Iveco Stralis AT/AD. Manual

61219

Figure 16

Taking care over the blocks (5) and springs (3 and 4) coming
out of the hub (2), extract the sliding sleeve (1) from the hub
and remove the seal (6).

Figure 17

61252

61221

Using the extractor composed of bridge (1), brackets (2),
reaction part (3) and clamp (4), extract the sliding sleeve hub
(6) from the ERG shaft (5).

61220

Take off the synchronizer ring (1) and the coupling body (3)
together with the plate (2).

Levering under the coupling body (3), extract it from the
plate (2).

Figure 18

Figure 19

COMPONENT PARTS OF THE EPICYCLIC REDUCTION GEAR UNIT SYNCHRONIZING DEVICE

108

GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER

TRALIS

AT/AD

Base - January 2003

61253

Figure 20

Figure 21

71128

Component parts of the epicyclic reduction
gear unit

COMPONENT PARTS OF THE ERG CONTROL AND BOX

1. Gasket - 2. ERG - 3. Plate - 4. Bushing - 5. Fifth wheel bearing - 6. Gear - 7. Gasket - 8. Sliding blocks - 9. Fork - 10. Nozzle tube

- 11. ERG box - 12. Pin for fork articulation with washer - 13. Gasket - 14. Cover - 15. Screw - 16. Ball bearing -

17. Adjustment ring - 18. Plug with seal - 19. Plug with seal - 20. Sensor - 21. Screw with washer - 22. Cylinder - 23. Seal -

24. Seal - 25. Nut - 26. Seal - 27. Spacer ring - 28. Piston - 29. Seal - 30. Rod - 31. Tube - 32. Pin.

Remove the epicyclic reduction gear unit as described for
gearboxes with no Intarder.

GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER

109

TRALIS

AT/AD

61222

Figure 22

Remove the ball bearing (1) from the ERG box (2).

Unscrew the screws (3) and remove the cover (4).

Unscrew the screw (5).

Figure 23

43408

Determine the thickness S of the ERG ball bearing end float
adjustment ring as follows:

- Measure the depth of the bearing seat in the ERG rear

box (1): distance A.

Figure 24

43809

Measure the depth of the bearing seat in the retarder:
distance B.

Figure 25

- Measure the thickness of the bearing (1): distance C;

- Measure the thickness of the gasket between the

retarder and the ERG box: distance D.

The thickness S of the adjustment ring to place between the
ball bearing and the retarder is given by the following
equation:

S =

A + B + D - C -Y

Where,

- A - B - C - D = measurements made;

- Y = 0.1 mm: end float of the ball bearing

(0.00

÷ 0.10 mm).

Fitting the epicyclic reduction gear unit (ERG)

To mount the epicyclic reduction gear unit, carry out the
steps described for removal in reverse order.

The operations and assembly phases requiring specific tools,
clearance checks, adjustments or special precautions are
described below.

43810

110

GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER

TRALIS

AT/AD

Base - January 2003

61254

Figure 26

43806

Figure 27

Position the plate (2) together with the tube (3) on the ERG (4).

Heat the seat of the ball bearing (1) on the ERG rear box (2)
to approx. 60ºC and mount the ball bearing (1).

43812

Figure 28

Place a new gasket (7) on the plate (6).

Partially fit the ball bearing (3) with the box (4) on the ERG
shaft (2).

Insert the rod (9) into its seat in the box (4).

Position the fork (8) in the slot in the rod (9) and, keeping
it in this position, complete the assembly of the ball bearing
(3) on the shaft (2).

61223

Figure 29

When fitting the bearing (3), guide the tube (5) with
a punch (1) so it goes into its seat (

→) in the box (4).

Set the fork (2) with its blocks on the sliding sleeve (1).

Fasten the fork (8, Figure 12) to the box with the articulation
pins (1) and tighten them to the required torque.

43802

Figure 30

Heat the gear (1) to a temperature of 160ºC for no
longer than 10 sec.
Fit the gear (1) on the ERG shaft (3).

GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER

111

TRALIS

AT/AD

Content .. 91 92 93 94 ..

Iveco Stralis AT/AD. Manual - part 93