2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Fiat - LINEA - eLearn

323001448 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

) Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT1. Undo the bolts (1a) securing the clutch control actuator (1b) to the gearbox and move it aside and also detach the electric speedometer connector.

1. Disconnect the electrical connection for the reversing light switch.- Detach the electric speedometer connector.

	Description	Connector
1	Reversing light switch	See I020 REVERSING LIGHTS SWITCH

2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the gearbox.

1. Disconnect the gear selector and engagement cables.2. Retract the safety ring and disconnect the gear selector and engagement cables from the bracket.

1. Undo the nut fixing the air supply pipe from the heat exchanger to the intake manifold.2. Release the electrical wiring and the engine cooling system pipe from the bands on the air supply pipe from the heat exchanger to the intake manifold.3. Loosen the band and disconnect the rigid air supply pipe from the heat exchanger to the intake manifold, intake manifold side and remove it.

1. Unscrew the nut, fit the tool and disconnect the left steering link from the strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the left front shock absorber to the strut.3. Undo the bolt and remove the ABS sensor.

- Move back the left half-axle from the differential.- Proceed in the same way for the right side.1. Undo the bolts (1a) securing the intermediate driveshaft support (1b).- Withdraw the right driveshaft complete with intermediate driveshaft from the differential and secure to the steering box.

1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount

2. Fit the tools (2a) and (2b), then connect them to the engine mounting brackets using the links (2c).

Tool	Description	Function	Validity
1860851000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount

1. Undo the bolts fixing the flexible mounting to the gearbox side rigid power unit support.

Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. - Loosen the fastenings for the two rods for the engine support equipment so that the power unit is tilted and then facilitate the removal of the gearbox without adversely affecting the timing side flexible support.1. Undo the bolts (1a) and remove the damper mass (1b) from the gear selection/engagement device.

The bolts are pre-treated with sealant therefore they should be replaced each time they are refitted.

1. Undo the upper bolts fixing the manual gearbox and differential unit to the engine block.

- Fit the gearbox mounting brackets on the hydraulic jack.

Tool	Description	Function	Validity
1870847000	Brackets	Gearbox support

1. Position the hydraulic jack underneath the gearbox and secure the bracket to the gearbox as illustrated.- Undo the remaining bolts fixing the gearbox to the engine block.- Remove the gearbox by moving it away firstly from the engine and then lowering it using the hydraulic jack.

Refitting ( Removing

) - Place the gearbox and differential back in its housing using the hydraulic jack and the support tool.- Tighten the bolts and the nut securing the gearbox to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M10	3.6 ÷ 4.4	1.3 Multijet

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Nut	M12	4.8 ÷ 7.2

- Remove the brackets and the hydraulic jack supporting the gearbox.- Tighten the two rods in the equipment supporting the engine to restore the power unit to its original position.- Fit the damper mass for the gear selection/engagement device back in its housing and secure it using new bolts. Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. - Tighten the bolts fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Bolt	M12	6.3 ÷ 7.7	1.4 8v1.3 Multijet

- Remove the tools used for supporting the power unit safely.- Place the intermediate driveshaft in position and secure the support tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft bearing support	Bolt	M8	2.0 ÷ 2.4	1.3 Multijet

- Place the left driveshaft back in its housing.- Tighten the new bolts fixing the left front shock absorber to the steering knuckle to the recommended torque.

To tighten to torque, position the torque wrench on the nut and not on the bolt.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber - strut side	Bolt (to be replaced)	M12	10.3 ÷ 12.6 + 45°

- Connect the left arm from the steering box to the knuckle and tighten the nut to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rod to pillar	Nut	M10	3.6 ÷ 4.4

- Proceed in the same way for the right side.- Connect the battery earth lead to the gearbox and secure it using the bolt.- Reconnect the speedometer.- Connect the electrical connection for the reversing light switch.- Place the rigid air supply pipe to the intake manifold in position, connect it and tighten the bands and the intermediate fixing nut.- Connect the gear selection and engagement cables and secure them to the reaction bracket.- Place the clutch operating cylinder in its housing and secure it using the bolts. Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 0010T40 CHANGE MANUAL GEARBOX OIL