DAF LF45, LF55 Series. Manual - part 252

©

 200508

3-1

Removal and installation

EATON FS/6309A GEARBOX

ΛΦ45/55 series

3

6

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY

Removing gearbox assembly
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.

Remove the attachment bolts from the 

intermediate bearing.

4.

Remove the attachment bolt from the 

exhaust bracket on the gearbox.

5.

Remove the clamping straps of the 

intermediate pipe and remove it.

6.

Remove the end of the exhaust by removing 

the clamping strap and the attachment bolt of 

the rubber suspension point at the end of the 

exhaust.

7.

Remove the attachment bolts from the clutch 

cylinder and remove it.

8.

Mark all the electrical connectors and 

remove them.

9.

Remove the compressor pipe bracket.

10. Mark the various air pipes and remove them.

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.

EATON FS/6309A GEARBOX

3-2

©

 200508

Removal and installation

6

ΛΦ45/55 series

3

Installing gearbox assembly
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 drive 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 intermediate pipe.

6.

Fit the exhaust end pipe.

7.

Install the compressor pipe bracket.

8.

Install the electronic connectors on the 

gearbox.

9.

Fit the clutch cylinder.

10. Fit the air pipes.

11. Install the intermediate bearing of the prop 

shaft and tighten the bolts by hand.

12. Fit the prop shaft flange onto the gearbox. 

Tighten the attachment bolts to the specified 

torque. See "Technical data".

13. Tighten the intermediate bearing attachment 

bolts to the specified torque. See "Technical 

data".

14. Check the oil level. See "Inspection and 

adjustment".

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

3-3

Removal and installation

EATON FS/6309A GEARBOX

ΛΦ45/55 series

3

6

3.2 REMOVAL AND INSTALLATION, DRIVE FLANGE

Removing drive flange
1.

Place a reference mark on the prop shaft in 

relation to the flange.

2.

Remove the bolts that attach the prop shaft 

to the flange.

3.

Support the prop shaft from a suitable 

location on the chassis.

4.

Support the prop shaft from a suitable 

location on the chassis.

5.

Fit special tool (DAF no. 0484977) to hold 

the flange in place. Remove the lock nut and 

washer.

6.

Remove the flange with a suitable puller.

Note:

In order to prevent the synchroniser for the 

high/low transmission ratios from coming 

loose, the output shaft must not slide out of 

the bearing.

Installing drive flange
1.

Place the flange on the output shaft.

2.

Place a shim between the flange and the lock 

nut and turn the flange in the oil seal. 

Remove the lock nut and shim.

3.

Fit special tool (DAF no. 0484977) to the 

flange. Fit a new lock nut. Tighten the lock 

nut to the specified torque. See "Technical 

data".

4.

Align the markings. Fit the prop shaft onto 

the flange. Tighten the bolts to the specified 

torque. See "Technical data".

EATON FS/6309A GEARBOX

3-4

©

 200508

Removal and installation

6

ΛΦ45/55 series

3

3.3 REMOVAL AND INSTALLATION, OUTPUT SHAFT OIL SEAL

Removing output shaft oil seal
1.

Remove the drive flange.

2.

Remove the attachment bolts from the oil 

seal housing. Remove the oil seal housing. 

Remove the oil seal.

3.

Clean the contact surfaces of the oil seal and 

the seal housing.

Installing output shaft oil seal
1.

Press the oil seal into the oil seal housing 

using special tool (DAF no. 1329358).

2.

Apply sealant to the contact surface of the 

seal housing. See "Technical data".

3.

Fit the seal housing and tighten the bolts to 

the specified torque. See "Technical data".

4.

Apply grease to the sealing lip of the oil seal.

5.

Fit the drive flange.

6.

If necessary, top up the gearbox. See 

"Inspection and adjustment".