Iveco EuroCargo (12 to 26 t). Manual — part 73
Figure 19
Figure 20
Figure 21
Figure 22
35451
35452
Figure 23
Figure 24
Remove gearbox (4) using puller 99341004 (1), brackets
99341017 (2) and reaction block 99341058 (3).
Tighten nut (1) on main shaft (2), lift the main shaft by approx.
10
÷ 20 mm and withdraw the transmission shaft (3) moving
it sideways.
35453
Lift and remove the main shaft (1) with gear control assembly
(2).
35454
Remove synchronising rings (1) and remove the input shaft (2)
using a plastic hammer.
35455
Remove transmission shaft bearing outer ring (1) using a
punch.
35456
Remove oil pipe (1), bearing outer ring (2) and ball bearing (3)
from the gearbox case.
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GEARBOX CASE
Gearbox case and related covers must not show cracks.
Contact surfaces between covers and gearbox case must not
be damaged or distorted.
Bearing seats must not be damaged or excessively worn.
SHAFTS - GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
HUBS — SLIDING SLEEVES — FORKS
Grooves on hubs and sliding sleeves must not be damaged.
The sliding sleeve must slide freely on the hub. Sliding sleeve
positioning rollers must not be damaged or worn. Sliding
sleeves engagement teeth must not be damaged.
Forks must be intact and not show any sign of wear.
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheating.
When keeping the bearings pressed by hand and making them
rotate simultaneously along both directions, no roughness or
noise must be detected.
Check wear of synchronising rings and coupling bodies: they
must not show signs of wear.
BEARINGS
!
At refitting always replace: rings, sealing gaskets and
springs for sliding sleeves positioning rollers.
SYNCHRONISERS — COUPLING BODIES
!
At assembling stage, do not mistake the components
with each other.
In order to guarantee oil seal at refitting, make sure
that sealing gaskets are already lubricated, or:
smear with oil or grease the sealing lip of input and
main shafts.
GEARBOX ASSEMBLING
!
Smear with sealing compound type “B” the threaded
part of all screws that have to be screwed into the
through-holes.
Clean joining surface of boxes and covers and apply
“LOCTITE 510” adhesive on one of the two
components before refitting.
Do not fill with oil before 20 min. and do not operate
the gearbox before 1h and 30 min.
Fit bearing cages into their seats and oil with TUTELA
ZC 90.
Figure 25
Figure 26
35457
Fit gauge (1) on base 99370466 (2).
Pre-load it at 5 mm and set it to zero on a surface plate.
Adjusting transmission shaft bearing pre - load
Transmission shaft bearing pre-load can be adjusted with
two procedures.
35458
Use a micrometer (2) to check gauged ring thickness (1).
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35459
35461
35460
35462
35463
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Fit temporarily cover (2) on front cover (1).
Place gauged ring 99396032 (2) in the tapered roller bearing
seat, without adjustment ring on front cover; place base
99370466 with gauge (1) previously set to zero as shown in
Figure 25.
First method —
Take note of the value read on the gauge
(Example: 2.43 mm).
Second method — Take note of the value read on the gauge
and add it to the gauged ring thickness
[Example: 2.43 + 50.5 = 52.93 mm
(Dimension B)].
Fit transmission shaft bearing outer ring (2) and main shaft ball
bearing (3) on the intermediate box (1).
Fit the oil pump (1) and tighten the screws to the specified
torque, rotate the intermediate box.
THICKNESS (S)
FRONT COVER
35464
Figure 32
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GEARBOX 2895.9
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35466
35467
Figure 33
Figure 34
Figure 35
Assemble and simultaneously rotate transmission shaft (3,
Figure 32) with bearings into rear case, so that it settles. Place
gauged rings 99396032 (2, Figure 32) on case (4, Figure 32).
Arrange as shown in figure, base 99370466 with gauge (1,
Figure 32) previously set to zero: gauge rod must rest on
bearing outer ring. Carry out the measurement on two
diametrically opposed points and obtain the arithmetic mean.
First method —
Take note of the value read on the gauge
(Example: 1.84 mm).
The adjustment ring value is obtained by
adding
the
two
measured
values
(Example: 2.43 + 1.84 = 4.27 mm)
Second method — Take note of the value read on the gauge
and subtract it from gauged ring thickness
[Example: 50.5 — 1.84 = 48.66 mm
(Dimension A)].
The adjustment ring value is obtained through formula
S = B — A
Example: 52.93 — 48.66 = 4.27 mm.
Fit input shaft (2) and transmission shaft outer ring (1) on front
cover.
Fit roller bearing into input shaft then fit the main shaft (1)
including gear engagement control.
INTERMEDIATE BOX
!
The adjustment ring rounding is carried out always by
excess. Example: thickness S = 4.27: thickness S = 4.3
is taken.
!
The measure for dimension “A” is carried out with
transmission shaft in vertical position that, in addition
to making the measure easier, enables to have axial
load on rear bearing.
After calculating the adjustment ring thickness value,
disassemble again transmission shaft (3, Figure 32) and cover
(2, Figure 27).
Figure 36
35468
Fit the transmission shaft (1), smear LOCTITE 510 adhesive
(arrow).
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Base - February 2003
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