2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Alfa - 159 - eLearn

939010726 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R 1. Undo the plug and drain the transmission fluid.

Collect the transmission fluid in a suitable container.

- Replace the brake-clutch fluid reservoir plug using the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake-clutch fluid reservoir cap

1. Release the retaining clip (1a) and disconnect the pipe (1b) between the damper and the clutch operating cylinder (1b), operating cylinder side.2. Undo the bolt (2a) and disconnect the earth lead (2b) (connector B) from the gearbox.

	Description	Connector
2b	Earth on engine	See C002 BATTERY EARTH ON ENGINE

1. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

1. Disconnect the gear selector cable.2. Disconnect the gear engagement cable.

1. Unscrew the bolts (1a) and move aside the bracket (1b) complete with gear selection and engagement cables (1c).

1. Undo the nuts fixing the exhaust manifold and catalytic converter to the cylinder head.

1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support

2. Fit the tools (2a) and (2b), then connect them to the bracket fitted previously on the engine using the rod (2c).

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support

1. Undo the bolts fixing power unit gearbox side rigid support to the manual gearbox.2. Undo the bolts fixing the gearbox side support flexible mounting to the bodyshell.3. Remove the gearbox side support flexible mounting (3a), complete with rigid support (3b).

1. Undo the upper bolts fixing the manual gearbox to the engine block.

1. Undo the bolts fixing the exhaust manifold and the catalytic converter to the mounting bracket.2. Remove the exhaust manifold and catalytic converter.

1. Disconnect the left driveshaft from the differential, move it to the side and secure it to the underbody.

1. Undo the bolts (1a) and remove the intermediate driveshaft (1b) from the differential and secure it to the underbody.

1. Fit the tool complete with hydraulic jack for removing the manual gearbox.

Tool	Description	Function	Validity
1870847000	Support	Removing/ refitting manual gearbox

2. Undo the bolts fixing the engine block sump to the manual gearbox.3. Undo the remaining bolts fixing the manual gearbox to the engine block.

1. Detach the manual gearbox and differential from the engine, then carefully lower the hydraulic jack.

Refitting ( Removing

) - Carefully raise the manual gearbox and differential using the hydraulic jack.- Align the manual gearbox and tighten it evenly to the engine.

Before fitting the manual gearbox to the engine, apply a thin layer of lubricating grease to the shaft teeth.

1. Tighten the bolts (1a) and (1b) securing the manual gearbox to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Bolt	M12	(engine block side) 4.8 - 7.2	1.9 JTS2.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M8	(gearbox side) 3.6 - 4.2	1.9 JTS2.2 JTS

The manual gearbox and differential at the bench is illustrated in the diagram to give a better representation of the fixing bolts.

- Remove the tool complete with hydraulic jack used for removing the manual gearbox.1. Connect the intermediate driveshaft (1a) to the differential and secure it to the support tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft	Bolt	M6	(support side) 0.7 - 1.1

- Connect the left driveshaft to the differential.- Place the exhaust manifold and catalytic converter in its housing.

Ensure the gasket is present and correctly positioned.

- Tighten the bolts fixing the exhaust manifold and the catalytic converter to the mounting bracket.1. Remove the gearbox side support flexible mounting (1a), complete with rigid support (1b).2. Tighten the bolts fixing the gearbox side support flexible mounting to the bodyshell to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting	Bolt	M10	(bodyshell side) 5.4 - 6.6

3. Tighten the new bolts fixing the power unit gearbox side support to the manual gearbox to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support	Bolt (to be replaced)	M12	(gearbox side) 6.3 - 7.7 + 45°

- Remove the tools used for supporting the engine.

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support

1. Tighten the nuts fixing the exhaust manifold and catalytic converter to the cylinder head to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold with catalytic converter	Nut	M8	(cylinder head side) 2.2 - 2.6	1.9 JTS2.2 JTS

1. Refit the bracket (1a) complete with gear selection and engagement cables (1b) and secure them tightening the bolts (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gear selection-engagement cables mounting bracket	Bolt	M8	(gearbox side) 1.9 - 2.9

- Connect the gear selector and engagement cables.- Connect the electrical connection to the reversing light switch.- Connect the earth lead to the gearbox and secure it using the bolt.- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.- Support the tool with the brake-clutch fluid reservoir plug.

Tool	Description	Function	Validity
2000001400	Plug	Brake-clutch fluid reservoir cap

1. Tighten the manual gearbox oil drain plug to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox oil drain plug	-	-	1.7 (gearbox side)

Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY - Connect the negative battery terminal.- Remove the vehicle from the lift.