It’s not uncommon for the gear change to become quite stiff in the Iveco Daily; both the 4×2 and 4×4 suffer from this.  The issue is that the bell-cranks seize-up over time and the process is accelerated by driving through deep water and mud.  On mine, the central tube had seized to the bushes and the only movement was the bell-crank revolving around the bolt!

As you can see in the photo above, there are bushes inserted into either end of the bell-crank and a central tube passes through the bushes, held in place with a central bolt.  The idea is that the tube is held in place by the bolt and the bell-crank rotates around the tube, using the two inserted bushes.  Unfortunately, this design seizes-up and the whole thing must be removed from the vehicle to be serviced and lubricated.

I decided to modify the bell-cranks by installing grease nipples. This will make it easy to lubricate the bell-cranks and keep the gearchange light and easy.

As you can see in the photo below, the two grease nipples are staggered so they cannot foul on each other.  You must remove the bracket as there is not enough clearance above to extract the central bolts on the bell-cranks.

The finished installation, with the clutch shield re-installed. The grease nipples are easily accessible for lubricating during normal servicing or following deep water crossings.

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