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. 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    Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1024B50 ENGINE FLYWHEEL COVER - R.R.    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE     Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. 1. Fit tool (1a) complete with mountings (1b).
ToolDescriptionFunctionValidity
1.870.595.000CrossmemberEngine supportall versions
ToolDescriptionFunctionValidity
1.870.650.000Support blocksAid for tool 1.870.595.000all versions
2. Fit tools (2a) and (2b), then connect them to the tool fitted previously.
ToolDescriptionFunctionValidity
1.860.851.003CrossmemberEngine support1.2 8V1.4 16V
ToolDescriptionFunctionValidity
1.871.001.300Vertical mountAid for tool 1.860.851.0031.2 8V1.4 16V
1. Position a suitable bracket to anchor the engine.
1. With a suitable tool, working on the sliding joint, prise up the driveshaft from its housing on the gearbox.
1. Prise up the gear selector cable head.2. Prise up the gear engagement cable head.3. Undo retaining bolts (3a) on the gearbox from the gear selection-engagement cables mounting bracket (3b).
1. Undo retaining nut (1a) and disconnect engine earth braid on gearbox (1b).2. Disconnect reversing switch (2a) and release the associated wiring from retaining bracket (2b).
DescriptionConnector
2aReversing light switch    See I020 REVERSING LIGHTS SWITCH
1. Fit the gear selector cable head.2. Fit the gear engagement cable head.3. Tighten retaining bolts (3a) on the gearbox from the gear selection-engagement cables mounting bracket (3b), to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Join between gearbox and engine (gearbox side)BoltM12x1.258.0all versions
1. Unscrew stroke adjustment device (1a) and disconnect clutch cable (1b) from lever (1c).
1. Using a hydraulic lift, fit tools (1a), (1b) and (1c).
ToolDescriptionFunctionValidity
1.870.835.001Gearbox supportRemoving-refitting gearboxall versions
ToolDescriptionFunctionValidity
1.870.847.000/1Gearbox vertical supportAid for tool 1.870.835.001all versions
ToolDescriptionFunctionValidity
1.870.847.000/2Gearbox vertical supportAid for tool 1.870.835.001all versions
1. Undo retaining 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.
ComponentFasteningdia  Value (daNm)Validity
Gearbox to engineBoltM12x1.254.5all versions (C514 gearbox)
- Remove the tools used for removing the gearbox from its housing.
ToolDescriptionFunctionValidity
1.870.835.001Gearbox supportRemoving-refitting gearboxall versions
ToolDescriptionFunctionValidity
1.870.847.000/1Gearbox vertical supportAid for tool 1.870.835.001all versions
ToolDescriptionFunctionValidity
1.870.847.000/2Gearbox vertical supportAid for tool 1.870.835.001all versions
- Position the clutch cable on the lever and tighten the stroke adjustment device. 1. Position the engine earth braid on gearbox (1a) and tighten nut (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox earthNutM81.5all versions
2. Connect reversing switch (2a) and release the associated wiring from retaining bracket (2b).
DescriptionConnector
2aReversing light switch    See I020 REVERSING LIGHTS SWITCH
1. Fit the gear selector cable head.2. Fit the gear engagement cable head.3. Tighten retaining bolts (3a) on the gearbox from the gear selection-engagement cables mounting bracket (3b), to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Join between gearbox and engine (gearbox side)BoltM12x1.258.0all versions
- Remove the tools used for supporting the engine.
ToolDescriptionFunctionValidity
1.870.595.000CrossmemberEngine supportall versions
ToolDescriptionFunctionValidity
1.870.650.000Support blocksAid for tool 1.870.595.000all versions
ToolDescriptionFunctionValidity
1.860.851.003CrossmemberEngine support1.2 8V1.4 16V
ToolDescriptionFunctionValidity
1.871.001.300Vertical mountAid for tool 1.860.851.0031.2 8V1.4 16V
- Fir the driveshaft in its housing on the gearbox.    Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R.     Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE     Op. 1024B50 ENGINE FLYWHEEL COVER - R.R.    Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R     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. 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.