Iveco Daily. Manual — part 183
44571
44570
Figure 3
Figure 4
Removal
The operation consists of:
- removal-refitting of transmission shafts (see section
505620);
- removal-refitting of gear box (see section 530210).
Insert the centering pin 99370205 (1) in the gear infeed shaft
support bearing, to facilitate clutch removal operations.
Remove the fixing screws (2) and remove the thrust pad (3)
from the engine flywheel.
Remove the clutch disk (3) by extracting the centring pin
99370205 (2).
Disk plate centering pin (1) located on the engine flywheel.
CHECKS
The checks to be made are as follows:
- the mating surface, on the engine flywheel, of the driven
disk must not be excessively worn or scored.
- the teeth of the toothed crown must not be worn or
broken.
If this is not the case, disassemble the engine flywheel
(operation 540850) as described in the relevant paragraph at
section 2.
Proceed on the engine flywheel as described in relevant
paragraph (operation 540853) at section 2.
Check that there are no oil leaks, even of a slight entity, from
the seal of the rear drive shaft; otherwise remove the flywheel
as described in the relevant paragraph. Remove the rear cover
complete with sealing rings and replace the same as described
at section 2.
Check that the support bearing or bushing of the take up shaft
on the gears fitted to the drive shaft are not worn or broken
and, if necessary, replace them as described in the relevant
paragraph (540852).
Check the condition of the thrust pad; the driven disk support
surface must not be scored or excessively worn or should
there be signs of overheating; the diaphragm spring must be
in perfect condition.
Check the condition of the driven disk:
- the friction seals must not be excessively worn or present
signs of overheating, or traces of oil or grease;
- there should be very little backlash between the hub and
gear take up shaft;
- the hub rings must not be loose or broken.
When any defects are found, replace the part in question.
The complete clutch is supplied with a spare kit.
The following are supplied singularly:
- the driven disk and collar bearing.
In this case it will necessary to assemble the new parts of the
driven disk spring that is to be reused.
505210
CLUTCH REMOVAL AND
REFITTING
CLUTCH
D
AILY
16
Base - May 2004
Refitting
Follow the same procedures as for removal in reverse order
and:
If the disk is out of line use a hook wrench (1) as in the figure.
- remove the guide pin;
- reconnect the gears after spreading the grooved shaft
with molybdenum disulphide Molikote as described in
Section 4;
- adjust the clutch travel as described in the relevant
paragraph (operation).
Before fitting a new driven disk check that it is centred as
follows:
Position the driven disk (1) on a lathe and, with the use of a
magnetic base dial gauge (2), check that the surface of the disk
is not out of line at any point.
Maximum tolerance allowed for the driven disk is 0.20 mm.
Figure 5
Figure 6
- carefully clean the faying surface of the flywheel
disk using methylated spirits or petrol; if any slight
scratches are noted remove with an abrasive
cloth;
- position the driven disk (3, Figure 4), using the guide pin
(2, Figure 4) to obtain perfect centring and to avoid
straining the hub when the gears are reconnected;
- position the thrust pad by aligning the holes with the
centring grub screws (1, Figure 4) on the engine flywheel;
- assemble and lock the thrust pad fixing screws to the
correct torque;
The operation consists of:
- removal-refitting of transmission shafts (see section
505620);
- removal-refitting of gear box (see section 530210).
By using the appropriate pliers open the split pin (1) and
extract the collar bearing (2) from the thrust pad.
To assemble, carry out the disassembly operations in reverse.
36800
Figure 7
The new part must be of the same supply as the
driven disk that is to be reused.
505254
THRUST BEARING REMOVAL
AND REFITTING
NOTE
CLUTCH
D
AILY
17
Base - May 2004
Figure 8
The hydraulic clutch drive is composed of:
- a master cylinder (1) mounted on the pedal board and
connected to the clutch pedal (5), with an integrated oil
tank (3).
- an operating cylinder (7) fixed to the gearbox (6).
- an oil pipe (4).
The components of the hydraulic drive must never be
dismantled or separated from each other in any way.
The cover (2) of the oil tank (3) must not be
removed.
50967
This assembly requires no maintenance and the hydraulic
circuit must not be vented.
In the event of defectiveness, the entire assembly needs to be
replaced as it is supplied as a spare part, proceeding as
described under the relevant heading.
The clip (8) holding the push rod (9) on the assembly supplied
as a spare part must not be removed or cut.
NOTE
CLUTCH
D
AILY
18
Base - May 2004
HYDRAULIC CLUTCH DRIVE
Figure 9
62090
SPECIFICATIONS AND DATA
CLUTCH
D
AILY
19
Base - May 2004
18 mm
Main cylinder section
254.47 mm
2
Operating cylinder diameter
22 mm
Operating cylinder section
346.36 mm
2
Clutch pedal ratio
5.85
Hydraulic ratio
1.36
Clutch disengagement lever ratio
1.67
Overall reduction ratio
13.28
Max disengagement stroke X
Y (94)
F (99)
J (98.7) mm
Max wear stroke Y
Y (67.5) F (70.8) J (69.1) mm
Y 9 ”
1
/
4
CLUTCH
F 10 ”
1
/
2
CLUTCH
J 11” CLUTCH
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