Iveco Daily. Manual

Check the assembly of the selection (6) and engagement (3)
levers. The selection (6) and engagement (3) levers must be
mounted on their respective shafts so that:

- between the c/c distance of the pin (5) of the selection

lever (6) and the outside of the bracket (1) there is a
distance X of 134 mm;

- between the c/c distance of the pin (2) of the engagement

lever (3) and the outside of the bracket (4) there is a
distance Y of 135 mm.

If a different value is measured, orientate the lever concerned
on the respective shaft appropriately.

Then tighten the nuts (7) for the screws (8) to the required
tightening torque.

Thoroughly clean the mating surfaces of the gear control box
(2) and apply LOCTITE 5206 sealant on them.

Fit the box (2) on the transmission, taking care that the levers
and shafts are positioned correctly in their respective seats.

Tighten the screws (1) to the required torque.

51388

51390

51391

51392

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Using a suitable punch, mount the O-rings (1) in the box (2),
positioning them at the height shown.

Pack the gap between the O-ring and roller bearing with grease.

Mount the selection and engagement levers (1) on their
respective shafts (2) and fasten them with the spring pins (3).

Lubricate the roller bearings (1, Figure 19) with TUTELA MR3
grease and mount the shafts (3 and 6) complete with the
internal levers (4 and 5) in the box (2). Mount the caps (8 and
9) and levers (1 and 10) on the shafts (3 and 6) in the position
marked during disassembly without tightening the nuts for the
fixing screw (7).

The spring pin (3) must be positioned with the cut
horizontal. Fit spring peg (4), with cutting edge
positioned at 180

° from spring peg (3) cutting edge,

in spring peg (3) engagement lever.

Check levers mounting

87896

NOTE

Revi - February 2005

5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS

AILY

Base - May 2004

51393

74956

51396

51397

51398

Figure 24

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

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).

74955

Revi - February 2005

5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS

AILY

Disassembling the transmission

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

51402

Figure 30

Figure 32

Figure 33

Figure 34

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).

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).

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).

74957

Figure 31

74965

74959

Revi - February 2005

5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS

AILY

Base - May 2004

51404

51406

51409

Figure 35

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

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).

74960

74961

74962

Revi - February 2005

5 S 200 - 5 S 270 - 5 S 300 - TRANSMISSIONS

AILY

Disassembling the rear cover bearings

Content .. 190 191 192 193 ..

Iveco Daily. Manual - part 192