DAF Clutch Service Manual
3
ΛΦ45/55 series
STRUCTURE
Structure
TECHNICAL DATA
0
DIAGNOSTICS
1
MECHANICAL GEARBOX CONTROL
2
PNEUMATIC GEARBOX CONTROL
3
ZF S5-42 GEARBOX
4
ZF 6S-850 GEARBOX
5
EATON FS/6309A GEARBOX
6
ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
7
ALLISON MD 3060 AUTOMATIC GEARBOX
8
CLUTCH
9
PROP SHAFTS
10
©
200508 DW23259302
3
TECHNICAL DATA
ΛΦ45/55 series
0 Technical data
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200508
2. PNEUMATIC GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200508
3. ZF S5-42 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200508
4. ZF 6S-850 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200508
4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200508
5. EATON FS/6309A GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200508
5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200508
Contents
0
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200508
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 . . . . . 200508
7. ALLISON MD3060 AUTOMATIC GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200508
7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 . . . . . 200508
8. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200508
8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . . 200508
9. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . 200508
©
200508 1
TECHNICAL DATA
3
0
Contents
ΛΦ45/55 series
2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
Mechanical gearbox control
1. MECHANICAL GEARBOX CONTROL
1.1 GENERAL
Switch button
Locking compound Loctite 243
Control rod
Lubricant Molykote BR2S or BR2 plus
Control rod underneath the cab
A
0
Length A
Engine Gearbox Cab suspension Class Length A [mm]
CE engine ZF 6S850 steel 1 669
CE engine ZF 6S850 rubber 1 664
CE engine ZF 6S850 steel 2 + 3 674
CE engine ZF 6S850 rubber 2 + 3 669
CE engine FS6309A steel 2 + 3 674
CE engine FS6309A rubber 2 + 3 669
Control rod behind the cab
B
V3 00 563
V3 00 564
Length B 60 - 62 mm
©
200508 1-1
TECHNICAL DATA
3
0
Mechanical gearbox control
1.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
ΛΦ45/55 series
1-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
Operating mechanism,
2 adjustment options
Mechanical gearbox control
0
1
2
4
Control rod (1)
Lubricant Molykote BR2S or BR2 plus
Torque rod (2)
Attachment nuts 48 Nm
Lock nuts 28 Nm
Ball joint (4)
Attachment nut 48 Nm
Lock nuts 45 Nm
3
V3 00 567
©
200508 1-3
TECHNICAL DATA
3
0
Mechanical gearbox control
Operating mechanism,
4 adjustment options
ΛΦ45/55 series
1
2
3
9
8
7
6
Control rod (1)
Lubricant Molykote BR2S or BR2 plus
Ball joint (2)
Attachment nut 48 Nm
Lock nuts 48 Nm
Torque rod (4)
Attachment nuts 48 Nm
Lock nuts 28 Nm
Ball joint (6)
Attachment nut 48 Nm
Lock nuts 48 Nm
4
5
V3 00 566
Ball joint (8)
Attachment nuts 48 Nm
Lock nuts 48 Nm
1-4
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
Torque rod (9)
Attachment nuts 48 Nm
Gear lever unit
Attachment bolts 18 Nm
Eaton switch button
Attachment nut 70 Nm
(1) Use Loctite 243
Mechanical gearbox control
0
(1)
(1)
©
200508 1-5
TECHNICAL DATA
3
0
Mechanical gearbox control
ΛΦ45/55 series
1-6
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
2. PNEUMATIC GEARBOX CONTROL
2.1 GENERAL
Filter/governor
Governed pressure 5.34 - 5.69 bar
Pneumatic gearbox control
0
©
200508 2-1
TECHNICAL DATA
3
0
Pneumatic gearbox control
2.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Filter/governor
M6 attachment bolts 13 Nm
Cover 25 Nm
Selector valve single-H
M6 attachment bolts 22 Nm
M16 discharge valve attachment bolts 19 Nm
M8 cover plate attachment bolts 22 Nm
ΛΦ45/55 series
Range-change cylinder
M8 cover attachment bolts 17 Nm
M16 nut on piston 105 Nm
Bleed valve
Attachment 19 Nm
Eaton switch button
Attachment nut 70 Nm
(1) Use Loctite 243
(1)
2-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
3. ZF S5-42 GEARBOX
3.1 GENERAL
Input shaft
Pre-tension 0.02 - 0.09 mm
Secondary shaft
Pre-tension 0.02 - 0.09 mm
ZF S5-42 gearbox
0
©
200508 3-1
TECHNICAL DATA
3
0
ZF S5-42 gearbox
3.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
'Direct drive' attachment nut 400 Nm
Overdrive attachment nut 330 Nm
Gearbox front cover
Attachment bolts 23 Nm
ΛΦ45/55 series
(1)
(2)
Selector shaft housing
Selector shaft housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Plugs
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
(1) Fit new nut and apply Loctite 270 to it
(2) Fit new nut and apply Loctite 262 to it
3-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
3.3 FILLING CAPACITIES
Gearbox Capacity
S5-42 3.5 litres
ZF S5-42 gearbox
0
©
200508 3-3
TECHNICAL DATA
3
0
ZF S5-42 gearbox
ΛΦ45/55 series
3-4
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
4. ZF 6S-850 GEARBOX
4.1 GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. This data can also
be found on the vehicle identity card for the
vehicle concerned.
ZF gearbox type plate
1. Type of gearbox
2. Serial no. (ZF)
3. Parts list (ZF)
4. Specification no.
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO
8. PTO speed
9. Gearbox oil capacity
10. Oil specification
ZF 6S-850 gearbox
0
1
3
6
8
2
4
5
7
Output shaft bearing axial play
Output shaft bearing axial play 0.00 - 0.10 mm
Bearing axial play, main and input shafts
Bearing axial play, main and input shafts 0.00 - 0.10 mm
Secondary shaft bearing axial play
Secondary shaft bearing axial play 0.00 - 0.10 mm
9
10
V300049
©
200508 4-1
TECHNICAL DATA
3
0
ZF 6S-850 gearbox
4.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
Drive flange ∧ 120 mm attachment bolt 120 Nm
Drive flange ∧ 150 mm attachment bolt 140 Nm
Gearbox front cover
Attachment bolts 23 Nm
ΛΦ45/55 series
Selector shaft housing
Selector housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Plugs
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
4-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
4.3 FILLING CAPACITIES
Gearbox type Filling amounts at oil change
ZF 6S-850 7.5 7.5
(litres)
ZF 6S-850 gearbox
0
First filling, e.g. on repair
(litres)
©
200508 4-3
TECHNICAL DATA
3
0
ZF 6S-850 gearbox
ΛΦ45/55 series
4-4
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
5. EATON FS/6309A GEARBOX
5.1 GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. You can also find
this data on the identity card for the vehicle
concerned.
Eaton gearbox type plate
1. Type of gearbox
2. Specification no. Eaton
3. DAF article Eaton code
4. Serial no. Eaton
5. Production date code
The Eaton specification number is unique to each
customer and gives detailed information on the
development level of the gearbox. The number
must be quoted whenever replacement parts are
ordered.
Eaton FS/6309A gearbox
0
2
3
41
5
V300378
Input shaft play of adjusting rings: Colour coding:
3.70 mm Red, green, white
3.75 mm Yellow, green, blue
3.80 mm Blue, green, white
3.85 mm Red, green, yellow
3.90 mm Green, green, white
3.95 mm Red, green, red
Secondary shaft pre-load
New bearings 0.075 - 0.125 mm
Original bearings 0.000 - 0.050 mm
Sealant
Gearbox housing front cover contact surfaces Loctite 518
Input shaft Lithium-based grease, class NLGI 3
Filter/governor
Governed pressure 5.3 - 5.7 bar
©
200508 5-1
TECHNICAL DATA
3
0
Eaton FS/6309A gearbox
5.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
M39 attachment nut 650 Nm
Drive flange oil seal housing attachment bolts 37 Nm
ΛΦ45/55 series
(1)
Gearbox front cover
Attachment bolts 37 Nm
Selector shaft housing
Selector shaft housing attachment bolts 37 Nm
M8 retaining cover attachment bolts 22 Nm
M8 shifting arm lock nut 25 Nm
M10 shifting arm lock nut 37 Nm
End cover attachment bolts 22 Nm
Bleeder 19 Nm
Bleed valve 22 Nm
Filter/governor
M6 attachment bolts 13 Nm
Cover 25 Nm
Plugs
Oil level check/filler plug 35 Nm
Drain plug 44 Nm
(1) Use new nut
(2) Use Loctite 243
(2)
5-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
5.3 FILLING CAPACITIES
Gearbox Contents
Eaton FS/6309A 8.5 litres
Eaton FS/6309A gearbox
0
©
200508 5-3
TECHNICAL DATA
3
0
Eaton FS/6309A gearbox
ΛΦ45/55 series
5-4
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
Allison 1000 & 2000 automatic gearboxes
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
6.1 GENERAL
Torque converter pilot bearing
Lubricant on installation Molykote BR2S or BR2 plus
0
©
200508 6-1
TECHNICAL DATA
3
0
Allison 1000 & 2000 automatic gearboxes
ΛΦ45/55 series
6.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Hydraulic pipes to oil cooler 25 Nm
Bolts attaching gearbox to flywheel housing 34 Nm
Flexplates
Flexplate adapter attachment bolts 64 Nm
Crankshaft attachment bolts 30 Nm + 60″ angular displacement
Selector switch
Attachment bolts 27 Nm
Attachment nut 24 Nm
Speed sensor
Attachment bolt 12 Nm
Oil sump
Attachment bolts 27 Nm
PTO cover
Attachment bolts 43 Nm
Plugs
Gearbox drain plug 35 Nm
Oil cooler drain plug 28 Nm
Oil cooler air bleed plug 28 Nm
Hydraulic lines
Attachment to gearbox 25 Nm
Drive flange
Attachment bolt 122 Nm
6-2
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
6.3 FILLING CAPACITIES
Gearbox Capacity
Allison 1000 & 2000 series Approx. 10 litre
Allison 1000 & 2000 automatic gearboxes
0
©
200508 6-3
TECHNICAL DATA
3
0
Allison 1000 & 2000 automatic gearboxes
ΛΦ45/55 series
6-4
©
200508
3
TECHNICAL DATA
ΛΦ45/55 series
Allison MD3060 automatic gearbox
7. ALLISON MD3060 AUTOMATIC GEARBOX
7.1 GENERAL
The Allison MD3060 automatic gearbox is
electronically controlled and has a diagnostics
system that can record possible 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. This selector keypad has a display and is
located next to the driver's seat; it replaces the
gear lever with manual gearboxes.
R
N
0
MODE
D
Torque converter pilot bearing
Lubricant on installation Molykote BR2S or BR2 Plus
V300392
©
200508 7-1
TECHNICAL DATA
3
0
Allison MD3060 automatic gearbox
7.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening torques
stated in the overview of the standard tightening
torques.
The other threaded connections not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Bleeder 14 Nm
Main connector 2.5 Nm
Coolant pipes 55 Nm
Rear mounting bracket 100 Nm
PTO bracket 55 Nm
Flywheel housing adapter, M10 x 1.5 55 Nm
ΛΦ45/55 series
Drive flange
Attachment bolt 75 Nm
Flexplates
Flexplate adapter attachment bolts 36 Nm
Torque converter attachment bolts 36 Nm
Oil cooler
Hydraulic lines 60 Nm
Plugs
Oil drain plug (1) 28 Nm
Oil filter cover attachment bolts (2) 55 Nm
2
1
V300371
7-2
©
200508
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