DAF LF45, LF55 Series. Manual — part 252

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200508

3-1

Removal and installation

EATON FS/6309A GEARBOX

ΛΦ45/55 series

3

6

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY

Removing gearbox assembly
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.

Remove the attachment bolts from the

intermediate bearing.

4.

Remove the attachment bolt from the

exhaust bracket on the gearbox.

5.

Remove the clamping straps of the

intermediate pipe and remove it.

6.

Remove the end of the exhaust by removing

the clamping strap and the attachment bolt of

the rubber suspension point at the end of the

exhaust.

7.

Remove the attachment bolts from the clutch

cylinder and remove it.

8.

Mark all the electrical connectors and

remove them.

9.

Remove the compressor pipe bracket.

10. Mark the various air pipes and remove them.

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.

EATON FS/6309A GEARBOX

3-2

©

200508

Removal and installation

6

ΛΦ45/55 series

3

Installing gearbox assembly
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 selector rod on the adjusting

mechanism. Use new self-locking nuts.

5.

Fit the exhaust intermediate pipe.

6.

Fit the exhaust end pipe.

7.

Install the compressor pipe bracket.

8.

Install the electronic connectors on the

gearbox.

9.

Fit the clutch cylinder.

10. Fit the air pipes.

11. Install the intermediate bearing of the prop

shaft and tighten the bolts by hand.

12. Fit the prop shaft flange onto the gearbox.

Tighten the attachment bolts to the specified

torque. See "Technical data".

13. Tighten the intermediate bearing attachment

bolts to the specified torque. See "Technical

data".

14. Check the oil level. See "Inspection and

adjustment".

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

3-3

Removal and installation

EATON FS/6309A GEARBOX

ΛΦ45/55 series

3

6

3.2 REMOVAL AND INSTALLATION, DRIVE FLANGE

Removing drive flange
1.

Place a reference mark on the prop shaft in

relation to the flange.

2.

Remove the bolts that attach the prop shaft

to the flange.

3.

Support the prop shaft from a suitable

location on the chassis.

4.

Support the prop shaft from a suitable

location on the chassis.

5.

Fit special tool (DAF no. 0484977) to hold

the flange in place. Remove the lock nut and

washer.

6.

Remove the flange with a suitable puller.

Note:

In order to prevent the synchroniser for the

high/low transmission ratios from coming

loose, the output shaft must not slide out of

the bearing.

Installing drive flange
1.

Place the flange on the output shaft.

2.

Place a shim between the flange and the lock

nut and turn the flange in the oil seal.

Remove the lock nut and shim.

3.

Fit special tool (DAF no. 0484977) to the

flange. Fit a new lock nut. Tighten the lock

nut to the specified torque. See "Technical

data".

4.

Align the markings. Fit the prop shaft onto

the flange. Tighten the bolts to the specified

torque. See "Technical data".

EATON FS/6309A GEARBOX

3-4

©

200508

Removal and installation

6

ΛΦ45/55 series

3

3.3 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Remove the attachment bolts from the oil

seal housing. Remove the oil seal housing.

Remove the oil seal.

3.

Clean the contact surfaces of the oil seal and

the seal housing.

Installing output shaft oil seal
1.

Press the oil seal into the oil seal housing

using special tool (DAF no. 1329358).

2.

Apply sealant to the contact surface of the

seal housing. See "Technical data".

3.

Fit the seal housing and tighten the bolts to

the specified torque. See "Technical data".

4.

Apply grease to the sealing lip of the oil seal.

5.

Fit the drive flange.

6.

If necessary, top up the gearbox. See

"Inspection and adjustment".