3024748 - 1004D10 power unit (manual gearbox), removed, remove and re-build

Dismantling ( Reassembling ) Place a suitable container under the differential to collect the gearbox oil.Undo the plug and drain the gearbox oil.Remove the oil container positioned under the differential.Disconnect the starter motor wiring.

NameConnector
-Starter' motor  A20 
1. Undo the fixing bolts (1a) and remove the starter motor (1b).2. Undo the fixing bolts (2a) and remove the intermediate driveshaft from its housing.
1. Undo the fastenings and remove the gearbox and differential.2. Undo the fixing bolts (2a) and remove the clutch drip tray (2b).3. Remove the clutch disc.
Reassembling ( Dismantling ) Fit the clutch disc and clutch cover, centring them using the tool.

NameCountry
-Tool for centering clutch1.870.081.000
Tighten the bolts fixing the clutch cover to the flywheel to the recommended torque.

FasteningComponentØValue(daNm)
-BoltCLUTCH ASSEMBLYM82.8
Fit the gearbox-differential unit tightening the nuts and bolts to torque.

FasteningComponentØValue(daNm)
-BoltMANUAL GEARBOXM12 x 1.258

FasteningComponentØValue(daNm)
-BoltMANUAL GEARBOXM10 x 1.255.5

FasteningComponentØValue(daNm)
-NutMANUAL GEARBOXM12 x 1.258
Fit the starter motor and tighten the bolts to torque.

FasteningComponentØValue(daNm)
-BoltSTARTER MOTORM82.7
Fit the intermediate driveshaft in its housing and press fit it into the housing on the differential.Tighten the bolts fixing the intermediate driveshaft to the engine mounting/intermediate shaft.Connect the starter motor electrical wiring.

NameConnector
-Starter' motor  A20