Content .. 89 90 91 92 ..

Iveco Daily Euro 4. Manual - part 91

5 S 300 TRANSMISSIONS

AILY

URO

TRANSMISSION

5 S 300

Type

Mechanical

Input torque

300

Weight

44.6

Speeds

5 forward speeds

1 reverse speed

Speed control

Mechanical

Power take-off

Optional

Speed engagement:

Forward speeds

- 5

/ 4

th /

Single-cone synchronizer

- 2

/ 1

Dual-cone synchronizer

Reverse speed

Rapid shift

Speed retention mechanism

Sliding sleeves retained by pawls and springs.

Gears

Helical-toothed constant mesh gears

Gear ratio

First

5.00

Second

2.62

Third

1.54

Fourth

1.00

Fifth

0.78

Reverse

4.58

Shaft bearings:

Main shaft

Straight roller bearing

watertight ball bearing

tapered roller

5 S 300 TRANSMISSIONS

AILY

URO

5 S 300

Transmission shaft bearing end play:

÷ 0.05 mm

Transmission shaft bearing end play adjustment

by shims

Shim thickness for transmission shaft bearing
end play adjustment

2.00 - 2.30 - 2.45 mm

with 0.05 mm progressive sequence

Main shaft
Assembly temperatures:
sliding sleeve hubs
2

and 3

speed gear bushings and spacer

speed gear spacer

150

170 ºC

÷ 160 ºC

90 ºC

Secondary shaft
Assembly temperatures:
bearings
5

speed gear

speed gear driving load

speed gear removing load

80 ºC (max 120 ºC)

140 ºC

÷ 170 ºC

31 KN

50 KN

Input shaft
Assembly temperatures:
front bearing*

80 ºC (max 120 ºC)

Gear axial backlash:
1

- 3

- 4

- R - 5

speed

0.15

÷ 0.3 mm

0.25

÷ 0.4 mm

and 4

speed sliding sleeve hub retaining

circlip axial backlash

÷ 0.05 mm

and 4

speed sliding sleeve hub retaining

circlip thickness

2 - 2.85 mm with progression of 0.05 mm

Transmission shaft rear bearing retaining ring
end float

÷ 0.05 mm

Transmission shaft rear bearing retaining ring
thickness

2.05

÷ 2.45 mm

with progression of 0.05 mm

242

LOCTITE sealant

510

5206

Type of oil:

TUTELA TRUCK GEARLITE

2 lit

Quantity

2 litres

1 8 k

1.8 kg

* = Do not use hot air equipment to heat bearing.

108855

Figure 7

Gearbox unit

5 S 300 TRANSMISSIONS

AILY

URO

DESCRIPTION

TORQUE

DESCRIPTION

kgm

Clutch housing, screw to fasten clutch housing to chassis

Screw to fasten clutch housing to box

± 15%

2.3

± 15%

Constant mesh shaft cover fastening screw

±15%

2.3

± 15%

Spring retaining plug

± 10%

3.2

± 10%

Grub screw securing gear selection sector to rod

±15%

6**

Screw securing p.t.o. side cover

± 15%

4.6

± 15%

Plug

÷30 ± 15% 2.8÷3 ± 15%

Screw securing reverse gear shaft

± 15%

2.2

± 15%

Screw securing rear cover

± 15%

2.3

± 15%

Screw locking sleeve for transmission coupling on main shaft

120

± 15%

11D

Screw securing ball bearing retaining ring

9.5

± 15%

0.9

± 15%

Screw securing control cable bracket

± 15%

2.3

± 15%

Screw securing gear control mounting

± 15%

2.3

± 15%

Nut for screw securing lever to control rod

± 15%

3.4

± 15%

Nut securing articulation pin to control lever

± 15%

2.3

± 15%

Nut for screw securing lever to control rod

± 15%

3.4

± 15%

Oil vapour breather

± 15%

Nut to secure articulation pin to control lever

± 15%

2.3

± 15%

Spread LOCTITE 5206 sealant on the contact surfaces

Spread LOCTITE 242 on the thread

** Spread LOCTITE 510 on the thread

108856

Figure 8

Gearbox control

5 S 300 TRANSMISSIONS

AILY

URO

TIGHTENING TORQUES

DESCRIPTION

TORQUE

DESCRIPTION

kgm

M8 screw for gearbox control support fastening

± 17

1.4

± 1.7

Nut securing the jointed heads to the cable

± 4.8

0.4

± 0.48

M8 screw securing the transfer case to the gearbox

± 25

2.1

± 2.5

M8 self-locking nut securing the flange to the cab

3.5

0.35

Nut securing the jointed head to the tie-rod

± 4.5

0.4

± 0.5

Plate fastening screw

7.8

± 9.25

0.78

± 0.95

After tightening nuts (4), the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected. After tightening
nuts (5), the vertical axes of tie-rod (5) jointed heads shall be aligned, with a maximum deviation of less than

α < 30˚ (lower).

Content .. 89 90 91 92 ..