Iveco Daily. Manual

Revi - February 2005

Fit the mounting 99395728 (2) with the dial gauge (1) on the
dummy pinion 99370286 (3).

Orientate the, previously zeroed, dial gauge so as to position
the rod on the lowest portion of the seat of the bearing
supporting the gear housing and note the difference A1.

Repeat the same operation on the seat of the other bearing
and note the difference A2.

Thickness S to be added to adjusting ring thickness (4,
Figure 49) used for measuring, for pinion positioning is
obtained by the following formula:

51840

18246

51838

A1 indicates the value measured on the right-hand seat.
A2 indicates the value measured on the left-hand seat.
B indicates the value marked on the bevel pinion (see
Figure 48).
For example:

Unscrew the retaining nut, the transmission connection
flange and remove it and the bearing from the dummy pinion.

Remove the dummy pinion with the mounting 99395728,
dial gauge and rear bearing from the axle housing.

If required, replace adjusting ring (4) with a new one having
the calculated thickness, after removing bearing outer ring
(3) from rear axle casing (5) by beater.

Then fit the new adjusting ring (4) into rear axle casing (5).

Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.

= A1 + A2

− ( B)

= 1.05 + 1.10

− (− 0.05) = 2.15

2 +

0.05

Figure 47

Figure 48

Figure 49

If the value marked on the pinion is preceded by a
positive sign (+), it must be subtracted from the
value of the sum divided by two for both seats,
whereas it has to be added if it is preceded by a
negative sign (-).

NOTE

1,125

The result of the formula must be added algebraically to the
value of the adjusting ring used to make the measurements.
Example:
if the value of the adjusting ring used is 3.00 mm, replace with
one measuring 4.125 mm (3.00 + 1.125).

REAR AXLE 450210

AILY

Base - May 2004

Position the fixed spacer (3) and the adjustment ring (2), used
previously to obtain the required rolling torque, on the bevel
pinion (1).

18251

18252

62097

Figure 50

Figure 51

Figure 52

Using a suitable punch (1) and a hydraulic press, mount the
internal ring (2) of the tapered roller bearing on the bevel
pinion (3).

Position the axle casing as indicated in the figure.
Fit the taper bearing internal ring (1) and the transmission
shaft flange (2).
Position a suitable pipe (3) on the stand so that the flange (2)
and the taper bearing internal ring (1) are correctly
supported.

Use tool 99370317 (2) to prevent the flange (1) from
rotating.

Tighten the bevel pinion retainer nut to the required torque
with a torque wrench (3).

Mount the bevel pinion (1) in the axle housing so as to enter
the internal ring (2) of the tapered roller bearing.

Tap on the end of the pinion (1) so that the transmission shaft
flange retaining nut (3) can be fitted.

51845

51846

Figure 53

Figure 54

REAR AXLE 450210

AILY

Revi - February 2005

102972

74728

Figure 55

Using the torque wrench 99389819 (1), measure the rolling
torque of the bevel pinion.

If the reading differs from the prescribed value, disassemble
the pinion (1, Figure 53), replace the adjuster ring (2,
Figure 51) with a ring of the correct thickness.

Refit the pinion and repeat the rolling torque check.

Figure 56

Assembly of differential unit

Fit the differential (1) unit and support (4) bearings in the axle
casing.

Refit the spacers and adjuster rings in exactly the original
positions and in the following order: adjuster ring (2), spacer
(3 and 5) and adjuster ring (4).

Figure 57

51849

Screw on the screws (1) and tighten them to the required
torque with the dynamometric wrench (3).

74728

Figure 58

Check the total rolling torque with the torque wrench
99389819 (1).

If the value of the measurement is not as required, replace
the adjustment rings (2 and 4, Figure 56) with another one
of a suitable thickness.

The rolling torque must be measured at an ambient
temperature of 25

°C, making the pinion turn at a

speed of 50 rpm after it has made 10 turns.

NOTE

Position the caps (2) making the marks made
during disassembly coincide.

NOTE

The rolling torque must be measured at an ambient
temperature of 25

°C, making the pinion turn at a

speed of 50 rpm after it has made 10 turns.

NOTE

When fitting the differential unit, carefully comply
with the tightening torque values specified, and
make use of a torque wrench.

NOTE

REAR AXLE 450210

AILY

Base - May 2004

Position the dial gauge 99395684 (1) with a magnetic base
and measure the clearance between the pinion and crown
wheel on four opposite teeth of the crown wheel (2).

The average of the measurements must equal the required
value.

If a different clearance is found, remove the caps (3) again and
swap over the assembly position of the adjustment rings (1
and 3, Figure 56).

If this is not sufficient, replace the adjustment rings with ones
of a different thickness, but the total thickness must still be
the same as that of the adjustment rings removed.

This is so as not to change the total rolling torque.

Apply a thin layer of Prussian blue on ring gear teeth by brush.

Turn the pinion and measure the impression of the contact
of the pinion toothing on the crown wheel toothing.

Here we illustrate the possible contacts with the corrections
to obtain precise coupling of the crown wheel and pinion.

51850

44603

Figure 59

Figure 60

A = Coupling depth
B = Crest
C = Side
D = Play

E = Greater base
F = Heel
G = Top land
H = Contact surface
I = Lateral surface

Figure 61

Figure 62

44604

Correct contact

44605

Excessive contact on tooth
bottom or flank.
Move away pinion and put
ring gear to pinion to adjust
clearance.

Figure 63

Excessive contact on heel
of tooth.
Move the ring bevel gear
towards the pinion and
then move the pinion away
from the ring bevel gear to
adjust clearance.

44606

REAR AXLE 450210

AILY

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Iveco Daily. Manual - part 237