Iveco Daily. Manual

Revi - February 2005

1. Sliding wedge - 2. Wedge (1) actuating spring - 3. Wear recovery ring (6 & 7) actuating spring - 4. Wear indicator - 5.

Retainer - 6. Wear recovery upper sliding ring - 7. Wear recovery lower ring - 8. Diaphragm spring

102089

Figure 19

Description

The automatic wear recovery device is placed between the diaphragm spring and the thrust plate of the pressure plate assembly.
It is essentially made up of wedge-shaped rings which recover, under sliding conditions, the clutch disc wear real-time, while keeping
both the diaphragm spring characteristics and the force required to actuate the spring unchanged.

CLUTCH WITH AUTOMATIC WEAR RECOVERY - COMBINED WITH 6 AS’300 VD GEARBOX

Operation

Automatic wear recovery takes place in two separate phases:

- Phase 1: every time the clutch is closed (engaged) and the clutch disc wear — as detected by retainer (3) — is such that the

pressure plate is made to travel an extra stroke, spring (4) will disengage wedge (1), which will be pulled by spring (2) and will
stop again against spring (4) and retainer (5) after travelling a stroke equal to the disc wear.

- Phase 2: when the clutch is opened (disengaged), diaphragm spring (8) will release wear recovery rings (6 & 7); as a result, spring

(3) will, by causing lower ring (6) to slide over upper ring (7) due to the inclined planes of the same, lift the latter by an amount
equal to the clutch disc wear.

CLUTCH

AILY

Base - May 2004

CLUTCH DISC AUTOMATIC WEAR RECOVERY DIAGRAM

A. Position of the diaphragm spring with a new clutch disc - B. Position of the diaphragm spring with a worn clutch disc prior

to operation of the automatic wear recovery device - C. Position of the diaphragm spring with a worn clutch disc after

operation of the automatic wear recovery device

1. Retainer - 2. Lower ring - 3. Upper ring - 4. Clutch disc - 5. Retainer (1) spring -

6. Diaphragm spring - 7. Wear recovery ring actuating spring

102090

Figure 20

ring (2) sliding

ring (3) lifting

CLUTCH

AILY

102092

Figure 21

Figure 22

Figure 23

Loosen screws (4) that secure pressure plate (1) to the
flywheel in 5 steps in crossed sequence until a distance of 2
mm is obtained between retainer (2) and the clutch. Also
make sure that retainer (2) is released from pressure plate
(1); otherwise, use a suitable beater (3) to hit the top of
retainer (2).
Then remove screws (4) and take the pressure plate off the
engine flywheel.

102091

44571

505210

REMOVAL AND REFITTING OF
CLUTCH

WITH

DEVICE

RECOVERY COMBINED

Removal

The operation consists of:
- removal-refitting of transmission shafts (see section

505620)

- removal-refitting of gear box (see section 530210).

Insert clutch centring pin 99370205 (1) in the shaft support
bearing.

Locate the position of retainer (2): it is positioned between
the engine flywheel plug for clutch assembly centering and a
hole for the screw used to fasten the same. It sticks out the
clutch assembly by approximately 3 mm.

Remove the clutch disk (3) by extracting the centring pin
99370205 (2).
Disk plate centering pin (1) located on the engine flywheel.

CHECKS

The checks to be made are as follows:

- the faying surface, on the engine flywheel, of the driven

disk must not be excessively worn or scored.

- the teeth of the toothed crown must not be worn or

broken.

If this is not the case, disassemble the engine flywheel
(operation 540850) as described in the relevant paragraph at
section 2.

Proceed on the engine flywheel as described in relevant
paragraph (operation 540853) at section 2.

Check that there are no oil leaks, even of a slight entity, from
the seal of the rear drive shaft; otherwise remove the
flywheel as described in the relevant paragraph.

Replace the seal ring as described in section 2.

Check that the support bearing or bushing of the take up
shaft on the gears fitted to the drive shaft are not worn or
broken and, if necessary, replace them as described in the
relevant paragraph (540852).

Check the condition of the thrust pad; the driven disk support
surface must not be scored or excessively worn or should
there be signs of overheating; the diaphragm spring must be
in perfect condition.

Check the condition of the driven disk:

- the friction seals must not be excessively worn or

present signs of overheating, or traces of oil or grease;

- there should be very little backlash between the hub and

gear take up shaft;

- the hub rings must not be loose or broken.

Should any anomaly be found, the full clutch shall be replaced.
Inspect the conditions of the clutch-release bearing and the
release lever, should any anomaly be found, the concerned
part shall be replaced.

In the event that the clutch release lever is replaced,
calibration shall be carried out after re-attaching
the gearbox, as described in the relevant charter of
the “Gearbox” section.

NOTE

CLUTCH

AILY

Revi - February 2005

Refitting

Follow the same procedures as for removal in reverse order
and:

- carefully clean the faying surface of the flywheel

disk using methylated spirits or petrol; if any
slight scratches are noted remove with an
abrasive cloth;

- position the driven disk (3, Figure 23), using the guide pin

to obtain perfect centring and to avoid straining the hub
when the gears are reconnected;

- position the thrust pad by aligning the holes with the

grub screws (1, Figure 23) on the engine flywheel;

- screw down the pressure plate fastening screws in four

subsequent steps and in crossed sequence, then tighten
them to the specified torque

CLUTCH

AILY

Content .. 183 184 185 186 ..

Iveco Daily. Manual - part 185