2110B34 MANUAL GEARBOX (6 SPEED) AND DIFFERENTIAL - DISMANTLING AND REASSEMBLING - WASHING AND CHECKING COMPONENTS - REPLACING SYNCHRONIZERS, INTERNAL CONTROLS, SHAFTS AND BEARINGS, IF NECESSARY - Lancia - THESIS - eLearn

495367 - 2110B34 MANUAL GEARBOX (6 SPEED) AND DIFFERENTIAL - DISMANTLING AND REASSEMBLING - WASHING AND CHECKING COMPONENTS - REPLACING SYNCHRONIZERS, INTERNAL CONTROLS, SHAFTS AND BEARINGS, IF NECESSARY

) See in Op. 2110B26 MANUAL GEARBOX (6 speed) and differential - Dismantling and reassembly - Washing components - Replacing synchronizers and internal controls, if necessary1. Remove the layshaft front bearing outer race (1a) using tools (1b) and (1c).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.655.000	Removing layshaft front bearing outer race

	Description	Code	Function
1c	Mallet	1.840.206.001	Removing layshaft front bearing outer race

1. Remove the main shaft front bearing outer race (1a) using the tool (1b).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.658.000	Removing main shaft front bearing outer race

1. Remove the gear control rod bushes (1a) from the bellhousing using the tool (1b).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.657.000	Removing bushes in gear control rod housing for support joining gearbox to engine

1. Remove the gear control rod bushes (1a) and plugs (1b) from the gearbox casing using the tool (1c).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.657.000	Removing bushes in gear control rod housing and gearbox casing plugs.

1. Remove the gear engagement safety casing (1a) using a special extractor (1b).

1. Remove the gear selector shaft guide bush (1a) using a suitable tool (1b).

Refitting ( Removing

) - Apply the recommended sealant to a new guide bush for the gear shaft.

	Description	Qty.	Component	Type	Classification
.	Loctite 270	-	GUIDE BUSH FOR GEAR SELECTOR SHAFT	Sealant	-

1. Fit the new control rod bushes (1a) on the gearbox casing using the tool (1b).

- Apply the recommended sealant to the new gear control rod bushes.

	Description	Qty.	Component	Type	Classification
.	Loctite 270	-	GEAR ENGAGEMENT SAFETY CASING	Sealant	-

1. Fit the new gear engagement safety casing (1a) using a suitable tool (1b).

- Apply the recommended sealant to the new gear control rod bushes.

	Description	Qty.	Component	Type	Classification
.	Loctite270	-	GEAR CONTROL ROD HOUSING BUSHES	Sealant	-

1. Fit the new control rod bushes (1a) on the gearbox casing using the tool (1b).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.657.000	Fitting gear control rod housing bushes on gearbox casing.

- Apply the recommended sealant to a new gear engagement safety casing.

	Description	Qty.	Component	Type	Classification
.	Loctite 270	-	GEAR CONTROL ROD PLUGS	Sealant	-

1. Fit the new gear control rod plugs (1a) using a suitable fitting tool (1b).

- Apply the recommended sealant to the new gear control rod plugs.

	Description	Qty.	Component	Type	Classification
.	Loctite270	-	GEAR CONTROL ROD HOUSING BUSHES	Sealant	-

1. Fit the new gear control rod plugs (1a) using a suitable fitting tool (1b).

	Description	Code	Function
1b	Extractor/Fitting tool	1.870.657.000	Fitting gear control rod bushes on gearbox casing.

1. Fit the main shaft front bearing outer race (1a) using a hydraulic press and tools (1b) and (1c).

	Description	Code	Function
1a	Fitting tool	1.870.656.000	Fitting main shaft front bearing outer race

	Description	Code	Function
1b	Grip	1.874.365.000	Fitting main shaft front bearing outer race

1. Fit the layshaft front bearing outer race (1a) using a hydraulic press and tools (1b) and (1c).

	Description	Code	Function
1b	Fitting tool	1.870.656.000	Fitting main shaft front bearing outer race

	Description	Code	Function
1c	Grip	1.874.365.000	Fitting main shaft front bearing outer race

See in Op. 2110B26 MANUAL GEARBOX (6 speed) and differential - Dismantling and reassembly - Washing components - Replacing synchronizers and internal controls, if necessary

Removing ( Refitting

) 1. Fit the gearbox and differential (1a) on the overhaul stand using the tool (1b).

Two mechanics are needed for this operation.

	Description	Code	Function
1b	Support	1.871.001.014	Supporting gearbox on overhaul stand

1. Undo the bolts (1a), extract the retaining clip (1b) and remove the coaxial clutch cylinder (1c) complete with oil pipe.2. Extract the hydraulic clutch fluid duct from the lower part of the gearbox.3. Undo the inner bolt (3a) fixing the clutch casing (3b) to the gearbox casing.

- Rotate the gearbox casing through 180° on the overhaul stand.1. Undo the outer bolts fixing the clutch casing to the gearbox casing.2. Separate the gearbox casing from the clutch casing cutting the sealant using the special tool.

	Description	Code	Function
2	Blade	1.870.718.000	Removing gearbox casing-clutch casing sealant

3. Remove the gearbox casing (3a) from the clutch casing (3b).

1. Simultaneously extract the main shaft (A) (1a) and first layshaft (B) (1b) assemblies complete with 1st - 2nd aand 5th - 6th speed selector forks.

Keep the assemblies joined until they are placed on the workbench.

To allow quick identification, each shaft is given a corresponding letter: main shaft (A), first layshaft (B) and second layshaft (C), as shown in the diagram.

1. Extract the second layshaft (C) upwards together with 3rd - 4th speed and Reverse selector forks.2. Remove the differential assembly.

1. Take the gearbox casing support tool (1a) and take pins (1b) marked with the letter (A) corresponding to the letters (A) on the plate (1c).

The identification letters for the position of the pins are on the plate for the support tool; position (A) should be used for the gearbox casing support, positions (B) and (C) should be used for the clutch casing support.

	Description	Code	Function
1a	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

2. Place the gearbox casing (2a) on the support tool positioning as illustrated in the diagram, then secure it using the nuts (2b).

1. Remove the oil duct from the gearbox casing.2. Using pliers, remove the lubrication ducts by the main shaft and the layshafts.

The operation of removing the lubrication ducts destroys them, therefore new parts must be used when refitting.

3. Remove the main shaft and layshaft rear bearing outer race using a USAG 468/2 tool and USAG 468/7 extractor or equivalent tools.

To facilitate recognizing the seats for each of the shafts, the main shaft seat is identified in the diagram by the letter (A), the first layshaft seat by the letter (B) and the second layshaft seat by the letter (C). The extraction operation is the same for all three rear bearing outer races.

4. Remove the main shaft scraper ring (A), the first layshaft scraper ring (B) and the second layshaft scraper ring (C).

1. Remove the magnet collecting any impurities in the transmission fluid from the gearbox casing.2. Remove the main shaft and layshaft front bearing outer race using a USAG 468/2 tool and USAG 468/7 extractor or equivalent tools.

- Proceed with dismantling the main shaft (A) following the instructions given below.1. Position the main shaft (A) in a vice with protective jaws, then undo the bolt (1b) retaining the 4th speed drive gear (1c) and the 6th speed drive gear (1d).

1. Position the reaction plates on the press support surface and fit the main shaft (A) by the 4 th speed drive gear.

	Description	Code	Function
1	Half plate	1.860.837.000	Dismantling main shaft

2. Using a press fitted with a reaction pin (2a, remove the rear bearing (2b), the 6th speed drive gear (2c), the 4th spedd drive gear (2d) and the spacer (2e).

The main shaft (A) should be supported at the bottom during this operation.

	Description	Code	Function
2a	Reaction pin	1.870.899.100	Dismantling main shaft

1. Remove the 3rd and 5th speed drive gear (1a) using a hydraulic press, the plates (1b) and the reaction pin (1c).

The main shaft (A) should be supported at the bottom during this operation.

	Description	Code	Function
1b	Half plate	1.860.837.000	Dismantling main shaft

	Description	Code	Function
1c	Reaction pin	1.870.899.100	Dismantling main shaft

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); place the tools assembled in this way on the main shaft (A) front bearing and secure them using the nuts (1c).

	Description	Code	Function
1a	Extraction half-rings	1.870.899.200	Extracting main shaft front bearing

	Description	Code	Function
1b	Extractor	1.870.845.100	Extracting main shaft front bearing

2. Position the main shaft (A) complete with extraction tools, on the press support surface then extract the front bearing.

The main shaft (A) should be supported at the bottom during this operation.

- Proceed with dismantling the layshaft (B) following the instructions given below.1. Remove the 1st and 2nd speed selector fork (1a) and the 5th and 6th speed selector fork (1b) from the layshaft (B).

1. Position the reaction plates on the press support surface and fit the layshaft (B) by the 6 th speed driven gear.

	Description	Code	Function
1	Half plate	1.860.837.000	Dismantling layshaft (B)

2. Using a press fitted with a reaction pin (2a), remove the rear bearing (2b), the 6th speed driven gear (2c) and the needle bearing (2d).

The layshaft (B) should be supported at the bottom during this operation.

	Description	Code	Function
2a	Reaction pin	1.870.899.100	Dismantling main shaft

1. Remove the 6th speed synchronizer assembly.2. Remove the 5th - 6th speed engagement sliding sleeve.3. Remove the pre-synchronizer mountings.

1. Remove the 5th - 6th speed sliding sleeve hub circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the 5th - 6th speed sliding sleeve hub (1a), the 5th speed synchronizer rings (1b), the 5th speed driven gear (1c) using a hydraulic press and the plates (1e) and the reaction pin (1f).

	Description	Code	Function
1e	Half plates	1.870.899.400	Extracting hub for 5th-6th speed sliding sleeve

	Description	Code	Function
1f	Reaction pin	1.870.899.100	Dismantling layshaft (B)

2. Remove the needle bearing.

The layshaft (B) should be supported at the bottom during this operation.

1. Lift up the retaining ring (1a), then remove the thrust washers (1b) retaining the 2nd speed driven gear, releasing them from the housings (1c) in the layshaft (B).2. Remove the 2nd speed driven gear (2a), the needle bearings (2b), and the 2nd speed synchronizer rings (2c).3. Remove the 1th -2th speed engagement sliding sleeve.4. Remove the pre-synchronizer mountings.

1. Remove the 1th -2th speed sliding sleeve hub circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the 1st - 2nd speed sliding sleeve hub (1a), the 1st speed synchronizer rings (1b), the upper roller bearing (1c) for the 1st speed driven gear, the 1st speed driven gear (1d) using a hydraulic press and the plates (1e) and the reaction pin (1f).

	Description	Code	Function
1e	Half plates	1.860.837.000	Extracting hub for 1st-2nd speed sliding sleeve

	Description	Code	Function
1f	Reaction pin	1.870.899.100	Dismantling layshaft (B)

2. Remove the lower roller bearing for the 1st speed driven gear.

The layshaft (B) should be supported at the bottom during this operation.

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); place the tools assembled in this way on the layshaft (B) front bearing and secure them using the nuts (1c).

	Description	Code	Function
1a	Extraction half-rings	1.870.899.600	Extracting layshaft front bearing (B)

	Description	Code	Function
1b	Extractor	1.870.845.100	Extracting layshaft front bearing (B)

2. Position the layshaft (B) complete with extraction tools, on the press support surface then extract the front bearing.

The layshaft (B) should be supported at the bottom during this operation.

- Proceed with dismantling the layshaft (C) following the instructions given below.1. Remove the 3rd and 4th speed selector fork (1a) and the Reverse selector fork (1b) from the layshaft (C).

1. Position the reaction plates on the press support surface and fit the layshaft (C) by the 4 th speed driven gear.

	Description	Code	Function
1	Half plates	1.870.899.400	Dismantling layshaft (C)

2. Using a press fitted with a reaction pin (2a), remove the rear bearing (2b), the 4th speed driven gear (2c) and the needle bearing (2d).

The main shaft (A) should be supported at the bottom during this operation.

	Description	Code	Function
2a	Reaction pin	1.870.899.100	Dismantling layshaft (C)

1. Remove the 4th speed synchronizer assembly.2. Remove the 3th -4th speed engagement sliding sleeve.3. Remove the pre-synchronizer mountings.

1. Remove the 3th -4th speed sliding sleeve hub circlip using suitable pliers.

When refitting, replace the circlip.

1. Remove the 3th -4th speed sliding sleeve hub (1a), the 3th speed synchronizer rings (1b), the 3th speed driven gear (1c) using a hydraulic press and the plates (1d) and the reaction pin (1e).

	Description	Code	Function
1d	Half plates	1.860.837.000	Extracting hub for 3rd-4th speed sliding sleeve

	Description	Code	Function
1e	Reaction pin	1.870.899.100	Dismantling layshaft (C)

2. Remove the needle bearing.

The layshaft (C) should be supported at the bottom during this operation.

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); place the tools assembled in this way on the spacer between the 3rd - 4th speed gears and Reverse gears and secure them using the nuts (1c).

	Description	Code	Function
1a	Extraction half-rings	1.870.899.700	Extracting spacer on layshaft (C)

	Description	Code	Function
1b	Extractor	1.870.845.100	Extracting spacer on layshaft (C)

2. Position the layshaft (C) complete with extraction tools on the press support surface, then extract the spacer between the 3rd - 4th gears and the Reverse gears (2a) using the reaction pin (2b).

The layshaft (C) should be supported at the bottom during this operation.

	Description	Code	Function
2b	Reaction pin	1.870.899.100	Dismantling layshaft (C)

1. Remove the Reverse engagement sliding sleeve.2. Remove the pre-synchronizer mountings.

1. Remove the circlip retaining the Reverse sliding sleeve hub using suitable pliers.

When refitting, replace the circlip.

1. Remove the Reverse sliding sleeve hub (1a), the Reverse synchronizer rings assembly (1b), the Reverse driven gear (1c) using a hydraulic press and the plates (1d) and the reaction pin (1e).

	Description	Code	Function
1d	Half plates	1.860.837.000	Extracting hub for reverse gear sliding sleeve

	Description	Code	Function
1e	Reaction pin	1.870.899.100	Dismantling layshaft (C)

2. Remove the needle bearing.

The layshaft (C) should be supported at the bottom during this operation.

1. Remove the spacer positioned underneath the Reverse driven gear.

1. Fit the extraction half-rings (1a) in the housing in the extractor (1b); place the tools assembled in this way on the layshaft (C) front bearing and secure them using the nuts (1c).

	Description	Code	Function
1a	Extraction half-rings	1.870.899.500	Extracting layshaft front bearing (C)

	Description	Code	Function
1b	Extractor	1.870.845.100	Extracting layshaft front bearing (C)

2. Position the layshaft (C) complete with extraction tools, on the press support surface then extract the front bearing.

The layshaft (C) should be supported at the bottom during this operation.

- In the case of repairs to the differential, proceed as described below.1. Remove the differential rear bearing outer race from the gearbox casing using a USAG 468/2 tool and USAG 468/8 extractor or equivalent tools.2. Remove the differential scraper ring underneath.

1. Remove the left driveshaft differential internal shaft seal from the gearbox using a drift.

The operation of removing the seal destroys it, therefore a new seal is required when refitting.

1. Remove the differential front bearing outer race from the clutch casing using a USAG 468/2 tool and USAG 468/8 extractor or equivalent tools.

1. Remove the right driveshaft differential internal shaft seal from the clutch casing using a drift.

The operation of removing the seal destroys it, therefore a new seal is required when refitting.

See in Op. 2110D26 DIFFERENTIAL INTERNAL HOUSING BEARINGS - REPLACE WITH DIFFERENTIAL INTERNAL HOUSING REMOVED

Refitting ( Removing

) - If the following components are being replaced: differential assembly, differential front bearing, differential rear bearing, gearbox casing, the size of the washer for the differential bearing pre-loading must be determined in order to ensure that the alignment between the differential ring gear and the layshaft gears remains correct; proceed as described below.- Thoroughly clean the bearing and gearbox casing support surfaces. See in Op. 2110D26 DIFFERENTIAL INTERNAL HOUSING BEARINGS - REPLACE WITH DIFFERENTIAL INTERNAL HOUSING REMOVED1. Position the gearbox casing supported by the tool (1a) on the press support surface, fit the scraper ring (1b) removed previously in its seat and the differential rear bearing outer race (1c).

	Description	Code	Function
1a	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

2. Fit the rear bearing outer race using the drift (2a) and the grip (2b).

	Description	Code	Function
2a	Drift	1.870.898.500	Fitting differential rear bearing outer race

	Description	Code	Function
2b	Grip	1.870.898.400	Fitting differential rear bearing outer race

- Remove the gearbox casing from the support tool.

	Description	Code	Function
.	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

- Remove the clutch casing from the overhaul stand.1. Undo the pins marked with the letter (A) from the support tool (1a) and tighten the pins marked with the letters (B) and (C) in the respective openings (B) and (C); tighten the differential support shim (1b) directly onto the plate (1a).

	Description	Code	Function
1a	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

2. Place the clutch casing (2a) on the support tool positioning as illustrated in the diagram, then secure it using the nut (2b) and the pin (2c).

1. Position the clutch casing supported by the tool (1a) on the press support surface and fit the differential front bearing outer race (1b) in its seat.

	Description	Code	Function
1a	Gearbox casing/clutch casing support	1.870.897.700	Clutch casing support for determining bearing pre-loading

2. Fit the front bearing outer race using the drift (2a) and the grip (2b).

	Description	Code	Function
2a	Drift	1.870.898.500	Fitting differential rear bearing outer race

	Description	Code	Function
2b	Grip	1.870.898.400	Fitting differential rear bearing outer race

- Determine the size of the scraper ring for the differential bearing pre-loading; this procedure should be carried out without the shafts fitted on the gearbox casing.- Position the clutch casing on the overhaul stand.1. Position the differential on the clutch casing.2. Fit the gearbox casing (2a) and tighten the fixing bolts (2b) and (2c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(to clutch casing) 2.4	Bolt	GEARBOX GEAR CASING	M8

	Value - daNm	Fastening	Component	Ø
2c	(to clutch casing) 5	Bolt	GEARBOX GEAR CASING	M10

1. Fit the lower bush for the tool (1a) through the lower differential half-casing and the upper bush (1b) through the upper half-casing so that the teeth (1c) are matched with the openings (1d); lock the tools using the bolt (1e).

This operation prevents the internal rotation of the planet and satellite gears making them rotate with the differential casing.

	Description	Code	Function
1a	Splined shaft	1.870.898.200	Measuring differential casing rolling torque

2. Fit a torque meter on the tool to measure the rolling torque; rotate the differential through several revolutions and read the measurement taken by the equipment.

	Subject	Value
2	Differential complete with manual gearbox
-	Differential rolling torque	1.5-2.0

- If the differential rolling torque figure measured is within the range given in the table then the size of the differential bearing pre-loading shim fitted is correct.- If the differential rolling torque figure measured is less than the figure in the table, the differential bearing pre-loading shim has to be removed, following the instructions given previously, a larger shim fitted and the test for determining the differential rolling torque repeated until the figures are correct.- If the differential rolling torque figure measured is more than the figure in the table, the differential bearing pre-loading shim has to be removed, following the instructions given previously, a smaller shim fitted and the test for determining the differential rolling torque repeated until the figures are correct.

- Once the correct size shim for the differential bearing pre-loading has been determined, undo the fixing bolts and separate the gearbox casing from the clutch casing.- After having washed all the components thoroughly and checked them, reassembly the layshaft (C) following the instructions given below.1. Fit the spacer on the layshaft (C).2. Fit the reverse driven gear.3. Fit the needle bearing for the reverse driven gear.4. Fit the Reverse synchronizer ring assembly.

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

1. Fit the Reverse sliding sleeve hub (1a) using a hydraulic press and the half-plates (1b) and the fitting tool (1c).

Before fitting the sliding sleeve hub, align the housings for the pre-synchronizer mountings in the hub and the Reverse synchronizer rings.

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting hub for reverse gear sliding sleeve

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting hub for reverse gear sliding sleeve

1. Fit a new Reverse sliding sleeve hub circlip.2. Fit the pre-synchronizer mountings in their housings in the sliding sleeve hub.3. Fit the Reverse engagement sliding sleeve.

1. Fit the spacer between the Reverse gears and the 3rd - 4th speed gears (1a) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting spacer between reverse gears and 3rd-4th speed gears

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting spacer between reverse gears and 3rd-4th speed gears

1. Fit the 3st speed driven gear.2. Fit the needle bearing for the 3st speed driven gear.3. Fit the 3rd speed synchronizer assembly.

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

1. Fit the hub for the 3rd - 4th speed sliding sleeve (1a) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

Before fitting the sliding sleeve hub, align the housings for the pre-synchronizer mountings in the hub and the 3rd synchronizer rings.

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting hub for 3rd-4th speed sliding sleeve

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting hub for 3rd-4th speed sliding sleeve

1. Fit a new 3rd-4th speed sliding sleeve hub circlip.2. Fit the pre-synchronizer mountings in their housings in the sliding sleeve hub.3. Fit the 3rd -4th speed engagement sliding sleeve.4. Fit the 4th speed synchronizer assembly

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

5. Fit the 4st speed driven gear.6. Fit the needle bearing for the 4st speed driven gear.

1. Fit a new rear bearing (1a) on the layshaft (C) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting layshaft rear bearing (C)

	Description	Code	Function
1c	Fitting tool	1.860.824.000	Fitting layshaft rear bearing (C)

1. Rotate the layshaft (C) and place it in the press on the half-plates (1a) supported by the tool (1b).

	Description	Code	Function
1a	Half plates	1.860.837.000	Fitting layshaft front bearing (C)

	Description	Code	Function
1b	Fitting tool	1.860.824.000	Fitting layshaft rear bearing (C)

2. Fit a new front bearing (2a) on the layshaft (C) using the fitting tool (2b).

	Description	Code	Function
2b	Fitting tool	1.870.710.000	Fitting layshaft front bearing (C)

1. Position the Reverse selector fork (1a) on the sliding sleeve (1b).2. Position the 3rd - 4th speed selector fork (2a) on the Reverse selector fork and then on the 3rd - 4th speed sliding sleeve (2b).

Check that the synchronizers rotate freely without interference.

- After having washed all the components thoroughly and checked them, reassembly the layshaft (B) following the instructions given below.1. Fit the 1st speed lower roller bearing (inner chamber).2. Fit the 1st speed driven gear.3. Fit the 1st speed upper roller bearing (outer chamber).4. Fit the 1st speed synchronizer assembly.

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

1. Fit the hub for the 1rd -2th speed sliding sleeve (1a) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

Before fitting the sliding sleeve hub, align the housings for the pre-synchronizer mountings in the hub and the 1st speed synchronizer rings.

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting hub for 1st-2nd speed sliding sleeve

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting hub for 1st-2nd speed sliding sleeve

1. Fit a new circlip retaining the 1st - 2nd speed sliding sleeve hub.2. Fit the pre-synchronizer mountings in their housings in the sliding sleeve hub.3. Fit the 1rd -2th speed engagement sliding sleeve.4. Fit the 2nd speed synchronizer assembly.

Check that the synchronizer teeth are properly fitted in the grooves in the sliding sleeve hub.

5. Fit the 2st speed driven gear.6. Fit the needle bearing for the 2st speed driven gear.

1. Fit the thrust washers (1a), inserting the teeth (1b) in the seats (1c) in the layshaft (B).2. Fit the retaining ring.

1. Fit the needle bearing for the 5th speed driven gear2. Fit the 5th speed driven gear3. Fit the 5th speed synchronizer assembly.

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

1. Fit the hub for the 5rd -6th speed sliding sleeve (1a) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

Before fitting the sliding sleeve hub, align the housings for the pre-synchronizer mountings in the hub and the 5rd synchronizer rings.

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting hub for 5th-6th speed sliding sleeve

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting hub for 5th-6th speed sliding sleeve

2. Fit a new circlip retaining the 5st -6nd speed sliding sleeve hub.

1. Fit the pre-synchronizer mountings in their housings in the 5th - 6th speed sliding sleeve hub.2. Fit the 5rd -6th speed engagement sliding sleeve.3. Fit the 6th speed synchronizer assembly.4. Fit the 6st speed driven gear.

Check that the synchronizer teeth are properly fitted in the grooves in the gear.

5. Fit the needle bearing for the 6st speed driven gear.

1. Fit a new rear bearing (1a) on the layshaft (B) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting layshaft rear bearing (B)

	Description	Code	Function
1c	Fitting tool	1.860.824.000	Fitting layshaft rear bearing (B)

1. Rotate the layshaft (B) and place it in the press on the half-plates (1a) supported by the tool (1b).

	Description	Code	Function
1a	Half plates	1.860.837.000	Fitting layshaft front bearing (B)

	Description	Code	Function
1b	Fitting tool	1.860.824.000	Fitting layshaft rear bearing (B)

2. Fit a new front bearing (2a) on the layshaft (B) using the fitting tool (2b).

	Description	Code	Function
2b	Fitting tool	1.870.710.000	Fitting layshaft front bearing (B)

1. Position the 1st - 2nd speed selector fork (1a) on the sliding sleeve (1b).2. Position the 5th -6th speed selector fork (2a) on the 1st -2nd speed selector fork and then on the 5th - 6th speed seliding sleeve (2b).

Check that the synchronizers rotate freely without interference.

- After having washed all the components thoroughly and checked them, reassembly the main shaft (A) following the instructions given below.1. Fit a new front bearing (1a) on the main shaft (A) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting main shaft front bearing (A)

	Description	Code	Function
1c	Fitting tool	1.870.899.300	Fitting main shaft front bearing (A)

1. Fit the the 3rd -5th speed drive gear (1a) on the main shaft (A) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting 3rd-5th speed drive gear on main shaft (A)

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting 3rd-5th speed drive gear on main shaft (A)

1. Fit the spacer.2. Fit the 4th speed drive gear (2a) on the main shaft (A) using a hydraulic press and the half-plates (2b) and the fitting tool (2c).

	Description	Code	Function
2b	Half plates	1.860.837.000	Fitting 4th speed drive gear on main shaft (A)

	Description	Code	Function
2c	Extractor/Fitting tool	1.870.658.000	Fitting 4th speed drive gear on main shaft (A)

1. Fit the 6th speed drive gear (1a) on the main shaft (A) using a hydraulic press and the half-plates (1b) and the fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting 6th speed drive gear on main shaft (A)

	Description	Code	Function
1c	Extractor/Fitting tool	1.870.658.000	Fitting 6th speed drive gear on main shaft (A)

1. Fit a new rear bearing (1a) on the main shaft (A) using a hydraulic press and the half-plates (1b) and fitting tool (1c).

	Description	Code	Function
1b	Half plates	1.860.837.000	Fitting main shaft rear bearing (A)

	Description	Code	Function
1c	Fitting tool	1.860.824.000	Fitting main shaft rear bearing (A)

1. Place the main shaft (A) in a vice with protective jaws, then tighten the 6th speed drive gear retaining bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	4.5	Bolt	CLUTCH MAIN SHAFT SPLINING	M20 X 1.5

- Remove the clutch casing complete with differential from the overhaul stand.- Clean the clutch casing thoroughly.1. Place the clutch casing on the support tool (1a), positioning it as illustrated in the diagram by the pins (1b) marked with the letters (B) and (C) and tightened in the openings (B) and (C); then secure the clutch casing using the nut (1c) and the pin (1d).

	Description	Code	Function
1a	Gearbox casing/clutch casing support	1.870.897.700	Clutch casing support for fitting bearing outer races

2. Position the clutch casing supported by the tool on the press support surface and fit the main and layshaft front bearing outer races in the seats.3. Fit the front bearing outer faces using drifts (3a), (3b) and (3c) together with the grip (3d).

To allow quick identification, each shaft is given a corresponding letter: main shaft (A), first layshaft (B) and second layshaft (C), as shown in the diagram.

	Description	Code	Function
3a	Fitting tool	1.870.898.900	Fitting main shaft (A) front bearing outer race on clutch casing

	Description	Code	Function
3b	Fitting tool	1.870.898.700	Fitting layshaft (B) front bearing outer race on clutch casing

	Description	Code	Function
3c	Fitting tool	1.870.898.800	Fitting layshaft (C) front bearing outer race on clutch casing

	Description	Code	Function
3d	Grip	1.870.898.400	Fitting main and layshaft front bearing outer races on clutch casing

- Remove the clutch casing complete with differential from the support tool and secure it to the overhaul stand using the bracket.

	Description	Code	Function
.	Support	1.871.001.014	Supporting gearbox on overhaul stand

- Fit the magnet collecting any impurities in the transmission fluid to the gearbox casing.1. Place the layshaft (C) complete with 3rd - 4th speed and Reverse selector forks in the housing (C) in the clutch casing.

1. Place tthe main shaft (A) (1a) and layshaft (B) (1b) assemblies, complete with 1st -2nd speed and 5th - 6th speed selector forks in the housings (A) and (B) in the gearbox casing.

- If the one of the following components is being replaced: main shaft, gearbox components, main shaft (A) front bearing, main shaft (A) rear bearing, layshaft (B) assembly, layshaft (C) assembly, layshaft (B) rear bearing, layshaft (C) rear bearing, determine the size of the shims for the main shaft (A), layshaft (B) and layshaft (C) bearing pre-loading following the instructions given below.- Clean the gearbox casing, the bearing support surfaces and the surfaces joined with the clutch casing thoroughly.1. Place the gearbox casing (1a) on the support tool (1b) postioning it as illustrated in the diagram by the pins (1c) marked with the letter (A) tightened in the openings (A); then secure the gearbox casing using the nuts (1d).

	Description	Code	Function
1b	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

1. Position the 3 gauges (1a) by the corresponding openings in the rear bearing outer race housings (1b) in the gearbox casing.

There is a letter on each gauge identifying the corresponding reference shaft: the letter (A) identifies the main shaft, the letter (B) identifies layshaft (B) and the letter (C) identifies layshaft (C).

	Description	Code	Function
1a	Gauges	1.870.898.000	Determining main and layshaft bearing pre-loading

1. Fit the reference crossmember (1a) on the gearbox casing and secure it using the nuts (1b).

Position the reference crossmember as illustrated in the diagram so that it is correctly aligned with the gauges positioned by the shafts.

	Description	Code	Function
1a	Reference crossmember	1.870.897.800	Determining main and layshaft bearing pre-loading

- Determining gearbox casing height (shaft housing)1. Loosen the bolts (1a) located by each gauge; in this way the springs inside the gauges will placethe cylinders (1b) in contact with the bottom surface of the reference crossmember; lock the bolts loosened previously in this position.

- The height of the gauges in contact with the lower surface of the reference crossmember corresponds to the height of the gearbox casing.- Remove the reference crossmember and the gauges from the gearbox casing.1. Fit the three gauges (1a) on the tool plate (1b).

	Description	Code	Function
1a	Gauges	1.870.898.000	Determining main and layshaft bearing pre-loading

	Description	Code	Function
1b	Gauges support	1.870.897.900	Determining main and layshaft bearing pre-loading

1. Match the support for determining the bearing pre-loading complete with gauges (1a) to the mounting plate complete with gauges (1b).

Position the support for determining the bearing pre-loading as illustrated in the diagram so that the references A-A, B-B and C-C are aligned with the shafts.

	Description	Code	Function
1a	Support complete with gauges	1.870.897.100	Determining main and layshaft bearing pre-loading

	Description	Code	Function
1b	Gauges support	1.870.897.900	Determining main and layshaft bearing pre-loading

2. Fasten the support for determining the bearing pre-loading to the plate using special bolts.3. Zero the dial gauge pointers with a pre-loading of 3 mm for each gauge.

- Remove the support for determining the bearing pre-loading from the base plate complete with gauges.1. Position the support for determining the bearing pre-loading on the gearbox casing ensuring that pointer A- main shaft A, pointer B-layshaft B and pointer C-layshaft C are correctly matched.2. Fasten the support for determining the bearing pre-loading to the gearbox casing using special bolts.3. Rotate the main and layshafts through ten revolutions using the tool (3a) and a suitable crank (3b).

	Description	Code	Function
3a	Bush for main shaft counter-torque	1.870.899.000	Determining main and layshaft bearing pre-loading

- Measure the differences in relation to the main shaft (A), the layshaft (B) and the layshaft (C) using the three dial gauges.- To determine the size of the main shaft (A) scraper ring to be used from the ones available from spares, subtract 0.01-0.06 mm, corresponding to the endfloat of the main shaft (A) bearing from the difference measured.- To determine the size of the layshaft (B) and layshaft (C) scraper ring to be used from the ones available from spares, subtract 0.05-0.10 mm, corresponding to the value of the bearing pre-loading.- Remove the tool for determining the bearing pre-loading from the gearbox casing.1. Fit the lubrication duct.2. Fit the main shaft (A) scraper ring of the size calculated.3. Fit the main shaft rear bearing outer race (3a) on the gearbox casing supported by the tool (3b) using a hydraulic press, the fitting tool (3c) and the grip (3d).

	Description	Code	Function
3b	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

	Description	Code	Function
3c	Fitting tool	1.870.898.600	Fitting main and layshaft rear bearing outer races

	Description	Code	Function
3d	Grip	1.870.898.400	Fitting main and layshaft rear bearing outer races

- Fit the lubrication ducts, the scraper rings of the size calculated and the rear bearing outer races for layshaft (B) and layshaft (C), proceeding as illustrated for the main shaft (A) and using the same equipment.- Ti the oil duct in the gearbox casing.- Apply the recommended sealant to the entire matching surface between the gearbox casing and the clutch casing.

	Description	Qty.	Component	Type	Classification
.	Loctite 510	-	GEARBOX COMPONENTS	Sealant	-

- Remove the gearbox casing from the support tool.

	Description	Code	Function
.	Gearbox casing/clutch casing support	1.870.897.700	Gearbox casing support for determining bearing pre-loading

- Fit the gearbox casing and secure it to the clutch casing tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to clutch casing) 2.4	Bolt	GEARBOX GEAR CASING	M8

	Value - daNm	Fastening	Component	Ø
.	(to clutch casing) 5	Bolt	GEARBOX GEAR CASING	M10

1. Fit a new seal (1a) for the left driveshaft side differential internal shaft using the fitting tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.899.800	Fitting differential seal (left side)

- Turn the gearbox on the overhaul stand.1. Fit a new seal (1a) for the right driveshaft side differential internal shaft using the fitting tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.899.800	Fitting differential seal (right side)

- Tighten the inner bolt fixing the clutch casing to the gearbox casing to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to clutch casing) 5	Bolt	GEARBOX GEAR CASING	M10

- Position the coaxial clutch cylinder and secure it using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	(clutch casing) 1	Bolt	CLUTCH CONTROL HYDRAULIC ACTIVATOR	M6

- Insert the hydraulic clutch oil duct through the special opening in the lower part of the gearbox.- Lock the hydraulic clutch oil duct on the coaxial cylinder using the retaining clip.- Undo the fastenings and remove the gearbox and differential from the tool.

Two mechanics are needed for this operation.

	Description	Code	Function
.	Support	1.871.001.014	Supporting gearbox on overhaul stand

- Remove the support tool from the overhaul stand and put it down.