Iveco Cargo 75e Service Manual

I occasionally drive an 18T Eurocargo box with a 6 speed automatic box. It's the one with 3 buttons, R/N/D, which gives Slow/Semi/Auto modes with the facility to change gear with the lever to the right of the steering wheel. Think that it's an Eutronic gearbox.

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It's a 58 plate, with 200,000 Kms.
The gearbox has suffered a fault in warm weather since 2011, despite some investigation / parts replacement by the dealer.
A fuller description below:
The fault occurs in warm weather, so happens often on the continent but has also happened in London and even in Edinburgh. The warmer the ambient temperature, the more likely that the fault will occur and the more severe the problem.
Scenario 1
Driving on the motorway for 4.5 hours in warm weather. Easy driving so the gearbox doesn't have to do much. Drive into the services and stop so that the truck can be manoeuvred into a parking space. Once the truck has stopped it can't be moved again - the engine can't be revved up. Pressing the gearbox buttons only changes the display to N and usually also the gearbox fault symbol. It's not a true neutral because the engine speed can't be increased above idle.There is a noise which sounds like a pump straining. It can take 10 to 40 minutes before a gear can be selected. The first thing to return is 1 SLOW but with the fault symbol still showing when the truck can be moved forward slowly. It needs more time before R can be selected. When it does select 1 or R, there is a thump and a lurch. If the truck is then driven for only 5 minutes and stopped, the fault is there again and it will take another long time before it can be moved. Leave the truck for the drivers 45 minute break and it can be used but the selection of 1 or R is very slow to happen - maybe 5 seconds.
This bit I don't understand - during the fault - if the engine is switched off and then restarted - the display will show N with no fault symbol - and it is a true neutral because the engine can be revved up but pressing either D or R will put it into the fault condition so that the display remains at N but with the fault symbol and the engine can't be revved. What changes it into neutral? Is it a different system? a spring? air pressure?
Scenario 2
Driving on the motorway for 3 to 4 hours in warm weather. Easy driving so the gearbox doesn't have to do much, but will change between 4, 5, and 6 normally. The traffic stops so the truck is braked to a stop - it changes down to 3 and stops. The traffic moves on but the truck can't be moved - it won't rev - it might show 3 for a while but will usually show N with the gearbox fault symbol. Then it's the same situation as above - needs time before 1 SLOW can be selected.
Again, this bit I don't understand. If I anticipate that the traffic is going to stop, and I use the column lever to change down to 2 or 1 just before the truck stops moving then it can be kept driving.
Scenario 3
When the truck appears to be working OK, in cool weather, even in Scotland it can be very slow to select 1 or R - a few seconds. The time is so significant that if someone is waving you back, then they will start to wonder why you aren't moving.
I don't know how the gearbox works - it seems to me that the system for selecting 1 / 2 or R is different to the gearchanges between 3 / 4/ 5 / 6 and different again to the system for putting the gearbox in N when the engine is stopped.
When the gearbox is at fault it feels to me as though hydraulic fluid is either aerated or has thinned down in the heat and so won't move the internals.
Has anyone came across this fault?
Any tips to get moving again? Another guy who drives the truck suggests revving it up in neutral, and then pressing D. I'm not convinced that it helps, the drive by wire pulls the revs down to idle anyway before attemting to select drive.
TIA
Ash


Iveco EuroCargo_Tector 2002-2008

MIVCECT0208OPMS.zipPrice: $29.99 USD
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 2002-2008 Iveco EuroCargo/Tector. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for 2002-2008 Iveco EuroCargo/Tector is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

MAKE: Iveco
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MODEL: EuroCargo / Tector
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YEAR: 2002, 2003, 2004, 2005, 2006, 2007, 2008
— — — — — — — — —
LANGUAGE: English/Italian
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FORMAT: PDF (272 MB)
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EXCERPT:
INDEX OF SECTIONS
Section
General Specifications 1
Engine 2
Clutch 3
Gearbox 4
Propeller shafts 5
Rear axles 6
Front Axles 7
Suspensions 8
Wheels and tyres 9
Steering 10
Pneumatic system — brakes 11
Body and chassis 12
Service plan 13
Electric/electronic system 14
Print 603.93.391 Base – October 2004

Iveco Cargo 75e Service Manual Free

32 FRONT AXLE 5845 EUROCARGO TECTOR 12-26 t
520615 Steering knuckle pin bearing replacement
Figure 56
Steering knuckle bearing replacement (5) is made using for their disassembly and assembly beater’s elements (1-2-3) 99374527 and handle 99370007 (4).
Use element (1) and handle (4) to disassemble the sealing ring (8) and the roller bearings (6-7) on the upper side.
Use element (3) and handle (4) to disassemble the sealing ring (9) and the roller bearings (10-11) on the lower side.
Figure 57
Roller bearing assembly (7): use element (1 and 2) and handle (4).
Roller bearing assembly (6): use element (2) and handle (4).
Roller bearing assembly (8): use elements (3 and 2) and handle (4).
Roller bearing assembly (9): use element (2) and handle (4).
Figure 58
Use beater 99374171 (4) and handle 99370007 (3) to place sealing rings (2 and 5) in the steering knuckle (1).
Refitting
Figure 59
Set on the axle (2) the steering knuckle (3) and place the articulated pin (1).
Set tool 99374400 (4) on the steering knuckle (3) and fasten it by using the same lower cover lock screws (5), clamping them with the right torque.
Place the pin (1) in the axle conical housing, screwing the pressure screw (6) with a torque having 10 ÷ 11 daNm.
Remove tool 99374400 (4) from the steering knuckle (3).
Before placing the pin (1), it is necessary to check that the conical housing on the axle and the pin surface are perfectly cleaned and dry, in order to avoid oil layers which could foster the pin rotation in its place during its introduction.

Category: Manual

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