Iveco Daily. Manual - part 213

90218

Figure 70

Figure 71

TRANSMISSION SHAFT ASSEMBLY DRAWING

1. Transmission shaft assembly - 2. Tapered roller bearing - 3. Transmission shaft with reverse gear toothing (A), 1st gear (B),

2nd gear (C) - 4. Tapered bearing - 5. 4th gear - 6. Synchronizer ring - 7. Sliding sleeve - 8. Ball - 9. Spring - 10. Plug -

11. Hub - 12. Retaining ring - 13. Half roller bearings - 14. 3rd gear - 15. 6th gear - 16. 5th gear.

51962

51424

Figure 72

Using a hydraulic press, remove the 4th gear (3), the
synchronizer ring (2) and the synchronizer assembly (1).

Remove the half roller bearings (4).

Remove the sleeve (2) for engaging the 3rd-4th gear from the
hub (1) and, taking care over the plugs (3) coming out with
their relative balls (4) and springs (5), recover them.

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Figure 73

PRIMARY SHAFT AND INPUT SHAFT ASSEMBLY

1. Input shaft with 5

speed gear. - 2. Retaining ring - 3. Roller bearing - 4. Single cone synchronizer ring - 5. Sliding sleeve -

6. Plug - 7. Ball - 8. Spring - 9. Hub - 10. 6th gear - 11. Main shaft with 3rd gear toothing (A), 4th gear toothing (B) -

12. Roller bearing - 13. 2nd gear - 14. Dual cone synchronizer - internal ring C, middle ring D, synchronizer ring E -

15. Bushing - 16. 1st gear - 17. Spacer ring - 18.

•

Reverse gear - 19.

•

Synchroniser ring - 20.

•

Gear.

90219

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85977

1ST-2ND GEAR DUAL CONE SYNCHRONIZER ASSEMBLY

85978

Figure 74

Figure 75

3RD - 4TH - 5TH - 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY

SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR

86130

Figure 76

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After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.

The transmission and relative covers must show no sign of
cracking.
The mating surfaces of the covers and transmission must not
be damaged or deformed. Remove any remains of sealant
from them.

The seats of the bearings, reverse gear shaft and gear control
rods must be neither damaged nor too worn.

Hubs - sliding sleeves - forks

The grooves on the hubs and relative sliding sleeves must not
be damaged. The sliding sleeve must run freely on the hub.
The plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves
must not be damaged. The forks must be sound with an end
float, in the radial groove of the sleeve, no greater than 1 mm.

Bearings

The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced.

Shafts - gears

The seats on the shafts, for bearings, must be neither damaged
nor worn. The toothing of the gears must be neither damaged
nor worn.

Synchronizing devices

Check the wear on the synchronizer rings, proceeding as
follows:

- See that the friction surface is not undulated.

52510

52511

Figure 77

Figure 78

BK-type single cone synchronizers for 3rd/4th/5th/6th
gears

Arrange the synchroniser ring (1) on the respective gear or
reverse taper ring (2).

With a feeler gauge, check the distance S on two diametrically
opposite points.

If the measured value S is less than 0.8 mm, replace the
synchronizer ring.

Turn the synchronizer ring (1) so as to ensure correct coupling
on the cog-wheel.

Position the internal ring (3), middle ring (2) and the
synchronizer ring (1) on the tapered cog-wheel (4) of the gear.

Turn the synchronizer ring (1) so as to ensure correct coupling
between the parts.

Applying a uniform force of 50 N on the synchronizer ring (1),
measure the distance S on two diametrically opposite points
with a feeler gauge.

If the average measured value S is less than 1.5 mm, replace
all the rings.

D-type dual cone synchronizers for 1st/2nd gears

Transmission

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CHECKS

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