Iveco Stralis AT/AD. Manual — part 88
During assembly, lubricate the gear roller bearings.
Figure 105
71120
Figure 106
61199
Mount the 4
th
speed gear as follows:
Heat the roller bearing (2) to 100
°C. Fit it on the main shaft
(1) with the lubrication holes (
→) facing as shown in the
figure and leave it to cool.
Mount the synchronizer ring (4) and the coupling body (3).
Figure 107
61200
Position the roller bearing (2) with the lubrication holes (
→)
facing as shown in the figure of the 4
th
speed gear (3), heat
them to 100
°C and mount them assembled in this way on
the main shaft (1).
!
Before assembly, heat the:
-
internal rings of the bearings to approx. 100
°C
-
bushings, hubs for sliding sleeves and toothed ring
for the reverse gear coupling to 120
°C
-
seats of the bearings on the box and cover to
60
°C
!
After mounting the gears, check their end float,
which has to be:
-
1
st
-2
nd
speed gears 0.2 mm;
-
4
th
speed gear 0.05 mm;
-
reverse gear 0.4 - 1.15 mm.
!
The split ring (1) is supplied as a spare with different
thicknesses.
Check the clearance between the split ring (1) and its seat
with a feeler gauge. The clearance has to be between 0.0 and
0.1 mm.
!
The main shaft is shown in the version with the end
with straight toothing.
88
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
Figure 108
Figure 109
Figure 110
Figure 111
61203
Determine the thickness of the adjustment ring (4,
Figure 109) of the coupling body (3, Figure 109) for the 4
th
speed gear as follows:
Measure the distance A between the end of the shaft (1) and
the seat (2) supporting the tapered roller bearing.
Mount the thrust washer (3) and measure the distance B
between this and the end of the main shaft (1).
The difference A - B must be between +0.07 and -0.08 mm..
61204
Position the coupling body (3) together with the adjustment
ring (4) on the 4
th
speed gear (1).
Measure the distance between the top of the coupling body
(3) and the thrust washer (2).
It has to measure 4.6 - 0.4 mm.
If you get a different value, replace the adjustment ring (4)
with another one of suitable thickness.
61205
Assemble the adjustment ring (1) having a thickness set in the
previous measurements.
61202
Mount the bearing (3), previously heated to 100
°C.
Mount the divided ring (2) whose thickness produces an end
float for it in its seat of -0.05
÷ +0.05 mm.
Mount the retaining ring (1) and notch it at several points the
same distance apart under the divided ring (2).
Adjusting the main shaft
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
89
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AT/AD
Figure 112
Figure 113
Figure 114
To mount the gearbox assembly, 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.
The tightening torques are given in the specific table.
!
The flat gaskets should be fitted dry, without any jointing
compound or grease.
Before fitting the twin-lipped seals, fill the gap
between the two lips with TUTELA MR3.
Any rings and seals, ring nuts, spring pins, safety plates
and self-locking screws found to be worn and all
parts that are not fully efficient or are scored, dented
or deformed must be replaced at the time of
assembly.
61204
Tighten the main shaft (11) in a vice. Position the coupling
body (10) on it together with the adjustment ring and
synchronizer ring (9).
Mount the drive input shaft (1).
Mount the tool 99360515 (2) on the drive input shaft (1).
Couple the transmission shaft (8) with the main shaft (11).
Tighten the screw (5) of the tool 99360515 (2) in the
transmission shaft. Adjust the nut (6) and the threaded
bushing (7) so that the transmission shaft (8) stays aligned
with the main shaft (11).
Position the associated forks together with blocks and rods
(4) on the sliding sleeves and position the sleeves (3) of the
tool 99360515 (2) on the rods.
61206
71126
Hook the tackle onto the tool 99360515 (1). Lift the shaft -
rod assembly (2) as assembled beforehand and insert it in the
gearbox. With a screwdriver inserted in the hole in the
gearbox, push the bolt so that the rods can go into their
respective seats.
Remove the tool 99360515 (1).
Mount tool 99370450 (2) on the gearbox and for
transmissions 16 S 181/221, a spacer (3) of the following
thickness must be fitted:
- 16 S 181 = 13.8 mm
- 16 S 221 = 13.5 mm.
Insert the splitter drive fork control rod and secure it by means
of nut (1).
Fitting the gearbox
90
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
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AT/AD
Base - January 2003
Adjusting the transmission shaft bearing end
float
Using the two socket-head screws (2), position the splitter
control fork (1) so that the two sliding blocks (4) are centred
in the throat of the sliding sleeve. Use a feeler gauge (3) for
this purpose.
After making the adjustment, tighten the two screws (2) to
the required torque.
Screw the splitter control rod setscrew onto the gearbox,
tightening it to the required torque.
Take the adjustment tool 99370450 (2, Figure 114) out of
the gearbox together with the spacer (3) after unscrewing
the nut (1, Figure 114).
37353
Figure 115
To dismantle the oil pump: unscrew the screws (1), take the
cover (2) off the pump body (5) and extract from this the
external (3) and internal (4) rotors.
To reassembly, carry out these steps in reverse order.
61208
Figure 116
534010
Oil pump
!
Apply a light layer of LOCTITE 547 on the mating
surface of the cover (2).
Tighten the screws (1) to the required torque.
61209
Figure 117
Determine the thickness S of the rings (2, Figure 118) for
adjusting the end float of the transmission shaft bearing (2)
as follows:
- Turn the shafts and check that the outer ring (2) of the
bearing rests without any clearance on the bearing
rollers.
- Measure the distance A between the plane of the front
box (1) and the outer ring (2) at two diametrically
opposite points.
Figure 118
61210
Measure the depth B of the seat of the bearing (2, Figure 117)
on the pump body (1).
The thickness S of the adjustment ring (2) is determined by
the following equation:
S= [ B - (A - C)] - D
Where:
-
A - B, measurements taken;
-
C, thickness of gasket;
-
D, end float of 0 - 0.1 mm.
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
91
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AT/AD
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