Iveco Daily. Manual — part 216
Screw on the screws (2) securing the rear cover (3) to the
transmission (1) without fully tightening them.
Mount the centring pins (4) in the rear cover (3) and in the
transmission (1).
Tighten the screws (2) to the required torque.
90229
90230
51936
90231
Figure 117
Figure 118
Figure 119
Figure 120
Apply some grease on the pin of the dragging device (2) and
fit the clutch fork (1) for the 3
rd
— 4
th
speed on this device.
Put the pawls (4) and springs (3) in the rear cover (1) and drive
in the retaining cups (2) with a suitable punch.
Apply LOCTITE 5206 on gearbox attachment.
Warm up the front bearing inner ring (2) at 90
÷110°C and fit
the gearbox (1) on the rear cover.
When fitting the gearbox, check that the shafts and
the control rods fit correctly in the respective seat and
that the fork (1, Figure 117) does not disconnect from
the clutch rod (2, Figure 117) for the 3
rd
— 4
th
speed.
1
NOTE
51931
Figure 121
Fit a new retaining ring (2) securing the front bearing (3) onto
the input shaft (1).
1
120
6 S 380 O.D. TRANSMISSION
D
AILY
Base - May 2004
Mount the cover (1) protecting the input shaft and tighten the
screws (2) to the required torque.
51932
52006
52007
Figure 122
Figure 123
Figure 124
Mount the push rod (1) and the spring (2). Screw on the plug
(4) with a new washer (3), tightening it to the required torque.
Mount the O-ring (2) in the rear cover (1) with the key
99374454 (4) and the grip 9937006 (3).
1
52005
Figure 125
Using the key 9937455 (3), mount the O-ring (2) in the trans-
mission (1).
Apply LOCTITE 242 to the thread of the pins (1).
Screw the pins (1) into the box, checking that their ends go
into the hole of the 3rd/4th gear engagement fork link (1,
Figure 117) and then tighten them to the required torque.
Drive in the pins (2) and check that their ends fit in the knuckle
hole of the clutch fork for the 5
th
— 6
th
speed and tighten it to
the prescribed torque.
90209
Figure 126
If during these assembly operations the fork (1,
Figure 117.) comes free of the control rod, it will not
be possible to mount the pins (1) until they have been
reconnected.
NOTE
Make sure that the clutch control rods are all in
neutral position.
NOTE
6 S 380 O.D. TRANSMISSION
121
D
AILY
Base - May 2004
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 127
Figure 128
Figure 129
Figure 130
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 131
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.
122
6 S 380 O.D. TRANSMISSION
D
AILY
Base - May 2004
6 AS 300 VD TRANSMISSION
122/1
D
AILY
Page
GENERAL
122/3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION AND ENGAGEMENT
122/4
. . . .
- Neutral arrangement and/or 3rd/4th gear selection
and engagement arrangement
122/4
. . . . . . . . . . . . .
- 1st/3rd gear selection election and engagement
arrangement
122/4
. . . . . . . . . . . . . . . . . . . . . . . . . .
- 5th/6th gear selection and engagement
arrangement
122/5
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Reverse gear selection and engagement
arrangement
122/5
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Safety device
122/5
. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA
122/6
. . . . . . . . . . . . .
MOTION TRANSMISSION GEAR SEQUENCE
122/8
DIAGNOSIS EQUIPMENT
122/12
. . . . . . . . . . . . . . . . .
MODUS - IT 2000 - E.A.SY. CONNECTION
122/13
. .
TIGHTENING TORQUES
122/14
. . . . . . . . . . . . . . . . .
TOOLS
122/15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX REMOVAL-REFITTING
122/16
. . . . . . . . . .
- Removal
122/16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
122/19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR WORK
122/23
. . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL UNIT
122/23
. . . . . . . . . . . . . . . . . . . . . . . .
- Removal
122/23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
122/24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH ACTUATOR
122/25
. . . . . . . . . . . . . . . . . . . .
- Removal
122/25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
122/26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX ACTUATOR
122/26
. . . . . . . . . . . . . . . . . .
- Removal
122/26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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