312001194 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R
Removing
(
Refitting
)
- Position the vehicle on a lift. Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R Op. 5520B10 STARTER MOTOR - R+R Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R. Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R. Op. 1088E10 RADIATOR COOLING FAN - R + R Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7210E10 R.R. FRONT BUMPER Op. 7210A48 R.R THIRD LOAD LINE
1. Undo nut (1a) and disconnect gearbox earth lead (1b).2. Disconnect reversing switch electrical connection (2a) and release the associated wiring from retaining bracket (2b).
1. Unscrew stroke adjustment device (1a) and disconnect clutch cable (1b) from lever (1c).
1. Unscrew bolt (1a) and remove air supply rigid pipe support bracket (1b) between the heat exchanger and intake manifold.
1. Prise up the end of the gear selector cable.2. Prise up the end of the gear engagement cable.3. Undo retaining bolts (3a) on the gearbox from gear selection-engagement cables mounting bracket (3b).
1. Undo nut (1a) and disconnect reaction rod (1b), wheel strut side.2. Undo the bolts securing the wheel strut to the suspension.3. Release brake system (3a) pipe and wheel rpm sensor (3b) electrical wiring from the retaining clips. | Carry out the operations described above on the wheel strut, gearbox side. |
1. Working on the gearbox side, undo the nut securing the steering rod head to the wheel hub.
1. Using tool (1a) prise up steering rod (1b) from wheel hub (1c). | Carry out the operations described above on the steering linkage, gearbox side. |
| Tool | Description | Function | Validity |
|---|
| 1.871.000.700 | Extractor | Separation of steering track rod end from wheel hub | all versions |
1. With a suitable tool, working on the sliding joint, prise up the driveshaft from its housing on the gearbox. | Carry out the operations described above on the sliding joint, differential side. |
1. Fit crossmember (1a) complete with mount adapted for power unit (1b) and with mounting blocks (1c) and support the power unit appropriately.| Tool | Description | Function | Validity |
|---|
| 1.870.595.000 | Crossmember | Engine support | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.650.000 | Support blocks | Aid for tool 1.870.595.000 | all versions |
| Tool | Description | Function | Validity |
|---|
| 2.000.025.400 | Adaptor support for R.R. power unit / gearbox | Aid for tool 1.870.595.000 | 1.3 Mjet |
Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R 1. Undo bolts (1a) and remove clutch cable bracket (1b).
1. Using a hydraulic lift, fit tools (1a), (1b) and (1c).| Tool | Description | Function | Validity |
|---|
| 1.870.835.001 | Gearbox support | Removing-refitting gearbox | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.847.000/1 | Gearbox vertical support | Aid for tool 1.870.835.001 | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.847.000/2 | Gearbox vertical support | Aid for tool 1.870.835.001 | all versions |
1. Undo bolts (1a) and remove gearbox (1b) from its housing.
Refitting
(
Removing
)
1. Position gearbox (1a) in its housing and tighten retaining bolts (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gearbox to engine | Bolt | M12x1.25 | 4.5 | all versions (C514 gearbox) |
- Remove the tools used for removing the gearbox from its housing.| Tool | Description | Function | Validity |
|---|
| 1.870.835.001 | Gearbox support | Removing-refitting gearbox | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.847.000/1 | Gearbox vertical support | Aid for tool 1.870.835.001 | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.847.000/2 | Gearbox vertical support | Aid for tool 1.870.835.001 | all versions |
1. Position clutch cable support bracket (1a) in its housing and tighten retaining bolts (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Clutch control cable reaction bracket | Bolt | M10x1.25 | 2.5 | all versions |
Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the tools used for supporting the engine.| Tool | Description | Function | Validity |
|---|
| 1.870.595.000 | Crossmember | Engine support | all versions |
| Tool | Description | Function | Validity |
|---|
| 1.870.650.000 | Support blocks | Aid for tool 1.870.595.000 | all versions |
| Tool | Description | Function | Validity |
|---|
| 2.000.025.400 | Adaptor support for R.R. power unit / gearbox | Aid for tool 1.870.595.000 | 1.3 Mjet |
- Fit the driveshaft in its housing on the gearbox, differential side.
1. Tighten the nut securing the steering link head to the wheel hub, gearbox side, to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Steering track rod end to steering knuckle | Nut | M10x1.25 | 4.0 | all versions |
1. Connect reaction rod (1a) to the wheel strut and tighten nut (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Reaction rod (on front shock absorber) | Nut | M10x1.25 | 5.0 | all versions |
2. Tighten the main retaining bolts securing the front wheel strut to the suspension to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Shock absorber (on steering knuckle) | Nut | M10x1.25 | 7.5 | all versions |
3. Connect brake system (3a) pipe and wheel rpm sensor (3b) electrical wiring to the retaining clips. | Carry out the operations described above on the wheel strut, gearbox side. |
1. Position the end of the gear selector cable.2. Position the end of the gear engagement cable.3. Tighten retaining bolts (3a) on the gearbox from gear selection-engagement cable mounting bracket (3b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Join between gearbox and engine (gearbox side) | Bolt | M12x1.25 | 8.0 | all versions |
- Fit the air supply rigid pipe mounting bracket in its housing between the heat exchanger and the intake manifold and tighten the retaining bolt.
1. Position the engine earth braid on gearbox (1a) and tighten nut (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Manual gearbox earth | Nut | M8 | 1.5 | all versions |
2. Connect reversing switch (2a) and release the associated wiring from retaining bracket (2b).
- Position the clutch cable on the levers and screw in the stroke adjustment device. Op. 7210A48 R.R THIRD LOAD LINE Op. 7210E10 R.R. FRONT BUMPER Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R. Op. 1088E10 RADIATOR COOLING FAN - R + R Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R. Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R. Op. 5520B10 STARTER MOTOR - R+R Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 0010T40 CHANGE MANUAL GEARBOX OIL - Remove the vehicle from the lift.
