GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
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Gearbox
EuroTronic 12 AS 2301 D.D./O.D.
Page
DESCRIPTION 115. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA 116. . . . . . . . . . . . .
TIGHTENING TORQUES 119. . . . . . . . . . . . . . . . .
TOOLS 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE GEARBOX 125. . . . . . . . . . .
- Checks 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Gearbox actuator 125. . . . . . . . . . . . . . . . . . . . . .
- Removal 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing the rear box 126. . . . . . . . . . . . . . . . . .
- Removing the rear box 127. . . . . . . . . . . . . . . . . .
- Removing the epicyclic reduction
gear train (E.R.G.) 128. . . . . . . . . . . . . . . . . . . . . .
- Fitting the epicyclic reduction gear train (E.R.G.) 130
- Adjusting epicyclic reduction gear train bearing
end float 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting main shaft end float 132. . . . . . . . . . . . .
- Synchronizing device assembly for engaging
normal or reduced gears 134. . . . . . . . . . . . . . . . .
- Removal 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing the middle box 137. . . . . . . . . . . . . . . .
- Removing the main shaft 139. . . . . . . . . . . . . . . . .
- Removing the drive input shaft 141. . . . . . . . . . . .
- Removing the splitter synchronizing device 142. . .
- Fitting the splitter synchronizing device 143. . . . . .
- Fitting the drive input shaft 144. . . . . . . . . . . . . . .
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Page
- Fitting the main shaft 144. . . . . . . . . . . . . . . . . . . .
- Splitter control fork 147. . . . . . . . . . . . . . . . . . . .
- Disassembly - Assembly 147. . . . . . . . . . . . . . . . .
- Gear control forks 147. . . . . . . . . . . . . . . . . . . . .
- Removal 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Transmission shafts 149. . . . . . . . . . . . . . . . . . . . .
- Disassembly - Assembly 149. . . . . . . . . . . . . . . . .
- Fitting the middle box 149. . . . . . . . . . . . . . . . . . .
- Fitting the front box 152. . . . . . . . . . . . . . . . . . . .
- Front cover 154. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting the front cover 154. . . . . . . . . . . . . . . . . . .
- Adjusting drive input shaft bearing end float 154. .
- Adjusting transmission shaft bearing end float 155
- Clutch release lever 157. . . . . . . . . . . . . . . . . . . .
DESCRIPTION
The EuroTronic gearbox 12 AS 2301 D.D./O.D. is mechanical with electro-pneumatic control.
The driver can choose whether to program gear selection/engagement manually or automatically. The shafts and gears have
helical toothing that reduces operating noise.
The main shaft gear coupling is obtained with sleeves with front toothing.
The splitter and epicyclic reduction gear unit engagement is synchronized.
The speeds are selected with finely staggered ratios and can be engaged in succession with the coupling of the epicyclic reduction
gear unit ”ERG” and the ”Splitter” slow or fast speed unit.
On engaging the ”ERG”, the speeds of the main shaft are doubled. The ratios obtained in this way are further doubled with the
engagement of the ”Splitter”. Each single ratio is thus divided into a fast or slow ratio.
D.D. = Direct drive
O.D. = Over Drive (Multiplied)
Figure 1
000418 t
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
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SPECIFICATIONS AND DATA
GEARBOXES EuroTronic Automated
12 AS 2301 D.D. 12 AS 2301 O.D.
Type Mechanical
Torque activated Nm
1900 2500
Forward gears
Reverse gears
12
2
Type of running control electronically-operated semi-automatic
Rear power takeoff optional
Gear engagement:
E.R.U.* and splitter engagement
by front engagement sleeves
free ring synchroniser
Gears constantly engaged straight toothed
Gear ratios
1
a
2
a
3
a
4
a
5
a
6
a
7
a
8
a
9
a
10
a
11
a
12
a
1aRM
2
a
RM
15.85
12.32
9.56
7.43
5.87
4.56
3.47
2.70
2.09
1.62
1.28
1.00
14.68
11.41
12.33
9.59
7.44
5.78
4.57
3.55
2.70
2.10
1.63
1.27
1.00
0.78
11.41
8.88
ERG* = Epicyclic Reduction Gearing
D.D. = Direct drive
O.D. = Over Drive (Multiplied)
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
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SPECIFICATIONS AND DATA
EuroTronic Automated
12 AS 2301 D.D./O.D.
Bearings
- drive input shaft
- ERG* shaft
- transmission shafts
with balls
with cylindrical rollers
with tapered rollers
Bearing end float:
- drive input shaft
- ERG* planet shaft
- transmission shafts
0 y 0.1 mm
0 y 0.1 mm
- 0.05 y + 0.05 mm
End float:
- main shaft
- drive input shaft split ring
0.2 mm
0 y 0.1 mm
Temperature for fitting bearings or bearing
seats on the boxes
120 qC
Forced lubrication with positive displacement pump flow rate (with 12
th
speed en-
gaged and oil at a temperature of 80ºC)
pressure with 12thspeed engaged at 2400
rpm and oil at a temperature of:
40ºC
80ºC
50 dm3/min
1.7 bar
1.2 bar
Oil type
litres
kg
Tutela Truck Fe-Gear
Tutela ZC 90
12
11
ERG* = Epicyclic Reduction Gearing
D.D. = Direct drive
O.D. = Over Drive (Multiplied)
Figure 2
LONGITUDINAL CROSS-SECTION OF EUROTRONIC 12AS 2301 GEARBOX
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TIGHTENING TORQUES
TORQUE
DESCRIPTION
Nm kgm
1 Screws fixing gearbox actuator 23 2.3
2 Screw fixing oil pump 10 1
3 Screws fixing drive input shaft cover 23 2.3
4
Screw fixing clutch uncoupling lever control pin:
- M 12 8.8
- M 12 10.9
79
115
7.9
11.5
5 Screws fixing cover (spread LOCTITE 241 on the thread) 79 7.9
6 Screws fixing clutch actuator 23 2.3
7 Screw cap to discharge air from clutch actuator 22 2.2
8 Screws fixing rear box to middle box 46 4.6
9 Screws fixing flange retaining plate 120 12
10 Screws fixing rear cover 5 4.6
11 Speed sensor 45 4.5
12 Screws fixing middle box to front box 50 5
Pin on rod (spread LOCTITE 262 on the thread) 23 2.3
Oil vapour vent 10 1
Screw plug M 10x1 on rear box 15 1.5
Screw plug M 24x1 on rear box 60 6
Screw M12 fixing power take-off bay cover 79 7.9
Screw plug M 24x1.5 on middle box 60 6
Screw fixing plates retaining fork joint pins on rear box 23 2.3
70824
Figure 3
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TOOLS
TOOL NO. DESCRIPTION
Hot air device
99305121
99322205
Rotary stand for overhauling assemblies
99322225
Mount to support assemblies (to fit onto stand 99322205)
99341003
Single-acting bridge
99341013
Reaction block
99341015
Clamp
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TOOLS
TOOL NO. DESCRIPTION
99341018
Pair of brackets with hole
99345057
Extractor reaction block
99345078
Extractor to remove drive input shaft bearing (use with 99345105)
993450998
Inserter to fit bearing on main shaft, rear side and to insert rear flange
of gearbox
99345105
Extractor for gearbox drive input shaft bearing (use with 99345078)
99347100
Small extractor (use with specific rings with 99347132)
122
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TOOLS
TOOL NO. DESCRIPTION
99347132
Ring grips to extract gearbox transmission shaft bearings (use with
99345057 - 99347100)
99360323
Tool to turn drive input shaft when refitting the gearbox to the
engine
99360526
Tool to extract and insert main shaft (use with 99360527) and to
drive in gearbox drive input shaft bearing (use with 99345098)
99360527
Tool retaining gearbox main shaft forks (use with 99360526)
99366811
Set of M10 eyebolts (3) to remove and refit gearboxes
99370006
Grip for interchangeable drifts
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 123
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TOOLS
TOOL NO. DESCRIPTION
99370007
Grip for interchangeable drifts
99370153
Tool for positioning main shaft when removing the transmission
shafts and for retaining gearbox reverse gear pins
99370172
Tools (6) to mount gearbox epicyclic reduction gear train
synchronizer rings
99370317
Reaction lever with extension to fasten drive output flange
99370415
Dial gauge base to adjust transmission shaft bearings (use with
99395604)
99370499
Guides (no. 3) to mount Splitter synchronizing device assembly
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TOOLS
TOOL NO. DESCRIPTION
99370629
Mount to support gearbox when removing and fitting it back on the
vehicle
99374092
Drift to mount outer races of bearings (69 y 91) (use with
99370007)
99374221
Driver to mount seals on back cover
99374336
Driver to fit seals on the front cover of the gearbox (use with
99370006)
99395604
Dial gauge (0 - 10 mm)
Figure 4
Checks
The gears, synchronizer rings, coupling bodies and sliding
couplings must show no sign of failure or excessive toothing
wear.
The main shaft must have no indentation, especially on the
sliding surfaces of the gear rotation and coupling sleeves.
The reverse idle gear shafts must have a polished surface free
from scoring.
The gearboxes must show no sign of cracking and the bearing
seats must be neither damaged nor worn, so as to prevent the
outer rings of the bearings from turning in their seats.
Check the shoulder spacers are neither worn nor damaged.
The gear coupling forks must show no sign of cracking and the
relevant control rods must slide freely, but without any
appreciable play, in their guide seats.
Check that the shoes of the drive forks are fully efficient.
Check that the holes, grooves and lubrication pipes are not
obstructed by grease or foreign bodies.
Check the bearings are not worn, damaged or overheated.
530210 OVERHAULING THE
GEARBOX
!
Wash the assembly thoroughly before overhauling.
The specific and/or general tools must be used in the
way for which they were designed.
To facilitate assembly, put the removed parts away on
the specific tray in their order of removal.
Upon assembly, the following must always be
replaced with new parts: the gaskets and seals, spring
pins, safety plates and springs. Nuts and screws must
be tightened to the prescribed torque with their
thread dry and degreased.
Keep to the specific regulations when disposing of
lubricant and detergents.
530520 Gearbox actuator
Removal
Unscrew the ring nut (1 and 5) and disconnect the electric
wiring (2) from the speed sensor (6 and 7).
Detach the wiring (2) from the clips (o) securing it to the
middle box.
Remove the nuts (4) and detach the actuator (3) from the
front box.
Figure 5
78649
78650
Fasten the gearbox (1) to brackets 99322225 (3) on the
rotating stand 99322205 (2).
Remove the plug and bleed the lubrication oil.
The following described and illustrated overhaul
operations regard transmission 16 A6 2601 and, save
different indications, are valid also for transmission 12
AS 2301.
!
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70863
70830
Figure 6
Figure 7
Figure 8
Figure 9
Set a new gasket (6) on the front case (7).
Lubricate the stems of the solenoid valves (3-4-5) with silicone
grease and put them into a neutral position. Put the rods
(8-9-10) into a neutral position. Fit the actuator (1) on the
front box (7) verifying thatthe end of the stems of the solenoid
valves is correctly positioned in the seats of the rods (8-9-10).
Tighten the fixing screws (2) to the prescribed torque. After
removing the gearbox from the stand used for overhaul, refit
the clutch actuator (3, Figure 4) and make sure the wiring (2,
Figure 4) is not damaged.
Extract the springs (6-7-8) and the pawls (6).
Block rotation of the sleeve (1) by applying the lever
99370317 (3) and slightly loosen the screws (2).
!
The springs (7 and 8) are of equal length, the spring
(6) is larger.
Remove the pin (4) from the rod (5).
Remove the switch (1) together with the gasket (2) and
extract the cap (3).
78651
Take out the screws (2) and detach the actuator (1) with its
gasket.
!
The electronic control unit is integrated in the
actuator and these cannot be overhauled. See under
the diagnosis heading for the check.
Check that the oil vapour vent (3) is not clogged; if it is, clean
it.
Disconnect speed actuators (1) as described in the relevant
chapter.
Refitting
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Removing the rear box
70831
70832
70833
70834
70835
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Remove the screws (1) fixing the plates (2) fastening the pins
(4) and extract these together with the seal (3) from the rear
box (7).
Extract the two centring pins (5). Remove the screws (6).
Fit the eyebolt 99366811 to the sleeve (8) and, using special
ropes and lifter, detach the rear box (7) from the middle one
(9).
Remove the oil pipe (1). Note down the assembly position of
the fork (3) and plugs (6) and remove them. Remove: the rod
(2), synchronizing device assembly (4) and connecting sleeve
(5).
Remove the adjustment ring (3) and the plate (1) together
with the coupling body (2).
Removing the rear box
Remove the screws (3), disc (4) and seal (5) and extract the
sleeve (2) from the spider shaft. Should extraction prove
difficult, use an extractor (1) applied as illustrated in the figure.
Remove the screws (2) andtake off the cover (1). Remove the
spider shaft bearing end float adjustment ring (3).
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45946
70837
70836
70838
70839
70840
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Using a press, extract the spider shaft (1) from the supporting
roller bearing (2). Turn the rear box (3) upside-down and
extract the roller bearing (2).
Removing the epicyclic reduction gear train
(E.R.G.)
Using a screwdriver, remove the circlip (3) fastening the ring
gear with internal toothing (4) to the ring gear with external
toothing (2) and remove them from the E.R.G. (1).
Extract the toothed ring (2) from the ring gear with internal
toothing (1).
Using pliers (2), tighten the ends of the circlip (3) and remove
the coupling body (4) from the E.R.G. shaft (1).
Using a punch, extract the pins (5) from the spider shaft (6).
Remove the planetary gears (3) from the spider shaft (6),
together with the rollers (2) and shim adjustment rings (1 and
4).
Extract the toothed shaft (3) from the spider shaft (1) together
with the rings (2).
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70841
70843
70842
Figure 21 Figure 22
Extract one of the pins (1) from the toothed shaft (2) and
extract the rings (3) from this.
Using a suitable extractor, remove the roller bearing ring (1)
from the spider shaft (2).
Using a punch, extract the disc (3) from the inside of the spider
shaft (2).
PARTS COMPRISING THE E.R.G.
1. Circlip - 2. Ring gear with external toothing - 3. Toothed ring - 4. Ring gear with internal toothing - 5. Bearing - 6. Circlip - 7.
Circlip - 8. Coupling body - 9. Pins - 10. Ring - 11. Toothed spindle - 12. Disc - 13. Spider shaft - 14. Pin - 15. Shim adjustment
ring - 16. Rollers - 17. Shim adjustment ring - 18. Planetary gear.
Figure 23
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70840
70845
70982
70838
70983
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Heat the inside ring (2) of the roller bearing to 120qC and fit
it on the spider shaft (3).
Fit on the circlip (1). Fit on the disc (4).
Drive the rings (1 and 3) onto the toothed spindle (2) and fit
on the pin (4).
Insert the spindle (3) together with the rings (2) onto the
spider shaft (1).
Smear grease into the hole of the planetary gear (5) and insert
the rollers (3) with the associated shim adjustment rings (2 and
4). Fit the planetary gears (5) onto the spider shaft (6),
fastening them to it with the pins (1).
Using pliers (2), tighten the ends of the circlip (3) and fit the
coupling body (4) onto the E.R.G. shaft (1).
Fit the ring gear with internal toothing (5) onto the spider shaft
(3) together with the toothed ring (4), and the ring gear with
external toothing (2) and fasten the two ring gears with the
circlip (1).
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Fitting the epicyclic reduction gear train (E.R.G.)
45951
45943
70847
Figure 30
Figure 31
Figure 32
Heat the seat of the bearing (1) of the rear box (2) to 120qC
and mount the bearing (1).
Rest the spider shaft (1) on an appropriate spacer.
Heat the inside ring of the bearing (2) to 120qC and drive it
together with the rear box (3) onto the spider shaft (1).
Determine the ball bearing end float adjustment thickness (3)
by proceeding as follows:
- measure the depth of the seat on the cover (1) of the
bearing (3), distance A;
- measure the protrusion of the bearing (3) from the
surface of the rear box (2), distance B.
The thickness S of the adjustment ring is determined by the
following equation:
S = (A - B) - C
Where:
A and B = measurements
C = end float 0y0.1 mm
For example:
A = 5.4 mm
B = 5 mm
C = 0y0.1 mm
S = (5.4 - 5) - (0y0.1 mm) = 0.3 y 0.4 mm
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 131
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Adjusting epicyclic reduction gear train bearing
end float
45954
70848
70849
70850
Figure 33
Figure 34
Figure 35
Figure 36
Using the driver 99374221 (1), fit the seal (2) in the cover (3).
Mount the adjustment ring (1), of the thickness determined in
the preceding measurement, on the bearing (2, Figure 31) of
the spider shaft (3).
Spread IVECO sealant 1905685 on the mating surface of the
cover (4) with the box (5) and fit it onto the box, tightening
the screws (2) to the prescribed torque.
Heat the sleeve (1) to 90qC and fit it onto the spider shaft (1).
Fit on a new seal (4), the disc (3) and screws (2) and tighten
them to the prescribed torque.
Adjusting main shaft end float
Position two calibrated blocks (2) on the rear box (4). Place
a calibrated rule (1) on them and, using a depth gauge (3),
measure the distance between the top side of the rule and the
end of the spider shaft (5), distance A.
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70851
70852
Figure 37
Figure 38
Fit the connecting sleeve (7) together with the circlip (5) on
the main shaft (6).
Position two calibrated blocks (2) on the middle box (4) and
place a calibrated rule (1) on them.
!
The calibrated blocks and rule must be the same ones
used in the preceding measurement.
Using a depth gauge (3), measure the distance between the
top end of the circlip (5) and the top side of the calibrated rule
(1), distance B.
The thickness S of the main shaft end float adjustment ring is
determined by the following equation:
S = (A - B) - 2
For your information (see Figure 39), subtracting the thickness
of the calibrated blocks and rule:
- from the distance A gives the distance X corresponding
to the distance between the end of the spider shaft (2)
from the mating surface of the rear box (1).
- from the distance B gives the distance Y corresponding
to the distance between the circlip (4) and the mating
surface of the middle box (3).
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Position the adjustment ring (2) (of the thickness determined
in the preceding measurements) on the main shaft (5). Mount
the connecting sleeve (1) and the tube (4).
Mount the plate (6) together with the coupling body (3).
70853
70854
70855
70856
70857
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Synchronizing device assembly for engaging
normal or reduced gears
Removal
1. Synchronizing device assembly - 2. Synchronizing device
ring - 3. Sliding sleeve - 4. Pawl - 5. Spring -
6. Synchronizing device ring.
Put a cloth on the synchronizing device assembly (1) so that,
when dismantlingit, the springs (5) and pawls (4) are held back
as they come out of their seats.
Put the springs (2) and pawls (3) into the seats of the
synchronizing device rings (1) and fasten them with the tools
99370172 (4).
Position the synchronizing device ring (2) on the synchronizing
device ring (3) so that it is possible to fit the sliding sleeve (1)
onto them. On completing assembly, remove the tools
99370172 (4).
Fit the synchronizing device assembly (1) on the coupling body
(3, Figure 39) with the ring groove (o) facing downwards.
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Fitting
70858
70860
70859
70831
70862
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Position the fork (1) with the plugs (3) and the reliefs(') facing
as illustrated in the figure.
Fit on the rod (4) and connect it to the fork (1). Fit on the oil
pipe (2).
Take out the screws (1) and remove the cover (2) with its seal
(3). Remove the screw (4) with the washer (5).
Spread IVECO sealant 1905685 onto the mating surface of
the middle box (6). Fit the eyebolts 99368811 (1) to the
sleeve (2). Using ropes and a lifter, position the rear box (4)
coaxially to the middle one (6).
Screw down the screws (6) without tightening them; insert the
centring pins (5) and tighten the screws (6) to the prescribed
torque.
Fit the fork joint pins (4) with fresh seals (3) and tighten the
screws (1) fixing the fastening plates (2) to the prescribed
torque.
Fit: the screw (4) with a new washer (5) and tighten it to the
prescribed torque.
Fit the cover (2) with a fresh seal (3) and tighten the fixing
screws (1) to the prescribed torque.
Block rotation of the sleeve (7) by applying the lever
99370317 (8) and tighten the fixing screws (6) to the
prescribed torque.
Insert the rod (3) of appropriate diameter in the hole for the
screw (4, Figure 45) and in the oil pipe (5) to guide this into
its seat, while lowering the rear box (4). Lower the rear box
(4), paying attention that the spider shaft, oil pipe (5) and rod
(7) go into their seat correctly.
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78299
70864
Figure 49 Figure 50
Fit the cap (3) and the switch (1) with a new gasket (2). Spread
LOCTITE 262 onto the thread of the pin (4), screw it onto the
rod (5) and tighten them to the prescribed torque.
Fit the pawls (9) and the springs (6-7-8).
Refit the gear actuator (1) as described under the relevant
heading.
Connect the electric wiring (2) to the speedsensor (6), tighten
the fixing ring nut (5) and secure the wiring (2) to the box by
inserting it in the clips (o).
Remove the transmission from the rotating stand.
Refit the clutch actuator (3) and tighten the nuts (4) to the
prescribed torque.
COMPONENT PARTS OF THE REAR BOX OF THE EPICYCLIC REDUCTION GEAR TRAIN
!
The springs (7 - 8) are of equal length, the spring (6)
is larger.
Figure 51
136
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Base - January 2003 Print 603.93.141
70865
78301
78302
78300
70870
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Detach the gear actuator and the rear box as described under
the relevant headings. Remove the E.R.G. drive rod (4),
connecting sleeve (5), adjustment ring (3) and the plate (1)
together with the coupling body (2).
Fit the plate 99370153 (1) to the middle box (2) so that the
groove inside the plate coincides with the key (5) of the main
shaft (6).
Fasten the pins (4) by fitting the brackets (3) of the plate
99370153 to the middle box (2).
Turn the gearbox through 180q.
Take out the screws (2) and remove the pin (3) in the joint
of the clutch uncoupling lever (1) with this lever.
Remove the screws (4) fixing the front cover (5) to the front
box.
Screw down two screws (1) into the front cover (2) and
detach this from the front box (3).
Remove the cap (3), the spring (4) from the transmission shaft
(5) and the adjustment rings (1-2-6).
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 137
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Removing the middle box
70871
78303
78306
70875
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Remove the circlip (4) fastening the bearing (1) to the drive
input shaft (3). Remove the circlip (2) from the bearing (1).
Using the extractors 99345078 (1) and 99345105 (2), extract
the ball bearing (4) from the drive input shaft (3).
Remove the speed sensor (5) and the cap (4) beneath.
Take out the four centring pins (1).
Remove the screws (2) fixing the middle box (6) to the front
box (3).
Fit the eyebolt 99366811 (1) onto the front box (2). Using
special ropes and a hoist, detach the front box (2) from the
middle one (3).
Take out the screws (1) and remove the brackets (2) of the
plate 99370153. Extract the reverse gear pins (3) from the
middle box (4).
Remove the phonic wheel (2) from the drive input shaft (1).
Extract the oil pipes (4-6) from the middle box (7).
Spread apart the transmission shafts (3-5) and remove them
from the middle box (7).
78305
78304
!
To perform the following operations, the gearbox
must be positioned as shown in Figure 62 in order to
avoid any chance of the transmission shafts falling.
138
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70876
70877
Figure 63
Figure 64
Figure 65
Figure 66
Fit tool 99360527 (1) onto the drive input shaft (9) and the
rods (2 and 3); fit parts (6-7 and 8) of tool 99360526 (4) onto
the drive input shaft (9).
Hook tool 899360526 (4) onto the lifter and extract the main
shaft (5) together with the drive input shaft (9) and rods (2and
3) from the supporting bearing.
Remove the reverse gears (3) together with the roller
bearings (2).
Remove the plate 99370153 (4).
If replacement is necessary, remove the centring pins (1).
Turn the middle box (1) upside-down, remove the circlip (2)
and, working from inside the box, remove the roller bearing
(4).
Using a punch, and operating through the openings (o) of the
middle box (1), remove the external rings (3) of the tapered
roller bearings for transmission shafts.
Clamp the main shaft (6) in a vice and remove tool 99360526
(1) and 99360527 (2).
Remove the rods (3 and 4) with the relevant forks.
78307
!
Before removing the pins (1) heat the seats of the box
to ~ 90qC.
!
To remove the fork (5), the ring of the synchronizing
device has to be in the middle position.
Removing the main shaft
78308
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 139
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70881
70882
Figure 67 Figure 68
Through the bay of the coupling sleeve (1), using suitable
pliers, tighten the ends of the circlip (2) and remove the drive
input shaft (3) from the main shaft (4), see Figure 68.
Remove the coupling sleeve (1) and the tube (2) from the
main shaft (4).
Turn the main shaft (3) upside-down andremove the coupling
sleeve (4) from it; remove the key (5) from the hole (o) in
the shaft (3) and extract it.
Extract:
- spacer (6);
- reverse gear (7);
- spacers (8 and 9) *;
- gear (10) *;
- spacer (11);
- coupling sleeve (12);
- spacer (13);
- 2
nd
gear (14);
- spacers (15 and 16);
- gear (17);
- spacer (18);
- tube (19).
* 16 AS 2601 only
!
To extract the shoulder spacers (6 - 8 * - 9 * - 11 13 - 15 - 16 - 18) it is necessary to turn them so that
their toothing is with the grooves of the shaft (3).
*
*
*
140
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70883
70885
70884
70886
Figure 69
Figure 70
Figure 71
Figure 72
If necessary, remove the circlips (1) from the gears (7 - 10 14 - 17, Figure 68) and extract the toothed ring (2).
Removing the drive input shaft
Extract the ring (2), key (3) and gear (4) from the drive input
shaft (1).
Turn the drive input shaft (1) upside-down, lift the notches
(o) of the safety cover (2) and take it off.
Remove the half rings (2) from the drive input shaft (1) and
extract from it:
- thrust washer (3);
- thrust bearing (4);
- bushing (6) together with circlip (5);
- thrust washer (7);
- thrust bearing (8);
- gear (9);
- thrust bearing (10);
- thrust washer (11);
- synchronizing device assembly (12).
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 141
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70887
70889
70888
Figure 73
Figure 74
Figure 75
If necessary, remove the circlips (1-3) from the gear (4) and
extract the toothed ring (2).
Put the synchronizing device assembly (1) on the workbench,
cover it with a cloth to prevent the pins (8) and springs (7)
getting lost during subsequent dismantling.
Holding back the synchronizing device ring (6), lift the
synchronizing device ring (2); these will get freed: toothed ring
(5), three clips (7) and three pins (8).
Remove the key (4) and extract the toothed sleeve (3) from
the toothed ring (5).
COMPONENT PARTS OF THE DRIVE INPUT SHAFT
142
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Removing the splitter synchronizing device
70759
70891
Figure 76
Figure 77
Fitting the splitter synchronizing device
Insert the three springs (7) and three pins (8) in the
synchronizing device ring (1) and keep them in their seat with
the centring pins 99370499 (2).
Position the toothed ring (4) on the synchronizing device ring
(6). Fit the synchronizing device ring (1) in the toothed ring (4)
and on the synchronizing device ring (6) so that the centring
pins 99370499 (2) drive onto the pins (5) of the synchronizing
device ring (6). Press on the synchronizing device ring (1)
uniformly so that the components of the assembly fit together
correctly. Take out the centring pins (2).
Insert the toothed sleeve (1) in the toothed ring (2) so that the race between the two toothings corresponds to the inside toothing
of the ring (2) and allows it to rotate.
Turn the sleeve (1) so that the hole in it coincides with one of the three bays (o) of the toothed ring (1).
Then insert the key (3) as shown in the figure.
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 143
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70892
70885
70884
70893
Figure 78
Figure 79
Figure 80
Figure 81
On the drive input shaft (1), fit:
- synchronizing device assembly (15);
- thrust washer (14);
- thrust bearing (13);
- gear (10) together with circlips (9 and 12) and toothed
ring (11);
- thrust bearing (8);
- thrust washer (7);
- bushing (6) with circlip (5);
- thrust bearing (4);
- thrust washer (3);
- half rings (2).
Fit on a new safety cover (2) and notch it (o) at three/four
equidistant points. Turn over the drive input shaft (1).
On the drive input shaft (1), fit: gear (4), key (3) and thrust
washer (2).
Fitting the drive input shaft
In the gears (4), fit: Reverse — 1st— 2nd— 3rdgears and toothed
rings (2) and fasten them to the gears with the circlips (1 and
3).
144
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Fitting the main shaft
78309
78310
78311
78312
Figure 82
Figure 83
Figure 84
Figure 85
Clamp the main shaft (2) in a vice. Fit on the tube (1). Put the
shoulder spacer (3) in the ring groove (o). Turn the spacer
(3) so that its internal toothing rests on that of the main shaft
(2).
Insert the key (4) in the spacer (3) so as to prevent rotation
and keep it in position.
Mount the 3
rd
speed gear (2), put the spacer (4) in the ring
groove (o). Turn the spacer (4) so that its internal toothing
rests on that of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position.
Put the spacer (3) in the ring groove (o). Turn the spacer (3)
so that its internal toothing rests on that of the main shaft (1).
Insert the key (2) in the spacer and keep it in position.
Mount the 2
nd
speed gear (2), put the spacer (4) in the ring
groove (o). Turn the spacer (4) so that its internal toothing
rests on that of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position.
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 145
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78314
78315
78316
78317
Figure 86
Figure 87
Figure 88
Figure 89
Fit on the 1
st/2nd
gear coupling sleeve (1) with the larger
internal groove (o) turned to the side of the key (2).
Put the spacer (3) in the ring groove (o). Turn the spacer (3)
so that its internal toothing rests on that of the main shaft (1).
Insert the key (2) in the spacer (3) and keep it in position.
For 16 AS 2061 gearboxes only, fit on the gear (2). Put the
spacer (5) in the ring groove (o) so that its internal toothing
rests on that of the main shaft (1). Put the spacer (4) in the ring
groove (o) so that its internal toothing rests on that of the
main shaft (1).
Insert the key (3) in the spacers (4 and 5) and keep it in
position.
For all gearboxes, fit on the reverse gear (2). Put the spacer
(4) in the ring groove (o) so that its internal toothing rests on
that of the main shaft (1).
Extract the key (3) and insert it from the top side of the shaft
(1) in the groove on this and in all the spacers, so that its bent
portion goes into the hole (o) of the shaft (1).
146
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70902
70904
70903
70879
70905
Figure 90
Figure 91
Figure 92
Figure 93
Figure 94
Fit on the reverse gear coupling sleeve (3) with the bay (2)
coinciding with the key (1).
Turn over the main shaft (2) and fit on the sleeve (1) with the
bay (4) coinciding with the key (5).
Fit on the tube (3).
Using suitable pliers, tighten the ends of the circlip (2) and fit
the drive input shaft (1) onto the main shaft (3).
Splitter control fork
Disassembly - Assembly
Extract the plugs (2) from the splitter synchronizing device
coupling fork (1) and fit on the new plugs.
Gear control forks
Removal
Dismantle the gear control fork assembly (1), suitably adjusting
the ring (3) to prevent the gears simultaneously coupling and
extracting from the rod (7): the coupling fork (6)*, pin (7),
coupling fork (5), fork (2) and ring (3).
* 16 AS 2601 gearbox only
!
Make sure thatthe circlip (2) gets correctly positioned
in the seat of the main shaft (3).
*
*
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 147
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70760
70761
70762
70763
Figure 95
Figure 96
Figure 97
Figure 98
Insert the pin (1) in the seat on the rod (3). Drive the reverse
gear coupling fork (2) onto the rod (3), adjusting it so that the
pin (1) gets positioned in the bay (o) of the fork (2).
Drive the ring (1) and the 1
st/2nd
gear coupling fork (3) onto
the rod (2). Position the fork (3) in the ring (1) so that on
turning it the bay (o) of the fork (3) is inserted in the ring (1).
16 AS 2601 gearbox only, drive the 3
rd/4th
gear coupling fork
(1) onto the rod (2).
Position the fork (1) in the ring (3) so that on turning it the bay
(o) of the fork (1) is inserted in the ring (3).
Position the fork assembly (2*-3) and the ring (1) assembled
in this way so that the bay (o) of the reverse gear coupling
fork (4) is inserted in the ring (1).
* 16 AS 2601 gearbox only
148
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Fitting
70906
78318
78319
70909
Figure 99
Figure 100
Figure 101
Figure 102
Remove the inside rings (1-3) of the roller bearings from the
transmission shaft (2), using the extractor 99347100 (4), grips
993471132 (6) and plug 99345057 (5).
To fit the rings (1 - 3) on the shaft (2) it is necessary to first
heat them to 120qC.
Heat the seat (3) of the cylindrical roller bearing (1) to ~ 90qC,
fit this and fasten it to the middle box with the circlip (2).
If removed, refit the centring pins (4) after heating the seats
of the box to ~ 90qC.
Fit the plate 99370153 (2) onto the middle box (1).
From inside the box (1), heat the seats of the rings (4) to ~
90qC, transmission shaft bearings. Fit on the rings (4) with
driver 99370092 (3) and grip 99370007 (2).
Place the reverse gears (1) together with the roller bearings
(2) in the middle box.
70910
Figure 103
Fitting the middle box
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Transmission shafts
Disassembly - Assembly
70913
70912
78320
70915
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Fit the fork assembly (1) onto the main shaft (2), verifying that
the forks are correctly positioned on their respective coupling
sleeves.
Mount the splitter coupling fork (1) positioning the plugs (2)
on the toothed coupling ring (3).
Fit tool 99360527 (1) onto the drive input shaft (8) and the
rods (2 and 3). Fit parts (5-6-7) of tool 99360526 (4) onto the
drive input shaft (8).
Hook the tool 99360526 (1) onto the lifter and fit the main
shaft assembly (5) in the gearbox, verifying that the shaft (5)
and the rods (3 and 4) get correctly inserted in their seats.
Remove the tools 99360526 (1) and 99360527 (2).
Mount the transmission shafts (1 and 3) so that on joining
them to the main shaft (2) the marks stamped on them are
aligned. Use the slots (o) of the phonic wheel (4) to check
this.
70911
150
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
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78305
70917
Figure 109 Figure 110
Insert the pins (3) in the middle box (4) and in the reverse
gears (1, Figure 103), fastening them to the box (4) with the
brackets (2) of plate 99370153 and the screws (1).
Fit on the oil pipes (1 and 2).
COMPONENT PARTS OF THE MIDDLE BOX
* For the 16 AS 2601 gearbox only
!
With no gears engaged, the shafts must turn freely,
otherwise the alignment of the marks (see
Figure 108) will not be correct.
70916
Figure 111
!
To perform the following operations, the gearbox
must be positioned as shown in Figure 110 in order
to avoid any chance of the reverse gears falling.
*
*
*
*
*
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 151
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Print 603.93.141 Base - January 2003
70918
Figure 112
COMPONENT PARTS OF THE FRONT BOX
152
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Fitting the front box
70819
70920
70921
78304
Figure 113
Figure 114
Figure 115
Figure 116
Remove the screw (1), lift the cover (2), remove the vents (3)
and clean them or replace them.
Then reassemble the parts.
Carefully clean the oil filter (6) and fit it back in its seat.
If the plugs (4) have been removed, it is necessary to fit them
back on with new seals (5).
Heat the front box (1) to 90qC in correspondence with the
seats for the external rings (2 and 3) of the tapered roller
bearings and fit these on.
Spread IVECO sealant 1905685 onto the mating surface of
the middle box (5).
Fit the eyebolt 99368811 (1) onto the front box (2).
Using ropes and a hoist, lift the box (2) and position it coaxially
to the middle box (5).
Insert the rods (6), of suitable diameter, into the seats in the
front box (2) of the oil pipes (7 and 8) and into these too.
Lower the box (2) checking that the rods (3 and 4) and the
oil pipes (7 and 8) are correctly inserted in their seat.
Remove the eyebolt (1) and the guide rods (6).
Screw down the screws (2) fixing the front box (3) to the
middle box (6). Insert the centring pins (1) and tighten the
screws (2) to the prescribed torque.
Mount the cap (4) and the speed sensor (5), tightening it to
the prescribed torque.
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 153
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70922
70985
70871
70924
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Using the tools 99345098 (1) comprising parts (3-4 and 5) and
99360526 comprising parts (6-7 and 8), fit the ball bearing
(11) on the drive input shaft (9) and in the front box (10).
Fit the circlip (4) fastening the bearing (1) to the drive input
shaft (3).
Fit the circlip (2) onto the bearing (1).
Front cover
Removal
Remove the screws (3) and take off the drive input shaft cover
(1) from the front cover (2).
Take out the screws (1) and, through the front cover (5), take
out the oil pump comprising: cover (2), rotor (3) and stator
(4).
Introduce compressed air through the hole (o) and expel
through the front cover (5): the overrun brake piston (8)
comprehensive of gasket (9), clutch plates with external
toothing (6), clutch plates with internal toothing (7) and
supporting ring (10).
Fitting the front cover
Recompose the front cover (5) by reversing the operations
described for removal, without parts (6 - 7 - 8).
Adjusting drive input shaft bearing end float
Determine the thickness S of the drive input shaft bearing
adjustment ring by proceeding in the following way:
- check that the circlip (1) of the bearing (2) rests in its seat;
- measure the protrusion of the bearing (2) from the
surface of the front box (3), distance A.
!
The gasket (9) must always be replaced.
78322
154
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70986
70925
70870
Figure 122
Figure 123
Figure 124
Figure 125
- measure the depth of the seat on the front cover (1) of
the bearing (2, Figure 121), distance B.
The thickness S of the adjustment ring is determined by the
following equation:
S = (A -B) - C
Where:
A-B = measurements
C = end float 0 y 0.1 mm
For example:
A = 5.50 mm
B = 3.90 mm
C = 0 y 0.1 mm
S = (5.50 -3.90) - 0 y 0.1=1.59 — 1.60 mm
Adjusting transmission shaft bearing end float
Determine the thickness S of the transmission shaft bearing
end float adjustment rings by proceeding in the following way:
- turn the shafts and check that the external rings (1 -3) of
the bearings rest with no play on the rollers of the
bearings;
- measure the distance between the surface of the front
box (2) and the external rings (1 - 3);
D external ring (1) pump side, distance A.
D external ring (3) overrun brake side, distance B
- measure the distance between the surface of the front
cover (2) and the oil pump (1), distance C;
- mount the overrun brake disc supporting ring (3) in the
seat on the front cover (2) and measure the distance
between this and the surface of the cover (2), distance D.
The thickness S of the adjustment rings is determined by the
following equation:
D oil pump side S = A + C + F
A - C = measurements
F = end float r 0.05
For example:
S = 2 + 0.05 (r 0.05) = 2 y 2.1
D overrun brake side S = B + D + F
B - C = measurements
F = end float r 0.05
For example:
S = 1.95 + 0.15 (r 0.05) = 2.05 y 2.15
On the external rings of the bearings supporting the drive
input and transmission shafts, mount the end float adjustment
rings (1 - 2 and 6) of the thickness determined in the preceding
measurements. Insert the spring (4) and the cap (3) in the
transmission shaft (5).
70926
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 155
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70869
70927
46007
70928
Figure 126
Figure 127
Figure 128
Figure 129
In the sequence shown in the figure, position: the supporting
ring (3), clutch plates with internal toothing (2) and clutch
plates with external toothing (1).
Spread IVECO sealant 1905685 onto the surface of the front
box (1) mating with the cover (2). Adjust the key of the oil
pump shaft so that it coincides with the coupling milling of the
transmission shaft. Fit on the cover (2) and tighten the screws
(3) to the prescribed torque.
Using the driver 99374336 (2) and grip 99370007 (1), fit the
seal (3) in the drive input shaft cover (4).
Lubricate the sealing surface of the seal with Unisilikon.
Spread IVECO sealant 1905285 onto the surface of the front
box (1) mating with the cover (2). Mount the cover (2).
Spread LOCTITE 241 onto the thread of the screws (3) and
tighten them to the prescribed torque.
156
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70929
70930
70865
Figure 130
Figure 131
Figure 132
Figure 133
The bushings (2 and 4) and seals (1 and 5) of the lever (3) are
changed by using a suitable drift for removing — fitting new
parts.
Insert the joint pin (4) into the lever (2) and tighten the screws
(3), fixing it to the front box (1), to the prescribed torque.
Turn over the gearbox.
Remove the plate 99370153 (1) and the brackets (3) fastening
the pins (4) from the middle box (2).
Fit: the plate (1) together with the coupling body (2),
adjustment ring (3), connecting sleeve (5) and rod (4).
Complete assembly of the gearbox by refitting the rear box
and the speed actuator as described under the relevant
headings.
On completing assembly, replenish the gearbox with the
prescribed grade and quantity of lubricating oil.
78301
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. 157
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Clutch release lever
158
GEARBOX EuroTronic 12 AS 2301 D.D./O.D.
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
159
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Gearbox EuroTronic
12 AS 2301 D.D./O.D. with Intarder (IT)
Page
SPECIFICATIONS AND DATA 161. . . . . . . . . . . . .
OVERHAULING THE GEARBOX 162. . . . . . . . . . .
- Removing the hydraulic retarder 163. . . . . . . . . . .
- Refitting the hydraulic retarder 163. . . . . . . . . . . .
- Adjusting epicyclic reduction gear train bearing
end float 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting stator end float 164. . . . . . . . . . . . . . . .
- Removing the rear box 165. . . . . . . . . . . . . . . . . .
- Removing the E.R.G 166. . . . . . . . . . . . . . . . . . . .
- Fitting the E.R.G. 167. . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS 172. . . . . . . . . . . . . . . . . .
160
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
161
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Print 603.93.141 Base - January 2003
SPECIFICATIONS AND DATA
GEARBOX
EuroTronicAutomated 12AS 2301 D.D./O.D.
Type
EuroTronicAutomated12AS2301
D.D./
O.D
.
with intarder
Maximum braking
torque Nm
3000
Braking capacity Kw
520
Type of oil
Quantity after overhauling
gearbox and retarder drained
completely
litres
kg
Tutela Truck FE-Gear
Tutela ZC 90
21
19
Figure 1
70831
!
This differs from the 12 AS 2301 D.D./O.D. gearbox in the following:
EuroTronic Automated 12 AS 2301 D.D./O.D. with intarder
D.D. = Direct Drive
O.D. = Over Drive (Multiplied)
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Unscrew the ring nut (1 and 5) and disconnect the electric
wiring (2) from the speed sensor (6 and 7).
Detach the wiring (2) from the clips (o) securing it to the
middle box.
Remove the nuts (4) and detach the actuator (3) from the
front box.
Fir spacers SP. 2396 (2) and fasten the gearbox (1) to
brackets 99322225 (3) on the rotating stand 99322205 (4).
Drain off the lubricating oil by removing the plugs from the
Intarder and from the gearbox.
If applicable, remove the four nuts (2) fixing the heat
exchanger (1) to the hydraulic retarder (3) and detach the
heat exchanger (1).
Remove the screw (1) and the washer (2) beneath. Extract
the plug (3) with the seal (4), oil filter (5) and magnet (6).
Block rotation of the sleeve (2) by applying the lever
99370317 (1) to it and remove the screws (3), disc (4) and
underlying seal (5).
78649
70934
70936
78324
78652
Removing the hydraulic retarder
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530210 OVERHAULING THE GEARBOX
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Using an extractor composed of the bridge 99341003 (3),
brackets 99341018 (2) and reaction block 993410134 (4),
remove the sleeve (1) from the shaft (5).
Remove the screws (1) fixing the hydraulic retarder (2) to the
rear box (3).
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2).
With special ropes and lifter, detach the hydraulic retarder
(2) from the rear box.
Remove the adjustment rings (3 and 4) and the gasket (6).
Determine the ball bearing end float adjustment thickness (1)
by proceeding as follows:
- measure the protrusion of the bearing (1) from the
surface of the rear box (2): distance A;
- measure the distance between the sealing surface (1) of
the half box of the retarder and the supporting surface
of the bearing (1, Figure 10): distance B;
- measure the thickness of the gasket between the
retarder and gearbox: distance C.
The thickness S of the adjustment ring is given by the
following equation:
S = [ B + C - A ] - G
where:
- B - C - A = measurements
- G = 0.1 mm: end float of the ball bearing (1 Figure 10)
(0 y 0.1 mm)
Before refitting, determine the thickness of the adjustment
rings (3 and 4 Figure 9) as follows:
Adjusting epicyclic reduction gear train
bearing end float
78344
78321
78325
44005
78326
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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Refitting the hydraulic retarder
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Determine the thickness S of the stator end float adjustment
ring:
- using a depth gauge (1) and calibrated rule (2), measure
the distance between the sealing surface of the half
boxes and the supporting surface of the stator (3):
distance A;
- measure the thickness of the gasket between the
retarder and gearbox: distance B.
The thickness S of the stator end float adjustment ring is given
by the following sum: S = A+B+C
- A and B = measurements
- C = 0.05 mm: stator end float adjustment ring
pre-load. (- 0.05 y 0.05 mm)
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2)
and lift it with a hoist.
Position the adjustment rings (3 and 5) of the thickness
determined in the preceding measurements on the bearing
(4) and on the seat (o) of the stator.
Fit a new gasket (6) on the rear box.
Mount the hydraulic retarder (2) on the rear box (7) making
sure that the gasket (6) gets positioned correctly.
Screw down the screws (2) fixing the hydraulic retarder (1) to
the rear box (3) and tighten them to the prescribed torque.
Heat the flange (2) to approx. 80qC and fit it onto the spider
shaft (1).
Fit on a new seal (5), the disc (4), screw down the screws (3)
and tighten them to the prescribed torque.
Block rotation of the sleeve (1) by applying the lever
99370317 (3) and tighten the fixing screws (2) to the
prescribed torque.
70946
70948
70949
78327
70954
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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Base - January 2003 Print 603.93.141
Adjusting stator end float
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Position the magnet (6) on the filter (5) and insert this into
the hydraulic retarder. Fit the plug (3) with a new seal (4).
Screw down the fastening screw (1) with the washer (2).
Fit two new seals (2) on the hydraulic retarder (3) and mount
the heat exchanger (1) (if applicable).
Screw down the four nuts (2) fixing the heat exchanger (1) to
the hydraulic retarder (3) and tighten them to the prescribed
torque.
Connect the electric wiring (1) to the speed sensor (3) and
tighten the ring nut (2).
Replenish the gearbox with the prescribed grade and
quantity of lubricating oil.
Removing the rear box
Disconnect the gear actuator, as described in the respective
chapter.
Remove the hydraulic retarder as described under the
relevant heading.
Remove the screws (4) fixing the plates (3) fastening the pins
(6) and extract these together with the seals (5) from the
central box (7).
Extract the two centring pins (2) and remove the screws (8)
of fixing rear box (1).
70936
70933
70955
70937
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Fit the eyebolt 99366811 (1) to the shaft (2) of the epicyclic
reduction gear (2). Using special ropes and lifter, detach the
rear box (3) from the middle box (4).
Removing the E.R.G.
Using a press, extract the E.R.G. spider shaft (1) from the
supporting ball bearing (2). Turn the rear box (3)
upside-down and extract the ball bearing (2).
Remove the screws (2) securing the gear (3) to the spider
shaft (1).
Using an extractor composed of: bridge 99341004 (1), stays
99341012 (2), reaction block 99345056 (3) and clamp
99341015 (5), extract the gear (6) from the spider shaft (4).
Using a screwdriver, remove the circlip (3) fastening the ring
gear with internal toothing (4) to the ring gear with external
toothing (2) and remove them from the E.R.G. (1).
Extract the toothed ring (2) from the ring gear with internal
toothing (1).
78328
70942
48941
70836
70941 70837
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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Base - January 2003 Print 603.93.141
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Using pliers (2), tighten the ends of the circlip (3) andremove
the coupling body (4) from the E.R.G. shaft (1).
Using a punch, extract the pins (5) from the spider shaft (6).
Remove the planetary gears (3) from the spider shaft (6),
together with the rollers (2) and shim adjustment rings (1 and
4).
Extract the toothed spindle (3) from the spider shaft (1)
together with the rings (2).
Using a suitable extractor, remove the roller bearing ring (1)
from the spider shaft (2). Using a punch, extract the disc (3)
from the inside of the spider shaft (2).
Extract one of the pins (1) from the toothed spindle (2) and
extract the rings (3) from this.
Fitting the E.R.G.
Heat the inside ring (2) of the roller bearing to and fit it on
the spider shaft (3).
Fit on the circlip (1). Fit on the disc (4).
70838
70842
70839
71841
70840 70844
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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70943
Figure 34
PARTS COMPRISING THE E.R.G.
1. Circlip - 2. Ring gear with external toothing - 3. Toothed ring - 4. Ring gear with internal toothing - 5. Bearing - 6. Circlip -
7. Circlip - 8. Coupling body - 9. Pins - 10. Ring - 11. Toothed spindle - 12. Disc - 13. Spider shaft - 14. Pin - 15. Shim
adjustment ring - 16. Rollers - 17. Shim adjustment ring - 18. Planetary gear - 19. Gear - 20. Screw.
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70845
70982
70840
70983
70941
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Drive the rings (1 and 3) onto the toothed spindle (2) and
fit on the pin (4).
Insert the spindle (3) together with the rings (2) onto the
spider shaft (1).
Smear grease into the hole of the planetary gear (5) and
insert the rollers (3) with the associated shim adjustment
rings (2 and 4).
Fit the planetary gears (5) onto the spider shaft (6), fastening
them to it with the pins (1).
On the spider shaft (3), fit: the ring gear with internal toothing
(5) together with the toothed ring (4), and the ring gear with
external toothing (2) and fasten the two ring gears with the
circlip (1).
Heat the gear (3) to 120qC y 130qC and fit it onto the spider
shaft (1). Screw down the fixing screws (2) and tighten them
to the prescribed torque.
Heat the seat of the bearing (1) of the rear box (2) to 90qC
and mount the bearing (1).
48944
Figure 40
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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48946
78329
70937
Figure 41
Figure 42
Figure 43
Figure 44
Rest the spider shaft (1) on an appropriate spacer. Heat the
inside ring of the bearing (2) to approx. 100qC and drive it
together with the rear box (3) onto the spider shaft (1).
Take out the screws (1) and remove the cover (2) with its
seal (3). Remove the screw (4) with the washer (5).
Spread IVECO sealant 1905685 onto the mating surface of
the middle box (7). Fit the eyebolt 99366844 (1) onto the
shaft (2).
Using ropes and a lifter, position the rear box (4) coaxially to
the middle one (7).
Insert a rod (3) of appropriate diameter in the hole for the
screw (4, Figure 42) and in the oil pipe (5) to guide this into
its seat while lowering the rear box (4).
Lower the rear box (4), paying attention that the spider shaft,
oil pipe (5) and rod (6) go into their seat correctly.
Screw down the screws (8) without tightening them; insert
the centring pins (2) and tighten the screws (8) to the
prescribed torque.
Fit the fork joint pins (6) with fresh seals (5) and tighten the
screws (4) fixing the fastening plates (3) to the prescribed
torque.
78364
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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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70950
Figure 45
Fit: the screw (4) with a new washer (5) and tighten it to the
prescribed torque.
Fit the cover (2) with a fresh seal (3) and tighten the fixing
screws (1) to the prescribed torque.
Then refit the hydraulic retarder (6) as described under the
relevant heading.
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
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