2110B34 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH, CHECK COMPONENTS, REPLACE SYNCHRONIZERS AND INTERNAL CONTROLS - Fiat - NUOVA 500 - eLearn

312002422 - 2110B34 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH, CHECK COMPONENTS, REPLACE SYNCHRONIZERS AND INTERNAL CONTROLS

Removing ( Refitting

) 1. Fit gearbox (1a) on the overhaul stand using tool (1b).

1. Remove o-ring (1a) and lever (1b).2. Remove the outer non-slip bush.

1. Remove the thrust bearing.2. Remove the inner thrust control linkage.3. Remove the inner non-slip bush.

1. Undo bolts (1a) and remove gear selector/engagement unit (1b).

1. Using a suitable tool, remove the differential left inner driveshaft.2. Undo bolts (2a) and remove flange (2b) complete with oil seal and O-ring.

1. Using a suitable tool, remove the differential right inner driveshaft.2. Release the oil seal and remove it.

1. Undo bolts (1a) and remove differential cover (1b).

1. Remove the differential complete with thrust rings and bearings.

1. Remove the magnet.

1. Undo bolts (1a) and remove rear cover (1b), applying leverage at point (1c) shown in the diagram.

1. Undo the 5th and 6th speed engagement fork retaining bolt.

1. Move the rod shown in the diagram downwards so that the dogs are aligned.

1. Lift up the synchronizer to engage the 5th and 6th speed.

The simultaneous engagement of two gears results in the gearbox shafts locking; this operation is necessary in order to be able to release the bolt and the nut securing the gears.

1. Straighten the staking and undo the nut securing the 5th and 6th speed gears to the main shaft.

The nut must be replaced whenever it requires removal.

2. Undo the left-threaded bolt securing the 5th and 6th gears to the layshaft.

1. Using special tools (1a) and tool (1b) as illustrated, remove layshaft (1c) rear bearing.

Tool	Description	Function	Validity
1.870.481.000	Extractor	Layshaft bearing removal	1.4 16V

1. Remove the 6th speed gear from the layshaft.2. Remove the spacer for the 5th and 6th speed gears.

1. Using suitable tools (1a) as illustrated, remove 6th speed gear (1b) complete with bush from the main shaft.

1. Remove 5th and 6th speed engagement sleeve (1b) and fork (1a).

1. Remove the 6th speed synchroniser ring.2. Remove the presynchronisation mountings from the 5th and 6th speed hub.3. Remove the 5th speed driven gear from the layshaft.

1. Using suitable tools (1a) as illustrated, remove the 5th and 6th speed hub (1b) from the main shaft.

1. Remove synchronizer ring (1a) and 5th speed gear (1b) from the main shaft.

1. Using suitable tools (1a) as illustrated, remove the bush for 5th speed gear (1b) from the main shaft.

1. Undo bolts (1a) and remove the rear bearing retaining plate to gearbox casing (1b).2. Remove the rear bearing retaining rings.

To remove the retaining rings, arrange them with their openings at the front.

1. Unscrew the reverse idler gear shaft bolt.2. Undo bolts (2a) and remove gearbox casing (2b).

1. Unscrew bolts (1a) and remove the mounting with reverse engagement fork lever (1b).

1. Unscrew bolt (1a) and withdraw gear engagement fork guide rod (1b).2. Remove the 3rd-4th speed engagement fork.3. Remove the reverse engagement fork drive dog.4. Remove the 5th gear engagement fork drive dog.5. Remove the 1st-2nd speed engagement fork.

1. Remove the reverse idler gear.2. Remove the main shaft assembly.3. Remove the layshaft assembly.

1. Remove the main shaft oil seal from the manual gearbox bell housing.

LAYSHAFT DISMANTLING1. Working on the press, remove rear bearing (1a) and 4th speed driven gear (1b) using tool (1c).

Tool	Description	Function	Validity
1.870.899.400	Half plates	Removing layshaft bearings - gears - hubs - synchronizer rings	1.4 16V

1. Withdraw the spacer between the 3rd and 4th speed driven gears.

1. Working on the press, remove 3rd speed driven gear (1a) and 2nd speed driven gear (1b) using tool (1c).

Tool	Description	Function	Validity
1.870.899.400	Half plates	Removing layshaft bearings - gears - hubs - synchronizer rings	1.4 16V

1. Remove the needle bearing.2. Remove 2nd speed synchroniser ring (2a) and 1st and 2nd speed sliding engagement sleeve (2b).3. Keep the pre-synchronizer mountings.

1. Working in a vice fitted with protective jaws, remove the hub retaining ring.

1. Working on the press, remove 1st-2nd speed sliding engagement sleeve hub (1a), 1st speed synchronizer ring (1b) and 1st speed driven gear (1c) using tool (1d).

Tool	Description	Function	Validity
1.870.899.400	Half plates	Removing layshaft bearings - gears - hubs - synchronizer rings	1.4 16V

1. Remove the needle bearing.

1. Working in a vice fitted with protective jaws, remove the front bearing retaining ring.

1. Working on the press, remove layshaft front bearing (1a) using tool (1b).

Tool	Description	Function	Validity
1.870.899.400	Half plates	Removing layshaft bearings - gears - hubs - synchronizer rings	1.4 16V

MAIN SHAFT DISMANTLING1. Working on the press, remove rear bearing (1a) and 4th speed drive gear (1b) using suitable tools (1c) and (1d).

1. Working in a vice fitted with protective jaws, remove 4th speed synchronizer ring (1a) and 3rd and 4th speed sliding sleeve (1b).2. Remove the pre-synchronizer mountings.

1. Working in a vice fitted with protective jaws, remove the 3rd-4th speed sliding sleeve hub retaining ring.

1. Working on the press, remove 3rd-4th speed sliding engagement sleeve hub (1a), 3rd speed synchronizer ring (1b) and 3rd speed drive gear (1c) using a suitable tool (1d).

1. Working on the press, remove main shaft front bearing (1a) using suitable tools (1b) and (1c).

Refitting ( Removing

) - Proceed with washing and checking the condition of all the components.MAIN SHAFT REASSEMBLY- Lubricate the relevant parts with transmission fluid before the final fitting.1. Working on the press, fit main shaft front bearing (1a) using tool (1b) and a suitable plate (1c).

Tool	Description	Function	Validity
1.875.088.000	Fitting tool	Fitting main shaft front bearing	all versions

1. Fit 3rd speed drive gear (1a) and 3rd speed synchronizer ring (1b).2. Working on the press, fit 3rd-4th speed sliding engagement sleeve hub (2a) using tool (2b) and a suitable plate (2c).

Tool	Description	Function	Validity
1.870.899.300	Fitting tool	Fitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear	1.4 16V

1. Working in a vice fitted with protective jaws, fit the 3rd-4th speed sliding sleeve O-ring.

1. Working in a vice fitted with protective jaws, fit the pre-synchronizer mountings.2. Fit 4th speed synchronizer ring (2a) and 3rd and 4th speed sliding sleeve (2b).

The sliding sleeve should be fitted with the groove shown in the diagram facing downwards.

The notches on the sliding sleeve should be aligned with the pre-synchronizer mountings.

- Place the 3rd-4th speed sliding sleeve in neutral.1. Fit the 4th speed drive gear.

1. Working on the press, fit rear bearing (1a) on the main shaft using tool (1b) and a suitable plate (1c).

Tool	Description	Function	Validity
1.870.899.300	Fitting tool	Fitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear	1.4 16V

The rear bearing should be fitted with the groove "a" shown in the diagram facing upwards.

LAYSHAFT REASSEMBLY- Lubricate the relevant parts with transmission fluid before the final fitting.1. Working on the press, fit layshaft front bearing (1a) using tool (1b).

Tool	Description	Function	Validity
2.000.007.900	Plate for bearing	Fitting layshaft front bearing	1.4 16V

1. Working in a vice fitted with protective jaws, fit front bearing retaining ring.

1. Working in a vice fitted with protective jaws, fit needle bearing (1a), 1st speed synchronizer rings (1b) and 1st speed driven gear (1c).

1. Working on the press, fit the 1st-2nd speed sliding sleeve hub (1a) using a suitable plate (1b) and tool (1c).

Tool	Description	Function	Validity
1.870.632.000	Fitting tool	Fitting layshaft front bearing	all versions

1. Working in a vice fitted with protective jaws, fit the hub retaining ring.

1. Working in a vice fitted with protective jaws, fit pre-synchronizer mountings (1a), 1st and 2nd speed engagement sliding sleeve (1b) and needle bearing (1c).2. Fit the 2nd speed synchronizer rings.

The notches on the sleeve should be aligned with the pre-synchronizer mountings.

1. Working in a vice fitted with protective jaws, fit the 2nd speed driven gear.

1. Working on the press, fit 3rd speed driven gear (1a) using tool (1b) and a suitable plate (1c).

Tool	Description	Function	Validity
1.870.632.000	Fitting tool	Fitting layshaft front bearing	all versions

1. Working on the press, fit spacer between 3rd-4th speed driven gears (1a) and 4th speed driven gear (1b) using tool (1c) and a suitable plate (1d).

Tool	Description	Function	Validity
1.870.899.300	Fitting tool	Fitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear	1.4 16V

1. Working on the press, fit rear bearing (1a) using tool (1b) and a suitable plate (1c).

Tool	Description	Function	Validity
1.870.899.300	Fitting tool	Fitting 3rd-4th speed sliding sleeve hub/main shaft-layshaft rear bearingFitting spacer between 3rd-4th driven gears and 4th speed driven gear	1.4 16V

1. Fit a new main shaft oil seal (1a) on the manual gearbox bellhousing using tools (1b) and (1c).

Tool	Description	Function	Validity
1.870.796.000	Fitting tool	Fitting main shaft oil seal	all versions

Tool	Description	Function	Validity
1.870.007.000	Fitting tool	Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential	all versions

1. Remove the layshaft assembly.2. Fit the mainshaft assembly.3. Fit the reverse idler gear.

1. Fit the 3rd-4th speed engagement fork.2. Fit the 1st-2nd speed engagement fork.3. Fit the 5th gear engagement fork drive dog.4. Fit the reverse engagement fork drive dog.5. Fit the gear engagement forks guide rod.6. Tighten the bolt securing the 5th speed engagement fork control dog to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
5^th speed pawl	Bolt	M6	1.2	all versions (C514 gearbox)

1. Fit the mounting with reverse engagement fork lever (1a) and tighten bolts (1b) to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Reverse fork support	Bolt	M8	1.5	all versions (C514 gearbox)

- Apply sealant to the contact surfaces between the gear casing and the manual gearbox bellhousing.1. Fit gearbox casing (1a) and secure it by tightening bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox casing (on gearbox/engine support)	Bolt	M8	2.0	all versions (C514 gearbox)

2. Tighten the reverse idler gear shaft bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Reverse shaft	Bolt	M8	2.6	all versions (C514 gearbox)

1. Fit the rear bearing retaining rings.

Position the retaining rings with their openings at the front to facilitate fitting.

2. Fit the rear bearing retaining plate and secure it by tightening bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bearing retaining plate (on gearbox casing)	Bolt	M8	2.0	all versions (C514 gearbox)

- Fit the 5th speed gear bush on the main shaft using the tool.

Tool	Description	Function	Validity
1.870.631.000	Fitting tool	Fitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve	all versions

- Place the 5th speed gear and the synchronizer ring in its housing on the main shaft.- Fit the 5th and 6th speed hub on the main shaft with the splining for the oil facing the gear, using the tool.

Tool	Description	Function	Validity
1.870.631.000	Fitting tool	Fitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve	all versions

- Place the 5th speed driven gear in position on the layshaft.- Fit the pre-synchronization mountings on the 5th and 6th speed hub.- Place the 6th speed synchronizer ring in position.- Place the 5th-6th speed engagement sleeve and fork in position.

The notches on the sleeve should be aligned with the pre-synchronizer mountings.

- Fit the 6th speed gear and bush using the tool.

Tool	Description	Function	Validity
1.870.631.000	Fitting tool	Fitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve	all versions

- Place the spacer for the 5th and 6th speed gears in position on the layshaft.- Place the 6th speed gear in position on the layshaft.- Fit the rear bearing on the layshaft using the tool.

Tool	Description	Function	Validity
1.870.631.000	Fitting tool	Fitting rear bearing on main shaftFitting 4th and 5th speed driven gearsFitting 5th speed drive gear bushFitting hub for 5th speed engagement sliding sleeve	all versions

1. Move the rod shown in the diagram downwards so that the dogs are aligned.

- Lift up the synchronizer to engage the 5th and 6th speed.

The simultaneous engagement of two gears results in the gearbox shafts locking; this operation is necessary in order to be able to lock the bolt and the nut securing the gears.

- Tighten the 5th and 6th speed engagement fork retaining bolt.- Tighten the left-threaded bolt securing the layshaft gears to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Layshaft	Nut	M12x1	10.5	1.4 16V

- Tighten the new nut securing the main shaft gears to the recommended torque and stake it using the tools.

Component	Fastening	dia	Value (daNm)	Validity
Main shaft	Nut	M16x1.5	11.5	1.4 16V

Tool	Description	Function	Validity
1.874.140.005	Pair of heads	Staking ring nuts locking 5th speed gear	all versions

Tool	Description	Function	Validity
1.874.140.001	Pliers	Staking ring nuts locking 5th speed gear	all versions

- Apply the recommended sealant to the contact surfaces between the rear cover and the gearbox casing.- Place the rear cover back in its housing and secure it using the bolts.- Place the differential complete with bearings in position.- Place the magnet back in its housing.- Apply sealant to the contact surfaces between the differential cover and the gear casing.- Place the differential cover in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Differential cover (on gearbox/engine support)	Bolt	M8	2.0	all versions (C514 gearbox)

Component	Fastening	dia	Value (daNm)	Validity
Differential cover (on gearbox/engine support)	Bolt	M10x1.25	3.5	all versions (C514 gearbox)

1. Fit tool (1a) complete with hundredth dial gauge (1b) on the differential seal cover support surface, then move the probe into contact with the taper roller bearing outer race.

Tool	Description	Function	Validity
1.895.655.000	Mount	Determining thickness of differential bearing scraper rings	all versions

- Zero the dial gauge with a preload of 1 mm.1. Position tool (1a) complete with hundredth dial gauge on differential sealing cover (1b) as shown in the figure and measure the difference.

Tool	Description	Function	Validity
1.895.655.000	Mount	Determining thickness of differential bearing scraper rings	all versions

- Calculate the size of the thrust ring for differential bearing pre-loading by adding 0.12 mm to the difference measured.

0.12 mm corresponds to the recommended interference for the bedding-in and pre-loading of the differential bearings.

- Place the thrust ring of exactly the size or the next largest size to that calculated for the differential bearings pre-loading in the housing. 1. Fit a new oil seal on the differential cover using tools (1a) and (1b).

Tool	Description	Function	Validity
1.870.629.000	Fitting tool	Fitting oil seal	all versions

Tool	Description	Function	Validity
1.870.007.000	Fitting tool	Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential	all versions

- Fit the new O-ring on the differential cover.

- Position the flange in its housing in the differential and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Differential casing retaining flange (on support)	Bolt	M8	2.0	all versions (C514 gearbox)

1. Fit the new oil seal using tools (1a) and (1b).

Tool	Description	Function	Validity
1.870.629.000	Fitting tool	Fitting oil seal	all versions

Tool	Description	Function	Validity
1.870.007.000	Fitting tool	Fitting differential mount bearing outer racesFitting main shaft oil seal on gearbox to engine mountFitting oil seal on differential coverFitting bearing on differential	all versions

- Place the left and right differential inner driveshafts in their housings.- Apply sealant to the contact surfaces between the gearbox casing and the gear selector-engagement assembly cover.- Place the gear selection and engagement unit in position and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gear selector and engagement assembly (on gearbox casing)	Bolt	M8	2.0	all versions (C514 gearbox)

1. Fit inner non-slip bush (1a) using tool (1b).

Tool	Description	Function	Validity
1.870.633.000	Fitting tool	Fitting clutch thrust bearing control linkage inner bush	all versions

- Place the thrust bearing inner control linkage and the outer non-slip bush in position.- Place the clutch control outer lever back in its housing and secure it using the retaining ring.- Place a new clutch thrust bearing in its housing. - Remove the gearbox from the support tool for the overhaul stand.