Iveco Daily Euro 4. Manual — part 114
Remove the straps (shown by arrows) that secure the electric
cable to the gearbox.
Remove reverse gear light connectors (1) and revs number
sensor (2).
Remove the power take-off electric connections (if any) from
the other side of the gearbox.
Push the safety retainer downwards, then remove the
connector form the control unit (see arrow).
Remove electric cable fastening strap (1) on the clutch
actuator side.
Press clutch actuator connector pull-back spring (1), as shown
by the arrow
Remove connector (1) from clutch actuator (2).
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102137
102135
102136
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102139
Disconnect the battery cable in engine opening.
Place the vehicle in a pit, or on an auto lift or special supporting
stands.
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 24
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GEARBOX REMOVAL/REFITTING
Removal
Remove the four clutch actuator fastening screws (1).
Take off actuator (2).
Remove screws (1) securing the starting motor to the gearbox
case front cover. Then, place it carefully in the engine
compartment.
Unscrew the four screws (2) securing drive shaft (1) to the
gearbox.
Properly secure drive shaft (1) to the chassis.
Remove the two hexagonal screws (1), then take off the
engine lower cover (opposite the axle).
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102143
102141
102163
102144
102145
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Prior to removing the actuator, verify that the clutch
is closed. This can be done either by means of the
diagnosis instrument or by visually inspecting the
position of the fork which must be perpendicular to
the gearbox axis.
In the event that the clutch has been left open, due
to a mechanic or electric fault, the fork will be loaded
by the actuator internal spring
Therefore, avoid touching the engaging tip straight
with your hands.
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Use a hydraulic jack to position bracket 99370629 (1) under
the gearbox; then, put the chain onto the gearbox and place
a ring of the same into the bracket slotted hole.
Screw down the nut so as to tightly secure, through the chain,
the gearbox to the bracket.
Remove screw (1) centrally securing the rear crossbar to the
gearbox.
Remove the crossbar fastening screws (1) on the left side.
Remove the crossbar fastening screws (1) on the right side,
then remove the crossbar, taking care not to drop it on the
floor.
Remove boot (1) from its housing.
This operation is necessary to make the fork travel the full
disengagement stroke when detaching the gearbox
Remove the remaining screws securing the gearbox to the
clutch bell.
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102149
102147
102148
102150
102151
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Before mounting bracket 99372069, remove a number of
screws securing gearbox to block.
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Use pliers to act on the retaining ring to disassemble bearing (1).
Remove bearing (1).
Press the pressure plate bearing onto the shaft and the fork
against the bearing, as shown in the figure. Apply grease MRM2
to the fork at the bearing pressure point.
Put rubber boot (1) into its housing.
Couple gearbox (2) with clutch (1).
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102153
102154
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102157
Move the gearbox backwards until the motion input shaft has
come out of the clutch disc hub. Fully take out the gearbox,
taking care not to hit it or get it caught in some component.
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
After the detachment operation has been completed,
pressure plate bearing (1) shall remain fitted into the clutch (as
shown in the figure).
Refitting
Gearbox is provided by spares in second gear in
order to enable primary shaft rotation through
transmission shaft connection flange rotation.
NOTE
In order to facilitate coupling, two guiding pins, fitted
onto two of the holes used to secure the gearbox
to the base unit, can be used.
NOTE
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