323002168 - 2110B20 MANUAL GEARBOX (5-6 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS AND INTERNAL CONTROLS IF NECESSARY
Removing
(
Refitting
)
- Release the gearbox and differential from the support tool used for removing-refitting from the vehicle.| Tool | Description | Function | Validity |
|---|
| 1860873000 | Gearbox support | Removing-refitting gearbox from the vehicle | 1.4 8v1.4 16v TJET1.3 Multijet |
1. Fit gearbox and differential (1a) on overhaul stand (1b) using tool (1c). | Two mechanics are needed for this operation. |
| Tool | Description | Function | Validity |
|---|
| 1871000000 | Rotating stand | Overhaul gearbox | 1.3 Multijet1.4 16v TJET |
| Tool | Description | Function | Validity |
|---|
| 1871001014 | Gearbox support | Overhaul gearbox | |
2. Unscrew bolt (2a) and remove mileometer idler gear (2b).3. Undo bolts (3a) and remove rear cover (3b).
1. Undo bolts (1a) and remove gear selection/engagement device mounting bracket (1b).
1. Remove left differential internal driveshaft (1a) using the tool made up of brackets (1b), strut (1c) and mallet (1d).| Tool | Description | Function | Validity |
|---|
| 1840005308 | Brackets | Removing left differential internal driveshaft | 1.3 Multijet1.4 16v TJET |
| Tool | Description | Function | Validity |
|---|
| 1840005001 | Strut | Removing left differential internal driveshaftExtracting main shaft front bearingRemoving layshaft front bearing inner raceRemoving 4th speed drive gear and rear bearingRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gearRemoving main shaft front bearing | |
| Tool | Description | Function | Validity |
|---|
| 1840206000 | Mallet | Removing left differential internal driveshaft | 1.3 Multijet1.4 16v TJET |
- 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. Straighten 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 5th speed synchronizer rollers and springs retaining flange.4. Remove the 5th speed control fork.5. Remove the 5th speed engagement sliding sleeve.6. Remove the pre-synchronizer mountings.7. Remove the 5th speed engagement 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.12. Undo bolt (12a) and remove main and layshaft rear bearing retaining plate (12b).
1. Lock sleeve (1a) in the vice fitted with 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. |
1. Remove the main and layshaft rear bearing retaining rings.
1. Undo the plugs for positioning the gear control rods.2. Undo the reverse shaft bolt.3. Unscrew the reversing light switch.
1. Undo the bolts and remove differential flange (1a) complete with O-ring (1b), oil seal (1c) and thrust ring (1d).
1. Undo the bolts securing the gearbox casing to the manual gearbox bell housing.2. Position the gear selector/engagement lever downwards.3. Remove the gearbox casing using two screwdrivers for leverage by the special projections.
1. Undo bolts (1a) and remove reverse fork mounting bracket (1b).2. Unscrew the 3rd-4th speed fork bolt.3. Unscrew the 1st-2nd speed drive fork bolt.
1. Remove 1st-2nd speed drive rod (1a) together with fork (1b). | If the rod offers resistance during the extraction, the other rods (2a) and (3a) must be adjusted to move pawls (4) and (2b). |
2. Remove 3rd-4th speed drive rod (2a). | Work carefully to prevent pawl (2b) from accidentally coming out. |
3. Simultaneously remove 5th-reverse gear drive rod (3a) and 3rd-4th speed fork (3b).4. Remove the two gear engagement safety pawls.
1. Remove the main and layshaft assemblies at the same time.2. Remove the reverse idler gear.3. Remove the layshaft front bearing.4. Remove the differential assembly.5. Remove the magnet.
1. Remove the engine side oil seal for the manual gearbox bell housing.
1. Undo the gear control dog bolt.2. Remove pin (2a) using a suitable drift and remove gear control dog (2b).
1. Undo bolts (1a) and remove gear selector/engagement lever (1b).
- Proceed with dismantling the layshaft following the instructions given below.
1. Remove rear bearing (1a), 4th speed driven gear (1b) and the spacer between 3rd and 4th speeds (1c) using tools (1d) and (1e).| Tool | Description | Function | Validity |
|---|
| 1840005002 | Extractor | Removing layshaft rear bearingRemoving layshaft front bearing | |
| Tool | Description | Function | Validity |
|---|
| 1840005303 | Clamps | Removing layshaft rear bearingRemoving 3rd speed driven gear and 2nd speed driven gearRemoving 3rd and 4th speed engagement sliding sleeve hub, synchronizer ring and 3rd speed drive gear | |
1. Remove 3rd speed driven gear (1a) and 2nd speed driven gear (1b) using tools (1c) and (1d).| Tool | Description | Function | Validity |
|---|
| 1840005002 | Extractor | Removing layshaft rear bearingRemoving layshaft front bearing | |
| Tool | Description | Function | Validity |
|---|
| 1840005306 | Clamps | Removing 1st, 2nd and 3rd speed driven gearsDismantling main shaftRemoving layshaft front bearing | |
1. Remove the 2nd speed double cone synchronizer ring assembly.2. Remove the needle bearing for the 2nd speed driven gear.3. Remove the 1st-2nd and reverse engagement sliding sleeve.4. Remove the pre-synchronizer mountings.
1. Remove the retaining ring securing the 1st-2nd speed and Reverse sliding sleeve hub, using suitable pliers. | When refitting, replace the retaining ring. |
1. Remove 1st-2nd and reverse sliding sleeve hub (1a), 1st speed synchroniser ring assembly (1b) and 1st speed driven gear (1c) using tools (1d) and (1e).| Tool | Description | Function | Validity |
|---|
| 1840005002 | Extractor | Removing layshaft rear bearingRemoving layshaft front bearing | |
| Tool | Description | Function | Validity |
|---|
| 1840005306 | Clamps | Removing 1st, 2nd and 3rd speed driven gearsDismantling main shaftRemoving layshaft front bearing | |
2. Remove the needle bearing. | The layshaft front bearing inner race cannot be removed; if necessary, replace it together with the layshaft. |
- Proceed with dismantling the mainshaft following the instructions given below.1. Remove rear bearing (1a), shim (1b), 4th speed drive gear (1c), 4th speed drive gear needle bearing (1d), 4th speed drive gear bush (1e), 3rd and 4th speed sliding sleeve (1f), presynchroniser pads (1g) for the 3rd and 4th speed sliding sleeve hub, 4th speed synchroniser ring (1h), hub for the 3rd and 4th speed sliding sleeve (1i), 3rd speed synchroniser ring (1l) and third speed drive gear (1m) using tools (1n) and (1o).| Tool | Description | Function | Validity |
|---|
| 1840005002 | Extractor | Removing layshaft rear bearingRemoving layshaft front bearing | |
| Tool | Description | Function | Validity |
|---|
| 1840005306 | Clamps | Removing 1st, 2nd and 3rd speed driven gearsDismantling main shaftRemoving layshaft front bearing | |
2. Remove the needle bearing for the 3rd speed drive gear.
Refitting
(
Removing
)
- Proceed with washing and checking the condition of all the components.- Proceed with reassembling the mainshaft following the instructions given below.1. Fit the needle bearing for the 3rd speed drive gear.2. Fit the 3rd speed drive gear.3. Fit the 3rd speed synchroniser ring.4. Fit the 3rd and 4th speed sliding engagement sleeve hub.5. Fit the 3rd and 4th speed sliding engagement sleeve.6. Fit the pre-synchronizer mountings in their housings in the sliding sleeve hub.7. Fit the 4th speed synchroniser ring.
1. Fit the bush for 4th speed drive gear (1a) using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.3 Multijet1.4 16v TJET |
2. Fit the roller bearing for 4th speed drive gear (2a) and 4th speed drive gear (2b).
1. Fit rear bearing (1a) using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.3 Multijet1.4 16v TJET |
- Proceed with reassembling the layshaft following the instructions given below.1. Fit the needle bearing for the 1st speed driven gear.2. Fit the 1st speed driven gear.3. Fit three 1st speed synchronizer rings (3a), aligning fastenings (3b).
1. Fit the hub for the 1st and 2nd speed sliding sleeve using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1860945000 | Fitting tool | Fitting 4th speed drive gear bush/main shaft rear bearing/1st and 2nd speed sliding sleeve hubFitting bearing | 1.3 Multijet1.4 16v TJET |
- Fit a new 1st and 2nd speed sliding sleeve hub retaining ring.1. Fit the 1st-2nd and reverse engagement sliding sleeve.2. Refit the pre-synchronizer mountings in their housings in the 1st-2nd speed and reverse sliding sleeve hub.3. Fit the needle bearing for the 2nd speed driven gear.4. Fit three 2nd speed synchronizer rings (4a), aligning fastenings (4b) and (4c).5. Fit the 2nd speed driven gear.
1. Fit 3rd speed driven gear (1a) using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1870465000 | Fitting tool | Fitting 3rd speed driven gear/4th speed driven gear | 1.3 Multijet1.4 16v TJET |
1. Fit the spacer between the 3rd speed driven gear and the 4th speed driven gear.2. Fit 4th speed driven gear (2a) using tool (2b).| Tool | Description | Function | Validity |
|---|
| 1870465000 | Fitting tool | Fitting 3rd speed driven gear/4th speed driven gear | 1.3 Multijet1.4 16v TJET |
1. Fit rear bearing (1a) using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1870448000 | Fitting tool | Fitting layshaft rear bearingFitting layshaft front bearing inner race | 1.3 Multijet1.4 16v TJET |
1. Fit gear selector/engagement lever (1a) and secure it by tightening bolts (1b) to torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gear selection/engagement lever | Bolt | M8 | 2.1 ÷ 2.6 | 1.4 16v TJET |
1. Fit gear control dog (1a) and secure it using pin (1b) and bolt (1c).
1. Fit a new engine side oil seal (1a) for the manual gearbox bell housing using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1875016000 | Fitting tool | Fitting engine side oil seal for manual gearbox to engine supportFitting differential flange oil seal | 1.3 Multijet1.4 16v TJET |
1. Fit the magnet.2. Fit the layshaft front bearing.3. Fit the differential assembly.4. Fit the reverse idler gear. | Make sure that the gear engagement teeth are facing downwards. |
5. Fit the main and layshaft assemblies at the same time.- Fit the gear engagement safety pawls using a suitable drift.
1. Fit the 5th speed and reverse drive rod.2. Fit 3rd - 4th speed control fork (2a) and control rod (2b). | Place the safety pawl on the rod before fitting it in its housing. |
3. Fit 1st-2nd speed drive rod (3a) together with fork (3b). | To facilitate installation, move the 1st-2nd speed control rod in the arrowed direction. |
4. Tighten the bolts securing 1st-2nd speed control forks (4a) and 3rd-4th speed control forks (4b) to the specified torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| 1st and 2nd speed control fork | Bolt | M6 | 1.5 ÷ 1.9 | 1.4 16v TJET |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| 3rd and 4th speed control fork | Bolt | M6 | 1.5 ÷ 1.9 | 1.4 16v TJET |
5. Fit reverse control fork mounting bracket (5a) and secure it by tightening bolts (5b) to torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Reverse control fork mounting bracket | Bolt | M6 | 8.5 ÷ 11.1 | 1.4 16v TJET |
- Place all the gear control forks in neutral.- Apply sealant to the contact surfaces between the manual gearbox bell housing and the gearbox casing.- Fit the gearbox casing on the manual gearbox bell housing. | Keep the gear selector/engagement lever upwards and check that the gear selection dog engages in the 3rd-4th speed control fork. |
- Tighten the gearbox casing bolts to torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gearbox casing | Bolt | M8 | 2.1 ÷ 2.6 | 1.4 16v TJET |
- Fit the gear control rod positioning plugs.- Tighten the reverse shaft bolt to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Reverse shaft | Bolt | M8 | 2.9 ÷ 3.6 | 1.4 16v TJET |
- Fit the reversing light switch.- Fit the main and layshaft rear bearing retaining rings. | Position the retaining rings with their openings at the front to facilitate fitting. |
- Apply sealant to the contact surfaces between the gearbox casing and the main and layshaft rear bearing retaining plate.- Fit the main and layshaft rear bearing retaining plate and secure it by tightening the bolt to torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Main and layshaft rear bearings retaining plate | Bolt | M8 | 2.1 ÷ 2.6 | 1.4 16v TJET |
1. Fit 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 engagement sliding sleeve hub.6. Fit the 5th speed engagement sliding sleeve.7. Place the synchronizer mountings in their housings.8. Fit the 5th speed control fork.9. Fit the 5th speed synchronizer rollers and springs retaining flange.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 fitted with 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 bearing retaining plate and the rear cover.1. Fit rear cover (1a) and secure it by tightening bolts (1b) to torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Rear cover | Bolt | M8 | 2.1 ÷ 2.6 | 1.4 16v TJET |
2. Fit mileometer idler gear (2a) and secure it with screw (2b).
1. Position tool (1a), complete with dial gauge, on differential flange (1b) and measure distance "H" (flange height).| Tool | Description | Function | Validity |
|---|
| 1895655000 | Mount | Determining thickness of differential bearing scraper rings | |
1. Position tool (1a) complete with dial gauge on differential flange support surface (1b) and measure distance "P" (depth between differential flange support plane and bearing outer race (1c).)| Tool | Description | Function | Validity |
|---|
| 1895655000 | Mount | Determining thickness of differential bearing scraper rings | |
- Calculate thickness "S" of the differential bearing pre-loading thrust ring, using the following formula:S = P - H + 0.12 | 0.12 corresponds to the recommended interference for the bedding in and pre-loading of the differential bearings.After determining the exact thickness of the thrust ring, try and pick a ring as close to this thickness as possible from the spares provided If you cannot make up the exact thickness using one or more of the shims provided, fit the next size/s up. |
1. Place the differential bearing pre-loading thrust ring(s) in position.
1. Fit a new oil seal (1a) on differential flange (1b) using tool (1c).| Tool | Description | Function | Validity |
|---|
| 1875016000 | Fitting tool | Fitting engine side oil seal for manual gearbox to engine supportFitting differential flange oil seal | 1.3 Multijet1.4 16v TJET |
- Fit the differential flange and secure it by tightening the bolts to torque.- Fit the left differential inner driveshaft.- Fit the gear selection/engagement mounting bracket and secure it using the bolts.- Undo the fastenings and remove the gearbox and differential from the support tool. | Two mechanics are needed for this operation. |
| Tool | Description | Function | Validity |
|---|
| 1871001014 | Gearbox support | Overhaul gearbox | |
- Remove the support tool from the overhaul stand and replace.- Position the gearbox and differential on the tool used for removing-refitting from the vehicle.| Tool | Description | Function | Validity |
|---|
| 1860873000 | Gearbox support | Removing-refitting gearbox from the vehicle | 1.4 8v1.4 16v TJET1.3 Multijet |
