DAF LF45, LF55 Series. Manual — part 248

©

200508

4-3

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

4.2 REMOVING AND INSTALLING GEARBOX, CE ENGINE

Removing gearbox, CE engine
1.

Disconnect the earth lead from the battery

terminal.

2.

Remove the attachment bolts of the prop

shaft flange and remove the prop shaft.

3.

If present, remove the attachment bolts from

the intermediate bearing.

4.

Remove the attachment bolt from the

exhaust bracket on the gearbox.

5.

Remove the clamping strip from the exhaust

pipe.

6.

Remove the attachment bolt of the rubber

suspension point on the end of the exhaust.

7.

Twist the end-pipe of the exhaust loose and

remove it.

8.

Remove the attachment bolts from the clutch

cylinder and remove it.

9.

Mark all the electrical connectors and

remove them.

10. Remove the compressor pipe bracket.

11. Remove the selector rod from the adjusting

mechanism in such a manner that the

settings are not changed.

12. Support the gearbox and remove the

attachment bolts around it.

13. Manoeuvre the gearbox to the rear until it is

free and then remove it.

ZF 6S-850 GEARBOX

4-4

©

200508

Removal and installation

5

ΛΦ45/55 series

3

Installing gearbox, CE engine
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 prop shaft 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 selector rod on the adjusting

mechanism. Use new self-locking nuts.

5.

Fit the exhaust bracket.

6.

Install the compressor pipe bracket.

7.

Fit the electronic connectors onto the

gearbox.

8.

Fit the clutch cylinder.

9.

Install the exhaust pipe, fasten it with the

clamping strap and fit the attachment bolt of

the suspension rubber.

10. Install the prop shaft intermediate bearing, if

it has been removed, and tighten the bolts by

hand.

11. Fit the prop shaft flange onto the gearbox.

Tighten the attachment bolts to the specified

torque. See "Technical data".

12. Tighten the intermediate bearing attachment

bolts to the specified torque. See "Technical

data".

13. Check the oil level. See "Inspection and

adjustment".

14. Fit the silencer cap.

15. Fit the earth lead to the battery terminal.

Note:

If a gearbox of a different type is mounted, or a

gearbox with a different reduction, this should be

reported. If the correct data are present, they can

be input into the VIC using DAVIE XD.

©

200508

4-5

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

4.3 REMOVAL AND INSTALLATION, DRIVE FLANGE

Removing the drive flange
1.

Make a reference mark on the prop shaft and

flange.

2.

Detach the prop shaft from the flange and

secure it.

3.

Fit special tool (DAF no. 0484977) to hold

the flange in place.

4.

Remove the attachment bolt and washer.

5.

Using special tool (DAF no. 0484978),

remove the drive flange from the shaft.

Installing the drive flange
1.

Heat the drive flange to a temperature of

max. 120

″C.

2.

Oil the output shaft lightly and slide the drive

flange over the shaft in its correct position.

3.

Fit the special tool (DAF no. 0484977) onto

the drive flange.

4.

Tighten the attachment bolt to the specified

torque. See "Technical data".

5.

Fit the prop shaft. Tighten the attachment

bolts to the specified torque. See "Technical

data".

V3 00 416

ZF 6S-850 GEARBOX

4-6

©

200508

Removal and installation

5

ΛΦ45/55 series

3

4.4 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Pull the oil seal from the gearbox housing

using special tool (DAF no. 0484899).

Installing output shaft oil seal
1.

Check the axial play of the output shaft. See

"Technical data".

2.

Around the oil seal, clean the gearbox

housing without letting dirt into the gearbox.

3.

Apply a small amount of liquid gasket 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.

4.

Fit the oil seal in the gearbox housing using

special tool (DAF no. 0694816). The tool will

position the oil seal at the correct depth in the

housing.

5.

Fit the drive flange.

W 3 03 048

7 mm