Iveco Daily. Manual — part 193
51410
51412
51411
51413
51414
51415
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Remove the screws (1) securing the plates (2).
Take out the plates (2).
Turn over the transmission.
Using a suitable punch, remove the ball bearing (1).
Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the roller bearing (3).
Clamp the main shaft (1) in a vice. Remove the roller bearing
(2) and the synchronizer ring (3). Remove the sliding sleeve
(6) for engaging 3
rd
-4
th
gear from the hub (5) and, taking care
as the plugs (8) come out with their relative balls (9) and
springs (7), recover them.
Remove the retaining ring (4, Figure 44). Extract the hub (2)
with the extractor 99348001 (1).
Remove the synchronizer ring (1), 3
rd
gear (2) and roller
bearing (3).
Disassembling the main shaft
Mark the assembly position of each synchronizing
device on the respective gears.
NOTE
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5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
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Base - May 2004
Using the bridge 99341003 (1), ties 99341012 (2) and clamp
99341015 (3), extract the 1
st
gear (6), with the synchronizer
ring (7), middle ring (8) and ring (9), hub (5) and bushing (4).
Remove the roller bearing (10).
Using bridge 99341003 (1), screw stays 99341019 (2), grips
99341025 (4) and clamp 99341015 (3), take out the 2
nd
gear
(7), spacer (6) and bushing (5).
51418
51417
51419
51420
51421
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52
Take out the synchronizer ring (4), middle ring (3), ring (2) and
roller bearing (1).
Remove the sleeve (2) for engaging 1
st
-2
nd
gear from the hub
(1) and, taking care as the plugs (5) come out with their relative
balls (3) and springs (4), recover them.
Turn over the main shaft (1). Take out the spacer ring (2) and
remove the 5
th
gear (3).
Remove the half roller bearings (1), the synchronizer ring (3)
and the retaining ring (4) holding the hub (2).
Force of extraction of the bushing (4) 40 kN.
76010
NOTE
Force of extraction of the bushing (4) 40 kN.
NOTE
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If the cog-wheel (2) of the input shaft gear (1) shows any sign
of damage, take out the retaining ring (3), replace the
cog-wheel (2) and refit the retaining ring (3).
Disassembling the transmission shaft
If the cog-wheel (2) of the 5
th
gear (1) shows any sign of
damage, take out the retaining ring (3), replace the cog-wheel
(2) and refit the retaining ring (3).
Drive input shaft
75416
51424
51423
51425
51426
51427
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Using the bridge 99341003 (1), ties 99341012 (2) and clamp
99341015 (3), extract the reverse gear (5) and the
synchronizer assembly (4).
Remove the roller bearing (1).
Remove the sliding sleeve (2) for engaging reverse - 5
th
gear
from the hub (1), taking care as the plugs (3) come out with
their relative balls (4) and springs (5), recover them.
Take out the retaining ring (1) and extract the internal ring (2)
of the rear bearing. Turn over the shaft (3) and extract the
internal ring (4) of the front bearing.
Shaft (3) gear (5) removal, if required, shall be performed by
hydraulic press; 50 kN removing load.
5
Revi - February 2005
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5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
51428
75413
51430
Figure 59
Figure 60
Figure 61
INPUT SHAFT ASSEMBLY DRAWING
MAIN SHAFT ASSEMBLY DRAWING
TRANSMISSION SHAFT ASSEMBLY DRAWING
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
31
D
AILY
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