GOL 124 Spider Spider 2000 Five-Speed Transmission Ciat AMintare af Alartkh Amaringa InnF328F Table of Contents GG 124 Spider INTRODUCTION . GENERAL INFORMATION . Spider 2000 Di snefonl Data Tool Equipment . DESCRIPTION ...... Physical . fee Operation DISASSEMBLY . : Transmission Assembly | | Input Shaft Assembly . . . . Main Shaft Assembly |. ° : Main Shaft and Third Gear Subassembly Fist, Second, and Third Gear Assemblies... Fifth Gear Assembly . : INSPECTION AND REPAIR . Cleaning... ... t Inspection and Reps REASSEMBLY ...... Fifth Gear Assembly . Fi Main Shaft and Third Gear Subassembly . - Main Shaft Assembly Input Shaft Assembly Transmission Assembly | iitINTRODUCTION This manual contains information on the 5-speed transmission as used in the Fiat 124 Spider and Spider 2000. The manuai hes physical description, operation, disassembly, inspection and repair, and reassembly procedures requirad for transmission mainte- nance. Much of the art used (exploded views! is similar to the art used in the parts catalog. This will aid the reader when ordering replacement parts. ittivGeneral Information DIMENSIONAL DATA Page 1 Speeds .. five forward and reverse. Synchronizers:. slip ring, inverted cone type . ‘1st ~ 2nd - 3rd ~ 4th gear snapting.... ss... eee eee : Bth gear Geer type: forward... . ++ constant mesh, helical toothed reverse. straight toothed Gear ratios: ©“ first 3.687 to 1 second. (2.100 to 1 third 1.361 to 1 fourth. 1 tot fifth : 0.881 to 1 reverse : 3.526 to 1 Gear lash ~ inch (mm) . 0.004 ~ (0.10) Ball beering radial play, max. limit’~ inch (mm)... 0,002 . (0.05) Ball bearing end play,.max. limit ~ inch (mm) ..... 2... . 0.020. {0.0} Max. allowabls shaft misalignment ~ inch (mm) 0,002 (0.08) Clearance between 1st gear and bushing and between 2nd-3rd : i 0.002 to 0.004 gears and seats on mainshaft — inchimm)........... 1005 2 O19) a e 4 0.002 to 0.004 Clearance between reverse shaft and gear bushing ~ inch (mm) . 10.08 10. 0-10) FILL-UP DATA LUBRICANT QUANTITY dm3. Kg _U.S. units SAE 90 (not EP) containing antiwear additives 1 65 1.50 1% atsPage 2 TORQUE SPECIFICATIONS ‘DESCRIPTION Throat torr orm s tmecicl | arr um fon t Detent spring cover bolt MBs R 80 Znt 25 | 18 1 ‘Transmission edse-to-bellhousing nut ..... | M10 x 1.25 R80 Znt 43) 36 | «i i | R5O:Znt Transmission Gaise-to-bellhousing nut M8 |. gant #80 ne) 25] 18 | R.5O Znt Rear housing nut : Ms (sea teen |. 23] 18 7 C40 'Ret'R 80 +70 Countershatt réar bearing nut M1815 (Shaft 20 Ned | 118] 87 2 Fost Lub) R50 Znt (Shaft. | Propeller shaft yoke-to-mainshaft nut . M20x1 20 Ned 2 Fosf Lub | 147 | 108 or 18 C8 Fost Lub} Countershaft front bearingbolt ......... | M12x 1.25 R80 Znt 93| 68 Shift fork bolt: M6 R100 1g] 14 Dog-to-selector shaft bolt ...... M6 R100 is | 14 Gear lever support bolt»... . +. Ms R 80-Cdt | 20] 14 Inner cup-to-gear lever lower self-lacking nut, R50 Cat. type S Me (Stem 12 Nc 3) iyo JGeneral Information . Page 3/4 TOOL EQUIPMENT ‘Ths following is @ list of tools used to service the transmission. Although only the * tools are required, all will aid to lessen work time. Tool No. A.50113 A,55087 ~ A.85130 A.57051 A.70159* 4.70166 A.70350* A.71001/19 A.74140/1 4.741404 Description Wrench, transmission oil draining plug Wrench, transmission casing oil ievel plug Adapter, flexible joint yoke tightening — use with torque wrench Wrench, rear cover oil drain plug Remover and installer, snap ring on main shaft Installer, Bth-speed synchronizer snap ring Remover and installer, spring washer on input shaft Support for fixing transmission to stand Ar. 22204, during overhaul Pliers for staking countershaft nut Staking heads (pair!, (use with 4.74140/1) countershaft nutDescription Page PHYSICAL (See cutaway view! The trensmission {s conventional (mainshatt meshed with: countershaft), with five forward and one reverse gear. The constant-mesh, helical type forward gears are silent and synchronized for quick engage. ment. Raverse is @ spur gear. The transmission is in four parts: the bellhousing, main case, rear housing, and shift tower, The bellhousing is attached to the main case, is used to attach the transmission to the engine, and con- tains the clutch and throwout bearing, The mein case contains: = the input shaft assembly. ~ the main shaft assembly. = the countershaft (sometimes called cluster gear or laygesr) 7 the first and second shift fork, third and fourth shift fork, and fork shafts for all speeds. the detent balls, dowels, and springs. the reverse switch. il fill and drain plugs. inspection cover (oil removed). ~ two ball bearings for the main shat countershat ; one double row ball bearing, and one roller bearing for the ‘The rear housing contains the fifth and reverse gears, reverse shaft, fifth and reverse shift fork, main shaft rear bearing, and engaging lever. It is attached to the main case, and serves as the mounting for the snift tower. A rear supporting cross strut is also attached to the rear housing. The shift tower contains a sliding shaft. At the front end is @ dog that engages the engaging lever in the rear housing. At the rear end of the shaft is mounted a spherical Bearing. Through the spherical bearing is mounted the shift lever.30. 29, Description ~ Transversal section through third and fourth gear sliding sleeve Input shaft (with fourth gear cogs) Fourth gear synchro - Third/fouren sieeve synchro Firstisecond sieeve First gear synchro Fifth gear assembiy Main shatt Fifth and reverse gear Gross-section B-8 - Transversal Page 7 tion through Fifth gear control and gear laver support 17. 18, 13, 20. at 22. 23, 24, 25. 28. D« 27. 28. 28. 30, 31 Countarshatt Reverse:siding gear sheit Reverse sliding gear Fifth end raverse fork shaft ‘Third and fourth fork shaft First and second fork shaft Fifth and reverss shift fork Shift lever Slicing shaft lection and engaging lever Engaging lever roc Third and fourth shift fore rst and second-shift fork HubPage & OPERATION Shift Mechanism (See Shift Mechanism Figure) When the driver moves the shift lever irom side to side, the shaft in the shift tower is rotated about its axis. The dog at the front end of the shaft contacts the engaging lever and moves it from side to side. ‘The knob on the engaging levar is then moved to one of the three shift forks. Once the shift fork is selected, the shift lever is moved elther forward or backward, causing the fork shaft to move forward or backward. Attached to the fork shat: are the shift forks which are used to engage the gears FIRST AND SECOND SHIFT FORK FIFTH AND REVERSE SHIFT FORK THIRD AND FOURTH SHIFT FORK ‘Shift MechanismDescription Page 9 Neutral (Seo Transmission Gear identification, Noutral Position Figure) The dtterenced figure is @ schematic view of the 5-apeed transmission in neutral position, Motion from {he engine is transferred through the clutch, to the input shatt. The gear on the inser trots transfers the Motion to the countershatt. Each gear on the countershaft transfers motion to he mating gear on’the main shaft, £8Gh Bait of mating gears ifirst/second and third/fourth) on the main shaft share a sleeve thetis keyed to and tums with the main shaft. Between the sieeve and each gear is a synchro used ro synchronize sleeve machined on are fey ens engagement. Each sieave has inner teeth that engage with oowe teon machined on the forward gears. in neutral position, all three sleeves ere disengaged from the forward or reverse gears, With no sleeves engaged, all gears are free wheeling. Only the reverse sliding gear does not turn. » THIRD / FOURTH FIRST/ SECOND.” FIFTH / REVERSE SLEEVE SLEEVE SLEEVE THIRD “SecoND’/ FIRST / RIETH INPUT Gear “GEAR {°° Gear GEAR SHAFT \ 4 [id. “f COUNTERSHAFT SHAFT, | REVERSE sLivine Gear . \ ON REVERSE SHAFT FIFTH AND REVERSE GEAR ‘Transmission Gear identification, Noutral PositionPage 10 First Gear (See First Gear Figure} When the shift lever is placed in first position; the first/second sleeve is moved rearward on the main shaft. In betwesn and perpendiiciler to the fork shafts are detent dowels and pin which prevent two gears from being engaged at the same time. The sleave contacts the synchro, which ie normaly keot one Of contact with the first gear by the spring between the synchro and first gear, As the synchro contacts the sléeve, friction betwéen the synchro’and the Cohical surface forces the sleeve (keyed to main shaft], synchro, and first gear (being turned by the countershaft] to approach the Same speed. Drive is finally achieved when the crown teeth inside the sleeve engage the crown teeth on first gear. Once fully engaged, the spring between the gear and synchro would return the sleeve to neutral: This is Prevented by the spring loaded detent balls engaging notches in the fork shafts, FIRST / SECOND SLEEVE PTR Second Gear (See Second Gear Figure! When the shift lever is placediin second position, the first/second sleeve is disengaged from first gear; then engaged with second gear. Synchronizing is the same as for first gear.Description Page 11 Third Gear (See Third Gear Figure} Togo from second tot hird gear, the shift lever is returned to ne! from second gear, It i ‘then moved to third position, I to disengage the first he third/fourth sleeve ‘second sleeve ngages the third gear. THIRD / FOURTH SLEEVE THIRD Third Gear Fourth Gear (See Fourth Gear Figure) . then the shift lever is placed in fourth position, the thitd/fourth sleeve te disengaged from third gear, then engaged with the crown testh on the input shat. As @ vesule eee a direct drive from the input Sheftto the main shaft, giving 1:1'ratio. The countarshatt conting ve ge driven, but does not transfer THIRD / FOURTH “SLEEVE .Page 12 Firth Gear (See Fifth Gear Figure) To go from fourth to fifth gear, the shift lever is returned to neutral to disengage the third/fourth sieeve from the input shaft. It is then moved to fifth position. The fifth/reverse position sleeve engages the fifth gear. : FirTH / REVERSE SLEEVE \ iets \ GEAR Fifth Gear Reverse Gear (Ses Reverse Gear Figure) Reverse gear is @ nonsynchro spur gear. As 2 result, the vehicls must be stopped before reverse can be engaged. Otherwise, damage may result. To.engage reverse, the shitt lever is first moved to the neutral Bosition. The shift lever smust then be pushed down and back to clear the reverse lockout screw. This lockout screw prevents accidental engagement of reverse gear when the car is moving, The fifth/reverse sleeve now moves the reverse sliding gear forward to engage the reverse gear on the countershaft and the reverse gear on the main shaft. With this third gear introduced into the systom, out- put direction is reversed. FIFTH / REVERSE SLEEVE REVERSE GEAR Reverse GearDisassembly Page 12 TRANSMISSION ASSEMBLY Mount Transmission and Drain’ Oil a.Mount_ transmission ‘on.-support (2) A.71001/18, part of rotating stand (1). b. Using tools A.50113, “A.55087, and 4.57081, remove ail drain plug (6), ofl level plug, and réar housing ail drain plug. ¢. Remove three self-locking nuts and-bolts.at- taching flexibie joint (4). G. Remove two nuts and. washers attaching rear supporting cross strut (3) to rear housing. @, Remove return spring and rubber boot (5) 4, Flexible joint. Soring and rubber boot Oil drain plug 83. Rear supporting cross’ seut eu Remove Yoke and Throwout Bearing 2, Unhook yoke (2) from pivot (41 by sliding yoke toward return spring end. b. When unhooked, guide yoke, and throwout bearing (3) off input shaft. ©. Remove pivot (4) and lockwasher (5) from bellhousing (1) only if damaged. 1. Bethousing 4, Plvot 2 Yoke 5. Lockwasher Trrowout bearing Remove Bellhousing.~ a. Remove six nuts (7), lockwashers (8), and one nut (8) and lockwasher (5) attaching bellhous- ing (4) to case (1). b. Remove gasket (3) and spring washer (2), Remove seal (9) from the bellhousing (4} only if the seal will be replaced, 1. Case 6. Nut 2. Spring washer 7. Nut 3. Gosker 8 Lockwasher 4 Bethousing 9. Seal 5. Lockwasher Transmission Mounted on Stand << Belthousing, RemovalPage 14 Remove Speedometer Drive : 2. Remove nut (2) and lockwasher (1) attaching speedometer drive (3) to rear housing (5). b, Remove speedometer drive (3) and gasket (4), Lockwasher Nut Speedometer drive Gasket ear housing Remove Shift Tower a. Remove four nuts (7) end lockwashers (6). b. Remove entire shift tower assembly (1) by lift- ing, then pushing shift lever forward until tab ‘on dog (2) clears engaging lever (4) in reat housing (3). Remove'gasket (5). Shi: tower assembly Dog Rear housing . Engaging lever Gasket Lockwasher Nut Shift Tower, RemovalDisassembly Page 15 Disassemble Shift Tower NOTE: Disassemble shift tower assembly only to the extent to replace defective components. a. Remove boot (15), ©. Remove four nuts and lockwashers.(14), cover (17), and gasket (16). Do not screw (18) and locknut (19) uniess damaged. &. Remove three nuts and lockwashers (141, and cover (12). &: Remove-nut and washer (11), bearings (10}, socket (24), cover (23), and spring (22). g. Lift shift lever (25) from shift tower. Remove spring clip (211. Remove bolt and lockwasher (9): Slide shaft out shift tower rear, then remove dog (81, 8: Remove cap (41, bearing (6), and studs (2, 13, and 20) only if damaged. remove reverse lockout 4. Nut and leckwasher 10. Beating 18. Locknut 2. Stud 11. Nut ane washer 20. Stud 3: Shift tower 12. Cover 21. Spring 4. Cap 13, Stud 22: Spring 5. Gasker 14. Nut and lockwasher 23. Cover 8. Bearing 18. Boot 24. Socket 7: Shatt 18. Gasket 25. Shift lever 8. Dag 17. Cover 8. Bolt and locksiasher 18: Reverse lockout ecrew Shift Tower, Exploded ViewRemove Countershaft a. Remove bolt (6), lockwasher (51, and washer (4). », Using a soft mallet, tap on output end of countershaft (2) until bearing (3) can be removed from case 7). «. Carefully tap on bearing (7) outer race to remove from case (7). d. Remove countershaft (2) from case. 1. Bearing 2. Countarshart 3. Bearing 4. Washer 5. Lockwasher 8. Bor 7. Case Countorshatt, Removal Page 20Disassembly Page 23 MAIN SHAFT ASSEMBLY Disassemble Main Shaft Assembly 2. Remove sleeve (7), . 5. Remove bushing (1, first gear assembly (2), hub (3, sleeve (4) and second gear assembly (5) fram main shaft and third gesr subassembly (6), 6. Bisessemble main shaft and third gear subecsembly (8) 28 specified in Main Shaft and Third: Gear Subassembly at Z 4; Disassemble first and'second gaar asderblias (2 and §) a8 Spetified in First, Second, and Third Géer Assemblies, 1. Bushing 4. Sleave 8..Main shaft and third gear 2. First gear assembly 5. Second gear assembly ‘subassembly 3. Hub 7. Sleeve Main Shaft Assembiy, Disassemblyi ' } Page 24 MAIN SHAFT AND THIRD GEAR SUBASSEMBLY Disassemble Main Shaft and Third Gear Subassembly a, Place subassembly in press. Do not support subassembly on gear, but on shoulder of main she 'b: Use press’éhd tool A.70159 to ¢oniptess spring washer (31. ¢. Unsnap snap ring (4) from its groove, then remove from press. d. Remove snap ring (41, spring washer (3) arid hub [2) from main shaft and third gear (1), ¢, Disassemble main.shatt.and third gear (1) a8 specified in First, Second, and Third. Geer Assemblies. 41.-Main shaft and third gear 2. Spring washer 2) Hus 4. Snap ring Main Shaft end Third Gear Subassambly, DisassemblyDisassembly Page 25/26 FIRST, SECOND, AND THIRD GEAR ASSEMBLIES Disassemble First, Second, and Third Gear Assemblies NOTE: Although different in size, the first, sec: ond, and third gear assemblies are similar in assembly. Also, the third gear assembly 's assembled on the main shaft, & Using tool 4.70788, remove snap ring (6) >. Remove synchro (5), spring (4) and spring re- tainer (3) from gear (2). ©. Remove third geer assembly from main shafe m. 1. Main shete third gear only) 2. Fret, second, or third gear Soring retainer Spring eho First, Second, and Third Gaar Assemblies, FIFTH GEAR ASSEMBLY Disassemble Fifth Gear Assembly a. Remove sieve (7), b. Remove synchromesh parts snap ring (6). Discard snap ring. & Using tool A.70166, remove syachromesh rina (5), 4d. Remove spring (3), lock (1), and stop (4) from fifth gear (2). 1. Looe 5. Synchromesh ring 2. Geer 8. Synchromesh parts snap ring 8. Spring 7. Sleave 4, Stop Fifth Gear Assembly, Disassembly Disassembly