Iveco EuroCargo (12 to 26 t). Manual — part 102
Remove nuts fixing mounting (1) to differential carrier and
take it out together with input shaft, oil pump, gear and inter-
axle differential.
Remove shims (2).
Separate the differential housing as described in the relative
chapter.
36346
36347
77230
36350
77231
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Turn the axle housing by 90
°. Insert support (1) with drive out-
put shaft (2) in the axle housing and tighten screw to the speci-
fied torque.
Stop flange (1) rotation by means of retainer 99370317 (4).
With wrench 99355131 (2) and torque adaptor (3) tighten
output shaft flange (1) retaining nut to the specified torque.
Once assembly operations are completed, pour the specified
quantity of TUTELA W140/M-DA oil into the axle housing.
Then check efficiency of differential lock connection sending
unit.
Position the transfer box differential gear housing (1) on the ro-
tary stand 99322205 (2) together with the mount 99322225 (3).
Unscrew the screws (4) and remove the guard.
Using tool 99360311 unscrew the oil filter (5).
Stop flange (1) rotation with tool 99370317 (2). Undo flange
retaining nut using wrench 99355088 (3) and torque adaptor
(4).
526060
REPAIRING INTER-AXLE UNIT
Dismantling inter-axle unit
77229
Figure 35
Detach the transfer box differential gear housing as described
under the relevant heading.
Remove cylinder (1) complete with inter-axle differential lock
piston (2) and withdraw yoke (4) drive pin (3).
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36353
36352
36354
84395
36356
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Remove the spring (1) and strip yoke (2), sleeve (3) and rear
planetary gear (4).
Use a punch to expel cup (1) of rear planetary gear bearing
(4, Figure 36).
Use extractor 99348001 (1) and reaction block (2) to dis-
mantle cone (3) of rear planetary gear (4) roller bearing.
Tighten drive input shaft in a vice.
Remove snap ring (1) and take out differential gear assembly
(2), gear (3) and thrust ring (4).
Remove nut (1) and separate flange (2) from drive input shaft
(3) by means of a suitable extractor.
84396
If the planet gear unit needs disassembling, make a mark (1),
by means of a punch, on both half cases, in order to ensure
correct match when re-assembling.
Unscrew screws (2), then separate the two half cases. Take
off the spider unit, remove the four gears and pinion and the
four spider thrust washers.
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36357
36358
36430
36359
36360
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Use a press to extract the drive input shaft (1) from bearing
cage (2) and oil pump (3).
Remove screws (1), separate oil pump (2) from bearing cage
(3) and take out bearing (4).
Remove spring (2), oil pressure relief valve (1) and cup (3) of
bearing (4, Figure 43) from bearing cage (4).
Checking inter-axle unit components
Tighten the drive input shaft (1) in a vice and install the oil pump
(3).
Heat the bearing (2) to 100
°C for 15 minutes and fit it on using
a drift.
Using drift 99374093 (2) partially press fit cup (3) of bearing
(2, Figure 43) in bearing cage (4). Complete installation man-
ually using handle 99370007 (1).
Accurately clean each single component and check for wear in
view of their possible re-use.
!
Make sure all screw, stud and ring nut threads are
cleaned accurately so that clearance and torque spec-
ifications are not effected.
Always renew sealing rings, retaining rings and washers.
Fitting inter-axle unit
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Smear the thrust ring (4) with grease and arrange it under gear
(3);
- secure the gear on the drive input shaft (6),
- then differential gear assembly (2) and fasten by means of
snap ring (1).
Turn the input shaft (6) upside down and spline flange (5) onto
it.
Fit washer (7) and screw in retaining nut (8) without fully
tightening it.
36361
84398
36363
36364
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Mount seal ring (3) with tool 99374162 on support (4).
Install bearing cage (4) on oil pump (5) so that exhaust (
→)
matches the valve seat (2).
Insert spring (1) in the seat for oil pressure relief valve and fit
the plug.
Use a feeler gauge to check distance X between sealing ring (3)
and mounting (4) at four equi-distant points. Distance X should
be between 0.38
÷ 0.76 mm.
Use drift 99374093 (2) and handle 99370007 (1) to fit bearing
(2, Figure 51) cup (3) in the rear-axle differential carrier.
Heat bearing (2) to 100
°C for 15 minutes and fit on rear side
gear shaft (1).
X
3
Mount the planet gear unit (if previously disassembled) by fol-
lowing the procedure below. Apply the specific lubricant used
for the rear axle housing on all the other parts of the planet gear
unit.
Mount the gears and pinion and the thrust washer on the spi-
der.
Place the pinion unit and spider in one of half cases (1). Mount
the remaining half case onto the half case with the spider unit.
Make sure that the marks (2) available on each half case are
aligned to one another.
Screw four of the cap screws (3) after applying LOCTITE.
Screw the remaining cap screws (3) after applying LOCTITE
on the thread, then tighten them to a torque of 60
÷ 75 Nm.
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