244001022 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting ) - Position the vehicle on a lift.
The removing and refitting of the differential unit described below refers to the 2.3 JTD version; as far as the procedures for removing and refitting the 2.8 JTD and 2.0 JTD engines are concerned, follow the same instructions as for the 2.3 JTD version, taking care over the refitting of the crossmember for supporting the gearbox and the anchorage point.
1. Disconnect the windscreen washer jet pipe.2. Undo the bolts fixing the bonnet lid hinges to the bodyshell.3. Remove the bonnet lid, with the help of a second mechanic, and place it on a surface taking care over the paintwork.
1. Undo the bolts fixing the cold air intake to the upper crossmember.2. Disconnect the intake hose from the air filter casing.3. Remove the cold intake and intake hose assembly from the engine compartment.
1. Remove the air delivery sleeve to the air-air heat exchanger (intercooler).
1. Undo the fixing bolts (1a) and remove the protective cover for the heater plugs control unit.2. Disconnect the electrical connections for the heater plugs control unit (2a) and (2b) and the control unit positive electrical connection (2c).
DescriptionConnector
2aHeater plugs control unitM015A
DescriptionConnector
2bEngine management control unitM010B
DescriptionConnector
2cHeater plugs control unitM015C
3. Undo the fixing nuts (3a) and remove the mounting bracket (3b) complete with heater plugs control unit.
1. Disconnect the band fastening the air supply hose to the turbocharger.2. Disconnect the vapour recovery pipe from the air supply hose to the turbocharger.3. Disconnect the band from the air filter casing (3a) and remove the air supply hose to the turbocharger (3b).
1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.
1. . Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.
1. Undo the retaining bolt.2. Disconnect the earth lead from the gearbox.
1. Disconnect the electrical connection for the reversing light switch.
DescriptionConnector
1Reversing lights switchI020
1. Disconnect the electrical connection for the voltage regulator on the alternator.
DescriptionConnector
1AlternatorA010A
2. Disconnect the remaining alternator electrical wiring.
DescriptionConnector
AlternatorA010B
1. Undo the bolts fixing the air filter casing mounting bracket.2. Undo the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.3. Remove the air filter casing from the engine compartment.
1. Disconnect the electrical connection for the speedometer sensor.
DescriptionConnector
1Speedometer sensorK084
1. Disconnect the brake servo vacuum pipe from the vacuum unit
1. Disconnect the two rapid connectors for the fuel supply and return pipes.
- Raise the vehicle.    Op. 7055B54 UNDER-ENGINE GUARD - R R- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.
DescriptionCodeFunction
.Spanner1.850.182.000Wrench for slackening/tightening differential fluid plug
- Position a hydraulic column lift under the track control arm to work safely.1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
DescriptionCodeFunction
2aHead extractor1.847.038.000Ball joint removal
1. Undo the fixing bolts (1a) and remove the brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
1. Remove the staking and undo the right hub nut.2. Undo the bolts fixing the steering knuckle to the shock absorber.3. Undo the nuts (3a) and remove the right driveshaft (3b) complete with intermediate shaft (3c).
1. Undo the fixing bolts (1a) and remove the left brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
DescriptionCodeFunction
2aHead extractor1.847.038.000Ball joint removal
3. Undo the bolts fixing the steering knuckle to the shock absorber.
1. Release the inner driveshaft (1a) from the differential and move the right driveshaft (1b) away from the work area.
1. Undo the fixing nuts (1a) and separate the ridid middle section of the exhaust pipe from the turbocharger hose flange (1b).2. Undo the bolts fixing the rear flange (2a) and remove the rigid middle section (2b) of the exhaust pipe.
1. Undo the nut (1a), remove the protective cover (1b) and disconnect the starter motor supply leads (1c).2. Undo the retaining bolts (2a) and remove the starter motor (2b), complete with spacer (2c).
DescriptionConnector
1cStarter motorA020A
DescriptionConnector
1cStarter motorA020B
1. Undo the retaining nuts.2. Remove the operating cylinder mounting bracket on the bellhousing.
1. Remove the cover (1a), undo the nut (1b) and remove the selector unit idler connecting rod (1c).
1. Undo the bolts fixing the gearbox side flexible mounting to the rigid support.2. Undo the bolts and the nut fixing the rigid support to the gearbox.- Gently lower the engine until the stud on the rigid support comes out of the housing in the flexible mounting.3. Remove the gearbox side rigid power unit support.
1. Take a hydraulic lift fitted with a plate and adjustment screws (1a) and fit the two brackets (1b) for securing the gearbox and differential unit on it.
DescriptionCodeFunction
1aAdjustable support1.870.856.000Removing - refitting gearbox
DescriptionCodeFunction
1bBrackets1.870.847.000Removing - refitting gearbox
1. Raise the hydraulic lift, tilt the base and position the bracket in contact with the gearbox-differential unit.
DescriptionCodeFunction
1Brackets1.870.847.000Removing - refitting gearbox
2. Fasten the second bracket to the gearbox unit at the back.
DescriptionCodeFunction
2Brackets1.870.847.000Removing - refitting gearbox
1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.
1. Undo the fixing bolts.2. Remove the gearbox-differential unit.
Refitting ( Removing ) 1. Undo the bolts (1a) and remove the pressure plate and the clutch disc (1b).
- Fit the gearbox-differential unit and tighten the nuts and bolts to torque.
Value - daNmFasteningComponentØ  
.7BoltMANUAL GEARBOX/DIFFERENTIALM12
Value - daNmFasteningComponentØ  
.6NutMANUAL GEARBOX/DIFFERENTIALM10
- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the gearbox side rigid engine support.- Tighten the bolts fixing the gearbox side flexible mounting to the rigid support.
Value - daNmFasteningComponentØ  
.(Rigid mount) 5BoltGEARBOX SIDE RUBBER MOUNTM10
- Tighten the bolts and the nut fixing the rigid support to the gearbox to torque.
Value - daNmFasteningComponentØ  
.(Gearbox) 9NutGEARBOX SIDE RUBBER MOUNTM14
Value - daNmFasteningComponentØ  
.(Gearbox) 9BoltGEARBOX SIDE RUBBER MOUNTM14
- Remove the tool complete with brackets positioned previously for supporting the gearbox.
DescriptionCodeFunction
.Adjustable support1.870.856.000Removing - refitting gearbox
DescriptionCodeFunction
.Brackets1.870.847.000Removing - refitting gearbox
DescriptionCodeFunction
.Brackets1.870.847.000Removing - refitting gearbox
- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.- Fit the operating cylinder mounting bracket on the bellhousing.- Tighten the fixing nuts. - Fit the starter motor and tighten the retaining bolts to torque.
Value - daNmFasteningComponentØ  
.2BoltSTARTER MOTORM8
- Connect the starter motor electrical wiring
DescriptionConnector
.Starter motorA020A
DescriptionConnector
.Starter motorA020B
- Fit the rigid middle section of the exhaust pipe and tighten the bolts securing it to the rear section to torque.
Value - daNmFasteningComponentØ  
.(Front section flange) 2.6BoltsREAR SILENCER EXHAUSTM8
- Tighten the nuts securing the front section of the exhaust pipe to the turbocharger to torque.
Value - daNmFasteningComponentØ  
.(Flange on turbocharger) 2.6NutREAR SILENCER EXHAUSTM8
- Fit the inner driveshaft in the housing on the differential for the right driveshaft.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNmFasteningComponentØ  
.(damper strut) 19BoltFRONT HUB STRUTM16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNmFasteningComponentØ  
.6.9NutADJUSTABLE LINK BALL JOINTSM16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNmFasteningComponentØ  
.21BoltFRONT BRAKE CALIPER BRACKETM16
- Fit the right driveshaft - intermediate driveshaft assembly.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNmFasteningComponentØ  
.(damper strut) 19BoltFRONT HUB STRUTM16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNmFasteningComponentØ  
.6.9NutADJUSTABLE LINK BALL JOINTSM16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the disc to torque.
Value - daNmFasteningComponentØ  
.21BoltFRONT BRAKE CALIPER BRACKETM16
1. Use a hammer and chisel to stake the wheel hub drive shaft retaining nut as shown in the figure.- The figure below refers to the 15 quintal version.
Value - daNmFasteningComponentØ  
.-NutFRONT HUBS COMPLETE WITH BEARINGM28
- The figure below refers to the 18 quintal version.
Value - daNmFasteningComponentØ  
.-NutFRONT HUBS COMPLETE WITH BEARINGM33
- Lower the vehicle.- Connect the two rapid connectors for the fuel supply and return pipes.- Connect the brake servo vacuum pipe to the vacuum unit- Connect the electrical connection for the speedometer sensor.
DescriptionConnector
.Speedometer sensorK084
- Fit the air filter casing.- Tighten the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.- Tighten the bolts fixing the air filter casing mounting bracket.- Connect the electrical connection for the voltage regulator on the alternator.
DescriptionConnector
.AlternatorA010A
- Connect the remaining alternator electrical wiring.
DescriptionConnector
.AlternatorA010B
- Disconnect the electrical connection for the reversing lights switch.
DescriptionConnector
.Reversing lights switchI020
- Connect the earth lead to the gearbox and tighten the fixing nut.- Lock the ends of the gear selector and engagement flexible cables.- Secure the cables to the mounting bracket.- Fit the clutch release operating cylinder in the housing on the gearbox and tighten the fixing bolts.- Fit the air supply hose to the turbocharger and secure it to the air filter casing.- Connect the vapour recovery pipe to the turbocharger air supply hose.- Fit the mounting bracket complete with heater plugs control unit.- Connect the electrical connections for the heater plugs control unit.
DescriptionConnector
.Heater plugs control unitM015A
DescriptionConnector
.Heater plugs control unitM015B
DescriptionConnector
.Heater plugs control unitM015C
- Fit the protective cover for the heater plugs control unit and tighten the fixing bolts.- Fit the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the cold intake and intake hose assembly in the engine compartment.- Connect the intake hose to the air filter casing.- Tighten the bolts fixing the cold air intake to the upper crossmember.- Fit the bonnet lid with the help of a second mechanic, taking care not to damage the paintwork.- Screw in the bolts securing the bonnet lid to the bodyshell without tightening them.- Connect the windscreen washer jet pipe.    Op. 0010T40 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY    Op. 7055B54 UNDER-ENGINE GUARD - R R 1. Place the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, under the engine oil sump in a central position.2. In order to be able to position the crossmember correctly and safely, the corners of the actual crossmember at the two ends have to be smoothed making sure that they match correctly with the front crossmember and the suspension crossmember.
DescriptionCodeFunction
1Crossmember1.870.735.000Lower engine mounting beam
1. In order to extract the for lever pin, a tool has to be made cutting a length of around 25 mm from a 26 mm diameter pipe.2. Fit a suitable washer (2a) on the tool and tighten an M6x1 bolt (2b) at least 55 mm long in the pin housing.- Tighten the tool produced on the pin and extract the shaft fixing the fork lever.
1. Remove the thrust bearing (1b) from the clutch using the tool (1a).
DescriptionCodeFunction
1aExtractor1.870.840.000Thrust bearing removal
1. Fit the driven disc and the pressure plate and align them using the clutch centering tool.
DescriptionCodeFunction
1Clutch locating tool1.875.029.000Driven plate locating
- Tighten the bolts fixing the clutch to the flywheel to torque.
Value - daNmFasteningComponentØ  
.3.2BoltCLUTCH ASSEMBLYM8
1. Position the thrust bearing (1a) on the main gearbox shaft hose and fit it on the clutch release lever (1b), then fit the release lever fixing shaft (1c).
- Remove the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, from under the engine oil sump.
DescriptionCodeFunction
.Crossmember1.870.735.000Lower engine mounting beam