Description

Iveco STRALIS 2004 Technical Manual – Factory Gearbox Rebuild Data

If you’re pulling a ZF 9 S 109 or a 16 S 109 out of an Iveco STRALIS, you need the print that came out of Turin, not some aftermarket translation that leaves out the shim clearance specs. This Technical Manual is the 2004 factory release – 151 pages, base print 603.93.333, revised through October 2005. It covers the gearboxes that move these trucks: ZF 9-speed, 16-speed, Eurotronic 12 AS 2301, and Allison MD 3060/3066. I’ve chased bad synchros on STRALIS units before, and the only reason I didn’t split the case twice was because the OEM procedure was on the bench in front of me.

The manual is in Italian, but torque values, shim calculations, and bearing clearances are numbers, not language. If you need English, keep a translator handy – the data itself is universal.

ZF 9 S 109 D.D. Overhaul: What the Factory Includes

The first transmission section (pages 1–42) walks through the 9-speed double‑countershaft. General description on page 3, characteristics and data on page 5, then diagnostics on page 8. The disassembly sequence starts on page 15 with G.R.E. box removal, then splits the main case. Page 26 covers input shaft and primary shaft removal – critical when the bearings are noisy. Page 39–40 gives the exact procedure for recording axial clearance on secondary shaft bearings and the primary shaft bearing. Miss this step, and you’ll cook the bearings inside 10,000 miles.

Torque Specs and Bolt Patterns

Page 11 lists all tightening torques for the ZF 9 S 109. Every bolt on the case, the range selector housing, and the PTO cover is specified in Newton‑meters and pound‑feet. The 16 S 109 section (pages 43–84) has its own torque table. Aftermarket manuals sometimes copy the numbers but leave out the tightening sequence – this factory print includes the order and the angle-tighten steps where required. I’ve seen stripped threads on the clutch housing because a tech used generic specs. Not here.

Does This Manual Cover the Eurotronic and Allison?

Yes. The Eurotronic 12 AS 2301 D.D./O.D. (pages 155–200) includes solenoid testing and shift calibration – you need this if you’re swapping an ECU or chasing drivability complaints. The Allison MD 3060 PR and MD 3066 PR section (pages 215–238) covers the hydraulic control body and lock‑up clutch adjustments. Both sections are separate from the ZF content, so you don’t have to wade through irrelevant steps. The Eurotronic with Intarder (IT) gets its own subsection (pages 201–214).

3 Transmission Families Covered in One Manual

You get three distinct families: ZF mechanical (9-speed and 16-speed), ZF with Intarder retarder (pages 84/1–84/4 and 137–154), and Allison electronic automatics. Each family includes disassembly, inspection, reassembly, and the special tool list (see page 12 for the 9-speed tools). The PTO section (pages 247–274) covers multiple power take‑off configurations, including the optional 2395 total PTO (pages 275–296). If you’re installing a PTO on a STRALIS, this is the only source that tells you which gear train to engage.

Get the Right Tool List Before You Start

Page 12 for the ZF 9 S 109, and equivalent tool lists inside each transmission section. The factory specifies pullers, press fixtures, and gauge blocks. I’ve watched guys try to fudge the input shaft bearing removal with a three‑jaw puller – then they grind the shaft shoulder. The tool numbers are Iveco part codes, and you can cross‑reference them with standard bearing separators. Worth the time to read before you open the case.

Speaking of sourcing, if you need additional electrical diagnostics, check the IVECO Stralis Wiring Diagram – Section: Central Locking With Remote Co for the harness routing. For broader engine and chassis work, the Iveco Stralis Repair Manual covers the rest of the truck. And if you’re focusing strictly on the braking and stability systems, the Iveco Stralis EBS/ESP/EBL Technical Manual has the ABS calibration data.

A word on documentation: this is an OEM scan, not a reprint. The page numbers match the original printed manual – you can call out “page 11 for torque” and the tech across the bay finds it instantly. Aftermarket versions often renumber sections, which costs you time when you’re under a deadline. This one is factory original, clean resolution, and searchable if your PDF reader handles Italian diacritics.

For background on how these transmissions function mechanically, consider reading about Manual Transmission design principles. The ZF constant‑mesh layout is a classic, and the STRALIS implementation uses single‑countershaft splits that require precise shimming. Another quick reference is Manual Transmission theory – helps when you’re explaining a grind noise to a customer.

Diagnostic Section: Reading the Symptoms

Each major transmission has a dedicated diagnostic page (page 8 for the ZF 9 S 109). It lists symptoms – gear clash, high shift effort, oil leaks – and the probable causes in order of likelihood. The Eurotronic section includes electronic fault codes. If you’re chasing a P0715 (input speed sensor) on a STRALIS with the 12 AS 2301, the factory diagnosis tells you which connector pins to test and what resistance range to expect. No guesswork, no swapping parts.

Oil Pump and Lubrication Circuit

Page 31 of the ZF 9 S 109 section covers the oil pump – removal, inspection, and clearance checks. The pump gear end‑float is specified, and the manual shows the oil flow path through the heat exchanger and to the bearings. A clogged pickup screen on a STRALIS that’s been running high idle hours will starve the countershaft bearings. This section tells you how to measure clearance without buying a specialty depth gauge – just a feeler and a straightedge.

Frequently Asked Questions

Is this manual in English?

No. It’s the original Italian factory print. All torque values, shim specifications, and tool numbers are numeric and universal. You can work from the diagrams and tables without speaking Italian.

Does it cover the ZF 16 S 151 D.D. with Intarder?

Yes – pages 85–136 cover the 16 S 151, 16 S 181, and 16 S 221 (direct drive and overdrive). Pages 137–154 address the same gearboxes fitted with the hydraulic Intarder retarder. The Intarder section includes the retarder valve body removal and pressure test ports. If your STRALIS has the “IT” badge on the gearbox, you need those pages.

This manual ends at the gearbox section. Access the Factory Manual if you need the complete STRALIS powertrain documentation – the engine and chassis volumes are separate. For this price, you get the gearbox bible that keeps these trucks moving through Texas heat and uphill grades alike. I’ve used it. I trust it. You will too.