- Page 1 and 2: D CLUTCH-GEARBOX-DIFFERENTIAL D1 GE
- Page 3 and 4: Gears Gear ratios Final reduction r
- Page 5 and 6: Pinion/Crown backlash (on 3 points
- Page 7 and 8: AV 3261 Tool for fitting the clutch
- Page 9 and 10: D1.04 TIGHTENING TORQUES NOTES To c
- Page 11: D2.01 DISMANTLING This paragraph de
- Page 15 and 16: • Detach the actuator's rear supp
- Page 17 and 18: • Release the oil pipes from the
- Page 19 and 20: • Unscrew the clutch pipe union (
- Page 21 and 22: • In the lower part of the engine
- Page 23 and 24: • Fasten the ends of the belt ont
- Page 25 and 26: • Sling the gearbox as described
- Page 27 and 28: • Lock the six nuts and the two l
- Page 29 and 30: • Fasten the engine service cable
- Page 31 and 32: • Re-assemble the oil coolant pip
- Page 33 and 34: • Re-assemble the gearbox support
- Page 35 and 36: • Replenish the engine oil ( A 3.
- Page 37 and 38: Vehicles with the N. 63614 (type F1
- Page 39 and 40: Starting from vehicle Ass.ly No. 53
- Page 41 and 42: • Unscrew and remove the eight sc
- Page 43 and 44: Therefore, for the engines installe
- Page 45 and 46: • Lubricate the ORings (9) and th
- Page 47 and 48: Use the tool AV 3079 to centre the
- Page 49 and 50: NOTES Replacement of the control an
- Page 51 and 52: to adjust the pedal into the restin
- Page 53 and 54: NOTES On the US versions, the switc
- Page 55 and 56: • Screw the adjusting screw (3) o
- Page 57 and 58: ( G 2.03). Tightening torques Nm Ca
- Page 59 and 60: • Fill and drain the clutch syste
- Page 61 and 62: • Press the clutch pedal and simu
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5- Press "ENTER" to activate the te
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D4.01 REPLACING THE EXTERNAL COMPON
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• Using a commercial bearing extr
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• Remove the left-hand side catal
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• Position the grommet with its c
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Flexible upper bushing on the gearb
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• Screw the nut (B) with the wash
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• Fit the spacers on every side o
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• Before fitting the new pad, che
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Gearshift selection levers (Mechani
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• Check that the equaliser (H) an
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• Clean the coupling surfaces of
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• Unscrew the three nuts and remo
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• Pull the two cables from the pa
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• Working from under the car, mak
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7 Check that the control lever is i
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In case of interference during 4th
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• Unscrew the four screws fasteni
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IMPORTANT In case of replacement of
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D4.04 DETACHING/RE-FITTING THE GEAR
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Note for the US version On these ca
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Support brackets for the pneumatic
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• Unscrew and remove the screw wi
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• Remove the movable frame from t
- Page 111:
• Remove the movable frame from t
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• Tighten screws (5), (7) and (8)
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D4.05 GEARBOX OVERHAUL Gearbox iden
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• Fix it on the housing, using th
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42 Lay shaft (pinion) 43 Flexible r
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the protective sheet for the oil-fl
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• Use the USAG 454N/2 extractor p
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• Fit the extracting tool arms US
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• Lock the base AV 3252 in a vice
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• Rivet the caulkings of the shou
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• Using the previously used armed
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• Lock the tool's support plate i
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odies. • To remove ball bushing (
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• When re-assembling, use the pun
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NOTES For oil pump disassembly and
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Starting FROM gearbox 10928, the ne
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and uniform. • Position this so f
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• When assembling the 3 rd - 4 th
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Unscrew the four fastening screws w
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Re-assembling the gearbox shaft com
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• Apply the recommended locking p
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• Reset the dial gauge on the che
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• Fit the outer race of the rear
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• Place the lay shaft on the chec
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• To determine the thickness (S3)
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• Again using the gauged blocks,
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• Fit the bushing AV 3284 in the
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• Using punch AV 3262 and a rubbe
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• Mount the intermediate plate us
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D5.01 COMPONENT REPLACEMENT Differe
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• Turn over the left-hand cover a
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Differential crown IMPORTANT The di
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• Re-assemble the differential un
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• Remove the outer race of the ro
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NOTE For positioning the pinion ( D
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• Proceed mounting the inner race
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NOTES The thickness of the spacers
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• Install the components on the l
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At this re-assembly stage, it is a
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D5.02 AXLE SHAFT Tightening Torques
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• Remove the screws and the shim
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• Re-assemble the components remo
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D6.02 GENERAL FEATURES The electron
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D6.03 TRANSMISSION CONTROL UNIT (TC
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D6.04 OPERATION The system is compo
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speed depending on how the accelera
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Key "Time history gear shifting " t
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Keys to Fig. 2 1 - Oil tank 2 - Pum
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• The Power Unit (A), fixed to th
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D6.06 POWER UNIT The Power Unit is
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• To replace the Power Unit: disc
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•Fasten the unit onto the chassis
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Disassembly CAUTION The hydraulic s
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• Unscrew the nuts (9) and remove
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The gear release device is obtained
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0÷5 V. NOTES We suggest you replac
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In order to allow the sensor to det
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• Detach the sensor's connection
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Hydraulic Circuit Pressure Sensor (
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The switch is placed on the door pi
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The two push-buttons (A) and (B) ar
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A set of warning lights indicates t
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The clutch control is based on the
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• With the engine running and the
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start-up the engine. In the diagnos
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NOTES To reassemble, follow the ope
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Practical checks • By means of th
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Components involved • Hydraulic p
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This value must never exceed the cl
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D6.13 CENTRING THE GEAR SHIFTING-SE
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This measurement is necessary to wo
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• Close the "Actuator centring "