Iveco Stralis AT/AD. Manual — part 74
30508
37666
Figure 76
Figure 77
The case and relevant covers shall not show cracks.
The faying surfaces between case and covers shall not be dam-
aged nor warped.
The seats of bearings and that of the R speed transmission gear
shall not be damaged nor too much worn out.
The covers shall not show cracks and the coupling surfaces
shall not be warped nor damaged; the roller bearings shall not
rotate in their seats; the assembling clearances of the shafts
shall not be excessive; the shafts and relevant conrol compo-
nents, the pawls, the spacer and the levers shall not be too
much worn out and the springs shall not be broken nor have
loosed proper flexibility.
GEAR SHAFTS
Check wear of synchronizer rings and relevant coupling el-
ements by operating as follows:
set the synchronizer ring (1) on the coupling element (2);
rotate the components to ensure proper coupling;
use a feeler gauge (3) at two opposite points to find gap X be-
tween the coupling element and the synchronizer ring. If the
value X found is less than 0.8 mm for the gearbox, or less than
1.2 mm for the E.R.U., replace the synchronizer ring and/or the
coupling element.
Use driver 993701131 (1) to disassemble the roller bearing
(2) and then fit in place the new one.
The bearing seats in the shafts shall not be damaged nor worn
out. Toothing of gears shall not be damaged nor worn out.
HUBS, SLIDING SLEEVES AND FORKS
The splines on hubs and relevant sliding sleeves shall not be
damaged. The sliding sleeve move on the hub shall be free.
The sliding sleeve dowels shall not be damaged nor worn out.
The forks shall be free from damages or defects and the back-
lash of relevant sliding shoes in the radial race of the sliding
sleeve shall not exceed 1 mm.
BEARINGS
The roller bearings or roller cages shall be in perfect conditions
and not show traces of wear or overheating.
While keeping the bearings pressed with your hand, make
them rotate to both directions at the same time: the move-
ment shall not be affected by binding or noise.
!
At assembling stage, always replace the safety plates
and rings, the spring washers, the sealing rings and
gaskets, the springs of the sliding sleeve dowels and
all other springs that are showing having lost the re-
quired elasticity. Also replace the spring caps, the self-
locking nuts and all those parts not perfectly efficient,
scored, cracked or warped.
Before installing the two-lip sealing gaskets, fill the gap
between the two lips with TUTELA MR3.
!
At assembling stage, do not mistake the components
with each other.
ASSEMBLING THE GEARCHANGE CASE
32
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
SYNCHRONIZERS AND COUPLING ELEMENTS
CASE AND COVERS
37667
37669
37668
37659
37670
37658
Figure 78
Figure 79
Figure 80
Figure 81
Figure 82
Figure 83
Fit the spacer (1), the stop sectors (2 and 3), the spacer (5)
in the box (4). Fit the paws (7) on the shaft (8), then, let the
shaft in the box and connect the prongs (6) to the shaft in the
same position as that noted at disassembling. Also connect the
shaft tothe parts already installed in the box.
Secure the stop sectors (2 and 3) and the spacer (4) to the
shaft (5) through the spring caps (1).
Install the washer (2), the spring (3), the washer (4) on the
shaft (1) and secure through the spring ring (5). Then install
the spring (6), the washer (7) and secure through the spring
ring (8).
Fit the levers (5) in place and also install the spacers (4) and
pins (3). Let the springs (2) in the box and install the plugs (1)
and relevant washers.
Use driver 99370113 (1) to install the bush (5), the sealing ring
(4) and the dustproofing (3) casing on the cover (2). The outer
surfaces of the elements shall be spread with sealant.
Fit in place the piston (3) and the springs (4), then, install the
cylinder (6) and the sealing ring (5). Fit in place the covers (2
and 7) and the valve (1) c.w.relevant gaskets.
GEARBOX ZF 9 S 109 D.D.
33
S
TRALIS
AT/AD
37657
24438
31038
30519
31039
Figure 84
Figure 85
Figure 86
Figure 87
Figure 88
Fit in place the pin (4). Install the casing (2) and the control
lever (1) on the shaft (3) to comply with the position noted
at disassembling.
Accurately clean the surfaces of the coupling seats of gears and
shaft.
Cool the shaft (1), if possible, or heat the gears at the tempera-
ture of 160
°C to 180°C, then, use a hydraulic press to carry
out the assembling sequence to install I-II speed gear (2), 3rd
speed gear (3) and 4th speed gear (4) on the shaft.
Fit in place the spring ring (5) and check that the axial backlash
of the ring in the seat is 0 to 0.1 mm.
If this is not so, select the proper thickness ring out of those
supplied spare.
Heat the inner rings of front and rear bearings at about 85
°C
for 15’, then, install them on the transmission shaft by using
suitable driver.
Clamp the main shaft (1) in a vice and fit in place the roller
bearing (3) and the pickup speed gear (2) on the shaft.
Heat the hub (2) of the sliding sleeve that engages R gear and
pickup gear at the temperature of 100
°C for about 15’, then,
fit it in place by using suitable driver (1).
Check that the axial backlash of the ring in the seat is 0 to 0,1
mm. If this is not so, select the proper thickness ring out of
those supplied spare.
Check that the axial backlash of the pickup gear (2) is 0.20 to
0.45 mm.
ASSEMBLING THE TRANSMISSION SHAFT
!
The action of the press shall be kept for about 1’ after
every single gears is bedded.
34
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
30521
30522
31040
30523
30524
31041
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
Figure 94
Fit in place the sliding sleeve (3) that engages R gear and pickup
gear, the roller bearing (2) and the R speed gear (1).
Heat the taper roller bearing (5) at 85
°C for about 15’ and in-
stall it by using suitable driver (4).
Check that the axial backlash of the R speed gear is 0.40 to
0.75 mm.
Heat the planet gears (1) at 160 to 180
°C for about 15’ and
install so as to make the oil holes (
→) on the planet gears co-
incide with those on the shaft (2).
Check that the axial backlash of the spring ring (1) in the seat
is 0 to 0.1, mm, otherwise select proper thickness ring out of
those supplied spare, then, fit it into place.
Upturn the shaft (4) in a vice and install: roller bearing (1), I
speed gear (3) and coupling element (2).
Install the synchronizer ring (2). Heat the hub (1) at the tem-
perature of 85
°C for approx 15’, then install it by using suitable
driver. Check that the projecting parts of the synchronizer ring
(2) suitably fit the seats in the hub (1).
Check that the backlash of the 1st speed gear (3) is 0.20 to
0.45 mm.
Install the sliding sleeve (2) that engages I-II speeds. Fit the pins
(3), the springs (4) and the pins (5) in the relevant seats on the
hub (1). Set the elements under the sliding sleeve (2) by com-
pressing them.
GEARBOX ZF 9 S 109 D.D.
35
S
TRALIS
AT/AD
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