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Subject to technical change without notice
Copyright by ZF
Reproduction in whole or in par t per mitted only with our prior written approval
Printed in Ger many
Edition: 03.98
1315 751 101d
16 S 151 / 8 S 151
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 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 Service Training Center
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 in 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.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen Division Service
General Information
Description of transmission
16 S 151 / 8 S 151
The ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmissions have been developed for heavy goods vehicle applications (from 220 to 370 kW).
16 S 151 and 8 S 151 transmissions main components:
- 4-speed section with reverse gear
- rear-mounted range-change of planetar y design
- front-mounted integ rated splitter g roup (not in 8 S 151)
ZF Friedrichshafen AG offers the following options with these transmissions:
- NMV 221, engine-dependent PTO
- torque conver ter clutch (WSK)
- fur ther engine-driven ZF PTO (NMV) together with the torque conver ter clutch
- various clutch-dependent ZF PTOs
- drive for emergency / dual-circuit steering pumps
- separate heat exchanger for extreme applications
- ZF Intarder
- ZF ES 2 shift system
- silent kit
Repair manual
NOTE: If clamping f ixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover before attaching the clamping f ixture.
When reassembling the transmission, inser t the reverse gear wheel before f itting the shaft set.
Then install the reverse idler gear pin.
CAUTION
The transmission must not be suspended by the input shaft nor by the output flange when transporting, removing, installing and repairing.
ENVIRONMENTAL HAZARD !
Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system.
• Request safety information for the products concerned from your local environmental protection authority, and follow any instructions herein at all times.
• Always collect used oil in a suitably large container.
• Always dispose of used oil, clogged f ilters, lubricants and cleaning agents in accordance with environmental protection laws.
• Always observe manufacturer instructions when dealing with lubricants and cleaning agents.
NOTE: Additional removal and installation instructions 1315 754 007 are available for transmissions with silent kit.
S 151 / 8 S 151
General
General Information
This repair manual shows how to repair a ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmission.
Layout of repair manual:
Section 1 includes adjustment data, tightening torques, spring characteristics and a list of specif ied ZF special tools.
Section 2 is a step-by-step guide to transmission repairs.
Directions for removal and assembly, general work instructions
This repair manual is based on the steps necessar y for the complete removal of transmission components and their subsequent reassembly. When circumstances require, the assembly procedure for cer tain components is described immediately after the removal procedure. Such cases include the section on the “mainshaft and layshaft’’, in which assembly instr uctions are given after removal instr uctions so as to ensure that only fully repaired components proceed to the complete assembly phase. This procedure reduces the risk of mixing up individual components and shor tens the overall assembly phase.
Always ensure cleanliness and appropriate high standard of work; therefore, clean all transmissions removed from vehicles before dismantling.
Specif ied ZF special tools must be used.
After dismantling, clean all transmission components. Par ticular attention should be paid to cor ners, recesses and protr uding edges on housings and covers.
Carefully remove old sealing compound and gaskets. Check for blocked of lubrication oil bores, g rooves and pipes. There must be no build-up of deposits, foreign matter or preser vatives. This is especially impor tant in the case of new components.
It is impossible to avoid damaging some components during dismantling; these must always be renewed ; e.g.shaft seals, O-rings, g rooved rings, flange packing, protective caps etc. Components such as roller bearings, thr ust washers, synchronizer par ts, etc., which are subject to nor mal wear during operation, must be checked by a specialist to deter mine whether they can be reused
Gaskets must be f itted dr y, i.e. free from oil and g rease. Sealing faces without gaskets must be sealed using a plastic-type, heat- oil-resistant sealing compound (e.g. WEVO-L 100 A).
During assembly, obser ve all adjustment values, test data and tightening torques.
Fill the transmission with transmission oil after repair. Procedure for this and per mitted oil types are given in the Operating Manual and List of Lubricants TE-ML 02. These documents may be obtained from all ZF After-Sales Ser vice points.
After f illing with oil, tighten oil check plugs and oil drain plugs to specif ied torque.
Important work 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 car r y out repairs on these ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that repair staff is properly trained.
The following safety instructions appear in this manual:
NOTE
CAUTION
DANGER
NOTE
Refers to special processes, techniques, data, use of auxiliar y equipment, etc.
This is used when incorrect, unprofessional working practices could damage the product.
This is used when lack of care could lead to serious injury or death.
Read this manual carefully before star ting any tests or repair work.
After completion of repair work and testing, skilled mechanics must satisfy themselves that the product is functioning cor rectly.
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.
16 S 151 / 8 S 151
Tightening torques for bolts and nuts from ZFN 148
Tightening Torques
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. Coating ZFB 811 Dacromet or coating ZFB 998 Deltatone - Deltaseal.
Surface condition of bolts: heat-treated blackened f inish and oiled or galvanized and oiled or galvanized, chromeplated and oiled.
NOTE: Tightening torques which differ from the values below are separately listed in the repair instr uctions.
Edition: August 1991 Metric coarse pitch thread Metric f ine pitch thread
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16 S 151 / 8 S 151
Description
01. Axial play on layshaft
0.0 - 0.10 mm
Depth gauge or dial gauge
Adjustment Data
Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on output end.
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
0.0 - 0.10 mm - 0.05 to + 0.05 mm 12.5 + 1.0 mm
Depth gauge or dial gauge
Micrometer or feeler gauge
Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on input shaft.
Always use correct tool.
Depth gauge and/or drift 1X56 137 124
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
0 - 0.10 mm Min. 0.20 mm Min. 0.20 mm
Min. 0.05 mm
0 - 0.05 mm
0.4 - 1.15 mm
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
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.
Adjustment Data
Description
11. Permitted axial play on planet gears in planet carrier
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. Adjustment dimension for splitter shift fork
to 1.30 mm
Feeler gauge
Feeler gauge
Tolerance includes permitted wear on thrust washers. If wear limit exceeded exchange thrust washers
Exchange synchronizer ring and/or clutch body if dimension too small
Feeler gauge
Exchange intermediate ring and/or outer ring and inner ring if wear limit is excluded.
Feeler gauge
Depth gauge
16. Adjusting mainshaft and determining thickness of shim and ring (in straightcut version)
Depth gauge
Exchange if play is excessive
Nominal dimension between piston and mid-housing sealing face without gasket. Fulcrum pads must have play of min. 0.10 mm upwards and downwards. Tightening torque for grub screw: 60Nm
Measured between upper edge of clutch body with ring inserted and midhousing with gasket attached. Select appropriate ring to ensure nominal dimension (see table)
Description Tolerance
Selection of ring and shim
17. Adjusting mainshaft and determining thickness of ring and shim (in helicalcut version)
18. Temperature for shrinkfitting helical gears onto layshaft
19. Tightening torque for breather
20. Tightening torque for M12 x 1.5 screws in housing
21. Tightening torque of union screws for plastic pipes
22. Tightening torque for detent plungers
23. Tightening torque for pressure switch/impulse sensor
24. Tightening torque of M12 bolts for output flange
25. Tightening torque for shift fork grub screws + 0.07 to - 0.08 mm (Shim) 4.6-0.4 mm (Ring)
Measuring device
Sliding caliper
Remarks
Depth gauge
-
Temperature probe
Table shows which shim is correct for which ring
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
Torque wrench
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Torque wrench
Torque wrench
Use new seal rings
Use new seal rings
Torque wrench
Torque wrench
Fit new retaining plate. Use Loctite No. 262.
Adjustment Data
Description Tolerance
26. Tightening torque for M38 x 1.5 magnetic screw
27. Tightening torque for locking bolts on reverse idler pin
New version with slotted pin
28. Tightening torque for locking nuts on rangechange and splitter pistons
29. Tightening torque for hex bolts between clutch housing and mid-housing
30. Tightening torque for M18 x 1.5 screw plugs on housing
31. Tightening torque for M22 x 1.5 screw plugs on housing
32. Tightening torque for M24 x 1.5 screw plugs on housing
33. Heating temperature for ring gear
34. Temperature of synchronizer hub, clutch body, bushes and counting disc
35. Temperature of output flange
36. Temperature of input shaft roller bearing
Measuring
Torque wrench
16 S 151 / 8 S 151
Remarks
Clean magnet and fit new seal ring
Torque wrench
Use new bolt and washer.
Torque wrench
Use new locking nut
Torque wrench
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
Temperature probe
Temperature probe
Temperature probe
Temperature probe
Do not exceed temperature
Do not exceed temperature
Do not exceed temperature
Do not exceed temperature
16 S 151 / 8 S 151
Description Tolerance
37. Temperature of 4th-speed helical gear with needle cages on mainshaft
38. Rolling-in torque for injection pipe
39. Lifting device for input shaft/ mainshaft/ layshaft
40. Tightening torque for pivot bolts on shift fork
41. Tightening torque for M8 hex bolts on shift cover
42. Tightening torque for M10 hex bolts on shift lever
43. Tightening torque for M8 hex bolts on shift housing cover (with detent piece)
44. Tightening torque for M8 hex bolts on cutoff valve
45. Tightening torque for M26 x 1.5 screw plugs on housing
46. Tightening torque for M48 x 1.5 screw plugs on housing
Temperature probe
Remarks
Do not exceed temperature
Torque wrench
Torque wrench
Torque wrench
Rolling-in tool 1X56 155 653
DANGER
Fit lifting device carefully
Use Loctite No. 241
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Use new seal rings
Torque wrench
Use new seal rings
SpecialTools16S151/8S151
16S151/8S151SpecialT
16 S 151 / 8 S 151Removing
1.Removing components/range-change
1.1Plastic pipes
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).
1.2Output flange
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).
1.3Cover
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), shim (6) and ball bearing (7).
3Using plastic drift, drive out ball bearing from cover. and remove loose shim.
NOTE: For helical gear version, use extractor 1X56 122 314 to remove ball bearing from output shaft.
4Using plastic drift, drive out shaft seal from cover.
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1.4 5/2-way valve
1 Unscrew 5/2-way valve (1) from centre housing.
2 Remove O-rings (2).
NOTE: Do not dismantle 5/2-way valve since it is a complete par t.
NOTE: 5/2-way valve is not included in 8 S 151 transmission.
1.5 Shift cylinder for range-change
1 Unscrew hex bolts, loosen cylinder (1) from range-change housing and remove from piston (2).
2 Remove O-rings (3 and 4) from cylinder.
3 Remove detent plunger (5). Screw f ixing device 1X56 137 579 into threaded bore and position f ixing element on shift rail (6). Tighten f ixing device.
Tightening torque = 50 Nm.
4 Unscrew locking nut (7) from piston (2).
5 Remove piston together with guide ring (8) and g rooved ring (9).
6 Remove g rooved ring (9) and seal ring (11, new version only) .
7 Remove guide ring and g rooved rings from piston.
8 Pull out flange packing (10) from range-change housing.
1.6 Housing/range-change
1 Remove mechanical speedometer or impulse sensor (15).
2 Remove pivot bolts (1) for shift fork (2).
3 Remove f ixing device 1X56 137 579.
4 Unscrew hex bolts from range-change housing (3).
DANGER Planet gear train is not secured on mainshaft. Secure this to prevent from falling.
5 Separate range-change housing (3) from centre housing (5) without tilting and remove. Use pins to ensure cor rect position (4).
6 Remove shift fork (2) together with fulcr um pads (6).
7 Remove inter mediate plate (7) together with gaskets (8).
8 Remove switch (9) together with seal ring and pin (10). New version (13 and 14) also possible.
9 Pull out shift rail (11) from centre housing.
10 Remove injection pipe (12).
1.7 Planet gear train with synchronizer
NOTE: Prevent planet gear train from falling out when removing.
1 Remove complete planet gear train from mainshaft together with synchronizer
1.7.1 Synchronizer
DANGER
Pressure pieces are under spring pressure . Secure them to prevent them flying out.
1 Place adapter onto planet car rier. Attach two-or three-leg puller under neath sliding sleeve (1) and pull off together with clutch body (2). Use a cloth to catch pressure pieces (4) and pressure springs (5) held by the sliding sleeve.
NOTE: In the straight-cut version, pull off speedo wor m or counting disc (3) with integ rated bush together with clutch body (2).
NOTE: Par ts marked * according to par ts list.
2 Remove synchronizer ring (6).
3 Remove circlip (7).
4 Place adapter onto planet car rier and pull off synchronizer hub (8) using 2- or 3-leg puller.
5 Remove synchronizer ring (9) and clutch body (10) from planet car rier (11).
16 S 151 / 8 S 151
1.7.2 Ring gear
1 Attach circlip (7) from Section 1.7.1 onto ring gear car rier. Place adapter onto planet car rier and f it using 2- or 3-leg puller under neath circlip.
Straight-cut version:
2 Pull off ring gear (1), ring gear car rier (2) and ball bearing (5) together.
3 Detach safety wire (4) from annular g roove in ring gear
4 Using plastic hammer, drive out ring gear car rier (2) from ring gear (1).
5 Detach snapring (3) from ring gear car rier and remove ball ball bearing (5).
6 Remove inter mediate ring (6) from planet car rier
Helical-cut version:
2 Pull off ring gear (1), ring gear car rier (2), inter mediate ring (3) and axial needle bearing (5) together
3 Detach safety wire (4) from annular g roove in ring gear
1.7.3 Planet carrier
1 Drive dowels (1) fully into planet pin (2).
2 Using plastic drift, drive out planet gear pin from planet car rier (3) towards “input’’.
3 Remove planet gear (4) from planet car rier together with thr ust washers (5).
NOTE: Thr ust washers (5) in straight-cut version only
4 Remove shims (6) and cylinder rollers (7) from planet gear
5 Drive out dowels (1) from planet pin.
Repeat steps 1) to 5) for remaining planet gears.
Removing Planet Carrier
Assembling Planet Carrier
1.8 Assembling planet gear train with rangechange synchronizer
1.8.1 Planet carrier
NOTE: Always exchange planet gears as complete sets.
1 Coat faces of planet gears and cylinder roller raceways with operating oil.
2 Stand planet gear pin (1) so that collar faces downwards.
3 Slide thr ust washer (2) over planet pin. Ensure coated side (bright side) faces towards planet gear
NOTE: Thr ust washers (2) in straight-cut version only.
4 Slide shim (3) over planet gear pin (either way up).
5 Place planet gear (4) onto planet pin (1) and align centrically
6 Inser t 14 cylinder rollers (5) into planet gear and slide shim (6) over planet pin.
7 Coat inside of the planet gear with operating oil and inser t remaining 14 cylinder rollers.
8 Coat cylinder rollers with operating oil and f it shim.
9 Fit thr ust washer on planet gear. Ensure coated side faces towards planet gear
10 Stand planet car rier (7) on on shaft section.
11 Carefully remove planet gear and thr ust washers from planet pin and slide into planet car rier
12 Align planet gear with bearing bore (8).
NOTE: Ensure “0” face of planet pin faces towards outside radius of planet car rier. (Oil bore must face towards the inner radius of planet car rier).
13 Radially align planet pin and inser t into bearing bore.
14 Using plastic hammer, drive in planet pin. Check for alignment with dowel bore
16 S 151 / 8 S 151
16 S 151 / 8 S 151
15 Drive new dowel (9) halfway into hole. Drive 2nd (new) dowel (10) into 1st dowel with slot offset 180°. Drive both dowels approx. 0.5 mm into planet car rier (refer to Assembly Specif ication) .
16 Check axial play on planet gears (0.4 to 1.3 mm).
Repeat steps 1) to 16) for remaining planet gears.
1.8.2 Ring gear
1 Place inter mediate ring (2) onto planet car rier (1). Ensure oil g rooves face towards output end (only in straight-cut version).
2 Drive ring gear car rier (3) flush into ring gear (4).
3 Inser t safety wire (5) into annular g roove in ring gear. Ensure entire safety wire is f ir mly seated.
Straight-cut version:
4 Inser t ball bearing (6) into ring gear car rier and attach snapring (7). Select snapring so as to ensure ball bearing axial play of 0.0 to 0.1 mm. Snaprings are available in 0.1 mm thicknesses (0.1, 0.2, 0.3 etc.).
Helical-cut version:
4 Slide inter mediate ring (7) and axial needle bearing (6) onto planet car rier.
DANGER
Always wear protective gloves when handling heated ring gear.
5 Heat complete ring gear to 60° C and place onto planet car rier. Rotate ring gear to bring teeth into mesh. Ensure bearing (6) is f ir mly seated.
Assembling Planet Carrier
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