Iveco Daily Euro 4. Manual — part 112

The combined action of the selector lever (2) and the engagement lever (1) cause the rotation and axial movement of the rod
(4) in two subsequent steps to engage the required gear by means of the rods (8-7-6 and 9).

The motion of speed selection/engagement levers occurs through the action of two electric motors (M) managed directly by the
gearbox electronic control unit.

Neutral arrangement and/or 3

rd

/4

th

gear

selection and engagement arrangement

3

rd

/4

th

gear selection

According to the angular position of the selector lever (2),
the slider (3) turns with the rod (4) (which is integral) and the
selector (5) arranges the slider on the 3

rd

/4

th

gear rod (9). At

the same time, the slider (3) moves the rod (10) to prevent
the simultaneous engagement of two gears, to keep the 3

rd

and 4

th

gear engagement rod (9) free and to prevent

movement of the other rods by engaging the grooves in the
rods.
3

rd

/4

th

gear engagement

According to the movement of the engagement lever (1), the
slider (3) axial moves the rod (4) (which is integral), the
selector (5) (previously arranged) and consequently the
chosen 3

rd

and 4

th

gear engagement rod (9).

Neutral position coincides with the 3

rd

/4

th

gear selection

arrangement.
In this case, the vertical axis of the selector lever (2) is exactly
at 90

° with respect to the horizontal axis of the control

corresponding to no angular variation of the rod (4).

This arrangement is obtained by moving the selector lever (2)
anticlockwise. In this way, the selector (4) is inserted in the
1

st

/2

nd

gear engagement rod (5).

By moving the lever (1), the slider (3) will axially move the
1

st

/2

nd

gear engagement rod (5).

1

st/

3

rd

gear selection election and engagement

arrangement

Figure 12

Figure 13

101935

101936

SECTION A-A

SECTION A-A

102

6 S 400 A O.D. TRANSMISSION

D

AILY

E

URO

4

5

th

/6

th

gear

selection

and

engagement

arrangement

This arrangement is obtained by moving the selector lever (2)
clockwise. In this way, the selector (4) is inserted in the 5

th

/6

th

gear engagement rod (5).
By moving the lever (1), the slider (3) will axially move the
5

th

/6

th

gear engagement rod.

This arrangement is obtained by moving the selector lever (2)
anticlockwise. In this way, the selector (4) is inserted in the re-
verse gear engagement rod (5).
By moving the lever (1), the slider (3) will axially move the re-
verse gear engagement rod (5).

Safety device

The transmission is equipped with a device which prevents the
simultaneous engagement of two gears.

It consists of a suitably shaped rod (6) fitted transversally in the
transmission box.

The slider (3), moves the rod (6) under the action of the lever
(2). This keeps the selected gear engagement rod free and
prevents movement of the other gears by engaging their
respective grooves.

Reverse

gear

selection

and

engagement

arrangement

Figure 14

101937

101938

Figure 15

SECTION A-A

SECTION A-A

6 S 400 A O.D. TRANSMISSION

103

D

AILY

E

URO

4

104

6 S 400 A O.D. TRANSMISSION

D

AILY

E

URO

4

TRANSMISSION

6 S 400 A O.D.

Type

Mechanical

Input torque

400 Nm

Weight

72 kg

Speeds

6 forward speeds

1 reverse speed

Speed control

Electronic

Power take-off

Optional

(HYDROCAR type only)

Speed engagement:

Forward speeds

- 5

th

/6

th

- 3

rd

/4

th

Single-cone synchronizer

- 1

st

/2

nd

Dual-cone synchronizer

Reverse speed

Quick-connect (non-synchronized) type

Speed retention mechanism

Sliding sleeves retained by pawls and springs.

Gears

Helical-toothed constant mesh gears

Gear ratio

First

6.727

Second

3.947

Third

2.555

Fourth

1.776

Fifth

1.289

Fifth

1.000

Reverse

6.055

Shaft bearings:

Main shaft

Transmission shaft

watertight ball bearing

tapered roller

6 S 400 A O.D. TRANSMISSION

105

D

AILY

E

URO

4

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 spacer ring

80

° ÷ 110

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

2.7 litres

2.43 kg

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