Iveco Daily. Manual — part 194
51431
Figure 62
Figure 63
1
st
-2
nd
GEAR DUAL CONE SYNCHRONIZER ASSEMBLY
3
rd
- 4
th
- 5
th
GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY
75414
Revi - February 2005
32
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
3
rd
- 4
th
GEAR SYNCHRONIZERS
A. Synchronization reserve
3
rd
- 4
th
gear
1.15 + 0.2 mm
B. 3
rd
- 4
th
gear release clearance 1.40 + 0.65 mm
Transmission
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.
Figure 64
1
st
- 2
nd
GEAR SYNCHRONIZERS
A. Synchronization reserve
1
st
-2
nd
gear
1.4
mm
B. 1
st
-2
nd
gear release clearance
0.9
mm
1. Sliding sleeve - 2. 1
st
gear cog-wheel - 3. Synchronizer ring - 4. Middle ring - 5. Ring - 6. Hub -
7. 2
nd
gear cog-wheel - 8. 3
rd
gear cog-wheel - 9. 4
th
gear cog-wheel - 10. Reverse gear - 11. 5
th
gear cog-wheel
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 (3, Figure 64)
proceeding as follows:
- position the synchronizer ring (3) on the respective
cog-wheel (2, 7, 8, 9 and 11, Figure 64);
- turn the synchronizer ring so as to ensure correct coupling
on the tapered surface of the cog-wheel of the gear.
- With a feeler gauge, check the distance A on two
diametrically opposite points.
If the average measured value A is less than 0.5 mm,
replace the synchronizer ring.
Force of sliding of sliding sleeves 80
÷ 95 Nm.
Maximum admitted wear on the synchronizers, distance A - 0,5 mm
5
th
GEAR SYNCHRONIZER
A. Synchronization reserve
5
th
gear
1.15 + 0.2 mm
B. 5
th
gear release clearance
1.10 + 0.4 mm
After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.
87897
+0,25
-0.35
+0,6
-0.35
NOTE
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
33
D
AILY
CHECKS
Gear (5) fitting on shaft (3), if required, shall be performed by
hydraulic press after heating the gear to 140
°C ÷ 170°C;
31 kN driving load.
Heat the internal rings (2 and 4) of the tapered roller bearings
to a temperature of approx. 80
°C and, with a suitable punch
(1), mount them on the transmission shaft (3).
Mount the retaining ring (1) whose thickness gives an end float
when in its seat of 0
÷ 0.05 mm.
Mount the synchronizer rings on their respective gears
according to the marks made during disassembly or
when checking in the case of replacement.
51433
75417
51434
75418
51437
51438
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Tighten the main shaft (1) in a vice and mount on it: the roller
cage (2), reverse gear (4) and synchronizer ring (3).
Heat the hub (2) for the 5
th
- reverse gear engagement sliding
sleeve to a temperature no higher than 150
°C and mount it
on the main shaft with a suitable punch (1).
Mount the retaining ring (1) whose thickness makes for null
clearance in its seat.
Check the end float of the reverse gear (2). It should be
0.15
÷ 0.3 mm.
Mount the sliding sleeve (5) on the hub (4) facing as shown
in the figure.
Put the springs (3), plugs (1) and balls (2) into the seats of the
hub (4), settling them under the sliding sleeve.
Mounting the main shaft
5
When fitting, make sure that the projecting parts (3)
of the synchronizer ring get positioned in the hub (2)
correctly.
NOTE
NOTE
Revi - February 2005
34
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
Mount the 1
st
gear (1).
Lubricate the ring (4), middle ring (3), synchronizer ring (2)
with TUTELA MR3 grease and mount them on the gear (1).
Heat the hub (1) for the 1
st
- 2
nd
gear sliding sleeve to a
temperature no higher than 150
°C and mount it on the main
shaft with a suitable punch.
Make sure the tongues of the rings (2 and 3) are
positioned correctly in their respective seats.
51439
51440
51420
51441
51442
Figure 71
Figure 72
Figure 73
Figure 74
Figure 75
Positioning the synchronizer ring (2) and the half roller
bearings (1).
Install the 5
th
speed gear (3).
Heat spacer ring (2) to 90
°C and install it.
Upset the main shaft (1).
Position the roller bearing (2) on the main shaft (1).
When assembling, make sure the tongues of the rings
(3 and 4, Figure 74) and the projections of the
synchronizer ring (2) are positioned correctly in the
hub (1). Check that the end float of the 1
st
gear (3)
is 0.15
÷ 0.30 mm.
NOTE
NOTE
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
35
D
AILY
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