3026028 - 2110D10 differential inner case - r + r with manual gearbox removed - includes gearbox dismantle and rebuild

Removing ( Refitting ) 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 ring (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. 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. Remove the differential assembly.
Refitting ( Removing ) Place the differential assembly back in its housing.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.
Keep 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. 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 zero the dial gauge on the bearing outer race with a pre-loading of 1 mm.

NameCountry
1Dial gauge mounting1.820.085.000
1. Position the tool (1a), complete with dial gauge, on the differential flange, engine side (1b) and measure the difference.

NameCountry
1aDial gauge mounting1.820.085.000
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).

NameCountry
1bGrip1.821.171.000

NameCountry
1cFitting tool1.821.225.000
Place the differential flange complete with new oil seal back in its housing and secure it using the bolts.Undo the fixings and remove the gearbox and differential from the tool.
Two operators are needed for this operation.

NameCountry
-Mount1.820.146.000
Remove the tool supporting the overhaul stand and put it back. Dismantling ( Reassembling ) Proceed with dismantling  - 2110B20  manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary. Reassembling ( Dismantling ) Proceed with re-assembly  - 2110B20  manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary.