Iveco Daily. Manual — part 206
Apply LOCTITE 242 to the thread of the pins (1).
Screw the pins (1) into the box, checking that their ends go
into the hole of the 3rd/4th gear engagement fork link (1,
Figure 116) and then tighten them to the required torque.
Screw on the screws (2) securing the rear cover (3) to the
transmission (1) without fully tightening them.
Mount the centring pins (4) in the rear cover (3) and in the
transmission (1).
Tighten the screws (2) to the required torque.
52004
51936
51933
52003
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Mount the 3rd/4th gear control rod (2) in the rear cover (4),
connecting it to the relative fork (1), and the main rod (3).
Put the pawls (4) and springs (3) in the rear cover (1) and drive
in the retaining cups (2) with a suitable punch.
Apply LOCTITE 5206 on gearbox attachment.
When mounting the transmission, check that the shafts
and control rods are positioned correctly in their re-
spective seats and that the rod (2, Figure 116) stays
connected to the 3rd/4th gear engagement fork (1).
If during these assembly operations the fork (1,
Figure 116.) comes free of the control rod, it will not
be possible to mount the pins (1) until they have been
reconnected.
1
NOTE
NOTE
1
90230
Warm up the front bearing inner ring (2) at 90
÷110°C and fit
the gearbox (1) on the rear cover.
80
6 S 300 TRANSMISSION
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AILY
Base - May 2004
Mount the cover (1) protecting the input shaft and tighten the
screws (2) to the required torque.
51932
52005
51931
52006
52007
52008
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126
Mount the push rod (1) and the spring (2). Screw on the plug
(4) with a new washer (3), tightening it to the required torque.
Fit a new retaining ring (2) securing the front bearing (3) onto
the input shaft (1).
Using the key 9937455 (3), mount the O-ring (2) in the trans-
mission (1).
Mount the O-ring (2) in the rear cover (1) with the key
99374454 (4) and the grip 9937006 (3).
Fit the transmission shaft coupling (1) onto the output shaft.
If there is any interference, use the tool 99370234 (2) for as-
sembly with the lever 99370317 (3) to lock the coupling.
1
1
6 S 300 TRANSMISSION
81
D
AILY
Base - May 2004
Mount the washer (3) and screw on the screw (4).
Lock the rotation of the flange (1) with the lever 99370317
(5) and tighten the screw (4) to the required torque.
Mount the tachograph sensor (2) and the reversing light
switch.
Fit a new gasket (1) onto the transmission.
Apply LOCTITE 510 on the screw threading (2).
Mount the side cover (3) and tighten the fixing screws (2) to
the required torque.
Mount the control box as described under the relevant hea-
ding.
Mount the oil drainage plug, tightening it to the required torque.
Fill the transmission with lubricating oil in the required quantity
and grade.
Mount the oil filler and level indicator cap, tightening it to the
required torque.
52009
51924
51925
52118
Figure 127
Figure 128
Figure 129
Figure 130
Mount the rod (1) preventing engagement of more than one
gear at the same time, in the position marked during disas-
sembly.
Apply sealant to the thread of the plugs (1 - 3), screw them
into the box, tightening them to the required torque.
Position the driver (4) on the rod (5).
Secure it with the screw (2) after applying LOCTITE 242 onto
its thread.
1
1
82
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AILY
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6 S 380 O.D. TRANSMISSION
83
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AILY
Base - May 2004
Page
GENERAL
85
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR SELECTION AND ENGAGEMENT
86
. . . . .
SPECIFICATIONS AND DATA
88
. . . . . . . . . . . . .
TIGHTENING TORQUES
90
. . . . . . . . . . . . . . . . .
TOOLS
91
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE TRANSMISSION
99
. . . . . . .
-
Gear control box
99
. . . . . . . . . . . . . . . . . . . . . . .
-
Disassembly
99
. . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Assembly
99
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Check levers mounting
100
. . . . . . . . . . . . . . . . . .
-
Disassembling the transmission
101
. . . . . . . . . . . .
-
Disassembling the rear cover bearings
104
. . . . . . .
-
Disassembling the transmission bearings
105
. . . . .
-
Disassembling the main shaft
105
. . . . . . . . . . . . . .
-
Disassembling the drive input shaft
107
. . . . . . . . .
-
Disassembling the transmission shaft
107
. . . . . . . .
CHECKS
111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Transmission
111
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Hubs - sliding sleeves - forks
111
. . . . . . . . . . . . . .
-
Bearings
111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Shafts - gears
111
. . . . . . . . . . . . . . . . . . . . . . . . . .
-
Synchronizing devices
111
. . . . . . . . . . . . . . . . . . .
-
Mounting the transmission shaft
113
. . . . . . . . . . . .
-
Mounting the main shaft
114
. . . . . . . . . . . . . . . . .
-
Rods - forks - selector - driver
117
. . . . . . . . . . . . .
-
Disassembly - assembly
117
. . . . . . . . . . . . . . . . . .
-
Mounting the transmission
117
. . . . . . . . . . . . . . . .
-
Adjusting the transmission shaft bearing
end float
117
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