DAF CF65 Series Manual
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DAF CF65 Series Manual

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Table of Contents

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CF65/75/85 series
PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)
200337
ZF 8/16S-151/181 AND 16S-221 GEARBOXES
https://www.truck-manuals.net/
TECHNICAL DATA
MECHANICAL GEARBOX CONTROL
GEARBOX - PNEUMATIC SECTION
ZF 6S-850 GEARBOX
ZF 8/9/16S-109 GEARBOX
EATON FS/6309A GEARBOX
AUTOMATIC GEARBOXES
AS TRONIC GEARBOX
STRUCTURE
DIAGNOSTICS
CLUTCH
PROP SHAFTS
ZF INTARDER
PTO
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Summary of Contents for DAF CF65 Series

  • Page 1 STRUCTURE CF65/75/85 series TECHNICAL DATA DIAGNOSTICS MECHANICAL GEARBOX CONTROL PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) GEARBOX - PNEUMATIC SECTION ZF 6S-850 GEARBOX ZF 8/9/16S-109 GEARBOX ZF 8/16S-151/181 AND 16S-221 GEARBOXES EATON FS/6309A GEARBOX AUTOMATIC GEARBOXES CLUTCH PROP SHAFTS ZF INTARDER AS TRONIC GEARBOX 200337 https://www.truck-manuals.net/...
  • Page 2 https://www.truck-manuals.net/...
  • Page 3 TECHNICAL DATA CF65/75/85 Serie Contents CONTENTS Page Date MECHANICAL GEARBOX CONTROL ........
  • Page 4 TECHNICAL DATA Contents CF65/75/85 Serie Page Date 12. PTO ..............12-1 .
  • Page 5 TECHNICAL DATA CF65/75/85 series Mechanical gearbox control 1. MECHANICAL GEARBOX CONTROL 1.1 GENERAL V300382 Within the entire CF65/75/85 vehicle series many gearbox variations as well as the accompanying controls are possible, both mechanical and pneumatic. A gearbox with a splitter and range-change switch will be equipped with several pneumatic valves.
  • Page 6 V300833 Bonding the gear lever into the ball De-greaser DAF No. 1322827 Glue DAF No. 1340646 Bonding the ball joint to the control rod De-greaser DAF No.
  • Page 7 TECHNICAL DATA CF65/75/85 series Mechanical gearbox control 1.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 8 TECHNICAL DATA CF65/75/85 series Mechanical gearbox control 200337 https://www.truck-manuals.net/...
  • Page 9 TECHNICAL DATA CF65/75/85 series Pneumatically assisted gearbox control (Servoshift) 2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) 2.1 GENERAL Servoshift unit Service pressure max. 10 bar 2.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques.
  • Page 10 TECHNICAL DATA CF65/75/85 series Pneumatically assisted gearbox control (Servoshift) 200337 https://www.truck-manuals.net/...
  • Page 11 TECHNICAL DATA CF65/75/85 series Pneumatic section of gearbox 3. PNEUMATIC SECTION OF GEARBOX 3.1 GENERAL If the vehicle is modified and the configuration changed, the electronic unit may have to be programmed. Note: If the vehicle’s drive configuration is changed, this must always be stated.
  • Page 12 TECHNICAL DATA CF65/75/85 series Pneumatic section of gearbox GEAR LEVER SELECTOR VALVE Range-change gear Connection point Colour Supply Black Bleed Range-change gear White command (A) V300488 PNEUMATIC SYMBOL Range V300267 200337 https://www.truck-manuals.net/...
  • Page 13 TECHNICAL DATA CF65/75/85 series Pneumatic section of gearbox GEAR LEVER SELECTOR VALVE Range-change gear and splitter Connection point Colour Supply Black Bleed Range-change gear White command (A) Splitter command (B) Yellow V300489 PNEUMATIC SYMBOL Range-change gear and splitter Position Function Range-change gear Splitter V300161...
  • Page 14 TECHNICAL DATA CF65/75/85 series Pneumatic section of gearbox 3.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 15 TECHNICAL DATA CF65/75/85 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 is also stated on the identity card of the relevant vehicle.
  • Page 16 TECHNICAL DATA CF65/75/85 series ZF 6S-850 gearbox 4.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 17 TECHNICAL DATA CF65/75/85 series ZF 8/9/16S-109 gearbox 5. ZF 8/9/16S-109 GEARBOX 5.1 GENERAL Gearbox type Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.
  • Page 18 TECHNICAL DATA CF65/75/85 series ZF 8/9/16S-109 gearbox 5.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 19 TECHNICAL DATA CF65/75/85 series ZF 8/9/16S-109 gearbox Plugs Gearbox with integrated intarder Drain plug (B) 60 Nm Drain plug (B) 120 Nm Drain plug (C) 60 Nm Level check/filler plug (A). 60 Nm Oil filter attachment bolt (1) 23 Nm M3017 V300372 M3052...
  • Page 20 TECHNICAL DATA CF65/75/85 series ZF 8/9/16S-109 gearbox 5.3 FILLING CAPACITIES Filling amounts, ZF gearboxes without intarder Gearbox type Filling amounts at oil change First filling, e.g. during repair (litres) (litres) ZF 8/16S-109 ZF 9/S-109 Filling amounts, ZF gearboxes with integrated intarder Gearbox type Filling amounts at oil change First filling, e.g.
  • Page 21 TECHNICAL DATA CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes 6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES 6.1 GENERAL Gearbox type Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.
  • Page 22 TECHNICAL DATA CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes 6.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 23 TECHNICAL DATA CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes Plugs Gearbox with integrated intarder Drain plug (B) 60 Nm Drain plug (B) 120 Nm Drain plug (D) 60 Nm Level check/filler plug (4) 60 Nm Filler plug (5) 60 Nm Oil filter attachment bolt (1) 23 Nm V300186...
  • Page 24 TECHNICAL DATA CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes 6.3 FILLING CAPACITIES Filling amounts, ZF gearboxes without intarder Gearbox type Filling amounts at oil change First filling, e.g. during repair (litres) (litres) ZF 8/16S-151 ZF 8/16S-181 ZF 16S-221 Filling amounts, ZF gearboxes with integrated intarder Gearbox type Filling amounts at oil change...
  • Page 25 Eaton gearbox type-plate Type of gearbox Specification no. Eaton DAF article Eaton code Series no. Eaton Production date code The Eaton specification number is unique for each customer and gives detailed information on the development level of the gearbox.
  • Page 26 TECHNICAL DATA CF65/75/85 series Eaton FS/6309A gearbox 7.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 27 TECHNICAL DATA CF65/75/85 series Eaton FS/6309A gearbox Plugs Drain plug 50 Nm Level check/filler plug 50 Nm Use new nut Loctite 243 7.3 FILLING CAPACITIES Gearbox capacity Type Contents FS/6309A 8.5 litres 200337 https://www.truck-manuals.net/...
  • Page 28 TECHNICAL DATA CF65/75/85 series Eaton FS/6309A gearbox 200337 https://www.truck-manuals.net/...
  • Page 29 TECHNICAL DATA CF65/75/85 series Allison automatic gearbox 8. ALLISON AUTOMATIC GEARBOX 8.1 GENERAL Allison transmission, used in the CF65/75, is electronically controlled and has its own diagnostic system that saves any faults in the memory of the ECU (Electronic Control Unit). The faults can be read at a later date.
  • Page 30 TECHNICAL DATA CF65/75/85 series Allison automatic gearbox 8.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 31 TECHNICAL DATA CF65/75/85 series Allison automatic gearbox 8.3 FILLING CAPACITIES Allison automatic gearbox oil capacities Type of gearbox Capacity at first filling Capacity at second filling MD 3060P 4″ oil sump 27 litres 20 litres MD 3066P 4″ oil sump 27 litres 20 litres MD 3560P 4″...
  • Page 32 TECHNICAL DATA CF65/75/85 series Allison automatic gearbox 200337 https://www.truck-manuals.net/...
  • Page 33 TECHNICAL DATA CF65/75/85 series Clutch 9. CLUTCH 9.1 GENERAL CLUTCH RELEASE ASSEMBLIES V300390 Clutch release assembly Engine type Clutch release assembly type Note MF 395 MF 395 with extended service life Automatically adjusting clutch release assembly and wear indicator MF 395 MF 395 with extended service life Automatically adjusting clutch release MFZ 430...
  • Page 34 TECHNICAL DATA CF65/75/85 series Clutch CLUTCH PLATE V300391 Clutch plate Engine type Clutch plate Lining thickness Splines Thrust bearing (mm) 395 WGTZ 1.5″ KZI-4 395 WGTZ 1.75″ KZI-4 395 WGTZ 1.5″ KZI-4 395 WGTZ 1.75″ KZI-4 395 WGTZ 1.75″ KZI-4 395 WGTZ 1.75″...
  • Page 35 TECHNICAL DATA CF65/75/85 series Clutch Clutch pedal Clutch pedal proximity sensor (A) 1 - 0 + 1 mm Clutch pedal free travel (B) approx. 2 - 4 mm GV valve begins to 2 mm open (C) Total clutch pedal 2 mm travel (D) V300315 200337...
  • Page 36 TECHNICAL DATA CF65/75/85 series Clutch Main cylinder Maximum piston stroke 34 mm Pressure pin setting (E) approx. 0.2 - 0.8 mm Mounting seals Silicone grease V300411 200337 https://www.truck-manuals.net/...
  • Page 37 TECHNICAL DATA CF65/75/85 series Clutch 9.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 38 TECHNICAL DATA CF65/75/85 series Clutch AS TRONIC gearbox M12 attachment bolts, clutch lever to gearbox 79 Nm AS TRONIC clutch unit Clutch unit attachment nut 23 Nm Clutch unit stud 10 Nm Bleed screw, clutch unit 22 Nm Compressed air connection 50 Nm 9.3 FILLING CAPACITIES Clutch operating unit...
  • Page 39 TECHNICAL DATA CF65/75/85 series Prop shafts 10. PROP SHAFTS 10.1 GENERAL For the CF 65/75/85 vehicle series, DAF has one manufacturer of prop shafts, Klein. Klein shafts can be identified by their highly bevelled flanges. Inspection There must be no clearly noticeable play on universal joints, centre bearing or sliding clutch.
  • Page 40 TECHNICAL DATA CF65/75/85 series Prop shafts Maximum permissible axial play of slide joint 0.25 mm V300444 10.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques.
  • Page 41 TECHNICAL DATA CF65/75/85 series Prop shafts 10.3 FILLING CAPACITIES Note: All prop shafts are maintenance-free, although vehicles that are used in heavy conditions are fitted as standard with lubricating nipples on the universal joints. Clean grease must emerge visibly from all four needle sleeve seals of the spider during greasing.
  • Page 42 TECHNICAL DATA CF65/75/85 series Prop shafts 200337 10-4 https://www.truck-manuals.net/...
  • Page 43 TECHNICAL DATA CF65/75/85 series ZF intarder 11. ZF INTARDER 11.1 GENERAL Axial play Stator 0.05 mm Output shaft bearing 0 - 0.1 mm Oil pump external rotor 0.03 - 0.05 mm Intarder drive sprocket Heat in oven for a maximum of 15 minutes 130_ - 150_C 11.2 TIGHTENING TORQUES The tightening torques stated in this section are...
  • Page 44 TECHNICAL DATA CF65/75/85 series ZF intarder Drive flange attachment bolts Attachment bolts (8.8) 60 Nm Attachment bolts (10.9) 120 Nm Shift control high/low Shifting fork high/low bolts 180 Nm Gear engaging cylinder piston lock nut 180 Nm Gear engaging cylinder attachment bolts 50 Nm Air connection banjo bolt 38 Nm...
  • Page 45 PTO: the DAF engine PTO and the ZF/Eaton gearbox PTOs. The DAF engine PTO can be recognised by the position of the PTO, i.e. on top of the flywheel housing. The ZF/Eaton PTOs can be recognised by the position at the rear of the gearbox.
  • Page 46 When attachment bolts and nuts are to be replaced, it is important that they are of exactly the same length and property class as the ones removed unless stated otherwise. DAF ENGINE PTO Main shaft lock nut 500 Nm Gear attachment bolt in flywheel housing...
  • Page 47 TECHNICAL DATA CF65/75/85 series Attachment N221/10 Drive flange 120 Nm Side cover attachment bolts 23 Nm Bolts for fastening attachment to gearbox 79 Nm Attachment N AS/10 Drive flange 120 Nm Side cover attachment bolts 23 Nm Bolts for fastening attachment to gearbox 79 Nm Secure with Loctite 243 EATON GEARBOX PTO...
  • Page 48 TECHNICAL DATA CF65/75/85 series 12.3 FILLING CAPACITIES Extra filling capacities, ZF gearbox PTOs PTO TYPE FILLING CAPACITY NH/1B NL/1B NH/1C NL/1C NH/4B NL/4B NH/4C NL/4C N221/10B N221/10C N221/10 IT N221/10 C IT N221/10 B PL N221/10 C-PL N AS/10 B N AS/10 B IT N AS/10 C N AS/10 C IT...
  • Page 49 TECHNICAL DATA CF65/75/85 series AS TRONIC gearbox 13. AS TRONIC GEARBOX 13.1 GENERAL Gearbox type Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.
  • Page 50 TECHNICAL DATA CF65/75/85 series AS TRONIC gearbox 13.2 TIGHTENING TORQUES The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 51 TECHNICAL DATA CF65/75/85 series AS TRONIC gearbox Plugs AS Tronic Drain plug (B, C) 60 Nm Level check/filler plug (A). 60 Nm G000243 AS Tronic with intarder Drain plug (B, C) 60 Nm Level check/filler plug (A). 60 Nm G000250 Oil filter attachment bolt (1) 23 Nm M3052...
  • Page 52 TECHNICAL DATA CF65/75/85 series AS TRONIC gearbox 13.3 FILLING CAPACITIES Filling amounts, ZF gearboxes without intarder Gearbox type Filling amounts at oil change First filling, e.g. during repair (litres) (litres) ZF 12 AS 1930 TD ZF 12 AS 2330 TO ZF 12 AS 2540 TD Filling amounts, ZF gearboxes with integrated intarder...
  • Page 53 DIAGNOSTICS CF65/75/85 series Contents CONTENTS Page Date MECHANICAL GEARBOX CONTROL ........
  • Page 54 DIAGNOSTICS Contents CF65/75/85 series 200337 https://www.truck-manuals.net/...
  • Page 55 DIAGNOSTICS CF65/75/85 series Mechanical gearbox control 1. MECHANICAL GEARBOX CONTROL 1.1 FAULT-FINDING TABLE SYMPTOM: GEAR LEVER VIBRATES Possible cause Remedy Excessive play at control hinge points Check/repair all points in the control SYMPTOM: ENGAGING GEARS IS HEAVY Possible cause Remedy Gearbox control pivot and hinge points dry or Check/repair all points in the control compressed...
  • Page 56 DIAGNOSTICS CF65/75/85 series Mechanical gearbox control 200337 https://www.truck-manuals.net/...
  • Page 57 DIAGNOSTICS CF65/75/85 series Pneumatically assisted gearbox control (Servoshift) 2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) 2.1 FAULT-FINDING TABLE SYMPTOM: ENGAGING GEARS IS HEAVY Possible cause Remedy Servoshift unit inoperative Inspect air pipes Servoshift unit leaking air internally Check air seals in unit Mechanical problem See “Mechanical gearbox control”...
  • Page 58 DIAGNOSTICS CF65/75/85 series Pneumatically assisted gearbox control (Servoshift) 200337 https://www.truck-manuals.net/...
  • Page 59 DIAGNOSTICS CF65/75/85 series Pneumatic section of gearbox 3. PNEUMATIC SECTION OF GEARBOX 3.1 FAULT-FINDING TABLE SYMPTOM: NOT POSSIBLE TO ENGAGE HIGH OR LOW RANGE Possible cause Remedy Air pressure too low Check air supply of circuit 4 Neutral position valve defective or incorrectly Connect valve properly or replace connected Defective downshift protection valve...
  • Page 60 DIAGNOSTICS CF65/75/85 series Pneumatic section of gearbox SYMPTOM: SPLITTING NOT POSSIBLE Possible cause Remedy Air pressure too low Check pneumatic system Defective or incorrectly set GV valve Check valve and adjust/replace as necessary Wrong relay valve fitted for splitter Fit correct relay valve type Broken or incorrectly connected air pipes Check air pipes and replace or connect properly, if necessary...
  • Page 61 DIAGNOSTICS CF65/75/85 series Pneumatic section of gearbox SYMPTOM: GATE 1/2 NOT SAFEGUARDED Possible cause Remedy No power supply to the gate protection valve Check the wiring Defective gate protection valve (B293) Replace the gate protection valve VIC does not receive a speed signal or receives Check speed signal from CTE an incorrect signal Leaking or blocked air pipes...
  • Page 62 DIAGNOSTICS CF65/75/85 series Pneumatic section of gearbox 200337 https://www.truck-manuals.net/...
  • Page 63 DIAGNOSTICS CF65/75/85 series Mechanical gearbox 4. MECHANICAL GEARBOX 4.1 FAULT-FINDING TABLE SYMPTOM: ENGAGING GEARS IS HEAVY Possible cause Remedy Gearbox oil level too low Top up oil level Oil with incorrect specification in the gearbox Fill gearbox with oil of correct specification Problem in mechanical gearbox control See “Mechanical gearbox control”...
  • Page 64 DIAGNOSTICS CF65/75/85 series Mechanical gearbox SYMPTOM: GEAR LEVER STUCK IN GATE 3/4 Possible cause Remedy Oil leak in gate protection piston Replace O-ring SYMPTOM: SINGLE H BECOMES DOUBLE H Possible cause Remedy Locking plate in control cover not positioned Check assembly of control cover correctly 200337 https://www.truck-manuals.net/...
  • Page 65 DIAGNOSTICS CF65/75/85 series Automatic gearbox 5. AUTOMATIC GEARBOX 5.1 READING/DELETING FAULT CODES Fault code reading mode To enter the fault code reading mode, briefly press the two arrow keystwice simultaneously. “D-1” appears on the display, followed by “- -”. This means that at that point there are no faults (active faults) in the system.
  • Page 66 DIAGNOSTICS CF65/75/85 series Automatic gearbox Deleting fault codes After faults have been remedied, the ECU memory must be deleted. This is done as follows. Press the arrow keys twice simultaneously. This is the fault code reading mode. Press the “MODE” key and hold it down until the red lamp flashes three times (the first flash will be after approx.
  • Page 67 DIAGNOSTICS CF65/75/85 series Automatic gearbox 5.2 TABLE OF FAULT CODES Main code Sub-code RECOMMENDED PROCEDURES Electronic control unit (ECU) supply 12 Low Check the following points: 23 High a. Earth and positive battery cables connected, firmly attached and clean. b. Batteries are charged. c.
  • Page 68 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Temperature in the gearbox sump too low Check the following points: a. Temperature is lower than -6°C. 1) If this is the case, it is a normal response to the ambient temperature.
  • Page 69 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Coupling 3 pressure switch open 1. Let the engine idle while the vehicle’s parking brake is applied. Check the following points: a. Specified dip stick. b. Correct oil level. 2. Check the following points: a.
  • Page 70 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Hardware/software not compatible 1. Replace ECU if possible. 2. Re-program ECU if possible. 3. If replacement or re-programming is not possible, contact your Allison dealer. Interruption or short circuit in electromagnetic valve circuit Check the following points: a.
  • Page 71 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Transmission ratio test on the gear to be changed from (during shifting). Check the following points: a. Output shaft engine speed sensor and rev sensor are connected. The connectors are undamaged and clean. b.
  • Page 72 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Transmission ratio test immediately after changing gear 01,07 Check the following points: 10,12 a. Output shaft engine speed sensor and rev sensor are connected. 17,21 The connectors are undamaged and clean. 23,32 b.
  • Page 73 DIAGNOSTICS CF65/75/85 series Automatic gearbox Main code Sub-code RECOMMENDED PROCEDURES Range test when using coupling C3 Check the following points: a. Output shaft engine speed sensor and rev sensor are connected. The connectors are undamaged and clean. b. No interruptions or short circuits between wires or earth in sensor wiring.
  • Page 74 DIAGNOSTICS CF65/75/85 series Automatic gearbox 200337 5-10 https://www.truck-manuals.net/...
  • Page 75 DIAGNOSTICS CF65/75/85 series Clutch 6. CLUTCH 6.1 FAULT-FINDING TABLE SYMPTOM: CLUTCH PEDAL FAILS TO RETURN Possible cause Remedy Broken pedal return spring Replace spring Worn clutch pedal bearing Check bearing and replace, if necessary Dirt in hydraulic system Clean system and fill with fresh fluid Incorrect fluid in hydraulic system Replace with fluid of correct specification Air in hydraulic system...
  • Page 76 DIAGNOSTICS CF65/75/85 series Clutch SYMPTOM: RESIDUAL PRESSURE IN CLUTCH SYSTEM Possible cause Remedy Bleed in reservoir cap closed off Check bleed in cap Compensation bore in main cylinder closed off Check free thrust pin travel or repair/replace by swollen seal or insufficient free thrust pin main cylinder travel.
  • Page 77 DIAGNOSTICS CF65/75/85 series Clutch SYMPTOM: CLUTCH RELEASE ASSEMBLY FAILS TO RELEASE Possible cause Remedy Fluid level in hydraulic system too low Top up fluid Incorrect pedal setting Check setting and adjust if necessary Air in hydraulic system Bleed hydraulic system Leak in hydraulic system Check hydraulic system Fingers of clutch release assembly broken...
  • Page 78 DIAGNOSTICS CF65/75/85 series Clutch 200337 https://www.truck-manuals.net/...
  • Page 79 DIAGNOSTICS CF65/75/85 series Prop shafts 7. PROP SHAFTS 7.1 FAULT-FINDING TABLE SYMPTOM: VIBRATION IN DRIVE LINE AT LOW SPEED Possible cause Remedy Universal joint angle too large caused by e.g. Check universal joint angle excessive caster Play in universal joints Replace universal joint Play in centre bearing Replace centre bearing...
  • Page 80 DIAGNOSTICS CF65/75/85 series Prop shafts 200337 https://www.truck-manuals.net/...
  • Page 81 DIAGNOSTICS CF65/75/85 series ZF intarder 8. ZF INTARDER 8.1 FAULT-FINDING TABLE SYMPTOM: NO BRAKING MOMENT Possible cause Remedy Oil level too low Check oil level Intarder is not filled with the specified oil Change the oil No pump pressure Check system No control pressure Check system No intarder pressure...
  • Page 82 DIAGNOSTICS CF65/75/85 series ZF intarder SYMPTOM: DELAYED RESPONSE Possible cause Remedy Air supply absent/too low Check air supply Intarder air supply valve is not activated Check system Intarder air supply valve does not empty Check system accumulator in spite of activation Idle pressure too low Check system SYMPTOM: DELAYED SWITCH-OFF...
  • Page 83 DIAGNOSTICS CF65/75/85 series AS Tronic 9. AS TRONIC 9.1 FAULT-FINDING TABLE Using DAVIE, the air pressure can be examined after the pressure regulator. The air pressure before the pressure regulator can be measured using a pressure gauge on the screw valve of the AS Tronic air reservoir.
  • Page 84 DIAGNOSTICS CF65/75/85 series AS Tronic SYMPTOM: AIR SUPPLY PRESSURE TOO HIGH Possible cause Remedy Defective or incorrectly functioning pressure Check pressure regulator set screw seal regulator on modulator (underside of pressure regulator under plastic cover) Pressure regulator factory setting disrupted Replace pressure regulator SYMPTOM: SYSTEM NOT AVAILABLE ONCE ENGINE STARTED Possible cause...
  • Page 85 MECHANICAL GEARBOX CONTROL CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 86 MECHANICAL GEARBOX CONTROL CF65/75/85 series Contents 0111 https://www.truck-manuals.net/...
  • Page 87 MECHANICAL GEARBOX CONTROL CF65/75/85 series General 1. GENERAL 1.1 DESCRIPTION OF MECHANICAL GEARBOX CONTROL Operating mechanism, LHD When the gear lever is moved forwards, the control rod moves backwards. When the gear lever is moved backwards, the control rod moves forwards. When the gear lever is moved left, the control rod moves right.
  • Page 88 MECHANICAL GEARBOX CONTROL CF65/75/85 series General 1.2 OVERVIEW DRAWING, GEAR LEVER UNIT Switch Gaiter Gear lever Retaining plate Inner gaiter Attachment tape Pressure spring Circlip Gear lever ball 10. Bearing housing 11. Spacer sleeve V300393 0111 https://www.truck-manuals.net/...
  • Page 89 MECHANICAL GEARBOX CONTROL CF65/75/85 series General 1.3 OVERVIEW DRAWING, GEAR LEVER Switch Gear lever Bearing housing Gear lever ball Circlip V300394 0111 https://www.truck-manuals.net/...
  • Page 90 MECHANICAL GEARBOX CONTROL CF65/75/85 series General 0111 https://www.truck-manuals.net/...
  • Page 91 MECHANICAL GEARBOX CONTROL CF65/75/85 series Inspection and adjustment 2. INSPECTION AND ADJUSTMENT 2.1 INSPECTION AND ADJUSTMENT OF GEARBOX CONTROL LHD/RHD Inspection, gearbox control LHD/RHD Push the control against the spring pressure to check whether it can move freely in neutral. The control should spring back independently into the 3/4 gate.
  • Page 92 MECHANICAL GEARBOX CONTROL CF65/75/85 series Inspection and adjustment Adjustment, gearbox control LHD/RHD Tilt the cab. Remove the lever from the selector shaft. Position the gear lever exactly in position A. See “Technical data”. Check that the gearbox is in neutral. Fit the selector shaft lever (4) to the selector shaft and fit the attachment bolt, tightening it to the specified torque.

  • Page 93: Removal And Installation

    MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3. REMOVAL AND INSTALLATION 3.1 REMOVAL AND INSTALLATION, ENTIRE GEAR LEVER UNIT Note: If the vehicle is equipped with a gearbox without range-change switching or splitter box e.g. the ZF 6S850, the gear lever unit can be removed without it being necessary to consider the air pipes.
  • Page 94 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Installation, entire gear lever unit Fit the entire gear lever unit including the set of air pipes to the bottom of the shift unit or on the manifold bracket and fit the attachment nuts (3), tightening to the specified tightening torque.
  • Page 95 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3.2 REMOVAL AND INSTALLATION, GEAR LEVER GAITER Removing the gear lever gaiter Make sure there are no loose items in the cab. Tilt the cab. After marking them, remove the air pipes that run from the switch to the various valves.
  • Page 96 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Loosen the gaiter from the locking plate by lifting the gaiter and pulling the gaiter lips away from the locking plate. W 302059 Then remove the Seeger ring that has become visible from the bearing cover. It is now possible to remove the entire gear lever from the bearing cover.
  • Page 97 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Installing the gear lever gaiter Slide the gaiter over the gear lever. Fit the ball. Fit the entire gear lever to the shift unit and lock it with the specific Seeger ring. Secure the gaiter by means of the lips.
  • Page 98 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3.3 REMOVAL AND INSTALLATION, GEAR LEVER UNIT INNER DUST COVER Removal, gear lever unit inner dust cover Remove the entire gear lever unit from the bracket. Loosen the gaiter from the locking plate by lifting the gaiter and pulling the gaiter lips away from the locking plate.
  • Page 99 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Remove the locking plate with the dust cover and spring from the bearing cover. Remove the dust cover from the locking plate. V300278 Installation, gear lever unit inner dust cover Fit the inner dust cover. Note: When fitting the inner dust cover, ensure that it is fitted properly to the locking plate...
  • Page 100 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Press the locking plate and spring down and fit the four attachment bands in the bearing cover slots. W 302057 Fit the gear lever with the bearing to the bearing cover and fit the snap ring. V300405 Secure the gaiter by means of the lips.
  • Page 101 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3.4 REMOVAL AND INSTALLATION OF GEAR LEVER BALL Removing the gear lever ball Make sure there are no loose items in the cab. Tilt the cab. After marking them, remove the air pipes that run from the switch to the various valves.
  • Page 102 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Installing the gear lever ball Apply a degreasing agent to the surfaces of the gear lever and ball that are to be glued. See “Technical data”. Immediately wipe the surfaces with a clean piece of paper or a lint-free cloth.
  • Page 103 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3.5 REMOVAL AND INSTALLATION, CONTROL ROD Removing the control rod Make sure there are no loose items in the cab. Tilt the cab. After marking them, remove the air pipes that run from the switch to the various valves.
  • Page 104 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation Installing the control rod Position the control rod. Fit the control rod (2) onto the gear lever unit and hand tighten the clamping bolt (1). For the required torque, see “Technical data”. V300275 Fit the torque rod to the control rod and tighten the ball joint lock nut (4) to the...
  • Page 105 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3.6 REMOVAL AND INSTALLATION, CONTROL ROD BALL JOINT Note: Ensure that the section of the control rod in which the ball joint is fitted is well supported when the ball is being forced on or off. This will prevent deformation of the control rod.
  • Page 106 MECHANICAL GEARBOX CONTROL CF65/75/85 series Removal and installation 3-14 0111 https://www.truck-manuals.net/...
  • Page 107 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 108 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 109 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series General 1. GENERAL 1.1 SYSTEM DESCRIPTION, PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) The “Servoshift” pneumatically assisted gearbox control is an assisted mechanical/pneumatic gear selector system for the gearbox. This system is identical to the mechanical gearbox controls, from the gear lever to the gearbox, however, the gearbox is pneumatically assisted.
  • Page 110 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series General Gate selection Gates are selected mechanically. To select a gate, move the gear lever to the left or to the right, which moves the selector shaft to the left or to the right. Engaging gears To engage the gears, move the gear lever forwards or backwards.
  • Page 111 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components 2. DESCRIPTION OF COMPONENTS 2.1 SERVOSHIFT UNIT OPERATION V300335 Supply pressure connection (circuit 4) Operating piston Venting valve Selector valve for operating piston, 1 , 7th gear Valve seat, 1 , 7th gear Valve, 1 gear...
  • Page 112 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components SERVOSHIFT SELECTOR SHAFT HOUSING Situation with separate air distribution block: V300345 200337 https://www.truck-manuals.net/...
  • Page 113 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components Situation with integrated air distribution block: 43 48 V300870 23. Attachment bolt 39. Hollow shaft (selector valve lever) 24. Selector housing cover 40. Selector shaft 25. Selector housing cover gasket 41.
  • Page 114 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components General The Servoshift unit consists of a selector valve and a double-action cylinder. When the control rod is moved forwards or backwards, the selector valve lever (2) is operated first. This operates the selector valve in the Servoshift unit, so that air acts on the piston and the piston will operate the servo lever (1).
  • Page 115 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components or 3 gear engaged V300331 Servoshift unit Selector valve Operating cylinder When the gear lever is moved forwards, the selector valve moves to the right. Supply pressure is thereby applied to the left side of the cylinder, and the cylinder moves to the right.
  • Page 116 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components or 4 gear engaged V300332 When the cylinder is in the 2 or 4 position and the gear lever is again released, the selector valve will again spring back to the middle position while the cylinder remains in the switched position due to the double-retaining arrangement.
  • Page 117 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components 2.2 FUNCTION OF THE EMERGENCY SELECTOR It is still possible to change all the gears even without pneumatic power if the air pressure should fail. In such case, a small amount of play between the selector shaft (3) and the attachment pin (4) will have to be bypassed before the selector finger (1) is operated.
  • Page 118 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Description of components 200337 https://www.truck-manuals.net/...
  • Page 119 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Removal and installation 3. REMOVAL AND INSTALLATION 3.1 REMOVAL AND INSTALLATION, SERVOSHIFT UNIT Removing Servoshift unit Ensure that the air pipe (1) is pressureless before the banjo bolt is removed. Remove the banjo bolt from the air pipe (1) and plug the connection on the unit so that no dirt can enter.
  • Page 120 PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) CF65/75/85 series Removal and installation Installing Servoshift unit Fit the Servoshift unit using a new gasket. Tighten the attachment bolts (2) to the specified torque. See “Technical data”. Fit the banjo bolt for the air pipe (1) with new sealing rings and tighten to the specified torque.
  • Page 121 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 122 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 123 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General 1. GENERAL 1.1 LOCATION OF COMPONENTS OF THE DOWNSHIFT PROTECTION FOR ZF/EATON GEARBOXES ZF gearboxes ZF 8/9/16S-109 Neutral position valve At the side of the selector shaft housing on the gearbox. V300140 Range-change gear engaging cylinder At the back of the gearbox.
  • Page 124 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Downshift protection valve At the left-hand side of the gearbox. Version CF75, production date < 2003-21 Electropneumatic downshift protection valve Pneumatic downshift protection valve V300879 Version CF75, production date ≥ 2003-21 V 300029 VIC electronic unit In the central box on the co-driver’s side (1).
  • Page 125 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Gear lever range-change switch Rocker switch (B) at the front of the gear lever. D000096 ZF gearboxes ZF 8/16S-151/181/221 Neutral position valve At the side of the selector shaft housing on the gearbox. With separate air distribution block: V300140 With integrated air distribution block:...
  • Page 126 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Range-change gear engaging cylinder At the back of the gearbox. V300141 Downshift protection valve At the left-hand side of the gearbox. Version CF75/85, production date < 2003-21 Electropneumatic downshift protection valve Pneumatic downshift protection valve V300879 Version CF75/85, production date ≥...
  • Page 127 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General VIC electronic unit In the central box on the co-driver’s side (1). V300418 Gear lever range-change switch Rocker switch (B) at the front of the gear lever. D000096 Eaton FS/6309A gearbox Neutral position valve (1) At the side of the gearbox.
  • Page 128 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Electropneumatic downshift valve (2) At the side of the gearbox. Filter/governor (3) At the side of the gearbox. Range-change gear engaging cylinder (4) At the side of the gearbox. V300452 Reversing switch (6) At the side of the gearbox.
  • Page 129 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Gear lever range-change switch Rocker switch (A) at the front of the gear lever. V3 00 562 1.2 SYSTEM DESCRIPTION, DOWNSHIFT PROTECTION The downshift protection prevents shifting down from the gearbox high range to the low range when the vehicle speed is too high.
  • Page 130 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Function, downshift protection of ZF gearboxes Version CF75/85, production date < 2003-21 V300369 If the range-change switch (5) on the gear lever is shifted to the low-range preference, the “GP” air-pressure valve will switch through to connection point 21.
  • Page 131 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Regardless of any pneumatic command from the gear lever range-change switch (5), it is now no longer possible to switch an air pressure to connection point 26 of the engaging cylinder (2) and hence to shift to the low range. Note: The air supply to the electropneumatic valve (6) is only available when the gear lever, and hence...
  • Page 132 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Version CF75, production date ≥ 2003-21 V300711 If the range-change switch (5) on the gear lever is shifted to the low-range preference, the “GP” air-pressure valve will switch through to connection point 21. This air pressure is now applied to connection point 4 of the electropneumatic valve (3).
  • Page 133 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Regardless of any pneumatic command from the gear lever range-change switch (5), it is now no longer possible to switch an air pressure to connection point 26 of the engaging cylinder (2) and hence to shift to the low range. Note: The air supply to the electropneumatic valve (3) is only available when the gear lever, and hence...
  • Page 134 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General 1.3 LOCATION OF GATE PROTECTION COMPONENTS Neutral position valve At the side of the selector shaft housing on the gearbox. V300140 Gate protection valve At the left-hand or right-hand side of the gearbox (depending on the vehicle type). V300714 200337 1-12...
  • Page 135 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Locking cylinder With separate air distribution block: at the rear of the selector shaft housing. V300002 With integrated air distribution block: at right angles to the selector shaft housing V300861 VIC electronic unit The electronic unit (1) is under the central box on the co-driver’s side.
  • Page 136 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Low-range switch Located at the rear of the gearbox. V300005 200337 1-14 https://www.truck-manuals.net/...
  • Page 137 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General 1.4 SYSTEM DESCRIPTION, GATE PROTECTION How gate protection works V300715 Situation with separate air distribution block V300860 Situation with integrated air distribution block The gate protection only operates in the low range. The low range is registered by the low-range switch (2).
  • Page 138 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General The moment when the protection is engaged is determined by the VIC electronic unit (3). The moment when the protection is engaged is dependent on the vehicle speed signal. The gate protection valve (1) is energised if the following conditions are met: The vehicle speed is above the set speed, i.e.
  • Page 139 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General 1.5 PNEUMATIC DIAGRAM, GEARBOX CONTROL Pneumatic diagram of 16 S Direct Drive Version CF75/85, production date < 2003-21 V300420 200337 1-17 https://www.truck-manuals.net/...
  • Page 140 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Version CF75/85, production date ≥ 2003-21 V300712 200337 1-18 https://www.truck-manuals.net/...
  • Page 141 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Pneumatic diagram of 16 S Overdrive Version CF75/85, production date < 2003-21 V300421 200337 1-19 https://www.truck-manuals.net/...
  • Page 142 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Version CF75/85, production date ≥ 2003-21 V300713 200337 1-20 https://www.truck-manuals.net/...
  • Page 143 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General The following applies to pneumatic diagram V300420 and V300421: NOTE: The mechanical position of the splitter switch engaging cylinder (Low (L) and High (H)) depends on the gearbox version: direct drive or overdrive. The gear lever (5) has two switches, one for the splitter group (GV) and one for the range group (GP).
  • Page 144 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General When the gearbox is in neutral, the air supply is connected via connection point 21 of the neutral position valve (1) to connections 1 and 21 of the downshift protection valve (3). If the GP switch (5) is moved to the high (H) position, the range-change gear engaging cylinder (2) is ventilated via connection 25, causing the...
  • Page 145 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General The following applies to pneumatic diagram V300712 and V300713: NOTE: The mechanical position of the splitter switch engaging cylinder (Low (L) and High (H)) depends on the gearbox version: direct drive or overdrive. The gear lever (5) has two switches, one for the splitter group (GV) and one for the range group (GP).
  • Page 146 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General If the GP switch (5) is moved to the low (L) position, the range-change gear engaging cylinder (2) is ventilated via connection 26, causing the range-change gear engaging cylinder to be moved to the low (L) position. If the vehicle speed is lower than a certain value, the electronic unit (4) will supply voltage to the downshift protection valve (3).
  • Page 147 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Pneumatic diagram of 8/9 S Direct Drive Version CF75, production date < 2003-21 V300491 200337 1-25 https://www.truck-manuals.net/...
  • Page 148 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Version CF75, production date ≥ 2003-21 V300880 200337 1-26 https://www.truck-manuals.net/...
  • Page 149 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General Pneumatic diagram, Eaton FS/6309A V300454 200337 1-27 https://www.truck-manuals.net/...
  • Page 150 GEARBOX - PNEUMATIC SECTION CF65/75/85 series General 200337 1-28 https://www.truck-manuals.net/...
  • Page 151 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2. DESCRIPTION OF COMPONENTS 2.1 INTEGRATED AIR DISTRIBUTION BLOCK There are two ways in which the air for the gearbox control unit can be distributed: With a separate air distribution block at the side of the gearbox With an integrated air distribution block on the selector housing.
  • Page 152 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Connection points on integrated air distribution block: Connection to PTO 10 1 Connection to intarder Gear lever air supply Connection to clutch servo Neutral position valve bleed opening Servoshift air supply for 8S gearbox Connection to gate protection valve Connection to downshift protection valve Connection from gate protection valve...
  • Page 153 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Sectional drawing of integrated air distribution block: V300868 Neutral position valve Neutral position valve attachment pin Air distribution block Neutral switch Neutral position valve attachment pin Locking cylinder Locking cylinder lever Reversing switch Reversing switch attachment pin 10.
  • Page 154 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.2 NEUTRAL POSITION VALVE Situation with separate air distribution block: V300140 Pneumatic symbol Connection Function point Supply Cut-in pressure, range-change switch Plugged Position Function Gearbox selector shaft in neutral Gearbox selector shaft engaged V300160 200337...
  • Page 155 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Operation Gearbox in neutral: In the neutral position, thrust pin A will be pushed into a recess in the selector shaft by means of the air pressure coming from connection 1 and a bore hole through sealing pin B.
  • Page 156 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Situation with integrated air distribution block V300862 Pneumatic symbol Connection Function point Supply Cut-in pressure, range-change switch Position Function Gearbox selector shaft in V300863 neutral Gearbox selector shaft engaged 200337 https://www.truck-manuals.net/...
  • Page 157 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.3 DOWNSHIFT PROTECTION VALVE Version CF75/85, production date < 2003-21 V300428 Pneumatic symbol Connection Function point Supply Control pressure High-range cut-in pressure Low-range cut-in pressure V300424 200337 https://www.truck-manuals.net/...
  • Page 158 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Version CF75/85, production date ≥ 2003-21 V 300029 Pneumatic symbol Connection Function point Supply Control pressure High-range cut-in pressure Low-range cut-in pressure Operation If the vehicle speed exceeds a particular value, the coil of the electropneumatic valve is interrupted.
  • Page 159 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.4 HIGH/LOW RANGE ENGAGING CYLINDER V300141 Pneumatic symbol Connection Function point Range-change gear high Range-change gear low Operation The engaging cylinder controlling the V300142 high/low section of the gearbox, receives its supply via the electropneumatic protection valve.
  • Page 160 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.5 GEAR LEVER SELECTOR VALVE Splitter-range switch A Range change gear B D000096 Pneumatic symbol Position Function Range-change gear Splitter V300161 200337 2-10 https://www.truck-manuals.net/...
  • Page 161 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components Operation of the range-change gear Changing to the low or high speed range is done with a switch (B) on the front of the gear lever: turn the switch down to select the low range and up to select the high range.
  • Page 162 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.6 GV VALVE V300177 Pneumatic symbol Connection Function point Supply Control pressure Operation of GV valve The GV (“Getriebevorschalt”) pre-selector valve ensures that when the clutch pedal is depressed pressure is supplied to the splitter cylinder via the relay valve.
  • Page 163 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.7 SPLITTER RELAY VALVE In 16 S gearboxes, the splitter relay valve is located at the left-hand side of the gearbox. The valve is a 5/2 valve. Depending on the type of gearbox (direct input or overdrive), two variants are possible.
  • Page 164 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Description of components 2.8 FILTER/GOVERNOR, EATON FS/6309A Filter/governor (1) on gearbox V300558 Overview drawing, filter/governor, Eaton FS/6309A Filter/governor housing Filter element Sealing ring O-ring Cover Plug Output Selector valve output plug Attachment bolt 10. Supply pressure input V300430 200337 2-14...
  • Page 165 3. INSPECTION AND ADJUSTMENT 3.1 SIMULATION OF THE SPEED SIGNAL The speed signal can be simulated using DELSI (DAF No. 0694941). DELSI must be connected to the speed sensor connector. To connect DELSI to the speed sensor connector, an adapter cable needs to be made.
  • Page 166 Switch off the vehicle ignition. The range-change gear should now D000096 automatically switch to the higher range. Inspection with the vehicle speed signal Ensure there is sufficient air pressure. Connect special tool Delsi-2 (DAF No. 0694941). V300425 200337 https://www.truck-manuals.net/...
  • Page 167 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment Position the gear lever in neutral. Switch the vehicle ignition on. Use the range-change switch (B) on the gear lever to select the lower range. The range-change gear should now switch to the lower range.
  • Page 168 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment 3.3 INSPECTION AND ADJUSTMENT, ZF/EATON GEARBOX GV VALVE Inspection, ZF gearbox GV valve Ensure that the gearbox is in neutral and the parking brake is engaged. Start the engine and run it at idling speed. Use the rocker switch (A ) on the gear lever to select the other splitter mode without depressing the clutch pedal.
  • Page 169 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment Adjusting ZF and/or Eaton gearbox GV valve Note: In order to perform the various adjustments to the clutch pedal, the grille must first be opened. Remove the stop (1) from the clutch housing.
  • Page 170 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment Using an Allen key (2) lowered into the opening of the stop, the adjusting screw (3) can be turned to correct the travel (C). See “Technical data”. Fit the stop. V300316 Adjust the travel (D) by means of the adjusting screw (1).
  • Page 171 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment 3.4 INSPECTION, FILTER/GOVERNOR, EATON FS/6309A Inspection, filter/governor, Eaton FS/6309A Remove plug (8) from the extra outlet and install a pressure gauge. Check the service pressure. See “Technical data”. V300430 200337 https://www.truck-manuals.net/...
  • Page 172 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 173 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, GEAR LEVER SELECTOR VALVE Removing the gear lever selector valve Disconnect the dust cover from the cab floor and raise it over the gear lever as high as possible.
  • Page 174 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Removal and installation Installing the gear lever selector valve Connect the air pipes to the selector valve by pushing them into the respective connections as far as possible. For the connection points in the selector valve, see “Technical data”.
  • Page 175 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Cleaning 5. CLEANING 5.1 CLEANING FILTER/GOVERNOR, EATON FS/6309A Cleaning filter/governor, Eaton FS/6309A Note: The filter must be regularly cleaned with water and a soap solution. Then blow clean the filter with compressed air from the inside. Take the pressure off the air pressure system Remove the plug (5).
  • Page 176 GEARBOX - PNEUMATIC SECTION CF65/75/85 series Cleaning 200337 https://www.truck-manuals.net/...
  • Page 177 ZF 6S-850 GEARBOX CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 178 ZF 6S-850 GEARBOX CF65/75/85 series Contents 0111 https://www.truck-manuals.net/...
  • Page 179 ZF 6S-850 GEARBOX CF65/75/85 series General 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 identity card for the vehicle concerned. ZF gearbox type-plate Type of gearbox Serial no.
  • Page 180 ZF 6S-850 GEARBOX CF65/75/85 series General 0111 https://www.truck-manuals.net/...
  • Page 181 ZF 6S-850 GEARBOX CF65/75/85 series Component description 2. COMPONENT DESCRIPTION 2.1 SYNCHRONISER B-lock synchronisation The synchroniser consists of the following parts: Gear Clutch body Synchromesh ring Synchroniser sleeve support Pressure spring Thrust piece Synchroniser sleeve Main shaft In neutral, the synchroniser sleeve (7) is in the centre position.
  • Page 182 ZF 6S-850 GEARBOX CF65/75/85 series Component description As a result of continued pressure on the synchroniser sleeve (7) (friction), the speed of the gear (1) to be shifted with the clutch body (2) matches the speed of the main shaft (8). The bevelled sides of the teeth on the synchromesh ring (3) and the synchroniser sleeve (7) cause the synchromesh ring (3) to be...
  • Page 183 ZF 6S-850 GEARBOX CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION, GEARBOX OIL LEVEL To prevent skin injury, avoid unnecessary contact with the drained oil. ZF 6S-850 gearbox Position the vehicle on a level surface. Wait for some minutes for the oil to flow back.
  • Page 184 ZF 6S-850 GEARBOX CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL CLEARANCE ZF 6S-850 gearbox Remove the gearbox. See “Removal and installation”. Remove the gearbox front cover from the input shaft. See “Removal and installation”. Press the outermost bearing race uniformly so that the bearing is free of play.
  • Page 185 ZF 6S-850 GEARBOX CF65/75/85 series Inspection and adjustment 3.3 INSPECTION AND ADJUSTMENT, SECONDARY SHAFT AXIAL PLAY Inspection and adjustment, secondary shaft axial play Press the outermost bearing race uniformly so that the bearing is free of play. Rotate the secondary shaft constantly while pressing, so that the bearing gets set.
  • Page 186 ZF 6S-850 GEARBOX CF65/75/85 series Inspection and adjustment 0111 https://www.truck-manuals.net/...
  • Page 187 ZF 6S-850 GEARBOX CF65/75/85 series Removal and installation, gearbox 4. REMOVAL AND INSTALLATION, GEARBOX 4.1 REMOVAL AND INSTALLATION , ENTIRE GEARBOX Removing the entire gearbox Make sure there are no loose items in the cab. Tilt the cab. Disconnect the negative terminal of the battery.
  • Page 188 ZF 6S-850 GEARBOX CF65/75/85 series Removal and installation, gearbox Installing the entire gearbox Before positioning the gearbox, one gear should be engaged in order to allow the input shaft to slide into the clutch plate during installation. Also, grease the input shaft sparingly with the specified grease.
  • Page 189 Make a reference mark on the prop shaft and flange. Detach the prop shaft from the flange and secure it. Fit special tool (DAF No. 0484977) to hold the drive flange in position. Remove the attachment bolt and washer. Remove the drive flange from the shaft V3 00 416 using special tool (DAF No.
  • Page 190 Removing the output shaft oil seal Remove the drive flange. Pull the oil seal from the gearbox housing using the special tool (DAF No. 0484899). Installing the output shaft oil seal Around the oil seal, clean the gearbox housing without letting dirt into the gearbox.
  • Page 191 V3 00 401 Fit the oil seal (2) to the gearbox front cover using special tools (DAF Nos. 0499809 and 0484924). Fit a new gasket (3). Check the input shaft axial play. See “Inspection and adjustment”.
  • Page 192 ZF 6S-850 GEARBOX CF65/75/85 series Removal and installation, gearbox 4.5 REMOVAL AND INSTALLATION, SELECTOR SHAFT OIL SEAL LHD version Removing the selector shaft oil seal Mark the gearbox lever relative to the selector shaft and remove the control lever with the gearbox control. If necessary, disconnect the torque rod.
  • Page 193 Sparingly apply a liquid gasket to the oil seal and fit it in the control cover using special tool (DAF No. 0535659). Now fit the dust seal in the control cover using special tool (DAF No. 0535659). Apply grease to the oil seal lips.
  • Page 194 Installing the selector shaft oil seal Sparingly apply a liquid gasket to the oil seal and fit it in the bearing housing using special tool (DAF No. 0535659). Now fit the dust seal in the bearing housing using special tool (DAF No. 0535659).
  • Page 195 ZF 6S-850 GEARBOX CF65/75/85 series Draining and filling 5. DRAINING AND FILLING 5.1 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. Draining, gearbox Place the vehicle on a level surface. Drain the gearbox at operating temperature using plug (B).
  • Page 196 ZF 6S-850 GEARBOX CF65/75/85 series Draining and filling 0111 https://www.truck-manuals.net/...
  • Page 197 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 198 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Contents 0111 https://www.truck-manuals.net/...
  • Page 199 ZF 8/9/16S-109 GEARBOX CF65/75/85 series General 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 identity card for the vehicle concerned. ZF gearbox type-plate Type of gearbox Serial no.
  • Page 200 ZF 8/9/16S-109 GEARBOX CF65/75/85 series General 1.1 SYSTEM DESCRIPTION, 16S GEARBOXES W303056 Integrated auxiliary gearbox or splitter gearbox (two gears) Main gearbox with four forward gears and one reverse gear Auxiliary gearbox or range gearbox (two gears) Input shaft Lubricating oil pump Main shaft Selector shafts with shifting forks Planetary gears for range group...
  • Page 201 ZF 8/9/16S-109 GEARBOX CF65/75/85 series General Integrated auxiliary gearbox This is an auxiliary gearbox located in the main gearbox housing. Using an additional set of gears, the auxiliary shaft of the main gearbox can be driven by two different ratios. In this way, each gear in the main box can be engaged in a low or high ratio, or split into two (also known as “splitting”).
  • Page 202 ZF 8/9/16S-109 GEARBOX CF65/75/85 series General 8/9S 109 The four gears in the main gearbox are doubled when the auxiliary gearbox is used, giving 4 x 2 = 8 or, with the crawler gear as well, 9 forward gears. The diagram shows the power distribution across the individual gear pairs for each gear.
  • Page 203 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Component description 2. COMPONENT DESCRIPTION 2.1 SYNCHRONISER B-lock synchronisation The synchroniser consists of the following parts: Gear Clutch body Synchromesh ring Synchroniser sleeve support Pressure spring Thrust piece Synchroniser sleeve Main shaft In neutral, the synchroniser sleeve (7) is in the centre position.
  • Page 204 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Component description As a result of continued pressure on the synchroniser sleeve (7) (friction), the speed of the gear (1) to be shifted with the clutch body (2) matches the speed of the main shaft (8). The bevelled sides of the teeth on the synchromesh ring (3) and the synchroniser sleeve (7) cause the synchromesh ring (3) to be...
  • Page 205 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Component description Double-cone synchronisation As a result of the speed difference to be eliminated in the lower gears, the synchronisation forces may be considerable. In order to achieve effective synchronisation, a synchroniser with a double cone is used. This synchroniser consists of an outer and an inner ring (synchromesh rings) connected to the main shaft of the gearbox by means of the...
  • Page 206 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Component description 0111 https://www.truck-manuals.net/...
  • Page 207 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION, GEARBOX OIL LEVEL To prevent skin injury, avoid unnecessary contact with the drained oil. ZF 8S/9S-109 gearboxes Position the vehicle on a level surface. Wait for some minutes for the oil to flow back.
  • Page 208 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL CLEARANCE Inspection and adjustment, input shaft bearing axial play Remove the gearbox. See “Removal and installation”. Remove the gearbox front cover attachment bolts and slide the cover off the input shaft. Use a depth gauge to determine the depth of the recess in the gearbox front cover.
  • Page 209 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Inspection and adjustment If necessary, adjust the axial play by means of another adjusting ring. Install a new gasket and the adjusting ring into the gearbox front cover and fit it to the gearbox. Install the attachment bolts and tighten them to the specified torque.
  • Page 210 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Inspection and adjustment 3.3 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL CLEARANCE Inspection and adjustment, output shaft bearing axial play Remove the rear gearbox bearing cover. Install a new gasket on the bearing cover. Use a depth gauge to determine the depth of the bearing cover recess, distance A.
  • Page 211 Check that the travel is about the same in all gears. Repeat the entire procedure, if necessary. Note: For an improved retention it is possible to fit a heavier retaining spring (191N instead of 168N) (DAF No. 1341343). Fit the shift control. 0111 https://www.truck-manuals.net/...
  • Page 212 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Inspection and adjustment 0111 https://www.truck-manuals.net/...
  • Page 213 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Removal and installation, gearbox 4. REMOVAL AND INSTALLATION, GEARBOX 4.1 REMOVAL AND INSTALLATION , ENTIRE GEARBOX Removing the entire gearbox Make sure there are no loose items in the cab. Tilt the cab. Disconnect the negative terminal of the battery.
  • Page 214 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Removal and installation, gearbox Installing the entire gearbox Before positioning the gearbox, one gear should be engaged in order to allow the input shaft to slide into the clutch plate during installation. Also grease the input shaft sparingly with the specified grease.
  • Page 215 Removing the drive flange Detach the prop shaft from the flange and secure it. Hold the drive flange in place with special tool (DAF No. 0484977). Remove the bolts and lock plate from the drive flange. Remove the O-ring. Recommendation: measure and note the distance from flange to shaft.
  • Page 216 Install the locking plate with the bolts and tighten them to the specified torque. See “Technical data”. Note: Bolts that will be re-used must be cleaned and lightly oiled. V300356 Fit a new locking plate (DAF No. 0699725) with stamp over the bolt heads. 0111 https://www.truck-manuals.net/...
  • Page 217 Installing the output shaft oil seal Fit the oil seal in the bearing cover using special tool (DAF Nos. 1240491 and 1240483). Apply small amount of liquid gasket to the oil seals fitted with a steel sleeve on the outside.
  • Page 218 Installing the gearbox front cover oil seal Pull the oil seal into the gearbox front cover using the special tool (DAF No. 0535423). Apply small amount of liquid gasket to the oil seals fitted with a steel sleeve on the outside.
  • Page 219 Installing the selector shaft oil seal Sparingly apply a liquid gasket to the oil seal and fit it in the bearing housing using special tool (DAF No. 0535659). Now fit the dust seal in the bearing housing using special tool (DAF No. 0535659).
  • Page 220 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Removal and installation, gearbox 0111 https://www.truck-manuals.net/...
  • Page 221 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Draining and filling 5. DRAINING AND FILLING 5.1 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. ZF 8/9/16S-109 gearbox Draining, gearbox Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 222 ZF 8/9/16S-109 GEARBOX CF65/75/85 series Draining and filling 5.2 GEARBOX ZF 8/9/16S-109 WITH INTEGRATED RETARDER Draining, gearbox Before draining take a short test drive. Do not activate the retarder during the test drive. Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 223 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 224 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 225 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series General 1. GENERAL Gearbox type Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle. ZF gearbox type-plate Type of gearbox Series no.
  • Page 226 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series General 1.1 SYSTEM DESCRIPTION W303056 A. Integrated front-mounted range box or splitter range (two gears) B. Main box with four forward gears and one reverse gear C. Rear-mounted range box or range group (two gears) Input shaft Lubricating oil pump...
  • Page 227 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series General A. Integrated front-mounted range box This is a front-mounted range box located in the main box housing. Using an additional set of gears, the auxiliary shaft of the main box can be driven by two different ratios.
  • Page 228 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series General 8S-151/181 The four gears of the main box are multiplied by 2 due to the addition of a rear-mounted range box, creating 4x2 = 8 or, if the crawler gear is counted, 9 forward gears. The diagram shows the power distribution across the individual gear pairs for each gear.
  • Page 229 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Description of components 2. DESCRIPTION OF COMPONENTS 2.1 SYNCHRONISER B-lock synchronisation The synchroniser consists of the following parts: Gear Selector ring Synchromesh ring Selector sleeve support Pressure spring Thrust piece Selector sleeve Main shaft In neutral, the selector sleeve (7) is in the centre position.
  • Page 230 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Description of components As a result of continued pressure on the selector sleeve (7) (friction), the speed of the gear (1) to be shifted with the selector ring (2) matches the speed of the main shaft (8). The bevelled sides of the teeth on the synchromesh ring (3) and the selector sleeve (7) cause the synchromesh ring (3) to be turned...
  • Page 231 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Description of components Double-cone synchronisation As a result of the speed difference to be eliminated in the lower gears, the synchronisation forces may be considerable. In order to achieve effective synchronisation, a synchroniser with a double cone is used. This synchroniser consists of an outer and an inner ring (synchromesh rings) connected to the main shaft of the gearbox by means of the...
  • Page 232 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Description of components 200337 https://www.truck-manuals.net/...
  • Page 233 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION OF GEARBOX OIL LEVEL To prevent skin injury, avoid unnecessary contact with the drained oil. ZF 8S/16S-151/181 and 16S-221 gearboxes Position the vehicle on a level surface. Wait for some minutes to allow the oil to flow back.
  • Page 234 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Inspection and adjustment ZF 8S/16S-151/181 and 16S-221 gearboxes with integrated retarder Place the vehicle on a level surface. Apply the brakes without activating the retarder. Wait for some minutes to allow the oil to flow back.
  • Page 235 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL PLAY Inspection and adjustment, input shaft bearing axial play Remove the gearbox front cover. Use a depth gauge to determine the depth of the recess in the gearbox front cover, distance B.
  • Page 236 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Inspection and adjustment 3.3 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL PLAY Remove the rear gearbox bearing cover. Install a new gasket on the bearing cover. Use a depth gauge to determine the depth of the bearing cover recess, distance A.
  • Page 237 Check that the travel is about the same in 5/7th gear all gears. Repeat the entire procedure, if necessary. Note: For improved retention a heavier retaining spring (191N instead of 168N) may be fitted (DAF No. 1341343). Fit the shift control. V300258 200337 https://www.truck-manuals.net/...
  • Page 238 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 239 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Removal and installation of gearbox 4. REMOVAL AND INSTALLATION OF GEARBOX 4.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY WITH OR WITHOUT NTEGRATED RETARDER Removing the gearbox assembly Disconnect the negative lead from the battery terminal. Disconnect the prop shaft from the gearbox flange and hang it on the chassis.
  • Page 240 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Removal and installation of gearbox Installing the gearbox Before positioning the gearbox, one gear should be engaged in order to allow the input shaft to slide into the clutch plate during installation. Install the thrust bearing over the gearbox front cover and check whether the circlip in the clutch release assembly is closed.
  • Page 241 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Removal and installation of gearbox Removing gearbox with integrated retarder Disconnect the earth lead from the battery terminal. Drain the engine coolant. Remove the coolant pipes from the retarder. Remove the coolant pipes between the retarder and the engine.
  • Page 242 Remove the prop shaft from the gearbox flange and hang it on the chassis. Hold the prop shaft flange in place with the special tool (DAF No. 0484977). Remove the attachment bolts from the prop shaft flange. Remove the bolts and locking plate from the prop shaft flange.
  • Page 243 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Removal and installation of gearbox Hold the prop shaft flange in place with the special tool (DAF No. 0484977). Note: For the new gearboxes the attachment bolts are no longer locked with a locking plate, but with self-locking screw thread in the output shaft.
  • Page 244 Drill two holes into the external cover of the oil seal and turn the special tool (DAF No. 0484899) into the oil seal. Then pull the oil seal out of the bearing cover using the special tool (DAF No. 0694928).
  • Page 245 Apply a thin layer of liquid gasket to the outer circumference of the oil seal and install the oil seal in the gearbox front cover using the special tool (DAF No. 0535703). Check the input shaft bearing axial play. See “Inspection and adjustment”.
  • Page 246 V300407 Remove the oil seals together with the bearing bush from the cover using the special tool (DAF No. 0535659). Check the bearing bush for damage. Replace if necessary. W 3 03 084 200337...
  • Page 247 Apply a thin layer of liquid gasket to the outer circumference of the second oil seal to be installed and install it in the cover using the special tool (DAF No. 0535659). Apply a thin layer of grease to the inside of both oil seals.
  • Page 248 Remove the selector housing with the Servoshift unit from the gearbox. Drill two holes into the seal and, using the special tool (DAF No. 0484899 and DAF No. 0694928), pull the seal out of the selector housing. Note: Check whether the oil seal has been removed completely.
  • Page 249 Apply a little grease to the inside of the oil seal. Fit the oil seal into the selector housing using the special tool (DAF No. 1329450). Install the selector housing with a new gasket on the gearbox and tighten the attachment bolts to the specified torque.
  • Page 250 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Removal and installation of gearbox 200337 4-12 https://www.truck-manuals.net/...
  • Page 251 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Draining and filling 5. DRAINING AND FILLING 5.1 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. ZF 8S/16S-151/181 and 16S-221 gearboxes Draining the gearbox Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 252 ZF 8/16S-151/181 AND 16S-221 GEARBOXES CF65/75/85 series Draining and filling ZF 8/16S-151/181 and 16S-221 gearboxes with integrated retarder Draining the gearbox Before draining take a short test drive. Do not activate the retarder during the test drive. Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 253 EATON FS/6309A GEARBOX CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 254 EATON FS/6309A GEARBOX CF65/75/85 series Contents 0111 https://www.truck-manuals.net/...
  • Page 255 Eaton gearbox type-plate Type of gearbox Specification no. Eaton DAF article Eaton code Serial no. Eaton Production date code The Eaton specification number is unique to each customer and gives detailed information on the development level of the gearbox.
  • Page 256 EATON FS/6309A GEARBOX CF65/75/85 series General 0111 https://www.truck-manuals.net/...
  • Page 257 EATON FS/6309A GEARBOX CF65/75/85 series Inspection and adjustment 2. INSPECTION AND ADJUSTMENT 2.1 INSPECTION, GEARBOX OIL LEVEL To prevent skin injury, avoid unnecessary contact with the drained oil. Position the vehicle on a level surface. Wait for some minutes for the oil to flow back.
  • Page 258 EATON FS/6309A GEARBOX CF65/75/85 series Inspection and adjustment 2.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL CLEARANCE Inspection, input shaft bearing axial play Remove the gearbox. See “Removal and installation”. Remove the gearbox front cover from the input shaft. See “Removal and installation”. Check whether the circlip (1) is flush in the groove.
  • Page 259 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox 3. REMOVAL AND INSTALLATION, GEARBOX 3.1 REMOVAL AND INSTALLATION , ENTIRE GEARBOX Removing the entire gearbox Make sure there are no loose items in the cab. Tilt the cab. Disconnect the battery negative terminal. Remove the attachment bolts of the prop shaft flange and remove the prop shaft.
  • Page 260 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox Installing the gearbox Engage the highest gear in order to align the keys of the input shaft with the clutch plate. Fit the gearbox to the engine. If necessary, rotate the drive flange in order to align the keys.
  • Page 261 Support the prop shaft from a suitable location on the chassis. Fit special tool (DAF No. 0484977) to hold the drive flange in position. Remove the lock nut and ring. Remove the flange with a suitable puller.
  • Page 262 Installing the output shaft oil seal Press the oil seal into its housing with special tool (DAF No. 1329358). Apply sealant to the contact surface of the oil seal housing. Fit the sealing housing and tighten the bolts to the specified torque.
  • Page 263 Installing the gearbox front cover oil seal Fit the oil seal in the gearbox front cover using special tool (DAF No. 1329354). Apply sealant to the contact surface of the gearbox front cover. Fit the gearbox front cover. Tighten the attachment bolts to the specified torque.
  • Page 264 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox 3.5 REMOVAL AND INSTALLATION, SELECTOR SHAFT OIL SEAL Removing the selector shaft oil seal Remove the nut (4) of the ball joint of the control rod on the selector shaft lever and the nut (5) of the torque rod.
  • Page 265 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox Drain the air reservoirs and remove the air connection from the selector shaft housing. Remove the bleed control valve and pin (16). Remove the attachment bolts from the selector shaft housing (15) and remove the housing.
  • Page 266 V3 00 475 Fit a new oil seal ring and, if necessary, new bushes (4) and (9) using special tool (DAF No. 1329352). Place the selector finger (18) in the selector shaft housing (15) with the long groove and the hole for the pin (19) pointing towards the rear.
  • Page 267 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox Fit a new pin (19). Make sure that the holes in the selector finger and the selector shaft are aligned. Fit the circlip (10) and a spring holder (11) onto the selector shaft. Fit the springs (12), a spring holder (11) and the circlip (13) onto the selector shaft.
  • Page 268 EATON FS/6309A GEARBOX CF65/75/85 series Removal and installation, gearbox 0111 3-10 https://www.truck-manuals.net/...
  • Page 269 EATON FS/6309A GEARBOX CF65/75/85 series Draining and filling 4. DRAINING AND FILLING 4.1 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. Draining, gearbox Place the vehicle on a level surface. Note: Drain the gearbox at operating temperature. Remove the combined drain plug/oil strainer (4) and level check/filler plug (1) and drain the oil.
  • Page 270 EATON FS/6309A GEARBOX CF65/75/85 series Draining and filling 0111 https://www.truck-manuals.net/...
  • Page 271 AUTOMATIC GEARBOXES CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 272 AUTOMATIC GEARBOXES CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 273 AUTOMATIC GEARBOXES CF65/75/85 series General 1. GENERAL Allison transmission, used in the CF65/75-series, is electronically controlled and has its own diagnostic system that saves any faults in the memory of the ECU (Electronic Control Unit). The faults can be read at a later date.
  • Page 274 AUTOMATIC GEARBOXES CF65/75/85 series General 1.1 SYSTEM DESCRIPTION “Gearbox” warning symbol When the vehicle ignition is switched on, the “gearbox” warning symbol will not appear on the DIP display. If the gearbox symbol appears in the main display, it indicates a fault in the gearbox (shifting), or that the gearbox oil temperature is too high.
  • Page 275 If after approximately two minutes the warning lamp has not gone out, the engine must be turned off and the nearest DAF dealer contacted. Use of the engine brake When the engine brake is operated in third or...
  • Page 276 AUTOMATIC GEARBOXES CF65/75/85 series General 200337 https://www.truck-manuals.net/...
  • Page 277 AUTOMATIC GEARBOXES CF65/75/85 series Description of components 2. DESCRIPTION OF COMPONENTS 2.1 AUTOMATIC GEARBOX SELECTOR KEYPAD The selector has the following functions: activating and deactivating the gearbox. choosing a shift program reading the oil level reading and deleting fault codes The selector has the following six keys: Neutral Neutral position...
  • Page 278 AUTOMATIC GEARBOXES CF65/75/85 series Description of components Shift program selection By pressing the “MODE” key briefly once, another shift program can be selected when stationary, but also when driving. Two selections are possible: Normal program: This program is chosen automatically when the vehicle ignition has been switched off.
  • Page 279 AUTOMATIC GEARBOXES CF65/75/85 series Description of components Faults If the oil level indicator cannot give the correct oil level, one of the following codes will appear in the display. OL - 50 Engine speed too low OL - 59 Engine speed too high OL - 65 Gearbox is not in neutral OL - 70...
  • Page 280 AUTOMATIC GEARBOXES CF65/75/85 series Description of components 200337 https://www.truck-manuals.net/...
  • Page 281 AUTOMATIC GEARBOXES CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION, OIL LEVEL Inspection, cold oil level Place the vehicle on a level surface. Make sure that the gearbox is in neutral and allow the engine to run for several minutes. Operate the service brake, put the gearbox in D, then in N, and finally put the gearbox in R.
  • Page 282 AUTOMATIC GEARBOXES CF65/75/85 series Inspection and adjustment Inspection, hot oil level Bring the gearbox to operating temperature (approx. 71_C - 93_C). Remove the dipstick when the engine is idling and wipe it clean with a lint-free cloth. Note: To take the dipstick out of the holder, the sealing cap must be held tightly and the dipstick turned anti-clockwise.
  • Page 283 AUTOMATIC GEARBOXES CF65/75/85 series Inspection and adjustment Checking the oil level using the selector keypad Apply parking brake, put the gearbox in the neutral position and bring the gearbox to operating temperature (approx. 71_C - 93_C). Run the engine at idling speed for 2 minutes.
  • Page 284 AUTOMATIC GEARBOXES CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 285 AUTOMATIC GEARBOXES CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY Removing the gearbox assembly Note: Before the gearbox can be removed, the gearbox oil must be drained. If necessary, remove the oil filler pipe to avoid damage.
  • Page 286 AUTOMATIC GEARBOXES CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL Removing the output shaft oil seal Remove the prop shaft and secure it so that it does not interfere with further operations. W 3 03 061 Unscrew the attachment bolt (5) of the flange without removing it from the locking plate.
  • Page 287 W 3 03 062 Drill two holes into the external cover of the oil seal and turn the special tool (DAF No. 0484899) into the oil seal. Pull the oil seal from the gearbox housing using the special tool (DAF No. 0694928).
  • Page 288 Hold the prop shaft flange in place with the special tool (DAF No. 0484977). Tighten the attachment bolt (5) to the specified torque. See “Technical data”. If the locking plate is not tightened...
  • Page 289 AUTOMATIC GEARBOXES CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, OIL FILTERS Removing the oil filters Remove the attachment bolts from the filter covers (2) and take the filter covers off. Collect any oil flowing out of the system. Remove the oil filters from the oil sump.
  • Page 290 AUTOMATIC GEARBOXES CF65/75/85 series Removal and installation 200337 https://www.truck-manuals.net/...
  • Page 291 AUTOMATIC GEARBOXES CF65/75/85 series Draining and filling 5. DRAINING AND FILLING 5.1 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the gearbox Bring the gearbox to operating temperature (approx. 71_C - 93_C) before the oil is drained, so that the oil can be drained more quickly and more completely.
  • Page 292 AUTOMATIC GEARBOXES CF65/75/85 series Draining and filling Check whether the oil level is at the “Cold full” mark. Note: To take the dipstick out of the holder, the sealing cap must be held tightly and the dipstick turned anti-clockwise. Use the selector keypad to check the oil level.
  • Page 293 CLUTCH CF65/75/85 series Contents CONTENTS Page Date SAFETY INSTRUCTIONS ..........
  • Page 294 CLUTCH CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 295 CLUTCH CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 296 CLUTCH CF65/75/85 series Safety instructions 200337 https://www.truck-manuals.net/...
  • Page 297 CLUTCH CF65/75/85 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION, CLUTCH The clutch is a single dry-plate clutch, which is hydraulically operated and pneumatically assisted. The clutch consists of: flywheel clutch plate clutch release assembly By clamping the clutch plate between the flywheel and the clutch release assembly, a torque can be transferred (by means of friction).
  • Page 298 CLUTCH CF65/75/85 series General Push-type clutch V 3 000 52 Fig. 1 200337 https://www.truck-manuals.net/...
  • Page 299 CLUTCH CF65/75/85 series General Pull-type clutch V300114 Fig. 2 200337 https://www.truck-manuals.net/...
  • Page 300 CLUTCH CF65/75/85 series General ZF AS Tronic gearbox clutch V300672 A diaphragm spring requires a self-centring thrust bearing. The type of clutch plate used depends on the following factors. The size of the clutch plate lining must correspond to the desired service life.
  • Page 301 CLUTCH CF65/75/85 series General 2.2 SYSTEM DESCRIPTION OF CLUTCH PROTECTION Pulling off in too high a gear puts excessive stress on the clutch. The clutch protection system makes it difficult to drive off in too high a gear. The clutch protection system prevents driving away in the 3 or higher gear.
  • Page 302 CLUTCH CF65/75/85 series General 2.3 OVERVIEW DRAWING, MAIN CYLINDER Thrust pin with eye Thrust pin adjustment Thrust pin Piston Valve Spring V300410 200337 https://www.truck-manuals.net/...
  • Page 303 CLUTCH CF65/75/85 series General 2.4 OVERVIEW DRAWING, CF75/85 CLUTCH SERVO V300412 Cross-section A - A Servo piston Air valve Spring Pressure pin Air piston Fluid piston Pressure spring Bleed bore Bleed 10. Vent opening 11. Wear indicator 200337 https://www.truck-manuals.net/...
  • Page 304 CLUTCH CF65/75/85 series General 2.5 OVERVIEW DRAWING, CF65 CLUTCH SERVO V3 00 436 Rubber protective bellows 17. Vent opening End-plate 18. Blow-off nipple O-ring 19. Piston seal Push rod 20. O-ring Fastening ring for push rod 21. O-ring Split seal 22.
  • Page 305 CLUTCH CF65/75/85 series General 2.6 OVERVIEW DRAWING, AS TRONIC CLUTCH UNIT V300702 Bleed screw Electronic unit Cable connection to modulator Bleed Compressed air connection Position sensor “Fast clutching” pneumatic valve “Fast declutching” pneumatic valve “Slow declutching” pneumatic valve 10. “Slow clutching” pneumatic valve 11.
  • Page 306 CLUTCH CF65/75/85 series General 2.7 OVERVIEW DRAWING, AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY (The example shown here is a pull-type clutch) V300487 The automatically adjusting clutch release assembly comprises the following parts: Thrust plate Stop plate Stop plate attachment bolt Clutch release assembly cover Stop spring Adjusting ring Slide plate...
  • Page 307 CLUTCH CF65/75/85 series General 2.8 OVERVIEW DRAWING, CLUTCH LEVER ATTACHMENT TO GEARBOX ZF 16S-151/181/221 Bearing Lever assembly Bracket Bearing bush Circlip Shim Lever bearing bush Lever Shaft V300439 AS Tronic Bearing Lever assembly Attachment bolt Bearing bush Oil seal Ball cup Clutch lever Shaft V300671...
  • Page 308 CLUTCH CF65/75/85 series General 2.9 OVERVIEW DRAWING, CLUTCH LEVER ATTACHMENT TO CLUTCH HOUSING V300440 Thrust bearing Lever Ball joint Clutch housing 200337 2-12 https://www.truck-manuals.net/...
  • Page 309 CLUTCH CF65/75/85 series Description of components 3. DESCRIPTION OF COMPONENTS 3.1 MAIN CYLINDER When the clutch pedal is depressed, the thrust pin (3) will move the piston (4) down against the spring (6). As a result, the valve (5) closes and the pressure starts to build up as the sleeve passes the bore hole (7) to the reservoir.
  • Page 310 CLUTCH CF65/75/85 series Description of components 3.2 CF75/85 CLUTCH SERVO V300412 Cross-section A - A Declutching Depressing the clutch pedal results in a build-up of hydraulic pressure. This causes the servo piston (1) to push the air valve (2) from the valve seat, against the force of the spring (3).
  • Page 311 CLUTCH CF65/75/85 series Description of components The pressure pin (4) is pushed forward by the air pressure building up on the air piston (5) and the hydraulic pressure on the fluid piston (6). The pressure pin (4) pushes against the clutch lever, which results in declutching.
  • Page 312 CLUTCH CF65/75/85 series Description of components 3.3 CF65 CLUTCH SERVO V300352 Cross-section A - A Declutching Depressing the clutch pedal results in a build-up of hydraulic pressure. 200337 https://www.truck-manuals.net/...
  • Page 313 CLUTCH CF65/75/85 series Description of components This causes the servo piston (1) to push the air valve (2) from the valve seat, against the force of the spring (3). Air pressure now flows into the cylinder. The pressure pin (4) is pushed forward by the air pressure building up on the air piston (5) and the hydraulic pressure on the fluid piston (6).
  • Page 314 CLUTCH CF65/75/85 series Description of components 3.4 AS TRONIC CLUTCH UNIT The clutch unit (1) is attached to the integrated clutch housing of the gearbox. ZF FRIEDRICHSHAFEN AG V300718 With AS Tronic gearboxes, the clutch is operated fully automatically by the electropneumatic clutch unit (1), which, in its turn, is controlled by the electronics inside the gearbox modulator (5).
  • Page 315 CLUTCH CF65/75/85 series Description of components Y17 Y15 V300802 The clutch unit does not just consist of the pneumatic operating piston (7), but also of four pneumatic valves, which can open or close the clutch either fast or slowly. Valve Y16 is for fast declutching, valve Y17 for slow declutching.
  • Page 316 CLUTCH CF65/75/85 series Description of components 3.5 AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY Automatically adjusting clutch release assembly The clutch can be fitted with an automatically adjusting clutch release assembly. The automatically adjusting clutch release assembly is used in both the push and pull clutch types. The automatic assembly is always combined with a clutch plate with a clearance of 5 mm for lining wear.
  • Page 317 CLUTCH CF65/75/85 series Description of components A push-type clutch with an automatically adjusting clutch release assembly is described here as an example. 1 2 3 As the result of wear, the lining of the clutch plate becomes thinner and the distance (A) between the flywheel and the diaphragm spring decreases.
  • Page 318 CLUTCH CF65/75/85 series Description of components The adjusting ring (6) twists as a result of the tension applied by the adjusting springs (10). The adjusting ring twists by the same amount as the former gap (B) in the recess in the adjusting ring (6).
  • Page 319 CLUTCH CF65/75/85 series Description of components The automatically adjusting clutch release assembly comprises the following parts: V300487 Thrust plate Stop plate Stop plate attachment bolt Clutch release assembly cover Stop spring Adjusting ring Slide plate Diaphragm spring Pre-adjusting spring 10. Adjusting spring 200337 3-11 https://www.truck-manuals.net/...
  • Page 320 CLUTCH CF65/75/85 series Description of components 3.6 CF75/85 CLUTCH WEAR INDICATOR CF75 and CF85 wear indicator The wear indicator consists of a pin (11) which protrudes out of the clutch servo housing. The part of the pin within the clutch servo lies loose against the air piston (5).
  • Page 321 CLUTCH CF65/75/85 series Description of components 3.8 THRUST BEARING The CF65/75/85-series has two versions of thrust bearing, one with and one without plastic coating. The thrust bearing without plastic coating can be recognised by the aluminium lining on the inner diameter.
  • Page 322 CLUTCH CF65/75/85 series Description of components 200337 3-14 https://www.truck-manuals.net/...
  • Page 323 CLUTCH CF65/75/85 series Inspection and adjustment 4. INSPECTION AND ADJUSTMENT 4.1 INSPECTION AND ADJUSTMENT, CLUTCH PEDAL Inspection, clutch pedal Check the total travel (D) of the clutch pedal: see “Technical data”. Check the free travel (B) of the clutch pedal: see “Technical data”.
  • Page 324 CLUTCH CF65/75/85 series Inspection and adjustment The free travel (B) of the clutch pedal is set indirectly by loosening the lock nut (2) and then screwing the ball joint (1) into or out of the thrust pin (3). This sets the distance (E) between the thrust pin (3) and the piston (4) in the main cylinder: see “Technical data”.
  • Page 325 CLUTCH CF65/75/85 series Inspection and adjustment 4.2 INSPECTION, CLUTCH SERVO Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 326 CLUTCH CF65/75/85 series Inspection and adjustment Check that there is no leakage via the vent opening (10). Note: A drop of oil on the vent opening (10) is normal and is not a reason to replace the clutch servo. If there is constant leakage, the clutch servo must be repaired or replaced.
  • Page 327 CLUTCH CF65/75/85 series Inspection and adjustment 4.3 INSPECTION, CLUTCH FLUID LEVEL Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 328 CLUTCH CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 329 CLUTCH CF65/75/85 series Removal and installation 5. REMOVAL AND INSTALLATION 5.1 REMOVAL AND INSTALLATION, CLUTCH SERVO Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 330 CLUTCH CF65/75/85 series Removal and installation Installing the clutch servo Fit the clutch servo. Make sure that the thrust pin fits into the cup-shaped recess in the clutch lever. Note: If the clutch servo with wear-indicator is used in the CF65, pay attention to the following.
  • Page 331 CLUTCH CF65/75/85 series Removal and installation 5.2 REMOVAL AND INSTALLATION, AS TRONIC CLUTCH UNIT Removing the clutch unit Remove the bolts (1) from the clutch inspection cover (2) and remove the clutch inspection cover. Remove the connector (4) on the left-hand side of the gearbox modulator and the speed sensor connector (3).
  • Page 332 CLUTCH CF65/75/85 series Removal and installation 5.3 REMOVAL AND INSTALLATION, PULL-TYPE CLUTCH THRUST BEARING Removing the pull-type clutch thrust bearing Remove the gearbox. Remove the thrust bearing from the clutch release assembly by releasing the retaining clip (A) from the clutch release assembly. Installing the pull-type clutch thrust bearing In the case of thrust bearings with a plastic coating, no grease should be...
  • Page 333 CLUTCH CF65/75/85 series Removal and installation Check whether the retainer plate (2) and circlip (1) and retaining clip (3) have been fitted in the correct locations. The diaphragm springs (4) have special recesses to accommodate the retaining clips (3). V300122 Fit the gearbox.
  • Page 334 CLUTCH CF65/75/85 series Removal and installation 5.4 REMOVAL AND INSTALLATION, PUSH-TYPE CLUTCH THRUST BEARING Removing the push-type clutch thrust bearing Remove the gearbox. Remove the thrust bearing from the clutch lever in the clutch housing. If fitted, remove the locking bolt (1). Note: This applies only to the fork of the CF75.
  • Page 335 CLUTCH CF65/75/85 series Removal and installation 5.5 REMOVAL AND INSTALLATION, PULL-TYPE CLUTCH LEVER Removing the pull-type clutch lever Remove the gearbox. Remove the thrust bearing. Remove the attachment bolts from the clutch lever. Installing the pull-type clutch lever Apply a little grease to the moving parts of the clutch lever.
  • Page 336 CLUTCH CF65/75/85 series Removal and installation 5.6 REMOVAL AND INSTALLATION, PUSH-TYPE CLUTCH LEVER V300440 Removing the push-type clutch lever Remove the gearbox. Remove the thrust bearing. Force the clutch lever (2) out of the ball joint (3) fitted in the clutch housing (4). Installing the push-type clutch lever Apply a little grease to the moving parts of the clutch lever.
  • Page 337 CLUTCH CF65/75/85 series Removal and installation 5.7 REMOVAL AND INSTALLATION, CLUTCH RELEASE ASSEMBLY/CLUTCH PLATE Removing the clutch release assembly/clutch plate Remove the gearbox. If necessary, remove the thrust bearing. Insert a dummy input shaft through the hub of the clutch plate in the flywheel pilot bearing.
  • Page 338 CLUTCH CF65/75/85 series Removal and installation Installing the clutch release assembly/clutch plate Apply a little grease to the input shaft and check the movement of the clutch plate on the splines of the input shaft. Use a dummy input shaft to position the clutch plate against the flywheel.
  • Page 339 CLUTCH CF65/75/85 series Removal and installation 5.8 REMOVAL AND INSTALLATION, AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY/CLUTCH PLATE Removing the automatically adjusting clutch release assembly/clutch plate Remove the gearbox. If necessary, remove the thrust bearing. Insert a dummy input shaft through the hub of the clutch plate in the flywheel pilot bearing.
  • Page 340 CLUTCH CF65/75/85 series Removal and installation Note: If you want to disassemble the entire clutch assembly, always loosen the attachment bolt (1) of the stop plate (2) first before removing the clutch release assembly. If you do not loosen the attachment bolt (1) of the stop plate (2) before removing the clutch release assembly, the stop spring (3) will be deformed.
  • Page 341 CLUTCH CF65/75/85 series Removal and installation Note: When refitting an existing clutch release assembly and clutch plate, the attachment bolt (1) of the stop plate (2) must be loosened before removing the clutch release assembly. This prevents deformation of the stop spring (3). A deformed stop spring (3) will deflect the automatically adjusting assembly to its maximum extent, causing it to stop working...
  • Page 342 CLUTCH CF65/75/85 series Removal and installation Installation of a new automatically adjusting clutch release assembly/clutch plate Note: The automatically adjusting clutch release assemblies have a transport mechanism. This transport mechanism prevents deformation of the stop spring in the clutch release assembly that might occur during transport.
  • Page 343 CLUTCH CF65/75/85 series Removal and installation 5.9 REMOVAL AND INSTALLATION, PILOT BEARING Removing the pilot bearing Remove the gearbox. Remove the clutch release assembly and the clutch plate. Use an internal puller (2) to remove the pilot bearing (1) from the flywheel. W 3 04 016 Fitting the pilot bearing Check the flywheel bore for dirt and...
  • Page 344 CLUTCH CF65/75/85 series Removal and installation 5.10 REMOVAL AND INSTALLATION, MAIN CYLINDER Hydraulic fluid is toxic and can therefore have a damaging effect on your health.Hence avoid any direct or indirect physical contact. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 345 CLUTCH CF65/75/85 series Removal and installation Installing the main cylinder Check the dust cover for wear and replace if necessary. Fit the main cylinder together with the pipe to the reservoir. Fit the clutch pipe. Fit the main cylinder attachment bolts to the bracket and tighten them.
  • Page 346 CLUTCH CF65/75/85 series Removal and installation 200337 5-18 https://www.truck-manuals.net/...
  • Page 347 CLUTCH CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING, CLUTCH SYSTEM Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 348 CLUTCH CF65/75/85 series Draining and filling 6.2 BLEEDING THE CLUTCH SYSTEM Hydraulic fluid is toxic and can have a damaging effect on your health. Direct or indirect physical contact should therefore be avoided. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 349 CLUTCH CF65/75/85 series Draining and filling Bleeding the clutch system by operating the clutch pedal Connect a transparent pipe to the clutch servo’s bleed nipple. Insert the pipe into a jar filled with the specified fluid. Ensure that the end is below the fluid level.
  • Page 350 CLUTCH CF65/75/85 series Draining and filling 6.3 BLEEDING AS TRONIC CLUTCH UNIT Note: The clutch unit must be bled before it is installed, to prevent it from being installed under tension. Undo the bleed screw (2) of the clutch unit (1). Push the control rod (3) inwards and tighten the bleed screw while the control rod is depressed.
  • Page 351 PROP SHAFTS CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 352 PROP SHAFTS CF65/75/85 series Contents 0111 https://www.truck-manuals.net/...
  • Page 353 1.1 OVERVIEW DRAWING, PROP SHAFT V300450 Intermediate shaft Centre bearing Drive flange Fork Slide joint Prop shaft Balancing plates For the CF65/75/85 vehicle series, DAF has one manufacturer of prop shafts, Klein. Klein shafts can be identified by their highly bevelled flanges. 0111 https://www.truck-manuals.net/...
  • Page 354 PROP SHAFTS CF65/75/85 series General 1.2 OVERVIEW DRAWING, CENTRE BEARING Sealing ring Rubber block Bearing Dust cover Flange W 3 06 023 0111 https://www.truck-manuals.net/...
  • Page 355 PROP SHAFTS CF65/75/85 series Inspection and adjustment 2. INSPECTION AND ADJUSTMENT 2.1 INSPECTION, PROP SHAFT Check the universal joints and centre bearing for play and damage. M3032 Check the slide coupling for radial play. M3019 There must be no clearly noticeable play on universal joints and centre bearing.
  • Page 356 PROP SHAFTS CF65/75/85 series Inspection and adjustment Now check the slide coupling radial play manually. If radial play is found in the slide coupling, first make sure that the play does not come from the universal joints. In order to ensure that the play noticed lies within the maximum permissible tolerance, remove and check the prop shaft.
  • Page 357 PROP SHAFTS CF65/75/85 series Removal and installation 3. REMOVAL AND INSTALLATION 3.1 REMOVAL AND INSTALLATION, PROP SHAFT/AUXILIARY SHAFT ASSEMBLY Removal, prop shaft/intermediate shaft assembly When removing one of the shafts in vehicles with multiple shafts (prop shaft and auxiliary shafts), the other shaft must be tied to the chassis or intermediate beam in such a way that it does not obstruct the various activities.
  • Page 358 PROP SHAFTS CF65/75/85 series Removal and installation 0111 https://www.truck-manuals.net/...
  • Page 359 PROP SHAFTS CF65/75/85 series Disassembly and assembly 4. DISASSEMBLY AND ASSEMBLY 4.1 DISASSEMBLY AND ASSEMBLY, UNIVERSAL JOINT Disassembly, universal joint Remove the entire prop shaft and/or intermediate shaft. If fitted, remove the lubricating nipple and all Seeger rings from the spider to be replaced. W 3 06 009 Place the shaft on a bush underneath a press, as shown, and press the entire...
  • Page 360 PROP SHAFTS CF65/75/85 series Disassembly and assembly Rotate the shaft 180_ and remove the bearing that has just been pressed out. If the first bearing to be removed fails to come out of the fork entirely, the bearing can be clamped to enable the fork to be pushed up by means of a lever.
  • Page 361 PROP SHAFTS CF65/75/85 series Disassembly and assembly Assembly, universal joint Note: After installation, it must be possible to move the drive flanges and spiders by hand. When mounting the spider, Seeger rings of the same thickness must be used. Install the sealing rings in their proper positions on the bearings and lubricate them lightly so that the needles remain in place.
  • Page 362 PROP SHAFTS CF65/75/85 series Disassembly and assembly Continue to press the bearing until a Seeger ring can be installed on the side that is pressed. Install the Seeger ring and press the opposite bearing further into the fork. Then also install a Seeger ring here. Install the sealing rings in their proper positions on the prop shaft bearings and lubricate them lightly so that the needles...
  • Page 363 Remove the bolts that attach the flange to the prop shaft and the auxiliary shaft. Also secure the prop shaft carefully to the chassis. Attach the special tool (DAF no. 0484977) to apply counter-pressure against the flange, and remove the central nut and the washer.
  • Page 364 PROP SHAFTS CF65/75/85 series Disassembly and assembly Use a plastic hammer to tap the flange and the centre bearing from the auxiliary shaft. If necessary, use a puller. W 3 06 028 W 3 06 027 Remove the lock plate from the mounting bracket.
  • Page 365 PROP SHAFTS CF65/75/85 series Disassembly and assembly Unscrew the flange with bearing and rubber block (2) from the bracket. W 3 06 022 Press the flange from underneath and press the bearing out. 10. Press the bearing with one sealing ring (1) out of the rubber block.
  • Page 366 PROP SHAFTS CF65/75/85 series Disassembly and assembly Assembling the centre bearing Press the sealing ring into the bush of the rubber block until it aligns with the outside of the bush. W 3 06 021 W 3 06 026 Press the bearing along the other side into the bush.
  • Page 367 PROP SHAFTS CF65/75/85 series Disassembly and assembly Press the assembly onto the flange, the larger space between bearing and sealing ring facing the flange. Install the centre bearing assembly in the bracket and lock it with the lock plate. W 3 06 024 Install the centre bearing onto the auxiliary shaft.
  • Page 368 PROP SHAFTS CF65/75/85 series Disassembly and assembly 0111 4-10 https://www.truck-manuals.net/...
  • Page 369 PROP SHAFTS CF65/75/85 series Lubrication 5. LUBRICATION 5.1 LUBRICATION, PROP SHAFT AND AUXILIARY SHAFT Note: Standard vehicles have a maintenance-free prop shaft. Vehicles that are to be used in heavy conditions are fitted as standard with lubricating nipples in the prop shaft spiders. The following applies to these vehicles: Before lubricating, clean the lubricating nipple with a cloth.
  • Page 370 PROP SHAFTS CF65/75/85 series Lubrication 0111 https://www.truck-manuals.net/...
  • Page 371 ZF INTARDER CF65/75/85 series Contents CONTENTS Page Date SAFETY INSTRUCTIONS ..........
  • Page 372 ZF INTARDER CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...
  • Page 373 ZF INTARDER CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS Be careful when changing the oil. Hot oil may cause serious injuries. Avoid unnecessary contact with drained oil. Frequent contact damages the skin. Various kinds of oil and other lubricants used on the vehicle may constitute a health hazard.
  • Page 374 ZF INTARDER CF65/75/85 series Safety instructions 200337 https://www.truck-manuals.net/...
  • Page 375 ZF INTARDER CF65/75/85 series General 2. GENERAL 2.1 OVERVIEW DRAWING, INTARDER V300074 Locking plate Bolt Plate O-ring Prop shaft flange Oil seal Flange bolt Output shaft shim Drive sprocket 10. Stator shim 11. Gasket 12. Intarder housing Intarder housing sealing surface Ball bearing sealing surface Stator contact surface 200337...
  • Page 376 ZF INTARDER CF65/75/85 series General 2.2 OVERVIEW DRAWING, HYDRAULIC CONTROL UNIT V300075 Attachment bolt Attachment plate Gasket Attachment bolt Plungers and springs Drain plug Control unit housing Gasket Proportional valve 10. O-ring 200337 https://www.truck-manuals.net/...
  • Page 377 ZF INTARDER CF65/75/85 series General 2.3 LOCATION OF MAIN COMPONENTS V300490 Intarder proportional valve control plunger Air supply solenoid valve Selector valve spring sealing plug Proportional valve Accumulator Attachment to gearbox Heat exchanger 10. Coolant temperature sensor Oil pump gear wheels 11.
  • Page 378 ZF INTARDER CF65/75/85 series General 200337 https://www.truck-manuals.net/...
  • Page 379 ZF INTARDER CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, OUTPUT SHAFT BEARING AXIAL PLAY V300070 Measure and note down distance “A - B” from sealing surface A with gasket to contact surface B. Measure and note down distance “D” from the ball bearing outer race to the gasket on the gearbox.
  • Page 380 ZF INTARDER CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, STATOR AXIAL PLAY V300070 Measure and note down distance “A - C” from sealing surface A with gasket to contact surface C. Example: Distance A - C = 1.10 mm Distance A - C should 0.05 mm Required thickness of...
  • Page 381 ZF INTARDER CF65/75/85 series Inspection and adjustment 3.3 INSPECTION, GEARBOX/INTARDER OIL LEVEL Inspection, gearbox/intarder oil level Slow the vehicle down without using the intarder and place the vehicle on a level surface. Wait for some minutes for the gearbox oil to flow back.
  • Page 382 ZF INTARDER CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 383 ZF INTARDER CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, INTARDER ASSEMBLY To prevent skin injury, avoid unnecessary contact with the drained oil. In the course of the following operations, oil will spill from the gearbox and intarder.
  • Page 384 Install the attachment bolts and tighten them to the specified torque. See “Technical data”. Fit the lock plate using the special tool (DAF No. 0694903). Connect the water hoses to the heat exchanger. Connect the air pipe to the solenoid valve.
  • Page 385 ZF INTARDER CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, AIR SUPPLY SOLENOID VALVE Removing the air supply solenoid valve Remove the air pipe from the solenoid valve. Remove the electric wiring from the solenoid valve. Remove the attachment bolts from the solenoid valve and remove the solenoid valve.
  • Page 386 ZF INTARDER CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, ACCUMULATOR To prevent skin injury, avoid unnecessary contact with the drained oil. In the course of the following operations, oil and water will escape from the heat exchanger. Collect the oil and water. To prevent skin injury, avoid unnecessary contact with the drained oil.
  • Page 387 ZF INTARDER CF65/75/85 series Removal and installation 4.4 REMOVAL AND INSTALLATION, HEAT EXCHANGER In the course of the following operations, oil and water will escape from the heat exchanger. Collect the oil and water. Take measures to prevent the heat exchanger from falling down.
  • Page 388 ZF INTARDER CF65/75/85 series Removal and installation Installing the heat exchanger Insert new O-rings into the circular slots of the control unit. Install the studs in the heat exchanger and tighten them to the specified torque. See “Technical data”. Apply Loctite to the contact surfaces, studs, and attachment nuts/bolt.
  • Page 389 ZF INTARDER CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, HYDRAULIC CONTROL UNIT In the course of the following operations, oil and water will escape from the heat exchanger and control unit. Collect the oil and water. Take measures to prevent the heat exchanger from falling down.
  • Page 390 ZF INTARDER CF65/75/85 series Removal and installation V300075 Remove the control unit (7) and the gasket (8). If necessary, remove and inspect the plungers and springs (5). Avoid damaging the plungers and plunger guides. Note: The sealed plunger (see arrow in illustration) must not be removed;...
  • Page 391 ZF INTARDER CF65/75/85 series Removal and installation 4.6 REMOVAL AND INSTALLATION, OIL PUMP Removing the oil pump Remove the heat exchanger. Remove the bolts attaching the oil pump (2) to the control unit. Remove the entire oil pump from the control unit and remove the O-ring.
  • Page 392 ZF INTARDER CF65/75/85 series Removal and installation 4.7 REMOVAL AND INSTALLATION, OIL FILTER To prevent skin injury, avoid unnecessary contact with the drained oil. Removing the gearbox oil filter Remove the attachment bolt (1) of the oil filter. M3052 Pull the filter cover with the filter from the filter housing.
  • Page 393 ZF INTARDER CF65/75/85 series Removal and installation Installing the gearbox oil filter Check the O-ring of the filter cover (2) for any damage. Replace the O-ring if necessary. Grease the O-ring. Grease the O-ring of the new filter (3) and place the filter on the filter cover.
  • Page 394 ZF INTARDER CF65/75/85 series Removal and installation 4.8 REMOVAL AND INSTALLATION, PROPORTIONAL VALVE Removing the proportional valve Remove the electrical wiring from the valve. Remove the attachment bolts and remove the proportional valve. Remove the O-ring. Installing the proportional valve Fit a new O-ring on the proportional valve and lightly grease the O-ring.
  • Page 395 ZF INTARDER CF65/75/85 series Removal and installation 4.9 REMOVAL AND INSTALLATION, INTARDER DRIVE V300077 Removing the intarder drive Remove the intarder. Remove the air connections from the high/low shift control to the cylinder (2). Remove the attachment bolts (1) of the cylinder (2) and remove the cylinder.
  • Page 396 ZF INTARDER CF65/75/85 series Removal and installation Remove the attachment bolts from the rear cover and remove the rear cover. Make sure the intarder remains in place. Remove the gearbox gasket. If necessary, use a tripod puller to remove the drive sprocket from the intarder. V300081 Installing the intarder drive Heat the drive sprocket and install the drive...
  • Page 397 ZF INTARDER CF65/75/85 series Removal and installation V300077 Install the piston (9) on the selector shaft and tighten the lock nut (6) to the specified torque. See “Technical data”. Install the cylinder (2) and tighten the attachment bolts to the specified torque. See “Technical data”.
  • Page 398 ZF INTARDER CF65/75/85 series Removal and installation 200337 4-16 https://www.truck-manuals.net/...
  • Page 399 ZF INTARDER CF65/75/85 series Disassembly and assembly 5. DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY, ACCUMULATOR Disassembling the accumulator Take out the bolts and/or nuts attaching the cylinder to the accumulator bracket, and remove the bracket. Remove the O-rings on the bottom of the sealing surfaces of the accumulator/heat exchanger.
  • Page 400 ZF INTARDER CF65/75/85 series Disassembly and assembly Assembling the accumulator Install the central scraper rings on the piston. Note: There are two different types of sleeve: one with and one without a steel inner spring. Install the sleeve with the steel inner spring at the oil side of the piston.
  • Page 401 ZF INTARDER CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING, GEARBOX/INTARDER Draining the gearbox ZF 8/9/16S-109 Before draining take a short test drive. Do not activate the intarder during the test drive. Place the vehicle on a level surface. Drain the gearbox at operating temperature via drain plugs 1 and 2.
  • Page 402 ZF INTARDER CF65/75/85 series Draining and filling Filling, gearbox (after repair or with a new gearbox) ZF 8/9/16S-109 Place the vehicle on a level surface. Fill the oil through the filler openings (5) until the oil reaches the rim of the level check/filler opening (4).
  • Page 403 ZF INTARDER CF65/75/85 series Draining and filling Draining the gearbox ZF 16S-151/181/221 Before draining take a short test drive. Do not activate the intarder during the test drive. Place the vehicle on a level surface. Drain the gearbox at operating temperature using plugs B, C and D.
  • Page 404 ZF INTARDER CF65/75/85 series Draining and filling Filling, gearbox (oil change) ZF 16S-151/181/221 Clean the drain plugs and tighten them to the specified torque. See “Technical data”. Top up oil through level check/filler opening (A) until the oil reaches the rim of the filler opening (A).
  • Page 405 ZF INTARDER CF65/75/85 series Draining and filling Filling, gearbox (after repair or with a new gearbox) ZF 16S-151/181/221 Place the vehicle on a level surface. Top up oil to the rim through the level check/filler opening (A). After filling take a short test drive. The intarder must be briefly fully activated at the beginning of the test drive.
  • Page 406 ZF INTARDER CF65/75/85 series Draining and filling 200337 https://www.truck-manuals.net/...
  • Page 407 ......... . . 200337 Inspection and adjustment, DAF engine PTO prop shaft axial play ...

  • Page 408: Table Of Contents

    ........... 200337 Removal and installation, DAF engine PTO flywheel housing ....
  • Page 409 CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS To prevent skin injury, avoid unnecessary contact with the drained oil. During work on the gearbox PTO, oil may flow from the gearbox. Collect this oil. Never park a vehicle with the PTO engaged.
  • Page 410 CF65/75/85 series Safety instructions 200337 https://www.truck-manuals.net/...
  • Page 411 CF65/75/85 series General 2. GENERAL 2.1 DAF ENGINE PTO DRIVE SIDE CROSS SECTION V300295 200337 https://www.truck-manuals.net/...
  • Page 412 CF65/75/85 series General 2.2 DAF ENGINE PTO ENGINE SIDE CROSS SECTION V300296 200337 https://www.truck-manuals.net/...
  • Page 413 CF65/75/85 series General 2.3 OVERVIEW DRAWINGS, DAF ENGINE PTO WITHOUT DRIVE FLANGE AND CONTROL V300297 200337 https://www.truck-manuals.net/...
  • Page 414 CF65/75/85 series General 2.4 OVERVIEW DRAWINGS, DAF ENGINE PTO WITH DRIVE FLANGE AND WITHOUT CONTROL V300299 200337 https://www.truck-manuals.net/...
  • Page 415 CF65/75/85 series General 2.5 OVERVIEW DRAWINGS, DAF ENGINE PTO WITH DRIVE FLANGE AND CONTROL V300298 200337 https://www.truck-manuals.net/...
  • Page 416 CF65/75/85 series General 2.6 OVERVIEW DRAWINGS, DAF ENGINE PTO WITH THIRD GEAR WHEEL FOR OPPOSITE DRIVE FLANGE DIRECTION OF ROTATION V300300 200337 https://www.truck-manuals.net/...
  • Page 417 CF65/75/85 series General 2.7 OVERVIEW DRAWINGS, PTO VERSIONS NL/1 AND NH/1 VERSIONS V300621 NL/4 AND NH/4 VERSIONS V300622 200337 https://www.truck-manuals.net/...
  • Page 418 CF65/75/85 series General N221/10 VERSION FOR GEARBOX WITHOUT INTARDER V300213 200337 https://www.truck-manuals.net/...
  • Page 419 CF65/75/85 series General N221/10 VERSION FOR GEARBOX WITH INTARDER V300214 200337 https://www.truck-manuals.net/...
  • Page 420 CF65/75/85 series General N AS/10 VERSION V300876 200337 2-10 https://www.truck-manuals.net/...
  • Page 421 CF65/75/85 series General Z81 VERSION FOR EATON GEARBOX V300624 2266 VERSION FOR EATON GEARBOX V300623 200337 2-11 https://www.truck-manuals.net/...
  • Page 422 CF65/75/85 series General 2.8 OVERVIEW DRAWING, NL/1 AND NH/1 PTO, B VERSION V300872 Studs Gasket NH/1 needle bearing width 16 mm NL/1 needle bearing width 12 mm PTO housing Lock washer and nut PTO control switch (depending on version, this may be of the reed switch type) 200337 2-12 https://www.truck-manuals.net/...
  • Page 423 CF65/75/85 series General 2.9 OVERVIEW DRAWING, NL/1 AND NH/1 PTO, C VERSION V300873 Studs Gasket PTO housing Gasket Synchroniser sleeve Spring Piston Centring ring PTO-housing cover 10. Lock washer and nut 11. PTO control switch (depending on version, this may be of the reed switch type) 200337 2-13 https://www.truck-manuals.net/...
  • Page 424 CF65/75/85 series General 2.10 OVERVIEW DRAWING, NL/4 AND NH/4 PTO, B VERSION V300874 Studs Gasket NH/4 needle bearing width 16 mm NL/4 needle bearing width 12 mm PTO housing Lock washer and nut Lock washer and nut PTO control switch (depending on version, this may be of the reed switch type) 200337 2-14...
  • Page 425 CF65/75/85 series General 2.11 OVERVIEW DRAWING, NL/4 AND NH/4 PTO, C VERSION V300875 Studs Gasket NH/4 needle bearing width 16 mm NL/4 needle bearing width 12 mm PTO housing Lock washer and nut Gear Gasket Transport cover Lock washer and nut 10.
  • Page 426 CF65/75/85 series General 2.12 OVERVIEW DRAWING, N221/10 PTO ON GEARBOX WITHOUT INTARDER Side cover attachment bolts Side cover Gasket PTO housing Long attachment bolts Short attachment bolts O-ring Centring ring Gasket 10. Adjusting ring V300221 2.13 OVERVIEW DRAWING, N221/10 PTO ON GEARBOX WITH INTARDER Side cover attachment bolts Side cover Gasket...

  • Page 427: Without Intarder

    CF65/75/85 series General 2.14 OVERVIEW DRAWING, N AS/10 PTO Side cover attachment bolts Side cover Gasket PTO housing Short attachment bolts Long attachment bolts O-ring O-ring Centring ring 10. Gasket V300877 2.15 OVERVIEW DRAWING, PTO INTERMEDIATE SHAFT FOR GEARBOX WITHOUT INTARDER Auxiliary shaft Taper roller bearing Gearbox housing...
  • Page 428 CF65/75/85 series General 2.16 OVERVIEW DRAWING, PTO INTERMEDIATE SHAFT FOR GEARBOX WITH INTARDER Intermediate shaft Ball bearing Circlip O-ring Intermediate housing Long attachment bolt Short attachment bolt Gasket V300224 200337 2-18 https://www.truck-manuals.net/...
  • Page 429 CF65/75/85 series General 2.17 OVERVIEW DRAWING, Z81 PTO, B VERSION V300629 Stud Gasket Adapter plate, lubrication PTO housing Air connection Synchroniser sleeve Sleeve spring Piston Spacer ring 10. PTO housing cover 11. Lock washer and nut 12. Shaft seal 13. Drive flange 200337 2-19 https://www.truck-manuals.net/...
  • Page 430 CF65/75/85 series General 2.18 OVERVIEW DRAWING, Z81 PTO, C VERSION V300630 Stud Gasket Adapter plate, lubrication PTO housing Air connection Synchroniser sleeve Sleeve spring Piston Spacer ring 10. Shim 11. Transport cover 12. Lock washer and nut 200337 2-20 https://www.truck-manuals.net/...
  • Page 431 CF65/75/85 series General 2.19 OVERVIEW DRAWING, 2266 PTO, B VERSION V300631 PTO cover Gasket Drive sprocket Spacer ring Piston Spring Shim PTO housing Gasket 10. PTO cover 11. Lock washer and nut 12. Output shaft 13. Drive flange 14. Locking plate 15.
  • Page 432 CF65/75/85 series General 2.20 OVERVIEW DRAWING, 2266 PTO, C VERSION V300632 PTO cover Gasket Drive sprocket Spacer ring Piston Spring Shim PTO housing Bolt 10. Output shaft 11. Gasket 12. Transport cover 13. Lock washer and nut 14. Air connection 15.
  • Page 433 CF65/75/85 series General 2.21 PNEUMATIC DIAGRAM, PTO CONTROL Description Depending on the version, the electropneumatic valve (1) is controlled by a switch or a combination of a switch and GV pressure sensor located in the cab. By operating the PTO control switch, voltage is applied to the VIC electronic unit (3).
  • Page 434 CF65/75/85 series General 200337 2-24 https://www.truck-manuals.net/...
  • Page 435 CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, DAF ENGINE PTO PROP SHAFT AXIAL PLAY Inspection and adjustment, DAF engine PTO prop shaft axial play Press the two outer bearing races into the PTO housing.
  • Page 436 CF65/75/85 series Inspection and adjustment Fit the inner bearing (5) and the knurled sleeve (6) onto the driving tool (the knurled sleeve is used to simulate the PTO gearwheel). Fit the lock nut (7) and tighten to the specified torque. See “Technical data”. V300633 Place the dial gauge holder onto the PTO housing and allow the stylus of the dial...
  • Page 437 CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, AXIAL PLAY OF DRIVE SPROCKETS IN FLYWHEEL HOUSING OF DAF ENGINE PTO Inspection and adjustment, axial play of drive sprockets in flywheel housing Note: The procedures apply to both sets of drive sprockets.
  • Page 438 CF65/75/85 series Inspection and adjustment Starting with the thickest, place two shims on the inner race and fit the second inner bearing race. Place another driving tool on the inner race and tighten it to a pressure of 1--5 tons. V300305 Place a dial gauge on the drive sprocket and inspect the axial play.
  • Page 439 CF65/75/85 series Inspection and adjustment 3.3 INSPECTION AND ADJUSTMENT, AXIAL PLAY ON GEARBOX OUTPUT SHAFT WITHOUT INTARDER WITH N221/10 PTO Remove the bearing cover of the output shaft from the gearbox. Install a new gasket on the bearing cover of the PTO housing.
  • Page 440 CF65/75/85 series Inspection and adjustment 3.4 INSPECTION AND ADJUSTMENT, AXIAL PLAY OF NL/1 PTO ON N221/10 PTO Remove the cover (1) and shim (2) of the N221/10 PTO. V300639 Use a depth gauge to measure the depth down to the outer bearing race, distance A. V300230 Install a new gasket (4) in the intermediate housing (3).
  • Page 441 CF65/75/85 series Inspection and adjustment Use a depth gauge to determine the distance from the centring edge to the gasket, distance B. Calculate the axial play. The axial play equals distance A -- distance B Compare the calculated value with the maximum allowable axial play.
  • Page 442 CF65/75/85 series Inspection and adjustment 200337 https://www.truck-manuals.net/...
  • Page 443 CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, ENTIRE DAF ENGINE PTO ON FLYWHEEL HOUSING Removing entire DAF engine PTO on flywheel housing If necessary, remove the prop shaft from the PTO flange. Remove the banjo bolts from the engine PTO oil pipes.
  • Page 444 CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, DAF ENGINE PTO FLYWHEEL HOUSING Removing DAF engine PTO flywheel housing Remove the gearbox. Remove the clutch release assembly and the flywheel. Remove the PTO housing from the flywheel housing. Remove the attachment bolt from the upper drive sprocket in the flywheel housing.
  • Page 445 CF65/75/85 series Removal and installation Fit the engine bracket attachment bolts. Fit the entire PTO to the flywheel housing. Fit the flywheel. Fit the clutch release assembly. Fit the gearbox. 4.3 REMOVAL AND INSTALLATION, NH/1 AND NL/1 PTO, B VERSION Removing NH/1 and NL/1 PTO, B version Drain as much gearbox oil as necessary and collect it in a clean container.
  • Page 446 CF65/75/85 series Removal and installation 4.4 REMOVAL AND INSTALLATION, NH/1 AND NL/1 PTO, C VERSION Removing NH/1 and NL/1 PTO, C version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 447 CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, NH/4 AND NL/4 PTO, B VERSION Removing NH/4 and NL/4 PTO, B version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 448 CF65/75/85 series Removal and installation 4.6 REMOVAL AND INSTALLATION, NH/4 AND NL/4 PTO, C VERSION Removing NH/4 and NL/4 PTO, C version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 449 CF65/75/85 series Removal and installation 4.7 REMOVAL AND INSTALLATION, N221/10 PTO ON GEARBOX WITHOUT INTARDER Removing N221/10 PTO without intarder Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 450 CF65/75/85 series Removal and installation Installing N221/10 PTO without intarder Check the bearing play of the gearbox output shaft and adjust if necessary. Install the O-ring and centring ring in the rear cover of the gearbox. Fit a new gasket and adjusting ring in the rear cover of the PTO.
  • Page 451 CF65/75/85 series Removal and installation 4.8 REMOVAL AND INSTALLATION, N221/10 PTO ON GEARBOX WITH INTARDER Removing N221/10 PTO with intarder Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 452 CF65/75/85 series Removal and installation 4.9 REMOVAL AND INSTALLATION, NL/1 PTO ON N221/10 PTO Removing NL/1 PTO on N221/10 PTO Drain as much gearbox oil as necessary and collect it in a clean container. Remove the electrical connector and air pipe from the PTO.
  • Page 453 Hold the drive flange in place with the special tool (DAF No. 0484977). Remove the attachment bolts from the drive flange. Remove the bolts and the locking plate from the prop shaft flange.
  • Page 454 Fit a new O-ring into the recess between the output shaft and the prop shaft flange. Hold the drive flange in place with the special tool (DAF No. 0484977). 10. Note: Bolts that will be re-used must be cleaned and lightly oiled.
  • Page 455 CF65/75/85 series Removal and installation 4.11 REMOVAL AND INSTALLATION, PTO INTERMEDIATE SHAFT ON GEARBOX WITHOUT INTARDER Removing intermediate shaft without intarder Drain as much gearbox oil as necessary and collect it in a clean container. Remove the PTO. Remove the centring sleeve. Remove the intermediate shaft with bearing and circlip from the rear cover of the gearbox.

  • Page 456: Removal And Installation, Pto Intermediate Shaft On Gearbox With Intarder

    CF65/75/85 series Removal and installation 4.12 REMOVAL AND INSTALLATION, PTO INTERMEDIATE SHAFT ON GEARBOX WITH INTARDER Removing intermediate shaft with intarder Drain as much gearbox oil as necessary and collect it in a clean container. Remove the PTO. Remove the intermediate housing from the rear cover of the gearbox.

  • Page 457: Removal And Installation, Z81 Pto, B Version

    CF65/75/85 series Removal and installation 4.13 REMOVAL AND INSTALLATION, Z81 PTO, B VERSION Removing Z81 PTO, B version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the lubricating oil pipe, electrical connector and air pipe from the PTO. Remove the drive flange, which is mounted against the PTO flange.

  • Page 458: Removal And Installation, Z81 Pto, C Version

    CF65/75/85 series Removal and installation 4.14 REMOVAL AND INSTALLATION, Z81 PTO, C VERSION Removing Z81 PTO, C version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the lubricating oil pipe, electrical connector and air pipe from the PTO. Remove the drive flange, which is mounted against the PTO flange.

  • Page 459: Removal And Installation, 2266 Pto, B Version

    CF65/75/85 series Removal and installation 4.15 REMOVAL AND INSTALLATION, 2266 PTO, B VERSION Removing 2266 PTO, B version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the lubricating oil pipe, electrical connector and air pipe from the PTO. Remove the drive flange, which is mounted against the PTO flange.

  • Page 460: Removal And Installation, 2266 Pto, C Version

    CF65/75/85 series Removal and installation 4.16 REMOVAL AND INSTALLATION, 2266 PTO, C VERSION Removing 2266 PTO, C version Drain as much gearbox oil as necessary and collect it in a clean container. Remove the lubricating oil pipe, electrical connector and air pipe from the PTO. Remove the drive flange, which is mounted against the PTO flange.

  • Page 461: Disassembly And Assembly

    CF65/75/85 series Disassembly and assembly 5. DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO Disassembling drive sprockets from flywheel housing Remove the lower drive sprocket attachment bolt and remove the sealing plate on the rear of the sprocket shaft.
  • Page 462 CF65/75/85 series Disassembly and assembly Mounting drive sprockets in flywheel housing Check that both drive sprocket assemblies have correct bearing play. Place the O-ring on the shaft. Press an inner bearing race (3) onto the sprocket shaft (2) (oil the shaft). Note: Take proper note of the original mounting direction of the drive sprockets in the...

  • Page 463: Disassembly And Assembly, Daf Engine Pto Housing

    CF65/75/85 series Disassembly and assembly 5.2 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO HOUSING Disassembly, DAF engine PTO housing If fitted, remove the drive flange. At the rear of the PTO housing, remove the sealing plate attachment bolts of the drive shaft with the gasket.
  • Page 464 CF65/75/85 series Disassembly and assembly Assembly, DAF engine PTO housing If necessary, press the two outer bearing races into the PTO housing. If necessary, press the inner bearing onto the prop shaft. Fit the assembly consisting of inner races, filler sleeve and shims (made earlier with...
  • Page 465 CF65/75/85 series Disassembly and assembly Fit the prop shaft and the second inner bearing into the PTO housing. V300645 Use a plastic or copper mallet to install the drive sprocket in the PTO housing. V300646 V300647 200337 https://www.truck-manuals.net/...
  • Page 466 CF65/75/85 series Disassembly and assembly Place a driving tool underneath the drive sprocket. V300648 Now press the prop shaft into the second inner bearing and drive sprocket, which are already in the PTO housing. V300649 Place the mounting ring onto the prop shaft and clamp it firmly into a vice.
  • Page 467 CF65/75/85 series Disassembly and assembly 11. Fit a gasket and the cover on the PTO housing next to the lock nut and tighten the attachment bolts to the specified torque. See “Technical data”. 12. Turn the PTO housing round. If necessary, apply Loctite to the studs and tighten them to the specified torque.
  • Page 468 CF65/75/85 series Disassembly and assembly 15. Fit the short drive shaft in the drive housing so that the circlip abuts the drive housing. V300652 16. If necessary, fit the shaft seals (1) in the cover. 17. If necessary, fit the cover with the gasket and oil seal and tighten the attachment nuts to the specified torque.

  • Page 469: Versions With And Without Drive Flange And Shift Control

    CF65/75/85 series Disassembly and assembly 5.3 VERSIONS WITH AND WITHOUT DRIVE FLANGE AND SHIFT CONTROL Version without prop shaft flange and shift control Note: Fit a gasket between the drive housing and PTO housing. Remember the oil channel in the gasket. Fit a gasket and cover on the front of the drive housing and tighten the attachment bolts to the specified torque.
  • Page 470 CF65/75/85 series Disassembly and assembly Fit the selector shaft together with the shifting fork and pressure spring into the selector housing. Fit the piston with O-ring into the cylinder and mount the cylinder with a gasket on either side and the cover against the gearbox housing.
  • Page 471 AS TRONIC GEARBOX CF65/75/85 series Contents CONTENTS Page Date GENERAL .............
  • Page 472 AS TRONIC GEARBOX CF65/75/85 series Contents 200337 https://www.truck-manuals.net/...

  • Page 473: General

    AS TRONIC GEARBOX CF65/75/85 series General 1. GENERAL Gearbox type Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle. ZF gearbox type-plate Type of gearbox ZF serial number Parts list (ZF) Specification number...

  • Page 474: System Description

    AS TRONIC GEARBOX CF65/75/85 series General 1.1 SYSTEM DESCRIPTION The AS Tronic gearbox (4) is a fully automatic gearbox based on a conventional mechanical gearbox combined with an electropneumatic shift and clutch control system. The gearbox modulator (3) consists of the electronic unit, sensors, a pressure limiting valve (5) and the pneumatic shift control.
  • Page 475 AS TRONIC GEARBOX CF65/75/85 series General V300662 A. Integrated front-mounted range box or splitter range (two gears) B. Main box with three or four forward gears and one reverse gear C. Rear-mounted range box or range group (two gears) Input shaft Transmission brake Lubricating oil pump Auxiliary shaft...
  • Page 476 AS TRONIC GEARBOX CF65/75/85 series General Type designation of AS Tronic gearbox Example of type designation 12 AS 2330 TO 12 gears automatic gear change 2330 maximum input engine torque 2331 version with intarder used on trucks Overdrive version (D = Direct drive) A.
  • Page 477 AS TRONIC GEARBOX CF65/75/85 series General In popular terms, the number of gears in the main box is “stacked”. This is why the term “stacking box” or range box was created. The diagrams show the power distribution across the individual gear pairs for each gear. AS Tronic 12 gears By means of the splitter range, the three gears in the main box are multiplied by two,...
  • Page 478 AS TRONIC GEARBOX CF65/75/85 series General AS Tronic 16 gears By means of the splitter range, the four gears in the main box are multiplied by two, while using the rear-mounted range box multiplies this figure by two again. This results in 2x4x2 = 16 forward gears.

  • Page 479: Description Of Components

    AS TRONIC GEARBOX CF65/75/85 series Description of components 2. DESCRIPTION OF COMPONENTS 2.1 GEARBOX MODULATOR The gearbox modulator (2) is integrated in the gearbox housing (1) (to save space) and has all mechanical, electrical and pneumatic connections that are necessary for correct shifting of the gearbox.
  • Page 480 AS TRONIC GEARBOX CF65/75/85 series Description of components The gearbox modulator is to ensure that the gearbox shifts fast and correctly, depending on the current driving conditions. All functions that are necessary for selection and checking of the correct gear are controlled inside the gearbox modulator.
  • Page 481 AS TRONIC GEARBOX CF65/75/85 series Description of components The figures alongside show the situations with a 12AS or 16AS gearbox. 12 AS V300659 16 AS V300658 200337 https://www.truck-manuals.net/...

  • Page 482: Operating Unit

    AS TRONIC GEARBOX CF65/75/85 series Description of components 2.2 OPERATING UNIT The operating unit (2) is not mechanically connected to the gearbox. Operation is effected via the selector switch (3) and the gear lever (1). The operating unit contains various position sensors that register the position of the gear lever.
  • Page 483 AS TRONIC GEARBOX CF65/75/85 series Description of components The transmission brake is operated pneumatically by the piston (4). During changing up the speeds of the secondary shafts, and therefore the speeds of the main-box gear wheels too, must be braked in respect of the main shaft.
  • Page 484 AS TRONIC GEARBOX CF65/75/85 series Description of components 200337 https://www.truck-manuals.net/...

  • Page 485: Inspection And Adjustment

    AS TRONIC GEARBOX CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, GEARBOX OIL LEVEL To prevent skin injury, avoid unnecessary contact with the drained oil. AS Tronic gearbox Position the vehicle on a level surface. Wait for some minutes to allow the oil to flow back.

  • Page 486: Inspection And Adjustment, Gearbox Output Shaft Bearing Axial Play

    AS TRONIC GEARBOX CF65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL PLAY Remove the drive flange. Remove the rear gearbox bearing cover. Clean the sealing surfaces of the bearing cover and the gearbox. Use a depth gauge to determine the depth of the bearing cover recess, distance A.

  • Page 487: Removal And Installation

    AS TRONIC GEARBOX CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY WITH OR WITHOUT INTEGRATED RETARDER Removing the gearbox assembly Disconnect the earth lead from the battery terminal. Disconnect the prop shaft from the gearbox flange and hang it on the chassis.
  • Page 488 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Installing the gearbox Install the thrust bearing over the gearbox front cover and check whether the retainer clip in the clutch release assembly is closed. Note: Carefully rotate the input shaft using extended pliers while fitting the gearbox, so that the input shaft can slide into the clutch plate upon assembly.
  • Page 489 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Removing the gearbox with integrated retarder Disconnect the earth lead from the battery terminal. Drain the engine coolant. Remove the drain plug of the intarder heat exchanger and drain the coolant. Remove the coolant pipes from the retarder. Remove the coolant pipes between the retarder and the engine.

  • Page 490: Removal And Installation, Gearbox Modulator

    AS TRONIC GEARBOX CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, GEARBOX MODULATOR Removing the gearbox modulator Disconnect the earth lead from the battery terminal. Remove the pressure regulator air pipe from the gearbox modulator. Remove the gearbox. Remove the attachment bolts (2) and the gearbox modulator (1).
  • Page 491 Fit the special tool (2) (DAF No. 1453138) and secure it using the bolts (4). CAUTION! Always put the central selector shaft (7) at a slant before moving it.
  • Page 492 Note: The alignment of the control rods can be checked with the aid of a simple tool. This tool can be made in your own workshop. It cannot be ordered from DAF. 10 0.1 20 0.1 212 0.1 2 x 45...
  • Page 493 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Check that the control rods (4) are properly adjusted, using the tool (1) if necessary. V300696 Put the recess of the pad (6) on the selection cylinder exactly in the centre of the control rod (4).
  • Page 494 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Put the round bolt (9) in upright position; it has to fall into the recess of the pad on the selection cylinder. Install the gearbox modulator (1) with a new seal (3); see that the control rods fall into the recesses in the selector shafts (7, 8 and 9).

  • Page 495: Removal And Installation, Operating Unit

    AS TRONIC GEARBOX CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, OPERATING UNIT Removing the operating unit Remove the gear lever cover (1) and the cap (2) from the selector switch button. Remove the attachment bolt from the gear lever knob and the knob from the selector switch.
  • Page 496 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Disconnect connector 4 from the selector switch. Remove the cover (5) with the selector switch. V300685 Disconnect connector 6 and remove the attachment bolts (7) from the gear lever unit; lift the gear lever unit and remove the bolts (8) from the bottom plate (9).
  • Page 497 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Fitting operating unit assembly Install the bottom plate (9) with the gear lever unit and fit connector 6. V300686 Connect connector 4 and fit the cover (5) with the selector switch. Note: Take care that the locking mechanism that is fitted to prevent the bottom plate from rotating relative to the gear lever does not...
  • Page 498 AS TRONIC GEARBOX CF65/75/85 series Removal and installation Install the gear lever knob and the bottom plate. Fit the attachment bolt and position the cover (1). Fit the selector switch knob. Fit the attachment bolt and the cap (2). V300683 200337 4-12 https://www.truck-manuals.net/...

  • Page 499: Removal And Installation, Drive Flange

    Remove the prop shaft from the gearbox flange and hang it on the chassis. Hold the drive flange in place with the special tool (DAF No. 0484977). Remove the attachment bolts from the drive flange. Remove the bolts and locking plate with seal from the drive flange.

  • Page 500: Removal And Installation, Output Shaft Oil Seal

    Drill two holes into the external cover of the oil seal and turn the special tool (DAF No. 0484899) into the oil seal. Then pull the oil seal out of the bearing cover using the special tool (DAF No. 0694928).

  • Page 501: Removal And Installation, Gearbox Front Cover Oil Seal

    Apply methylated spirit to the outer circumference of the oil seal and install the seal in the gearbox front cover using the special tool (DAF No. 14553145). V300705 Install the gearbox front cover with liquid gasket and tighten the attachment bolts to the specified torque.
  • Page 502 AS TRONIC GEARBOX CF65/75/85 series Removal and installation 200337 4-16 https://www.truck-manuals.net/...

  • Page 503: Draining And Filling

    AS TRONIC GEARBOX CF65/75/85 series Draining and filling 5. DRAINING AND FILLING 5.1 DRAINING AND FILLING, GEARBOX AS Tronic gearbox To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the gearbox Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 504 AS TRONIC GEARBOX CF65/75/85 series Draining and filling AS Tronic gearbox with integrated retarder Draining the gearbox Before draining take a short test drive. Do not activate the retarder during the test drive. Position the vehicle on a level surface. Drain the gearbox at operating temperature.

This manual is also suitable for:

Cf75 seriesCf85 series

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