Pex GEARBOK. DIFFERENTIAL 13-4 GROUP 13 tess GEARBOxX - DIFFERENTIAL INDEX ; GEARBOX TECHNICAL CHARACTERISTICS AND - = DESCRIPTION -() SPECIFICATIONS ..... ' 137 — REMOVING AND REFITTING..... 13-2 | - TECHNICALCHARACTERISTICS . 13-7 ~ DIS-ASSEMBLY . - (*) - Gearbox ratios ..........6. eee 13-7 = CHECKS & INSPECTIONS -() — GENERAL SPECIFICATIONS ..... 13-7 — RE-ASSEMBLY -@) ~ Fluids and lubricants ..... - Sealants and achesives... OS OROONE @) — CONTROLS AND ADJUSTMENTS . 13-7 7 . + Differential ..... 5.0. 2e0eeees 13-7 = SwonTacsio 7 — TIGHTENING TORQUES 13-8 ~ VERIFICHE E CONTROLLI....... (+) - SPECIALTOOLING .. For all the parts not mentioned herein, see the corresponding Group of the manual "155 - INSTRUCTIONS FOR REPAIR" - PA465500000000 - (pages with publication no PA4655C1000000) \ (+) See publication PA494200000000. "Instructions for Repair - OVERHAULING OF MECHANICAL UNITS" referring to overhauling of Gearbox C.510.5.XX.YY. Padg7BC116V003bs GEARBOX UNIT REMOVAL AND REFITTING = Setthe car on a lit. = Remove the front wheels with gravel guards. Remove the battery after disconnecting the termi nals. Remove the cougated intake pive between the cleaner and throttle, ater cisconnecting the air-fiow meter. Remove the battery tray alter separating the two injection retay support brackets. GEARBOX - DIFFERENTIAL 13-2 1, Disconnect tne reversing switch and speedometer ‘sensor connections from the gearbox. 2, Slacken the two screws and remove the clutch cy- linder from the gearbox, moving it upwards: the cylinder remains restrained by the pipe leasing from the clutch pump. fis= 16 Nm [1.9 + 1.6 Kem) pes GEARBOX 1. Remove the heater pipe fastening clamps trom the throttle body. 2. Aiter removing the cover, disconnect the lambda probe connection disconnecting it from its stay clamp. cy I 1. Slacken the two uoper screws fastening the gearbox tothe engine, PAa978C116VODI - DIFFERENTIAL Be [75292 Nm 1 17.6 = 9.4 Kgm| Remove the front grile (Group 75). |. Disconnect the hom fastening bracket. Position engine supportino.1.820.226.000, with sup- Ports 1. 820,239.000 and crossmember 41.820.581.000. Place a support square on the front of the crankcase. Place a support square on the rear of the erankease, between two injectors. Place @ chain between the two squares and the Support, hooking the engine to the supoort. (meee 4=e GEAnGOX - DIFFERENTIAL ~ Raise te car, 1, Slacken the plug and drain the gearbox-iferential ol into a sutable recipient, 2. Disconnect tne gearbox earth cable, Remove the reinforcement under the exhaust pipe. 2. Disconnact the exhaust pipe fastening bracket. 3. Remove the exnaust pipe, front section. , ~) \ NOTE: carefully retrieve the lambda probe wiring to avoid tearing or damaging it. 1 1 13-4 On both sides, slacken the two screws fastening the Slacken the two screws fastening the power steering to the front cross member. 2. Slacken the four front nuts and loosen the other screws fastening the gearshift controls support, which needs to be lowered slightly to enable release from the front crossmember, = GEARBOX- DIFFERENTIAL 1. Remove the engine rear support. 2. Position 2 suitable hydraulic jack under the cross- member 3. Slacken the six rear screws fastening the cross- member to the body, 1. Slacken the two front screws fastening the cross- member to the body. 2. Lower the front crossmember and remove it. PAs97BC116V001 p2stisNm | Joa: 115 Kom 1. Slacken the six iastening bolts and disconnect the left CN. joint of the differential axle shat. 2. Disconnect the thee gearshift control rods.bes cenRbog: Home neNTiAL 13-6 1. Stacken the three screws fastening tne starter motor to the gearbox. 1. Slacken the fours screws fastening the rear gearbox support to the gearbox. 2. Slacken the bolt fastening the support to the body and remove it. (a2=51 Nm 14.345.2 Kgm| PAsOrEC 1. Slacken the two lower gearbox cover fastening ‘screws and in their place insert bracket no 1.820.623.001 with support no, 1.820.208.000 NOTE: use screws slightly longer than those removed 2. Add a suitably-sizad bott in the hole on the right. 3, Slacken the two screws fastening the lower cover. 4. Slackenthe bot fastening the gearbox tothe engine. i75+82Nm | 1.620.623.001 17.6 + 9.4 Kgm| 1. Siacken the nut festering the gearbox to the engine. 2. Lower the geatbox disconnecting it from the engine. FE eesakomiq] TTT = Sea DARREL 13-7 TECHNICAL CHARACTERISTICS AND SPECIFICATIONS TECHNICAL CHARACTERISTICS GEARBOX RATIO Version Axle ratio Gear engeged Gearbox ratio Total ratio 17/57 na 121.620 1: 5.096 nee 123.353 an 121.156 1: 3.876 Shas Soonlnais teen | RM. % s se itr x oa ee x | 5 é “s : A67ASP 20168 nk “ | a a | > em | “om m OS z z { RM (*): "96 Versions. GENERAL SPECIFICATIONS FLUIDS AND LUBRICANTS: APPLICATION TYPE I NAME | |Gearbox-ditterentia! unit oi Om |TUTELA ZC 80/S | Gear engagement control rod bushes GREASE |TUTELA ZETA 2 | CHECKS AND ADJUSTMENTS DIFFERENZIAL Bearing preload (relieved) 012mm * in planetary gears backlash £0.10 mm * NOTE: The bearing preload adjustment is carried out using spare rings with a thickness of from 1.70 mm to 2.60 mm in steps of 0.05 mm. pasorecttévoo2= 13 -8 asad ~_ceARsox. pIEFERENTIAL 13-9 TIGHTENING TORQUES SPECIAL TOOLING im ] oat 1 ~ os TOOL NUMBER DESCRIPTION | Screws and nuts fastening gearbox-encine | 75~92 76-94 | Screw fastening front engine support to body [75 +92 76+94 | | .e20.017.000 atiriies pe fear ea shaft 4th speed driven gear |Sctews fastening lower gearbox cover 42 +51 [43-53 eee. [Screws fastening gearbox to front engine support wos 43253 11820.019.000 Plate for removing transmission shaft 2nd and 3rd speed driven gears [Screw fastening reversing shaft 29-36 29236 1 Ring nut for main and transmission shaft for tastening 5th gear 100 = 124 10+13 1.620.022.000 Hatt plates for fitting main shaft front beanng inner race [Screw fastening gearshit control forks 1519 16219 Half ring support plate and for removing transmission shaft tst speed driven ‘Screw fastening lever on gearshift control shaft [- “20-25 20-25 1.820.024.000 geurree p . [Screw fastening support reverse control lever. I g-11 Os 14 | ‘Tool tor measuring thickness of citferentil shim rings [Screw fastening bush for gearshift control shaft [a= | 09-44 | jee I 2 [Screw fastening differential crown wheel T 75=92 75+34 +1820.146.000 late for supporting gearbox on rotary stand [Screw fastening diferential retainer flange to gearbox [21 =26 22-27 - % Screw fastening tachometer suoport 8213 oB=15 i - 4.820.208.000 ‘Support for geartox removingretiting Magnetic threaded taper plug for filing gearbox oll 3048 31249 Threaded taper plug for filing gearbox of 3048 31249 1.820.228.000 Engine supprort [Screw fastening citferential nght-hand shaft support =n Tat aa re ane Sra SP = & 1.820.229.000 Fiange for removing ditferential lange [Threaded taper plug for Yst and 2nd gear rod housing on goarbox 43-21 1.3721 Front screws fastening gearbox controls support 3625 46-25 “tissnonai6n0 ‘Support for engine and cearbox Screw fastening differential side joint to flange 4052 41253 [Screw for reversing light switch 2032 20-32 4.820.581.000 Engine suppor crossrall | [Screw fastening starter motor to gearbox 20+ 25 20225 =| Screw festering earth cable 0 gearbox 7 10-13 | 10-13 1.820.628.001 Bracket ior removingiefiting gearbox | [Screws fastening rear engine suppor to busy 75=92 75294 Fe cuca ison paso woes ooea ace [Sctews fastening rear engine support to crossmember_ 32440 | 33s41 1.821.003.000 rift for 9 spport in [Screws fasiening suppor gearshit control lever to body 10+ 16 4.016 feoto28'000 Instaling ool for diferental suppor outer bearing race | Nut per pin fastening intermediate gear WO+16 | 10-16 Nut fastening engagement tie-rod to intermediate lever 10=16 10-16 % 1.821.034.000 Puller too! for differential bearings [Nut for screw fastoning selection transmission on gearbox torte | torts | +4.821.047.000 Instaling tool for safety pawis for tst- 3rd - Sth speed control rods 4.821.049.000 Hal plates for instaling main shalt rear bearing | j 1.821.050.000 Installing tool for 4th speed driven gear | 4.821.062.000 Instaling tool for ciferential bearings 1.821.092.000 Installing tool for 1st speed ¢riven gear | 19780116¥001pe GEARBOX - DIFFERENTIAL 13-10 TOOL NUMBER- | DESCRIPTION | 1.821.117.000 ___|Puller tool for removing transmission and main shalt Font Dearing inner race 11821. 161,000 [Matt fr exracing aferonal fan | 4.821.170.000 |instalting tool tor derential carrior gearbox side oll seal | 1.621.171,000 [Grip tor instating toos 7.621-225,000 [instaling tool ior diferential carter engine side ol Seat | Leet Instaling tool for: main shat tron! Deering inner race 8 eee 5 | | | i | Instating tool for: main and transmission: shaft rear bearing | | | nsteting toa! or synchronizer hub andtransmission shalt 2nd and Sré speed gears i | Pasg7scn1avodt