Iveco Daily Euro 4. Manual

Fit the mounting 99395728 (2) with the dial gauge (1) on the
dummy pinion 99370239 (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 43) used for measuring, for pinion positioning is
obtained by the following formula:

108407

18246

108406

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 42).
For example:

Unscrew check nut and transmission connection flange.
Unthread flange and bearing from 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 41

Figure 42

Figure 43

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

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).

1,125

REAR AXLE NDA RS

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Position fixed spacer (3) and adjusting ring (2) on bevel pinion
(1).

18251

18252

108408

Figure 44

Figure 45

Figure 46

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.

Beat on the top of pinion (1) until nut securing flange (3) can
be mounted.

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108421

Figure 47

Figure 48

REAR AXLE NDA RS

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108423

Figure 49

Using torque meter 99389819 (1), detect bevel pinion rolling
torque.

If the reading differs from the prescribed value, disassemble
the pinion (1, Figure 47), replace the adjuster ring (2,
Figure 45) with a ring of the correct thickness.

Refit the pinion and repeat the rolling torque check.

Figure 50

Assembly of differential unit

Fit the differential (1) unit and support (6) bearings in the axle
casing.
Mount spacers and adjusting rings in same quantity, thickness
and position as detecting on dismounting, according to
following sequence: stop ring (2), adjusting rings (3 and 5) and
stop ring (4).

Figure 51

108424

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

108423

Figure 52

Check total rolling torque using torque meter 99389819 (1).

If the value of the measurement is not as required, replace
the adjustment rings (3 and 5, Figure 50) with another one
of a suitable thickness.

Rolling torque must be detected at 25 ºC ambient
temperature having the pinion rotating at 50 rpm
speed, after the pinion has run 10 revolutions.

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

108422

REAR AXLE NDA RS

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Position the dial gauge 99395728 (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 50).

Should this not be sufficient, replace adjusting rings by other
rings having different thickness, on condition that total
thickness must be equal to the total thickness of the adjusting
rings that were dismounted.

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

Using a brush, apply a thin layer of Prussian blue on ring gear
teeth.

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.

108427

44603

Figure 53

Figure 54

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

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

Figure 55

Figure 56

44604

Correct contact.

44605

Excessive contact on tooth
bottom or flank.
Move pinion away from ring
gear, then move ring gear
close to pinion in order to
adjust clearance.

Figure 57

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 NDA RS

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URO

Content .. 128 129 130 131 ..

Iveco Daily Euro 4. Manual - part 130