Iveco EuroCargo (12 to 26 t). Manual

77240

Figure 70

INTER-AXLE DIFFERENTIAL COMPONENTS - EXPLODED VIEW

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

Thoroughly clean the individual parts making up the differen-
tial. Lubricate the bearings and spin the roller cages freely;
these should rotate evenly without tight spots.
Check the seating surfaces of the bevel crown wheel and the
bedding surface of the half cage so that the crown wheel ad-
heres to it perfectly; distortion of these faces would cause
vibration of the crown wheel attachment screws, compromis-
ing the satisfactory operation of the unit.

Use hook (1) to raise the gear cage assembly and position on
stand 99371047 (3).

19379

36316

Figure 71

Figure 72

Unscrew nuts (1) and remove them with screws. Drive out
bevel crown wheel (2).

Dismantling gear cage

36317

Figure 73

Use tool 99348001 (1) and reaction block 99345055 (2) to
remove bearing (3) and bearing (4).

19383

19382

Figure 74

Figure 75

Mark the two casing halves (2 and 3) and the spider as indi-
cated in the figure.
Unscrew screws (1) joining the casing halves. Lift the casing half
(2).

Remove differential gear (2) with the associated thrust washer
(1). Remove spider (6) with the four planetary gears (5) com-
plete with thrust washers (3). Take the spider/planetary gear
assembly apart. Remove the other differential gear with its
thrust washer from the half cage (4).

Checking differential components

Thoroughly clean threads of screws, studs and ring
nuts to prevent clearance or torque settings from
being altered.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

19397

19391

19383

36323

Figure 76

Figure 77

Figure 78

Figure 79

Heat the support bearing (2) for the opposite side of the lock-
ing differential in a circulating air oven to a temperature of
100

˚C for about 15’ and fit it to the gear cage (3) using a suit-

able drift (1).

Position half cage (2) on fixture 99371047.
Position differential gear thrust washer (1) in the half cage (2)
and then fit differential gear.

Fit spider (6) complete with planetary gears (5) and associated
thrust washers (3) to half cage (4).
Position second differential gear (2) with thrust washer (1).

Check that there is no excessive wear in the splined portion
for fitting the flange to the pinion; if there is, replace the pinion.

Check the planetary gears and associated thrust washers, the
spider and differential gears and thrust washers.
Replace all seals and gaskets, the locking pin for the adjustment
ring nut and all lock washers.

If it should be necessary to replace the crown wheel
or pinion, both must be replaced as the parts are sup-
plied as matched pairs.

Assembling gear cage

It is always advisable to renew screws (2).

34850

Figure 80

Heat bearing (1) in a circulating air oven to a temperature of
100

˚C for about 15’ and fit it to the gear cage (2) using a suit-

able drift.

Lock the differential with the parts (1); fit on the half box (3).
Check that the marks made at the time of removal coincide.
Apply a few drops of “LOCTITE 270” on the thread of the
screws (2).
Tighten the screws (2) to the prescribed torque.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

To determine the thickness of the shim pack to be inter-
posed between bearing cage and differential carrier proceed
as follows:

measure the thickness of the shim pack removed
with the old final drive gear set. Use a micrometer or
other suitable gauge and record the value found;

Pinion/crown wheel set manufacturing and inspection
month and year.

Specified pinion/crown wheel set clearance.

Part number and tooth combination number are stamped on
threaded end of all pinions. Number may alternatively be lo-
cated on outer diameter of crown wheel. On any pinion/
crown wheel set, crown wheel will always bear an even
stamped category number (e.g. 36786), whereas correspon-
ding pinion will bear an odd number (e.g. 36787).

Every crown wheel is marked with a variation number which
indicates the nominal assembly distance. Use this number to
calculate the thickness of the shim pack that is interposed be-
tween pinion bearing cage and differential carrier.
The variation number (CP + 0,1 or CP - 0,1) is stamped on
crown wheel outer face.

variation number needed to determine the thickness of
the shim pack interposed between pinion bearing cage
and differential carrier (in the example below, this number
is identified as CP).

part number;

tooth combination number.
This number (example: 12/41) indicates that the pinion
has 12 teeth and the crown wheel 41;

pinion/crown wheel pair set number.
All final drive sets are available as pairs: therefore pinion
and crown wheel bear the same number which is
stamped on head end for pinions and the outer face for
crown wheels;

Allow the bevel crown wheel to cool before positioning the
screws. Use torque wrench (1) to tighten self locking nuts (2)
to the specified torque.

36325

36324

Figure 81

Figure 82

Heat bevel crown wheel (1) in a circulating air oven to a tem-
perature of 100

˚C for about 15’ and position it on its seating

on the gear cage, ensuring that the holes for the bevel crown
wheel/gear cage attachment screws are lined up.

ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion position in differential
casing

Figure 83

19416

1,2

1,2,3

1,2,3,4,5,6

OPTION

If a new final drive set is installed, it will be necessary to know
the meaning of the markings on pinion and crown wheel in
order to position the pinion correctly:

Never use a pinion and crown wheel set unless both
components have the same number.

read the CP marked on pinion to be replaced: if it is
a plus (+) number or a minus (-) number respectively
subtract or add it from the value obtained under 1.
above;
Take note of the result.

The value obtained in 2. will be used to calculate the
thickness of the shim to be interposed between pinion
bearing cage and differential carrier for correct new
final drive assembly.

read the CP marked on the new pinion.
Either add or subtract this value - depending on
whether the sign is a plus or a minus - to or from the
value noted under 2. above.
The result indicates the thickness which the new shim
pack should have.

Refer to the following examples which cover all the possible
calculation cases.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

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Iveco EuroCargo (12 to 26 t). Manual - part 104