Iveco Daily Euro 4. Manual — part 107
51974
90221
51975
90222
90223
51973
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Mount the 3rd gear (1).
With a hydraulic press, mount the 6
th
gear (1) pre-heated to
approx. 170
°C.
Check the end float of the 3
rd
gear (2). It should be 0.15
÷0.40
mm.
With a hydraulic press, mount the 5
th
gear (1) pre-heated to
approx. 170
°C.
Mount the retaining ring (1) whose thickness produces null
end float in its seat.
Heat the internal rings (1-3) of the tapered roller bearings to
a temperature of approx. 80
°C and, with a suitable punch (1),
mount them on the transmission shaft (2).
Tighten the main shaft (1) and position the roller bearing (2)
on it.
Mounting the main shaft
Mount the synchronizer rings on their respective gears
according to the marks made during disassembly or
when checking in the case of replacement.
1
1
NOTE
82
6 S 400 O.D. TRANSMISSION
D
AILY
E
URO
4
51980
51981
51983
51984
Figure 100
Figure 101
Figure 102
Figure 103
Figure 104
Mount the 2nd gear (4) and position the ring (3), middle ring
(2) and synchronizer ring (1) on it, taking care that the tongues
(
→) of the middle ring (2) enter the slots (→) in the gear (4).
Heat the hub (2) to a temperature of 80
° ÷ 110°C and mount
it on the main shaft (1), taking care that the projections (3) of
the synchronizer ring and the tongues (
→) of the ring (3,
Figure 100) are positioned correctly in the seats in the hub (2).
Check the end float of the gear (4). It should be
0.25
÷ 0.5 mm.
Fit sliding sleeve (2) onto hub (1). Fit dowels (4) with built-in
springs (5) and balls (3) into hub (1) housings.
Position the synchronizer ring (3), middle ring (2) and ring (1)
on the hub (4), taking care that the tongues (
→) of the ring
(1) and the projections (
→) of the ring (3) enter the seats in
the hub (4).
Position the roller bearing (2). Mount the 1st gear (1) taking
care that the tongues (3) of the middle ring enter the slots in
the gear (1).
108866
6 S 400 O.D. TRANSMISSION
83
D
AILY
E
URO
4
85961
51952
Figure 105
Heat the spacer ring (2) to a temperature of approx.
~80°
÷ 110°C and mount it on the main shaft (1). Check the end
float of the gear (4); this should be 0.15
÷0.3 mm.
Heat the bushing (3) to a temperature of approx. 80
° ÷ 110°C
and mount it on the main shaft (1).
Mount the roller bearing (5).
Turn the main shaft over and position the half roller bearings
(3) on it.
Mount the 6th gear (2) and position the synchronizer ring (1)
on it.
1
Fit reverse gear (1).
Fit sliding sleeve (2) on reverse gear hub (1).
Insert the springs (5), the pads (3) and the balls (4) in the hub
seats (1) and arrange them with respect to the sliding sleeve
(2).
85950
85951
Figure 106
Figure 107
Fit the synchroniser ring (2).
Heat the gear ring (3) to 110
° ÷ 150° and fit on primary shaft
(1).
Check reverse gear play (4) which must be 0.15
÷ 0.4 mm.
Heat the hub (2) to a temperature of approx.
~ 80° ÷ 110°C
and mount it on the main shaft (1) taking care that the projec-
tions (3) of the synchronizer ring are positioned in the seats
in the hub (2).
Mount the retaining ring (4) whose thickness produces null
end float in its seat.
51990
51991
Figure 108
Figure 109
Mount the sliding sleeve (2).
Put the springs (3), plugs (5) and balls (4) into the seats in the
hub (1) and position them under the sliding sleeve (2).
1
Figure 110
84
6 S 400 O.D. TRANSMISSION
D
AILY
E
URO
4
During assembly, the gaskets, retaining rings, O-rings,
spring pins, safety plates and springs must always be
replaced with new parts.
The nuts and screws must be tightened to the re-
quired torque unless specified otherwise, with the
thread dry and degreased.
85952
Figure 111
Heat the bearing (2) to 80
÷110°C and fit on primary shaft (1).
Fit the circlip (4) and synchroniser ring (3).
Mounting the transmission
Adjusting the transmission shaft bearing end
float
The transmission shaft bearing end float is only ad-
justed if the bearings, transmission shaft gears, trans-
mission shaft, transmission or rear cover have been
replaced or if too much clearance has been found.
1. Rod with reverse gear engagement fork - 2. Main rod -
3. Rod with 1
st
-2
nd
gear engagement fork. - 4. Fork control
rod (5).- 5. 3
rd
-4
th
gear engagement fork - 6. Fork control
rod (7) - 7. 5
th
-6
th
gear engagement fork
Rods - forks - selector - driver
90224
Figure 112
Disassembly - assembly
Spring pegs must be positioned with the cutting edge
placed level.
NOTE
NOTE
NOTE
51993
Figure 113
Determine the thickness S of the ring (1) for adjusting the
transmission shaft bearing end float, proceeding as follows:
- position the thinner adjustment ring (1) 1.65 mm thick in
the seat in the transmission (3);
- heat the seat of the bearing (2) to approx. 60
°C. Mount
the external ring of the bearing (2) with the punch
99374091 and grip 99370007, see Figure 115;
- mount the transmission shaft complete with the internal
rings of the tapered roller bearings;
- mount the external ring of the rear bearing in the rear
cover in a similar manner to the front one (see
Figure 115);
- mount the rear cover on the transmission;
- screw on the 8 fixing screws so that between one screw
and another there is a hole for a free screw and tighten
them to the required torque;
- turn the transmission shaft to settle the bearings;
Check the state of the plugs (2) of the 3
rd
-4
th
-5
th-
6
th
gear en-
gagement fork and replace them if they are worn.
To replace the forks of the selector and driver from their re-
spective control rods it is sufficient to remove the retaining
spring pins with a suitable punch.
For assembly, carry out these steps in reverse order, replacing
the spring pins.
6 S 400 O.D. TRANSMISSION
85
D
AILY
E
URO
4
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст