Iveco Stralis AT/AD. Manual — part 63
Figure 1
Figure 2
Insert the clutch centring pin 99370264 (1) into the bearing
for the gearbox input shaft.
38438
Figure 3
40194
Fit the mount 99370547 (1) on the hydraulic jack and apply
the mount to the pressure plate (3). Unscrew the screws (2)
and remove the pressure plate from the engine flywheel.
40195
Take out the clutch plate (2) together with the centring pin
99370264 (1).
This operation comprises:
- Removing-refitting propeller shafts (see relevant section
505620).
- Removing-refitting gearbox (see relevant section 530210).
Removal
CHECKS
The checks to make are as follows:
- The supporting surface of the driven disc, on the engine
flywheel, must not be particularly worn or have too
much scoring.
- The toothing of the ring gear of the engine flywheel must
be neither deteriorated nor too badly worn.
If this is not the case, remove the engine flywheel (operation
540850).
In addition, check there is not even the slightest leakage of
lubricant from the seal of the crankshaft rear cover: in which
case, remove the flywheel as described under the relevant
heading. Remove the rear cover together with the seal and
replace it as described in section 2.
Check that the bearing or bushing supporting the gearbox
input shaft mounted on the crankshaft is neither worn nor
deteriorated, in which case it should be replaced.
Check the state of the pressure plate, the supporting surface
of the driven disc must have no deformation, wear or sign of
overheating and its spring or diaphragm must be sound.
Check the state of the driven disc:
- the friction linings must not be too worn, nor have any
sign of overheating, nor be fouled with oil or grease.
- its hub must not have too much play on the gearbox
input shaft.
- the torsion springs of the hub must not turn in their seats
or be broken.
If you find any trouble at all, replace the part concerned.
The clutch assembly is supplied as a spare in kit form.
The following are supplied singly:
- The driven disc and the thrust bearing.
In this case it is necessary to mount the new parts of the same
supply as the torsion spring being reused.
10
CLUTCH
S
TRALIS
AT/AD
Base - January 2003
REMOVING AND REFITTING THE CLUTCH
This operation comprises:
- Removing-refitting propeller shafts (see relevant section
505620).
- Removing-refitting gearbox (see relevant section 530210).
- clutch removal/refitting (operation 505210).
This operation comprises:
- Removing-refitting propeller shafts (see relevant section
505620).
- Removing-refitting gearbox (see relevant section 530210).
Using suitable pliers, open the snap ring (1), take the thrust
bearing (2) out of the pressure plate.
Reverse these steps for fitting.
- Fit the gearbox back on after spreading the splined shaft
with Molikote molybdenum disulphide grease.
- Adjust the push rod of the operator cylinder as de-
scribed under the relevant heading (operation 505272).
505254
REMOVING-REFITTING THE
THRUST BEARING
36800
Figure 4
Figure 5
Figure 6
Before fitting a new driven disc it is necessary to check its cen-
tring as follows:
Position the driven disc (1) on a lathe. Then, with the aid of
a dial gauge with a magnetic base (2), check that the surface
of the disc is not off centre anywhere.
The maximum permissible eccentricity of the driven disc is
0.20 mm.
If the disc is off centre, use a fork wrench (1) as shown in the
figure.
Refitting
Fit the clutch assembly back on by performing the operations
described for removal in reverse order and observing the fol-
lowing instructions:
- Thoroughly clean the supporting surface of the
clutch plate of the engine flywheel with spirits
or petrol. Any light scoring you find on it can
be removed with abrasive cloth.
- Position the driven disc, always using the guide pin for
perfect centring to prevent harmful stresses on the hub
when refitting the gearbox.
- Position the clutch plate by matching the holes for the
fixing screws with the ones on the engine flywheel.
- Mount and lock the fixing screws of the pressure plate
to the required torque.
!
The new part has to be of the same supply as the
pressure plate being reused.
540852
REPLACING THE SUPPORT BEAR-
ING OF THE CLUTCH SHAFT
40196
Using the appropriate pliers remove the split ring (3).
Using the universal extractor 99348004 (1) remove the
bearing (2).
For refitting, use the appropriate beater.
Refit the split ring.
Figure 7
CLUTCH
11
S
TRALIS
AT/AD
Disconnect the piping (2).
Take out the screws (3) and disconnect the steering control
mount (1) from the pedal unit (4).
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84419
72834
72835
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Remove the push-button panels (3 and 5) and the screw caps
(4) from the instrument panel (1). Take out the screws (2 and
4), remove the instrument panel (1) and put it aside.
Disconnect the connections (1) of the windscreen wiper, (2)
of the drive control system and (3) of the immobilizer.
Take out the screws (2), remove the heel rest (1) and lift the
mat (3).
Remove the screws (1 and 3) and the guard (2).
From outside the cab, lift the radiator cowling, extract the
grommet (1) with the wiring from the pedal unit (7). Discon-
nect the piping (5) from the coupling (6). Disconnect the
electric connections (2 and 3) from the control valve (4).
Removal (vehicles with EuroTronic Automated
gearbox)
12
CLUTCH
S
TRALIS
AT/AD
Base - January 2003
REMOVING-REFITTING THE PEDAL UNIT
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38805
38806
73154
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Take out the screws (4) fixing the cover (5) of the control
valve (6). Gradually lift the cover (5) to discharge the pressur-
ized air in the system.
Take out the screws (1-3) fixing the wiring clamps (2) and
pedal unit to the cab.
Take out the screw (2) fixing the bracket (1) supporting the
piping and wiring and disconnect the pedal unit from the cab.
Removal
(vehicles with ZF 16 S... gearbox)
Disconnect the steering control mount as described in fig-
ures 8 — 9 — 10 — 11 - 12.
Remove the bracket (1) stopping the clutch pedal. Take out
the screws (2) fixing the master cylinder to the pedal unit.
Remove the bracket (1) stopping the brake pedal. Take out
the three screws (2) fixing the control valve to the pedal unit.
This differs from removing the pedal unit on vehicles with the
EuroTronic Automated gearbox in the following.
Lift the radiator cowling, disconnect the piping (3-4) from the
splitter control button (5). Disconnect the electric connection
(1) of the master cylinder (2) and remove this, together with
the oil reservoir, from the pedal unit (6). Complete disconnect-
ing the pedal unit as described in figures 13 — 14 - 15.
CLUTCH
13
S
TRALIS
AT/AD
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