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

Removing ( Refitting ) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).
DescriptionConnector
-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. 1084A16 OIL DIPSTICK PIPE - R.R     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. 1. Release the vacuum intake pipe from the retaining collar.2. Undo the bolts (2a) and disconnect the air supply hose from the heat exchanger to the intake manifold (2b), throttle body side.
1. Undo the nut fixing the air supply pipe from the heat exchanger to the intake manifold.2. Release the retaining clip (2a) and disconnect the pipe between the damper and the clutch operating cylinder (2b), operating cylinder side.
Collect the bake/clutch fluid that comes out in a suitable container.
3. Disconnect the electrical connection from the reversing light switch.
DescriptionConnector
3Reversing lights switch    See I020 REVERSING LIGHTS SWITCH
1. Loosen the band and disconnect the air supply hose from the heat exchanger to the intake manifold, heat exchanger side. Then remove together with the rigid section.
1. Disconnect the gear selector cable.2. Disconnect the gear engagement cable.
1. Open the clips (1a) and release the gear selector and engagement cables (1b) from the mounting bracket.
- Undo the gearbox drain plug and collect the fluid in a suitable container.
Collect the transmission fluid in a suitable container.
Do not let the oil disperse into the environment as indiscriminate dispersion of this product causes pollution.
    Op. 4410A80 DAMPER LOWER FORK - R R (left side).1. Undo the nut (1a) and disconnect the upper left track control arm for the front suspension (1b) from the steering knuckle.
1. Disconnect the left driveshaft from the differential.
    Op. 4410A80 DAMPER LOWER FORK - R R (right side).1. Remove the two stakings and undo the nut (1a) securing the right front hub to the driveshaft using the tool (1b) for counter-torque.
ToolDescriptionFunctionValidity
1870815000Counter-torqueLoosen/ tighten nut securing front driveshaft to wheel hub
1. Undo the nut (1a) and disconnect the upper right track control arm for the front suspension (1b) from the steering knuckle.
1. Use the tool to move the right driveshaft back from the wheel hub.
ToolDescriptionFunctionValidity
2000001600ExtractorRetract driveshaft from front wheel hub
1. Loosen the bolts fixing the intermediate driveshaft to the mounting.2. Disconnect the intermediate driveshaft (2a) from the differential and remove it together with the right driveshaft (2b).
1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the starter motor.
DescriptionConnector
1bStarter motor    See A020 STARTER MOTOR
2. Undo the bolts (2a) and remove the starter motor (2b).
1. Fit the tool (1a) complete with support mountings (1b).
ToolDescriptionFunctionValidity
1820581000CrossmemberPower unit support
ToolDescriptionFunctionValidity
1870650000Support blocksPower unit support
2. Fit the tools (2a) and (2b), then connect them to the brackets on the engine using links (2c).
ToolDescriptionFunctionValidity
1860851003CrossmemberPower unit support
ToolDescriptionFunctionValidity
1870748000Vertical supportPower unit support
1. Undo the bolts fixing power unit gearbox side rigid support to the manual gearbox.
1. Undo the upper bolts fixing the manual gearbox to the engine block.
1. Fit the tool complete with hydraulic jack for removing the manual gearbox.
ToolDescriptionFunctionValidity
1870847000SupportRemoving/ refitting manual gearbox
1. Undo manual gearbox retaining bolts (1a) and nuts (1b).
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), (1b) and the nuts (1c) securing the manual gearbox to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearboxBoltM12(engine block side) 4.8 - 7.21.9 JTD 8V1.9 JTD 16V
ComponentFasteningdia  Value (daNm)Validity
Engine oil sumpBoltM10(gearbox side) 3.6 - 4.41.9 JTD 8V1.9 JTD 16V
ComponentFasteningdia  Value (daNm)Validity
Manual gearboxNutM12(engine block side) 4.8 - 7.21.9 JTD 8V1.9 JTD 16V
- Remove the tool complete with hydraulic jack used for removing the manual gearbox.
ToolDescriptionFunctionValidity
1870847000SupportRemoving/ refitting manual gearbox
1. Tighten the new bolts fixing the power unit gearbox side support to the manual gearbox to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox side power unit rigid supportBolt (to be replaced)M12(gearbox side) 6.3 - 7.7 + 45°
- Remove the tools used for supporting the engine.
ToolDescriptionFunctionValidity
1820581000CrossmemberPower unit support
ToolDescriptionFunctionValidity
1870650000Support blocksPower unit support
ToolDescriptionFunctionValidity
1860851003CrossmemberPower unit support
ToolDescriptionFunctionValidity
1870748000Vertical supportPower unit support
1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
STARTER MOTORBoltM8x452.2 ÷ 2.6
2. Connect the electrical connections (2a) to the starter motor and secure them using the nuts (2b).
- Connect the intermediate driveshaft complete with right driveshaft to the differential.- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Intermediate driveshaftBoltM6(support side) 0.7 - 1.1
- Place the right driveshaft in its housing on the hub and tighten a new nut to the recommended torque using the tool for counter-torque.
ComponentFasteningdia  Value (daNm)Validity
Front wheel hubNutM24(driveshaft side) see operation 4450C28
ToolDescriptionFunctionValidity
1870815000Counter-torqueLoosen/ tighten nut securing front driveshaft to wheel hub
1. Make two stakings on the nut collar as illustrated in the diagram.
1. Connect the upper right track control arm for the front suspension (1b) to the steering knuckle and tighten the nut (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Front suspension upper track control armsNutM10(steering knuckle side) 4.1 - 5.0
    Op. 4410A80 DAMPER LOWER FORK - R R (right side).