244001027 - 2110B20 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY
Removing
(
Refitting
)
1. Position the gearbox on the rotating stand (1a) using the support (1b).
| Description | Code | Function |
|---|
| 1a | Gearbox support rotating stand | 1.871.000.000 | Gearbox fastening for dismantling |
| Description | Code | Function |
|---|
| 1b | Support for 1871000000 | 1.871.001.014 | Support for fastening gearbox for dismantling |
- PROCEED WITH DISMANTLING THE MANUAL GEARBOX 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 fastening the 5th speed driven gear.
1. Extract the 5th speed engagement fork retaining pin.
- Engage 5th speed manually and, using the gear selector lever, engage any gear at all. 1. Undo the nut (1b) fastening the 5th speed driven gear using the tool (1a).
| Description | Code | Function |
|---|
| 1a | Spanner for removing/refitting 5th speed gear retaining nut | 1.870.405.000 | Dismantling 5th speed gear retaining nut |
 | The simultaneous engagement of two gears results in the gearbox shafts locking; this operation is necessary in order to be able to release the nut securing the gears to the layshaft. |
1. Remove the 5th speed synchronizer retaining ring using special pliers.
1. Position the tool for locking the 5th speed synchronizer.
| Description | Code | Function |
|---|
| 1 | Tool for locking 5th speed synchronizer | 1.870.411.000 | Locking 5th speed synchronizer |
- Position the gear selector lever in neutral, then release the synchronizer and the 5th speed drive gear with the engagement fork.- Release the 5th speed driven gear.1. Undo the bolts fixing the layshaft bearing stop.
1. Loosen the bolts fixing the gearbox casing.
| The arrows in the diagram show the points where the fixing bolts are tightened. |
1. Loosen the fixing bolts.2. Release the gearbox casing and remove it.
1. Remove the oil duct.
1. Remove the reverse gear and the shaft.
1. Release the pin fastening the reverse gear selector lever.
1. Remove the reverse gear selector lever complete with fork from the housing, releasing it in the direction shown by the arrow.
1. Undo the fixing bolts (1a) and remove the gear selector and engagement lever assembly (1b).
1. Extract the main and layshafts complete with gears from the housing.
1. Extract the bell housing main shaft front bearing outer race (1a) using the tool (1b).
| Description | Code | Function |
|---|
| 1b | Main shaft front bearing outer race extractor | 1.846.011.000 | Main shaft front bearing outer race removal |
1. Extract the magnet from the seat and remove any metal particles that may be present.
1. Remove the layshaft centering bush.
1. Undo the differential flange (1b) fixing bolts (1a).
1. Remove the differential flange from the housing and extract the oil seal.
1. Undo the fixing bolt (1a) and remove the speed sensor support (1b).
1. Undo the fixing bolts (1a) and remove the differential cover (1b).
1. Remove the differential unit.
1. Undo the fixing bolts (1a) and release the thrust bearing sleeve (1b).
- PROCEED WITH DISMANTLING THE MAIN SHAFT CARRYING OUT THE OPERATIONS DESCRIBED BELOW.
| Check that the gears do not have notches and that the teeth are not excessively worn. In the case of high mileage it is advisable to replace all the layshaft gears if the main shaft has to be replaced. |
1. Position the main shaft in the vice, placing two types of protection in between.
1. Extract the main shaft rear bearing.
| Check that the outer race, the inner race and the rollers do not have grooves or hot spots or excessive wear or elease the rear bearing assembly has to be replaced. |
1. Extract the main shaft front bearing.
| Check that the outer race, the inner race and the rollers do not have grooves or hot spots or excessive wear or elease the front bearing assembly has to be replaced. |
- PROCEED WITH DISMANTLING THE LAYSHAFT CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Extract the front bearing (1d) and the 4th speed gear (1e) using tools (1a), (1b) and (1c).
| Description | Code | Function |
|---|
| 1a | Feet for 1840005001 for dismantling layshaft front bearing | 1.840.005.302 | Dismantling layshaft front bearing |
| Description | Code | Function |
|---|
| 1b | Univeral extractor for dismantling layshaft bearing and differential bearings | 1.840.005.001 | Dismantling layshaft front bearing |
| Description | Code | Function |
|---|
| 1c | Flange for dismantling layshaft front bearing | 1.845.028.000 | Dismantling layshaft front bearing |
1. Release the 3rd and 4th speed synchronizer assembly.
 | Keep the synchronizer sleeve centered on the hub whilst carrying out this operation. Then release the sleeve, taking special care to ensure that the balls come out. |
1. Remove the retaining seal.
1. Release the 3rd speed gear.
1. Remove the retaining seal.
1. Release the 2nd speed gear.
1. Release the 1st and 2nd speed synchronizer assembly and reverse gear.
| Keep the synchronizer sleeve centered on the hub whilst carrying out this operation. Then release the sleeve, taking special care to ensure that the balls come out. |
1. Remove the retaining seal.
1. Release the 1st speed gear.
1. Remove the retaining seal.
1. Extract the rear bearing (1c) on the press using tools (1a) and (1b).
| Description | Code | Function |
|---|
| 1a | Support for 1860946000 | 1.846.017.000 | Removing layshaft rear bearing |
| Description | Code | Function |
|---|
| 1b | Half flange for extracting layshaft rear bearing | 1.860.946.000 | Removing layshaft rear bearing |
- PROCEED WITH DISMANTLING THE REVERSE IDLER GEAR CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Release the gear (1a) from the shaft (1b).
- Position the reverse gear in the vice, placing two types of protection in between.1. Extract the roller chamber (1a) from the toothed wheel (1b) using tool (1c).
| Description | Code | Function |
|---|
| 1c | Tool for extracting-fitting reverse gear roller chamber | 1.870.421.000 | Extracting reverse gear roller chamber |
- PROCEED WITH DISMANTLING THE GEAR SELECTOR AND ENGAGEMENT LEVER ASSEMBLY CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Separate the gear engagement levers from the assembly at the bench.
1. Release the fastening pin (1a) from the housing and remove the gear selector rod (1b) from the sleeve.
- Position the sleeve for the gear selector and engagement lever assembly in the vice placing two types of protection in between.1. Remove the fastening pin (1b) using a suitable diameter drift (1a).
1. Undo the inner bolt (1a) and release the gear selector and engagement lever sleeve (1b).
- Separate the gear selector and engagement lever assembly sleeve at the bench.1. Remove the pawl. 2. Remove the springs (2a) and (2b) from the housing.3. Remove the gasket.
Refitting
(
Removing
)
- PROCEED WITH REASSEMBLING THE GEAR SELECTOR AND ENGAGEMENT LEVER ASSEMBLY CARRYING OUT THE OPERATIONS DESCRIBED BELOW.- Reassemble the gear selector and engagement lever assembly sleeve at the bench.1. Fit the springs (1a) and (1b) in place.2. Fit the pawl (2a) and the gasket (2b) in place.
- Position the sleeve for the gear selector and engagement lever assembly in the vice placing two types of protection in between.1. Fit the gear selector and engagement lever assembly sleeve (1a) on the propeller shaft (1b).2. Tighten the fixing bolts.
1. Place the fastening pin in position.
- Remove the gear selector and engagement lever assembly sleeve from the vice.1. Fit the gear selector rod (1a) in place on the sleeve and fastent it using the pin (1b).
1. Fit the gear engagement levers in place on the assembly.
- PROCEED WITH REASSEMBLY OF THE REVERSE IDLER GEAR CARRYING OUT THE OPERATIONS DESCRIBED BELOW.- Position the reverse gear in the vice, placing two types of protection in between.1. Fit the roller chamber (1a) in position on the reverse gear (1b).
1. Fit the shaft (1a) in position on the reverse gear (1b).
- PROCEED WITH REASSMBLING THE LAYSHAFT CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Fit the layshaft (1b) rear bearing (1a) on the press.
1. Position the layshaft in the vice, placing two types of protection in between.2. Fit the rear bearing circlip.
1. Fit the 1st speed gear in place.
1. Fit the 1st speed gear circlip.
- PROCEED WITH THE REASSEMBLY OF THE 1ST AND 2ND SPEED SYNCHRONIZER COMPLETE WITH REVERSE GEAR CARRYING OUT THE OPERATIONS DESCRIBED BELOW.
| The synchronizer should not show any signs of wear or ovality on the inner surface. |
| It is always advisable to replace the synchronizer. |
| Check that the hub and the engagement sliding sleeve are free from any notches and that they slide without too much clearance or sticking. The sleeve inner teeth should not be worn or else they must be replaced. Check the condition of the thrust springs and balls and, if necessary, replace them. |
1. Fit the cylinders (1a) and thrust springs (1b) in the housings in the hub so that the projections (1c) on the actual cylinders are in line with the splining (1d) on the hub on both sides.2. Fit the sleeve (2a) so that the open section (2b) of the splining is opposite the projections on the cylinders.3. Position the balls on the cylinders and push them inside until the sleeve is completely inserted.4. Fit the seal (4a), the sleeve complete with hub and the synchronizer (4b) on the layshaft.
1. Check that the references for the synchronizers are aligned with the free balls.
1. Fit the reverse gear.
1. Fit the 2nd speed gear.
1. Fit the circlip.
1. Fit the 3rd speed gear.
1. Fit the circlip.
- PROCEED WITH REASSEMBLING THE 3RD AND 4TH SPEED SYNCHRONIZER CARRYING OUT THE OPERATIONS DESCRIBED BELOW.
| The synchronizer should not show any signs of wear or ovality on the inner surface. |
| It is always advisable to replace the synchronizer. |
| Check that the hub and the engagement sliding sleeve are free from any notches and that they slide without too much clearance or sticking. The sleeve inner teeth should not be worn or else they must be replaced. Check the condition of the thrust springs and balls and, if necessary, replace them. |
1. Fit the cylinders (1a) and thrust springs (1b) in the housings in the hub so that the projections (1c) on the actual cylinders are in line with the splining (1d) on the hub on both sides.2. Fit the sleeve (2a) so that the open section (2b) of the splining is opposite the projections on the cylinders.3. Position the balls on the cylinders and push them inside until the sleeve is completely inserted.4. Fit the seal (4a), the sleeve complete with hub and the synchronizer (4b) on the layshaft.
1. Check that the references for the synchronizers are aligned with the free balls.
1. Fit the 4th speed gear.2. Fit the front bearing (2b) using the tool (2a).
| Description | Code | Function |
|---|
| 2a | Tool for fitting layshaft front bearing | 1.875.082.000 | Fitting layshaft front bearing |
- PROCEED WITH REASSEMBLING THE MAIN SHAFT CARRYING OUT THE OPERATIONS DESCRIBED BELOW. Fit the 4th speed gear.1. Fit the front bearing (1a) using the tool (1b).
| Description | Code | Function |
|---|
| 1b | Tool for fitting main shaft front bearing | 1.860.945.000 | Fitting main shaft front bearing |
1. Fit the rear bearing (1a) using the tool (1b).
| Description | Code | Function |
|---|
| 1b | Tool for fitting main shaft rear bearing | 1.875.093.000 | Fitting main shaft rear bearing |
- PROCEED WITH REASSEMBLING THE MANUAL GEARBOX CARRYING OUT THE OPERATIONS DESCRIBED BELOW.1. Fit the sleeve (1a) for the thrust bearing and tighten the fixing bolts (1b) to torque.
| Value - daNm | Fastening | Ø |
|---|
| 1b | 2 daNm | bolt | |
1. Fit the differential unit in the bellhousing.
1. Fit the differential cover (1a) and tighten the fixing bolts (1 b) to the recommended torque.
| Value - daNm | Fastening | Ø |
|---|
| 1b | 4 daNm | bolt | M10 |
| Value - daNm | Fastening | Ø |
|---|
| 1b | 2 daNm | bolt | M8 |
1. Fit the speed sensor support (1a) and tighten the fixing bolt (1b).
1. Fit the gasket on the differential flange using the tools (1a) and (1b).
| Description | Code | Function |
|---|
| 1a | - | 1.870.426.000 | Fitting oil seal on differential flange |
| Description | Code | Function |
|---|
| 1b | Drift for 1870426000 | 1.870.007.000 | Fitting oil seal on differential flange |
1. Tighten the differential flange (1b) fixing bolts (1a) to torque.
| Value - daNm | Fastening | Ø |
|---|
| 1a | 2 daNm | bolt | - |
1. Fit the layshaft centering bush.
1. Fit the magnet in position.
| check that there are no metal particles or other impurities. |
1. Fit the main shaft front bearing outer race in position using the tools (1a) and (1b).
| Description | Code | Function |
|---|
| 1a | Tool for extracting-fitting main shaft rear bearing outer race | 1.860.957.000 | Fitting main shaft rear bearing outer race |
| Description | Code | Function |
|---|
| 1b | Drift for 1860957000 | 1.874.365.000 | Fitting main shaft rear bearing outer race |
1. Rest the main shaft on the bellhousing.
1. Fit the gearbox casing securing it using half the bolts.
1. Position a dial gauge resting the magnetic part on the differential flange.
1. Fit the tool and measure the main shaft endfloat.
| Description | Code | Function |
|---|
| 1 | Fork for measuring main shaft clearance | 1.860.956.000 | Measuring main shaft clearance |
| Subject | Value |
|---|
| - | endfloat | mm 0.05 - 0.15 |
| If the measurement is not within the recommended figures, replace the main shaft adjustment shim with one of a suitable size. |
- Remove the tools and the bellhousing.1. Fit the main and layshafts in position.
1. Fit the gear selector and engagement lever assembly (1a) and tighten the fixing bolts (1b) to torque.
| Check that the forks are correctly inserted in the grooves in the sleeves. |
| Value - daNm | Fastening | Ø |
|---|
| 1b | 1.5 daNm | bolt | - |
1. Fit the reverse gear selector lever complete with fork in position.
1. Fit the pin fastening the reverse gear selector lever in place.
1. Fit the reverse gear and the shaft.
1. Fit the oil duct.
1. Fit the gearbox casing2. Tighten the fixing bolts.
1. Tighten the gearbox casing fixing bolts to torque.
| Apply gearbox sealant to the contact surfaces between the bellhousing and the gearbox casing. |
| Value - daNm | Fastening | Ø |
|---|
| 1 | 2 daNm | bolt | - |
1. Tighten the bolts fixing the layshaft bearing stop to torque.
| Value - daNm | Fastening | Ø |
|---|
| 1 | 2 daNm | bolt | - |
- Fit the 5th speed drive gear on the main shaft.- Fit the 5th speed driven gear on the layshaft.1. Tighten the nut (1a) fastening the 5th speed driven gear using the tool (1b).
| Value - daNm | Fastening | Ø |
|---|
| 1a | 17 daNm | bolt | - |
| Description | Code | Function |
|---|
| 1b | Spanner for removing/refitting 5th speed gear retaining nut | 1.870.405.000 | Dismantling 5th speed gear retaining nut |
- Stake the nut fixing the 5th speed driven gear.1. Fit the 5th speed synchronizer (1b) and engagement fork on the main shaft using the tool (1a) and secure it using the circlip.
| Description | Code | Function |
|---|
| 1a | Tool for locking 5th speed synchronizer | 1.870.411.000 | locking 5th speed synchronizer |
1. Fit the 5th speed engagement fork retaining pin.
1. Fit the gearbox cover (1a) and tighten the fixing bolts (1 b) to the recommended torque.
| Value - daNm | Fastening | Ø |
|---|
| 1b | 2 daNm | bolt | - |
1. Tighten the reversing lights switch
