DAF LF45, LF55 Series. Manual - part 249

©

 200508

4-7

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

4.5 REMOVAL AND INSTALLATION, GEARBOX FRONT COVER OIL SEAL

Removing gearbox front cover oil seal
1.

Remove the gearbox.

2.

Remove the release mechanism assembly 

with fork and thrust bearing.

3.

Remove the attachment bolts from the 

gearbox front cover (1). Remove the gearbox 

front cover from the input shaft. Keep the 

filler plates of the input shaft and the 

secondary shaft.

4.

Remove the oil seal (2) from the gearbox 

front cover.

Installing the gearbox front cover oil seal
1.

Apply a small amount of sealant 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.

2.

Fit the oil seal (2) to the gearbox front cover 

using special tools (DAF no. 0499809) and 

(DAF no. 0535409). Fit a new gasket (3).

3.

Check the input shaft axial play. See 

"Inspection and adjustment".

4.

Install the gearbox front cover (1). Tighten 

the bolts to the specified torque. See 

"Technical data".

5.

Install the release mechanism on the 

gearbox. Tighten the bolts to the specified 

torque. See "Technical data".

6.

Fit the gearbox.

V3 00 401

1

3

2

ZF 6S-850 GEARBOX

4-8

©

 200508

Removal and installation

5

ΛΦ45/55 series

3

4.6 REMOVAL AND INSTALLATION, SELECTOR SHAFT OIL SEAL

LHD model

Removing selector shaft oil seal
1.

Mark the gearbox lever relative to the 

selector shaft and remove the control lever 

with the gearbox control. If necessary, 

disconnect the torque rod.

2.

Remove the selector shaft housing 

attachment bolts and remove the selector 

shaft housing assembly from the gearbox.

Seal the gearbox opening, so that no 

dirt can enter.

3.

Remove the locking pin and control stop 

from the selector shaft housing.

4.

Drive the two spring pins out of the selector 

fingers. Turn the selector fingers so that the 

spring pins can be driven into a slot in the 

cover.

5.

Remove the circlip and the springs from the 

rear of the cover. Then remove the shaft and 

the selector fingers from the cover.

V3 00 398

}

V3 00 399

W 3 03 052

©

 200508

4-9

Removal and installation

ZF 6S-850 GEARBOX

ΛΦ45/55 series

3

5

6.

Drive the oil seal and dust seal out of the 

selector shaft housing. If necessary, the 

selector shaft bearing bushes can now also 

be replaced with special tool 

(DAF no. 0694818). Press the bearing bush 

on the control side 2 mm under the edge.

LHD model

Installing selector shaft oil seal
1.

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.

2.

Fit the special tool ((DAF no. 0694817)), a 

guide sleeve, over the selector shaft and fit 

the selector fingers and the gear lever lock 

into the selector housing. Fit the selector 

shaft. Watch the control stop slot.

3.

First fit the control stop before fitting the 

spring pins.

4.

Fit the spring pins and the locking pin.

5.

Apply a small amount of sealant to the 

sealing cap. Install the springs, rings, and the 

sealing cap. Fit the circlip.

6.

Put the gearbox into neutral, install a new 

gasket in the selector shaft housing and fit it 

onto the gearbox housing. Tighten the bolts 

to the specified torque. See "Technical data".

7.

Fit the shift control and check that all gear 

changes function properly.

W 3 03 050

2 mm

ZF 6S-850 GEARBOX

4-10

©

 200508

Removal and installation

5

ΛΦ45/55 series

3

RHD model

Removing selector shaft oil seal
1.

Mark the gearbox lever relative to the 

selector shaft and remove the control lever 

with the gearbox control. If necessary, 

disconnect the torque rod.

2.

Remove the bearing housing attachment 

bolts and slide it off the selector shaft.

3.

Drive the dust and oil seals out of the bearing 

housing. If necessary, the selector shaft 

bearing bush can now also be replaced with 

special tool (DAF no. 0694818). Press the 

bearing bush on the spring side 2 mm under 

the edge.

Installing selector shaft oil seal
1.

Apply a small of amount of 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).

2.

Apply grease to the oil seal lips. Fit a new 

O-ring to the selector shaft housing. Fit the 

selector shaft housing over the selector 

shaft.

3.

Fit the attachment bolts and the gearbox 

control. Tighten the bolts to the specified 

torque. See "Technical data". Check that all 

gear changes function properly.

V3 00 400