Iveco Daily. Manual — part 204
85918
85919
85917
6
TH
/5
TH
GEAR SYNCHRONISERS
A. synchronization reserve 6
th
/5
th
gear: 1
÷ 1,4 mm
B. 6
th
/5
th
release clearance: 0,3
÷ 0,7 mm
85916
3
TH
/4
TH
GEAR SYNCHRONISERS
A. synchronization reserve 1
st
/2
nd
gear: 1
÷ 1,4 mm
B. 1
st
/2
nd
release clearance: 0,3
÷ 0,7 mm
1
ST
/2
ND
GEAR SYNCHRONISERS
A. synchronization reserve 1
st
/2
nd
gear: 1,6
÷ 2,0 mm
B. 1
st
/2
nd
release clearance: 0,9
÷ 1,5 mm
REVERSE GEAR SYNCHRONISER
A. Synchronization reserve: 0.9
÷ 1,4 mm
B. release clearance: 0,35
÷ 0,85 mm
1. Hub - 2. 6
th
gear - 3. Synchronizer ring - 4. Sliding sleeve - 5.
th
gear cog-wheel - 6. 3
rd
gear cog-wheel -
7.
th
gear cog-wheel - 8. 2
nd
gear cog-wheel - 9. Reverse gear - 10. Middle ring - 11. Ring - 12. Reverse gear -
13. Reverse gear ring
Figure 77
Figure 78
Figure 79
Figure 80
72
6 S 300 TRANSMISSION
D
AILY
Base - May 2004
51966
51968
51967
51969
51970
51971
Figure 81
Figure 82
Figure 83
Figure 84
Figure 85
Figure 86
Clamp the transmission shaft (1) in a vice and position the half
roller bearings (2) on it.
Mount the 4th gear (2) and position the synchronizer ring (1)
on this.
Heat the hub (2) to a temperature of 110
° ÷ 150°C and
mount it on the transmission shaft (1), taking care that the
protrusions (3) of the synchronizer ring are positioned
correctly in their seats in the hub (2).
Mount the retaining ring (1) whose thickness produces null
end float in its seat.
Check the end float of the 4th gear (2). It should be
0.15
÷ 0.40 mm.
Mount the sliding sleeve (1) on the hub (2). Put the springs (5),
plugs (3) and balls (4) into the seats in the hub (2), settling
them under the sliding sleeve (1).
Position the synchronizer ring (2) on the hub (3) so that its
protrusions enter the seats in the hub (3). Mount the roller
bearing (1).
1
1
1
1
1
1
6 S 300 TRANSMISSION
73
D
AILY
Base - May 2004
Heat the internal rings (1 - 3) of the tapered roller bearings to
a temperature of approx. 80
°C and, with a suitable punch (1),
mount them on the transmission shaft (2).
51974
51976
51975
51977
51978
51973
Figure 87
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Mount the 3rd gear (1).
With a hydraulic press, mount the 5th gear (1) pre-heated to
approx. 170
°C.
Check the end float of the 3rd gear (2). It should be
0.15
÷ 0.40 mm.
With a hydraulic press, mount the 6th gear (1) pre-heated to
approx. 170
°C.
Mount the retaining ring (1) whose thickness produces null
end float in its seat.
Tighten the main shaft (1) and position the roller bearing (2)
on it.
Mounting the main shaft
Mount the synchronizer rings on their respective gears
according to the marks made during disassembly or
when checking in the case of replacement.
1
1
1
1
1
NOTE
74
6 S 300 TRANSMISSION
D
AILY
Base - May 2004
51980
51981
51982
51983
51984
Figure 93
Figure 94
Figure 95
Figure 96
Figure 97
Mount the 2nd gear (4) and position the ring (3), middle ring
(2) and synchronizer ring (1) on it, taking care that the tongues
(
→) of the middle ring (2) enter the slots (→) in the gear (4).
Heat the hub (2) to a temperature of 80
° ÷ 110°C and mount
it on the main shaft (1), taking care that the projections (3) of
the synchronizer ring and the tongues (
→) of the ring (3,
Figure 93) are positioned correctly in the seats in the hub (2).
Check the end float of the gear (4). It should be
0.25
÷ 0.5 mm.
Mount the sliding sleeve (2) on the hub (1). Put the springs (5),
plugs (4) and balls (3) into the seats in the hub (1), settling
them under the sliding sleeve (2).
Position the synchronizer ring (3), middle ring (2) and ring (1)
on the hub (4), taking care that the tongues (
→) of the ring
(1) and the projections (
→) of the ring (3) enter the seats in
the hub (4).
Position the roller bearing (2). Mount the 1st gear (1) taking
care that the tongues (3) of the middle ring enter the slots in
the gear (1).
6 S 300 TRANSMISSION
75
D
AILY
Base - May 2004
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