199000943 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting )     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 5520B10 STARTER MOTOR - R+R     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R 1. Disconnect the electrical connection for the reversing switch.
DescriptionConnector
1Reversing light switch    See I020 REVERSING LIGHTS SWITCH (GEARBOX BRIDGE)
2. Undo the bolts and move the clutch control actuator aside.3. Undo the nut and disconnect the earth lead.
DescriptionConnector
3Battery earth on engine    See C002 BATTERY EARTH ON ENGINE
1. Disconnect the gear selector and engagement cables.2. Move the locking cursor (2a) backwards and remove the gear selector cable (2b).3. Move the locking cursor (3a) backwards and remove the gear engagement cable (3b).
1. Fit the tool (1a) complete with support mountings (1b).
ToolDescriptionFunctionValidity
1870595000CrossmemberPower unit mount1.2 8v1.4 8v1.4 16v1.3 Multijet
ToolDescriptionFunctionValidity
1870650000Support blocksPower unit mount1.2 8v1.4 8v1.4 16v1.3 Multijet
2. Fit the tools (2a) and (2b), then connect them to the brackets fitted previously using the links (2c).
ToolDescriptionFunctionValidity
1860851000CrossmemberPower unit mount1.2 8v1.4 8v1.4 16v1.3 Multijet
ToolDescriptionFunctionValidity
1871001300Vertical mountPower unit mount1.2 8v1.4 8v1.4 16v1.3 Multijet
1. Undo the bolts fixing the flexible mounting to the gearbox side rigid power unit support.2. Undo the upper bolt securing the gearbox side power unit rigid support.
1. Undo the upper bolts securing the gearbox to the engine.
1. Undo the bolt (1a) and move the ABS sensor (1b) from the pillar.2. Undo the bolt securing the front suspension left track control arm to the steering knuckle3. Unscrew the nut (3a), fit the tool (3b) and disconnect the left steering link (3c) from the knuckle.
ToolDescriptionFunctionValidity
1871000700ExtractorExtracting steering rod from strut
- Proceed in the same way for the right side.1. Disconnect the left driveshaft from the differential and secure it appropriately.
1. Disconnect the right driveshaft from the differential and secure it appropriately.
1. Undo the lower bolts and remove the power unit rigid support from the gearbox.
1. Support the gearbox as illustrated using the brackets (1a) and the hydraulic jack (1b).
ToolDescriptionFunctionValidity
1870847000BracketsGearbox support
ToolDescriptionFunctionValidity
1870835001Hydraulic liftGearbox support
2. Undo the nut (2a) and the remaining bolts (2a) and remove the gearbox (2c).
Refitting ( Removing ) - Place the gearbox and differential back in its housing using the hydraulic jack and the support tool.- Tighten the bolts and the nut securing the gearbox to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to engine - crankcase sideBoltM124.8 ÷ 7.2
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to engine - crankcase sideNutM124.8 ÷ 7.2
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to oil sumpBoltM103.6 ÷ 4.41.4 16v1.9 Multijet
- Place the power unit rigid support in position on the gearbox and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox side power unit rigid support to gearbox casingBoltM106.3 ÷ 7.71.2 8v1.4 8v1.4 16v1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed
- Place the right driveshaft back in its housing.- Place the left driveshaft back in its housing.- Connect the left steering rod to the knuckle and tighten the nut to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Steering rod to pillarNutM103.6 ÷ 4.4
- Tighten the bolt securing the front suspension left track control arm to the steering knuckle
ComponentFasteningdia  Value (daNm)Validity
Front suspension lower wishbone - strut sideBoltM105.4 ÷ 6.6
- Connect the ABS sensor to the knuckle and secure it using the bolt.- Tighten the upper bolt securing the gearbox side rigid support to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox side power unit rigid support to gearbox casingBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v
- Tighten the bolts fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox side support flexible mounting to rigid supportBoltM129.5 ÷ 10.51.2 8v1.4 8v1.4 16v1.3 Multijet
- Remove the tools fitted previously for supporting the engine.- Working in the engine compartment, introduce the two quick-fits for the gear selector and engagement cables in the openings in the bracket keeping the cursors retracted and inserting them fully into the seats using manual pressure until they are attached. Release the cursors.- Using manual pressure, connect the ends of the gear selection and engagement cables to the ball joints for the levers on the gearbox.- Connect the battery earth lead and tighten the nut.- Place the clutch control actuator in its housing and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Hydraulic clutch actuatorBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v1.3 Multijet 75CV
- Connect the electrical connection for the reversing switch.    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 5520B10 STARTER MOTOR - R+R     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 0010T40 CHANGE MANUAL GEARBOX OIL