ZF-ECOLITE S 5-42 Repair Manual 1307751103d – PDF DOWNLOAD

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S 5-42 1307 751 103d

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Subject to alterations in design

Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form Ð also in adapted, paraphrased or extracted form Ð in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.

Printed in Germany

Edition:

09.95

1307 751 103d

S 5-42

Contents

Seite Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G eneral i n fo r m at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important work safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutaway views of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spring table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-01 1-02 1-03 1-04 1-05 1-06 1-08 1-09 1-13

1.

Dismantling into sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-01

1.1 1.2 1.3

Removing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-01 Removing bearing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-02 Removing transmission shafts and selector rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-03

2.

Dismantling sub-assemblies into parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.1 2.2 2.3 2.4 2.5 2.6 2.7

Dismantling shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling bearing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling output housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling input housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.

Assembling parts into sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

3.1 3.2 3.3 3.4 3.5 3.6 3.7

Assembling shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling bearing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling output housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling input housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.

Installing/mounting sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.8.1 4.8.2

Fitting together transmission shafts and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting output housing and output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting tapered roller bearings for layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing and bolting together housing joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting taper roller bearings for input shaft and main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting bearing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting speedo and switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting speedo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12 2-14 2-15 2-16 2-23 2-25 2-27

2-29 2-32 2-34 2-35 2-45 2-47 2-48

2-51 2-54 2-57 2-59 2-61 2-63 2-65 2-67 2-67 2-67 1-01

8 S 180

Preface

This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products.

This manual deals with a ZF product in accordance with the state of development at the date of issue.

However, due to continuing development of the product, repair work may require work practices and test or adjustment data which differ from those contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical training updated on a regular basis at our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. specialized tools 3. Genuine ZF spares, to our latest specifications All work performed at these service points is carried out conscientiously and with care.

Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual warranty conditions.

Damage resulting from work performed by non-ZF personnel in an improper or unprofessional manner, and any follow-on costs resulting from such work, are excluded from the contractual warranty agreement.

This also applies where genuine ZF spares have not been used.

ZF FRIEDRICHSHAFEN AG Friedrichshafen Division After-Sales Service

1-02

S 5-42

General information

Repair manual This repair manual describes how to repair the ZF ECOLITE S 5-42 synchromesh transmissions.

Repair manual layout: Section 1:

Adjustment data, tightening torques, spring data and an illustrated list of specified ZF special tools.

Section 2:

Description of transmission repair, split into work steps.

General work notes Maintain cleanliness in all work, and carry out all work to a proper professional standard. After removing a transmission from the vehicle, clean the outside thoroughly before opening the housing.

Always use tools specified by ZF. Clean all components after dismantling. Pay particular attention to corners, recesses and angles of housings and covers.

Carefully remove all traces of old sealing compound.

Check that lube oil bores, grooves and pipes are clear. They must be free of deposits, foreign matter or preserving agents. Take special care to remove preserving agents from new parts.

All parts which cannot be removed without being damaged must always be replaced with new parts (e.g. shaft seals, O-rings, grooved rings, cap collars, protective caps, etc.).

Do not use impact wrench to pull off re-usable antifriction bearings.

Parts such as antifriction bearings, thrust washers, synchronizer parts etc., which are subject to normal wear during operation, must be inspected by an expert who should decide whether or not they can be re-used.

Fit gaskets dry, i.e. free from oil and grease. Sealing points without gaskets must be sealed using a heat and oil resistant sealing compound of plastic consistency (e.g.: WEVO-L 100 A).

During assembly, comply with all adjustment data, check data and tightening torques.

After completing repairs, fill the transmission transmission oil. For procedure and approved oils, see the transmission Operating Instructions and List of Lubricants TE-ML 02. These documents can be obtained from any ZF After-Sales Service point.

After filling the transmission with oil, tighten the oil level check plug and oil drain plug to the specified torques.

1-03

Important work safety notice

8 S 180

Important work safety notice: Persons repairing or overhauling ZF units are responsible for their own work safety at all times.

All current safety regulations and legal requirements must be complied with to prevent injury to persons or damage to the product during service and repair work. Repair personnel must familiarize themselves with such regulations before starting work.

Proper and correct repair of these ZF products requires suitably trained and skilled personnel. It is the duty of the organization responsible for repairs to provide for such training.

The following safety notes are used in this manual: NOTE:

Indicates special work procedures, methods, information, use of tools etc.

CAUTION

Is used when incorrect procedure can lead to product damage.

!

DANGER

Is used when lack of care may lead to personal injury or death.

NOTE Carefully read this manual before commencing inspection and repair work.

On completion of repairs and inspection, skilled personnel must satisfy themselves that the product has been restored to perfect working order.

CAUTION Illustrations, drawings and parts do not necessarily depict the original. They are merely used to illustrate work procedure.

Illustrations, drawings and parts are not drawn to scale. No assumptions must be made with regard to size and weight (even within the same illustration).

Work must be carried out as described in the text.

1-04

S 5-42

Tightening torques

Tightening torques for nuts and bolts. Excerpt from ZFN 148 This Standard applies for bolts as per DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts as per DIN 934.

This Standard contains data on tightening torques (MA) for nuts and bolts of strength classes 8.8. 10.9 and 12.9. as well as nuts of strength class 8. 10 and 12.

Surface condition of bolts: Heat-treated blackened finish + oiled or galvanized + oiled or galvanized + chromeplated + oiled.

Tighten bolts using a calibrated signal or pointer-type torque wrench.

Metric coarse pitch thread

Metric fine pitch thread

Size

Size

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

M 4 M 5 M 6

2.8 5.5 9.5

4.1 8.1 14

4.8 9.5 16.5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

M 10 x 1.25 M 12 x 1.25 M 12 x 1.5

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

M 14 x 1.5 M 16 x 1.5 M 18 x 1.5

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

M 18 x 2 M 20 x 1.5 M 22 x 1.5

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

M 24 x 1.5 M 24 x 2 M 27 x 1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M 27 x 2 M 30 x 1.5 M 30 x 2

1050 1550 1500

1500 2200 2100

1800 2550 2500

12.9 12

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

As at: August 1991

1-05

S 5-42

2 3 4

S 5-42 transmission Overdrive version

1

R

5

Cutaway view of transmission

005 292

1-06

5

4

3

S 5-42

S 5-42 transmission Direct drive version

2

1

R

1-07

Cutaway view of transmission

003 069

Spring table

S 5-42

Order no.

Installation location

0732 041 571

Synchronizers

0732 041 947

0732 041 946

1-08

No. of coil turns

Wire Ø in mm

Spring Ø in mm

Untensioned length in mm

9.5

0.95

5.96

14.8

Stop plate (Rev. gear interlock) on overdrive version

15.5

1.0

9.04

35.3

Shift detents

18.5

1.25

7.88

44.1

S 5-42

Adjustment data

Description

Permissible limits

Measuring device

Remarks

01. Axial bearing preload on input shaft and main shaft

0.02 to 0.09 mm

Dial gauge or depth gauge

Adjust as follows: Turn main shaft/input shaft in order to centre bearing rollers and adjust to zero play.

Then, fit shim to give specified preload.

02. Axial bearing preload on layshaft

0.02 to 0.09 mm

Dial gauge 1P01 137 513

Adjust as follows: Measure end play without shim. Then fit shim to give specified preload

03. End play of circlips on shafts

0 to 0.05 mm

Feeler gauge

Aim for 0 mm. Adjust by fitting circlip of suitable thickness

04. End play of reverse gear helical gear on main shaft

Overdrive 0.15 to 0.30 mm Direct drive 0.20 to 0.45 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

05. End play of 1st gear helical gear on main shaft

Overdrive 0.15 to 0.30 mm Direct drive 0.20 to 0.45 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

06. End play of 2nd gear helical gear on main shaft

Overdrive 0.15 to 0.40 mm Direct drive 0.20 to 0.35 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

07. End play of 3rd gear helical gear on main shaft

Overdrive 0.15 to 0.30 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

Direct drive 0.15 to 0.60 mm

1-09

Adjustment data

S 5-42

Description

Permissible limits

Measuring device

Remarks

08. End play of 4th gear helical gear on main shaft (for direct drive version)

0.15 to 0.55 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

09. End play of 5th gear helical gear on main shaft (for overdrive version)

0.15 to 0.30 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

10. End play of intermediate gear on pin (reverse idler)

Overdrive 0.35 to 0.55 mm

Feeler gauge

Play should be correct following assembly. Check to confirm.

Special tool 1X25 139 470

If special tool 1X29 139 470 is used, the correct depth is given.

This special tool is not used for the direct drive version.

12. Wear limit between synchro 0.6 mm rings and clutch bodies, measured between flat surfaces of rings and clutch bodies (tapers pushed together w/out play)

Feeler gauge

If gap is less, change synchro ring and/or clutch body with helical gear

13. Tightening torque for M24x1.5 oil drain plugs and oil overflow plugs

50 Nm

Torque wrench

Do not overtighten

14. Tightening torque for M18x1.5 screw plugs

40 Nm

Torque wrench

Fit new seal ring

15. Tightening torque for M18x1.5 indicator switch for reverse gear display or neutral position

50 Nm

Torque wrench

In some housings, a 5.0 mm spacer ring is used only for the neutral position display switch

Direct drive 0.25 to 0.95 mm 11.Insertion depth of shaft seal in output cover

Overdrive 7.0 +1 mm Direct drive to end of travel

1-10

S 5-42

Adjustment data

Description

Permissible limits

Measuring device

Remarks

16. Tightening torque for M32x1.5 locking nut for output flange, on direct drive version

400 Nm

Torque wrench

Also secure locking nut with Loctite no. 270

17. Tightening torque for M24x1.5 locking nut for output flange, on overdrive version

330 Nm

Torque wrench

Use new locking nut.

18. Tightening torque for M12x1.5 screw plugs in transmission housing

25 Nm

Torque wrench

Fit new seal ring

19. Tightening torque for M10 hex bolts in PTO side covers

53 Nm

Torque wrench

Caution! Only use genuine new bolts (sealing thread)

20. Tightening torque for M8 cylindrical bolt(s) for intermediate gear pin (reverse)

22 Nm

Torque wrench

Use new Usit ring(s)

21. Tightening torque for 3x M6 shoulder bolts for shift interlock

10 Nm

Torque wrench

After shoulder bolts have been tightened, ensure shift interlock moves easily and functions correctly

22. Tightening torque for 1/4" hex bolt for speedo connection on overdrive version

10 Nm

Torque wrench

Fit spring washer

23. Tightening torque for M30x1.5 for mechanical speedo connection.

Tightening torque for inductive sensor for elec. speedo conenction

100 Nm

Torque wrench

Fit new seal ring

__________

____________

_______________

50 Nm

Torque wrench

Do not overtighten

Use new output flange (see spec. list)

1-11

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