Iveco Daily. Manual — part 243
Mount a new O-ring on the differential locking attachment
plane.
Position the previously assembled support (3) so as to insert
the control lever in the spline on the sliding sleeve.
Insert the 4 screws (2) complete with washers and spring
washers and tighten the screws to the driving torque of 23
Nm (2.35 kgm).
Assemble the spring (1).
Adjust the differential locking device by following the
procedures below.
Remove gasket (4).
By means of a normal beater knock out the elastic pin (2),
remove the lever (1) complete with ring and washer.
Finally, remove the control lever (3) from the support (5).
Remove the spring (1).
Unscrew and remove the 4 screws (2) including washers and
then disconnect the differential locking device (3).
If required, remove the unit as described in the following
paragraphs.
61869
23227
61869
526210
DIFFERENTIAL REPAIR
OPERATIONS
526260
Disassembly of differential locking
Assemble the differential locking device by following the
removal operations in the reverse order.
Re-attach the differential locking device to the rear axle
casing as follows:
Assembling the differential locking device
Differential locking removal
Differential locking refitting
Figure 27
Figure 28
Figure 29
52
REAR AXLES 450311/1 - 450511
D
AILY
Base - May 2004
61871
18216
Figure 30
Figure 31
DIFFERENTIAL LOCKING DEVICE COMPONENTS
1. Flexible tie rod bracket (Bowden) - 2. Rear axle casing - 3. Spring - 4. Gasket - 5. Sealing ring - 6. Gasket - 7. Sleeve
control lever (9) - 8. Elastic pin to fix lever (7) to lever (12) - 9. Differential locking sliding sleeve - 10. Spring coupling
plate (11) - 11. Lever return spring (12) - 12. Transmission lever - 13. Adjusting screw nut - 14. Adjusting screw -
15. Differential locking device body.
Engage the sliding sleeve (9). Once this has been done,
loosen the nut (13), move the adjustment screw (14) so that
it is contact with the control lever (7). After this, unscrew the
adjustment screw by 9.5 turns (corresponding to 9.5 mm.
travel of the screw) and lock it with the fastening nut (13).
Adjusting the differential locking device
Disassembling the differential unit
Unscrew the screws (1) complete with tab washers and
spring washers and remove the gear housing inspection
cover (2) complete with gasket.
Before carrying out repair operations on the
differential unit you must drain off the oil and
disassemble the drive shafts. For the rear axle, you
must disassemble the differential locking as
described in the relevant paragraphs.
NOTE
REAR AXLES 450311/1 - 450511
53
D
AILY
44598
Figure 32
Mark the position of the caps (1 and 2) and remove them.
44599a
Figure 33
Take out the gear housing (1).
Note the assembly position of the adjustment rings (3) and
take them out of the housing together with the spacer rings
(2).
Extract the support bearing inner rings (3 and 5) and shoulder
ring (2) from the gear housing and, by means of the puller tool
99348001 (4), extract the counter block (1).
44600
Figure 34
Disassembly of gear housing
62099
18222
Figure 35
Figure 36
Unscrew the screws (2), remove the ring bevel gear (3) and
the gear housing (4) cover (1).
Remove the crown wheel (2) on the cover side with its thrust
washer (3) from the gear housing (1).
Using a generic beater to remove the long pin (4) and the
two short pins (5) from the gearing case (1).
The thrust ring (2) is only present with rear axles
fitted with differential locking.
NOTE
Mark the cover (1) and the gear housing (4).
NOTE
In the case of reuse, do not swap over the assembly
positions of the external rings (4) of the tapered
roller bearings.
NOTE
54
REAR AXLES 450311/1 - 450511
D
AILY
Base - May 2004
20378
18226
Figure 37
Remove the spider (1) and the four planetary gears (2) with
their shoulder washers (3) from the gear housing.
Remove the crown wheel (1) on the gear housing side with
the thrust washers.
51863
PARTS COMPRISING THE DIFFERENTIAL UNIT
1. Nut - 2. Transmission connection coupling - 3. Seal - 4. Front bearing - 5. Pinion shim ring - 6. Fixed
spacer - 7. Spacer ring - 8. Adjustment ring - 9. Rear bearing - 10. Bevel pinion - 11. Ring bevel gear - 12. Fixed ring -
13. Adjustment ring - 14. Bearing - 15. Thrust ring (axle with differential locking) - 16. Gear housing - 17. Crown wheel
thrust washer - 18. Spider - 19. Crown wheel - 20. Gear housing cover - 21. Screw - 22. Planetary gear thrust washer - 23.
Planetary gear - 24. Short pin - 25. Long pin.
Figure 38
Figure 39
REAR AXLES 450311/1 - 450511
55
D
AILY
Base - May 2004
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