Iveco Stralis AT/AD. Manual — part 85
Before putting the synchronizing devices back together, check
the wear of the synchronizer rings (1) and of the coupling
bodies (3). Using a feeler gauge (2), measure the distance
between the synchronizer ring (1) and the coupling body (3)
at two opposite points. If the measured distance (X) is less
than 1.2 mm, replace the synchronizer ring (1) or the coupling
body (3).
Do not get the checked parts mixed up (it is recommended
to mark them).
71119
71410
Figure 56
Figure 57
Figure 58
Figure 59
Check the clearance between the ring (2) and its seat.
The clearance has to be between 0.0 and 0.1 mm.
COMPONENT PARTS OF THE EPICYCLIC REDUCTION GEAR UNIT SYNCHRONIZING DEVICE
13211
!
When fitting the internal rings of the bearings and
the hub for the sliding sleeve, they will first need to
be heated to approximately 100
°C for roughly 15
minutes.
19529
Check that the end float between the planet wheel holder
(1) and the planet wheels (4) is between 0.40 and 1.30 mm.
After checking the end float, fit the pins (2) of the bearings
in the planet wheel holder (1), making the reference marks
”0” punched on the pins tally with the holes (3) for the spring
pins.
Fit the spring pins in the holes (3) and notch them.
!
The circlip (1) is supplied as a spare with a different
thickness.
76
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
19565
Using the keying device 99374221 (1) fit the seal in the cover
(2) of the drive output flange.
37343
Measure the depth of the bearing seat in the ERG box (1).
37344
Measure the thickness of the bearing (2).
37345
Measure the depth of the bearing seat in the cover (3)
together with the gasket (4).
37346
Determine the thickness of the adjustment ring (5) so that
between the bearing (2) and the box of the epicyclic
reduction gear (1, Figure 61) there is an end float of 0.0
÷ 0.1
mm.
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
77
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AT/AD
EXAMPLE
mm
-
Depth of bearing seat in box (1)
7.40+
-
Depth of bearing seat in cover (3)
together with gasket (4)
23.00=
-
Total
30.40-
-
Bedding of gasket (4)
0.0.5=
-
Total
30.35-
-
End float (0.0 - 0.1 mm), mean value
0.05=
-
Total
30.30-
-
Thickness of bearing
30.00=
-
Total
0.30
The thickness of the adjustment ring (5) has to be 0.30 mm.
Figure 65
Figure 66
Figure 67
Figure 68
To refit the rear box of the epicyclic reduction gear unit, 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.
37312
Screw the eyebolts (3) onto the rear box (2), fit the ropes
with hooks (4) and, with a movable lift, mount the rear box
on the gearbox.
Tighten the screws (1) to the required torque.
After tightening the two screws fixing the drive output flange
(2), fit the safety plate on them and notch it with tool
99370465 (1).
Take the gearbox off the stand and restore the oil level.
37359
61207
Remove the rear box of the epicyclic reduction gear unit as
described under the relevant heading.
Note down the assembly position of the switches (3) type
235N and (5) type 145N and unscrew them from the
gearbox (6).
Remove the oil vapour breather pipe (1) and the plug (2).
61177
Remove the splitter driving cylinder (3) together with the
rings (4-5).
!
There may be 3 rings on the cylinder (3).
!
The spacer ring (2) is only mounted on ZF 16 S 181
gearboxes.
Take off the ring (9). Unscrew the nut (7) and remove the
piston (8) from the rod (6).
Remove the spacer ring (2) from the main shaft (1).
Refitting the epicyclic reduction gear unit
(ERG) rear box
Removing the gearbox
78
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
61178
Figure 69
Extract the reverse gear shaft (1).
61179
Figure 70
Remove the tube (2) from the main shaft (3).
61180
Figure 71
Unscrew the nuts (1) and take off the drive input cover (2).
61181
Figure 72
!
With some gearboxes, in order to extract the shaft
(1), it is necessary to take out the screw fixing the
plate fastening it to the gearbox.
Unscrew the screws (1) and take off the cover (2).
Take out the reverse idler gear (1) together with the roller
bearings (2 and 3).
Take off the thrust washer (4), spring (3), thrust washer (2),
adjustment ring (1) and gasket (5).
61182
Figure 73
Unscrew the nuts (1) and remove the oil pump (2).
61183
Figure 74
!
To remove the oil pump (2), do not unscrew the
screws (4). These screws secure the cover (3) to the
pump body and are unscrewed when the part has
been removed solely to overhaul the oil pump.
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
79
S
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AT/AD
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