Iveco EuroCargo (12 to 26 t). Manual — part 91
84515
84517
84516
84518
84508
84519
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Figure 71
Mount synchronizing ring (1) so that the tangent stop
projections of the same are positioned in the wheel hub, then
mount matching body (2).
Lubricate roller cage (3) and insert it into the 4
th
speed gear
(2), then mount the same on output shaft (1).
Heat bushing (2) to a temperature of ~ 85
°C, then fit it onto
output shaft (1). Check axial play of 4
th
speed gear, which must
fall within the range of 0.35
÷ 0.48 mm.
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.
Lubricate roller cage (3), then fit it, together with 6
th
speed
gear (2), onto output shaft (1).
Mount matching body (2) and synchronizing ring (1).
GEARBOX EATON FSO 5206B
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Figure 72
Figure 73
Figure 74
Figure 75
Heat hub (2) to a temperature of ~ 85
°C, then fit it onto
output shaft (1) taking care that the tangent stop projections
(3) of the synchronizing ring are positioned in the openings of
the hub itself.
Check axial play of 6
th
speed gear (4), which must fall within
the range of 0.31
÷ 0.53 mm.
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.
Mount springs (5) and small pins (4) on hub (2).
Mount 3
rd
- 4
th
gear engagement sliding sleeve (1) on hub (2),
then place the former so that it is slightly lifted compared to
hub (2), then insert rollers (3) between small pins (4) and
sliding sleeve (2).
INTERNAL DRIVING SHAFT
Disassembling
Secure the internal driving shaft unit firmly in a vice.
!
Mark the assembly position of every single part of the
unit.
Take out gear engagement enable key (4) by turning
the forks in the proper direction.
Take forks (3 - 2 - 1) out of shaft (5).
GEARBOX EATON FSO 5206B
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84524
Figure 76
Figure 77
Remove screw (3), then take block (1), the selection key (5)
and selector (2) out of shaft (4).
PARTS MAKING UP THE INTERNAL DRIVING SHAFT UNIT
1. Selection key - 2. Shaft - 3. Gear engagement enable key - 4. Selector - 5. 5
th
- 6
th
speed control fork - 6. Pads - 7. Block - 8.
Screw - 9. Pin - 10. 3
rd
- 4
th
speed control fork - 11. 1
st
- 2
nd
speed control fork - 12. Reverse gear control fork.
The internal driving shaft unit is assembled by reversing the
order of disassembling operations.
!
Apply LOCTITE 270 on screw thread (3, Figure 76),
then tighten the screw to a torque of 35
÷ 39 Nm.
GEARBOX EATON FSO 5206B
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Figure 78
Figure 79
Figure 80
Figure 81
Figure 82
Prior to assembling the gearbox, verify that the half cases and
the covers are clean, and that all the gaskets and sealing
materials have been removed from the mating surfaces. When
fitting the fastening screws to the clearance holes, apply
LOCTITE 641 sealant to the threads.
Use a suitable beater (1) to replace, if necessary, internal
driving shaft bushings (2) and the caps below, the front half
case and rear half case.
Use beater 99374092 and handle 99370007 to mount the
tapered-roller bearing outer race (3) into rear half case (1), so
that it is slightly embedded compared to the case plane.
Mount spacer ring (2).
Apply LOCTITE 5900 on cover (2) mating surface, then
mount the cover on rear half case (1).
Tighten fastening screws (3) to the specified torque.
Mount output shaft roller bearing (4).
Temporarily mount output shaft rear cover (2) on rear case
(1), then tighten fastening screws (3) to the specified torque.
Place internal driving shaft (2) onto output shaft (1), then
secure it firmly by means of a suitable rope.
!
Apply LOCTITE 5900 on the outside of caps, then
mount the latter with their concave side facing the
inside of the half case.
GEARBOX EATON FSO 5206B
E
URO
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Base - February 2003
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