Iveco Daily. Manual — part 212
Turn over the rear cover (4).
Take out the O-ring (6).
Using a suitable punch, remove the ball bearing (5). Remove
the tachograph sensor (7) and the reversing light switch (1)
with the washer (2) and extract the push rod (3).
Remove the screws (1) securing the plates (2).
Take out the plates (2).
Turn over the rear cover (4) and remove the bearing (3).
51951a
51944
Figure 47
Figure 48
Disassembling the rear cover bearings
51943
74960
Figure 49
Figure 50
Using universal extractor 99348004 (1), remove the outer
ring (2) of the transmission shaft bearing.
Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3).
Figure 51
Clamp the primary shaft (6) in a vice.
Remove the rods (10 and 11) with the relevant forks. Remove
the forks (3 and 4) and the small blocks.
Remove the RM gear (4).
Remove the snap ring (8) and the tool 9936522 (9).
Remove the input shaft (7).
Support the secondary shaft (2), slacken the screw (1)
and remove the secondary shaft (2).
90214
1
1
104
6 S 380 O.D. TRANSMISSION
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51410
85945
Figure 52
Figure 53
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 (3).
Remove the sliding sleeve (2) for engaging 5
th
- 6
th
gear from
the hub (1) and, taking care as the plugs (5) come out with the
balls (4) and springs (3), recover them.
Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the roller bearing (4-3).
Mark the assembly position of each synchronizing de-
vice on the respective gear.
85944
Figure 54
Figure 55
Tighten the primary shaft (1) in a vice. Remove the
synchroniser ring (4) and the circlip (2). Remove the circlip (3)
from its housing.
Disassembling the main shaft
51948
NOTE
51946
Figure 56
Figure 57
Using universal extractor 99348004 (1), remove the outer
ring (2) of the transmission shaft bearing.
Disassembling the transmission bearings
Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3).
74962
1
3
6 S 380 O.D. TRANSMISSION
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90215
51424
Figure 58
Figure 59
Use the hydraulic vice to remove from the primary shaft (1):
the 1
st
speed gear (8), the spacer (7), the bush (6), the roller
cage (5), the R.M. gear (4) together with the coupling
elements, the synchronising ring (3) and the serrated ring (2).
Remove the sliding sleeve (2) for engaging 1
st
-2
nd
gear from
the hub (1) and, taking care as the plugs (3) come out with
their relative balls (4) and springs (5), recover them.
1
Take out the synchronizer ring (4), middle ring (3), ring (2) and
roller bearing (1).
Using a hydraulic press, remove the 2
nd
gear (10), ring (9),
middle ring (8), synchronizer ring (7), synchronizer assembly
(6) and the bushing (5). Take out the roller bearing (11).
51954
Figure 60
Figure 61
Remove the reverse gear engagement sliding sleeve (2) from
the reverse gear (1). Retrieve hub (1) and pads (3) with
respective balls (4) and springs (5).
85949
85946
85947
Figure 62
Figure 63
Use extractor 99348001 (6) as shown in the figure to extract
the primary shaft (1), the 5
th
gear (7), the synchroniser ring (5),
the hub (4), the circlip (3) and the roller bearing (2).
Remove the roller half cages (1).
1
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90216
51961
Figure 64
Figure 65
Using general tools, extract the internal ring (2) of the rear
tapered roller bearing from the transmission shaft (1).
Remove the 3rd gear (1) and the roller bearing (2).
Remove the synchronizer ring (3). Remove the retaining ring
(5) securing the hub (4).
51960
51959
Figure 66
Figure 67
Using a hydraulic press, extract the 6th gear (2) and the
internal ring (1) of the tapered roller bearing from the
transmission shaft.
Using a hydraulic press, remove the 5th gear (2) from the
transmission shaft (1).
51956
90217
Figure 68
To replace the cog-wheel (1), use the same general tools for
disassembly as for assembly, heat it to a temperature of 80ºC.
Take out the retaining ring (1) holding the 5
th
gear (2).
Disassembling the drive input shaft
Disassembling the transmission shaft
1
Figure 69
1
1
1
6 S 380 O.D. TRANSMISSION
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