Iveco Daily Euro 4. Manual — part 105
90215
108863
Figure 63
Figure 64
Use the hydraulic vice to remove from the primary shaft (1):
the 1
st
speed gear (8), the spacer (7), the bush (6), the roller
cage (5), the R.M. gear (4) together with the coupling
elements, the synchronising ring (3) and the serrated ring (2).
Take 1st/2nd gear engagement sliding sleeve (2) and dowels
(3), together with balls (4) and springs (5), off hub (1).
Take out the synchronizer ring (4), middle ring (3), ring (2) and
roller bearing (1).
Using a hydraulic press, remove the 2
nd
gear (10), ring (9),
middle ring (8), synchronizer ring (7), synchronizer assembly
(6) and the bushing (5). Take out the roller bearing (11).
51954
Figure 65
Figure 66
Remove the reverse gear engagement sliding sleeve (2) from
the reverse gear (1). Retrieve hub (1) and pads (3) with
respective balls (4) and springs (5).
85949
85946
85947
Figure 67
Figure 68
Use extractor 99348001 (6) as shown in the figure to extract
the primary shaft (1), the 5
th
gear (7), the synchroniser ring (5),
the hub (4), the circlip (3) and the roller bearing (2).
Remove the roller half cages (1).
1
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90216
51961
Figure 69
Figure 70
Using general tools, extract the internal ring (2) of the rear
tapered roller bearing from the transmission shaft (1).
Remove the 3rd gear (1) and the roller bearing (2).
Remove the synchronizer ring (3). Remove the retaining ring
(5) securing the hub (4).
51960
51959
Figure 71
Figure 72
Using a hydraulic press, extract the 6th gear (2) and the
internal ring (1) of the tapered roller bearing from the
transmission shaft.
Using a hydraulic press, remove the 5th gear (2) from the
transmission shaft (1).
51956
90217
Figure 73
To replace the cog-wheel (1), use the same general tools for
disassembly as for assembly, heat it to a temperature of 80ºC.
Take out the retaining ring (1) holding the 5
th
gear (2).
Disassembling the drive input shaft
Disassembling the transmission shaft
1
Figure 74
1
1
1
6 S 400 O.D. TRANSMISSION
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TRANSMISSION SHAFT ASSEMBLY DRAWING
1. Transmission shaft assembly - 2. Tapered roller bearing - 3. Transmission shaft with reverse gear toothing (A), 1st gear (B),
2nd gear (C) - 4. Tapered bearing - 5. 4th gear - 6. Synchronizer ring - 7. Sliding sleeve - 8. Ball - 9. Spring - 10. Plug -
11. Hub - 12. Retaining ring - 13. Half roller bearings - 14. 3rd gear - 15. 6th gear - 16. 5th gear.
90218
Figure 75
Figure 76
51962
51424
Figure 77
Using a hydraulic press, remove the 4th gear (3), the
synchronizer ring (2) and the synchronizer assembly (1).
Remove the half roller bearings (4).
1
Remove the sleeve (2) for engaging the 3rd-4th gear from the
hub (1) and, taking care over the plugs (3) coming out with
their relative balls (4) and springs (5), recover them.
1
1
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6 S 400 O.D. TRANSMISSION
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PRIMARY SHAFT AND INPUT SHAFT ASSEMBLY
1. Input shaft with 5
th
speed gear. - 2. Retaining ring - 3. Roller bearing - 4. Single cone synchronizer ring - 5. Sliding sleeve -
6. Plug - 7. Ball - 8. Spring - 9. Hub - 10. 6th gear - 11. Main shaft with 3rd gear toothing (A), 4th gear toothing (B) -
12. Roller bearing - 13. 2nd gear - 14. Dual-cone synchronizing unit for 1st/2nd speed - 15. Dowels with built-in ball springs
for 1st/2nd speed hub - 16. Bushing - 17. 1st gear - 18. Spacer ring - 19. Reverse gear - 20. Synchroniser ring - 21. Gear.
108864
Figure 78
6 S 400 O.D. TRANSMISSION
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