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

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
Removing ( Refitting ) 1. Undo retaining bolts (1a) and remove starter motor (1b).
1. Disconnect the pipe from the band on the turbocharger (1a) and with vapour recovery pipe (1b).2. Remove the turbocharger air intake pipe.
1. Disconnect the band from the turbocharger.2. Undo the bolts securing the pipe to the mount.3. Remove the rigid air delivery section from turbocharger to engine.
1. Disconnect the electrical connection for the rpm sensor.
DescriptionConnector
1Rpm sensorK046
1. Undo fastenings (1a) and remove the gearbox and differential (1b).
Refitting ( Removing ) - Fit the gearbox-differential unit and tighten the nuts and bolts to torque.
Value - daNmFasteningComponentØ  
.7BoltMANUAL GEARBOX/DIFFERENTIALM12
Value - daNmFasteningComponentØ  
.6NutMANUAL GEARBOX/DIFFERENTIALM10
- Connect the electrical connection for the rpm sensor.
DescriptionConnector
.Rpm sensorK046
- Fit the rigid air delivery section from turbocharger to engine.- Tighten the bolts securing the pipe to the mount and connect the band to the turbocharger.- Fit the air inlet pipe to the turbocharger and secure to the turbo using a band.- Connect the oil vapour recovery pipe.- Fit the starter motor and tighten the bolts to torque.
Value - daNmFasteningComponentØ  
.4.5BoltSTARTER MOTORM8