Iveco daily euro 4, Repair Manual

Page: 373 / 1132

Figure 1
Removal
Here we describe the removal-refitting operations for the 5 S 300 transmission
that, unless specified otherwise, also hold for the 6 S 400 O.D. transmission.
Position the vehicle over the pit or on a lift or on special stands.
Act from inside the engine compartment to remove the screws securing the
starting motor to the gearbox case front cover (the upper screw also secures
the fuel pipe supporting bracket).
Remove the starter motor and put it appropriately aside in the engine bay.
Act from under the vehicle to:
-
remove screws (11) and take sound-proofing guards (12) off;
- disconnect exhaust pipe (13) from the turboblower pipe.
On 6 S 400 O:D. gearbox units: remove screws (17) securing exhaust pipe
supporting bracket (16) to the gearbox unit.
Remove the sealing from ring (25), then unscrew the same and disconnect the
speed indicator control cable.
Disconnect reversing light electric connection (22) (on 6 S 400 O.D. gearbox
units, the reversing light switch is located on the left side of the gearbox unit).
Remove bolts (23) securing propeller shaft (24) to the gearbox unit; if
necessary, remove screws (19) securing elastic support (18) to the chassis, and
properly secure the propeller shaft to the chassis.
Disconnect the jointed heads:
- of the selection cable: 4 (max. pull-out load: 250 N - max. pull-in load: 60
N);
-
of the engagement cable: 5 (max. pull-out load: 100 N - max. pull-in load:
80 N, from lever 6 and 7). Use a suitable screwdriver to open out flexible
cable fins (3) so that the pawls are disengaged from the support (see detail
A).
Undo fastening screws (2), move clutch control cylinder (1) together with its
bracket and properly secure it to the chassis.
Use a hydraulic jack to place bracket 99370629 under the gearbox unit, then
lay the chain onto the gearbox unit and fit a link of the chain into the bracket
slot. Screw down the nut so as to firmly secure the gearbox unit to the bracket
through the chain. Remove screws (20) securing the gearbox case to the engine
base.
Undo fastening screws (15) and elastic dowel fastening screw (21), then
remove gearbox supporting crosspiece (14) together with its dowel.
Move the gearbox back until the gearbox input shaft has come off the clutch
disc hub. Then lower the hydraulic jack while simultaneously verifying that the
gearbox unit does not, during the downward movement, hit or get stuck into
a component.
Refitting
108848
Gearbox unit reattachment is not particularly difficult and is carried out by
properly reversing the order of the detachment operations. However, the
following instructions shall be followed when coupling the clutch with the
gearbox.
Use suitable pliers to open safety snap ring (10) and take pressure plate bearing
(9) out of clutch diaphragm spring (8). Fit the bearing onto the motion input
shaft cover quill, by connecting the same to the clutch disengagement lever.
Apply Molikote molybdenum disulfide grease to the gearbox input shaft.
Engage a gear to allow the output shaft to rotate by turning the propeller shaft
mount flange. Push the gear shift fully down so that pressure plate bearing (9)
is properly engaged into the diaphragm spring.
When connecting the propeller shaft, use new nuts for the fastening screws of
the respective flanges. All the bolts and nuts shall be tightened to the prescribed
torque values indicates in the relevant tables.
Prior to assembling, lubricate the flexible cable (Bowden) jointed head
connection points with MOLIKOTE 33 LIGHT or MOLIKOTE G72 grease.
After the gearbox unit has been reattached, check for correct connection of
electric cables.
Verify that the gears are engaged correctly; otherwise, proceed as described in
the ”Gear control check and adjustment” chapter.
6
TRANSMISSION
7
D
AILY
E
URO 4
Base - March 2006 Print 603.93.651
TRANSMISSION REMOVAL - REFITTING