Daf ZF Ecosplit 181 & 221 Series Official Component Manual

Daf ZF Ecosplit 181 & 221 Series Official Component Manual

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This is the COMPLETE Official Component manual for the Daf Trucks.
This manual contain high-quality diagrams, schematics, pictures, step-by-step instructions on how to service and repair your trucks DAF

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

Models And Serials :

 8 S 181
16 S 181
16 S 221
16 S 1920
16 S 2020
16 S 2220
16 S 2320
16 S 2520

CONTENTS : 

Contents …………………………………………………………………………………………………………………….1-01
Preface…………………………………………………………………………………………………………………………1-03
General information …………………………………………………………………………………………………1-04
Safety instructions…………………………………………………………………………………………………… 1-06
Tightening torques for nuts and bolts…………………………………………………………………..1-07
Spring table ……………………………………………………………………………………………………………….1-08
Adjustment data ………………………………………………………………………………………………………1-09
Special tools ……………………………………………………………………………………………………………..1-14
View of transmission…………………………………………………………………………………………………1-16
1 Removing components/range-change …………………………………………………………….2-01
1.1 Plastic pipes ……………………………………………………………………………………………………… 2-01
1.2 Output flange ……………………………………………………………………………………………………..2-01
1.3 Cover ……………………………………………………………………………………………………………………2-01
1.4 5/2-way valve …………………………………………………………………………………………………….2-02
1.5 Shift cylinder for range-change …………………………………………………………………….2-02
1.6 Housing/range-change …………………………………………………………………………………..2-03
1.7 Planet gear train with synchronizer………………………………………………………………. 2-04
1.8 Assembling planet gear train with range-change synchronizer ………………2-06
1.9Assembling range-change /housing/output flange/piston ……………………. 2-09
2 Removing components from centre housing ……………………………………………… 2-12
2.1 Splitter (GV) cylinder ……………………………………………………………………………………….2-12
2.2 Shift housing ………………………………………………………………………………………………….. 2-12
2.3 Shift housing, friction-optimized version ………………………………………………….. 2-16
2.4 Shift mechanism/selector patterns ……………………………………………………………. 2-21
3 Removing components from clutch housing………………………………………………… 2-24
3.1 Release fork ……………………………………………………………………………………………………….2-24
3.2 Connection plate with integral pump………………………………………………………… 2-25
3.3 Clutch housing ………………………………………………………………………………………………. 2-26
4 Removing components ……………………………………………………………………………….. 2-26
4.1 Removing components/clutch housing …………………………………………………. 2-26
4.2 Splitter shift rail /centre housing …………………………………………………………….. 2-26
4.3 Removing shafts……………………………………………………………………………………………..2-27
4.4 Removing components/centre housing …………………………………………………….. 2-27
4.5 Input shaft ………………………………………………………………………………………………………….2-28
4.6 Mainshaft ……………………………………………………………………………………………………………2-30
4.7 Assembling synchronizer…………………………………………………………………………………..2-37
4.7.1 Version ZF-BK……………………………………………………………………………………………………2-37
4.7.2 Version ZF-D …………………………………………………………………………………………………….2-38
4.8 Layshaft…………………………………………………………………………………………………………………. 2-39
5 Installing components…………………………………………………………………………………………… 2-41
5.1 Centre housing …………………………………………………………………………………………………….2-41
5.2 Clutch housing …………………………………………………………………………………………………….2-41
6 Synchronizer/wear limits………………………………………………………………………………………..2-42
6.1 Determining wear limit (except 1st and 2nd gears) ……………………………………. 2-42
6.2 Determining wear limit (1st and 2nd gears)………………………………………….2-42
7 Adjusting mainshaft……………………………………………………………………………………………………… 2-43
7.1 Selecting thrust washer and shim, straight-cut version…………………………..2-43
7.1 Selecting thrust washer and shim, helical-cut version …………………………….2-44
8 Installing shafts ………………………………………………………………………………………………….2-45
8.1 Installing input shaft, mainshaft, layshaft and shift rails …………………………2-45
9 Splitter shift fork ……………………………………………………………………………………………….. 2-46
9.1 Adjusting shift fork ……………………………………………………………………………………… 2-46
10 Clutch housing/centre housing …………………………………………………………………. 2-48
10.1 Fitting clutch housing to centre housing ……………………………………………….2-48
11 Adjusting shafts……………………………………………………………………………………………… 2-49
11.1 Input shaft …………………………………………………………………………………………………… 2-49
11.2 Layshaft…………………………………………………………………………………………………………… 2-50
12 Fitting clutch housing components……………………………………………………………….2-51
12.1 Connection plate with integral pump………………………………………………………. 2-52
12.2 Release fork …………………………………………………………………………………………………….2-53
13 Fitting centre housing components……………………………………………………………….. 2-55
13.1 Reverse idler gear/reverse idler pin…………………………………………………………….. 2-55
13.2 Cylinder……………………………………………………………………………………………………………… 2-55
13.3 5/2-way valve ………………………………………………………………………………………………….2-56
13.4 Compressed air test for piston and splitter cylinder…………………………………2-56
13.5 Injection pipe ………………………………………………………………………………………………… 2-57
14 Fitting complete range-change ……………………………………………………………………… 2-58
15 Fitting components…………………………………………………………………………………………….2-60
15.1 Shift housing ……………………………………………………………………………………………………2-60
15.3 Plastic pipes …………………………………………………………………………………………………..2-60
16 Compressed air test on breather …………………………………………………………………. 2-61

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