Iveco Daily. Manual — part 250
Remove gearing (1) inspection cover including the gasket.
33077
Figure 35
Figure 36
Figure 37
Figure 38
Remove caps (1) after marking them.
33078
Remove the spacer (1) and remove the gearing case (3) in-
cluding the crown wheel (4) and the outer rings (2) for sup-
porting bearings. Remove the other spacer and the adjust-
ment rings. Do not reverse the outer races of the gearing
case supporting bearings.
33079
Remove gearing case supporting bearings (1 and 2) using
puller 99348001 (3) and counter block 99345056 (4).
33081
Gearing case removal
Figure 39
Clamp the gearing case (2) in a vice and remove the ring
bevel gear (1) from the gearing case (2).
33082
33083
Mark gearing half-boxes (1 and 2), loosen the fastening
screws, position the gearing case on a bench and remove the
two half-boxes.
Figure 40
Before performing differential repair, drain oil and
remove axle shafts as described previously.
NOTE
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Base - May 2004
DIFFERENTIAL REPAIR
OPERATIONS
Differential unit removal
Figure 41
33084
Remove sun gears (5) and planetary gears (2) including the
spider (6) from the gearing half-box (4). Recover the shoul-
der washers (1 and 3).
Figure 42
Remove bevel pinion retaining nut safety crimp and loosen
the nut using the counter lever 99370317 (1).
33086
Figure 43
Remove transmission connection flange (1).
33087
Figure 44
Use a bronze beater in arrow direction to remove the bevel
pinion (1) including the rear bearing, the fixed spacer and the
adjustment rings from the rear axle casing (2).
33088
Figure 45
33089
Remove the sealing ring (1) and the front taper roller bearing
from the rear axle casing (2). Use a bronze beater to remove
the front taper roller bearing outer ring.
Figure 46
33090
Use a bronze beater to remove the rear taper roller bearing
outer ring (1) from the rear axle casing (2).
REAR AXLE 450517/2
81
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Figure 47
Use puller 99348001 (3) to remove the rear taper roller
bearing (2) from the bevel pinion (1).
33091
Differential components check
Carefully clean each differential component.
Lubricate the bearings and rotate the roller cage freely. The
rotation must be even and without sign of stiffness. Check the
ring bevel gear contact surfaces and the half-box striker plate
to ensure that the crown wheel adheres perfectly. Deforma-
tions on these surfaces cause the crown wheel fastening
screws to vibrate, thus jeopardizing the correct operation of
the unit.
Check that the splined section for flange-pinion connection
is not badly worn, otherwise replace the pinion.
Check the planetary gears and the relevant shoulder
washers, the spider and the crown wheels with the relevant
shoulder washers.
Replace all sealing elements, the bevel pinion retaining nut
and gearing case bearing adjustment nut with new parts.
Rear axle casing check
Check whether rear axle casing is not deformed.
Gearing case refitting
Figure 48
Fit in place the sun gear (2) with the shoulder washer set
below in gearing half-box (1).
33092
Figure 49
33084
Fit in place the planetary gears (2) with shoulder washers (3),
the spider (6) and the sun gear (5) with shoulder washer (1)
in the gearing half-box (4).
Figure 50
33094
Fit between them the half-boxes (1 and 2) and tighten the
fastening screws to the specified torque.
Carefully clean all threads in order to obtain exact
adjustments and accurate tightening torque.
NOTE
When replacing the crown wheel or pinion it is
necessary to replace both parts since they are
supplied in pairs.
NOTE
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REAR AXLE 450517/2
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Base - May 2004
Heat in air-circulation furnace at 100ºC for approx. 15’ the
taper roller supporting bearing (1) on toothing side and fit it
down onto the gearing case (2) completely.
Figure 51
33095
Figure 52
Heat in air-circulation furnace at 100ºC for approx. 15’ the
taper roller supporting bearing (1) on toothing opposite side
and fit it down onto the gearing case (2) completely.
33096
Figure 53
Pour few drops of LOCTITE 270 into crown wheel (1) holes,
fit the crown wheel (1) on the gearing case (2) and tighten
the fastening screws to the specified torque.
33097
Figure 54
33098
Figure 55
33099
Figure 56
33100
Use beater 99374093 (1) to fit in place front taper roller
bearing outer ring on rear axle casing. (See Figure 17 for ring
adjustment on beater 99374093).
Use beater 99374093 (1) to fit in place rear taper roller
bearing outer ring on rear axle casing (2) without adjustment
ring.
On surface plate (2), set to zero dial gauge 99395728 (1) on
support (3) and slightly preload it.
REAR AXLE 450517/2
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