198002920 - 2110B34 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH, CHECK COMPONENTS, REPLACE SYNCHRONIZERS AND INTERNAL CONTROLS
Removing
(
Refitting
)
1. Fit the gearbox (1a) on the overhaul stand using the tool (1b).
| Tool | Description | Function | Validity |
|---|
| 1870001014 | Mount | Gearbox support for overhaul stand | 1.4 16v TJet |
2. Undo the reverse sensor and remove it.3. Adjust the retaining clip and remove the three-way connector.4. Undo the bolts (4a) and remove clutch coaxial actuator (4b).5. Undo the bolts (5a) and remove the gear selection and engagement unit (5b).
1. Undo the bolts (1a), remove the sealant working at the three points (1b) and remove the gearbox casing (1c) from the clutch casing (1d).- Clean the support surfaces between the gearbox casing and the clutch casing thoroughly.
1. Using the tools (1a) and (1b) remove the outer races (1c) and the scraper rings (1d) for the main shaft and the layshafts.| Tool | Description | Function | Validity |
|---|
| 1870655000 | Extractor/ Fitting tool | Bearing race removal | 1.9 JTD1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1840206001 | Mallet | - | 1.9 JTD1.4 16v TJet |
1. Undo the bolt fixing the rear bearing to the main shaft using the special tool for counter-torque.| Tool | Description | Function | Validity |
|---|
| 1870853000 | Lever | Main shaft rotation | 1.4 16v TJet |
2. Remove the main shaft (2a), the layshaft (2b) and the selector forks (2c) from their housing.3. Remove the second layshaft from its housing.
PROCEED WITH DISMANTLING THE CLUTCH CASING AS DESCRIBED BELOW.1. Using the tools (1a) and (1b) remove the outer races (1c) for the front bearings for the main shaft and the layshafts.| Tool | Description | Function | Validity |
|---|
| 2000005400 | Extractor | Removing bearing outer races | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1840206001 | Mallet | - | 1.9 JTD1.4 16v TJet |
2. Remove the main shaft seal from the clutch casing.
1. Using the extractor (1a) and a suitable mallet (1b), remove the bearing for the gear selector shaft (1c).| Tool | Description | Function | Validity |
|---|
| 1840207812 | Extractor | Removing bearings | 1.4 16v TJet |
PROCEED WITH DISMANTLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 6th speed gear (1d), the 4th speed gear (1e) and the spacer (1f).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 2000004700 | Fitting tool | Removing/ refitting bearings | 1.4 16v TJet |
1. On the hydraulic press, using the tools (1a) and (1b), remove the 3rd and 5th speed drive gear (1c) from the main shaft (1d). | The main shaft should be supported at the bottom during this operation. |
| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 2000004700 | Fitting tool | Removing/ refitting bearings | 1.4 16v TJet |
1. On the hydraulic press, using the tools (1a), (1b) and (1c), remove the front bearing (1d). | The main shaft should be supported at the bottom during this operation. |
| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1846017000 | Half-rings | Half-rings for reaction in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1846001001 | Half-rings | Bearing removal | 1.9 JTD 8v1.4 16v TJet |
PROCEED WITH DISMANTLING THE LAYSHAFT (B) AS DESCRIBED BELOW.1. Remove the gear selector forks (1a) from the layshaft (1b).2. Remove the rear bearing circlip.
1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 4th speed gear (1d) and the needle bearing (1e).| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1870447000 | Reaction pin | Removing bearing | 1.4 16v TJet |
1. Remove the 4th speed synchronizer ring assembly.2. Remove the 3rd and 4th speed sliding engagement sleeve.3. Remove the pre-synchronizer mountings.
1. Remove the sliding sleeve hub circlip.
1. Remove the 3rd and 4th speed sliding sleeve hub (1a), the 3rd speed synchronizer ring assembly (1b) and the 3rd speed driven gear (1c) using a hydraulic press and tool (1d). | The layshaft should be supported at the bottom during this operation. |
| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
2. Remove the needle bearing.
1. Remove the spacer circlip.
1. On the press, using the tool (1a), remove the spacer (1b), the presynchronizer mountings (1c), the sliding sleeve (1d), the reverse synchronizer rings (1e), the reverse gear (1f) and the needle bearing (1g).| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
1. Remove the front bearing circlip.
1. On press, remove the front bearing using a suitable extractor. | The layshaft should be supported at the bottom during this operation. |
PROCEED WITH DISMANTLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.1. Remove the circlip.
1. On the press, using the tool (1a), remove the 6th speed gear and bearing (1b) and the needle bearing (1c). | The second layshaft should be supported at the bottom during this operation. |
| Tool | Description | Function | Validity |
|---|
| 2000004700 | Fitting tool | Removing/ refitting bearings | 1.4 16v TJet |
1. Remove the synchronizer circlip.
1. On the press, using the tool (1a), remove the 5th and 6th speed synchronizer (1b) and the 5th speed gear (1c).| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
1. Release the needle bearing (1a) and remove the spacer (1b), the two half rings (1c), the 2nd speed gear and the needle bearing (1e).
1. Remove the circlip (1a) and the 1st and 2nd speed synchronizer rings (1b).
1. On the press, using the tool (1a), remove the 1st and 2nd speed synchronizer (1b) and the 1st speed gear (1c).| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
1. Remove the bearing with a double row of rollers.
1. On press, remove the front bearing using a suitable extractor. | The second layshaft should be supported at the bottom during this operation. |
Refitting
(
Removing
)
PROCEED WITH REASSEMBLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW. | If the bearing, 1st speed gear or the presynchroniser are replaced, the thickness of the new circlip must be calculated as described below.Calculate the difference in thickness between the old and new components.The value of the difference should be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted.A circlip set is available from Parts. |
1. Position the two bearings (1a), the 1st speed gear (1b), the 1st and 2nd speed synchronizer rings (1c) and the ring nut (1d) on the second layshaft and fit them on the hydraulic press.
1. Fit the sleeve and three presynchronizer mountings (1a), the 1st and 2nd speed synchronizer rings (1b) and the circlip (1c).
1. Position the bearing (1a), the 2nd speed gear (1b), the two half rings (1c), the spacer (1d), the needle bearing (1e), the 5th speed gear (1f) and the 5th and 6th speed synchronizer assembly on the second layshaft and fit them on the hydraulic press.
1. Fit the circlip (1a), the needle bearing (1b) and the 6th speed gear (1c).
| If the rear bearing is replaced, calculate the thickness of the calibrated circlip as described below.Calculate the difference in thickness between the new and the old rear bearing and add this difference to or subtract it from the thickness of the removed circlip.A circlip set is available from Parts. |
1. Fit the rear bearing on the press.
1. Fit the rear bearing circlip.
PROCEED WITH REASSEMBLING THE LAYSHAFT (B) AS DESCRIBED BELOW. | If the thrust bearing is replaced, calculate the thickness of the new calibrated circlip as described below.Calculate the difference in thickness between the old and new thrust bearing. The value of the difference should be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted. A circlip kit is available as spares. |
1. On the press, use tools (1a) and (1b) to fit the thrust bearing (1c).| Tool | Description | Function | Validity |
|---|
| 2000005000 | Plate | Reaction plate in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1870658000 | Extractor/ Fitting tool | Fitting bearings | 1.9 JTD1.4 16v TJet |
2. Fit the circlip (2a), the needle bearing (2b), reverse gear (2c) and the synchronizer ring (2d).
1. On the press, using the tool (1a), fit the synchronizer sliding sleeve (1b).| Tool | Description | Function | Validity |
|---|
| 1870658000 | Extractor/ Fitting tool | Fitting bearings | 1.9 JTD1.4 16v TJet |
1. On the press, using the tool (1a), fit the spacer (1b).| Tool | Description | Function | Validity |
|---|
| 1870658000 | Extractor/ Fitting tool | Fitting bearings | 1.9 JTD1.4 16v TJet |
1. Fit a new circlip (1a), the three presynchronizer mountings (1b), the sliding sleeve for reverse gear (1c), the needle bearing (1d), the 3rd speed gear (1e) and the three synchronizer rings (1f).
1. On the press, using the tool (1a), fit the synchronizer ring nut (1b). Pay attention that the teeth shown in the diagram are in the correct position.| Tool | Description | Function | Validity |
|---|
| 1870658000 | Extractor/ Fitting tool | Fitting bearings | 1.9 JTD1.4 16v TJet |
1. Fit the synchronizer circlip.
1. Fit the three presynchronizer mountings (1a) and the sleeve (1b) complete with seals (1c).
1. Fit the needle bearing (1a) and the 4th speed gear (1b).2. On the press, using the tool (2a), fit the rear bearing (2b).| Tool | Description | Function | Validity |
|---|
| 1870658000 | Extractor/ Fitting tool | Fitting bearings | 1.9 JTD1.4 16v TJet |
1. Fit a new circlip (1a) retaining the rear bearing and position the forks (1b) on the layshaft (1c).
| If the rear bearing or the 4th speed gear is being replaced, the thickness of the new circlip must be calculated in the way described below. Calculate the difference in size between the new and old components. This value be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted. A circlip kit is available as spares. |
PROCEED WITH REASSEMBLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.1. On the press, using the tools (1b) and (1c), fit the front bearing (1a).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.4 16v TJet |
1. On the press, using the tools (1b) and (1c), fit the 3rd and 5th speed drive gear (1a).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.4 16v TJet |
1. Fit the spacer.2. On the press, using the tools (2b) and (2c), fit the 4th speed drive gear (2a).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.4 16v TJet |
1. On the press, using the tools (1b) and (1c), fit the 6th speed drive gear (1a).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.4 16v TJet |
1. On the press, using the tools (1b) and (1c), fit the rear bearing (1a).| Tool | Description | Function | Validity |
|---|
| 1860837000 | Plate | Plate for support in the press | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1860824000 | Fitting tool | Fitting bearing | 1.4 16v TJet |
PROCEED WITH REASSEMBLING THE CLUTCH CASING AS DESCRIBED BELOW.1. Fit the main shaft front bearing outer race (1a) using tools (1b) and (1c).| Tool | Description | Function | Validity |
|---|
| 2000005100 | Fitting tool | Fitting bearing | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1870007000 | Grip | Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential | |
1. Fit the layshaft front bearing outer races (1a) using tools (1b) and (1c).| Tool | Description | Function | Validity |
|---|
| 2000004600 | Fitting tool | Fitting bearing | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1870007000 | Grip | Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential | |
1. Fit the bearing for the gear selector and engagement shaft (1a) in its housing using the tools (1b) and (1c).| Tool | Description | Function | Validity |
|---|
| 2000004900 | Fitting tool | Fitting selector bearing | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1874365000 | Grip | Fitting bearing | 1.9 JTD 8v1.4 16v TJet |
- Fit the main shaft and the two layshafts complete with forks in their housings in the clutch casing.
PROCEED WITH DETERMINING THE SIZE OF THE SCRAPER RINGS AS DESCRIBED BELOW.1. Tighten the main shaft rear bearing retaining bolt to the recommended torque using the special tool for counter-torque.| Tool | Description | Function | Validity |
|---|
| 1870853000 | Lever | Main shaft rotation | 1.4 16v TJet |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Main shaft rear bearing | Bolt | M8 x 1.5 | 5.0 ÷ 7.0 | 1.4 16v TJet |
2. Fit the outer races on the gearbox shafts.
1. Tighten the rods with the spacers to the clutch casing.2. Fit the three gauges on the three gearbox shafts.| Tool | Description | Function | Validity |
|---|
| 2000002000 | Gearbox overhaul kit | Calculating thickness of thrust rings | 1.4 16v TJet |
3. Fit the gearbox casing (3a) on the rods fitted previously and tighten the nuts (3b) to a torque of 25 Nm starting with tightening the nuts by the centering bushes.4. Rotate the gearbox main and layshafts through about twenty revolutions using the special tool.| Tool | Description | Function | Validity |
|---|
| 1870853000 | Lever | Main shaft rotation | 1.4 16v TJet |
5. Measure the gap between the two cylinders for each of the three shafts using a feeler gauge.- Determine the size of the new scraper ring for the main shaft (A) by subtracting the maximum permitted clearance of 0.10 mm from the reading taken previously using the feeler gauge.- Determine the size of the new scraper ring for the layshaft (B) by adding the maximum pre-loading of 0.20 mm to the reading taken previously using the feeler gauge.- Determine the size of the new scraper ring for the second layshaft (C) by adding the maximum pre-loading of 0.30 mm to the reading taken previously using the feeler gauge.
- Remove the gearbox casing and all the components for the tool from the clutch casing.1. Fit the gearbox casing (1b) on the tool (1c) using two nuts (1a) taking care to position the three studs (1d) by the three shaft housings.| Tool | Description | Function | Validity |
|---|
| 2000005700 | Gearbox casing support frame | Fitting bearing outer races on gearbox casing | 1.4 16v TJet |
1. Fit the three new scraper rings (1a) and the outer races for the main and layshaft rear bearings (1b) using the tools (1c) and (1d).| Tool | Description | Function | Validity |
|---|
| 2000005200 | Fitting tool | Fitting bearing outer races on gearbox casing | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 2000005700 | Gearbox casing support frame | Fitting bearing outer races on gearbox casing | 1.4 16v TJet |
| Tool | Description | Function | Validity |
|---|
| 1870007000 | Grip | Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential | |
- Apply the LOCTITE 510 sealant to the entire matching surface between the gearbox casing and the clutch casing.- Remove the gearbox casing from the support tool and fit it on the clutch casing tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gearbox casing | Bolt | M8 | 2.2 | 1.4 16v TJet |
1. Fit a new main shaft oil seal on the clutch casing using the special fitting tool.| Tool | Description | Function | Validity |
|---|
| 2000004800 | Fitting tool | Fitting main shaft sealing ring | 1.4 16v TJet |
- Fit the gear selector and engagement assembly on the clutch casing tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gear selection and engagement assembly | Bolt | M8 | 2.0 | 1.4 16v TJet |
- Fit the clutch control coaxial actuator to the clutch casing tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Coaxial actuator | Bolt | M6 | 0.6 | 1.4 16v TJet |
- Connect the three-way connector to the oil pipe for the coaxial actuator and to the clutch casing.- Undo the fastenings and remove the gearbox and differential from the support tool.- Remove the support tool from the overhaul stand.
