Iveco Daily Euro 4. Manual — part 91
18
5 S 300 TRANSMISSIONS
D
AILY
E
URO
4
TRANSMISSION
5 S 300
Type
Mechanical
Input torque
Nm
300
Weight
kg
44.6
Speeds
5 forward speeds
1 reverse speed
Speed control
Mechanical
Power take-off
Optional
Speed engagement:
Forward speeds
- 5
th
/ 4
th /
3
nd
Single-cone synchronizer
- 2
nd
/ 1
st
Dual-cone synchronizer
Reverse speed
Rapid shift
Speed retention mechanism
Sliding sleeves retained by pawls and springs.
Gears
Helical-toothed constant mesh gears
Gear ratio
First
5.00
Second
2.62
Third
1.54
Fourth
1.00
Fifth
0.78
Reverse
4.58
Shaft bearings:
Main shaft
Straight roller bearing
watertight ball bearing
tapered roller
5 S 300 TRANSMISSIONS
19
D
AILY
E
URO
4
5 S 300
Transmission shaft bearing end play:
0
÷ 0.05 mm
Transmission shaft bearing end play adjustment
by shims
Shim thickness for transmission shaft bearing
end play adjustment
2.00 - 2.30 - 2.45 mm
with 0.05 mm progressive sequence
Main shaft
Assembly temperatures:
sliding sleeve hubs
2
nd
and 3
rd
speed gear bushings and spacer
5
th
speed gear spacer
150
o
C
170 ºC
÷ 160 ºC
90 ºC
Secondary shaft
Assembly temperatures:
bearings
5
th
speed gear
5
th
speed gear driving load
5
th
speed gear removing load
80 ºC (max 120 ºC)
140 ºC
÷ 170 ºC
31 KN
50 KN
50 KN
Input shaft
Assembly temperatures:
front bearing*
80 ºC (max 120 ºC)
Gear axial backlash:
1
st
- 3
rd
- 4
th
- R - 5
th
speed
2
nd
speed
0.15
÷ 0.3 mm
0.25
÷ 0.4 mm
3
rd
and 4
th
speed sliding sleeve hub retaining
circlip axial backlash
0
÷ 0.05 mm
3
rd
and 4
th
speed sliding sleeve hub retaining
circlip thickness
2 - 2.85 mm with progression of 0.05 mm
Transmission shaft rear bearing retaining ring
end float
0
÷ 0.05 mm
Transmission shaft rear bearing retaining ring
thickness
2.05
÷ 2.45 mm
with progression of 0.05 mm
242
LOCTITE sealant
510
5206
Type of oil:
TUTELA TRUCK GEARLITE
2 lit
Quantity
2 litres
1 8 k
1.8 kg
* = Do not use hot air equipment to heat bearing.
108855
Figure 7
Gearbox unit
20
5 S 300 TRANSMISSIONS
D
AILY
E
URO
4
DESCRIPTION
TORQUE
DESCRIPTION
Nm
kgm
1
Clutch housing, screw to fasten clutch housing to chassis
80
8
2
Screw to fasten clutch housing to box
23
± 15%
2.3
± 15%
3
Constant mesh shaft cover fastening screw
23
±15%
2.3
± 15%
4
Spring retaining plug
32
± 10%
3.2
± 10%
5
Grub screw securing gear selection sector to rod
60
±15%
6
±15%
6**
Screw securing p.t.o. side cover
46
± 15%
4.6
± 15%
7
Plug
28
÷30 ± 15% 2.8÷3 ± 15%
8
Screw securing reverse gear shaft
22
± 15%
2.2
± 15%
9
Screw securing rear cover
23
± 15%
2.3
± 15%
10
Screw locking sleeve for transmission coupling on main shaft
120
± 15%
12
± 15%
11D
Screw securing ball bearing retaining ring
9.5
± 15%
0.9
± 15%
12
Screw securing control cable bracket
23
± 15%
2.3
± 15%
13
Screw securing gear control mounting
23
± 15%
2.3
± 15%
14
Nut for screw securing lever to control rod
34
± 15%
3.4
± 15%
15
Nut securing articulation pin to control lever
23
± 15%
2.3
± 15%
16
Nut for screw securing lever to control rod
34
± 15%
3.4
± 15%
17
Oil vapour breather
10
± 15%
1
± 15%
18
Nut to secure articulation pin to control lever
23
± 15%
2.3
± 15%
*
Spread LOCTITE 5206 sealant on the contact surfaces
D
Spread LOCTITE 242 on the thread
** Spread LOCTITE 510 on the thread
108856
Figure 8
Gearbox control
5 S 300 TRANSMISSIONS
21
D
AILY
E
URO
4
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm
kgm
1
M8 screw for gearbox control support fastening
14
± 17
1.4
± 1.7
2
Nut securing the jointed heads to the cable
4
± 4.8
0.4
± 0.48
3
M8 screw securing the transfer case to the gearbox
21
± 25
2.1
± 2.5
4
M8 self-locking nut securing the flange to the cab
3.5
0.35
5
Nut securing the jointed head to the tie-rod
4
± 4.5
0.4
± 0.5
6
Plate fastening screw
7.8
± 9.25
0.78
± 0.95
After tightening nuts (4), the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected. After tightening
nuts (5), the vertical axes of tie-rod (5) jointed heads shall be aligned, with a maximum deviation of less than
α < 30˚ (lower).
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