M32 Gearbox Overhaul

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ALFA 159 1.9 JTD 16V MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL -
DISMANTLING AND REASSEMBLY - WASH, CHECK COMPONENTS, REPLACE
SYNCHRONIZERS AND INTERNAL CONTROLS 2110B34
Removing ( Refitting ) 1. Fit the gearbox (1a) on the overhaul stand using the
tool (1b).
Tool Description Function Validity
1.9 JTD 8v
Gearbox support for
1870001014 Support
overhaul stand
1.9 JTD 16v
2. Undo the reverse sensor and remove it.
3. Adjust the retaining clip and remove the three-way connector.
4. Undo the bolts (4a) and remove clutch coaxial actuator (4b).
5. Undo the bolts (5a) and remove the gear selection and engagement unit (5b).
1. Undo the bolts (1a), remove the sealant working at the three points (1b) and remove the
gearbox casing (1c) from the clutch casing (1d).
- Clean the support surfaces between the gearbox casing and the clutch casing thoroughly.
1. Using the tools (1a) and (1b) remove the outer races (1c) and the scraper rings (1d) for
the main shaft and the layshafts.
Removing differential
1870655000 Extractor
conical bearing race
1.9 JTD 8v
Removing bearing
1840206001 Mallet
outer races
1.9 JTD 16v
1. Undo the bolt fixing the rear bearing to the main shaft using the special tool for counter-
torque.
file:///C:/eLearn/Web/tempcontent5.html 02.02.2018
1.9 JTD 8v
1870853000 Lever Main shaft rotation
1.9 JTD 16v
2. Remove the main shaft (2a), the layshaft (2b) and the selector forks (2c) from their
housing.
3. Remove the second layshaft from its housing.
PROCEED WITH DISMANTLING THE CLUTCH CASING AS DESCRIBED BELOW.
1. Using the tools (1a) and (1b) remove the outer races (1c) for the front bearings for the
main shaft and the layshafts.
1.9 JTD 8v
Removing bearing
2000005400 Extractor
outer races
1.9 JTD 16v
1.9 JTD 8v
Removing bearing
1840206001 Mallet
outer races
1.9 JTD 16v
2. Remove the main shaft seal from the clutch casing.

1. Using the extractor (1a) and a suitable mallet (1b), remove the bearing for the gear
selector shaft (1c).
1.9 JTD 8v
1840207812 Extractor Removing bearings
1.9 JTD 16v
PROCEED WITH DISMANTLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.
1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 6th
speed gear (1d), the 4th speed gear (1e) and the spacer (1f).
1860837000 Plate Plate for support in

the press
1.9 JTD 8v
Removing-refitting
2000004700 Fitting tool
bearings
1.9 JTD 16v
1. On the hydraulic press, using the tools (1a) and (1b), remove the 3rd and 5th speed drive
gear (1c) from the main shaft (1d).
The main shaft should be supported at the bottom during this operation.
Plate for support in

1860837000 Plate
the press
1.9 JTD 8v
Removing-refitting
bearings
1.9 JTD 16v
1. On the hydraulic press, using the tools (1a), (1b) and (1c), remove the front bearing (1d).
The main shaft should be supported at the bottom during this operation.

1860837000 Plate
the press
Half-rings for reaction

1846017000 Half-rings
in the press
1.9 JTD 8v
Half-rings for
1846001001 Half-rings
removing bearing
1.9 JTD 16v
PROCEED WITH DISMANTLING THE LAYSHAFT (B) AS DESCRIBED BELOW.
1. Remove the gear selector forks (1a) from the layshaft (1b).
2. Remove the rear bearing circlip.
1. On the hydraulic press using tools (1) and (1b) remove the rear bearing (1c), the 4th
speed gear (1d) and the needle bearing (1e).
1.9 JTD 8v
Reaction plate in the
2000005000 Plate
press
1.9 JTD 16v
1.9 JTD 8v
1870447000 Reaction pin Removing bearing
1.9 JTD 16v
1. Remove the 4th speed synchronizer ring assembly.
2. Remove the 3rd and 4th speed sliding engagement sleeve.
3. Remove the pre-synchronizer mountings.
1. Remove the sliding sleeve hub circlip.
1. Remove the 3rd and 4th speed sliding sleeve hub (1a), the 3rd speed synchronizer ring
assembly (1b) and the 3rd speed driven gear (1c) using a hydraulic press and tool (1d).
The layshaft should be supported at the bottom during this operation.
1.9 JTD 8v
2000005000 Plate
press
1.9 JTD 16v
2. Remove the needle bearing.
1. Remove the spacer circlip.
1. On the press, using the tool (1a), remove the spacer (1b), the presynchronizer mountings
(1c), the sliding sleeve (1d), the reverse synchronizer rings (1e), the reverse gear (1f) and
the needle bearing (1g).
1.9 JTD 8v
2000005000 Plate Reaction plate in the 1.9 JTD 16v

press
1. Remove the front bearing circlip.
1. On press, remove the front bearing using a suitable extractor.
The layshaft should be supported at the bottom during this operation.
PROCEED WITH DISMANTLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.
1. Remove the circlip.
1. On the press, using the tool (1a), remove the 6th speed gear and bearing (1b) and the
needle bearing (1c).
The second layshaft should be supported at the bottom during this operation.
1.9 JTD 8v
Removing-refitting
bearings
1.9 JTD 16v
1. Remove the synchronizer circlip.
1. On the press, using the tool (1a), remove the 5th and 6th speed synchronizer (1b) and the
5th speed gear (1c).
1.9 JTD 8v
2000005000 Plate
press
1.9 JTD 16v
1. Release the needle bearing (1a) and remove the spacer (1b), the two half rings (1c), the
2nd speed gear and the needle bearing (1e).
1. Remove the circlip (1a) and the 1st and 2nd speed synchronizer rings (1b).
1. On the press, using the tool (1a), remove the 1st and 2nd speed synchronizer (1b) and
the 1st speed gear (1c).
1.9 JTD 8v
2000005000 Plate
press
1.9 JTD 16v
1. Remove the bearing with a double row of rollers.
1. On press, remove the front bearing using a suitable extractor.
The second layshaft should be supported at the bottom during this operation.
Refitting ( Removing )
PROCEED WITH REASSEMBLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.
1. Position the two bearings (1a), the 1st speed gear (1b), the 1st and 2nd speed
synchronizer rings (1c) and the ring nut (1d) on the second layshaft and fit them on the
hydraulic press.
1. Fit the sleeve and three presynchronizer mountings (1a), the 1st and 2nd speed
synchronizer rings (1b) and the circlip (1c).
1. Position the bearing (1a), the 2nd speed gear (1b), the two half rings (1c), the spacer
(1d), the needle bearing (1e), the 5th speed gear (1f) and the 5th and 6th speed
synchronizer assembly on the second layshaft and fit them on the hydraulic press.
1. Fit the circlip (1a), the needle bearing (1b) and the 6th speed gear (1c).
1. Fit the rear bearing on the press.
1. Fit the rear bearing circlip.
PROCEED WITH REASSEMBLING THE LAYSHAFT (B) AS DESCRIBED BELOW.
If the thrust bearing, reverse gear or the spacer are replaced, the thickness of the new
circlip must be calculated as described below.
Calculate the difference in thickness between the old and new components. The value
of the difference should be added to or subtracted from the thickness of the circlip
removed to determine the thickness of the new circlip that should be fitted. A circlip kit
is available as spares.
1. On the press, using the tools (1a) and (1b), remove the front bearing (1c).
1.9 JTD 8v
2000005000 Plate
press
1.9 JTD 16v
1.9 JTD 8v
1870658000 Fitting tool Fitting bearing
1.9 JTD 16v
2. Fit the circlip (2a), the needle bearing (2b), reverse gear (2c) and the synchronizer ring
(2d).
1. On the press, using the tool (1a), fit the synchronizer sliding sleeve (1b).
1.9 JTD 8v
1.9 JTD 16v
1. On the press, using the tool (1a), fit the spacer (1b).
1.9 JTD 8v
1.9 JTD 16v
1. Fit a new circlip (1a), the three presynchronizer mountings (1b), the sliding sleeve for
reverse gear (1c), the needle bearing (1d), the 3rd speed gear (1e) and the three
synchronizer rings (1f).
1. On the press, using the tool (1a), fit the synchronizer ring nut (1b). Pay attention that the
teeth shown in the diagram are in the correct position.
1.9 JTD 8v
1.9 JTD 16v
1. Fit the synchronizer circlip.
1. Fit the three presynchronizer mountings (1a) and the sleeve (1b) complete with seals (1c).
1. Fit the needle bearing (1a) and the 4th speed gear (1b).
2. On the press, using the tool (2a), fit the rear bearing (2b).
1.9 JTD 8v
1.9 JTD 16v
1. Fit a new circlip (1a) retaining the rear bearing and position the forks (1b) on the layshaft
(1c).
If the rear bearing or the 4th speed gear is being replaced, the thickness of the new
circlip must be calculated in the way described below. Calculate the difference in size
between the new and old components. This value be added to or subtracted from the
thickness of the circlip removed to determine the thickness of the new circlip that
should be fitted. A circlip kit is available as spares.
PROCEED WITH REASSEMBLIN THE MAIN SHAFT (A) AS DESCRIBED BELOW.
1. On the press, using the tools (1b) and (1c), fit the front bearing (1a).

1860837000 Plate
the press
1.9 JTD 8v
1.9 JTD 16v
1. On the press, using the tools (1b) and (1c), fit the 3rd and 5th speed drive gear (1a).

1860837000 Plate
the press
1.9 JTD 8v
1.9 JTD 16v
1. Fit the spacer.
2. On the press, using the tools (2b) and (2c), fit the 4th speed drive gear (2a).

1860837000 Plate
the press
1.9 JTD 8v
1.9 JTD 16v
1. On the press, using the tools (1b) and (1c), fit the 6th speed drive gear (1a).

1860837000 Plate
the press
1.9 JTD 8v
1.9 JTD 16v
1. On the press, using the tools (1b) and (1c), fit the rear bearing (1a).

1860837000 Plate
the press
1.9 JTD 8v
1.9 JTD 16v
PROCEED WITH REASSEMBLING THE CLUTCH CASING AS DESCRIBED BELOW.
1. Fit the main shaft front bearing outer race (1a) using tools (1b) and (1c).
2000005100 Fitting tool Bearing fitting tool

1.9 JTD 8v
1.9 JTD 16v
Grip for tool for

extracting
bearing/fitting main
1870007000 Grip
shaft oil seal/fitting
differential bearing
race
1. Fit the layshaft front bearing outer races (1a) using tools (1b) and (1c).
1.9 JTD 8v
2000004600 Fitting tool Bearing fitting tool
1.9 JTD 16v
Grip for tool for

extracting
bearing/fitting main
1870007000 Grip
shaft oil seal/fitting
differential bearing
race
1. Fit the bearing for the gear selector and engagement shaft (1a) in its housing using the
tools (1b) and (1c).
1.9 JTD 8v
Selector bearing
fitting tool
1.9 JTD 16v
1.9 JTD 8v
Grip for tool for fitting
1874365000 Grip
bearing
1.9 JTD 16v
- Fit the main shaft and the two layshafts complete with forks in their housings in the clutch
casing.
PROCEED WITH DETERMINING THE SIZE OF THE SCRAPER RINGS AS DESCRIBED BELOW.
1. Tighten the main shaft rear bearing retaining bolt to the recommended torque using the
special tool for counter-torque.
1.9 JTD 8v
1.9 JTD 16v
Component Fastening dia Value (daNm) Validity
1.9 JTD 8v
Main shaft rear
Bolt M18 x 1.5 5.0 ÷ 7.0
bearing
1.9 JTD 16v
2. Fit the outer races on the gearbox shafts.
1. Tighten the rods with the spacers to the clutch casing.
2. Fit the three gauges on the three gearbox shafts.
1.9 JTD 8v
Calculating thickness
2000002000 Gearbox overhaul kit
of scraper rings
1.9 JTD 16v
3. Fit the gearbox casing (3a) on the rods fitted previously and tighten the nuts (3b) to a
torque of 25 Nm starting with tightening the nuts by the centering bushes.
4. Rotate the gearbox main and layshafts through about twenty revolutions using the special
tool.
1.9 JTD 8v
1.9 JTD 16v
5. Measure the gap between the two cylinders for each of the three shafts using a feeler
gauge.
- Determine the size of the new scraper ring for the main shaft (A) by subtracting the
maximum permitted clearance of 0.10 mm from the reading taken previously using the feeler
gauge.
- Determine the size of the new scraper ring for the layshaft (B) by adding the maximum pre-
loading of 0.20 mm to the reading taken previously using the feeler gauge.
- Determine the size of the new scraper ring for the second layshaft (C) by adding the
maximum pre-loading of 0.30 mm to the reading taken previously using the feeler gauge.
- Remove the gearbox casing and all the components for the tool from the clutch casing.
1. Fit the gearbox casing (1b) on the tool (1c) using two nuts (1a) taking care to position the
three studs (1d) by the three shaft housings.
Fitting bearing outer 1.9 JTD 8v

Gearbox casing
2000005700 races on gearbox
support frame
casing 1.9 JTD 16v
1. Fit the three new scraper rings (1a) and the outer races for the main and layshaft rear
bearings (1b) using the tools (1c) and (1d).
Fitting bearing outer 1.9 JTD 8v

2000005200 Fitting tool races on gearbox
casing 1.9 JTD 16v
1.9 JTD 8v
Grip for tool for fitting
1870007000 Grip
bearing
1.9 JTD 16v
- Apply the LOCTITE 510 sealant to the entire matching surface between the gearbox casing
and the clutch casing.
- Remove the gearbox casing from the support tool and fit it on the clutch casing tightening
the bolts to the recommended torque.
1.9 JTD 8v
Gearbox casing Bolt M8 2.2
1.9 JTD 16v
1. Fit a new main shaft oil seal on the clutch casing using the special fitting tool.

Fitting main shaft 1.9 JTD 8v
seal 1.9 JTD 16v
- Fit the gear selector and engagement assembly on the clutch casing tightening the bolts to
the recommended torque.
Gear selection 1.9 JTD 8v

and engagement Bolt M8 2.0
assembly 1.9 JTD 16v
- Fit the clutch control coaxial actuator to the clutch casing tightening the bolts to the
recommended torque.
1.9 JTD 8v
Coaxial actuator Bolt M6 0.6
1.9 JTD 16v
- Connect the three-way connector to the oil pipe for the coaxial actuator and to the clutch
casing.
- Undo the fastenings and remove the gearbox and differential from the support tool.
- Remove the support tool from the overhaul stand.

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eLearn - Contents Page 1 of 19

Tool Description Function Validity

2. Undo the reverse sensor and remove it.

3. Adjust the retaining clip and remove the three-way connector.

Tool Description Function Validity

Tool Description Function Validity

Tool Description Function Validity

3. Remove the second layshaft from its housing.

PROCEED WITH DISMANTLING THE CLUTCH CASING AS DESCRIBED BELOW.

Tool Description Function Validity

Tool Description Function Validity

2. Remove the main shaft seal from the clutch casing.

Tool Description Function Validity

PROCEED WITH DISMANTLING THE MAIN SHAFT (A) AS DESCRIBED BELOW.

Tool Description Function Validity

1860837000 Plate Plate for support in

Tool Description Function Validity

Tool Description Function Validity

Plate for support in

Tool Description Function Validity

Tool Description Function Validity

Plate for support in

Tool Description Function Validity

Half-rings for reaction

Tool Description Function Validity

PROCEED WITH DISMANTLING THE LAYSHAFT (B) AS DESCRIBED BELOW.

2. Remove the rear bearing circlip.

Tool Description Function Validity

Tool Description Function Validity

1. Remove the 4th speed synchronizer ring assembly.

2. Remove the 3rd and 4th speed sliding engagement sleeve.

3. Remove the pre-synchronizer mountings.

1. Remove the sliding sleeve hub circlip.

The layshaft should be supported at the bottom during this operation.

Tool Description Function Validity

2. Remove the needle bearing.

1. Remove the spacer circlip.

Tool Description Function Validity

2000005000 Plate Reaction plate in the 1.9 JTD 16v

1. Remove the front bearing circlip.

1. On press, remove the front bearing using a suitable extractor.

The layshaft should be supported at the bottom during this operation.

PROCEED WITH DISMANTLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.

1. Remove the circlip.

Tool Description Function Validity

1. Remove the synchronizer circlip.

Tool Description Function Validity

Tool Description Function Validity

1. Remove the bearing with a double row of rollers.

1. On press, remove the front bearing using a suitable extractor.

PROCEED WITH REASSEMBLING THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.

1. Fit the rear bearing on the press.

1. Fit the rear bearing circlip.

PROCEED WITH REASSEMBLING THE LAYSHAFT (B) AS DESCRIBED BELOW.

Tool Description Function Validity

Tool Description Function Validity

Tool Description Function Validity

Tool Description Function Validity

Tool Description Function Validity

1. Fit the synchronizer circlip.

Tool Description Function Validity

PROCEED WITH REASSEMBLIN THE MAIN SHAFT (A) AS DESCRIBED BELOW.