Iveco Stralis AT/AD. Manual

30983

37594

37595

37596

37597

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

After tightening to proper torque the screws to fasten flange
(1) to main shaft, fit in place a new safety plate and upset tabs
by use of tool 99370465 (2).
Remove the gearbox from the stand.
Install the side cover and provide it with new gasket.
Fill the gearbox with the required type and amount of oil.

Set the E.R.U.box on the bench. Lift the safety plate tabs (1)
and remove the plate.
Remove the screws (2), the lock plate (3) and the sealing ring
(4).
Withdraw the flange (6) from the E.R.U. shaft.

Disassemble the E.R.U. control cylinder (1). Remove the fork
knuckle screws (2). Disengage the rod (4) from the fork and
withdraw the rod from the box along with the piston (3).

Withdraw the box (1) from the E.R.U. unit (2). Remove the
cover (3), overturn the case and remove the bearing (5). Re-
move the tachometer transmission control (4).

Remove the sliding sleeve (7), the fork (3) and relevant sliding
shoes (2). From the shaft (1), remove: gear (4); coupling el-
ement (5) and synchronizer ring (6).

DISASSEMBLING THE E.R.U. BOX

If withdrawing is difficult, use a puller (5) as shown in
the figure.

DISASSEMBLING THE E.R.U.

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Base - January 2003

37598

37600

37599

37601

37602

37603

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Withdraw the sliding sleeve (1) from the hub (2) and check
that pins (3) and relevant springs (4) do not come out from
the hub.

From the shaft (1), withdraw:bearing (2) c.w. hub (3), syn-
chronizer ring (4), crown gear (6) coupling element (5).
If the operation is difficult, use suitable puller.

Remove the spring retaining ring (2); set the block (7) on the
bearing (1); use puller (6) and clamp (8) to withdraw the hub
(3) and the synchronizer ring (4) from the bearing, then with-
draw the coupling element (5).

Remove the spring retaining ring (1) and remove the bearing
(2) from the support (3).

Remove the spring retaining ring (1) and separate the crown
gear (2) from the support (3).

Fit the spring caps (4) in the pins (5) and use a bronze driver
to remove the pins (5) from the spider (1).
From the spider, withdraw: planet gears (2) c.w.shim rings (3)
and roller bearings.

Take note of the assembling position of the sliding
sleeve so as to prevent uncorrect assembling of syn-
chronizer rings.

If even only one planet gear is to be replaced, also the
remainder four ones shall be replaced as planet gears
are not supplied single as spare.

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

30508

30990

Figure 18

Figure 19

The E.R.U. box shall be free from cracks.
The faying surfaces between: covers, gearbox, E.R.U.box shall
not be damaged.
The seats of bearings shall not be damaged nor worn out.

EPICYCLIC GEARS

Check wear of synchronizer rings and relevant coupling el-
ements by operating as follows:
set the synchronizer ring (1) on the coupling element (2);
rotate the parts to ensure proper coupling;
use a gauge and shims (3) on two opposite points to check
gap X between coupling element and synchronizer ring. If
value X is less than 0,8 mm, replace the synchronizer ring and/
or the coupling element.

The fork shall be free from damages and relevant dowels not
loose in the radial race of the sliding sleeve.

The fork control rod (1) shall not be too much worn out nor
warped.
The control cylinder (7) shall not be worn out or cracked.
The piston (3) shall not be cracked nor warped.
The rings (2 and 4) shall not be too much worn out.

Bearings

The bearing seats in the epicyclic gear shaft shall not be dam-
aged nor worn out.
Toothing of gears in the crown gear shall not be damaged nor
too much worn out.

EPICYCLIC GEAR ENGAGEMENT

Splines between hubs and sliding sleeves shall not be damaged
and the sliding sleeve movement play on the hub shall not be
excessive.
Dowels in the sliding sleeve shall not be too much worn out.

Hubs-sleeves-synchronizers-coupling elements-forks

At assembling stage, do not mistake the components
with each other.

Ball or roller bearings shall be in perfect conditions, not af-
fected by overheating or excessive wear.
Check proper efficiency by pressing the bearings with your
hand while making them rotate to both directions at the same
time: move shall be smooth and free from noise.

E.R.U. PNEUMATIC CONTROL

Check perfect conditions of air pipes and also proper effi-
ciency of the distributor valve.

At assembling stage, always replace: plate, retaining
rings

and washers, sealing rings and grommets,

springs for sliding sleeve dowels and spring caps, self-
locking nuts and all parts not perfectly efficient,
marked, cracked or warped. Before assembling the
two-lip seals, fill the gap between the two lips with
TUTELA MR3.

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Base - January 2003

BOX

30991

Figure 20

COMPONE

PICYCLIC

DUCT

ION

NIT

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Content .. 68 69 70 71 ..

Iveco Stralis AT/AD. Manual - part 70