2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD - Fiat - DOBLO - eLearn

2585317 - 2110D10 differential inner case - r + r with manual gearbox removed - includes gearbox dismantle and rebuild

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 driven gear.3. Remove the 5th speed synchronizer rollers and springs retaining flange.4. Remove the 5th speed control fork.5. Remove the 5th speed sliding sleeve.6. Remove the 5th speed hub pre-synchronizer mountings.7. Remove the 5th speed sliding sleeve hub.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.12. Undo the bolt (12a) and remove the plate (12b) retaining the main and layshaft rear bearings.

1. Dismantle the 5th speed engagement fork, lock 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. Place the gear selector lever downwards.3. Remove the gearbox casing using two screwdrivers in the special projections.

1. Remove the differential assembly.

Fit the differential assembly.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 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. Fit the 5th speed drive gear bush.2. Fit the needle bearing for the 5th speed drive gear.3. Fit the 5th speed drive gear.4. Fit the 5th speed synchronizer gear.5. Fit the 5th speed sliding sleeve hub.6. Fit the 5th speed sliding sleeve.7. Fit the pre-synchronizer mountings for the 5th speed sliding sleeve hub.8. Fit the 5th speed control fork.9. Fit the 5th speed synchronizer ring and roller retaining flange.10. Fit the 5th speed driven gear.11. Tighten the new rings nuts for the main and layshafts to torque.

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

12. 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 followign formula: S = P - H + 0.12S = P - H + 0.12

0.12 corresponds to the recommended interference for the bedding in 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