Iveco Daily Euro 4. Manual — part 97
51443
51417
51445
51446
Figure 81
Figure 82
Figure 83
Figure 84
Heat the bushing (2) to a temperature no higher than 170
°C
and mount it on the main shaft (1).
Mount the sliding sleeve (4) on the hub (3).
Put (3) the springs (7), plugs (5) and balls (6) into the seats in
the hub, settling them under the sliding sleeve (4).
Lubricate the synchronizer ring (4), middle ring (3) and the ring
(2) with TUTELA MR3 grease.
Mount the roller bearing (1).
Mount the 2
nd
gear (4).
Heat the spacer (3) to a temperature no higher than 170
°C
and mount it on the main shaft (1).
Check the end float of the 2nd gear (4). It should be
0.15
÷ 0.30 mm.
Heat the bushing (2) to a temperature no higher than 170
°C
and mount it on the main shaft (1).
Mount the roller bearing (1) and the 3
rd
gear (3). Position the
synchronizer ring (2) on the 3
rd
gear (3).
Make sure the tongues of the rings (2 - 3) and the
projections of the synchronizer ring (4) are
positioned correctly in their respective seats.
NOTE
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To replace the forks of the selector and driver from their
respective 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.
During assembly, the gaskets, retaining rings, O-rings,
spring pins, safety plates and springs must always be
replaced with new parts.
51447
51413
51449
Figure 85
Figure 86
Figure 87
Figure 88
Heat the hub (2) to a temperature no higher than 150
°C and
mount it on the main shaft (1) checking that the projections
(3) of the synchronizer ring are positioned in the
compartments of the hub (2).
Mount the retainer ring (4) whose thickness determines an
end float in its seat of 0
÷ 0.05 mm.
Check the end float of the 3
rd
gear (5). It should be
0.15
÷ 0.30 mm.
Mount the sliding sleeve (6) on the hub (5). Put the springs (7),
plugs (8) and balls (9) into the seats in the hub (5), settling
them under the sliding sleeve (6).
Grease the roller bearing (2) and fit it on the main shaft (1).
Position the synchronizer bearing (3) on the hub (5).
Rods - forks - selector - driver
Disassembly - assembly
Determine the thickness S of the ring (1) for adjusting the
transmission shaft bearing (2) end float, proceeding as follows:
- measure the distance A between the end of the
transmission (3) and the seat of the ring of the front
bearing (2);
Adjusting the transmission shaft bearing end float
51450
Spring pegs must be positioned with the cutting edge
placed level.
Mounting the transmission
NOTE
The nuts and screws must be tightened to the required
torque unless specified otherwise, with the thread dry and
greased.
NOTE
5 S 300 TRANSMISSIONS
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- mount the internal rings (2 - 4) of the tapered roller
bearings on the transmission shaft (5);
- position the external rings (1 - 3) on the internal ones
(2 - 4);
- apply a load F of 100
÷120 N on the external rings (1 - 3).
- In these conditions, measure the distance C between the
ends of the rings (1 - 3).
- The thickness S of the bearing end float adjustment ring
is given by:
51451
51452A
41452
51453
Figure 89
Figure 90
Figure 91
Figure 92
- measure the distance B between the end of the rear
cover (1) and the seat of the ring of the rear bearing;
Position the adjustment ring (1, Figure 88) of the thickness
determined with the above measurement in the transmission (1).
Heat the bearing seats of the box (1) to a temperature of
approx. 80
°C and mount:
- the external ring (6) of the front tapered roller bearing
with punch 99374091 and grip 99370007;
- the ball bearing (7) with a general punch;
- the bushing with ball bearing (4) and the roller bearing (5)
with a general punch.
Position the retaining plates (3) and secure them to the box,
tightening the screws (2) to the required torque.
Heat the bearing seats of the box (1) to a temperature of
approx. 80ºC and mount:
- the external ring (7) of the tapered roller bearing with
punch 99374091 and grip 99370007;
- the ball bearing (4) and the bushing with ball bearings (2)
with a general punch.
Position the retaining plates (6) and the engagement locking
plate (3) in their seats.
Secure these to the box, tightening the screws (5) to the
required torque.
S
= A + B − C − 0, 10
Where:
A - B - C are the measured values
0.10 = constant value, including the deformation of the
external rings (1 - 3) after driving them into their seats and the
end float of the bearings of 0.05 mm.
Apply LOCTITE 242 onto the thread of the screws
(2, Figure 91 and 5, Figure 92).
NOTE
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51454
74963
74964
74965
Figure 93
Figure 94
Figure 95
Figure 96
Clamp the main shaft in a vice.
Mount the input shaft (8) on the main shaft (4) and couple this
with the transmission shaft (5).
Fit tool 99360521 (6) on shafts (8 and 5) and tie it to input
shaft (8) by circlip (9) and to secondary shaft (5) by screw (7).
Set forks and rods thereof (1 - 2 - 3) on sliding sleeves and tie
by tool 99360521 sleeves (6).
Hook the hoist onto tool 99360521 (1). Lift the assembly (2)
as put together beforehand and mount it in the rear cover (3).
During this operation, check that the output shaft (7) goes into
the supporting ball bearing and the control rods (4 - 5 - 6) go
into their respective seats.
Set properly clutch locking plate (5) by setscrew wrench (2) to
avoid control rods (1 - 3 - 4) interference with plate during next
operation.
Screw the pin (11) of tool 99370234 into the hole in the output
shaft (6). Mount the bushing (8) and spacer (9) on the tool
99370234.
Screw on the nut (10) and at the same time lower the hoist so
the output shaft (6) is positioned on the ball bearing (7).
Remove the tool 99360521 and the parts (8 - 9 - 10 - 11) of
the tool 99370234.
Mount the rod (7) complete with selector (5) and driver (6).
Put the pawls (8) and springs (9) into the rear cover (4).
Mount the cups (10).
Mount the reverse gear idler (2) with the shaft (1) and secure
the shaft to the rear cover (4) tightening the screw (3) to the
required torque.
Apply LOCTITE 5206 sealant to the mating surfaces of the
transmission.
5 S 300 TRANSMISSIONS
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