244000621 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD

Removing ( Refitting ) 1. Undo retaining bolts (1a) and remove starter motor (1b).
1. Undo the fixing nuts (1a) and remove the clutch actuator cylinder bracket (1b).
1. Undo the bolts and the nut (1a) fixing the mounting bracket for the gear selection and engagement cables (1b).
1. Undo the fixing bolts (1a) and remove the engine flywheel guard (1b).
1. Release the shaft for the fork lever (1a) using the special tool and release the fork (1b).
DescriptionCodeFunction
.Extractor1.870.873.000Fork pin removal
1. Undo fastenings (1a) and remove the gearbox and differential (1b).
Refitting ( Removing ) 1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. Insert the release lever retaining shaft.
- Fit the gearbox differential unit and tighten the bolts to torque.- Fit the mounting bracket and support for the gear selection and engagement cables.- Fit the clutch actuator cylinder mounting bracket in place.- Fit the flywheel guard and tighten the fixing bolts.- Fit the starter motor in position and tighten to torque. Removing ( Refitting ) 1. Undo retaining bolts (1a) and remove starter motor (1b).2. Remove the spacer from the gearbox.
1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the gearbox bell housing.
1. Undo the fixing nuts.2. Remove the operating cylinder mounting bracket on the bellhousing.
1. Unscrew bolts and nut (1a) and remove the mount for gear selection and engagement cables (1b).
1. To remove the fork lever pin, use a M6 x 1 bolt (1a) fitted, in turn, into connector (1b) screwed into driver (1c).
DescriptionCodeFunction
1bExtractor1.860.959.000Clutch control fork lever pin removal
DescriptionCodeFunction
1cMallet1.847.017.001Clutch control fork lever pin removal
2. Tighten the resulting tool to the pin and exercise a pulling force in the arrowed direction (toward the operator) to remove the fork lever retaining shaft.
1. Undo fastenings (1a) and remove the gearbox and differential (1b).
Refitting ( Removing ) 1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. insert the release lever retaining shaft.
- Fit the gearbox-differential unit and tighten the fixing nuts and bolts to torque.
Value - daNmFasteningComponentØ  
.7BoltMANUAL GEARBOX/DIFFERENTIALM12
Value - daNmFasteningComponentØ  
.6NutMANUAL GEARBOX/DIFFERENTIALM10
- Fit the gear selection and engagement cable retaining and mount bracket.- Fit the release cylinder bracket to the gearbox.- Position the starter motor spacer.- Fit the starter motor and tighten the fixing bolts to torque.
Value - daNmFasteningComponentØ  
.2BoltSTARTER MOTORM8
Removing ( Refitting ) 1. Undo retaining bolts (1a) and remove starter motor (1b).2. Remove the spacer from the gearbox.
1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the gearbox bell housing.
1. Undo the fixing nuts.2. Remove the operating cylinder mounting bracket on the bellhousing.
1. Unscrew bolts and nut (1a) and remove the mount for gear selection and engagement cables (1b).
1. To remove the fork lever pin, use a M6 x 1 bolt (1a) fitted, in turn, into connector (1b) screwed into driver (1c).
DescriptionCodeFunction
1bExtractor1.860.959.000Clutch control fork lever pin removal
DescriptionCodeFunction
1cMallet1.847.017.001Clutch control fork lever pin removal
2. Tighten the resulting tool to the pin and exercise a pulling force in the arrowed direction (toward the operator) to remove the fork lever retaining shaft.
1. Undo fastenings (1a) and remove the gearbox and differential (1b).
Refitting ( Removing ) 1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. insert the release lever retaining shaft.
- Fit the gearbox-differential unit and tighten the fixing nuts and bolts to torque.
Value - daNmFasteningComponentØ  
.7BoltMANUAL GEARBOX/DIFFERENTIALM12
Value - daNmFasteningComponentØ  
.6NutMANUAL GEARBOX/DIFFERENTIALM10
- Fit the gear selection and engagement cable retaining and mount bracket.- Fit the release cylinder bracket to the gearbox.- Position the starter motor spacer.- Fit the starter motor and tighten the fixing bolts to torque.
Value - daNmFasteningComponentØ  
.2BoltSTARTER MOTORM8