Iveco Daily. Manual

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

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 for the screws to the required tightening
torque.

Thoroughly clean the mating surfaces of the gear control box
(2) and apply LOCTITE 5706 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

52508

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

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.

Lubricate the roller bearings (1, Figure 25) 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).

85941

85943

87896

Check levers mounting

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.

NOTE

100

6 S 380 O.D. TRANSMISSION

AILY

Base - May 2004

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).

Extract the sleeve (3) from the main shaft.

51924

51926

51925

51928

51829

Figure 30

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Shift to neutral.
Dismantle the gear control box as described under the
relevant heading.
Remove the two side plugs (1 - 3). Remove the screw (2) and
take off the rod (5) dragging device (4).

Mark the assembly position of the rod (1) preventing
engagement of more than one gear at the same time and
remove it from the transmission.

Remove the screws (1) and take off the cover (2) protecting
the input shaft (3).

If difficult, remove the sleeve (3) with extractor made
up of link 99341003 (1) and grips 99341017 (2) and
block (4).

When putting away the sleeve (1) take care not to
damage the phonic wheel (

→) obtained by machining.

NOTE

The screw threading (2) is treated with LOCTITE
242.

NOTE

90250

6 S 380 O.D. TRANSMISSION

101

AILY

Base - May 2004

Fit the drive input shaft (1) with tool 99345003 (2) and
secure this onto the gearbox (4), with the screws (3); screw
down the screw (5) of tool (2) to extract the gearbox from
the bearing (6).

Perforate the o-ring (2) with a suitable hook and ram extractor
99340205 (1) and remove the o-ring from the transmission
box.

51930

51932

51931

51934

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

Remove the circlip (2) retaining the front bearing (3) from the
input shaft (1).

Take out the plug (4) with the washer (3), and extract the
spring (2) and the push rod (1).

Push the two locating pins (2) downwards until taking them
out of the rear cover (4).
Remove the screws (3) securing the rear cover (4) to the
transmission (1).

Remove the two fork knuckle pins (1) which control the 3

— 4

speed and the two fork knuckle pins (2) which control

the 5

— 6

speed.

Figure 41

74957

90209

102

6 S 380 O.D. TRANSMISSION

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Base - May 2004

In order not to damage the rear cover (7), place
special protections between it and the ties (15).

Mount the tool 99360522 (3) onto the rods (4, 5 and 6), on
the input shaft (1) and on the transmission shaft (9).
Secure the tool 99360522 (3) on the input shaft (1) with the
retaining ring (2) and with the screw (8) to the transmission
shaft (9).
Insert the part (13) of the bracket (11) into the reverse gear
(14) and tighten the screw (12).
Hook the tool 99360522 (3) onto the lift.
Apply the extractor composed of the bridge 99341004 (16)
and ties 99341012 (15) onto the rear cover (7).

51936

Figure 42

Figure 43

Figure 44

Figure 45

Figure 46

Drill the cups (2), screw a special screw into them.

Using the screw, extract the cups (2) from the rear cover (1).
Remove the springs (3) and pawls (4).

Remove the rod (1) controlling the 3

gear and the main

rod (2) from the rear cover (3).

Take out the screw (3) and remove the reverse gear shaft (1)
with the mounting (2) from the rear cover (4).

Using the extractor screw and the lift on the main shaft (10),
remove the main shaft (10) from the rear ball bearing and ex-
tract the shaft-rod assembly from the rear cover (7).

NOTE

90210

90211

90212

90213

Remove the rod (1) from the rear cover (2).

6 S 380 O.D. TRANSMISSION

103

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Base - May 2004

Content .. 209 210 211 212 ..

Iveco Daily. Manual - part 211