199001077 - 2110B42 5TH SPEED GEARS FOR MANUAL GEARBOX WITH DIFFERENTIAL - R+R WITH GEARBOX REMOVED

Removing ( Refitting ) 1. Undo the bolts (1a) and remove the rear cover (1b). - Engage any gear using the gear selection/engagement lever.1. Undo the bolt fixing the 5th speed fork to the main shaft.- 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 and loosen 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 gear.3. Fit the 5th speed synchronizer roller and spring retaining flange.4. Remove the 5th speed engagement fork.5. Remove the 5th speed engagement sliding sleeve.6. Remove the pre-synchronizer mountings.7. Remove the 5th speed engagement sliding sleeve.8. Remove the 5th speed synchronizer ring.9. Remove the 5th speed drive gear.10. Remove the needle bearing for the 5th speed drive gear.11. Remove the 5th speed drive gear bush. 1. Lock the sleeve (1a) in the vice fitted with protective plates then, use a brass drift (1b) alternately on the two ends of the fork (1c) until it is released from the sleeve.

Take care not to nick the tapered part of the sleeve and the ends of the fork with the drift.

Refitting ( Removing ) 1. Remove the 5th speed drive gear bush.2. Remove the needle bearing for the 5th speed drive gear.3. Fit the 5th speed drive gear.4. Fit the 5th speed synchronizer ring.5. Fit the 5th speed engagement sliding sleeve.6. Fit the 5th speed engagement sliding sleeve.7. Place the synchronizer mountings in their housings.8. Fit the 5th speed engagement fork.9. Fit the 5th speed synchronizer roller and spring retaining flange.10. Fit the 5th speed driven gear.11. Tighten the new ring nuts for the main and layshafts to torque.

Component	Fastening	dia	Value (daNm)	Validity
Main and layshaft ring nuts	Ring nut	M20	10 ÷ 12.4	1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.4 16v TJet

12. Tighten the bolt for the 5th speed control fork to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
5th speed control fork	Bolt	M6	1.5 ÷ 1.9	1.3 Multijet 75 CV 1.3 Multijet 90 CV 5 speed1.4 16v TJet

1. Lock the sleeve in a vice fitted with protective plates;2. Position the fork so that the tapered part is in the same direction as that of the sleeve, resting it against the side of the sleeve with the smaller diameter.- fit the fork manually, exerting the necessary pressure, until it is completely inserted in the sleeve.

when the fitting is complete, check that the sleeve can rotate freely inside the fork.

- Apply sealant to the contact surfaces betwen the main and layshaft rear bearings retaining plate and the rear cover.- Fit the rear cover and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rear cover	Bolt	M8	2.1 ÷ 2.6	1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed1.4 16v TJet