Iveco Daily Euro 4. Manual — part 100

54

6 S 400 O.D. TRANSMISSION

D

AILY

E

URO

4

SPECIFICATIONS AND DATA

TRANSMISSION

6 S 400 O.D.

Type

Mechanical

Input torque

400 Nm

Weight

63 kg

Speeds

6 forward speeds

1 reverse speed

Speed control

Mechanical

Power take-off

Optional

Speed engagement:

Forward speeds

- 5

th

/6

th

- 3

rd

/4

th

Single-cone synchronizer

- 1

st

/2

nd

Dual-cone synchronizer

Reverse speed

clip-on, in new version transmission with

single taper synchroniser ring

Speed retention mechanism

Sliding sleeves retained by pawls and springs.

Gears

Helical-toothed constant mesh gears

Gear ratio

First

5.375

Second

3.154

Third

2.041

Fourth

1.365

Fifth

1

Fifth

0.791

Reverse

4.838

Shaft bearings:

Main shaft

Straight roller bearing

watertight ball bearing

tapered roller

O.D.. = Over Drive

6 S 400 O.D. TRANSMISSION

55

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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

-

Main shaft

Temperature for fitting:

- hubs for sliding sleeves

80

° ÷ 110

o

C

- 1

st

-R gear bushes and gear

110

° ÷ 150

o

C

- front bearing*

90

° ÷ 110

o

C

Transmission shaft

Temperature for fitting:

- bearings

80

°C (max 120

o

C)

- 5

th

-4

th

gears

170

° ÷ 160

o

C

Gear end float:
1

st

- 3

rd

- 4

th

- R - 5

th

gear

2

nd

gear

0.15

÷ 0.40 mm

0.25

÷ 0.5 mm

5

th

- 4

th

gear sliding sleeve hub retaining

ring end float

0

÷ - 0.15 mm

5

th

- 4

th

gear sliding sleeve hub retaining

ring thickness

-

Retaining ring end float:

- transmission shaft front bearing

0

÷ - 0.1 mm

- main shaft roller bearing

0

÷ - 0.1 mm

Transmission shaft rear bearing retaining
ring thickness

-

LOCTITE 510

Sealant

LOCTITE 242

LOCTITE 5206

Type of oil:

TUTELA TRUCK GEARLITE

Quantity

2.2 litres

* = Do not use hot air equipment to heat bearing.

108862

Figure 6

56

6 S 400 O.D. TRANSMISSION

D

AILY

E

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4

DESCRIPTION

TORQUE

DESCRIPTION

Nm

kgm

1

Plug retaining spring and reverse gear hardening push rod

32

±10%

3.2

±10%

2

M22x1.5 plug

50

5

3D

3rd and 4th gear fork articulation pins

45D

4.5

4

Plugs for rod preventing gear engagement

32

3.2

5

Clutch housing, screw to fasten clutch housing to crankcase

80

8

6

Constant mesh shaft cover fastening screw

23

±15%

2.3

±15%

7

J

Screw securing p.t.o. side cover

46

±15%

4.6

±15%

8

Screw securing reverse gear shaft

23

±15%

2.3

±15%

9

Side plug on rear cover

35

3.5

10

Screw securing rear cover

23

±15%

2.3

±15%

11

Speedometer transmitter fixing

50

5

12

Screw locking sleeve for transmission coupling on main shaft

235

23.5

13

Fixing switches and reversing lights

40

4

14D

Screw securing ball bearing retaining ring

9.5

±15%

0.9

±15%

15

Nut for screw securing lever to control rod

34

±15%

3.4

±15%

16

Screw securing gear control mounting

23

±15%

2.3

±15%

17

Oil vapour breather

10

±15%

1

±15%

18D

Screw securing driver to main rod

9.5D

0.9

19D

5th and 6th gear fork articulation pins

45

4.5

: Spread LOCTITE 5206 sealant on the contact surfaces
F Spread LOCTITE 242 on the thread
J Spread LOCTITE 510 on the thread

108856

Figure 7

Gearbox control

6 S 400 O.D. TRANSMISSION

57

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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

2,3

± 15%

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).