DAF LF45, LF55 Series. Manual — part 242

©

200508

4-1

Removal and installation

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

4. REMOVAL AND INSTALLATION

4.1 REMOVING AND INSTALLING THE GEARBOX

Removing the gearbox
1.

Disconnect the earth lead from the battery

terminal.

2.

Remove the silencer cap above the clutch.

3.

Remove the attachment bolts of the prop

shaft flange and remove the prop shaft.

4.

Remove the intermediate bearing, if fitted.

5.

Remove the attachment bolt from the

exhaust bracket on the gearbox.

6.

Remove the clamping strip from the exhaust

pipe.

7.

Remove the attachment bolt of the rubber

suspension point on the end of the exhaust.

8.

Twist the end-pipe of the exhaust loose and

remove it.

9.

Remove the attachment bolts from the clutch

cylinder and remove it.

10. Remove all electrical connectors.

11. Remove the compressor pipe bracket.

12. Remove the torque rod of the selector rod.

13. Remove the elbow of the selector rod on the

selector shaft fork.

14. Support the gearbox and remove the

attachment bolts around it.

15. Manoeuvre the gearbox to the rear until it is

free and then remove it.

ZF S5-42 GEARBOX

4-2

©

200508

Removal and installation

4

ΛΦ45/55 series

3

Installing the gearbox
1.

Engage the highest gear in order to align the

keys of the input shaft with the clutch plate.

2.

Fit the gearbox onto the engine. If

necessary, rotate the drive flange in order to

align the keys.

3.

Fit the gearbox attachment bolts all around

and tighten them to the specified torque. See

"Technical data".

4.

Install the torque rod and secure it by means

of new self-locking nuts.

5.

Install the elbow of the gearbox control on

the selector finger. Use a new self-locking

nut.

6.

Fit the exhaust bracket.

7.

Install the compressor pipe bracket.

8.

Fit the electrical connectors onto the

gearbox.

9.

Fit the clutch cylinder.

10. Install the exhaust pipe, fasten it with the

clamping strap and fit the attachment bolt of

the suspension rubber.

11. Fit the prop shaft flange onto the gearbox.

12. Fit the intermediate bearing, if present.

13. Check the oil level. See "Inspection and

adjustment".

14. Fit the silencer cap.

15. Fit the earth lead to the battery terminal.

©

200508

4-3

Removal and installation

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

4.2 REMOVING AND INSTALLING DRIVE FLANGE

Removing drive flange
1.

Disconnect the earth cable from the

batteries.

2.

Make a reference mark on the prop shaft in

relation to the gearbox drive flange.

3.

Remove the nuts and bolts, if any, with which

the intermediate bearing of the prop shaft is

fixed to the cross member of the chassis.

4.

Disconnect the prop shaft from the gearbox

drive flange. Support the shafts at a suitable

point on the chassis.

5.

Fit the special tool (DAF no. 0484977) onto

the drive flange.

6.

Remove the lock nut. Remove the special

tool from the drive flange.

Note:

Do NOT use the old lock nut again.

7.

Using special tool (DAF no. 0484978),

remove the drive flange from the main shaft.

Installing drive flange
1.

Heat the drive flange to a temperature of

70

″C and place it on the main shaft.

2.

Fit special tool (DAF no. 0484977) onto the

drive flange.

3.

Apply locking compound to the screw thread.

See "Technical data".

4.

Tighten the new lock nut to the specified

torque. See "Technical data".

5.

Fit the prop shaft to the gearbox drive flange.

Ensure that the reference markings are

placed opposite each other. Fix the

intermediate bearing onto the cross member

of the chassis. Tighten the bolts to the

specified torque. See "Technical data".

6.

Connect the earth clamp to the batteries.

ZF S5-42 GEARBOX

4-4

©

200508

Removal and installation

4

ΛΦ45/55 series

3

4.3 REMOVING AND INSTALLING OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Prise the seal (2) out of the rear housing of

the gearbox.

Installing output shaft oil seal
1.

Using special tool (DAF no. 0694816) (1), fit

the new seal in the rear housing.

2.

Fit the drive flange.

V301012

2

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