199001075 - 2110B20 MANUAL GEARBOX (5-6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY

Removing ( Refitting ) 1. Remove hydraulic jack (1a) from the gearbox with differential and tools (1b) and (1c) used for removal/refitting on the vehicle.
ToolDescriptionFunctionValidity
1870689000MountGearbox support1.2 8v1.4 8v
ToolDescriptionFunctionValidity
1860873000Gearbox supportRemoving-refitting gearbox from the vehicle1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).
Two mechanics are needed for this operation.
ToolDescriptionFunctionValidity
1871001014Gearbox supportOverhaul gearbox1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
1. Undo the bolts (1a) and remove the gearbox rear cover (1b).
Use a drier to help detach the sealant.
2. Remove the differential output shafts (2a) with external tripods using tool (2b).
ToolDescriptionFunctionValidity
1847056000ExtractorExtracting differential output shafts1.2 8v1.4 8v
- Engage any gear using the gear selection/engagement lever.1. Unscrew stud (1a) and bolts (1b), then remove the gear shift unit cover (1c).
1. Unscrew bolt (1a) of the 5th speed drive fork (1b).- Engage 5th speed by pressing the fork on the main shaft.
If two gears are engaged simultaneously the gear shafts will lock.
2. Remove the staking on the main and layshaft ringnuts using a suitable drift.3. Completely undo the ring nuts for the main and layshafts.
- Place the 5th speed control fork in neutral.
The positioning of the 5th speed control fork in neutral is necessary to prevent the synchronizer rollers from being lost.
1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed driven shaft (2a) using tool (2b).
ToolDescriptionFunctionValidity
1840005400ExtractorExtracting 5th speed driven gearRemoving hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v
1. Fit the 5th speed synchronizer roller and spring retaining plate.2. Remove the 5th speed engagement fork.3. Remove the 5th speed engagement sliding sleeve.4. Remove the 5th speed hub springs and rollers.
1. Remove the 5th speed sliding engagement sleeve hub (1a), 5th speed synchroniser ring (1b) and 5th speed drive gear (1c) with tool (1d).
ToolDescriptionFunctionValidity
1840005400ExtractorExtracting 5th speed driven gearRemoving hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v
1. Remove the 5th speed drive gear bush (1a) using tool (1b).
ToolDescriptionFunctionValidity
1845057000ExtractorRemoving 5th speed drive gear bush1.2 8v1.4 8v
1. Undo the bolts (1a) and remove the rear bearing retaining plate (1b).
1. Fit the rear bearing circlips.
To remove the circlips, arrange them with their openings at the front.
2. Unscrew the reverse idler gear shaft bolt.
1. Undo the bolts (1a) and remove the gearbox casing (1b).2. Unscrew bolts (2a) and remove the mount with reverse engagement fork lever (2b).
1. Unscrew bolt (1a) and withdraw the gear engagement fork guide rod (1b).2. Remove the 3-4th speed engagement fork.3. Remove the reverse engagement fork drive prong.4. Remove the 5th gear engagement fork drive prong.5. Remove the 1st-2nd speed engagement fork.
1. Remove the reverse idler gear.2. Remove the mainshaft assembly.3. Remove the layshaft assembly.
1. Undo the bolts (1a) and remove the differential casing cover (1b) complete with gasket (1c) and oil seal (1d).
The sealing ring and gasket must always be replaced.
1. Undo the bolts (1a) and remove the mileometer relay gear (1b).
1. Undo the bolts (1a) and remove the manual gearbox differential mount (1b) complete with oil seal (1c).2. Remove the magnet.3. Remove the differential bearing preload thrust ring.4. Remove the differential assembly.5. Remove the differential bearing outer races.
1. Remove the clutch thrust bearing external linkage retaining ring.2. Remove the clutch thrust bearing outer linkage (2a) and bush (2b).
1. Remove the clutch thrust bearing inner linkage (1a) and bush (1b).
Replace the outer and inner bushes whenever thrust bearing drive shaft play is excessive.
1. Remove the staking and remove the layshaft oil locating device from the manual gearbox bell housing.2. Remove the mainshaft oil seal from the manual gearbox bell housing.
- Proceed with dismantling the layshaft following the instructions given below.- Position the layshaft in a vice fitted with protective jaws.1. Remove the bearing retaining ring.2. Remove rear bearing (2a) and 4th speed driven gear (2b) using tools (2c), (2d) and (2e).
ToolDescriptionFunctionValidity
1840005002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8v1.4 8v1.4 16v TJet
ToolDescriptionFunctionValidity
1840005301ClampsRemoving 4th speed drive gear and rear bearingRemoving main shaft front bearingRemoving bearing from differential1.2 8v1.4 8v
ToolDescriptionFunctionValidity
1842133000ExtractorRemoving 4th speed driven gear and rear bearingRemoving bearing from differential1.2 8v1.4 8v
3. Withdraw the spacer between the 3rd and 4th speed driven gears.
1. Remove the 3rd speed driven gear (1a) and the 2nd speed driven gear (1b) using the tools (1c) and (1d).
ToolDescriptionFunctionValidity
1840005002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8v1.4 8v1.4 16v TJet
ToolDescriptionFunctionValidity
1840005303ClampsRemoving layshaft rear bearingRemoving 3rd speed driven gear and 2nd speed driven gearRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gear1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
2. Remove the 2nd speed synchroniser ring (2a) and the 1st and 2nd speed sliding engagement sleeve (2b).- Remove the 1st and 2nd speed hub springs and rollers.
1. Remove the hub retaining circlip.2. Remove the 1st speed driven gear (2a), 1st speed synchroniser ring (2b) and the hub for the 1st-2nd speed sliding engagement sleeve (2c) using tools (2d) and (2e).
ToolDescriptionFunctionValidity
1840005002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8v1.4 8v1.4 16v TJet
ToolDescriptionFunctionValidity
1840005306ClampsRemoving 1st, 2nd and 3rd speed driven gearsDismantling main shaftRemoving layshaft front bearing1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
To remove the layshaft front bearing, see    Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
- Proceed with dismantling the mainshaft following the instructions given below.1. Remove rear bearing (1a) and 4th speed drive gear (1b) using tools (1c) and (1d).
ToolDescriptionFunctionValidity
1840005001StrutRemoving left differential internal driveshaftExtracting main shaft front bearingRemoving layshaft front bearing inner raceRemoving 4th speed drive gear and rear bearingRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gearRemoving main shaft front bearing1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
ToolDescriptionFunctionValidity
1840005301ClampsRemoving 4th speed drive gear and rear bearingRemoving main shaft front bearingRemoving bearing from differential1.2 8v1.4 8v
2. Remove the 4th speed synchroniser ring (2a) and the 3rd and 4th speed sliding engagement sleeve (2b).3. Recover springs (3a) and rollers (3b) for the 3rd-4th speed hub.
1. Remove the 3rd-4th speed sliding sleeve hub circlip.2. Remove the 3rd-4th speed sliding engagement sleeve hub (2a), 3rd speed synchroniser ring (2b) and 3rd speed drive gear (2c) using tools (2d) and (2e).
ToolDescriptionFunctionValidity
1840005001StrutRemoving left differential internal driveshaftExtracting main shaft front bearingRemoving layshaft front bearing inner raceRemoving 4th speed drive gear and rear bearingRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gearRemoving main shaft front bearing1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
ToolDescriptionFunctionValidity
1840005303ClampsRemoving layshaft rear bearingRemoving 3rd speed driven gear and 2nd speed driven gearRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gear1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
To remove the mainshaft front bearing, see    Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
Refitting ( Removing ) - Proceed with washing and checking the condition of all the components.- Proceed with reassembling the mainshaft following the instructions given below.- Lubricate the relevant parts with transmission fluid before final fitting.1. Fit the 3rd speed drive gear (1a) and 3rd speed synchroniser ring (1b).2. Fit the 3rd-4th speed sliding engagement sleeve hub (2a) using tool (2b).
ToolDescriptionFunctionValidity
1870152000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8v1.4 8v
3. Fit the 3rd-4th speed sliding sleeve hub circlip.
1. Fit the springs on the hub for the 3rd and 4th speed sliding engagement sleeve.2. Fit the 3rd and 4th speed sliding engagement sleeve.
The notches in the sleeve should correspond with the springs.
3. Fit the rollers between the springs and the grooves on the 3rd and 4th speed sliding engagement sleeve.4. Fit the 4th speed synchronizer oil seal.- Place the 3rd-4th speed sliding sleeve in neutral to prevent the springs and rollers from being lost.5. Fit the 4th speed drive gear.
1. Fit the rear bearing (1a) on the mainshaft using the tool (1b).
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
- Proceed with dismantling the layshaft following the instructions given below.- Lubricate the relevant parts with transmission fluid before final fitting.1. Fit the 1st speed drive gear.2. Fit the 1st speed synchronizer oil seal.3. Fit the 1st-2nd speed sliding engagement sleeve hub (3a) using tool (3b).
ToolDescriptionFunctionValidity
1870152000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8v1.4 8v
4. Fit the 1st-2nd speed sliding sleeve hub circlip.
1. Fit the springs on the hub for the 1st-2nd speed sliding engagement sleeve.2. Fit the 1st-2nd speed sliding engagement sleeve.
The notches in the sleeve should correspond with the springs.
3. Fit the rollers between the springs and the grooves on the 1st-2nd speed sliding engagement sleeve.4. Fit the 2nd speed synchronizer ring.- Place the 1st-2nd speed sliding sleeve in neutral to prevent the springs and rollers from being lost.5. Fit the 2nd speed drive gear.6. Remove the 3rd speed driven shaft (6a) using tool (6b).
ToolDescriptionFunctionValidity
1870152000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8v1.4 8v
1. Withdraw the spacer between the 3rd and 4th speed driven gears.2. Fit the 5th speed driven shaft (2a) using tool (2b).
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
3. Fit the rear bearing (3a) using the tool (3b).
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
4. Fit the layshaft rear bearing circlip.
1. Fit the mainshaft oil seal (1a) on the manual gearbox bell housing using tools (1b) and (1c).
ToolDescriptionFunctionValidity
1870419000Fitting toolFitting main shaft oil seal on gearbox to engine mount1.2 8v1.4 8v1.4 16v
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v1.9 Multijet1.3 Multijet 90 CV 6 speed1.4 16v TJet
1. Fit the layshaft oil centring device on the manual gearbox bell housing.2. Stake the edge of the oil centring device seat in two points at 180°.
1. Fit the inner bush for the clutch thrust bearing linkage (1a) using tool (1b).
ToolDescriptionFunctionValidity
1870633000Fitting toolFitting clutch thrust bearing control linkage inner bush1.2 8v1.4 8v1.4 16v
1. Fit inner linkage (1a), outer bush (1b) and outer linkage (1c) of the cutch thrust bearing drive.2. Fit the clutch thrust bearing external linkage retaining ring.
1. Fit the differential assembly (1a) and differential bearing outer races (1b).2. Fit the magnet.- Apply sealant to the contact surfaces between the differential mount and gear casing.3. Fit the manual gearbox housing differential mount (3a) and fastening it by tightening the bolts (3b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox casing differential supportBoltM82.01.2 8v1.4 8v1.4 16v
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox casing differential supportBoltM103.51.2 8v1.4 8v1.4 16v
1. Fit the mileometer idler gear (1a) and tighten the bolt (1b) to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Speed signalling control supportBoltM60.51.2 8v1.4 8v
1. Remove the layshaft assembly.2. Fit the mainshaft assembly.3. Fit the reverse idler gear (3a) by inserting pin (3b) in its seat on the housing.
1. Fit the 3-4th speed engagement fork.2. Fitthe 1st-2nd speed engagement fork.3. Fit the 5th gear engagement fork drive prong.4. Fit the reverse engagement fork drive prong.5. Fit the gear engagement fork guide rod in its seat.6. Tighten the bolt for the 5th speed control fork drive prong to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
5th speed engagement fork control pawlBoltM61.1 ÷ 1.31.2 8v1.4 8v1.4 16v
1. Fit the mount with the reverse engagement fork lever (1a) and tighten the bolts (1b) to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Support with fork lever for reverse gear engagementBoltM81.4 ÷ 1.61.2 8v1.4 8v1.4 16v
2. Apply sealant to the contact surfaces between the gear casing and the manual gearbox bell housing.3. Fit the gearbox casing (3a) and secure it by tightening the bolts (3b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox casingBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v
1. Tighten the reverse idler gear shaft bolt to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox reverse gear idlerBoltM82.3 ÷ 2.81.2 8v1.4 8v1.4 16v
2. Fit the rear bearing circlips.
To facilitate the fitting of the rear bearing circlips, position them with the openings at the front.
1. Fit the rear bearing retaining plate (1a) and secure it by tightening the bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Main and layshaft rear bearings retaining plateBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v
1. Fit the 5th speed drive gear bush (1a) using tool (1b).
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
1. Fit the 5th speed drive gear.2. Fit the 5th speed synchronizer ring.3. Using the tool (3a), fit the hub for the 5th speed engagement sliding sleeve (3b) with the oil passage splines facing the gear.
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
1. Fit the springs on the hub for the 5th speed sliding engagement sleeve.2. Fit the 5th speed sliding engagement sleeve.
The notches in the sleeve should correspond with the springs.
3. Fit the 5th speed engagement fork.4. Fit the rollers between the springs and the 5th speed sliding engagement sleeve grooves.5. Fit the 5th speed synchronizer roller and spring retaining plate.- Place the 5th speed sliding sleeve in neutral to prevent the springs and rollers from being lost.
1. Fit the 5th speed driven gear (1a) on the layshaft using the tool (1b).
ToolDescriptionFunctionValidity
1870631000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve1.2 8v1.4 8v1.4 16v
- Fit the ring nuts on the main and layshafts without tightening them.
1. Apply sealant to the contact surfaces between the gearbox casing and the gear engagement assembly cover.2. Fit the gear engagement assembly cover (2a) and tighten the bolts (2b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox gear engagement unit coverBoltM62.01.2 8v1.4 8v1.4 16v
- Engage any gear using the gear selection/engagement lever.- Engage 5th speed by pressing the main shaft drive fork.
If two gears are engaged simultaneously the gear shafts will lock.
1. Tighten the bolt for the 5th speed control fork to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
5th speed control forkBoltM61.21.2 8v1.4 8v
2. Tighten the ring nuts securing the main and layshaft gears to torque.
ComponentFasteningdia  Value (daNm)Validity
Main and layshaft ring nutsRing nutM2011.81.2 8v1.4 8v
1. Stake the ring nuts (1a) securing the main and layshaft 5th speed gear using the tools (1b) and (1c).
ToolDescriptionFunctionValidity
1874140005Pair of headsStaking ring nuts securing main and layshaft 5th speed1.2 8v1.4 8v1.4 16v
ToolDescriptionFunctionValidity
1874140001CalliperStaking ring nuts securing main and layshaft 5th speed1.2 8v1.4 8v1.4 16v
1. Apply the recommended sealant to the contact surfaces between the gearbox rear cover and the gearbox casing.2. Fit the gearbox rear cover (2a) and secure it tightening the bolts (2b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Rear coverBoltM60.51.2 8v1.4 8v1.4 16v
1. Fit tool (1a) complete with dial gauge (1b) on the differential cover support surface, then move the probe into contact with the taper roller bearing outer race.
ToolDescriptionFunctionValidity
1895655000MountDetermining thickness of differential bearing scraper rings1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v1.4 16v TJet
- Zero the dial gauge with a preload of 1 mm.
1. Position tool (1a) complete with dial gauge on the differential sealing cover (1b) as shown in the figure and measure the difference.
ToolDescriptionFunctionValidity
1895655000MountDetermining thickness of differential bearing scraper rings1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v1.4 16v TJet
- Calculate the size of the scraper ring for 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.
1. Fit oil seal (1b) to differential cover (1a) using tools (1c) and (1d).
ToolDescriptionFunctionValidity
1870629000Fitting toolFitting oil seal on differential cover1.2 8v1.4 8v1.4 16v
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v1.9 Multijet1.3 Multijet 90 CV 6 speed1.4 16v TJet
2. Fit the gasket to the differential cover.
The sealing ring and gasket must always be replaced.
1. Fit the differential cover (1a) and tighten the fixing bolts (1 b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox differential seal flangeBoltM82.01.2 8v1.4 8v
1. Fit the gear casing differential mount oil seal (1a) with tools (1b) and (1c).
The oil seal must always be replaced.
ToolDescriptionFunctionValidity
1870630000Fitting toolFitting gearbox casing differential support oil seal1.2 8v1.4 8v
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v1.9 Multijet1.3 Multijet 90 CV 6 speed1.4 16v TJet
- Fit the differential output shafts with external tripods.- Undo the fastenings and remove the gearbox and differential from the tool.
Two mechanics are needed for this operation.
ToolDescriptionFunctionValidity
1871001014Gearbox supportOverhaul gearbox1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet
- Remove the support tool from the overhaul stand and replace.- Position the gearbox and differential on the tools used for the removing-refitting from the vehicle.
ToolDescriptionFunctionValidity
1870689000MountGearbox support1.2 8v1.4 8v
ToolDescriptionFunctionValidity
1860873000Gearbox supportRemoving-refitting gearbox from the vehicle1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.2 8v1.4 8v1.4 16v TJet