DAF LF45, LF55 Service manual

3

STRUCTURE

ΛΦ45/55 series

TECHNICAL DATA

DIAGNOSTICS

MECHANICAL GEARBOX CONTROL

PNEUMATIC GEARBOX CONTROL

ZF S5-42 GEARBOX

ZF 6S-850 GEARBOX

EATON FS/6309A GEARBOX

ALLISON 1000 & 2000 AUTOMATIC GEARBOXES

ALLISON MD 3060 AUTOMATIC GEARBOX

CLUTCH

PROP SHAFTS

© 200508

DW23259302

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4

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DAF LF Gearboxes and Clutch Service Manual

DAF LF Gearboxes and Clutch Service Manual

3			TECHNICAL DATA
ΛΦ45/55 series					Contents
CONTENTS
				Page	Date		0
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
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

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DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
Contents	ΛΦ45/55 series

0

2

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Mechanical gearbox control
1. MECHANICAL GEARBOX CONTROL
			0
1.1 GENERAL
Switch button
Locking compound	Loctite 243
Control rod
Lubricant	Molykote BR2S or BR2 plus

Control rod underneath the cab

A

				V3 00 563
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 00 564
Length B	60 - 62 mm
© 200508	1-1

DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA

Mechanical gearbox control

1.2 TIGHTENING TORQUES

0

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.

1-2

3

ΛΦ45/55 series

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Mechanical gearbox control

Operating mechanism, 2 adjustment options

0

1

2

3

4

V3 00 567

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

© 200508

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DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
Mechanical gearbox control	ΛΦ45/55 series

		Operating mechanism,
	0
		4 adjustment options

1

2

	3
	9
	4
	8
	7
	5
	6
	V3 00 566
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
Ball joint (8)
Attachment nuts	48 Nm
Lock nuts	48 Nm

1-4

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DAF LF Gearboxes and Clutch Service Manual

3		TECHNICAL DATA
ΛΦ45/55 series		Mechanical gearbox control
Torque rod (9)
				0
Attachment nuts	48 Nm
Gear lever unit	18 Nm (1)
Attachment bolts
Eaton switch button	70 Nm (1)
Attachment nut

(1) Use Loctite 243

© 200508

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DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
Mechanical gearbox control	ΛΦ45/55 series

0

1-6

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DAF LF Gearboxes and Clutch Service Manual

3		TECHNICAL DATA
ΛΦ45/55 series		Pneumatic gearbox control
2. PNEUMATIC GEARBOX CONTROL
				0
2.1 GENERAL
Filter/governor
Governed pressure	5.34 - 5.69 bar

© 200508

2-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA	3
		Pneumatic gearbox control	ΛΦ45/55 series
		2.2 TIGHTENING TORQUES
0
		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
		Range-change cylinder
		M8 cover attachment bolts	17 Nm
		M16 nut on piston	105 Nm
		Bleed valve
		Attachment	19 Nm
		Eaton switch button	70 Nm (1)
		Attachment nut

(1) Use Loctite 243

2-2

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	ZF S5-42 gearbox
3. ZF S5-42 GEARBOX
			0
3.1 GENERAL
Input shaft
Pre-tension	0.02 - 0.09 mm
Secondary shaft
Pre-tension	0.02 - 0.09 mm

© 200508

3-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA		3
		ZF S5-42 gearbox		ΛΦ45/55 series
		3.2 TIGHTENING TORQUES
0
		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		400 Nm (1)
		'Direct drive' attachment nut
		Overdrive attachment nut		330 Nm (2)
		Gearbox front cover
		Attachment bolts		23 Nm
		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

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	ZF S5-42 gearbox
3.3 FILLING CAPACITIES
			0
Gearbox	Capacity
S5-42	3.5 litres

© 200508

3-3

DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
ZF S5-42 gearbox	ΛΦ45/55 series

0

3-4

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	ZF 6S-850 gearbox

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

0

	1
3	2
	4
6	5
8	7

9

10

V300049

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

© 200508

4-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA	3
		ZF 6S-850 gearbox	ΛΦ45/55 series
		4.2 TIGHTENING TORQUES
0
		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
		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

DAF LF Gearboxes and Clutch Service Manual

3		TECHNICAL DATA
ΛΦ45/55 series		ZF 6S-850 gearbox
4.3 FILLING CAPACITIES
				0
Gearbox type	Filling amounts at oil change	First filling, e.g. on repair
	(litres)	(litres)
ZF 6S-850	7.5	7.5

© 200508

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DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
ZF 6S-850 gearbox	ΛΦ45/55 series

0

4-4

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Eaton FS/6309A gearbox

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.

Input shaft play of adjusting rings:

3.70 mm

3.75 mm

3.80 mm

3.85 mm

3.90 mm

3.95 mm

Secondary shaft pre-load

New bearings

Original bearings

Sealant

Gearbox housing front cover contact surfaces

Input shaft

Filter/governor

Governed pressure

0

	2
	3
1	4
	5
	V300378

Colour coding:

Red, green, white

Yellow, green, blue

Blue, green, white

Red, green, yellow

Green, green, white

Red, green, red

0.075 - 0.125 mm

0.000 - 0.050 mm

Loctite 518

Lithium-based grease, class NLGI 3

5.3 - 5.7 bar

© 200508

5-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA		3
		Eaton FS/6309A gearbox		ΛΦ45/55 series
		5.2 TIGHTENING TORQUES
0
		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	650 Nm(1)
		M39 attachment nut
		Drive flange oil seal housing attachment bolts	37 Nm
		Gearbox front cover
		Attachment bolts	37 Nm
		Selector shaft housing		Nm(2)
		Selector shaft housing attachment bolts	37
		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

5-2

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Eaton FS/6309A gearbox
5.3 FILLING CAPACITIES
			0
Gearbox	Contents
Eaton FS/6309A	8.5 litres

© 200508

5-3

DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
Eaton FS/6309A gearbox	ΛΦ45/55 series

0

5-4

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Allison 1000 & 2000 automatic gearboxes
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
			0
6.1 GENERAL
Torque converter pilot bearing
Lubricant on installation	Molykote BR2S or BR2 plus

© 200508

6-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA		3
		Allison 1000 & 2000 automatic gearboxes		ΛΦ45/55 series
		6.2 TIGHTENING TORQUES
0
		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

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Allison 1000 & 2000 automatic gearboxes
6.3 FILLING CAPACITIES
			0
Gearbox	Capacity
Allison 1000 & 2000 series	Approx. 10 litre

© 200508

6-3

DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA	3
Allison 1000 & 2000 automatic gearboxes	ΛΦ45/55 series

0

6-4

© 200508

DAF LF Gearboxes and Clutch Service Manual

3	TECHNICAL DATA
ΛΦ45/55 series	Allison MD3060 automatic gearbox
7. ALLISON MD3060 AUTOMATIC GEARBOX
			0
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 MODE

N

D

V300392

Torque converter pilot bearing
Lubricant on installation	Molykote BR2S or BR2 Plus

© 200508

7-1

DAF LF Gearboxes and Clutch Service Manual

		TECHNICAL DATA	3
		Allison MD3060 automatic gearbox	ΛΦ45/55 series
		7.2 TIGHTENING TORQUES
0
		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
		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
			2

1

V300371

Plugs
Oil drain plug (1)	28 Nm
Oil filter cover attachment bolts (2)	55 Nm

7-2

© 200508

DAF LF Gearboxes and Clutch Service Manual