Iveco Daily. Manual

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).

85961

51989

51988

85950

85951

51952

Figure 98

Figure 99

Figure 100

Figure 101

Figure 102

Figure 103

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).

Heat the ring with internal toothing (3) and the spacer ring (2)
to a temperature of 80

° ÷ 110°C and mount them on the

main shaft (1).

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.

Turn the main shaft over and position the half roller bearings
(3) on it.
Mount the 5th gear (2) and position the synchronizer ring (1)
on it.

For transmission without synchronised reverse, proceed as
follows

Mount the reverse gear (4), heat the hub (2) to a temperature
of 80

° ÷ 110°C and mount it on the main shaft (1). Check the

clearance of the gear (4); it should be 0.15

÷0.4 mm.

Mount the sliding sleeve (3).

For transmission with synchronised reverse, proceed as
follows

6 S 300 TRANSMISSION

AILY

Base - May 2004

1. Rod with 3rd/4th gear engagement fork - 2. Plugs - 3. Rod
with 5th/6th gear engagement fork - 4. Main rod - 5. Rod with
reverse gear engagement fork - 6. Rod with 1st/2nd gear en-
gagement fork.

Check the state of the plugs (2) of the 3rd/4th gear engage-
ment 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.

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.

Rods - forks - selector - driver

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

85952

51991

51992

Figure 104

Figure 105

Figure 106

Figure 107

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).

Heat the bearing (2) to 80

° ÷ 110°C and fit on primary shaft

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

Disassembly - assembly

Mounting the transmission

Adjusting the transmission shaft bearing end
float

NOTE

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.

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

NOTE

6 S 300 TRANSMISSION

AILY

Base - May 2004

Position the adjustment ring (1, Figure 108) 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.

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 110;

- 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 111);

- 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;

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;

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.

51993

52512

51996

51997

Figure 108

Figure 109

Figure 110

Figure 111

- 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:

= A + B + C

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

= 0.18 + 0.02 + 1.65 = 1.85 mm

6 S 300 TRANSMISSION

AILY

Base - May 2004

Clamp the main shaft in a vice (4).
Tighten the primary shaft (4) in a vice. Fit tool 99360522 (6) on
the input transmission shaft (1) and fasten with the circlip (7).
Couple the secondary shaft (9) to the primary shaft (4) and
fasten by tightening the screw (8) on the tool (6).
Fit the 3

gear engagement fork (14) onto the respective

sliding sleeve.
Position the forks with their rods (2 - 3 - 5) on the sliding sleeves
and secure them with the sleeves of tool 99360522 (6).
Couple the reverse gear (13) with the shafts (4 and 9) and
fasten it to them with the part (12) of the bracket (10) tighten
the screw (11).

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).

74989

74990

52000

52001

Figure 112

Figure 113

Figure 114

Figure 115

Place the roller bearings in the reverse gear.
Mount the spindle (2) and the mounting (1) so that the rel-
evant holes for the fixing screw are aligned with the relevant
hole of the rear cover (4).
Screw down the screw (3) fixing the spindle (2) and mounting
(1) to the rear cover (4) and tighten it to the prescribed
torque.

Hook hoist to tool 99360522 (1), lift the unit (2) as previously
mounted, and partially insert it into the rear cover (6).

During this operation, check that the output shaft goes into the
supporting ball bearing and the control rods (3 -4 - 5) go into
their respective seats.

6 S 300 TRANSMISSION

AILY

Base - May 2004

Content .. 203 204 205 206 ..

Iveco Daily. Manual - part 205