2009 LAMBORGHINI GALLARDO Workshop Manual

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4.
 )DVWHQWKHVSHFL¿FFODPS ()LJ) to connect pipe C4 to the union with pipe C3.
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Direct the pipe fastening clamp openings so that they are easy to access the next time they need to be disassembled.
• Assemble the propeller shaft (030705).
• Fill the circuit and then bleed the engine cooling system (012106).
• Start the engine and check that while the A/C system is on HI, hot air issues from the air conditioning system air
vents.
•  $VVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV .

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 1RWHAs mentioned already in the disassembly procedure, to assemble the heating system pipes it is necessary
to simultaneously assemble the air conditioning system pipes.
$VVHPEOLQJSLSHVOOODQGOLQVLGHWKHSDVVHQJHUFRPSDUWPHQW 1. Position the individual pipes ( OOODQGO) to piece together the assembly ( )LJ).
2. Position the pipe assembly in its housing inside the passenger compartment and pull the tabs to adjust the
gasket underneath the vehicle ( $)LJ).
3.  7LJKWHQ WKH VSHFL¿F VFUHZV WR FRQQHFW WKH WZR DLU FRQGLWLRQLQJ V\VWHP SLSHV  %)LJ) and the three heating
system pipes ( OODQGO) to connection pipe l4.
4.  2Q WKH ULJKW VLGH RI WKH SDVVHQJHU FRPSDUWPHQW WLJKWHQ WKH ¿[LQJ VFUHZV  ')LJ) to connect the two air
conditioning system pipes ( &)LJ).

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heating system pipes ( OODQGO).
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Direct the pipe fastening clamp openings so that they are easy to access the next time they need to be disassembled.
• Assemble the propeller shaft (030705).
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• Fill the circuit and then bleed the engine cooling system (012106).
• Start the engine and check that while the A/C system is on HI, hot air issues from the air conditioning system air
vents.
•  $VVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV .
• Assemble the center console end panels .
• Assemble the center console ornament .
• Assemble the BJA push-button panel unit .
• Assemble the air conditioner grille .
• Assemble the air conditioner control unit .
• Assemble the multimedia system .

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*HDUER[WHFKQLFDOGDWD • Fast engagement 6 gear ratios + reverse gear
•  6\QFKURQLVHUVZLWKÀRDWLQJULQJV
• Meshing clearance (all gears) 0.11 ÷ 0.03 mm
• Lubrication with gear pump
• Net Weight: 80 Kg
• Oil quantity: 4 Lt
• Number teeth: 25
• Gearbox ratios:
67' &20)257
(Comfort Package)
1st gear 1 : 3,313 1 : 2,563
2nd gear 1 : 2,053 1 : 1,850
3rd gear 1 : 1,458 1 : 1,423
4th gear 1 : 1,138 1 : 1,138
5th gear 1 : 0,939 1 : 0,939
6th gear 1 : 0,784 1 : 0,806
Reverse 1 : 2,813 1 : 2,813
countershaft/front differential input shaft 1 : 1,409
countershaft/rear differential input shaft 1 : 1,240
• 0DQXDOW\SH with cable control
• (*HDU W\SH robotised with electronically managed electro-hydraulic control and 4 function modes: normal,
automatic, sport and low adherence.
Hydraulic circuit pressure: approx. 40 – 50 bar
Valve trigger pressure approx. 90 bar
System capacity (000300)

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1 Clutch Housing
2 Ball Bearing
3 Clutch Shaft
4 Drive Shaft
5 Main Shaft Front Ring Nut
6 Ball Bearing
7 Thrust Washer
8 Roller Cage
9 Complete 4th Speed Gear
10 Retaining Ring
11
3rd-4th Speed Double/Triple Cone Synchroniser
12 Complete 3rd Speed Gear
13 Roller Cage
14 Complete 6th Speed Gear
15 6th Speed Gear Spacer
16 Retaining Ring
17 5th-6th Speed Double Cone Synchroniser
18 Complete 5 Th Speed Gear
19 Roller Cage
20 Complete 3rd-4th Speed Shaft
21 Complete 3rd-4th Speed Selector Fork
22 Complete 1st-2nd Speed Selector Fork
23 Complete Reverse Gear Shift Shaft
24 O-ring
25 Ball Bushing
26 Roller Bearing
27 Complete 5th-6th Speed Selector Fork
28 Reverse Drive Gear
29 Ring Nut
30 Complete Reverse Fork
31 Rear Cover
32 Complete Reverse Synchroniser
33 Roller Cage
34 Complete Reverse Idle Gear
35 Reverse Gear Bushing
36 Thrust Washer
37 Complete 1st Speed Gear 38
Roller Cage
39 Retaining Ring
40 1st-2nd Speed Triple Cone Synchroniser
41 Complete 2nd Speed Gear
42 Roller Cage
43 Spacer Ring
44 Ring
45 Lay Shaft
46 Bearings Retaining Plate
47 Intermediate Plate
48 Pinion Driving Gear
49 Drive Driving Gear
50 Drive Driven Gear
51 Roller Bearing
52 Radial Shaft Seal
53 Roller Bearing
54 Ring Nut
55 Drive Shaft
56 Ball Bearing
57 Drive Shaft Cover
58 Pinion Adjusting Washer
59 Tapered Roller Bearing
60 Preload Adjusting Washer
61 Pinion Driven Gear
62 Tapered Roller Bearing
63 Ring Nut
64 Manual Gearbox Gear Shift Mechanism
65 Complete Oil Pump
66 Roller Casing
67 Idle Gear Shoulder Ring
68 Idle Gear - Reverse
69 Driving Dowels
70 Driving Pin
71 Pinion
72 Gearbox Housing
73 Washer
74 Retaining Ring
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General instructions
Prior to starting work on the dismantling or assembing of the Gearbox and Differential assy, bear in mind the following points: •When working on the gearbox assy observe high standards of cleanliness. All parts should be cleaned throughly
prior to assembly.
• The location where the work is to be carried out should be dust-free clean.
• 0DNH VXUH WKDW DOO WKH QHFHVVDU\ WRROV DUH DYDLODEOH SDUWLFXODUO\ WKRVH PHQWLRQHG LQ WKLV PDQXDO 3DUWV ¿WWHG
incorrectly can cause serious damage, in the same way as metal chips or foreign bodies.
• During the differential assy overhaul, you are advised tu substitute the following with new parts: oil sealing rings,
gaskets, retaining rings and any parts damaged during dismantling.
• If breakage occurs inside the planetary gears side or differential, all lines, casing and should be cleaned thor-
oughl to prevent damage caused by residues left inside the system.
SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by one with a micrometer gauge and, then, summing up all values measured; do not trust incorrect measurement of pack as a
unit or sum of nominal value printed on each shim.
SEALS FOR REVOLVING SHAFTS
3URFHHGDVIROORZVIRUSURSHU¿WWLQJRIRLOVHDOV • prior assembly, seals should be soared, for at least half an hour, in a bath with the same oil to be sealed;
• FOHDQWKRURXJKO\VKDIWDQGPDNHVXUHWKDWZRUNLQJVXUIDFHLVQRWGDPDJHGSRVLWLRQVHDOLQJOLSDJDLQVWWKHÀXLG
to be sealed; in case of hydrodynamic lip lines should be oriented so as that, considering direction of revolving
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sealing lip and dust shield lip, if using double sealing lip type seals;
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mount seal;
• ZKHQSUHVV¿WWLQJVHDOPDNHVXUHWKDWLWEHFRUUHFWO\GULYHQLQUHOHYDQWSRVLWLRQLHVTXDUHZLWKUHVSHFWWRLWV
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• to prevent damage of seal lip when inserting shaft, duly protect component during assembly.

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O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.
SEALING COMPOUNDS
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Clean matching surface as follows prior, smearing compound:
• remove old deposits using a metal brush;
• degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and soda solu-
tion.
BEARINGS
When assembling them it is advisable to proceed as follows: • KHDWWKHPDWWR½&EHIRUH¿WWLQJRQUHOHYDQWVKDIWV
• cool them before inserting in relevant external position.
SPRING PINS
When using spring pins be sure that lengthwise slot be positioned toward stress on pin.
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Dispose of worn and replaced materials according to local regulation.

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In order to assure the right condition, handling and utilization of the product, perform the following instruction: •TEMPERATURE CONDITIONS
• Storage - 40 + 70° C
• Working - 30 + 60° C
• During the handling of the product avoid any collision in order not to damage the external and internal
components.
• In case of long inactivity of the product, before installing or starting, beware that the product has not suffered
any damage.
• Do not energize the electrical components with incompatible voltage.
• 1HYHU XVH SHWURO VROYHQWV RU RWKHU LQÀDPPDEOH ÀXLGV XVH RQO\ DSSURYHG FRPPHUFLDO VROYHQWV WKDW DUH ERWK
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• In case of stopping and before living the vehicle, make sure the parking brake is engaged.
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Failing to follow these instructions or an unproper use of the product may result in harm to persons and objects damages.
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