199000945 - 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).
1. Remove the circlip (1a) and the lever (1b).2. Remove the outer non-slip bush.
1. Remove the thrust bearing.2. Remove the inner thrust control linkage.3. Remove the inner non-slip bush.
1. Undo the bolts (1a) and remove the gear selector/engagement assembly (1b).
1. Using a suitable tool, remove the differential left inner driveshaft.2. Undo the bolts (2a) and remove the flange (2b) complete with oil seal and O-ring.
1. Using a suitable tool, remove the differential right inner driveshaft.2. Release the oil seal and remove it.
1. Undo the bolts (1a) and remove the differential cover (1b).
1. Remove the differential complete with scraper rings and bearings.
1. Remove the magnet.
1. Undo the bolts (1a) and remove the rear cover (1b) applying leverage at the point (1c) shown in the diagram.
1. Undo the 5th and 6th speed engagement fork retaining bolt.
1. Move the rod shown in the diagram downwards so that the selectors are aligned.
1. Lift up the synchronizer to engage the 5th and 6th speed.
The simultaneous engagement of two gears results in the gearbox shafts locking; this operation is necessary in order to be able to release the bolt and the nut securing the gears.
1. Straighten the staking and undo the nut securing the 5th and 6th speed gears to the main shaft.
The nut must be replaced whenever it requires removal.
2. Undo the left-threaded bolt securing the 5th and 6th gears to the layshaft.
1. Using the special tools (1a) and tool (1b) as illustrated, remove the layshaft (1c) rear bearing.
ToolDescriptionFunctionValidity
1870481000ExtractorLayshaft bearing removal1.4 16v
1. Remove the 6th speed gear from the layshaft.2. Remove the spacer for the 5th and 6th speed gears.
1. Using suitable tools (1a) as illustrated, remove the 6th speed gear (1b) complete with bush from the main shaft.
1. Remove the 5th and 6th speed engagement sleeve (1b) and fork (1a).
1. Remove the 6th speed synchroniser ring.2. Remove the presynchronisation mountings from the 5th and 6th speed hub.3. Remove the 5th speed driven gear from the layshaft.
1. Using suitable tools (1a) as illustrated, remove the 5th and 6th speed hub from the main shaft.
1. Remove the synchronizer ring (1a) and the 5th speed gear (1b) from the main shaft.
1. Using suitable tools (1a) as illustrated, remove the bush for the 5th speed gear (1b) from the main shaft.
1. Undo the bolts (1a) and remove the rear bearing retaining plate on the gearbox casing (1b).2. Remove the rear bearing circlips.
To remove the circlips, arrange them with their openings at the front.
1. Unscrew the reverse idler gear shaft bolt.2. Undo the bolts (2a) and remove the gearbox casing (2b).
1. Unscrew the bolts (1a) and remove the support with the reverse engagement fork lever (1b).
1. Unscrew the bolt (1a) and withdraw the gear engagement fork guide rod (1b).2. Remove the 3rd-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 main shaft assembly.3. Remove the layshaft assembly.
1. Remove the main shaft oil seal from the manual gearbox bell housing.
- Remove the lubrication oil centering device.1. Using a suitable tool (1a), remove the bearing (1b) from the gearbox rear cover.
LAYSHAFT DISMANTLING1. Working on the press, remove the rear bearing (1a) and the 4th speed driven gear (1b) using the tool (1c).
ToolDescriptionFunctionValidity
1870899400Half platesRemoving layshaft bearings - gears - hubs - synchronizer rings1.4 16v
1. Withdraw the spacer between the 3rd and 4th speed driven gears.
1. Working on the press, remove the 3rd speed driven gear (1a) and the 2nd speed driven gear (1b) using the tool (1c).
ToolDescriptionFunctionValidity
1870899400Half platesRemoving layshaft bearings - gears - hubs - synchronizer rings1.4 16v
1. Remove the needle bearing.2. Remove the 2nd speed synchroniser ring (2a) and the 1st and 2nd speed sliding engagement sleeve (2b).3. Keep the pre-synchronizer mountings.
1. Working in a vice fitted with protective jaws, remove the hub retaining circlip.
1. Working on the press, remove the 1st-2nd speed sliding engagement sleeve hub (1a), the 1st speed synchronizer ring (1b) and the 1st speed driven gear (1c) using the tool (1d).
ToolDescriptionFunctionValidity
1870899400Half platesRemoving layshaft bearings - gears - hubs - synchronizer rings1.4 16v
1. Remove the needle bearing.
1. Working in a vice fitted with protective jaws, remove the front bearing retaining circlip.
1. Working on the press, remove the layshaft front bearing (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1870899400Half platesRemoving layshaft bearings - gears - hubs - synchronizer rings1.4 16v
MAIN SHAFT DISMANTLING1. Working on the press, remove the rear bearing (1a) and the 4th speed drive gear (1b) using suitable tools (1c) and (1d).
1. Working in a vice fitted with protective jaws, remove the 4th speed synchronizer ring (1a) and the 3rd and 4th speed sliding sleeve (1b).2. Remove the pre-synchronizer mountings.
1. Working in a vice fitted with protective jaws, remove the 3rd-4th speed sliding sleeve hub circlip.
1. Working on the press, remove the 3rd-4th speed sliding engagement sleeve hub (1a), the 3rd speed synchronizer ring (1b) and the 3rd speed drive gear (1c) using a suitable tool (1d).
1. Working on the press, remove the main shaft front bearing (1a) using suitable tools (1b) and (1c).
Refitting ( Removing ) - Proceed with washing and checking the condition of all the components.MAIN SHAFT REASSEMBLY- Lubricate the relevant parts with transmission fluid before final fitting.1. Working on the press, fit the main shaft front bearing (1a) using the tool (1b) and a suitable plate (1c).
ToolDescriptionFunctionValidity
1875088000Fitting toolFitting main shaft front bearing1.2 8v1.4 8v1.4 16v
1. Fit the 3rd speed drive gear (1a) and 3rd speed synchronizer ring (1b).2. Working on the press, fit the 3rd-4th speed sliding engagement sleeve hub (2a) using the tool (2b) and a suitable plate (2c).
ToolDescriptionFunctionValidity
1870899300Fitting toolFitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear1.4 16v
1. Working in a vice fitted with protective jaws, fit the 3rd-4th speed sliding sleeve circlip.
1. Working in a vice fitted with protective jaws, fit the pre-synchronizer mountings.2. Fit the 4th speed synchronizer ring (2a) and the 3rd and 4th speed sliding sleeve (2b).
The sliding sleeve should be fitted with the groove shown in the diagram facing downwards.
The notches on the sliding sleeve should be aligned with the pre-synchronizer mountings.
- Place the 3rd-4th speed sliding sleeve in neutral.1. Fit the 4th speed drive gear.
1. Working on the press, fit the rear bearing (1a) on the main shaft using the tool (1b) and a suitable plate (1c).
ToolDescriptionFunctionValidity
1870899300Fitting toolFitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear1.4 16v
The rear bearing should be fitted with the groove "a" shown in the diagram facing upwards.
LAYSHAFT REASSEMBLY- Lubricate the relevant parts with transmission fluid before final fitting.1. Working on the press, fit the layshaft front bearing (1a) using the tool (1b).
ToolDescriptionFunctionValidity
2000007900Plate for bearingFitting layshaft front bearing1.4 16v
1. Working in a vice fitted with protective jaws, fit the front bearing retaining circlip.
1. Working in a vice fitted with protective jaws, fit the needle bearing (1a), the 1st speed synchronizer rings (1b) and the 1st speed driven gear (1c).
1. Working on the press, fit the 1st-2nd speed sliding sleeve hub (1a) using a suitable plate (1b) and the tool (1c).
ToolDescriptionFunctionValidity
1870632000Fitting toolFitting layshaft bearings - hubs - gears1.2 8v1.4 8v1.4 16v
1. Working in a vice fitted with protective jaws, fit the hub retaining circlip.
1. Working in a vice fitted with protective jaws, fit the pre-synchronizer mountings (1a), the 1st and 2nd speed engagement sliding sleeve (1b) and the needle bearing (1c).2. Fit the 2nd speed synchronizer rings.
The notches on the sleeve should be aligned with the pre-synchronizer mountings.
1. Working in a vice fitted with protective jaws, fit the 2nd speed driven gear.
1. Working on the press, fit the 3rd speed driven gear (1a) using the tool (1b) and a suitable plate (1c).
ToolDescriptionFunctionValidity
1870632000Fitting toolFitting layshaft bearings - hubs - gears1.2 8v1.4 8v1.4 16v
1. Working on the press, fit the spacer between the 3rd-4th speed driven gears (1a) and the 4th speed driven gear (1b) using the tool (1c) and a suitable plate (1d).
ToolDescriptionFunctionValidity
1870899300Fitting toolFitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear1.4 16v
1. Working on the press, fit the rear bearing (1a) using the tool (1b) and a suitable plate (1c).
ToolDescriptionFunctionValidity
1870899300Fitting toolFitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear1.4 16v
1. Fit a new main shaft oil seal (1a) on the manual gearbox bellhousing using tools (1b) and (1c).
ToolDescriptionFunctionValidity
1870796000Fitting toolFitting oil seal on bellhousing1.4 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. Remove the layshaft assembly.2. Fit the mainshaft assembly.3. Fit the reverse idler gear.
1. Fit the 3rd-4th speed engagement fork.2. Fit the 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 forks guide rod.6. Tighten the bolt securing the 5th speed engagement fork selector 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 support and 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
1. Fit the bearing (1c) on the rear cover using tools (1a) and (1b).
ToolDescriptionFunctionValidity
1870381000Fitting toolFitting gear cover rear bearing1.4 16v
ToolDescriptionFunctionValidity
1860945000Fitting toolFitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing1.4 16v1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.9 Multijet1.3 Multijet 90 CV 6 speed1.4 16v TJet
- Place the oil lubrication centering device in its housing.- Apply sealant to the contact surfaces between the gear casing and the manual gearbox bellhousing.1. Fit the gearbox casing (1a) and secure it tightening the bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox casingBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v
2. 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
1. Fit the rear bearing circlips.
Position the circlips with their openings at the front to facilitate fitting.
2. Fit the rear bearing retaining plate and secure it tightening the bolts (2b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Main and layshaft rear bearings retaining plateBoltM81.8 ÷ 2.21.2 8v1.4 8v1.4 16v
- Fit the 5th speed gear bush on the main shaft using the tool.
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
- Place the 5th speed gear and the synchronizer ring in its housing on the main shaft.- Fit the 5th and 6th speed hub on the main shaft with the splining for the oil facing the gear using the tool.
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
- Place the 5th speed driven gear in position on the layshaft.- Fit the pre-synchronization mountings on the 5th and 6th speed hub.- Place the 6th speed synchronizer ring in position.- Place the 5th-6th speed engagement sleeve and fork in position.
The notches on the sleeve should be aligned with the pre-synchronizer mountings.
- Fit the 6th speed gear and bush using the tool.
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
- Place the spacer for the 5th and 6th speed gears in position on the layshaft.- Place the 6th speed gear in position on the layshaft.- Fit the rear bearing on the layshaft using the tool.
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. Move the rod shown in the diagram downwards so that the selectors are aligned.
- Lift up the synchronizer to engage the 5th and 6th speed.
The simultaneous engagement of two gears results in the gearbox shafts locking; this operation is necessary in order to be able to lock the bolt and the nut securing the gears.
- Tighten the 5th and 6th speed engagement fork retaining bolt.- Tighten the left-threaded bolt securing the layshaft gears to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Layshaft gearsBolt (left hand thread)M1210.0 ÷ 11.01.4 16v
- Tighten the new nut securing the main shaft gears to the recommended torque and stake it using the tools.
ComponentFasteningdia  Value (daNm)Validity
Main shaft gearsNutM1610.4 ÷ 12.61.4 16v
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
- Apply the recommended sealant to the contact surfaces between the rear cover and the gearbox casing.- Place the rear cover in position and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Rear coverBoltM60.51.2 8v1.4 8v1.4 16v
- Place the differential complete with bearings in position.- Place the magnet back in its housing.- Apply sealant to the contact surfaces between the differential cover and the gear casing.- Place the differential cover in position and secure it tightening the bolts 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 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 the 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 mm corresponds to the recommended interference for the bedding in and pre-loading of the differential bearings.
- 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 a new oil seal on the differential cover using the tools (1a) and (1b).
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
- Fit the new O-ring on the differential cover.
- Position the flange in its housing in the differential and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Left flange on differentialBoltM82.01.2 8v1.4 8v1.4 16v
1. Fit the new oil seal using the tools (1a) and (1b).
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
- Place the left and right differential inner driveshafts in their housings.- Apply sealant to the contact surfaces between the gearbox casing and the gear selector-engagement assembly cover.- Place the gear selection and engagement unit in position and tighten the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox gear engagement unit coverBoltM62.01.2 8v1.4 8v1.4 16v
1. Fit the inner non-slip bush (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1870633000Fitting toolFitting clutch thrust bearing control linkage inner bush1.2 8v1.4 8v1.4 16v
- Place the thrust bearing inner control linkage and the outer non-slip bush in position.- Place the clutch control outer lever back in its housing and secure it using the circlip.- Place a new clutch thrust bearing in its housing. - Remove the gearbox from the support tool for the overhaul stand.