312002423 - 2110B20 MANUAL GEARBOX (5-6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY

Removing ( Refitting ) 1. Remove the hydraulic jack (1a) from the gearbox and differential and support tools (1b) and (1c) used for removing and refitting.
ToolDescriptionFunctionValidity
1.870.689.000MountGearbox support1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.860.873.000Gearbox supportGearbox support for removing-refitting gearbox1.2 8V1.3 Mjet
1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).
Two mechanics are needed for this operation.
ToolDescriptionFunctionValidity
1.871.000.000Overhaul standEngine overhaulall versions
ToolDescriptionFunctionValidity
1.871.001.014Gearbox supportOverhaul gearbox1.2 8V1.3 Mjet
1. Undo the bolts (1a) and remove the gearbox rear cover (1b).
Use a drier to help detach the sealant.
2. Remove the differential output shafts with external three-lobe joints.
Engage any gear using the gear selection/engagement lever.1. Unscrew the stud (1a) and the fixing bolts (1b), then remove the gear engagement assembly cover (1c).
1. Unscrew the bolt (1a) for the 5th speed control fork (1b).Engage 5th speed by pressing the fork on the main shaft.
If two gears are engaged simultaneously the gear shafts will lock.
2. Remove the staking on the main and layshaft ringnuts using a suitable drift.3. Completely undo the ring nuts for the main and layshafts.Place the 5th speed control fork in neutral.
The positioning of the 5th speed control fork in neutral is necessary to prevent the synchronizer rollers from being lost.
1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed driven gear (2a) using the tool (2b).
ToolDescriptionFunctionValidity
1.840.005.400ExtractorExtracting 5th speed driven gear Removing hub for 5th speed engagement sliding sleeve1.2 8V1.3 Mjet
1. Remove the roller retaining plate and the 5th speed synchronizer springs.2. Remove the 5 th speed engagement fork.3. Remove the 5th speed engagement sleeve.4. Remove the 5th speed hub springs and rollers.
1. Remove the 5th speed sliding engagement sleeve hub (1a), 5th speed synchroniser ring (1b) and 5th speed drive gear (1c) with tool (1d).
ToolDescriptionFunctionValidity
1.840.005.400ExtractorExtracting 5th speed driven gear Removing hub for 5th speed engagement sliding sleeve1.2 8V1.3 Mjet
1. Fit the bush for the 5th speed drive gear (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1.845.057.000ExtractorRemoving 5th speed drive gear bush1.2 8V1.3 Mjet
1. Undo the bolts (1a) and remove the rear bearing retaining plate (1b).
1. Remove the rear bearing circlips.
To extract the circlips, position the openings at the front.
2. Unscrew the reverse idler gear shaft bolt.
1. Undo the bolts (1a) and remove the gearbox casing (1b)2. Unscrew the bolts (2a) and remove the support with reverse engagement fork lever (2b).
1. Unscrew the bolt (1a) and withdraw the gear engagement fork guide rod (1b).2. Remove the 3rd - 4th speed engagement control fork.3. Remove the reverse engagement fork control lever.4. Remove the 5 th speed engagement fork control lever.5. Remove the 1st - 2nd speed engagement control fork.
1. Remove the reverse idler gear.2. Remove the main shaft assembly.3. Remove the layshaft assembly.
1. Undo the bolts (1a) and remove the differential casing cover (1b) complete with gasket (1c) and oil seal (1d).
The sealing ring and gasket must always be replaced.
1. Undo the bolts (1a) and remove the mileometer relay gear (1b).
1. Undo the bolts (1a) and remove the manual gearbox differential mount (1b) complete with oil seal (1c).2. Remove the magnet.3. Remove the differential bearing preload thrust ring.4. Remove the differential assembly.5. Remove the differential bearing outer races.
1. Remove the clutch thrust bearing external linkage retaining ring.2. Remove the clutch thrust bearing outer linkage (2a) and bush (2b).
1. Remove the clutch thrust bearing inner linkage (1a) and bush (1b).
Replace the outer and inner bushes whenever thrust bearing drive shaft play is excessive.
1. Remove the staking and, using the universal extractor (1a), remove the oil seal (1b) for the main shaft from the support joining the manual gearbox and engine.
Proceed with dismantling the layshaft.1. Remove the bearing retaining ring.2. Remove the rear bearing (2a) and 4th speed driven gear (2b) using tools (2c), (2d) and (2e).
ToolDescriptionFunctionValidity
1.840.005.002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.840.005.301ClampsRemoving 4th speed drive gear and rear bearingRemoving main shaft front bearingRemoving bearing from differential1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.842.133.000ExtractorRemoving 4th speed driven gear and rear bearingRemoving bearing from differential1.2 8V1.3 Mjet
3. Release the spacer between the 3rd and 4th speed driven gears.
1. Remove the 3rd speed driven gear (1a) and the 2nd speed driven gear (1b) using the tools (1c) and (1d).
ToolDescriptionFunctionValidity
1.840.005.002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.840.005.303ExtractorRemoving layshaft rear bearingRemoving 3rd speed driven gear and 2nd speed driven gearRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gear1.2 8V1.3 Mjet
2. Remove the 2nd speed synchronizer ring (2a) and the 1st and 2 nd speed engagement sliding sleeve (2b).Keep the presynchronizer mountings for the 1st and 2nd speed hub.
1. Remove the hub retaining circlip.2. Remove the 1st speed driven gear (2a), the 1st speed synchronizer ring (2b) and the hub for the 1st and 2nd speed engagement sliding sleeve (2c) using the tools (2d) and (2e).
ToolDescriptionFunctionValidity
1.840.005.002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.840.005.306ClampsRemoving 1st, 2nd and 3rd speed driven gearsDismantling main shaftRemoving layshaft front bearing1.2 8V1.3 Mjet
To remove the layshaft front bearing, see    Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
Proceed with dismantling the main shaft.1. Remove the rear bearing (1a) and 4th speed drive gear (1b) using tools (1c) and (1d).
ToolDescriptionFunctionValidity
1.840.005.002ExtractorRemoving 4th speed driven gear and rear bearingRemoving 3rd speed driven gear and 2nd speed driven gear1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.840.005.103ClampsRemoving 4th speed driven gear and 3rd,4th speed sliding sleeveDismantling main shaft1.2 8V1.3 Mjet
2. Remove the 4th speed synchronizer ring (2a) and the 3rd and 4 th speed sliding sleeve (2b).3. Keep the springs (3a) and the rollers (3b) for the 3rd and 4th speed hub.
1. Remove the circlip retaining the 3rd and 4th speed engagement sliding sleeve hub.2. Remove the 3rd and 4th speed engagement sliding sleeve hub (2a), the 3rd speed synchronizer ring (2b) and the 3rd speed drive gear (1c) using the tools (2d) and (2e).
ToolDescriptionFunctionValidity
1.840.005.001StrutRemoving left differential internal driveshaftExtracting main shaft front bearingRemoving layshaft front bearing inner raceRemoving 4th speed drive gear and rear bearingRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gearRemoving main shaft front bearing all versions
ToolDescriptionFunctionValidity
1.840.005.303ExtractorRemoving layshaft rear bearingRemoving 3rd speed driven gear and 2nd speed driven gearRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gear1.2 8V1.3 Mjet
Refitting ( Removing ) Proceed with washing and checking the condition of all the components.Proceed with reassembling the main shaft following the instructions given below.Lubricate the relevant parts with transmission fluid before final fitting.1. Fit the 3rd speed drive gear (1a) and 3rd speed synchronizer ring (1b).2. Fit the 3rd and 4th speed sliding sleeve hub (2a) using the tool (2b).
ToolDescriptionFunctionValidity
1.870.152.000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8V1.3 Mjet
1. Fit the springs for the 3rd and 4th speed sliding sleeve in their housings on the hub.2. Fit the 3rd and 4th speed sliding sleeve.
The notches in the sleeve should correspond with the springs.
3. Fit the rollers between the springs and the grooves on the 3rd and 4th speed sliding sleeve.4. Fit the 4th speed synchronizer ring.Place the 3rd and 4th speed sliding sleeve in neutral to prevent the springs and rollers from being lost.5. Fit the 4th speed drive gear.
1. Fit the rear bearing (1a) on the mainshaft using the tool (1b).
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
Proceed with reassembling the layshaft following the instructions given below.Lubricate the relevant parts with transmission fluid before final fitting.1. Fit the 1st speed driven gear.2. Fit the 1st speed synchronizer ring.3. Fit the 1st and 2nd speed sliding sleeve hub (3a) using the tool (3b).
ToolDescriptionFunctionValidity
1.870.152.000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8V1.3 Mjet
4. Fit the circlip retaining the 1st and 2nd speed engagement sliding sleeve hub.
1. Fit the 1st and 2nd speed sliding sleeve.2. Fit the presynchronizer mountings in the grooves for the 1st and 2nd speed sliding sleeve.3. Fit the 2nd speed synchronizer ring. Place the 1st and 2nd speed sliding sleeve in neutral.4. Fit the 2nd speed driven gear.5. Fit the 3rd speed driven gear (5a) using the tool (5b).
ToolDescriptionFunctionValidity
1.870.152.000Fitting toolFitting hub for 1st/2nd and 3rd/4th speed engagement sliding sleevesFitting 3rd speed driven gear1.2 8V1.3 Mjet
1. Fit the spacer between the 3rd and 4th speed driven gears.2. Fit the 4th speed driven gear (2a) using the tool (2b).
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
3. Fit the rear bearing (3a) using the tool (3b).
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
4. Fit the layshaft rear bearing circlip.
1. Fit the main shaft oil seal (1a) on the manual gearbox bell housing using fitting tool (1b) together with drift (1c).
ToolDescriptionFunctionValidity
1.870.796.000Fitting toolFitting main shaft oil sealall versions
ToolDescriptionFunctionValidity
1.870.007.000Fitting toolFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differentialall versions
1. Fit the inner bush for the clutch thrust bearing linkage (1a) using tool (1b).
ToolDescriptionFunctionValidity
1.870.633.000Fitting toolFitting clutch thrust bearing control linkage inner bushall versions
1. Fit inner linkage (1a), outer bush (1b) and outer linkage (1c) of the cutch thrust bearing drive.2. Fit the clutch thrust bearing external linkage retaining ring.
1. Fit the differential assembly (1a) and differential bearing outer races (1b).2. Fit the magnet.Apply the recommended sealant to the contact surfaces between the differential mounting and gear casing.
ComponentTypeDescriptionClassificationQuantityValidity
Manual gearbox casing differential/supportGear engagement coverManual gearbox rear coverSealantLOCTITE 573--1.2 8v1.3 Mjet
3. Fit the manual gearbox housing differential mounting (3a) and fastening it by tightening the bolts (3b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Differential cover (on gearbox/engine support)BoltM82.0all versions (C514 gearbox)
ComponentFasteningdia  Value (daNm)Validity
Gearbox oil filler tapered plug-22x1.52.5all versions (C514 gearbox)
1. Fit the mileometer idler gear (1a) and tighten the bolt (1b).
1. Remove the layshaft assembly.2. Fit the mainshaft assembly.3. Fit the reverse idler gear (3a) by inserting pin (3b) in its seat on the housing.
1. Fit the 3rd - 4th speed engagement control fork.2. Fit the 1st - 2nd speed engagement control fork.3. Fit the 5 th speed engagement fork control bracket.4. Fit the reverse engagement fork drive bracket.5. Fit the gear engagement fork guide rod in its seat.6. Tighten the 5 th speed engagement fork control bracket to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
5th speed forkBoltM61.2all versions (C514 gearbox)
1. Fit the mounting and the reverse engagement fork lever (1a) and tighten the bolts (1b) to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Reverse fork supportBoltM81.5all versions (C514 gearbox)
2. - Apply the recommended sealant to the contact surfaces between the gear casing and the manual gearbox bellhousing.
ComponentTypeDescriptionClassificationQuantityValidity
Manual gearbox casing differential/supportGear engagement coverManual gearbox rear coverSealantLOCTITE 573--1.2 8v1.3 Mjet
3. Fit the gearbox casing (3a) and secure it by tightening the bolts (3b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox casing (on gearbox/engine support)BoltM82.0all versions (C514 gearbox)
1. Tighten the reverse idler gear shaft bolt to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Reverse shaftBoltM82.6all versions (C514 gearbox)
2. Fit the rear bearing circlips.
To facilitate the fitting of the rear bearing circlips, position them with the openings at the front.
1. Fit the rear bearing retaining plate (1a) and secure it by tightening the bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Bearing retaining plate (on gearbox casing)BoltM82.0all versions (C514 gearbox)
1. Fit the 5th speed drive gear bush (1a) using tool (1b).
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
1. Fit the 5th speed drive gear.2. Fit the 5th speed synchronizer oil seal.3. Using the tool (3a), fit the hub for the 5th speed engagement sliding sleeve (3b) with the splining for the oil facing the gear.
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
1. Fit the springs on the hub for the 5th speed engagement sliding sleeve.2. Fit the 5 th speed engagement sliding sleeve.
The notches in the sleeve should correspond with the springs.
3. Fit the 5 th speed control fork.4. Fit the rollers between the springs and the notches for the 5th speed engagement sliding sleeve.5. Fit the roller retaining plate and the 5th speed synchronizer springs.Place the 5th speed sliding sleeve in neutral to prevent the springs and rollers from being lost.
1. Fit the 5th speed driven gear (1a) on the layshaft using the tool (1b).
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
Fit the ring nuts on the main and layshafts without tightening them.
1. Apply the recommended sealant to the contact surfaces between the gearbox casing and the gear engagement assembly cover.
ComponentTypeDescriptionClassificationQuantityValidity
Manual gearbox casing differential/supportGear engagement coverManual gearbox rear coverSealantLOCTITE 573--1.2 8v1.3 Mjet
2. Fit the gear engagement assembly cover (2a) and tighten the bolts (2b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gear selector and engagement assembly (on gearbox casing)BoltM61.0all versions (C514 gearbox)
ComponentFasteningdia  Value (daNm)Validity
Gear selector and engagement assembly (on gearbox casing)BoltM82.0all versions (C514 gearbox)
Engage any gear using the gear selection/engagement lever.Engage 5th speed by pressing the main shaft control fork.
If two gears are engaged simultaneously the gear shafts will lock.
1. Tighten the 5th speed control fork bolt to torque.
ComponentFasteningdia  Value (daNm)Validity
5th speed forkBoltM61.2all versions (C514 gearbox)
2. Tighten the ring nuts securing the main and layshaft gears to torque.
ComponentFasteningdia  Value (daNm)Validity
5th speed gear ring nut on main and layshaft -M20x1.511.8all versions (C514 gearbox)
1. Stake the ring nuts (1a) securing the main and layshaft 5th speed gear using the tools (1b) and (1c).
ToolDescriptionFunctionValidity
1.874.140.005Pair of headsStaking ring nuts locking 5th speed gearall versions
ToolDescriptionFunctionValidity
1.874.140.001PliersStaking ring nuts locking 5th speed gearall versions
1. Apply the recommended sealant to the contact surfaces between the gearbox rear cover and the gearbox casing.
ComponentTypeDescriptionClassificationQuantityValidity
Manual gearbox casing differential/supportGear engagement coverManual gearbox rear coverSealantLOCTITE 573--1.2 8v1.3 Mjet
2. Fit the gearbox rear cover (2a) and secure it tightening the bolts (2b) to the recommended torque.
1. Fit the tool (1a) complete with dial gauge (1b) on the differential cover support surface, then move the probe into contact with the taper roller bearing outer race.
ToolDescriptionFunctionValidity
1.895.655.000MountDetermining thickness of differential bearing scraper ringsall versions
Zero the dial gauge with a preload of 1 mm.
1. Position tool (1a) complete with dial gauge onto differential sealing cover (1b), as shown in the figure, and measure the difference.
ToolDescriptionFunctionValidity
1.895.655.000MountDetermining thickness of differential bearing scraper ringsall versions
Calculate the size of the scraper ring for the differential bearing pre-loading by adding 0.12 mm to the difference measured.
The value of 0.12 mm corresponds to the recommended interference for the bedding in and pre-loading of the differential bearings.
1. Place the thrust ring (of exactly the same size or the next largest size to that calculated for the differential bearing pre-loading) in the housing.
1. Fit oil seal (1b) to differential cover (1a) using tools (1c) and (1d).
ToolDescriptionFunctionValidity
1.874.140.001PliersStaking ring nuts locking 5th speed gearall versions
ToolDescriptionFunctionValidity
1.870.007.000Fitting toolFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differentialall versions
2. Fit the gasket to the differential cover.
The sealing ring and gasket must always be replaced.
1. Fit the differential cover (1a) and tighten the fixing bolts (1 b) to the recommended torque.
ToolDescriptionFunctionValidity
1.870.631.000Fitting toolFitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeveall versions
1. Fit the gear casing differential mount oil seal (1a) with tools (1b) and (1c).
The oil seal must always be replaced.
ToolDescriptionFunctionValidity
1.870.630.000Fitting toolFitting differential support oil seal1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.870.007.000Fitting toolFitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differentialall versions
Fit the differential output shafts with external three-lobe joints.Undo the fastenings and remove the gearbox and differential from the tool.
Two mechanics are needed for this operation.
ToolDescriptionFunctionValidity
1.871.001.014Gearbox supportOverhaul gearbox1.2 8V1.3 Mjet
Remove the support tool from the overhaul stand and put it down.Position the gearbox and differential on the tools used for the removal.
ToolDescriptionFunctionValidity
1.870.689.000MountGearbox support1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.860.873.000Gearbox supportGearbox support for removing-refitting gearbox1.2 8V1.3 Mjet