Iveco EuroCargo (12 to 26 t). Manual

Measure the thickness of the adjustment ring (6) found on re-
moval and note down the value (dimension A).
Tighten the tool 99395027 (8) in a vice and place the following
on it:

- the bearing (7) on the pinion side;
- the ring (6) previously measured.
- the gear (5);
- the spacer (4);
- the bearing (3).
Screw down the ring nut (2) and tighten it fully.
Position part (1) of tool 99395027 (8), equipped with a dial
gauge, on the bearing (3) and reset the dial gauge on the end
of the tool (8).
Then remove:

- the part (1);
- the ring nut (2);
- the bearing (3);
- the spacer (4);
- the gear (5);
- the ring (6) the bearing (7) from the tool (8).

Figure 84

COMPUTATIONAL EXAMPLES

The difference between the value of the thickness of
the new pack and that of the old one must be added
to or subtracted from, depending on the case, the
thickness of the adjustment ring (6, Figure 85).

Place the bevel pinion position adjustment rings (4) in the box
and, using grip 99370007 (1) and drift 99374094 (2), mount
the external ring (3) for the bevel pinion bearing.
Fit remaining bearing cups using drift 99374093.

36383

77239

Figure 85

Figure 86

77241

Insert the tool 99394027 (8, Figure 85) in the differential gear
housing, comprehensive of the bearing (7, Figure 85), ring (6),
gear (5), spacer (4), bearing (3). Screw down the ring nut (1)
on the tool 99394027.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

Original shim pack thickness

0.76

CP marked on pinion +2

+0.05

Resulting value

0.81

CP marked on new pinion +5

-0.12

Thickness for new shim pack

0.69

Case 2:

Original shim pack thickness

0.76

CP marked on pinion -2

-0.05

Resulting value

-0.71

CP marked on new pinion +5

-0.12

Thickness for new shim pack

-0.59

Case 3:

Original shim pack thickness

-0.76

CP marked on pinion + 2

+0.05

Resulting value

0.81

CP marked on new pinion -5

+0.12

Thickness for new shim pack

0.93

Case 4:

Original shim pack thickness

-0.76

CP marked on pinion -2

-0.05

Resulting value

0.71

CP marked on new pinion -5

+0.12

Thickness for new shim pack

0.83

36385

78313

36386

36387

Figure 87

Figure 88

Figure 89

Figure 90

Reposition part (1) of tool 99395027, with the dial gauge
previously reset on the bearing (3) and measure any difference
(dimension B).

The thickness S of the ring, or of the adjustment rings, is given
by the following formula:

S = A - (

± B) + C

where:

A = Thickness of the adjustment ring(s) fitted to reset the
dial gauge;

B = Value of the difference measured;

C = 0.2 mm coefficient that takes account of the expan-
sion of the bearings due to the interference of assembly
on the bevel pinion.

Heat the bearing (2) to 100

°C for 15 min. and, with a specific

drift, fit it on the bevel pinion.

Screw down the ring nut (2, Figure 88) tightening it until, with
a dynamometer, you measure a rolling torque of:

- 1.12 to 5.08 Nm if the bearings are new,

- 1.68 to 3.39 Nm if the bearings have already been used.

First example:

A = 13.12 mm
B = + 0.13 mm
C = 0.2 mm

S = 13.12 - (+ 0.13) + 0.2 =
S = 13.12 — 0.13 + 0.2 = 13.19 mm.

Second example:

A = 13.12 mm
B = - 0.13 mm
C = 0.2 mm

S = 13.12 - (- 0.13) + 0.2 =
S = 13.12 + 0.13 + 0.2 = 13.45 mm.

Remove from the box the tool 99395027 (8, Figure 85) and
take out the bearings, spacers and gear as shown in the figure.

Insert the bevel pinion (3) in the box, simultaneously keying
onto it the adjustment ring (1) of the thickness determined in
the preceding measurements and the gear (2); screw the part
99345029 (4) onto the bevel pinion (3).

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

Block rotation of the bevel pinion with the tool S.P. 2373 (1).
Screw down the nut fastening the bevel pinion bearings and
tighten it to the prescribed torque.

77242

77237

20670

94191

Figure 91

Figure 92

Figure 93

Figure 94

Block rotation of the bevel pinion with the tool S.P. 2373 (5).
Screw down the inserter 99345098 (4) onto the part (4,
Figure 90) and fully drive in the gear (3).
Remove the inserter (4).
Fit on the spacer ring (1).
Heat the bearing (2) to 100

°C for 15 min. and fit it onto the

pinion.
Screw the inserter (4) back onto the part (4, Figure 90) and
take the bearing (2) into contact with its seat.

To tighten the nut use the wrench 99355069 (2)
torque wrench and multiplier 99389816 (3).

Position the caps taking care to make the reference marks co-
incide.
Insert the screws, together with the washers, and tighten
them, using a torque wrench, to the prescribed torque.
Then check that the external rings of the bearings slide, with
a light pressure, in their respective seats without sticking.
Again unscrew the fastening screws with the washers and re-
move the caps.

Using the hook (1), lift the gear housing (2) previously as-
sembled and position it on the differential casing (3).

Figure 95

77245

Position the caps (2), screw down the screws (1) with the
washers and tighten them to the prescribed torque.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

77246

60636

77247

49248

Figure 96

Figure 97

Figure 98

Figure 99

Lubricate taper roller bearings (1) and fit outer races.
Screw in adjustment ring nuts (2).

Adjusting the cap gap

Adjusting and checking retraction of the caps can be done with
two methods:

METHOD

Use wrench 99355025 (3, Figure 98) to tighten the ad-
justment lock rings (4) of the bearings until eliminating the
pinion-crown wheel clearance and end float. At the same
time check that the crown wheel does not force on the
pinion;

using a suitable micrometer positioned diagonally and
centrally in points (X-Y-arrows, Figure 97);

measure and note the distance of the caps;

further tighten the two adjustment lock rings (4,
Figure 98) to obtain a retraction of the caps (2, Figure 98),
measured on Axis X or on axis Y as described in point ”2”
of: 0.08 to 0.22 mm which corresponds to a preload on
the bearings of 1.7 to 3.9 Nm (0.17 to 0.39 kgm).

METHOD

A. Diagonally and centrally on the outer machined seats of

both caps (2, Figure 98) position two dial gauges (1) with
magnetic base as shown in Figure 98;

proceed as described in point ”1”;

C. after eliminating the end float further tighten the two ad-

justment lock rings (4) to obtain a retraction of the caps
(2) of 0.08 to 0.22 mm, which corresponds to the sum of
the readings on the dial gauges (1).

Adjust the axial clearance between the teeth of the pinion -
crown wheel unit which must be 0.20 to 0.46 mm proceeding
as follows:

- stop the bevel pinion from turning using tool 99370317;

- position the magnetic-based dial gauge (1) as illustrated;

- using wrench 99355025 (3) slacken the adjustment lock

ring on the crown wheel side and tighten, to the same
extent, the adjustment lock ring (2) of the opposite side.
The purpose of this is to leave the previously-adjusted cap
retraction unchanged;

- proceed as described until obtaining the specified

clearance.

The clearance should be checked on 4 points the same
distance apart.

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12-26 t

AXLES IN TANDEM (INTERMEDIATE)

Base - February 2003

Content .. 103 104 105 106 ..

Iveco EuroCargo (12 to 26 t). Manual - part 105