Iveco Daily Euro 4. Manual — part 103
Remove the rev sensor (4).
Fit the gearbox (1) with the bracket 99371057 (6) and secure
this to the brackets 99322225 (3) on the rotary stand
99322205 (2).
Remove the plug (5) and drain off the lubricating oil.
85942
85941
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Shift to neutral.
Take out the fixing screws (1) and remove the gear control box
(2).
Loosen the nuts (4) for the retaining screws (5).
Extract the levers (1 and 7) from the shafts (2 and 6) and
extract these from the box (8). Take off the caps (4).
With a punch (3), remove the spring pin (4) and extract the
shaft (2) from the internal lever (1).
Repeat these steps for the other shaft.
530220
Gear control box
Disassembly
The used oil must be disposed of according to the law
in force.
The coupling lever is bound to the stem by two snap
pins.
NOTE
108857
Take tie-rod (3) off by disconnecting jointed heads (1) from
levers (4 and 7).
Take tie-rod (8) off by disconnecting jointed heads (9) from
levers (10 and 7).
Tie-rods (3 and 8) are interchangeable.
NOTE
Remove screws (5), then take transfer case (6) off the gearbox
unit.
51385
108640
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530210
OVERHAULING THE TRANSMISSION
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Lubricate the roller bearings (1, Figure 27) with TUTELA MR3
grease and mount the shafts (3 and 6) complete with the
internal levers (4 and 5) in the box (2). Mount the caps (8 and
9) and levers (1 and 10) on the shafts (3 and 6) and tightening
the nuts for the fixing screw (7).
51386
Use a punch on the point shown by the arrow and eject the
O-rings and roller bushes (2) from the box (1).
51387
Thoroughly clean the oil vapour vent (3).
With a suitable punch, mount the roller bearings (1) in the
box (2).
Assembly
51388
Using a suitable punch, mount the O-rings (1) in the box (2),
positioning them at the height shown.
Pack the gap between the O-ring and roller bearing with
grease.
Mount the selection and engagement levers (1) on their
respective shafts (2) and fasten them with the spring pins (3).
51390
87896
The spring pin (3) must be positioned with the cut
horizontal. Fit spring peg (4), with cutting edge
positioned at 180
° from spring peg (3) cutting edge,
in spring peg (3) engagement lever.
NOTE
Thoroughly clean the mating surfaces of the gear control box
(2) and apply LOCTITE 5706 sealant on them.
Fit the box (2) on the transmission, taking care that the levers
and shafts are positioned correctly in their respective seats.
Tighten the screws (1) to the required torque.
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Figure 31
Figure 32
Figure 33
Figure 34
l
Fit transfer case (1) into place, by tightening fastening screws
(2) to the prescribed torque.
Selection and adjustment tie-rod assembling
Verify that the tie-rod (4) length ”X”, as measured between
the jointed head centres is not greater than 342 mm.
Lubricate the jointed head inside with MOLIKOTE 33 LIGHT
or MOLIKOTE G 72 grease, then connect the jointed heads
to levers (1 and 5).
Measure the distance ”y” between transfer case (3) outer
surface and ball pin (6) centre: it shall be ”y” = 146 ± 1 mm.
Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
until the prescribed distance is obtained. Then tighten nuts (2)
to the prescribed torque, so that the vertical axes of the
jointed heads are aligned, with a maximum deviation of less
than
α < 30˚ (lower).
Verify that spring (3) ends come into contact with selection
lever (4) or are at least 1 mm within the same. Otherwise,
loosen screw (1) so that spring (3) is correctly positioned, due
to plate (2) being released.
108858
108859
108860
108861
Verify that the tie-rod (4) length ”X”, as measured between
the jointed head centres is not greater than 342 mm.
Lubricate the jointed head inside with MOLIKOTE 33 LIGHT
or MOLIKOTE G 72 grease, then connect the jointed heads
to levers (1 and 5).
Measure the distance ”y” between transfer case (3) outer
surface and ball pin (6) centre: it shall be ”y” = 146 ± 1 mm.
Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
until the prescribed distance is obtained. Then tighten nuts (2)
to the prescribed torque, so that the vertical axes of the
jointed heads are aligned, with a maximum deviation of less
than < 30˚ (lower).
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Block rotation of the sleeve (1) by applying the lever
99370317 (3). With the bushing (2) remove the screw (5)
with the washer beneath (4).
Take out the lever 99370317 (3).
Extract the sleeve (3) from the main shaft.
51924
51926
51925
90250
51928
51829
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Shift to neutral.
Dismantle the gear control box as described under the
relevant heading.
Remove the two side plugs (1 - 3). Remove the screw (2) and
take off the rod (5) dragging device (4).
Mark the assembly position of the rod (1) preventing
engagement of more than one gear at the same time and
remove it from the transmission.
Remove the screws (1) and take off the cover (2) protecting
the input shaft (3).
If difficult, remove the sleeve (3) with extractor made
up of link 99341003 (1) and grips 99341017 (2) and
block (4).
When putting away the sleeve (1) take care not to
damage the phonic wheel (
→) obtained by machining.
1
1
1
1
NOTE
NOTE
The screw threading (2) is treated with LOCTITE
242.
NOTE
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