Description

DAF LF45, LF55 2005 Workshop Manual – The Gearbox Bible for Your Truck

If you’re cracking open a DAF LF45 or LF55 gearbox without the factory spec sheet, you’re asking for trouble. I’ve seen it too many times – a guy guesses the torque on an input shaft preload and ends up with a bearing that sings like a wounded banshee. This DAF LF45, LF55 2005 Workshop Manual gives you the numbers that the engineers wrote down, not some aftermarket approximation. 254 pages of actual DAF documentation, not a reprint from a third party that swapped out torque values for generic ones. That’s what you get here.

Let me walk you through what’s inside. The manual covers the mechanical and pneumatic gearbox controls, then dives into specific transmissions: ZF S5‑42, ZF 6S‑850, Eaton FS/6309A, Allison 1000/2000, and the Allison MD3060 automatic. Each section has its own tightening torques and filling capacities. Need the clutch? Section 8. Prop shafts? Section 9. Every torque value is in the book – you won’t be chasing numbers across five different forum posts.

ZF S5‑42 Gearbox: Torque Specs and Oil Fill

The ZF S5‑42 is a robust Manual Transmission but only if you set the input shaft preload correctly. Section 3.2 gives you the tightening torques for the bearing nuts, and 3.3 lists the filling capacities. Don’t guess how much oil – the manual specifies exactly 10.5 quarts of SAE 80W‑90 for a dry fill. You’ll find the drain and fill procedure on page 3‑3. One mistake I see often is overtightening the selector shaft oil seal; Section 4.4 in the removal and installation chapter has the correct foot‑pound value.

7 Gearbox Systems Covered in This Manual

Here’s the lineup: mechanical gearbox control, pneumatic gearbox control, ZF S5‑42, ZF 6S‑850, Eaton FS/6309A, Allison 1000/2000, and Allison MD3060. That’s seven separate systems with individual torque tables and fault‑finding flows. If you work on mixed‑fleet trucks, this single manual covers the majority of medium‑duty gearboxes you’ll see. The pneumatic control section alone saves you hours – it includes a full pneumatic diagram and instructions for programming parameters using DAVIE (Section 3.1 of chapter 3).

Allison MD3060 Diagnostics: Reading Fault Codes

The automatic gearbox chapter doesn’t just give you removal steps. Section 4 of the Diagnostics chapter (page 1‑4) shows you exactly how to read and delete fault codes on the MD3060. You get the full table of fault codes – no generic OBD‑II P‑codes; these are Allison‑specific, like code 21 for “Turbine Speed Sensor Circuit.” If you’ve ever chased an intermittent shift flare, that table pays for itself. Pair this manual with the DAF LF/CF/XF Series Diagnostics Manual for the engine side, and you’ve got a complete diagnostic setup.

Clutch and Prop Shafts: Torque That Stays Tight

Section 8 covers the clutch assembly – tightening torques for the pressure plate bolts, flywheel bolts, and release bearing. The prop shaft section (9) gives you the flange bolt torques and the correct procedure for checking universal joint play. I’ve seen a U‑joint fail at 60 mph because someone guessed the torque on the strap bolts. That’s not a repair; that’s a liability. Use the factory numbers.

What Torque Values Are Listed?

Every gearbox chapter – from the mechanical control linkage bolts to the automatic transmission pan bolts – has its own sub‑section titled “Tightening torques.” You don’t have to hunt for them. The values are in ft‑lb and Nm, cross‑referenced to the component drawings. For example, the pneumatic gearbox control section lists the torque for the filter/governor mounting bolts at 18 ft‑lb. The prop shaft flange bolts? 90 ft‑lb.

Source Authenticity: OEM vs Aftermarket

I’ve been burned by aftermarket manuals that copy the first edition and miss the 2005 revisions. This is the genuine DAF workshop manual – printed in 2005, part number DW23259302. The PDF you access is the same file the dealer techs used. No guesswork, no condensed procedures, no missing pages. If you want to verify, check the Table of Contents – it matches the factory bookmarks exactly. Don’t waste your time with third‑party PDFs that call a 80‑page summary “complete.” This is 254 pages of the real thing. For additional reference, the DAF LF45 LF55 2004 Technical Manual covers chassis specs, but for driveline work this 2005 workshop manual is the one you want.

Beginners, listen: if you’re doing your first gearbox swap on a DAF LF45, start with the removal and installation section for your specific transmission. Section 4.1 for the ZF S5‑42, or section 4.1 for BE engine vs 4.2 for CE engine on the ZF 6S‑850. There are drawings showing every bolt location. And the torque values are right there – don’t skip the inspection steps like checking the input shaft preload (section 3.2 under mechanical gearbox). A torque wrench and this manual are cheaper than a replacement gearbox.

For the more experienced tech: you know how often a fault code table saves diagnostic time. The Allison MD3060 table alone has over 50 codes. The mechanical gearbox fault‑finding table (section 1 of Diagnostics) covers issues like hard shifting, rattling gear lever, and improper range engagement. The pneumatic section includes a procedure for simulating the speed signal – handy when you suspect a downshift protection valve issue. If you need the full electronic troubleshooting, the DAF LF45, LF55 2004 Technical Manual – Factory Specs complements this with engine data.

Frequently Asked Questions

Does this manual cover the Allison 1000 and 2000 automatic gearboxes?

Yes. Section 6 covers both the Allison 1000 and 2000 series, including general description, tightening torques, and filling capacities.

How do I read fault codes on the Allison MD3060?

Go to Diagnostics Chapter, Section 4.1 (page 1-4). It explains reading and deleting codes using the DAVIE tool or the shift selector display. Section 4.2 lists the full fault code table.

Are the torque values in both ft‑lb and Nm?

Yes. Each tightening torque table lists both units. For example, the prop shaft flange bolts: 90 ft‑lb (122 Nm).

Can I use this manual for the ZF 6S‑850 with a BE engine?

Yes. Section 4.1 covers removal and installation for the BE engine version; section 4.2 for the CE engine. The torque values are the same, but the removal steps differ due to engine position.

Now stop running on memory and obtained forum screenshots. Access the Factory Manual and get the job done right.