Iveco Daily Euro 4. Manual — part 106
1ST-2ND GEAR DUAL CONE SYNCHRONIZER ASSEMBLY
85978
Figure 79
Figure 80
3RD - 4TH - 5TH - 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY
SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR
86130
Figure 81
108865
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Transmission
The transmission and relative covers must show no sign of
cracking.
The mating surfaces of the covers and transmission must not
be damaged or deformed. Remove any remains of sealant
from them.
The seats of the bearings, reverse gear shaft and gear control
rods must be neither damaged nor too worn.
Hubs - sliding sleeves - forks
The grooves on the hubs and relative sliding sleeves must not
be damaged. The sliding sleeve must run freely on the hub.
The plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves
must not be damaged. The forks must be sound with an end
float, in the radial groove of the sleeve, no greater than 1 mm.
Bearings
The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced.
Shafts - gears
The seats on the shafts, for bearings, must be neither damaged
nor worn. The toothing of the gears must be neither damaged
nor worn.
Synchronizing devices
Check the wear on the synchronizer rings, proceeding as
follows:
- See that the friction surface is not undulated.
52510
52511
Figure 82
Figure 83
BK-type single cone synchronizers for 3rd/4th/5th/6th
gears
Arrange the synchroniser ring (1) on the respective gear or
reverse taper ring (2).
With a feeler gauge, check the distance S on two diametrically
opposite points.
If the measured value S is less than 0.8 mm, replace the
synchronizer ring.
Turn the synchronizer ring (1) so as to ensure correct coupling
on the cog-wheel.
Position the internal ring (3), middle ring (2) and the
synchronizer ring (1) on the tapered cog-wheel (4) of the gear.
Turn the synchronizer ring (1) so as to ensure correct coupling
between the parts.
Applying a uniform force of 50 N on the synchronizer ring (1),
measure the distance S on two diametrically opposite points
with a feeler gauge.
If the average measured value S is less than 1.5 mm, replace
all the rings.
!
After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.
D-type dual cone synchronizers for 1st/2nd gears
4
6 S 400 O.D. TRANSMISSION
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85918
85919
85917
5
TH
- 6
TH
GEAR SYNCHRONISERS
A. synchronization reserve 6
th
-5
th
gear: 1
÷1,4 mm
B. 5
th
-6
th
release clearance: 0,3
÷0,7 mm
90220
3
TH
/4
TH
GEAR SYNCHRONISERS
A. synchronization reserve 1
st
-2
nd
gear: 1
÷1,4 mm
B. 1
st
-2
nd
release clearance: 0,3
÷0,7 mm
2
ND
-1
ST
GEAR SYNCHRONISERS
A. synchronization reserve 2
nd-1st
gear: 1,6
÷2,0 mm
B. 1
st
-2
nd
release clearance: 0,9
÷1,5 mm
REVERSE GEAR SYNCHRONISER
A. Synchronization reserve: 0.9
÷1,4 mm
B. release clearance: 0,35
÷0,85 mm
1. Hub - 2. 5
th
gear - 3. Synchronizer ring - 4. Sliding sleeve - 5. 6
th
gear cog-wheel - 6. 3
rd
gear cog-wheel -
7. 4
th
gear cog-wheel - 8. 2
nd
gear cog-wheel - 9. 1
st
gear cog-wheel - 10. Middle ring - 11. Ring - 12. Reverse gear -
13. Reverse gear ring
Figure 84
Figure 85
Figure 86
Figure 87
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51966
51968
51967
51969
51970
51971
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
Clamp the transmission shaft (1) in a vice and position the half
roller bearings (2) on it.
Mount the 4th gear (2) and position the synchronizer ring (1)
on this.
Heat the hub (2) to a temperature of 110
° ÷ 150°C and
mount it on the transmission shaft (1), taking care that the
protrusions (3) of the synchronizer ring are positioned
correctly in their seats in the hub (2).
Mount the retaining ring (1) whose thickness produces null
end float in its seat.
Check the end float of the 4th gear (2). It should be
0.15
÷ 0.40 mm.
Mount the sliding sleeve (1) on the hub (2). Put the springs (5),
plugs (3) and balls (4) into the seats in the hub (2), settling
them under the sliding sleeve (1).
Position the synchronizer ring (2) on the hub (3) so that its
protrusions enter the seats in the hub (3). Mount the roller
bearing (1).
1
1
1
1
1
1
6 S 400 O.D. TRANSMISSION
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