Iveco Stralis AT/AD. Manual — part 97
124
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
S
TRALIS
AT/AD
Base - January 2003
TOOL NO.
DESCRIPTION
99370629
Mount to support gearbox when removing and fitting it back on the
vehicle
99374092
Drift to mount outer races of bearings (69
÷ 91) (use with
99370007)
99374221
Driver to mount seals on back cover
99374336
Driver to fit seals on the front cover of the gearbox (use with
99370006)
99395604
Dial gauge (0 - 10 mm)
Figure 4
Checks
The gears, synchronizer rings, coupling bodies and sliding
couplings must show no sign of failure or excessive toothing
wear.
The main shaft must have no indentation, especially on the
sliding surfaces of the gear rotation and coupling sleeves.
The reverse idle gear shafts must have a polished surface free
from scoring.
The gearboxes must show no sign of cracking and the bearing
seats must be neither damaged nor worn, so as to prevent the
outer rings of the bearings from turning in their seats.
Check the shoulder spacers are neither worn nor damaged.
The gear coupling forks must show no sign of cracking and the
relevant control rods must slide freely, but without any
appreciable play, in their guide seats.
Check that the shoes of the drive forks are fully efficient.
Check that the holes, grooves and lubrication pipes are not
obstructed by grease or foreign bodies.
Check the bearings are not worn, damaged or overheated.
530210
OVERHAULING THE
GEARBOX
!
Wash the assembly thoroughly before overhauling.
The specific and/or general tools must be used in the
way for which they were designed.
To facilitate assembly, put the removed parts away on
the specific tray in their order of removal.
Upon assembly, the following must always be
replaced with new parts: the gaskets and seals, spring
pins, safety plates and springs. Nuts and screws must
be tightened to the prescribed torque with their
thread dry and degreased.
Keep to the specific regulations when disposing of
lubricant and detergents.
530520
Gearbox actuator
Removal
Unscrew the ring nut (1 and 5) and disconnect the electric
wiring (2) from the speed sensor (6 and 7).
Detach the wiring (2) from the clips (
→) securing it to the
middle box.
Remove the nuts (4) and detach the actuator (3) from the
front box.
Figure 5
78649
78650
Fasten the gearbox (1) to brackets 99322225 (3) on the
rotating stand 99322205 (2).
Remove the plug and bleed the lubrication oil.
The following described and illustrated overhaul
operations regard transmission 16 A6 2601 and, save
different indications, are valid also for transmission 12
AS 2301.
!
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
125
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70828
70863
70830
Figure 6
Figure 7
Figure 8
Figure 9
Set a new gasket (6) on the front case (7).
Lubricate the stems of the solenoid valves (3-4-5) with silicone
grease and put them into a neutral position. Put the rods
(8-9-10) into a neutral position. Fit the actuator (1) on the
front box (7) verifying that the end of the stems of the solenoid
valves is correctly positioned in the seats of the rods (8-9-10).
Tighten the fixing screws (2) to the prescribed torque. After
removing the gearbox from the stand used for overhaul, refit
the clutch actuator (3, Figure 4) and make sure the wiring (2,
Figure 4) is not damaged.
Extract the springs (6-7-8) and the pawls (6).
Block rotation of the sleeve (1) by applying the lever
99370317 (3) and slightly loosen the screws (2).
!
The springs (7 and 8) are of equal length, the spring
(6) is larger.
Remove the pin (4) from the rod (5).
Remove the switch (1) together with the gasket (2) and
extract the cap (3).
78651
Take out the screws (2) and detach the actuator (1) with its
gasket.
!
The electronic control unit is integrated in the
actuator and these cannot be overhauled. See under
the diagnosis heading for the check.
Check that the oil vapour vent (3) is not clogged; if it is, clean
it.
Disconnect speed actuators (1) as described in the relevant
chapter.
Refitting
126
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
S
TRALIS
AT/AD
Base - January 2003
70831
70832
70833
70834
70835
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Remove the screws (1) fixing the plates (2) fastening the pins
(4) and extract these together with the seal (3) from the rear
box (7).
Extract the two centring pins (5). Remove the screws (6).
Fit the eyebolt 99366811 to the sleeve (8) and, using special
ropes and lifter, detach the rear box (7) from the middle one
(9).
Remove the oil pipe (1). Note down the assembly position of
the fork (3) and plugs (6) and remove them. Remove: the rod
(2), synchronizing device assembly (4) and connecting sleeve
(5).
Remove the adjustment ring (3) and the plate (1) together
with the coupling body (2).
Removing the rear box
Remove the screws (3), disc (4) and seal (5) and extract the
sleeve (2) from the spider shaft. Should extraction prove
difficult, use an extractor (1) applied as illustrated in the figure.
Remove the screws (2) and take off the cover (1). Remove the
spider shaft bearing end float adjustment ring (3).
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
127
S
TRALIS
AT/AD
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