DOWNLOAD PDF ZF Ecosplit 16 D 151, 8 S 151 Repair Manual 1315 751 101d

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16 S 151 8 S 151 1315 751 101d

16 S 151 / 8 S 151

Contents Page

Contents .........................................................................................................................................

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

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

Safety instructions..........................................................................................................................

Tightening torques for nuts and bolts.............................................................................................

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

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

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

View of transmission......................................................................................................................

1-01 1-03 1-04 1-06 1-07 1-08 1-09 1-14 1-16

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Removing components/range-change ........................................................................................

Plastic pipes ...................................................................................................................................

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

Cover ..............................................................................................................................................

5/2-way valve .................................................................................................................................

Shift cylinder for range-change .....................................................................................................

Housing/range-change ..................................................................................................................

Planet gear train with synchronizer................................................................................................

Assembling planet gear train with range-change synchronizer .....................................................

Assembling range-change /housing/output flange/piston ..............................................................

2-01 2-01 2-01 2-01 2-02 2-02 2-03 2-04 2-06 2-09

2 2.1 2.2 2.3 2.4

Removing components from centre housing .............................................................................

Splitter (GV) cylinder ....................................................................................................................

Shift housing ..................................................................................................................................

Shift housing, friction-optimized version ......................................................................................

Shift mechanism/selector patterns .................................................................................................

2-12 2-12 2-12 2-16 2-21

3 3.1 3.2 3.3

Removing components from clutch housing..............................................................................

Release fork ...................................................................................................................................

Connection plate with integral pump .............................................................................................

Clutch housing ...............................................................................................................................

2-24 2-24 2-25 2-26

4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.7.1 4.7.2 4.8

Removing components .................................................................................................................

Removing components/clutch housing ..........................................................................................

Splitter shift rail /centre housing ...................................................................................................

Removing shafts.............................................................................................................................

Removing components/centre housing .........................................................................................

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

Mainshaft .......................................................................................................................................

Assembling synchronizer...............................................................................................................

Version ZF-BK...............................................................................................................................

Version ZF-D .................................................................................................................................

Layshaft..........................................................................................................................................

2-26 2-26 2-26 2-27 2-27 2-28 2-30 2-37 2-37 2-38 2-39

1-01

Contents

16 S 151 / 8 S 151 Page

5 5.1 5.2

Installing components .................................................................................................................. 2-41 Centre housing .............................................................................................................................. 2-41 Clutch housing ............................................................................................................................... 2-41

6 6.1 6.2

Synchronizer/wear limits............................................................................................................. 2-42 Determining wear limit (except 1st and 2nd gears) ....................................................................... 2-42 Determining wear limit (1st and 2nd gears)................................................................................... 2-42

7 7.1 7.1

Adjusting mainshaft..................................................................................................................... 2-43 Selecting thrust washer and shim, straight-cut version.................................................................. 2-43 Selecting thrust washer and shim, helical-cut version ................................................................... 2-44

8 8.1

Installing shafts ............................................................................................................................ 2-45 Installing input shaft, mainshaft, layshaft and shift rails ............................................................... 2-45

9 9.1

Splitter shift fork .......................................................................................................................... 2-46 Adjusting shift fork ........................................................................................................................ 2-46

10 10.1

Clutch housing/centre housing ................................................................................................... 2-48 Fitting clutch housing to centre housing ....................................................................................... 2-48

11 11.1 11.2

Adjusting shafts............................................................................................................................ 2-49 Input shaft ..................................................................................................................................... 2-49 Layshaft.......................................................................................................................................... 2-50

12 12.1 12.2

Fitting clutch housing components............................................................................................. 2-51 Connection plate with integral pump ............................................................................................. 2-52 Release fork ................................................................................................................................... 2-53

13 13.1 13.2 13.3 13.4 13.5

Fitting centre housing components.............................................................................................

Reverse idler gear/reverse idler pin................................................................................................

Cylinder..........................................................................................................................................

5/2-way valve .................................................................................................................................

Compressed air test for piston and splitter cylinder.......................................................................

Injection pipe ................................................................................................................................

14

Fitting complete range-change ................................................................................................... 2-58

15 15.1 15.3

Fitting components....................................................................................................................... 2-60 Shift housing .................................................................................................................................. 2-60 Plastic pipes ................................................................................................................................... 2-60

16

Compressed air test on breather ................................................................................................ 2-61

1-02

2-55 2-55 2-55 2-56 2-56 2-57

16 S 151 / 8 S 151

Preface

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

This manual deals with the standard ZF product in accordance with the state of development on the date of issue.

However, due to continuing development of the product, repair work might require work practices and test or adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our Service Training Center.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. specialized tools 3. Genuine ZF spares, to our latest specifications

All work performed in these service points is carried out conscientiously and with care.

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

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies where genuine ZF spares have not been used.

ZF FRIEDRICHSHAFEN AG Friedrichshafen Division Service

1-03

General Information

16 S 151 / 8 S 151

Description of transmission The ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmissions have been developed for heavy goods vehicle applications (from 220 to 370 kW).

16 S 151 and 8 S 151 transmissions main components: - 4-speed section with reverse gear - rear-mounted range-change of planetary design - front-mounted integrated splitter group (not in 8 S 151) ZF Friedrichshafen AG offers the following options with these transmissions: - NMV 221, engine-dependent PTO - torque converter clutch (WSK) - further engine-driven ZF PTO (NMV) together with the torque converter clutch - various clutch-dependent ZF PTOs - drive for emergency / dual-circuit steering pumps - separate heat exchanger for extreme applications - ZF Intarder - ZF ES 2 shift system - silent kit

Repair manual NOTE: If clamping fixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover before attaching the clamping fixture.

When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set.

Then install the reverse idler gear pin.

CAUTION The transmission must not be suspended by the input shaft nor by the output flange when transporting, removing, installing and repairing. ! ENVIRONMENTAL HAZARD !

Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system.

• Request safety information for the products concerned from your local environmental protection authority, and follow any instructions herein at all times.

• Always collect used oil in a suitably large container.

• Always dispose of used oil, clogged filters, lubricants and cleaning agents in accordance with environmental protection laws.

• Always observe manufacturer instructions when dealing with lubricants and cleaning agents.

NOTE: Additional removal and installation instructions 1315 754 007 are available for transmissions with silent kit.

1-04

16 S 151 / 8 S 151

General Information

General This repair manual shows how to repair a ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmission.

Layout of repair manual: Section 1 includes adjustment data, tightening torques, spring characteristics and a list of specified ZF special tools.

Section 2 is a step-by-step guide to transmission repairs.

Directions for removal and assembly, general work instructions This repair manual is based on the steps necessary for the complete removal of transmission components and their subsequent reassembly. When circumstances require, the assembly procedure for certain components is described immediately after the removal procedure. Such cases include the section on the “mainshaft and layshaft’’, in which assembly instructions are given after removal instructions so as to ensure that only fully repaired components proceed to the complete assembly phase. This procedure reduces the risk of mixing up individual components and shortens the overall assembly phase.

Always ensure cleanliness and appropriate high standard of work; therefore, clean all transmissions removed from vehicles before dismantling.

Specified ZF special tools must be used.

After dismantling, clean all transmission components. Particular attention should be paid to corners, recesses and protruding edges on housings and covers.

Carefully remove old sealing compound and gaskets. Check for blocked of lubrication oil bores, grooves and pipes.

There must be no build-up of deposits, foreign matter or preservatives. This is especially important in the case of new components.

It is impossible to avoid damaging some components during dismantling; these must always be renewed ; e.g.shaft seals, O-rings, grooved rings, flange packing, protective caps etc. Components such as roller bearings, thrust washers, synchronizer parts, etc., which are subject to normal wear during operation, must be checked by a specialist to determine whether they can be reused Gaskets must be fitted dry, i.e. free from oil and grease. Sealing faces without gaskets must be sealed using a plastic-type, heat- oil-resistant sealing compound (e.g. WEVO-L 100 A).

During assembly, observe all adjustment values, test data and tightening torques.

Fill the transmission with transmission oil after repair. Procedure for this and permitted oil types are given in the Operating Manual and List of Lubricants TE-ML 02. These documents may be obtained from all ZF After-Sales Service points.

After filling with oil, tighten oil check plugs and oil drain plugs to specified torque.

1-05

Work Safety

16 S 151 / 8 S 151

Important work safety notice: Companies who repair ZF units are responsible for their own work safety.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.

Personnel required to carry out repairs on these ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that repair staff is properly trained.

The following safety instructions appear in this manual: NOTE

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 serious injury or death.

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

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

CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures.

Pictures, drawings and components are not to scale, and no information about size and weight should be inferred (even within a complete illustration).

Always follow the working steps as described in the text.

1-06

16 S 151 / 8 S 151

Tightening Torques

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

This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12. Coating ZFB 811 Dacromet or coating ZFB 998 Deltatone - Deltaseal.

Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chromeplated and oiled.

NOTE: Tightening torques which differ from the values below are separately listed in the repair instructions.

Metric coarse pitch thread

Metric fine pitch thread

Size

Size

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

M 4 M 5 M 6

2.8 5.5 9.5

4.1 8.1 14

4.8 9.5 16.5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

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

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

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

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

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

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

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

760 730 1100

1100 1050 1600

1250 1200 1850

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

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991

1-07

Spring Table

16 S 151 / 8 S 151

Part number

Installation point

0732 040 630

Shift mechanism: on shift shaft (depending on version)

6.5

2.4

39.6

89.9

0732 040 985

Shift mechanism: spherical roller for detent part or reverse gear interlock (depending on version)

6.5

2.0

14.8

23.4

0732 040 986

Shift mechanism: spherical roller for detent part or reverse gear interlock (depending on version)

5.5

2.25

14.8

21.6

0732 040 984

Shift mechanism: reverse gear interlock (depending on version)

9.5

1.4

9.4

23.3

0732 040 736

Shift mechanism: for detent pin and locking pin interlock

13.5

1.6

9.8

36.0

0732 040 409

Synchronizers input shaft and mainshaft

12.5

1.4

6.65

23.7

0732 042 126

Detent piece (compression spring)

9.5

1.0

9.4

25.0

0732 042 365

Detent piece (compression spring)

5.5

1.7

20.44

31.49

0732 042 366

Detent piece (compression spring)

4.5

1.5

15.03

15.6

0732 042 400

Detent piece (compression spring)

10.5

2.25

15.5

39.7

0732 042 401

Detent piece (compression spring)

12.5

1.5

10.1

36.0

1-08

No. of coils

Wire diam. in mm

Spring diam. Untensioned in mm length in mm

16 S 151 / 8 S 151

Adjustment Data

Description

Tolerance

Measuring device

Remarks

01. Axial play on layshaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on output end.

02. Combined axial play of mainshaft and input shaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on input shaft.

03. Axial play / prestress of split ring on input shaft and mainshaft (only in older version)

- 0.05 to + 0.05 mm

Micrometer or feeler gauge

Always use correct tool.

04. Insertion depth for shaft seal in output flange cover

12.5 + 1.0 mm

Depth gauge and/or drift 1X56 137 124

Measure depth of insertion between outside of cover and face of shaft seal. If drift is used with ring, depth is automatically given (must be flat).

05. Axial play on ball bearing in cover (range-change)

0 - 0.10 mm

Depth gauge/sliding caliper

Adjust using appropriate shims in cover.

06. Axial play on helical gear on input shaft

Min. 0.20 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

07. Axial play on helical gears on mainshaft

Min. 0.20 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

08. Axial play on 4th-speed helical gear

Min. 0.05 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

09. Axial play on circlips on layshaft and mainshaft

0 - 0.05 mm

Micrometer or feeler gauge

Use appropriate circlip.

Feeler gauge

Not adjustable. Measure as check only.

10. Axial play of reverse idler 0.4 - 1.15 mm gear

1-09

Adjustment Data

16 S 151 / 8 S 151

Description

Tolerance

Measuring device

Remarks

11. Permitted axial play on planet gears in planet carrier

0.4 to 1.30 mm

Feeler gauge

Tolerance includes permitted wear on thrust washers.

If wear limit exceeded exchange thrust washers

Feeler gauge

Exchange synchronizer ring and/or clutch body if dimension too small

12. Wear limit for synchronizer ring and clutch body, measured between flat surfaces of ring and body with cones firmly nested together.

4-gear section and splitter Range-change

0.80 mm 1.20 mm

13. Wear limit for 1st/2nd gear synchronizer parts, measured between outer ring and clutch disc, measured with cones nested firmly together ) and force F = 50 N applied on the outer ring.

1.5 mm

Feeler gauge

Exchange intermediate ring and/or outer ring and inner ring if wear limit is excluded.

14. Max. permitted play on fulcrum pads in sliding sleeves

0.6 - 1.2 mm

Feeler gauge

Exchange if play is excessive

15. Adjustment dimension for 94.0 mm splitter shift fork

Depth gauge

Nominal dimension between piston and mid-housing sealing face without gasket.

Fulcrum pads must have play of min. 0.10 mm upwards and downwards.

Tightening torque for grub screw: 60Nm

16. Adjusting mainshaft and determining thickness of shim and ring (in straightcut version)

Depth gauge

Measured between upper edge of clutch body with ring inserted and midhousing with gasket attached. Select appropriate ring to ensure nominal dimension (see table)

1-10

32.20 - 0.5 mm

16 S 151 / 8 S 151

Description

Adjustment Data

Tolerance

Selection of ring and shim

Measuring device

Remarks

Sliding caliper

Ring

Shim

3.6 mm

7.9 mm

4.0 mm

8.3 mm

Table shows which shim is correct for which ring 17. Adjusting mainshaft and determining thickness of ring and shim (in helicalcut version)

+ 0.07 to - 0.08 mm (Shim) 4.6-0.4 mm (Ring)

Depth gauge

Measure and determine thickness of shim first.

Then, measure and select ring.

18. Temperature for shrinkfitting helical gears onto layshaft

160 - 180 °C

Temperature probe

Gears and shaft seats must be free of oil and grease during assembly

19. Tightening torque for breather

10 Nm

Torque wrench

20. Tightening torque for M12 x 1.5 screws in housing

30 Nm

Torque wrench

Use new seal rings

21. Tightening torque of union screws for plastic pipes

35 Nm

Torque wrench

Use new seal rings

22. Tightening torque for detent plungers

50 Nm

Torque wrench

Use new seal rings

23. Tightening torque for pressure switch/impulse sensor

50 Nm

Torque wrench

Use new seal rings

24. Tightening torque of M12 bolts for output flange

60 Nm/120 Nm (chap. 1.9.1)

Torque wrench

Fit new retaining plate.

Use Loctite No. 262.

25. Tightening torque for shift fork grub screws

4-gear section: 50 Nm Splitter: 60 Nm

Torque wrench

1-11

Adjustment Data

16 S 151 / 8 S 151

Description

Tolerance

Measuring device

Remarks

26. Tightening torque for M38 x 1.5 magnetic screw

140 Nm

Torque wrench

Clean magnet and fit new seal ring

27. Tightening torque for locking bolts on reverse idler pin New version with slotted pin

86 Nm

Torque wrench

Use new bolt and washer.

28. Tightening torque for locking nuts on rangechange and splitter pistons

150 Nm

Torque wrench

Use new locking nut

29. Tightening torque for hex bolts between clutch housing and mid-housing

50 Nm

Torque wrench

30. Tightening torque for M18 x 1.5 screw plugs on housing

35 Nm

Torque wrench

Use new seal rings

31. Tightening torque for M22 x 1.5 screw plugs on housing

50 Nm

Torque wrench

Use new seal rings

32. Tightening torque for M24 x 1.5 screw plugs on housing

60 Nm

Torque wrench

Use new seal rings

33. Heating temperature for ring gear

60 °C

Temperature probe

Do not exceed temperature

34. Temperature of synchronizer hub, clutch body, bushes and counting disc

120 °C

Temperature probe

Do not exceed temperature

35. Temperature of output flange

Max. 70 °C

Temperature probe

Do not exceed temperature

36. Temperature of input shaft roller bearing

100 °C

Temperature probe

Do not exceed temperature

1-12

16 S 151 / 8 S 151

Adjustment Data

Description

Tolerance

Measuring device

Remarks

37. Temperature of 4th-speed helical gear with needle cages on mainshaft

120 °C

Temperature probe

Do not exceed temperature

38. Rolling-in torque for injection pipe

5 - 6 Nm

Torque wrench

Rolling-in tool 1X56 155 653

39. Lifting device for input shaft/ mainshaft/ layshaft

85 Nm

Torque wrench

DANGER Fit lifting device carefully

40. Tightening torque for pivot bolts on shift fork

250 Nm

Torque wrench

Use Loctite No. 241

41. Tightening torque for M8 hex bolts on shift cover

23 Nm

Torque wrench

42. Tightening torque for M10 hex bolts on shift lever

49 Nm

Torque wrench

43. Tightening torque for M8 hex bolts on shift housing cover (with detent piece)

23 Nm

Torque wrench

44. Tightening torque for M8 hex bolts on cutoff valve

23 Nm

Torque wrench

45. Tightening torque for M26 x 1.5 screw plugs on housing

70 Nm

Torque wrench

Use new seal rings

46. Tightening torque for M48 x 1.5 screw plugs on housing

150 Nm

Torque wrench

Use new seal rings

1-13

1-14

1X56 137 921

1X56 137 122

1X56 137 949

1X56 136 731

1X56 136 710

1X56 137 675

1X56 137 920

1X56 137 124

1X56 137 933

1X56 137 579

1X56 137 246

1X56 137 287

1X56 136 573

1X56 137 918

1X56 137 991

1X56 122 304

1X56 122 303

1X56 136 564

Special Tools 16 S 151 / 8 S 151

1X56 136 599

1X56 138 109

1X56 138 079

1X56 137 676

1X56 137 917

1X56 137 835

1X56 122 314

1X56 136 722

009526

1X56 137 651

1X56 138 064

1X56 137 200

1X20 155 653

1X56 119 916

1X56 103 766

1X56 136 743

137

1X56 138 063

1X56

1X56 122 310

16 S 151 / 8 S 151 Special Tools

200

1-15

View of Transmission

16 S 151 / 8 S 151

00 795

1-16

16 S 151 / 8 S 151 1.

Removing components/range-change

1.1

Plastic pipes

Removing Range-Change

3 6

NOTE: Label plastic pipes before removing to ensure correct re-assembly.

1

Unscrew union screws (1 and 2) from rangechange cylinder (3) and cutoff valve (4). Loosen pipe clip (5) on housing and remove complete together with plastic pipes (6).

5 2 6

1

2

4

1 001992

1.2

Output flange

1

Lever off retaining plate (1) from bolts (2).

2

Secure output flange to prevent it from turning.

3

Unscrew hex bolts (2) and remove clamping disc (3).

4

Place adapter onto planet carrier and remove output flange (4) using 2- or 3-leg puller

5

Remove O-ring (5).

5

4

3

2 1

001902

1.3

Cover

1

Unscrew hex bolts from cover (1) and remove together with gasket (2).

2

Unscrew hex bolts and remove cover (3) together with gasket (4), shaft seal (5), shim (6) and ball bearing (7).

3

7

6

1

4

3

5

Using plastic drift, drive out ball bearing from cover. and remove loose shim.

NOTE: For helical gear version, use extractor 1X56 122 314 to remove ball bearing from output shaft.

4

2

001903 001903

Using plastic drift, drive out shaft seal from cover.

2-01

Removing Range-Change 1.4

5/2-way valve

1

Unscrew 5/2-way valve (1) from centre housing.

2

Remove O-rings (2).

16 S 151 / 8 S 151

NOTE: Do not dismantle 5/2-way valve since it is a complete part.

NOTE: 5/2-way valve is not included in 8 S 151 transmission.

2 1

001904 001904

1.5

Shift cylinder for range-change

1

Unscrew hex bolts, loosen cylinder (1) from range-change housing and remove from piston (2).

2

Remove O-rings (3 and 4) from cylinder.

3

Remove detent plunger (5). Screw fixing device 1X56 137 579 into threaded bore and position fixing element on shift rail (6). Tighten fixing device.

Tightening torque = 50 Nm.

4

Unscrew locking nut (7) from piston (2).

5

Remove piston together with guide ring (8) and grooved ring (9).

6

Remove grooved ring (9) and seal ring (11, new version only) .

7

Remove guide ring and grooved rings from piston.

8

Pull out flange packing (10) from range-change housing.

2 10 11

8

11

7 4

1

3

9 9 8 2 10

7

1

4

3

5

6 001905

2-02

16 S 151 / 8 S 151 1.6

Housing/range-change

1

Remove mechanical speedometer or impulse sensor (15).

2

Remove pivot bolts (1) for shift fork (2).

3

Remove fixing device 1X56 137 579.

4

Unscrew hex bolts from range-change housing (3).

Removing Range-Change

4

15

! DANGER Planet gear train is not secured on mainshaft.

Secure this to prevent from falling.

5

6

Remove shift fork (2) together with fulcrum pads (6).

7

Remove intermediate plate (7) together with gaskets (8).

8

Remove switch (9) together with seal ring and pin (10). New version (13 and 14) also possible.

9

Pull out shift rail (11) from centre housing.

10

Remove injection pipe (12).

4

3

4 2

Separate range-change housing (3) from centre housing (5) without tilting and remove. Use pins to ensure correct position (4).

6

1

12

1

8 7 8

13 5

14

11 9 10 001906

2-03

Removing Planet Gear Train 1.7

1

16 S 151 / 8 S 151

Planet gear train with synchronizer NOTE: Prevent planet gear train from falling out when removing.

4

Remove complete planet gear train from mainshaft together with synchronizer.

5 3*

1.7.1 Synchronizer

2 1

! DANGER Pressure pieces are under spring pressure. Secure them to prevent them flying out.

1

Place adapter onto planet carrier. Attach two-or three-leg puller underneath sliding sleeve (1) and pull off together with clutch body (2). Use a cloth to catch pressure pieces (4) and pressure springs (5) held by the sliding sleeve.

7 8

6 10

9

11

NOTE: In the straight-cut version, pull off speedo worm or counting disc (3) with integrated bush together with clutch body (2).

001907

NOTE: Parts marked * according to parts list.

2

Remove synchronizer ring (6).

3

Remove circlip (7).

4

Place adapter onto planet carrier and pull off synchronizer hub (8) using 2- or 3-leg puller.

5

Remove synchronizer ring (9) and clutch body (10) from planet carrier (11).

2-04

16 S 151 / 8 S 151

Removing Planet Carrier

1.7.2 Ring gear 1

Attach circlip (7) from Section 1.7.1 onto ring gear carrier. Place adapter onto planet carrier and fit using 2- or 3-leg puller underneath circlip.

2 1

Straight-cut version: 2

Pull off ring gear (1), ring gear carrier (2) and ball bearing (5) together.

3

Detach safety wire (4) from annular groove in ring gear.

4

Using plastic hammer, drive out ring gear carrier (2) from ring gear (1).

5

Detach snapring (3) from ring gear carrier and remove ball ball bearing (5).

6

Remove intermediate ring (6) from planet carrier.

6

4

3

5

001908

Helical-cut version: 2

3

4

Pull off ring gear (1), ring gear carrier (2), intermediate ring (3) and axial needle bearing (5) together.

2 1

Detach safety wire (4) from annular groove in ring gear.

3

5

009518

1.7.3 Planet carrier 1 2 3

Drive dowels (1) fully into planet pin (2).

Using plastic drift, drive out planet gear pin from planet carrier (3) towards “input’’.

(5)

6 7

6

4

(5) 7 6

Remove planet gear (4) from planet carrier together with thrust washers (5).

1

NOTE: Thrust washers (5) in straight-cut version only.

4

Remove shims (6) and cylinder rollers (7) from planet gear.

5

Drive out dowels (1) from planet pin.

3 2

Repeat steps 1) to 5) for remaining planet gears.

009525

2-05

Assembling Planet Carrier 1.8

16 S 151 / 8 S 151

Assembling planet gear train with rangechange synchronizer

1.8.1 Planet carrier NOTE: Always exchange planet gears as complete sets.

1

Coat faces of planet gears and cylinder roller raceways with operating oil.

2

Stand planet gear pin (1) so that collar faces downwards.

3

Slide thrust washer (2) over planet pin. Ensure coated side (bright side) faces towards planet gear.

(2)

3

5

4

3

5

3 (2)

1

009513

NOTE: Thrust washers (2) in straight-cut version only.

4

Slide shim (3) over planet gear pin (either way up).

5

Place planet gear (4) onto planet pin (1) and align centrically.

6

Insert 14 cylinder rollers (5) into planet gear and slide shim (6) over planet pin.

7

Coat inside of the planet gear with operating oil and insert remaining 14 cylinder rollers.

8

Coat cylinder rollers with operating oil and fit shim.

9

Fit thrust washer on planet gear. Ensure coated side faces towards planet gear.

10

Stand planet carrier (7) on on shaft section.

11

Carefully remove planet gear and thrust washers from planet pin and slide into planet carrier.

12

Align planet gear with bearing bore (8).

NOTE: Ensure “0” face of planet pin faces towards outside radius of planet carrier. (Oil bore must face towards the inner radius of planet carrier).

13

Radially align planet pin and insert into bearing bore.

14

Using plastic hammer, drive in planet pin. Check for alignment with dowel bore

10 9 8

7

(2) (2)

009505 009505

2-06

16 S 151 / 8 S 151 15

Drive new dowel (9) halfway into hole. Drive 2nd (new) dowel (10) into 1st dowel with slot offset 180°. Drive both dowels approx. 0.5 mm into planet carrier (refer to Assembly Specification) .

16

Check axial play on planet gears (0.4 to 1.3 mm).

Assembling Planet Carrier

Repeat steps 1) to 16) for remaining planet gears.

1.8.2 Ring gear 1

Place intermediate ring (2) onto planet carrier (1).

Ensure oil grooves face towards output end (only in straight-cut version).

2

Drive ring gear carrier (3) flush into ring gear (4).

3

Insert safety wire (5) into annular groove in ring gear. Ensure entire safety wire is firmly seated.

2 1

6 5 3

Straight-cut version: 4

4

Insert ball bearing (6) into ring gear carrier and attach snapring (7). Select snapring so as to ensure ball bearing axial play of 0.0 to 0.1 mm.

Snaprings are available in 0.1 mm thicknesses (0.1, 0.2, 0.3 etc.).

001912

Helical-cut version: 4

Slide intermediate ring (7) and axial needle bearing (6) onto planet carrier.

1

! DANGER Always wear protective gloves when handling heated ring gear.

7 5

7

Heat complete ring gear to 60° C and place onto planet carrier. Rotate ring gear to bring teeth into mesh. Ensure bearing (6) is firmly seated.

6

5 3 4

009506

2-07

Assembling Planet Carrier

16 S 151 / 8 S 151

1.8.3 Synchronizer 2 1

Check wear limit of synchronizer parts, see Section 6.

2

Place clutch body (1) and synchronizer ring (2) onto planet carrier.

1

! DANGER Always wear protective gloves when handling heated synchronizer hub.

3

Heat synchronizer hub (3) to approx. 120° C and push on until firmly seated. Ensure long hub side faces towards planet carrier. Synchronizer ring lugs must engage into recesses in the synchronizer hub.

4

Attach circlip (4) into annular groove. Axial play must be 0.0 to 0.1 mm. Circlips are available in 0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).

5

Place sliding sleeve (5) onto synchronizer hub (3) with collar side facing towards output end.

NOTE: Recesses in sliding sleeve must be aligned with recesses in synchronizer hub.

6

Insert new compression springs (6) and pressure pieces (7) into synchronizer hub (3) and, using suitable tool, insert into sliding sleeve (5).

7

Place synchronizer ring (8) onto synchronizer hub (3).

NOTE: Synchronizer ring lugs (8) must engage into recesses in the synchronizer hub (3).

8

Bring sliding sleeve (5) into centre position by pressing synchronizer ring against synchronizer hub. Engagement of presssure pieces can be clearly heard.

! DANGER Always wear protective gloves when handling heated clutch body and counting disc.

9

Heat clutch body (9) to approx. 120° C and push flush onto planet carrier.

10

Heat speedo worm/counting disc (10) to approx.

120° C and push onto planet carrier. Ensure sensor lugs face towards planet carrier.

NOTE: Speedo worm and counting disc (10) in straight-cut version only.

2-08

9 5

7 3

6

10

8 4

001913

16 S 151 / 8 S 151 1.9

Assembling range-change /housing/ output flange/piston

1

Place intermediate plate (1) onto planet carrier/clutch body (2).

2

Insert shift fork (3) and fulcrum pads (4) into sliding sleeve (5).

3

Place new gasket (6) onto intermediate plate (1) and position.

4

Insert shift rail (11) from inside of housing and position roughly.

5

Insert injection pipe (2) into housing.

6

Place housing (7) onto intermediate plate (1), fit gasket and position. Check radial position of shift fork and engage.

Assembling Range-Change

21 22

10 7

6

1

WI 9

●

W II 9

20

NOTE: When using a new housing (7), drive in ball (8) in accordance with selector pattern I or II. 7

10

Coat pivot bolts (10) with Loctite No. 241, fit spring washers and insert. Position shift fork (3).

9

Coat new flange packing (12) with spirit, slide over shift rail (11) and, using soft drift, drive in until flush.

Place piston (13) onto shift rail the correct way up together with guide ring (14) and new grooved rings (15).

5 2

Tighten new locking nut once range-change is fitted.

Tightening torque = 150 Nm. NOTE: Installation of range-change cylinder is only possible once range-change has been subassembled on centre housing. Thread must be absolutely free of oil and grease.

11

16

14

19

18

24

13 12 23

NOTE: in the new version, place seal ring (23), piston (13) with guide ring (14) and seal ring (24) onto shift rail.

10

3

4

NOTE: Pivot bolt tightening torque = 250 Nm. Tighten when range-change is fitted.

8

8

17 19

18 12 13

15 14

15

16

17

Grease new O-rings (17 and 18) and insert into correct annular grooves (in cylinder and housing).

NOTE: Mounting switches (21 and 22) if required, see page 2-59, work step 16.

12

Carefully slide cylinder (19) over piston together with guide ring and piston gasket. Fix cylinder using two hex bolts.

11

NOTE: Align the compressed air bores.

009942

2-09

Assembling Range-Change

16 S 151 / 8 S 151

Measuring ball bearing axial play (nominal: 0 to 0.1 mm) 13

29 26

Fit new gasket (25) onto new cover (26) and measure insertion depth of cover together with gasket, e.g. 23.40 mm.

14

Measure extraction depth bearing seat depth of housing (7), (without gasket), e.g. 7.00 mm.

15

Measure width of ball bearing (28), e.g.

30.00 mm.

25 27 28

Example 23.40 mm insertion depth - cover + 7.00 mm insertion depth - housing 30.40 mm

001915

– 30.00 mm width of ball bearing = 0.40 mm axial play without shim i.e. a 0.3 to 0.4 mm shim (27) is required to give axial play of 0 to 0.1 mm. ! DANGER Always wear protective gloves when handling heated cover.

16

Heat cover (26) to approx. 60° C and insert correct shim (27) and ball bearing (28).

17

Drive in shaft seal (29) using special tool 1X56 137 124.

NOTE: Only use special tool with 12.5 mm wide ring. Installation dimension = 12.5 + 1.0 mm between edge of cover and shaft seal. Thinly coat outside of shaft seal with sealing compound.

Lubricate outside of shaft seal with rubber surround using soap wash.

18

Fit cover (26) with new gasket (25) and tighten using hex bolts and washers.

Tightening torque = 49 Nm.

19

Fit cover (30) with new gasket.

Tightening torque = 79 Nm.

30

26 25

001916

2-10

16 S 151 / 8 S 151

Assembling Range-Change

1.9.1 Output flange 1

Lightly oil shaft seal in cover.

! DANGER Always wear protective gloves when handling heated output flange.

2

Heat output flange (1) to max. 70° C.

3

Push output flange flush onto planet carrier shaft.

4

Pull on output flange until flush using disc (2) and two standard M12x75 hex bolts.

5

Remove disc and bolts.

6

Lightly oil new O-ring (3) and insert into gap between output flange and planet carrier shaft.

7

Insert disc (2) into output flange and attach to planet carrier using locking screws.

Tightening torque (straight-cut version) = 60 Nm Tightening torque (helical-cut version) = 120 Nm. If required, use flange holder to prevent flange from turning.

Insert locking screws with Loctite 262.

8

Using special tool 1X56 137 246 (straight-cut version) 1X56 137 651 (helical-cut version), drive new retaining plate (4) flush onto bolt heads.

1

3

2

4

001917

2-11

Removing Shift Housing 2

Removing components from centre housing

2.1

Splitter (GV) cylinder

1

Remove cylinder (1) by hand.

2

Remove detent plunger (9) together with circlip.

Insert fixing device 1X56 137 579.

3

Remove locking nut (2).

4

Remove spring (8) from housing.

5

Remove piston (3) from shift rail (4).

6

Remove double-grooved ring (5) from piston.

7

Remove two O-rings (6 and 7) from cylinder.

16 S 151 / 8 S 151

4 1

9 5

3

2

7 6 8 001918 001918

NOTE: There may be three O-rings in the cylinder.

2.2

Shift housing

1

Unscrew hex bolts from shift housing.

2

Take off complete shift housing (1) and remove gasket (2).

3

Remove switch (3) together with seal ring and pin.

4

Unscrew cover (4) together with gasket.

5

Remove shift detent (5) and washer (6) from detent piece (7). See Figure 001920.

6

Loosen shift lever (8) and remove together with protective cap (9). Mark selector shaft for installation.

7

Remove screw plug (10) together with seal spring (11) and pin (12).

8

Unscrew cutoff valve (13) and remove together with O-ring.

14

NOTE: In new version, remove reverse gear switch (14) together with seal ring.

2-12

4

3 13

11

1

12 2

10

9

8 001919

16 S 151 / 8 S 151 9

Unscrew hex bolts from shift cover (15) and remove together with gasket.

10

Drive out bush (16), wiper (17), shaft seal (18) and bearing bush (19) from shift cover.

11

Drive pin (20) towards cover.

12

Remove cover (21) from shift housing together with compression springs (22), detent piece (23) and O-ring (24).

13

Drive out dowels (25) from detent piece and remove compression springs (26) together with washers (27).

14

Drive out dowels (28) from drivers (29) and selector shaft (30).

15

By hand, pull out selector shaft (30) in direction of shift output.

16

Remove locking piece (31) and drivers from shift housing.

17

Remove pins (32) if necessary.

NOTE: Clamp pins in vice using aluminium clamping jaws and remove by striking shift housing.

18

Removing Shift Housing

16 15 19 18 17

20

7 6

22 5

21

24 23

Drive out needle sleeve (33) from shift housing.

25 27

26 27 33 30 32

28 29 31

001920 001920

2-13

Assembling Shift Housing

16 S 151 / 8 S 151

2.2.1 Assembling shift housing 1

Using special tool 1X56 119 916, drive new needle sleeve (1) into shift housing (2). Strike thicker coated side of needle sleeve.

2

Drive pins (3) into shift housing.

3

Insert driver (4) and locking piece (5) into shift housing the correct way round.

4

Insert selector shaft (6).

5

Using special tool 1X56 119 916, drive new bearing bush (7) into shift cover.

6

Using special tool 1X56 119 916, drive shaft seal ring (8) into shift cover. Sealing lip must face towards cover.

7

Using special tool 1X56 119 916, drive scraper disc (9) into shift cover. Sealing lip must point outwards.

1 2 3

12

4

5

NOTE: Smear shaft seal and wiper with sealing compound and install. Fill the gap between shaft seal and wiper with grease.

8

Push bush (10) into shift housing (2) and slide shift cover (11) and new gasket over selector shaft (6) until flush. Do not damage sealing lips.

9

Bolt shift cover (11) onto shift housing.

Tightening torque = 23 Nm.

10

Drive one dowel (12) through driver (4) and into selector shaft. Drive second dowel (12) into first, making sure slot is offset.

(Refer to Assembly Specification)

11

7 8 9 2

6 10

001921

2-14

16 S 151 / 8 S 151

Assembling Shift Housing/Detent Piece

2.2.2 Detent piece with compression springs 1

Place washer (1), compression spring (2) and second washer (1) onto selector shaft (3). Drive in pins (8) if necessary.

2

Place shift detent (6) with washer (7) into detent piece (4).

3

Place detent piece (4), shift detent (6) and washer (7) onto selector shaft against spring pressure and drive in dowels (5) offset.

NOTE: Axial play between detent piece and pins must be 0.1 mm. Adjust if required using washer (7) of different thickness. Washers are available in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.).

Grease shift detent (6) and pins (8).

4

5 1

4

1 6 7 18

14 8 11

17

15 10

3

13

16

12

Bolt on cover (9) together with new gasket.

Tightening torque = 23 Nm. NOTE: In the new version of the cover (a), screw in reverse gear switch (24) and new seal ring (25). In the old version, the reverse gear switch is on the centre housing (see page 2-59, items 20 and 21).

24 25

5

Insert cover (10) into shift housing together with compression springs (11), detent piece (12) and O-ring (13). Drive pin (14) into shift housing (countersink approx. 5 mm) and fit new cover (countersink approx. 2 mm).

9

6

Fit pin (15), spring (16) and screw plug (17) with new sealing ring and screw into shift housing.

Tightening torque = 60 Nm.

7

2

Fit cutoff valve (18) with new O-ring and screw onto shift housing.

Tightening torque = 23 Nm.

8

Insert pin (19) into cover and screw in switch (20) together with new sealing ring (21).

Tightening torque = 50 Nm.

9

Slide protective cap (22) onto selector shaft (3) and position shift lever (23) on selector shaft shaft depending on shift version.

Tightening torque for hex bolt and nut on shift lever = 49 Nm. Protective cap must sit on selector shaft without play.

19 21

20

22 23

001922

2-15

Shift Mechanism 2.3

Removing and dismantling friction-optimized shift housing (illustrations show superimposed “H” shift pattern)

1

Loosen hex bolts (1) and remove shift turret together with gasket (2).

2

Loosen shift lever (3) (depending on parts list) and remove together with protective cap.

3

Remove detent plunger (4) and screw plug or switch (5).

4

16 S 151 / 8 S 151 12

14

1

6

5 8

7

4 9 13

11

15 2

Take out cutoff valve and remove together with O-ring (7).

3

NOTE: Cutoff valve is a complete component and is not dismantled. In the version with double “H” shift pattern, there are 2 ball rollers (8) in the cutoff valve.

5

Remove screw plug (9) together with seal ring, spring (10) and bolt (11).

6

Remove screw plugs (12 and 13) together with seal rings.

7

Unscrew cover (14) together with piston and remove together with gasket.

009684

21 19

18 20

NOTE: In the version with double “H” shift pattern, a cover and switch are installed here.

22

8

Loosen housing (15) and remove together with gasket.

9

Remove detent plate (16) and detent (17) from housing.

23

10

Unscrew hex bolts from shift cover (18) and remove together with gasket.

16

11

Drive out shaft seal (19), bearing bush (20), shaft seal (21) and wiper (22) from shift cover.

12

Detach split ring (23) and remove detent (24) from housing together with O-ring.

13

Drive out dowels (25) from driver.

14

Remove selector shaft (26), driver (27) and locking piece (28).

15

Remove needle sleeve (29) from housing.

16

Detach split ring (30) and remove disc (31), spring (32) and disc (33) from selector shaft.

10

24 29

30

31 32

17 33

26

25

27

28 009685

2-16

16 S 151 / 8 S 151 17

Detach snapring (34) from cover. Remove piston (35) together with O-rings (36).

Shift Mechanism

36 35 36 34

009893

2-17

Shift Mechanism

16 S 151 / 8 S 151

2.3.1 Assembling shift housing 1

1 10

Drive new needle sleeve (1) into shift housing (2) using special tool 1X56 119 916. Hit onto the side of the needle sleeve with the thicker surround.

2

Insert driver (3) and locking piece (4) into shift housing.

3

Insert selector shaft (5).

8 7

2

NOTE: Engagement groove for detent and detent plate must face towards transmission 4

5

One after the other, drive dowel pins (6) through driver (3) and into selector shaft (observe assembly specifications).

9

5

Insert disc (7), spring (8), disc (9) and split ring (10) according to selector pattern.

6

3

4 009900

6

Drive shaft seal (11) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift housing.

7

Drive new bearing bush (12) into shift cover using special tool 1X56 119 916.

8

Drive shaft seal (13) into shift cover using special tool 1X56 119 916. Sealing lip must face towards shift lever.

9

10

Slide shift cover (15) over selector shaft together with new gasket and mount using bolts (16); Tightening torque = 23 Nm.

11

Insert detent (17) together with new O-ring and attach split ring (18).

16 13

15 12

Drive wiper (14) into shift cover using special tool 1X56 119 916. Sealing lip must face outwards.

NOTE: Lightly coat the outside of shaft seal and wiper with sealing compound. Fill gap between shaft seal and wiper with grease.

2-18

11

14

18 17

009685

16 S 151 / 8 S 151 12

Insert detent (19), spring (20) and screw plug (21) together with new seal ring and tighten; Tightening torque = 60 Nm.

13

Insert cutoff valve (22) into shift housing together with new O-ring, ensuring it is positioned the correct way round, and fix using hex bolts; Tightening torque = 23 Nm.

Shift Mechanism 22

23

NOTE: In the version with double “H” shift pattern, there are 2 ball rollers (23) in the cutoff valve.

14

Insert screw plugs (24 and 25) into housing (26) together with new seal ring and tighten; Tightening torque = 50 Nm.

15

Screw detent plunger (27) into housing together with new seal ring.

16

Insert greased pin (28) into bore. Close off using switch or screw plug (29) and new seal ring; Tightening torque = 35 Nm.

17

Insert detent (30) and detent plate (31) into housing, ensuring they are positioned the correct way round.

21 20 19

26

25

29 28

27

24 30 31

009687

2-19

Shift Mechanism 18

Fit new gasket (32).

19

Slide shift housing over detent plate and detent together with selector shaft.

16 S 151 / 8 S 151

36

NOTE: Center housing and shift housing.

20

38

Insert hex bolts (33) and tighten by hand.

34

NOTE: Check selector shaft for ease of movement by pushing against the spring force.

21

Tighten detent plunger; Tightening torque = 50 Nm.

22

Fit O-rings (34) onto piston (35).

23

Insert piston into cover (36) and secure using snapring (37).

24

Fit new gasket (38) and screw cover onto housing; Tightening torque = 23 Nm.

35 34

37

33 32

39

NOTE: In the version with double “H” shift pattern, a cover and switch are installed here.

25

2-20

Slide protective cap (39) onto selector shaft and position shift lever (40) on selector shaft (position depends on version). Tightening torque for hex bolt and hex nut on shift lever = 49 Nm. Ensure protective cap has no play when seated on selector shaft (according to parts list).

40

009688

16 S 151 / 8 S 151 2.4

Shift Mechanism

Shift patterns/shift mechanism left or right

Spring pack arrangement: Q 1 Selector pattern I Horizontal torque shaft left.

001923 001923

Spring pack arrangement: Q 2 Selector pattern I Horizontal torque shaft left.

001924 001924

Spring pack arrangement: Q 3 Selector pattern I Horizontal torque shaft left.

001925 001925

2-21

Shift Mechanism

16 S 151 / 8 S 151

Spring pack arrangement: Q 1 Selector pattern II Horizontal torque shaft left.

001926 001926

Spring pack arrangement: Q 2 Selector pattern II Horizontal torque shaft left.

001927 001927

Spring pack arrangement: Q 3 Selector pattern II Horizontal torque shaft left.

001928 001928

2-22

16 S 151 / 8 S 151

Shift Mechanism

Spring pack arrangement: Q 1 Selector pattern I Horizontal torque shaft left.

001929

Anordnung des Federpaketes: Q 2 Wählbild I Waagrecht Drehwelle rechts

Anordnung des Federpaketes: Q 3 Wählbild I Waagrecht Drehwelle rechts

2-23

Removing Clutch Housing 3

Removing clutch housing components

3.1

Release fork Release fork (pulled)

1 2

16 S 151 / 8 S 151

3

8

6 7

1

2

Detach circlips (1). Remove seals (2) and seal rings (3).

9

3

Loosen hex bolts (6) and remove together with bearing block (7).

4

Detach circlips (8) and remove plain spherical bearing (9) from bearing block.

8 3

Pull out pin (4) and remove release fork (5).

2

5

1

4 009520

Release fork (pushed) 1 2

Remove release fork (1) together with ball cup (2).

2

3

4

1

Remove ball pin (3) together with washer (4).

004484

004484

Release fork (pulled) 1

Loosen screw (5) and remove from shaft (2) together with clutch lever (3).

NOTE: Mark position of clutch lever before removing.

2

Remove dowels (4) from release fork (1).

3

Release and loosen grooved nut (6) and loosen.

4

Remove shaft (2), release fork (1), grooved nut (6) and tab washer.

5

Remove bearing bush (8).

6

If necessary, remove sheet (9) and four screws (10).

2-24

9 10 1 2 3 6 4 5

8 7 004483

16 S 151 / 8 S 151 3.2

Removing Clutch Housing

Connection plate with integral pump

3

1 Single-piece version

10 1

Unscrew hex bolts and nuts from connection plate (1) and pump cover (2).

2

Remove connection plate (1) together with pump/pump cover (2).

3

Remove washer (8), spacer ring (9) and washer (10) from connection plate / input shaft.

4

Remove gasket (3).

5

Using plastic drift, drive out shaft seal (4).

6

Lever off pump cover (2) from connection plate (1). Drive cylindrical pin (5) out of pump cover or connection plate.

7

Remove pump shaft, internal rotor (6) and external rotor (7).

8

Remove shim for input shaft and layshaft.

2 4

8

9

5 2

6 7 001996

Split version 1

Loosen hex nuts, hex bolts and washers (1 and 5).

2

Remove pump housing (6) together with pump/pump cover (2) and gasket (7).

3

Remove outer rotor (3) and inner rotor (4).

4

Loosen hex nuts (8) and remove connection plate (9) from input shaft together with gasket (10) and washer (11).

5

Remove shim for input shaft and layshaft.

6

2

3

7

4

11 9

5 10

1 8

009519

2-25

Removing Shift Rail / Centre Housing 3.3

16 S 151 / 8 S 151

Clutch housing

! DANGER Ensure mounting brackets and rope are firmly secured.

1

Remove 13 hex bolts from inside and 9 hex bolts from outside. Remove cylinder pins which are not easily accessible using special tool 1X56 138 063.

2

Fix two hooks 1X56 136 564 to clutch housing.

3

Exert tension on mounting brackets.

Hint: The clutch housing is positioned on the centre housing using 4 cylindrical pins (1). Ensure clutch housing is level before separating from centre housing.

4

2

1

3

Hit sidebars (2) of centre housing and clutch housing using plastic hammer.

CAUTION Do not use prybars on housing sealing faces.

5

Remove clutch housing and take off gasket (3).

4

Removing components

4.1

Removing components/clutch housing

1

Remove all screw plugs and seal rings if necessary.

2

Remove magnetic screw plug (1) and clean.

3

Renew sealing cap if necesary.

4

Drive out taper roller bearing outer races for input shaft and layshaft from clutch housing if necessary.

4.2

Splitter shift rail / centre housing

1

Remove grub screws (1) from shift fork (2).

2

Drive shift rail (3) out of shift fork (2) in direction of output end.

3

Remove shift fork (2) together with fulcrum pads (4).

4

2

1

001931

1

001932

2 1

3

4

Remove shift rail (3).

1 009943

2-26

16 S 151 / 8 S 151 4.3

Removing shafts For Steps 1 - 6, see Section 4.4

1 2

Unscrew cover (9) together with gasket.

Using drift, drive out reverse pin (3) from centre housing in direction of output. In older versions, loosen and remove fixing screw (3a) and fixingwasher.

CAUTION Reverse idler gear may fall out.

3 Remove reverse idler gear (4) together with needle cage (5).

4 Remove screw plug (6) together with seal ring.

5 Screw in fixture 1X56 137 287. Interlock locking pin (7) is pushed against spring pressure.

6 Bolt lifting device (17) 1X56 137 122 to centring bush 1X56 137 921 and place over input shaft (18) and shift rails (19) so that it lies on the layshaft (21). Place disc 1X56 137 933 between lifting device and layshaft. Place holder (20) 1X56 137 918 onto lifting device and insert into shift rail driver.

7 Bolt layshaft (21) to lifting device; tightening torque = 85 Nm. 8 Pull out shafts and shift rails from centre housing without tilting and place into device 1X56 137 675.

9 Remove lifting device (17) and accessories. Take out shift rails, forks and fulcrum pads.

10 Remove fulcrum pads from shift forks.

NOTE: Do not dismantle shift rails any further.

In this condition, they form a complete unit.

4.4

Removing components/ centre housing

1

Unscrew device 1X56 137 287 and remove locking pin (7) and compression spring (8).

Remove all screw plugs, seal rings, pressure switches, pins, filler necks and gasket.

If necessary, remove injection pipe (10), type plate (22) and roll pins (11).

Remove packing (12), circlip (13) and bearing bush (14).

Remove roller bearing outer races for mainshaft and layshaft from centre housing. Drive out towards inside of housing.

Renew filter (15).

Remove breather (16).

2 3 4 5

6 7

Removing Centre Housing ! DANGER Ensure mounting brackets and rope are firmly connected.

18 17 20 21

19

001995

6

22

7

16

8 o

3a

10 15

5

4 14 13 12

11

3 9 001934

2-27

Removing Input Shaft 4.5

16 S 151 / 8 S 151

Input shaft 2

4.5.1 Dismantling input shaft 1

Remove complete input shaft unit from mainshaft.

2

Remove clutch body (1) and synchronizer ring (2) from input shaft synchronizer.

3

Remove ring (6) from inside clutch body.

3

4 5

17

! DANGER Pressure pieces are under spring pressure. Prevent pressure pieces from flying out.

4

Pull off sliding sleeve (3) from input shaft. Catch released pressure pieces (4) and compresion springs (5).

5

Detach circlip (7) and remove.

NOTE: Detach and remove circlip (8). Remove split ring (9) (in older version only).

6

7

Pull off roller bearing inner race (10) from input shaft using gripper 1X56 136 722, extension 1X56 122 310, threaded insert 1X56 122 303 and basic tool 1X56 122 304. To do this, slide gripper 1X56 136 722 over roller bearing inner race until firmly seated against rollers and tighten using knurled ring.

Remove helical gear (11) from input shaft.

NOTE: Remove helical gear (11) from input shaft together with needle cages (12) (in older version only).

8

Remove clutch body (13) and synchronizer ring (14) from input shaft.

9

Remove oil baffle plate (17), detach circlip (15) and remove pipe (16) from input shaft.

2-28

6

1

16

15

14 11

(12)

13

(12) 10 7

(8)

(9)

009527

16 S 151 / 8 S 151

Assembling Input Shaft

4.5.2 Assembling input shaft 16 1

Check wear limits of synchronizer components (see Section 6, “Synchronizers/Wear Limits’’).

2

Insert pipe (1) into input shaft and attach circlip (2) into annular groove. Press new oil baffle (16) into input shaft using drift 1X56 138 109.

3

1 4

3

Place synchronizer ring (4) and clutch body (3) onto input shaft.

NOTE: Lugs of synchronizer ring must locate in recesses in synchronizer body on input shaft.

6

NOTE: In older version, lightly oil running areas for both needle cages (11) and slide onto input shaft. Slide helical gear (12) over needle cages.

4

2

10

8

7

5

9

Push helical gear (12) over needle cages.

NOTE: Engaging teeth of helical gear must face towards output end and mesh with inner spline of clutch body.

(11)

! DANGER Always wear protective gloves when handling heated roller bearing inner race.

12

17 5

(15)

(14)

13

(11)

Heat roller bearing inner race (13) to approx.

100°C and slide onto input shaft. Once the roller bearing has cooled down, it must firmly abut against the input shaft collar.

NOTE: In older version, insert split ring (14) into annular groove, ensuring it has axial play (prestress) of between -0.5 mm and + 0.5 mm (using special tool 1X56 136 573). Slide new circlip (15) onto split ring. The circlip must firmly abut against the ring. Secure circlip at three points (120° apart).

6

Attach circlip (17).

7

Place sliding sleeve (7) onto synchronizer body (8) and locate correctly. Insert new compresion springs (9) and pressure pieces (10) into synchronizer body (8) and, using suitable tool, guide into sliding sleeve (7).

8

Place synchronizer ring (5) and clutch body (6) onto input shaft.

9

Move sliding sleeve into centre position. To do this, push against clutch body (6). The pressure pieces can be clearly heard clicking into place.

009528

2-29

Removing Mainshaft 4.6

16 S 151 / 8 S 151

Mainshaft

4.6.1 Dismantling mainshaft CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device.

1

Clamp output end of mainshaft in vice.

Always use aluminium clamping jaws to protect mainshaft.

Hint: Use special tool 1X56 137 200 to position and rotate mainshaft. Remove the oil pipe before doing this.

2

Remove circlip (1) and split ring (2).

3

Slide gripper 1X56 136 743 over bearing inner race (3) and tighten firmly against bearing rollers using knurled ring. Screw on basic tool 1X56 122 304 and pull off bearing inner race.

4

Remove axial washer (4).

5

Clamp input end bearing journal of mainshaft in vice. Always use aluminium clamping jaws.

6

Remove pressure disc (5).

1

2

3

4

6

NOTE: In straight-cut version, there is no pressure disc (5).

7

Detach circlip (6) from annular groove.

8

Attach 2- or 3-leg puller underneath helical gear (7) and pull off gear together with roller bearing inner race (8). Use adapter.

9

Remove needle cage (9).

10

Attach 2- or 3-arm puller underneath 1st-speed helical gear (10) and pull off gear together with bush (11) and clutch body (12). Use adapter.

11

5

8 7 9

10

Remove needle cage (13).

12

11

13

009512 009512

2-30

16 S 151 / 8 S 151 12

Removing Mainshaft

Remove clutch disc (14) from 1st/5th gear dualcone synchronizer.

13

Remove inner ring (15).

14

Remove intermediate ring (16).

15

Remove outer ring (17).

16

Pull off sliding sleeve (18). Use cloth to catch released pressure pieces and compression springs.

17

Remove couplings (19).

18

Place 2- or 3-leg puller onto 2nd-speed helical gear (21). Pull off helical gear together with bush (22), clutch disc (23), inner ring (24), intermediate ring (25), outer ring (26) and synchronizer hub (20). Use adapter.

19

Remove needle cage (27).

20

Clamp output end of mainshaft.

21

Attach 2- or 3-leg puller underneath sliding sleeve (28) and pull off synchronizer ring (29), clutch body (30), roller bearing (31) and helical gear (32). Use adapter.

17

18

Remove pressure pieces and springs. Attach 2- or 3-leg puller underneath 3rd-speed helical gear (35) and pull off together with roller bearing (36), synchronizer hub (37), synchronizer ring (38) and clutch body (39). Use adapter.

CAUTION Do not attach puller to mainshaft collar (see arrow).

23

15

26

22

20

19

25

24 23

21 27

NOTE: Use cloth to catch released pressure pieces (33) and compression springs (34) when pulling off sliding sleeve.

22

16

14

32

36

30

31

29

37

33 28 34

38

35

40

Remove needle cage (40).

39

009511

2-31

Assembling Mainshaft

16 S 151 / 8 S 151

4.6.2 Assembling mainshaft

3 2

CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device 1

Clamp mainshaft (1) at output end.

2

Lightly oil needle cage (2) and slide onto mainshaft.

3

Push 2nd speed helical gear (3) onto mainshaft with clutch body engaging teeth facing the output end.

4

Check wear limit of synchronizer parts (see Section 6).

5

Fit clutch disc (4) onto engaging teeth of helical gear (3). Ensure the slightly raised internal spline in the clutch disc faces towards the output end.

6

Place inner ring (5) onto clutch disc. Ensure lugs face towards the output end.

7

Fit intermediate ring (6). Ensure lugs locate in recesses in clutch disc.

8

Fit outer ring (7). Ensure lugs face towards the output end.

9

Align lugs on outer ring (7) and lugs on inner ring (5) using 3 coupling (8). Position inner and outer ring lugs to cover coupling, so that the couplings will later locate in recesses in the synchronizer hub (9) and fit over the lugs. After adjustment, remove couplings.

! DANGER Always wear protective gloves when handling heated synchronizer hub.

10

2-32

Heat synchronizer hub (9) to approx. 120° C and push onto spline of mainshaft. Ensure lugs locate in recesses of the synchronizer hub. The outer ring tabs must engage in the synchronizer hub recessesd. Use plastic drift to drive on synchronizer hub.

1

7

8

9

6 4

5

001943 001943

16 S 151 / 8 S 151 11 12

Assembling Mainshaft

Helical gear (3) axial play must be at least 0.20 mm.

8

Insert couplings (8) into synchronizer hub (9).

13

Push sliding sleeve (10) over synchronizer body and outer ring and locate against clutch disc.

14

Insert new compresion springs (11) and pressure pieces (12) into the synchronizer hub, ensuring that they are the right way round.

Use suitable tool to guide pressure pieces into the synchronizer hub and sliding sleeve.

16

Fit outer ring (13). The lugs must engage in the couplings and and the tabs must engage in the synchronizer hub recesses.

17

Fit intermediate ring (14). Lugs must point towards the output end. Insert inner ring (15) and engage lugs into couplings.

18

Fit clutch disc (16) with raised inner teeth facing towards input end and engage with intermediate ring (14). Move sliding sleeve to neutral position, pressing against clutch disc. The pressure pieces can be heard clicking into place.

13

19

Heat bush (17) to 120 °C and push onto mainshaft until firmly seated. Use plastic drift to drive on if necessary.

20

Lightly oil needle cage (18) and push over bush (17).

21

Place 1st/5th speed helical gear (19) onto needle cage (18) so the engaging teeth mesh with clutch disc.

14

16

15

10

19 17

! DANGER Always wear protective gloves when handling heated bush.

11

9

3

NOTE: Place “dual-cone synchronizer’’ pressure pieces in correct position in the synchronizer hub.

15

12

18

001944 001944

2-33

Assembling Mainshaft ! DANGER Always wear protective gloves when handling heated clutch body.

22

16 S 151 / 8 S 151

21

20

22

Heat clutch body (20) to 120° C and push onto mainshaft until firmly located.

NOTE: Ensure clutch body collar faces towards output end.

23

Axial play on 1st/5th speed helical gear must be at least 0.20 mm.

! DANGER Always wear protective gloves when handling heated bush.

24

Heat bush (21) to 120° C and push onto mainshaft until firmly seated.

25

Lightly oil needle cage (22) and push over bush (21).

26

23

26 24

25

Push reverse speed helical gear (23) onto mainshaft and over needle cage. Ensure engaging teeth face towards input end.

009507

! DANGER Always wear protective gloves when handling heated roller bearing.

27

Heat roller bearing (24) to approx. 100° C and push onto mainshaft until firmly seated. Use plastic drift to drive on if necessary.

28

Attach circlip (25) into annular groove on mainshaft.

NOTE: Axial play on circlip must be between 0 and 0.05 mm. Select correct circlip from spare parts catalogue.

29

Push pressure disc (26) onto mainshaft.

NOTE: There is no pressure disc (26) in the older version.

30

Clamp output end of mainshaft.

CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device.

2-34

16 S 151 / 8 S 151 31

Oil needle cage (27) and push onto mainshaft.

32

Push 3rd speed helical gear (28) over needle cage.

Engaging teeth of helical gear face towards output end.

33

Place clutch body (29) onto engaging teeth of helical gear.

Refer to Chapter 6, check wear limits.

34

Place synchronizer ring (30) onto clutch body.

! DANGER Always wear protective gloves when handling heated synchronizer hub.

35

Assembling Mainshaft

32

31

34 30 33

28

27

29

Heat synchronizer hub (31) to 120° C and push onto mainshaft splines until axially flush. Use plastic drift to drive on if necessary.

NOTE: Synchronizer ring lugs must locate in recesses in synchronizer hub.

36

Fit sliding sleeve (32).

NOTE: Recesses inside sliding sleeve must line up with recesses in synchronizer hub for compression springs (33) and pressure pieces (34).

37

001946

Insert new compression springs and pressure pieces into holes in synchronizer hub and guide into sliding sleeve.

2-35

Assembling Mainshaft 38

Position synchronizer ring (35) so lugs locate in recesses in synchronizer hub.

Refer to Chapter 6, check wear limits.

39

Place clutch body (36) onto synchronizer ring.

40

Move sliding sleeve into neutral position, pressing synchronizer ring (35) and clutch body (36). The pressure pieces can be hear clicking into place.

41

16 S 151 / 8 S 151

43

42 41

40 39

37

36

35

38 37

Insert both roller bearings (37) into 4th speed helical gear (38).

NOTE: Lubricating bores (see arrows) on roller bearings must face outwards.

! DANGER Always wear protective gloves when handling heated roller bearing and helical gear.

42

Heat roller bearings and helical gear to 100° C and push onto mainshaft until bearing pack is correctly seated.

001947 001947

NOTE: The helical engaging teeth on the helical gear must face towards the output end.

43

Axial play of helical gear must be at least 0.05 mm.

37

37

NOTE: Hint: Axial washer (39), roller bearing (40), split ring (41), circlip (42) and ring (43) are only fitted in Section 11 “Adjusting shafts’’.

38 004915

2-36

16 S 151 / 8 S 151 4.7

Synchronizers

Assembling synchronizer 2

4.7.1 Version ZF-BK 1 1

Check wear limits according to Section 6.

2

Renew compression springs (5). This guarantees prescribed shift force for sliding sleeve (6).

3

Synchronizers may be subassembled first or assembled on the mainshaft itself.

4

Push sliding sleeve (6) onto synchronizer hub.

Insert new compression springs (5) and pressure pieces (4) into synchronizer hub (3). Hold drift against centre of pressure pieces and guide pressure pieces into sliding sleeve (6).

5

4 3

5

Position clutch body (1) and synchronizer ring (2) and push sliding sleeve (6) into middle position.

NOTE: Ensure correct position of pressure pieces.

1a 2a 6

009510 009510

4.7.1.1 Sectional view of synchronizer/ZF-BK

6

1 Clutch body 2 Synchronizer ring 3 Synchronizer hub

2

4 Pressure piece

1

5 Compression spring 6 Sliding sleeve

4

2a 5 1a

3 001940 001940

2-37

Synchronizers

16 S 151 / 8 S 151

4.7.2 Version ZF-D

2 1

7

Assembly procedure basically similar to version ZF-BK.

2

Teeth of sliding sleeve (6) have 3 recesses covering 3 teeth each. Align middle tooth with narrow recess in synchronizer hub (3) (pressure piece groove). Renew compression springs.

3

Insert new compression springs (5) and pressure pieces (4) into synchronizer hub. Fit pressure pieces so round head of pressure piece juts into recess in sliding sleeve teeth.

4

Insert couplings (9).

5

Insert outer ring (2), intermediate ring (7) and inner ring (8).

6

Place clutch disc (1) in position.

8 1

4 5

3

9

NOTE: Ensure correct position of pressure pieces.

1a 7a

8a

2a 6

001941

4.7.2.1 Sectional view of synchronizer/ZF-D

6 1 Clutch disc 2 Outer ring 3 Synchronizer hub 4 Pressure piece 5 Compression spring 6 Sliding sleeve

2 7 1 8

1a 2a 7a 8a 5

4

7 Intermediate ring 8 Inner ring

3 001942 001942

2-38

16 S 151 / 8 S 151 4.8

Removing Layshaft

Layshaft

5 4

4.8.1 Dismantling layshaft CAUTION Do not damage layshaft. Always use aluminium clamping jaws when clamping layshaft .

1

Clamp output end of layshaft so that roller bearing (6) cannot be damaged.

2

Detach circlip (1) from annular groove.

3

On input end slide gripper 1X56 136 731 over roller bearing inner race (2) and tighten knurled ring to grip roller bearing firmly. Screw on basic tool 1X56 122 304 and pull off roller bearing (2).

4

Clamp layshaft at input end.

5

On output end, slide gripper 1X56 136 731 over roller bearing inner race (6) and tighten knurled ring to grip roller bearing firmly. Place adapter on output end of layshaft. Screw on basic tool 1X56 122 304 and pull off roller bearing (6).

6

Press off helical gears (3, 4 and 5) individually and in sequence.

3 1

2

6

001948 001948

NOTE: The helical gear (3) is not included in the 8 S 151 transmission. In its place is a ring (7) (see figure 004477).

5 4 1

2

7

6

004477 004477

2-39

Assembling Layshaft

16 S 151 / 8 S 151

4.8.2 Assembling layshaft ! DANGER Always wear protective gloves when handling heated parts.

1

Ensure bores in helical gears (3, 4 and 5) and seats on layshaft are free of oil, grease and dust.

2

Heat helical gears to 160 - 180° C and push onto layshaft in sequence (3, 4 and 5). Press helical gears on immediately. There must be no play whatsoever.

3 4 5 2

1

6

NOTE: In the 8 S 151 transmission, there is a ring (7) in place of the helical gear (5) {see figure 004477/1).

3

Heat inner race of roller bearing (6) to 100° C and push onto layshaft. Press roller bearing on until firmly seated, with no play on output end.

4

Heat inner race of roller bearing (2) to 100° C and push onto layshaft. Press roller bearing on until firmly seated, with no play on input end.

5

Attach circlip (1) into annular groove on input end of layshaft. Axial play on circlip must not exceed 0.1 mm. Select correct circlip from spare parts catalogue.

001948 001948

3 4 2

1

7

6

004477/1

NOTE: a = Direct drive b = Overdrive

a

2-40

b 001949 001949

16 S 151 / 8 S 151

Assembling Clutch Housing / Centre Housing

5

Installing components

5.1

Centre housing

1

Fit all screw plugs, pressure switches and filler necks with new seal rings or gaskets and insert.

Tightening torques: see “Adjustment Data, Tightening torques’’section.

2

Insert injection pipe (1) if required. Roll ends into holes in housing using rolling tool 1X20 155 653 and insert O-ring (3).

Rolling torque = 5 to 6 Nm.

3

Insert new filter (4).

4

If necessary, fit type-plate (5) using pins.

5

If necessary, insert new cylindrical pins (6) into housing.

6

Drive new taper roller bearing outer races for mainshaft and layshaft into centre housing if necessary.

5

3

10 11 9 7 8

1

6 4 001950

NOTE: Heat bearing bore to approx. 60°C using hot air blower.

7

Insert bearing bush (7), circlip (8) and new packing using plastic drift (9). Ensure correct seating.

8

Insert compression spring (11) with locking pin (10) and align . Screw in fixture 1X56 137 287.

5.2

Clutch housing

1

If necessary, insert taper roller bearing outer races for the input shaft and layshaft into bearing bores in the clutch housing.

NOTE: Input shaft bearing outer race above.

Layshaft bearing outer race below.

2

Fit screw plugs with new seal rings and insert.

Tightening torque: M18 x 1.5 = 35 Nm, M22 x 1.5 = 50 Nm, M24 x 1.5 = 60 Nm.

3

Screw in cleaned oil drain plug and magnet (1).

Tightening torque = 140 Nm.

4

Fit cap (2).

1

2 001951 001951

2-41

Wear Limit/Synchronizer 6

Synchronizers/wear limit

6.1

Determining wear limit (except for 1st /2nd gear)

16 S 151 / 8 S 151

x

Check condition of synchronizer rings and clutch bodies before assembling synchronizers.

1

2

NOTE: Do not mix up synchronizer parts.

1

Place synchronizer ring (1) onto corresponding clutch body (2). Turn synchronizer parts so cones nest evenly and parallel together.

Wear limit for 3rd/4th gear and splitter synchronizer rings is 0.8 mm. Wear limit for range-change rings is 1.2 mm.

2

Using feeler gauge, measure distance (X) between clutch body and synchronizer ring at two opposing points. If wear limit is below 0.8 or 1.2 mm, exchange synchronizer ring and/or clutch body.

3

Check condition of synchronizer parts (visual check). Replace synchronizer parts if surface is not flat. Do not mix up parts which have been inspected together (mark parts accordingly).

001999

6.2

Determining wear limit (1st /2nd gear)

1

Place inner ring (3), intermediate ring (2) and outer ring (1) of 1st/2nd gear synchronizer onto clutch disc (4). Turn outer ring so cones nest evenly together. Evenly apply 50 Nm on outer ring.

2

Using a feeler gauge, measure distance (s) between clutch disc and outer ring at two opposing points. The wear limit is 1.5 mm. If distance (s) is below wear limit, use new intermediate and/or outer ring and inner ring.

F 50 N

s 1 2 3 4

001952 001952

2-42

16 S 151 / 8 S 151 7

Adjusting mainshaft

7.1

Determining ring and axial washer (straight-cut version)

Adjusting Mainshaft

2

1

Place mainshaft into centre housing using lifting device 1X56 137 200.

2

Place ring (1) into clutch body (2). Fit parts onto 4th speed helical gear.

3

Take several measurements of distance between top edge of clutch body and centre housing sealing face with gasket fitted. Calculate average distance.

4

Nominal dimension X of 32.2-0.5 mm must be ensured. If the average distance is different, select ring to ensure nominal distance (see table in under 5).

5

1

001953

Select thrust washer (3) from the following table.

If 3.6 mm ring is required, use 7.9 mm thrust washer.

Ring (1): 3.6 / 4.0 Thrust washer (3): 7.9 / 8.3 Remove mainshaft from centre housing and place thrust washer onto mainshaft with raised collar facing towards helical gear.

3

X

6

1

! DANGER Always wear protective gloves when handling heated bearing inner race.

7

8

Heat new bearing inner race (4) to 100° C and place onto bearing journal of main shaft ensuring it is firmly seated. Drive on using plastic drift.

001954 001954

Apply approx 4g of lubricating grease (Aralube HL2 or Texando F020) bearing inner race (collar side) on face of bearing output end (see arrow).

NOTE: Make sure no grease is applied to the outside of the bearing rollers. Grease applied here may block the input shaft lube bores.

9

10

Using drift 1X56 137 676, insert split ring (5) into annular groove on mainshaft to give axial play and prestress of - 0.05 mm to + 0.05 mm.

Split rings are available in 0.1 mm thicknesses.

3 4 6

5

Slide new circlip (6) over split ring and peen over at 3 points (120° apart) using punch.

001955

2-43

Adjusting Mainshaft 7.2

Determining ring and axial washer (helical-cut version)

1

Measure distance between mainshaft and bearing inner race contact point using depth gauge (dimension „a“).

2

Insert axial washer (1) and measure distance between mainshaft and axial washer using depth gauge (dimension „b“).

3

a – b must give a play of between + 0.07 mm and - 0.08 mm.

4

After selecting the correct axial washer, insert ring (2) into clutch body (3). Place parts onto 4thspeed helical gear.

5

Measure distance between axial washer and clutch body at several points. Calculate mean value. Nominal dimension = 4.6 - 0.4mm (select ring (2) accordingly).

16 S 151 / 8 S 151

4.6 -0.4

2

1

+0.07 bis to -0.08 +0.07 -0.08 009521 009521

! DANGER Always wear protective gloves when handling heated bearing inner race.

3 2

6

Heat new bearing inner race (4) to 100°C and place onto mainshaft bearing journal until it is in firm contact. Fully drive home using plastic drift.

7

Apply approx 4g of lubricating grease (Aralube HL2 or Texando F020) bearing inner race (collar side) on face of bearing output end (see arrow).

NOTE: Make sure no grease is applied to the outside of the bearing rollers. Grease applied here may block the input shaft lube bores.

001953

8

Use drift 1X56 137 676 to insert split ring (5) into annular groove in mainshaft to give axial play/prestress of between - 0.5 mm and + 0.05 mm. Split rings are available in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.).

9

Slide new circlip (6) over split ring and peen over in three places (120° apart) using punch.

1 4 6

5

001955

2-44

16 S 151 / 8 S 151 8

Installing shafts

8.1

Input shaft, mainshaft and layshaft

Installing Shafts

! DANGER Ensure fixture and rope are firmly secured.

5

1

4

Place alternating pin 1X56 137 920 onto the layshaft locator. Insert output end of mainshaft (1) into locator 1X56 137 675. Place clutch body, correct ring and synchronizer ring onto the teeth of the helical gear on the mainshaft. Place the complete input shaft onto the mainshaft. Position layshaft (2) with teeth at correct height for meshing. Push the layshaft against the mainshaft and bring the teeth into mesh.

2

Insert shift rails (3) and fulcrum pads into sliding sleeves on mainshaft.

3

Place centring bush 1X56 137 921 into lifting device 1X56 137 122 (4) and secure. Push lifting device over input shaft (5) and shift rails and push down onto layshaft.

4

Screw lifting device onto layshaft using disc 1X56 137 933 (6).

Tightening torque = 85 Nm.

5

7 6

2

1

3

001995

Place holder (7) in driver recesses and lifting device.

CAUTION Ensure holder (7) 1X56 137 918 is firmly located at both points. This guarantees safe lifting procedure.

6

Insert mainshaft, input shaft and layshaft into taper roller bearing outer races in centre housing without tilting.

NOTE: Ensure interlock is retracted and locked.

7

Remove all lifting equipment.

8

Remove device 1X56 137 287 for interlock.

9

Turn input shaft to centre bearing rollers.

.

2-45

Adjusting Shift Fork 9

Splitter shift fork / shift rail

9.1

Adjusting shift fork

1

Guide in shift rail (1) from inside (in centre housing). To protect packaging, slide correct size pin through packaging from outside to prevent damage to the packaging caused by shift rail threads.

16 S 151 / 8 S 151

6 3 4

CAUTION Do not damage flange packing when inserting shift rail.

1 2

Correctly position shift fork (3) and fulcrum pads against sliding sleeve (4) and place onto shift rail.

NOTE: Line up bores in shift rail with thread in shift fork.

3

Insert grub screws (6) (do not tighten yet).

4

Switch sliding sleeve to output.

5

Screw piston (2) and new double-grooved ring onto shift rail.

NOTE: Renew lock nut; Tightening torque = 150 Nm. Ensure the thread is absolutely free of grease.

6

Nominal dimension (X) between piston and centre housing (5) sealing face must be 94.0 mm.

Use grub screws (6) to adjust shift. Measure without gasket on centre housing .

7

Fulcrum pads in the sliding sleeve must have the same play above and below (check using feeler gauge).

8

Tighten grub screws evenly.

Tightening torque = 60 Nm.

2-46

2 5

x 001956 001956

16 S 151 / 8 S 151 I

Adjust as follows if using support plate 1X56 137 917:

9

Work steps 1) to 3) and 5). Fit splitter cylinder (7) (see work steps 1) to 4) in Section 13.2). Screw support plate onto the housing sealing face.

Switch the sliding sleeve to the output. Splitter piston must axially contact cylinder and cylinder must axially contact the supporting plate. This is the correct position. Then follow work steps 7) and 8).

Adjusting Shift Fork 5 8

7

001965

II

10

Adjust as follows (new version) if using centering device 1X56 138 079 and support plate 1X56 137 917:

8

Adjust as described under step 9).

Attach the centering device 1X56 138 079 before performing steps 7) and 8).

3 1 9

009944

2-47

Assembling Clutch Housing / Centre Housing 10

16 S 151 / 8 S 151

Clutch housing / centre housing

10.1 Fitting clutch housing 1

Fit new gasket to centre housing sealing face.

! DANGER Ensure fixtures and rope are firmly secured.

2

1

Using hook 1X56 136 564, place clutch housing (1) flat onto centre housing.

CAUTION End of injection pipe must engage in clutch housing bores in funnel and shift rails.

001957

NOTE: Position all cylindrical pins between clutch housing and centre housing. If necessary, push shift rail drivers inwards until clutch housing is fixed.

3

Screw in 13 hex bolts inside clutch housing and 9 hex bolts outside. Turn input shaft several times to centre bearing rollers.

Tightening torque = 49 Nm.

4

Remove hook 1X56 136 564.

2-48

16 S 151 / 8 S 151 11

Adjusting Mainshaft

Adjusting shafts

11.1 Input shaft and connection plate 1

To achieve correct setting, the input shaft rollerbearing must be play-free when measured. To ensure this, the outer race (1) must touch the bearing rollers (2). Use plastic drift to push taper roller bearing outer race towards output end. Rotate input bearing several times to centre bearing rollers.

1

NOTE: Bearing rollers should not move and should not be prestressed.

2

a

Measure distance between face of bearing outer race (1) and sealing face (3) using depth gauge.

Note down dimension “a”.

2

NOTE: Measure at two opposite points and calculate the average value.

3

001958 001958

Measure distance between sealing face (4) and locating face (5) for shim in connecting plate using depth gauge. Note down dimension “b”.

Measure gasket (6) and note down dimension.

NOTE: Measure at two opposite points and calculate the average value.

4

3

Calculate the difference “c” and note it down: c = (b + gasket) – a

4

b

6 5

NOTE: Axial play on roller bearing: 0.0 to 0.1 mm.

5

Select a shim of the same thickness as dimension “c” (max. 0 - 0.1 mm).

6

Place shim in the connection plate. Shims are available in 0.05 mm thicknesses.

NOTE: The same procedure is used for measuring split connection plates.

001959

2-49

Adjusting Layshaft

16 S 151 / 8 S 151

11.2 Layshaft 1

There must be no play on the layshaft taper roller bearing during measurement. Use plastic drift to push outer race (1) towards output until it is pressed firmly against the bearing rollers (2). Rotate input bearing several times to centre bearing rollers.

NOTE: Bearing rollers should not move and should not be presetressed.

2

Measure thickness of shim using depth gauge.

1

NOTE: Measure at two opposing points.

3

Measure distance between housing sealing face and bearing outer race (1) face. Measure gasket and add to dimension “a”.

4

Use average dimension “a” obtained from measurements taken to select correct shim NOTE: Axial play 0.0 to 0.1 mm.

5

Thickness of shim must correspond to measurement “a” (max. minus 0.1 mm).

6

Place shim onto taper roller bearing outer race.

Shims are available in 0.05 mm thicknesses.

2-50

a 2 001960 001960

16 S 151 / 8 S 151

Assembling Connection Plate

12. Fitting clutch housing components 12.1 Connection plate with integral pump

9

Single-piece version 7 1

Thinly coat outside of shaft seal (1) with sealing compound and, using drift 1X56 103 766, insert into connection plate.

NOTE: Sealing lip on shaft seal ring must face towards drift.

2

Place washer (8), spacer ring (9) and washer (10) onto input shaft.

3

Screw guide pin 1X56 137 949 into the threaded hole in the layshaft.

4

Fit new gasket (11) to connection plate (2), place over input shaft and onto clutch housing. Tighten hex bolts and nuts.

Tightening torque = 46 Nm.

5

Unscrew guide pin from the layshaft.

6

Place inner rotor (3) into pump housing (5).

Engage with layshaft.

7

Place outer rotor (4) into pump housing.

6

11

10

8 1

2

5

3

4

001993 001993

NOTE: Ensure there is axial play on outer and inner rotors.

8

Thinly coat cover sealing face (6) with Loctite No. 574 (from hole to hole) and place onto pump housing.

9

Drive cylindrical pins (7) into pump cover. Rotate inout shaft to check.

10

Affix pump cover Tightening torque = 46 Nm.

2-51

Assembling Connection Plate

16 S 151 / 8 S 151

Split version 1

Place washer (1) onto input shaft.

2

Place connection plate (2) over input shaft and onto clutch housing together with new gasket (3).

Tighten hex nuts (4).

Tightening torque = 46 Nm.

3

4

10

Insert outer rotor (9) into pump housing.

5

Lightly coat pump cover sealing face (10) with Loctite 574 (from bore to bore) and place onto pump housing.

6

Firmly attach pump cover.

Tightening torque = 46 Nm.

9

7

5

1 2

Fit new gasket (7). Bring pump housing (6) and inner rotor into mesh with layshaft and tighten (8).

Tightening torque = 46 Nm. NOTE: Ensure that there is axial play on the outer and inner rotors.

2-52

6

8 3

11 4

009519

16 S 151 / 8 S 151

Assembling Release Fork

12.2 Release fork 7

Released fork (pulled) 1 2

Insert plain spherical bearing (1) into bearing block (2) and attach circlips (3).

9

3

4 2

8

Fix bearing block using hex bolts (4).

1

Tightening torque = 115 Nm. 3

Slide release fork (5) over bearing block and insert pin (6).

4

Fit seal rings (7) and seals (8) onto pin.

5

Attach circlips (9) to pin.

3 7 8

5

9

6 009520

Release fork (pushed) 1

Screw in ball bolt (3) with washer (4).

Use Loctite no. 262.

Tightening torque = 100 Nm

2

Place ball cup (2) in clutch lever (1).

3

Place clutch lever (1) onto ball bolt (3).

2

3

4

1

004484

004484

2-53

Assembling Release Fork

16 S 151 / 8 S 151

Release fork (pulled) 1

Push shaft (2) into clutch bell housing. Fit new tab washer (7) and grooved nut (6) onto shaft.

2

Guide shaft into 1st bearing bore on connecting plate. Push release fork (1) onto shaft and guide this into 2nd bearing bore on the connecting plate.

3

Place bearing bush (8) over shaft and into clutch housing.

4

Hit slotted pins (4) into release fork (1) and shaft (refer to assembly specification).

5

9 10 1 2

3 4

5

6

8

7

Fit tab washer (7) and grooved nut (6) onto bearing bush. Secure grooved nut.

Tightening torque = 200 Nm

6

Fit shift lever (3) onto shaft using screw (5) (observe position); Tightening torque = 120 Nm.

7

Mount sheet (9) using four screws (10); Tightening torque = 23 Nm

004483

004483

8

7 6 1

2

4

004 917

004917

5

3 004 918

004918

2-54

16 S 151 / 8 S 151 13

Assembling Reverse Idler Gear

Fitting centre housing components 3

13.1 Reverse idler gear/reverse idler pin 1

Insert needle cages (1) into reverse idler gear.

2

Place reverse idler gear (2) into housing.

4 5

2

NOTE: Collar of reverse idler gear must face towards output end.

3

Push reverse idler pin (3) into centre housing from output side until firmly seated.

4

In “first version’’, screw in washer (4) and locking bolt (5).

Tightening torque = 86 Nm.

1

7 6

NOTE: In “2nd version’’, the reverse idler pin is secured using a centrally-mounted clamping pin (8) (figure 002000).

5

001962 001962

Fit cover (6) and new gasket (7) onto centre housing.

Tightening torque = 49 Nm. 3

8

2 1 002000

13.2 Cylinder 1

Remove supporting plate and cylinder.

2

Check locking nut on piston.

Tightening torque = 150 Nm.

3

Fit spring washer (1) onto housing.

4

Fit cylinder (2) with new O-rings (3 and 4).

1

4

3

2

NOTE: If necessary, fit 3 O-rings.

Hint: Lightly oil O-rings.

5

Insert cylinder onto centre housing.

NOTE: Line up lug on cylinder with groove in centre housing.

001963 001963

2-55

Compressed Air Test

16 S 151 / 8 S 151

13.3 5/2-way valve 1

Insert new O-ring (1) into 5/2-way valve.

2

Screw 5/2-way valve (2) onto centre housing.

Tightening torque = 9.5 Nm. NOTE: There is no 5/2-way valve in the 8 S 151 transmission.

1

2 001964 001964

13.4 Compressed air test for piston and splitter cylinder 1

Screw support plate 1X56 137 917 (1) for splitter cylinder (2) onto centre housing (3).

2

Supply compressed air (max. 6.8 bar) to 5/2-way valve and piston.

3

Wet outer edge of splitter cylinder and check for bubbles (leaks).

4

Supply compressed air to piston in opposite direction and check if air escapes through 5/2-way valve.

5

If bubbles form, fit new O-rings if necessary and check correct location.

6

If air escapes, renew double-grooved ring on piston.

7

Remove support plate (1).

2-56

3 1

2

001965 001965

16 S 151 / 8 S 151

Installing Components

13.5 Injection pipe 1

Using drift 1X56 137 835, drive injection pipe (1) into mainshaft until firmly located.

1

001966

2-57

Installing Range-Change Housing 14

Installing complete range-change

1

Fit new gasket (1) onto centre housing (2).

16 S 151 / 8 S 151

NOTE: There must 3 cylindrical pins in centre housing.

2

Fit 2 hex bolts to range-change housing to allow range-change to be suspended from a rope and positioned horizontally against centre housing.

1

CAUTION Secure hex bolts with nuts. Ensure rope is firmly secured.

2

Hint: Use threaded pins on centre housing to simplify positioning of range-change.

3

Push range-change against centre housing (2).

Turn output flange to bring planet gear train and mainshaft teeth into mesh if necessary.

4

Remove hex bolts and rope when range-change is held against centre housing.

5

Slide range-change (3) parallel to centre housing and bolt together.

Tightening torque = 49 Nm.

6

Switch piston to end position (high or low group).

3 2

001967

2-58

16 S 151 / 8 S 151

Assembling Centre and Range-Change Housing

7

Screw fixing device 1X56 137 579 into centre housing and into hole for detent plunger (6).

8

Screw new locking nut onto piston Tightening torque = 150 Nm.

13 14 20 21

NOTE: Renew locking nut. Make sure the thread is absolutely free of grease.

9

Remove fixing device.

10

Fit cylinder and tighten.

Tightening torque = 49 Nm.

6 7

11 8 10 9

NOTE: Carefully push cylinder over piston together with guide ring and piston gasket.

11

12

Screw in detent plunger (6) together with new seal ring (7).

Tightening torque = 50 Nm. Insert pin (8) and switch (9) together with new seal ring (10).

Tightening torque = 50 Nm. NOTE: In the new version, fit switch (9) onto the range-change housing.

13

Fit screw plug (13) with new seal ring (14).

Tightening torque = 50 Nm.

14

Insert pin (15) and switch (16) with new seal ring (17).

Tightening torque = 50 Nm.

15

Insert detent plunger (18) with new seal ring (19); Tightening torque = 50 Nm.

16

Screw in reverse gear pressure switch (20) with new sealing ring (21).

Tightening torque = 50 Nm.

22 19 18 15

23

17 16 001968 001968

NOTE: In the new version, the pressure switch (20) is mounted in the cover (shift housing).

17

Screw in screw plug (23) with new seal ring (22).

Tightening torque = 35 Nm.

18

Screw in mechanical speedometer and new seal ring or impulse sensor.

Tightening torque = 50 Nm.

19

Screw breather into bore (11).

Tightening torque = 10 Nm.

2-59

Installing components 15

Installing components

15.1

Shift housing

1

Place new gasket (1) onto clutch housing (2) and sealing face.

2

Place complete shift housing (3) in position. Line up bores in shift housing with bores in gasket.

Hint: Use threaded pins to simplify positioning of clutch housing, gasket and shift housing.

3

16 S 151 / 8 S 151

3 1

2

Shift through all the gears. There must be noticeable excess shift travel in each gear. If the shift angle is not within the specified tolerances, it must be adjusted using an angle measuring device. Finally, tighten all hex bolts.

Tightening torque = 23 Nm.

CAUTION The shift turret housing must be centered on the transmission housing so that equal play (excess shift travel) is obtained on both sides and the resultant shift angle is 14° 30’ +2° (see illustration).

001969

1st, 3rd, 5th, 7th gear

14°30'+2° 14°30'+ 2°

2nd, 4th, 6th, 8th gear

009894

15.2

Plastic pipes

1

Using union screws and new seal rings, screw plastic pipes (1) to cylinder (2) and shut-off valve (3) as marked.

Tightening torque = 38 Nm.

2

Fit pipe bracket (4) and fixed plastic pipes to housing.

NOTE: Observe the following assembly sequence if renewing the pipe bracket or plastic pipes.

1. Place insert (5) into pipe bracket (4) 2. Draw plastic pipes (1) through the pipe bracket.

3. Press rings (6) into plastic pipes (1).

2 1

5

6

3

6

4

1

6

6

001992

2-60

16 S 151 / 8 S 151 16

Compressed air test on breather

1

If necessary, remove breather and screw pressure gauge connection into bore (1).

Compressed Air Test

1

NOTE: Supply air to 5/2-way valve (2) over a long period (max. 6.8 bar) and check pressure gauge.

2

Reinsert breather Tightening torque = 10 Nm. NOTE: There is no 5/2-way valve in the 8 S 151 transmission. Therefore, this test is not required here.

2

001970 001970

2-61