DOWNLOAD PDF ZF AS Tronic 10 12 & 16-speed versions Repair Manual Level 3

Repair manual

10, 12 and 16-speed versions Repair level 3

1327 751 102a

Subject to technical changes

Copyright by ZF The present documentation is protected by copyright.

Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.

Printed in Germany ZF Friedrichshafen AG, MC-C / 2002-01

Edition: 2004-04

1327 751 102a

ZF-AS Tronic

Contents

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

Safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torques for nuts and bolts, extract from ZFN 148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screw plugs DIN 908, 910 and 7604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Union screws DIN 7643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5 6 6 10 11 11 14 15 16

1

Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

2 2.1 2.2

Clutch actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-2

3 3.1 3.2

Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1

4 4.1 4.2

Output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-1

5 5.1 5.2 5.3 5.4 5.5

Removing and fitting range-change housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing range-change housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main shaft planetary carrier clearance setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting range-change housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling range-change housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling range-change housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-3 5-6 5-9 5-9

6 6.1 6.2 6.3 6.4

Planetary carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling planetary carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial assembly of sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial assembly of planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sub-assembly of planetary carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-1 6-3 6-3 6-4

7

Moving transmission without range-change group (planetary group) into horizontal position . . .

7-1

8 8.1 8.2 8.3 8.4 8.5 8.6

Transmission actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove upper part from bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount upper part to bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exchange pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming transmission actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-1 8-2 8-4 8-4 8-5 8-6

1327 751 102 - 2004-04

3

ZF-AS Tronic 9

Contents

Moving transmission into vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

10 Clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 Removal of release fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 Fitting release fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 11 11.1 11.2 11.3

Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1 11-1 11-2 11-4

12 12.1 12.2 12.3 12.4

Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1 12-1 12-2 12-2 12-3

13 Shaft pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13.1 Removing shaft pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13.2 Fitting shaft pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 14 14.1 14.2 14.3

Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Synchronizer (02.200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

14-1 14-1 14-3 14-5

15 Main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 15.1 Dismantling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 15.2 Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 16 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 16.1 Removing countershafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 16.2 Fitting countershafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 17 Gear shift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 17.1 Dismantling gear shift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 17.2 Assembling gear shift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 18 Housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 18.1 Dismantling housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 18.2 Assembling housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2

1327 751 102 - 2004-04

4

Preface This repair manual is intended for skilled personnel 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 not contained in this manual.

We 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 centers.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually 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 utmost care.

Warranty: Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case.

ZF Friedrichshafen AG Nutzfahrzeug- und Sonder-Antriebstechnik Commercial Vehicle and Special Driveline Technology Service Werk 2 Tel. +49 (0)7541 77-0 Fax +49 (0)7541 77-908000 Internet: www.zf.com

2003-08

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.

5

Important information Safety notice

General information

Companies repairing ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

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.

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.

Conclusions about size and weight should not be drawn (even within a complete illustration).

Always follow the working steps as described in the text.

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.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.

The following safety instructions appear in this manual:

!

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.

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.

CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange.

2003-08

6

Instructions for repairs In case of doubt always turn to the relevant department within ZF After-Sales Services for advice.

All work on transmissions is to be performed expertly and under clean conditions.

Use specified tools to dismantle and assemble transmissions.

Gaskets, locking plates

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening.

Pay particular attention to the projections and recesses of housings and covers when cleaning.

Shaft seals

Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.

Parts joined with Loctite are easier to separate if warmed with a fan heater.

Reworking Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling.

Cleaning parts Remove remains of old gaskets on all seal-faces.

Carefully remove burrs or similar patches of roughness using an oil-stone.

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.

Lube bores and grooves must be free of anticorrosion agents and foreign matter; check for perfect passage.

Carefully cover opened transmissions to prevent foreign matter from entering.

Transmission assembly Find a clean site to assemble the transmission.

Gaskets are installed without the use of sealing compound or grease. When measuring siliconcoated 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.

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.

2003-08

7

Instructions for repairs d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.

Bearings If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet).

Temperature should be at approx. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

X

e) Fill the gap between the sealing lips so it is 60 % filled with 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 (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

Sealing If a specific sealing agent* is to be used for 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 enters the oil feeds when the surfaces are sealed.

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.

Shaft seals a) Apply a light coat of sealing agent* on outer edge of shaft seals with “steel surround”.

Transmission oil 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).

After completing repairs, fill transmissions 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 and on the internet under 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.

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).

* refer to expendable material

2003-08

8

ZF-AS Tronic

Index

Issue date

a

2004-02

1327 751 102 - 2004-04

List of changes: 1327 751 102

Section

Originator

Comment Validity of repair instructions is extended to cover ZF-AS Tronic transmissions with 10, 12 and 16 speeds.

9

Tightening torques Tightening torques for nuts and bolts, extract from ZFN 148 Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.

This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and to nuts acc. to DIN 934 as well as ISO 4032, ISO 8673.

Tighten screws with a calibrated torque spanner or wrench.

This Standard contains data on tightening torques (MA) for bolts and nuts in strength categories 8.8, 10.9 and 12.9, and nuts in strength categories 8, 10 and 12.

NOTE Irregular tightening torques are listed separately in the Repair Manual.

Regular screw thread

Fine screw thread

Size Bolt Nut

Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12

Size Bolt Nut

Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12

M4 M5 M6

2,8 5,5 9,5

4,1 8,1 14

4,8 9,5 16,5

M8x1 M9x1 M10x1

24 36 52

36 53 76

43 62 89

M7 M8 M10

15 23 46

23 34 68

28 40 79

M10x1,25 M12x1,25 M12x1,5

49 87 83

72 125 120

84 150 145

M12 M14 M16

79 125 195

115 185 280

135 215 330

M14x1,5 M16x1,5 M18x1,5

135 205 310

200 300 440

235 360 520

M18 M20 M22

280 390 530

390 560 750

460 650 880

M18x2 M20x1,5 M22x1,5

290 430 580

420 620 820

490 720 960

M24 M27 M30

670 1000 1350

960 1400 1900

1100 1650 2250

M24x1,5 M24x2 M27x1,5

760 730 1100

1100 1050 1600

1250 1200 1850

M27x2 M30x1,5 M30x2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 2003-08

10

Tightening torques Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643

The screw plug tightening torques MA were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys.

The values are based on experience and are intended as reference values for the fitter.

The values for the tightening torque MA apply analogously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys.

The 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 acc. to DIN 1651 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.

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.

Union screws (DIN 7643)

Screw plugs (DIN 908, 910, 7604) Dimensions

M8x1 M10x 1 M12x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M22x1,5 M24x1,5 M26x1,5 M27x2 M30x1,5 M30x2 M33x2 M36x1,5 M38x1,5 M42x1,5 M42x2 M45x1,5 M45x2 M48x1,5 M48x2 M52x1,5 M60x2 M64x2

Tightening torque in Nm screwed into steel / gray cast Al alloy 20* 10* 25 / 30* 15 / 20* 35 25 35 25 40 30 50 35 55 45 60 / 80* 50 / 65* 70 60 80 / 105* 70 / 90* 80 70 100 / 130* 90 / 130* 95 85 120 110 130 115 140 120 150 130 145 125 160 140 150 130 170 145 160 135 180 150 195 165 205 175

* DIN 7604 Form C

Thread

Tightening torque in Nm

4-5

M8x1

20 - 25

6

M10x1

25 - 35

8

M12x1,5

30 - 40

10

M14x1,5

35 - 40

12

M16x1,5

45

15

M18x1,5

50

18

M22x1,5

60

22

M26x1,5

90

28

M30x1,5

130

35

M38x1,5

140

Edition: October 1995

11 2003-08

Pipe outer diameter

Recoding from DIN to ISO standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 1

Tapered 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 7

Cylindrical pins

ISO 2338

- some can be replaced → changed to ISO 2338 - parts which cannot be replaced (e.g. diameter 13 and 14 and/or where 1 = 36 mm) documented as DIN 7 OLD

DIN 84

Cylindrical screws

ISO 1207

- some can be replaced → changed to ISO 1207 - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD

DIN 85

Flat head bolts

ISO 1580

- can be replaced → changed to ISO 1580

DIN 94

Split pins

ISO 1234

- can be replaced → changed to ISO 1234

DIN 417

Threaded pins

ISO 7435

- can be replaced → changed to ISO 7435

DIN 439-1 DIN 439-2

Hex nuts Hex nuts

ISO 4036 ISO 4035 ISO 8675

- cannot be replaced → documented as DIN 439 OLD

DIN 551

Threaded pins

ISO 4766

- can be replaced → changed to ISO 4766

DIN 553

Threaded pins

ISO 7434

- can be replaced → changed to ISO 7434

DIN 555

Hex nuts

ISO 4034

- cannot be replaced → documented as DIN 555 OLD

DIN 558

Hex bolts

ISO 4018

- some can be replaced → changed to ISO 4018 - parts which cannot be replaced (e.g. M12, with new SW) documented as DIN 558 OLD

DIN 601

Hex bolts

ISO 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 912

Cylindrical screws

ISO 4762

- some can be replaced → changed to ISO 4762 - parts which cannot be replaced (e.g. M18, M22, M27 and M33) documented as DIN 912 OLD

DIN 931-1

Hex bolts

ISO 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 933

Hex bolts

ISO 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 934

Hex nuts

ISO 4032 ISO 8673

- cannot be replaced replaced as a result of uneven nut height and for M10, M12, M14 and M22 with new SW.

DIN 960

Hex bolts

ISO 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 961

Hex bolts

ISO 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 963

Countersunk bolts

ISO 2009

- cannot be replaced as a result of modified head dimensions → documented as DIN 963 OLD

DIN 964

Countersunk bolts

ISO 2010

- cannot be replaced as a result of modified head dimensions → documented as DIN 964 OLD

1) refers to the productive components numbered at ZF 2003-08

12

Recoding from DIN to ISO standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 965

Countersunk bolts

ISO7046

- cannot be replaced as a result of modified head dimensions → documented as DIN 965 OLD

DIN 980

Locking nuts

ISO 7042 ISO 10513

- cannot be replaced → documented as DIN 980 OLD

DIN 985

Locking nuts

ISO 10511

- cannot be replaced → documented as DIN 985 OLD

DIN 1440

Washers

ISO 8738

- some can be replaced → changed to ISO 8738 - parts which cannot be replaced documented as DIN 1440 OLD

DIN 1443

Bolts

ISO 2340

- can be replaced → changed to ISO 2340

DIN 1444

Bolts

ISO 2341

- can be replaced → changed to ISO 2340

DIN 1471

Grooved pins

ISO 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 1472

Grooved pins

ISO 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 1473

Grooved pins

ISO 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 1474

Grooved pins

ISO 8741

- can be replaced → changed to ISO 8741

DIN 1475

Grooved pins

ISO 8742

- can be replaced → changed to ISO 8742

DIN 1476

Grooved stud

ISO 8746

- can be replaced → changed to ISO 8746

DIN 1477

Grooved stud

ISO 8747

- can be replaced → changed to ISO 8747

DIN 1481

Clamping pins

ISO 8752

- some can be replaced → changed to ISO 8752 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD

DIN 6325

Cylindrical pins

ISO 8734

- some can be replaced → changed to ISO 8734 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD

DIN 7346

Clamping pins Flange

ISO 13337

- some can be replaced → changed to ISO 13337 - parts which cannot be replaced (∅ 7, 11 and 23 mm) documented as DIN 6325 OLD

DIN 7976

Self-tapping screws

ISO 1479

- can be replaced → changed to ISO 1479

DIN 7978

Tapered pins

ISO 8736

- some can be replaced → changed to ISO 8736 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD

DIN 7979

Cylindrical pins

ISO 8733 ISO 8735

- some can be replaced → changed to ISO 8733/8735 - parts which cannot be replaced documented as DIN 7979 OLD

DIN 7981

Self-tapping screws

ISO 7049

- can be replaced → changed to ISO 1479

DIN 7982

Self-tapping screws

ISO 7050

- cannot be replaced → documented as DIN 7982 OLD

DIN 7985

Cheese-head Screws

ISO 7045

- can be replaced → changed to ISO 7045

1) refers to the productive components numbered at ZF 2003-08

13

ZF-AS Tronic

Consumables

Description ZF reference no.

Name

Approx. quantity

Application

Grease 0750 199 019

for example Spectron FO 20

1g 1g 2g

Shaft seal (02.510) Grooved ring (02.630) Shaft seal (31.080)

Grease 0671 190 050

Olista Longtime 3EP

5g 3g 5g

Shaft seals (68.060/140) Bush (68.130) Locating face release fork (68.060) bearing (68.050)

Sealing compound 0666 790 054

1215 grey

3g

Housing I / housing II sealing face

Sealing compound 0666 790 033

No. 574 1g 3g 0.5 g 0.5 g 1g

Sealing surface Release flange / connection plate Connection plate / housing I Cover (31.050) Sealing cover (32.010/050) Range-change housing / housing II

Jointing compound No. 241 0666 690 017

0.5 g

Hex bolt (02.670)

Jointing compound No. 262 0666 690 022

0.5 g

Ball pin (06.080)

for example MZK 150

1 ml

Pump shaft (02.560) Rotor (02.550)

refer to ZF List of Lubricants TE-ML 02

refer to type plate

Anti-corrosion protection oil 0750 199 008 Transmission oil

Transmission oil fill

NOTE: Inquire about container sizes before placing any orders!

1327 751 102 - 2004-04

14

Comments

ZF-AS Tronic

Adjustment data

Description

Dimension

Measurement device

Comments

Setting end float of countershaft (03.010).

-0.05 to +0.05 mm

Depth gauge

Move tapered roller bearing into a neutral position (no clearance) and measure.

Use shim (03.050) to set clearance.

Setting end float of countershaft (03.110).

-0.05 to +0.05 mm

Depth gauge

Move tapered roller bearing into a neutral position (no clearance) and measure.

Use shim (03.150) to set clearance.

End float of input shaft / connection plate

0 to 0.10 mm

Depth gauge

Use shim (02.100) to set clearance.

End float of circlip on input shaft

0 to 0.10 mm

Feeler gauge

Use circlip (02.120) to set clearance.

Output bearing end float

0 to 0.10 mm

Depth gauge

Use shim (31.030) to set clearance.

End float of main shaft / sun gear

2 mm +/-0.1

Depth gauge

Use shim (32.380) to set clearance.

Screw plug (31.200, 31.190)

60 Nm

Torque wrench

Screw plug (31.090)

15 Nm

Torque wrench

Hex bolt (32.550)

120 Nm

Torque wrench

Hex bolt (31.370)

50 Nm

Torque wrench

Impulse sensor (31.230, 31.260)

45 Nm

Torque wrench

1327 751 102 - 2002-01

15

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

Qty.

Alternatively order no.

1X56 137 391

1X56 137 795

1

3-section chain for raising the transmission

Comments

1 commercially available

Chapter 7, 9, 12

1T66 154 240

2

Lifting lug M10 for lifting the housing components Only M10 bolts of 8.8-plus quality may be used

2

Chapter 9

1X56 138 443

3

Support for moving transmission into vertical position

4

Gripper insert pulling off tapered roller bearing of countershafts (in conjunction with basic tool 1X56 122 304)

Alternatively: mobile or stationary assembly stand (see photos 13 and 14)

Chapter 16.1

1X56 136 740

4

commercially available or 1T66 160 494 for clearance hole

1

Chapter 12.1,

1X56 122 304

16.1

5

Basic tool in conjunction with tool 1X56 136 740 or 1X56 138 195

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

16

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

Qty.

1X56 122 314 for ball bearings with 10 balls 1X56 138 295 for ball bearings with 10 balls

6

Extractor for pulling ball bearings (31.020) off planetary carrier

Chapter 5.4 hydr. variant upon request

1 1X53 188 009 replaced by 1X56 138 295

Caution: Both extractors are not suited for impact wrench use.

Chapter 6.1

1X56 138 087

7

Extractor inner bearing race (32.310/1) on planetary carrier

1

Chapter 5.3

1X56 138 207

8

Bracket range-change synchronizer assembly

6

Chapter 7

1X56 138 208

9

Retaining bolt for securing R-gear intermediate gear

2

Chapter 7

1X56 138 203

10

Retaining plate for holding and centring main shaft

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

17

Comments

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

Variant A

Oder no.

Application

Qty.

Variant B Chapter 8.2

1X56 138 095

11

Setting fixture for selector rails

Only variant B is available

1

Chapter 10.2

1X56 138 215

12

Special tool for fitting the bushes and shaft seals of the release fork

2

Alternatively 4 supports 1X56 137 836

1P01 181 850

13

Assembly stand (stationary) in combination with base plate 1X56 138 297 and clamping plate 1X56 139 608.

1

Alternatively 4 supports 1X56 138 443

1X56 137 450 (optional) 14

Transmission swivel stand (mobile) in conjunction with adapter 1X56 138 232

1

Chapter 5 and 12

1X56 138 063

15

Drift key for driving out dowel pins

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

Comments

18

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

Qty.

Chapter 14.2

1X56 138 097

16

Assembly plate synchronizer (02.200)

To simplify assembly

1

Chapter 14.2

1X56 138 081

17

Assembly sleeve synchronizer (02.200)

3

Chapter 15.2

1X56 138 205

18

Assembly fixture pipe (04.020) on main shaft

1

Chapter 12.1

1X56 138 191

19

Bush (pressure piece) to protect shaft when pulling off

commercially available

1

Chapter 12.1

1X56 138 195

20

Extraction fixture ball bearing (02.080) on input shaft

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

19

Comments

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

21

22

Oder no.

Application

Qty.

1X56 138 200

Chapter 12.4

Assembly tool centring oil pipe (01.430)

Alternatively M4 stud bolt with nut

1

1X56 138 201

Chapter 12.4

Assembly tool centring oil pipe (01.420)

Alternatively M8 stud bolt with nut

1

Chapter 12.4, 13

1X56 138 216

23

Fixture lifting and extracting fixture for assembly and disassembly of input shaft

1

Chapter 12.4

1X56 045 808

24

Extraction fixture input shaft in conjunction with 1X56 138 216

1

Chapter 13, 14.3

1X56 138 197 Assembly fixture 25

1

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

Comments

20

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

Qty.

Chapter 11.3

1X56 099 063

26

Special tool for shaft seal in release flange

1

Chapter 4

1X56 137 124

27

Special tool for fitting shaft seal to output cover (in conjunction with spacer ring 1X56 138 189)

1

Chapter 4

1X56 138 189

28

Spacer ring for 105 x 125 x 12 shaft seal on output cover (in conjunction with special tool 1X56 137 124)

1

only for ZF-SSOs

6008 208 503 ZF-TESTMAN pro complete

29

Scope of supply: - 6008 208 013 TESTMAN pro with DPA04i + cable - 6008 208 015 Application CD - 6008 208 016 License

1

only for ZF-SSOs

6008 208 501 Diagnostic software ZF-TESTMAN pro

30

Scope of supply: - 6008 208 011 TESTMAN pro with DPA04i + cable - 6008 208 015 Application CD - 6008 208 016 License

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

21

Comments

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

6008 208 003 ZF-TESTMAN pro for ZF customers Scope of supply: - 6008 208 100 diagnostic tool (complete) - 6008 208 900 ZF-TESTMAN pro Software for user interface (CD-basic installation)

31

Qty.

Comments

after coordination with ZF Friedrichshafen AG

1

Single-user license

Application software ZF-AS Tronic 2 6008 308 819 32

1

6008 207 003 Table mode adapter ZF-AS Tronic 33

1

Adapter cable for programming and configuration purposes and diagnosis outside of the vehicle

112

15

74

M10

11

64

ø9H7

10±0.1

25

14

ø9r6

ø8.7±0.1

20±0.1

2x45°

2x45° 40

ø9H7 212±0.1

Setting aid for piston rods on transmission actuator

1

Chapter 6.1

1X56 138 420

35

Extractor Clutch body (32.280) on planet carrier in conjunction with pressure plate 1X56 138 424.

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

Simplifies assembly

37.5±0.1

34

Chapter 8.2

Sketch

M10

75 60.5

240

22

1

ZF-AS Tronic

Fig No.

Special tools

Diagram

Oder no.

Application

Qty.

Chapter 6.1

1X56 138 424 Pressure plate

Comments

1

36

Chapter 6.1

1X56 138 426

37

Fork Retaining ring (32.290)

NOTE: Please request packaging unit size before placing order.

1327 751 102 - 2004-04

23

1

ZF-AS Tronic 1

Preparatory work

Preparatory 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 These repair instructions contain a description of disassembly / assembly of ZF-AS Tronic transmissions (10, 12 and 16 speeds) without the use of a mobile transmission swivel stand 1X56 137 450.

1

To raise and transport, the 3-section chain 1X56 137 795 is attached to the lugs on the transmission.

2

Get oil collecting container ready.

3

Remove 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.

015 027

With transmission swivel stand * 1

Secure adapter 1X56 138 232 to mobile transmission swivel stand 1X56 137 450.

Secure transmission to adapter 1X56 138 232.

NOTE* For specialized workshops we recommend the stationary assembly stand 1P01 181 850 with base plate 1X56 138 297 and clamping plate 1X56 139 608.

For further information contact ZF Friedrichshafen AG, Dept. MKS-IP (Customer Service).

* Option

1327 751 102 - 2004-04

1-1

1327_50D_010_en

ZF-AS Tronic

Preparatory work

Without transmission swivel stand 1

Place two wooden blocks on a piece of flat firm ground.

2

Secure 2 M16x1.5 lifting lugs to the rangechange 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”.

015 181

3

Place transmission and clutch bell housing on the wooden blocks.

WARNING: Transmission must not be placed on the input shaft.

015 018

1327 751 102 - 2004-04

1-2

1327_50D_010_en

ZF-AS Tronic

Clutch actuator

68.320 68.010

6

68.210*

68.300

68.330 /020 /030

/120 /130

/010

/110

68.020 68.210*

68.150 68.060

68.154

018 202

2

Clutch actuator

2.1

Removal

1

Disconnect plug connection from transmission actuator and output speed sensor.

2

Remove 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).

4

Remove 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).

1327 751 102 - 2004-04

NOTE - For removal and fitting of release fork, refer to Chapter 10.

- Fastening wiring for transmission actuator, see also Service Information No. 02_04

2-1

1327_68D_020_en

ZF-AS Tronic

Clutch actuator

68.320 68.010

6

68.210*

68.300

68.330 /020 /030

/120 /130

/010

/110

68.020 68.210*

68.150 68.060

68.154 * depending on parts list 018 202

2.2

Fitting 3

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. 1

Insert push rod (68.210) in recess in release fork (68.060).

2

When 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

Secure 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.

* depending on parts list

1327 751 102 - 2004-04

2-2

1327_68D_030_en

ZF-AS Tronic

Clutch actuator

68.320 68.010

6

68.210*

68.300

68.330 /020 /030

/120 /130

/010

/110

68.020 68.210*

68.150 68.060

68.154 * depending on parts list 018 202

CAUTION • Do not bend the cable and do not tighten hard.

• Avoid chafing points.

• Fit connector with traction relief and check detent.

4

If damaged, replace cable terminals (68.300, 68.320 and 68.330).

5

Press wiring harness into cable terminals.

6

Reconnect connector to transmission actuator and output speed sensor.

1327 751 102 - 2004-04

2-3

1327_68D_030_en

ZF-AS Tronic 3

Output flange

3.1

Removal

1

Remove 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 O-ring (32.530).

Output flange

32.550 32.540 32.530 32.510

NOTE Shaft must not be damaged when pulled off, therefore use a pressure piece.

015 171

3.2

Fitting

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.

32.550 32.540 32.510

32.530

! DANGER Only touch heated output flange when wearing protective gloves.

2

3

32.520

Once the output flange has cooled down, press O-ring (32.530) into groove between shaft and output flange.

015 169

Secure disc (32.540) with 2 M12 hex bolts (32.550).

Tightening torque M12 = 120 Nm

1327 751 102 - 2004-04

3-1

1327_32D_010_en

ZF-AS Tronic 4

Output cover

Output cover NOTE Chapter 4 does not apply to transmission versions fitted with Intarders because the components are not used.

4.1

Removal

1

Remove 10 M10 hex bolts (31.070) and take off output cover (31.050).

31.080 31.050 31.030

31.070 Loctite 574

2

Take off shim (31.030).

3

Use appropriate tool to remove shaft seal (31.080), in so doing do not damage output cover.

015 170

31.090 4

Remove 4 M12 hex bolts (31.120) take off cover (31.110) and gasket (31.100).

31.110

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

31.100 31.120

Determining thickness “C” of shim 015 193

Dimension A: Measure output cover (31.050) between sealing face and bearing seat.

Shaft A

Dimension B: Measure from ball bearing (31.020) to sealing face of range-change housing (31.010).

31.050 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

31.020

B

31.010 015 194

1327 751 102 - 2004-04

4-1

1327_31D_010_en

ZF-AS Tronic 3

Select 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.

Output cover

31.080 31.050 31.030

NOTE Sealing faces have to be clean and free of oil and grease.

5

Attach shim (31.030) to output cover (31.050).

6

Tighten 10 M10 hex bolts (31.070) to 46 Nm.

31.070 Loctite 574

015 170

NOTE Only fit cover (31.110) once range-change housing has been fitted and the screw plug (31.090) has been fitted.

7

8

31.090

Clean sealing face on range-change housing and on cover (31.110).

31.110

Fit new gasket (31.100) and cover (31.110).

31.100

9

Tighten 4 M12 hex bolts (31.120) to 79 Nm.

31.120

018 225

1327 751 102 - 2004-04

4-2

1327_31D_010_en

ZF-AS Tronic 5

Removing and fitting range-change housing

5.1

Removing range-change housing

Range-change housing

Variant A 34.050 34.070

34.080

31.390 34.080

Variant A 1

34.060

34.060 34.050

Standard transmission in vertical position with output at top (refer to preparatory work).

34.070

Remove hex bolts (34.080), retaining plate (34.070) and king pin (34.050). Take the Orings (34.060) off the king pin.

31.390 31.370

Variant B Remove screw plug (34.100).

Remove joint bolt (34.050) and circlip (34.090).

015 167

Variant B NOTE The joint bolts (34.050) have an M8 pull-off thread.

2

34.100

34.050

31.390

Remove 2 cylindrical pins (31.390) – extraction thread M12 – and 22 hex bolts (31.370).

34.090

34.050 34.100

NOTE Use drift key 1X56 138 063 to drive out cylindrical pins.

34.090

3

4

Use a crane to carefully raise the complete range-change housing.

5

Remove spray pipe (31.400).

6

Raise selector rails (34.010) slightly and remove tumbler yoke (34.020) and fulcrum pads (34.030).

7

31.390

Secure 2 lifting lugs to the output flange or planetary carrier and attach chain.

31.370 021 762

31.400

34.010

33.010 34.030

Remove complete synchronization (33.010).

34.020 015 174

1327 751 102 - 2004-04

5-1

1327_31D_020_en

ZF-AS Tronic

Range-change housing

CAUTION Use a rag to cover synchronization (/010).

6 bushes (/150) and 6 compression springs (/170) are released when the synchronizer rings (/130) are removed.

8

/150 /170 /110 32.440 32.430

Use 2 prybars to raise plate (32.440) and remove clutch body (32.430).

/130

32.400

/150 /170

32.380 9

/130

Remove sleeve (32.400) with circlip (32.390) and shim (32.380).

33.010 32.390

021 763

1327 751 102 - 2004-04

5-2

1327_31D_020_en

ZF-AS Tronic 5.2

Main shaft – planetary carrier clearance setting

1

Precondition for measuring the shim.

Snap circlip (32.390) into sleeve (32.400) and place on main shaft (04.010).

2

Set up a measuring plane.

3

Dimension B1: Measure from measuring plane to circlip (32.390).

Range-change housing

Dimension B1

016 660

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).

01.400

Example: B2 – B1 = B 95 mm – 70 mm = 25 mm

32.390 04.010 32.400

Dimension B2

1327 751 102 - 2004-04

5-3

016 661

1327_31D_040_en

ZF-AS Tronic

Range-change housing

Determining dimension B

B2 B1

32.400 32.390

B2

B1

B

B 04.010

B2 – B1 = B

Determining dimension A

A1 A2

A2

A1

A A

32.190 31.010

A2 – A1 = A 015 200

1327 751 102 - 2004-04

5-4

1327_31D_040_en

ZF-AS Tronic 6

Range-change housing

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).

Dimension A1

016 662

Dimension A2

016 663

Example: A2 – A1 = A 84.3 mm – 55.1 mm = 29.2 mm 9

Determine 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

10

Select shim (32.380) using spare parts catalogue and prepare for installation.

1327 751 102 - 2004-04

5-5

1327_31D_040_en

ZF-AS Tronic 5.3

Fitting range-change housing

1

Place shim (32.380) on main shaft.

Range-change housing

/150 /170 /110 32.440

NOTE For how to measure the shim (32.380), refer to Chapter 2.2 2

32.430

Place sleeve (32.400) on main shaft.

Circlip (32.390) lies on the shim (32.380).

4

Place clutch body (32.430) and plate (32.440) on housing II.

5

In each synchronizer ring (/130) 3 compression springs (/170) and 3 bushes (/150) are to be inserted and secured with a bracket (8) 1X56 138 207.

6

Synchronizer rings (/130) are to be placed in sliding sleeve (/110) and the bracket (8) 1X56 138 207 is to be removed.

7

synchronizers complete with synchronizer rings (/130), bushes (/150) and compression springs (/170) are to be placed on clutch body (32.430).

/130

32.400

/150 /170

32.380

Insert circlip (32.390) in sleeve (32.400).

Circlip must make contact with groove base of sleeve.

3

/130

33.010 32.390

021 763

8

015 191

33.010

32.400

32.390

32.380 32.440

32.430

04.010 018 085

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5-6

1327_31D_030_en

ZF-AS Tronic

Range-change housing

3

31.010

34.010 1

31.400 33.010

Loctite 574

34.020 34.030

015 190

NOTE The sealing faces on housing II and rangechange housing must be clean and free of oil and grease.

8

Coat sealing face on housing II with Loctite no. 574.

9

Insert 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).

11

Screw two commercially available M10 guide pins (1) into housing II (01.400).

1327 751 102 - 2004-04

12

Secure 2 lifting lugs to output flange or planetary carrier and attach chain.

13

Attach chain to crane and carefully place range-change 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 range-change housing and driving in the cylindrical pins – risk of housing breakage.

5-7

1327_31D_030_en

ZF-AS Tronic 14

Tighten M10x1 screw plug (31.090) to 15 Nm.

15

Insert two cylindrical pins (31.390). Screw in 22 hex bolts (31.370) and tighten to 50 Nm.

Range-change housing

31.090 31.390

31.390

31.370

018 224

Variant A Variant A 16

Insert new O-rings (34.060) on king pin (34.050).

34.050 34.070

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.

17

34.060

34.060 34.050

34.080

31.390 34.080

34.070

Use the retaining plate (34.070) to guide the king pin through the range-change housing bore into the selector forks (34.020).

31.390 31.370

18

Secure retaining plate (34.070) with a hex bolt (34.080) and tighten to 23 Nm. 015 167

Variant B Variant B 16

Circlip (34.090) to be inserted on joint bolts.

17

Joint bolts to be inserted through GP-housing bore into selector fork (34.020).

18

34.100

34.050

31.390 34.090

34.050

Screw plug with gasket (34.100) to be tightened at 40 Nm.

34.100

34.090

31.390 31.370 021 762

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5-8

1327_31D_030_en

ZF-AS Tronic

Range-change housing

5.4

Dismantling range-change housing

1

Remove output flange (refer to Chapter 3) and output cover (refer to Chapter 4).

2

Remove all screw plugs and impulse sensors from range-change housing.

Use extractor (6) 1X56 122 314 for ball bearings with 10 balls or 1X56 138 295 for ball bearings with 11 balls to take ball bearing (31.020) and range-change housing (31.010) off planetary carrier.

3

6

Use a manual press to press ball bearing (31.020) out of range-change housing.

015 189

31.020

5.5

Assembling range-change housing

1

Insert ball bearing (31.020) in range-change housing (31.010).

2

31.090

31.260*

Heat inner bearing race of ball bearing (31.020) to max. 120 °C and place complete rangechange housing on planetary carrier until firmly home.

31.200

! DANGER Only touch heated parts when wearing protective gloves.

31.010 * see parts list or Service Info 08/00

31.230* 015 173

NOTE Only fit M10x1 screw plug (31.090) once rangechange housing has been fitted on housing II. 3

Replace steel rings on screw plugs.

Tightening torques: M24x1.5 screw plug (31.200) Impulse sensor (31.230) Impulse sensor (31.260)

4

60 Nm 45 Nm 45 Nm

Fit output cover (refer to Chapter 4) and output flange (refer to Chapter 3).

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5-9

1327_31D_050_en

ZF-AS Tronic

Planetary carrier

6

Planetary carrier

6.1

Dismantling planetary carrier

1

Pressure plate (1) 1X56 138 424 to be placed on planet carrier.

2

Tool (2) 1X56 138 426 to be used to contract circlip (32.290).

1

2

3

32.290

32.280 3

Split shells (3) to be removed from tool 1X56 138 420 and the narrow step to be pushed under the clutch body (32.280).

4

Ring (4) of tool 1X56 138 420 is to be pushed over both split shells (3) and the bolt (5) is to be tightened.

5

Use commercial three-armed puller (6) to pull off the clutch body (32.280).

023594

6

3

4 5

023595

1327 751 102 - 2004-04

6-1

1327_32D_020_en

ZF-AS Tronic

Planetary carrier

NOTE For transmissions with Intarder Remove 10 hex bolts (32.144) and use two-arm extractor to pull off step-up gear (32.140).

6

Place planetary carrier sideways on ring gear.

7

Remove locking wire (32.240) e.g. using 2 small screwdrivers.

32.120 32.230 32.240

32.290

! DANGER

32.130

Ring gear (32.130) is released and may fall out.

- Risk of injury -

32.280 8

Take off ring gear carrier (32.230).

9

Take thrust ring (32.120) out of ring gear (32.130).

10

Rotate planetary carrier through 180° and use a mandrel to drive planetary bolt (32.050) out of planetary carrier (32.010).

11

32.144* 32.010

32.310/1

Sun gear (32.190) is released.

13

Rotate thrust washers (32.200 and 32.180) through 1/2 a tooth so that the driving pins (32.204 and 32.184) are released.

32.140*

32.204 32.184

Take out planetary gear set (32.100) (contains 5 planet gears). Take spacers (32.070, 32.080) and rollers (32.090) out of planet gears.

12

/050

32.200

32.090

32.190 32.080

32.180

32.090 32.070 32.050

32.070 32.100

* depending on parts list 015 172

14

Remove driving pins (32.204 and 32.184).

15

Pull off inner bearing race (32.310/1) using extractor 1X56 138 087.

1327 751 102 - 2004-04

6-2

1327_32D_020_en

ZF-AS Tronic 6.2

Initial assembly of sun gear

1

Guide driving pin (32.204) into sun gear (32.190).

2

3

Planetary carrier

32.180

Slide thrust washer (32.200) – shorter offset facing planetary gear – into spline of sun gear (32.190) and rotate. The driving pin (32.204) is therefore secured.

32.190 32.184

Slide thrust washer (32.180) – shorter offset facing planetary gear – into spline of sun gear (32.190).

32.204 32.200

4

5

6.3

Guide driving pin (32.184) into bore of sun gear.

015 188

32.120

Slide thrust washer (32.180) upwards and rotate. The driving pin (32.184) is therefore secured.

32.230 32.240

Initial assembly of planetary gear set

CAUTION Planetary gears should only be replaced in sets.

32.290 32.130

1

Coat all rollers (32.090) with operating oil.

2

Place thin spacer (32.070) in planetary gear (32.100) and insert 14 rollers (32.090) into planetary gear.

3

4

32.280 32.144* 32.010

Insert thick spacer (32.080) and again insert 14 rollers (32.090) in planetary gear. Finally, fit one thin spacer (32.070).

32.310/1 /050

32.200

32.140*

32.204 32.184

This operation should be undertaken on all 5 planetary gears.

32.090

32.190 32.080

32.180

32.090 32.070 32.050

32.070 32.100

* depending on parts list 015 172

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6-3

1327_32D_030_en

ZF-AS Tronic 6.4

Planetary carrier

Sub-assembly of planetary carrier 32.120 32.230

! DANGER

32.240

Wear protective gloves when handling heated parts.

1

Heat inner bearing race (32.310/1) to max.

120 °C and slide on planetary carrier until firmly home.

2

Insert pre-assembled sun gear in planetary carrier (32.010).

32.290 32.130

! DANGER

32.280 32.144*

Fingers may be jammed.

32.010 3

4

Hold pressure disc (32.180) upwards and insert pre-assembled planetary gears (32.100).

Insert planetary bolt (32.050) and centre planetary gears.

32.310/1

Use a plastic hammer to carefully knock planetary bolt (32.050) into planetary carrier bore until it no longer protrudes.

32.080 32.090 32.070 32.050

* depending on parts list

Wear protective gloves when handling heated parts.

8

Insert thrust ring (32.120) ground side facing input ring gear (32.130).

1327 751 102 - 2004-04

32.070 32.100

! DANGER

Clutch body (32.280) to be heated to max.

120 °C and pushed to axial stop on planet carrier, in so doing use tongs to pull circlip (32.290) together. Circlip snaps into groove of clutch body.

32.090

32.190

Insert circlip (32.290) in planetary carrier (32.010).

7

32.140*

32.204 32.184

32.180 5

/050

32.200

015 172

9

Slide ring gear (32.130) from output end and ring gear carrier (32.230) from input end onto planetary carrier so that the locking wire (32.240) can be inserted in the ring gear groove (32.130) (e.g. using a small screwdriver).

NOTE Locking wire (32.240) must lie on base of ring gear groove.

6-4

1327_32D_040_en

ZF-AS Tronic

Planetary carrier

Only for Intarder version

32.120 32.230

Step-up gear assembly 32.240 1

Heat step-up gear (32.140) to 120 to 130 °C.

2

Screw two M12 guide pins into planetary carrier (32.010).

3

Place heated step-up gear (32.140) – offset facing output – on planetary carrier.

32.290 32.130

! DANGER

32.280

Only touch heated components when wearing protective gloves.

32.144* 32.010

4

Remove M12 guide pins.

32.310/1

5

/050

32.200

Screw in 10 M12 hex bolts (32.144) and tighten to 135 Nm.

32.140*

32.204 32.184

32.090

32.190 32.080

32.180

32.090 32.070 32.050

32.070 32.100

* depending on parts list 015172

1327 751 102 - 2004-04

6-5

1327_32D_050_en

ZF-AS Tronic 7

1

Moving transmission into horizontal position

Moving transmission without range-change group (planetary group) into horizontal position

05.010

05.110

Replace both reverse idler shafts (05.010 and 05.110) with tools (9) 1X56 138 208.

NOTE Tool (9) 1X56 138 208 secures the reverse gears.

018 269

2

10

Secure retaining plate (10) 1X56 138 203 on housing II.

9

3

Make oil collecting container and wooden blocks available.

9

4

Secure two lifting lugs (2) 1T66 154 240 onto housing II. Attach chain and use crane to move transmission into horizontal position.

2

NOTE Any remaining transmission oil may escape, position oil collecting container appropriately.

015 187

5

Remove lifting lugs.

6

For transmission actuator removal, refer to Chapter 8.

015 192

1327 751 102 - 2004-04

7-1

1327_50D_020_en

ZF-AS Tronic 8

Transmission actuator

Transmission actuator 74.140*

8.1

74.120*

74.130*

Removal

74.030 1

Depending on parts list: remove breather (74.120) and/or angle piece (74.140) and Cannon socket (74.130) from transmission actuator (74.030).

2

Remove 15 M8 hex bolts (74.090; 74.070) from transmission actuator (74.030).

3

Take transmission actuator (74.030) off transmission housing.

74.050 74.010

NOTE Ensure that the rubber gaskets (item /170 see Figure 017908 / Page 8-2) are also taken off otherwise they may fall into the transmission housing.

4

5

74.070

74.090

34.140 34.130

74.050

12.090 12.080 06.050 06.040

06.080

Remove compression springs (06.050; 34.140 and 12.090) and detent pins (06.040; 34.130 and 12.080). If damaged, replace two cylindrical pins (74.050).

Loctite 262

Remove gasket (74.010) and clean sealing faces on transmission housing and on transmission actuator.

* depending on parts list

015 166

NOTE A transmission actuator kit is available. This consists of transmission actuator (74.030), gasket (74.010) and breather (74.120).

6

If housing I (01.010 refer to Chap. 12) is removed, remove ball pin (06.080).

1327 751 102 - 2004-04

8-1

1327_74D_030_en

ZF-AS Tronic 8.2

Transmission actuator

Fitting NOTE Only fit transmission actuator once transmission has been completely installed.

1

06.080

Coat thread of ball pin (06.080) with Loctite no. 262. Tighten ball pin to 23 Nm.

Loctite 262 017 429

2

Secure fixture (11) 1X56 138 095. Use lever to connect open ends in relevant selector rails.

Turn input shaft by hand and use lever to select gears.

3

Shift splitter group and range-change selector rails towards output. Move centre selector rail into neutral position.

4

Disassemble fixture (11) and place new gasket (74.010) on transmission housing.

5

Shift piston rod (4) on transmission actuator into central position (neutral). The correct position is reached once slight resistance can be felt when pulling out the piston rod (4). Align the two other piston rods (3 and 5) to the same level.

11

015183

5 6

4

3

Selector gate (6) and piston rod (4) must be above one another (flush). Ensure that rubber gaskets (/170) are used on transmission actuator.

/170

6 017 908

1327 751 102 - 2004-04

8-2

1327_74D_040_en

ZF-AS Tronic

Transmission actuator

NOTE An auxiliary tool (34) can be produced for setting the piston rods. For sketch, refer to special tools Fig. no. 34.

One request, the auxiliary tool (34) can also be supplied by ZF under order number 1X56 138 244.

7

Insert detent bolts (06.040; 34.130 and 12.080) and compression springs (06.050; 34.140 and 12.090).

34 34

017 907

8

Align ball pin (06.080) vertically.

When the transmission actuator is fitted, the ball pin (06.080) meshes with the selector gate (6).

74.140* 74.120*

74.130*

74.030 9

Fit transmission actuator (74.030) and ensure that the transmission actuator piston rods (3, 4 and 5) mesh in the transmission selector rails.

10

Tighten M8 hex bolts (74.090 and 74.070) to 23 Nm.

11

Depending on parts list: Tighten Cannon socket (74.130) to 18 Nm and secure angle piece (74.140) and/or tighten breather (74.120) to 10 Nm

74.050 74.010

CAUTION If the transmission actuator has been changed or replaced, note the following.

• Re-program transmission actuator (refer to Chapter 8.5) • Transfer vehicle parameters from removed transmission actuator or re-enter.

12

13

Connect air line onto pressure limiting valve of transmission actuator.

74.070

74.090

34.140 34.130

74.050

12.090 12.080 06.050 06.040

06.080

Loctite 262

* depending on parts list

015 166

Connect up wiring harness otherwise function tests using the diagnosis device are not possible.

1327 751 102 - 2004-04

8-3

1327_74D_040_en

ZF-AS Tronic

Transmission actuator

CAUTION The transmission actuator has two type plates, one from Wabco (15) and one from ZF (16).

Please make a note of the data on the type plates.

1

8.3

Remove upper part from bottom part

1

Remove both bolts (/150-1).

2

Raise upper section (/110) of pressure limiting valve and carefully use both tabs (1) to insert sideways into grooves (2).

Disconnect plug connections (7 and 8).

3

Remove gaskets (/150-3 and /170).

4

Remove gasket (/150-2) and clean sealing faces.

/150-1

/110

74.030

/180

/150-2 2 /150-3 /130

/170

8.4

Mount upper part to bottom part

1

Insert gasket (/150-3).

2

Place gasket (/150-2) on lower section (/130).

3

Re-establish plug connections (7 and 8).

Again check that plug connection is tight.

4

Place upper part (/110) on bottom part (/130). Avoid slipping of the gasket (/150-2); fix if necessary. Tighten the two bolts (/150-1) applying 9.5 Nm.

5

Insert gaskets (/170).

019352

8 7

018205

1327 751 102 - 2004-04

8-4

1327_74D_005_en

ZF-AS Tronic 8.5

Transmission actuator

Exchange pressure relief valve 10

(Repair Set 0501 320 849) NOTE Mark installation position of the pressure relief valve (/180) for later installation.

1

4 nuts (10) and pressure relief valve (/180) and O-ring (12) are to be removed.

CAUTION Do not apply grease when mounting O-ring (12).

2

Insert new O-ring (12). Mount pressure relief valve (/180) on transmission actuator (74.030) using 4 nuts. Apply 7 Nm to tighten the 4 nuts (10).

019251

74.030

/180 12

019252

1327 751 102 - 2004-04

8-5

1327_74D_011_en

ZF-AS Tronic 8.6

Transmission actuator

Programming transmission actuator

When the transmission actuator and/or the upper section is changed, customer-specific programming and/or parameter setting (entering of EOL data) is necessary.

23 20.1

Parameterization involves inputting EOL-data into the electronics of the transmission actuator by means of the ZF-Testman pro and the relevant software.

20

22

21 Programming of the transmission actuator Pos. 20 Desktop adapter 20.1 Power supply 21 Cable to DPA04i 22 DPA04i 23 Cable to Laptop or PC

019643

CAUTION The vehicle parameters of the removed transmission actuator are to be used or re-entered in newly programmed transmission actuators.

1327 751 102 - 2004-04

8-6

1327_74D_012_en

ZF-AS Tronic 9

Moving transmission into vertical position

1

Secure 2 lifting lugs 1T66 154 240 onto housing I, in so doing use 2-3 shims to bridge the offset to the centring diameter (see arrow).

2

Attach chain and raise transmission.

Moving transmission into vertical position

NOTE Remaining transmission oil may escape, position oil collecting container appropriately.

015 184

3

Screw 4 supports (3) 1X56 138 443 into housing II.

3

3

3 015 185

4

Carefully place transmission on 4 supports.

015 186

1327 751 002 - 2004-04

9-1

1327_50D_030

ZF-AS Tronic

Clutch release mechanism

/110

/140

/130

68.060

/140 /130

/110

68.210

/130 /140 68.110 /120 68.050 68.130 021 714

10

bushes (/130) and shaft seals (/140) (note installation position) one after another.

Clutch release mechanism

10.1 Removal of release fork 1

Remove 2 M12 hex bolts (68.130) from release shaft (68.110).

2

Take release bearing (68.050) and release fork (68.060) off input shaft.

3

4

2

Fill shaft seals (/140) between sealing lips with grease.

Grease bushes (/130) using OLISTA LONGTIME 3EP (ZF-No. 0671 190 050).

3

Slide release shaft (68.110) into release fork (68.060) taking care not to damage the shaft seals.

4

Position release bearing (68.050) on release flange (guide tube). Do not grease “release bearing – release flange” sliding seat.

5

On the release fork (68.060), grease the mounting face for the release bearing (68.050) with Olista long-time 3EP (ZF no. 0671 190 050).

Mesh release fork (68.060) with release bearing (68.050).

6

Secure release shaft (68.110) to connection plate using 2 M12 hex bolts (68.130).

Tightening torque M12 10.9 = 115 Nm

Slide release shaft (68.110) off release fork (68.060).

Dismantle release fork (68.060).

Use appropriate tool to remove shaft seal (/140) and bush (/130). If damaged or worn, replace ball cup (/120).

10.2 Fitting release fork 1

Assemble release fork (68.060).

A special tool 1X56 138 215 is required as support for the release fork (/110). The other special tool 1X56 138 215 is used to press in both

1327 751 102 - 2004-04

10-1

1327 68D 010_en

ZF-AS Tronic

Connection plate

03.050 03.150 02.570

02.550

03.200*

03.250 03.270

02.100

02.560

03.210* 03.270

02.580 02.500

03.260 03.280

02.630*

A

03.280 02.670

03.270

Loc tit 574 e

02.610 Loctite 241

02.530 02.520

B

* depending on parts list 015 180

11

Connection plate

5

Use appropriate tool to remove shaft seal (02.510) (refer to Chap. 11.3 Fig. 015 856) from release flange (02.520).

11.1 Removing connection plate 1

Remove 22 M10 hex bolts (02.670).

6

2

Use appropriate tool to lift off connection plate (02.500) or use M8 disassembly thread (see arrows A, B).

Remove brake cover (03.250) from connection plate and remove outer clutch discs (03.270) and inner clutch discs (03.280).

7

NOTE It is easier to lift off the connection plate when the release flange (02.520) is not removed.

Otherwise, the connection plate tends to twist.

Take out brake piston (02.610) and when removing the grooved ring (02.630) note installation position for subsequent installation.

8

If defective, replace cylindrical pins (03.260).

9

Pump is dismantled for component visual inspection and cleaning.

10

Remove three Torx screws (02.580).

11

Take out pump cover (02.570), pump shaft (02.560) and rotor (02.550).

3

4

Remove shims (03.050, 02.100 and 03.150), detent bolt (03.120) and compression spring (03.200).

Remove four M8 hex bolts (02.530) and lift off release flange (02.520).

1327 751 102 - 2004-04

11-1

1327_02D_010_en

Connection plate

b b2 b1

ZF-AS Tronic

02.100

03.050

c

c2 c1

a

a2 a1

03.150

015 199

11.2 Measuring connection plate 1

Rotate input shaft back and forth several times. This aligns the bearing’s tapered rollers and they roll into the outer bearing races.

In order to be able to set the specified countershaft setting dimension of –0.05 to +0.05 mm, “zero clearance” must first be reached.

2

Use a mandrel to place outer bearing races on tapered rollers (no clearance).

3

Use a sharp object to check whether the bearing’s tapered rollers can move.

4

Measure distance between outer bearing race and housing sealing face: Countershaft Pump e.g. dimension c2 = 2.00 Transm. brake e.g. dimension a2 = 1.95 Input shaft e.g. dimension b2 = 3.90

5

Measure connection plate.

Distance between connection plate sealing face and pump cover e.g. dimension c1 = 0.05 break cover e.g. dimension a1 = 0.15 mounting face of shim (02.100) on input shaft e.g. dimension b1 = 5.50

NOTE Zero clearance is reached once the tapered rollers are secure but there is no preload.

1327 751 102 - 2004-04

11-2

1327_02D_020_en

Connection plate

b b2 b1

ZF-AS Tronic

02.100

03.050

c

c2 c1

a

a2 a1

03.150

015 199

6

Determine thickness of discs: Pump: c1 + c2 = c = shim (03.050) 2.00 + 0.05 = 2.05 mm = shim (03.050) Transmission brake: a1 + a 2 = a = shim (03.150) 1.95 + 0.15 = 2.10 mm = shim (03.150) Input shaft b 1 – b2 = b = shim (02.100) 5.50 – 3.90 = 1.60 mm = shim (02.100)

7

The following should be noted when selecting discs:

8

Place shims (03.050 and 03.150) on outer bearing races. Slightly grease shim (02.100) (for better assembly) and place in connection plate.

Countershafts: Preload or clearance –0.05 mm to +0.05 mm Input shaft: Clearance 0 to 0.10 mm The clearance is deducted from the shim thickness.

1327 751 102 - 2004-04

11-3

1327_02D_020_en

ZF-AS Tronic

Connection plate

03.050 03.150 02.570

02.550

03.200*

03.250 03.270

02.100

02.560

03.210* 03.270

02.580 02.500

03.260 03.280

02.630*

A

03.280 02.670

03.270

Loc tit 574 e

02.610 Loctite 241

02.530 02.520

B

* depending on parts list 015 180

11.3 Fitting connection plate 1

Clean sealing faces on following components: connection plate (02.500), release flange (02.520) and housing I (01.010).

NOTE All sealing faces and M10 threaded bores in housing I must be clean and free of oil and grease.

2

Fit pump.

Insert rotor (02.550), pump shaft (02.560) and pump cover (02.570).

Tighten 3 M6 bolts (02.580) to 10 Nm.

3

Insert new grooved ring (02.630) in piston (02.610), noting the installation position.

4

Insert piston (02.610) in connection plate (02.500).

1327 751 102 - 2004-04

5

If removed, insert three cylindrical pins (03.260) in housing I.

6

Place shims (03.150, 03.050 and 02.100) correctly on outer bearing races. Slightly grease shim (02.100).

WARNING: do not mix up shims 03.150 and 03.050.

7

Place brake cover (03.250) on housing sealing face. Collar of brake cover (03.250) faces clutch disc pack.

8

Fit outer clutch discs (03.270) and inner clutch discs (03.280) in accordance with parts list.

(The quantity and size of clutch discs depends on the parts list).

11-4

1327_02D_030_en

ZF-AS Tronic 9

Connection plate

Use tool 1X56 099 063 to press shaft seal (02.510) into release flange (02.520) until firmly home.

02.510

NOTE • Spray outer circumference of shaft sealed with spirits.

• Sealing lip must face towards inside of transmission.

10

11

02.530

Coat sealing face on release flange (02.520) with Loctite no. 574.

02.520

Loctite 574

Secure release flange (02.520) with 4 M8 hex bolts (02.530) on connection plate (02.500).

Tightening torque M8 = 23 Nm

015 856

12

Coat sealing face of connection plate (02.500) with Loctite no. 574.

13

Carefully move connection plate (02.500) over input shaft and place on transmission housing.

Align driver of pump (Z) so that it reaches into groove (Y) in the countershaft.

Loctite 574

Z

02.500

014 820

14

Spray 22 M10 hex bolts (02.670) M10 with Loctite no. 241 and tighten to 50 Nm.

Y

014 819

1327 751 102 - 2004-04

11-5

1327_02D_030_en

ZF-AS Tronic 12

Housing I

Housing I 06.270*

12.1 Removing housing I 1

06.260* 06.250*

Remove switch (06.260) and pin (06.250) and/or screw plug (6.270).

01.140

01.010

2

Remove circlip (02.120).

3

Remove snap ring (02.080/1) from ball bearing (02.080).

4

01.140

01.140

01.070

01.130 02.120

Remove filter (01.070).

02.080 02.080/1

* depending on parts list 015 176

5

6

Place intermediate piece 1X56 138 191 on input shaft. Fixture (20) 1X56 138 195 reaches into annular groove of ball bearing. Secure basic tool (5) 1X56 122 304 to fixture and pull off ball bearing (02.080).

5

Remove 24 M10 hex bolts (01.130).

Remove 4 cylindrical pins (01.140) – M12 extraction thread.

20

NOTE Drive out cylindrical pins (01.140) using drift key 1X56 138 063.

015 177

7

Secure 2 lifting lugs 1T66 154 240 to housing I. Do not damage housing centring in the process. Bridge the offset to the centring using 2-3 shims (see arrow).

Attach 3 section-chain 1X56 137 795 and care-fully lift off housing I (01.010).

01.010

016 690

1327 751 102 - 2004-04

12-1

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ZF-AS Tronic

Housing I

06.200 06.210 01.010 06.210

03.140 01.150 01.160 01.100

03.040

01.280

01.290

01.110*

* depending on parts list

01.040* 01.030* 015 175

12.2 Dismantling housing I The following components should be removed: outer bearing races (03.140, 03.040) type plate (01.150), M22x1.5 screw plugs (01.030, 01.040) M8 hex bolt (01.290) cover (01.280) breather (01.100, 01.110) spacer piece (06.200) and two clamping pins (06.210).

1327 751 102 - 2004-04

12.3 Assembling housing I 1

Insert outer bearing races (03.140, 03.040) in housing I (01.010).

2

Insert breather (01.100, 01.110) and secure cover (01.280) using M8 hex bolt (01.290).

3

Tighten M22x1.5 screw plugs (01.030, 01.040) and seal to 50 Nm.

4

Insert spacer piece (06.200) in housing I using clamping pins (06.210).

5

Secure type plate (01.150) using 4 blind rivets (01.160).

12-2

1327_01D_020_en

ZF-AS Tronic

Housing I

12.4 Fitting housing I 1

Clean sealing faces.

NOTE The sealing faces on housing I and housing II must be clean and free of oil and grease.

2

Coat sealing face on housing II with sealing compound 1215 (produced by Three Bond).

3

Use tools 1X56 138 200 and 1X56 138 201 (see arrow) to centre the spray pipes (01.420 and 01.430) in housing I (01.010). (For spray pipe installation, refer to Chap. 13)

4

Carefully place housing I (01.010) on housing II (01.400).

016 664

06.270* 5

Check whether the spray pipes (01.420 and 01.430) are seated correctly in housing I.

6

Insert cylindrical pins (01.140) (do not yet drive in all the way) and tighten 24 M10 hex bolts (01.130) to 50 Nm. Then drive in cylindrical pins (01.140) until firmly home.

7

8

06.260* 06.250*

01.140 01.140

01.010 01.140

01.070

01.130 02.120

Insert snap ring (02.080/1) in groove of ball bearing.

Use a heating mandrel to heat inner race of ball bearing (02.080) to approx. 80 - 90 °C.

02.080 02.080/1

* depending on parts list 015 176

! DANGER Only ever touch heated parts when wearing protective gloves.

1327 751 102 - 2004-04

12-3

1327_01D_030_en

ZF-AS Tronic 9

Housing I

Insert ball bearing (02.080) until snap ring (02.080/1) is lying on housing I, if necessary drive in using outer pipe of fixture (23) 1X56 138 216. Pull input shaft into ball bearing using fixture 1X56 138 216 in conjunction with mounting fixture (24) 1X56 045 808 and continue pulling until firmly home.

24

23

016 687

10

Remove fixtures and use a feeder gauge to measure thickness of snap ring (02.120).

When selecting the snap ring (02.120), a clearance of between 0 and 0.10 mm should be taken into consideration.

06.270* 06.260* 06.250*

01.140 01.140

01.010 11

Insert snap ring (02.120).

01.140

01.070 NOTE Snap ring (02.120) must lie on base of input shaft groove.

12

01.130 02.120

Insert pin (06.250) and tighten switch (06.260) to 45 Nm or tighten screw plug (06.270) to 35 Nm.

02.080 02.080/1

* depending on parts list 015 176

13

Insert filter (01.070).

14

For instructions on how to fit connection plate, refer to Chapter 11.3.

1327 751 102 - 2004-04

12-4

1327_01D_030_en

ZF-AS Tronic 13

Shaft pack

Shaft pack

13.1 Removing shaft pack 1

For removal of housing I, refer to Chap. 12.

2

Remove retaining bolt 1X56 138 208 and slide R-gear intermediate gears (05.040 and 05.140) to the side.

3

Remove the two spray pipes (01.420 and 01.430).

4

Tilt countershafts (03.010 and 03.110) to the side and take out.

5

Place fixture (25) 1X56 138 197 on input shaft. Slide sleeves (1 and 2) over selector rails. Then move fixture (23) 1X56 138 216 onto input shaft.

03.010

03.110 01.430

01.420

016 665

23

NOTE Fixture (23) 1X56 138 216 consists of two half shells, one pipe and one threaded piece.

On one side, insert the lugs of the two half shells in the groove of the input shaft and on the other side, insert threaded piece and fold over pipe. Screw a M10 lug bolt onto threaded piece of fixture 1X56 138 216.

6

25 1

2

05.140

05.040

Attach 3-section chain 1X56 137 795 onto lug bolt.

016 666

7

Use a crane to raise input shaft and main shaft together out of housing II.

8

Slide sleeves (1 and 2) upwards and take off selector rails.

If working with a 16 speed main shaft, hold the sliding sleeve (04.060) and then take off the selector rails.

9

Clamp main and input shaft in vice with protective jaws.

Main shaft 10 / 12-speed

Main shaft 16-speed

04.060 018 216

1327 751 102 - 2004-04

13-1

1327_05D_010_en

ZF-AS Tronic 10

Slide sliding sleeve (04.350) towards output. Circlip (02.350) becomes visible.

11

Use pointed flat tongs (3) to pull circlip (02.350) together and lift input shaft off main shaft.

Shaft pack

02.350 3

04.350

016 667

12

Take fixture 1X56 138 216 and sleeves (1 and 2) of fixture 1X56 138 197 off input shaft.

13

Secure guide plate (4) of fixture 1X56 138 197 with circlip (02.120).

02.120

14

For instructions on how to dismantle input shaft, refer to Chapter 14.1.

4

016 448

1327 751 102 - 2004-04

13-2

1327_05D_010_en

ZF-AS Tronic

Shaft pack

13.2 Fitting shaft pack 1

Attach fixtures (25) 1X56 138 197 and (23) 1X56 138 216 to input shaft.

2

Use a crane to place input shaft on main shaft. Slide sliding sleeve (04.350) towards output.

02.350 3

3

04.350

Use pointed flat tongs (3) to pull circlip (02.350) together and insert input shaft in main shaft.

CAUTION Check that the circlip has also snapped into the main shaft. If the circlip is not fitted correctly, this will result in total failure.

4

5

016 667

23

Insert gear shift forks of sub-assembled gear shift shafts in relevant sliding sleeves. Slide sleeves (1 and 2) of fixture 1X56 138 197 over the gear shift shafts.

If working with the 16-speed version, hold sliding sleeve (04.060) upwards and insert gear shift fork.

25 1

Assembly note: The intermediate gears (05.040 and 05.140) for the reverse gear are inserted in housing II. Use a crane to insert input shaft and main shaft in housing II. Remove fixtures (25) 1X56 138 197 and (23) 1X56 138 216.

1327 751 102 - 2004-04

05.140

2

05.040

016 666

13-3

1327_05D_020_en

ZF-AS Tronic 6

Shaft pack

Insert countershafts (03.010 and 03.110) – in accordance with marking.

CAUTION Each of the markings on the countershaft must be in the narrow window of the counting disc (02.060) (see arrow).

7

Select reverse gear and mesh intermediate gears (05.040 and 05.140) with the countershafts.

8

Fix intermediate gears (05.040 and 05.140) with retaining bolt 1X56 138 208.

016 449

9

10

Select neutral (move sliding sleeves into neutral position) and rotate through shaft pack once.

03.010

Insert the two spray pipes (01.420 and 01.430).

03.110

11

For instructions on housing I fitting, refer to Chapter 12.4.

01.420

01.430

016 665

1327 751 102 - 2004-04

13-4

1327_05D_020_en

ZF-AS Tronic

Input shaft

02.390 02.380 02.370 02.360 02.350 02.330 02.320 02.310 02.290 02.280

02.300 02.260

02.200

02.250 02.240

017 891

14

Input shaft

2

Remove the following components from the input shaft: split ring (02.380) washer (02.370) axial roller cage (02.360) bearing race (02.330) with circlip (02.350) washer (02.320) axial needle cage (02.310) helical gear for constant 2 (02.280) axial needle cage (02.250) washer (02.240)

3

Disassemble helical gear for constant 2 (02.280): Remove snap rings (02.290 and 02.260) and take out bearing disc (02.300).

4

Take out complete synchronizer (02.200).

For instructions on how to dismantle synchronizer, refer to Chapter 14.2.

14.1 Dismantling input shaft NOTE To dismantle the input shaft, clamp it in a vice with protective jaws.

1

Use a chisel to destroy circlip (02.390) of split ring (02.380) and remove. ! DANGER

Wear protective glasses when working with the chisel.

1327 751 102 - 2004-04

14-1

1327_02D_040_en

ZF-AS Tronic 5

Input shaft

Remove circlip (02.120) and guide plate (4).

02.120

4

017 926

6

7

Take counting disc (02.060) thrust washer (02.050) and helical gear for constant 1 (02.040) off input shaft. If necessary, use a manual press.

02.020 02.010 02.040

Remove bolt (02.020).

02.050

02.060

017 893

1327 751 102 - 2004-04

14-2

1327_02D_040_en

ZF-AS Tronic

Input shaft

14.2 Synchronizer (02.200)

Overdrive

Dismantling 1

/250 /240

02.200 /220

Place synchronizer (02.200) on table with collar facing downwards. Cover with a cloth.

Pull synchronizer ring K2 (/220) up and off.

17

/180 /160 /150

! DANGER

/210

/110

3 compression springs (/240) and 3 cylindrical rollers (/250) will jump out of the bores.

2

Slide bolt (/160) through sliding sleeve (/150).

Rotate plate (/180) through half a tooth and take off sliding sleeve (/150).

/120 016 691

3

The pins (/120) and (/210) can be pressed out of the synchronizer rings (/110) and (/220) if necessary.

Direct drive 02.200 /220

Assembling

17

/180 CAUTION Note component number on synchronizer ring (/220): Overdrive Direct drive 1328 302 014 1328 302 013 1328 302 086 1328 302 085 1328 302 113 1328 302 112

/160 /150

/210

/110

/240 /250

/120 1

2

Press the longer 3 pins (/120) into the synchronizer ring (/110) and the shorter 3 pins (/210) into the synchronizer ring (/220).

017 892

Place plate (/180) on sliding sleeve (/150) and rotate through half a tooth.

3

The hole in the sliding sleeve (/150) must be flush with one of the 3 recesses in plate (/180).

Insert bolt (/160) through sliding sleeve hole until firmly home.

4

In each of the three holes of the synchronizer ring (/220), insert one compression spring (/240) and one cylindrical roller (/250) and secure with assembly sleeves (17) 1X56 138 081.

1327 751 102 - 2004-04

/160 /220

/150 /180

14-3

/210

/110

Direct drive

Overdrive

/120

1327_02D_060_en

ZF-AS Tronic 5

Input shaft

Place synchronizer ring K1 (/110) and subassembled selector sleeve (/150) with plate (/180) on assembly plate (16) 1X56 138 097.

16

017 894

6

Put synchronizer ring K2 (/220) with 3 assembly sleeves (17) on locking bolt (/120) of synchronizer ring K1 (/110).

7

Evenly press synchronizer rings together.

8

Remove assembly sleeves (17) while pressing synchronizer ring K2 (/220) downwards.

17

017 895

9

Rotate synchronizer.

Move synchronizer into central position by lifting plate (/180) with sliding sleeve (/150) and in so doing pressing synchronizer ring (/110) downwards.

Check that the bolt (/160) has not fallen out.

017 896

1327 751 102 - 2004-04

14-4

1327_02D_060_en

ZF-AS Tronic

Input shaft

14.3 Assembling input shaft 1

To assemble the input shaft, clamp it in a vice with protective jaws.

02.020 02.010

2

Place bolt (02.020) in input shaft (02.010).

3

Fit helical gear for constant 1 (02.040) and thrust washer (02.050).

4

Slide on counting disc (02.060).

02.040 02.050

NOTE A clearance of up to 0.3 mm is permitted between the bolt (02.020) and counting disc (02.060).

5

Fit guide plate (4) of fixture 1X56 138 197 and use circlip (02.120) to secure.

6

Rotate input shaft through 180° and clamp in a vice with protective jaws.

02.060

017893

02.120

4

017926

1327 751 102 - 2004-04

14-5

1327_02D_050_en

ZF-AS Tronic

Input shaft

02.390 02.380 02.370 02.360 02.350 02.330 02.320 02.310 02.290 02.280

02.300 02.260

02.200

02.250 02.240

017891

7

Place synchronizer (02.200), washer (02.240) and axial needle cage (02.050) on input shaft.

8

Insert bearing disc (02.300) and both snap rings (02.260 and 02.290) in helical gear for constant 2 (02.280).

9

Place sub-assembled helical gear for constant 2 and input shaft.

1327 751 102 - 2004-04

10

Place the following components on the input shaft one after another. axial needle cage (02.310) washer (02.320) bearing race (02.330) with circlip (02.350) axial roller cage (02.360) washer (02.370) split ring (02.380) circlip (02.390)

11

Secure circlip (02.390) by peening 3x120°.

12

For instructions on how to fit the input shaft, refer to Chapter 13.2.

14-6

1327_02D_050_en

ZF-AS Tronic 15

Main shaft

Main shaft 04.300

15.1 Dismantling main shaft

04.310 04.350 1

Clamp main shaft in a vice with protective jaws.

2

Remove oil pipe (04.040).

3

04.280 04.290

04.110 04.130 04.110 04.140 04.150

04.160 04.200 04.210 04.220

04.230 04.240 04.250 04.270

Press wedge (04.030) out of hole, e.g. using a small screwdriver and pull downwards.

Secure the last helical gear with the wedge.

04.020 04.010 04.060 04.030 04.080

04.040

04.090 4

Take off sliding sleeve (04.350).

5

Rotate washer (04.310) through 1/2 tooth and take off.

04.100 Main shaft, 16-speed

Take off helical gear (04.300). Remove washer (04.290) and snap ring (04.280) from helical gear.

7

Rotate washers (04.270 and 04.250) through 1/2 tooth and take off main shaft.

8

Take off helical gear (04.220). Take washer (04.230) and snap ring (04.240) out of helical gear.

9

Rotate (04.210) through 1/2 tooth and take off.

10

Take off sliding sleeve (04.200).

Take following components off main shaft (04.010): washer (04.160*), helical gear (04.150*), washer (04.140*), snap ring (04.240*), 2* or 1 washer (04.110), snap ring (04.100), washer (04.090), helical gear (04.080), washer (04.070) and sliding sleeve (04.060*).

12

If oil pipe (04.020) is damaged, remove.

015 205

04.200 04.110 04.210 04.220 04.230 04.240 04.250 04.270 04.280 04.290 04.020 04.300 04.010 04.310 04.070 04.350 04.080 04.030 04.090 04.040 04.100

6

11

04.070

Main shaft, 10 and 12-speed

015 206

04.030 Main shaft, 10 and 12-speed

015 207

* only on 16-speed 1327 751 102 - 2004-04

15-1

1327_04D_010_en

ZF-AS Tronic

Main shaft

04.300

04.280 04.290

04.110 04.130 04.140

04.310 04.350

04.110

04.150 04.160 04.200 04.210 04.220

04.230 04.240 04.250 04.270

Snap ring

04.020 04.010 04.060 04.070

04.030 04.040

04.090 04.100

Main shaft, 16-speed

04.080 017 889

04.200 04.110 04.210 04.220 04.230 04.240 04.250 04.270 04.280 04.290 04.020

04.300 04.010 Snap ring

04.310 04.070

04.350 04.080

04.090 04.100

04.030 04.040

Main shaft, 10 and 12-speed 017 890

1327 751 102 - 2004-04

15-2

1327_04D_010_en

ZF-AS Tronic

Main shaft

15.2 Assembling main shaft 1

Drive oil pipe (04.020) into main shaft (04.010) using tool 1X56 138 205.

Check distance: oil pipe overhang 15-1 mm

2

Clamp main shaft in a vice with protective jaws.

3

If working with the 16-speed version, slide sliding sleeve (04.060*) onto main shaft so that recess in spline faces wedge (04.030).

4

Slide washer (04.070) onto main shaft. In groove of main shaft, rotate washer (04.070) through half a tooth and lock with the wedge (04.030).

04.070

04.030

10 /12-speed main shaft version 016 658

10

Fit washer (04.210) and rotate through half a tooth. Slide wedge (04.030) upwards and adjust washer.

11

In helical gear (04.220), insert snap ring (04.240) and washer (04.230). Slide sub-assembled helical gear (04.220) onto main shaft.

12

Fit the washers (04.250 and 04.270) and rotate through half a tooth. Slide wedge (04.030) upwards and adjust washer(s).

In helical gear (04.080), insert snap ring (04.100) and washer (04.090). Slide sub-assembled helical gear (04.080) onto main shaft.

13

In helical gear (04.300), insert snap ring (04.280) and washer (04.290). Slide sub-assembled helical gear (04.300) onto main shaft.

Fit 2* or 1 washer (04.110) and rotate through half a tooth. Slide wedge (04.030) upwards and adjust washer(s).

14

Fit washer (04.310) and rotate through half a tooth. Slide wedge (04.030) upwards and adjust washer.

15

Slide sliding sleeve (04.350) onto main shaft with recess facing upwards. Align recess on sliding sleeve and main shaft with one another.

16

Snap lug of wedge (04.030) into blind hole.

17

Insert oil pipe (04.040).

18

For installing main shaft, refer to Chapter 13.2.

NOTE The wedge is located in the main shaft spline where the blind hole is located.

CAUTION When sub-assembling the helical gears, ensure that the stamping thickness (see arrow in Figures 17889 and 17890) of washers (04.090), (04.230), (04.290), (04.140*) does not face the snap ring.

5

6

7

8

9

In helical gear (04.150), insert snap ring (04.130) and washer (04.140).

Slide sub-assembled helical gear (04.150) onto main shaft.

Fit washer (04.160*) and rotate through half a tooth. Slide wedge (04.030) upwards and adjust washer.

Slide sliding sleeve (04.200) onto main shaft.

* only on 16-speed 1327 751 102 - 2004-04

15-3

1327_04D_020_en

ZF-AS Tronic 16

Countershaft

Countershaft

16.1 Removing countershafts 03.020 1

Pull off inner bearing races (03.020, 03.040, 03.120 and 03.140) with gripper 1X56 136 740 and basic tool 1X56 122 304.

NOTE The countershaft cannot be dismantled any further. In other words, if a gearing is damaged, the complete countershaft always has to be replaced.

03.010 03.120 03.040

03.110

03.140

16-speed transmission

016 668

16.2 Fitting countershafts CAUTION Check tapered roller bearing and if damaged, replace because the roller bearings may be damaged when pulled off.

03.020 03.010

1

Heat up inner bearing races (03.020, 03.040, 03.120 and 03.140) to approx. 120 °C and place on countershaft with no clearance.

03.120 03.040

! DANGER

03.110

03.140

Only touch heated components when wearing protective gloves.

10 and 12-speed transmission

2

016 669

For instructions on how to fit countershafts, refer to Chapter 13.2

1327 751 102 - 2004-04

16-1

1327_03D_010_en

ZF-AS Tronic 17

Gear shift shaft

Gear shift shaft 06.100

17.1 Dismantling gear shift shaft 06.120 1

Unlock and take off gear shift forks (06.100*, 06.120 and 06.160).

2

Take interlock (06.140) and gear shift finger (06.010/120) off gear shift shaft (06.010/110).

06.080 06.140 06.160

/110 /120 06.010

16-speed transmission

015 209

17.2 Assembling gear shift shaft 1

Insert gear shift finger (06.010/120) in gear shift shaft (06.010/110).

2

Place interlock (06.140) on gear shift shaft.

3

Snap gear shift forks (06.100*, 06.120 and 06.160) into correct position in interlock.

06.120

06.140 06.160

CAUTION Do not mix up gear shift forks 06.120 and 06.160, if necessary refer to parts list.

4

For instructions on how to fit gear shift shaft, refer to Chapter 13.2.

/110 /120

06.010

10 and 12-speed transmission

015 208

* only with 16-speed transmissions

1327 751 102 - 2004-04

17-1

1327_06D_010_en

ZF-AS Tronic

Housing II

05.010 32.330

01.490*

32.310

01.400 01.440

01.490*

01.440 05.110

03.020

05.040 05.020

03.120

01.480* 05.140

01.480* 05.120 01.460 * depending on parts list 015 210

18

Housing II

18.1 Dismantling housing II

4

Remove snap ring (32.330).

5

Evenly heat housing II at bearing bore using a hot air blower to approx. 100 °C and carefully pull off roller bearing (32.310).

NOTE Reverse idler shafts (05.010 and 05.110) have already been removed.

!

1

Remove R-gear intermediate gears (05.040 and 05.140) and take out needle cages (05.020 and 05.120).

2

Remove the following components from housing II (01.400): screw plug (01.460) M24x1.5 screw plug (01.480) M24x1.5 screw plug (01.490) M24x1.5

3

Remove outer bearing races and tapered roller bearing (03.020 and 03.120) if inner bearing races are being replaced on countershaft.

1327 751 102 - 2004-04

DANGER Only touch heated parts when wearing protective gloves.

6

18-1

Only remove bolt (01.440) if defective or if housing II is being changed.

Heat housing II to approx. 90 °C and drive out bolts.

1327_01D_040_en

ZF-AS Tronic

Housing II

05.010 32.330

01.490*

32.310

01.400 01.440

01.490*

01.440 05.110

03.020

05.040 05.020

03.120

01.480* 05.140

01.480* 05.120 01.460 * depending on parts list 015 210

5

Insert R-gear intermediate gears (05.040 and 05.140) with needle cage (05.020 and 05.120).

Only touch heated parts when wearing protective gloves.

6

Reverse idler shafts (05.010 and 05.110) are fitted later.

1

7

If bolts (01.440) are missing, heat housing II to approx. 90 °C, grease bolts slightly and carefully drive in or press in using manual press.

18.2 Assembling housing II ! DANGER

Use a hot air blower to evenly heat bearing seat in housing II to approx. 100 °C and insert outer bearing race of roller bearing (32.310) in housing II until firmly home.

2

Snap in snap ring (32.330).

3

Use a hot air blower to evenly heat bearing seat in housing II to approx. 100 °C and insert outer bearing race of tapered roller bearings (03.020 and 03.120).

4

CAUTION Do not twist bolts during assembly otherwise there is a risk of housing failure.

8

For instructions on how to fit shaft pack, refer to Chapter 13.2.

Tighten screw plugs (01.460, 01.480 and 01.490) M24x1.5 to 60 Nm.

1327 751 102 - 2004-04

18-2

1327_01D_050_en