Iveco Daily Euro 4. Manual — part 109
Mount the washer (3) and screw on the screw (4).
Lock the rotation of the flange (1) with the lever 99370317
(5) and tighten the screw (4) to the required torque.
Mount the tachograph sensor (2) and the reversing light
switch.
Fit a new gasket (1) onto the transmission.
Apply LOCTITE 510 on the screw threading (2).
Mount the side cover (3) and tighten the fixing screws (2) to
the required torque.
Mount the control box as described under the relevant hea-
ding.
Mount the oil drainage plug, tightening it to the required torque.
Fill the transmission with lubricating oil in the required quantity
and grade.
Mount the oil filler and level indicator cap, tightening it to the
required torque.
52009
51924
51925
52118
Figure 132
Figure 133
Figure 134
Figure 135
Mount the rod (1) preventing engagement of more than one
gear at the same time, in the position marked during disas-
sembly.
Apply sealant to the thread of the plugs (1 - 3), screw them
into the box, tightening them to the required torque.
Position the driver (4) on the rod (5).
Secure it with the screw (2) after applying LOCTITE 242 onto
its thread.
1
1
52008
Figure 136
Fit the transmission shaft coupling (1) onto the output shaft.
If there is any interference, use the tool 99370234 (2) for as-
sembly with the lever 99370317 (3) to lock the coupling.
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Page
GENERAL
93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN COMPONENTS LOCATION
94
. . . . . . . . .
MAIN SYSTEM FUNCTIONS
95
. . . . . . . . . . . . . . .
- Startup/start procedure
95
. . . . . . . . . . . . . . . . . .
- Check procedures
95
. . . . . . . . . . . . . . . . . . . . . .
- Limp Home
96
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Buzzer
96
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Start up with tow
96
. . . . . . . . . . . . . . . . . . . . . .
HILL HOLDER (FUNCTION ONLY AVAILABLE TO
VEHICLES WITH ESP8 BRAKING SYSTEM)
97
.
- Functional features
97
. . . . . . . . . . . . . . . . . . . . .
SYSTEM STRUCTURE
98
. . . . . . . . . . . . . . . . . . . .
- System central unit
98
. . . . . . . . . . . . . . . . . . . . .
- Clutch actuator
99
. . . . . . . . . . . . . . . . . . . . . . . .
- Gears actuator
99
. . . . . . . . . . . . . . . . . . . . . . . .
- Accelerator pedal
100
. . . . . . . . . . . . . . . . . . . . . .
- Display unit
100
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Gear selector
101
. . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION AND ENGAGEMENT
102
. . . .
- Neutral arrangement and/or 3rd/4th gear selection
and engagement arrangement
102
. . . . . . . . . . . . .
- 1st/3rd gear selection election and engagement
arrangement
102
. . . . . . . . . . . . . . . . . . . . . . . . . .
- 5th/6th gear selection and engagement
arrangement
103
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Reverse gear selection and engagement
arrangement
103
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Safety device
103
. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA
104
. . . . . . . . . . . . .
TIGHTENING TORQUES
106
. . . . . . . . . . . . . . . . .
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TOOLS
107
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
108
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis instruments
108
. . . . . . . . . . . . . . . . . . .
MODUS - IT 2000 - E.A.SY. CONNECTION
109
. . . .
GEARBOX REMOVAL/REFITTING
110
. . . . . . . . . . . .
- Removal
110
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
113
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX UNIT OVERHAULING
117
. . . . . . . . . . . .
CONTROL UNIT
117
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal
117
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH ACTUATOR
119
. . . . . . . . . . . . . . . . . . . . . .
- Removal
119
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
120
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX ACTUATOR
120
. . . . . . . . . . . . . . . . . . . .
- Removal
120
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
121
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS WIRING GEARBOX
121
. . . . . . . . . . . . . . . .
- Removal
121
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
122
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX WRING - GEARBOX
122
. . . . . . . . . . . . .
- Removal
122
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
123
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION
124
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearboxes 6 S 400 A O.D are made up of an
electronic/mechanical system controlling and managing the
gearbox in the different conditions of vehicle use.
This is the automatic version of the 6 S 400 gearbox unit.
Driver’s intervention is just limited to using the gear
selection/engagement control lever and the accelerator
pedal, so making clutch control pedal application not
necessary any more.
The system is equipped with:
- Safety device preventing vehicle engine start up under
determined situations (gearbox central unit managing
the ignition).
- Sound and visual signalling device drawing driver’s
attention on system operation or faults.
- Diagnosis device.
- Provided display unit acquainting about:
Selected A/M mode;
Gear;
Faults status.
The system interfaces to EDC system and ABS8/ESP8 device
via CAN line.
1. Production series number - 2. 1st / 6th gears ratio - 3. Dry oil quantity - 4. Oil rules - 5. Tachograph report -
6. IVECO number - 7. ZF series number.
108867
Figure 1
On the rear cover there is the speed selection and
engagement control support.
On a side of the main casing there is a slot where it is possible
to apply a power take-off.
Motion transmission is carried out by a set of helical-toothed
constant mesh gears both for forward speeds and for reverse
speed.
Splined or machined gears are placed on four shafts: input,
main, transmission and reverse shaft.
Gears splined on main and on reverse shaft, idle on straight
roller bearings.
Input and main shaft are supported, in the gearbox, by
four-contact ball bearings.
Transmission shaft is supported, in the gearbox, by roller
bearings which can be adjusted, axially, by means of ring
shims.
The synchronization of the speed engagement is carried out
by means of free synchronizer rings having the same
dimension for: first, fourth, and fifth speed and a greater
dimension for second and third speed.
Speed engagement sliding sleeve control forks, are controlled
by one shaft only, the same which supports them.
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