2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY - Fiat - DOBLO - eLearn

2585314 - 2110B20 manual gearbox (5 speed) with differential - dismantle and rebuild - wash and check parts - replace synchronisers and internal controls if necessary

Release the gearbox and differential from the support tool used for the removal-refitting from the vehicle.

	Name	Country
-	Gearbox mount	1.860.873.000

1. Fit the gearbox and differential (1a) on the overhaul stand (1b) using the tool (1c).

Two operators are needed for this operation.

	Name	Country
1b	Rotating stand	1.871.000.000

	Name	Country
1c	Support	1.871.001.014

2. Undo the bolt (2a) and remove the speedometer idler gear (2b).3. Undo the bolts (3a) and remove the rear cover (3b).

1. Undo the bolts (1a) and remove the gear selector/engagement mounting bracket (1b).

Engage any gear using the gear selector/engagement lever.1. Undo the bolt securing the 5th speed selector fork to the main shaft.Engage 5th speed, pressing the selector fork onto the main shaft.

The simultaneous enagement of two gears will result in the gearbox shafts locking.

2. Remove the staking and loosen the ring nuts for the main and layshafts.Position the 5th speed selector fork in neutral.

Positioning the selector fork for 5th speed in neutral is necessary to prevent losing the synchronizer rollers.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed selector fork, complete with 5th speed sliding sleeve.3. Remove the 5th speed synchronizer mounting retaining flange (3a) and the hub (3b).4. Recover the pre-synchronizer mountings.5. Remove the 5th speed synchronizer ring.6. Remove the circlip.7. Remove the 5th speed drive gear.8. Remove the needle bearing for the 5th speed drive gear.9. Remove the 5th speed drive gear bush.10. Remove the spacer.11. Remove the 5th speed driven gear.12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.

1. Dismantle the 5th speed engagement fork, locking the sleeve (1a) in the vice, with the protective plates fitted then, use a brass drift (1b), alternately on the two ends of the selector fork (1c) until it is released from the sleeve.

take care not to damage the tapered part of the sleeve and the ends of the selector fork with the drift.

1. Remove the main and layshaft rear bearing circlips.

1. Undo the plugs for positioning the gear control rods.2. Undo the bolt fixing the Reverse gear shaft.3. Undo the reversing lights switch.

1. Undo the fixing bolts and remove the differential flange (1a), complete with O-Ring (1b) and scraper ring (1c).

1. Undo the bolts fixing the gearbox casing to the bell housing.2. Position the gear selector/engagement lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.

1. Undo the bolts (1a) and remove the Reverse gear selector fork mounting bracket (1b).2. Remove the Reverse idler gear.

1. Undo the bolts for the selector forks for the 1st-2nd speed (1a) and 3rd-4th speed (1b).2. Remove the 1st-2nd speed control rod (2a) together with the selector fork (2b) and 3rd-4th speed control rod (2c).3. Remove the 5th-Reverse control rod (3a) and 3rd-4th speed selector fork (3b) simultaneously.4. Remove the gear engagement safety pawls.

1. Remove the main shaft and layshaft assemblies simultaneously.2. Remove the layshaft front bearing.3. Remove the differential assembly.4. Remove the magnet.

1. Undo the gear selector bolt.2. Remove the pin (2a) using a suitable drift and remove the gear selector (2b).

1. Undo the bolts (1a) and remove the gear selector/engagement lever (1b).

Proceed with dismantling the layshaft, following the instructions given below.1. Remove the rear bearing (1a), 4th speed driven gear (1b) and spacer between 3rd and 4th speed (1c) using the tools (1d) and (1e).

	Name	Country
1d	Extractor	1.840.005.002

	Name	Country
1e	Clamps	1.840.005.303

1. Remove the 3rd speed driven gear (1a) and 2nd speed driven gear (1b) using the tools (1c) and (1d).

	Name	Country
1c	Extractor	1.840.005.002

	Name	Country
1d	Clamps	1.840.005.306

1. Remove the 2 ^nd speed synchronizer ring.2. Remove the needle bearing for the 2 ^nd speed driven gear.3. Remove the sliding sleeve for 1 ^st - 2 ^nd and Reverse gears.4. Remove the pre-synchronizer mountings.

1. Remove the circlip retaining the 1st-2nd and Reverse sliding sleeve hub using suitable pliers.

When refitting, replace the circplip.

1. Remove the 1st-2nd and Reverse sliding sleeve hub (1a), 1st speed synchronizer ring (1b) and 1st speed driven gear (1c) using tools (1d) and (e).

	Name	Country
1d	Extractor	1.840.005.002

	Name	Country
1e	Clamps	1.840.005.306

2. Remove the needle bearing.

Proceed with dismantling the main shaft, following the instructions given below.1. Remove:the rear bearing (1a),the 4th speed drive gear (1b),the 4th speed drive gear needle bearing (1c),the 4th speed drive gear bush (1d).the 3rd and 4th speed sliding sleeve (1e),the 3rd and 4th speed sliding sleeve hub pre-synchronizer mountings (1g),the 4th speed synchronizer ring (1h),the 3rd and 4th speed sliding sleeve hub (1i),the 3rd speed synchronizer ring (1l),the 3rd speed drive gear (1m), using tools (1n) and (1o).

	Name	Country
1n	Extractor	1.840.005.002

	Name	Country
1o	Clamps	1.840.005.306

2. Remove the needle bearing for the 3rd speed drive gear.

Proceed with washing and checking the condition of all the components.Proceed with the reassembly of the main shaft, following the instructions given below.1. Place the 3rd speed drive gear needle bearing back in its seating.2. Place the 5th speed drive gear back in its seating.3. Place the 3rd speed synchronizer back in its housing.4. Place the 3rd and 4th speed sliding sleeve hub back in its housing.5. Place the 3rd and 4th speed sliding sleeve back in its housing.6. Place the pre-synchronizer mountings on the sliding sleeve hub back in their housings.7. Place the 4th speed synchronizer back in its housing.

1. Fit the 4th speed drive gear bush (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

2. Fit the roller bearing for 4th speed drive gear (2a) and 4th speed drive gear (2b).

1. Fit the rear bearing (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

Proceed with the reassembly of the layshaft, following the instructions given below.1. Fit the needle bearing for 1st gear driven gear.2. Fit the 1st speed driven gear.3. Fit the 1st speed synchronizer ring.

1. Fit the 1st and 2nd speed sliding sleeve hub (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.945.000

Fit a new 1st and 2nd speed sliding sleeve hub circlip.1. Fit the 1st and 2nd and Reverse sliding sleeve.2. Fit the 1st-2nd and Reverse gear sliding sleeve hub pre-synchronizer mountings.3. Fit the needle bearing for 2nd speed driven gear.4. Fit the 2nd speed synchronizer ring.5. Fit the 2nd speed driven gear.

1. Fit the 3rd speed driven gear (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.465.000

1. Fit the spacer between the 3rd speed driven gear and 4th speed driven gear.2. Fit the 4th speed driven gear (2a) using the tool (2b).

	Name	Country
2b	Fitting tool	1.870.465.000

1. Fit the rear bearing (1a) using the tool (1b).

	Name	Country
1b	Drift	1.870.448.000

1. Fit the gear selector/engagement lever (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEAR ENGAGMENT SELECTOR LEVER	M8	1.5

1. Fit the gear selector (1a) and fix it with the pin (1b) and bolt (1c).

1. Fit the magnet.2. Fit the layshaft front bearing.3. Fit the differential assembly.4. Fit the main shaft and layshaft assemblies simultaneously.Fit the gear engagement safety pawls using a suitable drift.

1. Fit the Reverse idler gear.

Make sure that the gear engagement teeth are facing downwards.

2. Fit the 5th speed and Reverse control rod.3. Fit the 3rd-4th speed selector fork (3a) and the control rod (3b).

Position the safety pawl in the rod before fitting it in the housing.

4. Fit the 1st-2nd speed control rod (4a), complete with selector fork (4b).

To faciliate the fitting, move the 2nd-3rd control rods in the direction shown by the arrow.

5. Tighten the bolts for the 1st-2nd speed (5a) and 3rd-4th speed (5b) selector forks to torque.

	Fastening	Component	Ø	Value(daNm)
5a	Bolt	GEARBOX INTERNAL CONTROLS	M6	1.8

	Fastening	Component	Ø	Value(daNm)
5b	Bolt	GEARBOX INTERNAL CONTROLS	M6	1.8

6. Fit the Reverse selector fork mounting bracket (6a) and fix it tightening the bolts (6b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
6b	Bolt	GEARBOX INTERNAL CONTROLS	M6	10

Position all the gear selector forks in neutral.Apply sealant to the contact surfaces between the bell housing and the gearbox casing.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the gearbox casing on the bell housing.

Keep the gear selector/engagement lever upwards and check that the gear selector engages in the 3rd-4th speed selector fork.

Tighten the bolts fixing the gearbox casing to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	2.5

Fit the gear control rod positioning plugs.Tighten the Reverse shaft bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REVERSE IDLER	M7	3.4

Fit the reversing lights switch.Fit the main and layshaft rear bearing circlips.

To facilitate the fitting of the circlips, place them with their openings at the front.

Apply sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the main and layshaft rear bearing retaining plate and fix it tightening the bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER SPACER	M8	2.5

1. Place the 5th speed driven gear back in its seating.2. Place the spacer back in its housing.3. Place the 5th speed drive gear bush back in its seating.4. Place the 5th speed drive gear needle bearing back in its seating.5. Place the 5th speed drive gear back in its seating.6. Place the seal back in its housing.

Take care to fit the teeth on the seal correctly in the special groove.

7. Place the 5the speed synchronizer ring back in its seating.8. Place the flange (8a) and the hub for the 5th speed sliding sleeve (8b) back in their housings.9. Place the pre-synchronizer mountings back in their housings.10. Place the 5th speed selector fork complete with 5th speed sliding sleeve back in its housing.1. Tighten the new main shaft and layshaft ring nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	11.8

1. Tighten the 5th speed selector fork bolt to torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	GEARBOX INTERNAL CONTROLS	M6	1.8

1. Reassemble the 5th speed engagement fork, locking the sleeve in the vice, with the protective plates fitted;2. Position the selector fork that the its tapered part is in the same direction as that of the sleeve, resting it against the side of the sleeve which has the smaller diameter;fit the selector 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 selector fork.

Apply sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

1. Fit the rear cover (1a) and fix it tightening the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX REAR COVER	M8	2.5

2. Fit the speedometer idler gear (2a) and fix it using the bolt (2b).

1. Position the tool (1a), complete with dial gauge on the differential flange (1b), and measure distance ''H'' (flange height).

	Name	Country
1a	Support	1.895.655.000

1. Position the tool (1a), complete with dial gauge, on the differential flange support surface (1b), and measure distance ''P'' (depth between differential flange support plate and bearing (1c) outer race).

	Name	Country
1a	Support	1.895.655.000

Calculate the thickness ''S'' of the scraper ring for the differential bearing pre-loading using the following formula: S = P - H + 0.12S = P - H + 0.12

0.12 corresponds to the interference recommended for the correct positioning and pre-loading of the differential bearings. After having determined the exact value of the scraper ring, try and achieve the closest possible value to that obtained using the rings available as spares. If the value obtained does not correspond to the thickness of one or more adjustment shims available, fit the shim(s) giving the closest value which is immediately higher.

1. Place the scraper ring(s) for the differential bearing pre-loading in its/their housing.

Fit the differential flange and fix it tightening the bolts to torque.Fit the gear selector/engagement mounting bracket and fix it using the bolts.Undo the fixings and remove the gearbox and differential from the support tool.

Two operators are needed for this operation.

	Name	Country
1c	Support	1.871.001.014

Remove the tool supporting the overhaul stand and put it back.Position the gearbox and differential on the tool used for the removing-refitting from the vehicle.

	Name	Country
-	Gearbox mount	1.860.873.000