145 - MiTo   1.4 16v TJet   DIFFERENTIAL INTERNAL CASING, REMOVED - DISMANTLING AND REASSEMBLY, CHECK PLANET AND SATELLITE GEARS   2110D20   

Detail     Detail

Removing ( Refitting )

This procedure applies to the C544 (M32) gearbox.


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1. Fit the differential internal casing in a vice and undo the screws (1a) fixing the ring gear to the differential internal casing using a suitable tool.

2. Remove the bearings (2b) using a suitable extractor (2a).

3. Fit the differential internal casing on a suitable gauge and separate the ring gear from the differential internal casing.

Refitting ( Removing )

- Fit the differential ring gear in the differential internal casing using a rubber hammer and taking care to align the openings for the fixing screws.

- Fit the ring gear in the differential internal casing using new screws to be tightened to the prescribed torque.

 

Component

 

Fixing

 

dia

 

Value (daNm)

 

Validity

 

Manual gearbox differential ring gear

 

Screw

 

M10 x 1.25

 

6.0 + 90°

 

1.4 16v TJet 155 HP

1.6 JTD 16v M32

1.3 MultiJet 90 HP


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1. Fit the new bearings (1c) on the press using the tools (1a) and (1b).

 

Tool

 

Name

 

Function

 

Validity

 

2000005000

 

Plate

 

Reaction plate in the press

 

1.4 8v

1.4 16v TJet

1.6 JTD 16v M32

1.3 MultiJet

1.4 Turbo MultiAir

 

Tool

 

Name

 

Function

 

Validity

 

2000005300

 

Fitting tool

 

Fitting differential bearing

 

1.4 16v TJet 155 HP

1.6 JTD 16v M32

1.3 MultiJet 90 HP

Removing ( Refitting )

The two overhaul procedures of the C510.5 gearbox are described below. The first one is valid until 04/2012 the second one from 04/2012.


1. Remove the bearings (1a) from the differential internal casing using the tools (1b), (1c) and (1d).

 

Tool

 

Name

 

Function

 

Validity

 

1840005003

 

Extractor

 

Extracting differential internal housing bearing

Removing speedometer idler drive gear

Differential inner driveshafts removal

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

 

Tool

 

Name

 

Function

 

Validity

 

1840005302

 

Extractor arms

 

Extracting differential internal housing bearings

Removing speedometer idler drive gear

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

 

Tool

 

Name

 

Function

 

Validity

 

1875017000

 

Fitting tool

 

Extracting/fitting differential internal housing bearings

Removing speedometer idler drive gear

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP


1. Remove the odometer idler gear (1a) using tools 1b), (1c) and (1d).

 

Tool

 

Name

 

Function

 

Validity

 

1840005003

 

Extractor

 

Extracting differential internal housing bearing

Removing speedometer idler drive gear

Differential inner driveshafts removal

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

 

Tool

 

Name

 

Function

 

Validity

 

1840005302

 

Extractor arms

 

Extracting differential internal housing bearings

Removing speedometer idler drive gear

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

 

Tool

 

Name

 

Function

 

Validity

 

1875017000

 

Fitting tool

 

Extracting/fitting differential internal housing bearings

Removing speedometer idler drive gear

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP


- Mark the position of the ring gear and differential internal casing.

1. Undo the screws (1a) and remove the ring gear (1b).


1. Remove the satellite carrier pin using a suitable drift.

The flexible retaining pin is sheared during this operation.

2. Extract the satellites (2a) with the washers (2b).

3. Remove the planet gears.


Refitting ( Removing )

- Check that the satellite and planet gears are intact and show no signs of seizing.

- Fit the planet gears.

- Fit the satellite gears and washers.

- Fit the satellite carrier pin using a suitable drift.

- Fit a new satellite carrier shaft flexible retaining pin using a suitable drift.

- Using a screwdriver, check that the planet and satellite gears are correctly matched making sure that they rotate without clearance and with slight resistance.

- Fit the ring gear checking the marks made during the dismantling and secure it tightening the screws to the prescribed torque.

 

Component

 

Fixing

 

dia

 

Value (daNm)

 

Validity

 

Manual gearbox differential ring gear

 

Screw

 

M10

 

7.7 ÷ 9.2

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

- Fit the odometer idler drive gear after heating to 100° - 120°C.

1. Fit the bearings (1a) in the differential internal casing using the tool (1b).

 

Tool

 

Name

 

Function

 

Validity

 

1875017000

 

Fitting tool

 

Extracting/fitting differential internal housing bearings

Removing speedometer idler drive gear

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

APPLIES TO VERSIONS WITH: From 04/2012

Removing ( Refitting )

- Position the differential assembly in a vice fitted with protective jaws.

APPLIES TO VERSIONS WITH: From 04/2012


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1. Remove the bearing (1a) from the differential inner casing using a suitable commercial tool (1b) and the tool (1c).

 

Tool

 

Name

 

Function

 

Validity

 

1845028000

 

Reaction base

 

Removing bearing from differential

 

1.4 8v

1.4 16v

1.4 16v TJet 120 HP

1.4 MultiAir

1.4 Turbo MultiAir

1.3 MultiJet 85/95 HP

0.9 TwinAir

1.6 JTD 16v

APPLIES TO VERSIONS WITH: From 04/2012


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1. Remove the bearing (1a) from the differential inner casing using a suitable commercial tool (1b) and the tool (1c).

 

Tool

 

Name

 

Function

 

Validity

 

1845028000

 

Reaction base

 

Removing bearing from differential

 

1.4 8v

1.4 16v

1.4 16v TJet 120 HP

1.4 MultiAir

1.4 Turbo MultiAir

1.3 MultiJet 85/95 HP

0.9 TwinAir

1.6 JTD 16v

APPLIES TO VERSIONS WITH: From 04/2012

- Mark the position of the ring gear in relation to the differential casing.

APPLIES TO VERSIONS WITH: From 04/2012


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1. Undo the screws (1a) and remove the ring gear (1b).

APPLIES TO VERSIONS WITH: From 04/2012


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1. Remove the satellite carrier pin using a suitable drift.

The flexible retaining pin is sheared during this operation.

2. Remove the satellite gears with the relevant shims.

3. Remove the planet gears with the relevant shims.

APPLIES TO VERSIONS WITH: From 04/2012

Refitting ( Removing )

- Check that the satellite and planet gears are intact and show no signs of seizing.

APPLIES TO VERSIONS WITH: From 04/2012


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1. Use a suitable punch to break through the wall of the differential casing in the point shown in the figure.

Remove the residues of the old flexible pin from the satellite carrier pin and from the differential casing.

2. Fit the satellite carrier pin (2a) on the differential casing with the satellite gears (2b) and the relevant shims.

3. Fit the planet gears and the relevant shims.

APPLIES TO VERSIONS WITH: From 04/2012

- Fit a new satellite carrier shaft flexible retaining pin using a suitable drift.

After fitting the flexible pin, stake the differential casing to prevent it coming out.

- Using a screwdriver, check that the planet and satellite gears are correctly matched making sure that they rotate without clearance and with slight resistance.

APPLIES TO VERSIONS WITH: From 04/2012


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1. Fit the ring gear (1a) checking the marks made during the dismantling and secure it tightening the screws (1b) to the prescribed torque.

 

Component

 

Fixing

 

dia

 

Value (daNm)

 

Validity

 

Manual gearbox differential ring gear

 

Screw

 

M10

 

7.7 ÷ 9.2

 

1.4 16v TJet 120 HP

1.4 Turbo MultiAir (5 SPEEDS)

1.3 MultiJet 85/95 HP

APPLIES TO VERSIONS WITH: From 04/2012


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1. On the hydraulic press using the tool (1a), fit the bearing (1b) on the differential casing.
 

Tool

 

Name

 

Function

 

Validity

 

1870658000

 

Extractor/fitting tool

 

Fitting main/layshaft bearings/hubs/gears

 

1.4 8v

1.4 16v TJet

1.6 JTD 16v

1.3 MultiJet

1.4 Turbo MultiAir

APPLIES TO VERSIONS WITH: From 04/2012


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1. On the hydraulic press using the tool (1a), fit the bearing (1b) on the differential casing.

 

Tool

 

Name

 

Function

 

Validity

 

1870658000

 

Extractor/fitting tool

 

Fitting main/layshaft bearings/hubs/gears

 

1.4 8v

1.4 16v TJet

1.6 JTD 16v

1.3 MultiJet

1.4 Turbo MultiAir