Iveco Stralis AT/AD. Manual

61229

Figure 16

61230

Figure 17

Unscrew the screws (1) and take off the top cover (2).

Extract the pin (3).

Take off the circlip (3) and extract the piston (2) together with
the ring (1).

61259

Figure 18

Remove the circlip (2) from the rod (1).

Use the washer (4) to limit the action of the spring (5) and
remove the split ring (3), extract the washer (4), the spring
(5) and the washer (6).

61231

Figure 19

Unscrew the plugs (2) with the washers, extract the springs
(1) and remove the levers (6).

If necessary, take out the pins (3).

Unscrew the screws (4) and remove the cover (5).

Remove the circlips (1) and take out the pins (2) fastening the
drive (4) to the rod (3).

61232

Figure 20

Move the sleeve (1) in the direction of the arrow.

Strike a punch on the top of the lever (6) to make it come
out of the bearing (3) and pin (2), freeing the latter from the
groove (4) in the rod (5).

61233

Figure 21

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

TRALIS

AT/AD

Base - January 2003

61234

Figure 22

61235

Figure 23

Note down the assembly position of the levers (2 and 3) and
take them out of the box (4) extracting the rod (1).

Using the male extractor 99348004, extract the bushing (2)
and the seal (1) from the box (3).

61236

Figure 24

Note down the assembly position of the locking element (1)
and drive (2) and take them out of the box (4) after extracting
the sleeve (3).

Position the locking element (1) and the drive (2) in the box
(4) as marked during removal and put on the sleeve (3).

61236

Figure 25

Using a suitable drift, mount the bushing (2) in the box (3).

Using a suitable keying device, fit the seal (1) in the box (3).
Lubricate the inside of the seal (1) with grease.

61235

Figure 26

When assembling, always replace the sealing
elements with new parts: rings, copper washers, flat
gaskets, o-rings and roller bearings with the pins.
Check that the springs have not broken nor yielded.

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

TRALIS

AT/AD

Assembly

61234

Figure 27

Position the levers (2 and 3) in the box (4) as marked during
removal and put on the rod (1).

Figure 28

36804

Move the sleeve (1) in the direction of the arrow.

Fit a new roller bearing (3) and pin (2) on the lever (6).
Position the rod (5) so that the groove (4) corresponds with
the roller (3) and pin (2).

Resting the lever (6) on a flat surface, carefully strike the
bearing (3) and pin (2) so they go into a position flush with
the top of the lever (6) and correctly enter the groove (4)
in the rod (5).

Figure 29

61232

Fasten the drive (4) to the rod (3), putting on the pins (2) and
mount new circlips (1) on these.

Figure 30

61231

On the rod (1), position: the washer (6), spring (5), washer
(4) and fit on a new split ring (3).

Fit on a new circlip (2).

Figure 31

61259

Fit on the cover (5) with a new gasket, screw down the
screws (4) and tighten them to the required torque.

Position the levers (6) on the pins (3). Screw down the plugs
(2) with the new washers and springs (1) and tighten them to
the required torque.

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

TRALIS

AT/AD

Base - January 2003

61230

Figure 32

43806

Figure 33

Fit a new ring (1) on the piston (2) and fit this in the box,
securing it with the circlip (3).

Insert the pin (3) in the box.
Put the top cover (2) on with a new gasket.
Screw down the screws (1) and tighten them to the required
torque.

43812

Figure 34

Position the push rod (3) with the spring (4) in the box (2).

Refit the servoshift (1) with a new gasket.

61257

Figure 35

Complete gearbox assembly by fitting:
- push rod (11), spring (12), plug (13) with a new seal;
- push rods (2 and 10), switches (1 and 9) with the new

washers;

- cup (8), lever (7) on the rod (6) in the position marked

during removal and tighten the nut (5) to the required
torque.

- valve (3) and tighten screws (4) to the specified torque.

Screw down the screws (1) and tighten them to the required
torque.
Connect the air pipe (3) to the distributor (4), screwing
down the fitting (2) with new copper gaskets and tightening
it to the required torque.

61227

Figure 36

Figure 37

61226

Refit the gearbox (5), screw down the fixing screws (1) and
tighten them to the required torque.

Connect the pipes (3 and 4) to the box (5), in the position
found at removal, with the fittings (2 and 6) together with the
new washers.

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

TRALIS

AT/AD

Content .. 81 82 83 84 ..

Iveco Stralis AT/AD. Manual - part 83