Iveco Daily Euro 4. Manual — part 89
Flexible cable replacement
Removal
108850
Figure 3
Figure 4
Place the vehicle on a pit or auto lift.
Act from under the vehicle to disconnect the jointed heads of:
-
selection cable (2, max. pull-out load: 250 N - max. pull-in
load: 60 N) from lever (1);
-
engagement cable (4, max. pull-out load: 100 N - max.
pull-in load: 80 N) from lever (1).
Proceed as follows, by acting from inside the cab (see figure
4):
-
unscrew and remove knob (1);
-
remove protection boot (2);
-
remove the fastening screws, then take covering (3) off;
-
remove glove compartment (4);
-
remove the fastening screws, then take lower central
covering (5) off.
108851
Act from the upper part of the gearbox unit and use a suitable
screwdriver to open out flexible cable fins (6 and 7) so that the
pawls are disengaged from bracket (5).
10
TRANSMISSION
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Figure 5
Figure 6
Figure 7
Disconnect the jointed heads of:
-
selection cable (2, max. pull-out load: 250 N - max. pull-in
load: 60 N);
-
engagement cable (6, max. pull-out load: 100 N - max.
pull-in load: 80 N) from levers (1 and 5).
Use a suitable screwdriver to open out flexible cable fins (3
and 7) so that the pawls are disengaged from support (4).
Reattachment is carried out by reversing the order
of the detachment operations. Moreover, the
following instructions shall be observed:
- prior to assembling, lubricate the flexible cable
(Bowden) jointed head connection
points
with
MOLIKOTE
33
LIGHT
or
MOLIKOTE G72 grease;
- tighten the nuts and screws to the prescribed
torque;
- adjust the gear control, as described in the
respective chapter.
Remove nuts (3) securing flange (2) to the cab floor, then take
flexible cable assembly (1) out.
Refitting
Proceed as described in figures 5 and 6, by acting from inside
the cab.
Remove fastening screws (2), then take gear shift lever
support (1) off the cab.
Refitting
108852
108854
108853
GEAR SHIFT LEVER SUPPORT
Removal
- prior to assembling, lubricate the flexible cable
(Bowden) jointed head connection points with
MOLIKOTE 33 LIGHT or MOLIKOTE G72
grease;
- tighten the nuts and screws to the prescribed
torque;
- adjust the gear control, as described in the
respective chapter.
TRANSMISSION
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TRANSMISSION
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5 S 300 TRANSMISSIONS
13
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Page
GENERAL
15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION AND ENGAGEMENT
CONTROL
16
. . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY DEVICES
17
. . . . . . . . . . . . . . . . . . . . . . . .
-
Engagement locking device
17
. . . . . . . . . . . . . . .
-
Reverse gear anti-engagement device
17
. . . . . . .
SPECIFICATIONS AND DATA
18
. . . . . . . . . . . . .
TIGHTENING TORQUES
20
. . . . . . . . . . . . . . . . .
-
Gearbox uonit
20
. . . . . . . . . . . . . . . . . . . . . . . . .
-
Gearbox control
21
. . . . . . . . . . . . . . . . . . . . . . .
TOOLS
22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE TRANSMISSION
28
. . . . . .
-
Gear control box
28
. . . . . . . . . . . . . . . . . . . . . . .
-
Disassembly
28
. . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Assembly
29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Selection and adjustment tie-rod assembling
30
. .
-
Disassembling the transmission
31
. . . . . . . . . . . .
-
Disassembling the rear cover bearings
33
. . . . . . .
-
Disassembling the transmission bearings
33
. . . . .
-
Disassembling the main shaft
34
. . . . . . . . . . . . . .
-
Drive input shaft
36
. . . . . . . . . . . . . . . . . . . . . . .
-
Disassembling the transmission shaft
36
. . . . . . . .
CHECKS
39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Transmission
39
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Hubs - sliding sleeves - forks
39
. . . . . . . . . . . . . .
-
Bearings
39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Shafts - gears
39
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Synchronizing devices
39
. . . . . . . . . . . . . . . . . . .
-
Mounting the transmission shaft
40
. . . . . . . . . . . .
-
Mounting the main shaft
40
. . . . . . . . . . . . . . . . .
-
Rods - forks - selector - driver
43
. . . . . . . . . . . . .
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