Workshop Manuals Factory service & repair Lancia
Lancia Thesis Factory Service Manual (2002-2009)24 · Special tools
24 · General

Manual gearbox and differential – manual gearbox and differential components and synchronizers

Make
Lancia
Model
Thesis Factory Service Manual
Year
2002–2009
Section
Gearbox › Manual gearbox and differential – manual gearbox and differential components and synchronizers
Special toolsManual gearbox and differential – manual gearbox and differential components and synchronizers

MANUAL GEARBOX AND DIFFERENTIAL – MANUAL GEARBOX AND DIFFERENTIAL COMPONENTS AND SYNCHRONIZERS

DescriptionCodeFunctionValidity
Support1.870.644.001Gearbox support bracket whilst overhauling2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.871.001.014Gearbox support whilst overhauling2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Flange1.847.017.004Extracting left differential internal driveshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Mallet1.840.206.001Extracting left differential internal driveshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.655.000Extracting main shaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Mallet1.840.206.001Extracting main shaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.655.000Extracting main shaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Mallet1.840.206.001Extracting layshaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half-rings support1.846.017.001Extracting 6th speed rear bearing and driven gear2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half-rings1.870.676.000Extracting 6th speed rear bearing and driven gear2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half-rings support1.846.017.001Extracting 4-5th speed driven gear2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half-rings1.870.675.000Extracting 4-5th speed driven gear2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Plate1.874.290.000Extracting 3rd-2nd speed driven gear2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half plate1.874.290.000Dismantling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half plate1.874.290.000Dismantling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Reaction base1.870.660.000Dismantling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting front bearing2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Half-rings1.845.063.000Fitting front bearing2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.870.659.000,Reassembling layshaft2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Gauges1.870.648.000Determining main and layshaft bearing pre-loading2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Reference crossmember1.870.649.000Determining main and layshaft bearing pre-loading2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Gauges1.870.648.000Determining main and layshaft bearing pre-loading2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.870.647.000Determining main and layshaft bearing pre-loading2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Dial gauges1.895.881.000Determining main and layshaft bearing pre-loading2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Bush1.870.652.000Main shaft rotation2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.874.365.000Fitting main shaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.874.365.000Fitting layshaft rear bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.870.597.000Fitting seal2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Grips1.870.007.000Fitting seal2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.895.655.000Determining thickness of differential bearing scraper rings2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.895.655.000Determining thickness of differential bearing scraper rings2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.870.597.000Fitting seal2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Grips1.870.007.000Fitting seal2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.871.001.014Positioning gearbox and differential on overhaul stand2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.655.000Removing layshaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Mallet1.840.206.001Removing layshaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Removing main shaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.657.000Removing bushes in gear control rod housing for support joining gearbox to engine2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.657.000Removing bushes in gear control rod housing and gearbox casing plugs.2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.657.000Removing bushes in gear control rod housing and gearbox casing plugs.2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.657.000Fitting gear control rod housing bushes on gearbox casing.2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Extractor/Fitting tool1.870.657.000Fitting gear control rod bushes on gearbox casing.2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.870.656.000Fitting main shaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Grip1.874.365.000Fitting main shaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Fitting tool1.870.656.000Fitting main shaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Grip1.874.365.000Fitting main shaft front bearing outer race2.4 20 V,2.0 TB,2.4 JTD 10V,2.4 JTD 20V
Support1.871.001.014Supporting gearbox on overhaul stand2.4 JTD 20V
Blade1.870.718.000Removing gearbox casing-clutch casing sealant2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Extraction half-rings1.870.899.500Extracting layshaft front bearing (C)2.4 JTD 20V
Extractor1.870.845.100Extracting layshaft front bearing (C)2.4 JTD 20V
Half plates1.860.837.000Extracting hub for reverse gear sliding sleeve2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (C)2.4 JTD 20V
Extraction half-rings1.870.899.700Extracting spacer on layshaft (C)2.4 JTD 20V
Extractor1.870.845.100Extracting spacer on layshaft (C)2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (C)2.4 JTD 20V
Half plates1.860.837.000Extracting hub for 3rd-4th speed sliding sleeve2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (C)2.4 JTD 20V
Half plates1.870.899.400Dismantling layshaft (C)2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (C)2.4 JTD 20V
Extraction half-rings1.870.899.600Extracting layshaft front bearing (B)2.4 JTD 20V
Extractor1.870.845.100Extracting layshaft front bearing (B)2.4 JTD 20V
Half plates1.860.837.000Extracting hub for 1st-2nd speed sliding sleeve2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (B)2.4 JTD 20V
Half plates1.870.899.400Extracting hub for 5th-6th speed sliding sleeve2.4 JTD 20V
Reaction pin1.870.899.100Dismantling layshaft (B)2.4 JTD 20V
Half plate1.860.837.000Dismantling layshaft (B)2.4 JTD 20V
Reaction pin1.870.899.100Dismantling main shaft2.4 JTD 20V
Extraction half-rings1.870.899.200Extracting main shaft front bearing2.4 JTD 20V
Extractor1.870.845.100Extracting main shaft front bearing2.4 JTD 20V
Half plate1.860.837.000Dismantling main shaft2.4 JTD 20V
Reaction pin1.870.899.100Dismantling main shaft2.4 JTD 20V
Half plate1.860.837.000Dismantling main shaft2.4 JTD 20V
Reaction pin1.870.899.100Dismantling main shaft2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Drift1.870.898.500Fitting differential rear bearing outer race2.4 JTD 20V
Grip1.870.898.400Fitting differential rear bearing outer race2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Clutch casing support for determining bearing pre-loading2.4 JTD 20V
Drift1.870.898.500Fitting differential rear bearing outer race2.4 JTD 20V
Grip1.870.898.400Fitting differential rear bearing outer race2.4 JTD 20V
Support1.871.001.014Supporting gearbox on overhaul stand2.4 JTD 20V
Fitting tool1.870.899.800Fitting differential seal (right side)2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Fitting tool1.870.899.800Fitting differential seal (left side)2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Fitting tool1.870.898.600Fitting main and layshaft rear bearing outer races2.4 JTD 20V
Grip1.870.898.400Fitting main and layshaft rear bearing outer races2.4 JTD 20V
Support complete with gauges1.870.897.100Determining main and layshaft bearing pre-loading2.4 JTD 20V
Gauges support1.870.897.900Determining main and layshaft bearing pre-loading2.4 JTD 20V
Bush for main shaft counter-torque1.870.899.000Determining main and layshaft bearing pre-loading2.4 JTD 20V
Gauges1.870.898.000Determining main and layshaft bearing pre-loading2.4 JTD 20V
Gauges support1.870.897.900Determining main and layshaft bearing pre-loading2.4 JTD 20V
Reference crossmember1.870.897.800Determining main and layshaft bearing pre-loading2.4 JTD 20V
Gauges1.870.898.000Determining main and layshaft bearing pre-loading2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Gearbox casing support for determining bearing pre-loading2.4 JTD 20V
Support1.871.001.014Supporting gearbox on overhaul stand2.4 JTD 20V
Gearbox casing/clutch casing support1.870.897.700Clutch casing support for fitting bearing outer races2.4 JTD 20V
Fitting tool1.870.898.900Fitting main shaft (A) front bearing outer race on clutch casing2.4 JTD 20V
Fitting tool1.870.898.700Fitting layshaft (B) front bearing outer race on clutch casing2.4 JTD 20V
Fitting tool1.870.898.800Fitting layshaft (C) front bearing outer race on clutch casing2.4 JTD 20V
Grip1.870.898.400Fitting main and layshaft front bearing outer races on clutch casing2.4 JTD 20V
Half plates1.860.837.000Fitting main shaft rear bearing (A)2.4 JTD 20V
Fitting tool1.860.824.000Fitting main shaft rear bearing (A)2.4 JTD 20V
Half plates1.860.837.000Fitting 6th speed drive gear on main shaft (A)2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting 6th speed drive gear on main shaft (A)2.4 JTD 20V
Half plates1.860.837.000Fitting 4th speed drive gear on main shaft (A)2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting 4th speed drive gear on main shaft (A)2.4 JTD 20V
Half plates1.860.837.000Fitting 3rd-5th speed drive gear on main shaft (A)2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting 3rd-5th speed drive gear on main shaft (A)2.4 JTD 20V
Half plates1.860.837.000Fitting main shaft front bearing (A)2.4 JTD 20V
Fitting tool1.870.899.300Fitting main shaft front bearing (A)2.4 JTD 20V
Half plates1.860.837.000Fitting layshaft front bearing (B)2.4 JTD 20V
Fitting tool1.860.824.000Fitting layshaft rear bearing (B)2.4 JTD 20V
Fitting tool1.870.710.000Fitting layshaft front bearing (B)2.4 JTD 20V
Half plates1.860.837.000Fitting layshaft rear bearing (B)2.4 JTD 20V
Fitting tool1.860.824.000Fitting layshaft rear bearing (B)2.4 JTD 20V
Half plates1.860.837.000Fitting hub for 5th-6th speed sliding sleeve2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting hub for 5th-6th speed sliding sleeve2.4 JTD 20V
Half plates1.860.837.000Fitting hub for 1st-2nd speed sliding sleeve2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting hub for 1st-2nd speed sliding sleeve2.4 JTD 20V
Half plates1.860.837.000Fitting layshaft front bearing (C)2.4 JTD 20V
Fitting tool1.860.824.000Fitting layshaft rear bearing (C)2.4 JTD 20V
Fitting tool1.870.710.000Fitting layshaft front bearing (C)2.4 JTD 20V
Half plates1.860.837.000Fitting layshaft rear bearing (C)2.4 JTD 20V
Fitting tool1.860.824.000Fitting layshaft rear bearing (C)2.4 JTD 20V
Half plates1.860.837.000Fitting hub for 3rd-4th speed sliding sleeve2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting hub for 3rd-4th speed sliding sleeve2.4 JTD 20V
Half plates1.860.837.000Fitting spacer between reverse gears and 3rd-4th speed gears2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting spacer between reverse gears and 3rd-4th speed gears2.4 JTD 20V
Half plates1.860.837.000Fitting hub for reverse gear sliding sleeve2.4 JTD 20V
Extractor/Fitting tool1.870.658.000Fitting hub for reverse gear sliding sleeve2.4 JTD 20V
Splined shaft1.870.898.200Measuring differential casing rolling torque2.4 JTD 20V

Parts & tools for this job For 2002 Lancia Thesis

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