Page 1 DIAGNOSTICS MECHANICAL GEARBOX CONTROL PNEUMATIC GEARBOX CONTROL ZF S5-42 GEARBOX ZF 6S-850 GEARBOX EATON FS/6309A GEARBOX ALLISON 1000 & 2000 AUTOMATIC GEARBOXES ALLISON MD 3060 AUTOMATIC GEARBOX CLUTCH PROP SHAFTS © 200508 DW23259302 DAF LF Gearboxes and Clutch Service Manual...
Page 2 DAF LF Gearboxes and Clutch Service Manual...
Page 5 2 + 3 CE engine FS6309A steel 2 + 3 CE engine FS6309A rubber 2 + 3 Control rod behind the cab V3 00 564 Length B 60 - 62 mm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 6 When attachment bolts and nuts are replaced, it is important that - unless stated otherwise - these bolts and nuts are of exactly the same length and property class as those removed. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 7 Control rod (1) Lubricant Molykote BR2S or BR2 plus Torque rod (2) Attachment nuts 48 Nm Lock nuts 28 Nm Ball joint (4) Attachment nut 48 Nm Lock nuts 45 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 8 Torque rod (4) Attachment nuts 48 Nm Lock nuts 28 Nm Ball joint (6) Attachment nut 48 Nm Lock nuts 48 Nm Ball joint (8) Attachment nuts 48 Nm Lock nuts 48 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 9 TECHNICAL DATA ΛΦ45/55 series Mechanical gearbox control Torque rod (9) Attachment nuts 48 Nm Gear lever unit Attachment bolts 18 Nm Eaton switch button Attachment nut 70 Nm (1) Use Loctite 243 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 11 TECHNICAL DATA ΛΦ45/55 series Pneumatic gearbox control 2. PNEUMATIC GEARBOX CONTROL 2.1 GENERAL Filter/governor Governed pressure 5.34 - 5.69 bar © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 12 22 Nm Range-change cylinder M8 cover attachment bolts 17 Nm M16 nut on piston 105 Nm Bleed valve Attachment 19 Nm Eaton switch button Attachment nut 70 Nm (1) Use Loctite 243 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 13 TECHNICAL DATA ΛΦ45/55 series ZF S5-42 gearbox 3. ZF S5-42 GEARBOX 3.1 GENERAL Input shaft Pre-tension 0.02 - 0.09 mm Secondary shaft Pre-tension 0.02 - 0.09 mm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 14 Plugs Oil level check/filler plug 50 Nm Drain plug 50 Nm (1) Fit new nut and apply Loctite 270 to it (2) Fit new nut and apply Loctite 262 to it © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 15 TECHNICAL DATA ΛΦ45/55 series ZF S5-42 gearbox 3.3 FILLING CAPACITIES Gearbox Capacity S5-42 3.5 litres © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 17 Bearing axial play, main and input shafts Bearing axial play, main and input shafts 0.00 - 0.10 mm Secondary shaft bearing axial play Secondary shaft bearing axial play 0.00 - 0.10 mm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 18 Selector housing attachment bolts 23 Nm Shifting arm lock nut 46 Nm Gearbox control attachment nut 52 Nm Bleeder 10 Nm Plugs Oil level check/filler plug 50 Nm Drain plug 50 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 19 TECHNICAL DATA ΛΦ45/55 series ZF 6S-850 gearbox 4.3 FILLING CAPACITIES Gearbox type Filling amounts at oil change First filling, e.g. on repair (litres) (litres) ZF 6S-850 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 21 0.075 - 0.125 mm Original bearings 0.000 - 0.050 mm Sealant Gearbox housing front cover contact surfaces Loctite 518 Input shaft Lithium-based grease, class NLGI 3 Filter/governor Governed pressure 5.3 - 5.7 bar © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 22 Bleed valve 22 Nm Filter/governor M6 attachment bolts 13 Nm Cover 25 Nm Plugs Oil level check/filler plug 35 Nm Drain plug 44 Nm (1) Use new nut (2) Use Loctite 243 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 23 TECHNICAL DATA ΛΦ45/55 series Eaton FS/6309A gearbox 5.3 FILLING CAPACITIES Gearbox Contents Eaton FS/6309A 8.5 litres © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 25 TECHNICAL DATA ΛΦ45/55 series Allison 1000 & 2000 automatic gearboxes 6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES 6.1 GENERAL Torque converter pilot bearing Lubricant on installation Molykote BR2S or BR2 plus © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 26 Gearbox drain plug 35 Nm Oil cooler drain plug 28 Nm Oil cooler air bleed plug 28 Nm Hydraulic lines Attachment to gearbox 25 Nm Drive flange Attachment bolt 122 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 27 TECHNICAL DATA ΛΦ45/55 series Allison 1000 & 2000 automatic gearboxes 6.3 FILLING CAPACITIES Gearbox Capacity Allison 1000 & 2000 series Approx. 10 litre © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 28 TECHNICAL DATA ΛΦ45/55 series Allison 1000 & 2000 automatic gearboxes © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 29 This selector keypad has a display and is located next to the driver's seat; it replaces the gear lever with manual gearboxes. MODE V300392 Torque converter pilot bearing Lubricant on installation Molykote BR2S or BR2 Plus © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 30 Flexplate adapter attachment bolts 36 Nm Torque converter attachment bolts 36 Nm Oil cooler Hydraulic lines 60 Nm V300371 Plugs Oil drain plug (1) 28 Nm Oil filter cover attachment bolts (2) 55 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 31 TECHNICAL DATA ΛΦ45/55 series Allison MD3060 automatic gearbox V3 00 883 Oil cooler air bleed plug (1) 28 Nm Oil cooler drain plug (2) 28 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 32 The oil level when cold must be on the "Cold full" mark. "Cold add" add when cold "Cold full" full when cold "Hot add" add when hot "Hot full" full when hot W 3 03 099 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 33 8. CLUTCH 8.1 GENERAL Gearbox Clutch release assembly Clutch plate ZF S5-42 MF 362 WGTZ (1 ") ZF S6-850 MF 395 WGTZ (1 ") Eaton FS/6309A MF 395 WGTZ (1 ") © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 34 Clutch release assembly MF 362 clutch release assembly attachment bolts 40 Nm MF 395 clutch release assembly attachment bolts 80 Nm Tighten attachment bolts as illustrated MF 395 MF 362 V3 00 414 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 35 TECHNICAL DATA ΛΦ45/55 series Clutch 8.3 FILLING CAPACITIES Clutch First filling approx. 0.4 litres © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 37 LF 55 (17 - 19 ton) SPL 39 SPL 55 SPL 55 SPL 70 SPL 70 SPL 70 SPL 100 SPL 100 SPL 100 SPL 140 Monotron PEP 5 PEP 6 C2040 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 38 SPL 140 38 Nm Spicer suspension bearing Bracket attachment bolts 110 Nm + 30″ angular displacement Monotron suspension bearing M10 bracket attachment bolts 60 Nm M12 bracket attachment bolts 105 Nm © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 41 See "Mechanical gearbox" fault-finding table COMPLAINT: GEARBOX JUMPS OUT OF GEAR Possible cause Remedy Incorrect adjustment of control Check/adjust all points in the control Mechanical problem in gearbox See "Mechanical gearbox" fault-finding table © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 43 Connect engaging cylinder air pipes correctly are incorrectly connected COMPLAINT: NOT POSSIBLE TO ENGAGE LOW RANGE Possible cause Remedy VIC defective Check VIC and replace, if necessary Incorrect vehicle speed signal Check vehicle speed signal © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 45 Problem in mechanical gearbox control See "Mechanical gearbox control" fault-finding table COMPLAINT: SINGLE H BECOMES DOUBLE H Possible cause Remedy Locking plate in control cover not positioned Check assembly of control cover correctly © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 47 D1 to D5. Only when one of the faults has been remedied will the ECU be in a position to show a less important fault. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 48 Codes" can best be remedied by an Allison dealer. He has test and diagnostic apparatus at his disposal that can be connected to a special diagnostic socket in the central box (next to the V300392 DAVIE connector). © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 49 If this is the case, it is a normal response to the ambient temperature. If not, check whether the main gearbox is firmly connected and that the connectors are undamaged. If all these points are in order, contact your Allison dealer. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 50 ECU connector is connected, is firmly attached, is clean and undamaged. no interruptions or short circuits between wires or earth in wiring harness. If all these points are in order, contact your Allison dealer. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 51 Replace wiring harness if necessary. If all these points are in order, contact your Allison dealer. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 52 If all these points are in order, contact your Allison dealer. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 53 ECU connector is properly connected, clean and undamaged. rev sensor is properly connected, clean and undamaged. If all these points are in order, contact your Allison dealer. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 54 Delete the fault codes and try to re-start the vehicle. 14,15 If the fault re-occurs, replace the ECU. 16,21 If the fault has not been cleared, contact your Allison dealer. 22,23 24,25 26,32 33,34 35,36 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 55 Check free thrust pin travel or repair/replace main swollen seal or insufficient free thrust pin travel. cylinder Note: In the case of a swollen seal, clean the system and re-fill with new fluid © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 56 Defective clutch servo Check clutch servo and replace if necessary Thrust bearing incorrectly fitted Fit thrust bearing correctly Clutch housing disconnected from gearbox Tighten the clutch housing bolts to the correct torque © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 57 Play in slide coupling Replace prop shaft Forks not in line Align forks SYMPTOM: VIBRATION IN DRIVE LINE AT HIGH SPEED Possible cause Remedy Prop shaft imbalance Balance prop shafts or replace if necessary © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 59 Removing and installing rear control rod ......3-6 ..200508 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 61 For 5 and 6-gear boxes in combination with a 4-cylinder engine the operating mechanism has 2 adjustment options. For 6 and 9-gear boxes in combination with a 6-cylinder engine the operating mechanism has 4 adjustment options. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 62 MECHANICAL GEARBOX CONTROL ΛΦ45/55 series General 1.2 OVERVIEW DRAWING, OPERATING MECHANISM, 2 ADJUSTMENT OPTIONS V3 00 567 Control rod Torque rod Gearbox lever Ball joint © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 63 1.3 OVERVIEW DRAWING, OPERATING MECHANISM, 4 ADJUSTMENT OPTIONS V3 00 566 Control rod underneath the cab Ball joint Bracket Torque rod Gearbox lever Ball joint Control rod behind the cab Ball joint Torque rod © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 64 Telescopic control rod Attachment plate Retainer clip Vibration damper Pawl Spring holder Axle Centring spring Plug Bearing housing Gear lever pawl Spring Attachment nut Control rod pawl Attachment bolt Needle bearing © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 65 MECHANICAL GEARBOX CONTROL ΛΦ45/55 series General 1.5 OVERVIEW DRAWING, ZF GEARBOX GEAR LEVER V3 00 569 Switch button Gear lever Bearing housing © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 66 MECHANICAL GEARBOX CONTROL ΛΦ45/55 series General 1.6 OVERVIEW DRAWING, EATON GEAR LEVER V3 00 572 Cover plate Attachment nut O-ring Switch button Range group operating switch Clamping plate Gear lever Bearing housing © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 67 Loosen the lock nuts (3) of the gearbox lever. Loosen the lock nuts (2) of the torque rod on both sides. Remove attachment nut (1) from the torque rod on control rod side. V3 00 575 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 68 Centre the ball joint (1) by pressing it against the shoulder of the special tool (A). Note: On the special tool (A) (DAF no. 1453143) it is shown which side of the tool must be used for LHD vehicles and which side for RHD vehicles.
Page 69 (B) of the control rod. See "Technical data". 15. Remove the special tool and fit the gaiter. See "Removal and installation". 16. Fit the switch button. See "Removal and installation". V3 00 746 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 70 See "Technical data". If necessary, adjust the length of the ball joint. Remove the switch button (see "Removal and installation"). Remove the gaiter (see "Removal and installation"). V3 00 564 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 71 Centre the ball joint (1) by pressing it against the shoulder of the special tool (A). Note: On the special tool (A) (DAF no. 1453143) it is shown which side of the tool must be used for LHD vehicles and which side for RHD vehicles.
Page 72 19. Remove the special tool from the ball joint. 20. Remove the special tool and fit the gaiter. See "Removal and installation". 21. Fit the switch button. See "Removal and installation". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 73 Apply locking compound to the gear lever wire. See "Technical data". Fit the switch button onto the gear lever and tighten the attachment nut to the specified torque. See "Technical data". Fit the cover plate. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 74 Fit the top of the gaiter inside out over the gear lever and tighten the clamping strap (1). Pull the entire gaiter over the gear lever. Tighten the underside of the gaiter. V3 00 578 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 75 Fit the gear lever attachment bolts and tighten them to the specified torque. See "Technical data". Fit the gaiter. Fit the switch button. Check that the operating mechanism does not touch any vehicle parts during shifting. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 76 Removing control rod underneath the cab Remove the retainer clip (2) of the telescopic control rod (1). Remove the attachment nuts from the ball joint (4) and torque rod (5). V3 00 573 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 77 Tighten the attachment nuts of the ball joint (4) and the torque rod to the specified torque. See "Technical data". Check the functioning of the operating mechanism. See "Inspection and adjustment". V3 00 573 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 78 Remove the lock nut from the ball joint (5). Note: Make sure that the rearmost lock nut on the ball joint (5) is not moved. Remove the control rod (3). V3 00 574 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 79 Make sure that the control rod does not turn while the attachment and lock nuts are being tightened. Check the functioning of the operating mechanism. See "Inspection and adjustment". V3 00 574 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 80 MECHANICAL GEARBOX CONTROL ΛΦ45/55 series Removal and installation © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 83 PNEUMATIC GEARBOX CONTROL ΛΦ45/55 series General 1. GENERAL 1.1 LOCATION OF COMPONENTS IN PNEUMATIC SECTION OF GEARBOX CONTROL V3 00 360 Filter/governor Neutral position valve Electropneumatic downshift protection valve Range group engaging cylinder © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 84 VIC electronic unit Electropneumatic downshift protection valve Range group engaging cylinder Neutral position valve Filter/governor Range group operating switch Position "low" Position "high" Gearbox selector shaft in neutral Gearbox selector shaft engaged © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 85 (4) and the range group operating switch (6) located on the ball of the gear lever. When the range group operating switch is activated a pneumatic command will be sent to the electropneumatic downshift protection valve (2). © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 86 The neutral position valve is activated when the gear lever is moved through the neutral position. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 87 2. DESCRIPTION OF COMPONENTS 2.1 FILTER/GOVERNOR Filter/governor (1) on gearbox V300558-2 Overview drawing, filter/governor Filter/governor Filter element Seal O-ring Cover Plug Output Selector valve output plug Attachment bolt Supply pressure input V300430 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 88 The spring cannot be adjusted. The system pressure (see "Technical data") goes via connection point (2) to the range group operating switch and the neutral position valve. V302003 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 89 The pressure on connection 1 is the system pressure. When the switch is operated a pneumatic command will be sent from connection 21 to the electropneumatic downshift protection valve. V3 00 562 V3 00 477 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 90 The system pressure to connection point (1) on the electropneumatic downshift protection valve is only available when the gear lever, and hence also the neutral position valve, is in the neutral position. V3 00 478 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 91 At that moment the neutral position valve sends the system pressure from connection (21) to the electropneumatic V3 00 476 downshift protection valve. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 92 2.5 RANGE GROUP ENGAGING CYLINDER The range group engaging cylinder is mounted on the rear of the gearbox. The engaging cylinder is supplied from the electropneumatic downshift protection valve. V3 00 479 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 93 It is not possible to adjust the frequencies of the gate protection and the range-change protection with the standard program of DAVIE XD. If the vehicle configuration is changed, this should always be reported. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 94 Inspection and adjustment 3.2 SIMULATING SPEED SIGNAL The speed signal can be simulated with DELSI (DAF no. 0694941). DELSI must be connected to the speed sensor connector. Before connecting DELSI to the speed sensor connector, an adapter cable must be made.
Page 95 Switch the vehicle ignition on. Use the range group operating switch on the ball of the gear lever to select the lower range. The range group should now switch to the lower range. V300425 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 96 Use DELSI to decrease the simulated vehicle speed slowly to approximately 0 km/h. As the vehicle speed decreases, the range group should automatically switch to the lower range. V300426 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 97 ΛΦ45/55 series Inspection and adjustment 3.4 INSPECTION, FILTER/GOVERNOR Inspection, filter/governor Remove the plug from the extra outlet (9) and install a pressure gauge. Check the service pressure. See "Technical data". V300430 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 98 PNEUMATIC GEARBOX CONTROL ΛΦ45/55 series Inspection and adjustment © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 99 Tighten the attachment bolts to the specified torque. See "Technical data". Fit the air pipes. Pressurise the system. Check the system for air leakage. Check the operation of the valve. See "Inspection and adjustment". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 100 See "Technical data". Install a clamping strap on the inside of the gaiter. Pressurise the system. Check the system for air leakage. Check the operation of the range group operating switch. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 101 Replace the O-ring (4) and the sealing ring (3), if necessary. Fit the cover (5) and tighten it to the specified torque. See "Technical data". Pressurise the system. Check the system for air leakage. V300430 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 105 Type of gearbox ZF serial number Parts list (ZF) Specification number Pulse generator ratio Gearbox ratio Engine speed using PTO PTO speed Gearbox oil capacity Oil specification V300049 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 106 General 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. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 107 2. DESCRIPTION OF COMPONENTS 2.1 SYNCHRONISER B-lock synchronisation gear wheel selector ring synchromesh ring selector sleeve pressure spring thrust piece selector sleeve main shaft The synchroniser consists of the following parts: © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 108 (3) as far as a stop on the selector sleeve support (4), which is not in the figure, and thus prevents further movement of selector sleeve (7). W 3 03 046 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 109 This releases the lock and allows selector sleeve (7) to be moved into the teeth of selector ring (2). As a result, the relevant gear is engaged. Not connected Synchronise Connected V301005 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 110 ZF S5-42 GEARBOX ΛΦ45/55 series Description of components © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 111 The oil level must reach the rim of the level check/filler opening. After checking the oil level, tighten the level check plug to the specified torque. See "Technical data". V3 00 403 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 112 Uniformly press the outer bearing race (4), so that the bearing is free of play. Constantly rotate the input shaft while applying pressure so that the bearing is set. V3 00 413 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 113 10. Fit a new gasket (2) in the gearbox front cover (1) and fit it on the gearbox. See "Removal and installation". V3 00 413 11. Fit the gearbox. See "Removal and installation". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 114 ZF S5-42 GEARBOX ΛΦ45/55 series Inspection and adjustment © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 115 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. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 116 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 DAF LF Gearboxes and Clutch Service Manual...
Page 117 Disconnect the prop shaft from the gearbox drive flange. Support the shafts at a suitable point on the chassis. Fit the special tool (DAF no. 0484977) onto the drive flange. Remove the lock nut. Remove the special tool from the drive flange.
Page 118 Remove the drive flange. Prise the seal (2) out of the rear housing of the gearbox. Installing output shaft oil seal Using special tool (DAF no. 0694816) (1), fit the new seal in the rear housing. Fit the drive flange. V301012 ©...
Page 119 O-ring. Installing gearbox front cover oil seal Fit the oil seal using special tool (DAF no. 1240498) (1) at the right depth in the gearbox front cover (3). Install the gearbox front cover (3) with the O-ring on the gearbox. Tighten the attachment bolts to the specified torque.
Page 120 Remove the retainer (3) from the housing. Remove the oil seal (9) and the wiper seal (10) from the housing. Use the special tools (DAF no. 0535790) and (DAF no. 0535817) to remove the selector shaft bush (8) from the housing (2).
Page 121 Lubricate the circumference of the seal (9) with a soap solution. Fit the seal with special tool (DAF no. 0535659) in the housing, with the sealing lip on top. Fit the wiper seal (10). Place the special tool (DAF no. 0192546) on the selector shaft (7).
Page 123 (2) until the oil reaches the rim of the filling opening. After filling the gearbox, tighten the level check plug to the specified tightening torque. See "Technical data". V3 00 403 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 127 ZF gearbox type plate Type of gearbox Serial no. (ZF) Parts list (ZF) Specification no. Pulse generator ratio Gearbox ratio Engine speed using PTO PTO speed Gearbox oil capacity Oil specification V300049 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 128 The gearbox consists of six synchromesh forward gears and one non-synchromesh reverse gear. The first and second gears have double-cone synchronisation. The sixth gear is a direct drive or an overdrive, depending upon the model. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 129 2. DESCRIPTION OF COMPONENTS 2.1 SYNCHRONISER B-lock synchronisation gear wheel selector ring synchromesh ring selector sleeve pressure spring thrust piece selector sleeve main shaft The synchroniser consists of the following parts: © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 130 (3) to be turned back slightly after synchronisation. This releases the lock and allows selector sleeve (7) to be moved into the teeth of selector ring (2). As a result, the relevant gear is engaged. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 131 The ring between the two synchromesh rings is connected to the gear wheel by means of the selector ring. When the selector sleeve moves into the selector ring, two synchronisation surfaces are active. W 3 03 047 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 132 ZF 6S-850 GEARBOX ΛΦ45/55 series Description of components © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 133 The oil level must reach the rim of the level check/filler opening (A). After checking the oil level, tighten the level check plug to the specified torque. See "Technical data". M3038 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 134 See "Removal and installation". 10. Fit the attachment bolts. Tighten the bolts to the specified torque. See "Technical data". V3 00 435 11. Fit the gearbox. See "Removal and installation". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 135 Calculate the play for the correct size of the adjusting ring as follows: Distance A 2.95 mm Gasket thickness +0.40 mm Play (0 - 0.1) - 0.05 mm 3.30 ≥ 0.05 mm Required adjusting ring = V3 00 402 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 136 ZF 6S-850 GEARBOX ΛΦ45/55 series Inspection and adjustment © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 137 Place a jack under the gearbox and remove the bolts around the clutch housing. V300407 10. Use the jack to pull the gearbox away from the engine and remove the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 138 12. 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 DAF LF Gearboxes and Clutch Service Manual...
Page 139 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. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 140 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 DAF LF Gearboxes and Clutch Service Manual...
Page 141 Make a reference mark on the prop shaft and flange. Detach the prop shaft from the flange and secure it. Fit special tool (DAF no. 0484977) to hold the flange in place. Remove the attachment bolt and washer. V3 00 416 Using special tool (DAF no.
Page 142 7 mm outside of oil seals fitted with a rubber cover. 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. Fit the drive flange.
Page 143 Fit the oil seal (2) to the gearbox front cover V3 00 401 using special tools (DAF no. 0499809) and (DAF no. 0535409). Fit a new gasket (3). Check the input shaft axial play. See "Inspection and adjustment". Install the gearbox front cover (1). Tighten the bolts to the specified torque.
Page 144 Remove the circlip and the springs from the rear of the cover. Then remove the shaft and the selector fingers from the cover. W 3 03 052 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 145 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.
Page 146 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 V3 00 400 bearing bush on the spring side 2 mm under the edge.
Page 147 Top up oil through the level check/filling opening (A) until the oil reaches the rim of the filling opening. After filling the gearbox, tighten the level M3038 check plug to the specified torque; see "Technical data". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 151 The Eaton specification number is unique to each customer and gives detailed information on the V300378 development level of the gearbox. The number must be quoted whenever replacement parts are ordered. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 152 The group is changed as soon as the selector shaft passes through the neutral position. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 153 The oil level must reach the rim of the level check/filler opening (1). After checking the oil level, tighten the level check plug to the specified torque. See "Technical data". V3 00 376 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 154 Check at various places around the shaft. Fit a new gasket in the gearbox front cover and install the gearbox front cover. See "Removal and installation". Fit the gearbox. See "Removal and installation". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 155 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. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 156 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 DAF LF Gearboxes and Clutch Service Manual...
Page 157 Support the prop shaft from a suitable location on the chassis. Fit special tool (DAF no. 0484977) to hold the flange in place. Remove the lock nut and washer. Remove the flange with a suitable puller.
Page 158 Fit the seal housing and tighten the bolts to the specified torque. See "Technical data". Apply grease to the sealing lip of the oil seal. Fit the drive flange. If necessary, top up the gearbox. See "Inspection and adjustment". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 159 (DAF no. 1329354). Apply sealant to the contact surface of the gearbox front cover. Fit the gearbox front cover. Tighten the bolts to the specified torque. See "Technical data". Fit the gearbox. V301006 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 160 Remove the rubber sleeve (2). Drain the air reservoirs and remove the air connection from the selector shaft housing. Remove the bleed control valve and pin (16). © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 161 11. Remove the spring holders (11), the springs (12) and the spring clip (10). V3 00 506 12. Turn the selector shaft housing over and drive the plug (8) out of the housing. V3 00 497 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 162 If necessary, the selector shaft bearing bushes (4) and (9) can now also be removed using a suitable puller. V3 00 507 Installing selector shaft oil seal V3 00 475 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 163 Make sure that the holes in the selector finger and the selector shaft are aligned and fit a new pin (19). Fit the spring clip (10) and a spring holder (11) onto the selector shaft. V3 00 514 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 164 See "Technical data". 13. Install the shifting arm in the correct position on the selector shaft and tighten the lock nut to the specified tightening torque. See "Technical data". V301006 © 3-10 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 165 Fill the oil through level check/filler opening (1) until the oil reaches the rim of the level V3 00 376 check/filler opening. Fit the level check/filler plug, tightening it to the specified torque; see "Technical data". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 166 EATON FS/6309A GEARBOX ΛΦ45/55 series Draining and filling © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 167: Table Of Contents
Draining and filling gearbox ........5-1 ..200508 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 168 ALLISON 1000 & 2000 AUTOMATIC GEARBOXES ΛΦ45/55 series Contents © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 169 This results in lower fuel consumption. Starting To start the vehicle, the gearbox must be in the neutral position. If the gearbox is in a forward gear or in reverse, the vehicle cannot be started. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 170 As oil can be lost in this process, it must be avoided as much as possible owing to environmental concerns. Towing the vehicle without taking the above into consideration may lead to serious damage to the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 171 To reverse, the selector lever must be in the (R) position. A warning signal is also activated when V3 00 593 reversing. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 172 ECU. Before the vehicle can be started, the electronic unit must receive a signal from the selector switch confirming that the automatic gearbox is in neutral. V3 00 557 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 173 10. Oil needs to be added when the oil level is below the "Cold add" mark. 11. Check the oil level in the gearbox at operating temperature. W 3 03 099 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 174 "Hot full" mark. Note: The oil level must be checked at least twice. When there are differences between the measurements, check the bleeder for clogging. W 3 03 099 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 175 See "Technical data". Check in every gear that the positions of the selector lever in the cab correspond precisely to the selected gear. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 176 ALLISON 1000 & 2000 AUTOMATIC GEARBOXES ΛΦ45/55 series Inspection and adjustment © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 177 See what is best for gearboxes with PTO: remove the PTO from the gearbox, disconnect the hydraulic pipes from the pump or remove the prop shaft, if fitted. Remove the gearbox from the engine. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 178 Fit the oil pipes from and to the oil cooler. W 3 03 100 Fit and adjust the selector cable. See "Inspection and adjustment". If necessary, fit the oil filler pipe. Fill the gearbox; see "Draining and filling". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 179 See "Technical data". Fit the selector arm onto the selector shaft V3 00 481 and tighten the attachment nut to the specified torque. See "Technical data". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 180 Fit the selector cable into the selector arm. Note: The attachment of the selector cable must be fitted so that the connecting pin can move freely in every gear. V3 00 482 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 181 Drill two holes in the external cover of the oil seal and turn special tool (DAF no. 0484899) into the oil seal. Pull the oil seal out of the gearbox housing using special tool (DAF no.
Page 182 Remove the selector switch. V3 00 482 Fit special tool (DAF no. 1453124) over the selector shaft and turn it into the oil seal. Tighten the nut on the special tool (2) and remove the oil seal from the selector shaft bush.
Page 183 Fit the selector cable into the selector arm. V3 00 482 Note: The attachment of the selector cable must be fitted so that the connecting pin can move freely in every gear. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 184 Tighten the oil filters until they touch the contact surface. Manually tighten the oil filters another 360″. Check the oil level. See "Inspection and adjustment". V3 00 556 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 185 Remove the drain plug from the gearbox oil sump. Remove the drain plug (6) from the heat exchanger and loosen the bleed screw (3). Remove the oil filters. See "Removal and installation". V3 00 556 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 186 While the engine is idling, add gearbox oil until the oil level is between the "Cold add" mark and the "Cold full" mark. Check the oil level. See "Inspection and adjustment". W 3 03 099 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 188 ALLISON MD 3060 AUTOMATIC GEARBOX ΛΦ45/55 series Contents © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 189: General
Type designation: MODE Example MD3060 P Medium Duty Gearbox series Transmission ratios occurring in quick succession Number of gears possible Modification number PTO version V300392 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 190: System Description
It is now possible to drive the vehicle again, though the fault will still need to be remedied. In this situation, however, it is no longer possible to shift gears. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 191 Towing the vehicle without taking the above into consideration may lead to serious damage to the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 193: Description Of Components
Reverse If position "R" is chosen, the vehicle will also be immediately set in motion. First depress the brake pedal and then select position "R". "R" appears on the display. V300392 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 194 ™ Shifting up This key is used to change up to a higher gear. However, this is only possible after previously selecting to stay in a low gear. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 195 All diagnostic codes are preceded by the letter D followed by a number between 1 and 5. In this function, important fault codes could be deleted from the memory by an unqualified user. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 196 ALLISON MD 3060 AUTOMATIC GEARBOX ΛΦ45/55 series Description of components © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 197: Inspection And Adjustment
Remove the dipstick and check the oil level again. 10. Oil needs to be added when the oil level is below the "Cold add" mark. 11. Check the oil level in the gearbox at operating temperature. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 198 Oil needs to be drained when the oil level is above the "Hot full" mark. Note: The oil level must be checked at least twice. When there are differences between the measurements, check the bleeder for clogging. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 199: Checking Oil Level
LO followed by the number of litres lacking. Example LO-02 means that two litres have to be added. HI-03 means that three litres have to be drained. V300392 Press the N key to exit the system. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 200 ALLISON MD 3060 AUTOMATIC GEARBOX ΛΦ45/55 series Inspection and adjustment © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 201 See what is best for gearboxes with PTO: remove the PTO from the gearbox, disconnect the hydraulic pipes from the pump or remove the prop shaft, if fitted. Remove the gearbox from the engine. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 202 Fit the external oil pipes. Tighten the pipes to the specified torque; see "Technical data". If necessary, fit the oil filler pipe. Fill the gearbox with oil and check the oil level. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 203: Removing And Installing Output Shaft Oil Seal
V300529 Remove the bolt and locking plate from the flange. Pay attention to the sealing rings on the outer circumference and on the inside of the locking plate. V300559 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 204 Drill two holes in the external cover of the oil seal and turn special tool (DAF no. 0484899) into the oil seal. Pull the oil seal out of the gearbox housing using special tool (DAF no.
Page 205 (5) with clean gearbox oil and fit it on the heat exchanger. Tighten the oil filter until it touches the contact surface. Manually tighten the oil filter another 360″. Check the oil level. See "Inspection and adjustment". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 206 Fit the filter covers together with the oil filters on the gearbox and tighten the attachment bolts to the specified torque. See "Technical data". Check the oil level. See "Inspection and adjustment". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 207: Draining And Filling
Place the vehicle on a level and horizontal surface. Remove the drain plug (1) from the gearbox oil sump. Remove the oil filters (2). See "Removal and installation". V300371 W 3 03 098 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 208 To take the dipstick out of the holder, the sealing cap must be held while the dipstick is turned anti-clockwise. Check the oil level using the selector keypad. See "Inspection and adjustment". W 3 03 099 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 211 Avoid any contact with mineral oil. Even one drop of mineral oil in the system will damage the seals. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 213 For the clutch plate to engage smoothly the lining material must abut the flywheel and clutch release assembly evenly at all places when engaging. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 214 Spring seat housing Circlip Inlet valve Washer Spring seat Seal, hydraulic part, front Reset spring Seal, hydraulic part, rear O-ring Split bearing Connector housing Booster housing Allen screw Bleed nipple Air filter © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 215 CLUTCH ΛΦ45/55 series General 2.3 OVERVIEW DRAWING, CLUTCH LEVER ATTACHMENT TO CLUTCH HOUSING V300397 Screw adapter Ball joint Clutch lever Thrust bearing Clip Claw Yoke pin © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 217 Depressing the clutch pedal results in a build-up of hydraulic pressure. This causes the servo piston (1) to push the air valve (2) away from the valve seat, against the force of the springs (3) and (7). © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 218 (1) is no longer closed, and venting takes place via bleed vent (9). Vent opening The function of the vent opening (10) is to prevent a build up of pressure between both piston seals. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 219 (1) on the cover. If the wear indicator is no longer level with the mark on the clutch servo, replace the clutch plate. V3 00 375 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 220 The grease will attack the plastic coating and shorten the service life of the thrust bearing. LF 45 thrust bearing with ZF S5-42 gearbox V3 00 387 Thrust bearing, other LF versions V3 00 388 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 221 Avoid any contact with mineral oil. Even one drop of mineral oil in the system will damage the seals. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 222 Pressurise the air system. Check for any air leakage via the clutch servo bleed vent. Depress the clutch pedal and check whether there is any leakage via the clutch servo bleed vent. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 223 Depress the clutch pedal and check whether there is an air leak via the vent opening (10). © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 224 Check whether the fluid level is between the MINI and MAXI marks when the cab is in the driving position. G0 00 213 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 225 Make sure that the push rod falls into the cup- shaped recess in the wear indicator. Then tighten the attachment nuts evenly. Tighten the attachment nuts evenly. Connect the air and fluid pipes. Fill and bleed the clutch system. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 226 Ensure that the gearbox front cover is free of grease and dirt. Install the thrust bearing on the gearbox front cover. No grease is permitted. Fit the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 227 Install the yoke pin (7) in the claw (6) and put on the clip (5). Install the thrust bearing (4). Fit the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 228 Support the clutch release assembly and slide it onto the four studs. Fit the attachment bolts and tighten them crosswise to the specified torque. See "Technical data". V300124 Fit the gearbox. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 229 The pilot bearing (1) has a grease and dust seal (2) on one side only. When the pilot bearing is installed, the grease and dust seal must be on the clutch plate side. W 3 04 019 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 230 ΛΦ45/55 series Removal and installation Use a plastic mallet to install the bearing in the flywheel. W 3 04 017 Fit the clutch release assembly and clutch plate. Fit the gearbox. V300989 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 231 Screw the plastic fastening jig (1) out of the clutch pedal. If necessary, detach the spring (2). Remove the clutch cylinder. Fitting clutch cylinder Reposition the clutch cylinder in the holder. V3 00 579 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 232 V3 00 576 Screw the plastic fastening jig (1) into the pedal. Fit the spring (2) if it has been removed. Fill the clutch system; see "Draining and filling". V3 00 579 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 233 Reinstall the supply pipe. Filling clutch system Fill the reservoir with the specified fluid and bleed the system. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 234 Open the bleed nipple two full turns. As soon as no more air bubbles escape from the transparent pipe, the bleed nipple can be closed again. Check the fluid level. See "Inspection and adjustment". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 237 Disassembly and assembly, universal joint ......4-5 ..200508 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 239 PROP SHAFTS ΛΦ45/55 series General 1. GENERAL 1.1 OVERVIEW DRAWING, SPICER PROP SHAFT V3 00 747 Intermediate shaft Suspension bearing Prop shaft Clamping piece Fork Slider Prop shaft © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 240 PROP SHAFTS ΛΦ45/55 series General 1.2 OVERVIEW DRAWING, MONOTRON PROP SHAFT V300999 Drive flange Fork Intermediate shaft Suspension bearing Slider Prop shaft © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 241 Check the universal joints and suspension bearing for play and damage. M3032 Check the slide coupling for radial play. M3019 There must be no clearly perceptible play on universal joints and suspension bearing. M3020 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 243 W 3 06 019 Fit the shaft under the vehicle. Use a hoist if possible. Fit the attachment bolts. Tighten the attachment bolts to the specified torque. See "Technical data". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 244 Fit the shaft under the vehicle. Use a hoist if possible. W 3 06 019 Tighten the attachment bolts to the specified torque. See "Technical data". © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 245 Place the shaft on a bush underneath a press, as shown, and press the entire spider including bearings and drive flange down until the spider touches the fork of the shaft. W306010-2 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 246 Mounting universal joint Note: After mounting, it must be possible to move the drive flanges and spiders by hand. When mounting the spider, Seeger rings of the same thickness must be used. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 247 The opposite bearing can now be pressed into the fork, the spider serving as a guide. During the pressing action, the spider must be able to move freely. W306017-2 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 248 Seeger ring can now be fitted. W306013-2 10. Fit the circlips and the attachment bolts of the clamping pieces (1). 11. Install the prop shaft and/or intermediate shaft. V3 00 377 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 249 4.2 DISASSEMBLY AND ASSEMBLY, UNIVERSAL JOINT Disassembly, universal joint Remove the prop shaft and/or intermediate shaft assembly. If fitted, remove the lubricating nipple and all Seeger rings from the spider to be replaced. W306009-2 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 251 Install the sealing rings in their proper positions on the bearings and lubricate them lightly so that the needles remain in place. Press one bearing partly into the drive flange. © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 252 The opposite bearing can now be pressed into the fork, the spider serving as a guide. During the pressing action, the spider must be able to move freely. W306017-2 © 200508 DAF LF Gearboxes and Clutch Service Manual...
Page 253 Again, the Seeger ring can now be installed. 10. If fitted, install the lubricating nipple and lubricate the spider. W306013-2 11. Install the prop shaft and/or intermediate shaft. W306015-2 © 200508 DAF LF Gearboxes and Clutch Service Manual...

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