DAF LF45, LF55 Series. Manual — part 239

©

200508

1

Contents

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

4 ZF S5-42 gearbox

CONTENTS

Page

Date

1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1

ZF gearbox type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508

1.2

System description, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200508

2.

DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1

Synchroniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508

3.

INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1

Checking gearbox oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508

3.2

Inspecting and adjusting input shaft pre-load . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508

4.

REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1

Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508

4.2

Removing and installing drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200508

4.3

Removing and installing output shaft oil seal . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200508

4.4

Removing and installing gearbox front cover oil seal . . . . . . . . . . . . . . . . 4-5 . . . . . 200508

4.5

Removing and installing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200508

5.

DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1

Draining and filling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508

ZF S5-42 GEARBOX

2

©

200508

Contents

4

ΛΦ45/55 series

3

©

200508

1-1

General

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

1. GENERAL

1.1 ZF GEARBOX TYPE

Each gearbox has a type plate attached to it,

indicating the type of gearbox. This data can also

be found on the vehicle identity card for the

vehicle concerned.

V300049

1

2
4
5

3

8

6

7

10

9

1.

Type of gearbox

2.

ZF serial number

3.

Parts list (ZF)

4.

Specification number

5.

Pulse generator ratio

6.

Gearbox ratio

7.

Engine speed using PTO

8.

PTO speed

9.

Gearbox oil capacity

10.

Oil specification

ZF S5-42 GEARBOX

1-2

©

200508

General

4

ΛΦ45/55 series

3

1.2 SYSTEM DESCRIPTION, GEARBOX

The gearbox consists of five synchromesh

forward gears and one non-synchromesh reverse

gear. The fifth gear is "close ratio" or "wide ratio",

depending upon the model.