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 g