DAF LF45, LF55 Series. Manual - part 248

©

 200508

4-3

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

4.2 REMOVING AND INSTALLING GEARBOX, CE ENGINE

Removing gearbox, CE engine
1.

Disconnect the earth lead from the battery 

terminal.

2.

Remove the attachment bolts of the prop 

shaft flange and remove the prop shaft.

3.

If present, remove the attachment bolts from 

the intermediate bearing.

4.

Remove the attachment bolt from the 

exhaust bracket on the gearbox.

5.

Remove the clamping strip from the exhaust 

pipe.

6.

Remove the attachment bolt of the rubber 

suspension point on the end of the exhaust.

7.

Twist the end-pipe of the exhaust loose and 

remove it.

8.

Remove the attachment bolts from the clutch 

cylinder and remove it.

9.

Mark all the electrical connectors and 

remove them.

10. Remove the compressor pipe bracket.

11. Remove the selector rod from the adjusting 

mechanism in such a manner that the 

settings are not changed.

12. Support the gearbox and remove the 

attachment bolts around it.

13. Manoeuvre the gearbox to the rear until it is 

free and then remove it.

ZF 6S-850 GEARBOX

4-4

©

 200508

Removal and installation

5

ΛΦ45/55 series

3

Installing gearbox, CE engine
1.

Engage the highest gear in order to align the 

keys of the input shaft with the clutch plate.

2.

Fit the gearbox onto the engine. If 

necessary, rotate the prop shaft flange in 

order to align the keys.

3.

Fit the gearbox attachment bolts all around 

and tighten them to the specified torque. See 

"Technical data".

4.

Install the selector rod on the adjusting 

mechanism. Use new self-locking nuts.

5.

Fit the exhaust bracket.

6.

Install the compressor pipe bracket.

7.

Fit the electronic connectors onto the 

gearbox.

8.

Fit the clutch cylinder.

9.

Install the exhaust pipe, fasten it with the 

clamping strap and fit the attachment bolt of 

the suspension rubber.

10. Install the prop shaft intermediate bearing, if 

it has been removed, and tighten the bolts by 

hand.

11. Fit the prop shaft flange onto the gearbox. 

Tighten the attachment bolts to the specified 

torque. See "Technical data".

12. Tighten the intermediate bearing attachment 

bolts to the specified torque. See "Technical 

data".

13. Check the oil level. See "Inspection and 

adjustment".

14. Fit the silencer cap.

15. Fit the earth lead to the battery terminal.

Note:

If a gearbox of a different type is mounted, or a 

gearbox with a different reduction, this should be 

reported. If the correct data are present, they can 

be input into the VIC using DAVIE XD.

©

 200508

4-5

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

4.3 REMOVAL AND INSTALLATION, DRIVE FLANGE

Removing the drive flange
1.

Make a reference mark on the prop shaft and 

flange.

2.

Detach the prop shaft from the flange and 

secure it.

3.

Fit special tool (DAF no. 0484977) to hold 

the flange in place.

4.

Remove the attachment bolt and washer.

5.

Using special tool (DAF no. 0484978), 

remove the drive flange from the shaft.

Installing the drive flange
1.

Heat the drive flange to a temperature of 

max. 120

″C.

2.

Oil the output shaft lightly and slide the drive 

flange over the shaft in its correct position.

3.

Fit the special tool (DAF no. 0484977) onto 

the drive flange.

4.

Tighten the attachment bolt to the specified 

torque. See "Technical data".

5.

Fit the prop shaft. Tighten the attachment 

bolts to the specified torque. See "Technical 

data".

V3 00 416

ZF 6S-850 GEARBOX

4-6

©

 200508

Removal and installation

5

ΛΦ45/55 series

3

4.4 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Pull the oil seal from the gearbox housing 

using special tool (DAF no. 0484899).

Installing output shaft oil seal
1.

Check the axial play of the output shaft. See 

"Technical data".

2.

Around the oil seal, clean the gearbox 

housing without letting dirt into the gearbox.

3.

Apply a small amount of liquid gasket to the 

outside of oil seals fitted with a steel cover. 

Apply a small amount of green soap to the 

outside of oil seals fitted with a rubber cover.

4.

Fit the oil seal in the gearbox housing using 

special tool (DAF no. 0694816). The tool will 

position the oil seal at the correct depth in the 

housing.

5.

Fit the drive flange.

W 3 03 048

7 mm