Iveco Daily. Manual

Revi - February 2005

Raise the securing ring (

⇒) on the flange (1) nut (3).

Using tool 99370317 (2), block rotation of the coupling (1).

Remove the nut (3).

51824

51826

51825

61866

51828

Figure 30

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Take flange (1) out of bevel pinion (2).

Using a bronze punch, strike in the direction shown by the
arrow to eject the bevel pinion (1), with the rear bearing, the
fixed spacer and adjustment ring from the axle housing (2).

Remove the seal (1) and the internal ring (2) of the front
bearing.

Use a punch to remove the external rings (3 - 4) of the
tapered roller bearings from the axle housing (1) and take out
the adjustment shim (2).

With axle 99341003 (2), brackets 99341011 (1), press
99341015 (5) extract the internal ring (3) on the bevel pinion
(4).

74727

REAR AXLE 450210

AILY

Base - May 2004

Revi - February 2005

Check the planetary gears with their shoulder washers, the
pin and the crown wheels with their shoulder washers.

Replace all the sealing elements, the bevel pinion retaining
nut and the gear housing bearing adjustment ring nut with
new parts.

Carefully clean the single components of the differential
locking.
Lubricate the bearings and rotate the roller cage freely;
rotation must be even and without signs of stiffness. Check
the support surfaces of the ring bevel gear and the striking
surface of the half-casing so that the ring bevel gear fits
perfectly. Deformations of such parts, could determine
vibration of the ring bevel gear fastening screws, thus
compromising the perfect operation of the unit.

DIFFERENTIAL UNIT COMPONENTS

1. Nut - 2. Transmission coupling sleeve - 3. Seal ring - 4. Front bearing - 5. Pinion shim ring - 6. Fixed spacer - 7. Fixed ring -

8. Adjuster ring - 9. Rear bearing - 10. Bevel pinion - 11. Bevel ring - 12. Fixed ring - 13. Adjuster ring - 14. Bearing -

15. Gear casing - 16. Crown wheel thrust washer - 17*. Cross - 18. Crown wheel - 19. Gear casing - 20. Screw -

21. Fixed ring - 22. Adjuster ring - 23. Bearing - 24. Planetary gear thrust washer - 25. Planetary gear - 26*. Short pin -

27. Long pin.

* only for differential with four planetary gears.

61868

Figure 36

Check that the splined section for the flange-pinion
connection is not badly worn, if it is, replace the pinion.

Checking the parts comprising the differential

Assembly

If it is necessary to replace the ring bevel gear or
pinion, replace both parts since they are supplied
in pairs.

NOTE

Carefully clean all the threads in order to obtain
exact adjustments and accurate tightening torque.

The tapered roller bearings are supplied as spare
parts, lubricated with rustproof oil.

They must not be washed or heated for assembly.

The differential housing support bearings must
both be from the same supplier.

NOTE

REAR AXLE 450210

AILY

Revi - February 2005

Assemble the cover and make the marks made during
disassembly coincide. Assemble the ring bevel gear and fasten
this to the half-casing by means of the fixing screws.
By means of a dynamometric wrench (1) tighten the fixing
screws (2) to the required tightening torque.

Only for differential with four planetary gears: position the
other two planetary gears (1) complete with shoulder
washers and then insert the two short pins (2).
Rotate the planetary gears-crown wheel unit and check that
it is free without stiffness.
Assemble the other crown wheel complete with shoulder
washer.

Position the two planetary gears (1) complete with shoulder
washers, spider (2) only for differential with four planetary
gears and then insert the long pin (3).

Position the crown wheel (1), gear housing side, complete
with shoulder washer, into its own housing.

18226

20380

20379

18237

Figure 37

Figure 38

Figure 39

Figure 40

Assembly of gear housing

Only for axles with differential lock.
Using tool 99305121, heat thrust ring (1) to a temperature
of 120ºC

÷ 150ºC for 15’ and fit on the gear casing (2) from

the side with the differential lock.

18240

Figure 41

REAR AXLE 450210

AILY

Base - May 2004

Revi - February 2005

On a surface plate (2), zero a dial gauge (1) set on the
mounting 99395728 (3) and pre-load it slightly.

51837

18241

51838

51839

Figure 42

Figure 43

Figure 44

Figure 45

Figure 46

Using the punch 99374091 (3) and grip 99370006 (4), mount
the external ring (2) of the tapered roller bearing in the axle
housing (1).

Set adjusting ring (4), removed at disassembling, into rear
axle casing (5).
Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.

Fit tapered-roller bearing internal ring (2) onto false pinion
99370286 (1) with the washer supplied (3).

Position the dummy pinion 99370286 (1), assembled as
shown in Figure 45, on the external ring (2) of the tapered
roller bearing.
On the opposite side, fit the taper bearing internal ring (3)
on the dummy pinion (1) and the transmission shaft flange
(4) .

Screw on the nut (5) so that the dummy pinion turns freely
with no end float.

Assembling the bevel pinion assembly

New bearings are lubricated with rustproof oil and
must therefore not be washed or heated for
assembly.

NOTE

101977

REAR AXLE 450210

AILY

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Iveco Daily. Manual - part 236