Iveco Stralis AT/AD. Manual

31020

30486

30479

Figure 62

Figure 63

Figure 64

Remove the roller bearing (1) and the sliding sleeve (2) that
engages R gear and pickup gear.
Remove the spring ring (3).

Use the puller (4), block 993450097 (5) and the clamp (6) to
remove the hub (1) for the sliding sleeve that engages R speed
gear and pickup speed gear. Remove the pickup speed gear
(2) and the roller bearing (3).

MAIN SHAFT COMPONENTS

1. Main shaft - 2. Roller bearing - 3. Pickup speed gear - 4. Hub - 5. Engagement sliding sleeve - 6. Spring ring -7. Roller bear-

ing - 8. Reverse speed gear - 9. Taper roller bearing - 10. Planet gears - 11. Pipe - 12. 1st speed gear - 13. Coupling element -

14. Synchronizer ring - 15 .Hub - 16. Pin - 17. Pin - 18. Spring - 19. 2nd speed gear - 20. Bush - 21. 3rd speed gear - 22. Pawl

- 23. Small block - 24. Taper roller bearing

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Base - January 2003

37657

37658

Figure 65

Figure 66

Figure 67

Remove the cones from taper roller bearings (2) by using suit-
able tools.
Remove the spring retaining ring (6).

Mark the assembling position of the lever (1) on the shaft (3),
then remove it.
Withdraw the casing (2).
Remove the pin (4).

TRANSMISSION SHAFT COMPONENTS

Use a hydraulic press (80 tons), then, one by one, remove the
gears (5-4-3) from the transmission shaft (1).

Disassembly the cover (7), the valve (1), the cylinder (6) and
relevant retaining ring (5), then, withdraw the springs (4) and
the piston (3).
Remove the cover (2).

530520

REMOVING THE GEARCHANGE
CASE OF GEARBOX

1. Transmission shaft - 2. Taper roller bearing - 3. I-II speed gear - 4. III speed gear - 5. IV speed gear -

6. Spring retaining ring

30489

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

531030

REMOVING THE TRANSMISSION SHAFT

37659

37661

37660

37662

37663

37664

Figure 68

Figure 69

Figure 70

Figure 71

Figure 72

Figure 73

Remove the plugs (1) and relevant washers and withdraw the
springs (2). Remove: the pins (3), the spacers (4) and the
levers (5).

Remove the spring ring (2) from the shaft (1) and withdraw
the washer (3) and the spring (4).

Remove the spring ring (2) from the shaft (1) and withdraw
the washer (3), the spring (4) and the washer (5).

Disengage the spacer (1) from the shaft (2) after removing the
spring pin (3).

Position the shaft (1) so as the spring pins that connect the
stop sectors (2 and 3) to the shaft are towards the hole (

→).

Use a punch to pull out the spring pins.

Keep the three prongs (6) to prevent them from falling down
and remove the shaft (8) and relevant nine pawls (7).
Then, remove the spacer (1), the stop sectors (2 and 3) and
the spacer (4) from the case (5).

Take note of the assembling position of pawls (6).

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Base - January 2003

31029

37665

Figure 74

Figure 75

OIL PUMP

Remove the screws (1) and disassemble the components.
Check that the bodies (2 and 5) are free from defects or dam-
ages.

GEAR CHANGE CASE COMPONENTS

Check that the inner rotor (3) and the outer rotor (4) are not
too much worn out and also check that they are not too much
loose in their seats. If any fault or trouble is found out, replace
the oil pump.

GEARBOX ZF 9 S 109 D.D.

TRALIS

AT/AD

Content .. 71 72 73 74 ..

Iveco Stralis AT/AD. Manual - part 73