Iveco Stralis AT/AD. Manual — part 168
Lock the differential gear, operating as follows: unscrew the
screw (7) and screw it down in the hole (8): screw down the
screw fully to get the differential lock to go in.
526210
REMOVING DIFFERENTIAL GEAR
— TRANSFER BOX (with rear axle on
stand 99322215)
36344
77222
77227
77228
Figure 25
Figure 26
Figure 27
Figure 28
Use retainer 99370317 (3) to stop flange (1) rotation.
Unscrew drive flange (1) retaining nut using wrench 99355131
(2) and torque adaptor (4).
Remove screws (5) and disconnect axle housing output shaft
mounting (6).
Loosen differential carrier (1) retaining screws. Screw in three
screws to be used as extractors and separate differential
carrier from axle housing by means of eyebolts and metal
ropes.
Coat the axle housing to differential mating face with sealant.
Insert differential in axle housing. Tighten nuts (1) and screws
with lock washers to the specified torque using a torque
wrench (2).
Fit differential axle shafts as described in 525030 operation.
Backout screw (3) to release the differential lock device. Insert
screw (3) in its seat on cylinder cover and tighten plug and
washer in the threaded hole previously occupied by the screw
(3).
!
Use mounting 99370616 for differential carrier
removal with axle assembled on vehicle.
REFITTING
DIFFERENTIAL
GEAR
—
TRANSFER BOX (with rear axle on stand
99322215)
122
AXLES IN TANDEM MERITOR RP 160 E (R 2478) (INTERMEDIATE)
S
TRALIS
AT/AD
36346
36347
77229
77230
36350
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Turn the axle housing by 90
°. Insert support (1) with drive
output shaft (2) in the axle housing and tighten screw to the
specified torque.
Stop flange (1) rotation by means of retainer 99370317 (4).
With wrench 99355131 (2) and torque adaptor (3) tighten
output shaft flange (1) retaining nut to the specified torque.
Once assembly operations are completed, pour the specified
quantity of TUTELA W140/M-DA oil into the axle housing.
Then check efficiency of differential lock connection sending
unit.
Detach the transfer box differential gear housing as described
under the relevant heading. Position the transfer box differential
gear housing (1) on the rotary stand 99322205 (2) together with
the mount 99322225 (3).
Unscrew the screws (4) and remove the guard.
Using tool 99360311 unscrew the oil filter (5).
Stop flange (1) rotation with tool 99370317 (2). Undo flange
retaining nut using wrench 99355088 (3) and torque adaptor
(4).
Remove nuts fixing mounting (1) to differential carrier and
take it out together with input shaft, oil pump, gear and
inter-axle differential.
Remove shims (2).
Separate the differential housing as described in the relative
chapter.
AXLES IN TANDEM MERITOR RP 160 E (R 2478) (INTERMEDIATE)
123
S
TRALIS
AT/AD
526060
REPAIRING INTER-AXLE UNIT
Dismantling inter-axle unit
77231
36353
36352
36354
84395
84396
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Remove cylinder (1) complete with inter-axle differential lock
piston (2) and withdraw yoke (4) drive pin (3).
Remove the spring (1) and strip yoke (2), sleeve (3) and rear
planetary gear (4).
Use a punch to expel cup (1) of rear planetary gear bearing
(4, Figure 35).
Use extractor 99348001 (1) and reaction block (2) to
dismantle cone of rear planetary gear (4) roller bearing.
Tighten drive input shaft in a vice.
Remove snap ring (1) and take out differential gear assembly
(2), gear (3) and thrust ring (4).
If the planetary gear unit is to be removed, use a punch to mark
a reference point (1) on both half-cases, in order to make
them match during assembly. Slacken the screws (2) and split
the two half-cases. Remove the cross unit, take off the four
gears, the pinions and the four thrust washers from the cross
unit .
124
AXLES IN TANDEM MERITOR RP 160 E (R 2478) (INTERMEDIATE)
S
TRALIS
AT/AD
36356
Figure 40
Remove nut (1) and separate flange (2) from drive input shaft
(3) by means of a suitable extractor.
36357
36430
Figure 41
Figure 42
Use a press to extract the drive input shaft (1) from bearing
cage (2) and oil pump (3).
Remove screws (1), separate oil pump (2) from bearing cage
(3) and take out bearing (4).
36358
Figure 43
Remove spring (2), oil pressure relief valve (1) and cup (3) of
bearing (4, Figure 42) from bearing cage (4).
36359
Figure 44
Checking inter-axle unit components
Tighten the drive input shaft (1) in a vice and install the oil
pump (3).
Heat the bearing (2) to 100
°C for 15 minutes and fit it on using
a drift.
Accurately clean each single component and check for wear
in view of their possible re-use.
!
Make sure all screw, stud and ring nut threads are
cleaned accurately so that clearance and torque
specifications are not effected.
Always renew sealing rings, retaining rings and washers.
Fitting inter-axle unit
AXLES IN TANDEM MERITOR RP 160 E (R 2478) (INTERMEDIATE)
125
S
TRALIS
AT/AD
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