Iveco Daily. Manual

Revi - February 2005

Assemble the cover and make the marks made during
disassembly coincide. Assemble the ring bevel gear and fasten
this to the half-casing by means of the fixing screws.
By means of a torque wrench (1) tighten the fixing screws (2)
to the required tightening torque.

Position the other two planetary gears (1) complete with
thrust washers and then insert the two short pins (2).
Rotate the planetary gears-crown wheel unit and check that
it is free without stiffness.
Assemble the other crown wheel complete with thrust
washer.

Position the two planetary gears (1) complete with thrust
washers, spider (2) and then insert the long pin (3).

Position the crown wheel (1), gear housing side, complete
with thrust washer, into its own housing.

18226

20380

20379

18237

Figure 40

Figure 41

Figure 42

Figure 43

Assembly of gear housing

Only for axles with differential lock.
Using tool 99305121, heat thrust ring (1) to a temperature
of 120ºC

÷ 150ºC for 15’ and fit on the gear casing (2) from

the side with the differential lock.

18240

Figure 44

Fit tapered-roller bearing internal ring (2) onto false pinion
99370309 (1) with the washer supplied (3).

101977

Figure 44/1

Assembling bevel pinion unit

This differs from assembling of bevel pinion unit of rear axle
450210 differential in the following.

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

Lubricate the internal ring of the front bearing and position
it in the housing.

Using the key 99374022 (1) and grip 99370006 (2), mount
the pre-lubricated seal.

Determine the bevel pinion rolling torque adjustment ring as
described for axle 450210.

62100

51865

18252

Figure 45

Using a suitable punch, with a grip, drive the external ring (4)
for the front bearing into the axle housing (1).

Position the spacer ring (2), thickness 2 mm, and using a
suitable punch drive in the external ring (3) of the rear
bearing.

Determine the adjustment thickness and position of the
bevel pinion as described for axle 450210.

Remove the external ring (3) of the tapered roller bearing.

Position the adjusting ring (5) of the calculated thickness on
the spacer ring (2).

Refit the external ring (3) of the tapered roller bearing.

Heat the internal ring (4) of the tapered roller bearing to
80

°C ÷ 90°C for approximately 15 min. and drive it, with a

suitable punch, onto the bevel pinion (1).

Position the spacer ring (3) and adjustment ring (2),
calculated beforehand to obtain the required rolling torque,
on the bevel pinion (1).

51866

Position the axle housing as shown in the figure.

On the stand, set a pipe (3) of such diameter and length as
to provide a solid supporting surface for the flange (2) and
the internal ring (1) of the front bearing above, already
mounted in the axle housing.

Figure 46

Figure 47

Figure 48

The rolling torque of the bevel pinion must be
measured with lubricated bearings and seals.

NOTE

REAR AXLES 450311/1 - 450511

AILY

Differential unit refitting

Mount the spacers and adjustment rings in the same number,
thickness and position found during disassembly, in the
following order: spacer (1), adjustment ring (2), adjustment
ring (3) and spacer (4).

Position the sliding sleeve in the rear axle housing for
differential locking (if present). Mount the external rings (1)
for the gear housing support bearings and then position the
previously mounted gear housing in the rear axle housing.

Make a cut in the collar of the nut (1) by the milling of the
bevel pinion (2) as shown in the figure.

51867

51868

20384

44594

Figure 49

Insert the bevel pinion (1), assembled as shown in the figure,
in the internal ring of the front bearing (2) and in the flange
(3).

Block rotation of the transmission flange with the retainer
tool 99370317.

Using a suitable Allen wrench and the torque wrench, tighten
the bevel pinion retainer nut (1, Figure 50) to the required
torque.

To be on the safe side, check the rolling torque of the bevel
pinion with the dynamometer 99389819.

DIRECTION OF ROTATION
OF THE NUT

Figure 50

Figure 51

Figure 52

Strike the top of the bevel pinion until it is possible
to fit the nut (1, Figure 50) securing the flange (3).

Take out the support pipe (4).

Complete assembling the pinion by fully tightening
the nut.

NOTE

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

Revi - February 2005

18262

Figure 53

Complete assembly by checking the total rolling torque and
the bevel pinion coupling clearance as described for axle
450210.

Position a new seal ring over the gear housing inspection
attachment surface.

Mount the cover (3), insert the fixing screws (2) complete
with tab washers and spring washers.

Tighten the screws (2) with the torque wrench (1) to the
required tightening torque.

Mount the differential locking device (if present) and adjust
it as described under the relevant heading.

Mount the drive shafts as described under heading: “525030
Overhauling the Hubs”.

Screw on the oil drainage plug and tighten it to the required
torque.

Add lubricating oil in the required quantity and grade through
the hole.

Screw on the oil filler plug and tighten it to the required
torque.

Take the assembly off the stand.

Do not tighten the screws to a torque greater than
the value indicated since this would impair the
sealing effect of the gasket placed between the
coupling plane and the gear housing inspection
cover.

NOTE

The assembly should be put back on its mounting
to prevent the dust guards and/or brake discs from
getting damaged.

NOTE

REAR AXLES 450311/1 - 450511

AILY

Base - May 2004

Content .. 242 243 244 245 ..

Iveco Daily. Manual - part 244