Iveco Stralis AT/AD. Manual — part 81
60
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
TOOL No.
DESCRIPTION
99370420
Key for fitting gasket on gearbox front cover
(use with 99370006)
99370449
Tool to extract and insert main shaft
99370450
Tool to adjust splitter control fork
99370465
Tool to notch safety plates
99370629
Mount to support gearbox when removing and refitting
it on the vehicle
99371050
Brackets to support gearbox when overhauling
(use with 99322205 - 99322225)
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
61
S
TRALIS
AT/AD
TOOLS
TOOL No.
DESCRIPTION
99374093
Drift to mount external bearing races (91-134)
(use with 99370007)
99374421
Key to fit gaskets on rear cover
99374370
Key to fit oil deflector on direct drive shaft
(use 99370006)
99395604
Dial gauge (0-10 mm)
Principal operational anomalies:
1 - Noise;
2 - Spontaneous gear disengagement and irregular engagement;
3 - Gear engagement hard and difficult.
4 - Pneumatic control system defective or inefficient.
YES
Excessive clearance between gears.
Overhaul the gearbox and replace worn gears.
Gears, bearings, synchronizer rings and connecting
parts worn.
Replace worn parts.
Insufficient lubricating oil level in the gearbox.
Top up to correct level with Tutela ZC 90 or Tutela
Truck Fe-Gear oil.
Gears not properly engaged.
Fully engage gears before releasing clutch pedal.
YES
YES
1
NOISE
NO
NO
YES
2
GEARS DISENGAGE
SPONTANEOUSLY AND ENGAGE
INCORRECTLY
Gearshift forks broken.
Remove transmission, overhaul and replace parts as
necessary.
Synchroniser rings worn
Inspect gears and sliding sleeves for gear engagement,
replacing any which are damaged; replace synchroniser
rings
YES
YES
NO
NO
(continue)
62
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
S
TRALIS
AT/AD
Base - January 2003
4
PNEUMATIC CONTROL SYSTEM
DEFECTIVE OR INEFFICIENT *
Defective operation of epicyclic reduction gear
Inspect and replace damaged parts
Forks stiff on rods
Dismantle the transmission and look for the cause of
the stiffness; repair as necessary
GEARS DIFFICULT AND STIFF
TO ENGAGE
3
Movement of sliding sleeves obstructed
Inspect and repair as necessary
Transmission filled with unsuitable fluid.
Drain the oil and refill with Tutela ZC 90 or Tutela
Truck Fe-Gear oil
YES
YES
YES
NO
NO
YES
Clutch not disengaging
Adjust control or replace.
YES
NO
YES
NO
Defective air pipe connections
Check the connections and restore them if necessary.
Air pipe bent and/or crushed
Replace the pipe
YES
* The checks have to be made with the engine switched off and the air tanks full.
(continue)
GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.
63
S
TRALIS
AT/AD
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