Iveco Stralis AT/AD. Manual

Figure 14

Figure 15

52758

16. Change gearbox oil

The figure shows ZF 16 S 151 transmission.

- With the gearbox warm, take off the plug(s) (1) and

drain the oil into a specific container.

- The oil should be drained off taking care not to soil the

cross member beneath as it is near the outlet on some
types of gearbox.

- It is therefore wise to use a tool to convey the oil away.

- Pour in fresh oil through the hole closed by the plug (2)

(for the quantity, see under the FLUIDS heading of the
GENERAL section).

- Tighten the plugs to the required torque.

(ZF 12 AS 2301 / 16 AS 2601 gearbox)

72579

- With the gearbox warm, take off the plug(s) (1) and

drain the oil into a specific container.

- The oil should be drained off taking care not to soil the

cross member beneath as it is near the outlet on some
types of gearbox.

Figure 16

- With the gearbox warm, take off the plugs (1) and drain

the oil into a specific container.

72570

23. Change oil and filter of ZF 16 S 151/181/221

gearbox + Intarder

Figure 17

52571

Remove the oil filter as follows:

- unscrew the screw (5) fixing the filter;
- take off the cover and filter (1);
- remove the cover from the filter and replace it. Take care

not to lose the magnetic pad (4) on the outer edge of
the filter, as it has to be repositioned on the new filter;

- check the state of the o-ring (2) and replace it, if

necessary;

- grease the o-ring (3) inserted in the assembly opening of

the new filter;

- couple the new filter with its cover and insert it into its

seat as far as it will go. Secure the screw (5).

18. Check-up on EDC system with MODUS or

IT2000

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Base - January 2003

Figure 18

Figure 19

72572

- Screw the plugs back on and tighten them to the

required torque.

- Pour in fresh oil through the hole closed by the plug (7)

until oil comes out of the hole of plug (6) and screw the
plugs back on to the required torque.
(The filling quantity is given under the FLUIDS heading
of the GENERAL section.)

- Clean the gearbox oil vapour breather.

Change oil and filter of ZF Eurotronic

Automated gearbox with Intarder

72573

- With the gearbox warm, take off the plugs (1) and drain

the oil into a specific container.

- Remove the Intarder filter following the procedure

described in the above paragraph.

- Screw the plugs (1) back on and tighten them to the

required torque. Pour in fresh oil through the hole of
plug (3) until oil comes out of the hole of plug (2).
(See the FLUIDS table in the GENERAL section.)

- Screw the plugs back on to the required torque.
- Clean the gearbox oil vapour breather.

Have a short test run on the roads (at least one
minute at least 10 km/h), briefly operating the
Intarder just once (level 6) and then disengage it
(level 0). At the end of the test, stop the vehicle
without operating the Intarder. Stop the engine,
check the level again (plug 2) and top up, if necessary.

Figure 20

Figure 21

72566

16. Clean gearbox oil bleed

The figure shows ZF 16 S 151 transmission.
Remove the oil vapour breather (1) and clean it thoroughly.
Then fit it back on, checking it is in the right position, and
tighten it to the required torque.

15. Change rear axle oil

15. Clean rear axle oil breather

40657

The lubricating oil has to be drained with the oil warm.
Place a container under the plug (1), remove the plug and
drain off the oil.

Fit the plug (1) back on, remove the plug (2) and pour the
required grade and quantity of lubricating oil in through the
hole. Remove the oil vapour bleed and clean it thoroughly.

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Figure 22

Figure 23

77471

72558

11. Change front, middle or rear axle wheel

hub oil (where applicable)

For the wheel hubs with the cover illustrated in the figure,
proceed as follows:
- turn the wheel hub so as to bring the plug (1) downward;

unscrew the plug and drain off the oil into an appropriate
container;

- then turn the hub and take the hole closed by the plug

(1) back upward and replenish with fresh oil; for the
quantity, see CHARACTERISTICS AND DATA in the
“AXLES” section;

- screw the plug down to the prescribed torque.

Figure 24

Use no chlorothene based solvents to clean the
cover.

For the wheel hub with the cover illustrated in the figure,
proceed as follows:
- remove the plug (1) and draw up the oil with a suitable

string;

- fill the wheel hub with new oil (for the quantity and type

of oil, see CHARACTERISTICS AND DATA in the
“AXLES” section.

The oil level is checked through the window in the plug (1)
with max. and min. on the cover in a horizontal position.

10. Check steering box fixing and mounting

Check that the fastenings of the steering box and
mounting are tightened to the required torque.

Check headlight adjustment

72585

- Set the vehicle unladen with its tyres at the required

pressure on level ground facing a light wall.

- Mark two crosses on the wall corresponding to the

centres of the two headlights.

- Turn the switch onto 0.
- Set the vehicle at 10 metres and turn on the low beam.

The distance between the crosses and the points P,
which correspond to the angle of the headlights, has to
be 12.5 cm.

Light beam adjustment screw in horizontal direction.

Light beam adjustment screw in vertical direction.

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Base - January 2003

Figure 25

85503

ASSEMBLY DIAGRAM OF BELTS FOR FAN — WATER

PUMP — ALTERNATOR AND AIR-CONDITIONER

COMPRESSOR

1. Fan — 2. Alternator — 3. Drive belt — 4. Drive belt

automatic tensioner - 5. Compressor drive belt

6. Air-conditioner compressor — 7. Screw -

8. Air-conditioner compressor automatic tensioner —

9. Crankshaft - 10. Water pump

To remove and refit the belts (3-5) you need to apply suitable
tools to the tensioners (4-8) in the direction shown by the
arrows.
After removing the control belts (3 and 5), take off the screw
(7) and change the backstand (8).
Fasten screw (7) and tighten it to the specified torque.

The backstands are automatic and so no further
adjustments are planned after assembly.

21.

Check valve clearance and adjust if
necessary

To carry out these operations correctly, refer to the
procedures described in the relative chapter of the
“ENGINE” section.

The M3 service includes M1 operations without 1-2.
check control belts; 16. change oil and oil filter in
transmission with Intarder. Add also the following
operations.

M3 SERVICE

1-2. Change miscellaneous drive belts

Change

air

conditioner

automatic

compressor backstand

The M4 service includes M2 operations without 1-2.
“Check control belt conditions”. Add also operation
21.

“Check

valve

clearance

and

possible

adjustment”, 1-2. Change control belts and 3.
“Change air conditioner automatic compressor
backstand”.

M4 SERVICE

Figure 26

EP1 SERVICE

16. Change Allison automatic transmission oil

and filters

85504

Place the vehicle on a bridge.

Remove the draining plug (2) of the check module and drain
the transmission oil at operating temperature (71

° to 93°C).

Once the oil has been drained, refit the plug (2) to a tightening
torque corresponding to 25 to 32 Nm.

Slacken the 12 check module fastening screws (3) and remove
the oil filter covers (4). Remove the filters (5) and the gaskets
(6 - 7 - 8 ).

For refitting, reverse the removal procedure and attain to the
following prescriptions.

Lubricate the new O-rings before assembly. Tighten the
screws to the prescribed torque.

Once assembly has been completed, make sure the oil
draining plug (2) is well tightened and then pour 18 litres of
Tutela GI/A oil through the filling pipe.

16. Clean Allison automatic transmission oil

breather

Remove the oil vapour breather (1) and clean it accurately,
then refit it in the correct position and tighten it to the
prescribed torque.

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Content .. 276 277 278 279 ..

Iveco Stralis AT/AD. Manual - part 278