Iveco Daily. Manual — part 202
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
51943
51946
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
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).
Using universal extractor 99348004 (1), remove the outer
ring (2) of the transmission shaft bearing.
Disassembling the rear cover bearings
Disassembling the transmission bearings
Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3).
1
74960
74962
Figure 50
51944
1
7
6
5
4
2
3
1
1
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6 S 300 TRANSMISSION
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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.
51410
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
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).
Tighten the primary shaft (1) in a vice. Remove the
synchroniser ring (4) and the circlip (2). Remove the circlip (3)
from its housing.
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.
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).
Disassembling the main shaft
51948
3
85947
85944
85945
85946
NOTE
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To replace the cog-wheel (1), use the same general tools for
disassembly as for assembly, heat it to a temperature of 80ºC.
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.
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
51424
51956
51957
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Take out the retaining ring (1) holding the 6
th
gear (2).
Disassembling the drive input shaft
Disassembling the transmission shaft
1
1
1
2
85948
With the hydraulic press, remove the following from the pri-
mary shaft (1): 1
st
gear (10), shim (9), bushing (8), roller cage
(7); for transmission without synchronised reverse: reverse
gear (6); sliding sleeve (5), outer gear wheel (4), inner gear
wheel (3) and shim (2); for transmission with synchronised re-
verse: reverse gear (11) with engagement parts, synchroniser
ring (12) and gear (13).
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
Figure 62
1
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51958
51960
51959
51961
51962
51424
Figure 63
Figure 64
Figure 65
Figure 66
Figure 67
Figure 68
Using general tools, extract the internal ring (2) of the rear
tapered roller bearing from the transmission shaft (1).
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).
Remove the 3rd gear (1) and the roller bearing (2).
Remove the synchronizer ring (3). Remove the retaining ring
(5) securing the hub (4).
Using a hydraulic press, remove the 4th gear (3), the
synchronizer ring (2) and the synchronizer assembly (1).
Remove the half roller bearings (4).
Remove the sleeve (2) for engaging the 3rd-4th gear from the
hub (1) and, taking care over the plugs (3) coming out with
their relative balls (4) and springs (5), recover them.
1
1
1
1
1
1
1
6 S 300 TRANSMISSION
67
D
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Base - May 2004
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