DAF LF45, LF55 Series. Manual — part 249
©
200508
4-7
Removal and installation
ZF 6S-850 GEARBOX
ΛΦ45/55 series
3
5
4.5 REMOVAL AND INSTALLATION, GEARBOX FRONT COVER OIL SEAL
Removing gearbox front cover oil seal
1.
Remove the gearbox.
2.
Remove the release mechanism assembly
with fork and thrust bearing.
3.
Remove the attachment bolts from the
gearbox front cover (1). Remove the gearbox
front cover from the input shaft. Keep the
filler plates of the input shaft and the
secondary shaft.
4.
Remove the oil seal (2) from the gearbox
front cover.
Installing the gearbox front cover oil seal
1.
Apply a small amount of sealant to the
outside of oil seals fitted with a steel cover.
Apply a small amount of green soap to the
outside of oil seals fitted with a rubber cover.
2.
Fit the oil seal (2) to the gearbox front cover
using special tools (DAF no. 0499809) and
(DAF no. 0535409). Fit a new gasket (3).
3.
Check the input shaft axial play. See
"Inspection and adjustment".
4.
Install the gearbox front cover (1). Tighten
the bolts to the specified torque. See
"Technical data".
5.
Install the release mechanism on the
gearbox. Tighten the bolts to the specified
torque. See "Technical data".
6.
Fit the gearbox.
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1
3
2
ZF 6S-850 GEARBOX
4-8
©
200508
Removal and installation
5
ΛΦ45/55 series
3
4.6 REMOVAL AND INSTALLATION, SELECTOR SHAFT OIL SEAL
LHD model
Removing selector shaft oil seal
1.
Mark the gearbox lever relative to the
selector shaft and remove the control lever
with the gearbox control. If necessary,
disconnect the torque rod.
2.
Remove the selector shaft housing
attachment bolts and remove the selector
shaft housing assembly from the gearbox.
Seal the gearbox opening, so that no
dirt can enter.
3.
Remove the locking pin and control stop
from the selector shaft housing.
4.
Drive the two spring pins out of the selector
fingers. Turn the selector fingers so that the
spring pins can be driven into a slot in the
cover.
5.
Remove the circlip and the springs from the
rear of the cover. Then remove the shaft and
the selector fingers from the cover.
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W 3 03 052
©
200508
4-9
Removal and installation
ZF 6S-850 GEARBOX
ΛΦ45/55 series
3
5
6.
Drive the oil seal and dust seal out of the
selector shaft housing. If necessary, the
selector shaft bearing bushes can now also
be replaced with special tool
(DAF no. 0694818). Press the bearing bush
on the control side 2 mm under the edge.
LHD model
Installing selector shaft oil seal
1.
Sparingly apply a liquid gasket to the oil seal
and fit it in the control cover using special tool
(DAF no. 0535659). Now fit the dust seal in
the control cover using special tool
(DAF no. 0535659). Apply grease to the oil
seal lips.
2.
Fit the special tool ((DAF no. 0694817)), a
guide sleeve, over the selector shaft and fit
the selector fingers and the gear lever lock
into the selector housing. Fit the selector
shaft. Watch the control stop slot.
3.
First fit the control stop before fitting the
spring pins.
4.
Fit the spring pins and the locking pin.
5.
Apply a small amount of sealant to the
sealing cap. Install the springs, rings, and the
sealing cap. Fit the circlip.
6.
Put the gearbox into neutral, install a new
gasket in the selector shaft housing and fit it
onto the gearbox housing. Tighten the bolts
to the specified torque. See "Technical data".
7.
Fit the shift control and check that all gear
changes function properly.
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2 mm
ZF 6S-850 GEARBOX
4-10
©
200508
Removal and installation
5
ΛΦ45/55 series
3
RHD model
Removing selector shaft oil seal
1.
Mark the gearbox lever relative to the
selector shaft and remove the control lever
with the gearbox control. If necessary,
disconnect the torque rod.
2.
Remove the bearing housing attachment
bolts and slide it off the selector shaft.
3.
Drive the dust and oil seals out of the bearing
housing. If necessary, the selector shaft
bearing bush can now also be replaced with
special tool (DAF no. 0694818). Press the
bearing bush on the spring side 2 mm under
the edge.
Installing selector shaft oil seal
1.
Apply a small of amount of liquid gasket to
the oil seal and fit it in the bearing housing
using special tool (DAF no. 0535659). Now
fit the dust seal in the bearing housing using
special tool (DAF no. 0535659).
2.
Apply grease to the oil seal lips. Fit a new
O-ring to the selector shaft housing. Fit the
selector shaft housing over the selector
shaft.
3.
Fit the attachment bolts and the gearbox
control. Tighten the bolts to the specified
torque. See "Technical data". Check that all
gear changes function properly.
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