Iveco EuroCargo (12 to 26 t). Manual — part 65

Figure 54

35478

Tighten primary shaft (1) in a vice.
Withdraw sliding sleeve (2) for 4

th

-5

th

gear recovering springs,

pins and rollers (3).

Figure 55

35479

Through rounded-tip pliers, remove elastic ring (1).

Figure 56

35480

Through extractor 99341003 (1) completed with brackets (2)
and clamp 99341015 (3), withdraw fixed 4

th

-5

th

gear hub (4).

Figure 57

Figure 58

35481

Remove synchronising ring and coupling body (1).
Withdraw 4

th

speed gear (2) together with roller bearing.

35482

Remove elastic ring (1).

Figure 59

35483

Through extractor 99341003 (1) completed with tie-rods (2),
grips (4) and clamp 99341015 (3) extract 3

rd

speed gear (5)

together with bush (6) and roller bearing.

E

URO

C

ARGO

T

ECTOR

12-26 t

GEARBOX 2870.9

105

Base - February 2003

Figure 60

35484

Remove synchronising ring and coupling body (1), withdraw
sliding sleeve (2) recovering springs, pins and rollers.

35485

Through extractor 99341003 (1) completed with tie-rods (2),
grips (4) and clamp (6), extract 2

nd

-3

rd

gear fixed hub (3)

together with synchronising ring, coupling body and 2

nd

speed

gear (5); recover the roller bearing.

Figure 61

Figure 62

35486

Turn primary shaft over, then through extractor 99341003 (1)
completed with tie-rods (2), grips (3) and clamp (7), withdraw
reverse gear (4) together with internal bearing (6) ring and
shoulder ring (5).

Figure 63

Figure 64

35487

Withdraw roller bearing (1), synchronising ring and coupling
body (2).

35488

Through suitable pliers, remove elastic ring (1).

Figure 65

35489

Through extractor 99341003 (1), reaction block (2), tie-rods
(3), clamp (4), grips (5), withdraw 1

st

speed gear (6)

completed with sliding sleeve, synchronising ring and roller
bearing.

E

URO

C

ARGO

T

ECTOR

12-26 t

106

GEARBOX 2870.9

Base - February 2003

After having checked and possibly replaced all worn or broken
components, in order to assemble the primary shaft, suitably
reverse the previously-performed operations paying attention
that:

PRIMARY SHAFT ASSEMBLY

Figure 66

35490

- Fixed hubs (1) for 1

st

and reverse, 2

nd

— 3

rd

— 4

th

— 5

th

speed gears must be heated at a temperature of 100

÷

130

°C and driven into the primary shaft, paying attention

that synchronising ring stops (2) are inserted into the
respective fixed hub seats.

Figure 67

35491

- Elastic shoulder rings (1) are of an adequate thickness so

that they do not show an axial clearance with fixed hubs
(max. allowed 0.03 mm).

Figure 68

Figure 69

MOTION INLET SHAFT DISASSEMBLY

71869

Remove elastic ring (2) and adjustment ring (1).

71870

Abut bearing (1) on a vice, as shown in the figure, and by
beating onto shaft (2), extract it from the bearing itself.

Figure 70

71871

PARTS COMPOSING THE MOTION INLET SHAFT

1. Motion inlet shaft — 2. Elastic ring — 3. Adjustment ring —

4. Ball bearing — 5. Cylindric roller bearing

E

URO

C

ARGO

T

ECTOR

12-26 t

GEARBOX 2870.9

107

Base - February 2003

Figure 71

MOTION INLET SHAFT ASSEMBLY

71872

Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.

62455

Figure 72

- Assemble bearing on motion inlet shaft.

- Measure dimension “A”.

- Measure seeger “B” thickness.

- Define thickness of spacer ring to be inserted, by defect:

C = A — B.

Motion inlet shaft bearing adjustment spacer ring
thicknesses: mm 2.40 - 2.45 - 2.50 - 2.55 - 2.60 - 2.65
- 2.70 - 2.75 - 2.80.

Motion inlet shaft bearing adjustment

Assemble adjustment ring (1, Figure 68) whose thickness is
equal to the previously-obtained one and assemble elastic ring
(2, Figure 68).

33651

Figure 73

Remove elastic ring (1) from secondary shaft (3) and extract
bevel roller bearings (2 and 4) with a suitable punch
(destructive operation).

SECONDARY SHAFT DISASSEMBLY

Slightly heat bevel roller bearings (2 and 4, Figure 73)
and assemble them on secondary shaft (3, Figure 73).
Assemble elastic ring (1, Figure 73).

SECONDARY SHAFT ASSEMBLY

35497

Figure 74

INTERNAL DRIVE SHAFT DISASSEMBLY

Mark fork (3) assembling position. Unscrew screw (1),
withdraw shaft (2) and decompose the assembly.

E

URO

C

ARGO

T

ECTOR

12-26 t

108

GEARBOX 2870.9

Base - February 2003