Iveco Stralis AT/AD. Manual — part 87
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Figure 92
Figure 93
Figure 94
Figure 95
Figure 96
Take out the split ring (1) and remove the tube (2).
Take out the retaining ring (1) and the divided ring beneath.
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Tighten the drive input shaft (5) in the vice. Remove the
sliding sleeve (2) from the hub (1) and taking care over the
pins (3) and springs (4) coming out in order to collect them.
Extract the coupling body (5), gear (6) and internal ring (3)
of the drive input shaft bearing with an extractor composed
of:
- grips (7);
- tie rods (8);
- bridge (1);
- reaction block 99345058 (2);
- clamp (4).
Extract the bearings (1 and 2) and the synchronizer ring (3).
Removing the drive input shaft
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Figure 97
Take off the split ring (1) and using an appropriate extractor
take out the internal ring (2) of the bearing on the splitter
side.
Use the same method, after turning over the transmission
shaft, to extract the internal ring of the bearing on the ERG
side.
Figure 98
61193
Position the synchronizer ring (1) on the coupling body (2).
Turn the synchronizer ring (1) so as to ensure correct
coupling on the coupling body (2).
Using a feeler gauge, check the distance A on two
diametrically opposite points.
It must be no less than:
- 0.8 for the gears and splitter;
- 1.2 for the epicyclic reduction gear unit.
Synchronizing devices
Check the wear of the synchronizer rings as follows:
!
The two roller bearings of the transmission shaft are
not interchangeable. Take care to put them aside
separately and to mark them so they will not get
swapped over during assembly.
Using a hydraulic press, extract the gears (3, 4 and 5) from
the transmission shaft.
CHECKS
Gearbox
The gearbox and its covers must have no cracks.
The surfaces of contact between the covers and gearbox
must be neither damaged nor deformed, remove any remains
of sealant from them.
The seats of the bearings, shafts and gear control rods must
be neither damaged nor too worn.
Check that the holes, pipes and lubrication grooves are not
obstructed by grease or foreign bodies.
Hubs - sliding sleeves - forks
The grooves on the hubs and sliding sleeves must not be
damaged. The sliding sleeve has to slide freely on the hub. The
blocks or pins for positioning the sliding sleeve must not be
damaged or worn. The coupling teeth of the sliding sleeves
must not be damaged. The forks must be integral and their
blocks must have no end float, in the radial throat of the
sleeve, greater than 0.6
÷ 1.2 mm.
Bearings
The roller bearings or roller cages must be in a perfect state
of repair and show no signs of wear or overheating.
Shafts - gears
The bearing seats on the shafts must be neither damaged nor
worn. The gear teeth must be neither damaged nor worn.
!
After the check, the synchronizer rings must be marked
on the respective gears to prevent their position getting
swapped over at the time of assembly.
- Visually check that the friction surface is not undulated.
BK-type single-cone synchronizing devices
Figure 99
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1. Coupling body - 2. Synchronizer ring - 3. Compression
spring - 4. Pin - 5. Synchronizer hub - 6. Sliding sleeve.
Removing the transmission shaft
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Figure 100
Figure 101
Figure 102
If you need to replace the ring (3) of the drive input shaft (4),
to remove it use general tools, for assembly use the keying
device 99374370 (2) and grip 99370006 (1).
COMPONENT PARTS OF THE DRIVE INPUT SHAFT
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Heat the gears (5, 4 and 3) to 160
°C ÷ 180 °C for
approximately 15 minutes and drive them onto the shaft
using a press.
To mount the transmission shaft, carry out the steps
described for removal in reverse order. The operations and
assembly phases requiring specific tools, clearance checks,
adjustments or special precautions are described below.
!
For assembly, the internal rings of the tapered roller
bearings must first be heated to approximately
100
°C for roughly 15 minutes.
Mount the internal ring of the bearing (2) on the splitter side,
the circulip (1) and check the clearance between the circlip
(1) and its seat with a feeler gauge; the clearance has to be
between 0.0 and 0.1 mm.
To mount the drive input shaft, carry out the steps described
for removal in reverse order.
The operations and assembly phases requiring specific tools,
clearance checks, adjustments or special precautions are
described below.
Fitting the drive input shaft
Fitting the transmission shaft
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Figure 103
Figure 104
COMPONENT PARTS OF THE MAIN SHAFT
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Using a feeler gauge, check the end float of the drive input
gear (2), it must be at least 0.2 mm.
In addition, check the tolerance between the divided ring (1)
and its seat, it has to be between -0.05
÷ +0.05 mm.
!
The divided ring (1) is supplied as a spare with
different thicknesses.
After mounting the divided ring (1), fit onto it the retaining
ring and notch it at two diametrically opposite points.
To mount the main shaft and the drive input shaft, carry out
the steps described for removal in reverse order.
The operations and assembly phases requiring specific tools,
clearance checks, adjustments or special precautions are
described below.
1
2
Fitting the main shaft
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
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