AUTOMATIZED GEARBOX

ZF 16AS 2601 (Astronic 2)

SECTION 7.2
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 1

SECTION 7.2
Automatized gearbox ZF 16AS 2601
(Astronic 2)

Page
DESCRIPTION 3
- Version with Intarder (retarder) 4
- Standard version 4
- Identification plate 5
- Main components location 7

- EuroTronic transmission display --- Version V33

(lever selector) 8

- EuroTronic transmission display - Version V35

(lpush button selector) 9
- List of failure codes 10
SPECIFICATIONS AND DATA 30
TIGHTENING TORQUES 32
TOOLS 34
TRANSMISSION OIL CHANGE 39
GENERAL 39
- Safety instructions 39
- Vehicle preparation 39
- Hazardous and/or polluting substances 39
- Specific safety instructions 39
DESCRIPTION OF OPERATION 40
- Exhaust 40
- Filling 40
- Final operations 40
- Exhaust 41
- Filling 42
- Final operations 42
TRANSMISSION REMOVAL-REFITTING 43
GENERAL 43
- Safety instructions 43
- Vehicle preparation 43
2 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

- Hazardous and/or polluting substances 43 - Fitting 71

- Very heavy parts 43 - Transmission shafts 72
- Specific safety instructions 43 - Removal - Fitting 72
DESCRIPTION OF OPERATION 44 - Fitting the middle box 72
- Preliminary operation 44 - Fitting the front box 75
- Removal 44 - Front cover 77
- Inspections and checks 47 - Removal 77
- Refitting 47 - Fitting the front cover 77
- Final operations 47 - Adjusting drive input shaft bearing end float 77
OVERHAULING THE GEARBOX 48 - Adjusting transmission shaft bearing end float 78
- Checks 48 - Clutch release lever 80
- Gearbox actuator 48
- Removal 48
- Refitting 49
- Removing the rear box 49
- Removing the rear box 50
- Removing the epicyclic reduction gear train
(E.R.G.) 51

- Fitting the epicyclic reduction gear train (E.R.G.) 53

- Adjusting epicyclic reduction gear train bearing
end float 54
- Adjusting main shaft end float 55
- Synchronizing device assembly for engaging
normal or reduced gears 57
- Removal 57
- Removing the middle box 60
- Removing the main shaft 62
- Removing the drive input shaft 64
- Removing the splitter synchronizing device 65
- Fitting the splitter synchronizing device 66
- Fitting the main shaft 67
- Fitting the drive input shaft 67
- Splitter control fork 70
- Removal - Fitting 70
- Gear control forks 70
- Removal 70
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 3

DESCRIPTION
The AsTronic 16 AS 2601 is a dual-shaft, electro-pneumatically controlled mechanical transmission.
The driver may choose to program manual or automatic gear selection/engagement. For this purpose, the following components
are provided:
S an electronic control system
S a gear engagement/disengagement actuator
S a dry clutch engagement/disengagement actuator.

The shafts and gears have a helical toothing to ensure quiet operating noise.
The primary shaft gears are engage by means of front toothing sleeves. Engagement of the splitter and planetary reducer unit
is synchronised.
Gears are selected with finely graded ratios and may be engaged in sequence using the planetary gear reducer and the low or
high gears using the splitter.
The primary shaft gears are doubled by engaging the planetary gear reducer. The ratios thus obtained are further doubled by
engaging the splitter. Each ratio is therefore split into a low range and a high range.
The transmission may be equipped with a supplementary electro-pneumatically controlled retarder brake (intarder) equipped
with independent or integrated heat exchanger.

See SECTION 8 of this manual for more information on the retarder.

 4 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Standard version
Figure 1

357A072100R

1. Clutch actuator - 2. Transmission outlet speed sensor for tachograph - 3. Transmission outlet speed sensor for ECU -
4. Neutral position sensor - 5. ECU connector chassis side - 6. ECU - 7. ECU connector on transmission side

Version with Intarder (retarder)

Figure 2

360F072001R

1. Dry single plate clutch - 2. Clutch electro-pneumatic actuator - 3. ECU - Electro-hydraulic gear engagement/disengagement
actuator - 4. Intarder - 5. Integrated heat exchanger
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 5

Identification plate
Figure 3

360F0072002R

1. Transmission type - 2. ZF part number - 3. Serial number - 4. IVECO part number for spare parts - 5. Transmission
transmission ratio - 6. Tachometer transmission ratio - 7. PTO type - 8. PTO transmission ratio -
9. Dry oil change amount - 10. ZF lubricant list name
 6 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 4

360F0072016R

K1 = splitter low gears (GV)

K2 = splitter high gears (GV)
1 = 1st gear
2 = 2nd gear
3 = 3rd gear
4 = 4th gear
R = Reverse
GP = planetary gear reducer (H/L)
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 7

Main components location

Figure 5

357A072200R

1. Clutch actuator - 2. Nor used - 3. Transmission outlet speed sensor for control unit - 4. Neutral position sensor -
5. Control unit connector chassis side - 6. VDB (Vehicle Data Bus) CAN line - 7. System internal CAN line -
8. Transmission electronic control unit - 9. Control unit connector transmission side
 8 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

EuroTronic transmission display - Version V33 (lever selector)

The display shows information regarding transmission condition.

A Indication of gear engaged (e.g. 1./.16 or N, RL and RH).
Other information displayed:
CH = system self-diagnosis; shown with ignition key on.
AL = no air; shown in alternation with normal indication.
FP = bring the accelerator pedal to idle position : if the indication on the display remains, there is a system fault and it is
not possible to continue driving.
CL = alternates with the current indication and signifies a clutch overload.
CW = worn clutch; the clutch requires replacement.
__= gear change; shown during a gear shift.
EE = shown when there is a dialogue error between display and electronic control unit.
HT = electronic control unit temperature too high.
nn = alphanumeric code that identifies a fault found by the control unit : for example.
68 = fault 68 found in system.
B Up/down arrow: along with the number of the bars displayed it indicates possible gear shifts.
C Bars: along with the arrows, they indicate the number of gears that can be changed or down shifted (max 4).
D Wrench for bolts: system error. Displayed when running is only possible with some limitations.
Go to a specialised workshop as soon as possible.
E STOP: together with the previous indication: indicates an immediate stop is necessary due to a serious system failure.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 9

EuroTronic transmission display - Version V35 (push button selector)

1 2 1

Indications on the instrument display

Fig. 2, ref- 1
01 - 16 = Indicates the forward gear engaged
00 = idle
R1 = fast reverse gear
R2 = slow reverse gear
In addition, the display shows any information regarding faults:
AL = no air supply
AP = accelerator depressed at engine start
CH = system troubleshooting: at ignition.
CL = indicated clutch overloaded.
CW= indicates clutch wear; clutch must be replaced as soon as possible.
HT = excessive electronic control unit temperature.

Fig. 2, ref. 2
Mode symbol

The following cases may occur for the modes below (Fig. 3)
a. automatic mode
b. manual mode
The number of horizontal lines stands for the gears that can be shifted in the current condition: e.g: three lines = 3 speeds
c. manoeuvre mode at low speed
 10 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

List of failure codes

Buzzer
Code

Failure description System reaction

Short circuit to ground If the error occurs while shifting is in process, depending on the driving
at output stage to conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y2. try to engage a gear which is engageable with the current error.
For direct drive design: The driver is able to initiate shiftings both in driving and stationary
002 shifting into high splitter X X situations. The type of error will influence the shifting-process.
group not possible.
For overdrive design: If no allowed gear is correct engageble, the TCU shifts to „Neutral“
shifting into low splitter or the clutch remains open.
group not possible. Output stages with short circuit will be switched off.

Short circuit to ground If the error occurs while shifting is in process, depending on the driving
at output stage to conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y3. try to engage a gear which is engageable with the current error.
For direct drive design: The driver is able to initiate shiftings both in driving and stationary
003 shifting into low splitter X X situations. The type of error will influence the shifting-process.
group not possible.
For overdrive design: If no allowed gear is correct engageble, the TCU shifts to „Neutral“
shifting into high splitter or the clutch remains open.
group not possible. Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to ground The driver is able to initiate shiftings both in driving and stationary
004 at output stage to Y4 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to ground The driver is able to initiate shiftings both in driving and stationary
005 at output stage to Y5 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to ground The driver is able to initiate shiftings both in driving and stationary
006 at output stage to Y6 X X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 11

Buzzer
Code
Failure description System reaction

If the error occurs while shifting is in process, depending on the driving

conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to ground The driver is able to initiate shiftings both in driving and stationary
007 at output stage to Y7 X X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
Short circuit to ground try to engage a gear which is engageable with the current error.
at output stage to Y8
The driver is able to initiate shiftings both in driving and stationary
008 (Valve Range). X X situations. The type of error will influence the shifting-process.
Shifting into Range
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
”Low“ not possible.
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
Short circuit to ground try to engage a gear which is engageable with the current error.
at output stage to Y9
The driver is able to initiate shiftings both in driving and stationary
009 (Valve Range). X X situations. The type of error will influence the shifting-process.
Shifting into Range
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
”High“ not possible.
or the clutch remains open.
Output stages with short circuit will be switched off.
Short circuit to ground No gearshifting possible! No neutral shifting possible!
at output stage to Y10
010 (Main valve). Air supply X X X Selected gear remains engaged; Vehicle start permitted in engaged
not available. gear. After ignition on, system not available

Short circuit to ground

011 at output stage to X Warning-Buzzer permanently active
warning buzzer.
Vehicle without Mux:
Short circuit to ground
at output stage to
reverse light relay.
Reverse light respectively „add. manoeuvering mode lamp“
012 Vehicle with Mux: X permanently switched on. No other functional restrictions.
Short circuit to ground
at output stage to ”add.
Manoeuvering mode
lamp“.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
Short circuit to ground clutch, when coming to standstill. Neutral automatically engaged at
013 at output stage to PTO X X X standstill. Gearshifting blocked, continued driving not possible. System
1.
not available.
12 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Driving: Gearshifting blocked. Stationary: TCU tries to open the

Short circuit to ground clutch, when coming to standstill. Neutral automatically engaged at
014 at output stage to PTO X X X standstill. Gearshifting blocked, continued driving not possible. System
2.
not available.
TCU output switches off. Driving: Upshifts during driving are
controlled like downshifts. Input speed will be synchronized by engine
speed. Upshifts blocked, when input target speed is below engine idle
Short circuit to ground speed. Increased shifting time. Stationary: Increased self adjustment
017 at output stage to Y1 X X time.
(inertia brake valve).
Increased shifting time when shifting out of neutral.
Increased PTO engagement time.
Short circuit to ground
at output stage to Y17 TCU output switches off. Function taken on by valve Y16 (clutch
018 (valve clutch disengage X X disengage fast). Decreased comfort for clutch functions.
slow).
Short circuit to ground
at output stage to Y15 TCU output switches off. Function taken on by valve Y14 (clutch
019 (valve clutch disengage X X disengage fast). Decreased comfort for clutch functions.
slow).
Short circuit to ground
at output stage to Y16 TCU valve output switches off. Function taken on by valve Y17
020 X X (clutch disengage, slow). Increased shifting time. Decreased comfort
(valve clutch disengage
for clutch functions.
fast).
Short circuit to ground
at output stage to Y14 TCU valve output switches off. Function taken on by valve Y15
021 X X (clutch disengage, slow). Increased shifting time. Decreased comfort
(valve clutch disengage
for clutch functions.
fast).
Short circuit to ground
at output ADVP or
ADVP1 (wakeup Driving: Gearshifting blocked. Stationary: TCU tries to open the
control signal for shift clutch, when coming to standstill. Neutral automatically engaged at
022 X X X standstill. Gearshifting blocked, continued driving not possible. System
lever ECU, voltage
supply to ZF-display, not available.
warning buzzer, output
speed sensor 1).
Short circuit to ground
at transmission actuator
025 (TCU) output SD to X If ZF-display existing, display is flashing ”EE”. No system restrictions.
ZF-display.
Applied substitute parameters (P1 to P7) from data application field
will be taken. Reduced functionality for automatic mode and start gear
CAN engine
026 X X calculation, if deviation of substitute parameters and real values is high.
configuration timeout.
Target speed for downshifting can be reduced. Quality of clutch
disengagement for stopping can be reduced.
Applied substitute parameters (P1 to P7) from data application field
Error on ”engine will be taken. Reduced functionality for automatic mode and start gear
027 configuration message” X X calculation, if deviation of substitute parameters and real values is high.
(engine configuration). Target speed for downshifting can be reduced. Quality of clutch
disengagement for stopping can be reduced.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 13

Buzzer
Code
Failure description System reaction

Error on ”Actual
driveline retarder - No calculation of driving resistance possible. No automatic
028 X X calculation of start off gear. When coming to standstill, medium start
percent torque” signal
off gear will be shifted. No other functional restrictions.
(ERC1_DR).
Error on ”Engine
There are no downshift requests coming from retarder to increase
029 coolant load increase” X X engine speed to improve cooling power.
signal (ERC1_DR).
Error on ”Driveline
retarder configuration No calculation of driving resistance possible. No automatic
030 X X calculation of start off gear. When coming to standstill medium start
message” (Driveline
off gear will be shifted. No other functional restrctions.
retarder configuration).
No calculation of driving resistance possible. No automatic
Error on ”Actual engine calculation of start off gear. When coming to standstill medium start
retarder - percent off gear will be shifted. No other
031 torque” signal functional restrictions. No information about engine brake torque. If
(ERC1_ER). exhaust brake is active, shifting quality at start of shifting may be poor.
Engine brake is considered not active.
Error on ”Engine
retarder configuration No calculation of driving resistance possible. No automatic
032 X X calculation of start off gear. When coming to standstill medium start
message” (Engine
off gear will be shifted. No other functional restrctions.
retarder configuration).
No calculation of driving resistance possible. No automatic
CAN ”Engine retarder
033 X X calculation of start off gear. When coming to standstill medium start
configuration” timeout.
off gear will be shifted. No other functional restrctions.
Interruption at output If the error occurs while shifting is in process, depending on the driving
stage to splitter (GV) conditions either the current gear will be kept active or the TCU will
Valve Y2 try to engage a gear which is engageable with the current error.
For direct drive design: The driver is able to initiate shiftings both in driving and stationary
034 shifting into high splitter X X situations. The type of error will influence the shifting-process.
group not possible.
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
For overdrive design: or the clutch remains open.
shifting into low splitter
group not possible. Output stages with short circuit will be switched off.

Interruption at output If the error occurs while shifting is in process, depending on the driving
stage to splitter (GV) conditions either the current gear will be kept active or the TCU will
Valve Y3. try to engage a gear which is engageable with the current error.
For direct drive design: The driver is able to initiate shiftings both in driving and stationary
035 shifting into low splitter X X situations. The type of error will influence the shifting-process.
group not possible.
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
For overdrive design: or the clutch remains open.
shifting into high splitter
group not possible. Output stages with short circuit will be switched off.
14 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

If the error occurs while shifting is in process, depending on the driving

conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Interruption at output
The driver is able to initiate shiftings both in driving and stationary
036 stage to Y4 (Valve X X situations. The type of error will influence the shifting-process.
Select). If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Interruption at output
The driver is able to initiate shiftings both in driving and stationary
037 stage to Y5 (Valve X X situations. The type of error will influence the shifting-process.
Select). If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Interruption at output The driver is able to initiate shiftings both in driving and stationary
038 stage to Y6 (Valve X X X situations. The type of error will influence the shifting-process.
Shift).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Interruption at output The driver is able to initiate shiftings both in driving and stationary
039 stage to Y7 (Valve X X X situations. The type of error will influence the shifting-process.
Shift).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
Interruption at output try to engage a gear which is engageable with the current error.
stage to Y8 (Valve The driver is able to initiate shiftings both in driving and stationary
040 Range). Shifting into X X situations. The type of error will influence the shifting-process.
Range „Low“ not
possible. If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 15

Buzzer
Code
Failure description System reaction

If the error occurs while shifting is in process, depending on the driving

conditions either the current gear will be kept active or the TCU will
Interruption at output try to engage a gear which is engageable with the current error.
stage to Y9 (Valve The driver is able to initiate shiftings both in driving and stationary
041 Range). Shifting into X X situations. The type of error will influence the shifting-process.
Range „Low“ not
possible. If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
Interruption at output No gearshifting possible! No neutral shifting possible!
stage to Y10 (Main
042 valve). Air supply not X X X Selected gear remains engaged; Vehicle start permitted in engaged
available. gear. After ignition on, system not available

Interruption at output
043 to warning buzzer. X Warning -Buzzer can not be activated

Vehicle without Mux:

Interruption at output
stage to reverse light
relay
No reverse light respectively „add. manoeuvering mode lamp“
044 Vehicle with Mux: X activation possible. No further system restrictions.
Interruption at output
stage to “add.
manoeuvering mode
lamp“.
Interruption at output PTO1 not available. PTO1-engagement-Error will be surpressed.
045 X X PTO1-request is not accepted. No further restrictions.
stage to PTO 1.
Interruption at output PTO2 not available. PTO2-engagement-Error will be surpressed.
046 X X PTO2-request is not accepted. No further restrictions.
stage to PTO 2
Driving: Upshifts during driving are controlled like downshifts. Input
Interruption at output speed will be synchronized by engine speed. Upshifts blocked, when
049 X X input target speed is below engine idle speed. Increased shifting time.
stage to Y1 (inertia
brake valve). Stationary: Increased self adjustment time. Increased shifting time
when shifting out of neutral.
Interruption at output
Function taken on by valve Y16 (clutch disengage fast)
050 stage valve Y17 (clutch X X
Decreased comfort.
disengage slow).
Interruption at output
Function taken on by valve Y14 (clutch engagement fast) Decreased
051 stage valve Y15 X X comfort.
(clutch engage slow).
Interruption at output
Function taken on by valve Y17 (clutch engagement slow) Decreased
052 stage valve Y16 X X comfort.
(clutch engage fast).
16 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Interruption at output
Function taken on by valve Y15 (clutch engagement slow) Decreased
053 stage valve Y14 X X comfort.
(clutch engage fast).
Interruption at output
ADVP or ADVP1
Driving: Gearshifting blocked. Stationary: TCU tries to open the
(wakeup control signal clutch, when coming to standstill. Neutral automatically engaged at
054 X X X
for shift lever ECU, standstill. Gearshifting blocked, continued driving not possible. System
voltage supply to ZF- not available.
display, warning buzzer,
output speed sensor 1).
If PTO1 acknowledge signal is active before PTO1 request is active,
Acknowledge fault of
059 X X output stage PTO1 will be activeted after PTO1 request is activeted.
PTO 1.
No further system restrictions.
If PTO2 acknowledge signal is active before PTO2 request is active,
Acknowledge fault of
060 X X output stage PTO2 will be activeted after PTO2 request is activeted.
PTO 2.
No further system restrictions.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
clutch, when coming to standstill. Neutral automatically engaged at
Disengagement fault
061 X X X standstill. Gearshifting blocked, continued driving not possible. System
of PTO 1. not available.

Driving: Gearshifting blocked. Stationary: TCU tries to open the

clutch, when coming to standstill. Neutral automatically engaged at
Disengagement fault
062 X X X standstill. Gearshifting blocked, continued driving not possible. System
of PTO 2. not available.

Engagement fault of PTO activation is switched off. No PTO 1 available. No further system
063 PTO 1. X X restrictions.
Engagement fault of PTO activation is switched off. No PTO 2 available. No further system
064 PTO 2. X X restrictions.
Short circuit to positive
If the error occurs while shifting is in process, depending on the driving
at output stage to
conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y2
try to engage a gear which is engageable with the current error.
For direct drive design:
The driver is able to initiate shiftings both in driving and stationary
066 shifting into low splitter X X situations. The type of error will influence the shifting-process.
group not possible.
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
For overdrive design:
or the clutch remains open.
shifting into high splitter
Output stages with short circuit will be switched off.
group not possible.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 17

Buzzer
Code
Failure description System reaction

Short circuit to positive

If the error occurs while shifting is in process, depending on the driving
at output stage to
conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y3
try to engage a gear which is engageable with the current error.
For direct drive design:
The driver is able to initiate shiftings both in driving and stationary
067 shifting into low splitter X X situations. The type of error will influence the shifting-process.
group not possible.
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
For overdrive design:
or the clutch remains open.
shifting into high splitter
Output stages with short circuit will be switched off.
group not possible.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to positive The driver is able to initiate shiftings both in driving and stationary
068 at output stage to Y4 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to positive The driver is able to initiate shiftings both in driving and stationary
069 at output stage to Y5 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to positive The driver is able to initiate shiftings both in driving and stationary
070 at output stage to Y6 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to positive The driver is able to initiate shiftings both in driving and stationary
071 at output stage to Y7 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
18 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

If the error occurs while shifting is in process, depending on the driving

Short circuit to conditions either the current gear will be kept active or the TCU will
positive at output try to engage a gear which is engageable with the current error.
stage to Y8 (Valve The driver is able to initiate shiftings both in driving and stationary
072 X X situations. The type of error will influence the shifting-process.
range). Shifting into
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
Range „High“ not or the clutch remains open.
possible.
Output stages with short circuit will be switched off.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
Short circuit to positive try to engage a gear which is engageable with the current error.
at output stage to Y9 The driver is able to initiate shiftings both in driving and stationary
073 (Valve range). Shifting X X situations. The type of error will influence the shifting-process.
into Range “High“ not
possible. If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
Short circuit to positive
Driving: Gearshifting of all gears possible. Stationary: All starting gears
074 at output stage to Y10 X X can be engaged.
(Main valve).
Short circuit to positive
075 at output stage to X Warning-Buzzer not available
warning buzzer.
Vehicle without Mux:
Short circuit to positive
at output stage to
reverse light relay
No reverse light respectively „add. manoeuvering mode lamp“
076 Vehicle with Mux: X activation possible. No further system restrictions.
Short circuit to positive
at output stage to “add.
manoeuvering mode
lamp“.
Short circuit to positive
PTO1 not available. PTO1-engagement-Error will be surpressed.
077 at output stage to PTO X X PTO1-request is not accepted. No further restrictions.
1.
Short circuit to positive
PTO2 not available. PTO2-engagement-Error will be surpressed.
078 at output stage to PTO X X PTO2-request is not accepted. No further restrictions.
2.
Short circuit to positive Driving: Gearshifting blocked. Stationary: Shift of start off gears
081 at output stage to Y1 X X possible. Main valve will be only activated during shifting, if clutch is
(inertia brake valve). opened. Start off possible.
Gearshifting generally blocked, system not available.
Short circuit to positive
Driving and gear engaged: Attempt to keep clutch engaged
at output stage to valve
082 X X X (prevention with engagement valves).
Y17 (clutch disengage
slow). Stationary: Engagement valves are switched off, automatic neutral
shifting when clutch is disengaged.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 19

Buzzer
Code
Failure description System reaction

Gearshifting generally blocked, system not available.

Short circuit to positive
Driving and gear engaged: Attempt to keep clutch engaged
at output stage to valve
083 X X X (prevention with engagement valves).
Y15 (clutch engage
slow). Stationary: Engagement valves are switched off, automatic neutral
shifting when clutch is disengaged.
Gearshifting generally blocked, system not available.
Short circuit to positive
Driving and gear engaged: Attempt to keep clutch engaged
at output stage to valve
084 X X X (prevention with engagement valves).
Y16 (clutch disengage
fast). Stationary: Engagement valves are switched off, automatic neutral
shifting when clutch is disengaged.
Gearshifting generally blocked, system not available.
Short circuit to positive
Driving and gear engaged: Attempt to keep clutch engaged
at output stage to valve
085 X X X (prevention with engagement valves).
Y14 (clutch engage
fast). Stationary: Engagement valves are switched off, automatic neutral
shifting when clutch is disengaged.
Short circuit to positive
at output ADVP or 1. After ignition off/on failure will be detected during initialization. Shift
ADVP1 (wakeup lever ECU does not switch off. If ZFdisplay
control signal for shift
086 X X existing, display can not be switched off; after ignition off, ZF-display
lever ECU, voltage
supply to ZF- display, is flashing „EE“.No restrictions on system availability. 2. During
warning buzzer, output operation no restrictions on system availability.
speed sensor 1).
Short circuit to positive
089 at output SD to X If ZF-display existing, display is flashing „EE“. No system restrictions.
ZF-display.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
Communication error clutch, when coming to standstill. Neutral automatically engaged at
between controller 1 standstill. Gearshifting blocked, continued driving not possible. System
090 and controller 2 (TCU X X X
not available.
failure).

No calculation of driving resistance possible. No automatic

CAN EBC1 timeout
091 X X calculation of start off gear. When coming to standstill medium start
(brake messages).
off gear will be shifted. No other functional restrictions.
No calculation of driving resistance possible. No automatic
Error on „ABS active calculation of start off gear. When coming to standstill medium start
092 signal“ (EBC1). X X off gear will be shifted. No other functional restrictions.

No calculation of driving resistance possible. No automatic

Error on ”ASR engine calculation of start off gear. When coming to standstill medium start
093 control active” signal X X off gear will be shifted. No other functional restrictions.
(EBC1).

Error on ”ASR brake No calculation of driving resistance possible. No automatic

094 control active” signal X X calculation of start off gear. When coming to standstill medium start
(EBC1). off gear will be shifted. No other functional restrictions.
20 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Error on ”Cruise
095 control active” signal X X No other functional restrictions.
(CCVS).
Error on ”Cruise
No other functional restrictions, gear hunting in cruise control
096 control set speed”
possible
(CCVS).
Driving: Time based control of clutch during shifting.
Decreased clutch comfort after shifting. Clutch does open below
fixed value (No clutch opening according coasting condition) Engine
Error on ”Engine speed governor during upshift does not work. Stationary: No
097 speed” signal (EEC1). X X
manoeuvering operation possible.
Time based control of clutch during starting off.
Decreased clutch comfort of manoeuvering and starting.
Driving: Increased shifting time. During upshifting and downshifting
clutch will be partially closed when t/m in neutral to substitute input
Error on ZF speed by engine speed. If gear is engaged, input speed is substituted
098 transmission input X X by output speed.
speed signal “n_sek“.
Stationary: Increased shifting time. Decreased clutch comfort in
manoeuvering and starting.
Output speed signal will be calculated depending on system
application from redundant output speed information. Redundant
Error on ZF-output speed information will be taken depending on application from
099 speed signal 1 X X vehicle speed signal via CAN OR output speed signal from CAN
“n_ab_1“. tachograph.
Manual shifting of all gears possible.
Error on CAN output
100 speed signal 2 X X If outspeed signal 1 is available, no functional restrictions of system.
“n_Ab_2“.
Error on both output
speed signals: Driving: Gearshifting blocked. Stationary: TCU tries to open the
ZF-output speed signal clutch, when coming to standstill. Neutral automatically engaged at
101 X X X standstill. Gearshifting blocked, continued driving not possible. System
1 “n_ab_1“ and CAN
output speed signal 2 not available.
“n_Ab_2“.
Plausibility error
between transmission Driving: Gearshifting blocked during driving including neutral shift
102 input speed „n_sek“ X X attempt. Stationary: Start off gears can be engaged. Driving with start
and output speed off gear possible.
„n_ab_1“.
CAN CCVS Error on
In automatic mode the down shifting could be initiated relayed or
103 wheel based vehicle X X prematured.
speed.

High voltage (Vehicle No system restrictions while driving.

104 electrical system X If fault occurs before ’Ignition ON’ (key 15) the transmission does not
voltage too high). get out of the check phase.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 21

Buzzer
Code
Failure description System reaction

At all: Subsequent failure detection of all failures during low voltage

will be supressed.If PTO is engaged and relay cannot be kept active,
PTO will be disengaged.
Low voltage (Vehicle Driving: Gearshifting blocked. Clutch valves will be controlled
105 electrical system X X X independent on voltage level.
voltage too low).
Stationary: Gearshifting blocked. If gear is engaged and driver switches
off ignition, attempt to shift to neutral is allowed independent on
voltage level. TCU will be switched off independent on successful
neutral shifting after time out.
Driving: Clutch is disengaged and engaged by time control. Stationary:
Stabilised voltage
Manoeuvering not possible. If start does not occur within certain time,
supply at output AU
107 X X transmission is automatically shifted to neutral. New start off gear
(clutch sensor supply)
must be engaged by selector lever. Decreased clutch comfort during
out of valid range.
start off.
Control lever (joy stick):
No shifting during driving. At standstill in MANUAL (semiautomatic)
the last starting gear will be engaged, in AUTOMATIC the
AUTOMATIC starting gear. If at standstill NEUTRAL is activated or
NEUTRAL already available, no starting gear is shifted.
Error in selector lever NEUTRAL switch:
108 or tip lever. X X
No shifting during driving possible. At standstill starting gear
engagement possible and driving in starting gear.
REVERSE switches:
If at standstill one of the two REVERSE switches fails (no signal) and
REVERSE (-/--) actuated at selector lever, slow reverse gear (RL) will
be engaged.
1. After ignition off/on: Failure will be detected during
initialization. No shift lever information. System not available. 2.
During operation: No gearchange possible.
110 ZF CAN timeout. X X When coming to standstill, last selected startoff gear will be
automatically engaged. Continuous driving only with startoff gear
possible. If reverse gear has been engaged, transmission will
automatically shifted to neutral. No shift lever information.
Error on ”Driveline No calculation of driving resistance possible. No automatic
113 retarder configuration” X X calculation of start off gear. When coming to standstill medium start
timeout. off gear will be shifted. No other functional restrictions.
Clutch engaged Standstill: shift to neutral. If ”Neutral” is reached, no further system
114 unintentionally in X X X restrictions. Driving after a Neutral confirmation (shift lever to pos.
standstill, gear engaged. “N“) possible.
Error in clutch
117 selfadjustment process. X X X System not available.

Driving: Gearshifting blocked. Stationary: TCU tries to

Clutch does not open the clutch, when coming to standstill. Neutral automatically
118 disengage. X X X
engaged at standstill. Gearshifting blocked,
continued driving not possible. System not available.
22 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Driving: Gearshifting blocked. Stationary: TCU tries to

Clutch does not engage
open the clutch, when coming to standstill. Neutral automatically
119 / does not transmit X X X
engaged at standstill. Gearshifting blocked,
engine torque.
continued driving not possible. System not available.
Mechanical failure of
120 small disengagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
Mechanical failure of
121 large disengagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
Mechanical failure of
122 small engagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
Mechanical failure of
123 large engagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
Driving: Clutch is disengaged and engaged by time control. Stationary:
Error on clutch travel Manoeuvering not possible. If start does not occur within certain time,
124 X X transmission is automatically shifted to neutral. New start off gear
signal. must be engaged by selector lever. Decreased clutch comfort during
start off.
No system restrictions on availability, íf external air supply is sufficient.
Error on pressure No air pressure indication AL on display in case, air pressure is not
126 X X sufficient. Self adjustment of transmission and clutch is done time
sensor signal. based and not related to the sensor signal. Time for adjustment could
be longer.
Error on TCU
127 temperature sensor X X No system restrictions on availability.
signal.
Error on oil No system restrictions on availability. Shift monitoring
128 temperature sensor
signal. time will be depending on TCU temperature signal.

Driving: When failure occurs during shifting, gear engaged signal is

transmitted based on time control.
No shift sensor signal Further gearshifting blocked. Only shifting out of neutral possible
129 (Short circuit to X X Stationary: Neutralshifting will be verified by select test procedure.
positive). Engagement of starting gears possible. Change of starting gears
possible. Main valve and gear valves remain active until clutch
engagement exceeds defined threshold or driving condition is
detected (to overcome tooth-to-tooth).
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 23

Buzzer
Code
Failure description System reaction

Driving: When failure occurs during shifting, gear engaged signal is

transmitted based on time control.
No shift sensor signal Further gearshifting blocked. Only shifting out of neutral possible
130 (Short circuit to X X Stationary: Neutralshifting will be verified by select test procedure.
ground). Engagement of starting gears possible. Change of starting gears
possible. Main valve and gear valves remain active until clutch
engagement exceeds defined threshold or driving condition is
detected (to overcome tooth-to-tooth).
Driving: When failure occurs during shifting, gear engaged signal is
transmitted based on time control.
Further gearshifting blocked. Only shifting out of neutral possible
No shift sensor signal Stationary: Neutralshifting will be verified by select test procedure.
131 (Interruption). X X
Engagement of starting gears possible. Change of starting gears
possible. Main valve and gear valves remain active until clutch
engagement exceeds defined threshold or driving condition is
detected (to overcome tooth-to-tooth).
With ignition off, t/m will be automatically switched to neutral. With
ignition on, valve Y6 and Y7 (neutral) will be switched on together
with main air valve Y10. If sensor value is outside of neutral self
adjustment range and air pressure is sufficient, TCU tries three times
to adjust neutral position. If neutral position could not be adjusted,
self adjustment failure will be set. If air pressure is not sufficient and
neutral could not be adjusted, no adjustment failure will be set. If air
pressure sensor is faulty, N will be adjusted one time. If neutral could
not be reached, a waiting time will be started. After waiting time has
Self adjustment error of past, neutral adjustment will be tried again.
132 shift sensor. X X
The adjustment procedure will be repeated until a defined number
of attempts. If the maximum number of attempts will be exceeded,
then self adjustment failure will be set.
Stationary: Engagement of starting gears out of neutral possible, if air
pressure is sufficient. (Gear engaged signal created via time control)
Neutral position will be verified by select procedure. If air pressure is
not sufficient, shifting is blocked.
Driving: Gearshifting blocked.
Driving: Only forward gears can be selected, which are allocated in
opposite shift-position of the reverse gear. If failure occurs during
No gate select sensor
shifting, the target gate will be engaged by time control. Stationary: All
133 signal (Short circuit to X X
allowed starting gears can be switched, whose positions are allocated
positive).
in opposite shift-position of the reverse gear. No reverse gear
shiftable.
Driving: Only forward gears can be selected, which are allocated in
opposite shift-position of the reverse gear. If failure occurs during
No gate select sensor
shifting, the target gate will be engaged by time control. Stationary: All
134 signal (Short circuit to X X
allowed starting gears can be switched, whose positions are allocated
ground).
in opposite shift-position of the reverse gear. No reverse gear
shiftable.
Driving: Only forward gears can be selected, which are allocated in
opposite shift-position of the reverse gear. If failure occurs during
No gate select sensor shifting, the target gate will be engaged by time control. Stationary: All
135 signal (Interruption). X X
allowed starting gears can be switched, whose positions are allocated
in opposite shift-position of the reverse gear. No reverse gear
shiftable.
24 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

With ignition off, splitter remains in last engaged position.

Engine stationary: With ignition on TCU checks the splitter sensor
value. If sensor value is within defined end position range high or low,
the appropriate splitter valve combination will be activated and
together with main valve Y10 splitter end position will be adjusted.
If splitter position is not within defined end position range and air
supply is sufficient, TCU tries to shift once into high position. If splitter
position is not within defined end position range and air supply is not
sufficient or air pressure sensor is faulty, no splitter position will be
shifted.
Engine running: With ignition on TCU checks the splittersensor value.
If sensor value is within defined end position range high or low, the
appropriate splitter valve combination will be activated and together
with main valve Y10 splitter end position will be adjusted. If splitter
position is not within defined end position range , clutch remains
closed and TCU tries to shift into high position. If high position could
not be engaged, splitter shifts into low position. If low position could
not be engaged, TCU tries three times to engage high or low position.
Gate select sensor self If air supply is sufficient and all attempts failed to engage splitter, a self
136 adjustment error. X X
adjustment failure will be set. If air supply is not sufficient or air
pressure sensor is faulty and splitter sensor is not within defined end
position range ,clutch remains closed and TCU tries to shift into high
position. If high position could not be engaged, splitter shifts into low
position. If low position could not be engaged, TCU tries three times
to engage high or low position. If splitter could not be engaged, TCU
waits a defined time and retry splitter adjustment in high or low
position. The adjustment procedure will be repeated until a defined
number of attempts. If the maximum number of attempts will be
exceeded, then self adjustment failure will be set.
For cases: If no splitter position could be adjusted, no gear shifting is
possible. System is not available. If only low splitter could be adjusted,
gear shifting in low splitter group is possible. If only high splitter
couldbe adjusted, gear shifting in high splitter group is possible.
Attempt shift gear into not adjusted positionduring driving and
standstill is allowed. If splitter cylinder reaches adjustment range,
adjustment failure will be reset. If splitter cylinder does not reach
adjustment range, last gear will be reengaged. Subsequent splitter
shifting failures will be supressed.
Driving: When shifting from low range group to high group, the
highest gear in low range group will be shifted.
When shifting from high range group to low group, the lowest gear
Range change group
in high range group will be shifted.
145 (GP) disengagement X X
error. Stationary: If it is not possible to select low range group, the lowest
gear in high range group is selected as starting gear. New attempt to
shift range group is allowed under all driving conditions. No reverse
gear in high range group possible.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 25

Buzzer
Code
Failure description System reaction

Driving and stationary: If selected range group could not be engaged,

range cylinder tries to repeat engagement three times. If selected
range group could not be engaged, following gear will be shifted:
Changeover error When shifting from low range group to high group, the highest gear
146 during range change X X in low range group will be shifted. When shifting from high range
group (GP) shifting. group to low group, the lowest gear in high range group will be shifted.
Stationary: If it is not possible to select low range group, the lowest
gear in high range group is selected as starting gear. New attempt to
shift range group is allowed under all driving conditions.
Driving and stationary: If selected range group could not be engaged,
range cylinder tries to repeat engagement three times. If selected gear
Range change group could not be engaged, old range position will be selected.If
147 (GP) does not engage. X X X
engagement into old range position failed, failure will be set.T/m shifts
to neutral. New attempt to shift range group is allowed under all
driving conditions.
If failure occurs, t/m shifts into next upper gear. Following gear
restrictions are valid:
Driving: The highest gear which can be selected, is the highest gear
Splitter (GV) does not in last engaged splitterposition.The lowest gear which can be selected
148 disengage. X X
is the lowest gear in last engaged splitter position.
Stationary:The highest gear which can be selected, is the highest start
off gear in last engaged splitterposition.The lowest gear which can be
selected is the lowest start off gear in last engaged splitter position.
If failure occurs, t/m shifts into next upper gear. Following gear
restrictions are valid:
Driving: The highest gear which can be selected, is the highest gear
Change over error in last engaged splitterposition.The lowest gear which can be selected
149 during splitter shifting. X X
is the lowest gear in last engaged splitter position.
Stationary:The highest gear which can be selected, is the highest start
off gear in last engaged splitterposition.The lowest gear which can be
selected is the lowest start off gear in last engaged splitter position.
Splitter (GV) does not System not available. New attempt to shift splitter group is allowed
150 engage. X X X under all driving conditions.
Driving: When failure occurs during shifting, t/m shifts back into the
last gear. If last gear is not shiftable because of overspeed condition,
the next possible target gear, which is next to last gear will be shifted.
Selector cylinder does When highest shiftable gear could not be shifted because of
151 not disengage. X X overspeed condition, then t/m shifts to neutral.
Stationary: If target select position could not be engaged,t/m shifts
into neutral. New shifting of start off gear must be initiated by selector
switch.
Driving: When failure occurs during shifting, t/m shifts back into the
last gear. If last gear is not shiftable because of overspeed condition,
the next possible target gear, which is next to last gear will be shifted.
Change over error When highest shiftable gear could not be shifted because of
152 during gate selection X X overspeed condition, then t/m shifts to neutral.
procedure.
Stationary: If target select position could not be engaged,t/m shifts
into neutral. New shifting of start off gear must be initiated by selector
switch.
26 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Driving and stationary: T/m shifts into neutral position.

Selector cylinder does
153 not engage. X X X New shifting of gear must be initiated by selector switch.no gate could
be engaged, system not available.
Driving: Clutch engages in previous gear. Next attempt to shift must
be initiated by selector switch. Stationary:
Main transmission gear
154 does not disengage. X X X Gearshifting only permitted after neutral signal has been reached.
Start off and driving can be tried with engaged gear, if gear is equal or
lower than lowest gear in range high position.
Transmission tries automaticly shift to Neutral. During
Main transmission gear Neutral-shifting the clutch remains open. For solving the shifting
155 does not engage. X X X failure, the driver can after a Neutral-confirmation (shift lever to pos.
„N“) in all driving conditions induce a new shifting by the shift lever.
Transmission tries automaticly shift to Neutral. During
Neutral-shifting the clutch remains open. For solving the shifting
156 Wrong gear shifting. X X X failure, the driver can after a Neutral-confirmation (shift lever to pos.
„N“) in all driving conditions induce a new shifting by the shift lever.
Selector sensor signal
Main valve will be activated automatically together with selector
157 leaves engaged
valves to shift into end position (in cycles).
position.
Main valve will be activated automatically together with gear valves
Shift sensor signal to shift into end position. If gear has been disengaged completely, a
158 leaves engaged position X X suitable gear depending on speed condition will be shifted
during driving.
automatically.
Range-change group Main valve will be activated automatically together with gear valves
sensor signal leaves to shift into end position. If gear has been disengaged completely, a
159 engaged position during X X suitable gear depending on speed condition will be shifted
driving. automatically.

Splitter sensor signal Main valve will be activated automatically together with gear valves
to shift into end position. If gear has been disengaged completely, a
160 leaves engaged position X X suitable gear depending on speed condition will be shifted
during driving. automatically.
Engine does not react
Driving: Gearshifting blocked. Stationary: Starting allowed. Decreased
163 on ASTRONIC engine X X clutch functionality and comfort.
torque control.
Driving: No calculation of vehicle weight and driving resistance
possible. No calculation of startoff gear possible. Drivers demand will
be substituted by accelerator pedal position information. After
shifting finished, fuel quantity will be released up to accelerator pedal
Error on ”Drivers
value. Clutch engagement quality could be reduced. During cruise
164 demand engine percent X X
contol operation no fuel quantity release is possible, because
torque” (EEC1).
accelerator pedal value is 0. After clutch is engaged, fuel quantity will
be released by EDC. => Bad shift quality after shifing. Stationary: Start
off possible. When coming to standstill, medium start off gear will be
shifted. No other functional restrictions.
Driving: No calculation of vehicle weight and driving resistance
possible. No calculation of startoff gear possible. Accelerator pedal
Error on ”Accelerator position will be substituted by drivers demand information. Shift
165 pedal position” (EEC2). X X
quality could be reduced. Stationary: Start off possible. When coming
to standstill, medium start off gear will be shifted. Manoeuvering and
startoff quality could be reduced.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 27

Buzzer
Code
Failure description System reaction

Driving: Shifting during driving allowed. Stationary: No manoeuvering

166 Permanent idle signal. X X and startoff possible. System not available.
Driving: No functional restrictions during driving.
Stationary: After RESET AP or FP is shown on display as long as
No idle signal or error accelerator pedal value is in coast condition and idle signal is off. If idle
on ”idle signal switch” signal does not appear within defined time, failure will be set and
168 signal (EEC2) or never X X display indication AC or FP disappears. TCU checks point P1 from
active ”idle signal”. engine configuration (low idle speed).Start off will be allowed, if TCU
detects accelerator pedal value > threshold and engine speed
exceeds idle speed + defined speed threshold (-> verification of start
off intention)
Driving: Gearshifting blocked. Stationary: TCU tries to open the
Cut-off relay in TCU clutch, when coming to standstill. Neutral automatically engaged at
169 does not switch off. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
No voltage supply at pin Driving and Standstill: block shifting and clutchfunction.
30 or cut-off relay in
170 TCU does not switch X X X System not available. State of clutch and transmission remains
on. unchanged.

Driving: No calculation of vehicle weight and driving resistance

possible. No calculation of startoff gear possible. Actual engine
percent torque will be substituted by drivers demand information.
Error on ”Actual engine Shift quality (fuel load reduction and fuel load release) could be
171 percent torque” signal X X reduced.
(EEC1).
Stationary: Start off possible. When coming to standstill, medium start
off gear will be shifted. Warning for clutch overload detection and
reaction on overload detection could appear earlier.
Error on ”Kickdown No Kickdown operation mode possible. No other functional
174 switch” signal (EEC2). X X restrictions.
Driving: Gearshifting in general blocked, as soon as no ignition on
signal is detected (failure detection might be delayed). Standstill: If
engine is running , TCU does not switch off. Start off gear shiftable
(forward and reverse).
Error on ”Ignition lock”
175 signal (Key 15). X X
Driving with start off gear possible. If engine is not running, t/m will
be automatically shifted to neutral and TCU switches off. No
initialization of system possible.
System not available.
IVECO: Failure Additional Manoeuvring Mode not active: Additional Manoeuvring
176 manoeuvring tip switch X X Mode not available Additional Manoeuvring Mode: Additional
signal. Manoeuvring Mode is switched off
Driving: Gearshifting blocked. Stationary: TCU tries to open the
System-CAN Busoff clutch, when coming to standstill. Neutral automatically engaged at
177 error. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
clutch, when coming to standstill. Neutral automatically engaged at
178 CAN Error warning. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
28 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Buzzer
Code

Failure description System reaction

Driving: Gearshifting blocked. Stationary: TCU tries to open the

clutch, when coming to standstill. Neutral automatically engaged at
179 CAN queue overrun. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
clutch, when coming to standstill. Neutral automatically engaged at
180 CAN EEC1 timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
clutch, when coming to standstill. Neutral automatically engaged at
181 CAN EEC2 timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Wheel based vehicle speed missing (redundant output speed
information 2, if output speed will not be taken from 2nd output
speed sensor or CAN tachograph).
Service brake signal missing. In coast condition service brake signal is
182 CAN CCVS timeout. X X considered as active. Cruise control active information missing. No
calculation of vehicle weight and driving resistance possible. No
calculation of start off gear possible. Subsequent single failure of
message variables are suppressed. Clutch disengages always at foot
brake related engine speed (higher engine revolution).
No calculation of vehicle weight and driving resistance possible. No
calculation of startoff gear possible. No information about engine
CAN ERC1_ER brake torque. If exhaust brake is active, shifting quality at start of
183 timeout. X X shifting may be poor.
Engine brake is considered as not active. No further functional
restrictions.
No calculation of vehicle weight and driving resistance possible. No
CAN ERC1_DR
184 X X calculation of startoff gear possible. Medium start off gear will be
timeout.
shifted. No further functional restrictions.
TCU fault — wrong Driving: Gearshifting blocked. Stationary: TCU tries to open the
interrupt OR TCU and clutch, when coming to standstill. Neutral automatically engaged at
188 software not X X X standstill. Gearshifting blocked, continued driving not possible. System
compatible. not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
TCU fault — stack clutch, when coming to standstill. Neutral automatically engaged at
189 watch. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
EOL EEPROM clutch, when coming to standstill. Neutral automatically engaged at
190 parameter out of valid X X X standstill. Gearshifting blocked, continued driving not possible. System
range.
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
EOL EEPROM clutch, when coming to standstill. Neutral automatically engaged at
191 parameter checksum X X X standstill. Gearshifting blocked, continued driving not possible. System
error.
not available.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 29

Buzzer
Code
Failure description System reaction

TCU fault — EEPROM

access failure
No calculation of driving resistance possible. No automatic
192 OR X X calculation of start off gear. When coming to standstill, medium start
off gear will be shifted. No other functional restrictions.
checksum Error (only
processor 2).
Driving: Gearshifting blocked. Stationary: Clutch opens, when coming
to standstill. Neutral automatically engaged at standstill. Gearshifting
TCU temperature too
193 X X X blocked, continued driving not possible. Special display indication for
high.
TCU temperature too high alternating with gear information. System
not available.
Both sources for front
194 axle speed not available. X X ISMA is turned off. No other functional restrictions.

No calculation of driving resistance possible. No automatic

Error on ”Front axle
197 X X calculation of start off gear. When coming to standstill, medium start
speed” (WSI).
off gear will be shifted. No other functional restrictions.
No calculation of driving resistance possible. No automatic
199 CAN WSI timeout. X calculation of start off gear. When coming to standstill, medium start
off gear will be shifted. No other functional restrictions.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
IVECO:CAN message clutch, when coming to standstill. Neutral automatically engaged at
226 BC_TC timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
Application-Error clutch, when coming to standstill. Neutral automatically engaged at
227 database for X X X standstill. Gearshifting blocked, continued driving not possible. System
CANcommunication.
not available.
30 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

SPECIFICATIONS AND DATA

GEARBOXES AsTronic
16 AS 2601 O.D.
Type Mechanical
Torque activated Nm 2200 Nm

Forward gears 16
Reverse gears 2

Type of running control electronically-operated semi-automatic

Side rear power takeoff optional

Gear engagement: by front engagement sleeves

E.R.U.* and splitter engagement free ring synchroniser

Gears constantly engaged straight toothed

Gear ratios
1st 14.12
2nd 11.68
3rd 9.54
4th 7.89
5th 6.52
6th 5.39
7th 4.57
8th 3.78
9th 3.09
10th 2.56
11th 2.09
12th 1.73
13th 1.43
14th 1.8
15th 1.00
16th 0.83
1st RM 13.07
2nd RM 10.81

ERG* = Epicyclic Reduction Gearing

O.D. = Geared up
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 31

SPECIFICATIONS AND DATA

GEARBOXES AsTronic 16 AS 2601 .OD

Bearings
- drive input shaft with balls
- ERG* shaft with cylindrical rollers
- transmission shafts with tapered rollers
Bearing end float:
- drive input shaft 0 y 0.1 mm
- ERG* planet shaft 0 y 0.1 mm
- transmission shafts - 0.05 y + 0.05 mm
End float:
- main shaft 0.2 mm
- drive input shaft split ring 0 y 0.1 mm

Temperature for fitting bearings or

bearing seats on the boxes 120 qC

Forced lubrication with positive

displacement pump flow rate (with 12th
speed engaged and oil at a temperature
of 80ºC) 50 dm3/min
pressure with 12th speed engaged at
2400 rpm and oil at a temperature of:
40ºC 1.7 bar
80ºC 1.2 bar
Oil
liters 12
kg 11

ERG* = Epicyclic Reduction Gearing

O.D. = Geared up
32 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

TIGHTENING TORQUES

See SECTION 8 of this manual for more information on tightening torques of retarder.

Figure 6

307072001R
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 33

TIGHTENING TORQUES
Figure 7

70824

TORQUE
DESCRIPTION
Nm kgm
1 Screws fixing gearbox actuator 23 2.3
2 Screw fixing oil pump 10 1
3 Screws fixing drive input shaft cover 23 2.3
Screw fixing clutch uncoupling lever control pin
4 M 12 8.8 79 7.9
M 12 10.9 115 11.5
5 Screws fixing cover (spread LOCTITE 241 on the thread) 79 7.9
6 Screws fixing clutch actuator 23 2.3
7 Screw cap to discharge air from clutch actuator 22 2.2
8 Screws fixing rear box to middle box 46 4.6
9 Screws fixing flange retaining plate 120 12
10 Screws fixing rear cover 5 4.6
11 Speed sensor 45 4.5
12 Screws fixing middle box to front box 50 5
Pin on rod (spread LOCTITE 262 on the thread) 23 2.3
Oil vapour vent 10 1
Screw plug M 10x1 on rear box 15 1.5
Screw plug M 24x1 on rear box 60 6
Screw M12 fixing power take-off bay cover 79 7.9
Screw plug M 24x1.5 on middle box 60 6
Screw fixing plates retaining fork joint pins on rear box 23 2.3
34 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

TOOLS

TOOL NO. DESCRIPTION

99305121 Hot air device

99322205 Rotary stand for overhauling assemblies

99322225 Mount to support assemblies (to fit onto stand 99322205)

99341003 Single-acting bridge

99341013 Reaction block

99341015 Clamp
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 35

TOOLS

TOOL NO. DESCRIPTION

99341018 Pair of brackets with hole

99345057 Extractor reaction block

99345078 Extractor to remove drive input shaft bearing (use with 99345105)

993450998 Inserter to fit bearing on main shaft, rear side and to insert rear
flange of gearbox

99345105 Extractor for gearbox drive input shaft bearing (use with
99345078)

99347100 Small extractor (use with specific rings with 99347132)

36 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

TOOLS

TOOL NO. DESCRIPTION

99347132 Ring grips to extract gearbox transmission shaft bearings (use with
99345057 - 99347100)

99360323 Tool to turn drive input shaft when refitting the gearbox to the
engine

99360526 Tool to extract and insert main shaft (use with 99360527) and to
drive in gearbox drive input shaft bearing (use with 99345098)

99360527 Tool retaining gearbox main shaft forks (use with 99360526)

99366811 Set of M10 eyebolts (3) to remove and refit gearboxes

99370006 Grip for interchangeable drifts

HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 37

TOOLS

TOOL NO. DESCRIPTION

99370007 Grip for interchangeable drifts

99370153 Tool for positioning main shaft when removing the transmission
shafts and for retaining gearbox reverse gear pins

99370172 Tools (6) to mount gearbox epicyclic reduction gear train

synchronizer rings

99370317 Reaction lever with extension to fasten drive output flange

99370415 Dial gauge base to adjust transmission shaft bearings (use with
99395604)

99370499 Guides (no. 3) to mount Splitter synchronizing device assembly

38 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

TOOLS

TOOL NO. DESCRIPTION

99370629 Mount to support gearbox when removing and fitting it back on

the vehicle

99374092 Drift to mount outer races of bearings (69 - 91) (use with
99370007)

99374221 Driver to mount seals on back cover

99374336 Driver to fit seals on the front cover of the gearbox (use with
99370006)

99395604 Dial gauge (0 - 10 mm)

HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 39

TRANSMISSION OIL CHANGE Hazardous and/or polluting substances

GENERAL
Safety instructions The operation described requires handling of
hazardous and/or polluting substances
Do not touch with the hands.
Before carrying out any operation make certain to Avoid contact with painted parts.
have taken all precautions and clarified all aspects Collect and dispose of used lubricants and fluids,
concerning safety of the personnel involved in the according to the laws and local regulations.
operation. If in doubt, consult a more experienced
person. Read the instructions provided in the first
part of this manual.
Observe all the general recommendations to carry
out maintenance jobs correctly.
Specific safety instructions

Be very careful: drained oil and fluids, as well as filters

and surrounding parts, could be very hot.
Vehicle preparation

Take the vehicle onto a suitable flat, solid surface,

switch off the engine, remove the ignition key,
engage the parking brake and apply the warning
signboards.

Figure 8

2371801

- cut off the battery master switch or disconnect the

terminals from the battery (see arrow) to avoid the risk
of short circuits;
- restore vehicle operation at the end of the operations.
 40 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

DESCRIPTION OF OPERATION Filling

Version without Intarder Proceed as follows:

Exhaust Figure 11
Proceed as follows:
Figure 9

357ANM105L

- fill with required lubricant through the level/filler plug (1)

until it spills out;
357ANM105L
- clean the level/filler plug, check that the thread is in good
- clean the level/filler plug zone (1) and then remove the condition, replace the o-ring and close the plug.
plug;
Final operations
Figure 10 Proceed as follows:
- start the engine and check for lubricant leakage;
- check level following the Maintenance Instructions in the
USE AND MAINTENANCE HANDBOOK

357A072101R

- arrange a container of suitable capacity, remove the drain

plugs (1) and (2) and drain off the lubricant;
- clean the plugs, check that the threading is in good
condition, replace the o-ring with a new one and close
the drain plugs.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 41

Version with Intarder Figure 14

Exhaust
Proceed as follows:
Figure 12

357ANM105L

- clean the level plug zone (1) and then remove the plug;
357ANM104L

Figure 13 - arrange a container of adequate capacity;

- loosen the fastening screws (1) and remove the lid (2);
- remove the filter (3) from the lid;

Lubricate the o-rings of the filter (4) when refitting.

- refit the filter following the operations in reverse.

360F072003R

- arrange a container of suitable capacity, remove the drain

plugs (1) and (2) and drain off the lubricant;
- clean the drain caps, check that the threading is in good
condition, replace the o-ring with a new one and close
the drain caps;
 42 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Filling
Proceed as follows:
Figure 15

360F072004R

- fill with the specified lubricant through the filler plug (1)
until it flows out from the level plug (2);

The unit may be fitted through the level plug (2),

except for first filling after overhauling.

- clean the filler plug and the level plug, check that the
thread is in good condition, replace the o-ring and close
the plugs.

Final operations
Proceed as follows:
- start the engine and check for lubricant leakage;
- check level following the Maintenance Instructions in the
USE AND MAINTENANCE HANDBOOK
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 43

TRANSMISSION REMOVAL-REFITTING Very heavy parts

GENERAL
Safety instructions The following operation requires handling of heavy
parts. To lift and transport, use appropriate
equipment and accessories.

Before carrying out any operation make certain to

have taken all precautions and clarified all aspects
concerning safety of the personnel involved in the
operation. If in doubt, consult a more experienced Hazardous and/or polluting substances
person. Read the instructions provided in the first
part of this manual. The operation described requires handling of
Observe all the general recommendations to carry hazardous and/or polluting substances
out maintenance jobs correctly. Do not touch with the hands.
Avoid contact with painted parts.
Collect and dispose of used lubricants and fluids,
according to the laws and local regulations.

Vehicle preparation

Take the vehicle onto a suitable flat, solid surface,

switch off the engine, remove the ignition key, Specific safety instructions
engage the parking brake and apply the warning
signboards. Be very careful: drained oil and fluids, as well as filters
and surrounding parts, could be very hot.

Figure 16

2371801

- cut off the battery master switch or disconnect the

terminals from the battery (see arrow) to avoid the risk
of short circuits;
- restore vehicle operation at the end of the operations.
 44 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

DESCRIPTION OF OPERATION Removal

Preliminary operation
Proceed as follows: The removal of the tear/snap clips is not described
in detail. These clips must be cut or released and then
- tip the cab; restored while refitting to ensure the correct
fastening of the elements to be held.
- disconnect the hydraulic and electric connections from
the PTO and respective device fitted on the gearbox, if
applicable;
- remove any parts of the outfit with prevent access to the
transmission. Proceed as follows:
- drain off the lubricant as described in the
TRANSMISSION OIL CHANGE chapter in this Section. Figure 18
- For versions with steering pump on transmission only:
drain off the power steering fluid as described in
HYDRAULIC FLUID CHANGE chapter in section 15.
- For versions with Intarder and integrated water-oil heat
exchanger: drain off the engine coolant as described in
COOLANT CHANGE chapter in section 3.

Figure 17

357A006101R

- For versions with steering pump on transmission only:

disconnect the intake (11) and delivery (12) pipes from
the emergency steering pump;

Figure 19

360F072005R

- disconnect the propeller shaft from transmission outlet

(14) as described in the PROPELLER SHAFT
REMOVAL-REFITTING chapter in section 10.
- For front-wheel drive versions only: disconnect the front
wheel-drive propeller shaft from transmission outlet (13)
as described in the PROPELLER SHAFT
REMOVAL-REFITTING chapter in section 10.
- For four-axle drive versions only: disconnect the front
intermediate axle as described in the 360F072007R
REMOVAL-REFITTING chapter in section 12.2.
- disconnect the pneumatic connection (1) from the brake
booster.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 45

Versions with intarder and separate heat exchanger Figure 21

Figure 20

357A006102R

- disconnect and remove the lubricant delivery (15) and

return (16) pipes from the heat exchanger;
357A006103R

- disconnect the electric sensor and actuator connector

from the intarder ECU (10).

The ECU is fitted on the heat exchanger and located

on the chassis near the air cleaner.
DO NOT disconnect the vehicle electric interface
connector from the ECU.

- release the wiring from the chassis and position it on the

retarder.

The wiring remains fitted on the retarder because

the sensors cannot be disconnected from the
respective wire.
 46 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Versions with intarder and integrated heat exchanger Figure 23

Figure 22

360F072008R

- disconnect and remove the engine coolant delivery (17)

and return (18) pipes;

360F072009R

- disconnect the vehicle electric interface connector from

the intarder ECU (10).

DO NOT disconnect the electric sensor and

actuator connector from the ECU.
The wiring remains fitted on the retarder because
the sensors cannot be disconnected from the
respective wire.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 47

Figure 24 Inspections and checks

Proceed as follows:
- Check integrity of the connection flanges.
- Check integrity of the brackets and fastening buttons, if
needed, to replace the damaged component.
- Check the flexible mountings: if necessary replace
damaged component .
- Check perfect integrity of the electric wiring and
respective connections.

Refitting
Refit by reversing the removal sequence.

Final operations
360F072010R Proceed as follows:
- For four-axle drive versions only: refit the front
- disconnect the pneumatic connection (2) supplying the intermediate axle as described in the
transmission services and the vehicle interface electric REMOVAL-REFITTING chapter in section 12.2.
connection (3) from the ECU;
- For front-wheel drive versions only: refit the front
wheel-drive propeller shaft as described in the
PROPELLER SHAFT REMOVAL-REFITTING chapter in
Be careful not to damage the pneumatic pipe and the section 10.
wirings which remain on the unit during the
following operations. - refit the propeller shaft to the gearbox outlet as described
in the PROPELLER SHAFT REMOVAL-REFITTING
chapter in Section 10.
- For versions with Intarder and integrated water-oil heat
Figure 25 exchanger: top up the engine coolant as described in
COOLANT CHANGE chapter in Section 3.
- For versions with steering pump on transmission only: top
up the power steering fluid as described in HYDRAULIC
FLUID CHANGE chapter in Section 15;
- top up the lubricant as described in the TRANSMISSION
OIL CHANGE chapter in this section;
- run the engine for a few minutes and check for hydraulic
fluid leakage from the pipes;
- check the level operating as described in the USE AND
MAINTENANCE HANDBOOK.

360F072011R

- appropriately support the unit to keep it horizontal while

it is being retracted.
- For versions with upper rear mount only: loosen the
fastening screws (see arrow) of rear mounts to chassis;
- retract the unit to free the primary shaft of the clutch and
remove the unit by extracting it from the bottom.
48 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

OVERHAULING THE GEARBOX Gearbox actuator

Removal
Figure 26
Wash the assembly thoroughly before overhauling.
The specific and/or general tools must be used in the
way for which they were designed.
To facilitate assembly, put the removed parts away on
the specific tray in their order of removal.
Upon assembly, the following must always be
replaced with new parts: the gaskets and seals, spring
pins, safety plates and springs. Nuts and screws must
be tightened to the prescribed torque with their
thread dry and degreased.
Keep to the specific regulations when disposing of
lubricant and detergents.

78649

Unscrew the ring nut (1 and 5) and disconnect the electric

wiring (2) from the speed sensor (6 and 7).
Checks Detach the wiring (2) from the clips (o) securing it to the
The gears, synchronizer rings, coupling bodies and sliding middle box.
couplings must show no sign of failure or excessive toothing
wear. Remove the nuts (4) and detach the actuator (3) from the
front box.
The main shaft must have no indentation, especially on the
sliding surfaces of the gear rotation and coupling sleeves.
The reverse idle gear shafts must have a polished surface free
from scoring.
The gearboxes must show no sign of cracking and the bearing
seats must be neither damaged nor worn, so as to prevent the
outer rings of the bearings from turning in their seats.
Check the shoulder spacers are neither worn nor damaged.
The gear coupling forks must show no sign of cracking and the
relevant control rods must slide freely, but without any
appreciable play, in their guide seats. Figure 27
Check that the shoes of the drive forks are fully efficient.
Check that the holes, grooves and lubrication pipes are not
obstructed by grease or foreign bodies.
Check the bearings are not worn, damaged or overheated.

The following described and illustrated overhaul

operations regard transmission 16 A6 2601 and, save
78650
different indications, are valid also for transmission 12
AS 2301. Fasten the gearbox (1) to brackets 99322225 (3) on the
rotating stand 99322205 (2).
Remove the plug and bleed the lubrication oil.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 49

Figure 28 Removing the rear box

Figure 30

78651

Take out the screws (2) and detach the actuator (1) with its
gasket. 70863

The electronic control unit is integrated in the

actuator and these cannot be overhauled. See under Extract the springs (6-7-8) and the pawls (6).
the diagnosis heading for the check.
The springs (7 and 8) are of equal length, the spring
Check that the oil vapour vent (3) is not clogged; if it is, clean (6) is larger.
it.

Refitting Remove the pin (4) from the rod (5).

Remove the switch (1) together with the gasket (2) and
Figure 29 extract the cap (3).

ASTRA

Figure 31

70828

Put a fresh seal (6) on the front box (7).

Lubricate the stems of the solenoid valves (3-4-5) with silicone
grease and put them into a neutral position. Put the rods
(8-9-10) into a neutral position. Fit the actuator (1) on the
front box (7) verifying that the end of the stems of the solenoid
valves is correctly positioned in the seats of the rods (8-9-10).
Tighten the fixing screws (2) to the prescribed torque. After
removing the gearbox from the stand used for overhaul, refit 70830
the clutch actuator (3, Figure 28) and make sure the wiring (2)
is not damaged. Block rotation of the sleeve (1) by applying the lever
99370317 (3) and slightly loosen the screws (2).
 50 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 32 Figure 34

70833
70831
Remove the adjustment ring (3) and the plate (1) together
Remove the screws (1) fixing the plates (2) fastening the pins with the coupling body (2).
(4) and extract these together with the seal (3) from the rear
box (7).
Removing the rear box
Extract the two centring pins (5). Remove the screws (6).
Figure 35
Fit the eyebolt 99366811 to the sleeve (8) and, using special
ropes and lifter, detach the rear box (7) from the middle one
(9).

70834

Remove the screws (3), disc (4) and seal (5) and extract the
sleeve (2) from the spider shaft. Should extraction prove
difficult, use an extractor (1) applied as illustrated in the figure.

Figure 33 Figure 36

70832 70835

Remove the oil pipe (1). Note down the assembly position of Remove the screws (2) and take off the cover (1). Remove the
the fork (3) and plugs (6) and remove them. Remove: the rod spider shaft bearing end float adjustment ring (3).
(2), synchronizing device assembly (4) and connecting sleeve
(5).
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 51

Figure 37 Figure 40

45946 70838

Using a press, extract the spider shaft (1) from the supporting Using pliers (2), tighten the ends of the circlip (3) and remove
roller bearing (2). Turn the rear box (3) upside-down and the coupling body (4) from the E.R.G. shaft (1).
extract the roller bearing (2).

Removing the epicyclic reduction gear train Figure 41

(E.R.G.)
Figure 38

70839

Using a punch, extract the pins (5) from the spider shaft (6).
70836 Remove the planetary gears (3) from the spider shaft (6),
Using a screwdriver, remove the circlip (3) fastening the ring together with the rollers (2) and shim adjustment rings (1 and
gear with internal toothing (4) to the ring gear with external 4).
toothing (2) and remove them from the E.R.G. (1). Figure 42

Figure 39

70837 70840

Extract the toothed ring (2) from the ring gear with internal Extract the toothed shaft (3) from the spider shaft (1) together
toothing (1). with the rings (2).
 52 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 43 Figure 44

70842

Using a suitable extractor, remove the roller bearing ring (1)

from the spider shaft (2).
70841

Extract one of the pins (1) from the toothed shaft (2) and Using a punch, extract the disc (3) from the inside of the spider
extract the rings (3) from this. shaft (2).

Figure 45

70843

PARTS COMPRISING THE E.R.G.

1. Circlip - 2. Ring gear with external toothing - 3. Toothed ring - 4. Ring gear with internal toothing - 5. Bearing - 6. Circlip - 7.
Circlip - 8. Coupling body - 9. Pins - 10. Ring - 11. Toothed spindle - 12. Disc - 13. Spider shaft - 14. Pin - 15. Shim adjustment
ring - 16. Rollers - 17. Shim adjustment ring - 18. Planetary gear.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 53

Fitting the epicyclic reduction gear train (E.R.G.)

Figure 46 Figure 49

ASTRA

70982
70844
Smear grease into the hole of the planetary gear (5) and insert
Heat the inside ring (2) of the roller bearing to 120qC and fit the rollers (3) with the associated shim adjustment rings (2 and
it on the spider shaft (3). 4). Fit the planetary gears (5) onto the spider shaft (6),
Fit on the circlip (1). Fit on the disc (4). fastening them to it with the pins (1).
Figure 47 Figure 50

ASTRA ASTRA

70838

Using pliers (2), tighten the ends of the circlip (3) and fit the
coupling body (3) onto the E.R.G. shaft (1).

70845 Figure 51

Drive the rings (1 and 3) onto the toothed spindle (2) and fit
on the pin (4).
ASTRA
Figure 48

ASTRA

70983

Fit the ring gear with internal toothing (5) onto the spider shaft
70840 (3) together with the toothed ring (4), and the ring gear with
Insert the spindle (3) together with the rings (2) onto the external toothing (2) and fasten the two ring gears with the
spider shaft (1). circlip (1).
 54 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Adjusting epicyclic reduction gear train

Figure 52 bearing end float
Figure 54

45951
70847
Heat the seat of the bearing (1) of the rear box (2) to 120qC
and mount the bearing (1). Determine the ball bearing end float adjustment thickness (3)
by proceeding as follows:
- measure the depth of the seat on the cover (1) of the
bearing (3), distance A;
- measure the protrusion of the bearing (3) from the
surface of the rear box (2), distance B.

The thickness S of the adjustment ring is determined by the

following equation:
S = (A - B) - C
Where:
A and B = measurements
C = end float 0y0.1 mm
For example:
A = 5.4 mm
B = 5 mm
C = 0y0.1 mm
Figure 53 S = (5.4 - 5) - (0y0.1 mm) = 0.3 y 0.4 mm

45943

Rest the spider shaft (1) on an appropriate spacer.

Heat the inside ring of the bearing (2) to 120qC and drive it
together with the rear box (3) onto the spider shaft (1).
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 55

Figure 55 Figure 57

ASTRA

45954 70849

Using the driver 99374221 (1), fit the seal (2) in the cover (3). Heat the sleeve (1) to 90qC and fit it onto the spider shaft (1).
Fit on a new seal (4), the disc (3) and screws (2) and tighten
them to the prescribed torque.

Adjusting main shaft end float

Figure 56 Figure 58

70848 70850

Mount the adjustment ring (1), of the thickness determined in

the preceding measurement, on the bearing (2, Figure 53) of
the spider shaft (3).
Position two calibrated blocks (2) on the rear box (4). Place
Spread IVECO sealant 1905685 on the mating surface of the a calibrated rule (1) on them and, using a depth gauge (3),
cover (4) with the box (5) and fit it onto the box, tightening measure the distance between the top side of the rule and the
the screws (2) to the prescribed torque. end of the spider shaft (5), distance A.
 56 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 59 Using a depth gauge (3), measure the distance between the
top end of the circlip (5) and the top side of the calibrated rule,
distance B.
The thickness S of the main shaft end float adjustment ring is
determined by the following equation:
S = (A - B) - 2
For your information (see Figure 61), subtracting the thickness
of the calibrated blocks and rule:
- from the distance A gives the distance X corresponding
to the distance between the end of the spider shaft (2)
from the mating surface of the rear box (1).
- from the distance B gives the distance Y corresponding
to the distance between the circlip (4) and the mating
surface of the middle box (3).
70851

Fit the connecting sleeve (7) together with the circlip (5) on
the main shaft (6).
Position two calibrated blocks (2) on the middle box (4) and
place a calibrated rule (1) on them.

The calibrated blocks and rule must be the same ones

used in the preceding measurement.

Figure 60

70852
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 57

Figure 61 Figure 63

ASTRA

70855
70853
Put the springs (2) and pawls (3) into the seats of the
synchronizing device rings (1) and fasten them with the tools
Position the adjustment ring (2) (of the thickness determined
99370172 (4).
in the preceding measurements) on the main shaft (5). Mount
the connecting sleeve (1) and the tube (4). Figure 64
Mount the plate (6) together with the coupling body (3).

Synchronizing device assembly for engaging

normal or reduced gears
Removal
Figure 62 70856

Position the synchronizing device ring (2) on the synchronizing

device ring (3) so that it is possible to fit the sliding sleeve (1)
onto them. On completing assembly, remove the tools
99370172 (4).
Figure 65

70854

1. Synchronizing device assembly - 2. Synchronizing device

ring - 3. Sliding sleeve - 4. Pawl - 5. Spring -
6. Synchronizing device ring.
70857
Put a cloth on the synchronizing device assembly (1) so that,
when dismantling it, the springs (5) and pawls (4) are held back Fit the synchronizing device assembly (1) on the coupling body
as they come out of their seats. (3, Figure 61) with the ring groove (o) facing downwards.
 58 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 66 Insert the rod (3) of appropriate diameter in the hole for the
screw (4, Figure 67) and in the oil pipe (5) to guide this into
its seat, while lowering the rear box (4). Lower the rear box
(4), paying attention that the spider shaft, oil pipe (5) and rod
(7) go into their seat correctly.

Figure 69

ASTRA

70858

Position the fork (1) with the plugs (3) and the reliefs (') facing
as illustrated in the figure.
Fit on the rod (4) and connect it to the fork (1). Fit on the oil
pipe (2).

Figure 67 70831

Screw down the screws (6) without tightening them; insert the
centring pins (5) and tighten the screws (6) to the prescribed
torque.
Fit the fork joint pins (4) with fresh seals (3) and tighten the
screws (1) fixing the fastening plates (2) to the prescribed
torque.

70859 Figure 70
Take out the screws (1) and remove the cover (2) with its seal
(3). Remove the screw (4) with the washer (5).

Figure 68

ASTRA

70862

Fit: the screw (4) with a new washer (5) and tighten it to the
prescribed torque.
70860 Fit the cover (2) with a fresh seal (3) and tighten the fixing
Spread IVECO sealant 1905685 onto the mating surface of screws (1) to the prescribed torque.
the middle box (6). Fit the eyebolts 99368811 (1) to the Block rotation of the sleeve (7) by applying the lever
sleeve (2). Using ropes and a lifter, position the rear box (4) 99370317 (8) and tighten the fixing screws (6) to the
coaxially to the middle one (6). prescribed torque.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 59

Figure 71 Figure 72

ASTRA

70863

Fit the cap (3) and the switch (1) with a new gasket (2). Spread 78299
LOCTITE 262 onto the thread of the pin (4), screw it onto the
rod (5) and tighten them to the prescribed torque. Refit the gear actuator (1) as described under the relevant
heading. Detach transmission from turning stand.
Fit the pawls (9) and the springs (6-7-8). Refit the clutch actuator (3) and tighten the nuts (4) to the
prescribed torque.
The springs (7 - 8) are of equal length, the spring (6) Connect the electric wiring (2) to the speed sensor (6), tighten
is larger. the fixing ring nut (5) and secure the wiring (2) to the box by
inserting it in the clips (o).

Figure 73

70864

COMPONENT PARTS OF THE REAR BOX OF THE EPICYCLIC REDUCTION GEAR TRAIN
 60 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Removing the middle box

Figure 74 Figure 76

78302
70865
Take out the screws (2) and remove the pin (3) in the joint
Detach the gear actuator and the rear box as described under
of the clutch uncoupling lever (1) with this lever.
the relevant headings. Remove the E.R.G. drive rod (4),
connecting sleeve (5), adjustment ring (3) and the plate (1) Remove the screws (4) fixing the front cover (5) to the front
together with the coupling body (2). box.

Figure 75 Figure 77

78300

Screw down two screws (1) into the front cover (2) and
detach this from the front box (3).

78301

Fit the plate 99370153 (1) to the middle box (2) so that the Figure 78
groove inside the plate coincides with the key (5) of the main
shaft (6).
Fasten the pins (4) by fitting the brackets (3) of the plate
99370153 to the middle box (2).
Turn the gearbox through 180q.

70870

Remove the cap (3), the spring (4) from the transmission shaft
(5) and the adjustment rings (1-2-6 -).
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 61

Figure 79 Figure 82

78306

70871 Fit the eyebolt 99366811 (1) onto the front box (2). Using
special ropes and a hoist, detach the front box (2) from the
Remove the circlip (4) fastening the bearing (1) to the drive middle one (1).
input shaft (3). Remove the circlip (2) from the bearing (1).
Figure 83
Figure 80

78305

To perform the following operations, the gearbox

78303 must be positioned as shown in Figure 84 in order to
avoid any chance of the transmission shafts falling.
Using the extractors 99345078 (1) and 99345105 (2), extract
the ball bearing (4) from the drive input shaft (3). Take out the screws (1) and remove the brackets (2) of the
plate 99370153. Extract the reverse gear pins (3) from the
Figure 81 middle box (4).
Figure 84

78304
70875
Remove the speed sensor (5) and the cap (4) beneath.
Remove the phonic wheel (2) from the drive input shaft (1).
Take out the four centring pins (1). Extract the oil pipes (4-6) from the middle box (7).
Remove the screws (2) fixing the middle box (6) to the front Spread apart the transmission shafts (3-5) and remove them
box (3). from the middle box (7).
 62 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 85 Figure 87

70876 78307

Fit tool 99360527 (1) onto the drive input shaft (9) and the Turn the middle box (1) upside-down, remove the circlip (2)
rods (2 and 3); fit parts (6-7 and 8) of tool 99360526 (4) onto and, working from inside the box, remove the roller bearing
the drive input shaft (9). (4).
Hook tool 899360526 (4) onto the lifter and extract the main Using a punch, and operating through the openings (o) of the
shaft (5) together with the drive input shaft (9) and rods (2 and middle box (1), remove the external rings (3) of the tapered
3) from the supporting bearing. roller bearings for transmission shafts.

Removing the main shaft

Figure 86 Figure 88

70877 78308

Remove the reverse gears (3) together with the roller Clamp the main shaft (5) in a vice and remove tool 99360526
bearings (2). (1) and 99360527 (2).
Remove the plate 99370153 (4). Remove the rods (3 and 4) with the relevant forks.
If replacement is necessary, remove the centring pins (1).

Before removing the pins (1) heat the seats of the box To remove the fork (5), the ring of the synchronizing
to ~ 90qC. device has to be in the middle position.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 63

Figure 89 Figure 90

*
*

70881
*
Through the bay of the coupling sleeve (1), using suitable
pliers, tighten the ends of the circlip (2) and remove the drive
input shaft (3) from the main shaft (4), see Figure 90.
Remove the coupling sleeve (1) and the tube (2) from the
main shaft (3).
Turn the main shaft (3) upside-down and remove the coupling
sleeve (4) from it; remove the key (5) from the hole (o) in
the shaft (3) and extract it.

To extract the shoulder spacers (6 - 8 * - 9 * - 11 -

13 - 15 - 16 - 18) it is necessary to turn them so that
their toothing is with the grooves of the shaft (3).

Extract:
- spacer (6);
- reverse gear (7);
- spacers (8 and 9) *;
- gear (10) *;
- spacer (11);
- coupling sleeve (12);
- spacer (13);
- 2nd gear (14);
- spacers (15 and 16);
- gear (17);
- spacer (18);
- tube (19).
70882
* 16 AS 2601 only
 64 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 91 Figure 94

70883

If necessary, remove the circlips (1) from the gears (7 - 10 -

14 - 17, Figure 90) and extract the toothed ring (2).

Removing the drive input shaft 70886

Remove the half rings (2) from the drive input shaft (1) and
Figure 92 extract from it:
- thrust washer (3);
- thrust bearing (4);
- bushing (6) together with circlip (5);
- thrust washer (7);
- thrust bearing (8);
- gear (9);
- thrust bearing (8);
- thrust washer (11);
- synchronizing device assembly (12).

70884

Extract the ring (2), key (3) and gear (4) from the drive input
shaft (1).

Figure 93

70885

Turn the drive input shaft (1) upside-down, lift the notches
(o) of the safety cover (2) and take it off.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 65

Removing the splitter synchronizing device

Figure 95 Figure 97

70887 70889

If necessary, remove the circlips (1-3) from the gear (4) and Put the synchronizing device assembly (1) on the workbench,
extract the toothed ring (2). cover it with a cloth to prevent the pins (8) and springs (7)
getting lost during subsequent dismantling.
Holding back the synchronizing device ring (6), lift the
synchronizing device ring (2); these will get freed: toothed ring
(5), three clips (7) and three pins (8).
Remove the key (4) and extract the toothed sleeve (3) from
the toothed ring (5).
Figure 96

70888

COMPONENT PARTS OF THE DRIVE INPUT SHAFT

 66 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Fitting the splitter synchronizing device Figure 98

Insert the three springs (7) and three pins (8) in the
synchronizing device ring (1) and keep them in their seat with
the centring pins 99370499 (2).
Position the toothed ring (4) on the synchronizing device ring
(6). Fit the synchronizing device ring (1) in the toothed ring (4)
and on the synchronizing device ring (6) so that the centring ASTRA
pins 99370499 (2) drive onto the pins (5) of the synchronizing
device ring (6). Press on the synchronizing device ring (2)
uniformly so that the components of the assembly fit together
correctly. Take out the centring pins (2).

70891

Figure 99

70759

Insert the toothed sleeve (1) in the toothed ring (2) so that the race between the two toothings corresponds to the inside toothing
of the ring (2) and allows it to rotate.
Turn the sleeve (1) so that the hole in it coincides with one of the three bays (o) of the toothed ring (1).
Then insert the key (3) as shown in the figure.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 67

Fitting the main shaft

Figure 100 Figure 102

70884
On the drive input shaft (1), fit: gear (4), key (3) and thrust
washer (2).

70892
On the drive input shaft (1), fit:
- synchronizing device assembly (15);
- thrust washer (14);
- thrust bearing (13);
- gear (10) together with circlips (9 and 12) and toothed
ring (11);
- thrust bearing (8);
- thrust washer (7);
- bushing (6) with circlip (5); Fitting the drive input shaft
- thrust bearing (4); Figure 103
- thrust washer (3).

Figure 101

ASTRA

70885 70893

Fit on a new safety cover (2) and notch it (o) at three/four In the gears (4), fit: Reverse — 1st — 2nd — 3rd gears and toothed
equidistant points. Turn over the drive input shaft (1). rings (2) and fasten them to the gears with the circlips (1 and
3).
 68 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 104 Figure 106

78309 78311

Clamp the main shaft (2) in a vice. Fit on the tube (1). Put the Put the spacer (3) in the ring groove (o). Turn the spacer (3)
shoulder spacer (3) in the ring groove (o). Turn the spacer so that its internal toothing rests on that of the main shaft (1).
(3) so that its internal toothing rests on that of the main shaft Insert the key (2) in the spacer and keep it in position.
(2).
Insert the key (4) in the spacer (3) so as to prevent rotation
and keep it in position.

Figure 105 Figure 107

78310 78312

Mount the 3rdspeed gear (2), put the spacer (4) in the ring Mount the 2nd speed gear (2), put the spacer (4) in the ring
groove (o). Turn the spacer (4) so that its internal toothing groove (o). Turn the spacer (4) so that its internal toothing
rests on that of the main shaft (1). Insert the key (3) in the rests on that of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position. spacer (4) and keep it in position.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 69

Figure 108 Figure 110

78314 78316

Fit on the 1st/2nd

gear coupling sleeve (1) with the larger For 16 AS 2601 gearboxes only, fit on the gear (2). Put the
internal groove (o) turned to the side of the key (2). spacer (5) in the ring groove (o) so that its internal toothing
rests on that of the main shaft (1). Put the spacer (4) in the ring
groove (o) so that its internal toothing rests on that of the
main shaft (1).
Insert the key (3) in the spacers (4 and 5) and keep it in
position.

Figure 109 Figure 111

78317

78315
For all gearboxes, fit on the reverse gear (2). Put the spacer
Put the spacer (3) in the ring groove (o). Turn the spacer (3) (4) in the ring groove (o) so that its internal toothing rests on
so that its internal toothing rests on that of the main shaft (1). that of the main shaft (1).
Insert the key (2) in the spacer (3) and keep it in position.
Extract the key (3) and insert it from the top side of the shaft
(1) in the groove on this and in all the spacers, so that its bent
portion goes into the hole (o) of the shaft (1).
 70 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 112
Make sure that the circlip (2) gets correctly positioned
in the seat of the main shaft (3).

Splitter control fork

Removal - Fitting

Figure 115

ASTRA

70902

Fit on the reverse gear coupling sleeve (3) with the bay (2)
coinciding with the key (1).
Figure 113

70879

Extract the plugs (2) from the splitter synchronizing device

coupling fork (1) and fit on the new plugs.

70903

Turn over the main shaft (2) and fit on the sleeve (1) with the Gear control forks
bay (4) coinciding with the key (5). Removal
Fit on the tube (3). Figure 116

Figure 114

*
*

70905

Dismantle the gear control fork assembly (1), suitably adjusting

the ring (3) to prevent the gears simultaneously coupling and
70904
extracting from the rod (7): the coupling fork (6)*, pin (7),
coupling fork (5), fork (2) and ring (3).
Using suitable pliers, tighten the ends of the circlip (2) and fit
the drive input shaft (1) onto the main shaft (3). * For 16 AS 2601 gear boxes only.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 71

Fitting
Figure 117 Figure 119

70760 70762

Insert the pin (1) in the seat on the rod (3). Drive the reverse For 16 AS 2601 gear boxes only
gear coupling fork (2) onto the rod (3), adjusting it so that the Drive the 3rd/4th gear coupling fork (1) onto the rod (2).
pin (1) gets positioned in the bay (o) of the fork (2).
Position the fork (1) in the ring (3) so that on turning it the bay
(o) of the fork (1) is inserted in the ring (3).

Figure 120

Figure 118

70761 70763

Drive the ring (1) and the 1st/2nd gear coupling fork (3) onto Position the fork assembly (2*-3) and the ring (1) assembled
the rod (2). Position the fork (3) in the ring (1) so that on in this way so that the bay (o) of the reverse gear coupling
turning it the bay (o) of the fork (3) is inserted in the ring (1). fork (4) is inserted in the ring (1).
* For 16 AS 2601 gear boxes only.
 72 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Transmission shafts
Removal - Fitting Figure 123

Figure 121

78319

Fit the plate 99370153 (2) onto the middle box (1).
70906

Remove the inside rings (1-3) of the roller bearings from the
transmission shaft (2), using the extractor 99347100 (4), grips Figure 124
993471132 (6) and plug 99345057 (5).
To fit the rings (1 - 3) on the shaft (2) it is necessary to first
heat them to 120qC.

70909

From inside the box (1), heat the seats of the rings (4) to ~
90qC, transmission shaft bearings. Fit on the rings (4) with
Fitting the middle box driver 99370092 (3) and grip 99370007 (2).
Figure 122

Figure 125

78318

Heat the seat (3) of the cylindrical roller bearing (5) to ~ 90qC,
fit this and fasten it to the middle box with the circlip (2).
70910
If removed, refit the centring pins (4) after heating the seats
of the box to ~ 90qC. Place the reverse gears (1) together with the roller bearings
(2) in the middle box.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 73

Figure 126 Figure 129

70911

Fit the fork assembly (1) onto the main shaft (2), verifying that
the forks are correctly positioned on their respective coupling
sleeves.
Figure 127

78320

Hook the tool 99360526 (1) onto the lifter and fit the main
shaft assembly (5) in the gearbox, verifying that the shaft (5)
and the rods (3 and 4) get correctly inserted in their seats.
Remove the tools 99360526 (1) and 99360527 (2).

70912

Mount the splitter coupling fork (1) positioning the plugs (2)
on the toothed coupling ring (3).
Figure 128

Figure 130

70915
70913
Mount the transmission shafts (1 and 3) so that on joining
Fit tool 99360527 (1) onto the drive input shaft (8) and the
them to the main shaft (2) the marks stamped on them are
rods (2 and 3). Fit parts (5-6-7) of tool 99360526 (4) onto the
aligned. Use the slots (o) of the phonic wheel (4) to check
drive input shaft (8).
this.
 74 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 131 Figure 133

78305 70917

To perform the following operations, the gearbox With no gears engaged, the shafts must turn freely,
must be positioned as shown in Figure 132 in order otherwise the alignment of the marks (see
to avoid any chance of the reverse gears falling. Figure 130) will not be correct.

Fit on the oil pipes (1 and 2).

Insert the pins (3) in the middle box (4) and in the reverse
gears (1, Figure 126), fastening them to the box (4) with the
brackets (2) of plate 99370153 and the screws (1).

Figure 132

*
*

70916

COMPONENT PARTS OF THE MIDDLE BOX

* For the 16 AS 2601 gearbox only
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 75

Fitting the front box

Figure 134

70918
COMPONENT PARTS OF THE FRONT BOX
 76 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 135 Figure 137

ASTRA

70921

Spread IVECO sealant 1905685 onto the mating surface of

the middle box (5).
Fit the eyebolt 99368811 (1) onto the front box (2).
Using ropes and a hoist, lift the box (2) and position it coaxially
to the middle box (5).
Insert the rods (6), of suitable diameter, into the seats in the
front box (2) of the oil pipes (7 and 8) and into these too.
Lower the box (2) checking that the rods (3 and 4) and the
oil pipes (7 and 8) are correctly inserted in their seat.
70819
Remove the eyebolt (1) and the guide rods (6).
Remove the screw (1), lift the cover (2), remove the vents (3)
and clean them or replace them.
Then reassemble the parts.
Carefully clean the oil filter (6) and fit it back in its seat.
If the plugs (4) have been removed, it is necessary to fit them
back on with new seals (5).

Figure 136 Figure 138

70920 78304

Screw down the screws (2) fixing the front box to the middle
box (4). Insert the centring pins (1) and tighten the screws (2)
to the prescribed torque.
Heat the front box (1) to 90qC in correspondence with the
seats for the external rings (2) of the tapered roller bearings Mount the cap (4) and the speed sensor (5), tightening it to
and fit these on. the prescribed torque.
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 77

Figure 139 Figure 142

ASTRA

70922 78322

Using the tools 99345098 (1) comprising parts (3-4 and 5) and Take out the screws (1) and, through the front cover (5), take
99360526 comprising parts (6 and 7), fit the ball bearing (11) out the oil pump comprising: cover (2), rotor (3) and stator
on the drive input shaft (9) and in the front box (10). (4).
Introduce compressed air through the hole (o) and expel
Figure 140 through the front cover (5): the overrun brake piston (8)
comprehensive of gasket (9), clutch plates with external
toothing (6), clutch plates with internal toothing (7) and
supporting ring (10).
ASTRA

Fitting the front cover

Recompose the front cover (5) by reversing the operations
described for removal, without parts (6 - 7 - 8).

The gasket (9) must always be replaced.

70871
Adjusting drive input shaft bearing end float
Fit the circlip (4) fastening the bearing (1) to the drive input
shaft (3).
Figure 143
Fit the circlip (2) onto the bearing (1).
Front cover
Removal
Figure 141

70924

Determine the thickness S of the drive input shaft bearing

adjustment ring by proceeding in the following way:

70985
- check that the circlip (1) of the bearing (2) rests in its seat;
Remove the screws (3) and take off the drive input shaft cover - measure the protrusion of the bearing (2) from the
(1) from the front cover (2). surface of the front box (3), distance A.
 78 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Figure 144 Figure 146

70986 70926

- measure the depth of the seat on the front cover (1) of - measure the distance between the surface of the front
the bearing (2, Figure 143), distance B. cover (2) and the oil pump (1), distance C;
The thickness S of the adjustment ring is determined by the - mount the overrun brake disc supporting ring (3) in the
following equation: seat on the front cover (2) and measure the distance
between this and the surface of the cover (2), distance D.
S = (A -B) - C
The thickness S of the adjustment rings is determined by the
Where: following equation:
A-B = measurements D oil pump side S=A+C+F
A-C = measurements
C = end float 0 y 0.1 mm
F = end float r 0.05
For example:
For example:
A = 5.50 mm S = 2 + 0.05 (r 0.05) = 2 — 2.1
B = 3.90 mm D overrun brake side S = B + D + F
C = 0 y 0.1 mm B-C = measurements
F = end float r 0.05
S = (5.50 -3.90) - 0 y 0.1=1.59 — 1.60 mm
For example:
S = 1.95 + 0.15 (r 0.05) = 2.05 — 2.15
Adjusting transmission shaft bearing end float

Figure 145 Figure 147

70925
70870
Determine the thickness S of the transmission shaft bearing On the external rings of the bearings supporting the drive
end float adjustment rings by proceeding in the following way: input and transmission shafts, mount the end float adjustment
- turn the shafts and check that the external rings (1 -3) of rings (1 - 2 and 6) of the thickness determined in the preceding
the bearings rest with no play on the rollers of the measurements. Insert the spring (4) and the cap (3) in the
bearings; transmission shaft (5).
- measure the distance between the surface of the front
box (2) and the external rings (1 - 3);
D external ring (1) pump side, distance A.
D external ring (3) overrun brake side, distance B
HD9 Euro3 SECTION 7.2 AUTOMATIZED GEARBOX 79

Figure 148 Figure 150

ASTRA

46007

Using the driver 99374336 (2) and grip 99370007 (1), fit the
seal (3) in the drive input shaft cover (4).
70869

In the sequence shown in the figure, position: the supporting

ring (3), clutch plates with internal toothing (2) and clutch
plates with external toothing (1).

Figure 149 Figure 151

70927 70928

Lubricate the sealing surface of the seal with Unisilikon.

Spread IVECO sealant 1905685 onto the surface of the front Spread IVECO sealant 1905285 onto the surface of the front
box (1) mating with the cover (2). Adjust the key of the oil box (1) mating with the cover (2). Mount the cover (2).
pump shaft so that it coincides with the coupling milling of the Spread LOCTITE 241 onto the thread of the screws and
transmission shaft. Fit on the cover (2) and tighten the screws tighten them to the prescribed torque.
(3) to the prescribed torque.
 80 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro3

Clutch release lever

Figure 152 Figure 154

ASTRA

70929 78301

The bushings (2 and 4) and seals (1 and 5) of the lever (3) are Turn over the gearbox.
changed by using a suitable drift for removing — fitting new
Remove the plate 99370153 (1) and the brackets (3) fastening
parts.
the pins (4) from the middle box (2).

Figure 153 Figure 155

70930 70865

Insert the joint pin (4) into the lever (2) and tighten the screws Fit: the plate (1) together with the coupling body (2),
(3), fixing it to the front box (1), to the prescribed torque. adjustment ring (3), connecting sleeve (5) and rod (4).
Complete assembly of the gearbox by refitting the rear box
and the speed actuator as described under the relevant
headings.
On completing assembly, replenish the gearbox with the
prescribed grade and quantity of lubricating oil.