DAF LF45, LF55 Series. Manual - part 242

©

 200508

4-1

Removal and installation

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

4. REMOVAL AND INSTALLATION

4.1 REMOVING AND INSTALLING THE GEARBOX

Removing the gearbox
1.

Disconnect the earth lead from the battery 

terminal.

2.

Remove the silencer cap above the clutch.

3.

Remove the attachment bolts of the prop 

shaft flange and remove the prop shaft.

4.

Remove the intermediate bearing, if fitted.

5.

Remove the attachment bolt from the 

exhaust bracket on the gearbox.

6.

Remove the clamping strip from the exhaust 

pipe.

7.

Remove the attachment bolt of the rubber 

suspension point on the end of the exhaust.

8.

Twist the end-pipe of the exhaust loose and 

remove it.

9.

Remove the attachment bolts from the clutch 

cylinder and remove it.

10. Remove all electrical connectors.

11. Remove the compressor pipe bracket.

12. Remove the torque rod of the selector rod.

13. Remove the elbow of the selector rod on the 

selector shaft fork.

14. Support the gearbox and remove the 

attachment bolts around it.

15. Manoeuvre the gearbox to the rear until it is 

free and then remove it.

ZF S5-42 GEARBOX

4-2

©

 200508

Removal and installation

4

ΛΦ45/55 series

3

Installing the gearbox
1.

Engage the highest gear in order to align the 

keys of the input shaft with the clutch plate.

2.

Fit the gearbox onto the engine. If 

necessary, rotate the drive flange in order to 

align the keys.

3.

Fit the gearbox attachment bolts all around 

and tighten them to the specified torque. See 

"Technical data".

4.

Install the torque rod and secure it by means 

of new self-locking nuts.

5.

Install the elbow of the gearbox control on 

the selector finger. Use a new self-locking 

nut.

6.

Fit the exhaust bracket.

7.

Install the compressor pipe bracket.

8.

Fit the electrical connectors onto the 

gearbox.

9.

Fit the clutch cylinder.

10. Install the exhaust pipe, fasten it with the 

clamping strap and fit the attachment bolt of 

the suspension rubber.

11. Fit the prop shaft flange onto the gearbox.

12. Fit the intermediate bearing, if present.

13. Check the oil level. See "Inspection and 

adjustment".

14. Fit the silencer cap.

15. Fit the earth lead to the battery terminal.

©

 200508

4-3

Removal and installation

ZF S5-42 GEARBOX

ΛΦ45/55 series

3

4

4.2 REMOVING AND INSTALLING DRIVE FLANGE

Removing drive flange
1.

Disconnect the earth cable from the 

batteries.

2.

Make a reference mark on the prop shaft in 

relation to the gearbox drive flange.

3.

Remove the nuts and bolts, if any, with which 

the intermediate bearing of the prop shaft is 

fixed to the cross member of the chassis.

4.

Disconnect the prop shaft from the gearbox 

drive flange. Support the shafts at a suitable 

point on the chassis.

5.

Fit the special tool (DAF no. 0484977) onto 

the drive flange.

6.

Remove the lock nut. Remove the special 

tool from the drive flange.

Note:

Do NOT use the old lock nut again.

7.

Using special tool (DAF no. 0484978), 

remove the drive flange from the main shaft.

Installing drive flange
1.

Heat the drive flange to a temperature of 

70

″C and place it on the main shaft.

2.

Fit special tool (DAF no. 0484977) onto the 

drive flange.

3.

Apply locking compound to the screw thread. 

See "Technical data".

4.

Tighten the new lock nut to the specified 

torque. See "Technical data".

5.

Fit the prop shaft to the gearbox drive flange. 

Ensure that the reference markings are 

placed opposite each other. Fix the 

intermediate bearing onto the cross member 

of the chassis. Tighten the bolts to the 

specified torque. See "Technical data".

6.

Connect the earth clamp to the batteries.

ZF S5-42 GEARBOX

4-4

©

 200508

Removal and installation

4

ΛΦ45/55 series

3

4.3 REMOVING AND INSTALLING OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Prise the seal (2) out of the rear housing of 

the gearbox.

Installing output shaft oil seal
1.

Using special tool (DAF no. 0694816) (1), fit 

the new seal in the rear housing.

2.

Fit the drive flange.

V301012

2

1