Iveco Daily Euro 4. Manual

Figure 25

Figure 26

Figure 27

Figure 28

Fit transfer case (1) into place, by tightening fastening screws
(2) to the prescribed torque.

Selection and adjustment tie-rod assembling

Verify that the tie-rod (4) length ”X”, as measured between
the jointed head centres is not greater than 342 mm.
Lubricate the jointed head inside with MOLIKOTE 33 LIGHT
or MOLIKOTE G 72 grease, then connect the jointed heads
to levers (1 and 5).
Measure the distance ”y” between transfer case (3) outer
surface and ball pin (6) centre: it shall be ”y” = 146 ± 1 mm.
Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
until the prescribed distance is obtained. Then tighten nuts (2)
to the prescribed torque, so that the vertical axes of the
jointed heads are aligned, with a maximum deviation of less
than 30˚ (lower).

Verify that spring (3) ends come into contact with selection
lever (4) or are at least 1 mm within the same. Otherwise,
loosen screw (1) so that spring (3) is correctly positioned, due
to plate (2) being released.

108858

108859

108860

108861

Verify that the tie-rod (4) length ”X”, as measured between
the jointed head centres is not greater than 342 mm.
Lubricate the jointed head inside with MOLIKOTE 33 LIGHT
or MOLIKOTE G 72 grease, then connect the jointed heads
to levers (1 and 5).
Measure the distance ”y” between transfer case (3) outer
surface and ball pin (6) centre: it shall be ”y” = 180 ± 1 mm.
Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
until the prescribed distance is obtained. Then tighten nuts (2)
to the prescribed torque, so that the vertical axes of the
jointed heads are aligned, with a maximum deviation of less
than 30˚ (lower).

5 S 300 TRANSMISSIONS

AILY

URO

Figure 29

Figure 30

Figure 31

Figure 32

Figure 33

Figure 34

51393

74956

74955

51396

51397

51398

Dismantle the gear control box as described under the
relevant heading.

Remove the reverse gear stop plate (2) and the spring (1).

Block rotation of the sleeve (1) by applying the lever
99370317 (3). With the bushing (2) remove the screw (5)
with the washer beneath (4).

Take out the lever 99370317 (3).

Apply the bridge 99341003 (1) and clamps 99341017 (2)
onto the sleeve (3).
Extract the sleeve (3) from the main shaft.

Remove the screws (1) and take off the cover (2) protecting
the input shaft (3).

Drill the O-ring (2).

Using a suitable hook and extractor (1), remove the O-ring (2)
from the transmission.

Remove the circlip (2) retaining the front bearing (3) from the
input shaft (1).

5 S 300 TRANSMISSIONS

AILY

URO

Figure 35

Figure 37

Figure 38

Mount the tool 99360521 (3) onto the rods (4, 5 and 6), on
the input shaft (1) and on the transmission shaft (10). Secure
the tool 99360521 (3) on the input shaft (1) with the retaining
ring (2) and with the screw (9) to the transmission shaft (10).
Hook the tool 99360521 (3) onto the lift. Apply the extractor
composed of the bridge 99341004 (13) and ties 99341012
(12) onto the rear cover (7). Use the screw of the bridge (13)
and work on the lift to extract the main shaft (11) from the
rear bearing. Set this assembly on the workbench. Remove the
tool 99360521 (3) and separate the transmission shaft (10),
input shaft with relative synchronizing ring and the rods (4, 5
and 6) from the main shaft.

Take out the plug with the washer (1), extract the springs (2
and 3) and the push rod (4). Remove the screw (6) securing
the reverse gear shaft to the transmission (5). Push the two
centring pins (7) downwards to free them from the
transmission (5). Remove the screws (8) securing the rear
cover (9) to the transmission (5).

51399

74957

51402

74959

Fit the drive input shaft (1) with tool 99345003 (2) and secure
this to the gearbox (4) with screws (3). Screw down the screw
(5) of the tool (2) to extract the gearbox from the bearing (6).

Insert an Allen wrench (2) into the engagement locking plate
(5). Turn the Allen wrench (2) to position the engagement
locking plate (5) outside the slots (

⇒) in the engagement rods

(1, 3 and 4).

74965

Take out the screw (3) and extract the shaft (1) from the rear
cover (4). Remove the reverse gear (2). Drill the cups (10)
screw a special screw into them; with the aid of the screw,
extract the cups (10) from the rear cover (4). Remove the
springs (9) and the pawls (8). Extract the rod (7) together with
the selector (5) and driver (6).

Figure 36

Figure 39

5 S 300 TRANSMISSIONS

AILY

URO

51404

51406

74960

74961

51409

Figure 40

Figure 41

Figure 42

Figure 44

Figure 45

Remove the screws (2) securing the plates (3).

Take out the plates (3) and the engagement locking plate (1).

Using universal extractor 99348004 (1), remove the outer
ring (2) of the transmission shaft bearing.

Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3).

Turn over the rear cover (3). Take out the O-ring (1) and the
”phonic wheel” (2). Using a suitable punch, remove the ball
bearing (4, Figure 36). Remove the tachograph sensor (5) and
the reversing light switch (4).

Disassembling the transmission bearings

Using universal extractor 99348004 (1), remove the outer
ring (2) of the transmission shaft bearing.

Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3).

74962

Figure 43

5 S 300 TRANSMISSIONS

AILY

URO

Content .. 92 93 94 95 ..

Iveco Daily Euro 4. Manual - part 94