Iveco Daily. Manual — part 188
Figure 2
Before assembly, lubricate the points of connection
of the swivel heads with the Bowden cables with
TUTELA MRM2 grease.
GEAR CONTROL
Gear control is accomplished with two Bowden cables. The
blue cable (6) with the IVECO trademark operates the lever
(4) for engaging gears.
The white cable (1) with the IVECO trademark operates the
lever (8) for selecting gears.
The length of the cables measured between the c/c distances
of the swivel heads must be:
- 780
±2 mm engagement cable (6);
- 1280
±2 mm selection cable (1).
The selection (8) and engagement (4) levers must be
mounted on their respective shafts so that:
- between the c/c distance of the pin of the lever (8) for
connecting the swivel head and the outside of the
bracket (2) there is a distance X of 134
±0.75 mm;
- between the c/c distance of the pin of the lever (4) for
connecting the swivel head (3) and the outside of the
bracket (5) there is a distance Y of 135
±0.75 mm.
- Engagement cable (6):
¤ Left-hand drive vehicles, 758.5
±2 mm.
¤ Right-hand drive vehicles, 1058.5
±2 mm.
- Selector cable (1):
¤ Left-hand drive vehicles, 1216
±2 mm.
¤ Right-hand drive vehicles, 1566.5
±2 mm.
For vehicles fitting 6S300 transmission and synchronised
reverse only.
SELECTION WIRE (1) ADJUSTMENT.
Remove the screw (13) and detach the cover (12) from the
gear lever support.
Engage either 1
st
of 2
nd
gear and check that there is a distance
of 2 mm between the gear lever (10) and the stop (9);
proceed as follows if this is not so:
- remove the ball joint (14) from the connecting ball pin
(15);
- loosen the fastening nut (16);
- arrange a 2 mm shim (11) between stop (9) and lever
(10);
- hold the lever (10), shim (11) and stop (9) in contact and
turn the ball joint (15) until it reaches the ball pin (15);
- fasten and check that all the gears can be engaged;
- tightening the fastening nut (16);
- reattach the cover (12) and tighten the fastening screws
(13).
85960
NOTE
8
TRANSMISSION
D
AILY
Base - May 2004
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
9
D
AILY
Page
GENERAL
11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION AND ENGAGEMENT
CONTROL
12
. . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY DEVICES
13
. . . . . . . . . . . . . . . . . . . . . . . .
-
Engagement locking device
13
. . . . . . . . . . . . . . .
-
Reverse gear anti-engagement device
13
. . . . . . .
SPECIFICATIONS AND DATA
14
. . . . . . . . . . . . .
TIGHTENING TORQUES
16
. . . . . . . . . . . . . . . . .
TOOLS
17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE TRANSMISSION
23
. . . . . .
-
Gear control box
23
. . . . . . . . . . . . . . . . . . . . . . .
-
Disassembly
23
. . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Assembly
23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Disassembling the transmission
25
. . . . . . . . . . . .
-
Disassembling the rear cover bearings
27
. . . . . . .
-
Disassembling the transmission bearings
27
. . . . .
-
Disassembling the main shaft
28
. . . . . . . . . . . . . .
-
Drive input shaft
30
. . . . . . . . . . . . . . . . . . . . . . .
-
Disassembling the transmission shaft
30
. . . . . . . .
CHECKS
33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Transmission
33
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Hubs - sliding sleeves - forks
33
. . . . . . . . . . . . . .
-
Bearings
33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Shafts - gears
33
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Synchronizing devices
33
. . . . . . . . . . . . . . . . . . .
-
Mounting the transmission shaft
34
. . . . . . . . . . . .
-
Mounting the main shaft
34
. . . . . . . . . . . . . . . . .
-
Rods - forks - selector - driver
37
. . . . . . . . . . . . .
Revi - February 2005
10
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
-
Disassembly - assembly
37
. . . . . . . . . . . . . . . . . .
-
Mounting the transmission
37
. . . . . . . . . . . . . . . .
-
Adjusting the transmission shaft bearing
end float
37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The gears splined on the main and reverse gear shafts idle on
straight roller bearings.
The input and main shafts are supported, in the transmission,
by watertight, non-adjustable ball bearings.
The transmission shaft is supported, in the transmission, by
tapered roller bearings that can be adjusted axially by means
of ring shims.
Gear engagement synchronization is accomplished by means
of free ring synchronizing devices with a single cone for 5
th
-
4
th
- 3
rd
gears -R.G. and dual cone for 1
st
- 2
nd
gears.
Control inside the transmission is accomplished with four
rods:
- a main rod to select and engage gears;
- three rods equipped with forks for engaging gears.
The external engagement lever is equipped with two
opposing masses. These have the task of attenuating the force
of engagement of the control cable (BOWDEN) and
consequently the noise level.
51380
Figure 1
The 5 S 200 - 5 S 270 and 5 S 300 transmission is mechanical
with synchronized engagement of forward gears.
It is composed of a light alloy box (which also serves as a clutch
cover), a rear cover (where the speed engagement controls
and gearing are housed) and a control box.
There is an opening on the side of the transmission to apply
a power take-off.
Drive transmission is accomplished by a set of helical-toothed
constant mesh gears, for both forward and reverse gears.
The splined or machined gears are on four shafts: input, main,
transmission and reverse gear.
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
11
D
AILY
GENERAL
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