Iveco Daily Euro 4. Manual

51974

90221

51975

90222

90223

51973

Figure 94

Figure 95

Figure 96

Figure 97

Figure 98

Figure 99

Mount the 3rd gear (1).

With a hydraulic press, mount the 6

gear (1) pre-heated to

approx. 170

°C.

Check the end float of the 3

gear (2). It should be 0.15

÷0.40

mm.

With a hydraulic press, mount the 5

gear (1) pre-heated to

approx. 170

°C.

Mount the retaining ring (1) whose thickness produces null
end float in its seat.

Heat the internal rings (1-3) of the tapered roller bearings to
a temperature of approx. 80

°C and, with a suitable punch (1),

mount them on the transmission shaft (2).

Tighten the main shaft (1) and position the roller bearing (2)
on it.

Mounting the main shaft

Mount the synchronizer rings on their respective gears
according to the marks made during disassembly or
when checking in the case of replacement.

NOTE

6 S 400 O.D. TRANSMISSION

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51980

51981

51983

51984

Figure 100

Figure 101

Figure 102

Figure 103

Figure 104

Mount the 2nd gear (4) and position the ring (3), middle ring
(2) and synchronizer ring (1) on it, taking care that the tongues
(

→) of the middle ring (2) enter the slots (→) in the gear (4).

Heat the hub (2) to a temperature of 80

° ÷ 110°C and mount

it on the main shaft (1), taking care that the projections (3) of
the synchronizer ring and the tongues (

→) of the ring (3,

Figure 100) are positioned correctly in the seats in the hub (2).

Check the end float of the gear (4). It should be
0.25

÷ 0.5 mm.

Fit sliding sleeve (2) onto hub (1). Fit dowels (4) with built-in
springs (5) and balls (3) into hub (1) housings.

Position the synchronizer ring (3), middle ring (2) and ring (1)
on the hub (4), taking care that the tongues (

→) of the ring

(1) and the projections (

→) of the ring (3) enter the seats in

the hub (4).

Position the roller bearing (2). Mount the 1st gear (1) taking
care that the tongues (3) of the middle ring enter the slots in
the gear (1).

108866

6 S 400 O.D. TRANSMISSION

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85961

51952

Figure 105

Heat the spacer ring (2) to a temperature of approx.

~80°

÷ 110°C and mount it on the main shaft (1). Check the end
float of the gear (4); this should be 0.15

÷0.3 mm.

Heat the bushing (3) to a temperature of approx. 80

° ÷ 110°C

and mount it on the main shaft (1).
Mount the roller bearing (5).

Turn the main shaft over and position the half roller bearings
(3) on it.
Mount the 6th gear (2) and position the synchronizer ring (1)
on it.

Fit reverse gear (1).
Fit sliding sleeve (2) on reverse gear hub (1).
Insert the springs (5), the pads (3) and the balls (4) in the hub
seats (1) and arrange them with respect to the sliding sleeve
(2).

85950

85951

Figure 106

Figure 107

Fit the synchroniser ring (2).
Heat the gear ring (3) to 110

° ÷ 150° and fit on primary shaft

(1).
Check reverse gear play (4) which must be 0.15

÷ 0.4 mm.

Heat the hub (2) to a temperature of approx.

~ 80° ÷ 110°C

and mount it on the main shaft (1) taking care that the projec-
tions (3) of the synchronizer ring are positioned in the seats
in the hub (2).

Mount the retaining ring (4) whose thickness produces null
end float in its seat.

51990

51991

Figure 108

Figure 109

Mount the sliding sleeve (2).

Put the springs (3), plugs (5) and balls (4) into the seats in the
hub (1) and position them under the sliding sleeve (2).

Figure 110

6 S 400 O.D. TRANSMISSION

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During assembly, the gaskets, retaining rings, O-rings,
spring pins, safety plates and springs must always be
replaced with new parts.
The nuts and screws must be tightened to the re-
quired torque unless specified otherwise, with the
thread dry and degreased.

85952

Figure 111

Heat the bearing (2) to 80

÷110°C and fit on primary shaft (1).

Fit the circlip (4) and synchroniser ring (3).

Mounting the transmission

Adjusting the transmission shaft bearing end
float

The transmission shaft bearing end float is only ad-
justed if the bearings, transmission shaft gears, trans-
mission shaft, transmission or rear cover have been
replaced or if too much clearance has been found.

1. Rod with reverse gear engagement fork - 2. Main rod -

3. Rod with 1

-2

gear engagement fork. - 4. Fork control

rod (5).- 5. 3

-4

gear engagement fork - 6. Fork control

rod (7) - 7. 5

-6

gear engagement fork

Rods - forks - selector - driver

90224

Figure 112

Disassembly - assembly

Spring pegs must be positioned with the cutting edge
placed level.

NOTE

51993

Figure 113

Determine the thickness S of the ring (1) for adjusting the
transmission shaft bearing end float, proceeding as follows:

- position the thinner adjustment ring (1) 1.65 mm thick in

the seat in the transmission (3);

- heat the seat of the bearing (2) to approx. 60

°C. Mount

the external ring of the bearing (2) with the punch
99374091 and grip 99370007, see Figure 115;

- mount the transmission shaft complete with the internal

rings of the tapered roller bearings;

- mount the external ring of the rear bearing in the rear

cover in a similar manner to the front one (see
Figure 115);

- mount the rear cover on the transmission;

- screw on the 8 fixing screws so that between one screw

and another there is a hole for a free screw and tighten
them to the required torque;

- turn the transmission shaft to settle the bearings;

Check the state of the plugs (2) of the 3

-4

-5

th-

gear en-

gagement fork and replace them if they are worn.
To replace the forks of the selector and driver from their re-
spective control rods it is sufficient to remove the retaining
spring pins with a suitable punch.
For assembly, carry out these steps in reverse order, replacing
the spring pins.

6 S 400 O.D. TRANSMISSION

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Content .. 105 106 107 108 ..

Iveco Daily Euro 4. Manual - part 107