2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD - Alfa - 147 - eLearn

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

) 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 ring (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. 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.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 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 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. 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, engine side (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.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

) 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.