Iveco Daily. Manual - part 243

Mount a new O-ring on the differential locking attachment
plane.
Position the previously assembled support (3) so as to insert
the control lever in the spline on the sliding sleeve.
Insert the 4 screws (2) complete with washers and spring
washers and tighten the screws to the driving torque of 23
Nm (2.35 kgm).
Assemble the spring (1).
Adjust the differential locking device by following the
procedures below.

Remove gasket (4).
By means of a normal beater knock out the elastic pin (2),
remove the lever (1) complete with ring and washer.
Finally, remove the control lever (3) from the support (5).

Remove the spring (1).
Unscrew and remove the 4 screws (2) including washers and
then disconnect the differential locking device (3).
If required, remove the unit as described in the following
paragraphs.

61869

23227

61869

526210

DIFFERENTIAL REPAIR
OPERATIONS

526260

Disassembly of differential locking

Assemble the differential locking device by following the
removal operations in the reverse order.
Re-attach the differential locking device to the rear axle
casing as follows:

Assembling the differential locking device

Differential locking removal

Differential locking refitting

Figure 27

Figure 28

Figure 29

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

61871

18216

Figure 30

Figure 31

DIFFERENTIAL LOCKING DEVICE COMPONENTS

1. Flexible tie rod bracket (Bowden) - 2. Rear axle casing - 3. Spring - 4. Gasket - 5. Sealing ring - 6. Gasket - 7. Sleeve

control lever (9) - 8. Elastic pin to fix lever (7) to lever (12) - 9. Differential locking sliding sleeve - 10. Spring coupling

plate (11) - 11. Lever return spring (12) - 12. Transmission lever - 13. Adjusting screw nut - 14. Adjusting screw -

15. Differential locking device body.

Engage the sliding sleeve (9). Once this has been done,
loosen the nut (13), move the adjustment screw (14) so that
it is contact with the control lever (7). After this, unscrew the
adjustment screw by 9.5 turns (corresponding to 9.5 mm.
travel of the screw) and lock it with the fastening nut (13).

Adjusting the differential locking device

Disassembling the differential unit

Unscrew the screws (1) complete with tab washers and
spring washers and remove the gear housing inspection
cover (2) complete with gasket.

Before carrying out repair operations on the
differential unit you must drain off the oil and
disassemble the drive shafts. For the rear axle, you
must disassemble the differential locking as
described in the relevant paragraphs.

NOTE

REAR AXLES 450311/1 - 450511

AILY

44598

Figure 32

Mark the position of the caps (1 and 2) and remove them.

44599a

Figure 33

Take out the gear housing (1).

Note the assembly position of the adjustment rings (3) and
take them out of the housing together with the spacer rings
(2).

Extract the support bearing inner rings (3 and 5) and shoulder
ring (2) from the gear housing and, by means of the puller tool
99348001 (4), extract the counter block (1).

44600

Figure 34

Disassembly of gear housing

62099

18222

Figure 35

Figure 36

Unscrew the screws (2), remove the ring bevel gear (3) and
the gear housing (4) cover (1).

Remove the crown wheel (2) on the cover side with its thrust
washer (3) from the gear housing (1).

Using a generic beater to remove the long pin (4) and the
two short pins (5) from the gearing case (1).

The thrust ring (2) is only present with rear axles
fitted with differential locking.

NOTE

Mark the cover (1) and the gear housing (4).

NOTE

In the case of reuse, do not swap over the assembly
positions of the external rings (4) of the tapered
roller bearings.

NOTE

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

20378

18226

Figure 37

Remove the spider (1) and the four planetary gears (2) with
their shoulder washers (3) from the gear housing.

Remove the crown wheel (1) on the gear housing side with
the thrust washers.

51863

PARTS COMPRISING THE DIFFERENTIAL UNIT

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

spacer - 7. Spacer ring - 8. Adjustment ring - 9. Rear bearing - 10. Bevel pinion - 11. Ring bevel gear - 12. Fixed ring -

13. Adjustment ring - 14. Bearing - 15. Thrust ring (axle with differential locking) - 16. Gear housing - 17. Crown wheel

thrust washer - 18. Spider - 19. Crown wheel - 20. Gear housing cover - 21. Screw - 22. Planetary gear thrust washer - 23.

Planetary gear - 24. Short pin - 25. Long pin.

Figure 38

Figure 39

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

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