ZF-Synchroma-Gearbox

S 5-18/3

Assembly,Maintenance
and OperatingInstructions

AG
ZAHNRADTABRIKFRIEDRICHSHAFEN
SCHWAEBISCH GMUEND WORKS
D-7070SchwaebischGmuend
Graf.von-Sodon-Stra0e
$9
Germany

/601-l . telex 07 24880.| . cable:Zahnradfabrik

phone07171 SdrwaeblsdEnuond
07 24A825for servlc€deoartmsnt

1 2 5 57 5 1l 0 Prlnted In Germany
 S 5-18/3
ZF.SYNCHROMA.GEARBOX
Assembly,Maintenanceand OperatingInstructions

Contentg
Pag€
L Todrnical Data

ll. Do8crlption

lll. HandlingOperation.

lV. Mgint6n6nc6and Lubrication .

V. Tools .

Vl. Stripping ot Tranambsion . I

Vll. Ch6cklngof Individu.lCompon6nts 12

Vlll. Ass.mbly of G€arbor 12

lX. Ordering Sp6r6 Parts 23

X. Koy to lllustrationa 24

xl. Erplod6d Views

Xll. List of ZF Servico Stations . 3l

l. TedrnicalData

Input Bdor PTO

Torqu6 Md.Ab.. I outout
pgrm|agaDrg
I s.c*. ll.o"". ls.cea.i R.c"a.I speedokpm'
Typc max. kpm t.Gear] 2.Gear | ^
I uPooo
2,4 t,76 1,26 t,0 3,67 2,5
2,08 1,39 t.0 0.87 3,67 to
for CAR 't.0
30 2,99 I,76 t,3 0,87 3,67 3,4

't6 3,24 | 2,U t,3 't,0 5,47

for light 2,17
conmercial t6 6,0 3,03 |,81 1,3 1,0 5,47 IO 12 t,02xn
vqhlcl€8 t8 5,33 3,24 2,U t,3 1,0 5,47 4,0 Engln6

' For cor€ct value, rovcr to ZFF t€drniqal d€pgrtment.

W.lghk ca. $ kg Oll crprclty! ca. 1,6 liter

ll. Description

The ZF Synchroma5 sp€od ggarbox S $18/3 is an up to date ge€rbox syn.hronlsod ln all forward geara. Thg rcvora€ 96ar haa a
claw clutdl. Ths traosrnis8lonls flangod dlrotly to tho sngine and lo actueted by meana of a sst b;ck or a centrol flo6r Ehift or
bJ a atoerlng column dqpendlng on th€ type of vehlcle. Thg dosign ofthe transmlssionand the us6 of of push rods ior trEnsmttdng
th6 Ehlftlng iorces guar6nt96 easy 9nd accurats shifting of th6 trahsmission in all sttuations.
Ths.tr6namisslonls a countershaft (layshsft) typ€. Thg mating gears of all speed8 remain conatantly in m€8h. Whllst thg who€ls
on thq countsrshaft aro permanontly gttadr€d to ths shaft. the nssdls bearing count€r wh€ele can rdtatg freely on the mEtn 8h9ft.
During tho rhlftlng opgration, the 6pe€d8of tho membcrs to bo coupled 619 eyndrronleed by ZF-B syndtrontggre.The Idler gear of
thg pertinsnt Bpe6d 19couplgd to tho mainshatt by m€ang of a clawed eleevi and the powlr flow d gutded by the perinqni gearg
to ths outoul snd.
At dirsct epeod (that can bg 4th or sth g€ar according to gEarbox type) the countsrahaft is not Includsd in the powor flow i. e.
thg Input thaft.and th6 maln shaft ar€ coupled diroctly to eadr othg. and conaoqu€ntly tho ongine r€volution end the torquo
dlango to l:1. In revsrse gear ths diroction of tho output sp€ed i6 .fi6n9qd by I built-in intermedlatgggar (so-called reveree geir).
Tho shiftlng El€9vqs 8upply 8hlft forke whldr are guided by bearing gplgots €nt€.ino th6 gesrbox housinq and wht.h ar€ actuatod
by thg push rod8. Tho Ehlft forks arg hgld in th6 engsged pgsition by spring dot6nt8. A butlt-in shift lock luarantees that only ono
Bpo6d qan be snggg€d at a timo.
ZF-Synchroma-GearboxS 5-t 8/3

Assembly
Descriptionof ZF-B-Synchroniser
Oescription

The follow ng components are assembled between lhe

gear wheels of lst and reverse speed, of 2nd and 3rd
speeds as well as 4th and sth speeds.
1 The Synchrobody (A)
A x r a l l y a n d r a d r a l l yr m m o v e a b l eI n r e l a t i o nt o m a n -
shaft (B) on wh ch rl rs located
2 Synchro Sprrngs (C)
A synchro spflng is attached to each side of the
synchrobody. They press the pressure preces lightly
on the slrdrng sleeve (H)
3 Pressure Preces (D)
They are axrally drsplaced on selectron of the slrd-
ng sleeve and thus press the synchro rrngs onto
the cone of the clutch body (l)
4 Synchro Brngs (F)
These are placed loosely between gear wheel (G)
and synchrobody (A) There rs no synchro ring on
the reverse gear wheel. as this is not synchrontsed
These components permrt establ shrng of unrtorm angu-
lar speeds between the gear wheel to be coupled and
the shafi before the slrdrng sleeve (H) and rts Internal
teeth enter lhe cluich teeth of lhe (pertinent) gear
 Op€retion ot Syndronl.or A...nbly

1 . l d l i n g( F i g s .I a n d 2 )
Sliding slsevo (H) is in th€ centre positaon.h i9 hsld in
this position by 6 shift fork whidt is located by tho sslgctor
of the dstent bolt. The gear wheels (G) can rotate froely
J H

t I
on thg mainshaft.

N
Shifting Opsration(Figs.3 and 4)
Th€ sliding sleev€ (H) as pushgd forward axially in ono
direction (in th€ exampl€shown to the left). The pr€g8ure
piecos are tsk6n along by tho 8liding slosvo, as th€
pressurs pigcsa 9re push€d by th6 preloaded gynchronissr
8prin96 (C) with th€i. trapoziuh shop€d tops into the some-
$rhat wider 6nnular groov€ of tho sliding als€v€. Th6 two
syndrro rings (F) lie to lgft and right of the prossure

II pieces. When the sliding slogve movos to the left after

passing through ths fre€ lravol botw€on the sliding slsgvo
and the preasurs piece. the lgft Byndrro ring will be movod

FR to the left side in the sam6 way by thg prosgure pigcea.

After approximatgly0.5 mm the syndtro ring with lts conical
6urfaco is adjacent to the simil6r conical surfaca of the
clutdl body. This will rotate thg synciro ring by app.oxi-
mately 2 mm In relation to thg sliding sle€ve and the
synchro body (A) until ih6 syndrro.lng and its lugg 619
resting in tho slots of the gynchro body. The position of tho
syndrro ring in rolation to the sliding gleeve is thgrgfore
gudr that thg tggth on th€ out6r diam€ter of the rangare
offset in rel6tlon to the toothgaps ot the sliding 8le6ve
(Fig.3).Wh9nthe sleeve i3 pushodon further.itg tgethwill
rest againSt those of the aynchro ring and submit an
axial force against the ring. Th€ flat adjoiningangl6 on
the Eliding Eurface of the clutdr body (J) and the blocking
ring will €stablish forcos in radial direction whidl ar9
stronger than thg forces whidr are trsn6mitted to th6 slid-
ing slegve in axial direction. Thio $rill continually r€duce
tho diffgrgncs in sps€d betwe€n the g€ar to be 6ng6ggd
and th6 mainshaft (es well ae the 8liding sleevo). Only
wh€n the two apeeds aae synchronig6d will the synchro
ring and ths gsgr whe€l turn back slightly (approx. I to 2
mm) until thg teoth of ths sliding slsove are in line with
the tooth gaps of the syndrro ring. At thig momsnt, thg
rcsistanco whidr has prcvonted 9ny furthgr movsment of
the sliding 8la6ve during thg shifting operation will b€
overcomg and the slg€v€ is now pushod into thg coupling
teeth of th6 appropriate goar whesl (Fig. 4). This is th6 end
of th6 shifting cycl€.

A) Syndrro Body
B) Mainshatt
C) Syn.hro Springs
D) Prgsgure Piece
E) N€€dle B€aring
F) Syn.hro Ring
G) Geer whe€l
H) Sliding Sleeve
.,) Clutch Body

4
lll. HandlingOperation

Economicdrivingof a vehicle requiresthe engineto run constantlyin the most favourablospeed range. On most €ngines,thi6
speed range is restrictedbut a s-speedtransmiasionpermits easy adaptationof th€ engineto the varyingdriving conditions.
Since all forward gears on the S5-18/3 are fully syn.fironised,a fast reliableand noiselessg€ar changecan be effectedwithout
doublede-clutdringon shiftingup and without rewing up when 6hiftingdown.
On shifting, the sel€ctor lever of the syndrronised forward gears should b€ pressed in smoothly and evenly. Only when the synchro-
processis at an 6nd does the Eelectorlever move into final selectedposition.
To protectsynchronising componentsin the transmission,in the main clutc$ and the engine, shifting down should be effected
only when the driving speed corresponds to the max. speed of the next lower gear.
The rever6egear may be engagedonly when the vehicleis stationaryas otherwisethe dog teeth may be damaged.
The clutdl pedal should always be depressed when selecting both forward and reverse speeds. Por'oct adiustmeni of lhe main
clutdr contribute! considorably to the prov€ntion of .hifting trouble. The clutci should engage and disengagecompletely.The
6pecifiedpedal play shouldther€forebe checkedregularly.

lV, Maintenance and Lubrication

The followingtyp€s of oil can be used for lubricationof the gearbox unl6s5the lubricationinstructionsof the vehicle manufac-
turer are different.
1. Mild €P-Goarbox oll., prctcrably of viscosity cla3! SAE 8{,
2. HD-Engins oil3 ot vi.co3ity cla33 SAE 30
Mild gear oil types are those EP oil grade6whiah in the presenceof condensationdo not cause corrosionon steel and non-fer-
rous metal parts and hardeningof gasketsand Eeals.So-called multi-purposeor universaloils can be used if they meet our
"LubricationOil Roquirements for ZF Transmission
Nr. 13-118".In case of doubt,pleaseaek an oil supplier.
To facilitatethe choicoof oil for vehiclesused abroad,it should be mentionedthat multi-purposeoil SAE 80, with rnild EP-Addi-
tives, as per specification MIL-L- 2105 (A), can meet these requirements.

Oil Lovol Ch€d(

The oil level in the transmissionshouldbe ch€ckedregularly(approx. every 10.000km). The dleck should be undertakenonly
when tho vehicleis in a horizontalposition.lf this is carri€dout after drivjng,'thensome time shouldbe allowedto elapseuntil the
oil has settledin the transmigsion.
Ths oil filler plug should be removed fron the sid€ of the gearbox (to the right as seen on th6 output flange) to check the oil level.
The area aroundth6 plug shouldbe cleanedso that no dirt c6n fall antothe transmission.lf ths oil level has dropped below the
edge of the bore, then the oil should be filled to overflowingagain.Then close the oil filler plug. lf possible,the sam6 type of
oil should alwaysbe used.

Oil Change

The gearbox oil in.a new or repaired gearbox should be .tianged first after 4000 to 5000 km or 6fter 100/125 working hours, and
then every 16 000/20000 km or 400/500working hours.The old oil should always be drained after driving as it i6 th€n warm,
flows easily and flushes th6 driving parts and possibly removes the w6ter condonsationwhich has tormed tiom the gearbox more
ea9ry.
The oil drain is on the undersideof the transmigsion,
set furthestback. Prior to screwingthe drain plug back,the magnetshould
be cleanedof adheringabragiv€s.
The now oil shouldbe put in vja the oil fill€r and should in fact overtlowat the €nd of the bore (requiredoil capacityapprox.1,6 l).
Oft€n, lubricantsand additivesare offored in additionto the oil. The oils meeting our instructionsalrsady have their additives
whidl the transmission needs. An)4hing further is not nece9s6ry, and could even cause damage.
V. Tools Tool Nr.

Tool .1. 12538986s3

Device for fasteningtransmissioninto vice

f ool .2.
Tool for pullingout ball bearingof the mainshaft 1253898205
and input shaft.
ln a larggrnumb€rof thesegearboxeg, the ballbearings
ar€ fitted with divid€dinner ring. The followlngtools
are necegsaryfor the assemblyof thi6 boaring.
UniversalPuller 124889820r
fnsert for pufling ball bearings (212 and 423) 1253898203
Pullerfor ball bearing inner ring r 255898202

Tool .3. r211898206

Pullerfor reversebolt (only for heavyvehicleversions)

Tool .4. r 253898204

Ba6acTool

Tool .5.
Grippingpiece for pullingroll€r bearings
(303 and 309) off the counter shaft.
ts 1253898202

Tool .6.

trga
Bu6hes for presging synchroni66ronto mainshaft
for 1.--+l- g€ar 1255 898 052

2.---3. Gear 1255898 053

4.-5. Gear 1255898 054

 Tool Nr.
Tool .t.
Preasura pi€c€ for knocking spring rings onto
Syncnronlaaa r 2s3898054

Tool .8.
Tool for pr€8slng ball b€aring (212 a d 423)
on tho main- and input shafts | 253898652

Tool .0.
Prssslng mandril for tho sh6ft 8€al (207
in tho wlthdraviral bgaring carrlor (206) | 25s898051

Tool .t0.
Toolfor preeelngBhaftssal Into thg sp6€dobush ,,$e 1253898631

Tool .l |,
Mandril for presglng th6 tapergd roll bearing Inner
rlng onto ths countor shaft | 2r | 898051
Vl. Strippingof Transmission
Noi€: The numeralsIn bracketse.g. (611) refer to part numbersin explodedview at end of instructions.
Screw tool .1. into the thread of the oil drain plug (to fasten transmissionmore socurely,the full thread in the housingshould
be used) and secure gearboxwith the tool in the vice- Pull the lock nut of the tool .1. lightly.

A) Bemov.l of G€ar Shift

l. Remote lloor shllt (Car)
1.1Removeboot (643).Removecirclips(642)from the groove
of the gear lever turret (Fig. 1). Pull the geardrang€con-
trol lever (640) with the bushes (641) from the gear change
turret (Fig.2).

1.2Loosen the 4 screws (637) (Fig. 3) and lift off the gear
changeturret from the selectorarm (Fig-4). Take off guide
prare.

Fig.4
1 3 Pull pivot pins (630)from the gear changeturret.Take out
interlockswing (625)with torsion springs(633 and 633.1).

Screw off the 4 nuts (648)on the selectorarm (619)(Fig.5)

and plll selectorarm over the selectionrods. Take pivot
piece (624) out of solector arm.

Fig.2
 2 Loosennuts (808)and screws(803).Takeoff speedocover
(801).S ip off short drstancebushes (428).speedo worm
(427)and long spacingbushes(426).

Fs.5

I 5 T a L e o u t c y l ' n d ' r c a l s c e w s ( 6 4 5 ) r F g 6) and take off

vibration damper (644)
Fiq I

Snap sprrng ang (425) out of ball bearing groove (423)

and slide off the spacer (424) Pull the ball bearing frorn
the marnshaftwth tool 2. Attach the spacer (424)to the
ballbcaring.

Dismantlingof Front Part of Housing

1 Loosennuts (20r) (Frg.9) and front cover (203)

F r g .6

2. Centrallylocateddirect gear change(commercialvehicle)

2.1 Sl p off the gaiter (643) Unhookcap (655)frorn the prvot
pins (652) and p!ll selecton lever completelyout of the
gearchangeturret.
2 2 Loosenthe 4 nuts (648)and lrft up gearchangeturret from
housing(629) Removeselectorgate (653).
2.3Pull pivot plns (630)from the gearchangeturret Take out
interlockswing (625)with tors on spring(633and 633.1)
Fig 9
B) Dismanllingof SpeedoCover
2 Bemovecrrclp (208) (Fig. 10) and take off spacer (209)
I Push back the safety tab on the nut (430)and loosennut
(Fig 7). For this, 2 gears must be engaged Pull the output 3 D s m a n t l es p r n g r i n g P u l l o f f b a l l b e a r i n g( 2 1 2 )w r t ht o o l
flange (429) from the mainshaft. .2
4. Push back the 2 dowels (106)(Frg ll) D) Oi3mantlingof Gearbor Shaft3
l. Take off selectorfork 4th and 5th gear (601).
2 D i s m a n t l se e l e c t o r o d s ( 6 0 8 , 6 1 2a n d 6 1 a )( F r g .l 5 ) .

Loosen set screws (602) on the prvot prns (604 and 610)
( F i g 1 2 ) a n d p u l l p v o t p L n sf r o m t h e h o u s r n g
F9 15

Take gearbox shatl from the housrng (Frg 16) Pull the
2 detent plungers and lhe 2 ccmpressron spnngs (616)

Ftg 12

U n s c r e w n u t s ( 1 0 2 ) a n d t u r n c y l r n d rc a l s c r e w s ( F r g l 3 )

Fg 16

E) Oismantlingof Bever6eGear
I U n d o t h e s c r e w s( 1 1 8 )a n d t a k e o f f t h e c o v e rp l a t e( 1 1 7 )
2 Removethe set screws (507) from the hous ng (Frg. 17)
o r p u l lo u t t h e d o w e l( 5 1 1 ) P u l lo u t t h e r e v e r s er d l e rs h a f l

Fig l3
T a k eo f f f r o n t p a r t o f h o u s r n g( 1 0 1 )( F r g 1 a ) P u l l d e t e n r
p u n g e r( 6 17 ) a n d c o m p r e s s r osnp r n g ( 6 1 6 )f r o mt h e b o r e

it

Fg 17

(505) wrth specra too 3 or knock towards the output

s de wrth a frtteCmandril(Frg l8) Take out the reverse
gear (502) wrth the 2 thrust washers (501) Pull the 2
neede cages (503)from the bore of the gear.
 Fig. 18

F) Dismantlingol Mainshah
I Berrove thrust washers (422) and 1st gear (421) wrth
synchroring (402) and needle cage (408) from the main-
shaft.
Remove synchro spring (403) from the pressure piece
(aoa) (Fig. 19). Pull slrdingsleeve (420) from the synchro

Fig.21

Pull off synchrobody 4th and 5th gear (405)wrth 2 screws

M 8 and conventionalpullrng bridge (Fig. 22). Take off
synchroring (402),5th gear (a07)and needlecage (408).

Fig.1 9

body (419)and take off pressurepiece (404).Bemovecir'

clip (409)from groove (Fig.20) and mark posrtronof the
svnchrobodv on the mainshaft.

Fig.20

Fis.
Clamp mainshaftwith the input side upwardsbetweensoft
jaw6 of a vice. Removeinput shaft (213).roller cage bear-
tng (214) and synchro ring (402).Removesynchrospring
(403).Pull off sliding sleeve (406)and dismantlepressure Remove circlip (409). Push the thrust washer (410) with
piece (404).Removecirclip (401)and mark positionof the the 3rd gear (411) from the cylindricalspliningof the shaft.
synchrobodyon the shaft (Fig. 2i). Take off synchroring (402)and needlecage (412).
 B€move synchro spring (403) on the syncfiro body 2nd and
3rd gear (414). Pull off sliding sle6ve and r€move pres-
sure pieces(404).Removecirclip (413)(Fig.23) and mark
position of the synchro body on the shaft.
7 . With a press, press down first of all the roverEegear (418),
with the synchro body to the output side, and then the 2 nd
gear (415) with the 6ynchrobody (414) to the input sid€.
Take the 2 needle cages (416) from the mainshaft.Bend
back the circlip (419-2) on the synciro body rev€rse gear
(419). Bemove spring ring (419.1)and take off circlip,
spacing plate (419.3)and Eynchrospring (403).The synchro
spring (403) which lies bohind tho weldod angular plccc.
anthe synchro body reverse gear should not be removed.

G) Di3mantling of Layshaft
Removecirclip (301)and pull off roller bearings(303 and
309) with tools .4. and .5. The constant gear wheel (304),
the sth speed gear wheel (306) and the 3rd speed gear
wheel(307)can be pressedfrom the countershaft individu-
ally with the help of a 20 ton pres6, as theso geara are
shrunkfit.lt shouldbe notedthat the circlip (305)shouldbe
removed before the pres6ing of the sth speed gear wheel.
Removeall gasketpartssuchas shaft seals,(207,811, 812)
gasketsand O-Rangsfrom the housinghalves,the speedo
cover,the withdrawalbearingflangeand the pivot pins.

Fig.

Vll. Checkingof IndividualComponents

t . Check synchrorings (402)for wear. lt is advisablealwaystoreplacesynciro ringswith new ones when repairingtransmissions.
2. Check short teeth of clutch body for wear and damage.
3. Check all slide pieces for wear. The axaalplay in the groove of the slidang6leeve must be 0,2 mm to 0.45 mm for 15t and
reversegearsand 1,6 to 1,85mm for the remaininggears.
Check shift forks for damageand wear.
5. The runningsurfacosof th6 needlebearingson the mainshaft(417),on reverseshaft (505)and in the bores of gear wheels,as
well as the n€odlesthemselves,should show no signs of wear or pitting.
6 . Check teeth of all gear wheels for wear and pitting.
1 . Check outputflange(429)6nd input shaft for ecore marks caused by shaft sealingrings.
8. Ch€ck drive pins and guide grooveson shift rails (608.612, 614) for wear.
Gears of countershaft are shrunk-fit.They can be removedonly on a 20 ton press.For shrinking,heat gear6to 150 to l80o C
and then slide on counter shaft. Be sure to maintain the above temp€rature since a temperaturs in excess of l80o C may cause
structural dtanges which in turn might impair hardness. At temperatures below t50o C, the- expansion-of thg gear i9 too low
and the gear w-heolmight seize when pressed onto shaft (also refer to "Prca66embly of Countershaft").

Vlll. Assemblyof Transmission

Prior to assemblyof the transmission,all componentsshould be carefullycleand.The sealingsurfacesof the housingfront end
and rear end should always be smooth€ddown to remove remainingvarni6hand p€rtinentdamage.Prior to reassembly,ead!
part must be ctecked for w€ar or oth6r faults and lubricatedwell. Gaskets.shaft sealingrings, O-Ringsand lock washersshould
alwayg be replaced by new ones.
Mak€sure in particularthat no dlip6 or other foreign particlesremain in the hou6ing.For insertingshaftsand bolts, always use
a soft hammer(plastic,lead etc.).N€ver hit hardenedtransmissionparts with a ste€l hammer.When installingstuds, make sure
holes togetherwith sealingcompound(for good sealing).
that they are insertedinto tapped-through
The assemblyof the individualshaft and of the entiretransmissionproceedsvice versa to stripping.When assemblinggear levers
and the lik€with hubs on one side, correct positioningduring assemblyas important.
A) Preassembly
of HousingComponents
S c r e w s t u d s ( 1 0 4 .1 0 5 , 1 0 8 ,1 0 9 1 1 0 , 8 0 5 a n d 8 0 6 ) i n t o
t a p p e dh o l e so f h o u s r n g .
Note: New studs for through holes are Insta ed coated
w r t h s e a l i n gc o m p o u n d .
B) AssemblyoI ReverseGear Wheel
1 Put needle cages (503) nto reverse gear bore (502) and
strck needleswith grease.Stick a thrust washer (501 and
510) on each side of the wheei with grease (the turned
down faps lre outwards).Put the reverse gear Into the
housing.Push the reverse dler shaft wth the sma er .'
first into posrtronn the housrngbore from the output s de
(Fig 24). Take care that the thrust washersare not dama
ged by the shaft
2. Insertscrews (507)wrth spnng washer(506) (underneath)
a n d t i g h t e nt o 2 . 0 t o 2 . 5 k p m ( s e e F i g . l 7 ) T h e s e c ! r n g
bolt must come to lie behrndthe shaft (not rn the groove)
On various gearbox types a dowel (511) must be pLrt
throughthe housing nto the shaft bore
srng,the posrtronsot the hub and shafi, markedon
d s a s s e m yb . s h o u l db e I n l r n e .
1 . C l a m pm a r n s h a (f t4 1 7 )b e t w e e ns o f rj a w s i n t h e v i c e .O u t -
put end on top.
2 . S l i d e n e e d l ec a g e ( 4 1 6 )a n d 2 n d g e a r w h e e ( 4 1 5 )o n t o
rnainshaftwith dog teeth on top (Fig. 25). Placea synchro
nng (402)on the cone of the gear
3 Placc a synchrospnng (403)onto the side of the 2nd and
3rd gear synchrobody (414)whrchrs first pushedonto the
m a i n s h a fi e
t o n t h e s i d ew h L c h a st h e s p l n r n ga n d a t t a c h
the squaredoff end into the cross slot (Fig. 26) Heat the
preassembled 2nd and 3rd gear synchrobody up to 80oC
andwrththe spl nes Ined up Intothe positionmarkedduring
drsassembly, pressonto ma nshaft(Frg.27).Only assemble
the synchrobodywrth tool .6. or wrth a suitabe tube whrch
fits over the hub. Make sure that the lugs of the synchro
r ngs (402)lie in the recessof the synchrobody.SprLngon
the circl p (413)i this must sit tightly in the radralgroove
a n d i s t h e r e f o r ea v a r l a b l e
r n t h i c k n e s s eosf 1 . 8 i 1 , 9 a n d
2,00 mm Use loo 1 fot tapprngthe circlip into posrlron.

3 Fastengasket(116) and cover (117) onto the housrngw th

s e t s c r e w s( 1 1 8 )a n d s p n n g w a s h e r s( 1 0 3 )( u n d e r n e a t h )
Trghtentorque of the screws to 2 to 2.5 kpm

'\
Itl

c) P r e a s s e m b l y o f Mainshaft
ll
Note: New synchrobodies (405, 414 and 419) have no
cyl ndncal sp rn ng n their hob. Thrs rs pressed onto
Fig 26
t h e h a r d e n e d m a n s h a f t T h e r e f o r e . w h e n L r s i n go d
s y n c h r o b o d r e s ,r t s h o u l d b e n o t e d , t h a t b e f o r e p r e s -

F g 25 F'g 2 1
Attach the 3 pressurepreces(404)wrth greaseto the as-
sembledsynchrospring such that the wire is frxed In the
recessesof the pressurepieces.The squaredoff end of the
s y n c h r os p l n g m u s t c o m e t o l e o n t h e i n s r d eo f a p r e s
s u r e p r e c e( F i g . 2 8 )s o t h a t t h e s p n n gc a n n o td r s t o r t
F i g 28
P u s h t h e s l r d r n g s l e e v e ( 4 0 6 ) o n t o t h e s p L r nn g o f t h e s y n '
chrobody as shown in Fig.29 (This sliding sleeve is the
same on both sides). The 3 flat teeth lie on the pressure
pieces. Engage pressure pieces In the notches of the teeth
Fg.29
Attach secondsynchrospnng (403)in the pressurepreces
(Frg.30) The squaredoff end of the springmust le on the
nner srde of a pressurepiece. Moreover,take care that
the 2 sprLngends are assembledIn drfferentpos trons to
each other r. e lre In 2 drfferentpressurepeces. Lay the
second synchro rng (402) on the synchro body (see
F i o .3 1 )
Fig.30
Slide the needlecage (412)onto the mainshaftand place
t h e 3 r d g e a r( 4 1 1 )i n t ot h e s y n c h r or i n g ( F i g .3 1 ) .S l i d et h e
t h r u s tw a s h e r( 4 1 0 )o n t o t h e s p l i n r n ga n d s n a p a c r r c l i p
(409) Into the radialgroove of the shaft The ring must sit
trghtly In the groove and rs therefore availablein thick'
n e s s e so f 1 , 8 i 1 , 9 a n d 2 , 0 0 m m . U s e t o o l . 7 . f o r t a p p r n g
the circlip into position.
Frg.31
Fig 32
 Slide the needle cage (408) and 5th gear wheel (407) w th o f t h e m a i n s h a fTt h e c r r c l i pm u s ts L tt r g h t y I n t h e g r o o v e
the dog teeth upwards onto the bear ng seat of the shafl A v a i l a b l en n g t h i c k n e s s e s1 , 8 i 1 , 9 a n d 2 , 0 0 m m P u s h
(F g.32). Place a synchro ring (402) on the cone of the gear clrcl p up to stop In the groove with tool 7.

9 Place a synchro spnng (403) onto the side of the synchro-

body (405) with the longer hub and attach squared off end
to the cross slot (see Fig 26) Heat 4th and 5th gear syn-
chrobody toS0oCand press itwith the ongerhub frrst onto
m a r n s h a f t( F i g . 3 3 ) . U s e t o o l . 6 . a n d n o t e t h e m a r k e d
position when pressrng on and insert the lugs of the syn-
chro rings Into the notches of the synchrobody. Select a
c r r c l L p( 4 0 1 ) t h i c k e n o u g h t o s i t t i g h t l y I n t h e r a d a l g r o o v e
T h e r n g s a v a i l a b l e i n t h r c k n e s s e so f 1 , 8 i 1 , 9 a n d 2 . 0
Attach crrcl p and with tool .7 push into groove

Frq 35

I 3 . S t c k t h e 3 p r e s s u r ep e c e s ( 4 0 4 )w r t h g r e a s eo n t h e a s
A sembledsynchrospang (403)(see Fig.28). The wire must
strckin the groovesof the pressurepiecesand the squared
Fig 33 off ends lie on the inner srde of the pressureprece

14.SlLdethe sl drng sleeve (420) onto the synchrobody(see

F g. 29) such that the 3 flat teeth come to rest on the
10.Belease rnarnshaftand wrth output srde upwards fasten pressurepteces The narrowercollar and the small roun-
frrmlyagain In the vice. ded off teeth must lie agarfst reversegear. Engagep.es
sure p eces In the notchesof the teeth
l 1 . S l i d et h e n e e d l ec a g e ( 4 1 6 )a n d r e v e r s eg e a rw h e e ( 4 1 8 )
wrth the dog teeth upwardsonto the shaft (Fig 34). 15 Attach 2nd synchro spflng (403) In the pressure pieces
(see Fig. 30) The squaredoff ends of the spring must lie
on the nner side of a pressureptece Moreover,take care
that the 2 spnng ends are assembledin differentposrtions
to each other . e lying in 2 different pressure pieces.
P ace 2nd synchroring (402)onto synchrobody (see Frg
36).

1 6 S l i d en e e d l ec a g e( 4 0 8 )a n d l s t g e a r( 4 2 1 )w t h c l u t c ht e e t h
d o w n w a r d (sF i g . 3 6 )

Frg.34

l2 Heat lst and reverse gear synchrobody(419) B0oC and

wrth the longerhub placedfirst in the positronon the shaft
, a r k e dd u r L n gs t r i p p l n g(, F i g . 3 5 ) , p r e s s u p t o
s p l i n i n gm
stop wth tool .6. Insert crrcIp (409) in the radial groove Fg 36

15
 Fohrtrichtung
(directronof travel)

F,9 39

lnsert layshatt wth the small teeth first Into the housrng
(F 9. a0).

Frg 37 Place selector fork 1st and reverse gear (613) rn the
groove of the 1st and reverseslrdrngsleeve(420)and 2nd
and 3rd selector fork (609) In the 2nd and 3rd sldrng
l7 Plece on the thrust washer $22\ wllh step upwards sleeve (406).The detent pad must le on the side of the
(Fr9 37) 'nstalledreversegearwheel(502)

D) Preassemblyot Layshari
Make bores of helrcalgear and frttedseatson the layshafl
tree ot oil, grease and dust. Heat 3rd gear (307) and sth
g e a r ( 3 0 6 )t o 1 5 0 o- 1 8 0 oC a n d p u s h I n d r v r d ul ya a g a i n s t
stop on layshaft.Note that the 3rd gear is put on the shaft
with the side hav ng lhe locatrnghole and the somewhat
wider collar first Insertc rcl p (305) Warm constantgear
(304) lrkewise to l50o- 180oC and press on wrth rhe
longer hub first. Press on both Inner races of the taper
roller beanng (303 and 309) up to the stop The larger
drametersare each towardsthe gear wheels Placec rclrp
(301) n radralgroove On gearboxeswrth manufacturers
numberunder 1152,ball bear|ngsare used to some extent
In such a case the rear beanng (309) should not yet be
pressedon (only after the Installatron of gearboxshaft Into
the housing).

E) Installationot Gear Shatts

1 S t i c k p r e s s u r es p r L n g( 6 1 6 )a n d d e t e n tp l u n g e r( 6 1 7 )r n t o
the 3 retainng bores of the gearbox front and rear with
g r e a s e( F i g . 3 8 )

F,g 40

Note: The selectorfork 1st and reversegear has a detent

pad with open detenls,thereforewith only 1 notch
i n t h e m d d l e a s s h o w nl n F i g 4 1 . T h e d e t e n tp a d
of selectortork 4th and 5th gear has 3 notches

Pushpreassembled marnshattwith outputsrde frrst into the

beaflngbase of the housrng(Frg.42).Pay attentionto cor-
rect positionof forks (detentplunger(617)over the detent
pad)andthe 1st gear(421).

Snap the spnng nng (425) Into the radral groove of the
ball bearing(423) Push ball bearrngwrth the spacer (424)
d r s m a n t l eddu r i n gd r s a s s e m bol yn t ot h e m a i n s h a f( tF t 9 . 4 5 )
F,9 Brnd layshaftto the marnshaftwrth tape (see F g. 45).

Stick 2 selectorpads (607) with grease Into the bores of l Wrth pressingtool .8.,the threadedp eces belongingto lt
the selectorforks (601 609, 613), for selector fork (609) and the 2 distancebushes (426 and 428), press the ball
I n t h e m i d d l eh o l e sa n d f o r f o r k s( 6 0 1a n d 6 1 3 ) i n t h eo w e r bearingto the stop on the thrust washer (422) Then tap
h oe s ( F i g . 3 9 ) . the ball in the housrngbore Leavetool .8. tight.
 Fg 44

Turn the housrngsuch that the open side porntsupwafds

With a depth gauge measurefrom the face of the synchro-
body to the gearboxjoint face (withoutgasket) (Fig. 451.
A stralghtedge with the hrgh lip on which the slide of the
depth gauge rs set must be put onto the gearboxJointface
(Fig.45). The measurementestablishedplus the width of
the straight edge should amount to 53,5 1 0,i mm. The
differencebetweenthe measuredsize and the theoretical
size shows the thicknessof the spacer (424),which les
between the recess of the housrngand the spring ring
(425).The shrm (424)which is available n thicknessesof
0,6: 0,8; 1,0: 1,2 and 1,4 rirmmust,if necessary,be exchan'
F9.41 ged. Standgearboxin horizontalpos tion againand take of
pressingtool .8

Tfr/

Fig 45

9 Take off tape. Stick the 3 pressure preces (404) with

grease onto the installedsynchrospring on synchrobody
4th and sth gear (405) such that the wire is fixed in the
recessesand the squaredoff end on the lnner side of a
pressurepiece (see Frg.28).

l0 Push the sliding sleeve(426)onto the spliningof the syn'

chrobody(see Fig.29). The 3 flat teeth come to rest on
the pressurepieces.Engagepressurepiecesin notches.

ll.Attach the second synchro spring (403) to the pressure

preces (see Fig. 30). Attach the squared otf end of the
spring again as describedfor synchrobody2nd and 3rd
gear.

12.Put the secondsynchroring (402)on the cone of the input

shaft (213) (see Fig. 33). Place the roller cage bearing
into the spigot bearing bore of the input shaft. Push the
input shaft on the spigot of the mainshaft.
F) A!3embly of Shift Part. as shown in Fiq.49 into the bore of the selectorfork (609)
Install 4th and-sth gear selector rail (608) as prevaously
1. Place 1 off O-ring (605) into the grooves of each of the described(Fig. 50).
pivot pins (604and 610).Put 2 pivot pins (604)throughthe
rear housrnqbor€3 into the bores of the lst and reverse
aear eelect; fork (613)(beginwith pivot prn which lies on
ihe d.tent p"d side ss shown In Fig 46) Tightenscrews
(602)with sgrinqwashers(603) Push pivot prns (610)Into
setei:torfoti 2nd and 3rd gear (609) and fasten wrth the
screws (602) and spring tashers (underneath).Tighten
torque screws (602) to 0,8 to 1 2 kpm.

Fig 46

Place the 4th and sth gear selectorfork onto the sliding
sleeve as shown in Fig.47

Fig. 50

Slrde qasket (l07) over the protrudrngstuds and Install

oearbo-xhousrngfront part (101)(Fig.51) Screw the nuts
(l02) with sorinq washer (103) on the stud Tap in dowel
itOOi ana tiren-trghtennuts (l02) to a torque of 2 to
2,5 kpm.

Frg.47 Place O-rinq6 (605) into the pivot prns (604) lnsert pivot
orns throuohthe housinqinto the bore of the 4th and sth
fork. Screw in bolts (602)wrth sprrngwashet
oear selec-tor
Assembleshift rails. First the shortest reversegear shaft
ra'l (Fig.48).Note that the notchat the end of the rarl lres a6O3)and tighten to 0,8 to 1,2 kpm.
neai tlie shift lever (640) and should pornt upwards.This
aooliesalso for the 2 other shift rails. Insertweldedpivots
2nd and 3rd gear shift rails (612)with the 2 plastic bolts
( 6 11 ) .

Fig.48 F'ig 51

18
 G ) Installing Inpul Shaft
W t h a p l a s tc h a m m e r . t a p t h e b a l b e a r n 9 ( 4 2 3 ) o n t h e
I
output shaft nto the housng unt rt comes up aga nst the
s p r n g r n g ( a 2 5 ) ( t o e n s u r e t h a t m e a s u . e m e n t sa r e n o r

W t h a d e p t h g a u g e m e a s u r et h e s p a c e f r o m t h e f r o n t o l
t h e h o u s i n q t o t h e s e t t r n gs u r t a c e o f t h e b a l l b e a r n g ( 2 1 2 )
on the rnput shaft (Frg 52) Press nput shaft wth hanLi
I rmly and eveny to make i le n the bore ot the synchro
r ng

I
tJ_
f
t
I Fq 54

S e l e c l a s p r c e r ( 2 C g )s l c h t h a t t h e c r c r p ( 2 0 8 ) s t s t L g h t l y
r n t h e r a d a l q r o o v e o f t h e I n p u ts h a f t A s s e m be t h e s p a c e ,
dnd c,c p (Fs 5s)

"\\

t ^-\i'. \-
Er.'iff t
n Dt\
Fq 52

\
nsertsplng r fq l21l) Into the qroove of the ba bearnlr
( 2 T 2 ) M e a s u r e f r o m t h e u p p e r s L r r f a c eo f t h e b e . r n q t o
the sDnng flng The spr ng r ng must be pressedonto the
outef edqe of the beanng groove (F g 53)

Fct 55

H ) Assembling Speed Cover

l l F r s t y t a p t h e o L r t e ,' n g o f t h e r o e r b e a f i r c t { 3 0 3 ) o r
t h e a r g e s t d r a m e t e r n t o t h e h o u s n g b o r e F o r t h s L r s ei l

n pastc or ead hammer

I P a c e q a s k e t ( 8 0 2 ) o n t h e g e a r b o x , e a r h o L r sn g

C e n t l y w t h a p a s t c o r e a d h a n r n r e rt a p t h e o u t e r r n g
o f t h e b a I b e a n n g ( a 2 3 ) I n t o t h e h o u s , n g! p t o t h e s t o p
-F W th a depth gauge me.sure the d stancefrom the uppe,
s u r f a c eo f t h e o u t e r b e a r n g r n g t o t h e g e a r b o xl o n t f a c e
wrth q.sket n place (Frq 56)

Frq S3

The d fferencebetweenthe 2 meas!rements ess 0 5 mni

to 0I mm for the axra play of the 4th gea. synchror nfr
{a02)g ves the th ckncss of the spacer (209) wh,ch n !st
be placed under the ba I bearnq (212) The sh ms are
a v a a b l e n t h c k n e s s e so f 0 5 : 0 6 : 0 . 7 . 0 8 i 0 9 l 0 1 l
I 21 13: 14 and I 5 mm

Push the spac,nqwasher over the Input shaft Press the

ba bear ng (212)w th pressng too 8 up to the stop or,
t h e n p u t s h a f t a n d n t o t h e h o u s r n q( F g 5 4 )

Note: When pressng n rhe ball bear nq. the bal be.r nq
mlst De dr ven nto the housng bo'e w,th a p.st c
hanrnrea
r t t e r a p p r o x m a t ey 2 t u r n s o f t h e t o o

r9
4 Determinethe depthof the matinqbore In the speedocover
(Fig 57). The drfferenceof the 2 measurementsless O to
0,1 mm play gives the thicknessof the spacer(804)which
must be placedin the bore of the speedocover.The spa,
cers are availblein thrcknessesof 0,4t 0,5: 0,6; 0,7; 0,8t
0 . 9 a n d 1 . 0m m .

Press the needle bearing (810) and shaft seal (81l) wth
hot bearinggreasebetweensealinglip and dust lip up to
the stop on the output bore of the speedo cover. With
sealinglip to the inside of the gearbox.

Stickthe spacer(804)for the mainshaftbearingwrth grease

in the appropriatebore of the speedo.cover. On layshafts
with ball bearings (installedup to gearbox No. 1152) a
spacer(302) 1,5 mm thick mu6t be placedinto the smaller
bore of the speedo cover. The shim rs equivalentto the
differencein width betweenthe ball bearingand the equi-
valent roller bearing.The installationof both bearingver, Frq.59
sions is carriedout on the input srde.
Pushthe outputflange(429)onto the mainshaft.Screw nui
(430)onto the threadand tightento 14 to 16 kpm (forthis.
2 gears must be engaged).Tap lock tab of nut with a drift
Into the groove of the mainshaft(Fig.60).

Fig.57

Place long distancebush (426),speedo worm (427) and

short distancebush (428) on the mainshaft(Fig.58). Set
split ring into the groove of the hainshaft and push cir
clip over-With a depth gauge measurethe space between
the split ring and the shorter bush (a28).The space must Fig.60
be 0,17 to 0,22 mm. lt can be correctedby fitting varying
sizeddrstancebushes33,35i33,4;33,45;33,5;33,55t33.6;
33,65or 33,7 mm. long.
10.PlaceO-ring (815)in the radialgrooveof the speedobush
(814).Pressshaft seal (812)with tool -10.jnto the speedo
bush (sealinglip upwards).Put speedoshaft (813)into the
speedo bush and insert both together in the bore of the
speedocover. Screw in self lockingbolt (816)with spring
washer (807).

AssemblingWithdrawalBearingCarrier

1 With the larger internaldia facing the inside of the gear-

box, place the outer ring of bearing (303) into the bore
for the layshaftbearingof the front cover (101).

Push gasket (204)over the threadedstuds.

Press shaft seal (207) into the bors of the withdrawalbe-

aring carfler (206)with tool No. .9. Sealinglip must point
to inside of the housing.
Fig. 58
4 . Gently tap layshaftwith a plasticor lead hammertowards
rear (output side) until the bearingouter ring ljes on the
speedocover-Pressdown the front b€aringouter ring and
Pushthe speedocover over the studs and up to the hou, with a depth gauge,measurethe distancefrom the upper
sing Screw on nut (808) with spring washer underneath edge of the bearing outer ring to the gearboxjoint face
(807) and rightento 2 to 2,5 kpm. with the gasket in place (Fig.61).

20
 1 . Strckthe spacerfor the input shaft beanngand for the lay,
shaft bearingwith grease Into the appropnatebore of the
withdrawalbearingbarrier

Push the wrthdrawalbearng carner over the tnput shaft

and positionon the hous ng Tghten nuts (201)with spring
washer (202) underneathto 2 to 2,5 kpm.

I Fig.61

Determinethe depth of the appropriatebore in the wth

drawal bearing carrier (Fig.62). The drfferencebetween
the 2 measurementsgives the thicknessof the spacer
(302),which must be placed Lnthe bore of the withdrawal
beaflngcarner. The sh ms are avallableIn thtcknessesof
0 , 4 : 0 , 5 0; , 6 ; 0 , 7 ; 0 , 7 50:, 8 :0 , 8 5 0; , 9 , 0 , 9 51r , 0 ;1 , 0 5 1 ; .1r
1 , 1 5 :1 , 2 ; 1 , 2 5 r1 , 3 i 1 , 4 a n d 1 , 5 .T h e i n s t a l l e d
t a p e rr o l c r
hearingmust have between0 and 0,05 mm prc-load

Frg.64
Fig.62

K) AssemblingSelectorKnob
The selecnonof the spacer(804)for the ball bea ng must
give between0 and 0,05 mm pre-load.Hold the layshaft
l. Eemote gear levers (Cars)
i bearingand first y measurethe amountof the ball bear ng
prolectingover the sealingsurface(Fig.63) and then take
thrs measurement from the depth of the smallerbore n the 1.1Pushvibrationdamper(644)over the shrft rods and fasten
w i t h d r a w abl e a r i n gc a r r i e r( F i g . 6 4 ) .T h e r e s u l t a ndt r m e n with the set screws (645)and spring washers(646).
sion less 0 to 0,1 mm play gives the thtcknessof the spa-
cing washer(210)which rs avarlablein thicknessesof 0,4i
0 , 5 ; 0 , 6 t 0 , 7 ;0 , 8 ; 0 , 9 a n d 1 , 0 1.2Place the pivot piece (624) on the 2 locatingbolts In the
gear changeextenslon(619).Push shift arm over the shift
rods (Fig.65).Trghtennuts (648)with thrust washer(647)

Fig.63

21
l.3Place ring (659) wrth the bore to the taper compressron
spring(628)in the shift turret (629).Placetaper compres-
son spring on the ring. Fastentorsion 3prings (633 and
633.i) to Interlockswing as shown in Frg 66 The stronger
spr ng lles agarnstthe shortertang.
Fiq.66
1 . 4Placeinterlockswrng In the shrft turret (629)(F g. 67). The
weaker sping lies againstthe breatherhole Push n the
2 pivot prns (630) and press n the bore (Fig 68).
t 1.6Frt gasket (626).Placepreselectedshift turret on top (Frg
Ftg 61
2.1 Fastentorsron spring (633) on the InterlockswLng(625)
2 . 4Place gear lever ball (640) in the shift turret. Push pres-
Fig.68
22
I 5 Placeselectorgate (627)with the 2 bores to the breather
hole over the interlockswing and place on the shift turret
(629) (Fis. 69)
Frg.69
70). Screw and t ghten set screws (637)with spflng was-
her (636)to 2 to 2,5 kpm. Placegear lever ball (640) n the
shift turret (629).The flat side of the gearleverball must
point rearwards.Pushball socket(641)over the gear lever
ball and insert circlip (642)
)
a- - L
ld"-r
Fig.70
Cenirallymounteddirect gearchange(heavyvehicles)
Place nterlockswing in the shift turret (629)and fit the 2
prvot pins (630).
Place selector gate (653) with the nose potntrngto the
input shaft and the selector guides to the gearbox inner
onto the gearbox housrng.
Lay gasket (626) on and place preassembledshifr turret
on the gearbox housing. Screw nuts (648) with spring
washer (647) onto the studs (650) and tighten to 2 to
2,5 kpm. Screw breathervalve (635) in the thread of the
shift turret.
sure spring (628),socket (645) with cylindricalside first.
and cap (655) over the gear lever ball. Attach cap to the
pivot bolts (652).Pur boot (643) over cap.
Test transmssion.
lX. Ordering of Spare Parta

Od€rs for sparr part! shouldalwa!€provld. th9 iollowlngdat6 to guar6nl!! f6st and conact dlllvary.
l. Type ld6ntlflcatlon(on typ! ratlng plote)
2. Produqilonnumborof t lmmilslon (on typ€ratlng pl€t6)
3. DlrlgnEtlon of daslBd lpgra paft!. Ahlvay! uga ngma 9a ghown In Spsro Parts List and Assombly In8tructlonB.
4, Statsten-dlgltnunb.r pundrsdinor cast on part to b6 roplacod.Thls numbsrls tndlspen8ebb,
lf th! type numbqroi thc tron!-
mlaslgn c€nnot bc glvln.
5. lf you cannotsuppv rny or sov6ralof th6 dats listod undgrt. to 4. th! iollowlngIngtructlon.aro lmportant.
a) Nuntlr of lllulrr.t d tabb eupplledwlth Spa.e Parts Llst or numbsrof illustretld iable In tha plrthqnt Alsambv
lnstruction8,
b) Makg and typ€ deslgnadonof whicle, nano of drassis manufacturar-
6. Mathodof de8pstdr audr !r Poet, F,rlght, Expro6sotc. Unl€ss lndic€tsd, shipinsnt wlll be as sslectsd by ue.
A part ctly cl.ar ord.r should br rs iollowa:
I am ordcrlngharowtlfionc malnshaft12553{X073 for fanlml.slon:
S $18/3, productlonnumbqrdX{}, by expressmeil.
Inmodlatodoliwry requlrsd.
Ordorsplacsdby tolophoncor c.bb lhould ba acknowledgod
In wrltlng.
Shlpmantet rlsk of bqor, awn wh.n rgsr! pertr !r. not drarged ior. Sprro plrt !r! .xdungad ft.. of dr.rg. durlng thc war-
ranty p€rlod only lf dsmlgrd parta ar! alnt to us frla of coEt 6nd withor^ p]lrloit! dungar msdr thcrcon, and whln sn Insplc-
tlon of ths pgrtlngntcompgnaotlhov.' trat the d!rugc ls tho rulult of a productlon or matadal fault.
Drnlged p!rt! lrnt to u! wlll ba ecrappedunlee thelr roturn ls aN'fr|.ly raqurltld whsn shlppgd.

Prtmut: All Ep6r9part8 aro dollv6rc.o.d.

a
X. Key to lllustrations

Hou6ingG.oup 404 PressurePiece 620 Washer

405 4th & sth gear synchro body 621 Pressure Spring
101 Front Housing 406 Sliding sieeve 622 Pressure Spring
102 Nut 407 Complete5th gear/cpl.4th g. 623 Guide Body
103 Spring Washer 408 Needle Bearrnq 624
104 GuadePiec€
Stud 40S Circlip 625 Interlock Swing
105 Stud 410 ThrustWasher 626 Gasket
106 Dowel 411 Complete3rd Gear 627
107 Selector Gate
Gasket 412 Needle Bearing 62A Conicalcorl spring
108 Stud 413 Circlip 629 Gear lever turret
109 Stud 414 2nd & 3rd gear synchrobody
11 0 630 Pivot Pin
Stud 415 Complete2nd gear 631 Spring Washer
11i S e a l i n gW a s h e r 416 Needle Bearing
112 632 Bolt
MagneticDrain Plug 411 Mainshaft 633 Gear lever bias sorino
113 D r a i nP l u g 418 ReverseGcar 633.1 Gear lever bias sfrini
114 Boar Housing 419.1 S p r i n gB i n g 634 Pivot pin
115 Type Plate 419.2 Circlip oJc breather
116 Gasket 419.3 Cover Plate 636 Spring Ring
117 Cover 420 Sliding sleevefor tst & Rev. 637 Short Set Screw
118 Bolt 421 Complete16t gear 638
I l9 Long Set Screw
Cover 422 ThrustWasher 639 Selector Pad
120 Stop Plate 423 Ball bearing 640 Shift lever ball
121 Stud 424 Shim 641 Shift lever socket
122 Spring Washer 425 Spring Ring 642 V Ring
123 Nut 426 Distance Bush 643 Bubber Gaiter
124 Set Screw 421 Speedo Worm 644 VibrationDamper
125 Spring Ring 428 DistanceBush 645 Set Screw
126 OperatingShaft (Rev.Light) 429 Output flange 646 Spring Ring
430 Nut 647 Spring Washer
431 Washer 648 Nut
Input Sh.ft Group
650 Stud
201 Nut Reverse Gear Group 651 BayonetCap
202 Spring Washer 652 Guide Pin
203 CentralisingFlange 501 Thrust Washer 653 Interlock Plate
204 Gasket 502 Reverseldler 654 Dust Cap
205 Stud 503 Needle Bearing 655 Cap
206 ClutchWithdrawalBearina 504 DistanceBing 656 Locating Block
Carrier 505 Flevers€ldler Shaft 657 Gear Knob
207 506 Spring Washer 658 Nut
204 Circlip 507 Bolt 659 LockingBing
209 Shim 508 BollerBearing 660 IntermediatePlate
210 Shim 509 Washer 661 Gasket
211 Spring Ring 510 ThrustWashcr
212 Ball Bearing 511 Dowel
Input Shaft Speedo Driva Group
214 RollerCage Bearing Gear ChangeGroup 801 Speedo Cover
802 Gasket
601 4th & sth gear selectorfork 803 Set Screw
Layshaft Group 602 Bolt 804 Washer
301 Circlip 603 Spring Washer 805 Stud
302 604 Pivot Pin 806 Stud
Shim
303 Ball/RollerBearing 605 O Bing 806.1 Stud
304 ConstantGear 607 Selector Pad 807 Spring Washer
305 608 4th & 5th gear selectorFlod 808 Nut
Circlip
306 5th gearl4th Cear 609 2nd & 3rd gear selectorfork 809 Stud
307 3rd Gear 610 Pivot Pin 810 NeedleBearingHousing
308 Layshaft 6l I Pivot Bolt 811 Oil Seal
309 Ball Bearing 612 2nd & 3rd gear selectorBod A12 Oil Seal
613 lst & Rev.Gear SelectorFork 813 Speedo Shaft
614 lot & Rev. Cear SelectorRod 814 Speedo bush
Mainshaft Group 615 Ball 815 Ring
616 PressureSpring 816 Self Locking Nut
401 Circlip 617 Detent Plunger 817 Cover
402 SynchroBing 618 Casket 818 Gasket
403 SynchroRing 619 Gear changeextension 819 Set Screw

24
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Fig.30-6
X]l. List of ZF-Service-Stations
GERMANY Telephon€ Teler

B.rlin ZahnradfabrikFriedrichshafenAG. Werk Berlin 030/4rr209r 0t 81 789

1000 Berfin 26. Wilhelmsruher Damm 2311245,Postfa.h 24 zfbln d
EL
Blelefeld ZF-KundendienstHannoverGmbH 0521t200071 09 32 596
ZweigstelleBielefeld t200072 zfbie d
EL 4800 Bielefeld,Fleichenberger
Str. 42 1200073
Dglm6nho13t RichardUrbanek Ing., GmbH & Co. KG 0422t I60025 02 49 285
ZF-Kundendienst /60026 zfkdd d
2870 Delmenhorst, Fiedeweg 280, Postfach 74

Dortm!nd ZahnradfabrikFriedrichshafen
AC. 023r/8r 2891 0€227 @2
KundendienstDortmund 181A441 zfdo d
EL 4600 Dortmund, BornstraRe207

Ecagn Gustav Hennig & Co. GmbH.,ZF-Kundendienst o21411221951 08 57 785

4300 Essen-Buhr,KruppstraRe 74, Postfach 673

Franklun FranzBucherKG, ZF-Kundendienst 0611/415021 0417 272

6000 Frankfurt1/Main. HanauerLandstraBe336 buffm d

Frlcdrldr!hatcn ZahnradfabrikFriedricfi
shafenAG, 075411a4-1 07 34 363
Kundendienst - Werk ll zfkd d
EL 7990 Friedrichshafen/Bodensee,
Postfach307

Fulda ZF-Kundendienst Fulda 0661/3028 M9756

Arnold FikentscherKG, /3029 erzll d
EL 6400 Fulda, Frankfurter StraBe 45

Hamburg BichardUrban€k Ing., GmbH & Co. KG 040/6932041 02 r4 907

ZF-Kundendienst
2000 Hamburg70, AngerburgerStraRe 18

Hannovcr ZF-KundendienstHannoverGmbn 0511/456045 0 92 21 5 1

3000 Hannover-Linden,
Bernhard-Caspar-Straoe
7, /456046 zfhan d
EL Postfach 21265 /456047
K.'3.1 ZF-Kundendienst Kassel,Arnold FikentscherKG 056r/5 2141 09 97 25
3501 Sandershausen-Kassel, BettenhauserStr. 39, Postfach120 152142 ahfk d
EL (on the haghway tributary road Kassel East, entrance t5 2143
Osterholzstreet.)

Katln Gerhardvon Umbscheiden,ZF-Kundendienst /5510r1

0221 0888r01r
5000 K6ln 30, Ehrenfeldgiirtel
112l122 umoao

Mannhelrn FranzBu.her KG, ZF-Kundendienst 0621/372066 04 63 236

6800 Mannheim 1, WaldhofstraBe 82-84, Postfach 369 frabud

Miindr6n Beis6barth& MLilleroHG. ZF-Kundendienst 089/93105r 05 22 793

8000 Mrinc$en 80, Zamdorfer StraRe 90, Postfach 8002 60 bei d
EL (on the high road to the airport Riem)

Niimberg Lang GmbH & Co. KG, ZF-Kundendienst 0 9 r1 / 67 01 r 06 22 867

8504 Stein-NUrnberg.
Bogenstra[Je
3 1 6 7 0t 2 zfnbg d

Paosau ZahnradfabrikPassauGmbH, Kundendienst 0851/207r 05 78 49

8390 Passau 2, Postfaci 1, Grubweg zetpe d
EL

S.arbriid(cn Erich Bonn GmbH, ZF-Kundendienst 068r/6 6161 04 428 959

6600 Saarbriicken 3, Mainzer StraRe 269, Postfach 733 /6 8035 DOnno
Workshop and Spare parts storel 0681/66161 04 428 605
6604 Galdingen.
SaargemunderStraRe48 /6 80 35 DOnno

Sdrwebisdr Gmiind Zahnradlabrik FriedrichshafenAG. 071711601-1 07 248 825

Werk SchwabischGmUnd,Kundendienst zfgk d
EL 7070 Scfiwiibisch Gmund, Graf v. Soden Str. 5-9, Postfach 119

Tri6r ErichBonn GmbH,ZF-Kundendienst 0651/42815 04 ?2 634

EL 5500 Trier-Euren,lm Speyer 4 h2@2
'W = Workshop
EL = Sparepartsstore
ZF-Service-Stationsoutside Germany
EUROPE lolophono Tolor

Au.trfa Zahnradfabrik FriedrichshafenGes. m. b. H. Wien 02221671548 Ott 291

W ZF-Kundendienstfur Osterrei.h zfwien a
EL TriesterStresse 134-136. 1232 Wl€n.ln2erldorf
Cables: ZF-GetriebeWien
B.lgfun Agence ZF-Service S.P.B.L. 021724064 22 451
W 1440,Chaussde de Wavre, 1160 Bruxellcr-Audorgh.m 1727032 zetefservis bru
EL Cables: Zetefservis Bruxelles
Donmark Skandia-Motorimport, SjgellsndA/S 01/451599 2i 444
ry Lf""selager 21, 2600 Glo.trup/Kobenhavn skaglo dk
EL C6bl€s: Skandiamotor
Branch:
W Fr. l€ns€n A/S
Skandia-Motorimport, 0a1132244 69771
EL Egholmsgade7, g(x)oAalborg, P.O.Boxll7 skamo dk
Flnland Atoy OY, Industrydepartment 6?337, 12555
W Lauttasaarentie54, P.O.Box 10137,00200 Hel.inki 20 atoy sf
EL Cables: Atoy Helsinki
F6ncc ZF-France S.a.r.L. 6 86 68 40 26 954
W Bue de Villeneuve3/11, 94533Rungi. Sillc zl te
EL
w o.M.A.-zF 890239 4 34 6 3
EL Zone Industrielle fra
28. 4Cne Avenue, 13700Vitrollo.
W EtablissementCauchois 53 93 21
EL 150,Bue d€s Marquillies,59013Lillo Codox
W Str€sbourgGadouis,S.A. 333838 87 083
EL l-3, Bue des Pompisrs,673q)Sdtlltlgh.lrn
Post adresse: 9.P.27,67042 StrasbourgCeder
Groece U. J. Phostiropoulos& Cia. E. E. 520/.23 216360
W Leoforos Athinon 26, Ath€n 2m, P.O.Box 1122 52 05 42 fost gr
EL Cables: lngphostiAthen 533910
Branch:
EL U. J. Pho6tiropoulo6& Cia. E. E. 51 3313
MonastiriouStr. 61, Tho$alonlki 51 64 06
Gr.at Britain ZF Gears (Great Britain) Ltd. 0602/25 35 50 377 062
W Lilac Grove, Beeston, Nottinghan NG 9l QX 1221865 transgear nottm
EL Cables: TransgearNottm. 1221a66
Italy S.A.|.M. o2l38 15 70 33 393
W S.p.A.SviluppoApplicazioniIndustrialiMeccani.fre l3A44A1 saimspa
EL Via Leon Battista Alberti t0. 20149 Mllano
CablesrSviluooosaimMilano
Spare parts store: 31 51 93
Servicio Assistenza e Ricambi 34 47 43
Workshop: 9 04 60 15
Officina di Assistenza
20090 LiBiro/Milano, Nuova Strada Flivoltana
Branch:
s.A.r.M.
S.p.A. Sviluppo Applicazioni Industriali Meccanidte 578 440
Viale Aventino 32la, 00.|53 Fona
W CETRULLO VITTORIO 60 335
EL Viale Pindaro, 45---65,65100 P.rc.ra
W SCARPAZZA BALDO 66 11 76
EL Zona Industriale 90 strada, 18, 35ldt Padoya
W Autoriparazioni
BOMBARA 3217 1A
EL Strade del Barocchio. 39. 10136 Torino
W IGNAZIO ZAPPA S.r.l. 4233 A1
EL Circonvallazione Nomentana,474. 00l6il Bona 42 53 59
w Bossr BoMANo 26s47
EL VialeTrento.204,36100Vlcsnza
W AVLES-SELVA 53M 15
EL Via E. Mattei,50,Stradaper Ravenna,,Ol3,l Bologn.
w FADES 33 0042
EL LargoS. Mariadel Pianto,40/41,8|tlilit Napoli 51576l

32
 T.lcphonr Tcbr

w RICCI FRANCO 9fi35

EL Vla Rusqslll,50, 47qfa S. Pbro In B|gno (Forll)
w AUTOCAF 43250
EL Vla Au|llla Owst. 8l/a. 5al0 Mr.. 4 39 /tg
w SAPIENZALUCIANO 2t 2a46
EL Vla Golso Blanco.28. 051216t nh
w LONGOROCCO 2466 34
Vla S. Csterina,2 (FioneS. Glorglo),70l2a B.rl
w MONACHESI& MOZZONI 2a44
Via T6r.la, 4, 6:1100lLc.r.tr
w VALLEBONAS.p.A. 23864
EL C.P.2Ol (andrqper GM),OI00 C.glld

lugo.lavla Autocommgrcg
w Zastopnlako Podlotle 06r/32 30 46 3r r8g
EL TrdlnovaUlica ,1,Et00Oqub[.n., P.O.Box422 31 299
Cobles:Autocon€rcoLlubllana Ecllb yu
Workshoo:
G.al-Avtoobnova 06t /34 20 | 0 31 427
TitovaUlica 136,61000qubU.n|' P.O.Box280
Cablse:Gral LJubllana
Branch:
Autocomm€rcg 0t 14(}2 fi 328
EL ZEetopnlakoPodretle 0t 1421 acbgd yu
Katanlcova18, B.og.d 0t t4 36
Ndh.rl.ndt TodrnlsdrBureauM€dia B.V. 070/9825 20 3t 087
w Trqubatrsat31, 2100 Bl.wllk CZ-H),Postbus2 mqdia nl
FI

Norway A/S Auto Supply Co. 0211324g fi 629

w Ringedkevn,
243,Odo l, l3l4 Skui aaEon
EL Cabl6s:AutoBupply
Portug.l parEVelculoa,Lda,
SIPAVEL,Soclededsdo lsolamsntos 53 79 53 1 22 5
Rua RamalhoOrtlg6o,+rldl stt 86 05 fmtl p
Ll.bor I 56 28 40
Cablee:SIPAVELLISBOA 56 37 59
S0cdcn K.G.KnutssonAktiobolag 08/252660 t5 04
w Ulvslndevdg€n146,t6lit Bronn. | | /Stodrholrn,P.O.BoxI l0@ kgk s
EL Cabl6s:KnutlngStockholm
Brandls:
w Ruekvtd.rEgrtan 10, /m77 Gdbborf 48, P.O.Box48019 03r/53 04 60 20 955
EL kgk I
w Koepmengaten29, ESiI't Sond|vdl 060/!2 t9 45
EL
w Mumansgalan112,zlZE il.|fr 040/9323 45
EL
SI|E rl.nd SKAG- Steuerungenund KupplungrnAG 0t /50 50
w Androaestraoo17, m50 Zorldr P.O.Box636
EL Cableo: SKAG Zorlcfr
Spdn to. g..r borat grrr drlv|t, .d.r, 9..8,
loddng dlti.rnd.b |nd punp.:
w l.S.A. Industrl€8Avlscl6nda Subeldlerlae,
SA. 3528(D 72113
Apartado 250, Canetora d6 Carmona,Scvlll. 35 29 00 lga g
PollgonoIndustrlald€ Calong6
Cablss:ISA Sevllla
for d..rlng grrn whh pump. .nd .rhaurt bnkat:
w IMENASA 25fi @ 367t8
EL Indu8tdasMstdllcasde Navarra,S.A. gln o
ApartadoCor.eosli|o, CanoterEdo BaratlainlT, Pamplon!
Cables: IMENASA

Tr|rkly ArsimldisMusss€asaFotomobll.Malz€meslTlcErotlTA.S, 447460 22585

w lttrnbul-lbr.kdy
Fue Okcu MusaCadd€sl$/5'1, P.O.Box8112, ardr tt
EL C8blosrArchlmldislstEnbul

3:'
 AFEICA Tclcphonc Tcler

lvory Coa.t SociCtd d lmportataonde PadcesAutomobiles 32 30 18 698

w S.A.B.L.(S.|.P.A.) 3s s7 s0
EL B.P. 2171,34, Autorout€do lAeroporl
AbldJan/C6te d'lvol.c
Gabon ^,,,--,, -,,J EasternTradingCompany(Hamburg)G.m.b.H. 04 /34901 2125,23
;::::-' Krppingstr. 6, 2qr0 H.nburg 13 aerco d
Post adre6se: Hamburg 1, P.O.8ox fl4
'Cliiiliiiii-"i
iJiJirr" ra,"a
Rcoubtic cables,Ethrope
Hamburg

Company in chargeof 6ervice:

Gabon Hatton& CooksonMatforce,B- P. No.75
W Libr.Ylll., (F.p|lblic of cabon)
EL

Camcrun Ciacam Matforce, B. P. No. 4025

W Dou.la, (Fode.al R.publlc of Camorun)

s. c. K. N. conso Matforce, B. P. No. 6s2

".";:W Pointe Noirs, (R.publlc ot Congo)

B.public Tchad G. B. Ollivant(Congo)Ltd., P. B 712

W Avenue du Gen6ral de Gaulle,
EL Forl Latny, (Republic of Tdrad)

Ccntr.l Afric.n R.public S. C. K. N- CA

W B. P. No. 799 et 809
EL Bangul, (C6ntral Afrlcan Republic)

R.public of South Afrlca TRADE BELATIONSINTERNATIONAL (Pty.) Ltd. 834-4559

Rhod..ia P-O.Box 2259, lohenn.rburg (R.publlc ol South Atrics)
W Office and Workshoo:
EL P.O.Box4007,BosworthStreet.
Al.od€/Albonon,Transvaal,(Republicof South Af.ica) 869-82 16 43-0927
Cables: ZAFBUBG

South-We3t-Afrlca O&O Electricand Engineering(fiY) Ltd 2-6650 56465

W P.O.Box 5056, Krupp Str. 33. WtndhoGk/S.W.A.
EL

AMEBICA

Aig€ntin. Rehm S. C. P. A. 791-4088

W Avonide Maipi 3146/50,Casilla de Correo No. I 797-5394
EL Ollvor (Prov. BuenosAires)
Cables: ZETAEFE-SERVICE Olivog

Brazll ZF-DO BBASIL,S. A.

W Caixa Postal 1626. S5o P.ulo,
EL Work6 and Administrationl
Bua Senador Vergueiro, 428, 09500 Sao Caeteno do Sul 42-2122 023 865
Cablos: Ultramaran-Seo-Paulo zf sco

Ghllc RobertBoschde Chile,Equiposy Maquinarias, S. A. 25 96 48 03 53

W Av. San Eugenio68, Santiagodc Chll., Casilla832 259691 emasa sgo
EL Cables: CHILEBOSCH 25 97 93

Colombia AutomotoraLEMKO, Ltda. 37 27 16

EL Apartado A6reo 4989 37 46 83
Carrera 30/15-16,Bogoti D. E.
Cables: LEMKO
Branch:
Carrera5/24-10.Cali 77 1563

EL Safvador Servicio Centroamericano ZF, S.A. 21 3217

Guatamal. Boulevard Venezuela No. 1153
Hondura. San Salvador / El Salv.dor, C.A.
Nlc.r.gu. Cables: ZETAFEZA
Co.ta Rica
P.ru Tecnica lmport. S. A. 32 30 88
EL Llma, Palca201-Casilla 171
Cables: TECNICAIMPORT

V.d.zueb SEBVEPESA,Servicaosde VehiculosPe6ados.S.A. 342355 21 136

W Av€nida R€p0blicaDominicanaBoleito Norte. 34 24 55 zico servepesa
EL C.r6c.. l0?
Cables: Serveoesa

34
 ASIA T.l.phon. Tolcr

lnn G. Reza Sanaty, 3S38 39

w Ave. Saadl,PassagsSaadlNo. l l, Trh.r.n
EL Cablss:SonesadlTehran
Workshop: 95539l
Ave. GhazvlnEetegahoSoloymanlysh No. l42fl,|:}l, Teh€rqn

lordrn Ad66bM. SabbaghBros.Co.,MotorEnglnsera& Agentg 2 21 95 Oftics

w P.O.Box868.Ann.n 2 3089 Workohop
EL CEbles:AMS-Amman
Kur.h GLOBE.CommsrclalEstabllshmont 429829
w P.O.Box 4580, ltuwelt/Anble ia l0 73
FI Cables:Globecom
Lb.non Ado€bM. Sabbagh,Motor Englnsers& Agent8, 41275
FI P.O.Box3694,Bcyrourh
Cablea:AMS-Beyrouth
s.udl Ar.bl. Dlesel-Elqctrlc
Conpany 22222
w P.O.Box l(Xg. ,rd&htsludl Ar.bh
Cables:Delcent,laddah
Blandrgsl
P.O.Box297.J.ddlhrsludl Ar.bh 22122
EL C6bl6s:Dios€ctrlcroddah 221?3
w P.O.Box86, myldhrsludl Anbla 22222
EL CEblsB:Dlesoctlc Rlyedh 225?2,
P.O.Box24, Dlmn.mr8ludl Arrbl. 22 444
FI Cablos:DissectrlcDammam
'| 84 05
strl. AdoebM. Sabbagh,Motor Enghsers& Agente
EL B.O,Box743, D.m... .
CableE:AMs-Damascus

AUSTRALIA

VlcbrL TranspsqLlmltsd 3t4@22 30 225

w 570, Geelong Road, BrooklFr Cboum., vlc 3025 transp€c aa
FI ?.O.Box223,Footscray/Vlc.3011
Cablos:TransmotorMslboume
Brandrss:
W..irm-Audrdl! l,|4, W6lahpoolRoad 68 32 36 9:] 009
lryd.hpoolrP.t||r, w. A 6106
Cablsg:TrangmotorP€rth
Sou F^u.trdl. 5(l9. Grsnd Junctlon Road 626r 15 82 891
w wlngfr.ldr^dcldd., S. A. 5lrl3
Cables:TransmotorAdolelde
N.w Soulh W.lor '180,SllverwatorRoad 6482892 2l il43
w Aubunrsydrry, N. S. lY. 2l+l tranap6c
FI Cablss: Transrptor Sydney

Q0..ndrnd l&Il, lpswldr Rold 474!i 3!i 41 296

w Ro*ltrrBdtb.n., Qld. /tl6
EL CablsE:TrsnsnotorBrlsbang
T!.n.nh TggmsnlsTranspecLlmibd 3120 18
w G. P.O. Box 90
EL Llr|nccdoo t25O

35