2110D20 DIFFERENTIAL INNER CASE, REMOVED - DISMANTLE AND REBUILD, CHECK PLANET AND DIFFERENTIAL GEARS - Fiat - DUCATO - eLearn

244001032 - 2110D20 DIFFERENTIAL INNER CASE, REMOVED - DISMANTLE AND REBUILD, CHECK PLANET AND DIFFERENTIAL GEARS

) - Remove the mileometer gear.1. Remove the roller bearing (1a), differential side, using tools (1b), (1c) and (1d).

	Description	Code	Function
1b	Reaction flange for removing differential bearings	1.860.944.000	Removing differential bearings

	Description	Code	Function
1c	Leg for differential bearing removal tool 1840005001.	1.840.005.309	Removing differential bearings

	Description	Code	Function
1d	Universal extractor for removing layshaft front bearing and differential bearings	1.840.005.001	Removing differential bearings

1. Remove the roller bearing (1a), ring gear side, using tools (1b), (1c) and (1d).

	Description	Code	Function
1b	Reaction flange for removing differential bearings	1.860.944.000	Removing differential bearings

	Description	Code	Function
1c	Universal extractor for removing layshaft front bearing and differential bearings	1.840.005.001	Removing differential bearings

	Description	Code	Function
1d	Leg for differential bearing removal tool 1840005001.	1.840.005.309	Removing differential bearings

Check for notching and excessive wear on the ring gear teeth. The bearings must be replaced whenever they show signs of scoring, excessive play and wear.

1. Undo the fixing bolts (1a) and remove the ring gear (1b).

1. Remove the upper differential gear.

1. Remove the planet carrier pin.

The planet carrier pin should not show signs of binding, wear or excessive wear on the half casings.

1. Remove the planet wheels (1a) and the lower differential gear (1b).

The planet gears should not be chipped or worn on the working surfaces.

1. Separate the ring gear (1a) from the differential half-casing at the press (1b).

Refitting ( Removing

) 1. Tighten the retaining bolts to locate the ring gear on the differential half-casing correctly.2. Fit the ring gear (2a) to the differential casing on the press (2b).

1. Fit shim (1b) and lower differential gear (1c) in the seat in the differential half-casing (1a).

1. Fit planet carrier pin (1b) and planet gears (1c) into the differential half-casing (1a).

1. Position a dial gauge (1a) with a magnetic base so that its probe is in contact with the differential gear flat circular ring gear (1b).- Set the dial gauge to zero.

1. Introduce a screwdriver into the hole on the driveshaft and remove the differential gear.- Check the clearance is within specificed limits.

	Subject	Value
-	-	mm <0.1

- Otherwise, fit an appropriate shim.

Take the measurement at at least four diametrically opposed points.

- Fit the pin mount, short pins, missing planet gears and the upper differential gear with its shim to the seat in the differential half-casing.

Lubricate the relevant parts with transmission fluid before final fitting.

1. Secure the differential gear (1a) using tools (1b) and (1c).

	Description	Code	Function
1b	Leg for differential bearing removal tool 1840005001.	1.840.005.309	Fitting the upper differential gear

	Description	Code	Function
1c	Reaction flange for removing differential bearings	1.860.944.000	Fitting the upper differential gear

1. Position a magnetic base dial gauge (1a) to the flange with the gauge probe in contact with the shim (1b).2. Fit tools (2a), (2b), (2c).

	Description	Code	Function
2a	Feet for 1040005001	1.840.005.309	Removing the layshaft front bearing

	Description	Code	Function
2b	Universal extractor for removing the layshaft front bearing and differential bearings	1.840.005.001	Removing the layshaft front bearing and differential bearings

	Description	Code	Function
2c	Reaction flange for removing differential bearings	1.860.944.000	Removing differential bearings

- Set up the dial gauge and zero.

1. Position the calibrated dial gauge on the other differential half-casing and check that the clearance is within specified limits.

	Subject	Value
-	-	mm <0.10

- Otherwise, fit an appropriate shim.

Take the measurement at at least four diametrically opposed points.

- Tighten the bolts securing the ring gear to the differential casing to the specified torque.

	Value - daNm	Fastening	Component	Ø
	8,5	bolt	-	-

1. Use tool (1a) to fit the taper roller bearing (1b), ring gear side.

	Description	Code	Function
	Fit the differential bearings	1.860.943.000	Fit the differential bearing, ring gear side

1. Use tool (1a) to fit the taper roller bearing (1b), differential side.

	Description	Code	Function
	Fit the differential bearings	1.860.943.000	Fit the differential bearing, ring gear side

- Fit the mileometer gear.