2110E20 REAR DRIVE IDLER CASING REMOVED - DISMANTLING AND REASSEMBLY - Alfa - 159 - eLearn

939005300 - 2110E20 REAR DRIVE IDLER CASING REMOVED - DISMANTLING AND REASSEMBLY

) 1. Fit the tool (1a) on the rear drive idler casing (1b) and place it in the vice.

Tool	Description	Function	Validity
2000010200	Support	Rear drive idler casing support	3.2 JTS

1. Undo the bolts (1a) fixing the spacer (1b) to the rear drive idler casing.2. Cut the sealant using the tool.

Tool	Description	Function	Validity
1870718000	Blade	Cut sealant

1. Remove the support (1a) complete with intermediate shaft (1b).- Remove the intermediate shaft oil seals from the rear drive idler casing and from the spacer.

1. Remove the cover from the rear drive idler casing (which destroys it in the process).

1. Position the reaction tool on the crown wheel and pinion main shaft.

Tool	Description	Function	Validity
2000007200	Reaction spanner	Locking rear drive idler casing main shaft	3.2 JTS

2. Using the tool, undo the ring nut fixing the crown wheel and pinion layshaft.

Tool	Description	Function	Validity
2000008800	Adapator	Loosen the rear drive idler casing layshaft ring nut	3.2 JTS

1. Undo the bolts (1a) fixing the lower cover (1b) and remove it from the rear drive idler casing.

1. Remove the seals for the crown wheel and pinion main shaft.

1. Remove the crown wheel and pinion main and layshafts.

- Remove the rear drive idler casing from the vice.1. Fit the tool on the idler flange and place it in the vice.

Tool	Description	Function	Validity
2000007000	Reaction spanner	Locking rear transmission idler flange	3.2 JTS

2. Undo the nut fixing the idler flange to the pinion.

- Undo the fixing bolts and remove the rear drive idler casing from the reaction spanner used previously.1. On the press, use the rear drive idler casing support tool (1a) to remove the pinion (1b) and the flange (1c).

Tool	Description	Function	Validity
2000010000	Support	Rear drive idler casing support	3.2 JTS

1. Remove the rear oil seal (1a) and the inner race (1b) for the pinion rear bearing.

- Remove the spacer (which can be distorted) from the pinion.- Remove the residues of sealant from the casing-rear drive idler casing cover and spacer matching surfaces.

Refitting ( Removing

) - Fit a new spacer (which can be distorted) on the pinion.- Refit the inner race for the pinion rear bearing.1. Using the tool (1a) fit the rear oil seal (1b) in its housing on the rear drive idler casing.

Tool	Description	Function	Validity
2000006500	Fitting tool	Fitting rear drive idler casing rear oil seal	3.2 JTS

1. Place the idler flange in its housing.

- Place the pinion, complete with new spacer (which can be distorted), in its housing.1. Fit the tool on the idler flange.

Tool	Description	Function	Validity
2000007000	Reaction spanner	Locking rear transmission idler flange	3.2 JTS

2. Using the special tool (2a), tighten the nut (2b) fixing the flange to the pinion until the recommended rolling torque is reached 2.2 - 2.5 Nm.- Apply LOCTITE 2701 to the thread of the nut.

The definitive tightening torque for the nut (2b) is reached at the end of the various attempts made to produce the recommended rolling torque.

- Fit the tool on the rear drive idler casing and place it in the vice.

Tool	Description	Function	Validity
2000010200	Support	Rear drive idler casing support	3.2 JTS

- Place the crown wheel and pinion main and layshafts in position.- Apply a bead of LOCTITE 5910 sealant to the cover - rear drive idler casing matching surfaces.- Place the cover in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing cover	Bolt	M8	2.8	3.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing cover	Bolt	M10	5.3	3.2 JTS

- Apply LOCTITE 2701 to the thread of the bolts.1. Using the tool (1a), fit the two new oil seals (1b) on the crown wheel and pinion main shaft, gearbox side.

Tool	Description	Function	Validity
2000006400	Fitting tool	Fitting rear drive idler casing crown wheel and pinion main shaft oil seals	3.2 JTS

1. Position the reaction tool on the crown wheel and pinion main shaft.

Tool	Description	Function	Validity
2000007200	Reaction spanner	Locking rear drive idler casing main shaft	3.2 JTS

2. Using the tool, tighten the ring nut fixing the crown wheel and pinion layshaft to the recommended torque.

Tool	Description	Function	Validity
2000008800	Adapator	Loosen the rear drive idler casing layshaft ring nut	3.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing layshaft ring nut	Nut	M35	25	3.2 JTS

- Apply LOCTITE 2701 to the thread of the ring nut.

- Press fit the cover of the ring nut tightened previously on the rear drive idler casing.1. Using the tool, fit the new oil seal inside the main shaft

Tool	Description	Function	Validity
2000006600	Fitting tool	Fitting oil seal inside rear drive idler casing main shaft	3.2 JTS

1. Using the tool (1a) fit the new oil seal (1b) on the intermediate shaft support.

Tool	Description	Function	Validity
2000006700	Fitting tool	Fitting oil seal on rear drive idler casing intermediate shaft support	3.2 JTS

- Apply a bead of LOCTITE 5910 sealant to the intermediate shaft support - rear drive idler casing matching surfaces.- Place the support complete with intermediate shaft in position and secure it to the rear drive idler casing tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing intermediate shaft support	Bolt	M10	5.3	3.2 JTS

- Undo the bolts and remove the rear drive idler casing from the support tool.