hub (1a), the 1^st speed 'triple cone' synchronizer (1b), the 1^st speed driven gear (1c) using a hydraulic press and the plate (1d).

	Name	Country
1d	Plate	1.874.290.000

2. Remove the needle bearing for the 1^st speed driven gear.

1. Remove the circlip using pliers.

When refitting, replace the circplip.

1. Remove the front bearing (1a) using a hydraulic press, a suitable plate (1b), the reaction base (1c) with the outer race (1d) for the bearing in question on the inside.

	Name	Country
1c	Reaction base	1.870.660.000

Proceed with dismantling the main shaft, following the instructions given below.1. Check, in three places, that the gap between the gear teeth and the synchronizer ring support surfaces are within the recommended values.

	Measurement		Value
1	Gear. teeth clearance and synchronizer ring support. surfaces. (mm)		>= 0.8

1. Remove the rear bearing (1a), the retaining flange (1b), the 5^th speed sliding sleeve (1c), the 5^th speed slding sleeve hub (1d) with springs (1e) and rollers (1f), the 5^th speed synchronizer (1g) and the 5^th speed driven gear (1h) using a hydraulic press and the plate (1i) and half-rings (1l) using a suitable drift (1m).

	Name	Country
1i	Half-rings support	1.846.017.001

	Name	Country
1l	Half-rings	1.870.676.000

1. Remove the needle bearing for the 5^th speed drive gear.2. Remove the retaining ring.3. Remove the thrust rings.4. Remove the 4^th speed drive gear.5. Remove the needle bearing for the 4^th speed drive gear.6. Remove the spacer.7. Remove the 4^th speed synchronizer ring.8. Remove the 3^rd and 4^th speed sliding sleeve (8a) with the springs (8b) and rollers (8c).

1. Remove the circlip using pliers.

When refitting, replace the circplip.

1. Remove the hub for the 3^rd and 4^th speed sliding sleeve (1a), the 3^rd speed 'twin cone' synchronizer (1b), the 3^rd speed drive gear (1c), using a hydraulic press, the plate with support (1d) and the half rings (1e).

	Name	Country
1d	Half-rings support	1.846.017.001

	Name	Country
1e	Half-rings	1.870.675.000

2. Remove the needle bearing for the 3^rd speed drive gear.

1. Remove the front bearing (1a), using a hydraulic press, a suitable plate (1b), the support (1c) and the half rings (1d).

	Name	Country
1c	Half-rings support	1.846.017.001

	Name	Country
1d	Half-rings	1.846.001.001

Proceed with dismantling the Reverse gear shaft following the instructions given below.1. Remove the Reverse drive gear-synchronizer assembly from the Reverse gear shaft.

1. Remove the circlip using pliers.2. Remove the Reverse gear synchronizer.3. Remove the spring (3a) from the Reverse drive gear (3b).

1. Remove the O-ring.2. Remove the pin.3. Remove the needle bearing for the Reverse drive gear (3a) complete with bush (3b).4. Remove the Reverse driven gear.5. Remove the needle bearing for the Reverse driven gear.

Reassembling ( Dismantling

) Proceed with reassembling the Reverse shaft following the instructions given below.1. Fit the needle bearing for the Reverse drive gear (1a) in its seating on the Reverse shaft (1b).2. Place the Reverse driven gear back in its housing.3. Place the Reverse drive gear needle bearing back in its seating complete with bush.4. Place the pin back in its seating.5. Place a new O-ring in its seating.

1. Refit the clip (1a) in its seating on the Reverse drive gear (1b).2. Refit the Reverse gear synchronizer in its seating.3. Refit the spring clip in its seating.

Refit in its seating the Reverse drive gear - Reverse synchronizer assembly on the Reverse shaft.Proceed with the reassembly of the main shaft, following the instructions given below.

Lubricate the bearings with the recommended oil before refitting them.

	Type	Component	Name	Qty.
-	Oli [l]	MANUAL GEARBOX	TUTELA CAR ZC 75 SYNTH	-

1. Place the front bearing (1a) back in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

	Name	Country
1b	Plate	1.874.290.000

	Name	Country
1c	Fitting tool	1.870.659.000

1. Place the 3^rd speed drive gear needle bearing back in its seating.

1. Fit in its seating the 3^rd speed 'twin cone' synchronizer (1a) on the hub for the 3^rd and 4^th speed sliding sleeve (1b).2. Fit the 3^rd speed drive gear on the assembly constructed in the previous step.

1. Fit the assembly (1a) made up of the 3^rd speed drive gear complete with synchronizer and sliding sleeve, using a hydraulic press, the half plates (1b) and the fitting tool (1c).

	Name	Country
1b	Plate	1.874.290.000

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Refit a new spring clip in its seating.2. Place the spacer back in its housing.3. Fit the 4^th speed drive gear needle bearing in its seating.4. Place the 3^rd and 4^th speed sliding sleeve hub back in their housings.5. Place the 3^rd and 4^th speed sliding sleeve back in its housing.6. Place the rollers on the 3^rd and 4^th speed sliding sleeve, making sure that they fit correctly in the housings.

1. Fit the synchronizer (1a) - 4^th speed drive gear (1b) in its seating.

Lower the 3^rd and 4^th speed sliding sleeve, engaging 3^rd speed.1. Fit the thrust washers back in their housings.2. Fit the containing ring back in its seating.3. Place the 5^th speed drive gear needle bearing back in its seating.4. Place the 5^th speed drive gear back in its seating.5. Place the 5^th speed synchronizer back in its seating.

1. Fit the 5^th speed sliding sleeve hub (1a) using a hydraulic press, the half plates (1b) and the fitting tool (1c).

	Name	Country
1b	Plate	1.874.290.000

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Place the 5^th speed sliding sleeve hub springs back in their seating.2. Place the 5^th speed sliding sleeve back in its seating.3. Fit the rollers on the 5^th speed sliding sleeve, making sure that they fit correctly in their housings.4. Fit the retaining flange in its seating.

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

	Name	Country
1b	Plate	1.874.290.000

	Name	Country
1c	Fitting tool	1.870.659.000

Proceed with the reassembly of the layshaft, following the instructions given below.

Lubricate the bearings with the recommended oil before refitting them.

	Type	Component	Name	Qty.
-	Oli [l]	MANUAL GEARBOX	TUTELA CAR ZC 75 SYNTH	-

1. Fit the front bearing (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Using a feeler gauge, measure the housing for the front bearing circlip to be fitted.

1. Fit a new front bearing circlip in its seating.

The size of the circlip should be selected from those available as spares (1.975; 2.020; 2.065) according to the value of the housing measured previously.

2. Place the 1^st speed driven gear needle bearing back in its seating.3. Place the 1^st speed driven gear back in its seating.4. Fit the 1^st speed 'triple cone' synchronizer in its seating.

1. Fit the hub for the 1^st, 2^nd and Reverse sliding sleeve (1a), using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Refit a new spring clip in its seating.2. Fit the springs on the hub for the 1^st, 2^nd and Reverse sliding sleeve.3. Fit the 1^st, 2^nd and Reverse sliding sleeve so that the internal references correspond with the springs.

1. Fit the rollers on the 1^st, 2^nd and Reverse sliding sleeve, making sure that they fit correctly in the housings.2. Place the 2^nd speed driven gear needle bearing back in its housing.

1. Fit the 'triple cone' synchronizer (1a) on the 2^nd speed driven gear (1b).2. Fit the assembly constructed as described in the previous step on the layshaft.

1. Place the 3^rd speed driven gear (1a) back in its housing using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Place the spacer back in its housing.Heat the 4^th speed driven gear to 120 ° C.2. Fit the 4^th speed driven gear (2a), using a hydraulic press, a suitable plate (2b) and the top end of the tool (2c).

	Name	Country
2c	Tool for Extracting/Fitting	1.870.658.000

1. Fit the 5^th speed driven gear (1a), using a hydraulic press, a suitable plate (1b) and the top end of the tool (1c).

	Name	Country
1c	Tool for Extracting/Fitting	1.870.658.000

1. Place the rear bearing (1a) back in its housing using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Name	Country
1c	Fitting tool	1.870.659.000

1. Place the internal non-slip bush (1a) for the selector fork shaft back in its housing using the fitting tool (1b).

	Name	Country
1b	Grip	1.870.007.000

At the same time, fit the main and layshafts in their housings.

If the following components are replaced:

main shaft.
bell housing,
gearbox casing,
main shaft front bearing,
main shaft rear bearing,
hub for 5^th speed sliding sleeve
complete layshaft,
layshaft rear bearing,
3^rd , 4^th and 5^th speed driven gears
DETERMINE THE SIZE OF THE ADJUSTMENT SHIMS FOR PRELOADING THE MAIN SHAFT AND LAYSHAFT BEARINGS as described below.

complete layshaft, layshaft rear bearing,3^rd, 4^th and 5^th speed driven gearsdetermine the size of the adjustment rings for the main and layshaft bearing pre-loading following the instructions given below.Thoroughly clean the support surfaces of the bearings and gearbox casing.1. Position the two gauges in the rear bearing seats in the gearbox casing.

	Name	Country
1	Gauges	1.870.648.000

1. Position the reference crossbeam on the gearing box.

	Name	Country
1	Reference crossmember	1.870.649.000

1. Place the two cylinders for the gauges in contact (without force) with the lower surface of the reference crossmember acting via the two special openings using a screwdriver. 2. Lock the two cylinders using the bolts.

Remove the reference crossmember and the gauges from the gearbox casing.1. Place the two gauges (1a) on the tool plate (1b).

	Name	Country
1a	Gauges	1.870.648.000

	Name	Country
1b	Mount	1.870.647.000

1. Prepare the tool for checking the bearing (1a) pre-loading with the stud bolts (1b), the spacer (1c), the disc (1d) and the centering bush (1e) designed for the 5 speed gearbox.

	Name	Country
1a	Mount	1.870.647.000

1. Match the support for determining the bearing pre-loading prepared in this way with the base plate complete with gauges.2. Connect the tool to an air line and supply a pressure of 0.5 bar so that the two actuators come into contact with the gauges.3. Fit the two dial gauges on the tool and zero them with a pre-loading of 3 mm (see reference X in the example for calculating the size of the adjustment rings).

Remove the support for determining the bearing pre-loading from the base plate complete with gauges.1. Remove the disc.

1. Position the support for determining the bearing pre-loading on the gearbox casing support and fix it.2. Connect the tool to an air line and supply a pressure of 4 bar.3. Rotate the main and layshafts through ten revolutions using the tool (3a) and a suitable crank (3b).

	Name	Country
3a	Bush	1.870.652.000

Using the dial gauges, measure the differences for the layshaft and the main shaft, respectively (see reference Y in the example for calculating the size of the adjustment shims).Add 0.15 mm to the difference between X and Y for the layshaft to obtain the necessary measurement for selecting the correct size of adjustment shim to be used.Subtract 0.15 mm from the difference between X and Y for the main shaft to obtain the necessary measurement for selecting the correct size of adjustment shim to be used.

Below is an example of how to calculate the size of the adjustment shims.

REFERENCE DISTANCE X (CASING)Zero the dial gauge with a 3 mm pre-loading on the checking tool.

REFERENCE DISTANCE Y (SHAFTS)For simplicity, let us consider that we have detected a difference of 0.9 mm, both for the layshaft and the main shaft.

CALCULATION OF LAYSHAFT ADJUSTMENT RING0.15 mm should be added to the difference between X and Y; in order to understand the term 'added' better, let us imagine that the pointer will move forward by 0.15 mm i.e. 0.9 + 0.15 = 1.05 mm (size of adjustment shim).

CALCULATION OF MAIN SHAFT ADJUSTMENT RING0.15 mm should be subtracted from the difference between X and Y; in order to understand the term 'subtracted' better, let us imagine that the pointer will move back by 0.15 mm, i.e. 0.9 - 0.10 = 0.75 mm (size of adjustment shim).

Remove the tool for determining the bearing pre-loading from the gearbox casing support.1. Place the lubricating duct back in its housing.2. Place the main shaft adjustment shim of the thickness calculated in its seating.3. Fit the main shaft rear bearing outer race (3a), using a hydraulic press, a suitable plate (3b) and the fitting tool (3c).

	Name	Country
3c	Fitting tool	1.870.657.000

1. Place the layshaft adjustment ring of the thickness calculated in its seating.2. Fit the layshaft rear bearing outer race (2a), using a hydraulic press, a suitable plate (2b) and the fitting tool (2c).

	Name	Country
2c	Fitting tool	1.870.656.000

Fit the reverse shaft and the 1^st, 2^nd, 3^rd and 4^th speed control rods and selector forks.1. Lift up the Reverse driven gear and check that the Reverse shaft pin is correctly positioned.

1. Refit the 5^th speed selector fork on its control rod.2. Fit the reverse selector fork (2a) and the 5^th speed selector (2b) on the control rod.3. Tighten the bolts (3a) and (3b) to torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	5thª speed control rod	M8	2.1 - 2.6

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	5THª SPEED SELECTOR FORK	M8	2.1 - 2.6

Apply the recommended sealant to the entire matching surface of the gearbox casing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX GEAR CASING	Loctite 510	-

1. Place the gear box (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX GEAR CASING	M9	(Bell housing support side) 2.9 - 3.6

2. Tighten the Reverse shaft bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	REVERSE IDLER	M10	4.3 ÷ 5.3

Place the magnet back in its housing.Fit the differential complete with bearing outer races in its seating.Apply the recommended sealant to the entire matching surface of the differential internal housing support.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX DIFFERENTIAL MOUNT	Loctite 510	-

1. Fit the differential internal housing support (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX DIFFERENTIAL MOUNT	M10	4.3 ÷ 5.3

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX DIFFERENTIAL MOUNT	M8	2.1 ÷ 2.6

1. Fit the flange on the differential, gearbox side (1a), complete with a new seal and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	Flanges on differential	M8	2.1 ÷ 2.6

Using a suitable drift, tighten the pinion side bearing outer race.1. Position the tool, complete with dial gauge, on the surface of the differential, engine side, and zero the dial gauge with a pre-loading of 1 mm.

	Name	Country
1	Support	1.895.655.000

1. Position the tool (1a), complete with dial gauge, on the differential flange, engine side (1b) and measure the difference.

	Name	Country
1a	Support	1.895.655.000

Calculate the size of the adjustment ring for pre-loading the differential bearings adding 0.12 mm to the difference measured.

0.12 corresponds to the interference for bedding in and the pre-loading of the differential bearings.

1. Place in the housing the adjustment shim or shims for pre-loading the differential bearings, of the size calculated or the next size up.2. Fit the flange on the differential, engine side (2a), complete with a new seal and fix it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	Flanges on differential	M8	2.1 ÷ 2.6

3. Place the main shaft cover (3a) back in its housing and secure it using the bolts (3b).

Apply Molycote PG 21 grease to the mating surfaces between the mainshaft sealing cover and the thrust bearing.

Place the inner non-slip bush back in its housing.Place the clutch engagement thrust bearing fork back in its housing.Place the outer non-slip bush back in its housing.

'Permaglide' self-lubricated bushes should not, under any circumstances, be lubricated because the lubricant oil or grease would mix, over a period of time, with the abrasive material of the bush, forming a mixture which would increase the wear of the actual bush. The two thrust bearing fork levers should be lubricated with Molycote PG 21 grease.

Place the left internal driveshaft back in its housing.Undo the fixings and remove the gearbox and differential from the tool.

Two operators are needed for this operation.

	Name	Country
-	Support	1.871.001.014

Remove the tool supporting the overhaul stand and put it back.Position the gearbox and differential on the tool used for the removing-refitting from the vehicle.

	Name	Country
-	Mount	1.870.644.001