323003601 - 2110B34 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH, CHECK COMPONENTS, REPLACE SYNCHRONIZERS AND INTERNAL CONTROLS

Removing ( Refitting ) - Fit the gearbox on the overhaul stand using the tool.
ToolDescriptionFunctionValidity
1870001014MountGearbox support for overhaul stand1.3 Multijet MTA
    Op. 2127C35 HYDRAULIC UNIT/ELECTROHYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY - R.R. WITH GEARBOX REMOVED 1. Adjust the retaining clip and remove the three-way connector.2. Undo the bolts (2a) and remove clutch coaxial actuator (2b).
1. Undo the bolts (1a), remove the sealant, working at the three points (1b) and remove the gearbox casing (1c) from the clutch casing (1d).- Clean the support surfaces between the gearbox casing and the clutch casing thoroughly.
1. Using the tools (1a) and (1b) remove the outer races (1c) and the scraper rings (1d) for the main shaft and the layshafts.
ToolDescriptionFunctionValidity
1870655000ExtractorRemoving differential taper bearing race1.3 Multijet MTA
ToolDescriptionFunctionValidity
1840206001MalletRemoving bearing outer races1.3 Multijet MTA
1. Undo the bolt fixing the rear bearing to the main shaft using the special tool for counter-torque.
ToolDescriptionFunctionValidity
1870853000LeverMain shaft rotation1.3 Multijet MTA
2. Remove the main shaft (2a), the layshaft (2b) and the selector forks (2c) from their housing.3. Remove the second layshaft from its housing.
DISMANTLE THE CLUTCH CASING AS DESCRIBED BELOW.1. Using the tools (1a) and (1b) remove the outer races (1c) for the front bearings for the main shaft and the layshafts.
ToolDescriptionFunctionValidity
2000005400ExtractorRemoving bearing outer races1.3 Multijet MTA
ToolDescriptionFunctionValidity
1840206001MalletRemoving bearing outer races1.3 Multijet MTA
2. Remove the main shaft seal from the clutch casing.
1. Using extractor (1a) and a suitable mallet (1b), remove the bearing for gear selector shaft (1c).
ToolDescriptionFunctionValidity
1840207812ExtractorRemoving bearings1.3 Multijet MTA
PROCEED WITH DISMANTLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 6th speed gear (1d), the 4th speed gear (1e) and the spacer (1f).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
2000004700Fitting toolRemoving/Refitting bearings1.3 Multijet MTA
1. On the hydraulic press, using the tools (1a) and (1b), remove the 3rd and 5th speed drive gear (1c) from the main shaft (1d).
The main shaft should be supported at the bottom during this operation.
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
2000004700Fitting toolRemoving/Refitting bearings1.3 Multijet MTA
1. On the hydraulic press, using tools (1a), (1b) and (1c), remove front bearing (1d).
The main shaft should be supported at the bottom during this operation.
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1846017000Half-ringsHalf-rings for reaction in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1846001001Half-ringsHalf-rings for removing bearing1.3 Multijet MTA
PROCEED WITH DISMANTLING THE LAYSHAFT (B) AS DESCRIBED BELOW.1. Remove the gear selector forks (1a) from the layshaft (1b).2. Remove the rear bearing circlip.
1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 4th speed gear (1d) and the needle bearing (1e).
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1870447000Reaction pinRemoving bearing1.3 Multijet MTA
1. Remove the 4th speed synchronizer ring assembly.2. Remove the 3rd and 4th speed sliding engagement sleeve.3. Remove the pre-synchronizer mountings.
1. Remove the sliding sleeve hub circlip.
1. Remove the 3rd and 4th speed sliding sleeve hub (1a), the 3rd speed synchronizer ring assembly (1b) and the 3rd speed driven gear (1c) using a hydraulic press and tool (1d).
The layshaft should be supported at the bottom during this operation.
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
2. Remove the needle bearing.
1. Remove the spacer circlip.
1. On the press, using the tool (1a), remove the spacer (1b), the presynchronizer mountings (1c), the sliding sleeve (1d), the reverse synchronizer rings (1e), the reverse gear (1f) and the needle bearing (1g).
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
1. Remove the front bearing circlip.
1. At the press, remove the front bearing using a suitable extractor.
The layshaft should be supported at the bottom during this operation.
DISMANTLE THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.1. Remove the circlip.
1. On the press, using tool (1a), remove 6th speed gear and bearing (1b) and needle bearing (1c).
The second layshaft should be supported at the bottom during this operation.
ToolDescriptionFunctionValidity
2000004700Fitting toolRemoving/Refitting bearings1.3 Multijet MTA
1. Remove the synchronizer circlip.
1. On the press, using the tool (1a), remove the 5th and 6th speed synchronizer (1b) and the 5th speed gear (1c).
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
1. Release the needle bearing (1a) and remove the spacer (1b), the two half rings (1c), the 2nd speed gear and the needle bearing (1e).
1. Remove the circlip (1a) and the 1st and 2nd speed synchronizer rings (1b).
1. On the press, using the tool (1a), remove the 1st and 2nd speed synchronizer (1b) and the 1st speed gear (1c).
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
1. Remove the bearing with a double row of rollers.
1. At the press, remove the front bearing using a suitable extractor.
The second layshaft should be supported at the bottom during this operation.
Refitting ( Removing ) REASSEMBLE THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.
If the bearing, 1st speed gear or the presynchroniser are replaced, the thickness of the new circlip must be calculated as described below.Calculate the difference in thickness between the old and new components.The value of the difference should be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted.A circlip set is available from Parts.
1. Position the two bearings (1a), the 1st speed gear (1b), the 1st and 2nd speed synchronizer rings (1c) and the ring nut (1d) on the second layshaft and fit them on the hydraulic press.
1. Fit the sleeve and three presynchronizer mountings (1a), the 1st and 2nd speed synchronizer rings (1b) and the circlip (1c).
1. Position the bearing (1a), the 2nd speed gear (1b), the two half rings (1c), the spacer (1d), the needle bearing (1e), the 5th speed gear (1f) and the 5th and 6th speed synchronizer assembly on the second layshaft and fit them on the hydraulic press.
1. Fit the circlip (1a), the needle bearing (1b) and the 6th speed gear (1c).
If the rear bearing is replaced, calculate the thickness of the calibrated circlip as described below.Calculate the difference in thickness between the new and the old rear bearing and add this difference to or subtract it from the thickness of the removed circlip.A circlip set is available from Parts.
1. Fit the rear bearing at the press.
1. Fit the rear bearing circlip.
PROCEED WITH REASSEMBLING THE LAYSHAFT (B) AS DESCRIBED BELOW.
If the thrust bearing is replaced, calculate the thickness of the new calibrated circlip as described below.Calculate the difference in thickness between the old and new thrust bearing. The value of the difference should be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted. A retaining ring kit is available as a spare.
1. On the press, use tools (1a) and (1b) to fit the thrust bearing (1c).
ToolDescriptionFunctionValidity
2000005000PlateReaction plate in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1870658000Fitting toolFitting bearing1.3 Multijet MTA
2. Fit the circlip (2a), the needle bearing (2b), reverse gear (2c) and the synchronizer ring (2d).
1. At the press, using tool (1a), fit synchronizer sliding sleeve (1b).
ToolDescriptionFunctionValidity
1870658000Fitting toolFitting bearing1.3 Multijet MTA
1. At the press, using tool (1a), fit spacer (1b).
ToolDescriptionFunctionValidity
1870658000Fitting toolFitting bearing1.3 Multijet MTA
1. Fit a new circlip (1a), the three presynchronizer mountings (1b), the sliding sleeve for reverse gear (1c), the needle bearing (1d), the 3rd speed gear (1e) and the three synchronizer rings (1f).
1. At the press, using tool (1a), fit synchronizer ring nut (1b). Make sure that the teeth shown in the diagram are in the correct position.
ToolDescriptionFunctionValidity
1870658000Fitting toolFitting bearing1.3 Multijet MTA
1. Fit the synchronizer circlip.
1. Fit three presynchronizer mountings (1a) and sleeve (1b) complete with seals (1c).
1. Fit the needle bearing (1a) and the 4th speed gear (1b).2. At the press, using tool (2a), fit rear bearing (2b).
ToolDescriptionFunctionValidity
1870658000Fitting toolFitting bearing1.3 Multijet MTA
1. Fit a new circlip (1a) retaining the rear bearing and position the forks (1b) on the layshaft (1c).
If the rear bearing or the 4th speed gear is being replaced, the thickness of the new circlip must be calculated in the way described below. Calculate the difference in size between the new and old components. This value be added to or subtracted from the thickness of the circlip removed to determine the thickness of the new circlip that should be fitted. A retaining ring kit is available as a spare.
PROCEED WITH REASSEMBLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.1. At the press, using tools (1b) and (1c), fit front bearing (1a).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1860945000Fitting toolFitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing1.3 Multijet1.4 16v TJET
1. On the press, using the tools (1b) and (1c), fit the 3rd and 5th speed drive gear (1a).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1860945000Fitting toolFitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing1.3 Multijet1.4 16v TJET
1. Fit the spacer.2. On the press, using the tools (2b) and (2c), fit the 4th speed drive gear (2a).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1860945000Fitting toolFitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing1.3 Multijet1.4 16v TJET
1. On the press, using the tools (1b) and (1c), fit the 6th speed drive gear (1a).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1860945000Fitting toolFitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing1.3 Multijet1.4 16v TJET
1. At the press, using tools (1b) and (1c), fit rear bearing (1a).
ToolDescriptionFunctionValidity
1860837000PlatePlate for support in the press1.3 Multijet MTA
ToolDescriptionFunctionValidity
1860824000Fitting toolFitting bearing1.3 Multijet MTA
REASSEMBLE THE CLUTCH CASING AS DESCRIBED BELOW.1. Fit main shaft front bearing outer race (1a) using tools (1b) and (1c).
ToolDescriptionFunctionValidity
2000005100Fitting toolFitting bearing1.3 Multijet MTA
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer races
1. Fit layshaft front bearing outer races (1a) using tools (1b) and (1c).
ToolDescriptionFunctionValidity
2000004600Fitting toolFitting bearing1.3 Multijet MTA
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer races
1. Fit the bearing for gear selector and engagement shaft (1a) in its housing using tools (1b) and (1c).
ToolDescriptionFunctionValidity
2000004900Fitting toolFitting bearing1.3 Multijet MTA
ToolDescriptionFunctionValidity
1874365000GripFitting bearing1.3 Multijet MTA
- Fit the main shaft and the two layshafts complete with forks in their housings in the clutch casing. DETERMINE THE SIZE OF THE THRUST RINGS AS DESCRIBED BELOW.1. Tighten the main shaft rear bearing retaining bolt to the recommended torque using the special tool for counter-torque.
ToolDescriptionFunctionValidity
1870853000LeverMain shaft rotation1.3 Multijet MTA
ComponentFasteningdia  Value (daNm)Validity
Main shaft rear bearingBoltM8x1.55.0 ÷ 7.01.3 Multijet MTA
2. Fit the outer races on the gearbox shafts.
1. Tighten the rods with the spacers on the clutch casing.2. Fit the three gauges on the three gearbox shafts.
ToolDescriptionFunctionValidity
2000002000Gearbox overhaul kitCalculating thickness of thrust rings1.3 Multijet MTA
3. Fit gearbox casing (3a) on the rods fitted previously and tighten nuts (3b) to a torque of 25 Nm, starting with tightening the nuts near the locating bushes.4. Rotate the main and layshafts through about twenty revolutions using the special tool.
ToolDescriptionFunctionValidity
1870853000LeverMain shaft rotation1.3 Multijet MTA
5. Measure the gap between the two cylinders for each of the three shafts using a feeler gauge.- Determine the size of the new thrust ring for the main shaft (A) by subtracting the maximum permitted clearance of 0.10 mm from the reading taken previously using the feeler gauge.- Determine the size of the new thrust ring for the layshaft (B) by adding the maximum pre-loading of 0.20 mm to the reading taken previously using the feeler gauge.- Determine the size of the new thrust ring for the second layshaft (C) by adding the maximum pre-loading of 0.30 mm to the reading taken previously using the feeler gauge.
- Remove the gearbox casing and all the components for the tool from the clutch casing.1. Fit the gearbox casing (1b) on the tool (1c) using two nuts (1a) taking care to position the three studs (1d) by the three shaft housings.
ToolDescriptionFunctionValidity
2000005700Support frameGearbox casing - fitting bearing outer races on gearbox casing1.3 Multijet MTA
1. Fit three new thrust rings (1a) and the outer races for main and layshaft rear bearings (1b) using tools (1c) and (1d).
ToolDescriptionFunctionValidity
2000005200Fitting toolGearbox casing - fitting bearing outer races on gearbox casing1.3 Multijet MTA
ToolDescriptionFunctionValidity
1870007000GripFitting differential mount bearing outer races
- Apply the LOCTITE 510 sealant to the entire matching surface between the gearbox casing and the clutch casing.- Remove the gearbox casing from the support tool and fit it on the clutch casing tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox casingBoltM82.21.3 Multijet MTA
1. Fit a new main shaft sealing ring on the clutch casing using the special fitting tool.
ToolDescriptionFunctionValidity
2000004800Fitting toolFitting main shaft sealing ring1.3 Multijet MTA
- Fit the clutch control coaxial actuator to the clutch casing, tightening the bolts.- Connect the three-way connector to the oil pipe for the coaxial actuator and to the clutch casing.    Op. 2127C35 HYDRAULIC UNIT/ELECTROHYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY - R.R. WITH GEARBOX REMOVED - Undo the fastenings and remove the gearbox and differential from the support tool.- Remove the support tool from the overhaul stand.