2110B20 MANUAL GEARBOX (5-6SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY - Fiat - STILO - eLearn

3363586 - 2110B20 MANUAL GEARBOX (5-6SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY

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The main shaft cannot be dismantled on the Selespeed version.

1. Release the gearbox and differential (1a) from the hydraulic jack (1b) and from the tool (1c) used for removing-refitting it from the vehicle.

	Description	Code
1c	Support	1.870.644.001

1. Position the manual gearbox and differential (1a) on the overhaul stand using the tool (1b).

Two mechanics are needed for this operation.

	Description	Code
1b	Support	1.871.001.014

Undo the fastenings and remove the clutch hydraulic actuator detaching it from the sealant pad.1. Remove the left differential internal driveshaft (1a) using tools (1b) and (1c).

	Description	Code
1b	Flange	1.847.017.004

	Description	Code
1c	Mallet	1.840.206.001

1. Undo the bolts (1a) and remove the flanges on the differential (1b) complete with seals.2. Remove the scraper ring.

1. Undo the bolts (1a) and remove the differential internal casing support (1b).2. Remove the differential.3. Remove the differential bearing outer races.4. Remove the magnet.

1. Undo the reverse shaft bolt.2. Undo the bolts (2a) and remove the gearbox casing (2b).

The gearbox casing is sealed to the bellhousing: release the two parts using a wooden or resin hammer.

1. Undo the bolts (1a) and (1b).2. Release the 5 ^th speed control rod (2a) from the Reverse fork (2b) and the 5 ^th speed selector (2c).3. Release the 5^th speed fork from the control rod.

1. Simultaneously remove the main shaft, layshaft, reverse shaft and 1^st, 2^nd, 3^rd and 4^th speed fork assemblies.

Keep the assemblies joined until they are placed on the workbench.

Separate the forks from the rods.

1. Remove the main shaft rear bearing outer race (1a) using tools (1b) and (1c).

	Description	Code
1b	Extractor/Fitting tool	1.870.655.000

	Description	Code
1c	Mallet	1.840.206.001

2. Remove the main shaft scraper ring.3. Remove the lubrication duct.

1. Remove the layshaft rear bearing outer race (1a) using tools (1b) and (1c).

	Description	Code
1b	Extractor/Fitting tool	1.870.655.000

	Description	Code
1c	Mallet	1.840.206.001

2. Remove the layshaft scraper ring.

Proceed with dismantling the layshaft following the instructions given below.1. Check that the opening between the gear teeth and the synchronizer ring support planes is within the recommended values at three points. If the recommended values are not found, the worn synchronizer must be replaced during the reassembly.

Keep the sliding sleeve raised using a screwdriver.

	Measurement		Value
1	Clearance between gear teeth and synchronizer ring support surfaces (mm)		>= 0.8

1. Remove the rear bearing (1a), the 5^th speed driven gear (1b), the 4^th speed driven gear (1c) and the spacer (1d) using a hydraulic press, the plate (1e) and the half-rings (1f) using a suitable drift (1g).

	Description	Code
1e	Plate	1.874.290.000

	Description	Code
1f	Half-rings	1.870.675.000

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 half rings (1d).

	Description	Code
1c	Plate	1.874.290.000

	Description	Code
1d	Half-rings	1.870.675.000

1. Remove the needle bearing for the 2^nd speed driven gear.2. Remove the 2^nd speed triple cone synchronizer.3. Remove the engagement sliding sleeve for 1 ^st speed, 2^nd speed and reverse (3a) and the springs (3b) and rollers (3c).

1. Remove the circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the hub for the 1^st speed, 2^nd speed and reverse sliding sleeve (1a), the 1^st speed triple cone synchronizer (1b), the 1^st speed driven gear (1c), using a hydraulic press and the plate (1d).

	Description	Code
1d	Plate	1.874.290.000

2. Remove the needle bearing for the 1^nd speed driven gear.

1. Remove the circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the front bearing (1a) using a hydraulic press, a suitable plate (1b), the reaction base (1c) with the outer race (1d) for the bearing in question inside.

	Description	Code
1c	Reaction base	1.870.660.000

Proceed with dismantling the main shaft following the instructions given below.1. Check that the opening between the gear teeth and the synchronizer ring support planes is within the recommended values at three points. If the recommended values are not found, the worn synchronizer must be replaced during the reassembly.

Keep the sliding sleeve raised using a screwdriver.

	Measurement		Value
1	Clearance between gear teeth and synchronizer ring support surfaces (mm)		>= 0.8

1. Remove the rear bearing (1a), the retaining flange (1b), the 5^th speed engagement sliding sleeve (1c), the hub for the 5^th speed sliding sleeve (1d) and springs (1e) and rollers (1f), the 5^th speed synchronizer (1g), the 5^th speed driven gear (1h) using a hydraulic press, the plate and support (1i), the half-rings (1l) using a suitable drift (1m).

	Description	Code
1i	Half-rings support	1.846.017.001

	Description	Code
1l	Half-rings	1.870.676.000

1. Remove the needle bearing for the 5^th speed drive gear.2. Remove the retaining seal.3. Remove the thrust washers.4. Remove the 4^th speed drive gear.5. Remove the needle bearing for the 4^th speed drive gear.6. Remove the spacer.7. Remove the 4^th speed synchronizer ring.8. Remove the 3^rd and 4^th speed sliding sleeve (8a) with the springs (8b) and rollers (8c).

1. Remove the circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the hub for the 3^rd and 4^th speed sliding sleeve (1a), the 3^rd speed double cone synchronizer (1b), the 3^rd speed drive gear (1c) using a hydraulic press and the plate and support (1d) and the half-rings (1e).

	Description	Code
1d	Half-rings support	1.846.017.001

	Description	Code
1e	Half-rings	1.870.675.000

2. Remove the needle bearing for the 3^th speed drive gear.

1. Remove the front bearing (1a) using a hydraulic press, a suitable plate (1b), the support (1c) and the half rings (1d).

	Description	Code
1c	Half-rings support	1.846.017.001

	Description	Code
1d	Half-rings	1.846.001.001

Proceed with dismantling the reverse shaft following the instructions given below.1. Remove the reverse drive gear - reverse synchronizer assembly from the reverse shaft.

1. Remove the circlip using suitable pliers.2. Remove the reverse gear synchronizer.3. Remove the spring (3a) from the reverse drive gear (3b).

1. Remove the O-ring.2. Remove the pin.3. Remove the needle bearing for the reverse drive gear (3a) complete with bush (3b).4. Remove the reverse driven gear.5. Remove the needle bearing for the reverse driven gear.

Refitting ( Removing

) Proceed with reassembling the reverse shaft following the instructions given below.1. Fit the needle bearing for the reverse drive gear (1a) on the reverse shaft (1b).2. Place the reverse driven gear in position.3. Place the needle bearing for the reverse drive gear complete with bush in its housing.4. Place the pin back in its housing.5. Fit a new O-ring in the seat.

1. Fit the spring (1a) on the reverse drive gear (1b).2. Place the reverse synchronizer back in its housing.3. Place the circlip in position.

Fit the reverse drive gear - reverse synchronizer assembly on the reverse shaft.Proceed with reassembling the main shaft following the instructions given below.

Lubricate the bearings with the recommended oil before refitting them.

	Type	Component	Description	Qty.
-	Oil [l]	MANUAL GEARBOX/DIFFERENTIAL	TUTELA CAR ZC 75 SYNTH	-

1. Place the front bearing (1a) in its housing using a hydraulic press and the half-plates (1b) and the fitting tool (1c).

	Description	Code
1b	Plate	1.874.290.000

	Description	Code
1c	Fitting tool	1.870.659.000

1. Place the needle bearing for the 3^rd speed drive in its housing.

1. Place the 3^rd speed double cone synchronizer (1a) in its housing on the hub for the 3^rd and 4^th speed sliding sleeve (1b).2. Place the 3^rd speed drive gear in its housing in the assembly as indicated in the previous step.

1. Place the assembly (1a) comprising the 3^rd speed drive gear complete with synchronizer and sliding sleeve in its housing using a hydraulic press, the half-plates (1b) and the fitting tool (1c).

	Description	Code
1b	Plate	1.874.290.000

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Place a new circlip in position.2. Place the spacer back in its housing.3. Place the needle bearing for the 4^rd speed drive in its housing.4. Place the springs for the 3^rd and 4^th speed sliding sleeve in their housings on the hub.5. Place the 3^rd and 4^th speed sliding sleeve in its housing.6. Place the rollers in their housings on the 3^rd and 4^th speed sliding sleeve making sure that they are correctly fitted.

1. Place the synchronizer (1a) - 4^th speed drive gear assembly (1b) in its housing.

Lower the 3^rd and 4^th speed sliding sleeve engaging 3^rd speed.1. Place the thrust washers in their seats.2. Refit the retaining ring in its seat.3. Place the needle bearing for the 5^th speed drive in its housing.4. Place the 5 ^th speed drive gear in its housing.5. Place the 5 ^th speed synchronizer assembly in its housing.

1. Fit the hub for the 5^th speed sliding sleeve (1a) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code
1b	Plate	1.874.290.000

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Place the springs for the 5^th speed sliding sleeve in their housings on the hub.2. Place the 5 ^th speed sliding sleeve in its housing.3. Place the rollers in their housings on the 5^th speed sliding sleeve making sure that they are correctly fitted.4. Replace the retaining flange in its housing.

1. Place the rear bearing (1a) in its housing using a hydraulic press and the half-plates (1b) and the fitting tool (1c).

	Description	Code
1b	Plate	1.874.290.000

	Description	Code
1c	Fitting tool	1.870.659.000

Proceed with reassembling the layshaft following the instructions given below.

Lubricate the bearings with the recommended oil before refitting them.

	Type	Component	Description	Qty.
-	Oil [l]	MANUAL GEARBOX/DIFFERENTIAL	TUTELA CAR ZC 75 SYNTH	-

1. Place the front bearing (1a) in its housing using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Using a feeler gauge, measure the housing for the front bearing circlip to be fitted.

1. Place a new front bearing circlip in position.

The size of the circlip is selected from those available as spares (1.975; 2.020; 2.065) depending on the previous measurement of the housing.

2. Place the needle bearing for the 1^st speed driven gear in its housing.3. Place the 1 ^st speed driven gear in its housing.4. Place the 1 ^st speed triple cone synchronizer assembly in its housing.

1. Fit the hub for the 1^st speed, 2^nd speed and reverse sliding sleeve (1a) using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Place a new circlip in position.2. Place the springs for the 1^st and 2^nd speed sliding sleeve in their housings on the hub.3. Fit the 1^st speed, 2^nd speed and reverse sliding sleeve so that the internal references are aligned with the springs.

1. Place the rollers in their housings on the 1^st and 2^nd speed sliding sleeve making sure that they are correctly fitted.2. Place the needle bearing for the 2^nd speed driven gear in its housing.

1. Fit the triple cone synchronizer (1a) on the 2^nd speed driven gear (1b).2. Fit the assembly constructed as described in the previous stage on the layshaft.

1. Fit the 3^rd speed driven gear (1a) using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Place the spacer back in its housing.Heat the 4^th speed driven gear to 120 °C.2. Fit the 4^th speed driven gear (2a) using a hydraulic press, a suitable plate (2b) and the top part of the tool (2c).

	Description	Code
2c	Extractor/Fitting tool	1.870.658.000

1. Fit the 5^th speed driven gear (1a) using a hydraulic press, a suitable plate (1b) and the top part of the tool (1c).

	Description	Code
1c	Extractor/Fitting tool	1.870.658.000

1. Place the rear bearing (1a) in its housing using a hydraulic press, a suitable plate (1b) and the fitting tool (1c).

	Description	Code
1c	Fitting tool	1.870.659.000

Fit the main and layshafts simultaneously in their housings.If the following components are being replaced:main shaft,bellhousing support,gearbox casing,main shaft front bearing,main shaft rear bearing,hub for 5^th speed sliding sleeve,layshaft assembly,layshaft rear bearing3^rd, 4^th and 5^th speed driven gearsproceed with determining the thickness of the scraper rings and the shims for the main and layshaft bearing pre-loading following the instructions given below.Thoroughly clean the bearing and gearbox casing support surfaces.1. Position the two gauges in the rear bearing seats in the gearbox casing.

	Description	Code
1	Gauges	1.870.648.000

1. Fit the reference crossmember on the gearbox casing.

	Description	Code
1	Reference crossmember	1.870.649.000

1. Place the two cylinders for the gauges in contact (without force) with the lower surface of the reference crossmember using a screwdriver and working via the two special openings.2. Lock the two cylinders using the bolts.

Remove the reference crossmember and the gauges from the gearbox casing.1. Fit the two gauges (1a) on the tool plate (1b).

	Description	Code
1a	Gauges	1.870.648.000

	Description	Code
1b	Support	1.870.647.000

1. Fit the tool for checking the bearing pre-loading (1a) with the bolts (1b), the spacer (1c), the disc (1d) and the centering bush (1e) specially designed for 5 speed gearboxes.

	Description	Code
1a	Support	1.870.647.000

1. Match the support for determining the bearing pre-loading kitted out in this way with the base plate complete with gauges.2. Connect the tool to a compressed air line and supply it with a pressure of 0.5 bar so that the two actuators are in contact with the gauges.3. Fit two dial gauges on the tool and zero them with a pre-loading of 3 mm (see reference X in the example for calculating the scraper shims).

Remove the support for determining the bearing pre-loading from the base plate complete with gauges.1. Remove the disc.

1. Position the support for determining the bearing pre-loading on the gearbox casing support and secure it.2. Connect the equipment to an air line and supply it at a pressure of 4 bar.3. Rotate the main and layshafts through ten revolutions using the tool (3a) and a suitable crank (3b).

	Description	Code
3a	Bush	1.870.652.000

Measure the movements in relation to the layshaft and the main shaft using the dial gauges (see reference Y in the example for calculating the scraper shims).Add 0.15 mm to the difference between X and Y for the layshaft to obtain the necessary distance for selecting the size of the scraper ring to be used.Subtract 0.10 mm from the difference between X and Y for the main shaft to obtain the necessary distance for selecting the size of the scraper ring to be used.

Below is an example for calculating the size of scraper shims.

Reference distance X (casing)Zero with dial gauge with a pre-loading of 3 mm on the test equipment.

Reference distance Y (shafts)To simplify the situation, let us assume that the difference measured was 0.9 mm for both the layshaft and the main shaft.

Calculation of layshaft scraper shim- 0.15 mm must be added to the difference measured between X and Y; to understand this more easily, immagine that the pointer has to move to the test distance of 0.15 mm, i.e.: 0.9 + 0.15 = 1.05 mm (scraper shim).

Calculation of main shaft scraper shim- 0.10 mm must be subtracted from the difference measured between X and Y; to understand this more easily, immagine that the pointer has to move to the test distance of 0.10 mm, i.e.: 0.9 -0.10 = 0.80 mm (scraper shim).

Remove the tool for determining the bearing pre-loading from the gearbox casing support.1. Place the lubrication duct in its housing.2. Fit the main shaft scraper ring of the size calculated.3. Fit the main shaft rear bearing outer race (3a) using a hydraulic press, a suitable plate (3b) and the fitting tool (3c).

	Description	Code
3c	Fitting tool	1.870.657.000

1. Fit the layshaft scraper ring of the size calculated.2. Fit the layshaft rear bearing outer race (2a) using a hydraulic press, a suitable plate (2b) and the fitting tool (2c).

	Description	Code
2c	Fitting tool	1.870.656.000

Place the reverse shaft and the 1^st, 2^nd, 3^rd and 4^th speed forks and control rods in position. 1. Lift up the reverse driven gear and check that the reverse shaft pin is correctly positioned.

1. Place the 5^th speed fork in its housing on the control rod.2. Place the reverese fork (2a) and the 5^th selector (2b) in its housing on the control rod.3. Tighten the bolts (3a) and (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	5TH SPEED CONTROL ROD	M8	2.1 ÷ 2.6

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	5TH SPEED CONTROL FORK	M8	2.1 ÷ 2.6

Apply the recommended sealant to the entire surface matched with the gearbox casing.

	Type	Component	Description	Qty.
-	Sealant	GEARBOX GEAR CASING	Loctite 510	-

1. Place the gearbox casing (1a) in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX GEAR CASING	M9	(Gearbox to engine mounting side) 2.9 - 3.6

2. Tighten the reverse shaft bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	REVERSE IDLER	M10	4.3 ÷ 5.3

Place the magnet back in its housing.Fit the differential in its housing complete with bearing outer races.Apply the recommended sealant to the entire surface matched with the differential internal housing support.

	Type	Component	Description	Qty.
-	Sealant	MOUNTING FOR DIFFERENTIAL CASING MANUAL GEARBOX	Loctite 510	-

1. Place the differential internal casing support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MOUNTING FOR DIFFERENTIAL CASING MANUAL GEARBOX	M10	4.3 ÷ 5.3

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MOUNTING FOR DIFFERENTIAL CASING MANUAL GEARBOX	M8	2.1 ÷ 2.6

1. Position the flange in its housing on the gearbox side differential (1a) complete with a new seal and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	Flanges on differential	M8	2.1 ÷ 2.6

Using a suitable drift, move the pinion side tapered bearing outer race nearer.1. Position the tool complete with dial gauge on the surface of the engine side differential and zero the dial guage with a pre-loading of 1 mm.

	Description	Code
1	Support	1.895.655.000

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

	Description	Code
1a	Support	1.895.655.000

Calculate the size of the scraper ring for the differential bearing pre-loading by adding 0.12 mm to the difference measured.

0.12 corresponds to the recommended interference for the bedding in and pre-loading of the differential bearings.

1. Place the scraper ring or rings of exactly the size or the next largest size to that calculated for the differential bearing pre-loading in the housing.2. Position the flange in its housing on the engine side differential (2a) complete with a new seal and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	Flanges on differential	M8	2.1 ÷ 2.6

Place the left internal driveshaft in its housing.Place the clutch hydraulic actuator in its housing after having renewed the sealant pad and secure it.Undo the fastenings and remove the gearbox and differential from the tool.

Two mechanics are needed for this operation.

	Description	Code
-	Support	1.871.001.014

Remove the support tool from the overhaul stand and put it down.Position the gearbox and differential on the tool used for the removing-refitting from the vehicle.

	Description	Code
-	Support	1.870.644.001