Iveco Daily. Manual - part 203

TRANSMISSION SHAFT ASSEMBLY DRAWING

1. Transmission shaft assembly - 2. Tapered roller bearing - 3. Transmission shaft with reverse gear toothing (A), 1st gear (B), 2nd
gear (C) - 4. Tapered bearing - 5. 4th gear - 6. Synchronizer ring - 7. Sliding sleeve - 8. Ball - 9. Spring - 10. Plug - 11. Hub - 12. Retaining
ring - 13. Half roller bearings - 14. 3rd gear - 15. 5th gear - 16. 6th gear.

51964

52509

Figure 69

Figure 70

INPUT SHAFT ASSEMBLY DRAWING

1 - Input shaft - 2. Cog-wheel

6 S 300 TRANSMISSION

AILY

Base - May 2004

Figure 71

MAIN SHAFT ASSEMBLY DRAWING

1. Single cone synchronizer ring - 2. Roller bearing - 3. Retaining ring - 4. Sliding sleeve - 5. Plug - 6. Ball - 7. Spring - 8. Hub - 9.

5th gear - 10. Main shaft with 3rd gear toothing (A), 4th gear toothing (B) - 11. Roller bearing - 12. 2nd gear - 13. Dual cone

synchronizer - internal ring C, middle ring D, synchronizer ring E - 14. Bushing - 15. 1st gear - 16. Spacer ring -

17.* Reverse gear - 18.* Ring with external toothing - 19.* Ring with internal toothing - 20.* Spacer ring. - 21.

•

Reverse gear -

22.

•

Synchroniser ring - 23.

•

Gear.

Transmission without synchronised reverse

•

Transmission with synchronised reverse

90233

6 S 300 TRANSMISSION

AILY

Base - May 2004

85977

1ST-2ND GEAR DUAL CONE SYNCHRONIZER ASSEMBLY

85978

Figure 72

Figure 73

3RD - 4TH - 5TH - 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY

SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR

86130

Figure 74

6 S 300 TRANSMISSION

AILY

Base - May 2004

After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.

The transmission and relative covers must show no sign of
cracking.
The mating surfaces of the covers and transmission must not
be damaged or deformed. Remove any remains of sealant
from them.

The seats of the bearings, reverse gear shaft and gear control
rods must be neither damaged nor too worn.

Hubs - sliding sleeves - forks

The grooves on the hubs and relative sliding sleeves must not
be damaged. The sliding sleeve must run freely on the hub.
The plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves
must not be damaged. The forks must be sound with an end
float, in the radial groove of the sleeve, no greater than 1 mm.

Bearings

The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced.

Shafts - gears

The seats on the shafts, for bearings, must be neither damaged
nor worn. The toothing of the gears must be neither damaged
nor worn.

Synchronizing devices

Check the wear on the synchronizer rings, proceeding as
follows:

- See that the friction surface is not undulated.

52510

52511

Figure 75

Figure 76

BK-type single cone synchronizers for 3rd/4th/5th/6th
gears

Arrange the synchroniser ring (1) on the respective gear or
reverse taper ring (2).

With a feeler gauge, check the distance S on two diametrically
opposite points.

If the measured value S is less than 0.8 mm, replace the
synchronizer ring.

Turn the synchronizer ring (1) so as to ensure correct coupling
on the cog-wheel.

Position the internal ring (3), middle ring (2) and the
synchronizer ring (1) on the tapered cog-wheel (4) of the gear.

Turn the synchronizer ring (1) so as to ensure correct coupling
between the parts.

Applying a uniform force of 50 N on the synchronizer ring (1),
measure the distance S on two diametrically opposite points
with a feeler gauge.

If the average measured value S is less than 1.5 mm, replace
all the rings.

D-type dual cone synchronizers for 1st/2nd gears

Transmission

6 S 300 TRANSMISSION

AILY

Base - May 2004

CHECKS

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