Iveco Daily. Manual — part 203
TRANSMISSION SHAFT ASSEMBLY DRAWING
1. Transmission shaft assembly - 2. Tapered roller bearing - 3. Transmission shaft with reverse gear toothing (A), 1st gear (B), 2nd
gear (C) - 4. Tapered bearing - 5. 4th gear - 6. Synchronizer ring - 7. Sliding sleeve - 8. Ball - 9. Spring - 10. Plug - 11. Hub - 12. Retaining
ring - 13. Half roller bearings - 14. 3rd gear - 15. 5th gear - 16. 6th gear.
51964
52509
Figure 69
Figure 70
INPUT SHAFT ASSEMBLY DRAWING
1 - Input shaft - 2. Cog-wheel
1
1
68
6 S 300 TRANSMISSION
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AILY
Base - May 2004
Figure 71
MAIN SHAFT ASSEMBLY DRAWING
1. Single cone synchronizer ring - 2. Roller bearing - 3. Retaining ring - 4. Sliding sleeve - 5. Plug - 6. Ball - 7. Spring - 8. Hub - 9.
5th gear - 10. Main shaft with 3rd gear toothing (A), 4th gear toothing (B) - 11. Roller bearing - 12. 2nd gear - 13. Dual cone
synchronizer - internal ring C, middle ring D, synchronizer ring E - 14. Bushing - 15. 1st gear - 16. Spacer ring -
17.* Reverse gear - 18.* Ring with external toothing - 19.* Ring with internal toothing - 20.* Spacer ring. - 21.
•
Reverse gear -
22.
•
Synchroniser ring - 23.
•
Gear.
*
Transmission without synchronised reverse
•
Transmission with synchronised reverse
90233
6 S 300 TRANSMISSION
69
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Base - May 2004
85977
1ST-2ND GEAR DUAL CONE SYNCHRONIZER ASSEMBLY
85978
Figure 72
Figure 73
3RD - 4TH - 5TH - 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY
SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR
86130
Figure 74
70
6 S 300 TRANSMISSION
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After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.
The transmission and relative covers must show no sign of
cracking.
The mating surfaces of the covers and transmission must not
be damaged or deformed. Remove any remains of sealant
from them.
The seats of the bearings, reverse gear shaft and gear control
rods must be neither damaged nor too worn.
Hubs - sliding sleeves - forks
The grooves on the hubs and relative sliding sleeves must not
be damaged. The sliding sleeve must run freely on the hub.
The plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves
must not be damaged. The forks must be sound with an end
float, in the radial groove of the sleeve, no greater than 1 mm.
Bearings
The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced.
Shafts - gears
The seats on the shafts, for bearings, must be neither damaged
nor worn. The toothing of the gears must be neither damaged
nor worn.
Synchronizing devices
Check the wear on the synchronizer rings, proceeding as
follows:
- See that the friction surface is not undulated.
52510
52511
Figure 75
Figure 76
BK-type single cone synchronizers for 3rd/4th/5th/6th
gears
Arrange the synchroniser ring (1) on the respective gear or
reverse taper ring (2).
With a feeler gauge, check the distance S on two diametrically
opposite points.
If the measured value S is less than 0.8 mm, replace the
synchronizer ring.
Turn the synchronizer ring (1) so as to ensure correct coupling
on the cog-wheel.
Position the internal ring (3), middle ring (2) and the
synchronizer ring (1) on the tapered cog-wheel (4) of the gear.
Turn the synchronizer ring (1) so as to ensure correct coupling
between the parts.
Applying a uniform force of 50 N on the synchronizer ring (1),
measure the distance S on two diametrically opposite points
with a feeler gauge.
If the average measured value S is less than 1.5 mm, replace
all the rings.
!
D-type dual cone synchronizers for 1st/2nd gears
4
Transmission
6 S 300 TRANSMISSION
71
D
AILY
Base - May 2004
CHECKS
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