DAF LF45 Series Service Manual Download

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200508

4-5

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55

series

4.3 REMOVAL AND INSTALLATION, DRIVE FLANGE

Removing the drive flange

Make a reference mark on the prop shaft and

flange.

Detach the prop shaft from the flange and

secure it.

Fit special tool (DAF no. 0484977) to hold

the flange in place.

Remove the attachment bolt and washer.

Using special tool (DAF no. 0484978),

remove the drive flange from the shaft.

Installing the drive flange

Heat the drive flange to a temperature of

max. 120

″

Oil the output shaft lightly and slide the drive

flange over the shaft in its correct position.

Fit the special tool (DAF no. 0484977) onto

the drive flange.

Tighten the attachment bolt to the specified

torque. See "Technical data".

Fit the prop shaft. Tighten the attachment

bolts to the specified torque. See "Technical

data".

V3 00 416

DAF LF Gearboxes and Clutch Service Manual

Summary of Contents for LF45 Series

Page 1: ...e TECHNICAL DATA DIAGNOSTICS MECHANICAL GEARBOX CONTROL PNEUMATIC GEARBOX CONTROL ZF S5 42 GEARBOX ZF 6S 850 GEARBOX EATON FS 6309A GEARBOX ALLISON 1000 2000 AUTOMATIC GEARBOXES ALLISON MD 3060 AUTOMA...

Page 2: ...DAF LF Gearboxes and Clutch Service Manual...

Page 3: ...200508 4 3 Filling capacities 4 3 200508 5 EATON FS 6309A GEARBOX 5 1 200508 5 1 General 5 1 200508 5 2 Tightening torques 5 2 200508 5 3 Filling capacities 5 3 200508 6 ALLISON 1000 2000 AUTOMATIC GE...

Page 4: ...TECHNICAL DATA 2 200508 Contents 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 5: ...e cab Locking compound Loctite 243 Lubricant Molykote BR2S or BR2 plus V3 00 563 A Engine Gearbox Cab suspension Class Length A mm CE engine ZF 6S850 steel 1 669 CE engine ZF 6S850 rubber 1 664 CE eng...

Page 6: ...verview of the standard tightening torques The other threaded connections not specified must therefore be tightened to the torque mentioned in the overview of standard tightening torques When attachme...

Page 7: ...ries 3 0 Operating mechanism 2 adjustment options Control rod 1 Torque rod 2 Ball joint 4 Lubricant Molykote BR2S or BR2 plus Attachment nuts 48 Nm Lock nuts 28 Nm Attachment nut 48 Nm Lock nuts 45 Nm...

Page 8: ...l rod 1 Ball joint 2 Torque rod 4 Ball joint 6 Ball joint 8 Lubricant Molykote BR2S or BR2 plus Attachment nut 48 Nm Lock nuts 48 Nm Attachment nuts 48 Nm Lock nuts 28 Nm Attachment nut 48 Nm Lock nut...

Page 9: ...arbox control TECHNICAL DATA 45 55 series 3 0 Torque rod 9 Gear lever unit Eaton switch button 1 Use Loctite 243 Attachment nuts 48 Nm Attachment bolts 18 Nm 1 Attachment nut 70 Nm 1 DAF LF Gearboxes...

Page 10: ...TECHNICAL DATA 1 6 200508 Mechanical gearbox control 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 11: ...200508 2 1 Pneumatic gearbox control TECHNICAL DATA 45 55 series 3 0 2 PNEUMATIC GEARBOX CONTROL 2 1 GENERAL Filter governor Governed pressure 5 34 5 69 bar DAF LF Gearboxes and Clutch Service Manual...

Page 12: ...g torques When attachment bolts and nuts are replaced it is important that unless stated otherwise these bolts and nuts are of exactly the same length and property class as those removed Filter govern...

Page 13: ...8 3 1 ZF S5 42 gearbox TECHNICAL DATA 45 55 series 3 0 3 ZF S5 42 GEARBOX 3 1 GENERAL Input shaft Secondary shaft Pre tension 0 02 0 09 mm Pre tension 0 02 0 09 mm DAF LF Gearboxes and Clutch Service...

Page 14: ...ed it is important that unless stated otherwise these bolts and nuts are of exactly the same length and property class as those removed Gearbox Drive flange Gearbox front cover Selector shaft housing...

Page 15: ...200508 3 3 ZF S5 42 gearbox TECHNICAL DATA 45 55 series 3 0 3 3 FILLING CAPACITIES Gearbox Capacity S5 42 3 5 litres DAF LF Gearboxes and Clutch Service Manual...

Page 16: ...TECHNICAL DATA 3 4 200508 ZF S5 42 gearbox 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 17: ...earing axial play Bearing axial play main and input shafts Secondary shaft bearing axial play V300049 1 2 4 5 3 8 6 7 10 9 1 Type of gearbox 2 Serial no ZF 3 Parts list ZF 4 Specification no 5 Pulse g...

Page 18: ...n attachment bolts and nuts are replaced it is important that unless stated otherwise these bolts and nuts are of exactly the same length and property class as those removed Gearbox Drive flange Gearb...

Page 19: ...6S 850 gearbox TECHNICAL DATA 45 55 series 3 0 4 3 FILLING CAPACITIES Gearbox type Filling amounts at oil change litres First filling e g on repair litres ZF 6S 850 7 5 7 5 DAF LF Gearboxes and Clutch...

Page 20: ...TECHNICAL DATA 4 4 200508 ZF 6S 850 gearbox 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 21: ...henever replacement parts are ordered Secondary shaft pre load Sealant Filter governor V300378 2 3 4 1 5 1 Type of gearbox 2 Specification no Eaton 3 DAF article Eaton code 4 Serial no Eaton 5 Product...

Page 22: ...ese bolts and nuts are of exactly the same length and property class as those removed Gearbox Drive flange Gearbox front cover Selector shaft housing Filter governor Plugs 1 Use new nut 2 Use Loctite...

Page 23: ...200508 5 3 Eaton FS 6309A gearbox TECHNICAL DATA 45 55 series 3 0 5 3 FILLING CAPACITIES Gearbox Contents Eaton FS 6309A 8 5 litres DAF LF Gearboxes and Clutch Service Manual...

Page 24: ...TECHNICAL DATA 5 4 200508 Eaton FS 6309A gearbox 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 25: ...automatic gearboxes TECHNICAL DATA 45 55 series 3 0 6 ALLISON 1000 2000 AUTOMATIC GEARBOXES 6 1 GENERAL Torque converter pilot bearing Lubricant on installation Molykote BR2S or BR2 plus DAF LF Gearbo...

Page 26: ...se these bolts and nuts are of exactly the same length and property class as those removed Gearbox Flexplates Selector switch Speed sensor Oil sump PTO cover Plugs Hydraulic lines Drive flange Attachm...

Page 27: ...0508 6 3 Allison 1000 2000 automatic gearboxes TECHNICAL DATA 45 55 series 3 0 6 3 FILLING CAPACITIES Gearbox Capacity Allison 1000 2000 series Approx 10 litre DAF LF Gearboxes and Clutch Service Manu...

Page 28: ...TECHNICAL DATA 6 4 200508 Allison 1000 2000 automatic gearboxes 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 29: ...ble faults in the memory of the ECU Electronic Control Unit The faults can be read at a later date The system is operated and the faults are read via the selector keypad This selector keypad has a dis...

Page 30: ...ts and nuts are replaced it is important that unless stated otherwise these bolts and nuts are of exactly the same length and property class as those removed Gearbox Drive flange Flexplates Oil cooler...

Page 31: ...200508 7 3 Allison MD3060 automatic gearbox TECHNICAL DATA 45 55 series 3 0 2 1 V3 00 883 Oil cooler air bleed plug 1 28 Nm Oil cooler drain plug 2 28 Nm DAF LF Gearboxes and Clutch Service Manual...

Page 32: ...e oil level when cold must be on the Cold full mark Type of gearbox Capacity at first filling Capacity at second filling MD 3060P 4 oil sump 27 litres 20 litres HOT FULL COLD FULL HOT ADD COLD ADD W 3...

Page 33: ...ICAL DATA 45 55 series 3 0 8 CLUTCH 8 1 GENERAL Gearbox Clutch release assembly Clutch plate ZF S5 42 MF 362 WGTZ 1 1 2 ZF S6 850 MF 395 WGTZ 1 1 2 Eaton FS 6309A MF 395 WGTZ 1 1 4 DAF LF Gearboxes an...

Page 34: ...rque mentioned in the overview of standard tightening torques When attachment bolts and nuts are replaced it is important that unless stated otherwise these bolts and nuts are of exactly the same leng...

Page 35: ...200508 8 3 Clutch TECHNICAL DATA 45 55 series 3 0 8 3 FILLING CAPACITIES Clutch First filling approx 0 4 litres DAF LF Gearboxes and Clutch Service Manual...

Page 36: ...TECHNICAL DATA 8 4 200508 Clutch 0 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 37: ...ATA 45 55 series 3 0 9 PROP SHAFTS 9 1 GENERAL Spicer Monotron LF 45 LF 55 12 15 ton LF 55 17 19 ton SPL 39 SPL 55 SPL 55 SPL 70 SPL 70 SPL 70 SPL 100 SPL 100 SPL 100 SPL 140 PEP 5 PEP 6 C2040 DAF LF...

Page 38: ...tly the same length and property class as those removed Drive flange Spicer intermediate bearing Spicer universal joint Spicer suspension bearing Monotron suspension bearing M10 attachment bolts 60 Nm...

Page 39: ...Fault finding table 2 1 200508 3 MECHANICAL GEARBOX 3 1 200508 3 1 Fault finding table 3 1 200508 4 AUTOMATIC GEARBOX 4 1 200508 4 1 Reading deleting Allison MD 3060 fault codes 4 1 200508 4 2 Allison...

Page 40: ...DIAGNOSTICS 2 200508 Contents 1 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 41: ...ust all points in the control Mechanical problem in gearbox See Mechanical gearbox fault finding table COMPLAINT GEARS CANNOT BE ENGAGED Possible cause Remedy Gearbox control pivot and hinge points dr...

Page 42: ...DIAGNOSTICS 1 2 200508 Mechanical gearbox control 1 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 43: ...OO HIGH A SPEED Possible cause Remedy Incorrect VIC frequency value Adjust value COMPLAINT HIGH OR LOW RANGE ENGAGING IS SLOW Possible cause Remedy Air pressure too low Check air supply of circuit 4 P...

Page 44: ...DIAGNOSTICS 2 2 200508 Pneumatic gearbox control 1 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 45: ...oblem in mechanical gearbox control See Mechanical gearbox control fault finding table Range change switch does not work properly See Pneumatic section of gearbox control fault finding table COMPLAINT...

Page 46: ...DIAGNOSTICS 3 2 200508 Mechanical gearbox 1 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 47: ...that there is an active fault in the gearbox No message during reading means that the fault is inactive The ECU can save five active inactive fault codes in its memory and show them on the display Fau...

Page 48: ...ed their causes tracing and remedying as quickly as possible After the fault codes have been deleted the ignition must be switched off and re started otherwise it will not be possible to drive This ca...

Page 49: ...ct your Allison dealer Main code Sub code RECOMMENDED PROCEDURES Speed sensors 22 14 15 16 Check the following points 1 connectors are firmly attached clean and undamaged 2 the speed sensor attachment...

Page 50: ...etween wires or earth in wiring harness to sensor If all these points are in order contact your Allison dealer Coupling 3 pressure switch open 32 00 33 55 77 1 Let the engine idle while the vehicle s...

Page 51: ...lison dealer Hardware software not compatible 36 00 1 Replace ECU if possible 2 Re program ECU if possible 3 If replacement or re programming is not possible contact your Allison dealer Main code Sub...

Page 52: ...nts 1 engine speed sensor and output shaft speed sensor are connected The connectors are undamaged and clean 2 no interruptions or short circuits between wires or earth in sensor wiring 3 let the engi...

Page 53: ...wires or earth in sensor wiring 3 let the engine idle in neutral while the vehicle is on the brake Check the following points 1 specified dip stick 2 oil level If all these points are in order contac...

Page 54: ...lean 2 no interruptions or short circuits between wires or earth in sensor wiring 3 let the engine idle in neutral while the vehicle is on the brake Check the following points 1 specified dip stick 2...

Page 55: ...h servo Gearbox front cover worn or broken Check replace gearbox front cover SYMPTOM PEDAL FORCE TOO HIGH Possible cause Remedy No or insufficient pressure in circuit 4 of the brake system Check circu...

Page 56: ...necessary Clutch release assembly is not released Check clutch release assembly SYMPTOM CLUTCH RELEASE ASSEMBLY FAILS TO RELEASE Possible cause Remedy Fluid level in hydraulic system too low Top up fl...

Page 57: ...mple by excessive caster Check universal joint angle Play in universal joints Replace universal joint Play in suspension bearing Replace suspension bearing Play in slide coupling Replace prop shaft Fo...

Page 58: ...DIAGNOSTICS 6 2 200508 Prop shafts 1 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 59: ...r 1 5 200508 1 6 Overview drawing Eaton gear lever 1 6 200508 2 INSPECTION AND ADJUSTMENT 2 1 200508 2 1 Inspecting and adjusting operating mechanism 2 adjustment options 2 1 200508 2 2 Inspecting and...

Page 60: ...MECHANICAL GEARBOX CONTROL 2 200508 Contents 2 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 61: ...fixed in the neutral position This is done using the special tool The operating mechanism is then adjusted so that everything can be fitted without tension The versions with 4 adjustment options have...

Page 62: ...NTROL 1 2 200508 General 2 45 55 series 3 1 2 OVERVIEW DRAWING OPERATING MECHANISM 2 ADJUSTMENT OPTIONS V3 00 567 1 2 3 4 1 Control rod 2 Torque rod 3 Gearbox lever 4 Ball joint DAF LF Gearboxes and C...

Page 63: ...W DRAWING OPERATING MECHANISM 4 ADJUSTMENT OPTIONS V3 00 566 1 2 3 4 5 6 7 8 9 1 Control rod underneath the cab 2 Ball joint 3 Bracket 4 Torque rod 5 Gearbox lever 6 Ball joint 7 Control rod behind th...

Page 64: ...12 19 18 1 Switch button 11 Clamping pin 2 Gear lever 12 Telescopic control rod 3 Attachment plate 13 Retainer clip 4 Vibration damper 14 Pawl 5 Spring holder 15 Axle 6 Centring spring 16 Plug 7 Beari...

Page 65: ...8 1 5 General MECHANICAL GEARBOX CONTROL 45 55 series 3 2 1 5 OVERVIEW DRAWING ZF GEARBOX GEAR LEVER V3 00 569 1 2 3 1 Switch button 2 Gear lever 3 Bearing housing DAF LF Gearboxes and Clutch Service...

Page 66: ...5 series 3 1 6 OVERVIEW DRAWING EATON GEAR LEVER V3 00 572 1 2 3 4 5 6 7 8 1 Cover plate 2 Attachment nut 3 O ring 4 Switch button 5 Range group operating switch 6 Clamping plate 7 Gear lever 8 Bearin...

Page 67: ...l gears can be engaged without parts coming into contact with each other 3 During a test drive check that the gear remains engaged under changing conditions Adjusting the gearbox control 2 adjustment...

Page 68: ...special tool A DAF no 1453143 it is shown which side of the tool must be used for LHD vehicles and which side for RHD vehicles 8 Hand tighten the lock nuts 3 of the gearbox lever without moving the co...

Page 69: ...cal data 12 Remove the special tool from the ball joint 13 Clean part A of the control rod and remove any grease 14 Apply the specified lubricant lightly to section B of the control rod See Technical...

Page 70: ...ining clip and disassemble the control rods underneath the cab 2 Measure the length of the control rod and compare the measured reading A with the specified reading See Technical data 3 If necessary a...

Page 71: ...ool DAF no 1329488 over the gear lever and inserting the end of the gear lever through the appropriate opening 14 Fit the special tool DAF no 1453143 between the ball joint 1 and the arm 2 Centre the...

Page 72: ...e torque rod in such a way that it can be positioned in the control rod without tension Tighten the attachment nut 1 to the specified torque See Technical data 18 Tighten the lock nuts 2 on the torque...

Page 73: ...the gear change pattern from the top of the switch button 2 Remove the attachment nut from the switch button 3 Remove the switch button 4 Remove the gaiter 5 Position the gear lever as far forward as...

Page 74: ...r 3 Pull the gaiter over the switch button and remove the clamping strap 1 4 Remove the gaiter Installing gaiter 1 Fit a new clamping strap on the inside of the gaiter 2 Fit the top of the gaiter insi...

Page 75: ...ttachment bolts of the gear lever on the bottom of the cab Installing gear lever unit 1 Slide the gear lever unit and the telescopic control rod onto the gearbox control and fit the retainer clip 2 In...

Page 76: ...EMOVING AND INSTALLING CONTROL ROD UNDERNEATH THE CAB Removing control rod underneath the cab 1 Remove the retainer clip 2 of the telescopic control rod 1 2 Remove the attachment nuts from the ball jo...

Page 77: ...ply the specified lubricant lightly to section C of the control rod See Technical data 4 Fit the control rod 3 into the telescopic control rod 1 and fit the retainer clip 2 5 Tighten the attachment nu...

Page 78: ...ntrol rod behind the cab 1 Remove the attachment nut from the ball joint 2 2 Remove the attachment nut from torque rods 1 and 4 3 Remove the lock nut from the ball joint 5 Note Make sure that the rear...

Page 79: ...ol rod 3 and fit and hand tighten all attachment nuts 3 Tighten all attachment and lock nuts to the specified torque See Technical data Note Make sure that the control rod does not turn while the atta...

Page 80: ...MECHANICAL GEARBOX CONTROL 3 8 200508 Removal and installation 2 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 81: ...508 2 3 Electropneumatic downshift protection valve 2 4 200508 2 4 Neutral position valve 2 5 200508 2 5 Range group engaging cylinder 2 6 200508 3 INSPECTION AND ADJUSTMENT 3 1 200508 3 1 Programming...

Page 82: ...PNEUMATIC GEARBOX CONTROL 2 200508 Contents 3 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 83: ...3 1 GENERAL 1 1 LOCATION OF COMPONENTS IN PNEUMATIC SECTION OF GEARBOX CONTROL 1 4 3 2 V3 00 360 1 Filter governor 2 Neutral position valve 3 Electropneumatic downshift protection valve 4 Range group...

Page 84: ...00 359 4 5 6 2 1 3 1 VIC electronic unit 2 Electropneumatic downshift protection valve 3 Range group engaging cylinder 4 Neutral position valve 5 Filter governor 6 Range group operating switch L Posit...

Page 85: ...e filter governor 5 From the filter governor the system pressure goes to the neutral position valve 4 and the range group operating switch 6 located on the ball of the gear lever When the range group...

Page 86: ...s is so as to prevent damage to the drive line When the vehicle speed is low enough the electropneumatic downshift protection valve is activated and the system pressure goes from the neutral position...

Page 87: ...LTER GOVERNOR Overview drawing filter governor Filter governor 1 on gearbox 2 3 4 1 5 V300558 2 6 5 4 3 2 1 10 9 8 V300430 7 1 Filter governor 2 Filter element 3 Seal 4 O ring 5 Cover 6 Plug 7 Output...

Page 88: ...s through the air filter The supply pressure goes through the bore 1 in the valve and will force the piston down against the spring pressure The spring cannot be adjusted The system pressure see Techn...

Page 89: ...en or is being engaged When the switch is facing up the high speed range has been or is being engaged Pre selection is possible A particular range is switched only when the gear lever is moved through...

Page 90: ...tropneumatic downshift protection valve and earth will be broken Despite the pneumatic command from the range group operating switch to connection point 4 on the electropneumatic downshift valve it is...

Page 91: ...slot When a gear is engaged the neutral position valve pawl moves out of the slot thereby switching the valve In the neutral position the system pressure is sent to the electropneumatic downshift prot...

Page 92: ...45 55 series 3 2 5 RANGE GROUP ENGAGING CYLINDER The range group engaging cylinder is mounted on the rear of the gearbox The engaging cylinder is supplied from the electropneumatic downshift protectio...

Page 93: ...rate it will be necessary to reprogram the VIC by means of DAVIE XD This is to ensure that the downshift protection valve is enabled and disabled at the correct vehicle speeds It is not possible to ad...

Page 94: ...DELSI to the speed sensor connector an adapter cable must be made The adapter cable must consist of the following wiring When the speed sensor connector is disconnected a fault is stored in the tacho...

Page 95: ...wer range The range group should now switch to the lower range 5 Switch the vehicle ignition off The range group should now automatically switch to the higher range Inspection with the vehicle speed s...

Page 96: ...roximately 40 km h As the vehicle speed increases the range group should automatically switch to the higher range 7 Use DELSI to decrease the simulated vehicle speed slowly to approximately 0 km h As...

Page 97: ...5 55 series 3 3 3 4 INSPECTION FILTER GOVERNOR Inspection filter governor 1 Remove the plug from the extra outlet 9 and install a pressure gauge 2 Check the service pressure See Technical data 6 5 4 3...

Page 98: ...PNEUMATIC GEARBOX CONTROL 3 6 200508 Inspection and adjustment 3 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 99: ...Remove the two attachment bolts from the filter governor and remove the filter governor Installation filter governor 1 Install the filter governor on the attachment bracket Tighten the attachment bolt...

Page 100: ...the range change switch using a small screwdriver 8 Remove the range change switch and the clamping piece Installing range group operating switch 1 Install the clamping piece on the gear lever 2 Conne...

Page 101: ...er element 2 with cold water and soap or replace if necessary 4 Blow clean the filter element 2 and the housing 1 from the inside with compressed air 5 Replace the O ring 4 and the sealing ring 3 if n...

Page 102: ...PNEUMATIC GEARBOX CONTROL 5 2 200508 Cleaning 3 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 103: ...1 200508 3 2 Inspecting and adjusting input shaft pre load 3 2 200508 4 REMOVAL AND INSTALLATION 4 1 200508 4 1 Removing and installing the gearbox 4 1 200508 4 2 Removing and installing drive flange...

Page 104: ...ZF S5 42 GEARBOX 2 200508 Contents 4 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 105: ...box This data can also be found on the vehicle identity card for the vehicle concerned V300049 1 2 4 5 3 8 6 7 10 9 1 Type of gearbox 2 ZF serial number 3 Parts list ZF 4 Specification number 5 Pulse...

Page 106: ...series 3 1 2 SYSTEM DESCRIPTION GEARBOX The gearbox consists of five synchromesh forward gears and one non synchromesh reverse gear The fifth gear is close ratio or wide ratio depending upon the model...

Page 107: ...ENTS 2 1 SYNCHRONISER B lock synchronisation The synchroniser consists of the following parts 1 8 2 2 7 4 7 1 6 2 3 3 2 5 1 gear wheel 2 selector ring 3 synchromesh ring 4 selector sleeve 5 pressure s...

Page 108: ...ve freely around the main shaft 8 If the selector sleeve 7 is shifted to the right from the neutral position the synchromesh ring 3 is pushed against the friction cone of the selector ring 2 by the th...

Page 109: ...t 8 The bevelled sides of the teeth on the synchromesh ring 3 and selector sleeve 7 cause synchromesh ring 3 to be turned back slightly after synchronisation This releases the lock and allows selector...

Page 110: ...ZF S5 42 GEARBOX 2 4 200508 Description of components 4 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 111: ...oil 1 Place the vehicle on a flat and level surface 2 Wait for some minutes to allow the oil to flow back 3 Remove the level check filler plug 2 and check the oil level 4 The oil level must reach the...

Page 112: ...1 Remove the gearbox See Removal and installation 2 Remove the gearbox front cover from the input shaft See Removal and installation 3 Uniformly press the outer bearing race 4 so that the bearing is...

Page 113: ...r measure the thickness of the oil baffle 6 8 Calculate the thickness of the adjusting ring 5 according to the following example 9 Compare the value of the adjusting ring with the calculated value and...

Page 114: ...ZF S5 42 GEARBOX 3 4 200508 Inspection and adjustment 4 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 115: ...he gearbox 6 Remove the clamping strip from the exhaust pipe 7 Remove the attachment bolt of the rubber suspension point on the end of the exhaust 8 Twist the end pipe of the exhaust loose and remove...

Page 116: ...means of new self locking nuts 5 Install the elbow of the gearbox control on the selector finger Use a new self locking nut 6 Fit the exhaust bracket 7 Install the compressor pipe bracket 8 Fit the el...

Page 117: ...t Remove the special tool from the drive flange Note Do NOT use the old lock nut again 7 Using special tool DAF no 0484978 remove the drive flange from the main shaft Installing drive flange 1 Heat th...

Page 118: ...OIL SEAL Removing output shaft oil seal 1 Remove the drive flange 2 Prise the seal 2 out of the rear housing of the gearbox Installing output shaft oil seal 1 Using special tool DAF no 0694816 1 fit...

Page 119: ...out of the gearbox front cover Inspect the O ring If it is damaged replace the O ring Installing gearbox front cover oil seal 1 Fit the oil seal using special tool DAF no 1240498 1 at the right depth...

Page 120: ...Take the shifting arm 12 and the protective cover 11 off the selector shaft 3 Remove the spring washer 5 Drive the selector shaft 7 out of the selector finger and the housing 4 Remove the retainer 3 f...

Page 121: ...special tool DAF no 0192546 on the selector shaft 7 Fit the selector shaft 5 Heat the selector finger 6 to a max of 100 C Install the selector shaft 7 in the old position according to the markings ma...

Page 122: ...ZF S5 42 GEARBOX 4 8 200508 Removal and installation 4 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 123: ...surface 2 Drain the gearbox at operating temperature using drain plug 1 Filling gearbox 1 Clean the drain plug and fit it tightening to the specified torque see Technical data 2 Fill the oil through...

Page 124: ...ZF S5 42 GEARBOX 5 2 200508 Draining and filling 4 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 125: ...2 200508 3 3 Inspection and adjustment secondary shaft axial play 3 3 200508 4 REMOVAL AND INSTALLATION 4 1 200508 4 1 Removing and installing gearbox BE engine 4 1 200508 4 2 Removing and installing...

Page 126: ...ZF 6S 850 GEARBOX 2 200508 Contents 5 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 127: ...box You can also find this data on the identity card for the vehicle concerned ZF gearbox type plate V300049 1 2 4 5 3 8 6 7 10 9 1 Type of gearbox 2 Serial no ZF 3 Parts list ZF 4 Specification no 5...

Page 128: ...0 GEARBOX The gearbox consists of six synchromesh forward gears and one non synchromesh reverse gear The first and second gears have double cone synchronisation The sixth gear is a direct drive or an...

Page 129: ...NENTS 2 1 SYNCHRONISER B lock synchronisation The synchroniser consists of the following parts 1 8 2 2 7 4 7 1 6 2 3 3 2 5 1 gear wheel 2 selector ring 3 synchromesh ring 4 selector sleeve 5 pressure...

Page 130: ...ediately turns the synchromesh ring 3 as far as a stop on the selector sleeve support 4 which is not in the figure and thus prevents further movement of selector sleeve 7 As a result of continued pres...

Page 131: ...uble cone is used This synchroniser consists of an outer and an inner ring synchromesh rings connected to the main shaft of the gearbox by means of the selector sleeve support The ring between the two...

Page 132: ...ZF 6S 850 GEARBOX 2 4 200508 Description of components 5 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 133: ...oil ZF 6S 850 gearbox 1 Position the vehicle on a level surface 2 Wait for some minutes to allow the oil to flow back 3 Remove the level check plug and check the oil level 4 The oil level must reach t...

Page 134: ...cover distance A 5 Install a new gasket in the gearbox housing Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distance B 6 Calculate the play as follows...

Page 135: ...o that the bearing gets set 2 Use a depth gauge to determine the distance between the outer bearing race and the gearbox housing A 3 Compare the measured value with the specified permissible value See...

Page 136: ...ZF 6S 850 GEARBOX 3 4 200508 Inspection and adjustment 5 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 137: ...que rod bracket and the lever on the selector shaft 6 Remove the prop shaft and secure it so that it does not interfere with further operations 7 Remove the exhaust pipe between the engine brake and t...

Page 138: ...t bolts around the gearbox 4 Install the clutch servo and tighten the attachment bolts 5 Fit the exhaust pipe between the engine brake and the silencer 6 Fit the drive flange 7 Fit the shift control 8...

Page 139: ...he clamping strip from the exhaust pipe 6 Remove the attachment bolt of the rubber suspension point on the end of the exhaust 7 Twist the end pipe of the exhaust loose and remove it 8 Remove the attac...

Page 140: ...he clutch cylinder 9 Install the exhaust pipe fasten it with the clamping strap and fit the attachment bolt of the suspension rubber 10 Install the prop shaft intermediate bearing if it has been remov...

Page 141: ...washer 5 Using special tool DAF no 0484978 remove the drive flange from the shaft Installing the drive flange 1 Heat the drive flange to a temperature of max 120 C 2 Oil the output shaft lightly and...

Page 142: ...t shaft See Technical data 2 Around the oil seal clean the gearbox housing without letting dirt into the gearbox 3 Apply a small amount of liquid gasket to the outside of oil seals fitted with a steel...

Page 143: ...Installing the gearbox front cover oil seal 1 Apply a small amount of sealant to the outside of oil seals fitted with a steel cover Apply a small amount of green soap to the outside of oil seals fitte...

Page 144: ...attachment bolts and remove the selector shaft housing assembly from the gearbox Seal the gearbox opening so that no dirt can enter 3 Remove the locking pin and control stop from the selector shaft h...

Page 145: ...e to the oil seal lips 2 Fit the special tool DAF no 0694817 a guide sleeve over the selector shaft and fit the selector fingers and the gear lever lock into the selector housing Fit the selector shaf...

Page 146: ...special tool DAF no 0694818 Press the bearing bush on the spring side 2 mm under the edge Installing selector shaft oil seal 1 Apply a small of amount of liquid gasket to the oil seal and fit it in th...

Page 147: ...d horizontal surface 2 Drain the gearbox at operating temperature using plug B Filling the gearbox 1 Clean the drain plug and fit it tightening to the specified torque see Technical data 2 Top up oil...

Page 148: ...ZF 6S 850 GEARBOX 5 2 200508 Draining and filling 5 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 149: ...haft bearing axial play 2 2 200508 3 REMOVAL AND INSTALLATION 3 1 200508 3 1 Removal and installation gearbox assembly 3 1 200508 3 2 Removal and installation drive flange 3 3 200508 3 3 Removal and i...

Page 150: ...EATON FS 6309A GEARBOX 2 200508 Contents 6 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 151: ...y card for the vehicle concerned Eaton gearbox type plate The Eaton specification number is unique to each customer and gives detailed information on the development level of the gearbox The number mu...

Page 152: ...ynchronisation In the low range planetary system engaged the crawler gear and gears 1 2 3 and 4 can be engaged In the high range planetary system disengaged gears 5 6 7 and 8 can be engaged The switch...

Page 153: ...ed oil 1 Position the vehicle on a level surface 2 Wait for some minutes to allow the oil to flow back 3 Remove the level check filler plug 1 and check the oil level 4 The oil level must reach the rim...

Page 154: ...adjust the axial play by means of a thicker or thinner adjusting ring 2 Adjustment input shaft bearing axial play 1 Remove the circlip 1 of the input shaft bearing 2 Remove the adjusting ring 2 3 Plac...

Page 155: ...the intermediate pipe and remove it 6 Remove the end of the exhaust by removing the clamping strap and the attachment bolt of the rubber suspension point at the end of the exhaust 7 Remove the attachm...

Page 156: ...he compressor pipe bracket 8 Install the electronic connectors on the gearbox 9 Fit the clutch cylinder 10 Fit the air pipes 11 Install the intermediate bearing of the prop shaft and tighten the bolts...

Page 157: ...nut and washer 6 Remove the flange with a suitable puller Note In order to prevent the synchroniser for the high low transmission ratios from coming loose the output shaft must not slide out of the b...

Page 158: ...surfaces of the oil seal and the seal housing Installing output shaft oil seal 1 Press the oil seal into the oil seal housing using special tool DAF no 1329358 2 Apply sealant to the contact surface...

Page 159: ...t cover Clean the contact surfaces of the gearbox front cover and the gearbox housing 3 Remove the oil seal from the gearbox front cover Installing gearbox front cover oil seal 1 Fit the seal in the g...

Page 160: ...tive to the selector shaft 17 2 Remove the selector shaft lever with the gearbox control attached to it If necessary disconnect the torque rod 3 Remove the rubber sleeve 2 4 Drain the air reservoirs a...

Page 161: ...d vice 8 Remove the retaining cover 5 and pull out the retaining spring 6 and pin 7 9 Remove the bleeder 20 10 Remove the end cover 14 and the spring clip 13 11 Remove the spring holders 11 the spring...

Page 162: ...t 17 via the plug opening Remove the selector finger and the selector shaft 14 Remove the oil seal 3 from the selector shaft housing If necessary the selector shaft bearing bushes 4 and 9 can now also...

Page 163: ...ector shaft housing 15 with the long groove and the hole for the pin 19 pointing towards the rear 3 Fit the selector shaft 17 into the selector shaft housing 4 Make sure that the holes in the selector...

Page 164: ...ent bolts to the specified torque See Technical data 9 Fit the rubber sleeve 2 10 Tighten the bleeder 20 to the specified torque See Technical data 11 Fit the bleed control valve and pin 16 and tighte...

Page 165: ...nd level check filler plug 1 and drain the oil 3 Clean the oil strainer 4 in a suitable solvent and dry thoroughly Filling gearbox 1 Check and replace the O ring 3 and the sealing ring 2 if necessary...

Page 166: ...EATON FS 6309A GEARBOX 4 2 200508 Draining and filling 6 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 167: ...1 Checking oil level 3 1 200508 3 2 Inspecting and adjusting selector cable 3 3 200508 4 REMOVAL AND INSTALLATION 4 1 200508 4 1 Removing and installing entire gearbox 4 1 200508 4 2 Removing and ins...

Page 168: ...ALLISON 1000 2000 AUTOMATIC GEARBOXES 2 200508 Contents 7 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 169: ...s from the push button selector block the selector switch the accelerator pedal and several speed sensors On the basis of these signals the electronic unit computes the ideal switching moment The torq...

Page 170: ...stricted as regards changing up and down ceases to respond to changes from the selector lever ceases to respond to changes from the selector lever from the neutral position During a fault changes of d...

Page 171: ...ing and stopping the engine and for longer stationary periods when the engine is idling The gearbox must not be put in the neutral position when driving In the drive position D the gearbox automatical...

Page 172: ...tch is mounted on the gearbox housing The selector switch communicates the selector shaft angular displacement to the ECU Before the vehicle can be started the electronic unit must receive a signal fr...

Page 173: ...position and release the service brake 5 Remove the dipstick when the engine is idling and wipe it clean with a lint free cloth Note To take the dipstick out of the holder the sealing cap must be held...

Page 174: ...he dipstick and check the oil level 5 Remove the dipstick and check the oil level The oil level should be between the Hot add and Hot full marks 6 Clean the dipstick with a lint free cloth and put it...

Page 175: ...if applicable 4 Unscrew the lock nut 3 from the connecting pin 4 5 Determine the central position C of the connecting pin by first pushing the selector cable in A and then pulling it out B Mark the l...

Page 176: ...ALLISON 1000 2000 AUTOMATIC GEARBOXES 3 4 200508 Inspection and adjustment 7 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 177: ...om and to the oil cooler 4 Plug the external oil pipes after removing and or detaching them to prevent dirt entering the oil system 5 Disconnect the gearbox wiring harness connectors and secure the wi...

Page 178: ...orque converter to prevent noise after fitting See Technical data 2 If necessary fit the PTO 3 Fit the prop shaft 4 Fit the wiring harness connectors 5 Fit the oil pipes from and to the oil cooler 6 F...

Page 179: ...ove the connectors from the selector switch 5 Take the attachment bolts out of the selector switch and remove it Fitting selector switch 1 Put the selector shaft in the neutral position See the marks...

Page 180: ...ing loosened or tightened While loosening or tightening the attachment nut lock the selector shaft using the selector arm and an appropriate tool 6 Fit the selector cable into the selector arm Note Th...

Page 181: ...l seal and turn special tool DAF no 0484899 into the oil seal Pull the oil seal out of the gearbox housing using special tool DAF no 0694928 Installing output shaft oil seal 1 Fit the new oil seal as...

Page 182: ...tachment nut is being loosened or tightened While loosening or tightening the attachment nut lock the selector shaft using the selector arm and an appropriate tool 4 Remove the selector switch 5 Fit s...

Page 183: ...AF no 1451992 5 Fit the selector arm onto the selector shaft and tighten the attachment nut to the specified torque See Technical data The selector shaft must not be turned while the attachment nut is...

Page 184: ...e wear in the gearbox and the cause must be ascertained 4 Clean the magnetic rings and the contact surfaces on the gearbox housing and the heat exchanger Installing oil filters 1 Fit the magnetic ring...

Page 185: ...g temperature approx 71 C 93 C so that the oil can be drained more quickly and more completely 2 Place the vehicle on a level and horizontal surface 3 Remove the drain plug from the gearbox oil sump 4...

Page 186: ...ck holder with the specified quantity of oil see Technical data 3 Start the engine and run it at idling speed 4 If only gearbox oil escapes tighten the bleed screw 3 to the specified torque See Techni...

Page 187: ...200508 3 INSPECTION AND ADJUSTMENT 3 1 200508 3 1 Checking automatic gearbox oil level 3 1 200508 3 2 Checking oil level with selector keypad 3 3 200508 4 REMOVAL AND INSTALLATION 4 1 200508 4 1 Remo...

Page 188: ...ALLISON MD 3060 AUTOMATIC GEARBOX 2 200508 Contents 8 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 189: ...a later date The system is operated and the faults are read via the selector keypad This selector has a display and is located immediately next to the driver s seat The selector replaces the gear leve...

Page 190: ...e the vehicle to a safe place as soon as possible and switch the ignition off It will no longer be possible to shift the gearbox to neutral The ECU will prevent this After approximately 30 seconds sta...

Page 191: ...display has not disappeared the engine must be turned off and contact made with the nearest DAF dealer Use of the engine brake When the engine brake is operated in third or a higher gear the ECU will...

Page 192: ...ALLISON MD 3060 AUTOMATIC GEARBOX 1 4 200508 General 8 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 193: ...ely begin to move if the brake system is at pressure and the vehicle is not on the parking brake It is therefore advisable to depress the brake pedal before selecting position D In this position the g...

Page 194: ...is can be desirable on unpaved terrain Economy program The LED lights up on the selector display This program will in general change gear at somewhat lower engine speeds This results in more economica...

Page 195: ...again as this prompts the diagnostic code reading function All diagnostic codes are preceded by the letter D followed by a number between 1 and 5 In this function important fault codes could be delet...

Page 196: ...ALLISON MD 3060 AUTOMATIC GEARBOX 2 4 200508 Description of components 8 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 197: ...ion and release the service brake 5 Remove the dipstick when the engine is idling and wipe it clean with a lint free cloth Note To take the dipstick out of the holder the sealing cap must be held whil...

Page 198: ...tick back 4 Remove the dipstick and check the oil level 5 The oil level should be between the Hot add and Hot full marks 6 Clean the dipstick with a lint free cloth and put it back 7 Remove the dipsti...

Page 199: ...4 Press both arrow keys on the selector keypad simultaneously The display now shows the letters O and L Note O and L stand for Oil Level 5 When the oil level is correct the letters O K appear on the d...

Page 200: ...ALLISON MD 3060 AUTOMATIC GEARBOX 3 4 200508 Inspection and adjustment 8 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 201: ...iller pipe to avoid damage 3 Plug the external oil pipes after removing and or detaching them to prevent dirt entering the oil system 4 Disconnect the gearbox wiring harness connectors and secure the...

Page 202: ...pecified torque See Technical data 3 Install the PTO Tighten the attachment bolts to the specified torque See Technical data 4 If necessary fit the hydraulic pipes and or prop shaft Tighten the attach...

Page 203: ...t and secure it so that it does not interfere with further operations 2 Unscrew the attachment bolt 5 of the flange without removing it from the locking plate 3 Remove the bolt and locking plate from...

Page 204: ...ox housing using special tool DAF no 1240037 3 Apply a small amount of grease to the oil seal lips and slide the flange over the output shaft until it abuts 4 Fit new sealing rings 2 3 to the locking...

Page 205: ...it for wear particles Note If there are large wear particles in the wear swarf this indicates excessive wear in the gearbox and the cause must be ascertained 4 Clean the magnetic ring and the contact...

Page 206: ...ng oil filters 1 Lubricate the new O rings with clean gearbox oil and fit the various O rings on the filter covers Note Compare the new O rings to the old ones to ensure that the correct O rings are u...

Page 207: ...ed oil Draining gearbox 1 Bring the gearbox to operating temperature approx 71 C 93 C before the oil is drained so that the oil can be drained more quickly and more completely 2 Place the vehicle on a...

Page 208: ...nstallation 3 Fill the gearbox through the dipstick holder with the specified quantity of oil see Technical data 4 Check that the oil level reaches the Cold full mark Note To take the dipstick out of...

Page 209: ...AND ADJUSTMENT 4 1 200508 4 1 Inspecting clutch servo 4 1 200508 4 2 Checking clutch fluid level 4 4 200508 5 REMOVAL AND INSTALLATION 5 1 200508 5 1 Removal and installation clutch servo 5 1 200508...

Page 210: ...CLUTCH 2 200508 Contents 9 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 211: ...amage the paintwork of the vehicle Any contact between hydraulic fluid and paintwork should therefore be avoided Always use new and clean hydraulic fluid which has been kept in a sealed container that...

Page 212: ...CLUTCH 1 2 200508 Safety instructions 9 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 213: ...s used in the clutch release assembly A diaphragm spring constitutes a simple strong and cost effective construction Another advantage of the diaphragm spring is that the pressure exerted on a new clu...

Page 214: ...Piston seal 4 Push rod 20 O ring 5 Attachment ring for push rod 21 O ring 6 Split seal 22 Piston 7 Piston 23 Pressure spring 8 Piston seal 24 O ring 9 Conical spring 25 Spring seat housing 10 Circlip...

Page 215: ...55 series 3 9 2 3 OVERVIEW DRAWING CLUTCH LEVER ATTACHMENT TO CLUTCH HOUSING V300397 1 2 3 4 6 7 5 1 Screw adapter 2 Ball joint 3 Clutch lever 4 Thrust bearing 5 Clip 6 Claw 7 Yoke pin DAF LF Gearbox...

Page 216: ...CLUTCH 2 4 200508 General 9 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 217: ...TCH SERVO Declutching Depressing the clutch pedal results in a build up of hydraulic pressure This causes the servo piston 1 to push the air valve 2 away from the valve seat against the force of the s...

Page 218: ...ydraulic pressure status when the clutch pedal is not depressed any further The servo piston 1 again seals off against the valve seat closing the air supply and stopping the build up of pneumatic pres...

Page 219: ...1 will move towards the end mark 3 When the indicator 1 reaches the end mark 3 it may be assumed that the clutch plate is due to be replaced Automatically adjusting clutch release assembly Check that...

Page 220: ...he thrust bearing do not use any grease The gearbox front cover must be thoroughly cleaned before the thrust bearing is mounted The grease will attack the plastic coating and shorten the service life...

Page 221: ...it may damage the paintwork of the vehicle Any contact between hydraulic fluid and paintwork should therefore be avoided Always use new and clean hydraulic fluid which has been kept in a sealed contai...

Page 222: ...ressurise the air system 2 Check for any air leakage via the clutch servo bleed vent 3 Depress the clutch pedal and check whether there is any leakage via the clutch servo bleed vent 3 2 7 1 10 8 9 A...

Page 223: ...leakage via the vent opening 10 Note A drop of oil on the vent opening 10 is normal and is not a reason to replace the clutch servo If there is constant leakage the clutch servo must be repaired or r...

Page 224: ...paintwork should therefore be avoided Always use new and clean hydraulic fluid which has been kept in a sealed container that meets the specifications Hydraulic fluid which has absorbed water from th...

Page 225: ...he ambient air may have an adverse effect on the operation of the clutch system Avoid any contact with mineral oil Even one drop of mineral oil in the system will damage the seals Removing clutch serv...

Page 226: ...grease should be used on the gearbox front cover The grease will attack the plastic coating and shorten the service life of the thrust bearing 1 Check the clutch lever for wear 2 Check the pressure fi...

Page 227: ...ossible to remove the complete support point 1 by turning the attachment point out of the clutch housing Fitting clutch lever 1 Apply a little grease to the moving parts of the clutch lever 2 Lock the...

Page 228: ...iding it off the four studs 6 Remove the clutch plate with the dummy input shaft Installing clutch release assembly clutch plate 1 Check the free movement of the clutch plate on the splines of the gea...

Page 229: ...clutch plate 3 Use an internal puller 2 to remove the pilot bearing 1 from the flywheel Fitting pilot bearing 1 Check the flywheel bore for dirt and damage Note The pilot bearing 1 has a grease and du...

Page 230: ...and installation 9 45 55 series 3 2 Use a plastic mallet to install the bearing in the flywheel 3 Fit the clutch release assembly and clutch plate 4 Fit the gearbox W 3 04 017 V300989 DAF LF Gearboxes...

Page 231: ...ydraulic pipe 3 Remove the attachment screw from the fastening bridge 1 4 Using a screwdriver press the lock levers 2 back and remove the fastening bridge 1 5 Screw the plastic fastening jig 1 out of...

Page 232: ...e plastic fastening jig 1 around the clutch cylinder push rod and fit the switch control 2 over the jig 4 Screw the plastic fastening jig 1 into the pedal 5 Fit the spring 2 if it has been removed 6 F...

Page 233: ...lic fluid which has been kept in a sealed container that meets the specifications Hydraulic fluid which has absorbed water from the ambient air may have an adverse effect on the operation of the clutc...

Page 234: ...ambient air may have an adverse effect on the operation of the clutch system Avoid any contact with mineral oil Even one drop of mineral oil in the system will damage the seals Bleeding the clutch sy...

Page 235: ...leeding the clutch system via the clutch servo Note Sometimes it may be difficult to bleed the clutch system In such cases the clutch system can also be bled using a priming pump and the bleed nipple...

Page 236: ...CLUTCH 6 4 200508 Draining and filling 9 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 237: ...200508 2 1 Inspection prop shaft 2 1 200508 3 REMOVAL AND INSTALLATION 3 1 200508 3 1 Removing and installing Spicer prop shaft intermediate shaft assembly 3 1 200508 3 2 Removal and installation pro...

Page 238: ...PROP SHAFTS 2 200508 Contents 10 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 239: ...5 55 series 3 10 1 GENERAL 1 1 OVERVIEW DRAWING SPICER PROP SHAFT 1 2 3 4 5 6 7 V3 00 747 1 Intermediate shaft 2 Suspension bearing 3 Prop shaft 4 Clamping piece 5 Fork 6 Slider 7 Prop shaft DAF LF Ge...

Page 240: ...General 10 45 55 series 3 1 2 OVERVIEW DRAWING MONOTRON PROP SHAFT V300999 A B C E F A B B D A Drive flange B Fork C Intermediate shaft D Suspension bearing E Slider F Prop shaft DAF LF Gearboxes and...

Page 241: ...PECTION PROP SHAFT Inspection prop shaft 1 Check the universal joints and suspension bearing for play and damage 2 Check the slide coupling for radial play 3 There must be no clearly perceptible play...

Page 242: ...PROP SHAFTS 2 2 200508 Inspection and adjustment 10 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

Page 243: ...o avoid damage and subsequent imbalance Support the shaft in at least two places If possible hang the shaft in a hoist using two sturdy ropes 1 Remove the attachment bolts from the flanges and or clam...

Page 244: ...zontally to avoid damage and subsequent imbalance Support the shaft in at least two places If possible hang the shaft in a hoist using two sturdy ropes 2 Remove the attachment bolts from the flanges a...

Page 245: ...shaft and or intermediate shaft assembly 2 Remove the circlips and the attachment bolts of the clamping pieces 1 of the spider to be replaced 3 Place the shaft on a bush underneath a press as shown a...

Page 246: ...r including bearings and drive flange down until the spider touches the fork of the drive flange 8 Rotate the drive flange 180 and remove the bearing that has just been pressed out Place the drive fla...

Page 247: ...intenance free spiders do not have a mounting direction In the case of spiders fitted with lubricating nipples hole A for the lubricating nipple must point towards the shaft 4 Slide the spider a littl...

Page 248: ...shaft 8 Slide the spider a little into the fitted bearing and place everything on a bush underneath a press The opposite bearing can now be pressed into the fork the spider serving as a guide During...

Page 249: ...SASSEMBLY AND ASSEMBLY UNIVERSAL JOINT Disassembly universal joint 1 Remove the prop shaft and or intermediate shaft assembly 2 If fitted remove the lubricating nipple and all Seeger rings from the sp...

Page 250: ...e down until the spider touches the fork of the shaft 4 Rotate the shaft 180 and remove the bearing that has just been pressed out If the first bearing to be removed fails to come out of the fork enti...

Page 251: ...e bush 9 Push the spider down again in the direction of the shaft fork Again continue until the spider touches the fork 10 The spider can now be tipped out of the drive flange fork Note When spiders a...

Page 252: ...lubricating nipples hole A for the lubricating nipple must point towards the shaft 4 Slide the spider a little into the installed bearing and place everything on a bush underneath a press The opposite...

Page 253: ...op shaft 8 Slide the spider a little into the installed bearing and place everything on a bush underneath a press The opposite bearing can now be pressed into the fork the spider serving as a guide Du...

Page 254: ...PROP SHAFTS 4 10 200508 Demounting and mounting 10 45 55 series 3 DAF LF Gearboxes and Clutch Service Manual...

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