Iveco Daily. Manual

Properly secure the connector until the pull-back spring clicks
into position (see arrow).

Connect the reverse light (1) and revs number sensor (2)
connectors.

Connect the electrical connections of the power take-off, if
present, from the other side of gearbox.

Secure the wiring to the gearbox, as shown by the arrows in
the figure.

Secure drive shaft (1) to the gearbox by tightening fastening
screws (2) to torque.

102169

102172

102170

102171

102143

Figure 131/51

Figure 131/52

Figure 131/53

Figure 131/54

Figure 131/55

Connect connectors (1) to the control unit.

After re-attachment has been completed, perform
the specific calibration procedure by means of the
diagnosis instrument described on page 122/30.

NOTE

After the gearbox has been re-attached completely, check
for correct connection of electric cables.

122/22

6 AS 300 VD TRANSMISSION

AILY

Revi - February 2005

102162

Figure 131/56

Place the vehicle in a pit or on an auto lift.
Disconnect the battery cable in the engine compartment.

This charter describes the replacing operations for
the components available as spare parts only. No
overhauling work is permitted inside the gearbox.
In such case, the entire gearbox complete with
actuators, cable and control unit shall be forwarded
to the ZF service centre.

66136114

CONTROL UNIT

Removal

Remove connector (4) from control unit (1) by pulling the safety retainer downwards, as shown by the arrow.
Remove strap (6). Unscrew screws (2, 3).
Remove screw (5) while holding the control unit and taking care to recover spacer (7) placed behind screw (3). Take off control
unit (1).

6 AS 300 VD TRANSMISSION

122/23

AILY

REPAIR WORK

Refitting

Screw down screw (5), yet without tightening it to torque.

Fit spacer (7), between the control unit and the gearbox,
behind screw (3), then screw down the latter.

Screw down screws (2).

Screw down all screws (2, 3 & 5) to the specified torque.

Insert control unit connector (4) by securing it with the safety
hook, as shown by the arrow.

102164

Figure 131/57

Connect the battery cable.

After re-attachment has been completed, perform
the specific calibration procedure by means of the
diagnosis instrument described on page 122/30.

NOTE

122/24

6 AS 300 VD TRANSMISSION

AILY

Revi - February 2005

102166

Figure 131/58

Place the vehicle in a pit, or on an auto lift or special
supporting stands.

Disconnect the battery cable in the engine compartment.

Remove strap (1).

Take off connector (5) by pressing onto the fastening springs,
as shown by the arrows.

Removal

Remove the four fastening screws (3).

Take off clutch actuator (2).

505279104

CLUTCH ACTUATOR

Prior to removing the clutch actuator, make sure
that the clutch is closed.
Engaging lever (4) must be in the position shown
in box A (perpendicular to the gearbox axle).
If the lever is not found in that position, the clutch
will be open.
This condition can be inspected both visually and
by getting connected to the vehicle by means of
the diagnosis instrument and subsequently reading
the data memory. In the event that the clutch is

In the event that the actuator has been taken off
with the clutch open, release lever (4), previously
engaged, with the utmost care.
Avoid touching the lever straight with your hands,
owing to the lever being loaded.

open, it is required that the action of the lever is forced back,
since the lever is loaded by the clutch diaphragm spring.
Properly lock the motion of lever (4), and avoid, during the
subsequent actuator releasing phase, getting your hands
near the engaging tip area.

6 AS 300 VD TRANSMISSION

122/25

AILY

Content .. 220 221 222 223 ..

Iveco Daily. Manual - part 222