Iveco EuroCargo (12 to 26 t). Manual — part 103

Mount the spindle (1) governing the transfer box differential
locking, lubricate the new seal (2) and fit it on the piston (3)
and insert this into the cylinder (4). Apply sealant on the thread
of the cylinder (4). Screw this into the differential gear housing,
tightening it to the prescribed torque.

Figure 52

36367

Proceed as follows to adjust shaft bearing end play:
- fit the drive input shaft into the inter-axle differential

carrier;

- tighten screws (2) without washers;
- turn the input shaft in both directions to bed bearings; at

the same time, tighten screws (2) without locking them;

- use a feeler gauge (4) to measure, at four equally-spaced

points, the gap between bearing cage (3) and carrier rest
face;

- thickness S, corresponding to the shim pack necessary for

adjusting bearing end play is calculated as follows:
S = A + B

- where A is the mean value resulting from the four

measurements taken earlier;

- B = 0.013 is the mean value of bearing end play

(0.05

÷ 0.20 mm);

- remove screws (2) and raise the drive input shaft by

6

÷ 12 mm.

- fit the shim pack of the correct thickness.

!

The shim pack must consist of at least three shims,
with the thickest in the middle.
Shims are supplied as spares in the following range of
thickness: 0.076 - 0.127 - 0.254 mm.

Figure 53

Figure 54

Fit new oil filter (5), fit guard (4) and secure it to differential
carrier together with bearing cage (3) by screws (2).
Check input shaft bearing (1) end play using a dial gauge. End
play should be 0.05 to 0.20 mm.
In case of a different reading, replace the shim pack with
another one of the appropriate thickness.

36368

77232

Figure 55

36352

Place rear side gear (4) complete with sleeve (3) and fork (2)
on bearing cup (3, Figure 50). Then fit spring (1) on fork (2).

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Figure 56

Adjust shaft (2) end-stop as follows:

- loosen capscrew (1);

- let 6 bar compressed air into the cylinder (3);

- tighten capscrew (1) until in contact with shaft (2);

- furtherly tighten capscrew (1) by 1/4

÷ 1/2 turn and lock

jam nut (4);

- Use tool 99370317 to lock flange rotation (1, Figure 55)

and tighten the retaining nut to the specified torque.

77233

Figure 57

Figure 58

Adjusting differential lock and inter-axle
control pin end-stop

Figure 59

526210

REPAIRING MAIN DIFFERENTIAL-
DISMANTLING DIFFERENTIAL
CASING

77234

Take out the switch (1) signalling differential locking, unscrew
the screw (2) to cut in manual differential locking, the cylinder
(3) together with the ram (4) and the seal (5) and extract the
spindle (6).
Using a punch, eject the ram (4) from the cylinder (3).

77236

77235

Release the coupling (1) with a rubber skirt and remove it from
the fork (2).

Take out the spring (1) and the fork (2) from inside the differ-
ential gear housing.

Figure 60

36373

Remove split pin (3) and roll pin (1); dismantle caps (2) and
bearing adjusting nuts (4).

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36374

36349

Figure 61

Figure 62

Figure 63

Figure 64

Figure 65

Figure 66

Use a sling hook to extract the gear cage (1) complete with
crown wheel and bearings.

5

Stop rotation of flange (1) by means of retainer 99370317 (2);
with wrench 99355088 (3) and torque adaptor (4) loosen
flange (1) retaining nut.
Remove cover (5).

40678

Remove nuts retaining bearing cage (1) to differential carrier.
Pull out bearing cage complete with input shaft, oil pump, gear
and inter-axle differential.
Remove shims (2).

77231

36352

Remove the cylinder (1) together with the piston (2) of the
differential locking-transfer box and extract the pin (3) gov-
erning the fork (4).

Remove drive shaft (3, Figure 57).
Remove spring (1) and strip fork (2), sleeve (3) and rear plan-
etary gear (4).

Block rotation of the bevel pinion with the tool S.P. 2373 (1);
with wrench 99344069 (2) and the multiplier (3) remove the
nut fastening the bearings to the bevel pinion and the washer
beneath.

77237

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77238

36380

Figure 67

Figure 68

Figure 69

Apply on the housing a special extractor S.P. 2346, (5) and ex-
tract the pinion from the parts: spacer (1), gear (2), spacer (3)
and bearing (4).
Then remove the above-mentioned parts from the housing.

Dismantle carrier bearing cups (1, 2, 3) using a drift.

36381

Place tool 99348001 (2) under the taper roller bearing (1) and
pull it off the bevel pinion (3) using a press.

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