Iveco Daily Euro 4. Manual — part 93
26
5 S 300 TRANSMISSIONS
D
AILY
E
URO
4
75420
LONGITUDINAL SECTION
Figure 10
TRANSVERSE SECTION ON THE GEAR
SELECTION/ENGAGEMENT ROD
POSITIONING PUSH ROD
47369
Figure 11
TRANSVERSE SECTION ON THE REVERSE GEAR
ANTI-ENGAGEMENT DEVICE
47371
49368
49364
Figure 12
Figure 13
TRANSVERSE SECTION ON INTERNAL CONTROL BOX
SECTION ON GEAR ENGAGEMENT ROD POSITIONING PAWLS
5 S 300 TRANSMISSIONS
27
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AILY
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4
Remove the plug and drain off the lubricating oil.
108638
Figure 14
Figure 15
530220
Gear control box
Disassembly
Fit the gearbox (1) with the bracket 99371057 (4) and secure
this to the brackets 99322225 (3) on the rotary stand
99322205 (2).
The used oil must be disposed of according to the law
in force.
51384
51383
Take out the fixing screws (1) and remove the gear control box
(2).
Loosen the nuts (3) for the retaining screws (6).
Extract the levers (2 and 7) from the shafts (1 and 8) and
extract these from the box (5). Take off the caps (4).
Figure 16
Figure 17
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.
Figure 18
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 2).
Tie-rods (3 and 8) are interchangeable.
NOTE
Remove screws (5), then take transfer case (6) off the gearbox
unit.
51385
28
5 S 300 TRANSMISSIONS
D
AILY
E
URO
4
OVERHAULING THE TRANSMISSION
Thoroughly clean the mating surfaces of the gear control box
(2) and apply LOCTITE 5206 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.
51388
51390
87896
51391
Figure 21
Figure 22
Figure 23
Figure 24
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).
Lubricate the roller bearings (1, Figure 19) 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) tightening the
nuts for the fixing screw (7).
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
51386
51387
Figure 19
Figure 20
Use a punch on the point shown by the arrow and eject the
O-rings and roller bushes (2) from the box (1).
Assembly
Thoroughly clean the oil vapour vent (3).
With a suitable punch, mount the roller bearings (1) in the box
(2).
5 S 300 TRANSMISSIONS
29
D
AILY
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4
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