323001461 - 2110B42 5TH SPEED GEARS FOR MANUAL GEARBOX WITH DIFFERENTIAL - R+R WITH GEARBOX REMOVED

Removing ( Refitting ) 1. Undo bolts (1a) and remove rear cover (1b). - Engage any gear using the gear selection/engagement lever.1. Undo the bolt securing the 5th speed control fork to the main shaft.- 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 and loosen 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.3. Remove the retaining flange for the 5th speed synchronizer rollers and springs.4. Remove the 5th speed control fork.5. Remove the 5th speed sliding sleeve.6. Remove the pre-synchronizer mountings.7. Remove the 5th speed sliding sleeve hub.8. Remove the 5th speed synchroniser ring.9. Remove the 5th speed drive gear.10. Remove the needle bearing for the 5th speed drive gear.11. Remove the 5th speed drive gear bush. 1. Lock sleeve (1a) in the vice by interposing protective plates then use a brass drift (1b) alternately on the two ends of fork (1c) until it is released from the sleeve.

Take care not to nick the tapered part of the sleeve and the ends of the fork with the drift.

Refitting ( Removing ) 1. Remove the 5th speed drive gear bush.2. Fit the needle bearing for the 5th speed drive gear.3. Fit the 5th speed drive gear.4. Fit the 5th speed synchroniser gear.5. Fit the 5th speed sliding sleeve hub.6. Fit the 5th speed sliding sleeve.7. Place the synchronizer mountings in their housings.8. Fit the 5th speed control fork.9. Fit the retaining flange for the 5th speed synchronizer rollers and springs.10. Fit the 5th speed driven gear.11. Tighten the new ring nuts for the main and layshafts to torque.

Component	Fastening	dia	Value (daNm)	Validity
Main and layshaft ring nuts	Ring nut	M20	10.0 ÷ 12.4	1.4 16v TJET

12. Tighten the bolt for the 5th speed control fork to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
5th speed control fork	Bolt	M6	1.5 ÷ 1.9	1.4 16v TJET

1. Lock the sleeve in a vice by interposing protective plates.2. Position the fork so that the tapered part is in the same direction as that of the sleeve, resting it against the shoulder on the side where the sleeve diameter is smaller;- fit the fork manually, exerting the necessary pressure, until it is completely inserted in the sleeve.

When the fitting is complete, check that the sleeve can rotate freely inside the fork.

- Apply sealant to the contact surfaces between the main and layshaft rear bearings retaining plate and the rear cover.- Fit the rear cover and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rear cover	Bolt	M8	2.1 ÷ 2.6	1.4 16v TJET