2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Alfa - 147 - eLearn

3025121 - 2110A10 manual gearbox and differential - r + r

It is not possible to remove/refit the manual gearbox with differential in the car. The power unit has to be removed/refitted and then the manual gearbox with differential has to be separated from the engine at the bench.

Removing ( Refitting

) Place the car on a ramp. - 1016A10 sound-proofing cover - r + r - 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R.1. Open the band and disconnect the air pipe from the throttle body.

1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Disconnect collar (2a), prise up from the lower retaining pins (2b), release the filter casing from the cold air pipe outlet and then remove the air cleaner case assembly (2c).

1. Undo the nut securing the mounting bracket for the turbocharger's variable geometry solenoid. 2. Move the solenoid assembly and mounting bracket outside the working area.

1. Lift the retaining clip (1a) and withdraw the oil pipe (1b) of the hydraulic clutch release cylinder. 2. Undo the nut (2a) and disconnect the earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	C1

3. Undo the nuts securing the damper to the bracket.4. Disconnect the reverse gear sensor electrical connection on the gearbox.

	Name	Connector
4	Reversing lights switch	I20

1. Disconnect the two gear selection and engagement flexible transmission cable ends from the transfer unit. 2. Undo the fixing nuts (2a) and move the gear selection and engagement flexible transmission cables (2b) complete with mounting bracket outside the working area.

1. Undo nuts (1a) and move bonnet lid catch (1b) aside without disconnecting the bonnet opening cable.

1. Fit a bracket on the inlet manifold to support the propulsion unit safely as shown in the figure. 2. Fit the tool (2a), complete with support mountings (2b).

	Name	Country
2a	Crossmember	1.820.581.000

	Name	Country
2b	Support mountings	1.870.650.000

3. Fit the tools (3a) and (3b), then connect them via the links (3c) to the bracket previously fitted and to the exhaust manifold.

	Name	Country
3a	Crossmember	1.860.851.003

	Name	Country
3b	Vertical support	1.870.748.000

1. Undo the upper two bolts fixing the manual gearbox and differential to the engine.

- 4450B12 front or rear wheels (two) - r+r - 7055B54 under-engine guard - r r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.1. Unscrew the bolts securing the drive shafts to the internal differential/drive shaft.

1. Undo the nut for the bolts securing the fronts suspension lower wishbones to the knuckles. 2. Loosen the bolts fixing the front shock absorber forks to the lower track control arms. 3. Use the tool to disconnect the front suspension lower wishbone from the steering knuckles.

	Name	Country
3	Extractor	1.821.169.000

1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b) from the front damper forks.

1. Undo the bolt (1a) and the nut (1b) and remove the reinforcement rod (1c).

2. Undo the bolts securing the flexible block on the power unit rear rigid mounting to the front suspension crossmember. 3. Undo the bolts (3a) and the nut (3b), then remove the power unit rigid rear support (3c), complete with flexible mounting (3d).

- 1076B50 exhaust pipe attachment to engine - r + r1. Disengage the rubber blocks (1a) from the anchor pins (1b).2. Undo the nuts fixing the catalytic converter to the exhaust silencer.3. Remove the converter from its seating.

1. Undo bolts (1a) and nuts (1b) fixing the manual gear lever mounting. 2. Recover the plates.3. Slacken the rear bolts fixing the manual gear lever mounting. 4. Lower the manual gear lever mounting as much as necessary.

1. Fit the tool (1a) on the hydraulic jack (1b) to support the front suspension frame.

	Name	Country
1a	Flange	1.860.978.000

1. Undo the bolts securing the power steering box to the front suspension crossmember. 2. Undo the rear bolts fixing the front suspension crossmember to the bodyshell.3. Undo the side bolts fixing the front suspension crossmember to the bodyshell.

1. Undo the bolt (1a) and release the power assisted steering pipes mounting bracket (1b) from the front suspension crossmember.

1. Slowly lower the hydraulic jack and remove the front suspension crossmember (1a) complete with lower track control arms (1b) and anti-roll bar (1c).

1. Disconnect the bands (1a) and remove the turbocharger connecting duct to the heat exchanger (1b).

Undo the drain plug and drain the manual gearbox-differential oil.

Collect the gearbox-differential oil in a suitable container.

1. Undo the bolts (1a) and remove the intermediate drive shaft (1b). 2. Remove the dust excluder.

1. Undo the bolts (1a) and move the starter motor (1b) away from the gearbox, then secure it.

1. Undo the bolts (1a) and remove the engine flywheel protection (1b). 2. Undo the bolts fixing the manual gearbox and differential to the crankcase sump.3. Loosen the bolt fixing the manual gearbox and differential to the crankcase.

1. Fit the tool (1a) to support the bellhousing and secure it with the bolts (1b) to the holes present on the gearbox and by means of bolt (1c) to the gearbox bracket (1d).

	Name	Country
1a	Mount	1.870.826.000

Fit the pin of the gearbox support tool onto a column hydraulic jack.

1. Undo the bolt fixing the flexible mount to the gearbox side power unit rigid support.2. Undo the bolts (2a) and (2b), then remove the gearbox side rigid power unit support (2c).

1. Undo the bottom attachments securing the gearbox to the crankcase and oil sump. 2. Move the jack backwards and withdraw the gearbox from its seating. Check that the gearbox is balanced on the hydraulic jack.

Refitting ( Removing

) Place the manual gearbox and differential back in its housing using the hydraulic jack and the support tool and secure it using the lower bolt to the crankcase without tightening it. Refit in its seating the gearbox side power unit rigid mount, and tighten it to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	5

Undo the bolts and separate the supporting tool from the manual gearbox and differential, then replace it after having removed it from the hydraulic jack.

	Name	Country
-	Mount	1.870.826.000

Tighten the bolts fixing the manual gearbox and differential to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M10 x 1.25	5.5

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12 x 1.25	8

Place the engine flywheel protection back in its housing and secure it using the bolts. Refit the starter motor in its housing and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	2.7

Refit the intermediate drive shaft in its seating complete with dust excluder, and secure it with the relevant bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INTERMEDIATE DRIVE SHAFT	M6	0.8

Tighten the manual gearbox and differential fluid drain plug to the recommended torque. Connect the turbocharger-heat exchanger connecting pipe. Use a hydraulic jack with mounting tool to refit the front suspension beam with lower wishbones and anti-roll bar.

	Name	Country
-	Flange	1.860.978.000

Tighten the side bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

Tighten the rear bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
-	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 7.2 ÷ 8.8

Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.7 ÷ 14.3

Remove the hydraulic jack with mounting tool from the front suspension beam. Place the power assisted steering pipes mounting bracket back in its housing and secure it to the front suspension crossmember using the bolt.Refit the handbrake control mount and secure with bolts and nuts. - 1076B50 exhaust pipe attachment to engine - r + rFit the power unit rear support.Tighten the bolts fixing the support to the differential to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT RIGID REAR MOUNT	M12	6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT RIGID REAR MOUNT	M16	10.8 ÷ 13.2

Tighten the bolts fixing the engine support to the flexible mounting to torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Fit the rigid support reinforcement and secure it to the mounting and the cylinder block/crankcase. Tighten the reinforcement retaining bolt and nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	(Flexible mounting) 7.9 ÷ 9.7

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M10	(Cylinder block/crankcase) 4.5 ÷ 5.5

Connect the front anti-roll bar joints to the front damper forks and secure by tightening the nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT ANTI-ROLL BAR JOINTS	M8	(Front shock absorber fork side) 4.1 ÷ 5.0

Connect the front suspension lower wishbones to the knuckles and secure by tightening the nuts to the required torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT SUSPENSION LOWER LEVER	M14	(Steering knuckle side) 8.6 ÷ 9.5

Tighten the bolts securing the front damper forks to the lower wishbones to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Lower track control arm side) 10.8 ÷ 13.2

Tighten the bolts securing the drive shafts to the intermediate differential/drive shaft internal drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DRIVESHAFT	M8	(Differential. internal. driveshaft./side..) 3.5 ÷ 4.3

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B54 under-engine guard - r r - 4450B12 front or rear wheels (two) - r+rRemove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.860.851.003

	Name	Country
-	Vertical support	1.870.748.000

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Support mountings	1.870.650.000

Refit the bonnet lid catch and secure with nuts.Connect the gear selection and engagement flexible cables and secure them to the mounting bracket using the anchor clips. Connect the reverse gear sensor electrical connection to the gearbox.

	Name	Connector
-	Reversing lights switch	I20

Tighten the nuts securing the damper to the mounting bracket on the gearbox.Connect the earth lead to the gearbox.

	Name	Connector
-	Battery earth	C1

Connect the oil pipe on the hydraulic clutch release cylinder.

Check that the clip is fully engaged and that the pipe is positioned correctly.

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