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

244001031 - 2110D10 DIFFERENTIAL INNER CASE - R + R WITH MANUAL GEARBOX REMOVED - INCLUDES GEARBOX DISMANTLE AND REBUILD

) 1. Arrange the gearbox on rotary stand (1a) using stand (1b).

	Description	Code	Function
1a	Rotary stand used to support the gearbox	1.871.000.000	Secure the gearbox for dismantling

	Description	Code	Function
1b	Stand for 1871000000	1.871.001.014	Stand used to secure the gearbox for dismantling

- DISMANTLE THE MANUAL GEARBOX BY CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Undo and remove the reversing light switch.

1. Undo the fixing bolts (1a) and remove the gearbox cover (1b).

1. Remove the staking on the collar of the nut securing the 5th speed driven gear.

1. Remove the pin securing the 5th speed engagement fork.

- Insert 5th speed by hand and use the gear selection lever to select any gear.1. Use tool (1a) to unscrew the nut (1b) securnig the 5th speed driven gear.

	Description	Code	Function
1a	Wrench used to remove/refit the 5th speed retaining nut	1.870.405.000	Removing the 5th speed gear retaining nut

The gear shafts will lock if two speeds are engaged simultaneously. This operation is necessary to release the nut that secures the gears to the layshaft.

1. Use round-nosed pliers to remove the 5th speed synchroniser retaining ring.

1. Position the tool to lock the 5th speed synchroniser.

	Description	Code	Function
1	Tool used to lock the 5th speed synchroniser	1.870.411.000	Lock the 5th speed synchroniser

- Move the gear selection lever to neutral, then withdraw the synchroniser and 5th speed drive gear with the engagement fork.- Withdraw the 5th speed driven gear.1. Withdraw the bolts securing the layshaft bearing detent.

1. Tighten the bolts fixing the gearbox.

The arrows in the figure indicate the points where the retaining bolts are tightened.

1. Loosen the fixing bolts.2. Withdraw the gear casing and remove.

1. Remove the oil channel.

1. Remove the reverse shaft and gear.

1. Withdraw the gear selection lever pin.

1. Remove the reverse selection lever with fork from its seat by withdrawing in the arrowed direction.

1. Unscrew retaining bolts (1a) and remove the gear selection and engagement lever assembly (1b).

1. Remove the main and layshafts from their seat with gears.

1. Undo the bolts (1a) securing differential flange (1b).

1. Remove the differential flange from its seat and take out the oil seal.

1. Undo the fixing bolt (1a) and remove the detonation sensor mount (1b).

1. Undo the fixing bolts (1a) and remove the differential cover (1b).

1. Remove the differential unit.

Refitting ( Removing

) 1. Fit the differential unit in the bell housing.

1. Fit the differential cover (1a) and tighten the fixing bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	4 daNm	bolt		M10

	Value - daNm	Fastening	Component	Ø
1b	2 daNm	bolt		M8

1. Fit speed sensor mount (1a) and tighten bolt (1b).

1. Fit the gasket to the differential flange using tools (1a) and (1b).

	Description	Code	Function
1a	-	1.870.426.000	Fitting oil seal to the differential flange

	Description	Code	Function
1b	Drift for 1870426000	1.870.007.000	Fitting oil seal to the differential flange

1. tighten the bolts (1a) securing differential flange (1b) to torque.

	Value - daNm	Fastening	Component	Ø
1a	2 daNm	bolt	-	-

1. Rest the mainshaft on the gearbox bell housing.

1. Fit the gear casing and secure with half the bolts.

1. Position a dial gauge by resting the magnetic part on the differential flange.

1. Fit the tool and measure the mainshaft end float.

	Description	Code	Function
1	Fork for measuring mainshaft end float	1.860.956.000	Measuring mainshaft end float.

	Subject	Value
-	end float	0.05 - 0.15 mm

If the measurement is not as specified, replace the mainshaft shim with another shim of appropriate thickness.

- Remove the tools and the gearbox bell housing.1. Fit the mainshaft and layshaft in their seats.

1. Fit the gear selection and engagement lever assembly (1a) and tighten the bolts (1b) to torque.

Check the forks are correctly fitted into the grooves on the relevant sleeves.

	Value - daNm	Fastening	Component	Ø
1b	1.5 daNm	bolt	-	-

1. Fit the reversing selection lever with fork in its seat.

1. Fit the reverse selection lever pin into its seat.

1. Fit the reverse shaft and gear.

1. Fit the oil channel.

1. Fit the gear casing2. Tighten the fixing bolts.

1. Tighten the gear casing retaining bolts to torque.

Spread a sealant product for gearbox mating surfaces over the contact surfaces between the gearbox bell housing and casing.

	Value - daNm	Fastening	Component	Ø
1	2 daNm	bolt	-	-

1. Tighten the bolts securing the layshaft bearing detent to torque.

	Value - daNm	Fastening	Component	Ø
1	2 daNm	bolt	-	-

- Fit the 5th speed drive gear to the mainshaft.- Fit the 5th speed driven gear to the layshaft.1. Tighten nut (1a) securing the 5th speed driven gear using tool (1b).

	Value - daNm	Fastening	Component	Ø
1a	17 daNm	bolt	-	-

	Description	Code	Function
1b	Wrench used to remove/refit the 5th speed retaining nut	1.870.405.000	Removing the 5th speed gear retaining nut

- Chamfer the nut securing the 5th driven gear.1. Use tool (1a) to install the 5th speed synchroniser (1b) with its engagement fork to the mainshaft and secure with the retaining ring.

	Description	Code	Function
1a	Tool used to lock the 5th speed synchroniser	1.870.411.000	locking the 5th speed synchroniser

1. Fit the pin securing the 5th speed engagement fork.

1. Fit the gearbox cover (1a) and tighten the fixing bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	2 daNm	bolt	-	-

1. Tighten the brake light switch