dw232473 GROUP 3

3 CONTENTS
65/75/85CF series
TECHNICAL DATA
0
DIAGNOSIS
1
MECHANICAL GEARBOX CONTROL
2
PNEUMATIC SECTION OF GEARBOX
3
MECHANICAL GEARBOXES
4
AUTOMATIC GEARBOXES
5
CLUTCH
6
PROP SHAFTS
7
ZF INTARDER
8
VOITH RETARDER 133-2
9
PTO’S
10
SPLITTER BOX
11
9910
3 TECHNICAL DATA
65/75/85CF series Contents
CONTENTS
Page Date
0
1. MECHANICAL GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 . . . . . 9910
2. PNEUMATIC SECTION OF GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . . 9910
3. MECHANICAL GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 9910
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 9910
4. AUTOMATIC GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9910
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9910
5. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
6. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 9910
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 9910
7. ZF INTARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 9910
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 9910
7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . . 9910
8. VOITH RETARDER 133-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ...... 9910
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ...... 9910
9. PTO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ...... 9910
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ...... 9910
10. SPLITTER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 ..... 9910
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 ..... 9910
10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 ..... 9910
10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 ..... 9910
9910 1
TECHNICAL DATA 3
Contents 65/75/85CF series
2 9910
3 TECHNICAL DATA
65/75/85CF series Mechanical gearbox control
1. MECHANICAL GEARBOX CONTROL

1.1 GENERAL
0
V300265
- Within the entire 65/75/85CF vehicle series

many gearbox variations as well as the
accompanying controls are possible, both
mechanical and pneumatic.
- A gearbox with a splitter and group switch
will be equipped with several pneumatic
valves.
9910 1-1
TECHNICAL DATA 3
Mechanical gearbox control 65/75/85CF series
ADJUSTMENT, LINKAGE MECHANISM

LHD 65 vehicle series with S6 - 36/2 and
0 6S - 850 gearboxes
Distance A: 90
Distance B: 47 mm
Distance C: 385 mm
1-2 9910
3 TECHNICAL DATA
RHD 65 vehicle series with S6 - 36/2 and

6S - 850 gearboxes
Distance A: 90 0
Distance B: 47 mm
Distance C: 484 mm
9910 1-3
TECHNICAL DATA 3
LHD 65 vehicle series with 9S - 75 gearbox
0 Distance A: 90
Distance B: 47 mm
Distance C: 346 mm
1-4 9910
3 TECHNICAL DATA
RHD 65 vehicle series with 9S - 75 gearbox
Distance A: 90
Distance B: 47 mm 0
Distance C: 260 mm
9910 1-5
TECHNICAL DATA 3
RHD 75 vehicle series with 8S - 109 gearbox
0 Distance A: 90
Distance B: 68 mm
Distance C: 346 mm
1-6 9910
3 TECHNICAL DATA
LHD 75 vehicle series with 9/16S -

109 gearbox
Distance A: 90 0
Distance B: 68 mm
Distance C: 199 mm
9910 1-7
TECHNICAL DATA 3
RHD 75 vehicle series with 9/16S -

109 gearbox
0 Distance A: 90
Distance B: 68 mm
Distance C: 346 mm
1-8 9910
3 TECHNICAL DATA

151 gearbox
Distance A: 90 0
Distance B: 68 mm
Distance C: 269 mm
9910 1-9
TECHNICAL DATA 3

151 gearbox
0 Distance A: 90
Distance B: 68 mm
Distance C: 247 mm
1-10 9910
3 TECHNICAL DATA

151/181 gearboxes
With 270 mm long torque rod 0

Distance A: 90
Distance B: 68 mm
Distance C: 270 mm
9910 1-11
TECHNICAL DATA 3

151/181 gearboxes
0 With 273 mm long torque rod
Distance A: 90
Distance B: 68 mm
Distance C: 273 mm
1-12 9910
3 TECHNICAL DATA
LHD 85 vehicle series with 16S - 221 gearbox
Distance A: 90
Distance B: 68 mm 0
Distance C: 193 mm
9910 1-13
TECHNICAL DATA 3

151/181 gearboxes
0 With 272 mm long torque rod
Distance A: 90
Distance B: 68 mm
Distance C: 272 mm
1-14 9910
3 TECHNICAL DATA

151/181 gearboxes
With 292 mm long torque rod 0

Distance A: 90
Distance B: 68 mm
Distance C: 292 mm
9910 1-15
TECHNICAL DATA 3
LHD 85 vehicle series with TS 12612 Eaton

gearbox
0 Distance A: 90
Distance B: 68 mm
Distance C: 293 mm
1-16 9910
3 TECHNICAL DATA
RHD 85 vehicle series with TS 12612 Eaton

gearbox
Distance A: 90 0
Distance B: 68 mm
Distance C: 332 mm
9910 1-17
TECHNICAL DATA 3
Gluing gear lever into ball

Degreaser (DAF No. 1322827)
0 Adhesive (DAF No. 1340646)
1-18 9910
3 TECHNICAL DATA
1.2 TIGHTENING TORQUES
Control rod
Adjusting nut (4) 75 Nm
0
Locknut (2) 50 Nm
1 2 3 4
V300147
Clamping bolt (1), control rod to gear lever unit 40 Nm

Attachment nuts (3), gear lever unit 27 Nm
3 1 2
V300275
9910 1-19
TECHNICAL DATA 3
1-20 9910
3 TECHNICAL DATA
65/75/85CF series Pneumatic section of gearbox
2. PNEUMATIC SECTION OF GEARBOX

2.1 GENERAL
0
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
Frequency table
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁ
Engine
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
Gearbox
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Intarder Transfer
box
Gate safety
protection
Group safety
(Hz)
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
(Hz)
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 9S - 75 (DD) -- VG750 49 114
ÁÁÁÁ
ÁÁÁÁ
PF
ÁÁÁÁ
PF ÁÁÁÁÁ
8/16S - 109 (DD)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
8/16S - 109 (DD)
--
Intarder
-- 44
44
94
94
ÁÁÁÁ
ÁÁÁÁ
PF
ÁÁÁÁ
8S - 151 (DD)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
29 77
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
PF 9S - 109 (DD) -- -- 60 114
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
PF 9S - 109 (DD) Intarder -- 60 114
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
PF 16S - 151 (DD) -- -- 29 68
ÁÁÁÁ
ÁÁÁÁ
PF
ÁÁÁÁ
XF ÁÁÁÁÁ
16S - 151 (DD)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
8S - 151 (OD)
Intarder
--
--
--
40
29
85
77
ÁÁÁÁ
XF
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
8S - 181 (OD) -- -- 29 68
ÁÁÁÁ
ÁÁÁÁ
XF ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
8S - 151/181 (DD) -- 29 68
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
XF 16S - 181/221 (DD) -- -- 29 57
ÁÁÁÁ
ÁÁÁÁ
XF
ÁÁÁÁ
XF ÁÁÁÁÁ
16S - 151/181/221 (OD)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16S - 151/181/221 (DD) Intarder
-- 29
33
68
77
ÁÁÁÁ
XF
ÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16S - 151/181/221 (OD) Intarder -- 38 94
9910 2-1
TECHNICAL DATA 3
Pneumatic section of gearbox 65/75/85CF series
GV VALVE
GV valve begins to open (C) 140 2 mm
0 Total clutch pedal travel (D) 150 2 mm
V300315
NEUTRAL POSITION VALVE

2 x 3/2-way valve
Service pressure 6.5 to 10 bar
Line connection M14 x 1,5
2-2 9910
3 TECHNICAL DATA
EATON GEAR LEVER SELECTOR

Threaded end (A) 17 mm
0
W 3 02 100
EATON TS FILTER/GOVERNOR
Output pressure (8) 5.3 to 5.7 bar
Supply pressure (12) 8 to 10 bar
Plug/test connection (6) 8 to 10 bar
6
5
4
3
12
9 10
8
8
W 3 02 099
9910 2-3
TECHNICAL DATA 3
GEAR LEVER SELECTOR VALVE
0 ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ ÁÁÁÁÁÁ
Auxiliary gearbox
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁ
Connection point
ÁÁÁÁÁÁÁÁ
1
ÁÁÁÁÁÁ
Supply
Colour
Black
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
3
ÁÁÁÁÁÁ
Bleed Red
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
21 Service line auxiliary White
gearbox
21
1
3
V300266
ÁÁÁÁÁÁ
PNEUMATIC SYMBOL
ÁÁÁÁÁÁ
Auxiliary gearbox 1 3
ÁÁÁÁÁÁ
Position Function
ÁÁÁÁÁÁ
GP Auxiliary gearbox
I II
“Range”
21
V300267
2-4 9910
3 TECHNICAL DATA
GEAR LEVER SHIFTING VALVE
ÁÁÁ ÁÁÁÁÁÁ
Auxiliary gearbox group and splitter
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ 0
ÁÁÁ
Connection point
ÁÁÁÁÁÁÁÁ
1
ÁÁÁÁÁÁ
Supply
Colour
Black
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
3
ÁÁÁÁÁÁ
Bleed Red
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
21 Service line auxiliary White
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
gearbox
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
22 Service line splitter Yellow
21
1
22
3
V300046
PNEUMATIC SYMBOL
ÁÁÁÁÁÁ
Auxiliary gearbox group and splitter
ÁÁÁÁÁÁ
Position Function
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
GV Splitter
22 21
H H
L L
GV GP
V300161
9910 2-5
TECHNICAL DATA 3
EATON GEARBOX SELECTOR VALVE

DAF has two different selector valves for the
0 LHD and RHD vehicle series:
a version in which the three-position switch is
1
22
positioned to the left of the valve (LHD) and
21
a version in which the three-position switch is
23
positioned to the right of the valve (RHD).
The three air pipes emanating from the valve
run together to the piston cover on the gearbox.
Connection points: WAB
CO 3
1 = S-supply
21 = R-steering pressure pipe
22 = Plugged
23 = F-steering pressure pipe
3 = Bleed
W 3 02 093
F
R
W 3 03 031
23 21 22 2
1
3
W 3 02 096
Pneumatic symbol
R 1 3
N
2 4
W 3 02 097
Gear change pattern
2-6 9910
3 TECHNICAL DATA
Gear button on gear lever

Gear button locknut 70 Nm
0
Eaton selection valve
Selector valve Allen screw 16 Nm *
* Loctite 243
9910 2-7
TECHNICAL DATA 3
2-8 9910
3 TECHNICAL DATA
65/75/85CF series Mechanical gearboxes
3. MECHANICAL GEARBOXES
3.1 GENERAL
0
GEARBOX TYPE
Each gearbox has a type plate attached to it,
indicating the type of gearbox. These data can
also be found on the vehicle identity card for the
vehicle concerned.
1. Type of gearbox
2. Serial No. ( ZF )
3. Parts list ( ZF ) 1
4. Specification No.
5. Pulse generator ratio
6. Gearbox ratio 3 2
7. Engine speed using PTO
8. PTO speed
4
9. Gearbox oil capacity 6 5
10. Oil specification 8 7
9 10
V300049
ZF GEARBOXES
Axial bearing play
Axial bearing play on gearbox output shaft 0.00 - 0.10 mm
Axial bearing play, main and input shafts

S6 - 36/2, 6S - 850, 8/16S - 151/181/221 0.00 - 0.10 mm
Axial play, auxiliary shaft

S6 - 36/2 0.00 - 0.10 mm
6S - 850 0.00 - 0.10 mm
18/16 S - 151/181/221 0.00 - 0.10 mm
Axial bearing pre-load, main and input

shafts
9S - 75 0.05 - 0.12 mm
8/9S - 109 0.18 - 0.30 mm
16S - 109 0.18 - 0.30 mm
Axial bearing pre-load, auxiliary shaft

9S - 75 0.05 - 0.12 mm
8/9S - 109 0.18 - 0.30 mm
16S - 109 0.18 - 0.30 mm
9910 3-1
TECHNICAL DATA 3
Mechanical gearboxes 65/75/85CF series
EATON GEARBOX
Axial bearing play, main/input shaft and
0 output shaft
TS 12612 0.10 - 0.70 mm
Axial play, main shaft gears

TS 12612 0.10 - 0.70 mm
Input shaft Lithium-based grease, class NLGI 3
3-2 9910
3 TECHNICAL DATA
GEARBOX TO ENGINE 0
M8 attachment bolts - 8.8 30 Nm
ZF GEARBOXES
S6 - 36/2 and 6S - 850 gearboxes
Drive flange locknut, S6-36/2 360 Nm
Drive flange locknut, 6S-850 120 Nm
Gearbox cover 23 Nm
Air connection banjo bolt 23 Nm
Control bearing cover 38 Nm
Conical drain plug 50 Nm
Level check/filler plug 50 Nm
9S - 75 gearbox
Drive flange lock plate attachment bolts 60 Nm
Gearbox cover 23 Nm
Output shaft bearing cover 53 Nm
Drain plug 50 Nm
8/9/16S - 109 gearbox

Gearbox cover 25 Nm
Drain plug 140 Nm
8/16S - 151/181/221 gearboxes

Gearbox cover 46 Nm
Drain plug 140 Nm
9910 3-3
TECHNICAL DATA 3
Shift control high/low

Shifting fork bolts high/low 180 Nm
0 Piston gear engaging cylinder lock nut
Lock bolts gear engaging cylinder
180 Nm
50 Nm
Rear cover attachment bolts 50 Nm
Gearbox with intarder

M24 Drain plug (1) 60 Nm
M38 Drain plug (1) 120 Nm
Drain plug (2) 60 Nm
Level check/filler plug (4) 60 Nm
Filler plug (5) 60 Nm
1
3
4 5
V300261 V300260
EATON GEARBOXES
Eaton TS 12612
Prop shaft locknut 650 Nm *
Gearbox cover 65 Nm
Auxiliary shaft retaining cover 55 Nm
Drain plug 75 Nm
Lower cover 75 Nm **
* Loctite 262
** Loctite 243
3-4 9910
3 TECHNICAL DATA
3.3 FILLING CAPACITIES
0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ZF Gearbox oil capacity
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Type of gearbox Capacity without Capacity with intarder Replenishment
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
intarder capacity with intarder
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
S6 - 36/2 7.5 litres n/a n/a
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
S6 - 36/2 with N 10 9.0 litres n/a n/a
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
PTO
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
6S - 850 7.5 litres n/a n/a
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
9S - 75
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
8S - 109
9.5 litres
ÁÁÁÁÁÁÁÁÁ9 litres
n/a
22 liter
n/a
12.5 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
9S - 109
ÁÁÁÁÁÁÁÁ
16S - 109
ÁÁÁÁÁÁÁÁÁ
8 litres
9 litres
21 liter
22 liter
12 litres
12.5 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
8S - 151
ÁÁÁÁÁÁÁÁÁ
11 litres 18,5 liter 11 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
16S - 151 11 litres 18,5 liter 11 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
8S - 181
ÁÁÁÁÁÁÁÁÁ13 litres 21,5 liter 12 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
16S - 181/221
ÁÁÁÁÁÁÁÁ
gearboxes
ÁÁÁÁÁÁÁÁÁ
13 litres 21,5 liter 12 litres
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
EATON Gearbox oil capacity
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Type of gearbox Capacity
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Eaton TS 12612 approx. 13.5 litres
9910 3-5
TECHNICAL DATA 3
3-6 9910
3 TECHNICAL DATA
65/75/85CF series Automatic gearboxes
4. AUTOMATIC GEARBOXES
4.1 GENERAL
0
Allison transmission, used in the 65 and 75 CF,
is electronically controlled and has its own
diagnostic system that saves any faults in the
memory of the ECU (Electronic Control Unit).
The faults can be read at a later date. The
system is operated and the faults are read via
the selector keypad. The “Selector keypad”
fitted with a display is located next to the driver’s
seat and replaces the gear lever with manual 5
stick-shift gearboxes.
R MODE
Allison
V300290
9910 4-1
TECHNICAL DATA 3
Automatic gearboxes 65/75/85CF series
0 Gearbox bleeder
Prop shaft attachment bolts with locking plate
14 Nm
32 Nm
Prop shaft attachment bolts with sprung
locking plate 75 Nm
Gearbox rear mounting bracket 100 Nm
PTO bracket 55 Nm
Gearbox with flywheel housing adapter,
M10 x 1.5 55 Nm
Flex plate to flex plate adapter 26 Nm
Flex plate adapter to torque converter 26 Nm
Hydraulic pipes to oil cooler 60 Nm
Gearbox main connector 2.5 Nm
Vehicle interface module connector 2.5 Nm
Vehicle interface module, M6 5.5 Nm
Oil filter caps attachment bolts 55 Nm
Oil drain plugs 28 Nm
Molycote BR2 Plus for torque converter pilot

bearing for installation
4-2 9910
3 TECHNICAL DATA
0
ÁÁÁÁÁÁÁÁÁÁÁ
Automatic Allison gearbox oil capacities
Type of gearbox Capacity at first filling Capacity at second filling
MD 3060P 2″-oil sump 25 litres 18 litres
The oil level when cold must be on the “Cold

full” mark.
Dip-stick readings:
- “Cold add” = Top up cold oil
level
- “Cold full” = Cold oil level full
FULL
HOT
- “Hot add” = Top up hot oil level
- “Hot full” = Hot oil level full
HOT
ADD
COLD
FULL
COLD
ADD
W 3 03 099
9910 4-3
TECHNICAL DATA 3
4-4 9910
3 TECHNICAL DATA
65/75/85CF series Clutch
5. CLUTCH
5.1 GENERAL
0
CLUTCH RELEASE ASSEMBLIES
1
W304005
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
EngineÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Clutch release Releasing force (N) Press-on force (N) Design
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
type assembly type
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
NS 133 M MF 362 3900 12500 - 14100 Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 156 M
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 177 M ÁÁÁÁÁÁÁÁ
MF 362
ÁÁÁÁÁÁÁÁ
MF 362
ÁÁÁÁÁÁ
3900
3900
12500 - 14100
12500 - 14100
Diaphragm
Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
PF 183 M
GMF 430
ÁÁÁÁÁÁÁÁ
MFZ 430
ÁÁÁÁÁÁ
5500
8200
18200 - 20300
34200 - 38000
Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
PF 212 M ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
GMF 430
ÁÁÁÁÁÁ
5500 18200 - 20300 Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
MZF 430 8200 34200 - 38000
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
PF 235 M MFZ 430 8200 34200 - 38000 Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
XF 250 M
GMF 430
ÁÁÁÁÁÁÁÁ
MFZ 430
ÁÁÁÁÁÁ
8200
7000
34200 - 38000
24500 - 27500
Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
XF 280 M
ÁÁÁÁÁÁÁ
XF 280 M
ÁÁÁÁÁÁÁÁ
GMF 430
ÁÁÁÁÁÁÁÁ
MFZ 430
ÁÁÁÁÁÁ
7000
8200
24500 - 27000
34200 - 38000
Diaphragm
Diaphragm
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
XF 315 M ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
MFZ 430
ÁÁÁÁÁÁ
8200 34200 - 38000 Diaphragm
9910 5-1
TECHNICAL DATA 3
Clutch 65/75/85CF series
CLUTCH PLATES
0 1
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
W304006
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Engine typeÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
Clutch plate Design Lining Input
shaft
Clutch-
release
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 133 M
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
GTZ 362 Single dry plate Valeo asbestos-free F202
Splines
1.5″
bearing
KZIS-3
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 156 M
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
1.75″
1.5″
KZI-4
KZIS-3
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NS 177 M ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
1.75″
1.75″
KZI-4
KZI-4
ÁÁÁÁÁÁ
ÁÁÁÁÁ
PF 183 M
GTZ 400
ÁÁÁÁ
ÁÁÁÁÁ
GTZ 430
Single dry plate Valeo asbestos-free F202 1.75″
2.0″
KZIS-4
KZIZ-5
ÁÁÁÁÁÁ
ÁÁÁÁÁ
PF 212 M
GTZ 400
ÁÁÁÁ
ÁÁÁÁÁ
GTZ 430
Single dry plate Valeo asbestos-free F202 1.75″
2.0″
KZIS-4
KZIZ-5
ÁÁÁÁÁÁ
ÁÁÁÁÁ
PF 235 M
ÁÁÁÁÁÁÁ
XF 250 M ÁÁÁÁ
GTZ 430
ÁÁÁÁ
ÁÁÁÁÁ
GTZ 430
Single dry plate
Single dry plate
Valeo asbestos-free F202
Valeo asbestos-free F202
2.0″
2.0″
KZI-5
KZI-5
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
XF 280 M ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
2.0″
2.0″
KZI-5 *
KZI-5
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
2.0″ KZI-5 *
ÁÁÁÁÁÁ
*
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
XF 315 M
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁ
GTZ 430 Single dry plate
KZI-5 in combination with GMF 430 &

Valeo asbestos-free F202 2.0″ KZI-5
Eaton twin splitter gearbox.
5-2 9910
3 TECHNICAL DATA
Main cylinder
Maximum piston travel 34 mm
Pressure pin setting (E)
Mounting seals
approx. 0.2 - 0.8 mm
Silicone grease
0
Clutch pedal
E-gas proximity sensor (A) 1 - 0 + 1 mm
Clutch pedal free travel (B) approx. 2 - 4 mm
GV valve begins to open (C) 140 2 mm
Total clutch pedal travel (D) 150 2 mm
A
3
1
E
4
5
7
B
6
C
V300315 V300286
9910 5-3
TECHNICAL DATA 3
0 MAIN CYLINDER
Pressure pin attachment nut 55 5 Nm
Exhaust port 8 2 Nm
Steel line coupling 40 Nm
CLUTCH RELEASE ASSEMBLY

ZF gearboxes
Attachment bolts, clutch release assembly to
flywheel 54 4 Nm
Attachment bolts, clutch lever to gearbox 27 2 Nm
EATON gearboxes
Attachment bolts, clutch release assembly to
flywheel 54 4 Nm
Attachment bolts, clutch lever to gearbox 27 2 Nm
Clutch
First filling 0.4 litres
5-4 9910
3 TECHNICAL DATA
65/75/85CF series Prop shafts
6. PROP SHAFTS
6.1 GENERAL
0
For the 65/75/85 CF vehicle series, DAF has
two manufacturers of prop shafts, Gelenk
Wellenbau and Klein.
The Gelenk Wellenbau-shafts can be identified
by the two welded brackets and the balancing
plates with the letters GWB stamped into them.
Klein shafts can be identified by their highly
bevelled flanges.
The various components of the shafts are not
interchangeable, with the exception of some of
the spiders.
Complete shaft assemblies, however, can be
exchanged. It is also permitted to install
shafts from two different manufacturers in
one vehicle.
Inspection:
There must be no clearly noticeable play on
universal joints, centre bearing and sliding joint.
65CF
Balancing speed,
retracted length w1800 n/max = 2700 n/min
75/85CF
Balancing speed,
Balancing speed,
Centre bearings
If a lubricating nipple is fitted to the 65/75/85 CF,
it must be lubricated.
9910 6-1
TECHNICAL DATA 3
Prop shafts 65/75/85CF series
0 Gelenk Wellenbau
Attachment bolts, drive flange

M12 8.8 79 6 Nm *
M12 10.9 110 8 Nm *
M14 8.8 125 9 Nm *
M14 10.9 170 15 Nm *
Central bolt centre bearing 350 15 Nm *

Centre bearing attachment bolts 170 15 Nm *
Klein
Attachment bolts, drive flange

M12 8.8 79 6 Nm
M12 10.9 110 8 Nm
M14 8.8 125 9 Nm
M14 10.9 170 15 Nm
Central nut centre bearing

M24 x 1,5 250 + 50 Nm
M40 x 1,5 350 + 50 Nm
M55 x 1,5 380 + 70 Nm
Centre bearing attachment bolts 170 15 Nm *
* Loctite 243
Grease must be seen to seep from the

spider/sliding coupling or centre bearing.
6-2 9910
3 TECHNICAL DATA
65/75/85CF series ZF-intarder
7. ZF-INTARDER
7.1 GENERAL
0
Axial clearances
Stator 0 0.05 mm
Bearing output shaft 0 - 0.1 mm
External rotor oil pump 0.03 - 0.05 mm
Drive sprocket intarder

Heat in oven for a maximum of 15 minutes 130 - 150C
9910 7-1
TECHNICAL DATA 3
ZF-intarder 65/75/85CF series
0 Drive flange attachment bolts

Attachment bolts (8,8) 60 Nm
Attachment bolts (10.9) 120 Nm
Shift control high/low

Shifting fork bolts high/low 180 Nm
Piston gear engaging cylinder lock nut 180 Nm
Lock bolts gear engaging cylinder 50 Nm
Rear cover attachment bolts 50 Nm
Heat exchanger
Studs in heat exchanger 18 Nm *
Attachment nuts 62 Nm *
oil connection flange attachment bolt 23 Nm *
Heat exchanger attachment surfaces Loctite 574
Hydraulic control unit

M10 attachment bolts 50 Nm
Gauges and sensors

Temperature sensor 40 Nm
Air supply valve 23 Nm
Proportional valve 23 Nm
Attachment intarder to gearbox

M10 attachment bolts 50 Nm
Oil pump
Attachment bolts 23 Nm
Oil filter
Attachment bolt 23 Nm
* Fasten with Loctite 574
7-2 9910
3 TECHNICAL DATA
65/75/85CF series Voith-retarder 133-2
8. VOITH-RETARDER 133-2
8.1 GENERAL
0
Minimum brake torque 250 Nm
Maximum brake torque 4000 Nm
Service pressure 8 - 10 bar
Oil level gauge 80 Nm

Oil level plug 80 Nm
Oil-filler plug M24 x 1.5 80 Nm
M18 x 1.5 50 Nm
Oil drain plug retarder 150 Nm

Oil drain plug butterfly valve 65 Nm
Oil-filler plug M18 x 1.5 50 Nm
M24 x 1.5 80 Nm
Cooling water drain plug
Heat exchanger 50 Nm
Adapter plate attachment bolts M10 45 Nm
M12 80 Nm
Retarder attachment bolt/nuts 250 Nm
Attachment bolts, sealing plate (drive flange) 8 Nm *
Labyrinth cover attachment bolts 45 Nm
Attachment bolts, drive flange retaining plate 110 Nm
Prop shaft bolts M12 75 Nm
M14 115 Nm
Attachment nuts, heat exchanger/retarder 45 Nm **
Attachment bolts, heat exchanger support
strip 45 Nm
M6 attachment bolts, heat exchanger cover 10 Nm ***
M8 attachment bolts, heat exchanger element 25 Nm ***

** Self-locking
*** Loctite 243
9910 8-1
TECHNICAL DATA 3
Voith-retarder 133-2 65/75/85CF series
0 Oil change
New retarder (initial filling)
8.2 litres
9.5 litres
8-2 9910
3 TECHNICAL DATA
65/75/85CF series PTO’s
9. PTO’S
9.1 GENERAL
0
For the 65/75/85 CF vehicle series, DAF has two
sorts of PTO:
the DAF engine PTO and the ZF gearbox PTO.
The DAF engine PTO can be recognised by the
position of the PTO, on top of the flywheel
housing at the rear of the engine.
The ZF gearbox PTO can be recognised by the
position of the PTO, to the rear of the gearbox.
DAF ENGINE PTO

Axial bearing play
Drive gears between crankshaft and PTO 0.15 - 0.30 mm
PTO housing prop shaft bearings 0.02 - 0.1 mm
ZF GEARBOX PTO
Axial bearing play
Axial play on gearbox output shaft, in case of
attachment of N 211/10 PTO on gearbox
without intarder 0 - 0.1 mm
Axial play in case of attachment of N353/1
PTO on N211/10 PTO 0 - 0.2 mm
9910 9-1
TECHNICAL DATA 3
PTO’s 65/75/85CF series
0 DAF ENGINE PTO

Main shaft locknut 500 Nm *
Gear attachment bolt in flywheel housing 110 Nm
Flywheel housing rear sealing plate 30 Nm
Output shaft flange bolt 110 Nm
Gear shift lever 30 Nm
PTO operating cylinder cover 30 Nm
Operating cylinder housing expansion plug Loctite 510
Attachment bolts, shift control on gearbox 30 Nm
PTO gearbox stud 68 Nm *
Attachment nut, drive housing stud 68 Nm *
Attachment, PTO housing to flywheel housing Loctite 510
Attachment bolt, PTO housing to flywheel
housing 40 Nm
Oil pipe hollow screws 50 Nm
ZF GEARBOX PTO
Attachment, N71/1-/2 and N353/1-/2
Installing attachment studs with a liquid
jointing compound 25 Nm
Gearbox attachment nuts 86 Nm
Attachment N211/10
Drive flange 120 Nm
Side cover attachment bolts 23 Nm
Gearbox attachment bolts 79 Nm
9-2 9910
3 TECHNICAL DATA
65/75/85CF series PTO’s
0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Extra filling capacities, ZF gearbox PTS’s
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
PTO-TYPE
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
FILLING CAPACITY
(LITRES)
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/1C
ÁÁÁÁÁÁÁÁ
N353/1C
0.2
0.2
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/B 0.2
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N353/1B 0.2
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/2B 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N353/2B
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/2C
0.5
0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N353/2C
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/4B 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N353/4B 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N71/4C 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N353/4C
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10B
0.5
1.0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10C 1.0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10 IT 1.0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10 C TI 1.0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10 B PL
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N221/10 C-PL
1.0
1.0
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N36/5 B
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N36/5 C 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N352/3 B 0.5
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
N352/3 C 0.5
9910 9-3
TECHNICAL DATA 3
PTO’s 65/75/85CF series
9-4 9910
3 TECHNICAL DATA
65/75/85CF series Splitter box
10. SPLITTER BOX

10.1 GENERAL
0
Steyr splitter box
Axial bearing play on gearbox output shaft 0.05 - 0.10 mm
Output shaft bearing pre-tension 10 - 15 cm/kg
Intermediate shaft axial bearing play 0.3 - 0.4 mm
Adjust shifting fork control pressure 6.5 - 8 bar
Shifting fork 1/3 - 1/2 stroke back
Adjustable torque rod 2 reclined
Attachment nut, output shaft 1080 Nm *

Attachment nut, input shaft 300 Nm
Attachment bolts, splitter housing assembly 45 Nm
Attachment bolts, cover with oil seal 45 Nm
Allen screw, satellite halves 180 Nm
Locknut, gear lever 50 Nm
Drain plug 50 Nm
Filler/dip plug 60 Nm
* Loctite 243
Oil change 6.4 litres
9910 10-1
TECHNICAL DATA 3
Splitter box 65/75/85CF series
10-2 9910
3 DIAGNOSIS
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
2. PNEUMATIC SECTION OF GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
1
3. MECHANICAL GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
4. AUTOMATIC GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.2 Reading/deleting fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . . 9910
5. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
6. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 9910
7. ZF INTARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 9910
8. VOITH RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . . 9910
9. SPLITTER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . . 9910
9910 1
DIAGNOSIS 3
2 9910
3 DIAGNOSIS
1. MECHANICAL GEARBOX CONTROL

1.1 FAULT-FINDING TABLE
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
FAULT: GEAR LEVER VIBRATES
1
Possible cause Remedy
Excessive play at control hinge points Check/repair all points in the control
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFAULT: ENGAGING GEARS IS HEAVY
Possible cause
Gearbox control pivot and hinge points
Remedy
Check/repair all points in the control
dry or worn
Mechanical problem in gearbox See “Mechanical gearbox” fault-finding table
Possible cause
FAULT: GEARS CANNOT BE SHIFTED
Remedy
Gearbox control pivot and hinge points Check/repair all points in the control
dry or worn
FAULT: GEARBOX JUMPS OUT OF GEAR
Incorrect adjustment of control Check/adjust all points in the control
9910 1-1
DIAGNOSIS 3
1-2 9910
3 DIAGNOSIS
2. PNEUMATIC SECTION OF GEARBOX

FAULT: NOT POSSIBLE TO ENGAGE HIGH OR LOW GROUP
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1
Air pressure too low Check air supply of circuit 4
Neutral valve defective or incorrectly connected Connect valve properly or replace
Defective down-shift safety valve Replace valve
Defective high/low group engaging cylinder Check cylinder and replace if necessary
FAULT: HIGH/LOW GROUP ENGAGING CYLINDER ENGAGES LOW AT TOO HIGH A SPEED
Incorrect CTE frequency value Adjust value
FAULT: HIGH OR LOW GROUP ENGAGING IS SLOW
Air pressure too low Check air supply of circuit 4
Piping blocked Check piping and clean, if necessary
Defective neutral valve Replace valve
FAULT: HIGH/LOW GROUP ENGAGING CYLINDER WORKS THE WRONG WAY ROUND
Air pipes on the high/low group engaging
cylinder are incorrectly connected
Connect engaging cylinder air pipes correctly
9910 2-1
DIAGNOSIS 3
FAULT: NOT POSSIBLE TO ENGAGE LOW GROUP
CTE defective
Check CTE and replace, if necessary
Incorrect vehicle speed signal Check vehicle speed sensor and replace if
1 necessary
Check vehicle speed signal
FAULT: SPLITTING NOT POSSIBLE
Air pressure too low Check pneumatic system
Defective or incorrectly set GV valve Check and set/replace, if necessary
Wrong relay valve fitted for splitter Fit correct relay valve type
Broken or incorrectly connected air pipes Check air pipes and replace or connect properly,
if necessary
Wrong selector switch on gear lever Fit correct switch type
Wrong bore hole plugged in splitter cylinder Plug correct bore hole
Splitter cylinder not working Check cylinder and replace if necessary
FAULT: SPLITTER CYLINDER OPERATES IN REVERSE MODE
Wrong splitter relay valve fitted Fit correct relay valve type
Wrong gear lever selector valve fitted Fit correct selector valve type
Air pipes connected incorrectly Check air connections and correct as necessary
FAULT: SPLITTING IS SLOW
Air pressure too low Check pneumatic system
Blocked air pipes Check pipes
Defective or incorrectly set GV valve Check valve and replace as necessary
2-2 9910
3 DIAGNOSIS
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ FAULT: GATE 1/2 NOT SAFEGUARDED
Possible cause
Leaking or blocked air pipes Replace air pipes
Remedy
No air from neutral valve in neutral position Check neutral valve and replace if necessary
Defective gate safety valve (B184) Replace gate safety valve 1
CTE does not receive a signal Check CTE speed signal
CTE gives no output voltage Check CTE
Defective low group switch (E561) Replace low group switch
FAULT: GATES 1/2 AND 5/6 PERMANENTLY BLOCKED.
Defective gearbox gate safety valve (B184) Replace gearbox gate safety valve
Gate safety active in high and low group Check the low group switch
9910 2-3
DIAGNOSIS 3
2-4 9910
3 DIAGNOSIS
65/75/85CF series Mechanical gearbox
3. MECHANICAL GEARBOX
FAULT: ENGAGING GEARS IS HEAVY
1
Gearbox oil level too low Top up oil level
Use of oil with incorrect specification in the Fill gearbox with oil of correct specification
gearbox
Problem in mechanical gearbox operation See “Mechanical gearbox operation” fault-finding
table
Clutch plate is not released See “Clutch” fault-finding table
FAULT: GEARS CANNOT BE SHIFTED
Possible cause
Holding element fitted too deep
Remedy
Check/repair holding elements
table
Group switch does not work properly See “Pneumatic section of gearbox operation”
fault-finding table
Possible cause
FAULT: GEARBOX JUMPS OUT OF GEAR
Remedy
Adjustment of gear box cover Mount cover on gearbox without any play
Defective holding element or wrong type of Replace holding element or fit other type of
holding element fitted in gearbox cover holding element
table
9910 3-1
DIAGNOSIS 3
Mechanical gearbox 65/75/85CF series
FAULT: GEAR LEVER STUCK IN GATE 3/4
Oil leak in gate safety piston Replace the O-ring
1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
FAULT: SINGLE H BECOMES DOUBLE H
Possible cause
Locking plate in control cover not positioned
Remedy
Check composition of control cover
correctly
3-2 9910
3 DIAGNOSIS
4. AUTOMATIC GEARBOXES
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Main code Sub code Recommended procedures
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1
ÁÁÁÁÁ
ÁÁÁÁÁ
Electronic control unit (ECU) supply
ÁÁÁÁÁ
ÁÁÁÁÁ
13 12 Low Check the following points:
ÁÁÁÁÁ
ÁÁÁÁÁ
a. Earth and positive battery cables connected, firmly attached and
clean.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
b. Batteries are charged.
23 High
c. Vehicle loading system loads neither too little or too much.
d. VIM fuse (Vehicle Interface Module).
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
e. VIM - connections are firmly attached, clean and undamaged.
f. The correct wiring is used.
ÁÁÁÁÁ
ÁÁÁÁÁ
g. ECU - connections are firmly attached, clean and undamaged.
If all points are in order, contact your Allison dealer.
ÁÁÁÁÁ
ÁÁÁÁÁ
Throttle kick-down
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
21 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
12
23
Check the following points:
a. Kick-down connector is connected.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
b. Kick-down cable is correctly tensioned.
c. Fuel pump control lever is in the idling position.
ÁÁÁÁÁ
ÁÁÁÁÁ
d. Fuel pump control lever ensures that the kick-down cable makes the
correct stroke.
ÁÁÁÁÁ
ÁÁÁÁÁ
e. There are no interruptions or short circuits between wires or earth in
ÁÁÁÁÁ
ÁÁÁÁÁ
the wiring harness to the kick-down.
Replace the kick-down if necessary.
ÁÁÁÁÁ
ÁÁÁÁÁ
9910 4-1
DIAGNOSIS 3
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Speed sensors
ÁÁÁÁÁ
ÁÁÁÁÁ
22 14 Check the following points:
15 a. Connectors are firmly attached, clean and undamaged.
1 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
16 b. The speed sensor attachment bolt is tightened to the specified
tightening torque.
ÁÁÁÁÁ
ÁÁÁÁÁ
c. No interruptions or short circuits between wires or earth in wiring
harness to sensor.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Selector keypad
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
23
ÁÁÁÁÁ
12 Check the following points:
13 a. ECU connections - connectors are connected and clamped.
ÁÁÁÁÁ
ÁÁÁÁÁ
14 b. Selector keypad is connected and the wire loop has been cut
15 through.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
23 c. No interruptions or short-circuits between wires or earth in wiring
24 harness to selector.
ÁÁÁÁÁ
ÁÁÁÁÁ
Replace the selector if necessary.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Temperature in the gearbox sump too low
ÁÁÁÁÁ
ÁÁÁÁÁ
a. Temperature is lower than –6°C.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
1) If this is the case, it is a normal response to the ambient
temperature.
ÁÁÁÁÁ
ÁÁÁÁÁ
2) If not, check whether the main gearbox is firmly connected and
that the connectors are undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
4-2 9910
3 DIAGNOSIS
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Temperature in the gearbox sump is too high
ÁÁÁÁÁ
ÁÁÁÁÁ
24 23 1. Run the engine at idling speed.
2. Ensure that the vehicle is entirely horizontal.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
3. Check whether the correct dip stick has been installed.
4. Check the oil level. 1
ÁÁÁÁÁ
ÁÁÁÁÁ
5. As necessary, correct the oil level.
6. If the oil level is in order, check whether the engine system has
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
overheated, causing the gearbox to overheat.
7. Check that the ECU and gearbox connectors are correctly connected,
firmly attached and undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Output shaft speed sensor
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
25
ÁÁÁÁÁ
00
11
a. Connector is connected.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
22 b. Sensor bolt is firmly attached.
33
44
c. ECU is firmly attached with no damaged connectors.
d. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
55 e. No interruptions or short circuits between wires or earth in wiring
ÁÁÁÁÁ
ÁÁÁÁÁ
66 harness to sensor.
77 If all points are in order, contact your Allison dealer.
ÁÁÁÁÁ
ÁÁÁÁÁ
Coupling 3 pressure switch open
ÁÁÁÁÁ
ÁÁÁÁÁ
32 00 1. Let the engine idle while the vehicle’s parking brake is applied.
ÁÁÁÁÁ
ÁÁÁÁÁ
55 a. Specified dip stick.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
77 b. Correct oil level.
2. Check the following points:
a. Gearbox main connector is connected, is firmly attached, is clean
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
and undamaged.
b. ECU connector is connected, is firmly attached, is clean and
ÁÁÁÁÁ
ÁÁÁÁÁ
undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
harness.
9910 4-3
DIAGNOSIS 3
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Sensor fault in gearbox oil sump
ÁÁÁÁÁ
ÁÁÁÁÁ
23 a. Gearbox main connector is connected, is firmly attached, is clean and
1 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
undamaged.
b. ECU connector is connected, is firmly attached, is clean and
ÁÁÁÁÁ
ÁÁÁÁÁ
undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
harness.
ÁÁÁÁÁ
ÁÁÁÁÁ
EEPROM fault
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
34
ÁÁÁÁÁ
12 1. Re-calibrate if necessary.
13 2. If re-calibration is impossible, replace the ECU.
ÁÁÁÁÁ
ÁÁÁÁÁ
14 3. If ECU replacement is impossible, contact your Allison dealer.
15
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
16
EEPROM writing error as a result of loss of power supply
ÁÁÁÁÁ
ÁÁÁÁÁ
35
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
16 a. ECU is firmly attached, clean and undamaged.
b. VIM (Vehicle Interface Module) is firmly attached, clean and
undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
c. The vehicle manufacturer has used the specified wiring for power
supply and earth connection.
ÁÁÁÁÁ
ÁÁÁÁÁ
d. Battery positive pole.
e. Battery earth connection.
ÁÁÁÁÁ
ÁÁÁÁÁ
f. Specified connections for vehicle contact.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Hardware/software not compatible
ÁÁÁÁÁ
36
00 1. Replace ECU if possible.
ÁÁÁÁÁ
ÁÁÁÁÁ
2. Re-program ECU if possible.
ÁÁÁÁÁ
ÁÁÁÁÁ
3. If replacement or re-programming is not possible, contact your Allison
dealer.
4-4 9910
3 DIAGNOSIS
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Interruption or short circuit in circuit electromagnetic valves
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
14
15
undamaged.
b. ECU connector is connected, is firmly attached, is clean and 1
ÁÁÁÁÁ
ÁÁÁÁÁ
16 undamaged.
20 c. Visual inspection of the wiring harness: no damage, no chafed or too
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
22
23
24
taut wires, no screws through the wiring harness.
d. No interruptions or short circuits between wires or earth in wiring
harness.
ÁÁÁÁÁ
ÁÁÁÁÁ
25 e. Replace wiring harness (if necessary).
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Short circuit in the electro-magnetic valve circuit to the battery
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
42
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
14 undamaged.
15 b. ECU connector is connected, is firmly attached, is clean and
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
16
21
undamaged.
c. Visual inspection of the wiring harness: no damage, no chafed or too
ÁÁÁÁÁ
ÁÁÁÁÁ
22
taut wires, no screws through the wiring harness.
23 d. No interruptions or short circuits between wires or earth in wiring
ÁÁÁÁÁ
ÁÁÁÁÁ
24 harness.
ÁÁÁÁÁ
ÁÁÁÁÁ
25 e. Replace wiring harness (if necessary).
26 f. Incompetent repairs.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ECU circuits
ÁÁÁÁÁ
ÁÁÁÁÁ
43
21 1. Replace the ECU.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
25 2. Contact your Allison dealer.
26
9910 4-5
DIAGNOSIS 3
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Transmission ration test on the gear to be changed from (during shifting)
ÁÁÁÁÁ
ÁÁÁÁÁ
10 a. Output shaft engine speed sensor and rev sensor are connected.
1 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
12
21
The connectors are undamaged and clean.
b. No interruptions or short circuits between wires or earth in sensor
ÁÁÁÁÁ
ÁÁÁÁÁ
23 wiring.
45 c. Let the engine idle in neutral while the vehicle is on the brake.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
65
1. Specified dip stick.
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Coupling 3 pressure switch open
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
52
ÁÁÁÁÁ
01
08
a. Output shaft engine speed sensor and rev sensor are connected.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
32
34
54
wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
78 1. Specified dip stick.
79 2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
99 d. Check that there is no interruption or short circuit between wires or
earth connection in the main wiring harness to the gearbox.
4-6 9910
3 DIAGNOSIS
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Engine and turbine rev test when engaging neutral
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
28
29
b. No interruptions or short circuits between wires or earth in sensor 1
ÁÁÁÁÁ
ÁÁÁÁÁ
38 wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
48
49
58
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
68
ÁÁÁÁÁ
ÁÁÁÁÁ
69
78
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
99
Transmission ration test immediately after changing up
ÁÁÁÁÁ
ÁÁÁÁÁ
54
01,07 Check the following points:
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
10,12 a. Output shaft engine speed sensor and rev sensor are connected.
17,21
23,32
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
34,43
45,54
wiring.
c. Let the engine idle in neutral while the vehicle is on the brake.
ÁÁÁÁÁ
ÁÁÁÁÁ
56,65 Check the following points:
70,71 1. Specified dip stick.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
80,81
83,85
86,92
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
93,95
96,97
9910 4-7
DIAGNOSIS 3
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Pressure in connection 3 immediately after changing up.
ÁÁÁÁÁ
ÁÁÁÁÁ
1 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
97 The connectors are undamaged and clean.
ÁÁÁÁÁ
ÁÁÁÁÁ
wiring.
c. Let the engine idle in neutral while the vehicle is on the brake.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
d. Check that there is no interruption or short circuit between the wiring
or earth connection in the connection 3 pressure switch wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
e. Check the following points:
1. Main connector is properly connected, is clean and undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
2. ECU connector is properly connected, is clean and undamaged.
3. Rev sensor is properly connected, is clean and undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
Range test
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
22 The connectors are undamaged and clean.
33 b. No interruptions or short circuits between wires or earth in sensor
ÁÁÁÁÁ
ÁÁÁÁÁ
44 wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
77 1. Specified dip stick.
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
4-8 9910
3 DIAGNOSIS
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Range test when using connection C3
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
44
66
b. No interruptions or short circuits between wires or earth in sensor 1
ÁÁÁÁÁ
ÁÁÁÁÁ
88 wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
2. Oil level.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
d. Check that there is no interruption or short circuit between the wiring
or earth connection in the connection 3 pressure switch wiring.
ÁÁÁÁÁ
ÁÁÁÁÁ
e. Check the following points:
1. Main connector is properly connected, is clean and undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
2. ECU connector is properly connected, is clean and undamaged.
3. Rev sensor is properly connected, is clean and undamaged.
ÁÁÁÁÁ
ÁÁÁÁÁ
Fault in ECU
ÁÁÁÁÁ
ÁÁÁÁÁ
69 12.13 1. Delete the fault codes and try to re-start the vehicle.
14.15 2. If the fault re-occurs, replace the ECU.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
16.21 3. If the fault has not been cleared, contact your Allison dealer.
22.23
ÁÁÁÁÁ
ÁÁÁÁÁ
24.25
26.32
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
33.34
35.36
9910 4-9
DIAGNOSIS 3
4.2 READING/DELETING FAULT CODES
Fault code reading mode

To enter fault code reading mode, briefly press
the two arrow keys simultaneously.
“D-1” appears on the display
1 followed by “-”.
This means that at that point there are no faults
(active faults) in the system. No faults have
been registered either that were earlier
temporarily present, but have now been cleared
(inactive faults) The oil level reading function
can be left by pressing “D”, “N”, or “R” or the
arrow keys.
If the red lamp lights up while reading a fault
code, this means that there is an inactive fault in
the gearbox.
No message during reading means that the fault
is inactive.
The ECU can save five active/inactive fault
codes in its memory and show them on the
display. Fault codes consist of two sets of two
figures (main codes and subcodes). To read the
codes consecutively, the “MODE” button must 5
be pressed each time.
The letters and figures appear one at a time and
after each other on the display.
Example: D1
D2
25 - 22
21 - 12
R MODE
D3 24 - 12
D4 -
The hyphen after D4 means that there are no
N
further faults and that it is therefore not
necessary to look at level D5.
As the ECU can only contain the five most D
important codes, the five most important codes
will be seen by D1 to D5. Only when one of the
faults has been remedied will the ECU be in a
position to show a less important fault. Allison
V300290
4-10 9910
3 DIAGNOSIS
Deleting fault codes

After faults have been remedied, the ECU
memory must be deleted. This is done as
follows.
Press the arrow keys twice simultaneously. This
is the fault code reading mode. Press the
“MODE” key and hold it down until the red lamp
flashes three times (the first flash will be after
5
1
approx. three seconds, the second after approx.
10 seconds). All codes, active or inactive, have
now been deleted. Codes which return following
deleting and can therefore no longer be deleted
are active. Both types of fault need their causes
tracing and remedying as quickly as possible.
After the fault codes have been deleted the
R MODE
contact must be switched off and re-started;

otherwise it will not be possible to drive. This
can be seen from the flashing on the gear lever N
area.
Inactive faults are automatically deleted by the
ECU if the fault no longer occurs after the
contact has been switched on 25 times.
D
It is not possible to remedy all fault codes. Fault
codes that cannot be found in the section on
Fault Tracing can best be remedied by the Allison
Allison dealer.
He has the use of test and diagnostic apparatus
that can be connected to a special diagnostic V300290
socket in the central box (next to the DAVIE
connector).
9910 4-11
DIAGNOSIS 3
4-12 9910
3 DIAGNOSIS
5. CLUTCH
FAULT: CLUTCH PEDAL FAILS TO RETURN
Broken pedal return spring Replace spring
Worn clutch pedal bearings Check bearings and replace, if necessary
Dirt in hydraulic system Clean system and fill with fresh fluid
Incorrect fluid in hydraulic system Replace by fluid with correct specification
Air in hydraulic system Bleed the system
FAULT: CLUTCH PEDAL STICKS WHEN PRESSED
Leak in hydraulic system Check system
Air in hydraulic system Bleed hydraulic system
Declutching bearing incorrectly fitted Fit declutching bearing correctly
Fork hinge points or fork itself pressed in Check hinge points and fork, replace if
necessary
Defective clutch servo Repair and/or replace clutch servo
Gearbox cover pressed in or broken Check, replace gearbox cover
FAULT: PEDAL FORCE TOO HIGH
No or insufficient pressure in circuit 4 of the Check circuit 4 of the brake system
brake system
Kinked air pipe Check pipe and replace, if necessary
Kinked hydraulic pipe Check pipe and replace, if necessary
Worn clutch pedal bearings Check bearings and replace, if necessary
Defective clutch servo and/or main cylinder Repair and/or replace clutch servo and/or main
cylinder
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid
9910 5-1
DIAGNOSIS 3
FAULT: RESIDUAL PRESSURE IN CLUTCH SYSTEM
Possible cause
Vent in reservoir cap closed off Check vent in cap
Remedy
Compensation bore in main cylinder closed off Check free push rod travel or repair/replace
1 by swollen seal or insufficient free push rod
travel.
main cylinder
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid
FAULT: COOLANT LEAK VIA VENT OPENING
Leak through piston seal in clutch servo Repair or replace clutch servo
Note: A drop of oil in the vent opening is a
normal situation and is not a reason to
repair/replace the clutch servo
FAULT: CLUTCH PLATE SLIPS
Worn lining Replace lining
Oil on lining Replace lining and check engine and gearbox
sealing rings
Dirt on clutch plate and flywheel Clean plate and surrounding area
Burnt clutch plate Check entire clutch and replace, if necessary
Clamping force of pressure group too low or Check pressure group and replace, if necessary
absent
Pressure group is not released Check clutch plate assembly
5-2 9910
3 DIAGNOSIS
FAULT: PRESSURE GROUP FAILS TO RELEASE
Possible cause
Fluid level in hydraulic system too low Top up fluid
Remedy
Incorrect pedal setting Check setting and adjust if necessary

Air in hydraulic system Bleed hydraulic system 1
Leak in hydraulic system Check hydraulic system
Fingers of pressure group broken Replace pressure group
Wrong pressure group has been fitted. Fit correct pressure group
Clutch fork is broken Replace fork
Pressure group severely contaminated Clean entire clutch assembly
Defective clutch servo Check clutch servo and replace, if necessary
Thrust bearing incorrectly fitted Fit thrust bearing correctly
Clutch housing disconnected from gearbox Tighten the clutch housing bolts to the correct
torque
9910 5-3
DIAGNOSIS 3
5-4 9910
3 DIAGNOSIS
65/75/85CF series Prop shafts
6. PROP SHAFTS
FAULT: VIBRATION IN DRIVE LINE AT LOW SPEED
Universal joint angle too large caused by Check universal joint angle
e.g. excessive caster
Play in universal joints Replace universal joint
Play in centre bearing Replace centre bearing
Play in sliding joint Replace prop shaft
Forks not in line Align forks
FAULT: VIBRATION IN DRIVE LINE AT HIGH SPEED
Prop shaft unbalance Balance prop shafts or replace if necessary
9910 6-1
DIAGNOSIS 3
Prop shafts 65/75/85CF series
6-2 9910
3 DIAGNOSIS
65/75/85CF series ZF intarder
7. ZF INTARDER
FAULT: NO BRAKE POWER
1
Oil level too low Check oil level
Intarder does not contain the specified oil Change the oil
No pump pressure Check system
No control pressure Check system
No intarder pressure Check system
FAULT: INSUFFICIENT BRAKE PRESSURE
Pump pressure too low Check system
Control pressure too low Check system
Intarder pressure too low Check system
FAULT: CONSTANT BRAKE POWER WHEN INTARDER IS SWITCHED OFF
Oil level too high
Possible cause
Check oil level
Remedy
Control pressure is independent of the position Check system

of the control lever
Possible cause
FAULT: DELAYED RESPONSE
Remedy
Air supply absent/too low Check air supply
Air supply intarder valve is not activated Check system
Air supply intarder valve does not empty Check system
accumulator in spite of activation
Idle pressure too low Check system
9910 7-1
DIAGNOSIS 3
ZF intarder 65/75/85CF series
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ FAULT: DELAYED SWITCH-OFF
Slow decrease of intarder pressure after Check system
switch-off
1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
FAULT: OIL LEAKAGE
Oil level too high Check oil level
Oil leak between gearbox housing and intarder Replace gasket
Oil leak in pump Replace O-ring
Oil leak in proportional valve Replace O-ring
Oil leak in the accumulator Replace O-ring
Oil leak in the drive flange Replace O-ring
FAULT: AIR LEAKAGE
Air leak via air supply intarder valve
Replace O-ring
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ FAULT: COOLANT TEMPERATURE TOO HIGH
Possible cause
Coolant level too low/high
Remedy
Checking the coolant level
Temperature adjustment Check system
Intarder pressure after intarder has been Check system
switched off
7-2 9910
3 DIAGNOSIS
65/75/85CF series Voith retarder
8. VOITH RETARDER
FAULT: NO/INSUFFICIENT BRAKE POWER
Reservoir pressure absent or too low See under “Air leakage”
No pneumatic service pressure Check system
Pneumatic service pressure too low Check system
No hydraulic service pressure Check system
Hydraulic service pressure too low Check system
FAULT: RETARDER REMAINS ENGAGED
Oil level too high Draining and filling
Service pressure is independent of the position Check system
of the control lever
Possible cause
FAULT: DELAYED RESPONSE
Remedy
Air reservoir pressure absent or too low See under “Air leakage”
Slow build-up of pneumatic service pressure Check system
Venting valve remains closed Check system
Stator valves remain open Check system
Shifting valve hangs Check system
FAULT: DELAYED DECREASE OF BRAKE POWER
When switching off the retarder no air escapes Clean silencer
9910 8-1
DIAGNOSIS 3
Voith retarder 65/75/85CF series
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ FAULT: OIL LEAKAGE
Possible cause
Remedy
Oil leak between adapter plate and retarder Check system

1 Oil leak between gearbox housing and adapter Check system
plate
Oil leakage at valve exhaust port Check system
Oil leak in the drive flange Replace O-ring
Butterfly valve defective Check system
FAULT: AIR LEAKAGE
Air leakage via proportional valve Replace O-ring
FAULT: COOLANT TEMPERATURE TOO HIGH
Possible cause
Coolant level too low
Remedy
Checking the coolant level
Temperature sensor or control unit defective Check system
Retarder service pressure after intarder has Check system
been switched off
8-2 9910
3 DIAGNOSIS
65/75/85CF series Splitter box
9. SPLITTER BOX
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
FAULT: SPLITTER BOX DOES NOT ENGAGE IN FRONT WHEEL DRIVE
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1
Air reservoir pressure absent or too low Check service pressure
Defective pneumatic switch Check pneumatic switch
Leak through shifting piston seal Check shifting piston seal
FAULT: SPLITTER BOX DOES NOT ENGAGE IN HIGH OR LOW
Possible cause
Air reservoir pressure absent or too low
Remedy
Check service pressure
Defective high/low shifting valve Replace high/low shifting valve
Leak through shifting piston seal Check shifting piston seal
Clutch shaft mechanical travel incorrectly Check clutch shaft adjustment
adjusted
9910 9-1
DIAGNOSIS 3
Splitter box 65/75/85CF series
9-2 9910
3 MECHANICAL GEARBOX CONTROL
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 9910
1.1 Description of the mechanical gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 9910
1.2 Overview drawing, gear lever unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 9910
1.3 Overview drawing, ZF-Eaton gear lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 9910
1.4 Overview drawing, Eaton and ZF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 ...... 9910
1.5 Overview drawing, ZF LHD gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 ...... 9910
1.6 Overview drawing, ZF RHD gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Overview drawing, gearbox operation, Eaton LHD . . . . . . . . . . . . . . . . . . . . . .
1-6
1-7
......
......
9910
9910 2
1.8 Overview drawing, gearbox operation, Eaton RHD . . . . . . . . . . . . . . . . . . . . . . 1-8 ...... 9910
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 Inspection and adjustment, gearbox control LHD/RHD . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
3.1 Removal and installation, entire gear lever unit . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
3.2 Removal and installation, gear lever gaiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . . 9910
3.3 Removal and installation, gearbox unit inner dust cover . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 9910
3.4 Removal and installation, gear lever ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 9910
3.5 Removal and installation, control rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 . . . . . 9910
9910 1
MECHANICAL GEARBOX CONTROL 3
2 9910
65/75/85CF series General
1. GENERAL
1.1 DESCRIPTION OF THE MECHANICAL GEARBOX CONTROL
Control mechanism, LHD

When the gear lever is moved forwards, the
control rod moves backwards.
When the gear lever is moved backwards, the
control rod moves forwards.
When the gear lever is moved left, the control
2
rod moves right.
When the gear lever is moved right, the control
rod moves left.
Control mechanism RHD
In the RHD version, the control mechanism
remains mounted in place. An additional control
rod, passing over the engine to the right-hand
side of the vehicle, is added to the control
mechanism.
9910 1-1
General 65/75/85CF series
1.2 OVERVIEW DRAWING, GEAR LEVER UNIT
1. Sealing cover
2. Gear lever
3. Retaining plate
4. Inner sealing cover 1
5. Attachment tape
6. Pressure spring
7. Circlip 2
8. Gear knob
2 9.
10.
Bearing housing
Spacer sleeve
4
5
7
8
10
V300268
1-2 9910
1.3 OVERVIEW DRAWING, ZF EATON GEAR LEVER
1. ZF switch
2. EATON switch
3. Gear lever
4. Bearing housing 1
5. Gear knob
2
6. Circlip
5
4
6
V300269
9910 1-3
1.4 OVERVIEW DRAWING, EATON AND ZF SWITCHES
1 1
4
5
2
3
6 2
2
V300274
Eaton switch ZF switch

1. Operating valve 1. Switch
2. Screw-thread insert 2. Gear lever
3. Shoulder stud
4. Locknut
5. Protective cover
6. Gear lever
1-4 9910
1.5 OVERVIEW DRAWING, ZF LHD GEARBOX CONTROL
2
8
7
9
3
5
3
3
4 6
V300270
1. Gear lever bracket

2. Control rod
3. Ball joint
4. Torque rod
5. Torque rod bracket
6. Screw-thread insert
7. Lever
8. Protective cover
9. Shaft circlip
9910 1-5
1.6 OVERVIEW DRAWING, ZF RHD GEARBOX CONTROL
2
2
3
4 5
13
6 12
11
8
6 10
6
7 9
V300271
1. RHD control rod

2. Corner bracket
3. Control rod bracket
4. Split pin
5. Control rod
6. Ball joint
7. Torque rod
10. Split pin
11. Lever
12. Shaft circlip
13. Protective cover
1-6 9910
1.7 OVERVIEW DRAWING, GEARBOX OPERATION, EATON LHD
1
3
2
3
4
2 5
9
8
V300272
1. Gear lever bracket

2. Control rod
3. Ball joint
4. Torque rod
6. Split pin
7. Lever
8. Ball joint
9910 1-7
1.8 OVERVIEW DRAWING, GEARBOX OPERATION, EATON RHD
2
2
3
6
4
6
5 7
8
12
10
11
V300273
1. RHD control rod

2. Split pin
3. Corner bracket
4. Control rod bracket
5. Control rod
6. Ball joint
7. Torque rod
9. Split pin
11. Ball joint
12. Lever
1-8 9910
65/75/85CF series Inspection and adjustment
2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT OF GEARBOX CONTROL LHD/RHD
Inspection, gearbox control RHD

1. Push the control against the spring
pressure to check whether it can move
freely in neutral. The control must spring
back independently into the gate 3/4. If this
90°
proves impossible, the ball joint and
screw-thread insert must be adjusted. 2
2. Ensure that the lever on the selector shaft
is at a 90° angle to the gearbox. If
necessary, correct the position of the lever.
3. Check that all gears can be engaged
without parts coming into contact with each
other.
V300151
9910 2-1
Inspection and adjustment 65/75/85CF series
Adjustment, gearbox control LHD/RHD

1. Tilt the cab.
X
2. Remove the castle nut from the torque rod
ball joint and remove the torque rod from
the control rod.
3. Remove the castle nut from the lever ball
joint of the gearbox control and remove the
control rod from the gearbox lever.
2 4. Loosen lock nuts (2) and (4) and adjust the

length of the ball joint in such a way that,
1 2 3 4
when installed, the control can move freely V300147
in neutral by pushing it against the spring
pressure. The control must spring back
independently in gate 3/4. Install the castle
nut and split pin.
Note:
If the ball joint (1) and the screw-thread insert
(3) have been separated, the ball joint (1) must
first be screwed for its full length (X),
(X = 69 mm) into the screw-thread insert (3)
before screwing the screw-thread insert (3) into
the control rod.
When the ball joint (1) and the screw-thread
insert (3) have been installed and adjusted, the
distances (D) and (E) must be approximately
68 mm and 27 mm respectively. D
5. Fit the castle nut to the torque rod ball joint.
E
6. Check that all gears can be engaged
without parts coming into contact with each
other.
V300136
2-2 9910
65/75/85CF series Removal and installation
3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, ENTIRE GEAR LEVER UNIT
Note:
If the vehicle is equipped with a gearbox
without group switching or splitter box
e.g. the S 6.36/2, the gear lever unit can be
removed without it being necessary to
consider the air pipes.
Removal, entire ZF gear lever unit 2
1. Make sure there are no loose items in the
cab. Tilt the cab.
2. After marking them, remove the air pipes
from the that run from the switch to the
various valves.
3. Remove the clamping bolt (1) and remove
the gear lever control rod (2) and secure it
so that it cannot cause any damage to the
air pipes. 3 1 2
V300275
4. Remove the attachment nuts (3) on the
bottom of the gear lever unit or those on the
manifold bracket and then remove the entire
gear lever unit including the set of air pipes.
Installation, entire ZF gear lever unit
1. Fit the entire gear lever unit including the
set of air pipes to the bottom of the shift unit
or on the manifold bracket and fit the
attachment nuts (3), tightening to the
specified tightening torque. See “Technical
data”.
W 3 02 049
9910 3-1
Removal and installation 65/75/85CF series
2. Note:
When fitting the set of air pipes, make sure
that these are away from any moving parts.
Fit the air pipes that run from the switch to
the various valves.
3. Fit the gear lever control rod (2) to the gear
lever unit and fit the clamping bolt (1),
tightening to the specified tightening torque.
See “Technical data”.
2 4. Check that the pneumatic system is airtight.
5. Check that all switches, both mechanical
and pneumatic, function properly.
3-2 9910
Removal, entire Eaton gear lever unit

cab. Tilt the cab.
2. Slide the cover over the threaded bush and
then loosen it from the connection piece
between the gear lever and the shifting
valve.
W 3 02 090
3. Slide the protective cover of the valve down

so that the bottom of the valve, with the air
connection, becomes visible.
4. Mark the air pipes directly beneath the
switching valve.
W 3 02 091
9910 3-3
5. Using a small screwdriver to depress the

edge of the air connection the pipes can be
pulled from the valve. The shifting valve and
threaded bush will also come completely
free from the gear lever.
W 3 02 092

so that it cannot cause any damage to the
air pipes.
7. Remove the attachment nuts (3) on the
bottom of the gear lever unit or those on the
manifold bracket and then remove the entire
gear lever unit. The set of air pipes remains
on the engine.
3 1 2
V300275
3-4 9910
Installation, entire gear lever unit

1. Fit the entire gear lever unit including the
set of air pipes to the bottom of the shift unit
or on the manifold bracket and fit the
attachment nuts (3), tightening to the
data”.
2. Note:
When fitting the set of air pipes, make sure
that these are away from any moving parts.
Fit the air pipes that run from the switch to
2
the various valves.
3. Fit the gear lever control rod (2) to the gear
lever unit and fit the clamping bolt (1),
tightening to the specified tightening torque.
4. Check that the pneumatic system is airtight.
3 1 2
V300275
9910 3-5
3.2 REMOVAL AND INSTALLATION, GEAR LEVER GAITER
Removal, gear lever gaiter

cab. Tilt the cab.
various valves.
2 3. Slide the cover over the threaded bush and

valve.
4. Remove the gear lever control rod and
secure it so that no damage can be caused
to the air pipes.
V300276
5. Remove the switch with the shifting valve

and air pipes from the gear lever.
V300277
3-6 9910
6. Loosen the gaiter from the locking plate by

lifting the gaiter and pulling the gaiter lips
away from the locking plate.
2
W 302059
7. Then remove the Seeger ring that has

become visible from the bearing cover. It is
now possible to remove the entire gear
lever from the bearing cover.
8. Use a press to remove the ball from the
gear lever. Heat the ball if necessary.
9. Remove the gaiter.
W 302060
9910 3-7
Installation, gear lever gaiter

1. Slide the gaiter over the gear lever.
2. Fit the ball.
3. Fit the entire gear lever to the shift unit and
lock it with the specific Seeger ring.
4. Secure the gaiter by means of the lips.
These must be pulled through the slots in
the locking plate.
2
W 302055
5. Feed the air pipes through the gear lever

and fit the switch with the valve to the gear
lever. Tighten the threaded bush and slide
the gaiter over the threaded bush.
6. Fit the selector rod.
7. Connect the air pipes. Ensure that the pipes
are free of any moving parts.
8. Check that the pneumatic system is airtight. W 302069

3-8 9910
3.3 REMOVAL AND INSTALLATION, GEARBOX UNIT INNER DUST COVER
Removal, gearbox unit inner dust cover

1. Remove the entire gearbox unit from the
bracket.
2
W 302059

now possible to remove the entire gear
lever from the bearing cover.
W 302060
4. Press the locking plate down and slide the

four attachment bands from the bearing
cover slots.
W 302057
9910 3-9
5. Remove the locking plate with the dust

cover and spring from the bearing cover.
6. Remove the dust cover from the locking
plate.
V300278
Installation, gearbox unit inner dust cover

1. Note:
When fitting the inner dust cover, ensure
that it is fitted properly to the locking plate B
as can be seen in position A. Fitting as in
position B will lead to irritating engine noise
in the cab.
A
W 302058
3-10 9910
2. Press the locking plate and spring down

and fit the four attachment bands in the
bearing cover slots.
2
W 302057
3. Fit the gear lever with the bearing to the

bearing cover and fit the snap ring.
W 302060

the locking plate.
W 302059
9910 3-11

2 3.4 REMOVAL AND INSTALLATION OF GEAR LEVER BALL
Removal, gear lever ball

cab. Tilt the cab.
various valves.
between the gear lever and the shifting W 302069
valve.
4. Remove the gear lever control rod and
secure it so that no damage can be caused
to the air pipes.
3-12 9910

now possible to remove the gear lever from
the bearing cover.
8. Use a press to remove the ball from the
gear lever. Heat the ball if necessary.
Installation, gear lever ball
2
1. Apply a degreasing agent to the surfaces of
the gear lever and ball that are to be glued.
See “Technical Data”. Immediately wipe the
surfaces with a clean piece of paper or a
lint-free cloth.
2. Apply glue to the gluing surface of the gear
lever and all around the ball. See “Technical
Data”.
3. Place the lever into the ball and turn it
around several times to distribute the glue
evenly.
9910 3-13
4. Put aside the gear lever and ball, storing

them vertically. Let the assembly set; it
may be moved after 1 hour and fitted after
3 hours. Maximum shear strength is
achieved after 24 hours of setting.
5. Fit the gear lever into the bearing cover and
fit the snap ring.
2 the locking plate.
3-14 9910
3.5 REMOVAL AND INSTALLATION, CONTROL ROD
Removal, control rod

cab. Tilt the cab.
various valves.
3. Remove the castle nut from the torque rod
ball joint and remove the torque rod from 2
the control rod.
4. Remove the castle nut from the ball joint on
the gearbox lever and remove the control
V300138
rod.
the control rod (2) from the gear lever unit.
3 1 2
V300275
9910 3-15
Installation, control rod

1. Position the control rod.
2. Fit the ball joint in the control arm hole, but
do not fasten it yet. Fit the torque rod ball
joint to the control rod.
3. Fit the control rod (2) onto the gear lever
and hand tighten the clamping bolt (1).
4. Adjust the gearbox control. See “Inspection
2 and Adjustment”.
and pneumatic, function properly. 3 1 2
V300275
3-16 9910
3 PNEUMATIC SECTION OF GEARBOX
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 Location of components, down-shift safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.2 System description, down-shift safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . 9910
1.3 Location of gate safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . . 9910
1.4 System description, gate safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 . . . . . . 9910
1.5 Pneumatic diagram, gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 . . . . . 9910
2. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 Neutral position valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.2 Down-shift safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . 9910
2.3 Engaging cylinder, high/low group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . 9910
2.4 Gear lever shifting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 GV valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 . . . . . .
2-7 . . . . . .
9910
9910
3
2.6 Splitter relay valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . . 9910
2.7 Filter/governor, Eaton TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . . 9910
2.8 Eaton transmission brake relay valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 . . . . . 9910
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.1 Programming parameters using DAVIE 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.2 Inspection of down-shift safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 9910
3.3 Inspection and adjustment, ZF and Eaton gearbox GV valve . . . . . . . . . . . . . 3-3 ...... 9910
4.1 Removal and installation, gear lever shifting valve . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
9910 1
PNEUMATIC SECTION OF GEARBOX 3
2 9910
1. GENERAL
1.1 LOCATION OF COMPONENTS, DOWN-SHIFT SAFETY
1. Neutral position valve

At the side of the gearbox cover.
3
V300140
2. Auxiliary gearbox engaging cylinder

At the back of the gearbox.
V300141
3. Gate safety valve

At the left-hand side of the gearbox.
V 300029
9910 1-1
4. CTE-3 electronic unit

In the central box on the co-driver’s
side (1).
3
V300314
5. Gear lever group switch

Rocker switch (B) at the front of the gear
lever.
A
B
D000096
1-2 9910
1.2 SYSTEM DESCRIPTION, DOWN-SHIFT SAFETY
The down-shift safety prevents shifting down

from the high auxiliary gearbox to the low
auxiliary gearbox when the vehicle speed is too
high.
Shifting down from the high to the low auxiliary
gearbox when the vehicle speed is too high
could cause serious damage to the clutch plate,
gearbox and engine because of the reduction in
the auxiliary gearbox.
The safety is enabled automatically when the
vehicle speed (frequency value) exceeds a
certain pre-programmed value.
This vehicle speed (frequency signal) is
3
programmed with DAVIE 2.0 in the CTE-3.
9910 1-3
Operation, down-shift safety

5
4
22 21
H H
3
L L
GV GP
1
3
L
1 21
H 22
N
V
4 1
22
21
1 2
26 25
H L
V300118
The following applies to pneumatic diagram

V300118
- Vehicle contact switched off
- Gearbox in neutral

3. Electropneumatic valve
L. Position, low auxiliary gearbox
H. Position, high auxiliary gearbox
N. Gearbox selector shaft in neutral
V. Gearbox selector shaft engaged
1-4 9910
If the vehicle speed exceeds a particular value

(frequency value), the electronic unit (4)
interrupts the connection between the
electropneumatic valve (3) and the earth.
Regardless of any pneumatic activation of the
gear lever group switch (5), it is now no longer
possible to switch down to the lower group.
Note:
The air supply to the electropneumatic valve (3)
is only available when the gear lever, and hence
also the neutral valve, are in the neutral
position (N).
9910 1-5
1.3 LOCATION OF THE GATE SAFETY COMPONENTS

At the side of the gearbox cover.
3 V300140

At the left-hand or right-hand side of the
gearbox (depending on the vehicle type).
V300006
3. Locking cylinder
At the rear of the gearbox cover.
V300002
1-6 9910

The electronic unit (1) is under the central
box on the co-driver’s side.
3
V300314
5. Low-gear switch
Located at the rear of the gearbox.
V300005
9910 1-7
1.4 SYSTEM DESCRIPTION, GATE SAFETY
The gate safety only operates in the low group.

It prevents shifting from third or fourth gear
(gate 3-4) to first or second gear (gate 1-2) if the
vehicle speed is too high.
This shifting error occurs if the driver fails use
the group switch at the front of the gear lever to
switch to the high group before shifting from
fourth to fifth gear.
The moment when the safety is engaged is
determined by the gate safety’s electronic
3 CTE-3 unit.
The moment when the safety is engaged is
dependent on the vehicle speed signal
(frequency signal).
1-8 9910
Operation of the gate safety

4
3
2
22
1
21
V300279

2. Low-gear switch
3. CTE-3
5. Locking cylinder
The gate safety valve (1) is energised if the

following conditions are met:
The vehicle speed is above the set speed, i.e.
the CTE supplies voltage to the low group
switch (2).
The low-group switch (2) is closed if the gearbox
is shifted to the low group.
When the gearbox is in neutral, the neutral valve
(4) will send pressure via the electronic gate
safety valve to the locking cylinder (5) at the
rear end of the gearbox cover. In this way,
gate 1-2 can no longer be engaged.
However, if the high group is selected, the gate
safety valve (1) can no longer be energised as
the low group switch (2) has been opened.
Gate 5-6 (1-2) can again be engaged.
Note:
For reasons of safety, down-shifting must
always be possible. Hence, by exerting
additional shifting power, it is still possible to
reach gate 1-2 against the pressure of the
cylinder.
9910 1-9
1.5 PNEUMATIC DIAGRAM, GEARBOX CONTROL
Pneumatic diagram of 16 S direct input shaft
8
6
41
2 1
H
1
3
L H
5
4
22 21
H H
3
L L
GV GP
1
1 21
H 22
N
V
4 1
22
21
1
2
26 25
H L
V300165
1-10 9910
Pneumatic diagram of 16 S direct input shaft

The following applies to pneumatic
diagram V300165
- Group switch position “high”
- Splitter box position “high”
- Clutch pedal not activated

6.
8.
GV valve
Splitter relay valve with splitter cylinder
3
L Position “low”
H Position “high”
N Gearbox selector shaft in neutral
V Gearbox selector shaft engaged
9910 1-11
Pneumatic diagram of 16 S overdrive
6 7
41
2 1
H
1
3
H L
5
4
22 21
H H
3
L L
GV GP
1
1 21
H 22
N
V
4 1
22
21
1 2
26 25
H L
V300166
1-12 9910
Pneumatic diagram of 16 S overdrive

The following applies to pneumatic diagram
V300166
- Splitter box position “high”

6.
7.
GV valve
Splitter relay valve with splitter cylinder
3
H Position “high”
N Gearbox selector shaft in neutral
9910 1-13
Pneumatic diagram of 8/9 S direct input

shaft
L
GP 4
A
3
4 3
L
1 21
3 H
22
1
N
V
22 V
5
N 21
H L
1
V300280
1-14 9910
Pneumatic diagram of 8/9 S direct input

shaft
diagram V300280

H
N
Position “high”
Gearbox selector shaft in neutral
3
9910 1-15
Pneumatic diagram, Eaton TS
F R 3
21
23 22 2
1
3
3
2 1 S
1
INTERLOCK
t 2
4
o
1
2
W 3 02 087
1-16 9910
Pneumatic diagram, Eaton TS

diagram W 302087
- Gear lever shifting valve in position 1
- Gear lever in neutral
1. Governor on the side of the gearbox

2. Shifting valve on the gear lever
3. Cylinders and control pistons in the
gearbox
4. GV valve
5. Relay valve on the side of the gearbox
6. Transmission brake spring-loaded cylinder
1. Position “low”
3
2. Position “middle”
3. Position “high”
9910 1-17
1-18 9910
65/75/85CF series Description of components
2. DESCRIPTION OF COMPONENTS
2.1 NEUTRAL POSITION VALVE
3
V300140
ÁÁÁÁÁÁ
Pneumatic symbol
ÁÁÁÁÁÁ
Connection
ÁÁÁÁÁÁ
point
Function
N
V
ÁÁÁÁÁÁ
1 Supply
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
21
Auxiliary gearbox cut-in
pressure 22
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
22
Plugged
ÁÁÁÁÁÁ
21
Position Function
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
N Gearbox selector shaft in
neutral 1
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
V Gearbox selector shaft
engaged
V300160
9910 2-1
Description of components 65/75/85CF series
Operation 3
Gearbox in neutral:
In the neutral position, push rod (A) will be 1
pushed into a recess in the drive shaft by means
of the air pressure coming from connection (1)
and a bore hole through sealing pin (B). Sealing
pin (B) will provide a spring-loaded seal on seat B
(C). The air flow may now leave the valve via C
the connection (21) and subsequently operate 21
the range cylinder through the electropneumatic
valve. 22
3
A
W 3 02 098
Gearbox engaged: 3
When a gear has been engaged, the drive shaft
will push the push rod (A) up against the sealing
pin (B). This closes off the bore hole in this pin 1
and causes the pin to be lifted of seat (C)
against the spring pressure. The air pressure in
the gear engaging cylinder can now flow back to B
the neutral valve via the electropneumatic valve, C
and leave the valve housing through the vent
opening (3). 21
22
A
W 3 02 102
2-2 9910
2.2 DOWN-SHIFT SAFETY VALVE
3
V 300029
ÁÁÁÁÁÁ
Pneumatic symbol
ÁÁÁÁÁÁ
Connection Function
ÁÁÁÁÁÁ
point
ÁÁÁÁÁÁ
1 Supply
ÁÁÁÁÁÁ
4 Control pressure
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
21
High group cut-in
pressure
L
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
22
Low group cut-in
pressure
H
21
22
Operation
If the vehicle speed exceeds a particular value
(frequency value), the coil of the
electropneumatic valve is interrupted. 4 1
Regardless of any pneumatic command from
the gear lever group switch to the connection V300144
point (4), it is now no longer possible to switch
down to the lower group.
The air supply (1) to the electropneumatic valve
is only available when the gear lever, and hence
also the neutral valve, are in the neutral
position.
9910 2-3
2.3 ENGAGING CYLINDER, HIGH/LOW GROUP
V300141
ÁÁÁÁÁÁ
Pneumatic symbol
ÁÁÁÁÁÁ
Connection Function 26 25
ÁÁÁÁÁÁ
point
ÁÁÁÁÁÁ
25 High auxiliary gearbox H L
group
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
26 Low auxiliary gearbox
group
V300142
Operation
The engaging cylinder controlling the high/low
section of the gearbox, receives its supply via
the electropneumatic safety valve. This safety
valve is operated by the shifting valve on the
gear lever. The gear engaging cylinder is
located at the rear end of the gearbox.
2-4 9910
2.4 GEAR LEVER SHIFTING VALVE
Splitter group switch A

Splitter group switch B
A
B
D000096 3
ÁÁÁÁÁÁ
Pneumatic symbol
ÁÁÁÁÁÁ
Position Function
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
GV Splitter
22 21
H H
L L
GV GP
V300161
9910 2-5
Operation of the group switch

Changing to the low or high speed range is done
with a switch (B) on the side of the gear lever.
Turn the switch down to select the low range
and up to select the high range. shifting down:
low group, switching up: high group.
Preselection is permitted. Switching itself takes
place when the gear lever passes neutral. A
Operation of the splitter switch
B
The splitter is operated with the switch (A) on
the side of the gear lever. Tip the lower end of
the switch for low split selection, and the upper D000096
end of the switch for high split selection.
Pressed in on the underside. high gear.
3 When the switch has been operated, the clutch
pedal must be fully depressed, after which the
gear-change is made.
Preselection is permitted.
When the splitter is in low split position, the
splitter warning lamp on the instrument panel
will illuminate.
2-6 9910
2.5 GV VALVE
V300177
ÁÁÁÁÁÁ
Pneumatic symbol
ÁÁÁÁÁÁ
Connection
ÁÁÁÁÁÁ
point
Function
ÁÁÁÁÁÁ
1 Supply
ÁÁÁÁÁÁ
2 Control pressure
2
GV valve operation for ZF gearboxes
The GV (“Getriebevorschalt”) pre-shifting valve 1
ensures that when the clutch pedal is
depressed, pressure is supplied to the splitter
cylinder via the relay valve.
If the clutch pedal is not depressed, this bleeds
the splitter cylinder.
The splitter cylinder will stay in the position in
which it was last switched. V300164
9910 2-7
GV valve operation for Eaton gearboxes

The GV valve in the Eaton twin splitter gearbox
is used to operate the transmission brake
indirectly.
The gearbox must be disengaged when doing
this, so as to prevent excessive transmission
brake wear.
As the driver does not always need to make use
of the transmission brake, a pressure point has
been fitted to the pedal stop.
2-8 9910
2.6 SPLITTER RELAY VALVE
In 16 S gearboxes, the splitter relay valve is

located at the left-hand side of the gearbox.
The valve is a 5/2 valve.
Depending on the type of gearbox (direct input
or overdrive), two variants are possible.
V300169
3
Pneumatic symbol 41
V300162 overdrive gearbox
V300163 direct input gearbox
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
L
Connection Function
ÁÁÁÁÁÁ
point
1
ÁÁÁÁÁÁ
H
1 Supply
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
41
Control pressure
ÁÁÁÁÁÁ
Position Function
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
L Splitter high
H L
ÁÁÁÁÁÁ
H Splitter low
V300162
41
1
H
L H
V300163
9910 2-9
2.7 FILTER/GOVERNOR, EATON TS
Valve on gearbox
3 W 3 02 094
Wash out the filter regularly with water and a 6

soap solution. Then blow clean the filter with
compressed air both inside and out. 5
Depressurise the air pressure system. 4
3
Remove plug 5.
Take out the filter and wash through. 2
Clean the filter housing, removing the valve if
necessary.
1
Replace the sealing ring and O-ring.
Assemble and inspect the filter. See “Technical
data”.
1. Filter/governor housing
2. Filter element
3. Sealing ring 12
4. O-ring 9
5. Cover 10
6. Plug/test connection
8. Output
9. Shifting valve output plug
8
8
10. Attachment bolt
12. Supply pressure connection point
W 3 02 099
2-10 9910
Pneumatic symbol
2
1 3
W 3 02 106
Operation
Full vehicle supply pressure (large arrow) from
circuit four of the brake system must pass
through the air filter.
The supply pressure goes through the bore in
the valve and will force the piston down against
the spring pressure.
The spring cannot be adjusted.
Output pressure. See “Technical Data”. The left
bore is connected to connection point “S” on the
control cover.
The right bore is connected to connection point
“1” on the gear lever shifting valve.
W 3 02 103
9910 2-11
2.8 EATON TRANSMISSION BRAKE RELAY VALVE
Relay valve on the gearbox
3 Twin Splitter
Eaton W 3 02 095
Operation of the transmission brake relay

valve:
Whenever the clutch pedal is fully depressed,
air pressure will be supplied through the GV
valve to the relay valve.
The relay valve passes the pressure directly
through to the transmission brake in the
gearbox. At the same time, pressure is built up A
in a chamber in the relay valve. The volume of
this (adjustable) chamber determines how long
the transmission brake is operated.
When the pressure in the chamber is high W 3 02 104
enough, a piston in the chamber will switch the

relay valve against the spring pressure. This
shuts off the supply pressure to the relay valve
and bleeds the transmission brake.
The chamber is shown schematically by
restriction A.
The time is factory set to 0.45 seconds. Due
to the danger of damaging the transmission A
brake, this time must not be exceeded.
W 3 02 105
2-12 9910

3.1 PROGRAMMING PARAMETERS USING DAVIE 2.0
After a gearbox has been replaced by a gearbox

which uses a different reduction rate, it will be
necessary to reprogram the CTE-3 by means of
DAVIE 2.0.
This is to ensure that the down-shift safety is
enabled and disabled at the correct vehicle
speeds.
See the system manual “CTE-3” for information
on programming the CTE-3.
For the correct hertz figure, see “Technical
Data”. 3
9910 3-1
3.2 INSPECTION OF DOWN-SHIFT SAFETY VALVE
Inspection without vehicle speed signal

1. Ensure there is sufficient air pressure.
2. Position the gear lever in neutral.
3. Switch the vehicle contact on.
4. Use the group switch (B) on the gear lever A
to select the lower group. The auxiliary
gearbox should now switch to the lower B
group.
5. Switch the vehicle contact off. The auxiliary
3 gearbox should now automatically switch to
the higher group.
D000096
Inspection with the vehicle speed signal

1. Ensure there is sufficient air pressure.
2. Connect special tool Delsi-2
(DAF no. 0694941).
V300281
3. Position the gear lever in neutral.

4. Switch the vehicle contact on.
5. Use the group switch (B) on the gear lever
to select the lower group. The auxiliary
gearbox should now switch to the lower
group. A
B
D000096
3-2 9910
6. Use Delsi-2 to raise the simulated vehicle

speed steadily to approximately 40 km/h.
As the vehicle speed increases, the
auxiliary gearbox should automatically
switch to the higher group.
7. Use Delsi-2 to decrease the simulated
vehicle speed steadily to approximately
0 km/h. As the vehicle speed decreases,
the auxiliary gearbox should automatically
switch to the lower group.
V300282
3.3 INSPECTION AND ADJUSTMENT, ZF AND EATON GEARBOX GV VALVE
Inspection, ZF gearbox GV valve

1. Ensure that the gearbox is in neutral and
the parking brake is engaged.
2. Start the engine and run it at idling speed.
3. Use the rocker switch (A) on the gear lever
to select the other splitter mode without A
depressing the clutch pedal.
B
4. Carefully push the gear lever in the
direction of reverse, until the teeth in the
gearbox start to rattle.
D000096
5. Slowly depress the clutch pedal until the
gear can be engaged in regular fashion
(without rattling).
Note:
After the gear has been engaged or the
rattling has stopped, the splitter must switch
to the pre-selected mode (high or low,
depending on the pre-selected position).
9910 3-3
Inspection, Eaton gearbox GV valve

1. Ensure that the gearbox is in neutral and
the parking brake is engaged.
2. Start the engine and run it at idling speed.
3. Carefully push the gear lever in the
direction of reverse, until the teeth in the
gearbox start to rattle.
4. Slowly depress the clutch pedal until the A
gear can be engaged in regular fashion
(without rattling). This point must be the
same as the distance (C). See “Technical
data”.
3
1
V300315
3-4 9910
Adjustment, ZF and/or Eaton gearbox GV

valve (old-type clutch pedal)
1. Note:
In order to perform the various adjustments
to the clutch pedal, dashboard parts A and
B must first be removed. A
3
B
W 3 04 011
9910 3-5
Adjust the stop (C) by means of the

adjusting screw (2) in such a way that the 2
GV valve starts to be activated. See
“Technical Data”.
2. Adjust the stop (D) by means of the
adjusting screw (1). See “Technical data”.
3. Check the operation of the GV valve.
V300176
V300315
3-6 9910
Adjustment, ZF and Eaton gearbox GV valve

(new type clutch pedal)
1. Note:
In order to perform the various adjustments
to the clutch pedal, the grille must first be
removed.
Remove the stop (1) from the clutch
housing.
V300317
2. Fit an Allen key (2) at the place the stop

comes out.
V300318
9910 3-7
3. Using an Allen key (2) lowered to the

opening of the stop, the adjusting screw (3) 3
can be turned to correct the stop (C). See
“Technical data”.
4. Fit the stop.
3
V300316
5. Adjust the stop (D) by means of the

adjusting screw (1). See “Technical data”.
6. Check the operation of the GV valve.
V300315
3-8 9910

4.1 REMOVAL AND INSTALLATION, GEAR LEVER SHIFTING VALVE
Removal, gear lever shifting valve

cab. Tilt the cab.
various valves.
valve. 3
so that it cannot cause any damage.
6. Raise the coloured rings over the air pipes.
These coloured rings also serve as
markers.
7. Use a small screwdriver to depress the
edge of the air connection, after which the
pipes can be pulled from the switch button.
V300159
9910 4-1
Installation, gear lever shifting valve

1. Connect the air pipes to the shifting valve
by pushing them into the respective
connectors as far as possible.
For the connection points in the shifting
valve, see “Technical Data”.
2. Slide the coloured rings back over the
connection points.
3. Feed the air pipes through the gear lever
and fit the switch with the valve to the gear
lever. Tighten the threaded bush and slide
the gaiter over the threaded bush.
3 4. Connect the air pipes. Ensure that the pipes

4-2 9910
3 MECHANICAL GEARBOXES
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 System description of 16 S gearbox systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 9910
1.2 System description, Eaton TS gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . . 9910
2. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 Synchroniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
3.1 Inspection, gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
3.2 Inspecting and adjusting of the gearbox output shaft
bearing axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 9910
3.3 Inspection and adjustment, input shaft bearing axial clearance . . . . . . . . . . . 3-5 . . . . . . 9910
3.4 Inspection and adjustment, gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . . 9910
4. REMOVAL AND INSTALLATION, ZF S6-36/6S-850 GEARBOXES . . . . . . . . . . . . . 4-1 ...... 9910
4.1 Removal and installation, entire gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Removal and installation, drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-3
......
......
9910
9910
4
4.3 Removal and installation, output shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 9910
4.4 Removal and installation, sliding bush sealing ring . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 9910
4.5 Removal and installation, selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 ...... 9910
5. REMOVAL AND INSTALLATION, ZF 9 S 75 GEARBOX . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.1 Removal and installation, entire gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.2 Removal and installation, drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 9910
6. REMOVAL AND INSTALLATION, ZF 8/9/16 S 109 GEARBOXES . . . . . . . . . . . . . . 6-1 ...... 9910
7. REMOVAL AND INSTALLATION, ZF 8/16S 151/181/221 GEARBOXES . . . . . . . . 7-1 ...... 9910
7.1 Removal and installation, gearbox with integrated retarder . . . . . . . . . . . . . . . 7-1 ...... 9910
9910 1
MECHANICAL GEARBOXES 3
Page Date
8. REMOVAL AND INSTALLATION, EATON TS 12612 GEARBOX . . . . . . . . . . . . . . 8-1 ...... 9910
9. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . . 9910
9.1 Draining and filling, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . . 9910
2 9910
1. GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. These data can
also be found on the vehicle identity card for the
vehicle concerned.
1. Type of gearbox
2. Serial No. ( Z / F )
3. Parts list ( Z / F )
4. Specification No. 1
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO 3 2
8. PTO speed 4
9. Gearbox oil capacity
10. Oil specification 6 5
8 7
4
9 10
V300049
9910 1-1
1.1 DESCRIPTION OF 16 S GEARBOX SYSTEMS
1 3 4 5 6
4
7
2 8
A B C
W303056
A. Integrated auxiliary gearbox or gearbox

splitter (two gears)
B. Main gearbox with four forward and one
reverse gear
C. Auxiliary gearbox or range gearbox (two
gears)
1. Input shaft
2. Lubricating oil pump
3. Main shaft
4. Selector shafts with shifting forks
5. Planetary gears for range group
6. Output shaft
7. Connection point for PTO
8. Auxiliary shaft
Example of a type indicator 16 S 181

16 = 16 gears
S = all forward gears synchronised
181 = mark for the input engine
torque
1-2 9910
A. Integrated auxiliary gearbox

This is an auxiliary gearbox located in the main
gearbox housing. Using an additional set of
gears, the auxiliary shaft of the main gearbox
can be driven by two different ratios. In this way,
each gear in the main box can be engaged in a
low or high ratio, or split into two (also known as
“splitting”) Hence, the number of gears of the
main gearbox is doubled.
B. Main gearbox
The main gearbox consists of four or six (six in
the case of the S 6-36) synchronised forward D
gears, to which a non-synchronised forward 1 S
crawler-gear is added in the case of the 9S D
2
gearbox. The main gearbox also has one S
non-synchronised reverse gear. 3

D
S
C. Planetary auxiliary gear D
This is a gearbox mounted onto the rear of the

main gearbox, consisting of one planetary gear
4 S
D
4
5 S
wheel set.
D
Using this set of gears, all gears of the main 6 S
gearbox can be used once with the auxiliary
D
gearbox in a low ratio, and once with the 7 S
auxiliary gearbox in a 1:1 ratio. D
Hence, the number of gears of the main 8 S
gearbox is doubled. D
In popular terms, the number of gears in the RS
gearbox is “stacked”. This is why the term
“stacking box” or range box arose.
W 3 03 055
16 S 109/151/181/221
By means of the gearbox splitter, the four gears
in the main gearbox are multiplied by two, while
the use of the auxiliary gearbox multiplies this
figure by two again, which results in
4x2x2 = 16 “forward” gears.
9910 1-3
8S-109/151/181 and 9S 75.

The four gears of the main gearbox are
augmented by two each from the auxiliary
gearbox, thus there are 4x2 = 8 or, if the crawler
gear is included, 9 forward gears.
S 6 - 36/6S - 850
The gearbox 6-36/6S-850 is fitted in CF 65
vehicles and consists just of one main gearbox
with 6 forward gears.
The figure shows the power distribution across
the individual gear pairs for each gear. D
1 S
Direct input shaft version of the ZF 16 S 151 D
D = splitter “Direct” 2 S
S = splitter “Fast” D
3 S
D
4 4 S
D
5 S
D
6 S
D
7 S
D
8 S
D
RS
W 3 03 055
1-4 9910
1.2 SYSTEM DESCRIPTION, EATON TS GEARBOXES
W 3 03 057
Eaton type indicator

T Two auxiliary shafts
S Splitter box
O Overdrive version
12 Torque on input shaft = 1250 lbs.ft
= 1695 Nm
6 Code for fine gearing
12 12 forward gears
The Eaton twin splitter gearbox consists of a

main gearbox with four forward gears and one
reverse gear. Behind the main gearbox is an
auxiliary gearbox with three splitter gears.
Every gear can be “split” three times, so that
twelve equally divided forward gears and three
reverse gears are created.
This Eaton gearbox is distinguished by one main
shaft and two auxiliary shafts with straight
gearing. In addition, none of the gears are
synchronised.
9910 1-5
The main gearbox can be engaged according to

the single-H pattern, whereby every split gear
can be engaged with a selector switch on the
shifting valve. Pre-selection of another splitter
position without actually shifting is not permitted
with this gearbox. As soon as a further step up
or down is selected, pressure is applied to the
engaging cylinder.
The piston, with a shifting fork attached, cannot
yet engage a gear as there is still force being
applied to the drive line.
In this situation, The piston with the shifting fork
will none the less try to move the synchroniser
sleeve, which can lead to serious damage. Only
when the force is no longer exerted on the drive
line will the engaging cylinder be in a position to
engage a gear. The above shows that in order
to engage a gear with the auxiliary gearbox, it is
4 only necessary that the drive line has no force
exerted on it and that depressing the clutch
pedal is not necessary. Pressure can be
removed from the drive line by briefly
decelerating, for example.
The transmission brake
The twin splitter has a pneumatically controlled
transmission brake which ensures that when the
clutch pedal is fully depressed, the speed of the
auxiliary shaft and also the gears of the main
shaft are slowed down.
While slowing a point is passed when the speed
of the main shaft and therefore the speed of the
synchroniser sleeve is the same as the speed of
the auxiliary shaft. At this point, it is possible for
the driver to change gear silently.
When a main gearbox gear is engaged and it is
necessary to engage a splitter gear, the
transmission brake will slow down the whole
main gearbox and the main shaft of the splitter
box when the clutch pedal is depressed. The
speed of the main gearbox and that of the W 3 03 058
splitter box output shaft will match each other,

enabling selection if a gear by the splitter.
A split position must be selected
immediately before selecting a gear.
1-6 9910
2.1 SYNCHRONISER
B-lock synchronisation
The synchroniser consists of the following parts:
1. Gear-wheel
2. Clutch body
3. Synchromesh ring
4. Synchroniser sleeve support
5. Pressure spring
6. Thrust piece
7. Synchroniser sleeve
8. Main shaft
In neutral, the synchroniser sleeve (7) is in the

centre position.
Pressure springs (5) push the thrust pieces (6)
into a wedge-shaped recess in the synchroniser
sleeve (7).
The gear wheels (1) and corresponding clutch
bodies (2) move freely around the main
shaft (8). 2
7
3
If the synchroniser sleeve (7) is shifted to the
right from the neutral position, the synchromesh 5
ring (3) is pushed against the friction cone of the 6
1
clutch body (2) by the thrust pieces (6).
The difference in speed immediately turns the 4
synchromesh ring (3) to a stop on the 8
synchroniser sleeve support (4), which is not in
the figure, and thus prevents further movement
of the synchroniser sleeve (7).
W 3 03 046
9910 2-1
As a result of continued pressure on the

synchroniser sleeve (7) (friction), the speed of
the gear (1) to be shifted with the clutch body
(2) matches the speed of the main shaft (8).
The bevelled sides of the teeth on the
synchromesh ring (3) and the synchroniser
sleeve (7) cause the synchromesh ring (3) to be
turned back slightly after synchronisation.
This releases the lock and allows the
synchroniser sleeve (7) to be moved into the
teeth of the clutch body (2).
Hence the relevant gear is engaged.
4
A. Not engaged
B. Synchronise 7 3 2
C. Engaged
A B C
W 3 03 015
Double-cone synchronisation
As a result of the speed difference to be
eliminated in the lower gears, the
synchronisation forces may be considerable. In
order to achieve effective synchronisation, a
synchroniser with a double cone is used.
This synchroniser consists of an outer and an
inner ring (synchromesh rings) connected to the
main shaft of the gearbox by means of the
selector sleeve support.
The ring between the two synchromesh rings is
connected to the gear wheel by means of the
clutch body.
When the selector sleeve moves into the clutch
body, two synchronisation surfaces are active.
W 3 03 047
2-2 9910

3.1 INSPECTION, GEARBOX OIL LEVEL
To prevent skin injury, avoid

unnecessary contact with the
drained oil.
ZF S6-36/2, 6S-850 and 9S-75 gearboxes

1. Place the vehicle on a horizontal surface.
2. Wait for some minutes for the oil to flow
back. A
3. Remove the level check plug and check the
oil level.
4. The oil level must reach the rim of the level
check/filler opening (A).
4
5. After checking the oil level, tighten the level
check plug to the specified tightening
B
torque. See “Technical data”.
M3038
ZF 8S/9S-109 / 151, 16S-109/151 gearboxes

back.
oil level.
A
B B
torque. See “Technical data”. M3017
9910 3-1
ZF 8S/16S-181/221 gearbox
back.
oil level.
check/filler opening (A). A
B C D
M3023
3-2 9910
ZF 8S/9S-109, 16S109/151/181/221 gearboxes

with integrated retarder
1. Place the vehicle on a flat horizontal
surface. Brake the vehicle without activating
the retarder.
back.
oil level.
4. The oil level must reach the rim of the level A
check/filler opening (A). M3051

Eaton TS 12612 gearbox
1. Place the vehicle on a horizontal surface. 4
back.
oil level.
check plug to the specified tightening A
M3024
9910 3-3
3.2 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING

AXIAL CLEARANCE
ALL ZF GEARBOXES EXCEPT S6-36/6S-850

1. Remove the rear gearbox bearing cover.
A
2. Install a new gasket on the bearing cover.
Use a depth gauge to determine the depth
of the bearing cover chamber, distance A.
V300227
4 3. Use a depth gauge to determine the height

the ball bearing protrudes above the
gearbox housing, distance B.
4. Calculate the axial play.
The axial play equals distance A
B
distance B.
5. Compare the calculated value with the
maximum allowable axial play. see
6. If necessary, adjust the axial play by means
of another adjusting ring.
V300216
3-4 9910
3.3 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL

CLEARANCE
S6-36/6S-850 GEARBOXES
1. Remove the gearbox. See “Removal and
Installation”.
2. Remove the gearbox cover attachment
bolts and slide it off the input shaft.
3. Use a depth gauge to determine the depth
of the chamber in the gearbox cover,
distance B. B
V300240
4. Install a new gasket in the gearbox housing.

Use a depth gauge to determine the height
gearbox housing, distance A.
The axial play equals distance B
distance A.
maximum allowable axial play. See
“Technical Data”. A
V300239
9910 3-5
8. Drive the auxiliary shaft outer bearing race

into the auxiliary gearbox housing until the
auxiliary shaft bearing no longer has any
play.
9. Using a depth gauge, measure the height
from the gasket to the outer bearing race.
Make a note of this measurement.
10. Deduct a clearance of 0 to 0.1 mm from the
measurement taken in point 9. The result is
the thickness of the auxiliary shaft adjusting
ring that should be fitted.
11. Install a new gasket in the gearbox cover
and fit it to the gearbox.
12. Install the attachment bolts and tighten
them to the specified tightening torque. See
4 “Technical Data”.
13. Fit the lubricating oil cooler. See “Removal
and Installation”.
9S-75 GEARBOX
Installation”.
2. Remove the clutch housing, the thrust
bearing and the fork.
3. Remove the Seeger ring and the sealing
plate from the gearbox cover.
W 3 03 073
5. Remove the adjusting ring and the oil

splash plate.
W 3 03 077
3-6 9910

of the chamber in the gearbox cover. Make
a note of this measurement.
W 3 03 075

Using a depth gauge, measure the height
that the ball bearing protrudes above the
gearbox housing and deduct this
measurement from the measurement taken
in point 6.
Compare the calculated value with the
maximum allowable axial play. See
W 3 03 076
10. Fit the adjusting ring and the oil splash plate
to the gearbox cover.
and fit it to the gearbox. Ensure that the oil
channels are fitted in the correct place.
W 3 03 079
9910 3-7

13. Fit the sealing plate and Seeger ring to the
gearbox cover.
14. Fit the clutch housing, thrust bearing and
fork.
W 3 03 080
4
8/9/16S-109 GEARBOXES
Installation”.

of the chamber in the gearbox cover. Make
a note of this measurement.
3-8 9910

Using a depth gauge, measure the height
that the ball bearing protrudes above the
gearbox housing and deduct this
in point 3.
7. Install a new gasket and the adjusting ring
into the gearbox cover and fit it to the
gearbox.
them to the specified tightening torque. See 4
9910 3-9
8/16S-151/181/221 GEARBOXES
Installation”.
2. Remove the clutch fork and the thrust
bearing from the clutch housing.
W 3 03 072
3. Remove all nuts in the area surrounding the

gearbox cover, if the gearbox cover is
4 equipped with an oil pump. If an oil pump
has not been fitted, remove the attachment
bolts. The two oil pump cover bolts may
remain in the cover. These ensure that the
oil pump will remain intact.
W 3 03 086
4. Carefully slide the gearbox cover off the

input shaft. Make sure not to lose any of the
oil and adjusting rings.
W 3 03 091
3-10 9910

of the chamber in the cover with the
adjusting ring. Make a note of this
measurement.
W 3 03 088
6. Measure the height from the bearing to the

new gearbox housing gasket. Deduct this
in point 5. Calculate the axial play.
4
W 3 03 090
8. Knock the auxiliary shaft outer bearing race

into the gearbox housing with a soft drift
until the bearing is free of play. Using a
depth gauge, measure the distance from
the gasket to the auxiliary shaft bearing
outer race. Deduct 0.00 to 0.10 mm from
this distance. The remaining distance is the
thickness of the adjusting ring to be fitted.
W 3 03 089
9910 3-11
9. Fit the two oil rings with the adjusting ring to

the input shaft and align the oil pump with
the auxiliary shaft slot before sliding over
the gearbox cover with the adjusting rings.
10. Slide the gearbox cover over the studs and
fit the attachment nuts. Tighten the nuts to
the specified tightening torque. See
11. Fit the clutch fork and the thrust bearing to
the clutch housing.
W 3 03 092
3-12 9910
3.4 INSPECTION AND ADJUSTMENT, GEARBOX COVER
Adjustment, gear box shift cover B A

1. Slacken the shift control from the lever (1). A B
2. Check in 5th and 6th gear how far the
lever (1) can still be pressed through. The
transfer (P) should be identical in both
gears.
1
V300257
Adjustment, gear box shift cover

1. Note:
If the transfer (P) is different, carry out the
following procedure.
4
Slacken the attachment bolts of the control
housing slightly.
2. Shift the control housing forwards or
backwards as such that this transfer is
identical in both gears (direction A-A).
3. Then repeat point 2 for the 7th and 8th
gears.
P P
4. If 1st or 2nd gear cannot be engaged, the 6/8th gear
5/7th gear
control housing must be shifted
transversely (direction B-B).
5. Tighten the control housing attachment
bolts.
6. Check by hand whether the engaging shaft
will lightly and easily spring back into its rest
position. V300258
7. Check that the travel is about the same in

all gears.
8. Repeat the entire procedure, if necessary.
9. Note:
For an improved stop it is possible to fit a
heavier stop spring (191N instead of 168N)
(DAF no. 1341343).
10. Fit the control housing.
9910 3-13
3-14 9910
65/75/85CF series Removal and installation, ZF S6-36/6S-850 gearboxes
4. REMOVAL AND INSTALLATION, ZF S6-36/6S-850 GEARBOXES

4.1 REMOVAL AND INSTALLATION , ENTIRE GEARBOX
Removal, entire gearbox

cab. Tilt the cab.
2. Disconnect the negative terminal of the
battery.
3. Remove the gearbox cable harness and
secure it.
4. Loosen the tachometer connection.
5. Remove the shift control by loosening the
torque rod bracket and the lever on the V300138
selector shaft. 4
6. Remove the prop shaft and secure it so that
it does not form a hindrance in further
operations.
7. Remove the exhaust pipe between the
engine brake and the silencer.
8. Remove the clutch servo. No air or
hydraulic pipes need be removed. Secure
the servo and ensure that no-one in the cab
can operate the clutch pedal as long as the
servo is not fitted.
9. Place a jack under the gearbox and remove
the bolts around the clutch housing.
10. Use the jack to pull the gearbox from the
engine and remove the gearbox.
9910 4-1
Removal and installation, ZF S6-36/6S-850 gearboxes 65/75/85CF series
Installation, entire gearbox

1. Before positioning the gearbox, one gear
should be engaged in order to allow the
input shaft to slide into the clutch plate
during installation. Also grease the input
shaft sparingly with the specified grease.
2. Fit the thrust bearing.
3. Use the jack to move the gearbox towards
the engine and install the attachment bolts
around the gearbox.
4. Install the clutch servo and tighten the
attachment bolts.
5. Fit the exhaust pipe between the engine
brake and the silencer.
4 6.
7.
Fit the drive flange.
Fit the control housing.
8. Fit the cable harness and tachometer
connection.
9. Connect the negative terminal of the
battery.
10. Check the switch control and adjust if
necessary.
11. Check the oil level after the gearbox has
been installed.
12. If a different gearbox type has been fitted,
or a gearbox with a different reduction, the
correct data must be re-entered in the CTE
using DAVIE 2.0.
4-2 9910
4.2 REMOVAL AND INSTALLATION, DRIVE FLANGE
Removal, drive flange

1. Detach the prop shaft from the flange and
secure it.
2. Fit a flange retainer and remove the
locknut.
3. Pull the flange from the shaft with a
commercially available puller.
Installation, drive flange
1. Heat the drive flange to a temperature of W 3 03 049
max. 120°C.
2. Oil the output shaft lightly and slide the
drive flange over the shaft in its correct
position.
3. Fit a flange retainer.
4
4. Sparingly apply a liquid gasket to the
abutting surfaces between the flange.
5. Tighten the locknut to the specified
tightening torque. See “Technical Data”.
6. Fit the locking plate and drive the locking
plate into a hole or slot in the flange using a
drift.
7. Attach the prop shaft.
9910 4-3
4.3 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL
Removal, output shaft oil seal

1. Remove the drive flange.
2. Drill two holes into the external cover of the
oil seal and turn the special tool
(DAF no. 0484899). Pull the seal evenly
from the wheel hub using special tool
(DAF no. 0694928).
Installation, output shaft oil seal
1. Around the oil seal, clean the gearbox
housing without letting dirt into the gearbox.
2. Apply small amount of liquid gasket to the
oil seals fitted with a steel sleeve on the
outside.
7 mm
Apply a rubber coating to the oil seals’
4 exterior and apply green soap sparingly.
3. Pull the oil seal 6 + 0.5 mm into the bearing
cover using the special tool
(DAF no. 0694816).
4. Fit the drive flange.
W 3 03 048
4-4 9910
4.4 REMOVAL AND INSTALLATION OF SLIDING BUSH SEALING RING
Removing the sliding bush sealing ring

1. Remove the gearbox.
2. Remove the clutch housing complete with
fork and thrust bearing.
bolts and slide it off the input shaft. Make
sure not to lose the adjustment rings of the
auxiliary and input shafts.
4. Remove the oil seal from the gearbox
cover.
Installation, gearbox cover oil seal
(DAF no. 0535409). Apply small amount of
liquid gasket to the oil seals fitted with a
4
steel sleeve on the outside.
exterior and apply green soap sparingly.
2. Inspect the bearing play and pre-tension of
the input shaft and adjust if necessary. See
“Inspection and adjustment”.
3. Slide the entire gearbox cover with oil seal
and adjusting rings over the auxiliary shaft.
Fit the attachment bolts and tighten them to
4. Fit the clutch housing and install the
gearbox.
5. Check the oil level after the gearbox had
been installed.
9910 4-5
4.5 REMOVAL AND INSTALLATION, SELECTOR SHAFT OIL SEAL
LHD version
Removal, selector shaft oil seal
1. Mark the gearbox lever relative to the
selector shaft and remove the control lever
with the gearbox control. If necessary,
disconnect the torque rod.
2. Remove the cover attachment bolts and
remove the gearbox cover.
Seal the gearbox opening, so that no
dirt can enter.
4 W 3 03 051
3. Remove the locking pin and control stop

from the cover.
4. Drive two spring pins from the selector

fingers. Turn the selector fingers so that the
spring pins can be driven into a slot in the
cover.
5. Remove the circlip and the springs from the
rear of the cover. Then remove the selector
fingers from the cover.
W 3 03 052
4-6 9910
6. Drive the oil seal and dust seal out of the

cover. If necessary, the selector shaft
2 mm
bearing bushes can be replaced with
special tool (DAF no. 0694818). Press the
bearing bush on the control side 2 mm
under the edge.
LHD version
Installation, selector shaft oil seal
1. Fit the oil seal, having sparingly applied a
liquid gasket, using special tool (DAF no.
0535659) into the control cover. Fit the dust
seal using special tool (DAF no. 0535659)
to the control cover. Apply grease to the oil
seal lips.
2. Note:
Fit the special tool (DAF no. 0694817), a
guide sleeve, over the selector shaft and fit
the selector fingers and the gear lever lock
4
into the control housing. Fit the selector
shaft. Watch the control stop slot. W 3 03 050
3. First fit the control stop, before fitting the

spring pins.
4. Fit the spring pins and the locking pin.
5. Fit the springs, washers and the sealing
cap, having sparingly applied a liquid gasket
and fit the circlip.
6. Put the gearbox into neutral and install a
new gasket in the cover and fit it to the
gearbox housing.
7. Fit the shift control and check that all
switches function properly.
9910 4-7
RHD version
1. Mark the gearbox lever relative to the
selector shaft and remove the control lever
with the gearbox control. If necessary,
disconnect the torque rod.
2. Remove the bearing housing attachment
bolts and slide it off the selector shaft.
3. Drive the dust and oil seals out of the
bearing housing. If necessary, the selector W 3 03 059
shaft bearing bush can also be replaced
with the stamp intended for this
(DAF No. 0694818). Press the bearing
bush on the spring side 2 mm under the
edge.
4 Installation, selector shaft oil seal

liquid gasket, using special tool
(DAF No. 0535659) into the bearing
housing. Fit the dust seal using special tool
housing.
2. Grease the oil seal lips and fit an O-ring to
the bearing housing, sliding it over the
selector shaft.
3. Fit the attachment bolts and the gearbox
control. Check that all switches function
properly.
4-8 9910
65/75/85CF series Removal and installation, ZF 9S 75 gearbox
5. REMOVAL AND INSTALLATION, ZF 9S 75 GEARBOX

5.1 REMOVAL AND INSTALLATION, ENTIRE GEARBOX

cab. Tilt the cab.
battery.
3. Discharge the supply pressure from circuit
4 of the braking system.
4. Detach the air pipes and the neutral valve.
5. Detach the group cylinder air pipes.
W 3 03 063
6. Remove the electropneumatic valve bracket
and the supply block on the side of the
gearbox. Secure all these to the chassis.
4
7. Remove the prop shaft and secure it.
8. Remove the entire clutch servo with all
pipes and secure it.
9. Remove the gearbox cable harness and the
various suspension supports of the wiring
harness.
10. Remove the air engaging cylinder air
connection of the engine brake.
13. Use the jack to pull the gearbox slightly
away from the engine and remove the
gearbox.
9910 5-1
Removal and installation, ZF 9S 75 gearbox 65/75/85CF series

around the clutch housing.
3. Fit the electropneumatic valve and the
supply block.
4. Fit the air pipes in the group cylinder.
5. Connect the air pipe to the neutral valve.
4 7.
attachment bolts.
Fit the exhaust pipe between the engine
8. Fit the engine brake operating cylinder air
connection.
9. Fit the suspending brackets and the cable
harness.
11. Fit the control housing.
12. Fit the tachometer connection.
battery.
14. Check the shift control and adjust if
necessary. See “Inspection and
adjustment”.
If a different gearbox type has been fitted,
using DAVIE 2.0.
5-2 9910

secure it.
2. Remove the lock plate from the bolt heads
in the drive flange.
3. Hold the drive flange with a commercially
available flange retainer.
4. Remove the bolts and lock plate from the
drive flange.
5. Slide the drive flange off the output shaft or
pull it out, if necessary, with a commercially
available puller.
6. Remove any traces of sealant from the
shaft and flange. W 3 03 064
4
1. Lightly oil the oil seal in the bearing cover.
2. Heat the drive flange to a maximum of
60° C. Slide the drive flange as far as
possible onto the output shaft.
Do not press or hit the flange on the
shaft under any circumstances.
3. Hold the flange with a flange retainer.
4. Sparingly apply sealant to the locking plate
and flange.
5. Install the locking plate with the bolts and
tighten them to the specified tightening
torque. See “Technical Data”.
6. Use the special tool (DAF no. 0535928) to
drive the new locking plate over the bolt W 3 03 069
heads.
7. Fit the prop shaft and tighten the
attachment bolts to the specified tightening
torque.
W 3 03 065
9910 5-3

(DAF no. 0694928).
3. If the above is not possible, the bearing
cover can be removed as follows:
Remove the attachment bolts from the
bearing cover and remove the cover
together with the O-ring and adjusting ring
from the gearbox housing.
Remove the oil seal from the cover with a W 3 03 068
4 soft drift.
(DAF no. 1240426 and 6). Apply small
amount of liquid gasket to the oil seals fitted
with a steel sleeve on the outside.
2. Check the output shaft bearing play. See
3. Fit the adjusting ring and a new O-ring to
the bearing cover and fit the bearing cover
to the gearbox. Be aware of the oil
channels.
4. Install the attachment bolts and tighten to
5. Fit the drive flange. W 3 03 070
5-4 9910

2. Remove the clutch housing complete with
fork and thrust bearing.
3. Remove the Seeger ring and the sealing
plate from the gearbox cover.
W 3 03 073
4. Remove the gearbox cover attachment 4

5. Remove the oil splash plate and the
adjusting ring from the gearbox cover.
6. With a soft drift, tap the blade plate from the
gearbox cover.
7. Remove the oil seal.
W 3 03 077
9910 5-5

(DAF No. 0535423). Apply small amount of
2. Check the input shaft bearing play and
adjust if necessary. See “Inspection and
adjustment”.
3. Fit the blade plate with the blades facing
the oil seal.
4. Fit the adjusting ring and the oil splash plate
to the gearbox cover.
W 3 03 074

and fit it to the gearbox. Make sure the oil
channels are in the correct place.
W 3 03 079
5-6 9910

7. Fit the sealing plate and Seeger ring to the
gearbox cover.
8. Fit the clutch housing, thrust bearing and
fork.
9. Fit the gearbox.
W 3 03 080
W 3 03 073
9910 5-7

1. Disconnect the shift control from the
gearbox lever in the area of the round bolt
2. Mark the gear lever handle in relation to the
selector shaft and then remove it.
3. Loosen the bolts of the sealing ring cover
and remove the cover.
4. Check the selector shaft for damage.
Lightly sand the shaft, if necessary, with
fine sand paper.
5. Drive the oil seals out and check the
bearing bush. If necessary, the bearing
bush can now be removed from the cover.
4 Installation, selector shaft oil seal
(DAF no. 0535659) into the bearing
(DAF no. 0535659) into the bearing
housing. W 3 03 082
2. Carefully slide the cover over the selector

shaft and hand-tighten the bolts. Move the
selector shaft from one side to the other
several times, allowing the cover to centre
itself. Tighten the attachment bolts to the
specified tightening torque.
3. Fit the gearbox lever. Remember the
marks.
4. Fit the gearbox control and tighten the
round bolt to the specified tightening torque.
W 3 03 081
5-8 9910
65/75/85CF series Removal and installation, ZF 8/9/16 S 109 gearboxes
\
6. REMOVAL AND INSTALLATION, ZF 8/9/16 S 109 GEARBOXES


cab. Tilt the cab.
battery.
3. Remove the entire steering oil tank with the
bracket and secure it so that no steering oil
is lost.
4. Remove the entire air filter with the bridge.
5. Remove the insulation behind the engine.
6. Disconnect the drive shaft and flange from
the gearbox.
4
7. Remove the clutch servo without
disconnecting the pipes.
8. Disconnect the tachometer connection from
the gearbox.
9. Remove the spare wheel (dependant on the
vehicle type).
10. Disconnect the gearbox wiring harness
connector.
11. Remove the various air pipes. Pipes that
are not recognisable must be marked.
12. Disconnect the selector rod from the
gearbox lever and the gearbox torque rod
and hang the gearbox control on the
chassis.
engine brake and silencer (depending on
the vehicle type). V300138

9910 6-1
Removal and installation, ZF 8/9/16 S 109 gearboxes 65/75/85CF series

brake and the silencer (depending on the
vehicle type).
3. Fit the selector rod and bracket.
4. Fit the air pipes.
5. Fit the gearbox connectors and the
tachometer connection.
4 6. Fit the spare wheel (depending on the

vehicle type).
7. Fit the clutch servo.
9. Remove the insulation at the rear of the
engine.
10. Fit the air filter and bridge.
11. Fit the steering oil tank.
battery.
13. Check the oil level after installing the
gearbox.
adjustment”.
using DAVIE 2.0.
6-2 9910
\

secure it.
3. Hold the drive flange with a commercially
available flange retainer.
drive flange.
5. Remove the O-ring.
Advice: measure and note the distance W 3 03 071
from flange to shaft. The same distance
must be observed when the flange is
reinstalled. Then the flange will be fitted far
enough on the shaft.
4
6. Pull the flange from the shaft with a
commercially available puller.
2. Heat the drive flange to 70°C. Slide the
drive flange as far as possible onto the
output shaft. With the locking plate and two
standard bolts, pull the flange further onto
the shaft. Check the position of the flange,
comparing it with the above-mentioned
measurement in point 5. Remove the
locking plate and bolts.
3. Press the new O-ring into the slot between
the shaft and flange.
4. Hold the flange with a flange retainer.
5. Install the locking plate with the bolts and
6. Fit a new locking plate with stamp over the
bolt heads.
9910 6-3

secure it.
3. Remove the attachment bolts from the area
of the bearing cover.
4. Tap the bearing cover with a plastic mallet.
5. Remove the bearing cover, filler ring and oil
seal.
6. Drive the oil seal out of the cover with a
plastic driver.
4 Installation, output shaft oil seal

(DAF No. 1240491 and 1240483). Apply
small amount of liquid gasket to the oil
seals fitted with a steel sleeve on the
outside.
gearbox.
6-4 9910
\

2. Disconnect the clutch housing from the
gearbox.
3. Remove the attachment bolts from the
water pump.
4. Remove the entire gearbox cover with the
gasket and filler ring.
cover.
(DAF No. 0535423). Apply small amount of
4
2. Slide the entire gearbox cover with oil seal,
adjusting ring and gasket over the input
shaft into its place. Fit the attachment bolts
and tighten them to the specified tightening
3. Fit the clutch housing.
4. Fit the gearbox.
9910 6-5

1. Disconnect the shift control from the
gearbox lever in the area of the round bolt
2. Mark the gear lever handle in relation to the
selector shaft and then remove it.
4 3. Loosen the bolts of the sealing ring cover

and remove the cover.
fine sand paper.
5. Drive the oil seal out and inspect the

bearing bush.
housing.
2. Carefully slide the cover over the selector
shaft and hand-tighten the bolts. Move the
selector shaft from one side to the other
several times, allowing the cover to centre
itself. Tighten the attachment bolts to the
specified tightening torque.
3. Fit the gearbox lever. Remember the
marks.
round bolt to the specified tightening torque.
6-6 9910
65/75/85CF series Removal and installation, ZF 8/16S 151/181/221 gearboxes
7. REMOVAL AND INSTALLATION, ZF 8/16S 151/181/221

GEARBOXES
7.1 REMOVAL AND INSTALLATION, GEARBOX WITH INTEGRATED RETARDER

1. Disconnect the earth lead from the battery
terminal.
2. Remove the insulation at the rear end of the
engine and underneath the gearbox.
3. Disconnect the drive shaft from the gearbox
flange and hang the drive shaft on the
chassis.
disconnecting the pipe. Remove the
attachment bolts from the clutch servo and
hang the clutch servo assembly on the 4
chassis.
5. Remove the spare wheel, if necessary.
6. Disconnect the connectors of the gearbox
wiring harness.
7. Disconnect the air pipes from the central air
distribution block at the side of the gearbox.
8. Remove the ball joint from the control rod
on the gearbox lever, as well as the torque
rod bracket which is mounted on the clutch
housing, and hang the gearbox control on
the chassis.
9. If necessary, remove the section of the
exhaust pipe underneath the gearbox.
10. Place a jack underneath the gearbox and
remove the gearbox attachment bolts
around the clutch housing.
11. Note:
When the gearbox is removed from the
engine, the thrust bearing remains in the V300138
clutch release assembly.
Use the jack to pull the gearbox from the
9910 7-1
Removal and installation, ZF 8/16S 151/181/221 gearboxes 65/75/85CF series
Installation, gearbox
during installation.
2. Install the thrust bearing over the sliding
bush and check whether the circlip in the
clutch release assembly is closed.
around the gearbox.
4. Pull on the clutch lever so as to lock the
thrust bearing in the clutch release
assembly. When the thrust bearing has
been installed in the clutch release
assembly, the clutch lever can no longer be
4 moved by hand.
attachment bolts.
6. If the exhaust pipe was removed, reinstall it.
7. Connect the connectors of the gearbox
wiring harness.
8. Connect the air pipes of the central air
distribution block at the side of the gearbox.
9. If the spare wheel was removed, reinstall it.
10. Install the ball joint control rod onto the
gearbox lever and the torque rod on the
clutch housing.
11. Check the setting of the exhaust brake. See
“Inspection and Adjustment”.
12. Fit the insulation at the rear end of the
engine and underneath the gearbox.
13. Reconnect the earth lead to the battery
terminal.
V300138
using DAVIE 2.0.
7-2 9910
Removal, gearbox with integrated retarder

1. Disconnect the earth lead from the battery
terminal.
2. Drain the engine coolant.
3. Remove the coolant pipes from the
retarder.
4. Remove the coolant pipes between the
retarder and the engine.
5. Remove the electrical connectors and air
pipes from the retarder.
6. Remove the gearbox including the retarder.
Installation, gearbox with integrated retarder
1. Fit the gearbox.
2. Install the coolant pipes between the
retarder and the engine.
4
3. Connect the coolant hoses to the retarder.
4. Install the electrical connectors and air
pipes of the retarder.
5. Check/fill the gearbox and integrated
retarder with oil.
6. Fill the engine cooling system.
9910 7-3

1. Remove the drive shaft from the gearbox
chassis.
3. Remove the bolts and locking plate from
the drive flange.
4. Note: Measure and make a note of the
distance from the drive flange to the shaft.
The same distance must be observed when
the drive flange is reinstalled. W 3 03 071
Remove the drive flange and O-ring using a

4 commercially available tripod puller.
2. Heat the drive flange to 70°C. Slide the
flange as far as possible onto the output
shaft. Use a locking plate and two standard
bolts (M12x75) to pull the drive flange
further onto the shaft.
3. Remove the bolts and measure whether the
drive flange has reached the correct
position on the output shaft.
4. Fit a new O-ring into the recess between
the output shaft and the drive flange.
5. Fit the locking plate and tighten the
6. Use the special tool (DAF no. 1240460) to
drive the new lock plate over the bolt
heads.
7-4 9910

chassis.
(DAF no. 0694928).
4. If the above is not possible, the bearing
cover can be removed as follows:
bearing cover and remove the cover
together with the gasket and adjusting ring
from the gearbox housing.
4
Remove the oil seal from the cover with a
soft drift.
outside.
2. Pull the oil seal into the bearing cover using
the special tool
(DAF no. 0694780).
gearbox.
5. Install the attachment bolts and tighten to W 3 03 095

9910 7-5

2. Remove the clutch lever from the clutch
housing.
3. Remove the attachment nuts from the
sliding bush and remove the gearbox cover.
cover.
5. Remove the old gasket from the gearbox
cover and/or from the gearbox housing.
V300127

1. Apply a thin liquid gasket to the outer
circumference of the sealing ring and install
the sealing ring in the gearbox cover using
the special tool (DAF no. 0535703).
2. Check the axial play of the input shaft
bearing. See “Inspection and adjustment”.
3. Slide the gearbox cover over the input shaft
and tighten the gearbox cover to the
Data”.
4. Install the clutch lever into the clutch
housing.
5. Fit the gearbox.
V300128
7-6 9910

1. Remove the ball joint from the control rod
on the gearbox arm, as well as the torque
rod which is mounted on the clutch housing.
Hang the control rod on the chassis.
2. Remove the locking bolt and the circlip, if
necessary, from the selector shaft and
remove the gearbox lever together with the
dust cover.
V300138
3. Loosen the bolts of the sealing ring cover

and remove the cover. 4
fine sand paper.
5. Remove the oil seals together with the
bearing bush from the cover, using the
special tool (DAF No. 0535659).
6. Check the bearing bush for damage. If
necessary, replace it.
W 3 03 084
9910 7-7

1. Fit the bearing bush in the cover, using
circumference of the first sealing ring to be
installed and install it in the cover, using
circumference of the second sealing ring to
be installed and install it in the cover, using
4. Apply a thin layer of grease to the inside of
both sealing rings.
5. Install a new gasket and carefully slide the
cover over the selector shaft and
4 hand-tighten the bolts. Move the selector
shaft from one side to the other several
times, allowing the cover to centre itself.
Tighten the attachment bolts to the
W 3 03 082
Data”.
6. Fit the dust cap on the shifting arm. Ensure
that the dust cap is free of play relative to
the shifting arm and fit the locking bolt and,
if necessary, the circlip.
7. Install the ball joint control rod onto the
gearbox lever and the torque rod on the
clutch housing.
8. Check the setting of the exhaust brake. See
V300138
7-8 9910
65/75/85CF series Removal and installation, Eaton TS 12612 gearbox
8. REMOVAL AND INSTALLATION, EATON TS 12612 GEARBOX


cab. Tilt the cab.
2. Disconnect the battery negative terminal.
3. Remove the prop shaft.
disconnecting the pipes.
5. Remove the tachometer connection from
the gearbox.
6. Remove the gearbox wiring harness
connector.
4
7. Remove the various air pipes. Pipes that
are not recognisable must be marked.
8. Disconnect the selector rod from the
gearbox lever and the gearbox torque rod
bracket.
the attachment bolts around the flywheel
housing.
9910 8-1
Removal and installation, Eaton TS 12612 gearbox 65/75/85CF series
Installation, gearbox
1. Also grease the input shaft and clutch plate
hub sparingly with the specified grease.
input shaft to slide into the clutch plate hub
during installation.
3. Install the gearbox and tighten the
5. Fit the gearbox selector rod and torque rod.
6. Fit the various air pipes.
4 7. Fit the wiring harness with connectors and

the tachometer connections.
8. Fit the clutch servo.
battery.
11. Check the oil level, after having fitted the
gearbox and top up if necessary.
adjustment”.
using DAVIE 2.0.
8-2 9910

1. Disconnect the prop shaft from the flange
and hang it on the chassis so that it cannot
form an obstruction to further operations.
2. Install a flange retainer and remove the
flanged nut and O-ring.
3. Remove the flange.
W 3 03 036

2. Slide the drive flange on to the shaft.
4
3. Install the oil filler pipe having fitted it with a
new O-ring.
4. Tighten the flanged nut to the specified
5. Fit the prop shaft and tighten the
torque.
W 3 03 041
9910 8-3

2. Remove the electronic tachograph indicator.
4. Remove all attachment bolts around the
bearing cover and remove the cover.
5. Remove the oil seal from the bearing cover.
W 3 03 035

4 1. Apply small amount of liquid gasket to the
outside.
exterior and apply thin green soap
sparingly.
the special tool
(DAF no. 0535898).
3. Fit a new gasket to the bearing cover and fit
the bearing cover. Make sure that the hole
in front of the tachograph connection is
fitted in the correct place.
4. Fit the attachment bolts. If present, fit the
bolt with the plastic sealing ring in the hole
next to the tachometer indicator. In this
version, the bolt hole is in direct connection
with the space behind the bearing, in which
the oil is stored. Tighten the bolts to the
specified tightening torque. See “Technical W 3 03 034
Data”.
6. Fit the tachometer indicator.
W 3 03 033
8-4 9910

2. Remove the clutch fork and the thrust
bearing from the clutch housing.
3. Remove the attachment bolts around the
gearbox cover.
4. Slide the gearbox cover from the input shaft
and remove the oil seal.
W 3 04 015

the special tool
(DAF no. 1240038 and 1240039). Apply
small amount of liquid gasket to the oil
seals fitted with a steel sleeve on the
outside.
2. Fit the gearbox cover complete with the oil
seal and gasket over the input shaft
against the gearbox housing.
3. Apply a locking compound and fit the
attachment bolts, tightening them to the
Data”.
4. Fit the clutch fork and the thrust bearing.
5. Fit the gearbox.
W 3 03 037
9910 8-5

1. Mark the gearbox lever in relation to the
selector shaft.
2. Disconnect the shift control around the
clamping bolt.
W 3 03 032
4 3. Remove the dust cover (A) and bolts (B)

from the oil seal cover and remove the
B
cover.
4. Check the selector shaft for damage. A
fine sand paper.
5. Drive the oil seal out and inspect the
bearing bush.
B
B
W 3 03 043
8-6 9910

1. Fit the bearing bush in the cover, using
circumference of the first sealing ring to be
installed and install it in the cover, using
circumference of the second sealing ring to
be installed and install it in the cover, using
4. Apply a thin layer of grease to the inside of
both sealing rings.
5. Install a new gasket and carefully slide the
cover over the selector shaft and
hand-tighten the bolts. Move the selector
shaft from one side to the other several
W 3 03 038 4
times, allowing the cover to centre itself.
Tighten the attachment bolts to the
Data”.
clamping bolt to the specified tightening
torque.
W 3 03 039
9910 8-7
8-8 9910
65/75/85CF series Draining and filling
9. DRAINING AND FILLING

9.1 DRAINING AND FILLING, GEARBOX

drained oil.
ZFS6-36/2 6S-850 en 9S-75 gearboxes

Draining, gearbox
surface.
2. Drain the gearbox at operating temperature
A
using plug (B).
Filling, gearbox
1. Clean the drain plugs and fit them,
tightening to the specified torque. See 4
2. Fill the oil through level check/filler opening B
(A) until the oil reaches the rim of the filling
opening. M3038
3. After filling the gearbox, tighten the level

9910 9-1
Draining and filling 65/75/85CF series
ZF 8S/9S-109, 8S-151 en 16S-109/151

gearboxes
Draining, gearbox
surface.
using the drain plugs (B).
Filling, gearbox A
tightening to the specified torque. See
B B
“Technical Data”. M3017
2. Fill the oil through level check/filler opening

opening.
4 3. After filling the gearbox, tighten the level

9-2 9910
ZF 8S/16S 181/221 gearbox

Draining, gearbox
surface.
using plugs (B), (C), and (D).
Filling, gearbox
A
“Technical Data”. B C D
M3023
opening.
torque. See “Technical data”. 4
ZF 8S/9S-109, 8S-151 and 16S-109/151
gearboxes
1
4
2 5
3 V300263 V300262
Draining, gearbox
1. Before draining take a short test drive. Do
not activate the intarder during the test
drive.
surface.
via drain plugs (1) and (2).
4. Replace the oil filter (3). See “ZF Intarder”.
9910 9-3
Filling, gearbox (re-filling)

(4) until the oil reaches the rim of the filling
opening (4).
4. After filling take a short test drive. Do not
activate the intarder during the test drive.
5. After the test drive, check the oil level. The
oil level must reach the rim of the
oil-level/filler opening (4).
4 6. Tighten the level check/filler opening (4) to
Filling, gearbox (after repair or with a new
gearbox)
surface.
2. Fill the oil through the filler opening (5) until
the oil reaches the rim of the level
check/filler opening (4).
4. After filling take a short test drive. The
intarder must be briefly fully activated at
the beginning of the test drive.
6. Tighten the filler plug (5) and the level
check plug (4) to the specified tightening
9-4 9910
ZF gearbox 16S151/181/221 with intarder
1
3
4 5
V300261 V300260
Draining, gearbox
drive. 4
surface.
4. Replace the oil filter (3). See “ZF Intarder”.
opening (4).
3. Fit level check/filler plug (A), tightening it to
the specified torque. See “Technical Data”.
9910 9-5

gearbox)
surface.
3. Tighten the filler plug (5) and the level
4 oil-level/filler opening (4).
6. Tighten the level check plug (4) to the
specified torque. See “Technical Data”.
Eaton TS 12612 gearbox
Draining, gearbox
surface.
using plug (B).
A B
M3027
Filling, gearbox
1. Clean the drain plug (B) and fit, tightening to
opening.
3. Tighten the level check/filler opening to the
Data”.
A
M3024
9-6 9910
3 AUTOMATIC GEARBOXES
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 9910
2. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 Selector keypad, Allison automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
3.1 Inspection, oil level with dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.2 Inspection, oil level with selector keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 9910
3.3 Adjustment, setting the throttle position sensor (TPS) . . . . . . . . . . . . . . . . . . . 3-4 ...... 9910
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9910
4.3 Removal and installation, oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 9910
5.1 Draining and filling, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
9910 1
AUTOMATIC GEARBOXES 3
2 9910
1. GENERAL
The Allison transmission, used in the 65/75CF
series, is electronically controlled and has its
own diagnostic system that saves any faults in
the memory of the ECU (Electronic Control
Unit). The faults can be read at a later date. The
system is operated and the faults are read via
the selector keypad. The “Selector keypad”
fitted with a display is located next to the driver’s
seat and replaces the gear lever with manual 5
stick-shift gearboxes.
Type indicator:
Example MD3060 P
MD Medium Duty
3 Gearbox series
R MODE
0 Short successive transmission ratios

6 Number of gears possible
0
P
Changing figure
PTO version
N
D 5
Allison
V300290
9910 1-1
1.1 SYSTEM DESCRIPTION
“DON’T SHIFT” LAMP

When the vehicle contact is switched on this DON'T
warning lamp will light up. If there are no faults SHIFT
in the system, the warning lamp will go out after

the engine has been started.
If an error occurs whereby the gearbox no 70
80
90
15
60
20
longer can or may be shifted, the warning lamp 50
100 10
will light up with “DON’T SHIFT”. The selector 40

120
110
40
25
keypad LED will also flash three times. The VDO
5
I
accompanying fault code can be read from the 1
min
x100
30
selector display. The ECU will block the 4
5
6 7
8
VDO
20
functions of the selector and the gearbox will 3 9
shift to a “safe gear” for the gearbox. It is W 3 02 109
important to drive the vehicle to a safe place as

soon as possible and switch the contact off. It
will no longer be possible to shift the gearbox to
neutral. The ECU will prevent this.
After approximately 30 seconds try starting the
engine again and shifting the gearbox. If it
5 concerns an error whereby the gearbox must in
no circumstances be shifted, the ECU will no
longer shift the gearbox.
Driving is therefore no longer possible.
If it concerns an error whereby the gearbox may
still be shifted, the “DON’T SHIFT” lamp will
then go out. The ECU will have recorded the
error as an inactive error.
The vehicle can once again be driven, even if
the fault returns in due course. In this situation
however it is no longer possible to shift gear.
1-2 9910
OIL TEMPERATURE WARNING LAMP

If, during driving the oil temperature warning
lamp lights up, this means that the gearbox oil
has reached the maximum temperature of
121°C.
In this situation the ECU limits the gearbox to
shifting in the first four gears.
It is important to drive to a safe place as soon
as possible and let the engine idle in neutral at
an increased stationary idling speed.
By this means the cooling system of the engine
can try to cool the gearbox oil.
If after approximately two minutes the lamp has
not gone out, the engine must be turned off and
contact made with the closest DAF dealer.
ENGINE BRAKE USE

When the engine brake is operated in third or
higher gear, the ECU will change down to
second gear as soon as the engine speed
permits.
On the selector display, the second gear
5
selected by ECU is displayed.
TOWING THE VEHICLE

To tow the vehicle, the prop shaft must be
detached at the rear axle.
It is also possible to remove the half axles. As
oil can be lost doing this, it must be avoided as
much as possible owing to environmental
concerns.
If the vehicle is towed without taking the
above into consideration it can lead to
serious damage to the gearbox.
9910 1-3
1-4 9910
65/75/85CF series Components
2. COMPONENTS
2.1 SELECTOR KEYPAD, ALLISON AUTOMATIC GEARBOX
The selector has the following functions:

- Activating and deactivating of the gearbox
- Choosing a shift program
- Reading the oil level 5
- Reading and deleting error codes
R MODE
The selector has the following six keys:

N
Allison
D000390
Neutral Neutral position Display shows “N”

Drive Automatic drive Highest gear
Reverse Reverse Display shows “R”
MODE
°
Shift program selection
Changing up
Normal or economy (LED on) program
Display does not show the gear selected
5
± Changing down Display does not show the gear selected
Neutral position
No gears are activated in the “N” position. The
vehicle is not locked in this position and can
thus roll.
Use the parking brake to lock the vehicle.
“N” appears on the display.
Automatic drive
If the “D” position is selected, the vehicle will 5
immediately begin to move (if the brake system
is at pressure and the vehicle is not on the
parking brake). It is therefore advisable to
depress the brake pedal before selecting
position “D”. In this position the gearbox can R MODE
automatically change up to the higher gear.

The highest gear to which the gearbox can
change up to is shown on the display.
N
Reverse
If position “R” is chosen the vehicle will also be
immediately set in motion. First depress the
brake pedal and then select position “R”.
D
“R” appears on the display.
Allison
V300290
9910 2-1
Components 65/75/85CF series
Shift program selection

By pressing the “MODE” key briefly once,
another shift program can be selected from not
only a stationary, but also a driving position.
There are two selection possibilities, namely:
Normal program:
This program is chosen automatically when the
vehicle contact has been switched off. No report
is displayed. This program allows the gearbox to
change gear if necessary, so that driving at
higher speeds is possible. This can be desirable
on unmetalled terrain.
Economy program:
The LED lights up on the selector display. This
program will , in general, change gear at
somewhat lower engine speeds. This results in
economical fuel consumption.
± Changing down
After selecting the “D” key when the vehicle is
driving, this key is used to keep the gearbox in a
5 lower gear. The selected gear can be seen in
the display. The gear box will not change up
further until the “±” or “D” key is pressed. The
number of gears which can be used will appear
in the display.
° Changing up
This key is used to allow the gearbox to change
up to a higher gear. This is however only
possible after previously selecting to stay in a
low gear.
2-2 9910

3.1 INSPECTION, OIL LEVEL WITH DIPSTICK
A dip stick is mounted on the side of the

gearbox. To take out the dip-stick from the
holder, the sealing cap must be held tightly while
the dip-stick is turned anti-clockwise. The
dipstick holder is also the filler pipe for the
gearbox oil.
When changing the oil, the oil should be filled up
to the “cold full” point. The gearbox oil should
then be brought to operating temperature and
checked with the selector keypad.
- “Cold add” Top up cold oil level
- “Cold full” Cold oil level full
- “Hot add” Top up hot oil level
- “Hot full” Hot oil level full
W 3 03 098 5
FULL
HOT
HOT
ADD
COLD
FULL
COLD
ADD
W 3 03 099
9910 3-1
3.2 INSPECTION, OIL LEVEL WITH SELECTOR KEYPAD
Reading the oil level

In order to be able to read the gearbox oil level,
the following conditions must be met:
- vehicle on a flat surface
- engine idling
- engine and gearbox at operating
temperature
- vehicle stationary and with parking brake 5
applied
- selector in the neutral position
When these conditions have been met, a two
minute “waiting period” must be taken into
account. R MODE
Press the two arrow keys simultaneously. The

letters O and L (oil level) now appear on the
display one after the other. If the vehicle is not N
stationary long enough, at first a hyphen
appears in the display followed by a flashing
5 number 8. The Selector now counts from 8 back
to 0 (taking approx. 2 minutes). On reaching 0, D
the letters O and L appear after which the oil
level is indicated by the letters O and K (in
sequence). For a vehicle that has been
stationary for a period of time, and which meets Allison
the above conditions, the count-down will be
done. An oil level that is too high is indicated by
HI followed by the number of litres. An oil level
V300290
that is too low indicated by the letters LO
followed by the number of litres.
For example:
LO - 02 means add two litres.
HI - 03 means drain three litres.
If the oil level indicator is not in a position to give
the correct oil level, the following codes will
appear in the display one after the other.
3-2 9910
Code Error
OL - 50 Engine speed too low
OL - 59 Engine speed too high
OL - 65 Gearbox is not in neutral
OL - 70 Gearbox oil temperature too low
OL - 79 Gearbox oil temperature too high
OL - 89 Output shaft is not stationary
(handbrake)
OL - 95 Oil level indicator is defective
In case of a faulty oil level indicator,

(code OL-95), contact the nearest DAF
dealer as soon as possible.
The oil level reading function can be left by
pressing “D”, “N”, or “R”.
Caution: the function cannot be left by pressing
the arrow keys again, as this prompts the
diagnostic code reading function. All diagnostic
codes are preceded with the letter D followed by
a figure between 1 and 5. In this function,
important fault codes could be deleted from the
memory by an unqualified user. 5
9910 3-3
3.3 ADJUSTMENT, SETTING THE THROTTLE POSITION (TPS)
The accelerator pedal is self-calibrating. This

means that when the vehicle contact is on, the
ECU determines a reference point for the
accelerator pedal sensor. The ECU translates
both into “counts”. If you possess the Allison
diagnostic equipment, this machine can be used
to precisely determine the sensor range using
“counts” and the throttle position sensor can be
set.
To adjust the throttle position sensor without the
above-mentioned diagnostic apparatus, do the
following:
1. Fit the accelerator pedal sensor strip to the
fuel pump control lever. W 3 03 102
2. Put the fuel pump control lever in the idling

position.
3. Ensure that the sensor cable is in the idling
position is extended 11 to 16 mm before
5 fitting the locking pin. This point is in the
sensor range.
A Sensor cable fully extended.
B Sensor cable reading of the fuel pump
control lever at full load. A B C D
C Sensor cable reading of the fuel pump
control lever at idling position.
D Sensor cable in rest position.
W 3 03 101
3-4 9910

4.1 REMOVAL AND INSTALLATION, ENTIRE GEARBOX

1. Note:
Before the gearbox can be removed, the
gearbox oil must be drained.
2. If necessary, remove the oil filler pipe to
avoid damage.
3. Plug the external oil pipes after removing
and/or detaching to prevent dirt entering the
system.
4. Disconnect the gearbox cable harness
connectors and secure the cable harness.
Plug the openings.
6. See what is best for gearboxes with PTO:
remove the PTO from the gearbox,
disconnect the hydraulic pipes from the
5
pump or removal of the prop shaft.
7. Remove the gearbox from the engine.
1. Apply grease sparingly to the nose of the
clutch servo to prevent noise after fitting.
2. If necessary, fit the hydraulic pipes and/or
prop shaft.
3. Fit the PTO.
5. Connect the gearbox wiring harness
connectors.
6. Fit the external oil pipes.
7. If necessary, fit the oil filler pipe. W 3 03 100
8. Fill the gearbox with oil and check the oil

level.
9910 4-1

1. Remove the prop shaft and secure it so that
it does not form a hindrance in further
operations.
W 3 03 061
2. Note:
Locking devices are present in two versions
of prop shaft: one with a flat locking plate
and one with a spring locking plate.
5 Proceed as follows with the flat locking
plate. Undo the attachment bolts on the
locking device and unscrew the attachment V300283
bolts from the flange without removing

them.
V300284
3. Remove the bolts and locking plate from

the flange. Pay attention to the sealing rings
on the outer circumference and on the
inside of the locking plate.
W 3 03 060
4-2 9910
If the drive shaft is fitted with spring locking

plate, the following step must be completed.
Unscrew the attachment bolts of the flange
without removing them.
Remove the bolts and spring locking plate
from the flange. Pay attention to the sealing
ring on the outer circumference and on the
inside of the locking plate.
4. Slide the flange from the output shaft or, if
necessary, use a tripod puller to pull the
flange from the shaft.
V300285
(DAF No. 0484899). Pull the seal evenly
from the gearbox housing using special tool
(DAF No. 0694928).
outside.
Apply a rubber coating to the oil seals’ 5
(DAF No. 1240037).
3. Sparingly apply grease to the oil seal lips W 3 03 062
and slide the flange over the output shaft

until it abuts.
4. Note:
If the drive shaft is fitted with a flat locking
plate, the following steps must be
completed.
V300284
9910 4-3
Fit new sealing rings to the locking plate

and fit the locking plate with the attachment
bolts to the flange (apply grease sparingly
to the sealing rings).
W 3 03 060
Tighten the bolts to the specified tightening

torque and lock them with a new locking
plate. See “Technical data”.
V300284
If the drive shaft is fitted with spring locking

plates, the following step must be
5 completed.
V300285
Fit new sealing rings to the locking plate

and fit it with the attachment bolts and
springs outward to the flange (apply grease
sparingly to the sealing rings).
Tighten the bolts to the specified tightening
If the locking plate is not tightened to the
specified tightening torque, there is the
chance that the locking plate could be bent W 3 03 060
during fitting which could lead to serious

oil leakage.
4-4 9910
4.3 REMOVAL AND INSTALLATION, OIL FILTERS
Removal, oil filters

1. Make sure the gearbox is at operating
temperature (approx. 71°C - 93°C) before
the oil is drained, so that the oil can be
drained more quickly more completely.
surface.
3. Remove the drain plug from the gearbox oil
sump.
4. Remove the attachment bolts from the two
filter covers at the bottom of the gearbox oil
sump.
5. Remove the two covers and filters and the
various O-rings from the oil sump.
Installation, oil filters
1. Oil the O-rings and insert the oil filters with
the covers in the gearbox oil sump. Ensure
that the covers are correctly positioned.
5
Never centre the covers with the bolts.
2. Fit the cover attachment bolts and the oil
drain plug and tighten them to the specified
W 3 03 103
3. Fill the gearbox with oil. See “Draining and
Filling”.
9910 4-5
4-6 9910

5.1 DRAINING AND FILLING, GEARBOX
Draining, gearbox
1. Bring the gearbox to operating temperature
(approx. 71°C - 93°C) before the oil is
drained, so that the oil can be drained more
quickly more completely.
surface.
3. Remove the drain plug from the gearbox oil
sump.
4. Remove the oil filters. See “Removal and
installation”.
Filling, gearbox
1. Note:
A dip stick is mounted on the side of the
gearbox. To take out the dip-stick from the
holder, the sealing cap must be held tightly
while the dip-stick is turned anti-clockwise.
5
The dipstick holder is also the filler pipe for
the gearbox oil.
When changing the oil, the oil should be
filled up to the point “cold full”. The gearbox
oil should then be brought to operating
temperature and checked with the selector
keypad.
W 3 03 098
- “Cold add” Top up cold oil level

- “Cold full” Cold oil level full
- “Hot add” Top up hot oil level
- “Hot full” Hot oil level full
FULL
HOT
2. Tighten the drain plug to the specified

3. Install the oil filters. See “Removal and
installation”.
HOT
ADD
4. Fill the specified amount of oil using the

COLD
FULL
dipstick. See “Technical data”.

5. Check the oil level. See “Inspection and
Adjustment”.
COLD
ADD
W 3 03 099
9910 5-1
5-2 9910
3 CLUTCH
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.1 Description of the clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.2 Overview drawing, main cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 9910
2.3 Overview drawing, clutch servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 9910
2.4 Overview drawing, clutch lever attachment to gearbox . . . . . . . . . . . . . . . . . . 2-7 ...... 9910
2.5 Overview drawing, clutch lever attachment to clutch housing . . . . . . . . . . . . . 2-8 ...... 9910
3. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.1 Main cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.2 Clutch servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 9910
3.3 Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 9910
4.1 Inspection and adjustment, clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9910
4.2 Inspection, clutch servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 9910
4.3 Inspection, clutch fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 9910
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.1 Removal and installation, clutch servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.2 Removal and installation, drawn clutch thrust bearing . . . . . . . . . . . . . . . . . . . 5-2 ...... 9910
5.3 Removal and installation, pushed clutch thrust bearing . . . . . . . . . . . . . . . . . .
5.4 Removal and installation, drawn clutch clutch lever . . . . . . . . . . . . . . . . . . . . .
5-4
5-5
......
......
9910
9910 6
5.5 Removal and installation, pushed clutch clutch lever . . . . . . . . . . . . . . . . . . . . 5-6 ...... 9910
5.6 Removal and installation, clutch release assembly/clutch plate . . . . . . . . . . . 5-7 ...... 9910
5.7 Removal and installation, pilot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 9910
5.8 Removal and installation, main cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ...... 9910
6.1 Draining and filling, clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 9910
6.2 Bleeding the clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . . 9910
9910 1
CLUTCH 3
2 9910
3 CLUTCH
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
1.1 SAFETY PRECAUTIONS
Hydraulic fluid is toxic and can

therefore have a damaging effect
on your health.
Hence avoid any direct or indirect
physical contact.
As hydraulic fluid is also a
corrosive fluid, it may damage the
paintwork of the vehicle. Avoid any
contact between hydraulic fluid and
paintwork.
Always use new and clean

hydraulic fluid which has been kept
in a sealed container and complies
with the specifications.
Hydraulic fluid which has absorbed
water (from the ambient air) may
have an adverse effect on the
operation of the clutch system.
Avoid any contact with mineral oil.
Even one drop of mineral oil in the
system will damage the seals.
6
9910 1-1
CLUTCH 3
Safety precautions 65/75/85CF series
1-2 9910
3 CLUTCH
2. GENERAL
2.1 DESCRIPTION OF THE CLUTCH SYSTEM
The clutch is a single dry-plate clutch, which is

hydraulically operated and pneumatically
assisted.
The clutch consists of:
- flywheel
- clutch plate
- clutch release assembly
By clamping the clutch plate between the
flywheel and the clutch release assembly, a
torque can be transferred (by means of friction).
The extent of the torque that must be
transferred by the clutch is determined by the
maximum engine torque multiplied by the safety
factor (usually 1.3).
To clamp the clutch plate, a diaphragm
(pressure)spring is used in the clutch release
assembly.
A diaphragm spring constitutes a simple, strong
and cost-effective construction.
Another advantage of the diaphragm spring is
that the pressure exerted on a new clutch plate
almost equals the pressure exerted on a worn
6
clutch plate.
The operation of the diaphragm spring (the
coupling and uncoupling of the clutch plate) can
take place in:
- a pushed version
- a drawn version
9910 2-1
CLUTCH 3
Pushed version (see fig. 1)
V 3 000 52
Fig. 1
2-2 9910
3 CLUTCH
Drawn version (see fig. 2)
V300114
Fig. 2
9910 2-3
CLUTCH 3
A diaphragm spring requires a self-centring

thrust bearing.
The type of clutch plate used depends on the
following factors.
The size of the clutch plate lining must be the
same as the desired service life.
The character of the engine (the engine
vibrations to be damped) determines the version
of the vibration damper construction in the hub.
For the clutch plate to engage smoothly it is
necessary that the lining material abuts the
flywheel and clutch release assembly evenly at
all places during engaging.
The “drawn clutch” has the following advantages
over a “pushed clutch”:
- favourable transfer ratio, resulting in lighter
pedal pressure
- lower weight of the clutch release assembly
- simple clutch release assembly construction
2-4 9910
3 CLUTCH
2.2 OVERVIEW DRAWING, MAIN CYLINDER
1. Push rod with eye

2. Push rod adjustment
3. Push rod 1
4. Piston
5. Valve
6. Spring
7. Compensation bore 2
E
4
5
6
7
V300286
9910 2-5
CLUTCH 3
2.3 OVERVIEW DRAWING, CLUTCH SERVO
5 10
A
4 6
1
8 7
2
9 3
Doorsnede A-A
V300287
1. Energising piston
2. Air valve
3. Spring
4. Pressure pin
5. Air piston
6. Fluid piston
7. Pressure spring
8. Vent bore hole
9. Bleed
10. Vent opening
2-6 9910
3 CLUTCH
2.4 OVERVIEW DRAWING, CLUTCH LEVER ATTACHMENT TO GEARBOX
1. Thrust bearing
2. Lever assembly
3. Bracket 3
4. Bearing bush 2 4
1 9
5. Circlip
6
6. Shim 8
7. Lever bearing bush
8. Lever 7
9. Shaft 6
5
4
3
V300292
9910 2-7
CLUTCH 3
2.5 OVERVIEW DRAWING, CLUTCH LEVER ATTACHMENT TO CLUTCH

HOUSING
3 4 5 6
2
6
V300293
1. Thrust bearing
2. Lock bolt
3. Lever
4. Spring clip
5. Ball joint
6. Clutch housing
2-8 9910
3 CLUTCH
3.1 MAIN CYLINDER
When the clutch pedal is depressed, push rod

(3) will move the piston (4) down against the
spring (6). 1
As a result, valve (5) will close and start to build
up pressure as the sleeve passes the bore hole
of the reservoir.
2
When the clutch pedal is released, spring (6)
ensures that piston (4) returns to the original
position.
Any shortage of fluid underneath the piston (4)
is refilled via a bore hole in the piston (6) and
the valve (5).
3
It is important that after depressing the clutch
pedal, the piston (4) returns fully to the original
position, so that the compensation hole (7),
0.6 mm, is not closed by the piston (4) seal.
If the compensation hole is not entirely free,
residual pressure will build up causing excessive
E
damage to the clutch mechanism. The piston (4)
can return fully to the original position if there is 4
sufficient play (E) between the push rod (3) and
piston (4). See “Technical data”. 6
5
7
V300286
9910 3-1
CLUTCH 3
3.2 CLUTCH SERVO
5 10
A
4 6
1
8 7
2
9 3
Doorsnede A-A
V300287
Declutching
Depressing the clutch pedal results in a
hydraulic pressure build-up.
This causes the servo piston (1) to push the air
valve (2) from the valve seat, against the force
of spring (3).
3-2 9910
3 CLUTCH
Air pressure now flows into the cylinder.

The pressure pin (4) is pushed forward by the
air pressure building up on the air piston (5) and
the hydraulic pressure on fluid piston (6).
The pressure pin (4) pushes against the clutch
lever, which results in declutching.
State of balance
When the hydraulic pressure and pneumatic
support push pressure pin (4) forwards, a state
of balance is achieved between the air pressure
and hydraulic pressure (status when the clutch
pedal is not depressed any further).
The servo piston (1) again seals off against the
valve seat, closing the air supply and stopping
the build-up of pneumatic pressure.
Clutching
When the clutch pedal is released, there is no
longer any hydraulic pressure and the servo
piston (1) will be pushed back into its original
position by the pressure spring (7) and any
remaining pneumatic support.
As a result, the vent bore hole (8) in the servo
piston (1) is no longer closed, and venting takes
place via the exhaust (9).
6
Vent opening
The function of the vent opening (10) is to
prevent a build up of pressure between both
piston seals.
9910 3-3
CLUTCH 3
3.3 THRUST BEARING
The 65/75/85CF series has two versions of

thrust bearing, one with and one without plastic
coating.
The thrust bearing without plastic coating can be
recognised by the aluminium lining on the inner
diameter.
6
V300288
The thrust bearing with plastic coating can be

recognised by the spline shaped inner diameter.
V300173
3-4 9910
3 CLUTCH

4.1 INSPECTION AND ADJUSTMENT, CLUTCH PEDAL
Inspection, clutch pedal

1. Check the total travel (D) of the clutch
pedal. See “Technical Data”.
2. Check the free travel (B) of the clutch
pedal. See “Technical Data”. Free travel
can be felt by manually depressing the
clutch pedal in its original position to clearly A
identify the travel (B).
Adjustment, clutch pedal
1. Use the adjusting screw (1) to adjust the
total travel (D). See “Technical Data”. 1
C
6
D
2. The free travel (B) of the clutch pedal is

V300315
indirectly set by loosening the locknut (2)
and then screwing the ball joint (1) in or out
of the push rod (3). This sets the distance
(E) between the push rod (3) and the piston 1
(4) in the main cylinder. See “Technical
Data”.
2
E
4
5
7
V300286
9910 4-1
CLUTCH 3
4.2 INSPECTION, CLUTCH SERVO

on your health.
physical contact.
paintwork.

1. Pressurise the air system.

6 2. Check for any air leakage via the clutch
servo exhaust.
3. Depress the clutch pedal and check
whether there is any leakage via the clutch
servo exhaust.
Note:
While releasing the clutch pedal, the clutch
servo should bleed itself via the exhaust.
4. Depress the clutch pedal and check that
there is no leakage via the clutch servo
exhaust.
4-2 9910
3 CLUTCH
5. Check that there is no leakage via the vent

opening (10).
Note:
A drop of oil on the vent opening (10) is
normal and is not a reason to replace the
clutch servo.
If there is constant leakage, the clutch
servo must be repaired or replaced.
If in doubt as to whether the clutch servo
situation is normal or whether there is a
leak, inspect the fluid level in the clutch
reservoir. 10
V300289
6. Depress the clutch pedal and check
whether there is a leak via the vent
opening (10).
9910 4-3
CLUTCH 3
4.3 INSPECTION, CLUTCH FLUID LEVEL

on your health.
physical contact.
paintwork.

hydraulic fluid which has been kept C
Avoid any contact with mineral oil. B
1. Check whether the fluid level is between the A

6 (A) and (B) marks when the cab is in the
driving position.
2. Mark (C) applies to fully tilted cabs.
3. Fit the reservoir sealing cap by hand.
Note:
In the cap is a vent that can be closed if the
cap is tightened with too great a force. If the
vent is closed off, residual pressure will V300178
build up in the system
4-4 9910
3 CLUTCH

5.1 REMOVAL AND INSTALLATION, CLUTCH SERVO

on your health.
physical contact.
paintwork.

with the specifications. Hydraulic
fluid which has absorbed water
(from the ambient air) may have an
adverse effect on the operation of
the clutch system. Avoid any
contact with mineral oil. Even one
drop of mineral oil in the system
will damage the seals.
Removal, clutch servo

6
1. Remove the air pipe from the clutch servo.
2. Place a container under the clutch servo
and remove the fluid pipe. Then plug the
pipe.
3. Note:
The clutch servo is mounted on the clutch
housing under pre-tension.
Remove the attachment nuts from the
clutch servo.
Installation, clutch servo
1. Apply a little anti-seize compound to the
V300064
pressure side of the push rod.
2. Fit the clutch servo. Make sure that the
push rod fits into the cup-shaped recess in
the clutch lever.
Then evenly tighten the attachment nuts.
3. Connect the air and fluid pipes.
4. Fill and bleed the clutch system.
9910 5-1
CLUTCH 3
5.2 REMOVAL AND INSTALLATION, DRAWN CLUTCH THRUST BEARING
Removal, drawn clutch thrust bearing

2. Remove the thrust bearing from the clutch
release assembly by releasing the circlip
from the clutch release assembly.
B
B
A
V300059
Installation, drawn clutch thrust bearing

1. Note:
- No more grease need be used for the
gearbox cover.
- The thrust bearing chamber has been
greased for the full service life.
6 - Apply a little grease to all pressure

surfaces of the declutching fork.
- Grease the thrust washer sparingly.
Install the thrust bearing, the lip
pointing up, dry onto the sliding box.
2. Move the clutch lever, causing the thrust
bearing to engage behind the rolls of the
clutch lever.
V300123
5-2 9910
3 CLUTCH
3. Note:
Before installing the gearbox, check 4
whether the circlip in the pressure group
has been locked.
3
Check whether the retainer plate (2) and
lock ring (1) and circlip (3) have been fitted 2 1
in the correct locations. The diaphragm
springs (4) have special recesses to
accommodate the circlips (3).
4 3
6
V300122
4. Move the clutch lever so as to lock the

thrust bearing in the clutch release
assembly.
V300126
9910 5-3
CLUTCH 3
5.3 REMOVAL AND INSTALLATION, PUSHED CLUTCH THRUST BEARING
Removal, pushed clutch thrust bearing

2. Remove the thrust bearing from the fork in
the clutch housing by loosening a lock bolt
(1) from the fork.
Installation, pushed clutch thrust bearing
1. Note:
- Grease the gearbox cover sparingly.
- Fill the thrust bearing with grease.
- Apply a little grease to all pressure
surfaces of the declutching fork.
- Grease the thrust washer sparingly.
2. Insert the thrust bearing between the forks
and attach it with a lock bolt (1).
Note:
When tightening the lock bolt (1) in the 1
thrust bearing groove, ensure that the thrust
bearing can move relative to the fork.
3. Fit the gearbox.
V300291
5-4 9910
3 CLUTCH
5.4 REMOVAL AND INSTALLATION, DRAWN CLUTCH CLUTCH LEVER
Removal, drawn clutch clutch lever

2. Remove the thrust bearing.
clutch lever.
Installation, drawn clutch clutch lever
1. Apply a little grease to the moving parts of
the clutch lever.
2. Install the clutch lever on the gearbox and
tighten the attachment bolts.
4. Fit the gearbox.
V300127
9910 5-5
CLUTCH 3
5.5 REMOVAL AND INSTALLATION, PUSHED CLUTCH CLUTCH LEVER
Removal, pushed clutch clutch lever 3 4 5 6

2. Remove the thrust bearing. 1
3. Remove the clutch lever (3) with force from

the ball joint (5) fitted in the clutch
housing (6).
Installation, pushed clutch clutch lever
1. Apply a little grease to the moving parts of 2
the clutch lever.
2. Fit the snap ring (4) into the clutch lever.
3. Fit the clutch lever (3) with force to the ball
joint (5) fitted in the clutch housing (6).
V300294

5. Fit the gearbox.
5-6 9910
3 CLUTCH
5.6 REMOVAL AND INSTALLATION, CLUTCH RELEASE ASSEMBLY/CLUTCH

PLATE
Removing the clutch release

assembly/clutch plate
2. If necessary, remove the thrust bearing.
3. Insert a dummy input shaft through the hub
of the clutch plate in the flywheel pilot
bearing.
4. Remove four attachment bolts distributed
around the circumference from the clutch
release assembly and replace them with
studs.
5. Gradually remove the remaining attachment
bolts of the clutch release assembly.
6. Remove the clutch release assembly by
sliding it from the four studs.
7. Remove the clutch plate with the dummy
input shaft.
Installing the clutch release assembly/clutch
plate 6
1. Apply a little grease to the input shaft and
the movement of the clutch plate on the V300124
splines of the input shaft.
2. Use a dummy input shaft to position the
clutch plate against the flywheel.
3. Install four studs in the flywheel, distributed
evenly around the circumference.
4. Support the clutch release assembly and
slide it onto the four studs.
5. Fit the attachment bolts and tighten them
evenly to the specified tightening torque.
See “Technical Data”.
6. Apply a little grease to all pivoting points of
the declutching fork.
7. If necessary, fit the thrust bearing.
8. Fit the gearbox.
9910 5-7
CLUTCH 3
5.7 REMOVAL AND INSTALLATION, PILOT BEARING
Removal, pilot bearing

1. Remove the gearbox. 1
2
2. Remove the clutch release assembly and
the clutch plate.
3. Use an internal puller (2) to remove the pilot
bearing (1) from the flywheel.
Installation, pilot bearing
1. Check the flywheel bore for dirt and
damage.
W 3 04 016
2. Note:
The pilot bearing (1) has a grease and dust
seal (2) on one side only.
When the pilot bearing is installed, the
grease and dust seal must face the clutch
plate.
6
1
2
W 3 04 019
Use a plastic mallet to install the bearing in

the flywheel.
3. Install the clutch release assembly and
clutch plate.
4. Fit the gearbox.
W 3 04 017
5-8 9910
3 CLUTCH
5.8 REMOVAL AND INSTALLATION, MAIN CYLINDER

on your health.
physical contact.
paintwork.

with the specifications. Hydraulic
fluid which has absorbed water
(from the ambient air) may have an
adverse effect on the operation of
the clutch system.
Removal, main cylinder

1. Connect a transparent plastic hose to the
clutch servo’s bleed nipple.
6
2. Open the bleed nipple (collect the fluid) and
drain the system.
3. Remove the clutch spring from the clutch
pedal.
4. Remove the attachment bolt from the clutch
pedal and the main cylinder.
5. Remove the pipe between the reservoir and
the main cylinder.
6. Disconnect the fluid pipe at the bottom of
the main cylinder.
7. Remove the two attachment bolts from the
main cylinder and take the cylinder from the
bracket.
V300179
9910 5-9
CLUTCH 3
Installation, main cylinder

1. Check the dust cover for wear and replace,
if necessary.
2. Install the main cylinder together with the
pipe to the reservoir.
3. Install the connector pipe.
4. Install the main cylinder attachment bolts on
the bracket and tighten them.
5. Install the dust cover in the push rod lock
ring.
6. Fit the attachment bolt from the clutch
pedal and the main cylinder.
7. Install the clutch pedal clutch spring.
8. Install the connection pipe clamping bracket
bolt underneath the main cylinder.
9. Fill the clutch system. See “Draining and
filling”.
10. Adjust the clutch pedal. See “Inspection
and Adjustment”.
6 11. Bleed the clutch system. See “Bleeding the
clutch system”.
5-10 9910
3 CLUTCH

6.1 DRAINING AND FILLING THE CLUTCH SYSTEM

therefore have a damaging effect on
your health.
physical contact.
paintwork.
Always use new and clean hydraulic

fluid which has been kept in a
sealed container and complies with
the specifications. Hydraulic fluid
which has absorbed water (from the
ambient air) may have an adverse
effect on the operation of the clutch
system.
Draining the clutch system

6
1. Place a tray beneath the clutch servo.
2. Disconnect the steel supply pipe from the
clutch servo and drain the oil from the
reservoir by moving the pedal up and down.
3. Reinstall the steel supply pipe.
Filling the clutch system
1. Fill the reservoir with the specified fluid and
bleed the system.
V300064
9910 6-1
CLUTCH 3
6.2 BLEEDING THE CLUTCH SYSTEM

therefore have a damaging effect on
your health.
physical contact.
paintwork.
Always use new and clean hydraulic

fluid which has been kept in a
sealed container and complies with
the specifications.
Bleeding the clutch system using the

6 “servo” bleed tank
1. Connect the “servo” bleed tank to the
reservoir.
2. Note:
Filling too quickly causes foaming, which
makes bleeding virtually impossible.
Fill the system via the “servo” bleed tank.
3. Connect a transparent pipe to the clutch
servo’s bleed nipple.
Insert the pipe into a jar.
4. Open the bleed nipple two full turns.
As soon as no more air bubbles escape
from the transparent pipe, the bleed nipple
can be closed again.
5. Check the fluid level. See “Inspection and
adjustment”.
6-2 9910
3 CLUTCH
Bleeding the clutch system by operating the

clutch pedal
1. Connect a transparent pipe to the clutch
servo’s bleed nipple.
Insert the pipe into a jar filled with the
specified fluid. Ensure that the end is below
the fluid level.
2. Open the bleed nipple.
3. Gradually depress the clutch pedal and
close the bleed nipple. Gradually release
the clutch pedal.
Repeat this operation. The fluid in the
reservoir must be topped up continually.
4. Repeat the pump action with the clutch
pedal and topping up the fluid until no more
air bubbles escape through the transparent
pipe.
5. Check the fluid level. See “Inspection and
adjustment”.
9910 6-3
CLUTCH 3
Bleeding the clutch system via the clutch

servo
1. Note:
Sometimes it may be difficult to bleed the
clutch system. In such cases, the clutch
system can also be bled using a priming
pump and the bleed nipple on the clutch
servo.
Ensure that the priming pump is thoroughly
cleaned inside.
Connect a transparent pipe to a priming
pump (e.g. oil can) and fill the pump with
the specified fluid.
2. Continue pumping until fluid without air
bubbles flows from the pipe.
3. Then connect the pipe to the bleed nipple of
the clutch servo and open the bleed nipple.
4. Pump the fluid into the system.
In doing so, observe the following:
- Do not depress the clutch pedal.
- Make sure that no air bubbles are
introduced into the system.
- Monitor the fluid level in the priming
6 -
pump.
Monitor the fluid level in the clutch
reservoir.
6-4 9910
3 PROP SHAFTS
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.1 Overview drawing of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9910
1.2 Overview drawing, “Klein” centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 9910
2.1 Inspection, drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
3.1 Removal and installation, prop shaft/auxiliary shaft . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
4. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.1 Disassembly and assembly, universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.2 Disassembly and assembly, GWB centre bearing . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 9910
4.3 Disassembly and assembly, Klein centre bearing . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . . 9910
5. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
5.1 Lubrication, centre bearing prop shaft and auxiliary shaft . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
9910 1
PROP SHAFTS 3
2 9910
3 PROP SHAFTS
1. GENERAL
1.1 OVERVIEW DRAWING OF DRIVE SHAFT
G
H
D
G
A
B
C E F
W 3 06 001
A
B
Auxiliary shaft
Centre bearing 7
C Drive flange
D Fork
S Sliding joint
F Drive shaft
G Balancing plates
H Welded brackets (GWB)
For the 65/75/85 CF vehicle series, DAF has

two manufacturers of prop shafts, Gelenk
Wellenbau and Klein.
The Gelenk Wellenbau-shafts can be identified
by the two welded brackets and the balancing
plates with the letters GWB stamped into them.
Klein shafts can be identified by their highly
bevelled flanges.
The various components of the shafts are not
interchangeable, with the exception of some of
the spiders.
Complete shaft assemblies, however, can be
exchanged. It is also permitted to install shafts
from two different manufacturers in one vehicle.
9910 1-1
PROP SHAFTS 3
1.2 OVERVIEW DRAWING, “KLEIN” CENTRE BEARING
1. Dust rings 1 2 3 1 4 5
2. Rubber block
3. Bearing
4. Dust cover
5. Flange
W 3 06 023
1-2 9910
3 PROP SHAFTS

2.1 INSPECTION, DRIVE SHAFT
1. Check the universal joints and centre

bearing for play and damage.
M3032
2. Check the sliding joint for axial and radial

play.
7
M3019
3. There must be no clearly noticeable play on

universal joints, centre bearing and sliding
joint.
M3020
9910 2-1
PROP SHAFTS 3
2-2 9910
3 PROP SHAFTS

3.1 REMOVAL AND INSTALLATION, PROP SHAFT/AUXILIARY SHAFT
ASSEMBLY
Removal, prop shaft/auxiliary shaft

assembly
1. When removing one of the shafts in
vehicles with multiple shafts (prop shaft and
auxiliary shafts), the other shaft must be
tied to the chassis or auxiliary beam in such
a way that it does not obstruct the various
activities.
2. Note:
Always transport and store shafts
horizontally to avoid damage and
subsequent imbalance. W 3 06 016
Support the shaft in at least two places. If

possible, hang the shaft in a hoist, using
two sturdy ropes.
flanges and carefully lower the shaft to the
ground.
Now remove the shaft from under the = = W 3 06 019
vehicle.
Installation, prop shaft/auxiliary shaft
assembly
1. Note:
After repairs have been carried out or a 7
shaft has been replaced, the forks of all
shafts must be aligned. The universal joints
must also be lubricated.
Fit the shaft under the vehicle. Use a hoist
if possible.
2. Tighten the attachment bolts to the
Data”.
9910 3-1
PROP SHAFTS 3
3-2 9910
3 PROP SHAFTS
65/75/85CF series Disassembly and assembly
4. DISASSEMBLY AND ASSEMBLY

4.1 DISASSEMBLY AND ASSEMBLY, UNIVERSAL JOINT
Disassembly, universal joint

1. Remove the entire prop shaft and/or
auxiliary shaft.
2. Remove the lubricating nipple and all
Seeger rings from the spider to be
replaced.
W 3 06 009 7
3. Place the shaft on a bush underneath a
press, as shown, and press the entire
spider including bearings and drive flange
down, until the spider touches the fork of
the shaft.
W 3 06 010
9910 4-1
PROP SHAFTS 3
Disassembly and assembly 65/75/85CF series
4. Rotate the shaft 180° and remove the

bearing that has just been pressed out. If
the first bearing to be removed fails to come
out of the fork entirely, the bearing can be
clamped to enable the fork to be pushed up
by means of a lever. Replace the shaft onto
the bush.
W 3 06 012
5. Push the spider down again in the direction

of the shaft fork. Again, continue until the
spider touches the fork.
6. The spider and the drive flange can now be
tilted from the shaft fork.
7. Place the drive flange on a bush
underneath a press and press the entire
7 spider including bearings and drive flange
down, until the spider touches the fork of
the drive flange.
8. Rotate the drive flange 180° and remove
the bearing that has just been pressed out.
Replace the drive flange onto the bush.
9. Push the spider down again in the direction
of the drive flange fork. Again, continue until
the spider touches the fork.
10. The spider can now be tilted from the drive
flange fork.
11. Note:
When spiders are being replaced, always
replace them including their bearings.
Check the components to be reused for any
cracks and/or damage.
W 3 06 011
4-2 9910
3 PROP SHAFTS
Assembly, universal joint

1. Note:
After installation, it must be possible to
move the drive flanges and spiders by
hand. When mounting the spider, Seeger
rings of the same thickness must be used.
Install the sealing rings in their proper
positions on the bearings and lubricate
them lightly so that the needles remain in
place.
2. Press one bearing partly into the drive
flange. A
3. Tilt the spider into the drive flange, hole A
for the lubricating nipple pointing in the
direction of the shaft.
W 3 06 014
4. Slide the spider a little into the installed

bearing and place everything onto a bush
underneath a press. The opposite bearing
can now be pressed into the fork, the spider
serving as a guide. During the press action,
the spider must be able to move freely.
W 3 06 017
9910 4-3
PROP SHAFTS 3
5. Continue to press the bearing until a

Seeger ring can be installed on the side that
is pressed. Install the Seeger ring and
press the opposite bearing further into the
fork. Then also install a Seeger ring here.
6. Install the sealing rings in their proper
positions on the prop shaft bearings and
lubricate them lightly so that the needles
remain in place.
7. Press one bearing partly into the prop shaft.
8. Slide the spider a little into the installed
bearing and place everything onto a bush
underneath a press. The opposite bearing
can now be pressed into the fork, the spider
serving as a guide. During the press action,
the spider must be able to move freely.
7 W 3 06 013
9. Continue to press the bearing until a

Seeger ring can be installed on the side that
is pressed. Install the Seeger ring and
press the opposite bearing further into the
fork. Then also install a Seeger ring here.
10. Install the lubricating nipple and lubricate
the spider.
11. Install the prop shaft and/or auxiliary shaft.
W 3 06 015
4-4 9910
3 PROP SHAFTS
4.2 DISASSEMBLY AND ASSEMBLY, “GWB” CENTRE BEARING
Disassembly, “GWB” centre bearing

1. Hang the auxiliary shaft carefully on the
chassis.
2. Remove the attachment bolts from the drive
flange. Also secure this prop shaft carefully
to the chassis.
W 3 06 003
3. Remove the central centre bearing

attachment bolt.
centre bearing and the chassis bracket.
5. Install a long bolt (part of special tool
DAF No. 1329375 and DAF No. 1329364,
or DAF No. 1329376) as far as possible into
the auxiliary shaft.
7
W 3 06 002
6. Install a commercially available puller on

the drive flange.
Use the puller to pull the drive flange a little A
from the auxiliary shaft. Before the drive B
flange with centre bearing can be pulled out
of the shaft, it must be marked so that all
forks can later be fitted in one line.
W 3 06 008
9910 4-5
PROP SHAFTS 3
7. Remove the steel bracket including the

circlip of the silent block.
W 3 06 007
8. Remove the silent block from the centre

bearing.
W 3 06 006
4-6 9910
3 PROP SHAFTS
9. Use the puller to pull the bearing from the

drive flange.
W 3 06 004
10. Remove the steel dust ring from the drive

flange.
7
W 3 06 005
9910 4-7
PROP SHAFTS 3
Assembly, “GWB” centre bearing

Note:
In case of damage, always replace the entire
centre bearing.
1. Use the special tool (DAF No. 1329375 and
DAF No. 1329364, or DAF No. 1329376) to
install the steel dust rings, without sealing
rubber, onto the drive flange and auxiliary
shaft.
V300170
2. Install the sealing rubbers into the steel

dust rings.
V300171
4-8 9910
3 PROP SHAFTS
3. Use the special tool (DAF no. 1329375 and

DAF No. 1329364, or DAF No. 1329376) to
install the centre bearing assembly on the
drive flange.
V300172
4. Note:
When the drive flange and centre bearing
are installed, ensure that the marks applied
A
earlier match. B
Install the drive flange and centre bearing in
7
the auxiliary shaft.
5. Fit the centre bearing to the chassis and
hand-tighten the attachment bolts.
W 3 06 008
9910 4-9
PROP SHAFTS 3
6. Tighten the central attachment bolt to the

Data”.
7. Tighten the attachment bolts of the centre
bearing to the chassis to the specified
8. If the centre is provided with a lubricating
nipple, it must be lubricated.
W 3 06 002
4.3 DISASSEMBLY AND ASSEMBLY, “KLEIN” CENTRE BEARING
Disassembly, “Klein” centre bearing

1. Hang the auxiliary shaft carefully on the
chassis.
2. Remove the bolts that attach the flange to
the prop shaft and the auxiliary shaft. Also
secure this prop shaft carefully to the
chassis.
3. Install a flange retainer and remove the
central nut and washer.
7 4. Mark the flange and axle end with a centre
point to ensure that the forks can all be
fitted later in one line.
centre bearing and the chassis bracket.
W 3 06 029
4-10 9910
3 PROP SHAFTS
6. Use a plastic hammer to tap the flange and

the centre bearing from the auxiliary shaft.
If necessary, use a puller.
W 3 06 028
7
W 3 06 027
7. Remove the lock plate from the support

bracket.
W 3 06 020
9910 4-11
PROP SHAFTS 3
8. Unscrew the flange with bearing and rubber

block (2) from the bracket.
W 3 06 022
9. Press the flange from underneath and 1 2 3 1 4 5

press the bearing out.
10. Press the bearing with one dust ring (1)
from the rubber block.
11. If necessary, remove the second dust
ring (1).
Note:
In case of damage, always replace the entire
centre bearing.
7 W 3 06 023
4-12 9910
3 PROP SHAFTS
Assembly, “Klein” centre bearing

1. Press the dust ring into the bush of the
rubber block until it aligns with the outside
of the bush.
W 3 06 021
W 3 06 026
7
2. Press the bearing along the other side into
the bush. Then the other plastic ring can be
pressed into the bush. Apply grease to the
dust rings (1).
3. Press everything onto the flange, the larger
space between bearing and dust ring facing
the flange. 1
W 3 06 025
9910 4-13
PROP SHAFTS 3
4. Install the centre bearing assembly in the

bracket and lock it with the lock plate.
W 3 06 024
5. Install the centre bearing onto the auxiliary

shaft. Make sure that the centre points are
aligned to ensure that later all forks are in
one line.
W 3 06 029
6. Attach the centre bearing to the chassis by

means of bolts, but do not tighten the bolts.
7. Tighten the central nut of the centre bearing
to the specified tightening torque. See
“Technical Data”. Then apply Loctite 243 to
the attachment bolts of the centre bearing
to the chassis and carry out final tightening
W 3 06 018
4-14 9910
3 PROP SHAFTS
65/75/85CF series Lubrication
5. LUBRICATION
5.1 LUBRICATION, CENTRE BEARING, PROP SHAFT AND AUXILIARY SHAFT
1. Lubricate the universal joints of the prop

shaft, until grease comes out.
2. Lubricate the lubricating nipples on the
centre bearings (if present).
3. The maximum lubricating pressure should
not exceed 15 bar.
M9030
9910 5-1
PROP SHAFTS 3
Lubrication 65/75/85CF series
5-2 9910
3 ZF INTARDER
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.1 Overview drawing, intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.2 Overview drawing, hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 9910
2.3 Location of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 9910
3.1 Inspection and adjustment, axial clearance of the output shaft bearing . . . . . 3-1 ...... 9910
3.2 Inspection and adjustment, axial clearance of the stator . . . . . . . . . . . . . . . . . 3-2 ...... 9910
3.3 Inspection, gearbox/intarder oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 9910
4.1 Removal and installation, entire intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.2 Removal and installation, magnetic valve of air supply . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . 9910
4.3 Removal and installation, accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 9910
4.4 Removal and installation, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . . 9910
4.5 Removal and installation, hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . . 9910
4.6 Removal and installation, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 9910
4.7 Removal and installation, oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . . 9910
4.8 Removal and installation, proportional valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 9910
4.9 Removal and installation, intarder drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 9910
5.1 Disassembly and assembly, accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
6.1 Draining and filling, gearbox/intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 9910
9910 1
ZF INTARDER 3
2 9910
3 ZF INTARDER
- Be careful when changing the oil. Hot oil
may cause serious injuries.
- Avoid unnecessary contact with drained oil.
Frequent contact damages the skin.
- Various sorts of oil and other lubricants
used on the vehicle may constitute a health
hazard.
This also applies to coolants.
So avoid inhaling and direct contact.
9910 1-1
ZF INTARDER 3
1-2 9910
3 ZF INTARDER
2. GENERAL
2.1 OVERVIEW DRAWING, INTARDER
1
2
3
4
5
12 6
A
7
B
8
9
A
11
C
10
V300074
1.
2.
Locking plate
Bolt
8
3. Plate
4. O-ring
5. Drive flange
6. Oil seal
7. Flange bolt
8. Output shaft filler ring
9. Drive sprocket
10. Stator filler ring
11. Gasket
12. ntarder housing
A Intarder housing sealing surface

B Ball bearing contact surface
C Stator contact surface
9910 2-1
ZF INTARDER 3
2.2 OVERVIEW DRAWING, HYDRAULIC CONTROL UNIT
4 1
5 2
3
5
10 9
8 7
V300075
1. Attachment bolt
2. Attachment plate
3. Gasket
4. Attachment bolt
5. Plungers and springs
6. Drain plug
7. Control unit housing
8. Gasket
8 9.
10.
Proportional valve
O-ring
2-2 9910
3 ZF INTARDER
2.3 LOCATION OF MAIN COMPONENTS
9 10
8
6 1 8
V300236
1. Intarder proportional valve control plunger

2. Shifting valve spring sealing plug
3. Accumulator
4. Heat exchanger
5. Oil pump gear wheels
6. Stator and rotor
7. Air supply magnetic valve
8. Proportional valve
9. Attachment to gearbox
10. Coolant temperature sensor
9910 2-3
ZF INTARDER 3
2-4 9910
3 ZF INTARDER

3.1 INSPECTION AND ADJUSTMENT, AXIAL CLEARANCE OF THE OUTPUT
SHAFT BEARING
A A
B
C
V300070
1. Measure and note down distance “A - B”

from sealing surface (A) with gasket to
contact surface (B).
2. Measure and note down distance “D” from
the outer ball bearing race to the gasket on
the gear box.
Example:
Distance
A-B = 10.5 mm
Distance D = 10.0 mm
Difference = 0.5 mm
Maximum
clearance 0.1 mm
Required thickness of filler
ring 0.4 mm
9910 3-1
ZF INTARDER 3
3.2 INSPECTION AND ADJUSTMENT, AXIAL CLEARANCE OF THE STATOR
A A
B
C
8
V300070
1. Measure and note down distance “A - C”

from sealing surface (A) with gasket to
contact surface (C).
Example:
Distance
A-C = 1.10 mm
Distance A - C should be 0 0.05 mm
Required thickness of filler
ring 1.1 0.05 mm
3-2 9910
3 ZF INTARDER
3.3 INSPECTION, GEARBOX/INTARDER OIL LEVEL
Inspection, gearbox/intarder oil level

1. Slow the vehicle down without using the
intarder and place the vehicle on a flat,
horizontal surface.
2. Wait for some minutes for the gearbox oil to
flow back.
3. The oil level must reach the rim of the oil
level opening (A).
A
M3051
9910 3-3
ZF INTARDER 3
3-4 9910
3 ZF INTARDER

4.1 REMOVAL AND INSTALLATION, ENTIRE INTARDER

drained oil.
In the course of the following
operations, oil will spill from the
gearbox and intarder. Collect this
oil.
Removal, entire intarder

1. Remove the prop shaft bolts and hang the
prop shaft to the side in the chassis.
2. Drain the gearbox via drain plugs (1 and 2). 1
3. Drain as much coolant and gearbox oil as
3
necessary and collect these in clean
containers.
4. Disconnect the water pipes from both sides
of the heat exchanger.
2
5. Remove the air pipe from the magnetic
valve of the intarder.
6. Remove all electric wiring from the intarder.
7. Remove the locking plate from the external
V300261
drive flange, remove the disk with the
O-ring, and pull the drive flange from the
shaft using a tripod puller.
operations, the intarder is disconnected 8
from the gearbox. Take measures to
prevent the intarder from dropping.
intarder and remove the intarder.
9. Remove the gasket and filler rings from the
adjustment stator/output shaft.
V300129
9910 4-1
ZF INTARDER 3
Installation, entire intarder

1. Stick the correct filler rings onto the contact
surfaces using a little grease. See
2. Fix the gasket in the gearbox with as many
long studs as possible. The studs also
serve as guiding pins to facilitate mounting
of the intarder.
3. Carefully position the intarder on the
gearbox and tighten the attachment bolts to
4. Insert the prop shaft attachment bolts from
the correct side into the external drive
flange (bolt end faces drive shaft).
5. Install the external drive flange without
heating it.
6. Install the O-ring and the disk. V300078

Fit the lock plate using special tool
(DAF No. 0694903).
8. Connect the water pipes to the heat
exchanger.
9. Connect the air pipe to the magnetic valve.
10. Install all electric connections to the
8 intarder.
11. Install the drive shaft and tighten the prop
shaft attachment bolts to the specified
12. Fill the coolant system (see Group 2 of the
workshop instructions) and fill the intarder
and gearbox with oil.
13. Check the operation of the intarder and
check for leaks.
14. Check the oil level of the retarder. See
4-2 9910
3 ZF INTARDER
4.2 REMOVAL AND INSTALLATION, MAGNETIC VALVE OF AIR SUPPLY
Removal, magnetic valve of the air supply

valve.
2. Remove the electric wiring from the
magnetic valve.
magnetic valve and remove the magnetic
valve.
Installation, magnetic valve of the air supply
1. Fit a new O-ring in the slot on the magnetic
valve.
2. Install the magnetic valve.
3. Connect the electric wiring to the magnetic
valve.
V300184
9910 4-3
ZF INTARDER 3
4.3 REMOVAL AND INSTALLATION, ACCUMULATOR

drained oil.
operations, oil and water will spill
from the heat exchanger. Collect
this oil and water.
drained oil.
Removal, accumulator
1. Drain as much coolant and oil as
necessary.
2. Disconnect the water pipe from the
left-hand side of the heat exchanger.
valve.
magnetic valve.
5. Remove the attachment bolt from the water
pipe bracket and the attachment bolts on
top of the accumulator bracket.
6. Remove the accumulator attachment bolts
on the heat exchanger and remove the
accumulator.
Installation, accumulator
8 1. Fit new O-rings on the accumulator bracket
and install the accumulator on the heat
exchanger.
2. Install the accumulator bracket attachment
bolts at the top.
V300183
3. Fit the water pipe bracket attachment bolt.
4. Install the magnetic valve.
4-4 9910
3 ZF INTARDER
6. Connect the electric wiring to the magnetic

valve.
7. Install the water pipe at the left-hand side.
8. Fill the cooling system.
9. Fill the gearbox with oil. Check the oil level
of the retarder. See “Inspection and
Adjustment”.
9910 4-5
ZF INTARDER 3
4.4 REMOVAL AND INSTALLATION, HEAT EXCHANGER

from the heat exchanger. Collect
this oil and water. Take measures to
prevent the heat exchanger from
being dropped.
Removal, heat exchanger

1. Drain as much coolant and oil as
necessary.
2. Remove the water pipes from the heat
exchanger.
valve.
4. Remove all electric wiring from the intarder.
5. Remove the attachment nuts from the studs
attaching the heat exchanger to the
hydraulic control unit.
6. Remove an attachment bolt from the heat
exchanger oil connector flange attached to
the rear cover of the gearbox.
7. Remove the heat exchanger together with V300185
the accumulator.
8. Remove the two O-rings for the oil ducts of
the heat exchanger from the control unit.
8 9. If necessary, remove the accumulator and

the magnetic valve.
10. If the heat exchanger displays any leaks,
the heat exchanger must be replaced as it
cannot be repaired.
V300195
4-6 9910
3 ZF INTARDER
Installation, heat exchanger

1. Insert new O-rings into the circular slots of
the control unit.
2. Install the studs in the heat exchanger and
3. Apply Loctite to the contact surfaces, studs,
and attachment nuts/bolt. See “Technical
data”.
4. Install the heat exchanger on the control
unit and tighten the attachment bolts to the
data”. V300195
5. Install the heat exchanger oil connector

flange attachment bolt which is attached to
the rear cover of the gearbox, and tighten to
6. Connect the water pipes to the heat
exchanger.
8. Connect the electric wiring to the intarder.
9. Fill the cooling system.
10. Fill the gearbox with oil.
11. Check the oil level of the retarder. See
V300185
8
9910 4-7
ZF INTARDER 3
4.5 REMOVAL AND INSTALLATION, HYDRAULIC CONTROL UNIT

from the heat exchanger and
control unit. Collect this oil and
water. Take measures to prevent the
heat exchanger from being
dropped.
Removal, hydraulic control unit

1. Remove the heat exchanger.
proportional valve.
control unit on the gearbox. Leave one
attachment bolt of the oil pump in place,
see illustration.
4. Remove the control unit (7) and the
V300076
gasket (8).
5. If necessary, remove and inspect the 5
4 1
2
plungers and springs (5). Avoid damaging
3
the plungers and plunger guides. 5
Note:
10
The sealed plunger (see arrow in 9
illustration) must not be removed; after

5
removal, the intarder must be set again on
the test bench.
8 7
Installation, hydraulic control unit
8 1. Fix the gasket (8) in the gearbox with as
many long studs as possible. The studs
6
V300075
also serve as guiding pins to facilitate

mounting of the control unit.
2. Line up the end of the oil pump with the
output side of the stator.
3. Fit the control unit over the studs and be
sure to position the control unit carefully
against the housing to make sure that the
oil pump is in its place in the stator. Tighten
the attachment bolts to the specified torque.
4. Install the heat exchanger.
4-8 9910
3 ZF INTARDER
4.6 REMOVAL AND INSTALLATION, OIL PUMP
Removal, oil pump 1 2

2. Remove the attachment bolts from the oil
pump (2) on the control unit.
3. Remove the entire oil pump from the control
unit and remove the O-ring.
4. Check the axial clearance of the outer rotor.
Check the pump housing for the presence
of grooves. If necessary, replace the entire
oil pump.
Installation, oil pump
1. Fit a new O-ring in the slot on the control
unit.
2. Install the outer rotor so that the mark (1) is
visible.
3. Fit the entire oil pump (2) to the control unit.
Ensure that the flat end of the inner rotor is
in line with the stator.
4. Install the oil pump attachment bolts and
tighten them to the specified tightening V300072
5. Install the heat exchanger.
9910 4-9
ZF INTARDER 3
4.7 REMOVAL AND INSTALLATION, OIL FILTER

drained oil.
Removal of the gearbox oil filter

1. Remove the attachment bolt (1) of the oil
filter.
1 M3052
2. Pull the filter cover with the filter from the

filter housing.
8
M3053
3. Remove the filter (3) from the filter cover

(2). Do not clean the filter. Filters must 3
always be replaced.
Note:
If the magnetic disk is still attached to the
back of the filter, separate it from the filter
element and fit it on the new filter element.
2
M3054
4-10 9910
3 ZF INTARDER
Installation, oil filter of the gearbox

1. Check the O-ring of the filter cover (2) for 3
any damage. If necessary, replace the
O-ring.
Grease the O-ring.
2. Grease the O-ring of the new filter (3) and
place the filter on the filter cover.
Then insert the filter and the filter cover into
the filter housing. 2
3. Use a plastic mallet to tap the filter cover
into the filter housing. M3054
4. Tighten the attachment bolt (1) to the

specified torque. See “Technical data”.
1 M3052
9910 4-11
ZF INTARDER 3
4.8 REMOVAL AND INSTALLATION, PROPORTIONAL VALVE
Removal, proportional valve

1. Remove the electric wiring from the valve.
2. Remove the attachment bolts and remove
the proportional valve.
Installation, proportional valve
1. Fit a new O-ring on the proportional valve
and lightly grease the O-ring.
2. Install the proportional valve and tighten the
3. Connect the electric wiring to the valve.
V300011
4-12 9910
3 ZF INTARDER
4.9 REMOVAL AND INSTALLATION, INTARDER DRIVE
2 1
3
5
7
8
9
10
11
6 4
12
13
V300077
Removal, intarder drive

1. Remove the intarder.
8
2. Remove the air connectors of the high/low
shift control on the cylinder (2).
3. Remove the attachment bolts (1) of the
cylinder (2) and remove the cylinder.
4. Remove the lock nut (6) of the piston (9)
and remove the piston and its O-rings.
5. Remove the two locking bolts of the
high/low shifting fork.
9910 4-13
ZF INTARDER 3
6. Remove the attachment bolts from the rear

cover and remove the rear cover. Make
sure the intarder remains in place.
7. Remove the gearbox gasket.
V300081
8. If necessary, use a tripod puller to remove

the drive sprocket from the intarder.
Installation, intarder drive
1. Heat the drive sprocket and install the drive
sprocket onto the intarder. See “Technical
data”.
2. Install the gasket on the gearbox housing.
3. Install the rear cover over the guiding pins.
Note the shifting fork when doing so. Insert
the locking bolts of the shifting fork and
hand-tighten them.
4. Install the rear cover attachment bolts and
V300079
5. Tighten the locking bolts of the shifting fork
8 to the specified tightening torque. See
4-14 9910
3 ZF INTARDER
2 1
3
5
7
8
9
10
11
6 4
12
13
V300077
6. Install the piston (9) on the shifting shaft

and tighten the lock nut (6) to the specified
tightening torque. See “Technical data”.
7. Install the cylinder (2) and tighten the
8
8. Connect the air supply.
9. Install the intarder.
9910 4-15
ZF INTARDER 3
4-16 9910
3 ZF INTARDER

5.1 DISASSEMBLY AND ASSEMBLY, ACCUMULATOR
Disassembly, accumulator
1. Detach the attachment bolts and/or the
attachment nuts from the cylinder to the
accumulator bracket, and remove them.
2. Remove the O-rings on the bottom of the
sealing surfaces of the accumulator/heat
exchanger.
3. Remove the O-rings from the accumulator
cylinder.
4. Remove the piston and sleeves from the
cylinder.
5. Remove the sleeves from the piston and
V300197
the scrapers from the middle of the piston.
6. Check the cylinder for damage.
9910 5-1
ZF INTARDER 3
Assembly, accumulator
1. Install the central scrapers on the piston.
Note:
There are two different types of sleeve: one
with a steel inner spring and one without a
steel inner spring.
2. Install the sleeve with the steel inner spring
at the oil side of the piston.
3. Install the sleeve without the steel inner
spring at the air side of the piston.
4. Thoroughly cover the piston and cylinder
with grease and install the piston in the
cylinder.
V300196
5. Fit the two O-rings at both sides of the
cylinder.
Apply grease to the O-rings to make sure
they remain in position.
6. Install the cylinder on the accumulator
bracket.
7. Install new O-rings at the bottom of the
accumulator/heat exchanger and install the
accumulator.
V300197
5-2 9910
3 ZF INTARDER

6.1 DRAINING AND FILLING, GEARBOX/INTARDER
1
4
2 5
3 V300263 V300262
Draining, gearbox
drive.
surface.
4. Replace the oil filter (3). See “Removal and
installation”.
9910 6-1
ZF INTARDER 3

1. Clean the drain plugs and tighten them to
opening (4).
5. Tighten the level check/filler opening to the
Data”.
gearbox)
surface.
8 5. Tighten the filler plug (5) and the level
6-2 9910
3 VOITH RETARDER 133-2
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
2.1 Location of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 9910
3.1 Inspection, retarder oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9910
3.2 Inspection, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 9910
4.1 Removal and installation, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.2 Removal and installation, output shaft drive flange . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 9910
4.3 Removal and installation, entire retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 9910
4.4 Removal and installation of the gearbox output shaft . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 9910
4.5 Removal and installation, adapter plate/gasket . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . . 9910
5.1 Disassembly and assembly, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
6.1 Draining and filling, retarder oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 9910
9910 1
VOITH RETARDER 133-2 3
2 9910
- Be careful when changing the oil. Hot oil
may cause serious injuries.
- Avoid unnecessary contact with drained oil.
Frequent contact damages the skin.
- Various sorts of oil and other lubricants
used on the vehicle may constitute a health
hazard.
This also applies to coolants.
So avoid inhaling and direct contact.
9910 1-1
1-2 9910
2. GENERAL
2.1 LOCATION OF MAIN COMPONENTS
7
2
11
10 9
3 8
9
V300199
1. Proportional valve
2. Venting valve
3. Butterfly valve
4. Heat exchanger
5. Stator valves
6. Rotor
7. Stator
8. Oil sump shut-off valve
9. Coolant temperature sensor
10. Oil temperature sensor
11. Shifting valve
9910 2-1
2-2 9910

3.1 INSPECTION, RETARDER OIL LEVEL

drained oil.
Note:
Depending on accessibility, oil level checks can 1
be carried out using the dip-stick or via the
oil-level plug.
Inspection, oil level with the dip-stick
1. Checking must be done with the retarder at
operating temperature.
surface.
3. Pressurise the compressed-air braking
system (governor should cut out).
4. Fully activate the retarder and switch off
after 5 seconds.
Repeat this operation twice.
5. After five minutes, take the dip-stick (1)
from the retarder housing, clean the
dip-stick, and replace it in the threaded hole
(do not turn).
V300190
9910 3-1
6. Then check the oil level.

The oil level should be between the
minimum and maximum mark on the dip
stick.
1 Max
Min
M3048
7. Top up if necessary via the bore hole of the

dip-stick (1) or via the filler plug (2). 2
If you use the filler plug (2), top up the oil
slowly to prevent leaks via the vent
opening.
8. Then tighten the dip-stick and filler plug,
with new sealing rings in place, to the
specified torques. See “Technical Data”.
V300191
3-2 9910
Checking the oil level with the oil-level plug

1. Checking must be done with the retarder at
surface.
after 5 seconds.
Repeat this operation twice.
5. After five minutes, remove the oil-level plug
(3) from the retarder housing and check the
level.
The oil level must reach the bottom of the
bore hole.
3
V300101
6. Top up if necessary via the oil level bore

hole (3) or via the filler plug (2).
2
If filler plug (2) is used, top up the oil slowly
to prevent leaks via the vent opening.
7. Then tighten the oil level plug and filler plug,
with new sealing rings in place, to the
specified torques. See “Technical Data”.
9
3
V300192
9910 3-3
3.2 INSPECTION, HEAT EXCHANGER

2. Remove the oil elements from the heat
exchanger.
3. Fit the pressure plates in the oil element
using special tool (DAF No. 1240476 and
1240477).
4. With special tool (DAF No. 1240476),
connect an air pipe to the plate intended for
it. The pressure can be up to approx. 8 bar. V300207
5. Submerge the oil element in warm water

(approx. 50°C) and check for leaks.
6. If the oil element shows any leaks, it must
be replaced as it cannot be repaired.
3-4 9910

4.1 REMOVAL AND INSTALLATION, HEAT EXCHANGER

drained oil.
Removal, heat exchanger

1. Drain the oil and coolant from the retarder
and the heat exchanger.
2. Remove the coolant hoses from the heat
exchanger.
3. Remove the connectors from the coolant
and oil sensors on the heat exchanger.
4. Remove the attachment bolts and nuts from
the heat exchanger and remove the heat
exchanger from the retarder.
5. Remove the O-rings and the throttle disk in
the retarder housing. V300203

1. Thoroughly clean the contact surfaces
between the heat exchanger and the
retarder, and replace the O-rings.
2. Install the throttle disk into the retarder
housing.
3. Install the heat exchanger and tighten the
torque, see main group “Technical Data”. V300208
4. Install the connectors on the coolant and oil

sensors.
5. Connect the coolant hoses to the heat
exchanger.
9
6. Fill the coolant system and fill the retarder
with oil.
7. Inspect the operation of the retarder and
check for leaks.
9910 4-1
4.2 REMOVAL AND INSTALLATION, OUTPUT SHAFT DRIVE FLANGE
Removing the output shaft drive flange

1. Apply the parking brake. 4
2. Remove the prop shaft bolts and hang the
prop shaft to the side in the chassis. 6
3. Remove the attachment bolts (1) from the
cover plate and remove the cover plate
without damaging the O-ring (beware of oil
2
spillage). 1
4. Remove the locking plate, attachment bolts
(2) and retaining plate (3) of the drive
3
flange (6).
5. Remove the drive flange. Use a tripod puller
for this. V300090
6. If the oil pipe (4) remains in the output shaft

of the gearbox when the drive flange is
removed, thread must be cut in the oil pipe
(M16) in order to be able to remove the oil
pipe with an impact puller.
Installing the output shaft drive flange
1. Note:
On oil pipe (4) has been fitted to the drive
flange by means of a press-fitting. Note the
position of the tapered leading edge (5)
when doing this.
Check the drive flange for damage. Always
replace the O-ring on the drive flange.
2. Check whether the oil pipe can be inserted
smoothly in the bore hole of the gearbox 4 5
output shaft.
V300091
4-2 9910
3. Install two studs in the gearbox output shaft

to make it possible to install the drive flange
in the correct position (6).
4
4. Lightly grease the splines of the drive 6
flange, the end of the oil pipe (4), and the
O-ring, and install the drive flange.
5. Remove the studs and install the two fixing
2
bolts (2) and retainer plate (3). Tighten
these evenly to the specified tightening
1
torque, see main group “Technical Data”. 3
6. Fit a new locking plate.
7. Always replace the O-ring of the cover plate
and lightly grease it before installation. V300090
8. Apply a locking compound (Loctite 510) to

the cover plate fixing bolts, and install the
cover plate. Tighten the attachment bolts
(1) evenly to the specified tightening torque,
see main group “Technical Data”.
9. Install the drive shaft and tighten the prop
shaft attachment bolts to the specified
9910 4-3
4.3 REMOVAL AND INSTALLATION, ENTIRE RETARDER
When the coolant is hot, there is an

overpressure in the cooling system.
Carefully remove the filler cap, to
release the overpressure.
Coolant is a noxious fluid. Contact

with the skin should therefore be
avoided.
Removing the entire retarder

Note:
The retarder must be removed with the special
tool to prevent damage to the rotor and/or stator
during removal.
1. Apply the parking brake.
2. Remove the spare wheel, if applicable.
3. Remove the filler cap of the cooling system
and drain the coolant via the drain plug (1)
at the bottom of the heat exchanger.
4. Drain as much oil from the retarder and
gearbox as is necessary.
V300103
5. Remove the drive flange (2).

2
9 6. Remove the fixing bracket bolt from the
water ducts on the adapter plate.
7. Remove the flexible coolant pipes from the
heat exchanger.
8. Bleed the brake system, mark and remove
the air pipes.
V300083
4-4 9910
9. Remove the shock absorbers from the

attachment brackets. Then remove the
retarder shock absorber attachment
brackets (3).
3
V300084
10. Remove the three attachment bolts from

the labyrinth cover and install the
attachment plate (4), special tool
(DAF No. 0694993), using three attachment 4
bolts (M10x60).
Evenly tighten the three attachment bolts to
make sure the centring ring is properly
positioned all around.
11. Support the retarder or suspend it in the
hoist by means of a lifting eye, and remove
the fixing bolt with spacer and the fixing
nuts of the retarder.
12. Remove the retarder and the spacers
behind it (beware of oil and coolant
spillage).
V300085
9
9910 4-5
Note:
Perform the following two measurements 5 7 6 5
before installing the retarder:
Measurement 1
Determine the thickness of spacers “5”, see
example.
Measurement 2
Determine distance “C”. This is done to be
able to determine later whether the retarder
has been installed correctly.
Measurements
1. Install the measuring gauge (6) special tool
8
(DAF No. 0694997) using two attachment
bolts (tightening torque 60 Nm) onto the
gearbox output shaft.
Measurement 1
1. Use a straightedge (7) and a depth gauge
(8) to determine the distance to the three V300086
contact points on the adapter plate. Then
determine the average value of the
distances measured.
2. Measured value - straightedge value =
distance “A”.
3. Spacer thickness =
(“A” - 30 mm) - 0.2 mm.
Where 30 mm is a fixed value and -0.2 mm
is the allowable tolerance.
Measurement 2
1. Use a straight edge (7) and a depth gauge
(8) in the bore hole of the measuring gauge
(6) to determine the distance to the front of 8 7 6
the gearbox output shaft.
9 2. Measured value - straightedge value =

distance “D”.
3. Distance “C” = 82 mm - “D”.
Where 82 mm is a fixed value.
4. Remove the measuring gauge.
V300087
4-6 9910
Installing the entire retarder

Note:
It is advisable to replace the sealing rings in
the adapter plate before installing the
retarder.
1. Remove the three attachment bolts from
the labyrinth cover and install the
attachment plate (g), special tool
(DAF No. 0694993), using three attachment
bolts (M10x60). Evenly tighten the three
attachment bolts to make sure the centring
ring is properly positioned all around.
2. Install the centring plate (10), special tool
(DAF No. 0694994) onto the output shaft
(11) of the gearbox.
9
3. Lightly grease the external circumference of
the hollow spline shaft in the area where the
sealing rings make contact, and install the
spacers and retarder onto the adapter plate
studs.
4. Install the spindle (12) with the
thrust bearing (13), special tool
(DAF No. 0694990 and 0694992), and turn
the spindle nut to press the retarder onto
the output shaft of the gearbox.
5. Install the fixing bolt with spacer washer
11 10 13 12
V300088
and tighten the fixing bolt and fixing nuts to
the specified tightening torque, see main
group “Technical Data”.
6. Remove the fixing plate and tighten the
three fixing bolts of the labyrinth cover to
the specified tightening torque, see main
group “Technical Data”.
7. Remove the centring plate.
9
9910 4-7
8. Use a depth gauge to determine the

distance between the hollow spline shaft
(14) of the retarder and the front of the
gearbox output shaft.
The measured value is distance “B”.
Distance “B” should correspond to:
(208 mm - “C”) ± 0.2 mm.
14
Where 208 mm is a fixed value, “C” is a
value determined by measurement 2, and
0.2 mm is the allowable tolerance.
Note:
If the measured value “B” deviates from the
calculated value, the retarder must be
removed and measurements 1 and 2 must
be repeated.
10. Install the fixing bracket bolt for the water
ducts on the adapter plate.
11. Fit the air pipes.
12. Install the shock absorber brackets.
13. Connect the coolant pipes to the retarder. V300089
14. Install the connectors on the coolant and oil

sensors.
15. Connect the coolant hoses to the heat
exchanger.
check for leaks.
4-8 9910
4.4 REMOVAL AND INSTALLATION OF THE GEARBOX OUTPUT SHAFT

drained oil.
Removing the output shaft sealing ring

1. Remove the retarder. 1 2
2. Remove the sealing rings (1) from the
adapter plate (2). The following method can
be used to remove the sealing rings:
Drill two little holes in the sealing ring, in
opposite directions, and use the adapter
and the impact puller of special tools
(DAF No. 0484899 and 0694928) to pull the
sealing ring from the adapter plate.
Installing the output shaft sealing ring
Note:
If sealing rings with an external steel cover
are used, a liquid gasket must be applied.
If sealing rings with an external rubber
cover are used, a lubricant such as soap, V300092
must be applied.
1. Slide the adapter ring (3) onto the stamp
(4), see special tool (DAF No. 0694780)
and use the stamp to install the front
sealing ring in the adapter plate (2).
2. Remove the adapter ring from the stamp
4
and use the stamp to install the rear sealing
ring in the adapter plate.
3
3. Install the retarder. 2
9
5. Check the oil level in the retarder and the
gearbox.
check for leaks.
V300093
9910 4-9
4.5 REMOVAL AND INSTALLATION, ADAPTER PLATE/GASKET

unnecessary contact with the 1
drained oil.
Removing the adapter plate/gasket

1. Remove the retarder.
2. Remove the adapter plate fixing bolts (1).
3. Insert two guide bolts in the adapter plate
and remove the adapter plate.
4. Remove the filler ring and the gasket.
V300094
Installing the adapter plate/gasket

1. Clean the contact surfaces of the adapter 4 3 2
plate (1) and gearbox housing (2).
9 2. Lightly grease the new gasket and install it

on the gearbox housing.
3. Ensure that the ball bearing (3) is properly
situated in the gearbox housing and use a
depth gauge (4) to determine the distance
from the ball bearing to the gasket on the
gearbox housing (distance “A”).
V300095
4-10 9910
4. Use a depth gauge (4) to determine the

depth of the ball bearing chamber in the
adapter plate (1), (distance “B”).
5. Thickness of the filler ring = (“B” - “A”) - 4
0.05 mm.
Where 0.05 mm is a value for gasket
setting. 1
Note:
Installation tolerance of the bearing must be
between 0 and 0.1 mm.
6. Replace the sealing ring in the adapter
plate.
7. Install the adapter plate. Tighten the fixing
bolts to the specified tightening torque, see
V300096
main group “Technical Data”.
8. Install the retarder.
10. Check the oil level in the retarder and the
gearbox.
check for leaks.
9910 4-11
4-12 9910

5.1 DISASSEMBLY AND ASSEMBLY, HEAT EXCHANGER
Disassembly, heat exchanger

1. Remove the top cover from the heat
exchanger.
2. Remove the attachment bolts from the heat
exchanger elements and remove the heat
exchanger elements.
3. Remove all gaskets, O-rings and the rubber
plate between the heat exchanger
elements.
4. Replace the two O-rings at the bottom of
the heat exchanger elements and install the
V300209
heat exchanger elements in the heat
exchanger housing.
5. Install the rubber plate between the two
heat exchanger elements.
6. Install new gaskets on the heat exchanger
elements and the heat exchanger housing.
7. Tighten the attachment bolts to the
Data”.
9910 5-1
5-2 9910

6.1 DRAINING AND FILLING, RETARDER OIL

drained oil.
Draining the retarder

1. Drain off the oil when the retarder is at
surface.
after 5 seconds. Repeat this operation
twice.
5. Remove the retarder oil drain plug (3) and
drain off the oil.
6. Remove the butterfly valve oil drain plug (4)
and drain the leak-off oil.
7. Install the drain plugs with new sealing rings
4 3
V300102
9910 6-1
Filling the retarder

1. Fill the retarder with the prescribed amount 2
of oil, either through the dip-stick bore hole
(1) or through the filler plug (2). If you use
the filler plug (2), top up the oil slowly to
prevent leaks via the vent opening.
2. Then tighten the plugs with new sealing
rings in place to the specified tightening
torques. See “Technical Data”.
3. Then check the oil level. See “Inspection
and adjustment”.
V300191
6-2 9910
3 PTO’S
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.1 DAF engine PTO drive side cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.2 DAF engine PTO engine side cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 9910
2.3 Overview drawing, DAF engine PTO without drive flange and control . . . . . . 2-3 ...... 9910
2.4 Overview drawing, DAF engine PTO with drive flange and control . . . . . . . . . 2-4 ...... 9910
2.5 Overview drawing, DAF engine PTO with drive flange and without control . . 2-5 ...... 9910
2.6 Overview drawings, DAF engine PTO
with third gear wheel for opposite drive flange direction of rotation . . . . . . . . 2-6 . . . . . . 9910
2.7 Overview drawings, PTO versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . . 9910
2.8 Overview drawing N71/1 and N353/1 PTO, B-version . . . . . . . . . . . . . . . . . . . 2-11 . . . . . 9910
2.9 Overview drawing N71/1 and N353/1 PTO, C-version . . . . . . . . . . . . . . . . . . . 2-12 . . . . . 9910
2.10 Overview drawing N71/2 and N353/2 PTO, B-version . . . . . . . . . . . . . . . . . . . 2-13 . . . . . 9910
2.11 Overview drawing N71/2 and N353/2 PTO, C-version . . . . . . . . . . . . . . . . . . . 2-14 . . . . . 9910
2.12 Overview drawing N221/10 PTO on gearbox without intarder . . . . . . . . . . . . . 2-15 . . . . . 9910
2.13 Overview drawing N221/10 PTO on gearbox with intarder . . . . . . . . . . . . . . . . 2-15 . . . . . 9910
2.14 Overview drawing PTO auxiliary shaft for gearbox without intarder . . . . . . . . 2-16 . . . . . 9910
2.15 Overview drawing PTO auxiliary shaft for gearbox with intarder . . . . . . . . . . . 2-16 . . . . . 9910
2.16 Pneumatic diagram PTO control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 . . . . . 9910
3.1 Inspection and adjustment, DAF engine PTO prop shaft axial play . . . . . . . . 3-1 . . . . . . 9910
3.2 Inspection and adjustment, DAF engine PTO gear wheel axial play . . . . . . . 3-2 . . . . . . 9910
3.3 Inspection and adjustment, axial play on gearbox output shaft
N221/10 PTO on gearbox without intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 9910
3.4 Inspection and adjustment, axial clearance of N353/1 PTO
on N221/10 PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 9910
10
9910 1
PTO’S 3
Page Date
4.1 Removal and installation, entire DAF flywheel housing engine PTO . . . . . . . 4-1 . . . . . . 9910
4.2 Removal and installation, DAF engine PTO flywheel housing . . . . . . . . . . . . . 4-2 . . . . . . 9910
4.3 Removal and installation, N71/1 AND N353/1 PTO, B-version . . . . . . . . . . . . 4-3 . . . . . . 9910
4.4 Removal and installation, N71/1 AND N353/1 PTO, C-version . . . . . . . . . . . . 4-4 . . . . . . 9910
4.5 Removal and installation, N71/2 AND N353/2 PTO, B-version . . . . . . . . . . . . 4-5 . . . . . . 9910
4.6 Removal and installation, N71/2 AND N353/2 PTO, C-version . . . . . . . . . . . . 4-6 . . . . . . 9910
4.7 Removal and installation, N221/10 PTO on gearbox without intarder . . . . . . 4-7 . . . . . . 9910
4.8 Removal and installation, N221/10 PTO on gearbox with intarder . . . . . . . . . 4-9 . . . . . . 9910
4.9 Removal and installation, N353/1 PTO on N221/10 PTO . . . . . . . . . . . . . . . . . 4-10 . . . . . 9910
4.10 Removal and installation, PTO auxiliary shaft on gearbox without intarder . . 4-11 . . . . . 9910
4.11 Removal and installation, PTO auxiliary shaft on gearbox with intarder . . . . 4-12 . . . . . 9910
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.1 Disassembly and assembly, DAF engine PTO . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 9910
5.2 Disassembly and assembly, DAF engine PTO housing . . . . . . . . . . . . . . . . . . 5-2 ...... 9910
5.3 Versions with and without prop shaft and shift control . . . . . . . . . . . . . . . . . . . . 5-4 ...... 9910
10
2 9910
3 PTO’S
drained oil.
During work on the gearbox PTO,
oil may flow from the gearbox.
Collect this oil.
Never park a vehicle with the PTO
engaged. In the case of air leakage,
the pressure in the air system may
drop, causing the PTO to switch
off. During the gradual build-up of
pressure in the air system, the PTO
will also be re-engaged, which may
result in the shifting teeth on the
auxiliary gearbox shaft and the
selector sleeve of the PTO being
damaged beyond repair.
10
9910 1-1
PTO’S 3
10
1-2 9910
3 PTO’S
2. GENERAL
2.1 DAF ENGINE PTO DRIVE SIDE CROSS SECTION
V300295
10
9910 2-1
PTO’S 3
2.2 DAF ENGINE PTO ENGINE SIDE CROSS SECTION
V300296
10
2-2 9910
3 PTO’S
2.3 OVERVIEW DRAWING, DAF ENGINE PTO WITHOUT DRIVE FLANGE AND
CONTROL
V300297
10
9910 2-3
PTO’S 3
2.4 OVERVIEW DRAWING, DAF ENGINE PTO WITH DRIVE FLANGE AND
CONTROL
V300298
10
2-4 9910
3 PTO’S
2.5 OVERVIEW DRAWING, DAF ENGINE PTO WITH DRIVE FLANGE AND
WITHOUT CONTROL
V300299
10
9910 2-5
PTO’S 3
2.6 OVERVIEW DRAWINGS, DAF ENGINE PTO WITH THIRD GEAR WHEEL FOR
OPPOSITE DRIVE FLANGE DIRECTION OF ROTATION
10
V300300
2-6 9910
3 PTO’S
2.7 OVERVIEW DRAWINGS, PTO VERSIONS
N71/1 - N353/1 VERSION
V300211
10
9910 2-7
PTO’S 3
N71/2 - N353/2 VERSION
V300212
10
2-8 9910
3 PTO’S
N221/10 VERSION FOR GEARBOX WITHOUT INTARDER
V300213
10
9910 2-9
PTO’S 3
N221/10 VERSION FOR GEARBOX WITH INTARDER
10 V300214
2-10 9910
3 PTO’S
2.8 OVERVIEW DRAWING, N71/1 AND N353/1 PTO, B-VERSION
3
4
1 2
V300217
1. Studs
2. Gasket
3. N71/1 needle bearing width 16 mm
N353/1 needle bearing width 12 mm
4. PTO housing
5. Lock washer and nut
10
9910 2-11
PTO’S 3
2.9 OVERVIEW DRAWING, N71/1 AND N353/1 PTO, C-VERSION
3 9 7 8
6
4
2
V300218
1. Lead screw nut/washer

2. Studs
3. Gasket
4. PTO housing
5. Selector block
6. Synchroniser sleeve
7. Lock washer
8. Nut
9. Lead cover
10
2-12 9910
3 PTO’S
2.10 OVERVIEW DRAWING, N71/2 AND N353/2 PTO, B-VERSION
1 5
2
3
4
1
V300219
1. Studs
2. Needle bearing
3. PTO housing
4. Gasket
10
9910 2-13
PTO’S 3
2.11 OVERVIEW DRAWING, N71/2 AND N353/2 PTO, C-VERSION
5 6 7
1 2
3
5
4
1
V300220
1. Studs
2. Gasket
3. Needle bearing
4. PTO housing
6. Circlip
7. Gear-wheel
8. Gasket
10
2-14 9910
3 PTO’S
2.12 OVERVIEW DRAWING, N221/10 PTO ON GEARBOX WITHOUT INTARDER
1. Side cover attachment bolts 1 2

2. Side cover
3. Gasket
4. PTO housing 3
5. Long attachment bolts
6. Short attachment bolts 4
7. O-ring 5
8. Centring ring
9. Gasket
10. Adjusting ring 6
7
8
10
V300221
2.13 OVERVIEW DRAWING, N221/10 PTO ON GEARBOX WITH INTARDER
1. Side cover attachment bolts 1

2. Side cover 2
3. Gasket
3
4. PTO housing 5
5. Short attachment bolts 4
6. Long attachment bolts
7. O-ring
8. Gasket 1
9. O-ring
10. Centring ring
6
7
5
10
6
8 9 10
V300222
9910 2-15
PTO’S 3
2.14 OVERVIEW DRAWING PTO AUXILIARY SHAFT FOR GEARBOX WITHOUT

INTARDER
1. Auxiliary shaft 1 2 3 4 5 6 7 8
2. Tapered roller bearing
3. Gearbox housing
4. Auxiliary shaft
5. Rear gearbox cover
6. Circlip
7. Ball bearing
8. Centring sleeves
V300223
2.15 OVERVIEW DRAWING, PTO AUXILIARY SHAFT FOR GEARBOX WITH

INTARDER
1. Auxiliary shaft 1 3 4 5 6
2. Ball bearing
3. Circlip
4. O-ring
5. Intermediate housing
6. Long attachment bolt
7. Short attachment bolt
8. Gasket
2 8 7
V300224
2.16 PNEUMATIC DIAGRAM PTO CONTROL
10 DESCRIPTION
Depending on the version, the electropneumatic
valve (1) is controlled by a switch or a 6
1
combination of a switch and GV pressure
sensor located in the cab. 2
Upon activation of the electropneumatic valve
(1), there is system pressure on the PTO 3 2 2
connection, causing the PTO (2) to be activated. PTO
1
V300237
2-16 9910
3 PTO’S

3.1 INSPECTION AND ADJUSTMENT, DAF ENGINE PTO PROP SHAFT AXIAL
PLAY
Inspection and adjustment, DAF engine PTO

prop shaft axial play
1. Press the two outer bearing races into the
PTO housing.
2. Place the PTO housing into a mould or
vice.
3. Note:
Use a dummy to determine the correct
assembly of the filler sleeve with
adjustment rings.
V300301
4. Fit an inner bearing with filler sleeve (note

the position of the filler sleeve) and two
adjustment rings to the dummy and fit it into
the PTO housing. Fit the second inner
bearing to the dummy with the spacer
sleeve and mount the locknut. Tighten the
locknut (A) to the specified tightening
V300302
5. Place a dial gauge on the dummy shaft and

inspect the play. See “Technical data”. If the A
play is too great or too little, choose the
correct filler ring.
6. Disassemble the dummy after adjusting the
prop shaft.
10
V300304
9910 3-1
PTO’S 3
3.2 INSPECTION AND ADJUSTMENT, DAF ENGINE PTO GEAR WHEEL AXIAL
PLAY
Inspection and adjustment, gear wheel axial

play
1. Note:
The procedures apply to both sets of drive
sprockets.
On both sides, press the outer bearing race
in.
2. On one side of the gear wheel, mount the
bearing inner race.
3. Place the gear wheel on the inner bearing
race underneath a press.
4. Starting with the thickest, place two
adjusting rings on the inner race and fit the
second inner bearing race.
V300305
5. place a dial gauge on the drive sprocket

and check the axial play using a stamp at a
pressure of approx. 1 to 5 tonnes. See
“Technical data”. If the play is too great or
too little, choose the correct filler ring.
6. Place the O-ring on the shaft.
7. Press one of the inner bearing races on to
the shaft (oil the shaft).
8. Mount the drive sprocket and the adjusting
rings on the shaft and press the second
bearing inner race onto the shaft. Put aside
the shaft and drive sprocket assembly.
V300306
10
3-2 9910
3 PTO’S
3.3 INSPECTION AND ADJUSTMENT, AXIAL PLAY ON GEARBOX OUTPUT

SHAFT N221/10 PTO ON GEARBOX WITHOUT INTARDER
1. Remove the bearing cover of the output

shaft from the gearbox. A
2. Install a new gasket on the bearing cover of

the PTO housing. Use a depth gauge to
determine the depth of the bearing cover
chamber, distance A.
V300227
3. Use a depth gauge to determine the height

gearbox housing, distance B.
4. Calculate the axial play. The axial play B
equals distance A distance B.
V300216
10
9910 3-3
PTO’S 3
3.4 INSPECTION AND ADJUSTMENT, AXIAL CLEARANCE OF N353/1 PTO ON

N221/10 PTO
1. Remove the cover and spacer of the

N221/10 PTO. A
2. Use a depth gauge to measure the depth
down to the outer bearing race, distance A.
V300230
3. Install a new gasket on the intermediate

housing and use a depth gauge to measure B
the distance from the centring ring,
distance B.
4. Calculate the axial play. The axial play
equals distance A distance B.
10
V300231
3-4 9910
3 PTO’S

4.1 REMOVAL AND INSTALLATION, ENTIRE DAF FLYWHEEL HOUSING
ENGINE PTO
Removal, entire DAF flywheel housing

engine PTO
1. If necessary, remove the prop shaft from
the PTO flange.
2. Remove the hollow screws from the engine
PTO oil pipes.
3. If necessary, remove the electrical and air
connections of the engine PTO.
4. Remove the attachment bolts of the entire
PTO on the flywheel housing.
5. Remove the entire PTO from the flywheel
housing.
6. Remove the PTO centring ring dowel pins
from the flywheel housing.
Installation, entire DAF flywheel housing
engine PTO
1. Fit the PTO centring ring dowel pins to the
flywheel housing.
2. Fit the entire PTO to the flywheel housing.
4. Install the oil pipes and hollow screws and
5. If necessary, fit the electrical and air
connections of the engine PTO.
6. If necessary, tighten the prop shaft to the
PTO flange.
10
7. Check the PTO operation.
9910 4-1
PTO’S 3
4.2 REMOVAL AND INSTALLATION, DAF ENGINE PTO FLYWHEEL HOUSING
Removal, DAF engine PTO flywheel housing

2. Remove the flywheel.
3. Remove the PTO housing from the flywheel
housing.
4. Remove the attachment bolt from the upper
drive sprocket.
5. Suspend the engine in a hoist.
6. Suspend the clutch housing in a hoist.
7. Remove the engine bracket attachment
bolts.
flywheel housing on the engine block.
9. Remove the flywheel housing.
10. Remove the two drive sprockets on the
flywheel housing.
11. Remove the oil seal from the flywheel
housing.
Installation, DAF engine PTO flywheel
housing
1. Fit a new oil seal in the flywheel housing.
2. Fit the two drive sprockets into the flywheel
housing.
3. Install the flywheel housing and tighten the
upper drive sprocket attachment bolt to the
Data”.
4. Fit the flywheel housing attachment bolts to
the engine block and tighten them to the
10 specified tightening torque. See “Technical
Data”.
5. Fit the engine bracket attachment bolts.
6. Fit the entire PTO to the flywheel housing.
7. Fit the flywheel.
8. Fit the clutch release assembly.
9. Fit the gearbox.
4-2 9910
3 PTO’S
4.3 REMOVAL AND INSTALLATION, N71/1 AND N353/1 PTO, B-VERSION
Removal, N71/1 and N353/1 PTO, B-version

1. Drain as much gearbox oil as necessary
and collect it in a clean container.
2. Remove the electrical connector and air
pipe from the PTO.
3. Remove the drive flange, which is mounted
against the PTO flange.
4. Remove the attachment nuts of the PTO to
the gearbox and remove the PTO including
needle bearing and gasket.
5. If necessary, remove the auxiliary shaft.
Overview drawing, N71/1 and N353/1 PTO,
B-version
1. If necessary, fit the auxiliary shaft.
2. Install the gasket over the studs.
3. Install the PTO with needle bearing onto the
gearbox.
4. Install the attachment nuts onto the studs of
the gearbox and the PTO.
5. Connect the electrical connector and air
pipe to the PTO.
6. Install the drive flange against the PTO
flange.
7. Check the oil level in the gearbox.
10
9910 4-3
PTO’S 3
4.4 REMOVAL AND INSTALLATION, N71/1 AND N353/1 PTO, C-VERSION
Removal, N71/1 and N353/1 PTO, C-version

pipe from the PTO.
selector sleeve, selector block and gasket.
Installation, N71/1 and N353/1 PTO,
C-version
3. Install the PTO with selector sleeve and
selector block onto the gearbox.
pipe to the PTO.
flange.
10
4-4 9910
3 PTO’S
4.5 REMOVAL AND INSTALLATION, N71/2 AND N353/2 PTO, B-VERSION
Removal, N71/2 and N353/2 PTO, B-version

pipe from the PTO.
needle bearing and gasket.
Overview drawing, N71/2 and N353/2 PTO,
B-version
3. Install the PTO with needle bearing onto the
gearbox.
pipe to the PTO.
flange.
10
9910 4-5
PTO’S 3
4.6 REMOVAL AND INSTALLATION, N71/2 AND N353/2 PTO, C-VERSION
Removal, N71/2 and N353/2 PTO, C-version

pipe from the PTO.
selector sleeve, selector block and gasket.
Installation, N71/2 and N353/2 PTO,
C-version
3. Install the PTO with selector sleeve and
selector block onto the gearbox.
pipe to the PTO.
flange.
10
4-6 9910
3 PTO’S
4.7 REMOVAL AND INSTALLATION, N221/10 PTO ON GEARBOX WITHOUT

INTARDER
Removal, N221/10 PTO without intarder

pipe from the PTO.
3. Remove the drive flange, mounted against
the PTO flange.
4. Remove the attachment bolts from the PTO
side cover and remove the side cover with
the gasket.
5. Remove the gearbox drive shaft and hang
the drive shaft on the side of the chassis.
drive flange.
8. Note:
Measure and make a note of the distance
from the drive flange to the shaft. The same
distance must be observed when the drive
flange is reinstalled.
Remove the drive flange and O-ring using a
commercially available flange holder and
tripod puller.
bearing cover of the PTO and the two
attachment bolts located on the inside of
the PTO. Remove the entire PTO.
10. Remove the gasket, O-ring, centring ring
and spacer ring from the bearing of the
output shaft.
10
9910 4-7
PTO’S 3
Installation, N221/10 PTO without intarder

1. Check the bearing play of the gearbox
output shaft and adjust if necessary.
2. Install the O-ring and centring ring in the
rear cover of the gearbox.
3. Install a new gasket and spacer ring in the
rear cover of the PTO.
4. Install the PTO on the gearbox and install
the attachment bolts.
5. Fit a new gasket on the side cover of the
PTO and fit the side cover.
6. Heat the gearbox drive flange to
approximately 70°C. Slide the drive flange
as far as possible onto the output shaft.
Use a locking plate and two standard bolts
(M12x75) to pull the drive flange further
onto the shaft. Check the position of the
drive flange on the basis of the
above-mentioned measurement. Remove
the locking plate and bolts again.
7. Fit a new O-ring into the recess between
the output shaft and the drive flange.
8. Hold the drive flange with a flange retainer.
9. Fit the lock plate with the bolts (M12x75)
torque, see main group “Technical Data”.
10. Fit a new lock plate using special tool
(DAF No. 1240460).
pipe to the PTO.
flange.
10 14. Check the oil level in the gearbox.
4-8 9910
3 PTO’S
4.8 REMOVAL AND INSTALLATION, N221/10 PTO ON GEARBOX WITH

INTARDER
Removal, N221/10 PTO with intarder

pipe from the PTO.
4. Remove the attachment bolts from the PTO
side cover and remove the side cover with
the gasket.
5. Remove the PTO attachment bolts on the
rear cover of the gearbox and the two
attachment bolts on the inside of the PTO.
Remove the entire PTO.
6. Remove the gasket, the O-ring and centring
ring from the rear cover of the gearbox.
Installation, N221/10 PTO with intarder
1. Install a new O-ring and centring ring in the
2. Install a new gasket and in the rear cover of
the gearbox.
3. Fit the PTO.
4. Fit a new gasket on the side cover of the
PTO and fit the side cover.
pipe to the PTO.
flange.
10
9910 4-9
PTO’S 3
4.9 REMOVAL AND INSTALLATION, N353/1 PTO ON N221/10 PTO
Removal, N353/1 PTO on N221/10 PTO

pipe from the PTO.
N353/1 PTO on the N221/10 PTO.
5. Remove the PTO, gasket and intermediate
housing.
Installation, N353/1 PTO on N221/10 PTO
1. Check and adjust the axial play before
attaching the N353/1 PTO to the
N221/10 PTO.
2. Fit a new gasket and fit the intermediate
housing.
3. Fit the PTO.
pipe to the PTO.
flange.
10
4-10 9910
3 PTO’S
4.10 REMOVAL AND INSTALLATION, PTO AUXILIARY SHAFT ON GEARBOX

WITHOUT INTARDER
Removal, auxiliary shaft without intarder

2. Remove the PTO.
3. Remove the centring sleeves.
4. Remove the auxiliary shaft with bearing and
lock ring from the rear cover of the gearbox.
5. Remove the lock ring and the auxiliary shaft
bearing, if necessary.
Installation, auxiliary shaft without intarder
1. Note:
The auxiliary shaft can be installed without
any measurements being taken.
Install the bearing and the lock ring on the
auxiliary shaft.
2. Install the auxiliary shaft in the rear cover of
the gearbox.
3. Install the centring sleeves on the rear
cover of the gearbox.
4. Fit the PTO.
10
9910 4-11
PTO’S 3
4.11 REMOVAL AND INSTALLATION, PTO AUXILIARY SHAFT ON GEARBOX

WITH INTARDER
Removal, auxiliary shaft with intarder

2. Remove the PTO.
3. Remove the intermediate housing from the
4. Remove the O- ring and the gasket.
5. Remove the auxiliary shaft with bearing and
lock ring from the rear cover of the gearbox.
6. Remove the lock ring and the auxiliary shaft
bearing.
Installation, auxiliary shaft with intarder
1. Note:
The auxiliary shaft can be installed without
any measurements being taken.
Install the bearing and the lock ring on the
auxiliary shaft.
2. Install the auxiliary shaft in the rear cover of
the gearbox.
3. Install the intermediate housing with O-ring
and gasket onto the rear cover of the
gearbox.
4. Fit the PTO.
10
4-12 9910
3 PTO’S

5.1 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO
Disassembly, drive sprockets from flywheel

housing
1. Remove the lower drive sprocket
attachment bolt and remove the sealing
plate.
2. Place the flywheel housing under a hand
press and press one of the drive sprocket
shafts out of the flywheel housing.
3. Remove the drive sprocket and the
adjusting rings from the flywheel housing.
4. In the same way, remove the second drive
sprocket from the flywheel housing, with the
exception of the attachment bolt.
5. If necessary, remove the inner bearing race
from the shaft.
Assembly, drive sprockets in flywheel
housing
1. Place the flywheel housing under a hand
press and press the first of the drive
sprocket assembly into the lower part of the
flywheel housing.
2. Fit an O-ring on the shaft, oil it lightly and
press the shaft through the flywheel housing
into the drive sprocket until the shaft collar
abuts the flywheel housing. Mount the
sealing plate to the rear of the flywheel
housing. Mount the O-ring on the
attachment bolt, oil it lightly and tighten the
bolt to the specified tightening torque. See
3. Fit an O-ring on the shaft, oil it lightly and
press the shaft through the flywheel housing
into the drive sprocket until the shaft collar
abuts the flywheel housing. The attachment
bolt and O-ring are mounted together with
10
the flywheel housing against the engine
block.
9910 5-1
PTO’S 3
5.2 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO HOUSING
Disassembly, DAF engine PTO housing

1. If fitted, remove the drive shaft.
2. On the rear of the PTO housing remove the
sealing plate attachment bolts of the drive
shaft with the gasket.
3. Remove the locknut from the drive shaft.
4. If fitted, remove the pneumatic valve.
5. If fitted, remove the shift control.
6. Remove the drive housing attachment nuts
and the drive side oil seal cover, if fitted.
7. If necessary, remove the drive shaft with
bearing and clutch body from the PTO
housing.
8. Remove the prop shaft from the PTO
housing with the adjusting rings and drive
sprocket.
9. If necessary, remove the needle bearing for
the drive shaft from the prop shaft.
10. If necessary, remove the two outer bearing
races from the PTO housing.
11. If necessary, remove the bearing from the
prop shaft.
10
5-2 9910
3 PTO’S
Assembly, DAF engine PTO

1. If necessary, press the two outer bearing
races into the PTO housing.
2. Place the PTO housing into a mould or vice.
3. If necessary, fit the smallest inner bearing
race to the prop shaft.
4. If necessary, fit the needle bearing for the
drive shaft to the prop shaft.
5. Fit the prop shaft assembly described
earlier into the PTO housing using the
dummy and drive sprocket. Not the position
of the spacer sleeve on the prop shaft.
6. Press the second inner bearing race on to
the prop shaft. Apply Loctite to the locknut.
Tighten the locknut to the specified
7. Fit a sealing gasket and the cover to the
side of the locknut and tighten them to the
data”.
8. Turn the PTO housing round. If necessary,
apply Loctite to the studs and tighten them
to the specified torque. See “Technical
Data”.
9. Fit the drive housing.
10. If necessary, fit the drive shaft and bearing.
11. If necessary, fit the cover with the gasket
and oil seal and tighten the attachment bolts
12. If necessary, fit the drive shaft.
13. If necessary, fit the sealing ring and O-ring
and tighten the attachment bolts to the
Data”.
10
9910 5-3
PTO’S 3
5.3 VERSIONS WITH AND WITHOUT PROP SHAFT AND SHIFT CONTROL
1. Note:
Version without drive flange and shift
control.
Fit a gasket between the drive housing and
PTO housing. Note the oil channel in the
gasket.
2. Fit a gasket and cover on the front of the
drive housing and tighten the attachment
bolts to the specified tightening torque. See
3. Fit a guide block, gasket and cover to the
side of the drive housing. Tighten the
1. Note:
Version with drive flange and shift control.
Fit the gasket and drive housing over the
studs against the PTO housing.
2. Fit a needle bearing into the prop shaft.
3. Fit the drive shaft and bearing against the
prop shaft.
4. Fit the cover with gasket and oil seal
against the drive housing and tighten the
torque, see “Technical Data”.
5. Fit the prop shaft with locking plate and
O-ring and tighten the attachment bolts to
10
5-4 9910
3 PTO’S
6. On the rear of the gearbox housing, fit a

sealing cap. Fit the gearbox housing with
gasket to the drive housing and tighten the
7. Fit the clutch shaft together with the clutch
fork and pressure spring to the gearbox
housing.
8. Fit the piston with O-ring to the cylinder and
mount the cylinder with a gasket on either
side and the cover against the gearbox
housing. Tighten the attachment bolts to the
data”.
9. If necessary, fit a push/pull switch to the
side.
10. Check the PTO control.
10
9910 5-5
PTO’S 3
10
5-6 9910
3 SPLITTER BOX
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.1 Gearbox pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9910
2.2 Overview drawing, splitter box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 9910
2.3 Overview drawing, front wheel drive shift mechanism . . . . . . . . . . . . . . . . . . . . 2-6 ...... 9910
2.4 Overview drawing, high-low shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ...... 9910
2.5 Overview drawing, adjustable torque rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 ...... 9910
2.6 Overview drawing, splitter box switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 ...... 9910
3.1 Inspection, oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 9910
3.2 Adjustment, adjustable torque rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 9910
3.3 Adjustment, front wheel drive shift stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 9910
3.4 Adjustment, high/low drive shift stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 9910
4.1 Removal and installation, splitter box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 9910
4.2 Removal and installation, splitter box oil seals, front axle and/or
gearbox drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 9910
4.3 Removal and installation, rear wheel drive splitter box oil seal . . . . . . . . . . . . 4-5 . . . . . . 9910
5.1 Draining and filling, splitter box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 9910
11
9910 1
SPLITTER BOX 3
11
2 9910
3 SPLITTER BOX
Ensure that the splitter box does not tilt during
removal either to the side, forwards or
backwards.
Carefully suspend the prop shafts on the side of
the chassis.
11
9910 1-1
SPLITTER BOX 3
11
1-2 9910
3 SPLITTER BOX
2. GENERAL
2.1 GEARBOX PNEUMATIC DIAGRAM
Description, engaging front wheel drive 1

In the illustrated position of the pneumatic 3
pressure switch (1) which is found in the cab, 2 1
the splitter box cylinder (2) is engaged via ports
1 and 2 of the system pressure, causing the
front wheel drive to be engaged.
V300313
1. Pneumatic pressure cylinder

2. Front wheel drive splitter box cylinder
11
9910 2-1
SPLITTER BOX 3
Disengaging front wheel drive 1

If the pneumatic pressure switch (1) is pushed
into another position, the cylinder (2) will bleed
the splitter box via ports 2 and 3, causing the 3
front wheel drive to be disengaged. 1
2
V300319

2. Front wheel drive splitter box cylinder
11
2-2 9910
3 SPLITTER BOX
Engaging low with the gearbox 1

If the pneumatic pressure switch (1) is switched 3
to the “splitter box in low” position, the command
2 1
pressure is given via ports 1 and 2 to the
high/low shift valve.
The system pressure is switched to connection
point 2 of the cylinder (3) on the splitter box via
the shifting valve. Connection point 3 of the
cylinder is switched with the vent via the shifting
valve.
3 1 5 2
4 2
3
3
V300320

2. Shift valve high/low
3. Splitter box high/low cylinder
11
9910 2-3
SPLITTER BOX 3
Engaging high with the gearbox 1

If the pneumatic pressure cylinder (1) is
switched to the “splitter box in high” position, the
high/low switch valve is switched with the vent 3
via ports 2 and 3. The system pressure is 1
switched to connection point 3 of the cylinder (3) 2
on the splitter box via the shifting valve.
Connection point 2 of the cylinder is switched
with the vent via the shifting valve.
2 3 1 5
4 2
3
3
V300321

2. Shift valve high/low
3. Splitter box high/low cylinder
11
2-4 9910
3 SPLITTER BOX
2.2 OVERVIEW DRAWING, SPLITTER BOX
2 3
V300307
1. Input shaft
2.
3.
Output shaft, front wheel drive
Output shaft, rear wheel drive
11
9910 2-5
SPLITTER BOX 3
2.3 OVERVIEW DRAWING, FRONT WHEEL DRIVE SHIFT MECHANISM
1. Front wheel drive shifting fork

2. Front wheel drive shift sleeve
2
V300308
11
2-6 9910
3 SPLITTER BOX
2.4 OVERVIEW DRAWING, HIGH-LOW SHIFT MECHANISM
4 5
3
7
2
V300309
1. Connection point for switching splitter box

to neutral (pluged off)
to low
to high
4. Shift sleeve high/low
5. Shifting fork high/low
6. Clutch shaft stop bolt splitter box in high
7. Clutch shaft stop bolt, splitter box in low
11
9910 2-7
SPLITTER BOX 3
2.5 OVERVIEW DRAWING, ADJUSTABLE TORQUE ROD
1. Adjustable torque rod

2. Chassis bracket 4
3. Splitter box bracket
4. Adjustment, torque rod
2
V300322
2.6 OVERVIEW DRAWING, SPLITTER BOX SWITCHES
1. Overview, switch instructions

2. Front wheel drive switch 1
3. Rear wheel drive high switch
4. Rear wheel drive low switch
2
11
3
4
V300324
2-8 9910
3 SPLITTER BOX

3.1 INSPECTION, OIL LEVEL

surface.
back.
A B
V300255
11
9910 3-1
SPLITTER BOX 3
3.2 ADJUSTMENT, ADJUSTABLE TORQUE ROD
1. Note:
Before adjustment, check the torque rod 4
rubber bushes for hair-line cracks and wear.
The vehicle must be on a flat horizontal
surface.
2
The vehicle should be unloaded.
The splitter box tilt can be measured using
a protractor or wheel-aligning equipment.
3
2. Using the adjusting nuts (4), the splitter box
tilt can be corrected.
3. See “Technical Data” for the correct angle.
V300322
11
3-2 9910
3 SPLITTER BOX
3.3 ADJUSTMENT, FRONT WHEEL DRIVE SHIFT STOP
1. Note:
The front wheel drive stop bolt must be set
so that the shifting fork (1) does not drag
against the edge of the groove in the clutch
body (2).
2. Engage the front wheel drive and unscrew 1
the locknut from the adjusting bolt in the
clutch shaft.
3. Screw in the clutch shaft adjusting bolt as
far as resistance can be felt. Now unscrew
the adjusting bolt half a turn and tighten the
locknut.
2
V300308
11
9910 3-3
SPLITTER BOX 3
3.4 ADJUSTMENT, HIGH/LOW DRIVE SHIFT STOP
4 5
3
7
2
V300309
1. Note:
The high/low drive stop bolt must be set so
that the shifting fork (5) does not drag
against the edge of the groove in the clutch
body (4).
2. Engage high drive and loosen the locknut
(6) from the clutch shaft adjusting bolt.
locknut (6).
4. Engage low drive and loosen the locknut (7)
from the clutch shaft adjusting bolt.
locknut (7).
11
3-4 9910
3 SPLITTER BOX

4.1 REMOVAL AND INSTALLATION, SPLITTER BOX

drained oil.
Removal, splitter box

1. Remove the oil from the splitter box.
2. Remove the prop shaft from the gearbox
drive and carefully suspend the shaft on the
side of the chassis.
3. Remove the front wheel drive shaft and
carefully suspend the drive shaft on the
4. Remove the rear wheel drive shaft and
carefully suspend the drive shaft on the
5. Remove the front wheel drive switch
connector.
V300310
6. Remove the front wheel drive cylinder air
connection.
11
9910 4-1
SPLITTER BOX 3
7. Remove all air connections on the splitter

box 5/2 valve.
V300311
8. Remove the speed sensor connector.

9. Note:
The splitter box is sensitive to tilting.
Therefore ensure a good support before
removing the splitter box.
10. Remove the adjustable torque rod on the
splitter box and chassis if necessary.
11. Remove the brackets on the side of the
splitter box.
12. Remove the splitter box.
V300312
11
4-2 9910
3 SPLITTER BOX
Installation, splitter box

1. Fit the splitter box brackets to the chassis.
2. Fit the adjustable torque rod to the splitter
box and chassis if necessary.
3. Connect the air supply.
4. Fit the connectors.
5. Fit the gearbox front and rear drive shafts.
6. Adjust the timing gear adjustable torque
rods. See “Inspection and Adjustment”.
7. Fill the splitter box with oil. See “Draining
and Filling”.
8. Check the operation of the splitter box.
11
9910 4-3
SPLITTER BOX 3
4.2 REMOVAL AND INSTALLATION, SPLITTER BOX OIL SEALS, FRONT AXLE
AND/OR GEARBOX DRIVE

drained oil.
Removal, splitter box oil seals, front axle

and/or gearbox drive
1. If necessary, remove the oil from the splitter
box.
2. Remove the splitter box drive shaft from the
gearboxes/front wheel drive and hang the
drive shaft on the chassis.
3. Fit a flange retainer and remove the flanged
nut.
4. If necessary, remove the flange with a
tripod puller.
(DAF No. 484899). Pull the seal evenly
from the gearbox housing using special tool
(DAF No. 0694928).
Installation, splitter box oil seals, front axle
and/or gearbox drive
outside.
2. Fit an oil seal to the bearing cover.
3. Fit the drive flange and tighten the flanged
nut to the specified tightening torque. See
adjustment”.
11
4-4 9910
3 SPLITTER BOX
4.3 REMOVAL AND INSTALLATION, REAR WHEEL DRIVE SPLITTER BOX OIL
SEAL

drained oil.
Removal, rear wheel drive splitter box oil

seal
1. If necessary, remove the oil from the splitter
box.
flange and hang the rear drive shaft on the
chassis.
3. Fit a flange retainer and remove the flanged
nut.
4. If necessary, remove the flange with a
tripod puller.
bearing cover and remove the bearing
cover.
Remove the oil seal from the cover with a
soft drift.
Installation, rear wheel drive splitter box oil
seal
outside.
2. Fit an oil seal to the bearing cover.
3. Apply Loctite to the bearing cover and fit it
to the splitter box housing.
11
adjustment”.
9910 4-5
SPLITTER BOX 3
11
4-6 9910
3 SPLITTER BOX

5.1 DRAINING AND FILLING, SPLITTER BOX

drained oil.
Draining the splitter box

surface.
2. Drain the splitter box at operating
temperature using plug (B).
3. Remove level check/filler plug (A).
Filling the splitter box
tightening them to the specified torque. See
opening.
3. Fit level check/filler plug tightening it to the
specified torque. See “Technical Data”.
A B
V300255
11
9910 5-1
SPLITTER BOX 3
11
5-2 9910

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3 CONTENTS

1. MECHANICAL GEARBOX CONTROL

- Within the entire 65/75/85CF vehicle series

ADJUSTMENT, LINKAGE MECHANISM

RHD 65 vehicle series with S6 - 36/2 and

LHD 65 vehicle series with 9S - 75 gearbox

RHD 65 vehicle series with 9S - 75 gearbox

RHD 75 vehicle series with 8S - 109 gearbox

LHD 75 vehicle series with 9/16S -

RHD 75 vehicle series with 9/16S -

LHD 75 vehicle series with 8/16S -

RHD 75 vehicle series with 8/16S -

LHD 85 vehicle series with 8/16S -

With 270 mm long torque rod 0

LHD 85 vehicle series with 8/16S -

LHD 85 vehicle series with 16S - 221 gearbox

RHD 85 vehicle series with 8/16S -

RHD 85 vehicle series with 8/16S -

With 292 mm long torque rod 0

LHD 85 vehicle series with TS 12612 Eaton

RHD 85 vehicle series with TS 12612 Eaton

Gluing gear lever into ball

1.2 TIGHTENING TORQUES

Clamping bolt (1), control rod to gear lever unit 40 Nm

2. PNEUMATIC SECTION OF GEARBOX

NEUTRAL POSITION VALVE

EATON GEAR LEVER SELECTOR

GEAR LEVER SELECTOR VALVE

GEAR LEVER SHIFTING VALVE

EATON GEARBOX SELECTOR VALVE

positioned to the left of the valve (LHD) and

Gear change pattern

2.2 TIGHTENING TORQUES

Gear button on gear lever

Axial bearing play, main and input shafts

Axial play, auxiliary shaft

Axial bearing pre-load, main and input

Axial bearing pre-load, auxiliary shaft

Axial play, main shaft gears

Input shaft Lithium-based grease, class NLGI 3

3.2 TIGHTENING TORQUES

8/9/16S - 109 gearbox

8/16S - 151/181/221 gearboxes

Shift control high/low

Gearbox with intarder

3.3 FILLING CAPACITIES

4.2 TIGHTENING TORQUES

Molycote BR2 Plus for torque converter pilot

4.3 FILLING CAPACITIES

The oil level when cold must be on the “Cold

KZI-5 in combination with GMF 430 &

Eaton twin splitter gearbox.

5.2 TIGHTENING TORQUES

CLUTCH RELEASE ASSEMBLY

5.3 FILLING CAPACITIES

6.2 TIGHTENING TORQUES

Attachment bolts, drive flange

Central bolt centre bearing 350 15 Nm *

Attachment bolts, drive flange