Iveco Stralis AT/AD. Manual

Air leaks from the pipe.

Check there are no leaks in the pipes and fittings; use an
acoustic appliance or soapy water. Replace or tighten the
seal if necessary.

Air leaks from the pressure reduction valve.

Replace the valve or its seals.

Defective pressure reduction valve setting.

Check the valve pressure. Replace if necessary.

YES

Air leaks from the inhibitor valves. Inhibitor valves do
not work.

Check the inhibitor valves. If necessary, replace the
valves or their seals.

YES

Air leaks from the driving cylinders.

Replace the gaskets and seals of the driving cylinders.

YES

GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.

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AT/AD

Base - January 2003

71751

Figure 9

To remove the gearbox, proceed as follows:

- Set the vehicle over a pit or on a lift.

- Disconnect the battery cables to prevent any short-cir-

cuiting.

- Disconnect the cable (11) using the connectors (

→) and

breaking the safety lead off the screw (10).

- Disconnect the connector (7) and the pipe (8) from the

power take-off (if applicable).

- Disconnect the air pipes (4) and (5).

- Free the pipes (6) from the clamps (12).

- Undoing the fasteners (13), disconnect the tie rod (14)

from the gearbox.

- Loosen the screw (2) and extract the lever (3) together

with the tie rod (1) from the gearbox after marking its
position for reassembly.

- Remove the fasteners (15) of the gearbox bell, accessible

from above.

Removal

For gearboxes with the intarder, proceed as follows:

- Drain off the engine coolant and disconnect the

pipes from the heat exchanger.

- If the cross member of the chassis frame pre-

vents you from removing the gearbox, you need
to drain off the oil from the intarder; take out the
nuts and screws fixing the heat exchanger to the
intarder, remove the stud bolts and detach the
heat exchanger.

GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.

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530210

REMOVING-REFITTING THE GEARBOX

45369

Figure 10

Working from under the vehicle:

- Disconnect the pipes (1) and (2), previously freed from

the clamps.

- Unscrew the nuts (5) and tie the clutch cylinder (6) to

the vehicle’s chassis frame appropriately.

- Undoing the side fasteners (8), take off the cross

member (7).

- Place a hydraulic jack equipped with the mount

99370629 (1, Figure 10) under the gearbox.

- Disconnect the propeller shaft (10) by undoing the

screws (9) and tie it to the vehicle’s chassis frame ap-
propriately so it will not interfere with the removal of the
gearbox.

- Complete removing the gearbox bell fasteners (4).

- Afterwards, extract the gearbox from the engine by

bringing it suitably back out of the space occupied by the
exhaust pipe (3). Then lower the jack and take out the
gearbox.

Figure 11

For gearboxes with the intarder, proceed as follows:

- Refit the heat exchanger to the intarder,

inserting new seals; fit the stud bolts and tighten
the fixing screw and nuts to the required torque.

- Connect the coolant pipes to the heat

exchanger and replenish the gearbox with the
required amount of oil.

- Fill the engine cooling system as described in

Section 2 Engine.

Carry out the operations performed for removal in
reverse order and tighten the fixing nuts and screws
to the required torque.

71752

Refitting

GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.

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Base - January 2003

Figure 12

Figure 13

Figure 14

Figure 15

530220

Servoshift gear box

Removal

There follows a description of the operations for
overhauling the ZF 16 S 151 gearbox that, unless
stated otherwise, hold for the ZF 16 S 181/221
gearboxes too.

Thoroughly wash the outside of the gearbox and drain the
oil off into a container.

To dispose of the lubricant and detergents, keep to
the specific regulations.

Fit the supporting brackets 99371031 to the assembly.

Using ropes with hooks and a movable lift, position the
assembly on the rotary stand 99322205 together with the
mount 99322225.

Use the specific tools for overhauling.
During removal, it is advisable to put the parts down
in the working sequence made in order to make
reassembly easier.

61226

Note down the assembly position of the pipes (3 and 4) and
disconnect them from the gearbox (5) by unscrewing the
fittings (2 and 6) together with the washers.

Unscrew the fixing screws (1) and remove the gearbox (5)
together with the servoshift from the gearbox.

The servoshift cannot be overhauled. Replace it if
you find any trouble.

Refitting

For refitting, carry out the steps described for removal in
reverse order, fitting new seals and tightening the fixing
screws (1) and fittings (2 and 6) to the required torque.

61227

Unscrew the fitting (2) and disconnect the air pipe (3) from
the distributor (4).

61257

Unscrew the screws (1, Figure 13) and disconnect the
servoshift (1) from the gearbox (2).

Take out the push rod (3) with the spring (4).

61228

Mark the assembly position of the lever (7) on the rod (6).
Loosen the nut (5) and remove the lever (7) from the rod
(6).
Extract the cup (8).
Remove:
- The valve (3) after taking out the screws (4).
- The switches (1 and 9) with their washers and push rods

(2 and 10).

- The plug (13) with its washer, the spring (12) and the

push rod (11).

530210

OVERHAULING THE GEARBOX

Disassembly

GEARBOX ZF 16 S 151 D.D. - 181 D.D./O.D. - 221 D.D.

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Content .. 80 81 82 83 ..

Iveco Stralis AT/AD. Manual - part 82