Iveco Daily. Manual

Figure 57

Figure 58

33101

Fit the rear bearing (2) on the false pinion 99370296 (1).

Position the false pinion 99370296 (1) including the rear
bearing (2) into its seat on rear axle casing (3).

Fit the front bearing, the transmission connecting flange and
the bevel pinion retaining nut and tighten so as to remove
end play and to enable false pinion rotation.

33102

8.00

S =

- 0.05

3.90 + 4.10

S =

- (

± 0.05)

Set dial gauge 99395728 (1) including support (3) on false
pinion 99370296 (2).
Direct suitably the dial gauge previously set to zero (see
Figure 51) to position the rod to the bottom of the gearing
case supporting bearing housing.

33103

Repeat this operation for the other bearing and take note of
both found values.

Pinion adjustment ring thickness is obtained through the
following formula:

S =

- ( + B )

+ A

”S” = thickness of the adjustment rings to be positioned
between bevel pinion rear bearing outer ring and rear axle
casing.
”A1” = value found on right housing
”A2” = value found on left housing
”B” = reference value marked on bevel pinion (see Figure 60)

Example:

S = 4.00 - 0.05

S = 3.95

Adjustment ring thickness shall therefore be: 3.95 mm.

Figure 59

REAR AXLE 450517/2

AILY

Base - May 2004

Figure 60

33104

Figure 61

33099

Choose an adjustment ring having the same thickness ob-
tained by using the formula shown in Figure 59 and fit it into
the rear axle casing after removing rear taper roller bearing
outer ring previously mounted.
Use beater 99374093 (1) to fit definitely the rear taper roller
bearing outer ring into rear axle casing (2).

Figure 62

Heat the rear bearing (1) to 100

°C for approx. 15’ into an

air-circulation furnace and then fit it down onto the bevel
pinion (2).

32481

Figure 63

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

32482

Figure 64

Position the complete bevel pinion into the rear axle casing.
Heat the front bearing (1) to 100

°C for approx. 15’ into an

air-circulation furnace and then fit it down onto the bevel
pinion (2).

33111

If the value marked on the pinion is preceded by
positive sign (+), it shall be subtracted from the
value obtained by the sum divided by two of the
housings, whereas it shall be added if preceded by
negative sign (-).

NOTE

REAR AXLE 450517/2

AILY

Figure 65

74730

Fit the seal ring (2) in the axle casing with tool 99374201 (1).

Figure 66

Fit the transmission connecting flange (1) and the bevel
pinion retaining nut (2).

33113

Figure 67

74731

Assemble the flange (3) and prevent rotation with tool
99370317 (1).
Using the torque wrench (2), tighten the bevel pinion flange
(3) retaining nut to the correct torque value.

Figure 68

32480

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

If the value is incorrect disassemble the pinion (2, Figure 64),
and replace the adjuster ring (3, Figure 63) with a suitable
ring.
Refit the pinion and repeat the rolling torque check.

Figure 69

33116

Fit gearing case supporting bearing outer rings (2) and then
position the gearing case (1), previously fitted, in the rear axle
casing.

Differential unit refitting

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

REAR AXLE 450517/2

AILY

Base - May 2004

Figure 70

Insert the spacer (2), adjuster ring (1), adjuster ring (4) and
then spacer (3).

33117

Figure 71

Refit caps (1) taking into account the marks made at removal.
Use dynamometric wrench 99389827 (2) to tighten the
fastening screws to the specified torque.
Set gearing case supporting bearings and check total rolling
torque.

33119

Figure 72

33107

Use dynamometric wrench 99389819 (1) to check total
rolling torque:

Figure 73

Position magnetic dial gauge 99395684 (1) and check the
clearance between the pinion and crown on four equidistant
teeth on the crown. 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 4, Figure 70).
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.

33121

If the value is incorrect, replace the adjuster rings (1 and 4,
Figure 70) with rings of the correct thickness.

Ct = 2.5 + (

x 0.99)

Cp = bevel pinion bearing rolling torque

Cd = 2

÷ 2.8 Nm (0.2 ÷ 0.29 kgm)

Ct = Cp + (

x 0.99)

Ct = total rolling torque

R = Rear axle reduction ratio

Example:

Ct = 2.5 + 0.71

Ct = 3.21 Nm (0.33 kgm)

2.8

3.91

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

REAR AXLE 450517/2

AILY

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Iveco Daily. Manual - part 251