2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Fiat - DOBLO - eLearn

2584581 - 2110A10 manual gearbox and differential - r + r

) Place the car on the ramp.Disconnect the battery negative terminal.

	Name	Connector
-	Battery	See A001 BATTERY

Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 5520B10 STARTER MOTOR - R+R1. Disconnect the gear engagement/selector cables.2. Undo the fixing bolts (2a) then move the mounting bracket (2b) complete with gear engagement/selector cables.

1. Undo the fixing bolts (1a) and move the clutch release cylinder (1b) to the side.

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

2. Undo nut (2a) and disconnect the earth cable from motor (2b).

	Name	Connector
2b	Earth on engine	See C040 ENGINE EARTH

1. Undo the fixing bolts (1a) and remove the engine flywheel shield (1b).

1. Disconnect the electrical connection for the speedometer sensor.

	Name	Connector
1	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

1. Position the crossmember (1a) complete with support mountings (1b) as illustrated in the diagram.

	Name	Country
1a	Crossmember	1.870.595.000

	Name	Country
1b	Support mountings	1.870.650.000

2. Position a ring bracket (2a), securing it with a nut on the exhaust manifold; then connect the linkage of the crossmember (2b) to this bracket, and operate the handwheel (2c) to tension the propulsion unit on the crossmember.

Cut the bands securing the driveshaft boots to the differential.1. Undo the bolts securing the shock absorber strut.2. Undo the nut (2a) and, using the tool (2b), remove the track rod end from the steering knuckle.

	Name	Country
2b	Head extractor	1.847.035.000

3. Tilt the brake disc/hub assembly outwards and disconnect the driveshafts from the differential releasing them from their housings.

Secure the driveshafts to a fixed point on the vehicle so that they do not interfere with the operations.

Repeat the operation for the right front driveshaft.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.1. Undo the upper bolts securing the gearbox bellhousing.

1. Position and fit the tool (1a) as illustrated in the figure, using the bolts (1b) previously unscrewed from the gearbox bellhousing.

	Name	Country
1a	Gearbox mount	1.860.873.000

Op. 1008a42 GEARBOX SIDE POWER UNIT RIGID SUPPORT - R.R.1. Position the hydraulic lift on the gearbox support tool fitted previously, then unto the bolt (1a) on the gearbox bellhousing and undo the nut (1b) securing the gearbox bellhousing to the engine block. Manoeuvre the hydraulic jack as appropriate to release the gearbox from the fixing pins. Take the utmost care not to damage the components in the surrounding area, then withdraw the gearbox and differential unit from the propulsion unit.

Refitting ( Removing

) Position the gearbox-differential unit, secured to the tool used for the removal, in the engine compartment and lift it slowly using the hydraulic jack, taking care not to damage the surrounding components.Centre the gearbox-differential unit on the centring pins and secure it, tightening the lower nuts and bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(below gearbox) 8

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12 x 1.25	(below gearbox) 8

Remove the tool positioned previously for manoeuvring the gearbox during the removal stage.

	Name	Country
-	Gearbox mount	1.860.873.000

Remove the hydraulic jack and lower the lift. Op. 1008a42 GEARBOX SIDE POWER UNIT RIGID SUPPORT - R.R.Tighten to torque the top bolts securing the gearbox bellhousing.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(upper gearbox) 8

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R. Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.Position the driveshafts in the special housings in the gearbox/differential.Tighten the upper and lower nuts fixing the hub to the shock absorber to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT DAMPER	M12 x 1.25	(Shock absorber side) 12

Position the steering box rods on the front steering knuckles and tighten the nuts fixing the track rod ends to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE LINK BALL JOINTS	M10 x 1.25	3.4

Lock the driveshaft boots with new bands.Remove the engine support crossmember fitted previously and the relevant blocks supporting the crossmember itself.

	Name	Country
-	Crossmember	1.870.595.000

	Name	Country
-	Support mountings	1.870.650.000

Raise the vehicle.Connect the electrical connection of the speedometer sensor.

	Name	Connector
-	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

Fit the engine flywheel shield and tighten the fixing bolts.Connect the electrical connection for the reversing lights switch.

	Name	Connector
-	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

Connect the engine earth lead and tighten the fixing nut.

	Name	Connector
-	Earth on engine	See C040 ENGINE EARTH

Lower the lift.Position the clutch release cylinder and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH SLAVE CYLINDER	M8	(On bell housing) 2.8

Position the complete mounting bracket for the gearbox control cables and tighten to torque the bolts securing the gearbox bellhousing.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	IDLER UNIT ON GEARBOX	M8	(Gearbox bell housing) 2.5

Connect the gear engagement/selection cables on their gear linkage attachments. Op. 5520B10 STARTER MOTOR - R+R Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 5530B10 BATTERY - R+R Op. 4450B12 FRONT WHEELS (TWO) - R.R.Connect the battery negative terminal.

	Name	Connector
-	Battery	See A001 BATTERY

Remove the car from the ramps.