Lombardini GEARBOX Service Repair Manual – PDF Download

WORKSHOP MANUAL GEARBOX cod. 1-5302-826

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table.

Drafting body CUSE/ATLO

Document code

Model N°

Edition

Revision

Issue date

Review date

1-5302-826

51177

1°

00

15.03.2008

15.03.2008

Endorsed

PREFACE - Every attempt has been made to present within this service manual, accurate and up to date technical information.

However, development on the LOMBARDINI series is continuous.

Therefore, the information within this manual is subject to change without notice and without obligation.

- The information contained within this service manual is the sole property of LOMBARDINI. As such, no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI.

Information presented within this manual assumes the following: 1 - The person or people performing service work on LOMBARDINI series engines is properly trained and equipped to safely and professionally perform the subject operation; 2 - The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation; 3 - The person or people performing service work on LOMBARDINI series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand.

-

This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.

-

As well as employing good operating techniques and observing the right timing for operations, operators must read the information very carefully and comply with it scrupulously.

-

Time spent reading this information will help to prevent health and safety risks and financial damage.

Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases.

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

INTRODUCTION

This manual contains the most important information for the repair GEARBOX. This information is current upto15.03.2008.

TABLE OF CONTENTS 1

GENERAL REMARKS AND SAFETY INFORMATION ........................................................................ Pag. 5-7 WARRANTY CERTIFICATE ................................................................................................................................................ 5 GENERAL SERVICE MANUAL NOTES .............................................................................................................................. 5 SAFETY AND WARNING DECALS ..................................................................................................................................... 5 SAFETY REGULATIONS ................................................................................................................................................. 6-7 GENERAL SAFETY DURING OPERATING PHASES ......................................................................................................... 7 SAFETY AND ENVIROMENTAL IMPACT ............................................................................................................................ 7

2

TECHNICAL INFORMATION ...................................................................................................................... 8-9 GEARBOX TECHNICAL SPECIFICATIONS ....................................................................................................................... 8 GERARBOX MAINTENANCE .............................................................................................................................................. 8 EXTRAORDINARY MAINTENANCE .................................................................................................................................... 8 ORDINARY MAINTENANCE ................................................................................................................................................ 8 OIL CHANGE ...................................................................................................................................................................... 9 OIL LEVEL CHECK ............................................................................................................................................................. 9

3

DISASSEMBLY ....................................................................................................................................... 10-19 GEARBOX ........................................................................................................................................................................ 10 FLANGES ......................................................................................................................................................................... 11 GEAR CONSENT SENSORS ...................................................................................................................................... 11-12 GERABOX OIL CHANGE .................................................................................................................................................. 12 OIL SEALS ........................................................................................................................................................................ 12 4 WD COUPLING BOX ..................................................................................................................................................... 13 GEARBOX ........................................................................................................................................................................ 13 GEAR SELECTOR PLUGS .............................................................................................................................................. 13 PUSH-ROD PLUG ............................................................................................................................................................ 13 GEARBOX HOUSING ....................................................................................................................................................... 14 SEMI-HOUSINGS ......................................................................................................................................................... 14-17 4WD SELECTOR ........................................................................................................................................................ 17-19

4

REASSEMBLY ....................................................................................................................................... 20-33 SEMI-HOUSING ................................................................................................................................................................ 20 IDLE GEAR SHAFT PIN OF THE REVERSE GEAR ......................................................................................................... 20 OUTPUT DRIVE SHAFT ................................................................................................................................................... 21 PRIMARY INPUT DRIVE SHAFT ....................................................................................................................................... 21 INTERMEDIATE SHAFT .................................................................................................................................................... 23 GEAR UNITS - REASSEMBLY ..................................................................................................................................... 24-25 REVERSE GEAR SHAFT ............................................................................................................................................ 25-28 4 WD BOX ................................................................................................................................................................... 28-31 4 WD COUPLING BOX - REASSEMBLY ..................................................................................................................... 31-33

5

SPECIAL TOOLS .......................................................................................................................................... 34

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GENERAL REMARKS AND SAFETY INFORMATION

1

WARRANTY CERTIFICATE - The products manufactured by LOMBARDINI Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user.

- For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

- If no hour-meter is fitted , 12 working hours per calendar day will be considered.

- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

- For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the documentation supplied with each engine.

- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out by qualified personnel only.

- The list of the LOMBARDINI authorized dealers is reported in the “Service” booklet, supplied with each engine.

- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering system, turbo-charged models, will require special written warranty agreements.

- Within the above stated periods LOMBARDINI Srl directly or through its authorized network will repair and/or replace free of charge any own part or component that, upon examination by LOMBARDINI or by an authorized LOMBARDINI agent, is found to be defective in conformity, workmanship or materials.

- Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use or from both the total or partial impossibility of use, is excluded.

- The repair or replacement of any component will not extend or renew the warranty period.

LOMBARDINI warranty obligations here above described will be cancelled if: -

LOMBARDINI engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered.

LOMBARDINI engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with each engine.

Any seal affixed to the engine by LOMBARDINI has been tampered with or removed.

Spare parts used are not original LOMBARDINI. Feeding and injection systems are damaged by unauthorized or poor quality fuel types.

Electrical system failure is due to components, connected to this system, which are not supplied or installed by LOMBARDINI. Engines have been disassembled, repaired or altered by any part other than an authorized LOMBARDINI agent.

- Following expiration of the above stated warranty periods and working hours, LOMBARDINI will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete.

- Any warranty request related to a non-conformity of the product must be addressed to the LOMBARDINI Srl service agents.

GENERAL SERVICE MANUAL NOTES 1 - Use only genuine Lombardini repair parts.

Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.

2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented in Newtonmeters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).

SAFETY AND WARNING DECALS -

Important remarks and features of the text are highlighted using symbols, which are explained below:

Danger – Attention This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

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Caution – Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid financial damage.

Important This indicates particularly important technical information that should not be ignored.

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1

General remarks and safety information

SAFETY REGULATIONS • LOMBARDINI Engines are built to supply their performances in a safe and long-lasting way.

To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below.

• The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.

All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by LOMBARDINI which thus declines all liability for any accidents deriving from such operations.

• The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular, along with the relative routine maintenance work.

• The user must read these instructions carefully and become familiar with the operations described.

Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine.

• The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers.

This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the existing documentation.

• Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve LOMBARDINI from all and every liability for deriving accidents or for failure to comply with the laws in merit.

• On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ.

In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous objects, also considering the movements made by the operator.

Pull-starting with a free cord (thus excluding self-winding starting only), is not permitted even in an emergency.

• Make sure that the machine is stable to prevent the risk of overturning.

• Become familiar with how to adjust the rotation speed and stop the engine.

• Never start the engine in a closed place or where there is insufficient ventilation.

Combustion creates carbon monoxide, an odourless and highly poisonous gas.

Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.

• The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the machine.

• To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.

• Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation.

• Fuel is inflammable.

The tank must only be filled when the engine is off.

Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil.

Make sure that no soundproofing panels made of porous material are soaked in fuel or oil.

Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.

• Fully tighten the tank plug each time after refuelling.

Do not fill the tank right to the top but leave an adequate space for the fuel to expand.

• Fuel vapour is highly toxic.

Only refuel outdoors or in a well ventilated place.

• Do not smoke or use naked flames when refuelling.

• The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or machine itself.

Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).

• Before starting, remove any tools that were used to service the engine and/or machine.

Make sure that all guards have been refitted.

• During operation, the surface of the engine can become dangerously hot.

Avoid touching the exhaust system in particular.

• Before proceeding with any operation on the engine, stop it and allow it to cool.

Never carry out any operation whilst the engine is running.

• The coolant fluid circuit is under pressure.

Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or expansion chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill.

Only clean the coolant system when the engine is at a standstill.

• When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to safeguard the environment.

The spongy filtering material in oil-cooled air filters must not be soaked in oil.

The reservoir of the separator pre-filter must not be filled with oil.

• The oil must be drained whilst the engine is hot (oil T ~ 80°C).

Particular care is required to prevent burns.

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General remarks and safety information

1

Do not allow the oil to come into contact with the skin.

• Pay attention to the temperature of the oil filter when the filter itself is replaced.

• Only check, top up and change the coolant fluid when the engine is off and cold.

Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine", dangerous for the health, can form.

The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment.

• During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being energized.

• Only check belt tension when the engine is off.

• Only use the eyebolts installed by LOMBARDINI to move the engine.

These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.

GENERAL SAFETY DURING OPERATING PHASES – – –

– – – – – –

The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods.

A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations.

All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely.

It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.

Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this operation to avoid the risk of amputation.

Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.

Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.

Use the oils and greases recommended by the manufacturer.

Do not mix different brands or combine oils with different characteristics.

Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.

Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.

SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities (products, services, etc.) on the environment.

Procedures for identifying the extent of the impact on the environment must consider the following factors:

In order to minimise the impact on the environment, the manufacturer now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.

-

-

Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact

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-

-

All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.

Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution.

When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them separately.

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2

TECHNICAL INFORMATION

GEARBOX TECHNICAL SPECIFICATIONS

4WD coupling exit gear ratios

Slow forward:

8.40:1

Fast forward:

5.28:1

Reverse gear:

7.0:1

AMBRA STANDARD TRANSHYDRAULIC

PRESCRIBED LUBRICANT

134-D CNH 86556175

specifications

SAE 80W-90 API GL-5

OIL CAPACITY OIL VOLUME AT MAX LEVEL

1,2

Litres

GEARBOX MAINTENANCE Warning

Failure to respect the operations described below can lead to technical damage to the gearbox and to the car on which it is mounted

EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS

Gearbox oil change

ORDINARY MAINTENANCE OPERATION DESCRIPTION CHECK

FREQUENCY x HOURS

100

LEVEL ENGINE

Danger – Attention - The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.

- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.

- Do not disperse the oil in the ambient, as it has a high pollution power.

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2

Technical information Oil change Gear box oil change Position the car on a level surface and unscrew the oil drain plug 6 to drain the oil from the gear box.

Important Plug 6 is magnetised to gather the metal particles.

Clean it carefully and replace the sealing washer before reassembling it.

Unscrew oil level plug 7.

Unscrew oil filler plug 8 and add the quantity of oil specified.

Via oil level plug 7 check the overflow of excessive oil, or the reaching of the correct oil level that should remain 5 mm below the hole of plug 7

8

Caution - Warning Plug 8 is provided with a vent hole, therefore you must reassemble it in the same position.

Screw on oil level plug 7 and oil filler plug 8.

7

Oil level - Check Position the car on a level surface and unscrew the oil level plug 7.

Check that the oil level is 5 mm under the hole of plug 7, otherwise top up via the hole of oil filler plug 8.

6

Gearbox External components: 1 2 3 4 5 6 7 8

8

Gear consent sensors Odometer sensor (if mounted).

Transmission flanges Main input drive shaft 4WD coupling box Oil drain plug Oil level plug Vent plug and oil filler plug.

1 7

3

2

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4

5

6

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3

DISASSEMBLY Gearbox

1

External components: 1 2 3 4 5 6 7 8

Gear consent sensors Odometer sensor (if mounted).

Transmission flanges Main input drive shaft 4WD coupling box Oil drain plug Oil level plug Vent plug and oil filler plug.

2

3 1

Important Before starting any operation on the gearbox carefully protect the electric sensors of gear consent (1) and odometer (2) sensors (if mounted).

Never clean the gearbox with a high pressure water jet.

7

4 6

5

2

8 2 1 3

Insert tool 1 code 175.3675.041.8 for closing the transmission flange 2 for disassembling both the forward transmission flange and the 4WD.

1

2 4

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Disassembly

3

Flanges Components: 1 2 3 4

4

5

3

1

Main transmission flange Self-locking flanged nut M16x1.5 4WD transmission flange Self-blocking flanged nut M12x1.25

2 Disassemble odometer 1 (if mounted) and gear consent sensors 2.

2

1 6

Important Gear consent sensors 2 should be disassembled together with the supports.

2

7

Gear consent sensors Components: 1 2 3 4

4

3

2

Consent sensor Sensor spring Ball Ball and spring holder bushing

1

8

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3

Disassembly Gear consent sensor When you need to replace only the consent sensor, fit it on the bushing/ support spreading Loctite 510 on the sensor’s thread.

9

Gearbox oil change Unscrew the oil drain plug to drain the oil from the gearbox.

A

Important Plug A is magnetised to gather the metal particles. Clean it carefully and replace sealing washer 1 before reassembling it.

A 1

10

Oil seals

Caution - Warning Be careful not to damage the shafts, oil seal housings and surface P. Insert a Phillips screwdriver, turn it approximately 45° as shown in the figure, then lever out the oil seal.

P 11

P P 12

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Disassembly

3

4WD coupling box

Important Before starting the disassembly make a reference mark (R) for the original position.

The 4WD gear selector (S) should be disconnected (gear selector lever positioned towards the gearbox) for both disassembly and reassembly.

1

2

Unscrew the 6 M8 fastening screws from the 4WD box and take out the box.

S 1 - 2 M8x1.25 L75 flanged screws.

2 - 4 M8x1.25 L25 flanged screws.

R 13

Gearbox Disassemble the D 20 lock snap ring and remove the 4WD fixed coupling bushing 1.

1

14

Remove the plugs of the gear selector housing 1.

Remove the plug of the safety push-rod housing 2.

1

2

15

4

2

3

1

Gear selector plugs Components: 1 Gear selector ball housing plug 2 Gear selector ball spring 3 Selector ball Push-rod plug Components:

5

3

2

1

4 Safety push-rod plug 5 Safety push-rod

16

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3

Disassembly Gearbox housing Unscrew all the screws that keep the two semi-housings together.

1.

2.

3.

4.

5 M8x1.25 L160 screws 2 M8x1.25 L150 screws 4 M8x1.25 L140 screws 3 M8x1.25 L 55 screws

17

1

2

3

4

18

Semi-housings 2

Strike alternately on the semi-housings on the position shown 1, and on output drive shaft 2 to separate the two semi-housings.

1

19

2

20

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Disassembly

3

Take out right semi-housing D. 2

Main components: 1 Primary input drive shaft 2 Output drive shaft 3 Intermediate shaft

1

3 D 21

Important Before taking out the gearbox shafts remove clearance washer 1, idle gear with bushing 2 and the second clearance washer 3 3 2

1 22

Strike alternately on the input drive shaft 3 and output shaft 1 to contemporaneously take out the three shafts of the left semi-housing.

1

Components 1 Output drive shaft 2 Intermediate shaft 3 Primary input drive shaft 4 Reverse gear shaft 5 Left semi-housing 3 23

4 5

2

1

3

24

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3

Disassembly To disassemble the bearings use a bearing extractor available on the market.

25

Use pliers for SP type external safety rings, to proceed with the disassembly of the other components.

26

Take out bearing 1 and the first gear 2 using a universal extractor, then remove roller cage 3, the swivel ring 4 and reverse gear 5

2 1

27

3 4

5

28

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Disassembly

3

Take out safety ring 6 using pliers for SP type seeger rings

6 29

Dismount clearance washer 7 and the idle gear of the fast gear

8

8 7

7 30

6

31

4WD Selector Loosen self-locking nut 11 fastening the gear selector 10

10

11 32

Take out safety ring 9 of the selector pin

9

33

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3

Disassembly Dismount the selector spring holder bushing 7 and selector pin bushing 8

8

7 34

Moving selector pin 6 towards the outside take out bushing 5

5

6

35

Take out safety ring 4 that fastens the 4WD drive shaft

4

36

Moving selector pin 6 towards the outside take out drive shaft 2 along with bearings 3

3

6 2 37

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Disassembly

3

Take out selector pin 6

6

38

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4

REASSEMBLY Semi-housing Clean off with a scraper, any sealant residue on the coupling surfaces of the two semi-housings.

Important Clean carefully with degreaser liquid.

39

Check the integrity of the O-rings of the two selector rods and their correct positioning

OR

Important If damaged, replace the O-rings before reassembly.

OR

40

S S

Important Check that the two centring pins S are in their correct place and, if damaged, replace them.

41

Idle gear shaft pin of the reverse gear Start reassembling from the left semi-housing, positioning the idle gear shaft pin of the reverse gear.

42

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Reassembly

4

Output drive shaft Mount the bearings on the output drive shaft.

43

Primary input drive shaft

8

7

Components: 1 Fast gear running gear 2 Safety snap ring 3 Toothed clearance washer 4 Roller cage 5 Slow gear idle gear 6 Reverse gear pinion 7 Bearing 8 Input drive shaft

1

2

3

4

5

3

2

6

2

7

44

Rest on a suitable support for assembling the main input drive shaft.

8

- Position input drive shaft 8 with the tang for pulley connection downwards, with bearing 7 already inserted.

- Assemble gear 1 with the recess for selector fork A turned downwards as in the figure.

1

A 7 45

- Insert safety ring 2 in the appropriate housing using pliers for seeger rings.

4

3

Important Apply grease to toothed clearance washer 3 so that it does not move from the shaft slot.

If toothed clearance washer 3 moves it could block the gear.

- Mount toothed clearance washer 3.

Insert roller cage 4 and oil it.

46

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4

Reassembly Mount slow gear idle gear 5.

Mount in sequence toothed clearance washer 3 and the second safety snap ring 2, taking care to insert it properly in the housing.

2

3 5 47

Insert the third safety ring 3 on the last slot.

3

48

Mount the gear of the reverse gear pinion 6.

6

49

Mount bearing 7 to its limit stop.

7 50

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Reassembly

4

Intermediate shaft

2

3

4

1

5

Components:

6

7

8

9

10

1 Intermediate shaft 2 Bearing 3 Speed reduction gear with bushing 4 Clearance washer 5 Safety snap ring 6 Slow gear running gear 7 Swivel ring 8 Roller cage 9 Reverse gear 10 Bearing

51

Note: When reassembling the gears there is no need for adjustments, in that all the swivel rings and clearances have been previously calculated.

After having assembled bearing 2 on the intermediate shaft, assemble speed reduction gear 3 with the bushing already preassembled.

3

2

52

Insert clearance washer 4 and, using the pliers, insert safety snap ring 5.

5 4

53

Assemble slow gear running gear 6 with the recess for selector fork G turned upwards.

Insert swivel ring 7 and roller cage 8.

Oil the roller cage and mount reverse gear 9.

The two notches of reverse gear C should be turned upwards.

C

7 8 9 G

6

54

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4

Reassembly Mount bearing 10 to its limit stop.

10

55

Gear units - Reassembly

2 3

Important To correctly insert the shafts you should support the left semihousing in order to set it to a proper distance from the workbench.

5

1

Proceed only as described below to reassemble the units in the semihousing: a- Mount reverse gear shaft 1. b- Lay down and keep at a slant (see photo), the primary input drive shaft 2, complete with selector fork rod 3 in the 4WD left semi-housing, without inserting bearing 4 into its housing.

4 56

5 2

c- Assemble at the same time intermediate shaft 5 along with selector fork rod 7 and output drive shaft 6 proceeding as follows: Bring shafts 5 and 6 near to their seats and then insert all three shafts 2, 5 and 6 into their seats.

6

7 57

Rotate the shafts manually to check if they run smoothly, making sure that they are free from impediments.

58

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

Reassembly

4

Position the selector fork rods so that notches 8 of the safety system (and safety pin) are not aligned.

8

59

Reverse gear shaft

1

Components: 1 Reverse gear shaft 2 Safety snap ring 3 Clearance washer 4 Idle gear + bushing

3

2

4

3

60

Mount the following components in sequence on reverse gear shaft 1: 1) snap ring 2; 2) washer 3; 3) idle gear with bushing 4; 4) second washer 3.

1 4

3 61

Oil all bearings before closing the gearbox with the right semi-housing.

62

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

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4

Reassembly Grease the selector fork rods.

63

Apply Loctite sealant 510 on the seal surface.

Apply sealant evenly over the whole surface.

64

Assemble the two semi-housings with the help of a tool.

65

Tighten service screws M 8x1.25 ( L55 ) at a torque of 30 Nm.

66

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

Reassembly A

4

Insert the selector stop balls A, springs B, and plugs C.

B

67

Tighten plugs at a torque of 25 Nm.

C

68

Insert safety pin S and check that it functions correctly.

S

The purpose of safety pin S is to avoid the accidental or intentional insertion of more than one gear at a time.

69

P

With the idle gear inserted, pin S is free inside its housing.

With the gear inserted, safety pin S is forced in the housing that is on both selector rods, thus blocking the unused rod.

Amply grease the housing of pin P.

S

70

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

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4

Reassembly Apply Loctite 510 on the safety pin plug.

Tighten the plug at a torque of 25 Nm

71

4WD box

1

Components:

2

7

3

4

5

6

12

9

8

11

10

72

1 4WD coupling box 2 4WD drive shaft 3 4WD drive shaft bearings 4 Seeger safety ring 5 4WD coupling running bushing 6 Selector pin 7 Spring holder selector bushing 8 Selector pin bushing 9 Safety ring 10 Selector lever 11 Self-locking nut M8x 1.25 12 Selector pin O-ring Insert selector pin 6 in the appropriate housing.

12 Important Before reassembling check the state of the O-ring 12.

6

73

Pulling selector pin 6 towards the outside insert 4WD drive shaft 2 along with the already mounted bearings 3.

3

6 2 74

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

Reassembly

4

Insert safety ring 4 to block the 4WD drive shaft.

4

75

Insert 4WD coupling running bushing 5, assuring that selector pin 6 is inserted correctly in the recess of the bushing.

5

6

76

Montare e serrare la boccola 8 sul perno selettore ad una coppia di 25 Nm.

8 77

Mount bushing 8 on the selector pin Tighten at a torque of 25 Nm.

8

7 78

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

- 29 -

4

Reassembly Mount safety ring 9 on the selector pin.

9

79

Mount selector lever 10 and tighten it with self-locking nut 11.

Check the position of the lever that should be parallel to the ribbing 13 on the 4WD coupling box.

The picture shows the correct position of lever 10.

13 10

11 80

When the assembly is completed, check that the selector operates correctly and that the selector stop ball S is correctly positioned.

S

81

1 Snap ring Ă˜ 20 2 4WD coupling fixed bushing

2 1

82

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

4

Reassembly

Assemble the 4WD coupling fixed bushing 2 on output drive shaft, on the side of the oil drain plug, and lock it with the safety ring 1.

Apply Loctite 510 sealant evenly on the support surface of 4WD gearbox.

2

1 83

Oil 4WD coupling selector and mount the 4WD box on the gearbox.

84

4WD coupling box - Reassembly

Important Position the box on the gearbox being careful to reference (R) of the original position.

When reassembling the 4WD selector (S) must be disconnected.

1

2

Screw the 6 M8 4WD box fastening screws.

1 - 2 M8x1.25 L75 flanged screws.

2 - 4 M8x1.25 L25 flanged screws.

S Tighten the 6 fastening screws at a torque of 30 Nm.

R 85

Odometer (if mounted).

1

Important Only use ISO Promoblock screws, which are already supplied with the blocker on the thread.

1 ISO 7380 Promoblock M4x0.7-12 CDQ 10.9 fastening screws.

2 Gasket 3 Odometer

2

3

86

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

- 31 -

4

Reassembly Spread the grease as shown in the photo so as to avoid that gasket 2 moves.

2 87

Make odometer tang E coincide with notch F on the gearbox shaft, as shown in the figure.

F E

Tighten the fastening screws of the odometer.

88

Remount the gear consent sensors.

89

Mount the oil seal ring, on the drive output flange side, using the protection as shown in the figure.

90

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

Reassembly

4

Fit the oil seal ring and with the appropriate buffer, insert it until its limit stop.

91

Repeat the same operation on the input drive shaft (fig. 106) and on the drive shaft (fig.107).

92

93

Fasten the transmission flange 2 using tool 1, code 175.3675.041.8, and tighten with torque wrench at the specified torques.

Tighten bolts :

M 16 .................. a 200 Nm M 12 ................. a 90 Nm

1

2 94

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

- 33 -

5

SPECIAL TOOLS

Code and description

175.3675.041.8 Transmission Flange Stop

B

A) 175.8960.028.8 Hitting device for 4 WD drive shaft oil seal A

B) 175.8960.029.8 Hitting device for output shaft oil seal

C

C) 175.8960.030.8 Hitting device for 4WD input shaft oil seal F D

D) 175.1460.307.8 Hollow punch for input shaft oil seal E) 175.1460.308.8 Hollow punch for output shaft oil seal

E

F) 175.1460.309.8 Hollow punch for 4WD drive shaft oil seal

- 34 -

Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 00

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Workshop Manual Gearbox_cod. 1.5302.826_.1° ed_ rev. 0

- 35 -

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