Iveco Daily. Manual — part 189
1. Gear engagement lever - 2. Gear selection lever - 3. Driver - 4. Gear selection/engagement control rod -
5. Selector - 6. Driver - 7. Rod for 3
rd
/4
th
gear engagement fork - 8. Rod for 1
st
/2
nd
gear engagement fork -
9. Rod for 5
th
/reverse gear engagement fork.
The combined action of the selection (2) and engagement (1) levers bring about the rotation and/or axial shift of the rod (4) in
two successive stages, engaging the desired gear by means of one of the rods (9, 8 or 7).
First Stage
Depending on the angular position of the selection lever (2), the driver (3) (integral with it) turns the selector (5) with the rod
(4) (connected together), setting the selector on the rod of the chosen gear.
Second Stage
Depending on the movement given to the engagement lever (1), the driver (3) (integral with it) shifts the selector (5) (already
prepared) axially with the rod (4) and consequently also the engagement rod of the chosen gear.
SECTION A-A
SECTION A-A
This arrangement is accomplished by shifting the selection
lever (2) anticlockwise by 7.1
° to the control axis, which
corresponds to a clockwise change in the angle of the rod (4)
of 10
°.
49373
49372
Figure 2
Figure 3
Position of transmission in neutral and/or ready
to select 3
rd
/4
th
gear
The position of the transmission in neutral coincides with
being ready to select 3
rd
/4
th
gear.
In this case the vertical axis of the selection lever (2) is exactly
90
° from the horizontal control axis, corresponding to no
change in the angle of the rod (4).
Ready for 1
st
/2
nd
gear
Revi - February 2005
12
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
This device is composed of a plate (8) and a spring (7) housed in the transmission. When passing from the 4
th
gear position (Figure
A) to the 5
th
gear position (Figure B), the driver (9), moving in the direction of the arrow, disengages the plate (8), which under
the action of the spring (7) moves onto the driver (9) preventing reverse gear from getting engaged in the opposite manoeuvre.
SECTION A-A
1. Gear engagement lever - 2. Gear selection lever -
3. Driver - 4. Gear selection/engagement control rod -
5. Selector - 6. Driver - 7. Rod for 3
rd
/4
th
gear
engagement fork - 8. Rod for 1
st
/2
nd
gear engagement fork
- 9. Rod for 5
th
/reverse gear engagement fork.
This device is composed of a plate (1), housed in the rear
cover, operated by the gear selection/engagement control rod
(2).
When
selecting/engaging
a
gear,
the
rod
(2)
simultaneously turns the plate (1) in which it is inserted. In this
way, the plate (1) will free itself from the slot of the rod
involved in engaging the gear and will lock the other two rods
by inserting itself into their slots.
Above presetting is implemented by moving selector (2)
clockwise by 7.1º with respect to control vertical axis, that
corresponds to 10º anticlockwise angular displacement of rod
(4).
49374
51381
Figure 4
Figure 5
Figure 6
SAFETY DEVICES
The transmission is equipped with two mechanical safety
devices:
Engagement locking device to prevent more than one gear
getting engaged at the same time.
Reverse gear anti-engagement device when passing from 5
th
to 4
th
gear.
Engagement locking device
49375
Reverse gear anti-engagement device
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
13
D
AILY
Ready to select 5
th
/reverse gear
Revi - February 2005
14
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
D
AILY
Base - May 2004
TRANSMISSION
5 S 200
5 S 270
5 S 300
Type
Mechanical
Input torque
Nm
250
270
300
Weight
kg
44.6
Speeds
5 forward speeds
1 reverse speed
Speed control
Mechanical
Power take-off
Optional
Speed engagement:
Forward speeds
S
- 5
th
/ 4
th /
3
nd
Single-cone synchronizer
- 2
nd
/ 1
st
Dual-cone synchronizer
Reverse speed
y
Single-cone synchronizer
Sliding sleeves retained by pawls and springs
Speed retention mechanism
Gears
Helical-toothed constant mesh gears
Gear ratio
4.99
First
2.60
Second
1.52
Third
1.00
Fourth
0.78
Fifth (overdrive)
4.51
Reverse
4.51
Shaft bearings:
Main shaft
Transmission shaft
watertight ball bearing
tapered roller
Revi - February 2005
5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS
15
D
AILY
TRANSMISSION
5 S 200
5 S 270
5 S 300
Transmission shaft bearing end play:
0
÷ 0.05 mm
Transmission shaft bearing end play adjustment
by shims
Shim thickness for transmission shaft bearing
end play adjustment
2.00 - 2.30 - 2.45 mm
with 0.05 mm progressive sequence
Main shaft
Assembly temperatures:
sliding sleeve hubs
2
nd
and 3
rd
speed gear bushings and spacer
5
th
speed gear spacer
150
o
C
170ºC
÷ 160ºC
90ºC
Secondary shaft
Assembly temperatures:
bearings
h
80ºC (max 120ºC)
g
5
th
speed gear
5
th
speed gear driving load
5
th
speed gear removing load
140ºC
÷ 170ºC
31 KN
50 KN
Input shaft
Assembly temperatures:
front bearing*
80ºC (max 120ºC)
Gear axial backlash:
1
st
- 3
rd
- 4
th
- R - 5
th
speed
2
nd
speed
0.15
÷ 0.3 mm
0.25
÷ 0.4 mm
3
rd
and 4
th
speed sliding sleeve hub retaining
circlip axial backlash
0
÷ 0.05 mm
3
rd
and 4
th
speed sliding sleeve hub retaining
circlip thickness
2 - 2.85 mm with progression of 0.05 mm
Transmission shaft rear bearing retaining ring
end float
0
÷ 0,05 mm
Transmission shaft rear bearing retaining ring
thickness
2.05
÷ 2.45 mm
with progression of 0.05 mm
242
LOCTITE sealant
510
5206
Type of oil:
TUTELA TRUCK GEARLITE
Quantity
2 litres
1.8 kg
* = Do not use hot air equipment to heat bearing.
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