10 AS 2301
12 AS 2301,16 AS 2601 Repair
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Subjects to alterations in design
Copyright by ZF
This document is protected by copyright. Any reproduction and dissemination in whatever form – even in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as 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
ZF Friedrichshafen AG, MKS-K / 2002-01
Edition: 2002-01
ZF FRIEDRICHSHAFEN AG
Commercial Vehicles/Special Transmissions Division
Service plant 2
Tel.: +49 75 41 77-0
Fax: +49 75 41 77-5726
Internet: www.zf.com
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 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.
Warranty:
Repair work carried out at ZF service points is covered by warranty 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 warranty agreement. This also applies where genuine ZF spares have not be used.
SAFETY NOTICE
Companies who repair ZF units are responsible for their own work safety.
To avoid injury to personnel and damage to products, compliance must be maintained with all safety regulations and legal requirements which apply to repair and maintenance work. 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 all companies to ensure that their repair staff are 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.
•Collector used oil in 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
Transmission must NOT be hung on the input shaft NOR on the output flange.
In any cases of doubt,always contact the relevant department within ZF After-Sales Services. Whenever working on the transmission,ensure complete cleanliness and professional work. When dismantling and assembling the transmission, use the tools intended for this purpose.
After removing the transmission, clean thoroughly with an appropriate cleaning agent 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 remains of gaskets from all sealing faces. Carefully remove burrs or other similar patches of roughness using an oil stone.
Lube holes 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 roller bearings, multi-discs, thrust washers etc. must be inspected by a competent person who should decide whether or not they can be reused. Replace parts which are damaged or have suffered from excessive wear.
GASKETS,LOCKING PLATES
Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gasket and locking plates).
SHAFT SEALS
Always change shaft seals with rough, torn or hardened sealing lips. Sealing contact surfaces must be totally clean and in perfect condition.
REWORK
Rework may only be carried out on the sealing contact surfaces using plunge-cut grinding, never use an emery cloth. Ensure that there are no signs of grinding traces or rifling from grinding.
If rework is needed on spacer washers or 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 given in the Repair Manual.
BEARINGS
If the bearings are pulled on while hot, they should be heated up evenly (e.g. in heating cabinet). The temperature should be approx. 85 °C and must 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 agent to enter oil ducts and bores. When working with 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 thin 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 surrounds as described above in section (b).
d)Duo shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.
e)Fill the gap between the sealing lips so that it is 60% filled with grease* (use 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 in the shaft seal with special tool or face plate level to the relevant installation depth.
RETAINING AGENTS
Retaining agents* may only be used in places specified in the parts list. Always comply with the manufacturer’s directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data and tightening torques specified.
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 plates) which are available from any ZF After-Sales Service Point and on the Internet at www.zf.com. 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 consumables X
IndexEdition dateSectionRequested byComments
Tightening torques for nuts and bolts,extract from ZFN 148
This standard applies to bolts as specified in DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014,ISO 4017, ISO 8765, ISO 8676, and for nuts as specified in DIN 934 as well as ISO 4032, ISO 8673.
This standard contains data on tightening torques (MA) for bolts and nuts of strength categories 8.8, 10.9 and 12.9, as well as nuts of stength categories 8, 10 and 12.
Surface condition of bolts/nuts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.
Bolts are tightened using an appropriate snap torque wrench or tightening torque wrench.
NOTE
Deviating tightening torques are listed separately in the Repair Manual. Edition: August
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Screw plugs DIN 908,910 and 7604
The tightening torques MA were determined using screw plugs as defined in 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 fitter.
The values for tightening torque MA shall also be used for screw plugs in acc. with 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 as defined in DIN 7604 Surface condition: as manufactured (without surface protection) and lighly oiled or galvanized, chrome-plated and lightly oiled.
Screw plugs (DIN 908, 910, 7604)
SizeTightening torque in Nm screwed into steel/grey castAl alloy
M8x120*10*
M10x 125 / 30*15 / 20*
M12x1.535 25
M14x1.53525
M16x1.54030
M18x1.55035
M20x1.555 45
M22x1.560 / 80*50 / 65*
M24x1.57060
M26x1.580 / 105*70 / 90*
M27x28070
M30x1.5100 / 130*90 / 130*
M30x29585
M33x2120110
M36x1.5130115
M38x1.5140120
M42x1.5150130
M42x2145125
M45x1.5160140
M45x2150130
M48x1.5170145
M48x2160135
M52x1.5180150
M60x2195165
M64x2205175
Union screws DIN 7643
The tightening torques MA were determined for screwing into steel, grey cast and aluminium alloys. Values are based on experience and are intended as reference values for the fitter.
General rule: Screw/bolt class 5, ZFN 148-1
Material: 9SMnPb28K as defined in DIN 1651
Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chrome-plated and lightly oiled.
Union screws (DIN 7643)
PipeThreadTightening outertorque diameterin Nm
4 - 5M8x120 - 25 6M10x125 - 35
8M12x1.530 - 40
10M14x1.535 - 40
12M16x1.545
15M18x1.550
18M22x1.560
22M26x1.590
28M30x1.5130
35M38x1.5140
Edition: October 1995
WithdrawnTitleSubstituteResult of check/measures 1)
DINISO standard
DIN 1Tapered pins ISO 2339- some can be replaced → changed to ISO 2339 - parts which cannot be replaced (e.g. where 1 = 36 mm) documented as DIN 1 OLD
DIN 7CylindricalISO 2338- some can be replaced → changed to ISO 2338 pins- parts which cannot be replaced (e.g. diameter 13 and 14 and/or where 1 = 36mm) documented as DIN 7 OLD
DIN 84Cylindrical ISO 1207- some can be replaced → changed to ISO 1207 screws- parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD
DIN 85Flat head boltsISO 1580- can be replaced → changed to ISO 1580
DIN 94 Split pinsISO 1234- can be replaced → changed to ISO 1234
DIN 417Threaded pinsISO 7435- can be replaced → changed to ISO 7435
DIN 439-1Hex nutsISO 4036- cannot be replaced → documented as DIN 439 OLD
DIN 439-2Hex nutsISO 4035 ISO 8675
DIN 551 Threaded pinsISO 4766- can be replaced → changed to ISO 4766
DIN 553 Threaded pinsISO 7434- can be replaced → changed to ISO 7434
DIN 555Hex nutsISO 4034- cannot be replaced → documented as DIN 555 OLD
DIN 558Hex boltsISO 4018- some can be replaced → changed to ISO 4018 - parts which cannot be replaced(e.g.M12,with newSW)documented as DIN 558 OLD
DIN 601Hex boltsISO 4016- some can be replaced → changed to ISO 4016 - parts which cannot be replaced (e.g. M10 and M12, with new SW) documented as DIN 601 OLD
DIN 912Cylindrical ISO 4762- some can be replaced → changed to ISO 4762 screws- parts which cannot be replaced (e.g. M18, M22, M27 and M33) documented as DIN 912 OLD
DIN 931-1Hex boltsISO 4014- some can be replaced → changed to ISO 4014 - parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new SW) documented as DIN 931 OLD
DIN 933Hex boltsISO 4017- some can be replaced → changed to ISO 4017 - parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new SW) documented as DIN 933 OLD
DIN 934Hex nutsISO 4032- cannot be replaced replaced as a result of uneven nut height and for ISO 8673 - M10, M12, M14 and M22 with new SW.
DIN 960Hex boltsISO 8765- some can be replaced → changed to ISO8765 - parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new SW) documented as DIN 960 OLD
DIN 961Hex boltsISO 8676- some can be replaced → changed to ISO 8676 - parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new SW) documented as DIN 961 OLD
DIN 963CountersunkISO 2009- cannot be replaced as a result of modified head dimensions → documented bolts - as DIN 963 OLD
DIN 964Countersunk ISO 2010- cannot be replaced as a result of modified head dimensions → documented bolts - as DIN 964 OLD
1) refers to the productive components numbered at ZF
WithdrawnTitleSubstituteResult of check/measures 1)
DINISO standard
DIN 965Countersunk ISO7046- cannot be replaced as a result of modified head dimensions → documented bolts - as DIN 965 OLD
DIN 980Locking nutsISO 7042- cannot be replaced → documented as DIN 980 OLD ISO 10513
DIN 985Locking nutsISO 10511- cannot be replaced → documented as DIN 985 OLD
DIN 1440WashersISO 8738- some can be replaced → changed to ISO 8738 - parts which cannot be replaced documented as DIN 1440 OLD
DIN 1443BoltsISO 2340- can be replaced → changed to ISO 2340
DIN 1444BoltsISO 2341- can be replaced → changed to ISO 2340
DIN 1471Grooved pinsISO 8744- some can be replaced → changed to ISO 8744 - parts which cannot be replaced (e.g. 1=6 mm) documented as DIN 1471 OLD
DIN 1472Grooved pinsISO 8745- some can be replaced changed to ISO 8745 - parts which cannot be replaced (e.g. 1=6 and 25 mm) documented as DIN 1472 OLD
DIN 1473Grooved pinsISO 8740- some can be replaced → changed to ISO 8740 - parts which cannot be replaced (e.g. 1=4, 5, 6, 25 and 50 mm) documented as DIN 1473 OLD
DIN 1474Grooved pinsISO 8741- can be replaced → changed to ISO 8741
DIN 1475Grooved pinsISO 8742- can be replaced → changed to ISO 8742
DIN 1476Grooved studISO 8746- can be replaced → changed to ISO 8746
DIN 1477Grooved studISO 8747- can be replaced → changed to ISO 8747
DIN 1481Clamping pinsISO 8752- some can be replaced → changed to ISO 8752 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD
DIN 6325CylindricalpinsISO 8734- some can be replaced → changed to ISO 8734 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD
DIN 7346Clamping pinsISO 13337- some can be replaced → changed to ISO 13337 Flange- parts which cannot be replaced (∅ 7, 11 and 23 mm) documented as DIN 6325 OLD
DIN 7976 Self-tappingISO 1479- can be replaced → changed to ISO 1479 screws
DIN 7978Tapered pinsISO 8736- some can be replaced → changed to ISO 8736 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD
DIN 7979CylindricalpinsISO 8733- some can be replaced → changed to ISO 8733/8735 ISO 8735- parts which cannot be replaced documented as DIN 7979 OLD
DIN 7981 Self-tappingISO 7049- can be replaced → changed to ISO 1479 screws
DIN 7982 Self-tappingISO 7050- cannot be replaced → documented as DIN 7982 OLD screws
DIN 7985Cheese-headISO 7045- can be replaced → changed to ISO 7045 screws 1) refers to the productive components numbered at ZF
DescriptionNameApprox.ApplicationComments ZF reference no.quantity
Greasefor example
0750 199 019Spectron FO 201 gShaft seal (02.510)
1 gShaft (02.560)
2 gShaft seal (31.080)
GreaseOlista Longtime 3EP5 gShaft seals (68.060/140)
0671 190 050
5 gLocating face release fork (68.060) / bearing (68.050)
Sealing compound1215 grey3 gHousing I / housing II sealing face 0666 790 054
Sealing compoundNo. 574
Sealing surface 0666 790 0331 gRelease flange / connection plate
3 gConnection plate / housing I
0.5 gCover (31.050)
0.5 gSealing cover (32.010/050)
1 gRange-change housing / housing II
Jointing compoundNo. 2410.5 gHex bolt (02.670) 0666 690 017
Jointing compoundNo. 2620.5 gBall pin (06.080) 0666 690 022
Anti-corrosion
protection oilfor example 0750 199 008MZK 1501 mlRotor (02.550)
Transmission oilrefer to ZF List ofrefer toTransmission oil fill Lubricants TE-ML 02type plate
NOTE: Inquire about container sizes before placing any orders!
DescriptionDimensionMeasurement deviceComments
Setting end float of countershaft (03.010).
Setting end float of countershaft (03.110).
-0.05 to +0.05 mm -0.05 to +0.05 mm
Depth gauge
Depth gauge
End float of input shaft / connection plate
End float of circlip on input shaft
Output bearing end float
End float of main shaft / sun gear
Screw plug (31.200, 31.190)
Screw plug (31.090)
Hex bolt (32.550)
Hex bolt (31.370)
Impulse sensor (31.230, 31.260)
to 0.10 mm
to 0.10 mm
to 0.10 mm
mm +/-0.1
Depth gauge
Feeler gauge
Depth gauge
Depth gauge
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Move tapered roller bearing into a neutral position (no clearance) and measure. Use shim (03.050) to set clearance.
Move tapered roller bearing into a neutral position (no clearance) and measure. Use shim (03.150) to set clearance.
Use shim (02.100) to set clearance.
Use circlip (02.120) to set clearance.
Use shim (31.030) to set the clearance.
Use shim (32.380) to set clearance.
Fig.DiagramOrder
1X56 137 795
3-section chain for raising the transmission1
Alternatively order no. 1X56 137 391 commercially available
1X56 138 234
M10 lifting lugs for lifting the housing components2
1X56 137 836
Support for moving transmission into vertical position 4
Chapter 7, 9, 12 commercially available
Chapter 9 Alternatively: Adapter 1X56 138 233 in conjunction with transmission swivel stand 1X56 138 450
1X56 136 740
Gripper insert pulling off tapered roller bearing of countershafts (in conjunction with basic tool 1X56 122 304) 1 Chapter 16.1
1X56 122 304
Basic tool in conjunction with tool 1X56 136 740 or 1X56 138 195 1 Chapter 12.1, 16.1 5
NOTE: Please request packaging unit size before placing order.
Fig.DiagramOrder
1X56 122 314 for ball bearings with 10 balls
1X53 188 009 for ball bearings with 11 balls
Extractor for pulling ball bearings (31.020) off planetary carrier 1
Chapter 5.4
Individual extractor arms and hydr. variants on request
1X56 138 087
Extractor inner bearing race (32.310/1) on planetary carrier 1 Chapter 6.1
1X56 138 207
Bracket range-change synchronizer assembly6 Chapter 5.3
1X56 138 208
Retaining bolt for securing R-gear intermediate gear2
Chapter 7
1X56 138 203
Retaining plate for holding and centring main shaft 1 Chapter 7
NOTE: Please request packaging unit size before placing order.
1X56 138 095
Setting fixture for selector rails1 Chapter 8.2
1X56 138 215
Special tool for fitting the bushes and shaft seals of the release fork
10.2
1X56 138 232 (optional)
Adapter transmission swivel stand 1X56 138 450
Alternatively 4 supports 1X56 137 836
1X56 137 450 (optional)
Transmission swivel stand in conjunction with adapter 1X56 138 233
Alternatively 4 supports 1X56 137 836
1X56 138 063
Drift key for driving out dowel pins1 Chapter 5 and 12
NOTE: Please request packaging unit size before placing order.
1X56 138 097
Assembly plate synchronizer (02.200) 1
1X56 138 081
Assembly sleeve synchronizer (02.200)3
Chapter 14.2 To simplify assembly
1X56 138 205
Assembly fixture pipe (04.020) on main shaft1
Chapter 14.2
1X56 138 191 Bush (pressure piece) to protect shaft when pulling off1
Chapter 15.2
Chapter 12.1 commercially available
1X56 138 195
Extraction fixture ball bearing (02.080) on input shaft1 Chapter 12.1
NOTE: Please request packaging unit size before placing order.
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NOTE: Please request packaging unit size before placing
1X56 099 063
tool for shaft seal in release flange
1X56 137 124
Special tool for fitting shaft seal to output cover (in conjunction with spacer ring 1X56 138 189)
4
1X56 138 189
Spacer ring for 105 x 125 x 12 shaft seal on output cover (in conjunction with special tool 1X56 137 124)
211 103 (included in Testman scope of supply)
9141 cable connection
006 002
programming device
NOTE: Please request packaging unit size before placing order.
Chapter 8 PLUG IN cards refer to Fig. no. 35
Fig.DiagramOrder
6008 208 003
Testman set (not including laptop) for WINDOS 95, 98, 2000, for WINDOS NT,ME and XP
6008 308 019 de
6008 207 003
Table mode adapter for diagnosing/programming transmission/transmission actuator once removed
Setting aid for piston rods on transmission actuator
298 029 PLUG INcard for EPD1 programming device When ordering, always specify the program no. given on the parts list
NOTE: Please request packaging unit size before placing order.
Includes:
6008 308 600 DPA 04I
6008 308 601 Cable RS232
0501 211 103
Cable ISO 9141
6008 308 901
Testman diagnosis software
The number of diskettes differs depending on the program no.
1Preparatory work
WARNING
Whenever repairs have been carried out,the transmission must be placed on a test rig and its function and seal integrity tested.
General
This repair manual contains descriptions of how to disassemble and assemble transmissions 10 AS 2301, 12 AS 2301 and 16 AS 2601 without using the transmission swivel stand 1X56 137 450.
1To raise and transport, the 3-section chain 1X56 137 795 is attached to the lugs on the transmission.
2Get oil collecting container ready.
3Remove oil drain plugs and drain oil.
If you are repairing a transmission with an Intarder, you will also need the Intarder repair manual e.g.6085 751 022. This contains descriptions on how to remove and fit the Intarder.
With transmission swivel stand *
1Secure adapter 1X56 138 232 to transmission swivel stand 1X56 137 450.
Secure transmission to adapter 1X56 138 232. * Option
Without transmission swivel stand
1Place two wooden blocks on a piece of flat firm ground.
2Secure 2 M16x1.5 lifting lugs to the range-change housing (see arrow). Attach chain and use a crane to lift the transmission.
CAUTION
Do not use the lug on the range-change housing.One lug is not strong enough for the entire transmission weight:“risk of housing breakage”.
3Place transmission and clutch bell housing on the wooden blocks.
WARNING: Transmission must not be placed on the input shaft.
2Clutch actuator
2.1 Removal
1Disconnect plug connection from transmission actuator and output speed sensor.
2Remove wiring harness from cable terminals (68.300,68.320 and 68.330).
3 Remove 4 M8 hex bolts (68.154) and take off cover (68.150)
4Remove 4 M8 hex nuts and washers (/030)) and take off clutch actuator (68.010).
5 Take complete push rod (68.210) out of the release fork (68.060)
NOTE
For removal and fitting of release fork, refer to Chapter 10.
2.2Fitting
NOTE
Refer to the parts list for the setting dimension (total length) of the adjustable push rod* (68.210)
Tighten hex nut (/130) to 52 Nm.
1Insert push rod (68.210) in recess in release fork (68.060).
2When fitting the clutch actuator (68.010), check connections are in correct position and that push rod (68.210) is seated correctly. If damaged, change M8 stud bolt (/010)
Tightening torque:
M8 hex nuts (/030) = 23 Nm M8 stud bolts (/010)= 10 Nm
* depending on parts list
* depending on parts list
3Secure cover (68.150) with 4 M8 hex bolts (68.154). M8 tightening torque= 23 Nm
Venting clutch actuator
To vent the clutch actuator, unfasten screw (6) M12x1.5.
If the seal on the screw is worn, replace seal. Retighten screw (6) to 22 Nm.
CAUTION
◆ Do not bend the cable and do not tighten hard.
◆ Avoid chafing points.
◆ Fit connector with traction relief and check detent.
4If damaged, replace cable terminals (68.300, 68.320 and 68.330)
5 Press wiring harness into cable terminals.
6Reconnect connector to transmission actuator and output speed sensor.
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3 Output flange
3.1Removal
1Remove two hex bolts (32.550) and take off disc (32.540)
2 Use commercially available three-arm extractor to remove output flange (32.510) and Oring (32.530).
NOTE
Shaft must not be damaged when pulled off, therefore use a pressure piece.
3.2Fitting
1 Heat output flange (32.510) to max. 70 °C and slide on to spline of planetary carrier until firmly home. If working with an Intarder version, ensure that the bolts (32.520) are inserted.
DANGER
Only touch heated output flange when wearing protective gloves.
2Once the output flange has cooled down, press O-ring (32.530) into groove between shaft and output flange.
3Secure disc (32.540) with 2 M12 hex bolts (32.550)
Tightening torqueM12 = 120 Nm
4Output cover
NOTE
Chapter 4 does not apply to transmission versions fitted with Intarders because the components are not used.
4.1Removal
1 Remove 10 M10 hex bolts (31.070) and take off output cover (31.050)
2 Take off shim (31.030)
3 Use appropriate tool to remove shaft seal (31.080), in so doing do not damage output cover.
4Remove 4 M12 hex bolts (31.120) take off cover (31.110) and gasket (31.100)
4.2 Fitting
1 Coat outer edge of shaft seal (31.080) with spirits and use special tool 1X56 137 124 in conjunction with ring 1X56 138 189 to press into the output cover (31.050) until firmly home. Grease sealing lip slightly.
2 Determining thickness “C” of shim
Dimension A: Measure output cover (31.050) between sealing face and bearing seat.
Dimension B: Measure from ball bearing (31.020) to sealing face of range-change housing (31.010)
Sample calculation:A – B = C
Dimension A = 5.4 mm
– dimension B= 5.0 mm
Shim without clearance = 0.4 mm
End float of ball bearing 0 to 0.1 mm
Thickness of shim dimension C = 0.3 to 0.4 mm
3Select appropriate shim (31.030) using spare parts catalogue and prepare for fitting.
4 Coat sealing face of output cover (31.050) with Loctite no.574
NOTE
Sealing faces have to be clean and free of oil and grease.
5 Attach shim (31.030) to output cover (31.050)
6Tighten 10 M10 hex bolts (31.070) to 46 Nm.
NOTE
Only fit cover (31.110) once range-change housing has been fitted and the screw plug (31.090) has been fitted.
7Clean sealing face on range-change housing and on cover (31.110)
8Fit new gasket (31.100) and cover (31.110)
9Tighten 4 M12 hex bolts (31.120) to 79 Nm.
5Removing and fitting range-change housing
5.1Removing range-change housing
Standard transmission in vertical position with output at top (refer to preparatory work).
1Remove hex bolts (34.080), retaining plate (34.070) and king pin (34.050). Take the O-rings (34.060) off the king pin.
2Remove 2 cylindrical pins (31.390) – extraction thread M12 – and 22 hex bolts (31.370)
NOTE
Use drift key 1X56 138 063 to drive out cylindrical pins.
3Secure 2 lifting lugs to the output flange or planetary carrier and attach chain.
4Use a crane to carefully raise the complete rangechange housing.
5Remove spray pipe (31.400)
6Raise selector rails (34.010) slightly and remove tumbler yoke (34.020) and fulcrum pads (34.030).
7Take off cpl. sliding sleeve (33.010) with synchronizer rings (33.030)
CAUTION
Cover sliding sleeve (33.010) with a cloth.
6 bushes (33.050) and 6 compression springs (33.070) will jump out when the synchronizer rings are removed.
8Use 2 prybars to raise plate (32.440) and remove clutch body (32.430).
9Remove sleeve (32.400) with circlip (32.390) and shim (32.380)
5.2Main shaft - planetary carrier clearance setting
1Precondition for measuring the shim. Snap circlip (32.390) into sleeve (32.400) and place on main shaft (04.010)
2Set up a measuring plane.
3 Dimension B1: Measure from measuring plane to circlip (32.390).
4 Dimension B2:Measure from measuring plane to sealing face on housing II (01.400)
5 Dimension B: Determine distance between circlip (32.390) and sealing face on housing II (01.400).
Example: B 2 – B 1 = B 95 mm – 70 mm = 25 mm
Determining dimension B
2 – B 1 = B
Determining dimension A
2 – A 1 = A
6 Dimension A1: Measure from measuring plane to sealing surface on range-change housing (31.010).
7 Dimension A2: Measure from measuring plane to sun gear (32.190)
8 Dimension A: Determine distance between sun gear (32.190) and sealing face on range-change housing (31.010)
Example: A2 – A1 = A 84.3 mm – 55.1 mm = 29.2 mm
9Determine thickness (S) of shim (32.380)
S = (A – B) – clearance
NOTE
A clearance of 2 +/- 0.1 mm is specified for between the sun gear (32.190) and main shaft (04.010).
Example:
S =(A – B) – 2 mm (clearance)
S = (29.2 mm – 25 mm) – 2 mm
S = 4.2 mm– 2 mm
S = 2.2 mm
10Select shim (32.380) using spare parts catalogue and prepare for installation.
5.3Fitting range-change housing
1Place shim (32.380) on main shaft.
NOTE
For how to measure the shim (32.380), refer to Chapter 2.2
2Insert circlip (32.390) in sleeve (32.400). Circlip must make contact with groove base of sleeve.
3Place sleeve (32.400) on main shaft. Circlip (32.390) lies on the shim (32.380).
4Place clutch body (32.430) and plate (32.440) on housing II.
5Insert 3 compression springs (33.070) and 3 bushes (33.050) in both synchronizer rings (33.030) and use bracket (8)1X56 138 207 to secure.
6Insert synchronizer rings (33.030) in sliding sleeve (33.010) and remove bracket (8) 1X56 138 207
7Place cpl. sliding sleeve (33.010) with synchronizer rings (33.030) bushes (33.050) and compression springs (33.070) on clutch body (32.430)
NOTE
The sealing faces on housing II and range-change housing must be clean and free of oil and grease.
8Coat sealing face on housing II with Loctite no. 574
10 AS 2301, 12 AS 2301,16 AS 2601
9Insert spray pipe (31.400)– longer end facing range-change housing.
10 Insert fulcrum pads (34.030) in selector forks (34.020) and position correctly in sliding sleeve (33.010) and selector rail (34.010)
11Screw two commercially available M10 guide pins (1) into housing II (01.400).
12Secure 2 lifting lugs to output flange or planetary carrier and attach chain.
13Attach chain to crane and carefully place rangechange housing (31.010) on housing II. Use an aid (3) (e.g. pin) to guide spray pipe (31.400) into bore of screw plug (31.090) Remove the two M10 guide pins (1)
CAUTION
Professional work is essential when fitting the rangechange housing and driving in the cylindrical pins –risk of housing breakage.
14Tighten M10x1 screw plug (31.090) to 15 Nm.
15Insert two cylindrical pins (31.390). Screw in 22 hex bolts (31.370) and tighten to 50Nm.
16Insert new O-rings (34.060) on king pin (34.050) NOTE
If the king pin (34.050) is inserted too far into the range-change housing, the range-change housing will have to be removed again.
17Use the retaining plate (34.070) to guide the king pin through the range-change housing bore into the selector forks (34.020).
18Secure retaining plate (34.070) with a hex bolt (34.080) and tighten to 23 Nm.
5.4Dismantling range-change housing
1Remove output flange (refer to Chapter 3) and output cover (refer to Chapter 4).
2Remove all screw plugs and impulse sensors from range-change housing.
Use extractor (6)1X56 122 314 for ball bearings with 10 balls or 1X53 188 009 for ball bearings with 11 balls to take ball bearing (31.020) and range-change housing (31.010) off planetary carrier.
3Use a manual press to press ball bearing (31.020) out of range-change housing.
5.5Assembling range-change housing
1Insert ball bearing (31.020) in range-change housing (31.010)
2Heat inner bearing race of ball bearing (31.020) to max. 120 °C and place complete range-change housing on planetary carrier until firmly home.
DANGER
Only touch heated parts when wearing protective gloves.
NOTE
Only fit M10x1 screw plug (31.090) once rangechange housing has been fitted on housing II.
3Replace steel rings on screw plugs.
Tightening torques:
M24x1.5 screw plug (31.200) 60 Nm
Impulse sensor (31.230) 45 Nm
Impulse sensor (31.260) 45 Nm
4Fit output cover (refer to Chapter 4) and output flange (refer to Chapter 3).
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