Iveco Stralis AT/AD. Manual

61184

Figure 75

Fit suitable hooks (1) onto the front cover (2) and, using a
rope and lift, remove it from the gearbox (3).

61185

Figure 76

Remove the adjustment rings (1) from the tapered roller
bearing (3). Take off the gasket (2).

Using the extractor 99340205, take out the pins (3) centring
the front cover (1) with the gearbox (2).

Unscrew the screws (4) and the nuts fixing the front cover (1)
to the gearbox (2).

61186

Figure 77

Take the oil filter (4) out of the gearbox. Unscrew the two
socket-head screws (2), take out the splitter control rod (1)
and extract the fork (3) together with the sliding blocks from
the sliding sleeve.

37322

Figure 78

Position the tool 99360515 (2) on the drive input shaft (1)
and its sleeves (3) on the rods (4).

Screw the screw (5) of the tool 99360515 (2) into the
transmission shaft (8), adjust the nut (6) and the threaded
bushing (7) so that the transmission shaft (8) stays aligned
with the main shaft (9) when it is successively extracted.

Hook the tool 99360515 (2) onto the lift.

With a screwdriver in the hole (

→) of the gearbox, push the

bolt (2, Figure 81) so as to free the control rods (4) and at
the same time extract the shaft - rod assembly from the
gearbox.

61188

Figure 79

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

TRALIS

AT/AD

Base - January 2003

Lift the notch of the retaining ring (1) and remove the half
rings (2). Using a suitable extractor, remove the ring inside
the tapered roller bearing (3), extract the thrust washer (4).

37324

37325

Figure 80

Figure 81

Figure 82

Figure 83

Unscrew the 2 screws (1) and take out the splitter control
valve (2).

61189

Tighten the main shaft (9) in a vice.

Unscrew the screw (5) and remove the transmission shaft
(6).

Lift sleeves (3) from rods (4), remove tool (2) and take rods
(4) off their respective sliding sleeves.

Remove the drive input shaft (1) from the main shaft (9).

Remove the synchronizer ring (8) and the coupling body (7).

Remove the gear bolt (2) together with the spring from the
gearbox (1). Using an appropriate drift, extract the two outer
rings (3) and (4) of the bearings, ERG side, of the transmission
and main shafts. Clean the lubricating oil delivery pipes with a
jet of compressed air.

61190

Do not dismantle the splitter control valve (2), it
cannot be overhauled. Replace it if you find any
trouble.

Removing the main shaft

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

TRALIS

AT/AD

71120

71121

71122

Figure 84

Figure 85

Figure 86

Figure 87

Overturn the main shaft in the vice and take out the split ring
(1).

Take out the reverse gear (4) and the internal ring (6) of the
bearing, ERG side, with an extractor composed of:

- grips (3);

- tie rods (2);

- bridge (1);

- reaction block 99345058 (7);

- clamp (5).

Extract the roller bearing of the reverse gear (4) from the
main shaft.

Extract the 1st speed gear (5), the coupling body (4) and the
internal ring (3) of the bearing of the reverse gear with an
extractor composed of:

- grips (6);

- tie rods (8);

- bridge (1);

- reaction block 99345058 (2);

- clamp (7).

Extract the 1st speed gear roller bearing from the shaft.

27464

Extract the coupling body (1).

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

TRALIS

AT/AD

Base - January 2003

71123

27466

71124

Figure 88

Figure 89

Figure 90

Figure 91

Remove the synchronizer ring (2) from the main shaft (1).

Extract the sliding sleeve (2) together with the springs and
thrust elements and take out the three connecting blocks (1).

Extract the 2nd speed gear (5), coupling body, synchronizer
ring, fixed sleeve (4) and bushing (3) with an extractor
composed of: grips (6), tie rods (8), bridge (1), reaction block
99345058 (2), clamp (7).

Extract the 2

speed gear roller bearing from the shaft.

61191

Using a hydraulic press, extract the 3rd speed gear (13),
coupling body (12), synchronizer ring (11), synchronizer unit
(6), synchronizer ring (5), coupling body (4), roller bearings
(3), 4

speed gear (2) and roller bearing (1) from the main

shaft and take out the roller bearing (14).

Dismantle the synchronizer unit (6): remove the sliding sleeve
(10) from the hub (7), taking care over the pins (9) and springs
(8) coming out in order to collect them.

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

TRALIS

AT/AD

Content .. 84 85 86 87 ..

Iveco Stralis AT/AD. Manual - part 86