Iveco Stralis AT/AD. Manual — part 83
61229
Figure 16
61230
Figure 17
Unscrew the screws (1) and take off the top cover (2).
Extract the pin (3).
Take off the circlip (3) and extract the piston (2) together with
the ring (1).
61259
Figure 18
Remove the circlip (2) from the rod (1).
Use the washer (4) to limit the action of the spring (5) and
remove the split ring (3), extract the washer (4), the spring
(5) and the washer (6).
61231
Figure 19
Unscrew the plugs (2) with the washers, extract the springs
(1) and remove the levers (6).
If necessary, take out the pins (3).
Unscrew the screws (4) and remove the cover (5).
Remove the circlips (1) and take out the pins (2) fastening the
drive (4) to the rod (3).
61232
Figure 20
Move the sleeve (1) in the direction of the arrow.
Strike a punch on the top of the lever (6) to make it come
out of the bearing (3) and pin (2), freeing the latter from the
groove (4) in the rod (5).
61233
Figure 21
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GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
61234
Figure 22
61235
Figure 23
Note down the assembly position of the levers (2 and 3) and
take them out of the box (4) extracting the rod (1).
Using the male extractor 99348004, extract the bushing (2)
and the seal (1) from the box (3).
61236
Figure 24
Note down the assembly position of the locking element (1)
and drive (2) and take them out of the box (4) after extracting
the sleeve (3).
Position the locking element (1) and the drive (2) in the box
(4) as marked during removal and put on the sleeve (3).
61236
Figure 25
Using a suitable drift, mount the bushing (2) in the box (3).
Using a suitable keying device, fit the seal (1) in the box (3).
Lubricate the inside of the seal (1) with grease.
61235
Figure 26
!
When assembling, always replace the sealing
elements with new parts: rings, copper washers, flat
gaskets, o-rings and roller bearings with the pins.
Check that the springs have not broken nor yielded.
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
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AT/AD
Assembly
61234
Figure 27
Position the levers (2 and 3) in the box (4) as marked during
removal and put on the rod (1).
Figure 28
36804
Move the sleeve (1) in the direction of the arrow.
Fit a new roller bearing (3) and pin (2) on the lever (6).
Position the rod (5) so that the groove (4) corresponds with
the roller (3) and pin (2).
Resting the lever (6) on a flat surface, carefully strike the
bearing (3) and pin (2) so they go into a position flush with
the top of the lever (6) and correctly enter the groove (4)
in the rod (5).
Figure 29
61232
Fasten the drive (4) to the rod (3), putting on the pins (2) and
mount new circlips (1) on these.
Figure 30
61231
On the rod (1), position: the washer (6), spring (5), washer
(4) and fit on a new split ring (3).
Fit on a new circlip (2).
Figure 31
61259
Fit on the cover (5) with a new gasket, screw down the
screws (4) and tighten them to the required torque.
Position the levers (6) on the pins (3). Screw down the plugs
(2) with the new washers and springs (1) and tighten them to
the required torque.
70
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
61230
Figure 32
43806
Figure 33
Fit a new ring (1) on the piston (2) and fit this in the box,
securing it with the circlip (3).
Insert the pin (3) in the box.
Put the top cover (2) on with a new gasket.
Screw down the screws (1) and tighten them to the required
torque.
43812
Figure 34
Position the push rod (3) with the spring (4) in the box (2).
Refit the servoshift (1) with a new gasket.
61257
Figure 35
Complete gearbox assembly by fitting:
- push rod (11), spring (12), plug (13) with a new seal;
- push rods (2 and 10), switches (1 and 9) with the new
washers;
- cup (8), lever (7) on the rod (6) in the position marked
during removal and tighten the nut (5) to the required
torque.
- valve (3) and tighten screws (4) to the specified torque.
Screw down the screws (1) and tighten them to the required
torque.
Connect the air pipe (3) to the distributor (4), screwing
down the fitting (2) with new copper gaskets and tightening
it to the required torque.
61227
Figure 36
Figure 37
61226
Refit the gearbox (5), screw down the fixing screws (1) and
tighten them to the required torque.
Connect the pipes (3 and 4) to the box (5), in the position
found at removal, with the fittings (2 and 6) together with the
new washers.
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
71
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AT/AD
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