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DAF Dealernet

VIN:
Vehicle Type: XF_E6-XF 460 FT
H 1506 392800 001 000
replace gearbox (Gearbox)

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DAF Dealernet
replace gearbox
(Gearbox)

1 replace gearbox (Gearbox) 04:35

1.1 remove gearbox (Gearbox) 01:40
1.1.1 disconnect battery clamp, negative pole 00:03
1.1.1.1 remove battery box cover between the chassis (Battery box) < 00:01
1.1.1.2 disconnect battery clamp, negative pole < 00:01
Explanation

Warning, battery clamp, negative pole

Eject the driver's card before disconnecting the battery clamp from the negative
pole.
To prevent damage to electronic components, never disconnect the battery
clamps when the engine is running.
Switch off the ignition before disconnecting the battery clamp from the negative
pole.

After switching off the ignition, wait at least 80 seconds before

disconnecting the battery clamp from the negative pole.
Non-observance of this waiting time results in clogging of the AdBlue
lines.
Always disconnect the battery clamp from the negative pole before working on the
vehicle.
Do not place any tools or other materials on top of or close to the batteries. This
can cause a short circuit and, in the worst case, a battery explosion.

M014591 - 15/08/2019
1.1.1.3 install battery box cover between the chassis (Battery box) 00:01
Technical Data

Tightening torque, battery box cover between the chassis

Attachment bolt 30 Nm

M039060 - 30/08/2013
1.1.2 use oil bin + 00:01
1.1.3 drain oil gearbox (Gearbox) 00:04
Explanation

Warning, lubricating oil

Lubricating oil can cause skin irritation or skin injury.
To prevent skin injury, avoid unnecessary contact with the lubricating
oil.

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Wear protective clothing, eyewear and gloves.

After maintenance or repairs, carefully review the DAF lubrication

specifications.
Inadequate lubrication can cause drive line failure.
Make sure that the vehicle is in neutral gear position before starting the engine.

M036499 - 26/02/2013
Draining gearbox

1. Position the vehicle on a level surface.

2. Drain the gearbox at operating temperature.
3. Remove the drain plugs (1), (3) and the level
check/filler plug (2) and drain the oil.

1 2 3

V301241

M030545 - 28/08/2019
1.1.4 depressurize air reservoir 00:02
1.1.5 remove step plate, front (Catwalk left + right) 00:02
1.1.6 tilt cabin 00:04
Explanation

Warning, tilting cabin

Checking cabin before tilting

If the vehicle has been involved in a collision, under no circumstances should the
cabin be tilted without due precautions. The internal mechanism of the lift cylinder
may have been damaged to such an extent that the cylinder is no longer locked by
the internal stop collar.
In these circumstances, there is a danger of the cabin no longer being held back
and falling forward to the ground.

Make sure that:

There is nobody immediately in front of the vehicle during or after tilting the cabin.
The cabin is secured in the tilted position before repairs are carried out in front of
the cabin.
No work is carried out under the cabin if the cabin has not been tilted fully
forward.
There is nobody in the cabin.
There are no loose objects in the cabin.

Do not remove or install the driver or workshop tachograph card when the
cabin is in the tilted position.

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This may cause the card inside the tachograph to be come jammed.
The cooler box - refrigerator is switched off and, if necessary, unplugged before
tilting (depending on the type).
The cooler box - refrigerator remains switched off for at least 30 minutes after the
cabin has been tilted back to its original position.
Both the emergency and service line hose couplings are removed from their
storage box before tilting the cabin.
The auxiliary heater is switched off.

M014592 - 29/06/2017
Setting cabin tilting pump
You can stop the cabin tilting forward at any time by turning the valve to the reverse tilting
position (B).

D000551

A Tilting the cabin forward.

B Lower the cabin back into the driving position.

M030437 - 09/08/2019
1.1.7 remove assembly gearbox (Gearbox) 00:59
1.1.7.1 disconnect hose smaller than 15mm (Pneumatic gearbox control) < 00:01
1.1.7.2 loosen assembly bracket, electrical system (Electrical system, engine) 00:02
1.1.7.3 remove exhaust pipe between silencer and flexible pipe (Exhaust) 00:05
Explanation

Warning, exhaust components

The exhaust and exhaust components may still be hot after the vehicle stops moving.
To reduce the risk of fire, property damage, burns or other serious personal injury,
allow the exhaust system to cool before beginning this procedure or repair. Make sure
that no combustible materials are located where they are likely to come into contact
with a hot exhaust or exhaust components.

M032307 - 10/10/2012
1.1.7.4 remove gearbox cover (Gearbox) 00:02
Explanation

Removing gearbox cover

1. Remove the bolts (1) from the clutch inspection

cover (2) and remove the cover.

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1 2 1 5 4
V300669

M016218 - 25/10/2005
1.1.7.5 remove clutch actuator (Gearbox) 00:06
Explanation

Removing clutch actuator

4 5 2 3
1. Remove the connector (4) on the left side of the
gearbox modulator (5) and the connector (3) of
the speed sensor.
2. Remove the attachment nuts of the clutch
actuator (1) and remove the actuator including
the cable harness (2).
3. Disconnect the gear box air pipe from the clutch
ZF FRIEDRICHSHAFEN AG

actuator.

8 1 9
V300718

M016232 - 18/09/2008
1.1.7.6 remove pin (Gearbox) < 00:01
1.1.7.7 loosen main prop shaft (Prop shaft) 00:07
1.1.7.8 loosen assembly bracket, electrical system (Flywheel housing) 00:02
1.1.7.9 disconnect wiring harness, gearbox (Switches, gearbox) < 00:01
1.1.7.10 remove gearbox (Gearbox) 00:33
1.1.7.11 remove clutch release bearing (Gearbox) 00:02
Explanation

Removing clutch release bearing

B
1. Remove the clutch release bearing of the clutch B
release assembly by unhooking the retainer clip A
(A) of the clutch release assembly.

M023479 - 06/08/2007
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1.1.8 remove assy from hydraulic ramp (Gearbox) 00:08

1.1.9 dismount assembly wiring harness, gearbox (Switches, gearbox) 00:03
1.1.10 dismount omega bracket (Gearbox air supply) 00:01
1.1.11 dismount cable guide, chassis (Switches, gearbox) 00:01
1.1.12 remove clutch release assembly (Clutch release assembly) 00:05
Explanation

Removing clutch release assembly

1. Insert a dummy input shaft into the clutch plate

and flywheel bearing.
2. Remove four attachment bolts evenly around
the circumference of the clutch release
assembly and replace them with guide studs.
3. Remove the remaining attachment bolts of the
clutch release assembly.
4. Remove the clutch release assembly.

V3 00 456

M023481 - 28/08/2019
1.1.13 remove clutch plate assembly (Clutch plate) < 00:01
1.1.14 check flywheel (Flywheel) 00:05
Explanation

Checking flywheel

Checking flywheel contact surface

1. Check the contact surface for visible cracks or
damage.

If damaged, the flywheel may be

turned down until the indicator
groove on the outer
circumference of the contact
surface is no longer visible. This
corresponds to a maximum of
2 mm [0.08 in].
Cracks are not allowed:
Within 5 mm [0.2 in] of the
outer edge.

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In the contact surface,

deeper than 2 mm [0.08 in].

Checking flywheel run-out

1. Clean the flywheel.

2. Place a metal strip on the edge of the flywheel
housing to fit a dial gauge.
3. Place the stylus of the dial gauge at the
specified radial distance from the centre line.
4. Set the dial gauge to '0'.

M200230

5. Use the special tool (DAF no. 1961375) to

crank the engine through 360°, and measure
the maximum dial gauge reading.
6. Compare the measured value with the specified
data.

i405015

M020261 - 28/08/2019
Technical Data

Checking data, flywheel

Radial run-out (A),
measured on the inside
of the flywheel outer maximum 0.10 mm
A
edge. [0.004 in]
Axial deviation (B),
measured at a distance
(C) of 210 mm [8.3 in]
from the centre of the maximum 0.10 mm
flywheel. [0.004 in]

M201882

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M020584 - 26/03/2013
Special Tools

Special tool category Mandatory special tool for: DAF Service Partners, DAF Service Support Points
1453158

Engine cranking tool

T00110

ST1453158 - 11/07/2007
1.2 install gearbox (Gearbox) 02:55
1.2.1 install clutch plate assembly (Clutch plate) 00:03
Explanation

Installing clutch plate assembly

1. Apply a small amount of the specified grease to

the clutch plate axle connection.
2. Check the clutch plate movement on the
splines of the input axle.
3. Use a dummy input axle to position the clutch
plate.

V300124

M023482 - 26/03/2013
Technical Data

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Dry-plate clutch
Clutch plate axle connection: Lithium-based EP grease, NLGI 3
Thrust bearing:
Thrust bearing with plastic inner sleeve: Dry mounting
Thrust bearing with steel inner sleeve: Lithium-based EP grease, NLGI 3
Clutch lever
Clutch lever with rollers (Ecosplit III gearbox): Dry mounting
Clutch lever without rollers (AS Tronic gearbox): Lithium-based EP grease, NLGI 3
Clutch lever with rollers (AS Tronic and Ecosplit IV
gearbox): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton transmission, hybrid
application): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton 18S RTLO): Lithium-based EP grease, NLGI 3

M012551 - 28/08/2019
1.2.2 install clutch release assembly (Clutch release assembly) 00:10
Explanation

Installing clutch release assembly

1. Clean the contact surfaces of the clutch release

assembly and the flywheel.
2. Fit four guide studs, evenly around the
circumference, in the flywheel.

V300124

3. Fit the clutch release assembly by sliding it over

the four guide studs onto the flywheel.
4. Fit the attachment bolts and replace the guide
studs for attachment bolts.

Make sure that the outer edge of the

clutch release assembly is fully
inside the flywheel standing edge.

5. Tighten the attachment bolts to the specified

torque.
6. Remove the dummy input shaft.

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V3 00 456

V301469

M023484 - 15/09/2011
Technical Data

Tightening torque, clutch release assembly

Attachment bolts 60 Nm [531 lb-in](1)
(1) Tighten crosswise

M022214 - 25/06/2018
1.2.3 mount cable guide, chassis (Switches, gearbox) 00:03
Technical Data

Tightening torque, cable guide, chassis

Attachment bolts 30 Nm

M031317 - 05/09/2013
1.2.4 mount omega bracket (Gearbox air supply) 00:02
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Technical Data

Tightening torque, bracket, electrical system

Bracket attachment bolts M16 110 Nm

M023676 - 11/09/2007
1.2.5 mount assembly wiring harness, gearbox (Switches, gearbox) 00:03
1.2.6 fill oil gearbox (Gearbox) 00:13
Explanation

Warning, lubricating oil

Lubricating oil can cause skin irritation or skin injury.
To prevent skin injury, avoid unnecessary contact with the lubricating
oil.
Wear protective clothing, eyewear and gloves.

After maintenance or repairs, carefully review the DAF lubrication

specifications.
Inadequate lubrication can cause drive line failure.
Make sure that the vehicle is in neutral gear position before starting the engine.

M036499 - 26/02/2013
Filling gearbox

To prevent skin injury, avoid

unnecessary contact with the drained
oil.

1 1
1. Check the oil specification on the gearbox type
plate at position 10. 2 3

5 6

7 8

9 10

1. Clean the drain plugs (1) and (3), fit them and
tighten them to the specified torque.
2. Fill the oil through the level check/filler opening
(2) until the oil reaches the rim of the filler
opening.
3. Fit the level check/filler plug (2) and tighten it to
the specified torque.

1 2 3

V301241

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M016018 - 28/08/2019
Technical Data

Filling capacities, gearbox

First fill (litres) Service fill (litres)

Filling capacity 12 11

M016012 - 07/08/2018
Tightening torque, gearbox level check/filler and drain plugs
Level check/filler plug (2) 60 Nm
Drain plugs (1) and (3) 60 Nm

1 2 3

V301241

M015224 - 28/08/2019
1.2.7 install assy to hydraulic ramp (Gearbox) 00:08
1.2.8 install assembly gearbox (Gearbox) 01:11
1.2.8.1 install clutch release bearing (Gearbox) < 00:01
Explanation

Mounting clutch release bearing

Do not apply grease on the sliding

surface for the clutch release bearing
on the gearbox front cover! The
grease attacks the plastic coating and
shortens the service life of the clutch
release bearing. The inner
circumference of the clutch release
bearing is wear-resistant for life!

1. Slide the fork pin (5) into the lever (1).

2. Grease instruction for clutch lever with ZFnr:

1328 368 047 indicated by the arrow. This is
part of assembly ZFnr: 1328 268 013 (DAF nr:
1956924).
Do NOT apply grease between the pin
(5) and the bearing bush (8) in the lever
(1).

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Grease instruction for previous clutch levers

with numbers before ZFnr: 1328 368 047.
These are part of assembly ZFnr: 1328 268 012
(DAF nr: 1860299).

Make sure that there is grease between

the pin (5) and the bearing bush (8) in
the lever (1).
If necessary, clean the pin (5) and the
bearing bush (8) and apply a small
amount of the specified grease.
New components are factory-greased.

3. Grease instruction for all clutch levers

Apply a small amount of the specified
grease to the contact face of the clutch
release bearing (9) and the lever (1) as
indicated by the arrows.

Do not grease the radial contact E505022

face of the lever rollers (10) and

the clutch release bearing (9).
The sliding fit surface of the
clutch release bearing (9) must 9 10
not be greased!

Apply a small amount of the specified

grease to the holder (3).
1

4. Mount the lever (1) by fitting the attachment

bolts (6) and tighten them to the specified
torque.
8

6 5 4 3 2

V30 1173-4

5. Check that the retaining clip in the clutch

release assembly is properly closed.

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V300123-2

6. Check that the locking plate (2) with locking 4

washer (1) and retainer clip (3) are fitted in the
correct position. The diaphragm springs (4)
have recesses for the retainer clip (3). 3

2 1

4 3
V300122-2

M041013 - 01/04/2014
Technical Data

Dry-plate clutch
Clutch plate axle connection: Lithium-based EP grease, NLGI 3
Thrust bearing:
Thrust bearing with plastic inner sleeve: Dry mounting
Thrust bearing with steel inner sleeve: Lithium-based EP grease, NLGI 3

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Clutch lever
Clutch lever with rollers (Ecosplit III gearbox): Dry mounting
Clutch lever without rollers (AS Tronic gearbox): Lithium-based EP grease, NLGI 3
Clutch lever with rollers (AS Tronic and Ecosplit IV
gearbox): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton transmission, hybrid
application): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton 18S RTLO): Lithium-based EP grease, NLGI 3

M012551 - 28/08/2019
1.2.8.2 install gearbox (Gearbox) 00:37
Explanation

Installing gearbox

Make sure that no water

containing cleaning agent is left
on the gearbox.
Restore the paint layer of the
gearbox if it is damaged or starts
to come off. Use a two-
component polyurethane (PUR)
paint for this purpose.
Pay special attention to the
reinforcing ribs at the top of the
gearbox.

1. Apply a small amount of the specified grease to

the splines of the input shaft.
2. Gradually rotate the input shaft with extended
pliers to enable the input shaft splines to slide
into the clutch plate.

Avoid damaging the splines while

rotating the input shaft.

3. Install the gearbox to the flywheel housing.

4. Install and tighten the gearbox attachment bolts
to the specified torque.
5. Remove the hoisting tool/lift adapter.

M031352 - 23/12/2014
Technical Data

Dry-plate clutch
Clutch plate axle connection: Lithium-based EP grease, NLGI 3
Thrust bearing:
Thrust bearing with plastic inner sleeve: Dry mounting
Thrust bearing with steel inner sleeve: Lithium-based EP grease, NLGI 3
Clutch lever
Clutch lever with rollers (Ecosplit III gearbox): Dry mounting
Clutch lever without rollers (AS Tronic gearbox): Lithium-based EP grease, NLGI 3
Clutch lever with rollers (AS Tronic and Ecosplit IV
gearbox): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton transmission, hybrid
application): Lithium-based EP grease, NLGI 3
Clutch lever (Eaton 18S RTLO): Lithium-based EP grease, NLGI 3

M012551 - 28/08/2019
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Tightening torque, gearbox

Tightening torque
Attachment bolts 60 Nm

Inspection torque
Attachment bolts 50 Nm(1)
(1) Tighten the bolts to the specified 'inspection' value. The bolts
must not move.
If the bolts move, undo the connection and check the
components for damage. If no damage is found, tighten the
connection to the specified 'Tightening torque'.

M023709 - 28/08/2019
1.2.8.3 connect wiring harness, gearbox (Switches, gearbox) 00:01
1.2.8.4 fixing assembly bracket, electrical system (Flywheel housing) 00:05
Technical Data

Tightening torque, assembly bracket, electrical system

Attachment bolts M8 30 Nm [265 lb-in]

M036178 - 05/03/2013
1.2.8.5 fixing main prop shaft (Prop shaft) 00:07
Technical Data

Tightening torque, main prop shaft

Prop shaft, drive flange, attachment bolts 155 Nm(1)
(1) Apply with Loctite 243

M021819 - 11/06/2018
1.2.8.6 install pin (Gearbox) < 00:01
1.2.8.7 install clutch actuator (Gearbox) 00:10
Explanation

Installing clutch actuator

1 2

The clutch actuator must be bled before

being installed, so that it is not installed
under tension.

1. Loosen the bleed screw (2) of the clutch

actuator (1).
2. Push the control rod (3) inward and fasten the
bleed screw when the control rod is pressed in.

3
V300730

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3. Install the clutch actuator (1) and tighten the 4 5 2 3

attachment nuts to the specified torque.
4. Fit the cable harness (2), with connector (4) to
the modulator (5) and connector (3) to the
speed sensor.
5. Connect the gearbox pipe to the clutch actuator
(1) and tighten it to the specified torque. ZF FRIEDRICHSHAFEN AG

8 1 9
V300718

M016234 - 18/09/2008
Technical Data

Tightening torque, clutch actuator

Clutch actuator bleed
1 2
screw (2) 22 Nm
Clutch actuator studs 10 Nm
Clutch actuator
attachment nuts 23 Nm
Coupling of gearbox pipe
to clutch actuator 50 Nm

3
V300730

M016261 - 18/09/2008
1.2.8.8 install gearbox cover (Gearbox) 00:02
Explanation

Installing gearbox cover

1. Install the clutch inspection cover (2) and

tighten the bolts (1) to the specified torque.

1 2 1 5 4
V300669

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M016223 - 06/04/2010
Technical Data

Tightening torque, gearbox cover

Attachment bolts 23 Nm

M031054 - 03/05/2012
1.2.8.9 install exhaust pipe between silencer and flexible pipe (Exhaust) 00:05
Explanation

Warning, exhaust system

Assemble the exhaust system carefully to prevent deformation of pipes and brackets.

M023507 - 19/01/2011
Technical Data

Tightening torque, exhaust pipe

V-clamps (1), (3) and (5) 15 Nm(1)
Exhaust pipe attachment 1
bolt 60 Nm(2)
2
Exhaust pipe bracket
attachment bolt (M16) 260 Nm
(1) Always install new gaskets
and new V-clamps. Mount
them in the orientation
shown.
(2) Apply Loctite 243to the
bolt.

3 4 5
C901085

M030714 - 11/04/2019
1.2.8.10 fixing assembly bracket, electrical system (Electrical system, engine) 00:03
Technical Data

Tightening torque, assembly bracket, electrical system

Bracket attachment bolts M8 30 Nm [266 lb-in]

M036112 - 15/07/2013
1.2.8.11 connect hose smaller than 15mm (Pneumatic gearbox control) < 00:01
1.2.9 install step plate, front (Catwalk left + right) 00:03
Explanation
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Warning, mounting step plates

It is prohibited to have more than 10 mm height difference between the step
plates.

M042021 - 17/04/2014
1.2.10 lower cabin 00:03
Explanation

Setting cabin tilting pump

You can stop the cabin tilting forward at any time by turning the valve to the reverse tilting
position (B).

D000551

A Tilting the cabin forward.

B Lower the cabin back into the driving position.

M030437 - 09/08/2019
1.2.11 connect battery clamp, negative pole 00:03
1.2.11.1 remove battery box cover between the chassis (Battery box) < 00:01
1.2.11.2 connect battery clamp, negative pole 00:01
Technical Data

Tightening torque, battery clamp

Battery clamp,
attachment nut (1) 7 Nm (1)
Battery clamp, attachment
nut (2) 15 Nm (1)
(1)Apply Petroleum jelly to
the outside of the connection
to prevent corrosion.

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2 1

K102948

M019252 - 04/06/2018
1.2.11.3 install battery box cover between the chassis (Battery box) 00:01
Technical Data

Tightening torque, battery box cover between the chassis

Attachment bolt 30 Nm

M039060 - 30/08/2013
1.2.12 check operation gearbox (Gearbox) 00:07
Explanation

Checking operation gearbox

After replacing the gearbox, before starting the vehicle:

Make sure that the gearbox is in neutral and check the signal from the neutral
position switch.
Check the gearbox oil level.
Check the clutch function.
Check the speed signal and tacho function.
Check the reversing light switch.

Perform a test drive to check:

The clutch function.
The clutch protection.
All forward and rearward gears.
The gate protection.
The range and splitter functions.
The downshift protection.
The 5-3 protection on 12-speed gearboxes.
M030692 - 28/08/2019
1.2.13 programming gearbox modulator (Gearbox) 00:23
1.2.14 on operating pressure air reservoir 00:05
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1.2.14.1 on operating pressure air reservoir 00:03

1.2.14.2 check air leakage (Air supply, brake system) 00:02
Explanation

Checking air leakage

1. Depress the brake pedal.
2. Release the park brake valve.

Make sure that the system

pressure ≥ 7.5 bar.
If the system pressure is below
7.5 bar, it is not possible to
release the park brake.

3. Check the brake pipes and brake components

for audible air leakage.
4. Operate the park brake valve after the
inspection.

If the brake system of a vehicle has been charged to the maximum pressure, it must
generally be possible to drive the vehicle after a period of 16 hours of uninterrupted
standstill.
This is without having to first charge the brake system to adequate operating pressure.
This implies a maximum pressure drop of approximately 0.4 bar per hour at normal
system pressure.

M027560 - 28/03/2018
1.2.15 check operation gearbox modulator (Gearbox) 00:01
1.2.16 fill and bleed retarder 00:16
1.2.16.1 perform test drive 00:10
1.2.16.2 top up oil gearbox (Gearbox) 00:07
Explanation

Warning, lubricating oil

Lubricating oil can cause skin irritation or skin injury.
To prevent skin injury, avoid unnecessary contact with the lubricating
oil.
Wear protective clothing, eyewear and gloves.

After maintenance or repairs, carefully review the DAF lubrication

specifications.
Inadequate lubrication can cause drive line failure.
Make sure that the vehicle is in neutral gear position before starting the engine.

M036499 - 26/02/2013
Technical Data

Tightening torque, gearbox level check/filler and drain plugs

Level check/filler plug (2) 60 Nm
Drain plugs (1) and (3) 60 Nm

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1 2 3

V301241

M015224 - 28/08/2019
This information applies exclusively to the entered chassis number or the selected vehicle series. Please take into account that this information may
change daily. Therefore the provided information is only valid on You cannot derive any rights from the information provided with respect to
vehicles and/or components of another series, with another chassis number and/or of another date

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DAF Dealernet
replace gearbox
(Gearbox)
# MPA Number Optional Exchange part Description Comp. group Description Bulletin Supersession
1 PCE 1912135 X gearbox 1506 Gearbox PB00264

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