DOWNLOAD PDF ZF-ECOSPLIT 16 S 251 Repair Manual 1316 751 102
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Subject to alterations in design
Copyright by ZF
Reproduction in whole or in part,is only allowed with our written approval and authorization.
Printed in Germany
Edition: 11.98
NOTE: If clamping fixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover before attaching the clamping fixture. When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set. Then install the reverse idler gear pin.
ZF FRIEDRICHSHAFEN AG
Division Comm. Vehicle/Special Transmissions
Service Werk 2
Tel.: (0 75 41) 77-0
Fax: (0 75 41) 77-5726
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 the standard ZF product in accordance with the state of development on the date of issue.
However,due to continuing development of the product, repair work might require work practices and test or adjustment data which are not 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 knowledge 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. special 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 conditions.
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work,is excluded from the contractual guarantee agreement. This also applies where genuine ZF spares have not been used.
Important information
SAFETY NOTICE
Companies who repair ZF units are responsible for their own work safety.
To avoid injury to personnel and damage to products,all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to.
Before starting work,mechanics must familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
GENERAL INFORMATION
Read this manual carefully before starting any tests or repair work.
CAUTION
Pictures,drawings and components do not always represent the original object,but are used to illustrate working procedures.
Pictures,drawings and components are not to scale and no information about size and weight should be inferred (even within a complete illustration).
Always follow the working steps as described in the text.
The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, data, use of auxiliary equipment, etc.
CAUTION
This is used when incorrect,unprofessional working practices could damage the product.
DANGER
This is used when lack of care could lead to personal injury or death.
After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.
THREATS TO THE ENVIRONMENT!
Lubricants and cleaning agents must not be allowed to enter the soil,ground water or sewage system.
•Ask your local environment agency for safety information on the relevant products and adhere to their requirements.
•Collect used oil in a suitably large container.
•Dispose of used oil,dirty filters,lubricants and cleaning agents in accordance with environmental protection guidelines.
•When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.
CAUTION
The transmission must NOT be hung on the input shaft NOR on the output flange.
In any cases of doubt always turn to the the relevant department within ZF After-Sales Services for advice.
After removing the transmission from the vehicle clean thoroughly before opening. Pay particular attention to the corners and angles of housings and covers when cleaning. Parts held on with Loctite can be slightly loosened if warmed with a hot air blower.
CLEANING PARTS
Remove the old remains of gaskets on all gaskets. Carefully remove burrs or other similar patches of roughness using a oil-stone
Lube bores and grooves must be free of anti-corrosion agents and foreign matter, check that they can move without encountering any problems.
Carefully cover opened transmissions to prevent the entry of foreign matter..
REUSING PARTS
Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear.
Instructions for carrying out repairs
GASKETS,LOCKING PLATES
Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).
SHAFT SEALS
Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.
REWORKING
Rework may only be carried out on the seal contact surfaces using plunge-cut grinding, never use an emery cloth. Ensure that there are no traces of grinding traces or rifling from grinding.
If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.
TRANSMISSION ASSEMBLY
Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement.
During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.
Instructions for carrying out repairs
BEARINGS
If the bearings are filled while hot, these should be warmed up accordingly (e.g. in a heating cabinet). The temperature should be approx. 85 °C and may not exceed 120 °C. All bearings must be coated with transmission oil after assembly.
SEALING
If a sealing agent* is to be used for carrying out sealing, comply with the manufacturer’s directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent penetrates the oil feeds when the surfaces are sealed.
SHAFT SEALS
a)Apply a light coat of sealing agent on outer edge of shaft seals with “steel surround”.
b) Never apply sealing agent to shaft seals with “rubber surround” but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive).
c)Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).
d)Duo shaft seals have two packing washers. The dust-proof packing washer (X) must face outwards.
e)Fill the gap between the packing washers so it is 60% filled with grease (use a grease e.g. produced by Aral such as Aralub HL2 or by DEA such as Spectron FO 20).
f)If possible heat shaft seal bores to between 40 and 50°C (this makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.
RETAINING AGENTS
Retaining agents* may only be used in places as specified in the parts list.
Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data, checking data and tightening torques.
TRANSMISSION OIL
After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.
* refer to expendable material
Tightening torques for nuts and bolts,extract from ZFN 148
This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934. This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.
Tightening torques
Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.
This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 wrench.
NOTE
Divergent tightening torques are listed separately in the Repair Manual.
SizeTightening torqueSizeTightening torque MA (Nm) forMA (Nm)for Bolt8.810.912.9Bolt8.8 10.912.9 Nut81012Nut81012
M 42,84,14,8M 8 x 1243643
M 55,58,19,5M 9 x 1365362
M 69,51416,5M 10 x 1527689
M 7152328M 10 x 1,25497284 M 8233440M 12 x 1,2587125150
M 10466879M 12 x 1,583122145
M 1279115135M 14 x 1,5135200235
M 14125185215M 16 x 1,5205300360
M 16195280330M 18 x 1,5310 440520
M 18280390460M 18 x 2290 420490
M 20 390560650M 20 x 1,5430620 720
M 22530750880M 22 x 1,5580820960
M 246709601100M 24 x 1,576011001250
M 27100014001650M 24 x 273010501200
M 30135019002250M 27 x 1,5110016001850
M 27 x 2105015001800 M 30 x 1,5155022002550 M 30 x 2150021002500
Edition: August 1991 / checked 1997
Tightening torques
Screw plugs DIN 908,910 and 7604
The screw plug tightening torques MA were determined according to DIN 7604, for screwing into steel, grey cast, and aluminium alloys. The values are based on experience,and are intended as reference values for the designer. The values for the tightening torque MA shall also be used for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.
General rule: Screw/bolt class 5, ZFN 148-1
Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled
Screw plugs (DIN 908, 910, 7604)
DimensionsTightening torque screwed into steel/grey castAl alloy
M 8 x 12010
M 10 x 125 / 30*15 / 20*
M 12 x 1.535 25
M 14 x 1.53525
M 16 x 1.54030
M 18 x 1.55035
M 20 x 1.555 45
M 22 x 1.560 / 80*50 / 65*
M 24 x 1.57060
M 26 x 1.580 / 105*70 / 90*
M 27 x 28070
M 30 x 1.5100 / 130*90 / 130*
M 30 x 29585
M 33 x 2120110
M 36 x 1.5130115
M 38 x 1.5140120
M 42 x 1.5150130
M 42 x 2145125
M 45 x 1.5160140
M 45 x 2150130
M 48 x 1.5170145
M 48 x 2160135
M 52 x 1.5180150
M 60 x 2195165
M 64 x 2205175
* DIN 7604 Form C
Union screws DIN 7643
The tightening torques MA were determined for screwing into steel,grey cast and aluminium alloys. The values are based on experience and are intended as reference values for the designer.
General rule:screw/bolt class 5,ZFN 148-1
Material 9SMnPb28K acc. to DIN 1651
Surface conditions:as manufactured (without surface protection) and lightly oiled or galvanized,chromated and lightly oiled
Union screws (DIN7643)
PipeThreadTighteningoutertorque MA diameterin Nm
4 - 5M 8 x 130
6M 10 x 135
8M 12 x 1.540
10M 14 x 1.540
12M 16 x 1.545
15M 18 x 1.550
18M 22 x 1.560
22M 26 x 1.590
28M 30 x 1.5130
35M 38 x 1.5140
Status October 1995
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16 S 251Consumables
DescriptionNameApprox.ApplicationRemarks
ZF reference no.quantity
Sealing compound
0666 690 017Loctite Nr. 2410,25 gcovershift system
5 gbreatherselector housing
300 mm3 articulation boltplanetary range
Sealing compound
0666 690 022Loctite Nr 262120 mm3 threaded insert M10, M12GP-housing
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
Adjustment data
DescriptionToleranceMeasuring
01.Axial play on layshaft
02.Combined axial play of mainshaft and input shaft
03.Axial play / prestress of split ring on input shaft and mainshaft (only in older version)
04.Insertion depth for shaft seal in output flange cover
05.Axial play on ball bearing in cover (range-change)
06.Axial play on helical gear on input shaft
07.Axial play on helical gears on mainshaft
08.Axial play on 4th-speed helical gear
09.Axial play on circlips on layshaft and mainshaft
10.Axial play of reverse idler gear
11.Permitted axial play on planet gears in planet carrier
Depth gauge or dial gauge
Depth gauge or dial gauge
Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on output end.
Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on input shaft.
Micrometer or feeler gauge
Depth gauge and/or drift 1X56 137 124
Always use correct tool.
Depth gauge/sliding caliper
Depth gauge or feeler gauge
Depth gauge or feeler gauge
Depth gauge or feeler gauge
Micrometer or feeler gauge
Feeler gauge
Feeler gauge
Measure depth of insertion between outside of cover and face of shaft seal. If drift is used with ring, depth is automatically given (must be flat).
Adjust using appropriate shims in cover.
Not adjustable. Measure as check only.
Not adjustable. Measure as check only.
Not adjustable. Measure as check only.
Use appropriate circlip.
Not adjustable. Measure as check only.
Tolerance includes permitted wear on thrust washers. If wear limit exceeded exchange thrust washers
DescriptionToleranceMeasuring
12.Wear limit for synchronizer ring and clutch body, measured between flat surfaces of ring and body with cones firmly nested together.
4-gear section and splitter Range-change
13.Wear limit for 1st/2nd gear synchronizer parts, measured between outer ring and clutch disc, measured with cones nested firmly together and force F = 50 N applied on the outer ring.
14.Max. permitted play on fulcrum pads in sliding sleeves
15.Adjusting mainshaft and determining thickness of ring and shim
16.Temperature for shrinkfitting helical gears onto layshaft
17.Tightening torque for breather
18.Tightening torque for M12 x 1.5 screws in housing
19.Tightening torque of union screws for plastic pipes
Feeler gauge
Adjustment data
Exchange synchronizer ring and/or clutch body if dimension too small
mm
mm
mm
Feeler gauge
Exchange intermediate ring and/or outer ring and inner ring if wear limit is excluded.
- 1.2 mm
Feeler gauge Depth gauge Temperature probe
Exchange if play is excessive
Measure and determine thickness of shim first. Then, measure and select ring.
Gears and shaft seats must be free of oil and grease during assembly
Use new seal rings
Use new seal rings
Torque wrench
Torque wrench
Torque wrench
DescriptionToleranceMeasuring
20.Tightening torque for detent plungers
21.Tightening torque for pressure switch/impulse sensor
22.Tightening torque of M12 bolts for output flange
23.Tightening torque for shift fork grub screws
24.Tightening torque "M24 x 1,5 magnetic screw"
25.Tightening torque for locking nuts on rangechange and splitter pistons
26.Tightening torque for hex bolts between clutch housing and mid-housing
27.Tightening torque for hex bolts between mid-housing and GP housing
28.Tightening torque for M18 x 1.5 screw plugs on housing
29.Tightening torque for M22 x 1.5 screw plugs on housing
30.Tightening torque for M24 x 1.5 screw plugs on housing
31.Heating temperature for ring gear
32.Temperature of synchronizer hub, clutch body, bushes and counting disc
Torque wrench
Torque wrench
Use new seal rings
Use new seal rings
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Fit new retaining plate. Use Loctite No. 262.
Torque wrench
Clean magnet and fit new seal ring
Use new locking nut
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Temperature probe
Temperature probe
Do not exceed temperature
Do not exceed temperature
16 S251
DescriptionToleranceMeasuring
33.Temperature of output flange
34.Temperature of input shaft roller bearing
35.Temperature of 4th-speed helical gear with needle cages on mainshaft
36.Rolling-in torque for injection pipe
37.Lifting device for input shaft/ mainshaft/ layshaft
38.Tightening torque for pivot bolts on shift fork
39.Tightening torque for M8 hex bolts on shift cover
40.Tightening torque for M10 hex bolts on shift lever
41.Tightening torque for M8 hex bolts on shift housing cover (with detent piece)
42.Tightening torque for M8 hex bolts on cutoff valve
48.Tightening torque hex screws M8x65 cut off valve
49.Tightening torque hex screws M10x65 shift lever
50.Permitted axial play on mainshaft/planetary drive
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Measuring bush 1X56 138 158
16 S251
Use new sealing ring.
Adjust using appropriate shim
0732 040 385
0732 040 386
0732 040 409
0732 040 736
0732 040 904
0732 040 985
0732 040 986
0732 042 684
1204 307 030
synchr./planet carrier
synchr./planet carrier synchronization drive shaft and main shaft
Table of springs
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for installation and dismantling of shafts together with 1X56 137 675
Distance ring for shaft sealing ring / output, together with 1X56 137 124
Extraction tool for cylinder pins on clutch housing that are difficult to reach
Centering aid for selector rail / splitter group
1Removing components / range-change
1.1Plastic pipes
Removal
NOTE
Label plastic pipes before removing to ensure correct re-assembly.
1Unscrew union screws (1 and 2) from rangechange cylinder (3) and cutoff valve (4). Loosen pipe clip (5) on housing and remove complete together with plastic pipes (6).
Mounting
1Using union screws and new seal rings, screw plastic pipes (6) to cylinder (3) and shut-off valve (4) as marked.
Tightening torque = 38 Nm.
2Strap up plastic pipes an fix cable strap (5) together with plastic pipes to housing.
1.2Output flange
Removal
1Lever off retaining plate (1) from bolts (2).
2Secure output flange to prevent it from turning.
3Unscrew hex bolts (2) and remove clamping disc (3).
4Place adapter onto planet carrier and remove output flange (4) using 2- or 3-leg puller.
5Remove O-ring (5).
Mounting
1Lightly oil shaft seal in cover.
DANGER
Always wear protective gloves when handling heated output flange.
4Pull on output flange until flush using disc (2) and two standard M12x75 hex bolts.
5Remove disc and bolts.
6Lightly oil new O-ring (3) and insert into gap between output flange and planet carrier shaft.
7Insert disc (2) into output flange and attach to planet carrier using locking screws. Tightening torque = 120 Nm. If required, use flange holder to prevent flange from turning.
Insert locking screws with Loctite 262.
8Using special tool 1X56 137 651, drive new retaining plate (4) flush onto bolt heads.
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1.3Cover Removal
1Unscrew hex bolts from cover (1) and remove together with gasket (2).
2Unscrew hex bolts and remove cover (3) together with gasket (4), shaft seal (5) and shim (6).
3Use Rillex extractor 1X56 122 314 to remove ball bearing (7) from output shaft.
4Using plastic drift, drive out shaft seal (5) from cover.
Mounting
Measuring ball bearing axial play (nominal:0 to 0.1 mm)
1Fit new gasket (1) onto new cover (2) and measure insertion depth of cover together with gasket, e.g. 23.40 mm.
2Measure extraction depth bearing seat depth of housing (without gasket), e.g. 7.00 mm.
3Measure width of ball bearing (3), e.g. 30.00 mm.
Example
23.40 mm insertion depth - cover + 7.00 mm insertion depth - housing 30.40 mm – 30.00 mm width of ball bearing = 0.40 mm axial play without shim
i.e. a 0.3 to 0.4 mm shim (4) is required to give axial play of 0 to 0.1 mm.
DANGER
Always wear protective gloves when handling heated cover.
4Heat cover (2) to approx. 60°C and insert correct shim (4) and ball bearing (3).
5Drive in shaft seal (5) using special tool 1X56 137 124
Only use special tool with 12.5 mm wide ring. Installation dimension = 12.5 + 1.0 mm between edge of cover and shaft seal. Thinly coat outside of shaft seal with sealing compound. Lubricate outside of shaft seal with rubber surround using soap wash.
6Fit cover (2) with new gasket (1) and tighten using hex bolts and washers.
Tightening torque = 49 Nm.
7Fit cover (6) with new gasket.
Tightening torque = 79 Nm.
1.4 5/2-way valve
Removal
1Unscrew 5/2-way valve (1) from centre housing.
2Remove O-rings (2).
NOTE
Do not dismantle 5/2-way valve since it is a complete part.
1Unscrew hex bolts, loosen cylinder (1) from range-change housing and remove from piston (2).
2Remove O-rings (3 and 4) from cylinder.
3Remove detent plunger (5). Screw fixing device 1X56 137 579 into threaded bore and position fixing element on shift rail (6). Tighten fixing device.
Tightening torque = 50 Nm.
4Unscrew locking nut (7) from piston (2).
5Remove piston together with guide ring (8).
6Remove seal rings (11).
7Remove guide ring from piston.
8Pull out flange packing (10) from range-change housing.
Mounting
1Coat new flange packing (10) with spirit, slide over shift rail (6) and, using soft drift, drive in until flush.
2Place sealing ring (11), piston (2) together with guide ring (8) and sealing ring (11) on shift rail (6).
3Tighten new locking nut (7) once range-change is fitted.
Tightening torque = 150 Nm.
NOTE
Installation of range-change cylinder is only possible once range-change has been subassembled on centre housing. Thread must be absolutely free of oil and grease.
4Grease new O-rings (4 and 3) and insert into correct annular grooves (in cylinder and housing).
5Carefully slide cylinder (1) over piston together with guide ring and piston gasket. Fix cylinder using two hex bolts.
NOTE Align the compressed air bores.
1.6 Housing/range-change
Removal
1Remove mechanical speedometer or impulse sensor (15).
2Remove pivot bolts (1) for shift fork (2).
3Remove fixing device 1X56 137 579
4Unscrew hex bolts from range-change housing (3).
DANGER
Planet gear train is not secured on mainshaft.Secure this to prevent from falling.
5Separate range-change housing (3) from centre housing (5) without tilting and remove. Use pins to ensure correct position (4).
6Remove shift fork (2) together with fulcrum pads (6).
7Remove intermediate plate (7) together with gaskets (8).
8Remove switch (9) together with seal ring and pin (10). Other version (13 and 14) also possible.
9Pull out shift rail (11) from centre housing.
10Remove injection pipe (12).
Mounting
1Place intermediate plate (1) onto planet carrier/clutch body (2).
2Insert shift fork (3) and fulcrum pads (4) into sliding sleeve (5).
3Place new gasket (6) onto intermediate plate (1) and position.
4Insert shift rail (11) from inside of housing and position roughly.
5Insert injection pipe (20) into housing.
6Place housing (7) onto intermediate plate (1), fit gasket and position. Check radial position of shift fork and engage.
7With the range change group installed, coat pivot bolt threads (10) with Loctite No. 241, place spring disks and screw in.
Tightening torque = 250 Nm
NOTE
When using a new housing (7), drive in ball (8) in accordance with selector pattern I or II.
Installing complete range-change
NOTE
Main shaft / planetary drive must be measured prior to installation of the range-change group; see Section 10.4.
1Fit new gasket (1) onto centre housing (2).
NOTE
There must be 3 cylindrical pins in centre housing.
2Fit 2 hex bolts to range-change housing to allow range-change to be suspended from a rope and positioned horizontally against centre housing.
CAUTION
Secure hex bolts with nuts.Ensure rope is firmly secured.
Hint: Use threaded pins on centre housing to simplify positioning of range-change.
3Push range-change against centre housing (2). Turn output flange to bring planet gear train and mainshaft teeth into mesh if necessary.
4Remove hex bolts and rope when range-change is held against centre housing.
5Slide range-change (3) parallel to centre housing and bolt together.
Tightening torque = 49 Nm.
6Switch piston to end position (high or low group).
1.7 Planetary drive with synchronization
Dismantling
NOTE
Prior to removing the planetary drive, make sure it cannot drop.
1Remove entire planetary drive together with synchronization from main shaft.
1.7.1Synchronization
DANGER
Pressure pieces are in a state of spring tension. Safeguard these against disengagement.
1Place pressure piece on planet carrier. Position two or three-arm puller under sliding sleeve (1) and extract together with clutch body (2). The pressure pieces (4) and pressure springs (5) fixed by sliding sleeve may be intercepted in a “jumping sheet”.
2Remove synchronizer ring (6).
3Disengage circlip (7).
4Place pressure piece on planet carrier and remove sychronizer (8) by positioning two or threearm puller under sychronizer and extracting it.
5Remove synchronizer (9), clutch body (10) and clutch disc (11) from planet carrier.
6Disengage circlip (12) on clutch body.
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Mounting
1Check wear limit of synchronizer parts, see Section 9
2Place clutch disc (11) on planet carrier.
3Insert snap-ring (12) in clutch body (10) and slide onto planet carrier.
4Place synchronizer ring (9) on planet carrier.
DANGER
Always wear protective gloves when handling heated synchronizer hub.
5Heat synchronizer hub (8) to approx. 120°C and push on until firmly seated. Ensure long hub side faces planet carrier. Synchronizer ring lugs must engage into recesses in the synchronizer hub.
6Enter circlip (7) in groove with an end float of between 0 and 0.1 mm. Circlips are available in 0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).
7Place sliding sleeve (1) onto synchronizer hub (8) with collar side facing towards output end.
NOTE
Recesses in sliding sleeve must be aligned with recesses in synchronizer hub.
8Insert new compression springs (5) and pressure pieces (4) into synchronizer hub (8) and, using suitable tool, insert into sliding sleeve (1).
9Place synchronizer ring (6) onto synchronizer hub (8).
NOTE
Synchronizer ring lugs (6) must engage into recesses in the synchronizer hub (3).
DANGER
Always wear protective gloves when handling heated clutch body.
10Heat clutch body (2) to approx. 120°C and push flush onto planet carrier.
11Press sunchronizer ring (6) against synchronizer hub (2) and bring sliding sleeve (1) into central position. You will be able to clearly hear the pressure pieces snapping in.
1.7.2 Ring gear
Removal
1Detach safety wire (4) from annular groove in ring gear.
2Attach circlip (7), from Section 1.7.1, onto ring gear carrier. Place pressure piece on planet carrier and fit using two leg or three leg puller underneath circlip. Take off ring gear carrier (2).
3Remove ring gear (1) together with thrust ring (5) from planet carrier.
4Remove thrust ring (5) from ring gear.
5Remove spacer ring (3) from planet carrier.
Mounting
1Place thrust ring (5) on support in ring gear (1).
DANGER
Always wear protective gloves when handling heated ring gear.
2Heat ring gear to 60°C and place planet carrier in ring gear by turning planet gear achieve meshing.
3Slide spacer ring (3) onto the planet carrier (6).
4Drive ring gear carrier (2) into the ring gear (1) to bring about axial alignment.
5Snap locking wire (4) into ring groove of ring gear and bring about snug fit around entire circumference.
1.7.3Planet carrier
Removal
1Drive dowels (1) fully into planet pin (2).
2Using plastic drift, drive out planet gear pin form planet carrier (3) towards “input”.
3Remove planet gear (4) from planet carrier together with bush (5).
4Remove shims (6) and cylinder rolls (7) from planet gear.
5Drive dowels (1) from planet pin. Repeat steps 1) to 5) for remaining planet gears.
6Remove thrust washer (8) from planet carrier.
7Remove snap-rings (9 and 10) and lift off with cover (11).
8Remove axial ball bearing (13) and 4 plate springs (12).
16 S 251Range-change /
1Insert 4 plate spring (11) and axial ball bearing (10) into planet carrier.
NOTE
For teh arrangement of the 4 plate springs (11) see Fig. 012317.
2Insert cover (12) and snap-rings (13 and 14)
NOTE For propper installation of the snap-ring (13) see Fig. 012318.
3Add thrust washer (15).
NOTE
Always exchange planet gears as complete sets.
4Coat faces of planet gears and cylinder roller raceways with oil.
5Stand planet gear pin (1) so that collar faces downwards.
6Slide intermediate disk (2) onto planetary gear pin.
8Insert 14 cylindrical rollers (5) in planet gear and slide bush (3) onto planetary gear pin.
9Coat inside of the planet gear with oil and insert remaining 14 cylinders.
10Coat cylinder rolls with oil and fit shim (2a).
11Stand planet carrier (6) on shaft section.
12Carefully remove planet gear and thrust washers from planet pin and slide into planet carrier.
13Align planet gear with bearing bore (7).
NOTE
Ensure “0” face of planet pin faces towards outside radius of planet carrier. (Oil bore must face towards the inner radius of planet carrier).
14Radially align planet pin and insert into bearing bore.
15Using plastic hammer, drive in planet pin. Check for alignment with dowel bore.
16Drive new dowel (8) halfway into hole. Drive 2nd (new) dowel (9) into 1st with slot offset 180°. Drive both dowels approx. 0.5 mm into planet carrier (refer to Assembly Specification).
17Check end float on planet gears (0.4 to 1.3 mm). Repeat steps 4) to 17) for remaining planet gears.
2Servoshift
2.1Non-integrated version
Removal
1Remove cable connector (16) and union screws (6,7,9,11 and 15).
NOTE
Mark the installation point of the Tecalan pipes.
2Remove Tecalan pipes (5,8 and 10)
3Remove retaining nuts (2,12 and 13)
4Lift off shift cylinder (1) and valve (14).
NOTE
If the reaction linkage is fitted on the valve (14), it should not be dismantled as it is adjusted to suit the vehicle.
3Fix pipe (3) together with new sealing rings to shift turret using a hollow screw (1) Tightening torque = 20 Nm.
4Fix pipe together with new sealing rings to pneumatic servo-unit using a hollow screw (2). Tightening torque = 20 Nm.
16 S 251Shift mechanism
3Shift mechanism
3.1Double “H” shift pattern Removing and dismantling shift housing
1Loosen hex bolts (1) and remove shift turret together with gasket (2).
2Loosen shift lever (3) (depending on parts list) and remove together with protective cap.
3Remove detent plunger (4) and screw plug or switch (5).
4Take out cutoff valve (6) and remove together with O-ring (7)
NOTE
Cutoff valve is a complete component and is not dismantled.
5Remove screw plug (9) together with seal ring, spring (10) and bolt (11)
6Remove screw plugs (12 and 13) together with seal rings and springs.
7Remove switch (14) together with seal ring.
8Loosen housing (15) and remove together with gasket.
9Remove detent plate (16) and detent (17) from housing.
10Unscrew hex bolts from shift cover (18) and remove together with gasket.
11Drive out shaft seal (19), bearing bush (20), shaft seal (21) and wiper (22) from shift cover.
12Detach split ring (23) and remove detent (24) from housing together with O-ring.
13Drive out dowels (25) from driver.
14Remove selector shaft (26), driver (27) and locking piece (28).
15Remove needle sleeve (29) from housing.
16Detach split ring (30) and remove washer (31), spring (32) and washer (33).
Shift mechanism16 S 251
Assembling shift housing
1Drive new needle sleeve (1) into shift housing (2) using special tool 1X56 119 916. Hit onto the side of the needle sleeve with the thicker surround.
2Insert driver (3) and locking piece (4) into shift housing.
3Insert selector shaft (5)
NOTE
Engagement groove for detent and detent plate must face towards transmission.
4One after the other, drive dowel pins (6) through driver (3) and into selector shaft (observe Assembly Specifications).
5Insert washer (7), spring (8), washer (9) and split ring (10) according to selector pattern.
6Drive shaft seal (11) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift housing.
7Drive new bearing bush (12) into shift cover using special tool 1X56 119 916.
8Drive shaft seal (13) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift lever.
9Drive wiper (14) into shift cover using special tool 1X56 119 916. Sealing lip must face outwards.
NOTE
Lightly coat the outside of shaft seal and wiper with sealing compound. Fill gap between shaft seal and wiper with grease.
10Slide shift cover (15) over selector shaft together with new gasket and mount using bolts (16). Tightening torque = 23 Nm.
11Insert detent (17) together with new O-ring and attach split ring (18).
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16 S 251Shift mechanism
12Insert detent (19), spring (20) and screw plug (21) together with new seal ring and tighten. Tightening torque = 60 Nm.
13Insert cutoff valve (22) into shift housing together with new O-ring, ensuring it is positioned the correct way round, and fix using hex bolts. Tightening torque = 23 Nm.
14Screw detent plunger (27) into housing together with new seal ring.
15Insert greased pin (28) into bore. Close off using switch or screw plug (29) and new seal ring. Tightening torque = 35 Nm.
16Insert detent (30) and detent plate (31) into housing, ensuring they are positioned the correct way round.
17Fit new gasket (32)
18Slide shift housing over detent plate and detent together with selector shaft.
NOTE
Center housing and shift housing.
19Insert hex bolts (33) and tighten by hand.
NOTE
Check selector shaft for ease of movement by pushing against the spring force.
20Insert springs, screw plugs (24 and 25) into housing together with seal ring and tighten. Tightening torque = 50 Nm.
22Slide protective cap (39) onto selector shaft and position shift lever (40) on selector shaft (position depends on version). Tightening torque for hex bolt and hex nut on shift lever = 49 Nm. Ensure protective cap has no play when seated on selector shaft (according to parts list).
23Screw on switch (41) together with new seal ring and tighten.
Tightening torque = 50 Nm.
3.2Superimposed “H” shift pattern
Removing and dismantling shift housing
1Loosen hex bolts (1) and remove shift turret together with gasket (2).
2Loosen shift lever (3) (depending on parts list) and remove together with protective cap.
3Remove detent plunger (4) and screw plug or switch (5).
4Take out cutoff valve and remove together with O-ring (7).
NOTE
Cutoff valve is a complete component.
5Remove screw plug (9) together with seal ring, spring (10) and bolt (11).
6Remove screw plugs (12 and 13) together with seal rings.
7Unscrew cover (14) together with piston and remove together with gasket.
8Loosen housing (15) and remove together with gasket.
9Remove detent plate (16) and detent (17) from housing.
10Unscrew hex bolts from shift cover (18) and remove together with gasket.
11Drive out shaft seal (19), bearing bush (20), shaft seal (21) and wiper (22) from shift cover.
12Detach split ring (23) and remove detent (24) from housing together with O-ring.
13Drive out dowels (25) from driver.
14Remove selector shaft (26), driver (27) and locking piece (28).
15Remove needle sleeve (29) from housing.
16Detach split ring (30) and remove disc (31), spring (32) and disc (33) from selector shaft.
16 S 251Shift
17Detach snapring (34) from cover. Remove piston (35) together with O-rings (36)
Assembling shift housing
1Drive new needle sleeve (1) into shift housing (2) using special tool 1X56 119 916. Hit onto the side of the needle sleeve with the thicker surround.
2Insert driver (3) and locking piece (4) into shift housing.
3Insert selector shaft (5).
NOTE
Engagement groove for detent and detent plate must face towards transmission
4One after the other, drive dowel pins (6) through driver (3) and into selector shaft (observe assembly specifications).
5Insert disc (7), spring (8), disc (9) and split ring (10) according to selector pattern.
6Drive shaft seal (11) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift housing.
7Drive new bearing bush (12) into shift cover using special tool 1X56 119 916.
8Drive shaft seal (13) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift lever.
9Drive wiper (14) into shift cover using special tool 1X56 119 916. Sealing lip must face outwards.
NOTE
Lightly coat the outside of shaft seal and wiper with sealing compound. Fill gap between shaft seal and wiper with grease.
10Slide shift cover (15) over selector shaft together with new gasket and mount using bolts (16). Tightening torque = 23 Nm.
11Insert detent (17) together with new O-ring and attach split ring (18).
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