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16 S 151
8 S 151
1315 751 101d
 16 S 151 / 8 S 151 Contents

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Contents ......................................
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...................... 1-01
Preface......................................................................................
Preface.............................................................................................................................
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............... 1-03
General information .......................................................................
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......... 1-04
Safety instructions..............................................................
instructions....................................................................................................
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...................... 1-06
Tightening torques for nuts and bolts.............................................
bolts....................................................................................
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......... 1-07
Spring table ........................................................................
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...................... 1-08
Adjustment data .......................................
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......... 1-09
Special tools ......................................
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............... 1-14
View of transmission..........................................................
transmission................................................................................................
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...................... 1-16

1 Removing components/range-change ........................................................................................ 2-01

1.1
1.1 Plast
Plastic
ic pipe
pipess ....
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.... 2-01
2-01
1.2
1.2 Outp
Outputut flan
flangege ....
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2-01
1.3 Cove
Coverr ......
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..... 2-01
2-01
1.4
1.4 5/2-
5/2-wa
way y valv
valvee ....
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.... 2-02
2-02
1.5
1.5 Shif
Shiftt cylind
cylinder er for rang
range- e-ch
chan
ange ge .....
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.. 2-02
2-02
1.6
1.6 Hous
Housin ing/
g/rarang
nge-e-ch
chan ange
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.. 2-03
2-03
1.7
1.7 Plane
Planett gear
gear train
train with
with syncsynchr hron
onizizer.
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.... 2-04
2-04
1.8
1.8 Asse
Assembmbli ling
ng plan
planet et gear
gear trai
trainn with
with range
range-c -cha
hang ngee synch
synchro roninize
zerr ....
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.... 2-06
2-06
1.9
1.9 Assem
Assembl blin
ingg rang
range- e-ch
chanangege /hou
/housinsing/g/ou
outp tputut flan
flange ge/p /pisisto
ton n ....
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.. 2-09
2-09

2 Removing components from centre housing ............................................................................. 2-12

2.1
2.1 Spli
Splitte
tterr (GV)
(GV) cylin
cylinde derr ....
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2-12
2.2
2.2 Shif
Shiftt hous
housin
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g ....
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.. 2-12
2-12
2.3
2.3 Shif
Shiftt hou
housin
sing,
g, fric
frictio
tion-
n-op
optim
timiz ized
ed vers
versio ionn ....
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2-16
2.4
2.4 Shif
Shiftt mech
mechananism
ism/s /sele
elect
ctor
or pat
patte terns
rns ....
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.... 2-21
2-21

3 Removing components from clutch housing .............................................................................. 2-24

3.1
3.1 Rele
Release
ase fork
fork ....
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.... 2-24
2-24
3.2
3.2 Conn
Connececti
tion
on plat
platee with
with int integ
egra
rall pump...
pump..... ....
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2-25
3.3
3.3 Clut
Clutch
ch hous
housin
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g ....
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.... 2-26
2-26

4 Removing components ...........................................................................

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...................................... 2-26
4.1
4.1 Remo
Removi ving
ng comp
compon onenents/
ts/cl
clututch
ch hous
housin ingg ....
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2-26
4.2
4.2 Spli
Splitt
tter
er shif
shiftt rail
rail /cent
/centre re hous
housin ingg ....
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2-26
4.3
4.3 Remo
Removi ving
ng shaf
shafts..
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.... 2-27
2-27
4.4
4.4 Remo
Removi ving
ng comp
compon onenentsts/ce
/centntrere housi
housing ng ..........
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2-27
4.5
4.5 Inpu
Inputt shaf
shaftt ....
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.. 2-28
2-28
4.6
4.6 Main
Mainsh shaf
aftt ....
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.... 2-30
2-30
4.7
4.7 Assem
Assembl blin
ing g sync
synchr hrononizizer...
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2-37
4.7.1
4.7.1 Version
ersion ZF-BK....
ZF-BK....... ......
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2-37
4.7.2
4.7.2 Version
ersion ZF-D
ZF-D ......
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... 2-38
2-38
4.8 Laysh
Layshaft...
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... 2-39
2-39

1-01
 Contents 16 S 151 / 8 S 151

Page

5 Installing components .........................................................................

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... 2-41
5.1
5.1 Cent
Centre
re hous
housin
ing
g ....
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.. 2-41
2-41
5.2
5.2 Clut
Clutch
ch hous
housin
ing
g ....
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.... 2-41
2-41

6 Synchronizer/wear limits .....................................

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................................. 2-42
6.1
6.1 Determ
Determin
inin
ing
g wear
ear limi
limitt (exc
(excep
eptt 1st
1st and
and 2nd2nd gear
gears)s) ....
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.... 2-42
2-42
6.2
6.2 Determ
Determin
inin
ing
g wear
wear limit
limit (1st
(1st and
and 2nd2nd gear
gears).s)...
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.. 2-42
2-42

7 Adjusting mainshaft ........................................................................

...............................................................................................................
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...... 2-43
7.1
7.1 Sele
Select
ctin
ing
g thrus
thrustt wash
washer
er and
and shim
shim,, straig
straight ht-c
-cut
ut vers
versio ion...
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.... 2-43
2-43
7.1
7.1 Sele
Select
ctin
ing
g thrus
thrustt wash
washer
er and
and shim
shim,, heli
helicacal-
l-cu
cutt vers
versioion n ....
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.... 2-44
2-44

8 Installing shafts .....................................

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.......... 2-45
8.1
8.1 Insta
Install
llin
ing
g inpu
inputt shaf
shaft,t, main
mainsh shafaft,
t, lays
layshahaftft and
and shif
shiftt rail
railss ....
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.... 2-45
2-45

9 Splitter shift fork ..........................................................................

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  .............................................................................
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......... 2-46
9.1
9.1 Adju
Adjust
stin
ing
g shif
shiftt fork....
fork......
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.. 2-46
2-46

10 Clutch housing/centre housing ........................................................................

...................................................................................................
........................... 2-48
10.1
10.1 Fitt
Fittin
ing
g clutch
clutch hous
housin
ing
g to centre
centre hous
housiningg ....
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.... 2-48
2-48

11 Adjusting shafts ........................................................................

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....................................................
.............. 2-49
11.1
11.1 Input
Input shaft
shaft ......
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..... 2-49
2-49
11.2
11.2 Laysh
Layshaft...
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... 2-50
2-50

12 Fitting clutch housing components ............................................................................................. 2-51

12.1
12.1 Conn
Connecectio
tion
n plat
platee with
with inteintegra
grall pump...
pump..... ....
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.. 2-52
2-52
12.2
12.2 Releas
Releasee fork
fork ......
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......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
.....
.. 2-53
2-53

13 Fitting centre housing components ............................................................................................. 2-55

13.1
13.1 Rever
Reversese idler
idler gear/r
gear/rev evers
ersee idler
idler pin.....
pin..............
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
..... 2-55
2-55
13.2
13.2 Cylind
Cylinder..
er.....
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
..... 2-55
2-55
13.3
13.3 5/2-w
5/2-way
ay valv
valvee ......
.........
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
... 2-56
2-56
13.4
13.4 Comp
Compre resse
ssed d air
air test
test for
for pisto
piston n and
and split
splitte terr cyli
cylind nder.
er.......
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
.. 2-56
2-56
13.5
13.5 Inject
Injection
ion pipe
pipe ......
.........
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
.....
.. 2-57
2-57

14 Fitting complete range-change ........................................................................

...................................................................................................
........................... 2-58

15 Fitting components.........................................................................
................................................................................................................
..............................................
....... 2-60
15.1
15.1 Shift
Shift housing
housing ......
.........
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
..... 2-60
2-60
15.3
15.3 Plastic
Plastic pipes
pipes ......
.........
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
......
.....
.. 2-60
2-60

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

1-02
 16 S 151 / 8 S 151 Preface

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

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

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

Service points equipped by ZF Friedrichshafen AG all over the world offer you:

1. Well-trained personnel

2. Specified equipment, e.g. specialized tools

3. Genuine ZF spares, to our latest specifications

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

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

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

ZF FRIEDRICHSHAFEN AG

Friedrichshafen Division
Service

1-03
 General Information 16 S 151 / 8 S 151

Description of transmission

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

16 S 151 and 8 S 151 transmissions main components:

- 4-sp
4-spee
eed
d secti
section
on wit
with
h reve
revers
rsee gear 
gear 
- rear-
rear-mou
mounte
nted
d range-
range-cha
change
nge ofof planet
planetary
ary desig
designn
- front-
front-mou
mounte
nted
d integr
integrate
atedd splitter
splitter grou
group
p (not
(not in 8 S 151)

ZF Friedrichshafen AG offers the following options with these transmiss ions:

- NMV
NMV 221,
221, eng
enginine-
e-de
depe
pend
ndenentt PTO
PTO
- torq
torque
ue con
conveverte
rterr clut
clutch
ch (WS
(WSK) K)
- further
further engine-dri
engine-driven ven ZF PTOPTO (NMV) together
together with the torqu
torquee converter
converter clutch
- vario
various
us clutch
clutch-de
-depen
penden
dentt ZF PTOs
PTOs
- drive
drive for
for emerg
emergencency y / dual-ci
dual-circu
rcuit
it steeri
steering
ng pumps
pumps
- separat
separatee heat
heat exchan
exchangerger for
for extre
extreme
me appli
applicat
cation
ionss
- ZF Intarder  
- ZF ES 2 shif
shiftt sys
syste
tem
m
- silent kit

Repair manual

NOTE: If clamping fixture 1X56 137 944 is used for dismantling

dis mantling the transmission, remove the reverse gear cover 
 before attaching the clamping fixture.
When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set.
Then install the reverse idler gear pin.

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

!ENVIR
ENVIRONMONMENT ENTALAL HAZARD
HAZARD !
Lubricants and cleaning agents must not be allowed
allowed to enter the ground, the water table or t he sewage system.
• Request safety information for the products concerned from from your local environmental
environmental protection
authority, and follow any instructions herein at all times.
• Alway
Alwayss collect used
used oil in a suitably
suitably large
large containe
containerr.
• Always
Always dispose ofof used oil, clogged
clogged filters, lubricants
lubricants and cleaning
cleaning agents in accordance with
environmental protection laws.
• Always
Always observe
observe manufacturer
manufacturer instructions
instructions when dealing with lubricants
lubricants and cleaning
cleaning agents.

NOTE: Additional removal

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

1-04
 16 S 151 / 8 S 151 General Information

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

Layout of repair manual:

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

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

Directions for removal and assembly, general work instructions

This repair manual is based on the steps necessary for the complete removal of transmission components and their 
subsequent reassembly.
reassembly. When circumstances require, the assembly procedure for certain components is described 
immediately after the removal procedure. Such cases include the section on the “mainshaft and layshaft’’,
layshaft’’, in which
assembly instructions are given after removal instructions so as t o ensure that only fully repaired components
 proceed to the complete assembly
assembly phase. This procedure reduces the risk of mixing up individual components and 
shortens the overall
overall assembly phase.

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

Specified ZF special tools must be used.

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

Carefully remove
remove old sealing compound and gaskets. Check for blocked of lubrication oil bores, grooves
grooves and pipes.
There must be no build-up of deposits, foreign matter or preservatives. This is especially important in the case of 
new components.

It is impossible to avoid damaging some components during dismantling; these must always
always be renewed ; e.g.shaft
seals, O-rings, grooved rings, flange packing, protective caps etc. Components such as roller bearings, thrust
washers, synchronizer parts, etc., which are subject to normal wear during operation, must be checked by a
specialist to determine whether they can be reused 

Gaskets must be fitted dry, i.e. free from oil and grease. Sealing faces without gaskets must be sealed using a
 plastic-type, heat- oil-resistant sealing compound (e.g. WEVO-L
WEVO-L 100 A).

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

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

1-05
 Work Safety 16 S 151 / 8 S 151

Important work safety notice:

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

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

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

The following safety instructions appear in this manual:

NOTE Refers to special processes, techniques, data, use

of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional

working practices could damage the product.

! DANGER This is used when lack of care could lead to

serious injury or death.

NOTE
Read this manual carefully before star ting any tests or repair work.
After completion of repair work and testing, skilled mechanics must satisfy themselves that the product is
functioning correctly.
correctly.

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

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

Always follow the working steps as described in the text.

1-06
 16 S 151 / 8 S 151 Tightening Torques

Tightening torques for bolts and nuts from ZFN 148

This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934.

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

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

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

Metric coarse pitch thread Metric f ine pitch thread

Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for  
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
 Nut 8 10 12 Nut 8 10 12

M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 5 5.5 8.1 9.5 M 9x1 36 53 62
M 6 9.5 14 16.5 M 10 x 1 52 76 89

M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145

M 12 79 115 135 M 14 x 1.5 135 200 235

M 14 125 185 215 M 16 x 1.5 205 300 360
M 16 195 280 330 M 18 x 1.5 310 440 520

M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1.5 430 620 720
M 22 530 750 880 M 22 x 1.5 580 820 960

M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850

M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500

Edition: August 1991

1-07
 Spring Table 16 S 151 / 8 S 151

Part number Installation point No. of Wire diam. Spring diam. Untensioned
coils in mm in mm length in mm

0732
0732 04
040
0 630
630 Shiftt mec
Shif mecha
hanism:: on shift shaft
nism 6.5 2.4 39.6 89.9
(depending on version)

0732
0732 04
040
0 985
985 Shiftt mec
Shif mecha
hani sm:: spherical
nism 6.5 2.0 14.8 23.4
roller for detent part or reverse
gear interlock 
(depending on version)

0732
0732 04
040
0 986
986 Shiftt mec
Shif mecha
hani sm: spherical
nism 5.5 2.25 14.8 21.6
roller for detent part or reverse
gear interlock
(depending on version)

0732
0732 04
040
0 984
984 Shiftt mec
Shif mecha
hanism:: reverse
nism 9.5 1.4 9.4 23.3
gear interlock
(depending on version)

0732
0732 04
040
0 736
736 Shiftt mec
Shif mecha
hanism:: for detent pin
nism 13.5 1.6 9.8 36.0
and locking pin interlock 

0732
0732 04
040
0 40
409
9 Synchr
Synchron
oniz
izer
erss 12.5 1.4 6.65 23.7
input shaft and mainshaft

0732
0732 04
042
2 12
126
6 Dete
Detent
nt piecee (compression spring)
piec 9.5 1.0 9.4 25.0

0732
0732 04
042
2 365
365 Dete
Detent
nt piecee (compression spring)
piec 5.5 1.7 20.44 31.49

0732
0732 04
042
2 366
366 Dete
Detent
nt piecee (compression spring)
piec 4.5 1.5 15.03 15.6

0732
0732 04
042
2 400
400 Dete
Detent
nt piecee (compression spring)
piec 10.5 2.25 15.5 39.7

0732
0732 04
042
2 401
401 Dete
Detent
nt piecee (compression spring)
piec 12.5 1.5 10.1 36.0

1-08
16 S 151 / 8 S 151 Adjustment Data

Description Tolerance Measuring device Remarks

01. Axial play

play on layshaft
layshaft 0.0 - 0.10 mm Depth gauge or dial Centre bearings (zero play)
gauge and measure play. Adjust
using shims on roller 
 bearing outer race on output
end.

02. Combined
Combined axial
axial play
play of  0.0 - 0.10 mm Depth gauge or dial Centre bearings (zero play)
mainshaft and input shaft gauge and measure play. Adjust
using shims on roller 
 bearing outer race on input
shaft.

03. Axial play

play / prestres
prestresss of  - 0.05 to + 0.05 mm Micrometer or feeler  Always use correct tool.
split ring on input shaft gauge
and mainshaft (only in
older version)

04. Insertion
Insertion depth
depth for shaft
shaft 12.5 + 1.0 mm Depth gauge and/or  Measure depth of insertion
seal in output flange drift 1X56 137 124  between outside of cover 
cover  and face of shaft seal. If 
drift is used with ring, depth
is automatically given (must
 be flat).

05. Axial play

play on ball
ball bearing
bearing 0 - 0.10 mm Depth gauge/sliding Adjust using appropriate
in cover (range-change) caliper  shims in cover.

06. Axial play

play on helical
helical gear 
gear  Min. 0.20 mm Depth gauge or feeler   Not adjustable. Measure as
on input shaft gauge check only.

07. Axial play

play on helical
helical Min. 0.20 mm Depth gauge or feeler   Not adjustable. Measure as
gears on mainshaft gauge check only.

08. Axial play

play on 4th-speed 
4th-speed  Min. 0.05 mm Depth gauge or feeler   Not adjustable. Measure as
helical gear  gauge check only.

09. Axial play

play on circlips
circlips on 0 - 0.05 mm Micrometer or feeler  Use appropriate circlip.
layshaft and mainshaft gauge

10. Axial play

play of reverse
reverse idler 
idler  0.4 - 1.15 mm Feeler gauge  Not adjustable. Measure as
gear  check only.

1-09
 Adjustment Data 16 S 151 / 8 S 151

Description Tolerance Measuring device Remarks

11. Permitted
Permitted axial
axial play on 0.4 to 1.30 mm Feeler gauge Tolerance includes permit-
 planet gears in planet ted wear on thrust washers.
carrier  If wear limit exceeded 
exchange thrust washers

12. Wear
Wear limit
limit for  Feeler gauge Exchange synchronizer ring
synchronizer ring and  and/or clutch body if 
clutch body, measured  dimension too small
 between flat surfaces of 
ring and body with cones
firmly nested together.

4-gear section and

splitter 0.80 mm
Range-change 1.20 mm

13. Wear limit

limit for
for 1st/2nd 
1st/2nd  1.5 mm Feeler gauge Exchange intermediate ring
gear synchronizer parts, and/or outer ring and inner 
measured between outer  ring if wear limit is
ring and clutch disc, excluded.
measured with cones
nested firmly together )
and force F = 50 N
applied on the outer ring.

14. Max.
Max. permi
permitte
tted
d play
play on
on 0.6 - 1.2 mm Feeler gauge Exchange if play is
fulcrum pads in sliding excessive
sleeves

15. Adjustment dimension for  94.0 mm

Adjustment dimension Depth gauge  Nominal dimension
dimension between
between
splitter   piston and mid-housing
mid-housing
shift fork  sealing face without gasket.
Fulcrum pads must have
 play of
of min. 0.10 mm
mm
upwards and downwards.
Tightening torque for grub
screw: 60Nm

16. Adjusting
Adjusting mainshaf
mainshaftt and  32.20 - 0.5 mm Depth gauge Measured between upper 
determining thickness of  edge of clutch body with
shim and ring (in straight- ring inserted and mid-
cut version) housing with gasket
attached. Select appropriate
ring to ensure nominal
dimension (see table)

1-10
16 S 151 / 8 S 151 Adjustment Data

Description Tolerance Measuring device Remarks

Selection of ring and  Sliding caliper  Ring Shim

shim
3.6 mm 7.9 mm

4.0 mm 8.3 mm

Table shows which shim is

correct for which ring

17. Adjusting mainshaft and  + 0.07 to - 0.08 mm Depth gauge Measure and determine
determining thickness of  (Shim) thickness of shim first.
ring and shim (in helical- 4.6-0.4 mm Then, measure and select
cut version) (Ring) ring.

18. Temperature
Temperature for shrink-
shrink- 160 - 180 °C Temperature probe Gears and shaft seats must
fitting helical gears onto  be free of oil and grease
layshaft during assembly

19. Tightening
Tightening torque
torque for  10 Nm Torque wrench
 breather 

20. Tightening
Tightening torque
torque for
for 30 Nm Torque wrench Use new seal rings
M12 x 1.5 screws in
housing

21. Tightening
Tightening torque
torque of  35 Nm Torque wrench Use new seal rings
union screws for plastic
 pipes

22. Tightening
Tightening torque
torque for  50 Nm Torque wrench Use new seal rings
detent plungers

23. Tightening
Tightening torque
torque for  50 Nm Torque wrench Use new seal rings
 pressure switch/impulse
sensor 

24. Tightening
Tightening torque
torque of M12
M12 60 Nm/120 Nm Torque wrench Fit new retaining plate.
 bolts for output flange (chap. 1.9.1) Use Loctite No. 262.

25. Tightening
Tightening torque
torque for  4-gear
4-gear secti
section:
on: 50 Nm Torque wrench
shift fork grub screws Splitter: 60 Nm

1-11
 Adjustment Data 16 S 151 / 8 S 151

Description Tolerance Measuring device Remarks

26. Tightening
Tightening torque
torque for
for 140 Nm Torque wrench Clean magnet and fit new
M38 x 1.5 magnetic seal ring
screw

27. Tightening
Tightening torque
torque for  86 Nm Torque wrench Use new bolt and washer.
locking bolts on reverse
idler pin
New version with slotted 
 pin

28. Tightening
Tightening torque
torque for  150 Nm Torque wrench Use new locking nut
locking nuts on range-
change and splitter 
 pistons

29. Tightening
Tightening torque
torque for
for hex 50 Nm Torque wrench
 bolts between clutch
housing and mid-housing

30. Tightening
Tightening torque
torque for  35 Nm Torque wrench Use new seal rings
M18 x 1.5 screw plugs on
housing

31. Tightening
Tightening torque
torque for  50 Nm Torque wrench Use new seal rings
M22 x 1.5 screw plugs on
housing

32. Tightening
Tightening torque
torque for  60 Nm Torque wrench Use new seal rings
M24 x 1.5 screw plugs on
housing

33. Heating
Heating temperature
temperature for 
for  60 °C Temperature probe Do not exceed temperature
ring gear 

34. Temperature
Temperature of synchro-
synchro- 120 °C Temperature probe Do not exceed temperature
nizer hub, clutch body,
 bushes and counting disc

35. Temperature
Temperature of
of output
output Max. 70 °C Temperature probe Do not exceed temperature
flange

36. Temperature
Temperature of of input
input 100 °C Temperature probe Do not exceed temperature
shaft roller bearing

1-12
16 S 151 / 8 S 151 Adjustment Data

Description Tolerance Measuring device Remarks

37. Temperature
Temperature ofof 4th-speed 
4th-speed  120 °C Temperature probe Do not exceed temperature
helical gear with needle
cages on mainshaft

38. Rolling-in
Rolling-in torque
torque for  5 - 6 Nm Torque wrench Rolling-in tool
injection pipe 1X56 155 653

39. Lifting
Lifting device
device for input
input 85 Nm Torque wrench DANGER 
shaft/ mainshaft/ layshaft Fit lifting device carefully

40. Tightening
Tightening torque
torque for  250 Nm Torque wrench Use Loctite No. 241
 pivot bolts on shift fork 

41. Tightening
Tightening torque
torque for
for M8 23 Nm Torque wrench
hex bolts on shift cover 

42. Tightening
Tightening torque
torque for  49 Nm Torque wrench
M10 hex bolts on shift
lever 

43. Tightening
Tightening torque
torque for
for M8 23 Nm Torque wrench
hex bolts on shift housing
cover (with detent piece)

44. Tightening
Tightening torque
torque for
for M8 23 Nm Torque wrench
hex bolts on cutoff valve

45. Tightening
Tightening torque
torque for  70 Nm Torque wrench Use new seal rings
M26 x 1.5 screw plugs on
housing

46. Tightening
Tightening torque
torque for  150 Nm Torque wrench Use new seal rings
M48 x 1.5 screw plugs on
housing

1-13
 Special Tools 16 S 151 / 8 S 151

   4    1    6    0    5

   2    9    4    2    7
   1    9    2    9    6
   7    7    7    7    7
   3    3    3    3    3
   1    1    1    1    1
   6    6    6    6    6
   5    5    5    5    5
   X    X    X    X    X
   1    1    1    1    1

   9    0
   7    1
   5    7
   7    6
   3    3
   1    1
   6    6
   5    5
   X    X
   1    1

   7    1
   8    3
   2    7
   7    6
   3    3
   1    1
   6    6
   5    5
   X    X
   1    1

   8    9
   1    4
   9    9
   7    7
   3    3
   1    1
   6    6
   5    5
   X    X
   1    1

   4    2
   0    2
   3    1
   2    7
   2    3
   1    1
   6    6
   5    5
   X    X
   1    1

   4    3    3    3    1

   6    0    7    3    2
   5    3    5    9    9
   6    2    6    7    7
   3    2    3    3    3
   1    1    1    1    1
   6    6    6    6    6
   5    5    5    5    5
   X    X    X    X    X
   1    1    1    1    1

1-14
16 S 151 / 8 S 151 Special Tools

 2 0 0
 3 7
 5 6 1
 1 X

   0    3    1    4    5

   0    5    5    1    3
   2    6    6    3    8
   7    5    7    2    7
   3    5    3    2    3
   1    1    1    1    1
   6    0    6    6    6
   5    2    5    5    5
   X    X    X    X    X
   1    1    1    1    1

   7
   1
   9
   7
   3
   1
   6
   5
   X
   1

   6    6
   1    7
   9    6
   9    7
   1    3
   1    1
   6    6
   5    5
   X    X
   1    1

        6
        2
        5
        9
        0
        0

   3    9
   4    7
   7    0
   6    8
   3    3
   1    1
   6    6
   5    5
   X    X
   1    1

   3    9
   6    0
   0    1
   8    8
   3    3
   1    1
   6    6
   5    5
   X    X
   1    1

   0    6    4    2    9

   1    6    6    2    9
   3    7    0    7    5
   2    3    8    6    6
   2    0    3    3    3
   1    1    1    1    1
   6    6    6    6    6
   5    5    5    5    5
   X    X    X    X    X
   1    1    1    1    1

1-15
 View of Transmission 16 S 151 / 8 S 151

00 795

1-16
 16 S 151 / 8 S 151 Removing Range-Change

1. Remo
Removi
ving
ng co
comp
mpon
onen
ents
ts/r
/ran
ang
ge-
e-ch
chan
ang
ge
3
1.1 Plastic pi
pipes
6
NOTE: Label plastic pipes before removing to 5
ensure correct
cor rect re-assembly.
re-assembly. 2
1 Unscre
Unsc rew
w uni
nion
on sc
scre
rews
ws (1 an
andd 2) fro
rom
m ran
ange
ge--
change cylinder (3) and cutoff valve (4). Loosen
1 6
 pipe clip (5) on housing and remove
remove complete 2
together with plastic pipes (6).
4

1
001992

1.2 Output fl
flange

1 Leve
Leverr of
offf re
reta
tain
inin
ing
g pl
plat
atee (1
(1)) fr
from
om bo
bolt
ltss (2)
(2)..
2 Secu
Secure
re ou
outp
tput
ut fl
flan
ange
ge to pr
preeve
vent
nt it fr
from
om tu
turn
rnin
ing.
g.
3 Unscre
Unsc rew
w hex
hex bo
bolt
ltss (2)
(2) an
and
d rem
remo
ove cla
clamp
mpin
ing
g dis
discc
(3). 1
2
4 Placee ad
Plac adap
apte
terr on
onto
to pl
plan
anet
et ca
carr
rrie
ierr an
and
d re
remo
mov
ve 3
5
output flange (4) using 2- or 3-leg puller  4

5 Remove O-ring (5).

001902

1.3 Cover
2 1
1 Unscre
Unsc rew
w hex
hex bo
bolt
ltss fro
from
m co
cover (1
(1)) and
and re
remo
move
ve
together with gasket (2).
2 Unscre
Unsc rew
w hex
hex bo
bolt
ltss and
and rem
remo
ove co
cov
ver (3
(3)) to
toge
geth
ther 
er  5
with gasket (4), shaft seal (5), shim (6) and ball 3
4
 bearing (7). 6
7
3 Using
Using pla
plast
stic
ic dr
drif
ift,
t, dr
driive out
out ba
ball
ll be
bear
arin
ing
g fro
from
m
cover. and remove loose shim.
NOTE: For helical gear version, use extractor
1X56 122 314 to remove ball bearing from output
shaft.
001903
001903
4 Usin
Using
g pla
plast
stic
ic dri
drift
ft,, dri
driv
ve out
out shaf
shaftt seal
seal fro
from
m cov
cover
er..

2-01
 Removing Range-Change 16 S 151 / 8 S 151

1.4 5/2-way valve

1 Unsc
Unscre
rew
w 5/2
5/2-w
-waay val
valv
ve (1)
(1) from
from cent
centre
re hous
housin
ing.
g.
2 Remove O-rings (2).
NOTE: Do not dismantle 5/2-way valve since it
is a complete part.
NOTE: 5/2-way valve
valve is not included i n 8 S 151
transmission.
2 1

001904
001904

1.5
1.5 Shif
Shiftt cyl
cylin
inde
derr for
for rang
range-
e-ch
chan
ange
ge

1 Unsc
Unscre
rew
w hex
hex bolt
bolts,
s, loos
loosen
en cylin
ylinde
derr (1)
(1) from
from 1
range-change housing and remove from piston 7 4
8 11
(2). 2
10 11
2 Remo
emove O-r
O-rin
ings
gs (3 and
and 4)
4) fro
from
m cy
cylin
linder
der.
3 Remo
Remov ve det
deten
entt plu
plung
nger
er (5).
(5). Scre
Screw
w fixi
fixing
ng devi
device
ce
1X56 137 579 into threaded bore and position 3
fixing element on shift rail (6). Tighten fixing
device.
Tightening torque = 50 Nm.
4 Unsc
Unscre
rew
w loc
locki
kin
ng nu
nut (7)
(7) from
from pist
piston
on (2)
(2). 1
7 4
5 Remo
Removve pis
pisto
ton
n to
togeth
gether
er with
with guid
guidee rin
ring
g (8)
(8) and 
and  9
9 8
grooved ring (9). 10 2
6 Remo
Removeve groo
groov
ved ring
ring (9)
(9) and
and seal
seal ring
ring (11,
(11, new
new
version only) .
3
7 Remo
Remov ve gui
guide
de ring
ring and
and gr
groov
ooved ring
ringss fro
from
m
 piston.
8 Pull
Pull out
out fla
flang
ngee pac
packi
king
ng (10)
(10) from
from rang
range-
e-ch
chan
ange
ge
housing. 5

6
001905

2-02
 16 S 151 / 8 S 151 Removing Range-Change

1.6
1.6 Hous
Housin
ing/
g/ra
rang
nge-
e-ch
chan
ang
ge
1
1 Remo
Removve mec
mecha
han
nical
ical spee
speedo
dome
mete
terr or
or imp
impul
ulse
se 12
sensor (15).
2 Remo
Remov
ve pi
pivot bol
bolts
ts (1)
(1) for
for shif
shiftt for
fork
k (2)
(2)..
3 Remove f ix
ixing device 1X56 137 579. 4
4 Unsc
Unscre
rew
w hex
hex bolt
boltss from
from rang
range-
e-ch
chan
ange
ge hous
housin
ing
g
(3).

15
!
DANGER 
Planet gear train is not secured on mainshaft. 6 4
3
Secure this to prevent from falling. 4

5 Sepa
Separa
rate
te rang
range-
e-ch
chan
ange
ge hous
housin
ingg (3)
(3) from
from cent
centre
re 2
housing (5) without tilting and remove. Use pins 1
to ensure correct position (4).
6 Remo
Removve shi
shift
ft fork
fork (2)
(2) to
togeth
gether
er with
with fulc
fulcru
rum
m pad
padss
(6).
7 Remo
Removve inte
interm
rmed
edia
iate
te plat
platee (7)
(7) toge
togeth
ther
er with
with 8
gaskets (8). 7
8 Remo
Remov ve swi
switc
tch
h (9)
(9) toge
togeth
ther
er with
with seal
seal ring
ring and
and pin
pin 8
(10). New version (13 and 14) also possible.
9 Pull
Pull out
out shif
shiftt rail
rail (11)
(11) from
from cent
centre
re hous
housin
ing.
g.
10 Remo
Remov
ve inj
injec
ecti
tio
on pip
pipee (12
(12).
).

13
5 14

11

10

001906

2-03
 Removing Planet Gear Train 16 S 151 / 8 S 151

1.7
1.7 Plan
Planet
et gea
gearr tra
train
in wit
with
h syn
synch
chrroniz
onizer
er

NOTE: Prevent planet gear train from falling out

when removing. 4
1 Remo
Removve com
complplet
etee pla
plane
nett gea
gearr tr
train
ain fro
from
m
mainshaft together with synchronizer.
synchronizer. 5

3*
1.7.
1.7.1
1 Sync
Synchr
hron
onize
izerr 2
1
!
DANGER  6
7
Pressure pieces are under spring pressure.
pressure. Secure 9
8 10
them to prevent them flying out.

1 Plac
Placee ada
adapt
pter
er onto
onto plan
planet
et carr
carrie
ierr. Att
Attac
ach
h tw
two-or 
o-or  11
three-leg puller underneath sliding sleeve
sl eeve (1) and 
 pull off together
together with clutch body (2). Use a cloth
to catch pressure pieces (4) and pressure springs
(5) held by the sliding sleeve.
s leeve.
NOTE: In the straight-cut version, pull off 
speedo worm or counting disc (3) with integrated 
 bush together with clutch body (2).
(2).
001907

NOTE: Parts marked * according to parts list.

2 Remove synchronizer ring (6).
3 Remove circlip (7).
4 Plac
Placee ada
adapt
pter
er onto
onto plan
planet
et carr
carrie
ierr and
and pull
pull off 
off 
synchronizer hub (8) using 2- or 3-leg puller.
puller.
5 Remo
Remov ve syn
synch
chro
roni
nize
zerr ring
ring (9)
(9) and
and clut
clutch
ch body
body
(10) from planet carrier (11).

2-04
 16 S 151 / 8 S 151 Removing Planet Carrier

1.7.
1.7.2
2 Ring
Ring gear
ear

1 Atta
Attach
ch circ
circli
lip
p (7)
(7) from
from Sect
Sectio
ion
n 1.7.
1.7.1
1 ont
onto
o rin
ring
g 3
5
gear carrier. Place adapter onto planet carrier and  6
4
fit using 2- or 3-leg puller underneath circlip.
2
1
Straight-cut version:
2 Pull
Pull of
off rin
ring
g gea
gearr (1)
(1),, rin
ring
g gea
gearr carr
carrie
ierr (2)
(2) and
and bal
balll
 bearing (5) together.
together.
3 Deta
Detach
ch safe
safety
ty wire
wire (4)
(4) from
from annu
annula
larr gro
groo
ove in
ring gear.
4 Usin
Usingg pla
plast
stic
ic hamm
hammerer,, dri
driv
ve out
out ring
ring gear
gear carr
carrie
ier 
r 
001908
(2) from ring gear (1).
5 Deta
Detach
ch snap
snapri
ring
ng (3)
(3) from
from ring
ring gear
gear carr
carrie
ierr and 
and 
remove
remove ball ball bearing (5).
6 Remo
Remove
ve inte
interm
rmed
edia
iate
te ring
ring (6)
(6) fro
from
m pla
plane
nett car
carri
rier
er..

Helical-cut version:
2 Pull
Pull off
off ring
ring gear
gear (1),
(1), ring
ring gear
gear carr
carrie
ierr (2)
(2),, 4
intermediate ring (3) and axial needle bearing (5) 2
together. 1
3 Deta
Detach
ch safe
safety
ty wire
wire (4)
(4) fro
from
m ann
annul
ular
ar groo
groove
ve in
ring gear.

5
3

009518

1.7.
1.7.3
3 Plan
Planet
et carr
carrier
ier

1 Dri
Drive do
dowels
els (1)
(1) full
fully
y int
into
o pla
plane
nett pin
pin (2).
(2). (5)
4 7 6
2 Usin
Using
g pla
plast
stic
ic drif
drift,
t, dri
drive out
out pla
plane
nett gea
gearr pin
pin from
from 6
6 7
 planet carrier (3) towards
towards “input’’.
“input’’. (5)
3 Rem
Remove pla
plan
net gear
gear (4) from
rom pla
plane
nett car
carri
rier 
er 
together with thrust washers (5).
NOTE: Thrust washers (5) in straight-cut version 1
only. 3
4 Remo
Remov ve shi
shims
ms (6)
(6) and
and cylin
ylinde
derr rol
rolle
lers
rs (7)
(7) fro
from
m 2
 planet gear.
gear.
5 Dri
Drive out
out dowels
els (1)
(1) from
rom plan
planet
et pin.
pin.
Repeat steps 1) to 5) for remaining planet gears.

009525

2-05
 Assembling Planet Carrier 16 S 151 / 8 S 151

1.8
1.8 Asse
Assemb
mbli
ling
ng pla
plane
nett gear
gear tra
train
in with
with ran
range
ge--
change synchronizer
synchronizer
(2)
1.8.
1.8.1
1 Plan
Planet
et carr
carrie
ierr 5 3
4
NOTE: Always
Always exchange planet gears as 3
5
3
complete sets. (2)
1
1 Coat
Coat face
facess of
of pla
plane
nett gea
gears
rs and
and cyl
cylin
inde
derr roll
roller 
er 
raceways
raceways with operating oil.
2 Stan
Stand
d pla
plan
net gear
gear pin (1)
(1) so
so tha
thatt col
colla
larr fac
faces
es
downwards.
3 Slid
Slidee thr
thrus
ustt was
washe
herr (2)
(2) over plan
planet
et pin.
pin. Ensu
Ensure
re
coated side (bright side) faces towards planet 009513

gear.
NOTE: Thrust washers (2) in straight-cut version
only.
4 Slid
Slidee shi
shim
m (3)
(3) over
ver pla
plane
nett gea
gearr pin
pin (eit
(eithe
herr wa
way
up).
5 Plac
Placee pla
plane
nett gea
gearr (4)
(4) onto
onto plan
planet
et pin
pin (1)
(1) and
and ali
align
gn
centrically.
6 Inse
Insert
rt 14 cylin
ylinde
derr rol
rolle
lers
rs (5)
(5) int
into
o pla
plane
nett gea
gearr and 
and 
slide shim (6) over planet pin.
7 Coat
Coat insi
inside
de of the
the pla
plane
nett gea
gearr wit
with
h ope
opera
rati
ting
ng oil
oil
and insert remaining 14 cylinder rollers.
8 Coat
Coat cyli
cylind
nder
er roll
roller
erss wit
with
h ope
opera
rati
ting
ng oil
oil and
and fit
shim. 10
9
9 Fit
Fit thr
thrus
ustt was
washe
herr on
on pla
plane
nett gea
gearr. Ens
Ensur
uree coa
coate
ted 
d 
side faces towards
towards planet gear.
8 7
10 Stan
Stand
d pla
plane
nett carr
carrie
ierr (7)
(7) on on shaft
shaft secti
section
on..
11 Care
Carefu
full
lly
y remo
remove
ve pla
plane
nett gear
gear and
and thru
thrust
st wash
washer
erss
from planet pin and slide into planet carrier.
12 Alig
Align
n pla
plane
nett gear
gear wit
with
h bea
beari
ring
ng bor
boree (8)
(8)..
NOTE: Ensure “0” face of planet pin faces
towards
towards outside radius of planet carrier. (Oil bore (2)
must face towards the inner radius of planet
carrier). (2)
13 Radi
Radiall
ally
y alig
align
n plan
planet
et pin
pin and
and inse
insert
rt int
into
o bea
beari
ring
ng
 bore.
14 Using
Using plas
plastic
tic hamm
hammer
er,, driv
drivee in plan
planet
et pin
pin.. Che
Check 
ck 
for alignment with dowel
dowel bore

009505
009505

2-06
 16 S 151 / 8 S 151 Assembling Planet Carrier

15 Driv
Drivee new
new dow
dowel (9)
(9) hal
halfw
fwaay into
into hol
hole.
e. Dri
Drive
ve 2nd 
2nd 
(new) dowel
dowel (10) into 1st dowel with slot offset
180°. Drive both dowels approx. 0.5 mm into
 planet carrier (refer to Assembly Specification) .
16 Chec
Check
k axia
axiall pla
play on
on pla
plane
nett gear
gearss (0.4
(0.4 to
to 1.3
1.3 mm)
mm)..
Repeat steps 1) to 16) for remaining planet gears.

1.8.
1.8.2
2 Ring
Ring gear
gear
2
1
1 Plac
Placee int
inter
erme
medi
diat
atee rin
ring
g (2)
(2) onto
onto plan
planet
et carr
carrie
ierr (1)
(1)..
Ensure oil g rooves
rooves face towards
towards output end (only
in straight-cut version).
2 Dri
Drive rin
ring
g gea
gearr car
carri
rier
er (3)
(3) flu
flush
sh into
into ring
ring gear
gear (4).
(4).
3 Inse
Insert
rt safe
safety
ty wire
wire (5)
(5) int
into
o ann
annul
ular
ar groo
groov
ve in
in rin
ring
g 7
6
gear. Ensure entire safety wire is firmly seated.
5
3
Straight-cut version:
4
4 Inse
Insert
rt ball
ball bear
bearin
ing
g (6)
(6) into
into ring
ring gear
gear carr
carrie
ierr and 
and 
attach snapring (7). Select snapring so as to
ensure ball bearing axial play of 0.0 to 0.1 mm.
Snaprings are available in 0.1 mm thicknesses
(0.1, 0.2, 0.3 etc.).
001912
Helical-cut version:

4 Slid
Slidee int
inter
erme
medi
diat
atee rin
ring
g (7)
(7) and
and ax
axial
ial nee
needl
dlee
 bearing (6) onto planet carrier.
carrier. 1

!
DANGER 
Always wear protective gloves when handling heated
ring gear.
gear.
6
7
5 Heat
Heat com
complplet
etee ring
ring gea
gearr to 60°
60° C and
and plac
placee onto
onto 5
3
 planet carrier. Rotate ring gear to bring
bring teeth into
mesh. Ensure bearing (6) is firmly seated. 4

009506

2-07
 Assembling Planet Carrier 16 S 151 / 8 S 151

1.8.
1.8.3
3 Sync
Synchr
hron
onize
izerr
2
1 Chec
Checkk wea
wearr lim
limit
it of syn
synchro
chron
nizer
izer part
parts,
s, see
see 1
Section 6.
2 Plac
Placee clu
clutc
tch
h bod
body
y (1)
(1) and
and syn
synch
chro
roni
nize
zerr rin
ring
g (2)
(2)
onto planet carrier.

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

10
3 Heat
Heat sync
synchhron
ronizer
izer hub
hub (3)
(3) to app
approx.
rox. 120
120° C and 
and  9
 push on until firmly seated. Ensure long hub side 5
faces towards planet carrier. Synchronizer ring 7 8
lugs must engage into recesses in the
4
synchronizer hub. 3 6
4 Atta
Attach
ch circ
circli
lip
p (4)
(4) into
into annu
annula
larr groo
groove
ve.. Axi
Axial
al pla
play
must be 0.0 to 0.1 mm. Circlips are available
available in
0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).
5 Plac
Placee sli
slidi
ding
ng slee
sleev
ve (5)
(5) onto
onto sync
synchr
hron
oniz
izer
er hub
hub (3)
(3)
with collar side facing towards output end. 001913

NOTE: Recesses in sliding sleeve must be

aligned with recesses in synchronizer hub.
6 Inse
Insert
rt new
new com
comprpres
essi
sion
on spri
spring
ngss (6)
(6) and
and pre
press
ssur
uree
 pieces (7) into synchronizer hub (3) and, and, using
suitable tool, insert into sliding sleeve (5).
7 Plac
Placee syn
synch
chro
roni
nize
zerr rin
ring
g (8)
(8) onto
onto sync
synchr
hron
oniz
izer
er hub
hub
(3).
NOTE: Synchronizer ring lugs (8) must engage
into recesses in the synchronizer hub (3).
8 Brin
Bring
g sli
slidi
ding
ng slee
sleev
ve (5)
(5) into
into cent
centre
re posi
positi
tion
on by
 pressing synchronizer ring against synchronizer 
hub. Engagement of presssure pieces can be
clearly heard.

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

9 Heat
Heat clu
clutch
tch bo
body (9) to appr
appro
ox. 120°
20° C an
and pus
push
h
flush onto planet car rier.
10 Heat
Heat spee
speedo
do worm/c
orm/cou
ount
ntin
ing
g disc
disc (10)
(10) to
to app
appro
rox.
x.
120° C and push
push onto planet carrier. Ensure
sensor lugs face towards
towards planet carrier.
car rier.
NOTE: Speedo worm and counting disc (10) in
straight-cut version only.

2-08
 16 S 151 / 8 S 151 Assembling Range-Change

1.9 Assemb
Assemblin
ling
g range
range-ch
-chang
angee /housi
/housing/
ng/ output
output
flange/piston
10 21
1 Plac
Placee int
inter
erme
medi
diat
atee pla
plate
te (1)
(1) on
onto plan
planet
et 22
carrier/clutch body (2).
7
2 Inse
Insert
rt shif
shiftt for
fork
k (3)
(3) and
and ful
fulcr
crum
um pads
pads (4)
(4) int
into
o 6 WI 8
sliding sleeve (5). 1 9


3 Plac
Placee ne
new gas
gaske
kett (6)
(6) onto
onto inte
interm
rmed
edia
iate
te plat
platee (1)
(1) 20 W II
and position. 9
4 Inse
Insert
rt shif
shiftt rai
raill (11
(11)) fro
from
m ins
insid
idee of
of hou
housi
sing
ng and 
and 
 position roughly.
roughly.
5 Inse
Insert
rt inje
inject
ctio
ion
n pipe
pipe (2) into
into hou
housing
sing..
6 Plac
Placee hou
housi
sing
ng (7)
(7) ont
onto
o int
inter
erme
medi
diat
atee pla
plate
te (1),
(1), fit
gasket and position. Check radial position of shift
fork and engage.
NOTE: When using a new housing (7), drive in 10
 ball (8) in accordance with selector pattern I or II.
7 Coat
Coat piv
pivot bolt
boltss (10
(10)) wit
with
h Loct
Loctit
itee No.
No. 241,
241, fit 3
4
spring washers and insert. Position shift fork (3).
NOTE: Pivot bolt tightening torque =
250 Nm. Tighten when range-change is fitted.
5
8 Coat
Coat new
new fla
flang
ngee pack
packin
ing
g (12)
(12) with
with spir
spiritit,, slid
slidee
over
over shift rail (11) and, using soft drift, drive in 2
until flush. 19
18
9 Plac
Placee pis
pisto
ton
n (13
(13)) ont
onto
o shi
shift
ft rail
rail the
the cor
corre
rect
ct way 24
13
up together with guide ring (14) and new grooved 
grooved  12 23
rings (15).
NOTE: in the new version, place seal ring (23),
 piston (13) with guide ring (14) and seal ring (24) 16 17
14
onto shift rail.
10 Tight
ighten
en new
new loc
locki
king
ng nut
nut onc
oncee ran
range
ge-c
-cha
hang
ngee is
is 19
fitted. 18
Tightening torque = 150 Nm. 15
15 14
NOTE: Installation of range-change cylinder is 12 13
only possible once range-change has been
16 17
subassembled on centre housing. Thread must be
absolutely free of oil and grease.
11 Grea
Grease
se new
new O-r
O-rin
ings
gs (17
(17 and
and 18)
18) and
and inse
insert
rt int
into
o
correct annular groov
g rooves
es (in cylinder and housing).
NOTE: Mounting switches (21 and 22) if 
required,
required, see page 2-59, work step 16.
12 Care
Carefu
full
lly
y slide
slide cyl
cylin
inde
derr (19)
(19) ove
overr pisto
piston
n toge
togeth
ther 
er 
with guide ring and piston gasket. Fix cylinder  11
using two hex bolts.
NOTE: Align the compressed air bores.
009942

2-09
 Assembling Range-Change 16 S 151 / 8 S 151

Measuring ball bearing axial play

(nominal: 0 to 0.1 mm)
29
13 Fit new
Fit new gask
gasket
et (25
(25)) ont
onto
o new
new cov
cover
er (2
(26)
6) an
and 
d  26
measure insertion depth of cover together with 25
gasket, e.g. 23.40 mm. 27
28
14 Measur
Meas uree ext
extra
ract
ctio
ion
n dep
depth
th be
bear
arin
ing
g sea
seatt dep
depth
th of 
housing (7), (without gasket), e.g. 7.00 mm.
15 Measur
Meas uree widt
width
h of
of bal
balll bea
beari
ring
ng (2
(28)
8),, e.g.
e.g.
30.00 mm.
Example
23.40 mm insertion depth - cover 
+ 7.00 mm insertion depth - housing
30.40 mm 001915

 – 30.00 mm width of ball bearing

= 0.40 mm axial play without shim
i.e. a 0.3 to 0.4 mm shim (27) is required to give
axial play of 0 to 0.1 mm.

! DANGER 
Always wear protective gloves when handling heated
cover.

16 Heat co
Heat cove
verr (26
(26)) to
to app
appro
rox.
x. 60
60°° C and
and in
inse
sert
rt
correct shim (27) and ball bearing (28).
17 Drivee in
Driv in sh
shaf
aftt sea
seall (29
(29)) usin
using
g spe
speci
cial
al to
tool
ol
1X56 137 124.
NOTE: Only use special tool with 12.5 mm wide
ring. Installation dimension = 12.5 + 1.0 mm
 between edge of cover and shaft seal. Thinly coat
outside of shaft seal with sealing compound. 30
Lubricate outside of shaft seal with rubber 
surround using soap wash.
18 Fit cov
Fit cover
er (2
(26)
6) wit
with
h new
new ga
gask
sket
et (2
(25)
5) an
and
d tig
tight
hten
en
using hex bolts and washers.
Tightening torque = 49 Nm.
19 Fit cov
Fit cover
er (3
(30
0) wit
with
h new
new ga
gask
sket
et..
Tightening torque = 79 Nm.

26
25

001916

2-10
 16 S 151 / 8 S 151 Assembling Range-Change

1.9.
1.9.1
1 Ou
Outp
tput
ut flan
flange
ge

1 Lightly oil sha

shaft sea
seal in cover.
4
!
DANGER  2
3
Always wear protective gloves when handling heated 1
output flange.

2 Heat output flange (1) to max. 70° C.

3 Push
Push outp
output
ut flan
flange
ge flus
flush
h ont
onto
o pla
plane
nett car
carri
rier
er shaf
shaft.
t.
4 Pull
Pull on outp
output
ut flan
flange
ge unti
untill flu
flush
sh usin
using
g dis
discc (2)
(2)
and two standard M12x75 hex bolts.
5 Remove disc and bolts.
001917
6 Ligh
Lightl
tly
y oil
oil new
new O-ri
O-ring
ng (3)
(3) and
and inse
insert
rt into
into gap
gap
 between output flange and planet carrier shaft.
7 Inse
Insert
rt disc
disc (2)
(2) into
into outp
output
ut flan
flange
ge and
and atta
attach
ch to
 planet carrier using locking screws.
Tightening torque (straight-cut version) = 60 Nm
Tightening torque (helical-cut version) = 120 Nm.
If required, use flange holder to prevent flange
from turning.
Insert locking screws with Loctite 262.
8 Using special tool
1X56 137 246 (straight-cut version)
1X56 137 651 (helical-cut version),
drive new retaining plate (4) flush onto bolt
heads.

2-11
 Removing Shift Housing 16 S 151 / 8 S 151

2 Rem
Removin
oving
g co
compon
mponen
entts ffro
rom
m cen
centr
tree hou
houssing
ing

2.1 Split
litter
ter (GV
(GV)) cy
cylin
linder

1 Remove cylinder (1) by hand.

4
2 Remo
Removeve dete
detent
nt plun
plunge
gerr (9)
(9) toge
togeth
ther
er with
with circ
circli
lip.
p.
1
Insert fixing device 1X56 137 579.
3 Remove locking nut (2
(2).
4 Remove spr
spring (8) from housing.
5 Remov
emovee pist
piston
on (3)
(3) fro
from shif
shiftt rail
rail (4)
(4).
9
6 8 7
2
5
6 Remo
Remove
ve doub
double
le-g
-gro
roov
oved
ed ring
ring (5)
(5) from
from pist
piston
on.. 3 001918
001918

7 Remov
emovee two
two O-ri
O-ring
ngss (6
(6 and
and 7) from
rom cy
cylin
linder.
der.
NOTE: There may be three O-rings in the
cylinder.

2.2 Shift ho
housing
14
1 Unsc
Unscre
rew
w hex
hex bolt
boltss fro
from shif
shiftt hous
housin
ing.
g.
2 Take
Take off
off comp
comple
lete
te shif
shiftt hou
housi
sing
ng (1)
(1) and
and remo
remove
ve 4
gasket (2). 3

3 Remo
Remove
ve swit
switch
ch (3)
(3) toge
togeth
ther
er with
with seal
seal ring
ring and 
and  13 11
 pin.
1 10
4 Unsc
Unscre
rew
w cov
cover
er (4)
(4) tog
toget
eth
her with
with gask
gasket
et.. 12
5 Rem
Remove
ove shi
shift
ft deten
etentt (5)
(5) and
and was
washe
herr (6)
(6) from
rom 9
detent piece (7). See Figure 001920. 2

6 Loos
Loosen
en shif
shiftt lev
lever
er (8)
(8) and
and remo
remove
ve toge
togeth
ther
er with
with
 protective cap (9). Mark selector shaft for 
installation.
7 Remo
Removeve scre
screw
w plu
plug
g (10
(10)) tog
toget
ethe
herr wit
with
h sea
seall spr
sprin
ing
g 8
(11) and pin (12).
001919
8 Unsc
Unscre
rew
w cuto
cutoff
ff valv
valvee (13)
(13) and
and remo
remove
ve toge
togeth
ther 
er 
with O-ring.
NOTE: In new version, remove reverse gear 
switch (14) together with seal ring.

2-12
 16 S 151 / 8 S 151 Removing Shift Housing

9 Unsc
Unscre
rew
w hex
hex bolts
olts from
rom shi
shift
ft cove
coverr (15
(15)) and 
and 
remove together with gasket.
10 Driv
Drivee out
out bush
bush (16)
(16),, wip
wiper
er (17)
(17),, sha
shaft
ft seal
seal (18
(18))
and bearing bush (19) from shift cover. 16
15
11 Driv
Drivee pin
pin (20
(20) tow
towar
ards
ds cove
cover.
r.
19
12 Remo
Removeve cove
coverr (21
(21)) fro
from
m shi
shift
ft hous
housin
ing
g tog
toget
ethe
her 
r 
18
with compression springs (22), detent piece (23) 17
and O-ring (24).
13 Driv
Drivee out
out dowe
dowels
ls (25)
(25) from
from dete
detent
nt piec
piecee and 
and 
remove compression springs (26) together with
washers (27).
14 Driv
Drivee out
out dowe
dowelsls (28)
(28) from
from driv
driver
erss (29
(29)) and 
and 
selector shaft (30).
20
7
15 By hand
hand,, pull
pull out
out sele
select
ctor
or shaf
shaftt (30)
(30) in dir
direc
ectio
tion
n
of shift output. 22 5 6

16 Remo
Remove
ve loc
locki
king
ng piec
piecee (31
(31)) and
and dri
drive
vers
rs fro
from
m shif
shiftt
housing.
17 Remo
Remove
ve pin
pins (32
(32)) if
if nec
neces
essa
sary
ry..
NOTE: Clamp pins in vice using aluminium 21 24
clamping jaws and remove by striking shift
housing.
18 Driv
Drivee out
out need
needle
le slee
sleeve
ve (33)
(33) from
from shif
shiftt hou
housi
sing
ng.. 23

25

27
26
27
33

30

32

28

29

31

001920
001920

2-13
 Assembling Shift Housing 16 S 151 / 8 S 151

2.2.1
2.2.1 Assemb
Assemblin
ling
g shift housi
housing
ng
1
1 Using special tool 1X56 119 916, driv
drivee new 2
needle sleeve (1) into shift housing (2). Strike 3
thicker coated side of needle sleeve.
2 Drive pins (3
(3) int
into sh
shift ho
housin
sing.
3 Inse
Insert
rt driv
driver
er (4)
(4) and
and lock
lockin
ing
g pie
piece
ce (5)
(5) int
into
o shi
shift
ft
housing the correct way round.
4 Insert se
selector sh
shaft (6
(6).
5 Using special tool 1X56 119 916, drive new 12
 bearing bush (7) into shift cover.
6 Using special tool 1X56 119 916, drive shaft seal
4
ring (8) into shift cover. Sealing lip must face
towards cover.
7 Using special tool 1X56 119 916, drive scraper 
disc (9) into shift cover. Sealing lip must point
outwards. 5
NOTE: Smear shaft seal and wiper with sealing
compound and install. Fill the gap between shaft
seal and wiper with grease.
8 Push
Push bush
bush (10)
(10) into
into shif
shiftt hou
housi
sing
ng (2)
(2) and
and slid
slidee
shift cover (11) and new gasket over selector 
shaft (6) until flush. Do not damage sealing lips.
9 Bolt
olt sh
shift
ift cov
cover
er (11)
(11) onto
onto shif
shiftt hou
housi
sing
ng..
Tightening torque = 23 Nm. 11

10 Driv
Drivee one
one dowel
dowel (12)
(12) thro
throug
ugh
h dri
drive
verr (4)
(4) and
and int
into
o
selector shaft. Drive second dowel (12) into first,
making sure slot is offset.
(Refer to Assembly Specification)
7
8
9
2

6
10

001921

2-14
 16 S 151 / 8 S 151 Assembling Shift Housing/Detent Piece

2.2.2 Detent
Detent piece with compr
compressio
ession
n springs
springs
5
1 Plac
Placee was
washe
herr (1)
(1),, com
compr
pres
essi
sio
on spr
sprin
ing
g (2)
(2) and 
and  1
second washer (1) onto selector shaft (3). Drive 4 2
in pins (8) if necessary. 1
2 Plac
Placee shi
shift
ft dete
detent
nt (6)
(6) wit
with
h was
washe
herr (7)
(7) into
into dete
detent
nt 7
6
 piece (4).
14 18
3 Plac
Placee det
deten
entt pie
piece
ce (4),
(4), shif
shiftt det
deten
entt (6)
(6) and
and was
washe
her 
r 
(7) onto selector shaft against spring pressure and  8
drive in dowels (5) offset.
11
NOTE: Axial play between detent piece and pins
15 17
must be 0.1 mm. Adjust if required using washer 
(7) of different thickness. Washers are available 10 13 3
in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.). 16
Grease shift detent (6) and pins (8). 12
4 Bolt
Bolt on cove
coverr (9)
(9) toge
togeth
ther
er with
with new
new gas
gaske
ket.
t.
Tightening torque = 23 Nm.
NOTE: In the new version of the cover (a), screw 24
in reverse gear switch (24) and new seal ring 25
20
(25). In the old version, the reverse gear switch is 21
19
on the centre housing (see page 2-59, items 20
and 21).
5 Inse
Insert
rt cove
coverr (10
(10)) int
into
o shi
shift
ft hous
housin
ing
g tog
toget
ethe
herr wit
with
h 9
compression springs (11), detent piece (12) and 
O-ring (13). Drive pin (14) into shift housing
(countersink approx. 5 mm) and fit new cover 
(countersink approx. 2 mm).
22
6 Fit
Fit pin
pin (15)
(15),, spr
sprin
ing
g (16
(16)) and
and scre
screw
w plu
plug
g (17
(17)) wit
with
h
new sealing ring and screw into shift housing.
Tightening torque = 60 Nm. 23
7 Fit
Fit cut
cutof
offf val
valve
ve (18)
(18) with
with new
new O-r
O-rin
ing
g and
and scre
screw
w
onto shift housing.
Tightening torque = 23 Nm. 001922

8 Inse
Insert
rt pin
pin (19
(19)) int
into
o cov
cover
er and
and scr
screw
ew in swit
switch
ch (20)
(20)
together with new sealing ring (21).
Tightening torque = 50 Nm.
9 Slid
Slidee pro
prote
tect
ctiv
ivee cap
cap (22)
(22) onto
onto sele
select
ctor
or shaf
shaftt (3)
(3)
and position shift lever (23) on selector shaft
shaft depending on shift version.
Tightening torque for hex bolt and nut on shift
lever = 49 Nm. Protective cap must sit on selector 
shaft without play.

2-15
 Shift Mechanism 16 S 151 / 8 S 151

2.3 Removi
Removingng and disman
dismantli
tling
ng fricti
friction-
on-opt
optimi
imized
zed
14 12 1 6
shift housing (illustrations show superimposed 5
“H” shift pattern)
7
8
1 Loo
Loosen
sen hex
hex bolt
boltss (1)
(1) and
and rem
remov
ovee shi
shift
ft tur
turret
ret
together with gasket (2). 4
9
2 Loos
Loosen
en shif
shiftt lev
lever
er (3)
(3) (de
(depe
pend
ndin
ing
g on
on par
parts
ts list
list))
and remove together with protective cap.
13 11 10
3 Remov
emovee det
deten
entt plu
plun
nger
ger (4)
(4) and
and scr
screw
ew plug
plug or  15
switch (5). 2
4 Take
Take out
out cut
cutof
offf val
valve
ve and
and remo
remove
ve toge
togeth
ther
er with
with
O-ring (7). 3
NOTE: Cutoff valve is a complete component
and is not dismantled. In the version with double
“H” shift pattern, there are 2 ball rollers (8) in the 009684

cutoff valve.
5 Remo
Removeve scre
screw
w plu
plug
g (9)
(9) toge
togeth
ther
er with
with seal
seal ring
ring,,
spring (10) and bolt (11).
6 Remov
emovee scr
screw
ew plugs
lugs (12
(12 and
and 13)
13) to
togeth
gether
er with
with
21
seal rings.
7 Unsc
Unscre
rew
w cov
cover
er (14)
(14) toge
togeth
ther
er with
with pisto
iston
n an
and 
19
remove together with gasket. 18
NOTE: In the version with double “H” shift 20
 pattern, a cover and switch are installed here. 22
8 Loos
Loosen
en hous
housin
ing
g (15)
(15) and
and remo
remove
ve toge
togeth
ther
er with
with
gasket. 24

9 Remo
Remove
ve dete
detent
nt plat
platee (16)
(16) and
and dete
detent
nt (17)
(17) from
from 23
housing. 29
30
10 Unsc
Unscre
rew
w hex
hex bolts
bolts from
from shif
shiftt cov
cover
er (18)
(18) and 
and  16 31
remove together with gasket.
32
11 Driv
Drivee out
out shaf
shaftt seal
seal (19
(19),
), bear
bearin
ing
g bus
bush
h (20)
(20),, shaf
shaftt 17
seal (21) and wiper (22) from shift cover. 33
12 Deta
Detach
ch spli
splitt rin
ring
g (23
(23)) and
and remo
remove
ve dete
detent
nt (24)
(24)
from housing together with O-ring.
13 Driv
Drivee out
out dowe
dowels
ls (25)
(25) from
from driv
driver
er..
14 Remo
Removeve selec
selecto
torr sha
shaft
ft (26)
(26),, dri
drive
verr (27
(27)) and 
and 
locking piece (28).
26
15 Remo
Remove
ve need
needle
le sle
sleev
evee (29)
(29) from
from hou
housi
sing
ng..
16 Deta
Detach
ch spli
splitt rin
ring
g (30
(30)) and
and remo
remove
ve disc
disc (31)
(31),,
spring (32) and disc (33) from selector shaft.

25 27

28
009685

2-16
16 S 151 / 8 S 151 Shift Mechanism

17 Detac
Detachh sna
snapr
prin
ing
g (34
(34)) fro
from
m cov
cover
er.. Rem
Remov
ovee pist
piston
on
(35) together with O-rings (36).
36
35
36
34

009893

2-17
 Shift Mechanism 16 S 151 / 8 S 151

2.3.1
2.3.1 Assemb
Assemblin
ling
g shift housi
housing
ng
1
10
1 Driv
Drivee new
new need
needle
le slee
sleeve
ve (1)
(1) int
into
o shi
shift
ft hous
housin
ing
g (2)
(2) 9
using special tool 1X56 119 916. Hit onto the
side of the needle sleeve with the thicker  8
surround.
2 Inse
Insert
rt driv
driver
er (3)
(3) and
and lock
lockin
ing
g pie
piece
ce (4)
(4) int
into
o shi
shift
ft 7
housing.
3 Insert se
selector sh
shaft (5
(5).
2
NOTE: Engagement groove for detent and detent
 plate must face towards transmission
4 One
One aft
after
er the
the oth
other
er,, dri
drive
ve dowe
dowell pin
pinss (6)
(6) thro
throug
ugh
h
driver (3) and into selector shaft (observe 5
assembly specifications).
5 Inse
Insert
rt disc
disc (7),
(7), spri
spring
ng (8),
(8), disc
disc (9)
(9) and
and spli
splitt rin
ring
g
(10) according to selector pattern.

6
3

4
009900

6 Driv
Drivee sha
shaft
ft seal
seal (11)
(11) into
into shif
shiftt cov
cover
er usin
using
g spe
speci
cial
al
tool 1X56 119 916. Sealing lip must face towards 11 16
shift housing.
7 Driv
Drivee new
new bear
bearin
ing
g bu
bush (12
(12) int
into
o shi
shift
ft cove
cover 
r 
13
using special tool 1X56 119 916.
8 Driv
Drivee sha
shaft
ft seal
seal (13)
(13) into
into shif
shiftt cov
cover
er usin
using
g spe
speci
cial
al
tool 1X56 119 916. Sealing lip must face towards
15
shift lever.
12
9 Driv
Drivee wip
wiper
er (14)
(14) into
into shif
shiftt cov
cover
er usin
using
g spe
speci
cial
al
14
tool 1X56 119 916. Sealing lip must face
outwards.
NOTE: Lightly coat the outside of shaft seal and 
wiper with sealing compound. Fill gap between
shaft seal and wiper with grease.
17
18 009685
10 Slid
Slidee shif
shiftt cove
coverr (15)
(15) ove
overr sele
selecto
ctorr shaf
shaftt toge
togeth
ther 
er 
with new gasket and mount using bolts (16);
Tightening torque = 23 Nm.
11 Inser
Insertt det
deten
entt (17
(17)) tog
toget
ethe
herr wit
with
h new
new O-ri
O-ring
ng and 
and 
attach split ring (18).

2-18
16 S 151 / 8 S 151 Shift Mechanism

12 Inse
Insert
rt det
deten
entt (19)
(19),, spri
spring
ng (20
(20)) and
and scr
screw
ew plu
plug
g (21)
(21)
together with new seal ring and tighten; 22
Tightening torque = 60 Nm.
13 Inse
Insert
rt cut
cutof
offf valv
valvee (22)
(22) int
into
o shif
shiftt hous
housin
ing
g toge
togeth
ther 
er  23
with new O-ring, ensuring it is positioned the
correct way round, and fix using hex bolts;
Tightening torque = 23 Nm.
NOTE: In the version with double “H” shift 21
 pattern, there are 2 ball rollers (23) in the cutoff 
20
valve.
19
14 Inse
Insert
rt scre
screw
w plu
plugs
gs (24
(24 and
and 25)
25) int
into
o hou
housin
sing
g (26
(26))
together with new seal ring and tighten;
Tightening torque = 50 Nm.
15 Scre
Screw
w det
deten
entt plu
plung
nger
er (27)
(27) into
into hous
housin
ing
g tog
togeth
ether 
er 
with new seal ring. 29
25 28
16 Inse
Insert
rt gre
grease
ased
d pin
pin (28
(28)) into
into bor
bore.
e. Clo
Close
se off
off usin
using
g 26
switch or screw plug (29) and new seal ring;
Tightening torque = 35 Nm.
17 Inse
Insert
rt dete
detent
nt (30)
(30) and
and det
deten
entt pla
plate
te (31)
(31) into
into
housing, ensuring they are positioned the correct
27
way round.

24
30
31

009687

2-19
 Shift Mechanism 16 S 151 / 8 S 151

18 Fit new gasket (32).

19 Slid
Slidee shi
shift
ft housi
housing
ng over
over dete
detent
nt plate
plate and
and dete
detent
nt
together with selector shaft.
NOTE: Center housing and shift housing. 36

20 Inse
Insert
rt hex
hex bol
bolts
ts (33)
(33) and
and tig
tight
hten
en by hand
hand.. 38
34
NOTE: Check selector shaft for ease of  35
movement by pushing against the spring force. 34
37
21 Tighten det
deteent pl
plunger;
Tightening torque = 50 Nm.
22 Fit
Fit O-r
O-rin
ings
gs (34)
(34) onto
onto pist
piston
on (35)
(35)..
23 Inse
Insert
rt pisto
piston
n int
into
o cov
cover
er (36)
(36) and
and sec
secur
uree usin
using
g
snapring (37).
33
24 Fit
Fit new
new gask
gasket
et (38)
(38) and
and scr
screw
ew cove
coverr ont
onto
o 39
housing; 32
Tightening torque = 23 Nm.
NOTE: In the version with double “H” shift
 pattern, a cover and switch are installed here.
25 Slid
Slidee prot
protec
ectiv
tivee cap
cap (39
(39)) ont
onto
o sele
select
ctor
or sha
shaft
ft and 
and  40
 position shift lever (40) on selector shaft (position
depends on version). Tightening torque for hex
 bolt and hex nut on shift lever = 49 Nm. Ensure
Ensure
 protective cap has no play when seated on 009688

selector shaft (according to parts list).

2-20
 16 S 151 / 8 S 151 Shift Mechanism

2.4 Shift
Shift patter
patterns/
ns/shi
shift
ft mechan
mechanism
ism left
left or
or righ
rightt

Spring pack arrangement: Q 1

Selector pattern I

Horizontal torque shaft left.

001923
001923

Spring pack arrangement: Q 2

Selector pattern I

Horizontal torque shaft left.

001924
001924

Spring pack arrangement: Q 3

Selector pattern I

Horizontal torque shaft left.

001925
001925

2-21
 Shift Mechanism 16 S 151 / 8 S 151

Spring pack arrangement: Q 1

Selector pattern II

Horizontal torque shaft left.

001926
001926

Spring pack arrangement: Q 2

Selector pattern II

Horizontal torque shaft left.

001927
001927

Spring pack arrangement: Q 3

Selector pattern II

Horizontal torque shaft left.

001928
001928

2-22
 16 S 151 / 8 S 151 Shift Mechanism

Spring pack arrangement: Q 1

Selector pattern I

Horizontal torque shaft left.

001929

Anordnung des Federpaketes: Q 2

Wählbild I

Waagrecht Drehwelle rechts

Anordnung des Federpaketes: Q 3

Wählbild I

Waagrecht Drehwelle rechts

2-23
 Removing Clutch Housing 16 S 151 / 8 S 151

3 Remo
Removi
vin
ng cl
clut
utch
ch hou
oussin
ing
g co
comp
mpon
onen
ents
ts

3.1 Release fork   3

8 6
Release fork (pulled) 7
1
2
1 Detach
Deta ch ci
circ
rcli
lips
ps (1
(1).
). Re
Remo
move
ve se
seal
alss (2)
(2) an
and
d sea
seall
rings (3). 9
8
2 Pull
Pull ou
outt pin
pin (4
(4)) and
and re
remo
mov
ve rel
relea
ease
se for
ork
k (5)
(5).. 3
5 2
3 Loosen
Loos en he
hex
x bol
bolts
ts (6
(6)) and
and re
remo
mov
ve to
toge
geth
ther
er wi
with
th 1
 bearing block (7).
4 Detach
Deta ch ci
circ
rcli
lips
ps (8
(8)) and
and re
remo
movve pla
plain
in sp
sphe
heri
rica
call
4
 bearing (9) from bearing block.
block. 009520

Release fork (pushed)

1 Remov
Remo ve rel
relea
ease
se fo
fork
rk (1
(1)) to
toge
geth
ther
er wi
with
th ba
ball
ll cu
cup
p 4
3
(2). 2
1
2 Remo
Remov
ve bal
balll pin
pin (3
(3)) to
toge
geth
ther
er wi
with
th was
ashe
herr (4
(4).
).

004484
004484

Release fork (pulled)

1 Loose
Loo sen
n scr
screew (5)
(5) an
and
d rem
remoove fr
from sh
shaf
aftt (2)
(2)
together with clutch lever (3). 9
NOTE: Mark position of clutch lever before 10
removing. 1

2 Remo
Remov
ve do
dowel
elss (4)
(4) fro
rom
m rel
relea
ease
se fo
fork
rk (1)
1)..
2
3 Rele
Releas
asee and
and lo
loos
osen
en gr
groo
oov
ved nu
nutt (6)
(6) an
and
d loo
loose
sen.
n.
4 Remov
Remo ve sha
shaft
ft (2
(2),
), re
rele
leas
asee for
fork
k (1)
(1),, gro
groo
oved nu
nutt 3
(6) and tab washer
washer.. 8
6
7
5 Remove bearing bush (8). 4
6 If ne
nece
cess
ssar
ary
y, rem
remo
ove she
sheet
et (9
(9)) and
and fo
four
ur sc
scre
rews
ws 5 004483

(10).

2-24
 16 S 151 / 8 S 151 Removing Clutch Housing

3.2
3.2 Conn
Connec
ecti
tion
on plat
platee wit
with
h int
integ
egra
rall pum
pump
p
3
1
Single-piece version
10
1 Unsc
Unscre
reww he
hex bol
bolts
ts and
and nu
nuts from
from conn
connec
ecti
tion
on 2 9
 plate (1) and pump cover
cover (2). 8
4
2 Remo
Remov
ve conn
connec
ecti
tion
on plat
platee (1)
(1) toge
togeth
ther
er with
with 5
 pump/pump cover
cover (2).
2 6
3 Remo
Remov ve was
washe
herr (8)
(8),, spa
space
cerr rin
ring
g (9)
(9) and
and was
washe
her 
r 
(10) from connection plate / input shaft.
4 Remove gasket (3). 7
001996

5 Usin
Using
g plas
plasti
ticc dri
drift
ft,, dri
drive out
out sha
shaft
ft seal
seal (4).
(4).
6 Leve
Leverr of
off pum
pumpp co
cover
ver (2)
(2) from
from conn
connec
ecti
tion
on plat
platee
(1). Drive cylindrical pin (5) out of pump cover
cover or 
connection plate.
7 Remo
Remov ve pum
pump p sha
shaft
ft,, int
inter
erna
nall rot
rotor
or (6)
(6) and
and exte
exter-
r-
nal rotor (7).
8 Remo
Remov
ve sh
shim for
for inp
inpu
ut sha
shafft and
and lay
layshaf
shaft.
t.

Split version

1 Loos
Loosen
en hex
hex nut
nuts,
s, hex
hex bol
bolts
ts and
and was
washe
hers
rs (1 and
and 5).
5). 6
7
2 Remo
emove pum
pump
p hous
housin
ing
g (6
(6) to
togeth
ether with
with
 pump/pump cover
cover (2) and gasket (7).
(7). 4
3 11
3 Remo
Remov
ve oute
outerr roto
rotorr (3)
(3) and
and inne
innerr roto
rotorr (4).
(4). 2
9
4 Loos
Loosenen hex
hex nut
nutss (8)
(8) and
and rem
remo
ove conn
connec
ecti
tion
on plat
platee
(9) from input shaft t ogether with gasket (10) and 
washer (11).
5
5 Remo
Remov
ve shi
shim
m fo
for inp
inpu
ut sh
shaft
aft and
and lay
layshaf
shaft.
t.
1 10

8
009519

2-25
 Removing Shift Rail / Centre Housing 16 S 151 / 8 S 151

3.3 Clutch housing

!DANGER 
Ensure mounting brackets and rope are firmly secu-
red.

1 Remo
Remov ve 13
13 hex
hex bolt
boltss fro
from
m ins
insid
idee and
and 9 he
hex bol
bolts
ts 2
from outside. Remove cylinder pins which are not
easily accessible using special tool 1X56 138 063.
2 Fix two hooks 1X56 136 564 to clutch housing.
3 Exer
Exertt tens
tensio
ion
n on moun
mounti
ting
ng brac
brack
kets.
ets.
Hint: The clutch housing is positioned on the cen- 1
3
tre housing using 4 cylindrical pins (1). Ensure
clutch housing is level before separating from
centre housing.
4 Hit
Hit sid
sideb
ebar
arss (2)
(2) of cent
centre
re hous
housin
ing
g and
and clut
clutch
ch hou-
hou-
sing using plastic hammer.
CAUTION
Do not use prybars on housing sealing faces.
1 2 001931
5 Remo
Remov
ve clu
clutc
tch
h hou
housi
sing
ng and
and tak
takee of
off gas
gaske
kett (3)
(3)..

4 Removing components

4.1
4.1 Remo
Removing
ving com
compo
pone
nent
nts/
s/cl
clut
utch
ch hou
housi
sing
ng

1 Remo
Remov ve all
all scre
screw
w plu
plugs
gs and
and sea
seall rin
rings
gs if nece
neces-
s-
sary.
2 Remo
Remov
ve mag
magn
netic
etic scre
screw
w plu
plug
g (1
(1) and
and clea
clean.
n.
1
3 Renew sealing
ing cap if necesary.
ry.
4 Dri
Drive out
out tape
taperr rol
rolle
lerr bea
beari
ring
ng oute
outerr rac
races
es for
for inpu
inputt
shaft and layshaft from clutch housing if neces-
sary.
001932

4.2
4.2 Split
Splitte
terr shi
shift
ft rail
rail / cent
centre
re hous
housin
ing
g

1 Remo
Remov
ve grub
grub scr
screws (1)
(1) fr
from shif
shiftt fo
fork (2).
2).
2 Dri
Drive shif
shiftt rai
raill (3)
(3) out
out of
of shi
shift
ft fork
fork (2)
(2) in
in dir
direc
ecti
tion
on 2
of output end.
1 3
3 Remo
Remove
ve shif
shiftt for
fork
k (2)
(2) toge
togeth
ther
er with
with fulc
fulcru
rum
m pad
padss
(4).
4
4 Remove shift rail (3).

009943

2-26
 16 S 151 / 8 S 151 Removing Centre Housing

4.3 Removing shafts

! DANGER 
For Steps 1 - 6, see Section 4.4
Ensure mounting brackets and rope are firmly
f irmly
connected.
1 Unsc
Unscrrew co
cover (9)
(9) to
togeth
gether
er with
with gask
asket.
et.
2 Usin
Usingg dri
drift
ft,, dri
driv
ve out
out reve
revers
rsee pin
pin (3)
(3) fro
from
m cen
centr
tree
housing in direction of output. In older versions,
loosen and remove fixing screw (3a) and fixing-
washer.
CAUTION
Reverse idler gear may fall out.
18
3 Remo
Remov ve re
reverse
erse idle
idlerr gea
gearr (4)
(4) toge
togeth
ther
er with
with need
need--
le cage (5).
17
4 Remo
Remove
ve scre
screw
w plu
plug
g (6)
(6) toge
togeth
ther
er with
with seal
seal ring
ring..
5 Screw in f ixture 1X56 137 287. Interlock locking 20
 pin (7) is pushed against spring pressure.
6 Bolt li
lifting device (1
(17) 1X56 137 122 to centring 21
 bush 1X56 137 921 and place over input shaft
(18) and shift rails (19) so that it lies on the lays-
haft (21). Place disc 1X56 137 933 between lif- 19
ting device and layshaft. Place holder (20) 1X56
137 918 onto lifting device and insert into shift
rail driver.
7 Bolt
Bolt lay
layshaf
shaftt (21
(21)) to
to lif
lifti
ting
ng devi
device
ce;;
tightening torque = 85 Nm.
8 Pull
Pull out
out sha
shaft
ftss and
and shif
shiftt rai
rails
ls from
from cent
centre
re 001995
housing without tilting and place into device
1X56 137 675.
9 Remo
Removeve lift
liftin
ing
g de
device
vice (17
(17)) and
and acc
acces
esso
sori
ries
es.. Tak
Takee
out shift rails, forks and fulcrum pads.
10 Remo
Remove
ve fulc
fulcru
rum
m pad
padss fro
from
m shi
shift
ft fork
forks.
s.
NOTE: Do not dismantle shift rails any further.
In this condition, they form a complete unit.

4.4
4.4 Remo
Removi
ving
ng com
compo
pone
nent
nts/
s/ cent
centrre hous
housin
ing
g 6
22
7
1 Unscrew device 1X56 137 287 and remove 16
locking pin (7) and compression spring (8). 8
2 Remo
Remov ve all
all scre
screww plu
plugs
gs,, sea
seall rin
rings
gs,, pre
press
ssur
uree swi
swit-
t-
o
ches, pins, filler necks and gasket.
3 If nece
necess
ssar
ary
y, rem
remo
ove inje
inject
ctio
ionn pip
pipee (10
(10),
), type
type
 plate (22) and roll pins (11). 10 3a
4 Remo
Remov ve pac
packi
king
ng (12)
(12),, cir
circl
clip
ip (13)
(13) and
and bea
beari
ring
ng
 bush (14). 15 4
5 14 13 12
5 Remo
Removeve roll
roller
er bear
bearin
ing
g out
outer
er race
racess for
for main
mainsh
shaf
aftt
and layshaft from centre housing. Drive out
11 3
towards
towards inside of housing.
6 Renew f ilter (15).
9
7 Remove breather (16).
001934

2-27
 Removing Input Shaft 16 S 151 / 8 S 151

4.5 Input shaft 6

1
4.5.1
4.5.1 Disman
Dismantli
tling
ng input
input shaft
shaft 2
4 3
1 Remo
Remove ve comp
comple
lete
te inpu
inputt shaf
shaftt unit
unit from
from main
main-- 5
shaft.
2 Remo
Removeve clut
clutch
ch body
body (1)
(1) and
and sync
synchr
hron
oniz
izer
er ring
ring (2)
(2)
from input shaft synchronizer.
synchronizer.
3 Rem
Remove rin
ring
g (6
(6) fr
from insi
inside
de clut
clutch
ch body
body..

17
!
DANGER  15
Pressure pieces are under spring pressure. Prevent 16
pressure pieces from flying out.

4 Pull
Pull off
off sli
slidi
ding
ng slee
sleev
ve (3)
(3) from
from inpu
inputt shaf
shaft.
t. Catc
Catch
h
released pressure pieces (4) and compresion
springs (5).
14
5 Detac
tach circlip (7) and remove. 13
(12)
NOTE: Detach and removeremove circlip (8). Remove
Remove 11
split ring (9) (in older version only). (12)

6 Pull
Pull off
off rol
rolle
lerr bea
beari
ring
ng inne
innerr rac
racee (10
(10)) fro
from
m inp
input
ut 10
shaft using gripper 1X56 136 722, extension (9)
1X56 122 310, threaded insert 1X56 122 303 and  (8)
 basic tool 1X56 122 304. To do this, slide gripper  7
1X56 136 722 over over roller bearing inner race until
firmly seated against rollers and tighten using
knurled ring.
7 Remo
Remov
ve hel
helic
ical
al gear
gear (11)
(11) fro
from inp
inpu
ut sha
shafft. 009527

NOTE: Remove
Remove helical gear (11) from input
shaft together with needle cages (12) (in older 
version only).
8 Remo
Remov ve clu
clutc
tch
h bod
body
y (13
(13)) and
and sync
synchr
hron
oniz
izer
er ring
ring
(14) from input shaft.
9 Remo
Remov ve oil
oil baf
baffle
fle pla
plate
te (17)
(17),, det
detac
ach
h cir
circl
clip
ip (15)
(15)
and remove pipe (16) from input shaft.

2-28
 16 S 151 / 8 S 151 Assembling Input Shaft

4.5.2
4.5.2 Assemb
Assemblin
ling
g input
input shaft
shaft
16
1 Chec
Checkk wear
ear limi
limits
ts of sync
synchr
hron
oniz
izer
er comp
compon
onen
ents
ts 2
(see Section
S ection 6, “Synchronizers/Wear
“Synchronizers/Wear Limits’’). 1

2 Inse
Insert
rt pip
pipee (1)
(1) into
into inpu
inputt sha
shaft
ft and
and att
attac
ach
h cir
circl
clip
ip
4
(2) into annular groove. Press new oil baffle (16) 3
into input shaft using drift 1X56 138 109.
3 Plac
Placee syn
synch
chro
roni
nize
zerr rin
ring
g (4)
(4) and
and clu
clutc
tch
h bod
body
y (3)
(3)
onto input shaft.
NOTE: Lugs of synchronizer ring must locate in
recesses in synchronizer body on input shaft.
6
NOTE: In older version, lightly oil running areas 5
10 7
for both needle cages (11) and slide onto input 8
shaft. Slide helical gear (12) over needle cages.
9
4 Push
Push heli
helica
call gea
gearr (1
(12) over need
needle
le cage
cages.
s.
NOTE: Engaging teeth of helical gear must face
towards
towards output end and mesh with inner spline
s pline of 
clutch body.
(11)
!DANGER  12
Always wear protective gloves when handling heated  (11)
roller bearing inner race. 13
(14)
(15)
17

5 Heat
Heat roll
roller
er bear
bearin
ingg inne
innerr race
race (13)
(13) to appr
appro
ox.
100°C and slide onto input shaft. Once the roller
 bearing has cooled down,
down, it must firmly
fir mly abut
against the input shaft collar.
NOTE: In older version, insert split ring (14) into 009528

annular groove, ensuring it has axial play (pre-

stress) of between -0.5 mm and + 0.5 mm (using
special tool 1X56 136 573). Slide new circlip (15)
onto split ring. The circlip must firmly abut
against the ring. Secure circlip at three points
(120°
(120° apart).
apart).
6 Attach circlip (17).
7 Plac
Placee sli
slidi
ding
ng slee
sleeve
ve (7)
(7) ont
ontoo syn
synch
chro
roni
nize
zerr bod
body
y
(8) and locate correctly
cor rectly.. Insert new compresion
springs (9) and pressure pieces (10) into synchro-
nizer body (8) and, using suitable tool, guide into
sliding sleeve (7).
8 Plac
Placee syn
synch
chro
roni
nize
zerr rin
ring
g (5)
(5) and
and clu
clutc
tch
h bod
body
y (6)
(6)
onto input shaft.
9 Move
Move slid
slidin
ing
g sle
sleeeve int
into
o cen
centr
tree pos
posit
itio
ion.
n. To do
do
this, push against clutch body (6). The pressure
 pieces can be clearly heard clicking into place.

2-29
 Removing Mainshaft 16 S 151 / 8 S 151

4.6 Mainshaft

4.6.1
4.6.1 Disman
Dismantlin
tling
g mainshaf
mainshaftt

CAUTION 4
3
Do not damage mainshaft. Always use aluminium 2
1
clamping jaws when clamping mainshaft in vice or
similar device.

1 Clam
Clampp outp
output
ut end
end of main
mainsh
shaf
aftt in
in vice
vice..
Always
Always use aluminium clamping jaws to protect
mainshaft.
Hint: Use special tool 1X56 137 200 to position
and rotate mainshaft. Remove the oil pipe before
doing this.
2 Rem
Remove cir
circl
clip
ip (1) and
and spl
split
it ring
ring (2).
2).
3 Slide gripper 1X56 136 743 over bearing inner 
race (3) and tighten firmly against bearing rollers
using knurled ring. Screw on basic tool
1X56 122 304 and pull off bearing inner race.
4 Remove axial washer (4).
5 Clam
Clamp p inpu
inputt end
end bear
bearin
ing
g jour
journa
nall of
of main
mainsh
shaf
aftt in
in
vice. Always use aluminium clamping j aws.
6 Remove pr
pressure di
disc (5
(5). 5
6
NOTE: In straight-cut version, there is no 8
 pressure disc (5).
7
7 Deta
Detach
ch circ
circli
lip
p (6)
(6) from
rom an
annula
nularr gr
groov
oove. 9

8 Atta
Attach
ch 2- or 3-le
3-leg
g pul
pulle
lerr und
under
erne
neat
ath
h hel
helic
ical
al gear 
gear 
(7) and pull off gear together with roller bearing
inner race (8). Use adapter.
9 Remove needle cage (9).
10 Atta
Attach
ch 2- or 3-arm
3-arm pulle
pullerr und
undern
ernea
eath
th 1st-
1st-sp
spee
eed 
d 
helical gear (10) and pull off gear together with
 bush (11) and clutch body (12).
(12). Use adapter. 11
12
11 Remove ne
needle ca
cage (1
(13). 10
13

009512
009512

2-30
 16 S 151 / 8 S 151 Removing Mainshaft

12 Remo
Removeve clut
clutch
ch disc
disc (14)
(14) fro
from
m 1st/
1st/5t
5th
h gea
gearr dua
dual-
l-
cone synchronizer.
synchronizer. 22
14
13 Remove in
inner ri
ring (1
(15). 15
16
14 Remo
Remov
ve inte
interm
rmed
edia
iate
te ring
ring (16)
(16).. 17
18
15 Remove ou
outer
ter ri
ring (1
(17).
16 Pull
Pull off
off slid
slidin
ing
g sle
sleev
evee (18
(18).
). Use
Use clo
cloth
th to catc
catch
h
released pressure pieces and compression springs. 20
19
17 Remove co
coupling
ings (1
(19). 26
25
18 Place
Place 2- or 3-le
3-legg pul
pulle
lerr ont
onto
o 2nd
2nd-s
-spe
peed
ed heli
helica
call 24
gear (21). Pull off helical gear together with bush 23
(22), clutch disc (23), inner ring (24), intermedia-
te ring (25), outer ring (26) and synchronizer hub
(20). Use adapter.
adapter.
21
19 Remove ne
needle ca
cage (2
(27).
27
20 Clam
Clamp
p out
outpu
putt en
end of
of mai
mains
nsha
haft
ft..
21 Attac
Attachh 2- or 3-l
3-leg
eg pulle
pullerr unde
underne
rneat
ath
h slid
slidin
ing
g slee
sleeve
ve
(28) and pull off synchronizer ring (29), clutch
 body (30), roller bearing (31) and
and helical gear 
(32). Use adapter.
adapter.
NOTE: Use cloth to catch released pressure pie-
30
ces (33) and compression springs (34) when pul- 36
ling off sliding sleeve. 32
31
22 Remo
Removeve pres
pressu
sure
re pie
piece
cess and
and spri
spring
ngs.
s. Att
Attach
ach 2- or 
3-leg puller underneath 3rd-speed helical gear 
(35) and pull off together with roller bearing (36),
synchronizer hub (37), synchronizer ring (38) and 
clutch body (39). Use adapter. 38
33
28
CAUTION 37 34
29
Do not attach puller to mainshaft collar (see arrow).
arrow).

23 Remo
emove need
needle
le cage
cage (40)
(40)..

35 40
39

009511

2-31
 Assembling Mainshaft 16 S 151 / 8 S 151

4.6.2
4.6.2 Ass
Assemb
emblin
ling
g mainsha
mainshaft
ft 3
2
CAUTION
Do not damage mainshaft. Always use aluminium 1
clamping jaws when clamping mainshaft in vice or
similar device

1 Clamp ma
mainshaft (1
(1) at
at ou
output en
end.
2 Lightl
Ligh tly
y oi
oill nee
needl
dlee ca
cage
ge (2
(2)) and
and sl
slid
idee ont
onto
o mai
main-
n-
shaft.
9
3 Push 2n
Push 2ndd spe
speed
ed he
heli
lica
call gea
gearr (3)
(3) on
onto
to ma
main
insh
shaf
aftt 8
7
with clutch body engaging teeth facing the output 6
end. 5
4
4 Che
heck
ck we
wear
ar li
limi
mitt of
of sy
sync
nchr
hron
oniz
izer
er par
arts
ts (se
seee
Section 6).
5 Fit clu
Fit clutc
tch
h dis
discc (4)
(4) on
onto
to en
enga
gagi
ging
ng te
teet
eth
h of
of hel
helic
ical
al
gear (3). Ensure the slightly raised internal spline
in the clutch disc faces towards the output end.
001943
001943
6 Placee inn
Plac inner
er ri
ring
ng (5
(5)) ont
onto
o clu
clutc
tch
h dis
disc.
c. En
Ensu
sure
re lu
lugs
gs
face towards the output end.
7 Fit int
Fit inter
erme
medi
diat
atee rin
ring
g (6)
(6).. Ens
Ensur
uree lug
lugss loc
locat
atee in
in
recesses in clutch disc.
8 Fit out
Fit outer
er ri
ring
ng (7
(7).
). En
Ensu
sure
re lu
lugs
gs fa
face
ce to
towa
ward
rdss the
the
output end.
9 Align
Alig n lug
lugss on
on out
outer
er ri
ring
ng (7
(7)) and
and lu
lugs
gs on in
inne
nerr rin
ring
g
(5) using 3 coupling (8). Position inner and outer 
ring lugs to cover coupling, so that the couplings
will later locate in recesses in the synchronizer 
hub (9) and fit over the lugs. After adjustment,
remove couplings.

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

10 Heat
He at syn
synch
chro
roni
nize
zerr hub
hub (9
(9)) to ap
appr
prox
ox.. 120
120°° C and 
and 
 push onto spline of mainshaft. Ensure lugs locate
in recesses of the synchronizer hub. The outer 
ring tabs must engage in the synchronizer hub
recessesd. Use plastic drift to drive on
synchronizer hub.

2-32
 16 S 151 / 8 S 151 Assembling Mainshaft

11 Helic
Helical
al gear
gear (3)
(3) axia
axiall pla
play
y must
must be at least
least
0.20 mm. 12
8
12 Inse
Insert
rt cou
coupl
plin
ings
gs (8)
(8) into
into syn
synch
chro
roni
nize
zerr hub
hub (9).
(9). 9 11
3
13 Push
Push slidi
sliding
ng sleev
sleevee (10
(10)) ove
overr syn
synch
chro
roni
nize
zerr bod
body
y
and outer ring and locate against clutch disc.
14 Inse
Insert
rt new
new com
compr
pres
esio
ion
n spr
sprin
ings
gs (11)
(11) and
and pre
pressu
ssure
re
 pieces (12) into the synchronizer hub, ensuring
that they are the right way round.
NOTE: Place “dual-cone synchronizer’’ pressure 16
15
 pieces in correct position in the synchronizer hub. 14
13
15 Use suit
suitab
able
le too
tooll to guid
guidee pre
pressu
ssure
re piec
pieces
es int
into
o the
the
10
synchronizer hub and sliding sleeve.
16 Fit oute
outerr rin
ring
g (13
(13).
). The
The lug
lugss mus
mustt eng
engag
agee in
in the
the
couplings and and the tabs must engage in the
synchronizer hub recesses.
17 Fit inte
interm
rmed
edia
iate
te ring
ring (14)
(14).. Lug
Lugss mus
mustt poi
point
nt
towards the output end. Insert inner ring (15) and 
engage lugs into couplings.
18 Fit clut
clutch
ch disc
disc (16
(16)) with
with raise
raised
d inn
inner
er teeth
teeth faci
facing
ng
towards input end and engage with intermediate
ring (14). Move sliding sleeve to neutral position,
 pressing against clutch disc. The pressure pieces
can be heard clicking into place. 19
18
17 001944
001944

! DANGER 
Always wear protective gloves when handling heated
bush.

19 Heat
Heat bush
bush (17)
(17) to 120
120 °C
°C and
and push
push onto
onto main
mainsh
shaf
aftt
until firmly seated. Use plastic drift to drive on if 
necessary.
20 Ligh
Lightl
tly
y oil
oil need
needle
le cage
cage (18)
(18) and
and pus
push
h ove
overr bush
bush
(17).
21 Place
Place 1st
1st/5
/5th
th spe
speed
ed helic
helical
al gea
gearr (19)
(19) ont
onto
o need
needle
le
cage (18) so the engaging teeth mesh with clutch
disc.

2-33
 Assembling Mainshaft 16 S 151 / 8 S 151

! DANGER 
Always wear protective gloves when handling heated 22
21
clutch body. 20

22 Heat
Heat clut
clutch
ch body
body (20)
(20) to 120°
120° C and
and push
push onto
onto
mainshaft until firmly located.
NOTE: Ensure clutch body collar faces towards
output end.
23 Axia
Axiall play
play on 1st/5
1st/5th
th speed
speed heli
helica
call gear
gear must
must be
at least 0.20 mm.

! DANGER  23
Always wear protective gloves when handling heated
bush.

24 Heat
Heat bush
bush (21)
(21) to 120°
120° C and
and push
push onto
onto main
mainsh
shaf
aftt
until firmly seated.
25 Ligh
Lightly
tly oil
oil nee
needl
dlee cag
cagee (22
(22)) and
and push
push over
over bush
bush 26
(21). 24 25

26 Push
Push reve
revers
rsee speed
speed heli
helica
call gea
gearr (23
(23)) ont
onto
o mai
main-
n-
shaft and over needle cage. Ensure engaging teeth
face towards input end.
009507

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

27 Heat
Heat roll
roller
er bear
bearin
ing
g (24
(24)) to
to app
appro
rox.
x. 100°
100° C and 
and 
 push onto mainshaft until firmly seated. Use
 plastic drift to drive on if necessary.
28 Atta
Attach
ch cir
circl
clip
ip (25
(25)) into
into ann
annul
ular
ar gro
groov
ovee on
on main
main--
shaft.
NOTE: Axial play on circlip must be between 0
and 0.05 mm. Select correct circlip from spare
 parts catalogue.
29 Push
Push pre
press
ssur
uree dis
discc (26
(26)) ont
onto
o mai
mains
nsha
haft
ft..
NOTE: There is no pressure disc (26) in the
older version.
30 Clam
lamp ou
output
tput end
end of
of mai
main
nshaf
shaft.
t.

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

2-34
 16 S 151 / 8 S 151 Assembling Mainshaft

31 Oil
Oil nee
needl
dlee cag
cagee (27
(27)) and
and push
push onto
onto main
mainsh
shaf
aft.
t.
34
30
32 Push
Push 3rd
3rd speed
speed heli
helica
call gear
gear (28
(28)) ove
overr nee
needl
dlee cage
cage.. 31
Engaging teeth of helical gear face towards 32 33
output end.
33 Place
Place clut
clutch
ch body
body (29)
(29) onto
onto enga
engagi
ging
ng teeth
teeth of 
helical gear.
Refer to Chapter 6, check wear limits.
34 Place
Place sync
synchr
hron
oniz
izer
er ring
ring (30)
(30) onto
onto clut
clutch
ch body
body..
27
28
! DANGER 
Always wear protective gloves when handling heated 29
synchronizer hub.

35 Heat
Heat sync
synchr
hron
oniz
izer
er hub
hub (31
(31)) to
to 120
120°° C and
and push
push
onto mainshaft splines until axially flush. Use
 plastic drift to drive on if necessary.
NOTE: Synchronizer ring lugs must locate in
recesses in synchronizer hub.
36 Fit
Fit sl
slidi
iding sl
sleeve (3
(32).
NOTE: Recesses inside sliding sleeve must line
up with recesses in synchronizer hub for 
compression springs (33) and pressure pieces 001946

(34).
37 Inse
Insert
rt new
new com
comprpres
essio
sion
n spri
spring
ngss and
and pres
pressu
sure
re
 pieces into holes in synchronizer hub and guide
into sliding sleeve.

2-35
 Assembling Mainshaft 16 S 151 / 8 S 151

38 Posit
Positio
ion
n sync
synchr
hron
oniz
izer
er rin
ring
g (35)
(35) so
so lugs
lugs loca
locate
te in
in 39
40
recesses in synchronizer hub.
43 42 41
Refer to Chapter 6, check wear limits.
39 Place
Place clutch
clutch body
body (36)
(36) onto
onto sync
synchr
hron
oniz
izer
er ring
ring..
40 Move
Move slidi
sliding
ng sleev
sleevee into
into neut
neutra
rall pos
positi
ition
on,, 35
36
 pressing synchronizer ring (35) and clutch body body 37
(36). The pressure pieces can be hear clicking 38
into place. 37
41 Inser
Insertt bot
both
h rol
roller
ler bear
bearin
ings
gs (37)
(37) into
into 4th
4th spe
speed 
ed 
helical gear (38).
NOTE: Lubricating bores (see arrows) on roller 
 bearings must face outwards.

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

42 Heat
Heat roll
roller
er bear
bearin
ings
gs and
and hel
helic
ical
al gear
gear to 100°
100° C
001947
001947
and push onto mainshaft until bearing pack is
correctly seated.
NOTE: The helical engaging teeth on the helical
gear must face towards the output end.
43 Axia
Axiall play
play of hel
helic
ical
al gea
gearr must
must be
be at leas
leastt
0.05 mm. 37 37
NOTE: Hint: Axial washer (39), roller bearing
(40), split ring (41), circlip (42) and ring (43) are
only fitted in Section 11 “Adjusting shafts’’.

38

004915

2-36
 16 S 151 / 8 S 151 Synchronizers

4.7
4.7 Asse
Assemb
mbli
ling
ng sync
synchr
hron
oniz
izer
er
2
4.7.
4.7.1
1 Versi
Version
on ZF-
ZF-BK 
BK 
1
1 Chec
Check
k wea
wearr lim
limit
itss acc
accor
ordi
ding
ng to Sect
Sectio
ion
n 6.
6.
2 Rene
Reneww com
compr
pres
essi
sion
on spri
spring
ngss (5)
(5).. Thi
Thiss gua
guara
ran
ntees
tees
 prescribed
 prescribed shift
shift force
force for sliding sleeve (6).
(6).
3 Sync
Synchr
hro
onize
nizers
rs may
may be
be su
subass
bassem
emb bled
led fir
first
st or 
assembled on the mainshaft itself.
4
4 Push
Push slid
slidin
ing
g slee
sleeve
ve (6)
(6) ont
onto
o syn
synch
chro
roni
nize
zerr hub.
hub.
Insert new compression springs (5) and pressure
3
 pieces (4) into synchronizer hub (3). Hold drift
drift 5
against centre of pressure pieces and guide
 pressure pieces into sliding sleeve (6).
5 Posi
Positi
tion
on clut
clutch
ch body
body (1)
(1) and
and sync
synchr
hron
oniz
izer
er ring
ring (2)
(2)
and push sliding sleeve (6) into middle position.
NOTE: Ensure correct position of pressure
 pieces. 1a
2a
6

009510
009510

4.7.1.1 Sectional view of synchronizer/ZF-BK 

1 Clut
lutch body 6
2 Sync
Synchr
hron
oniz
izer
er ring
ring
3 Sync
Synchr
hron
oniz
izer
er hub
hub 2 2a
4 Pres
Pressu
sure
re piec
piecee 1
5 Comp
Compre
ress
ssio
ion
n spri
spring
ng 5

6 Slid
Slidin
ing
g slee
sleeve
ve 4 1a

3
001940
001940

2-37
 Synchronizers 16 S 151 / 8 S 151

4.7.
4.7.2
2 Vers
Versio
ion
nZZF-
F-D
D
2
1 Asse
Assemb
mbly
ly proc
proced
edur
uree bas
basic
ical
ally
ly simi
simila
larr to
to ver
versi
sion
on 7
ZF-BK. 8
1
2 Teet
Teeth
h of
of sli
slidi
ding
ng slee
sleeve
ve (6)
(6) hav
havee 3 reces
ecesse
sess
covering 3 teeth each. Align middle tooth with
narrow recess in synchronizer hub (3) (pressure
 piece groove). Renew compression springs.
3 Inse
Insert
rt new
new com
compr
pres
essi
sion
on spri
spring
ngss (5)
(5) and
and pre
press
ssur
uree
 pieces (4) into synchronizer hub. Fit pressure
 pieces so round head of pressure piece juts into
recess in sliding sleeve teeth. 4
4 Insert couplings (9).
5 3
5 Inse
Insert
rt oute
outerr rin
ring
g (2)
(2),, int
inter
erme
medi
diat
atee rin
ring
g (7)
(7) and 
and 
inner ring (8).
9
6 Place cl
clutch dis
discc (1
(1) in
in po
positi
ition.
NOTE: Ensure correct position of pressure 1a
 pieces. 8a
7a
2a
6

001941

4.7.2.1 Sectional view of synchronizer/ZF-D

6
1 Clutch di
disc
1a
2 Outer ring 2 2a
3 Sync
Synchr
hron
oniz
izer
er hub
hub 7 7a
1
4 Pres
Pressu
sure
re piec
piecee 8a
8
5 Comp
Compre
ress
ssio
ion
n spri
spring
ng 5
4
6 Slid
Slidin
ing
g sle
sleev
evee
7 Inte
Interm
rmed
edia
iate
te ring
ring
8 Inner ring
3
001942
001942

2-38
 16 S 151 / 8 S 151 Removing Layshaft

4.8 Layshaft
5
4.8.1
4.8.1 Disman
Dismantli
tling
ng laysha
layshaft
ft 4
3
CAUTION 2
Do not damage layshaft. Always use aluminium 1
clamping jaws when clamping layshaft .

1 Clam
Clampp out
outpu
putt en
end of
of lay
laysh
shaf
aftt so
so tha
thatt ro
roller 
ller 
 bearing (6) cannot be damaged.
2 Deta
Detach
ch cir
circlip
clip (1)
(1) fro
from
m ann
annu
ular
lar gro
groov
ove.
e. 6
3 On input end slide gripper 1X56 136 731 over 
roller bearing inner race (2) and tighten knurled 
ring to grip roller bearing firmly. Screw on basic
tool 1X56 122 304 and pull off roller bearing (2).
4 Clamp layshaft at input end.
5 On ou
output en
end, sl
slide gripper 1X56 136 731 over  001948
roller bearing inner race (6) and tighten knurled  001948

ring to grip roller bearing firmly. Place adapter on

output end of layshaft. Screw on basic tool 1X56
122 304 and pull off roller bearing (6).
6 Pres
Presss off
off heli
helica
call gea
gears
rs (3,
(3, 4 and
and 5)
5) ind
indiv
ivid
idua
uall
lly
y
and in sequence.
NOTE: The helical gear (3) is not included in the
8 S 151 transmission. In its place is a ring (7) (see 5
figure 004477). 4
7
2
1

004477
004477

2-39
 Assembling Layshaft 16 S 151 / 8 S 151

4.8.2
4.8.2 Assemb
Assemblin
ling
g laysha
layshaft
ft 3
4
!
DANGER  5
Always wear protective gloves when handling heated 2
parts. 1

1 Ensu
Ensurre bor
bores
es in heli
helica
call gea
gears
rs (3,
(3, 4 and
and 5) and 
and 
seats on layshaft are free of oil, grease and dust.
2 Heat
Heat heli
helica
call gea
gears
rs to 160 - 180
180°° C and
and push
push onto
onto
6
layshaft in sequence (3, 4 and 5). Press helical
gears on immediately. There must be no play
whatsoever.
NOTE: In the 8 S 151 transmission, there is a
ring (7) in place of the helical gear (5) {see figure
004477/1).
3 Heat
Heat inne
innerr rac
racee of
of rol
rolle
lerr bea
beari
ring
ng (6) to 100
100° C an
and  001948
001948

 push onto layshaft. Press roller bearing on until

firmly seated, with no play on output end.
3
4 Heat
Heat inne
innerr rac
racee of
of rol
rolle
lerr bea
beari
ring
ng (2) to 100
100° C an
and 
4
 push onto layshaft. Press roller bearing on until
7
firmly seated, with no play on input end. 2
1
5 Atta
Attach
ch circ
circli
lip
p (1)
(1) into
into annu
annula
larr groo
groove
ve on inpu
inputt
end of layshaft. Axial play on circlip must not
exceed 0.1 mm. Select correct circlip from spare
 parts catalogue.

004477/1

NOTE: a = Direct drive

 b = Overdrive

a b
001949
001949

2-40
 16 S 151 / 8 S 151 Assembling Clutch Housing / Centre Housing

5 Installing components

5.1 Centre ho
housing
5 10
1 Fit
Fit all
all scre
screw
w plu
plugs
gs,, pre
press
ssur
uree swi
switc
tche
hess and
and fill
filler 
er  3
necks with new seal rings or gaskets and insert. 11
Tightening torques: see “Adjustment Data,
Tightening torques’’section.
9
2 Inse
Insert
rt inje
inject
ctio
ion
n pip
pipee (1)
(1) if requ
requir
ired
ed.. Rol
Rolll end
endss into
into 1 7 8
holes in housing using rolling tool 1X20 155 653
and insert O-ring (3).
Rolling torque = 5 to 6 Nm.
3 Insert new filter (4). 6
4
4 If nece
necess
ssar
ary,
y, fit
fit typ
type-
e-p
plate
late (5)
(5) usi
using
ng pins
pins..
5 If nece
necess
ssar
ary,
y, inse
insert
rt new
new cyl
cylin
indr
dric
ical
al pins
pins (6)
(6) int
into
o 001950

housing.
6 Driv
Drivee new
new tape
taperr roll
roller
er bear
bearin
ing
g out
outer
er race
racess for 
for 
mainshaft and layshaft into centre housing if 
necessary.
NOTE: Heat bearing bore to approx. 60°C using
hot air blower.
7 Inse
Insert
rt beari
earing
ng bush
ush (7
(7), circ
circli
lip
p (8
(8) and
and new
new
 packing using plastic drift (9). Ensure correct
seating.
8 Inse
Insert
rt comp
compre
ress
ssio
ion
n spr
sprin
ing
g (11
(11)) wit
with
h loc
locki
king
ng pin
pin
(10) and align . Screw in fixture 1X56 137 287.

5.2 Clutch housing

1 If nece
necess
ssar
ary,
y, inse
insert
rt tap
taper
er rol
rolle
lerr bea
beari
ring
ng oute
outerr rac
races
es
for the input shaft and layshaft into bearing bores
in the clutch housing.
NOTE: Input shaft bearing outer race above.
Layshaft bearing outer race below.
2 Fit
Fit scre
screw
w plug
plugss wit
with
h new
new seal
seal ring
ringss and
and inse
insert
rt..
Tightening torque: M18 x 1.5 = 35 Nm,
M22 x 1.5 = 50 Nm,
M24 x 1.5 = 60 Nm.
3 Scre
Screw
w in
in cle
clean
aned
ed oil
oil dra
drain
in plug
plug and
and mag
magne
nett (1)
(1)..
Tightening torque = 140 Nm.
1 2
4 Fit cap (2).
001951
001951

2-41
 Wear Limit/Synchronizer 16 S 151 / 8 S 151

6 Synchronizers/wear limit
x
6.1 Determ
Dete rmin
inin
ingg wea
wearr lim
limit
it
(except for 1st /2nd gear)

Check condition of synchronizer rings and clutch

 bodies before assembling synchronizers.
1 2
NOTE: Do not mix up synchronizer parts.
1 Placee syn
Plac synch
chro
roni
nize
zerr rin
ring
g (1)
(1) on
onto
to co
corr
rres
espo
pond
ndin
ing
g
clutch body (2). Turn synchronizer parts so cones
nest evenly and parallel together.
Wear limit for 3rd/4th gear and splitter 
synchronizer rings is 0.8 mm. Wear limit for 
range-change rings is 1.2 mm.
2 Using
Usin g fee
feele
lerr gau
gauge
ge,, mea
measu
sure
re di
dist
stan
ance
ce (X
(X))
 between clutch body and synchronizer ring at two
opposing points. If wear limit is below 0.8 or
1.2 mm, exchange synchronizer ring and/or 
clutch body.
3 Check
Chec k con
condi
diti
tion
on of sy
sync
nchr
hron
oniz
izer
er pa
part
rtss (vi
(visu
sual
al
check). Replace synchronizer parts if surface is
not flat. Do not mix up parts which have been
inspected together (mark parts accordingly).
001999

6.2
6.2 Dete
Determ
rmin
inin
ing
g wear
wear lim
limit
it (1s
(1stt /2nd
/2nd ge
gear
ar))

1 Placee inn
Plac inner
er ri
ring
ng (3
(3),
), in
inte
term
rmed
edia
iate
te ri
ring
ng (2
(2)) an
and 
d 
outer ring (1) of 1st/2nd gear synchronizer
onto clutch disc (4). Turn outer ring so cones nest F 50 N
evenly together. Evenly apply 50 Nm on outer 
ring.
2 Using
Usin g a fe
feel
eler
er ga
gauuge
ge,, mea
measu
sure
re dis
ista
tanc
ncee (s)
(s)
 between clutch disc and outer ring at two s
opposing points. The wear limit is 1.5 mm. If 
distance (s) is below wear limit, use new 1 2 3 4
intermediate and/or outer ring and inner ring.

001952
001952

2-42
 16 S 151 / 8 S 151 Adjusting Mainshaft

7 Adjusting mainshaft
2
7.1
7.1 Deter
Determi
mini
ning
ng ring
ring and
and axia
axiall was
washe
herr
(straight-cut version) 1

1 Plac
Placee mai
mains
nsha
haft
ft into
into cent
centre
re hous
housin
ing
g usi
using
ng lift
liftin
ing
g
device 1X56 137 200.
2 Plac
Placee rin
ring
g (1)
(1) into
into clut
clutch
ch body
body (2).
(2). Fit
Fit par
parts
ts onto
onto
4th speed helical gear.
3 Take
Take seve
severa
rall meas
measur
urem
emen
ents
ts of dist
distan
ance
ce betw
betwee
een
n
top edge of
of clutch body and centre housing
sealing face with gasket fitted. Calculate average
distance.
4 Nominal dimension X of 32.2 -0.5 mm must be
001953
ensured. If the average distance is different, select
ring to ensure nominal distance (see table in
under 5).
5 Sele
Select
ct thru
thrust
st wash
washer
er (3)
(3) fro
from
m the
the foll
follow
owin
ing
g tab
table
le..
If 3.6 mm ring is required, use 7.9 mm thrust
washer.
Ring (1): 3.6 / 4.0 3
Thrust washer (3): 7.9 / 8.3 1

6 Remo
Removeve main
mainsh
shaf
aftt fro
from
m cen
centr
tree hous
housin
ing
g and
and pla
place
ce
     X
thrust washer onto mainshaft with raised collar 
facing towards helical gear.

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

7 Heat
Heat new bear
bearin
ing
g inne
innerr race
ace (4)
(4) to 100°
100° C and 
and 
 place onto bearing journal of main shaft ensuring 001954
001954
it is firmly seated. Drive on using plastic drift.
8 Appl
Applyy appr
approx
ox 4g of lubr
lubric
icat
atin
ing
g grea
grease
se (Ara
(Aralu
lube
be
HL2 or Texando F020) bearing inner race (collar 
side) on face of bearing output end (see arrow).
NOTE: Make sure no grease is applied to the
outside of the bearing rollers. Grease applied here
may block the input shaft lube bores. 3
9 Using drift 1X56 137 676, insert split ring (5) 4
into annular groove on mainshaft to give axial 5
6
 play and prestress of - 0.05 mm to + 0.05 mm.
Split rings are available in 0.1 mm thicknesses.
10 Slide
Slide new
new circ
circli
lip
p (6)
(6) over
over spl
split
it rin
ring
g and
and peen
peen over 
over 
at 3 points (120°
(120° apart) using
using punch.
punch.

001955

2-43
 Adjusting Mainshaft 16 S 151 / 8 S 151

7.2
7.2 Dete
Determ
rmin
inin
ing
g rin
ring
g and
and axia
axiall was
washe
herr
(helical-cut version)

1 Meas
Measur
uree dis
dista
tanc
ncee bet
betwe
ween
en main
mainsh
shaf
aftt and
and bear
bearin
ing
g
inner race contact point using depth gauge
(dimension „a“).
2 Inser
nsertt axi
axial
al wash
washer
er (1)
(1) and
and measu
easurre dis
dista
tan
nce 4.6 -0.4
2
 between mainshaft and axial washer using depth
gauge (dimension „b“).
3 a – b mus
mustt giv
givee a play
play of betwe
etween
en + 0.0
0.07
7 mm
mm an
and 
- 0.08 mm.
1
4 Afte
Afterr sel
selec
ecti
ting
ng the
the cor
corre
rect
ct axia
axiall was
washe
her,
r, inse
insert
rt
ring (2) into clutch body (3). Place parts onto 4th-
speed helical gear.
5 Meas
Measururee dis
dista
tanc
ncee bet
betwe
ween
en axia
axiall was
washe
herr and 
and 
clutch body at several points. Calculate mean +0.07 bis
+0.07 to -0.08
-0.08
value. Nominal dimension = 4.6 - 0.4mm (select
ring (2) accordingly). 009521
009521

!
DANGER 
Always wear protective gloves when handling heated 3
bearing inner race.
2

6 Heat
Heat new
new bea
beari
ring
ng inne
innerr rac
racee (4)
(4) to 100
100°C and 
and 
 place onto mainshaft bearing journal until it is in
firm contact. Fully drive home using plastic drift.
7 Appl
Applyy app
appro
rox
x 4g of lubr
lubric
icat
atin
ing
g gre
greas
asee (Ar
(Aral
alub
ubee
HL2 or Texando F020) bearing inner race (collar 
side) on face of bearing output end (see arrow).
NOTE: Make sure no grease is applied to the
outside of the bearing rollers. Grease applied here
may block the input shaft lube bores.
001953
8 Use drift 1X56 137 676 to insert split ring (5) into
annular groove in mainshaft to give axial
 play/prestress of between - 0.5 mm and + 0.05
mm. Split rings are available in 0.1 mm
thicknesses (0.1 mm, 0.2 mm etc.).
9 Slid
Slidee new
new circ
circli
lip
p (6)
(6) over
over spli
splitt rin
ring
g and
and peen
peen over 
over  1
in three places (120°
(120° apart) using
using punch. 4
5
6

001955

2-44
 16 S 151 / 8 S 151 Installing Shafts

8 Installing sh
shafts

8.1
8.1 Inpu
Inputt sha
shaft
ft,, main
mainsh
shaf
aftt and
and lays
laysha
haft
ft

!
DANGER 
Ensure fixture and rope are firmly secured. 5

1 Place al
alternating pin 1X56 137 920 onto the 4
layshaft locator. Insert output end of mainshaft 7
(1) into locator 1X56 137 675. Place clutch body, 6
correct ring and synchronizer ring onto the teeth
of the helical gear on the mainshaft. Place the
complete input shaft onto the mainshaft. Position 2
layshaft (2) with teeth at correct height for 
meshing. Push the layshaft against the mainshaft
and bring the teeth into mesh. 3
1
2 Inse
Insert
rt shif
shiftt rai
rails
ls (3)
(3) and
and fulc
fulcru
rum
m pad
padss int
into
o sli
slidi
ding
ng
sleeves on mainshaft.
3 Place centring bush 1X56 137 921 into lifting
device 1X56 137 122 (4) and secure. Push lifting
device over input shaft (5) and shift rails and 
 push down onto layshaft.
4 Scre
Screw
w lif
lifti
ting
ng devi
device
ce onto
onto lays
laysha
haft
ft usin
using
g disc
disc
1X56 137 933 (6). 001995
Tightening torque = 85 Nm.
5 Plac
Placee hol
holde
derr (7)
(7) in driv
driver
er rece
recess
sses
es and
and lif
lifti
ting
ng
device.

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

6 Inse
Insert
rt main
mainshshaf
aft,
t, inpu
inputt sha
shaft
ft and
and lay
laysh
shaf
aftt int
into
o
taper roller bearing outer races in centre housing
without tilting.
NOTE: Ensure interlock is retracted and locked.
7 Remove all lifti
iftin
ng equipment.
8 Remove device 1X56 137 287 for interlock.
9 Turn
Turn inpu
inputt sha
shafft to
to cen
centr
tree bea
beari
ring
ng rolle
ollers
rs..
.

2-45
 Adjusting Shift Fork 16 S 151 / 8 S 151

9 Split
litter shift fork / shift rail

9.1 Adju
Adjust
stin
ing
g shift
ift fork 
fork 
6
1 Guid
Guidee in
in sh
shift
ift rai
raill (1)
(1) from
from insi
insid
de (in
(in cent
centre
re
housing). To protect packaging, slide correct size
 pin through packaging from outside
outside to prevent 3
damage to the packaging caused by shift rail
threads. 4

CAUTION
Do not damage flange packing when inserting shift
rail.
1
2 Corr
Correcectl
tly
y pos
posit
itio
ion
n shi
shift
ft fork
fork (3)
(3) and
and fulc
fulcru
rum
m pad
padss
against sliding sleeve (4) and place onto shift
rail.
NOTE: Line up bores in shift rail with thread in
shift fork.
3 Inser
nsertt gru
grub
b scr
screw
ewss (6
(6) (d
(do not
not tig
tighten
hten yet)
et). 2 x
5
4 Switch
tch sli
sliding slee
leeve to output.
001956
001956
5 Scre
Screw
w pist
piston
on (2)
(2) and
and new
new doub
double
le-g
-gro
roov
oved
ed ring
ring
onto shift rail.
NOTE: Renew lock nut;
Tightening torque = 150 Nm.
Ensure the thread is absolutely free of grease.
6 Nomi
Nominanall dim
dimen
ensi
sio
on (X)
(X) betw
betwee
een
n pis
pisto
ton
n and 
and 
centre housing (5) sealing face must be 94.0 mm.
Use grub screws (6) to adjust shift. Measure
without gasket on centre housing .
7 Fulc
Fulcru
rum
m pad
padss in
in the
the sli
slidi
ding
ng slee
sleeve
ve must
must have
have the
the
same play above and below (check using feeler 
gauge).
8 Tighten grub screws evenly.
Tightening torque = 60 Nm.

2-46
 16 S 151 / 8 S 151 Adjusting Shift Fork  

I Adju
Adjust
st as foll
follow
owss if
if usi
usin
ng sup
supp
port
ort pla
plate
te
5
1X56 137 917:

9 Work
Work step
stepss 1)
1) to
to 3)
3) and
and 5).
5). Fit
Fit spli
splitt
tter
er cyli
cylind
nder
er (7)
(7) 8
(see work steps 1) to 4) in Section 13.2). Screw
support plate onto the housing sealing face.
Switch the sliding sleeve to the output. Splitter 
 piston must axially contact cylinder and cylinder 
must axially contact the supporting plate. This is
the correct position. Then follow work steps 7)
and 8).
7

001965

II Adju
Adjust
st as foll
follow
owss (ne
(new
w ver
versi
sion
on)) if
if usi
using
ng
centering device 1X56 138 079 and support
plate 1X56 137 917:
8
10 Adju
Adjust
st as desc
descri
ribe
bed
d unde
underr ste
step
p 9).
9).
Attach the centering device 1X56 138 079 before
 performing steps 7) and 8). 3
1

009944

2-47
 Assembling Clutch Housing / Centre Housing 16 S 151 / 8 S 151

10 Clut
Clutch
ch ho
hous
usin
ing
g / ce
cent
ntrre hou
housi
sing
ng

10.1
10.1 Fi
Fitt
ttin
ing
g clut
clutch
ch hou
housi
sing
ng

1 Fitt ne
Fi new gas
gaske
kett to
to cen
centr
tree hou
housi
sing
ng se
seal
alin
ing
g fa
face
ce..

!
DANGER  1
Ensure fixtures and rope are firmly secured.

2 Using hook 1X56 136 564, place clutch housing

(1) flat onto centre housing.

CAUTION
End of injection pipe must engage
engage in clutch
cl utch housing
bores in funnel and shift rails.
001957

NOTE: Position all cylindrical pins between

clutch housing and centre housing. If necessary,
 push shift rail drivers inwards
inwards until clutch housing
is fixed.
3 Screw
Scre w in
in 13
13 hex
hex bo
bolt
ltss ins
insid
idee clu
clutc
tch
h hou
housi
sing
ng an
and
d9
hex bolts outside. Turn input shaft several times
to centre bearing rollers.
Tightening torque = 49 Nm.
4 Remove hook 1X56 136 564.

2-48
 16 S 151 / 8 S 151 Adjusting Mainshaft

11 Adjusting shafts

11.1
11.1 Input
Input shaf
shaftt and
and conne
connecti
ction
on plat
platee

1 To ach
achie
ieve
ve corr
correc
ectt sett
settin
ing,
g, the
the inpu
inputt shaf
shaftt roll
roller
er--
 bearing must be play-free when measured. To To
ensure this, the outer race (1) must touch the bea-
ring rollers (2). Use plastic drift to push taper rol-
ler bearing outer race towards
towards output end. Rotate
input bearing several times to centre bearing rol-
lers.
NOTE: Bearing rollers should not move and  1 3
should not be prestressed. a
2 Meas
Measururee dist
distan
ance
ce betw
betwee
een
n face
face of bear
bearin
ing
g out
outer 
er 
race (1) and sealing face (3) using depth gauge.
 Note down dimension “a”. 2

NOTE: Measure at two opposite points and  001958

001958
calculate the average value.
3 Meas
Measururee dist
distan
ance
ce betw
betwee
een
n seal
sealin
ing
g face
face (4)
(4) and 
and 
locating face (5) for shim in connecting plate
using depth gauge. Note down dimension “b”.
Measure gasket (6) and note down dimension.
NOTE: Measure at two opposite points and cal-
culate the average value. 4 b
4 Calc
Calcul
ulat
atee the
the dif
differe
ferenc
ncee “c”
“c” and
and not
notee it
it do
down:
wn: 6
c = (b + gasket) – a
5
NOTE: Axial play on roller bearing: 0.0 to
0.1 mm.
5 Sele
Select
ct a shi
shim
m of
of the
the sam
samee thi
thick
ckne
ness
ss as dime
dimens
nsio
ion
n
“c” (max. 0 - 0.1 mm).
6 Plac
Placee shi
shim
m in
in th
the con
conn
necti
ectio
on pla
plate
te.. Shi
Shims
ms are
are
available
available in 0.05 mm thicknesses.
001959
NOTE: The same procedure is used for
measuring split connection plates.

2-49
 Adjusting Layshaft 16 S 151 / 8 S 151

11.2 Layshaft

1 Ther
Theree mus
mustt be
be no
no pla
play
y on
on the
the lays
laysha
haft
ft tape
taperr rol
rolle
ler 
r 
 bearing during measurement. Use plastic drift to
 push outer race (1) towards
towards output until it is pres-
sed firmly against the bearing rollers (2). Rotate
input bearing several times to centre bearing rol-
lers.
NOTE: Bearing rollers should not move and 
should not be presetressed.
2 Meas
Measur
uree thic
thickn
knes
esss of shim
shim usin
using
g dept
depth
h gaug
gauge.
e.
NOTE: Measure at two opposing points. 1

3 Meas
Measur
uree dist
distan
ance
ce betw
betwee
een
n hous
housin
ing
g sea
seali
ling
ng face
face a
and bearing outer race (1) face. Measure gasket
and add to dimension “a”.
2
4 Use
Use av
averag
eragee dim
dimen
ensi
sion
on “a”
“a” ob
obtain
tained
ed fro
from
measurements taken to select correct shim 001960
001960

NOTE: Axial play 0.0 to 0.1 mm.

5 Thic
Thickn
knes
esss of
of shim
shim must
must corr
corres
espo
pond
nd to meas
measur
ure-
e-
ment “a” (max. minus 0.1 mm).
6 Plac
Placee shi
shim
m ont
onto
o tap
taper
er roll
roller
er bear
bearin
ing
g out
outer
er race
race..
Shims are available in 0.05 mm thicknesses.

2-50
 16 S 151 / 8 S 151 Assembling Connection Plate

12. Fitting clutch housing components

12.1 Connec
Connectio
tion
n plate
plate with
with integr
integral
al pump
pump 10
9
8
Single-piece version 11 1
7 2
1 Thin
Thinlly coa
coatt ou
outsid
tsidee of
of sha
shaft
ft seal
seal (1)
(1) wit
with
h
sealing compound and, using drift
1X56 103 766, insert into connection plate. 6 5

NOTE: Sealing lip on shaft seal ring must face

towards
towards drift. 4
3
2 Plac
Placee was
washe
herr (8)
(8),, spa
space
cerr rin
ring
g (9)
(9) and
and was
washe
herr (10
(10))
onto input shaft.
3 Screw guide pin 1X56 137 949 into the threaded  001993
hole in the layshaft.
4 Fit
Fit ne
new gas
gaske
kett (11
(11)) to
to con
conne
nect
ctio
ion
n pla
plate
te (2),
(2), plac
placee
over
over input shaft and onto clutch housing. Tighten
hex bolts and nuts.
Tightening torque = 46 Nm.
5 Unsc
Unscre
rew
w guid
guidee pin
pin from
from the
the lays
laysha
haft
ft..
6 Plac
Placee inn
inner
er roto
rotorr (3
(3) int
into
o pum
pump
p hou
housi
sing
ng (5)
(5).
Engage with layshaft.
7 Plac
Placee out
outer
er rotor
otor (4) into
into pum
pump ho
housin
using.
g.
NOTE: Ensure there is axial play on outer and 
inner rotors.
8 Thin
Thinlly coa
coatt co
cover
ver sea
seali
ling
ng face
face (6)
(6) wit
with
h Loc
Locti
tite
te
 No. 574 (from hole to hole) and place onto
onto pump
housing.
9 Dri
Drive cylin
ylindr
dric
ical
al pin
pinss (7)
(7) into
into pump
pump cov
cover.
er. Rota
Rotate
te
inout shaft to check.
10 Aff ix
ix pump cover  
Tightening torque = 46 Nm.

2-51
 Assembling Connection Plate 16 S 151 / 8 S 151

Split version

1 Plac
lace wa
washer (1) onto in
input sh
shaft. 6
7
2 Plac
Placee con
conne
nect
ctio
ion
n pla
plate
te (2)
(2) ov
over inpu
inputt sha
shaft
ft and 
and 
onto clutch housing together with new gasket (3). 5 1
9
Tighten hex nuts (4). 10
Tightening torque = 46 Nm. 2

3 Fit
Fit ne
new gas
gaske
kett (7)
(7).. Bri
Bring
ng pump
pump hous
housin
ing
g (6)
(6) and 
and 
inner rotor into mesh with layshaft and tighten
(8). 8
Tightening torque = 46 Nm.
11 3
4 Inse
Insert
rt oute
outerr rot
rotor
or (9)
(9) in
into pump
pump housi
ousing
ng..
NOTE: Ensure that there is axial play on the 4
outer and inner rotors. 009519

5 Ligh
Lightl
tly
y coa
coatt pum
pump
p co
cover seal
sealin
ing
g fac
facee (10
(10)) wit
with
h
Loctite 574 (from bore to bore) and place onto
 pump housing.
6 Firmly attach pump cover.
Tightening torque = 46 Nm.

2-52
 16 S 151 / 8 S 151 Assembling Release Fork  

12.2
12.2 Rele
Relea
ase for
fork 
k 

Released fork (pulled) 7

3 4
1 Inse
Insert
rt plai
plain
n sphe
spheri
rica
call bea
beari
ring
ng (1)
(1) into
into bear
bearin
ing
g 2
9
 block (2) and attach circlips (3). 8
2 Fix beari
earing
ng block
lock usin
using
g hex
hex bolt
boltss (4)
(4)..
1
Tightening torque = 115 Nm. 3
7
3 Slid
Slidee rel
relea
ease
se fork
fork (5)
(5) ove
overr bea
beari
ring
ng block
lock and
and 5 8
9
insert pin (6).
4 Fit seal
seal ring
ringss (7)
(7) and
and sea
seals
ls (8)
(8) ont
onto
o pin
pin..
6
5 Attach circlips (9) to pin. 009520

Release fork (pushed)

1 Scr
Screw in
in ball
ball bolt
bolt (3) with
with washe
asherr (4).
(4).
Use Loctite no. 262.
4
Tightening torque = 100 Nm 3
2
2 Plac
Placee bal
balll cup
cup (2) in clu
clutch
tch lev
lever (1).
(1). 1
3 Plac
Placee clu
clutc
tch
h le
lever (1)
(1) ont
onto
o bal
balll bol
boltt (3)
(3)..

004484 004484

2-53
 Assembling Release Fork 16 S 151 / 8 S 151

Release fork (pulled)

9
1 Push
Push shaf
shaftt (2)
(2) into
into clut
clutch
ch bell
bell hous
housin
ing.
g. Fit
Fit ne
new 10
tab washer (7) and grooved nut (6) onto shaft.
2 Guid
Guidee sha
shaft
ft into
into 1st
1st bea
beari
ring
ng bore
bore on conn
connec
ecti
ting
ng 1
 plate. Push release fork (1) onto shaft and guide
this into 2nd bearing bore on the connecting plate.
2
3 Plac
Placee bea
beari
ring
ng bush
bush (8)
(8) ove
overr sha
shaft
ft and
and int
into
o clu
clutc
tch
h
housing.
5
4 Hit
Hit slo
slott
tted
ed pins
pins (4)
(4) int
into
o rel
relea
ease
se fork
fork (1)
(1) and
and shaf
shaftt 3 6 8
(refer to assembly specification). 7
4
5 Fit
Fit tab
tab washe
asherr (7)
(7) and
and gro
groo
oved
ved nut
nut (6)
(6) ont
onto
o bea
bea--
ring bush. Secure g rooved
rooved nut. 004483

Tightening torque = 200 Nm

004483
6 Fit
Fit shi
shift
ft leve
leverr (3)
(3) onto
onto shaf
shaftt usi
using
ng scre
screw
w (5)
(5)
(observe position);
Tightening torque = 120 Nm.
7 Mou
Mount shee
sheett (9)
(9) usin
using
g fo
four scre
screws
ws (10
(10);
Tightening torque = 23 Nm

7
6

1 2
4 004 917
004917

3
004 918

004918

2-54
 16 S 151 / 8 S 151 Assembling Reverse Idler Gear

13 Fitt
Fittin
ing
g cen
centr
tree hou
housi
sing
ng comp
compon
onen
ents
ts

13.1 Reverse
Reverse idler gear/re
gear/rever
verse
se idler pin 3
4
5
1 Inse
Insert
rt nee
needl
dlee cag
cages
es (1)
(1) int
into
o re
revers
versee idl
idler
er gear
gear..
2 Plac
Placee reve
revers
rsee idle
idlerr gear
gear (2)
(2) into
into hous
housin
ing.
g.
2
NOTE: Collar of reverse idler gear must face
towards
towards output end. 1
3 Push
Push rev
reverse
erse idle
idlerr pin
pin (3)
(3) into
into cent
centre
re hous
housin
ing
g
from output side until firmly seated.
4 In “firs
“firstt ver
versi
sion
on’’’, scre
screw
w in
in washe
asherr (4)
(4) and 
and  7
locking bolt (5).
Tightening torque = 86 Nm. 6
NOTE: In “2nd version’’,
version’’, the reverse idler pin is 001962
001962
secured using a centrally-mounted clamping pin
(8) (figure 002000).
5 Fit
Fit co
cover (6)
(6) and
and new
new gas
gask
ket (7)
(7) onto
onto cent
centre
re hou-
hou-
sing.
Tightening torque = 49 Nm.

3 8

2
1
002000

13.2 Cylinder

1 Rem
Remove sup
supp
porti
ortin
ng pla
plate
te and
and cy
cylin
linder
der.
2 Check locking nut on piston.
Tightening torque = 150 Nm. 2
3
3 Fit sp
spring
ing wa
washer (1
(1) on
onto ho
housing. 4
1
4 Fit cylin
ylinde
derr (2)
(2) with
with new
new O-r
O-rin
ing
gs (3
(3 and
and 4).
4).
NOTE: If necessary, fit 3 O-rings.
Hint: Lightly oil O-rings.
5 Inser
nsertt cylin
linder
der onto
nto cent
centrre hou
housing
sing..
NOTE: Line up lug on cylinder with groove in
centre housing.

001963
001963

2-55
 Compressed Air Test 16 S 151 / 8 S 151

13.3
13.3 5/2-
5/2-wa
way
y val
valv
ve

1 Inse
Insert
rt new
new O-r
O-rin
ing
g (1
(1) int
into
o 5/2
5/2-w
-waay val
valv
ve.
2 Scre
Screw
w 5/2
5/2-w
-waay val
valv
ve (2)
(2) onto
onto cent
centre
re hous
housin
ing.
g.
Tightening torque = 9.5 Nm.
NOTE: There is no 5/2-way valve in the 8 S 151
transmission.
1

001964
001964

13.4 Compressed
Compressed air test
test for
for piston
piston and splitter
splitter
cylinder
3
1 Screw su
support pl
plate 1X56 137 917 (1) for splitter 
cylinder (2) onto centre housing (3). 1
2 Supp
Supplly com
compr
pres
esse
sed
d air
air (max
(max.. 6.8
6.8 bar)
bar) to 5/2-
5/2-w
way
valve and piston.
3 Wet oute
outerr edg
edgee of
of spl
split
itte
terr cyl
cylin
inde
derr and
and chec
check
k for 
for 
 bubbles (leaks).
4 Supp
Supplly com
compr
pres
esse
sedd air
air to pist
piston
on in oppo
opposi
site
te dire
direc-
c-
tion and check if air escapes through 5/2-way
valve.
5 If bubb
bubble
less for
form,
m, fit new
new O-r
O-rin
ings
gs if nece
necess
ssar
ary
y and 
and  2
check correct location.
6 If air
air esc
escap
apes
es,, ren
reneew dou
doub
ble-g
le-gro
roo
oved ring
ring on
 piston.
001965
7 Remove su
support pl
plate (1
(1). 001965

2-56
 16 S 151 / 8 S 151 Installing Components

13.5
13.5 Inje
Inject
ctio
ion
n pip
pipee

1 Using drift 1X56 137 835, drive injection pipe (1)

into mainshaft until firmly located.

001966

2-57
 Installing Range-Change Housing 16 S 151 / 8 S 151

14 Inst
Instal
alli
ling
ng com
compl
plet
etee rang
range-
e-ch
chan
ang
ge

1 Fit new
new gas
gask
ket (1)
(1) ont
onto
o cen
centr
tree ho
housin
using
g (2
(2).
NOTE: There must 3 cylindrical pins in centre
housing.
2 Fit
Fit 2 hex
hex bol
bolts
ts to rang
range-
e-ch
chan
ange
ge hous
housin
ing
g to
to all
allo
ow 1
range-change to be suspended from a rope and 
 positioned horizontally against centre housing.
housing.

CAUTION 2
Secure hex bolts with nuts. Ensure rope is firmly
secured.

Hint: Use threaded pins on centre housing to sim-

 plify positioning of range-change.
3 Push
Push rang
range-
e-ch
chan
ange
ge agai
agains
nstt cen
centr
tree hous
housin
ing
g (2).
(2).
Turn output flange to bring planet gear train and 
mainshaft teeth into mesh
mes h if necessary.
4 Remo
Remov ve hex
hex bolt
boltss and
and rope
rope when
hen ran
range
ge-c
-cha
hang
ngee is
is
held against centre housing. 3

5 Slid
Slidee ran
range
ge-c
-cha
hang
ngee (3)
(3) para
parall
llel
el to cent
centre
re hous
housin
ing
g 2
and bolt together.
together.
Tightening torque = 49 Nm.
6 Swit
Switch
ch pist
piston
on to end
end pos
posit
itio
ion
n (hi
(high
gh or low
low gro
group
up).
).

001967

2-58
 16 S 151 / 8 S 151 Assembling Centre and Range-Change Housing

7 Screw f ixing device 1X56 137 579 into centre

housing and into hole for detent plunger (6).
8 Screw ne
new lo
locking nut on
onto pi
piston 13 14
Tightening torque = 150 Nm.
20 6
NOTE: Renew locking nut. Make sure the thread 
is absolutely free of grease. 21 7

9 Remove f ix
ixing device.
11
10 Fit cy
cylinder an
and tig
tigh
hten.
Tightening torque = 49 Nm.
8
NOTE: Carefully push cylinder over piston
10
together with guide ring and piston gasket.
9
11 Scre
Screw in dete
detent
nt plun
plunge
gerr (6)
(6) toge
togeth
ther
er with
with new
new
seal ring (7). 22
19 23
Tightening torque = 50 Nm.
18 15
12 Inse
Insert
rt pin
pin (8)
(8) and
and switc
switch
h (9)
(9) toge
togeth
ther
er with
with new
new
seal ring (10).
17
Tightening torque = 50 Nm.
16
NOTE: In the new version, fit switch (9) onto the
range-change housing. 001968
001968
13 Fit
Fit scre
screw
w plu
plug
g (13
(13)) with
with new
new sea
seall rin
ring
g (14
(14).
).
Tightening torque = 50 Nm.
14 Inse
Insert
rt pin
pin (15
(15)) and
and swi
switc
tch
h (16)
(16) wit
with
h new
new seal
seal rin
ring
g
(17).
Tightening torque = 50 Nm.
15 Inse
Insert
rt dete
detent
nt plun
plunge
gerr (18)
(18) wit
with
h new
new seal
seal rin
ring
g (19)
(19);;
Tightening torque = 50 Nm.
16 Screw
Screw in rev
rever
erse
se gea
gearr pre
pressu
ssure
re swit
switch
ch (20
(20)) with
with
new sealing ring (21).
Tightening torque = 50 Nm.
NOTE: In the new version, the pressure switch
(20) is mounted in the cover (shift housing).
17 Scre
Screw
w in scre
screw
w plug
plug (23)
(23) with
with new
new seal
seal rin
ring
g (22
(22).
).
Tightening torque = 35 Nm.
18 Screw
Screw in mech
mechan
anic
ical
al speed
speedom
omet
eter
er and
and ne
new sea
seall
ring or impulse sensor.
Tightening torque = 50 Nm.
19 Scre
Screw
w bre
breat
athe
herr in
into bore
bore (11
(11).
Tightening torque = 10 Nm.

2-59
 Installing components 16 S 151 / 8 S 151

15 Installing components

15.1 Shift housing 3

1 Plac
Placee ne
new gas
gaske
kett (1)
(1) onto
onto clut
clutch
ch hous
housin
ing
g (2)
(2) and
and
1
sealing face.
2 Plac
Placee com
compl
plet
etee shi
shift
ft hous
housin
ing
g (3)
(3) in posi
positi
tion
on.. Lin
Linee
up bores in shift housing with bores in gasket.
Hint: Use threaded pins to simplify positioning of 
clutch housing, gasket and shift housing. 2
3 Shif
Shiftt thr
throu
ough
gh all
all the
the gear
gears.
s. Ther
Theree mus
mustt be
be
noticeable excess shift travel in each gear. If the
shift angle is not within the specified tolerances,
it must be adjusted using an angle measuring
device. Finally,
Finally, tighten all hex bolts. 001969
Tightening torque = 23 Nm.

CAUTION
 0 +2°
'
 1 4 ° 3
The shift turret housing must be centered on the 1st, 3rd, 5th, 7th gear  14° 3 
30 
   
0 '   + 2 
°   

transmission housing so that equal play (excess shift 2nd, 4th, 6th,
travel) is obtained on both sides and the resultant 8th gear 
shift angle
angle is 14°
14° 30’ +2° (see illustr
illustration
ation).
).

009894

15.2 Plastic pipes

1 Usin
Usingg uni
unioon scr
screews and
and ne
new sea
seall rin
ring
gs, scre
screw
w 2
 plastic pipes (1) to cylinder (2) and shut-off
shut-off valve
(3) as marked. 6
Tightening torque = 38 Nm. 1 4
5
2 Fit
Fit pip
pipee bra
brack
cket
et (4)
(4) and
and fixed
fixed plas
plasti
ticc pip
pipes
es to hou-
hou-
sing.
6 1
NOTE: Observe the following assembly sequen- 6
ce if renewing the pipe bracket or plastic pipes.
6
1. Place insert (5) into pipe bracket (4) 3
2. Draw plastic pipes (1) through the pipe bracket.
3. Press rings (6) into plastic pipes (1).

001992

2-60
 16 S 151 / 8 S 151 Compressed Air Test

16 Comp
Comprresse
essed
d air
air test
test on brea
breath
ther
er

1 If nece
necess
ssar
ary
y, rem
remo
ove brea
breath
ther
er and
and scre
screw
w pres
pressu
sure
re
gauge connection into bore (1).
1
NOTE: Supply air to 5/2-way valve (2) over a
long period (max. 6.8 bar) and check pressure
gauge.
2 Reinsert breather
Tightening torque = 10 Nm.
NOTE: There is no 5/2-way valve in the 8 S 151
transmission. Therefore, this test is not required  2
here.

001970
001970

2-61