Iveco Daily Euro 4. Manual

52512

Figure 114

Figure 115

- using a comparator (2) zeroed on the 5th gear toothing

of the transmission shaft (1) measure its end float A
through the opening for the power take-off connection
and note it down.

The thickness S is given by:
S

= A + B + C

Where:

A = measured end float, e.g. 0.18 mm;

B = average bearing pre-load, e.g. 0.02 mm;

C = adjustment value used for the measurement 1.65 mm;

Position the adjustment ring (1, Figure 119) of the thickness
determined with the above measurement. Heat the bearing
seats of the box to a temperature of approx. 80

°C and

mount:
- the external ring (3) of the front tapered roller bearing

with punch 99374091 (2) and grip 99370007 (1);

- the ball bearing (6) with a general punch;
- the bushing with ball bearing (9) and the roller bearings

(4-5) with a general punch.

Position the retaining plates (7) and secure them to the box,
tightening the screws (8) to the required torque.

51996

= 0, 18 + 0, 02 + 1, 65 = 1, 85

Then mount the rear cover, transmission shaft and external
ring of the front bearing.

Heat the bearing seats of the rear cover (1) to a temperature
of approx.

~ 80°C and mount:

- the external ring (3) of the tapered roller bearing with

punch 99374091 (2) and grip 99370007 (1);

- the ball bearing (4) and the bushing with ball bearings (7)

with a general punch.

Position the retaining plates (6). Secure these to the rear
cover, tightening the screws (5) to the required torque.

51997

Figure 116

Clamp the primary shaft (13) in a vice, fit on it the synchronis-
ing ring and the input shaft (8).
Fit tool 99360522 (10) on the input transmission shaft (8) and
fasten with the circlip (9).
Couple the secondary shaft (2) to the primary shaft (13) and
fasten by tightening the screw (1) on the tool (10).
Fit the clutch forks: 3

— 4

speed (4) and 5

— 6

speed (3)

on the relevant sliding sleeves.
Couple the rods (11 and 13), fit the relevant forks on the slid-
ing sleeves and clamp the rods with the sleeves of tool
99360522 (10).
Couple the reverse gear (7) with the shafts (2 and 13) and
fasten it to them with the part of the bracket (5) tighten the
screw (6).

90225

Figure 117

6 S 400 O.D. TRANSMISSION

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90226

Figure 118

Figure 119

Place the roller bearings (2) in the reverse gear (1).

Fit the stem (2) and the support (3) so that the respective
holes for the fastening screw are aligned with the relevant hole
on the rear cover (5).
Drive in the fastening screw (6) of the stem (3) and the
support (4) on the rear cover (5) and tighten it to the
prescribed torque.

Fit the rod (3) in the rear cover (4).

Hook hoist to tool 99360522 (1), lift the unit (2) as previously
mounted, and partially insert it into the rear cover (4).

During this operation, check that the output shaft goes into the
supporting ball bearing and the control rods (5 -6) go into their
respective seats.

Screw tool 99370234 pin (7) into output shaft hole (2) and
fit bushing (4) and spacer (5) on tool.

Screw on the nut (6) and at the same time lower the hoist so
the output shaft (2) is positioned on the rear ball bearing (3).

Remove tools 99360522 (1) and 99370234 (4-5-6-7).

52000

Figure 120

Figure 121

90210

Fit the control rod (1) of the 3

— 4

speed and the main rod

(2) in the rear cover (3).

90227

eft

6 S 400 O.D. TRANSMISSION

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Screw on the screws (2) securing the rear cover (3) to the
transmission (1) without fully tightening them.

Mount the centring pins (4) in the rear cover (3) and in the
transmission (1).

Tighten the screws (2) to the required torque.

90229

90230

51936

90231

Figure 122

Figure 123

Figure 124

Figure 125

Apply some grease on the pin of the dragging device (2) and
fit the clutch fork (1) for the 3

— 4

speed on this device.

Put the pawls (4) and springs (3) in the rear cover (1) and drive
in the retaining cups (2) with a suitable punch.
Apply LOCTITE 5206 on gearbox attachment.

Warm up the front bearing inner ring (2) at 90

÷110°C and fit

the gearbox (1) on the rear cover.

When fitting the gearbox, check that the shafts and
the control rods fit correctly in the respective seat and
that the fork (1, Figure 117) does not disconnect from
the clutch rod (2, Figure 122) for the 3

— 4

speed.

NOTE

51931

Figure 126

Fit a new retaining ring (2) securing the front bearing (3) onto
the input shaft (1).

6 S 400 O.D. TRANSMISSION

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Mount the cover (1) protecting the input shaft and tighten the
screws (2) to the required torque.

51932

52006

52007

Figure 127

Figure 128

Figure 129

Mount the push rod (1) and the spring (2). Screw on the plug
(4) with a new washer (3), tightening it to the required torque.

Mount the O-ring (2) in the rear cover (1) with the key
99374454 (4) and the grip 9937006 (3).

52005

Figure 130

Using the key 9937455 (3), mount the O-ring (2) in the trans-
mission (1).

Apply LOCTITE 242 to the thread of the pins (1).

Screw the pins (1) into the box, checking that their ends go
into the hole of the 3rd/4th gear engagement fork link (1,
Figure 122) and then tighten them to the required torque.

Drive in the pins (2) and check that their ends fit in the knuckle
hole of the clutch fork for the 5

— 6

speed and tighten it to

the prescribed torque.

90209

Figure 131

If during these assembly operations the fork (1,
Figure 122.) comes free of the control rod, it will not
be possible to mount the pins (1) until they have been
reconnected.

NOTE

Make sure that the clutch control rods are all in
neutral position.

NOTE

6 S 400 O.D. TRANSMISSION

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Content .. 106 107 108 109 ..

Iveco Daily Euro 4. Manual - part 108