ALMDV

Service Manual
ZF 9 S 109 Gear Box
27.02 ZF 9 S 109 GEAR BOX

CONTENTS

GROUP - 27

ZF-SYNCHROMESH 9 S 109 GEAR BOX

Section Subject Page No.

27.0 General Information ................................................................................................... 27.04

27.0.1 Description ......................................................................................................................................... 27.04
27.0.2 Technical Data ................................................................................................................................. 27.04
27.0.3 Gear Shift Pattern ........................................................................................................................... 27.05
27.0.4 Draining the Oil .............................................................................................................................. 27.06
27.0.5 Repair Data ....................................................................................................................................... 27.07
27.0.6 Linkage Setting Dimensions ........................................................................................................ 27.08
27.0.7 Sequences of Removal and Installation .................................................................................. 27.09

27.1 Tecalan pipe for range-change group ................................................................... 27.10

27.1.0 Removal ............................................................................................................................................... 27.10
27.1.1 Assembly ............................................................................................................................................. 27.10

27.2 Output .......................................................................................................................... 27.11

27.2.0 Removal of Output Flange and Cover .................................................................................. 27.11
27.2.1 Removal of Bearing Cover .......................................................................................................... 27.11
27.2.2 Mounting of Bearing Cover ........................................................................................................ 27.11
27.2.3 Mounting of Output Flange and Cover ................................................................................ 27.12

27.3 Range-change group ................................................................................................... 27.13

27.3.0 Removal of Range-Change Group ............................................................................................ 27.13
27.3.1 Mounting of Range-Change Group ......................................................................................... 27.14
27.3.2 Dismantling Range-Change Group ........................................................................................... 27.15
27.3.3 Assembling Range-change Group ............................................................................................. 27.17

27.4 Planetary gear with synchronizer .......................................................................... 27.20

27.4.0 Dismantling Synchronizer ............................................................................................................. 27.20
27.4.1 Dismantling Ring Gear ................................................................................................................. 27.20
27.4.2 Dismantling Planet Carrier.......................................................................................................... 27.21
27.4.3 Assembling Planet Carrier ........................................................................................................... 27.21
27.4.4 Assembling Ring Gear .................................................................................................................. 27.22
27.4.5 Assembling Synchronizer .............................................................................................................. 27.22

27.5 Sun gear ........................................................................................................................ 27.24

27.5.0 Removal of Sun Gear .................................................................................................................... 27.24
27.5.1 Mounting of Sun Gear .................................................................................................................. 27.24

27.6 Shift mechanism .......................................................................................................... 27.25

27.6.0 Removal of Shift Mechanisms ..................................................................................................... 27.25
27.6.1 Mounting of Shift Mechanism ..................................................................................................... 27.25
27.6.2 Dismantling Shift Mechanism ...................................................................................................... 27.26
27.6.3 Shift Mechanism Assembly ........................................................................................................... 27.31
27.6.4 Assembling Shift Mechanism ....................................................................................................... 27.32

PUB. NO. SM:ZFS9109&Clutch(CS380):816:0405:XA75:11

 ZF 9 S 109 GEAR BOX 27.03

CONTENTS

CHAPTER - 27

ZF-SYNCHROMESH 9 S 109 GEAR BOX

Section Subject Page No.

27.7 Connecting plate-lubricating oil pump ................................................................. 27.36

27.7.0 Removal of Connection Plate .................................................................................................... 27.36
27.7.1 Removal and dismantling of lubricating oil pump ............................................................ 27.36
27.7.2 Assembly and mounting of lubricating oil pump .............................................................. 27.37
27.7.3 Assembly and mounting of connection plate ..................................................................... 27.38

27.8 Adjusting bearings on mainshaft, inputshaft and layshaft .............................. 27.39

27.8.0 Adjusting Mainshaft and Inputshaft ......................................................................................... 27.39
27.8.1 Adjusting Layshaft ........................................................................................................................... 27.40

27.9 Shift rail and reverse gear ....................................................................................... 27.42

27.9.0 Removal of Shift Rails ................................................................................................................... 27.42
27.9.1 Removal of Reverse Gear ............................................................................................................ 27.44
27.9.2 Installation of Shift Rails .............................................................................................................. 27.44
27.9.3 Installation of Reverse Gear ....................................................................................................... 27.47

27.10 Input shaft, mainshaft and layshaft ....................................................................... 27.48

27.10.0 Removal of the Shafts ................................................................................................................... 27.48
27.10.1 Installation of the Shafts .............................................................................................................. 27.49

27.11 Input shaft ..................................................................................................................... 27.52

27.11.0 Dismantling the Input shaft ........................................................................................................ 27.52
27.11.1 Assembly of the Input Shaft .................................................................................................... 27.52

27.12 Mainshaft ....................................................................................................................... 27.53

27.12.0 Dismantling the Mainshaft .................................................................................................................... 27.53
27.12.1 Assembly of the Mainshaft ................................................................................................................... 27.54

27.13 Layshaft .......................................................................................................................... 27.57

27.13.0 Dismantling the Layshaft .............................................................................................................. 27.57
27.13.1 Assembly of the Layshaft ............................................................................................................. 27.57

27.14 Housing .......................................................................................................................... 27.59

27.14.0 Dismantling the Housing .............................................................................................................. 27.59
27.14.1 Assembly of the Housing ............................................................................................................. 27.59

27.15 Clutch Housing ............................................................................................................ 27.60

27.15.0 Removal ............................................................................................................................................... 27.60
27.15.1 Installation .......................................................................................................................................... 27.60

27.16 Special Tools ................................................................................................................ 27.61

27.17 Tightening torque ....................................................................................................... 27.62

27.18 Recommended lubricants .......................................................................................... 27.62

27.19 Filling capacity ............................................................................................................ 27.62

27.20 Maintenance programme ........................................................................................... 27.62

27.04 ZF 9 S 109 GEAR BOX

27.0 GENERAL INFORMATION Gear shifts

The ZF 9 S 109 synchronous transmission of The 4-speed section with reverse gear and
the Ecomid construction range has been rear-mounted range-change group is
specially developed for use in commercial operated mechanically by a double-H
vehicles of the upper medium duty class control.

9 S 109 transmissions is basically consist of:
- a fully synchronized four gear component
- an integrated crawler and reverse gear
- a rear-mounted range-change group
built into the planet.
27.0.1 Description
Design
The synchromesh transmission with range-
change group
(ZF 9 S 109) consists of a 4-speed section
(with dog clutch operated crawler and
reverse gear) of countershaft type together
with a rear-mounted range-change group of
planetary design. The range-change group
doubles the number of gears available in
the 4-speed section, thereby increasing the
number of consecutively selectable forward
gears to 9, including the crawler,
With this type of control, each of the
forward gears and the reverse gear is
allocated its own position in the gear shift
pattern. A range of spring detents of
different loads ensures perfect orientation
through the shift pattern, i.e. accurate
location of individual gears.
The shifting process of the range-
change group is carried out automatically
under pneumatic control while the gate 3/4
is being shifted to 5/6 or while 5/6 is
being shifted back to 3/4 . The control
system for shifting the range-change group
consists of a shift valve and a double
acting shift cylinder integrated in the
transmission. The shift valve is controlled by
the turning shaft of the 4-speed section
and only releases the air pressure to the
shift cylinder in neutral position.

27.0.2 Technical Data

Type ZF 9 S-109 Synchromesh Ecomid - 8 Forward,

1 Crawler Speed & 1 Reverse

Input Torque 1100 Nm

No of Gears 9

Gear Selection Forward - Gears Lock - Synchronized

Reverse - Dog Clutch Arrangement

Gear Ratios Crawler - 12.91 : 1

1st - 8.96 : 1
2nd - 6.37 : 1
3rd - 4.71 : 1
4th - 3.53 : 1
5th - 2.54 : 1
6th - 1.81 : 1
7th - 1.34 : 1
8th - 1.00 : 1
Rev. - 12.20 : 1
 ZF 9 S 109 GEAR BOX 27.05

27.0.3 Gear Shift Pattern

The gears are arranged in a double-H
pattern. The shift pattern includes two neutral
positions in gates 3/4 (low range - change
group) and 5/6 (high range-change group). R 1 3 5 7

Fig - 1
N N
The selector lever springs back to the
neutral position if released in the central
C 2 4 6 8
area. In order to select gears 1/2 or 7/8,
move the selector lever against the spring
force in the required direction and hold the
lever against this force when making the
engagement stroke. Fig. 1
Gates 3/4 and 5/6 are separated by a
stronger spring detent. The range-change
group is changed over automatically when
the selector lever is moved between these
gates. A range of spring detents of different
loads ensures perfect orientation through the
shift pattern, i.e. accurate location of
individual gears. The reverse gate is fitted
with a spring loaded stop which must be
overcome by deliberate effort.

Changing gear
Move between gate 3/4 and 5/6 (or vice
versa) by knocking the selector lever with
the palm of your hand and briskly moving
the selector lever into the required gear.
You must move the selector lever quickly,
but you do not have to move it particularly
forcefully. We recommend keeping your hand
open when selecting gears.
Fig - 2
NOTE: - When engaging a gear, hold the selector
lever against the end stop until the
synchronizer unit has completed the gearshift.
Fig. 2
- Change gears quickly to reduce shift effort.
This is particularly important when the
transmission is cold. If the transmission is
below operating temperature, the driver
has to work harder to change gear. If the
range-change group does not change over
when changing down from gate 5/6 into
gate 3/4, slow your vehicle and engage the
appropriate gear at a lower speed.
CAUTION: Never change down a gear unless the
vehicle and engine speeds are below
the maximum values for the gear you
are going to engage. Failure to comply
can lead to transmission or engine
damage. The maximum transmission
input and output speed is 2500 rpm.
27.06 ZF 9 S 109 GEAR BOX

27.0.4 Draining the Oil

Drain the oil when the transmission is at
operating temperature. When you need to
drain the oil, always do so immediately after
the vehicle has been driven.
To drain the oil, unscrew and remove both
oil drain plugs on the underside of
transmission (2 and 3).
Fig - 3
Before reinserting plug (3), remove any
attached debris from the magnet and fit the
plug with a new sealing ring.
Fig. 3

Filling the Transmission with Oil and

Checking the Oil Level
Park the vehicle on level ground before filling
the transmission with oil or checking the oil
level. Clean the area around the oil filler
hole(1) before opening it. The oil filler hole
also serves as an overflow check and as an
oil level check. Fig - 3
NOTE: Fill the transmission with oil until it
overflows!
CAUTION: Too little oil leads to insufficient lubrication.
The consequences of this are particularly
severe when operating on hilly terrain.
Excess oil causes churning losses and
leads to the transmission overheating.
Check the oil level in the transmission at
regular intervals. In order to avoid incorrect
measurements as a result of the oil
expanding on being heated, the oil level
should not be checked immediately after a
journey but only once the oil has had time to
settle and has cooled. If an oil check indicates
that the oil level has fallen below the edge of
the filling hole, add more oil until it overflows.
Whenever the oil level is checked, the
Fig. 4
transmission should also be checked for any
signs of leakage (sweating or leakage areas).
Transmission breather
The transmission oil heats up during
operation. This causes over-pressure in the
transmission which must be continually
vented through a breather valve.
Fig - 4
Check that this valve is always
operating correctly. Keep the
breather clean and do not cover it
with a plastic cap.
 ZF 9 S 109 GEAR BOX 27.07

27.0.5 Repair Data

Sl. No. Description Dimension

01. Axial preload of layshaft 0.18 - 0.30 mm

02. Axial preload of mainshaft and inputshaft 0.18 - 0.30 mm

03. Axial play of grooved ball bearing situated on output (range-change group) 0 - 0.10 mm

04. Installation dimension for shaft seal in bearing cover 8 + 0.5 mm

05. Axial play of circlip on sun gear 0 - 0.05 mm

06. Axial play of snap ring for grooved ball bearing in ring gear carrier 0 - 0.1 mm

07. Axial play of circlip on mainshaft and layshaft 0 - 0.1 mm

08. Axial play of reverse gear 0.40 - 0.75 mm

09. Axial play of crawler and first gear 0.20 - 0.45 mm

10. Axial play of 2nd speed helical gear 0.20 - 0.40 mm

11. Axial play of 3rd or 4th speed helical gear 0.20 - 0.45 mm

12. Axial play of reverse gear situated on the idler shaft 0.20 - 0.60 mm

13. Permitted axial play of planetary gears in planet carrier 0.10 - 0.70 mm

14. Limit of wear of synchronizer rings and/or clutch bodies, measured between
flat surfaces of ring and body with cones nested firmly together
Main transmission 0.80 mm
Range-change group 1.20 mm

15. Information on synchronous play (axial) 0.60 mm

16. Information on shifting force of synchronizer's shift sleeves

Shift transmission 270 to 310 N
Range-change group 850 to 950 N

17. Axial play on Speedo pinion shaft Min. 0.10 mm

18. Backlash on pinion shaft 0.10 - 0.20 mm

19. Temperature for shrink fitting helical gears onto layshaft

Heating up temperature Max 170°C.

20. Temperature for "assembly of sun gear" Max. 170°C

21. Delivery rate of lubricating oil pump during separate check 5.15 - 6.45 l/min.
and 0.155 bar
27.08 ZF 9 S 109 GEAR BOX

27.0.6 Linkage Setting Dimensions

Setting Dimensions"

Reaction Rod : A = 425 mm

Connection Flange : B = 93 mm

Connection Flange
Pitch (Top Hole) : C = 47 mm

Outer Lever Pitch Fig. 1

(Middle Hole) : D = 65 mm

Fig - 1 & 2

Fig 3
 ZF 9 S 109 GEAR BOX 27.09

27.0.7 Sequences of Removal and Installation

When performing a basic overhaul of the transmission, the sequence for removal (steps 01 - 14)
and the sequence for installation (steps 14 - 01), as shown below, should be strictly followed.

Tecalan Pipe Output, range-change group, planet carrier

Sun gear Shift mechanism

Connection plate, shift rails Input Shaft, reverse gear Shafts with clamps, housings
and oil sieve, bearing and pivot
adjustment of shafts.
27.010 ZF 9 S 109 GEAR BOX

27.1 TECALAN PIPE FOR RANGE-

CHANGE GROUP

NOTE: Make the Tecalan pipes at connection points

before removal

27.1.0 Removal

1. Remove union screws on range-change group

cylinder and shut-off valve. Take off tecalan
pipes.
Fig. 1
2. Remove cable.

27.1.1 Assembly

1. Screw Tecalan pipes onto shut-off valve and

range-change group cylinder with union
screws. Use new sealing rings on the union
screws. Fit Tecalan pipes in accordance with
marks. Tightening torque for union screws
M14 x 1.5 is 35Nm.

2. Attach cable

Fig - 1

CAUTION: Tecalan pipes can be incorrectly

connected. If they were not marked
during removal, proceed as follows:
Use selector shaft to select R gear
position. Pressurize entry to main
shut-off valve with compressed air, not
higher than operating pressure. (Refer
to arrow in Fig - 1).
Fig. 2

Air for low ratio group will exit from

valve exit. Connect tecalan pipe at this
exit and on cylinder connection “2”
(Fig - 2). This provides the
connection for the second Tecalan
pipe.

Note: Ensure that minimum distance between

Tecalan pipe and housing is 5 mm.
 ZF 9 S 109 GEAR BOX 27.11

27.2 OUTPUT

27.2.0 Removal of Output Flange and Cover

1. Remove retaining plate (1).

2. Secure output flange to stop it rotating using

standard flange holder.

3. Remove two hex bolts (2) and take off

washer (3).

4. Place intermediate part on planet carrier and

Fig. 1
pull off output flange (5) using standard two
leg or three leg puller.

5. If necessary, remove flange bolts (6).

6. Remove O-ring (4).

7. Remove four hex bolts (7). Lift off cover

(8) and seal (9).

Fig - 1

27.2.1 Removal of Bearing Cover

Fig. 2
1. Unscrew eight hex bolts on bearing cover.

2. Release bearing cover by hitting it gently

with plastic hammer.

Fig - 2

3. Lift off bearing cover with seal and washer.

4. Use plastic mandrel to drive shaft seal out

of bearing cover

Fig - 3
Fig. 3
27.2.2 Mounting of Bearing Cover

NOTE: To avoid measurement errors, tap bearing

cover home onto collar of housing III by
gently hitting it with plastic mandrel hammer.

1. Adjust axial play of ball bearing with washer,

aim for play of 0.0 mm.
Permitted axial play : 0 - 0.1 mm

2. Measure dimension “A” from the bearing

cover face end to the housing sealing face.
Fig - 4 Fig. 4
27.12 ZF 9 S 109 GEAR BOX

3. Measure dimension “B” from bearing cover

with seal added to contact face of ball
bearing

4. Determine the washer thickness “C”

C = B - A
C = washer thickness when axial play is 0

Fig - 5

5. Apply lubricant to outer diameter of shaft

seal.

6. Use drift 1X56 126 467 and ring 1X56

137 484 to drive shaft seal into bearing Fig. 5
cover. This gives an installation diameter of
+0.5
8.0 mm

NOTE: Lightly grease sealing lip of shaft seal.

Fig - 6

7. Place washer in recess of bearing cover.

8. Add new seal to bearing cover.

9. Screw in eight M8 hex bolts with spring

washers. Tightening torque = 23 Nm.

Fig - 7
Fig. 6

27.2.3 Mounting of Output Flange and Cover

1. Add new seal (9) to cover (8), screw in

four M12 hex bolts (7). Tightening torque
is 79 Nm.

2. If necessary, add and/or press in flange

bolts(6).

3. Push output flange (5) onto planet carrier

shaft.

4. Use washer (3) and two assembly aid bolts

to pull up output flange unit it is fully home.
Fig. 7
5. Remove washer and assembly aid bolts.

6. Lightly oil new O-ring (4) and insert in gap

between output flange and planet carrier
shaft.

7. Insert washer (3) in output flange, screw in

two bolts (2) and tighten to 60 Nm. If
possible, secure output flange to stop it
rotating, using standard flange holder.

8. Fully drive on new retaining plate (1) over

bolts heads using drift 1x56 136 452.

Fig - 8
Fig. 8
 ZF 9 S 109 GEAR BOX 27.13

27.3 RANGE-CHANGE GROUP

NOTE: If the range-change group is not dismantled
and only cap collar and/or piston are to be
replaced on the cylinder, proceed as follows;
Screw fixing attachment into threaded bore
of pawl stop and tighten to 50 Nm. In so
doing, set the fixing piece so that the shift
rail is fixed radially. Remove cylinder (refer
to section 27.3.2). Remove locking nut from
piston, lift off piston and take grooved ring
from Piston. Press cap collar out of
housing, e,g using screw driver.

27.3.0 Removal of Range-Change Group Fig. 1

1. Remove pawl stop (1) for range-change

group and Screw plug (3).
Fig - 1
2. Screw out plug screw (2) and use magnet to
take ball out of bore.
Fig - 2
3. Screw out impulse sensor.
NOTE: Speedo input is a single component and is
not dismantled.
Fig - 3
4. Remove hex bolts at edge of housing. Fig. 2
Fig - 4
5. Screw hook 1X56 136 599 into housing.
6. Suspend range-change group on hook.
CAUTION: If output flange has been removed,
secure planet carrier in housing. Place
suitable bush on shaft of planet carrier.
Fasten bush with previously removed
washer and two hex bolts.
7. Use two mounting levers to separate
housing parts.
8. Remove seal and clean sealing faces.
Fig - 5 Fig. 3

Fig. 5 Fig. 4
27.14 ZF 9 S 109 GEAR BOX

27.3.1 Mounting of Range-Change Group

CAUTION: If output flange has been removed,

secure planet carrier in housing. Place
suitable bush on shaft of planet carrier.
Fasten bush with previously removed
washer and two hex bolts.

1. Carefully insert two cylinder pins (refer to

arrow)

2. Screw standard M10 guiding bolts into

housing.

Fig - 6 Fig. 6

3. Slide new seal over guiding bolts and place

on housing.

4. Suspended range-change group on crane and

carefully drive onto transmission housing.

NOTE: Drive shift rail into bearing plate opening for

shift locking (interlock).

5. Use guiding bolts to drive range-change

group fully home.

Fig - 7
Fig. 7
NOTE: Engage gear teeth on sun gear and planetary
gears.

6. Screw in hex bolts in accordance with parts

list, M10 tightening torque = 50 Nm.

Fig - 8

NOTE: Screw hex bolts with bore into head of

Speedo input (wire lock).

NOTE: If the range-change group is not dismantled

and cap collar and/or piston, locking nut and
cylinder are to be replaced on the cylinder,
proceed as follows before screwing in the
pawl stop: Screw fixing attachment into Fig. 8
threaded bore of pawl stop (1) and tighten
to 50 Nm, In so doing set the fixing piece
so that the shift rail is fixed radially Spray
new cap collar on outer edge with spirits.
With sealing ring facing housing, slide it over
shift rail and place on housing bore. Use
suitable tool to drive cap collar fully home.
(Assembly of following parts is described in
section 27.3.3). Assemble shim, piston and
locking nut. Assembly double-grooved ring,
O-ring and Cylinder. Unscrew fixing
attachment.

Fig - 9
Fig. 9
 ZF 9 S 109 GEAR BOX 27.15

7. Screw in pawl stop (1) for range-change

group with new sealing ring

- M16 x 1.5 tightening torque = 50 Nm

8. Screw in screw plug (3) with new sealing

ring. Tightening torque = 35 Nm.

9. Insert ball in housing bore

Screw in screw plug (2) with new sealing

ring. Tightening torque = 35 Nm.

Fig - 10

27.3.2 Dismantling Range-Change Group Fig. 10

1. Screw both pivot bolts out of housing

Fig - 11

2. Lift housing from planet carrier.

Fig - 12

NOTE: If the range-change group is not dismantled,

Cylinder, locking nut, piston with grooved
rings, guiding rings and cap collar are
disassembled as is described below.

3. Remove four hex bolts from cylinder.

Fig. 11
Fig - 13

4. Use O-ring to carefully lift cylinder

5. Take guiding ring out of piston groove (refer

to arrow).

6. Use piston to make out shift rail

Fig - 14

CAUTION: The cap collar may be damaged. It

should therefore always be replaced.

Fig. 12

Fig. 14 Fig. 13
27.16 ZF 9 S 109 GEAR BOX

7. Press cap collar out of housing, e,g using

screwdriver.

Fig - 15

Fig. 15

8. Clamp shift rail in vice and place square

material in recess.

CAUTION: Protect shift rail with aluminium

wedges.

Fig - 16

Fig. 16

9. Unscrew locking nut and take off piston

10. Take both grooved rings out of piston

groove

Fig - 17

Fig. 17

11. Use mandrel to drive ball bearing out of

housing and then place housing on two
wooden blocks in reverse order.

12. Screw out screw plugs in housing.

Fig - 18

Fig. 18
 ZF 9 S 109 GEAR BOX 27.17

27.3.3 Assembling Range-change Group

1. Screw Screw plugs into housing and use new

sealing ring.

M18 x 1.5 tightening torque = 35 Nm

NOTE: Use hot air blower to heat bearing seat in

housing to max 70°C.

2. Use plastic mandrel to drive ball bearing

into housing and ensure that it is driven
home. Fig. 19

3. Use sealing compound to slide sealing cover

(refer to arrow) onto sealing face and use
suitable tool to drive in flush to the housing
bore.

Fig - 19

4. Clamp shift rail in vice and place square

material in recess.

CAUTION: Protect shift rail with aluminium

wedges Fig. 20

Fig - 20

NOTE: If the range-change group is not dismantled,

cap collar, piston with grooved rings, guiding
ring, locking nut and cylinder are
disassembled as is described below.

NOTE: Spray cap collar on outer edge with spirits.

5. Use suitable tool to drive new cap collar

into housing.
Fig. 21
Fig - 21

6. Insert new grooved ring in piston.

CAUTION: The grooved sides of the ring should

face outwards.

7. Apply thin coat of grease to sealing lips of

grooved ring.

Fig - 22

Fig. 22
27.18 ZF 9 S 109 GEAR BOX

8. Place piston on shift rail.

NOTE: Recess in piston faces upwards.
9. Screw in new locking nut.
M16 x 1.5 tightening torque = 150 Nm
Fig - 23
10. Insert shift rail and piston into housing bore
and in so doing turn shift rail.
11. Insert guiding ring into middle piston ring
groove.
Fig - 24
Fig. 23
12. Apply thin coat of grease to sealing lips of
grooved ring.
13. Coat new 'O' ring with grease and place in
ring groove of cylinder.
14. Carefully push cylinder over piston.
Fig - 25
NOTE: During this process, the guiding ring must be
at the base of the piston ring groove.
CAUTION: Try to avoid damaging O-ring, groove
and guiding rings.
15. Rotate cylinder into position.
Fig. 24
16. Screw in four hex bolts with spring disks.
M8 tightening torque = 23 Nm.
17. Radially position shift rail on that both
detents face upwards for the fitting of the
range-change group (27.3.1).
Fig - 26
NOTE: The recesses in the shift rail for shift fork
engagement can be found in the installation
position.
Fig - 27

Fig. 25

Fig. 27 Fig. 26
 ZF 9 S 109 GEAR BOX 27.19

18. Use group synchronizer to place range-

change group housing on planet carrier and
drive firmly home.

19. Engage shift fork nose with recess to shift rail.

Fig - 28

NOTE: Clutch body journals must engage in housing

recesses.

20. Align shift fork to threaded bores in housing

so that guiding bores of shift fork are flush
with threaded bores of housing.
Fig. 28
Fig - 29

NOTE: - Threads must be clean and free of oil

and grease.

- Spray pivot bolt threads with Loctite

no. 241.

21. Screw in pivot bolts with spring washers:

M24 x 1.5 tightening torque = 250 Nm

Fig - 30

22. Fit cover as described in Section 27.2.2.

Fig. 29

23. Fit output flange as described in Section

27.2.3.

24. Screw in screw plug with new sealing ring.

Tightening torque = 100 Nm.

Note: Do not disassemble defective shaft seals but

use drift 1X56 100 632 to drive new shaft
seal firmly home.

25. Check axial play and backlash of Speedo

shaft by hand
- Axial play = min. 0.1 mm
- Backlash = min. 0.1 - 0.2 mm Fig. 30

26. Tighten impulse sensor to 50 Nm.

Fig - 31

Fig. 31
27.20 ZF 9 S 109 GEAR BOX

27.4 PLANETARY GEAR WITH

SYNCHRONIZER

27.4.0 Dismantling Synchronizer

1. Remove shift fork.

2. Take fulcrum pad out of shift fork.

3. Place intermediate part on planet carrier.

Fig - 1
Fig. 1

4. Insert split ring (3) 1X56 137 648 between

clutch body (2) and synchronizer ring (4).
Grip bottom of sliding sleeve (5) with two-
leg or three leg-puller and pull off
synchronizer ring (4), clutch body (2) and
impulse washer (1) or Speedo worm. The
pressure pieces (7) and compression springs
(8) retained by the sliding sleeve can be
caught in a cloth.

5. Spring out circlip (6)

6. Grip bottom of synchronizer hubs (9) with

two leg puller and pull off.

7. Remove synchronizer ring (10) and clutch

bodies (11) from planet carrier.

Fig - 2

27.4.1 Dismantling Ring Gear

1. Pull ring gear completely off planet carrier

(18). Fig. 2

2. Remove snap ring (12) from ring groove of

ring gear carrier (14) and remove ball
bearing (13).

3. Remove safety wire (15) from ring groove in

ring gear (11) and use plastic hammer to
drive ring gear carrier (14) out of ring gear.

Fig - 3

Fig. 3
 ZF 9 S 109 GEAR BOX 27.21

27.4.2 Dismantling Planet Carrier

1. Drive the full length of each clamping pin
(16) into planetary bolts (17).
2. Use hammer and plastic mandrel to drive all
four planetary bolts (17) out of the planet
carrier in the direction of the input.
3. Take the four planetary gears (22) and
washers (19) intermediate washers (20) and
needle rollers (21) out of planet carrier (18).
4. Drive clamping pin (16) out of planetary
bolts (17).
Fig - 4

27.4.3 Assembling Planet Carrier

CAUTION: Do not replace planet gears
individually but always as a set.
1. Lightly oil front face of planet gear (22) and
the cylinder roller race.
2. Assembly planetary bolts (17) with collar
facing downwards.
3. Slide washer (19) over planetary bolt with
marked side facing planet carriers.
4. Slide an intermediate washer (20) over
planetary bolt.
5. Place planetary gear (22) on planetary bolt.
6. Insert 20 needle rollers (21) in planetary
gear and slide intermediate washer (20) over Fig. 4
planetary bolt.
NOTE: Only use needle rollers of the same
dimensions.
7. Insert the remaining 20 needle rollers, slightly
oil and add intermediate washer (20).
8 Slide washer (19) over planetary bolt with
marked side facing planet carrier.
9. Place planet carrier (18) on front face of
shaft.
10. Carefully take planetary gear (22) and
washers (19) off planetary bolts (17) and
insert in planet carrier .
11. Align planetary gear (22) and washers (19)
to bearing bore.
NOTE: The 'O' mark on the front face of the
planetary bolt must face the outer radius of
the planet carrier (oil bore must face inner
radius of planet carrier).
12. Align planetary bolt (17) radially and insert
in bearing bore.
13. Use plastic hammer to drive in planetary
bolt. Check that clamping pin bore is flush.
14. Drive new clamping pin (16) into planet carrier.
NOTE: Countersink clamping pin approximately 0.5
mm into planet carrier.
15 Check axial play of planetary gears (0.1 to
0.7 mm).
16. Repeat steps 1 to 15 on the other three
planetary gears.
Fig - 4
27.22 ZF 9 S 109 GEAR BOX

27.4.4 Assembling Ring Gear

1. Drive ring gear carrier (14) firmly home in

the ring gear (11).

2. Insert safety wire (15) into groove ring of

ring gear.

NOTE: The safety wire must lie on the groove base.

3. Insert ball bearing (13) in ring gear carrier

and insert snap ring (12). Use suitable snap
ring to adjust ball bearing axial play 0 to
0.1 mm.

4. Heat ball bearing (13) to approx 60°C and

place on planet carrier with ring gear. In so
doing, turn ring gear and engage gear teeth.
Ball bearing must lie axially on planet carrier.

Fig - 5

27.4.5 Assembling Synchronizer

CAUTION: Check, mark and store parts IN

PAIRS. Do not mix up parts.
Fig. 5
1. Place synchronizer ring on center of clutch
body. Move the cones by turning the parts.

2. Use feeler gauge to measure distance

between clutch body and synchronizer ring.

NOTE: Compare dimension found with permitted

limits of wear. These are:

Main transmission = 0.8 mm

Range-change group = 1.2 mm

1 = Synchronizer ring
2 = Clutch body
NOTE: If your dimension is below these, install new
Fig. 6
synchronizer ring and / or clutch body.

Fig - 6
 ZF 9 S 109 GEAR BOX 27.23

3. Place clutch body (11) and synchronizer ring

(10) on planet carrier.

4. Push on clutch body (11) with long hub side

facing planet carrier. The cams of the
synchronizer ring (10) must reach into the
recesses of the synchronizer hub.

5. Insert circlip (6) in ring groove with axial

play of 0 to 0.1 mm.

NOTE: Select a circlip suitabley.

6. Place sliding sleeve (5) on synchronizer hub

(9) and drive home.

NOTE: Sliding sleeve recesses must cover the same

area as the synchronizer hub recesses.

7. Insert new compression springs (8) with

pressure pieces in synchronizer hub and
guide into sliding sleeve with suitable tool.

8. Place synchronizer ring (4) on synchronizer

hub. The cams of the synchronizer ring (10)
must reach into the recesses of the
synchronizer hub.
Fig. 7
9. Press on synchronizer ring (4) and bring
sliding sleeve into middle position. You will
clearly be able to hear the pressure pieces
snapping in.

10. Heat clutch bodies (2) to approx. 120°C

and push onto planet carrier.

11. Heat speedo worm or impulse washer (1)

to approx. 80°C and push onto planet
carrier.

Fig - 7

12. Insert fulcrum pad into shift fork.

13. Insert shift fork into sliding sleeve.

NOTE: Shift fork nose should be located in the

appropriate recess in clutch body.

Fig - 8

Fig. 8
27.24 ZF 9 S 109 GEAR BOX

27.5 SUN GEAR

27.5.0 Removal of Sun Gear

1. Remove circlip.

Fig - 1

2. Push drift 1X56 137 456 over pipe used

for pressurized oil lubrication.

3. Use standard two-leg puller to pull sun gear Fig. 1

off mainshaft.

Fig - 2

27.5.1 Mounting of Sun Gear

1. Evenly heat sun gear to max 170°C so that

it can be pushed on with one manual tug.

CAUTION: Do not exceed maximum temperature

of 170°C and do not maintain this
temperature for more than 15 minutes.
Fig. 2

2. Push sun gear onto mainshaft and drive

firmly home.

Fig - 3

CAUTION: Only mount sun gear when it has

been heated. Never drive the sun
gear onto the mainshaft as the taper
roller bearing on the journal bearing of
the mainshaft can be destroyed or
damaged if hit or pushed too hard.
Fig. 3
NOTE: Collar and bore face inputshaft

3. Insert circlip.

Fig - 4

NOTE: Circlip axial play is 0 to 0.5 mm. Select

circlip accordingly.

4. Use drift 1X56 137 456 to drive oil pipe

firmly home in the mainshaft.
Fig. 4
 ZF 9 S 109 GEAR BOX 27.25

27.6 SHIFT MECHANISM

27.6.0 Removal of Shift Mechanisms

1. Remove the four hex bolts (16) and (21)

from the shift housing and cover (20).

CAUTION: Cover (20) is spring loaded.

2. Take off cover (20) seal (19) and the three

compression springs (18) and shift detents
(17).

Fig - 1
Fig. 1
NOTE: Cover is a single part and is not dismantled.

3. Take off shift mechanism.

Fig - 2

4. Remove sealing ring (9).

5. Remove pipe (8).

Fig - 3

27.6.1 Mounting of Shift Mechanism

1. Switch shift mechanism to "neutral", place

Fig. 2
new sealing ring (9) on housing sealing faces.

NOTE: Insert pipe (8).

2. Add shift mechanism and in so doing engage

it with driver (refer to arrow).

Fig - 4

3. Place new sealing ring (19) on shift housing

Insert three shift detents (17) and three
compression springs (18) and add cover
(20).

4. Screw in hex bolts (16 and 21) on shift

housing and cover temporarily only tighten Fig. 3
them slightly. (Fig - 1).

NOTE: The shift housing must be centered to the

shift components in the transmission. For
this, proceed as follows:

5. Engage a gear by activating the shift lever

(refer in arrow).

6. Engage opposite gear.

7. Compare shift travel/excess shift travel with

the central position.

Fig. 4
27.26 ZF 9 S 109 GEAR BOX

8. If the shift travel/excess shift travel are not

of the same size, loosen the hex bolts
slightly and displace the shift housing by
gently tapping it with a plastic hammer.

Fig - 5

NOTE: Repeat procedure until the shift travel/excess

shift travel are of the same size.

Fig. 5

9. Tighten all hex bolts on the shift mechanism

M8 Tightening torque - 23 Nm.

Fig - 6

Fig. 6

27.6.2 Dismantling Shift Mechanism

1. Clamp shift mechanism in vice.

Fig - 7

CAUTION: Protect shift housing from damage

with aluminium wedges

2. Remove locking nut from ball joint.

Fig. 7

3. Remove ball joint from shift lever and take

off reaction linkage.

Fig - 8

Fig. 8
 ZF 9 S 109 GEAR BOX 27.27

4. Mark the position of the shift lever on the

selector shaft.

5. Remove hex bolts and screw from shift

lever.

6. Use standard two leg puller to pull shift

lever off selector shaft.

Fig - 9

Fig. 9

7. Take protective cap off selector shaft

Fig - 10

Fig. 10

8. Remove hex bolts (1) from shift cover (2).

9. Lift shaft over off selector shaft.

10. Remove seal (3) and bush (4).

Fig - 11

Fig. 11

11. Remove scraper (1), shift seals (2 and 5)

from shift cover (4).

12. Use drift 1X56 137 135 to drive bearing

bush (3) out of shift cover.

Fig - 12

Fig. 12
27.28 ZF 9 S 109 GEAR BOX

Fig. 13

13. Remove four cylinder bolts (1).

14. Take off shut-off valve (2) and O-ring (4).

NOTE: Shut-off valve is a single part and is not

dismantled.
Unscrew throttle screw (3) on shut-off valve.

15. .Remove two screws (18) from cover (17).

NOTE: Cover (17) is spring loaded.

16. Take off cover (17) with compression

springs (15/14) and sealing ring (16).

17. Take out insert (12) with O-ring (11) sealing

ring (10) and tapered roller (13).

18. Remove detent plunger (7) for reverse gear.

19. Remove plug screws (5/9) and compression

springs (6/8) from the both sides of the
shift housing.

NOTE: Screw plugs are spring loaded.

20. Take bolts (20) and detent lever (19) out

of shift housing.

Fig - 13

21. Remove four hex bolts (1).

22. Take off cover (2) and sealing ring (4).

check needle bearing (3) in cover (2) and
replace if necessary.

Fig - 14
Fig. 14
 ZF 9 S 109 GEAR BOX 27.29

NOTE: Make site of circlips and washers to allow

for easy future assembly.

23. Remove circlip from ring groove of selector

shaft.

Fig - 15

NOTE: Circlip is spring loaded. Hold back washer

on circlip against spring pressure.

24. Take washer and compression springs off Fig. 15

selector shaft.

25. Remove circlip, washer and second

compression spring.

Fig - 16

Fig. 16

26. Use a suitable amount of force to drive

double clamping pin in detent bush out
through the open threaded bore onto the
upper side of the shift housing.

Fig - 17

NOTE: Bring selector shaft into proper position.

Fig. 17

27. Mark position of detent bush. Pull detent

bush off selector shaft.

Fig - 18

Fig. 18
27.30 ZF 9 S 109 GEAR BOX

28. Use an appropriate amount of force to

drive detent piece clamping pin out through
insert aperture.

Fig - 19

NOTE: Position selector shaft correspondingly.

Fig. 19

29. Pull selector shaft out of shift housing.

30. Take detent piece and driver out of shift

housing.

Fig - 20

NOTE: Driver could fall out, secure appropriately.

Fig. 20

31. Take rollers out of selector shaft (Refer to

arrow).

Fig - 21

Fig. 21

32. Use drift 1X56 137 135 to drive needle

sleeve out of shift housing.

Fig - 22

Fig. 22
 ZF 9 S 109 GEAR BOX 27.31

27.6.3 Shift Mechanism Assembly

Shift mechanism installation position is

horizontal right.

Fig - 23 & 24

Driver Arrangement
Driver arrangement install position is
horizontal right.

Fig - 25 Fig. 23

Fig. 24

SIDE POSITION OF DETENT BUSH (2)

Fig. 25

1. Driver

2. Detent bush

3. Compression spring(s)

4. Selector shaft

5. Shift housing
27.32 ZF 9 S 109 GEAR BOX

27.6.4 Assembling Shift Mechanism

1. Use shift 1X56 137 135 to drive needle

sleeve into ridge of shift housing (side of
needle sleeve which is written should be
facing drift).

Fig - 1

NOTE: The Needle sleeve is positioned opposite

the ridge faces, on the detent piece, back
approximately 1 mm. Fig. 1

2. Insert six roller in bores of selector shaft

and slightly grease bores for this (refer to
arrow)

Fig - 2

Fig. 2

3. Assembly suitable drive for shift mechanism

type as is shown in Section 27.6.3.

4. Hold driver in installation point of shift

housing.

5. Use selector shaft to slide on the driver.

Fig - 3
Fig. 3

6. Slide detent piece onto selector shaft.

NOTE: Detent level (refer to arrow) of detent piece

faces installation point for shut-off valve.

Fig - 4

Fig. 4
 ZF 9 S 109 GEAR BOX 27.33

7. Slide detent bush, onto selector shaft (as

marked during disassembly).

NOTE: Move bores for clamp pins on licking unit

and detent bush up until flush.

Fig - 5

NOTE: Apply light coat of sealing compound to

outer edge of shaft seals with steel surround
Apply coat of Vaseline or water-soluble
concentrated washing-up liquid to outer edge
of shift seals with rubber surround.
Fig. 5

Shift output version horizontal

Drive shift seal (7) into shift cover (5) using

drift 1X56 137 135 to dimension “A”

Drive bush bearing (4) into shift cover (5)

using drift 1X56 137 135 to dimension “B”.

Fig - 6

Shift output version below:

Fully drive in shaft in seal (2) using drift Fig. 6

1X56 119 916.

NOTE: Sealing lips of the shaft seals (7) and (2)

must face towards the bearing bush (4).

Fully drive in scraper (1) using drift

1X56119 916, until it is flush with the shift
cover.

Fill the pockets (3) and (6) with grease.

Fig - 7

Insert bush (4). Fig. 7

Place shift cover (2) and new sealing ring

(3) on shift housing.

CAUTION: Do not damage shaft seal and scraper

when sliding onto selector shaft. Use
protective sleeve 1X56 137 134.

8. Tighten four M8 hex bolts (1) to torque 23

Nm.

Fig - 8

Fig. 8
27.34 ZF 9 S 109 GEAR BOX

9. Drive both clamping pins and mandrel into

detent piece and detent bush.

Fig - 9

CAUTION: Do not confuse clamping pins.

Clamping pin for

detent piece = 36 mm.

Clamping pin for

detent bush = 30 or 28 mm.

NOTE: Assemble circlips and washers as marked. Fig. 9

10. Place washer on selector shaft.

11. Insert circlip in appropriate ring groove.

12. Place small washer on selector shaft.

13. Place compression spring on selector shaft.

14. Place washer (small) on selector shaft.

15. Insert circlip (small) and circlip tongs in ring

groove and in so doing push back
compression spring. Fig. 10

16. Place compression spring (large) on selector

shaft.

17. Add washer (large), push back compression

spring.

Fig - 10

18. Insert circlip (large) and circlip tongs in outer

ring groove.

Fig - 11

Fig. 11
NOTE: Position selector shaft as far as is possible
in the direction of compression springs.

19. Bring shift mechanism into neutral position.

20. Use drift 1X56 137 135 to drive needle

bearing (3) into cover (2) (side of needle
sleeve written on should be facing drift).

21. Add cover (2) and new sealing ring (3).

Screw in four hex bolts (1) and spring
washers and tighten to 23 Nm.

Fig - 12
Fig. 12
 ZF 9 S 109 GEAR BOX 27.35

CAUTION: You must be able to move selector

shaft easily in both directions.

22. Insert both detent levers (19) in shift housing.

23. Insert bolts (20) through detent lever bore

into shift housing.

24. Insert compression springs (6/8) and tighten

screw plugs (5/9) to 35 Nm.

25. Insert O-ring (11) in insert (12).

Fig. 13
26. Grease ball rollers (13).

27. Fit item 10 to 18.

28. Tighten screw (18) to 23 Nm.

29. Insert O-ring (4) on shut-off valve (2).

30. Fit shut-off valve (2) and in so doing note

position of pneumatic connections.

31. Tighten screw (1) to 23 Nm.

32. Screw in throttle screw (3) and new sealing

Fig. 14
ring. Tightening torque = 50 Nm.

33. Screw in pawl stop (7) and new sealing ring

tightening torque = 50 Nm.

Fig - 13

34. Place protective cap on selector shaft.

Fig - 14

35. Push shift lever onto selector shaft as

marked and in so doing fix protective cap.
Fig. 15
36. Insert hex bolt and nut and tighten M1

Tightening torque = 46 Nm

Fig - 15

37. Place ball pivot in shift lever and tighten with

hex nut.

M10 x 1 Tightening torque = 46 Nm

Fig - 16

Fig 16
27.36 ZF 9 S 109 GEAR BOX

27.7 CONNECTING PLATE-LUBRICATING

OIL PUMP

27.7.0 Removal of Connection Plate

1. Remove six hex bolts (3), take off

connection plate (4) and shim (7) and
sealing ring (6).

2. Remove shaft seal (5) from connection plate

(4) and in so doing ensure you do not
damage sealing faces of connection plate.

Fig - 1

27.7.1 Removal and dismantling of

lubricating oil pump

1. Remove eight hex bolts and compression

washers.

Fig - 2

2. Use mounting levers to press lubricating oil

pump out of housing, remove sealing ring.
Fig. 1
Fig - 3

NOTE: Add mounting lever to cast pockets.

3. Take shim from outer bearing ring of layshaft.

NOTE: Lubricating oil pump is a single component,

only dismantle for visual checks and cleaning
purposes.

4. Remove screws from lubricating oil pump.

Fig - 4

Fig. 2

Fig 4
Fig. 3
 ZF 9 S 109 GEAR BOX 27.37

5. Press pump housing off pump cover. Do

not damage sealing face in the process.

Fig - 5

Fig. 5

6. Take out inner and outer rotors from pump

cover.

NOTE: First mark installation point of outer rotor

7. If necessary, extract cylinder pin.

27.7.2 Assembly and mounting of

lubricating oil pump

1. Clean and visually check pump parts.

2. If necessary, insert cylinder pin in bores of

pump cover.

3. Insert outer rotor in marked installation point

and insert inner rotor in pump cover, add
some oil. Fig. 6

Fig - 6

4. Add pump housing and drive firmly home.

5. Screw screws into lubricating oil pump.

M5 Tightening torque = 6 Nm.

Fig - 7

Fig 7
27.38 ZF 9 S 109 GEAR BOX

6. Check that the lubricating oil pump moves

easily, if necessary, loosen screws and
retighten again.

7. Place new sealing ring on sealing faces for

lubricating oil pump.
Fig - 8

NOTE: When adjusting the layshaft, the shim used

must lie on the roller bearing outer race.
CAUTION: Before fitting the lubricating oil pump
and connection plate, layshaft,
mainshaft and inputshaft must be
adjusted (refer to Section 27.8).
Fig. 8
8. Use hot air blower to heat housing slightly
around bearing bore, add lubricating oil
pump and drive fully home.

NOTE: Engage pump driver with layshaft recess.

9. Screw in eight hex bolts and compression

washers.
M8 Tightening torque = 23 Nm.
Fig - 9

27.7.3 Assembly and mounting of

connection plate

1. Coat outer edge of shaft seal (5), e.g. with soap.

Fig. 9
2. Use drift 1X56 103 768 to drive shaft seal
(5) fully home into connection plate (4).

NOTE: Sealing lip of shaft seal must face drift.

3. Lightly grease sealing lip.

NOTE: The shim (7) used during the adjustment

mainshaft and inputshaft must be lying in
connection plate.

4. Place connection plate (4) and new sealing

ring (6) on transmission.

5. Use protective sleeve 1X56 138 065 as

assembly aid.

CAUTION: Do not damage shaft seal when

adding connection plate.

6. Tighten six hex bolts (3) to 23 Nm.

7. To check bearing setting, engage 1st gear

and fully rotate transmission on inputshaft.
You must be able to feel an appropriate
amount of resistance.

Fig - 10

Fig. 10
 ZF 9 S 109 GEAR BOX 27.39

27.8 ADJUSTING BEARINGS ON

MAINSHAFT, INPUTSHAFT AND
LAYSHAFT

27.8.0 Adjusting Mainshaft and Inputshaft

CAUTION: Adjust mainshaft and layshaft with

preload. preload is 0.18 to 0.30 mm.

1. Bring transmission into vertical position

2. Adjust input bearing to zero play. To do

this, use mandrel to drive outer bearing ring
in direction of mainshaft.

Fig - 1

CAUTION: Do not press or hit anything near the

oil ducts, otherwise housing will be
damaged.

3. Rotate inputshaft and mainshaft several times

to center bearing rollers and bearing points.
Use a sharp object to test whether the
bearing rollers can be moved.

NOTE: When there is zero play, the bearing rollers

must have no play, i.e. they must not be
able to move. However no preload should
be present.
Fig 1
4. Use depth gauge to measure distance
between upper edge of outer bearing ring
and housing, adhere to dimension “a”.

Example: a = 5.40 mm

Fig - 2

NOTE: Make measurements at two opposite points

and take the mean value.

5. Place new sealing ring on connection plate,

6. Use depth gauge to measure distance between

sealing ring and face for shim. Adhere to
dimension “b” Example: b = 7.80 mm. Fig. 2

Fig - 3

NOTE: Make measurement at two opposite points

and take the mean value.

7. Determine and adhere to difference “c”

Example:

c = b - a (7.80 - 5.40 mm)

c = 2.40 mm

NOTE: You should aim at a preload of 0.25 mm

dimension on “e”).
Fig. 3
27.40 ZF 9 S 109 GEAR BOX

8. Calculate thickness “d” of shim:

Example:
d = c + e (2.40 + 0.25 mm)
d = 2.65 mm

9. Select shim from spare parts catalogue, grind

to correct dimension.

Note: Experience shows that later tightening of the

hex bolts on the connection plate causes the
sealing to settle be 0.03 to 0.05mm. This
should be taken into consideration when
selecting the shim.

10. Insert shim in connection plate.

Fig - 4

27.8.1 Adjusting Layshaft

NOTE: Adjusting layshaft with preload. Preload is

0.18 to 0.30 mm.

1. Transmission should be in vertical position.

2. Adjust layshaft roller bearing to zero play.

To do this, use mandrel to drive to outer
bearing ring in direction of layshaft. Fig. 4

Fig - 5

CAUTION: Do not press or hit anything near the

oil ducts. Other wise housing will be
damaged.

3. Rotate layshaft several times to centre

bearing rollers and bearing points. Use a
sharp object to test whether the bearing
rollers can be moved.

NOTE: When there is zero play, the bearing rollers

must have no play, i.e. they must not be
Fig 5
able to move. However no preload should
be present.

4. Use depth gauge to measure distance

between upper edge of outer bearing ring
and housing, adhere to dimension 'A'.

Example: A = 17.80 mm

Fig - 6

NOTE: Make measurements at two opposite points

and take the mean value.
Fig. 6
 ZF 9 S 109 GEAR BOX 27.41

5. Place new sealing ring on pump.

6. Use depth gauge to measure distance

between sealing ring and face for shim.
Adhere to dimension “B”.

Example : B = 15.50 mm.

Fig - 7

7. Determine and adhere to difference “C”.

Fig. 7
Example :

C = A - B (17.80 - 15.50 mm)

C = 2.30 mm

NOTE: You should aim at preload of 0.25 mm

(dimension 'E').

8. Calculate thickness “D” of shim:

Example D = C + E (2.30 + 0.25 mm)

D = 2.55 mm

9. Select shim from spare parts catalogue, grind

to correct dimension.

NOTE: Experience shows that later tightening of the

hex bolts on the pump causes the Sealing
to settle by 0.03 to 0.05 mm. This should
be taken into consideration when selecting
the shim.

10. Insert shim layshaft bearing outer race.

Fig. 8
Fig - 8
27.42 ZF 9 S 109 GEAR BOX

27.9 SHIFT RAIL AND REVERSE GEAR

27.9.0 Removal of Shift Rails

1. Remove ring in mechanical shift lock

(interlock) from ring groove.

Fig - 1

2. Take out bearing plate.

Fig - 2 Fig 1

3. Unscrew screw plug for interlock

compression spring.

4. Take out compression spring and locking

lever.

Fig - 3

5. Remove circlip from reserve gear bolts

Fig - 4
Fig. 2

6. Bring transmission into vertical shaft position.

Transmission should be face upwards.

7. Remove seven M10 hex bolts from housing.

Fig - 5

Fig. 3

Fig. 5 Fig. 4
 ZF 9 S 109 GEAR BOX 27.43

8. Separate housing by gently tapping (By

plastic mandrel) the housing recesses.

9. Remove screw plugs, oil-carrying pipe and if

necessary cylinder pins from housing.

Fig - 6

10. Use plastic mandrel to drive bearing outer

race from housing.

11. Remove seal and clean sealing faces. Fig 6

Fig - 7

12. Take filter out of housing.

Fig - 8

13. Take off blocking piece. Slightly press down

shift rails to do this. Depress indented side
of blocking piece, pull opposite side over
shift rail edge.

Fig. 7
14. Take off bearing plate.

Fig - 9

15. Unscrew screw plug from plate.

16. Unscrew hex bolts on plate for neutral

position switch.

17. Remove plate and seal.

Fig - 10
Fig. 8

Fig. 10 Fig. 9
27.44 ZF 9 S 109 GEAR BOX

18 Take bolt out of housing.

19 Remove pivot bolts and separate shift rails
from selector forks and remove individually
from housing.
Fig - 11
27.9.1 Removal of Reverse Gear
1. Circlip (1) was removed in Section 27.9.0.
2. Use a rod (5) to drive reverse gear bolts
(2) in direction of output.
3. Push reverse gear (4) towards housing wall.
4. Lift mainshaft and layshaft out of housing, as
described in section 27.10. Fig 11

5. Take reverse gear (4) and 2 roller rings (3)

out of housing.
Fig - 12 & 13
6. Remove hex bolts.
7. Take off cover, remove seal and clean
sealing faces.
Fig - 14

27.9.2 Installation of Shift Rails

1. Bring transmission into vertical shaft position.
Transmission should face upwards.
2. Individually insert shift rails into housing, Fig. 12
engage sector fork noses with recesses in
shift rails. To do this, use hook 1X56 137
451 to guide selector forks.
Order to installation
1st = 1st - 2nd or 5th - 6th speed
2nd = 3rd - 4th or 7th - 8th speed
3rd = R gear / crawler
Fig - 15
NOTE: Compare shift rail part numbers shift rail with
different number must be placed in centre.

Fig. 13

Fig 15 Fig. 14
 ZF 9 S 109 GEAR BOX 27.45

3. Slide bearing plate over shift rails, recessed

side is placed alongside housing sealing face.

Fig - 16

4. Slip on blocking piece. To do this, slightly

depress central shift rail. Lower blocking
piece over shift rail edge.

Fig - 17

NOTE: Studs on blocking piece reach into bearing

plate bore.
Fig. 16

5. Insert cleaned or new filter in housing.

Fig - 18
Coat sealing faces with sealing compound.

6. Insert two cylinder pins in transmission housing.

7. Insert bearing outer race in housing.

8. Insert oil-carrying pipe in housing. Bores in

pipe must not be blocked.

9. Add housing and use plastic hammer to Fig. 17

gently hit housing and drive it home.

Fig - 19

CAUTION: Do not press or hit anything near the

oil ducts. Otherwise housing will be
damaged.

10. Screw in seventeen M10 hex bolts. M10

tightening torque = 50 Nm.

Fig - 20

Fig. 18

Fig. 20 Fig. 19
27.46 ZF 9 S 109 GEAR BOX

11. Screw screwplug and new sealing ring into

housing. M16x1.5 tightening torque = 45 Nm.

Fig - 21

12. Insert bolts in transmission housing.

Fig - 22

13. Fit plate with new seal and screw plug.

Tightening torque
M18 screws = 23 Nm
Fig 21
M18 x 1.5 screw plugs = 35 Nm

Fig - 23

NOTE: Bring transmission into vertical shaft position.

Output side should be on top.

14. Push locking lever over shift rails.

15. Push bearing plate over shift rails.

I6. Insert compression spring in housing bore

and engage with locking lever. Fig. 22

Fig - 24

17. Insert ring to secure bearing plate in ring

groove.

NOTE: Ring must not be located near the area

where the range-change group shift rail is to
be inserted.

Fig - 25

Fig. 23

Fig. 25 Fig. 24
 ZF 9 S 109 GEAR BOX 27.47

18. Screw in screw plugs for interlock

compression spring with new sealing ring.

M14 x 1.5 torque is 35 Nm.

Fig - 26

27.9.3 Installation of Reverse Gear

1. Insert roller ring (3) in reverse gear (4)

2. Insert reverse gear and roller rings in housing

and push towards housing wall. Fig. 26

Fig - 27

NOTE: The larger recess should face the output.

3. Install mainshaft and layshaft as is described

in Section 27.10.1.

NOTE: Transmission is completely assembled on

input side.

4. Align reverse gear to bearing bores.

5. Use hot air- blower to slightly heat housing Fig. 27

bores,

6. Drive in bolts until ring groove in circlip is

fully in housing

7. Insert circlip and circlip tongs in ring groove,

check that it is seated correctly.

8. Use feeler gauge to check axial play on

reverse gear

- Axial play 0.20 - 0.60 mm

Fig. 28
Fig - 28

NOTE: Cover with sealing web may only be used

once.

9. Place new cover with new seal on sealing

face

10. Screw in six M10 x 22 hex bolts

M10 - tightening torque = 46 Nm

Fig - 29
Fig 29
27.48 ZF 9 S 109 GEAR BOX

27.10 INPUT SHAFT, MAINSHAFT AND

LAYSHAFT

27.10.0 Removal of the Shafts

1. Lift input shaft off mainshaft

Fig - 1

NOTE: For instruction on how to dismantle

inputshaft, refer to section 27.11.0.
Fig. 1
2. Remove six pivot bolts from housing.

Fig - 2

3. Take 3rd/4th speed selector fork (if

necessary, with shift lever) out of sliding
sleeve. Lift it up and out of transmission
housing.

Fig - 3

4. Take fulcrum pad out of 3rd/4th speed

selector fork. Fig. 2

Fig - 4

5. Use hook 1X56 137 451 to take 1st/2nd

speed selector fork out of sliding sleeve.
Lift it up and out of transmission housing.

6. Take fulcrum pad out of 1st/2nd speed

selector fork

Fig - 5
Fig. 3

Fig 5 Fig 4
 ZF 9 S 109 GEAR BOX 27.49

NOTE: Remove reverse gear bolt and push reverse

gear towards housing wall (refer to section
27.9.1).

7. Screw hook 1X56 136 599 in layshaft.

8. Lift layshaft out of housing and in so doing

press mainshaft to one side.

Fig - 6

9. Push lifting rod 1X56 137 200 into

mainshaft central bore and in so doing push Fig. 6
oil pipe out of mainshaft. Secure lifting rod
on output side with associated hex nut.

10. Use lifting rod to lift mainshaft out of

transmission housing. In so doing, secure R
gear/crawler selector fork with hook 1X56
137 451.

11. Take of R gear/crawler selector fork out of

mainshaft.

12. Take fulcrum pad out of selector fork.

Fig. 7
Fig - 7

27.10.1 Installation of the Shafts

1. Use Lifting rod 1X56 137 200 to push

mainshaft into central bore and secure on
output side with associated hex nut.

2. Use lifting rod to guide mainshaft over

transmission housing.

Fig - 8

Fig 8
NOTE: Insert reverse gear and roller rings in housing
and push towards housing wall.

3. Insert fulcrum pad in crawler/R gear selector

fork.

4. Place selector fork in crawler/R gear sliding

sleeve and secure with hook 1x56 137 451.
Once the mainshaft has been installed,
selector fork nose must engage with shift
mechanism housing opening.

Fig - 9
Fig. 9
27.50 ZF 9 S 109 GEAR BOX

5. Guide mainshaft into bearing point of

transmission housing.

6. Take lifting fork 1X56 137 200 out of

mainshaft.

Fig - 10

7. Screw hook 1X56 136 599 into layshaft

8. Place layshaft in bearing point in transmission

housing, in so doing press mainshaft to one Fig. 10
side.

9. Engage mainshaft and layshaft gear teeth,

unscrew hook 1X56 136 599 out of
layshaft.

Fig - 11

10. Align crawler/R gear selector fork with hook

1X56 137 451 so that you can see the
selector fork guiding bores in the threaded
bores of the transmission housing.
Fig. 11

11. Insert fulcrum pads in 1st/2nd speed

selector fork and 3rd/4th speed selector
fork.

12. Insert selector forks in sliding sleeve so that

selector fork nose faces shift mechanism
housing opening.

13. Align selector forks with hook 1x56137 451

so that can you see the selector fork guiding
bores in the threaded bores of the
transmission housing. Fig 12

Fig - 12

14. Coat thread of pivot bolt with loctite.

Screw pivot bolts and compression washers
into each side of the transmission housing.

M18x1.5 tightening torque 160 Nm.

Fig - 13

Fig. 13
 ZF 9 S 109 GEAR BOX 27.51

NOTE: For input shaft assembly, refer to section

27.11.1.

15. Carefully place input shaft on mainshaft. Do

not damage sealing lip of baffle plate.

16. Engage input shaft gear teeth with those of

clutch body.

Fig - 14

Fig. 14
27.52 ZF 9 S 109 GEAR BOX

27.11 INPUT SHAFT

27.11.0 Dismantling the Input shaft

1. Place gripper 1X56 136 719 on inner race

of input shaft tapered roller bearing. Turn
knurled ring until gripper is firmly secured.

2. Screw extension 1X56 122 310 and adapter

1X56 122 137 onto basic puller 1X56 122
304.
Fig. 1
3. Screw extension 1X56 122 310 onto
gripper 1X56 136 719.

4. Pull inner race (1) of taper roller bearing off

input shaft (2).

5. Use suitable tool to remove baffle plate (5).

Remove circlip (4) and cover (3) from input
shaft (2).

Fig - 1

27.11.1 Assembly of the Input Shaft

1. Insert cover (3) is input shaft (2) and inset

circlip (4)

2. Use tool 1X56 138 026 to press baffle

plate (5) until it is flush with input shaft.

3. Heat tapered roller bearing inner race (1) to

approx 120°C and place on input shaft (2).
Ensure that it is firmly driven home.
Fig 2

Fig - 2
 ZF 9 S 109 GEAR BOX 27.53

27.12 MAINSHAFT

Fig. 1

27.12.0 Dismantling the Mainshaft 7. Remove 3rd speed helical gear (12) with
clutch body (11) and two needle cages
Fig - 1 (13) from mainshaft (28).

NOTE: Instructions for removing mainshaft are 8. Turn mainshaft over and clamp input end in
described in section 27.10.0. vice with soft jaws.

1. Clamp output end of mainshaft in a vice 9. Place appropriate intermediate part on

with soft jaws. mainshaft. Attach standard 2 leg puller to
R gear spur gear (35) and pull off gear
2. Remove clutch body (3) and synchronizer and inner race of taper roller bearing (36).
ring (4) from mainshaft.
10. Remove needle cage (34) and circlip (33).
3. Pull off 3rd/4th speed sliding sleeve (5).
11. Lift off crawler/R gear sliding sleeve (32).
4. Place gripper 1x56 136 737 on inner race
of taper roller bearing. Turn knurled ring 12. Place suitable intermediate part on
until gripper is firmly secured. Screw basic mainshaft. Place standard two leg puller
puller 1X56 122 304 onto gripper and pull on crawler helical gear (30).
off bearing inner race (1).
13. Pull off crawler (30) an sleeve carrier (31).
5. Remove circlip (2).
14. Remove needle cage (29).
6. Insert puller 1X56 137 457 between
synchronizer ring (10) and 3rd speed clutch 15. Turn mainshaft over again and clamp input
body (11). Place appropriate intermediate end in vice with soft jaws.
part on mainshaft. Place standard two
leg puller and pull off synchronizer hub (6) 16. Remove circlip (14).
and synchronizer ring (10).
17. Place suitable intermediate piece on
mainshaft.
27.54 ZF 9 S 109 GEAR BOX

18. Use Standard two leg puller to grip the rear

of 1st speed helical gear (26) and pull off
entire pack (item 15 to 26).

Fig - 2

NOTE: Ensure that the pullers teeth do not grip the

shaft collar.

19. Take bearing bush (15) and needle cage

(16) out of 2nd speed helical gear (17).

20. Take clutch body (18) and synchronizer ring

(19) off synchronizer hub (21).

21. Lift 1st/2nd speed sliding sleeve (20) off Fig 2

synchronizer hub (21).

CAUTION: Pressure pieces (3) and compression

springs (9) will be released during
extraction process. These parts are
spring loaded. Secure pieces to
prevent them flying out.

22. Remove 1st speed helical gear (26) clutch

body (25), synchronizer ring (24) and
synchronizer hub (21) from the mainshaft (28).

23. Remove two needle cages (29).

27.12.1 Assembly of the Mainshaft

1. Check that the Lubricating oil bores can be

freely accessed on the mainshaft.

2. Clamp output end of mainshaft in a vice

with soft jaws.

NOTE: Lightly grease running face and bearing race

of needle cages and helical gears with
operating oil.

3. Slide needle cage (29) onto mainshaft

4. Push crawler helical gear (30) over needle

cage onto mainshaft by gently twisting it.
Drive teeth should face out put.

5. Heat sleeve carrier (31) to approx. 120°C

and push onto mainshaft (hub facing
crawler). If necessary, drive fully home.

6. Check axial play of crawler helical gear.

- Axial play 0,20 to 0.45mm

7. Remove circlip (33).

CAUTION: Ensure circlip remains absolutely free

of burrs as it serves as a running
surface for the needle cage.

NOTE: Circlip must have axial play of 0 - 0.1 mm.

Select suitable circlip in a accordance with
spare parts catalogue.

8. Place crawler/R gear sliding sleeve (32) on
sleeve carrier. Sliding sleeve is symmetrical
and can therefore be placed on either side
of the carrier.
9. Slide needle cage (34) onto mainshaft.
10. Push R speed helical gear (35) over needle
cage onto mainshaft by gently twisting it.
Drive teeth should face output.
11. Heat inner race of taper roller bearing (36)
to approx. 120°C and slide onto mainshaft
and drive firmly home.
12. Check axial play of R speed helical gear.
Axial play 0.40 to 0.75mm.
13. Turn over mainshaft and clamp output end
in vice with soft jaws.
14. Slide both needle cages (27) onto mainshaft.
15. Push 1st speed helical gear (26) over needle
cage onto mainshaft by gently twisting it.
Drive teeth should face output.
16. Place clutch body (25) and synchronizer ring
(24) on driver gear teeth.
CAUTION: Check limits of wear for all
synchronizer rings or clutch bodies as
described in Section 27.4.5. Lightly oil
bearing races of all synchronizer rings.
17. Heat synchronizer hub (21) to approx. 120°C
and place on mainshaft gear teeth.
Synchronizer hub is symmetrical and can
therefore be placed on either side of
mainshaft. Drive synchronizer hub firmly home.
NOTE Synchronizer ring noses must engage in
recesses of synchronizer hub.
18. Check axial play of 1st speed helical gear
– Axial play 0.20 to 0.45mm
19. Slide 1st/2nd speed sliding sleeve (20) over
synchronizer hub, synchronizer ring and clutch
body and place on 1st speed helical gear.
Ensure that recesses in sliding sleeve interior
cover the same areas of the synchronizer
hub locating points (for compression springs
and compression pieces).
ZF 9 S 109 GEAR BOX 27.55
20. Use suitable tool to insert three
compression springs (23) and compression
pieces (22) in synchronizer hub bores or to
guide them into sliding sleeve.
NOTE: Use new compression springs.
21. Add synchronizer ring (19). The
synchronizer ring noses must engage in
recesses of synchronizer hub.
22. Place clutch body (18) on synchronizer ring
(19) and pull sliding sleeve into central
position (neutral position). In so doing,
press synchronizer ring and clutch body.
23. Push needle cage (16) and 2nd speed
helical gear (17) onto bush (15) and heat
it all to approx. 120°C.
24. Place parts together on mainshaft and drive
home bush (15) without any play. Bush
collar should face input. (Fig - 2).
25. Check axial play of 2nd speed helical gear.
- Axial play to 0.20 to 0.40mm
26. Insert circlip (14).
CAUTION: Ensure circlip remains absolutely free
of burrs as it serves as a running
surface for the needle cage.
27. Slide both needle cages (13) onto
mainshaft.
28. Push 3rd speed helical gear (12) over
needle cage onto mainshaft by gently
twisting it. Driver teeth should face output.
29. Place clutch body (11) on 3rd speed helical
gear (12).
30. Add synchronizer ring (10).
31. Heat synchronizer ring (6) to approx.
120°C and place on mainshaft with the
longer nose facing output. If necessary,
drove fully home.
NOTE: Synchronizer ring noses must engage in
recesses of synchronizer hub.
27.56 ZF 9 S 109 GEAR BOX

32. Insert circlip (2).

NOTE: Circlip must have axial play of 0-0.1mm.

Select circlip accordingly.

33. Check axial play of 3rd speed helical gear.

- Axial play 0.20 to 0.45mm.

Fig - 2

34. Slide 3rd/4th speed sliding sleeve (5) (nose

on upper side) over synchronizer hub,
synchronizer ring (10) and clutch body (11)
Fig. 2
and place on 3rd speed helical gear. Ensure
that recesses in sliding sleeve interior cover
the same areas of the synchronizer hub
locating points (for compression springs, ball
pins and compression pieces).

35. Use suitable tool to insert three compression

springs (9) with ball pins (8) and
compression pieces (7) in synchronizer hub
bores or to guide them into sliding sleeve.

NOTE: Use new compression springs.

36. Add synchronizer ring (4). The synchronizer

ring noses must engage in recesses of
synchronizer hub (6).

37. Place clutch body (3) on synchronizer ring

(4) and pull sliding sleeve (5) into central
position (neutral position). In so doing,
press synchronizer ring and clutch body.

NOTE: Do not reuse the inner race of taper roller

bearing which is removed when mainshaft is
dismantled.

38. Heat new inner race of taper roller bearing

(1) to approx. 120°C and push onto journal
bearing of mainshaft. Drive inner race of
taper roller bearing fully home.

39. Grease bottom of inner race of taper roller

bearing (1) between inner race and cage
with grease. It is not permitted to apply
grease on the outside on the roller bearing
itself since this could block the lubricating
bores in the input shaft.

Fig - 3

NOTE: For instructions on installation of the

mainshaft, refer to section 27.10.1.

Fig 3
 ZF 9 S 109 GEAR BOX 27.57

27.13 LAYSHAFT

Fig - 1

NOTE: For instructions on the removal of the

layshaft, refer to section 27.10.0.

27.13.0 Dismantling the Layshaft

1. Place gripper 1X56 136 708 on inner race

(1) of taper roller bearing. Turn knurled ring
until gripper is firmly secured.
Fig. 1
2. Place suitable intermediate part of layshaft.

3. Screw basic puller 1X56 122 304 on gripper.

4. Pull inner race of taper roller bearing off

layshaft (2).

5. Remove circlips (7).

6. Place gripper 1X56 136 711 on inner race

(6) of taper roller bearing. Turn knurled ring
until gripper is firmly secured.

7. Screw basic puller 1X56 122 304 on gripper.

8. Pull inner race (6) of taper roller bearing off

layshaft.

9. Because of the large force required, the

helical gears (5,4) and double helical gear (3)
should be pressed off the layshaft singly
using a suitable hydraulic press.

Fig - 2
Fig. 2
27.13.1 Assembly of the Layshaft

1. Clean bores in helical gears and shrink-fit

seats on layshaft.

2. Heat double helical gear (3) and helical

gears (4, 5) to max. 170°C. Keep at a
temperature difference of 150°C to the part
to be added.

3. Stack up the heated helical gears (5,4 and 3)

on a hydraulic press and align them accurately.

Fig - 2
27.58 ZF 9 S 109 GEAR BOX

I 4th speed helical gear – hub upwards

II 3rd speed helical gear – hub

downwards

III 1st/2nd speed double helical gear.

4. Press layshaft into the bores helical gears.

Press gears into firm end contact
immediately. Let parts cool down.

Fig - 3 Fig. 3

NOTE: Press layshaft into bores in helical gears.

Press gears into firm end contact
immediately. Let parts cool down.

5. Heat inner races of taper roller bearings (1

and 6) to max 120°C and slide onto
layshaft. Drive inner races fully home.

6. Insert circlip (7) in layshaft groove.

NOTE: Circlip play must be between 0 and 0.1mm,

select circlip accordingly.
 ZF 9 S 109 GEAR BOX 27.59

27.14 HOUSING

Fig. 1

27.14.0 Dismantling the Housing 4. Insert pipe (8) (Refer to Section 27.6.1)
Fig - 1
5. Fasten cover (2) and new seal (3) with
1. Use soft mandrel to drive taper roller four hex bolts (1)
bearing outer races (9,10) out of housing.
– M8 tightening torque = 23 Nm
2. Remove breather (18).
6. Screw breather (18) into housing: tightening
3. Remove four hex bolts (1) and take off torque= 10Nm
cover (20) and seal (3).
7. Use hot-air blower to heat housing around
4. Oil spray bores on pipe (8) must not be bearing bores to approx. 80°C.
blocked.
8. Use plastic mandrel or suitable tool to
When changing the housing insert taper roller bearing outer races
(9,10) of mainshaft and layshaft into
5. Take two cylinder pins (11) out of housing housing and drive firmly home.
and remove screw plugs.

27.14.1 Assembly of the Housing

1. Carefully drive in two cylinder pins (11).

2. Insert screw plug (13) and sealing covers (6

and 15) with sealing compound.

3 Screw in screw plugs

Tightening torque
M18 x 1.5 (14, 16) = 35 Nm
M24 x 1.5 (4, 5, 12, 13) = 50 Nm
M38 x 1.5 (7) = 120 Nm
Inductive sensor (17)
tightening torque = 50 Nm
27.60 ZF 9 S 109 GEAR BOX

27.15 CLUTCH HOUSING

27.15.0 Removal

1. Remove 10 Nos. M18x1.5 hex bolts (1)

from clutch housing and do not use screw
driver to do so.

2. Lift off clutch housing.

27.15.1 Installation
Fig. 1
1. Set up the clutch housing in correct position.

2. Tightening 10 nos. M18 x 1.5 hex bolts (1)

on clutch housing to 280 Nm.

Fig - 1
 ZF 9 S 109 GEAR BOX 27.61

27.16 SPECIAL TOOLS

Tool Number Application Quantity

1X56 100 632 Drift with conical sleeve for inserting shaft seat 10 x 15 x 3 into
speedo connecting piece 1

1X56 103 768 Drift for fitting shaft seal 48 x 65 x 10 on input 1¾" 1

1X56 119 916 Drift for fitting shaft seal and scraper 25 X 35 X 7 in shift housing 1

1X56 122 304 Basic puller M65 X 2 for use with grippers 1

1X56 122 310 Extension M65 X 2 only for taper roller bearings on input 1

1X56 122 317 Adapter of M95 X 2 and M65 X 2 for use with grippers 1

1X56 126 467 Drift for fitting shaft seal 95 X 115 X 10 on input, for use with ring 1X56 137 484 1

1X56 136 599 Hook M12 for lifting layshaft 1

1X56 136 708 Gripper M95 X 2 for layshaft taper roller bearings on input side 1

1X56 136 711 Gripper M65 X 2 for layshaft taper roller bearings on output side 1

1X56 136 719 Gripper M95 X 2 for taper roller bearings on input 1

1X56 136 737 Gripper M65 X 2 for taper roller bearings on mainshaft journal bearing 1

1X56 137 135 Drift for bearing bush 25 X 32 X 20 in shift housing 1

1X56 137 200 Lifting rod for mainshaft 1

1X56 137 451 Hook for guiding shift forks 1

1X56 137 452 Drift for lock plate 4132 304 015 on output flange 1

1X56 137 456 30.0 mm Drift for oil pipe mainshaft on output side 1

1X56 138 101 40.5 mm Drift for oil pipe, mainshaft on output side 1

1X56 137 457 Puller, split, for mainshaft synchronizer hubs 1

1X56 137 484 Ring for distancing shaft seal 95 X 115 X 10 on output, for use with
drift 1X56 126 467 1

1X56 137 579 Fixing attachment for radial fixing of GP shift rail 1

1X56 137 648 Divided ring for extracting output side clutch body of range-change group 1

1X56 137 134 Protective sleeve assembly aid for assembling shift cover on selector shaft 1

1X56 138 026 Drift for assembling baffle plate in input shaft 1

1X56 138 065 Protective sleeve assembly aid for fitting connection plate 1

1X56 137 450 Assembly stands for use with adapters 1X56 136 998 and 1X56 137 459 1
 27.62 ZF 9 S 109 GEAR BOX

27.17 TIGHTENING TORQUE

01. Breather in transmission housing or shift mechanism 10 Nm
02. M10 x 1 lock nut on reaction links and ball joints 46 Nm
03. M12 Hex nuts on reaction links 50 Nm
04. Pawl stop on transmission and shift mechanism housing 50 Nm
05. M 24 x 1.5 screw plug (conical) on transmission housing 50 Nm
06. Impulse sensor 50 Nm
07. M12 Hex screws on output flange 60 Nm
08. Speedo connecting piece 100 Nm
09. Screw plug with M38 x 1.5 magnet on transmission housing 120 Nm
10. Pivot bolts on transmission on housing 160 Nm
11. M16 x 1.5 lock nut on piston for range change group shaft mechanism 150 Nm
12. Pivot bolts on range-change group housing 180 Nm

27.18 RECOMMENDED LUBRICANTS

ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Sah
Ambient Gulf Oil Indian Oil Hindustan Bharat Karol Pennzoil Meguin
Aggregate Leyland IBP Castrol Chemoleums Petroleums
Temp. °C India Corporation Petroleum Petroleum Lubricants Quaker Oil India
Specification IPOL
API GL4 IBP Gear Plus Meguin
MAK® Hypoy
ZF 9S 109 with Gulf Gear Servo Gear HP Gear Oil Special Auto Gear XP Turbo GL4 IPOL Syncro Gear Super Gear Oil
>0 SPIROL 90 EP
Gear box Anglamol 99 XP 90 HP 90 (T) Special 90 Gear oil 90 SAE 90 (AL) Plus EP 90 GL4 Premium
XEP 90 (AL)
Additive 90(A) SAE 90 EP 90

$ - Castrol LMM Grease to be used for lubricating Gear shift linkage ball joints 10.02.2004

27.19 FILLING CAPACITY

Aggregates Filling Capacity (l)

ZF 9 S 109 Gear box 8.5

27.20 MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly

Remarks
No. of
points

Every

Every
Every
Daily
PDI

A. Lubrication
1. Lubricate gear shift lever fulcrum joint G 1 ✓ ✓
2. Check oil level and top up O 1 ✓
3. Change oil when hot. Refill upto correct level O 1 ✓ 80
B. Maintenance
1. Check for correct operation of gear shift
linkage and setting ✓
2. Check and clean transmission breather
provided on selector housing ✓
3. Check tightness of clutch housing mounting bolts ✓