Iveco Stralis AT/AD. Manual — part 69
12
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
TOOL NO.
DESCRIPTION
99322205
Revolving stand for overhauling units
99322225
Units holder (to be used with stand 99322205)
99345097
Thrust block for pullers
99347101
Puller, large size (to be used with relevant special rings)
99347148
Ring grips to remove fixed sleeves of 1st - 2nd speed
(to be used with 99347101)
99360502
Eyebolt to lift the reduction gear and transmission shaft box
GEARBOX ZF 9 S 109 D.D.
13
S
TRALIS
AT/AD
EQUIPMENT
TOOL NO.
DESCRIPTION
99370006
Handle for interchangeable drivers
99370113
Driver to fit the bushes in the gear control cover
99370449
Hook to lift the main shaft
99370465
Tool to set the safety plates of output flange screws
99370629
Support for holding the gearbox during removing/refitting from/on
vehicle
99371052
Brackets to hold the gearbox during overhaul
(to be used with 99322205-9932225)
14
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
TOOL NO.
DESCRIPTION
99374357
Connection tool for assembling ring. operations on front gearbox
cover (to be used with 99370006)
99374139
Connection tool for assembling ring. operations on rear gearbox cover
(to be used with 99370006)
Drain the lubricating oil from the gearbox and remove the side
cover from the reverse speed transmission gear opening (4).
Set the unit on the revolving stand 99322205 (3) c.w.support
99322225 (1) and brackets 99371048 (2).
Take note of the assembling position of pipe on the cylinder
and remove the cylinder.
37590
30981
37592
37593
Figure 3
Figure 4
Figure 5
Figure 6
Set the gearbox vertical with the E.R.U. box turned upwards;
remove the pin (1) and relevant gasket, the gear range indica-
tor light switch (2) and relevant gasket and the ball (3).
Remove the nuts and screws that fasten the E.R.U box to the
gearbox. Apply eyebolts 99360502 (1) to the flange, engage
the eyebolts to the cables, then, use a hoister to remove the
E.R.U. box (2) from the gearbox.
Check the conditions of planetary gears (1).
If faults are found out, remove the spring retaining ring (2), set
block 99345097 (6) on the main shaft (3) and use a puller (4)
and clamp (5) to remove the planetary gears (1) from the main
shaft (3).
Reverse the disassembling operations and comply with the in-
structions below.
If the planetary gears (1) are to be replaced, at assembling
stage the new part shall be heated at 160 to 180
° C for 15’
and set on the main shaft (3) so that the oil holes (
→) in the
gear coincide with those in the shaft. Select a spring retaining
ring, out of those supplied spare (2), featuring suitable thick-
ness free from backlash when bedded in its seat. Paper and
metal gaskets shall be replaced with new ones.
Tighten screws and nutS to proper torque.
Reassembling the E.R.U.box
GEARBOX ZF 9 S 109 D.D.
15
S
TRALIS
AT/AD
533010
REMOVAL
Removing the E.R.U.box
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