78158 - 2110A10 MANUAL GEARBOX and differential - R.R.

Refitting

    See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R.1. Undo the plug and drain the transmission fluid

Collect the gearbox oil in a suitable container.

1. Disconnect the electrical connections from the starter motor.

	Description	Connector
1	Starter motor	A020A

	Description	Connector
1	Starter motor	A020B

2. Undo the bolts (2a) and remove the starter motor (2b).

1. Disconnect the band for the left and right driveshafts secured to the differential and the intermediate driveshaft.

1. Undo the bolts (1a) and release the intermediate shaft (1b) from the differential.

- Lower the vehicle on the lift.1. Lift up the retaining spring (1a) and release the oil pipe (1b) for the hydraulic clutch release cylinder.2. Undo the nut (2a) and disconnect the earth lead (2b) from the gearbox.

1. Move the pin (1a) backwards until it is released from the housing in the bracket (1b).2. Press the two tabs (2a) and lift up the head (2b) until it is released from the ball joint.- Carry out the same operation on the other flexible cable.3. Release the two flexible cables and place them well away from the work area.4. Undo the nut fixing the starter motor wiring to the mounting bracket.

1. Undo the two upper bolts fixing the gearbox.

    See in Op. 1008A42 Power unit RIGID MOUNT - GEARBOX side - R and R1. Disconnect the electrical connection on the gearbox for the reversing lights switch.

	Description	Connector
1	Reversing lights switch	I020

1. Position the tool (1a) for supporting the bellhousing and secure it using the bolts (1b) to the openings in the gearbox and using the bolt (1c) to the gearbox bracket (1d).

	Description	Code	Function
1a	Support	1.870.826.000	Removing - refitting gearbox

2. Position the pin for the tool supporting the gearbox on a hydraulic lift.

1. Undo the lower bolts fixing the gearbox to the crankcase and to the oil sump.2. Move the jack backwards and extract the gearbox from its housing.- Check that the gearbox is balanced on the lift.

Refitting ( Removing ) - Place the manual gearbox and differential back in its housing using the hydraulic lift and the support tool.

	Description	Code	Function
.	Support	1.870.826.000	Removing - refitting gearbox

- Tighten the bolts and the nut fixing the manual gearbox and differential to the engine to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	8	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M12 X 1.25

	Value - daNm	Fastening	Component	Ø
.	5.5	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
.	8	Nut	MANUAL GEARBOX/DIFFERENTIAL	M12 X 1.25

- Undo the fixing bolts and remove the tool used for refitting the gearbox.- Connect the electrical connection on the gearbox for the reversing lights switch.

	Description	Connector
.	Reversing lights switch	I020

    See in Op. 1008A42 Power unit RIGID MOUNT - GEARBOX side - R and R- Connect the gearbox flexible control cables.- Tighten the nut fixing the starter motor wiring.- Connect the earth lead to the bellhousing.- Connect the oil pipe for the hydraulic clutch release cylinder and secure it using the retaining spring.- Raise the vehicle on the lift.- Position the intermediate driveshaft and secure it using the bolts.

	Value - daNm	Fastening	Component	Ø
.	0.8	Bolt	INTERMEDIATE DRIVE SHAFT	M6

- Position the starter motor and secure it tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.7	Bolt	STARTER MOTOR	M8

- Connect the electrical connections from the starter motor.

	Description	Connector
.	Starter motor	A020A

	Description	Connector
.	Starter motor	A020B

    See in Op. 0010T40 MANUAL GEARBOX OIL - Change    See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R.- Proceed with refitting the front suspension frame; carry out the appropriate operations    See in Op. 4410D10 Front suspension FRAME - R.R.    See in Op. 0010T20 Engine REFRIGERANT FLUID - Change