2hl250-270-290 - SM en

Order No.
: 5871 042 002
ZF – HYDROSTATIC POWERSHIFT
TRANSMISSION
2 HL – 250/270/290
ZF Passau GmbH
Donaustr. 25 - 71
D- 94 034 Passau
Edition: 2003/11
REPAIR INSTRUCTIONS
for the
ZF - HYDROSTATIC POWERSHIFT
TRANSMSSION
2 HL – 250/270/290
I M P O R T A N T N O T E:
The great variety of ZF units compels a restriction of the Disassembly and Assembly Manuals to a
current ZF production unit. Technical development of the ZF units as well as extensions concerning
the design possibilities may require differing steps, which can be carried out by qualified Specialists
without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare
Parts Lists.
The described Disassembly and Assembly Manual is based on the design level of a ZF production unit
at the time of preparation of the Repair Manual.
For information about the Description, Operation and Maintenance, refer to the corresponding
operating instructions (ZF Order No.: 5872 014 002).
The ZF Passau GmbH reserve the right to replace the present Disassembly and Assembly Manual by
a successional edition without advance notice. Upon request, the ZF Passau GmbH will advise what
edition is the latest one.
----------------------------------------------------------------------------------------------------------
ATTENTION:
For the Installation as well as for the commissioning of the unit,
the Instructions and Specifications of the Vehicle Manufacturer
have to be observed!
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous reserve de modifications techniques!
1.Auflage / 1.Edition
Off-Road Transmissions
Repair Manual and Axle Systems
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PREFACE
This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair
and Maintenance operations on ZF-Units.
Treated is a ZF-Serial product according to the design stage of the date of Edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and
theoretical training is constantly completed to the actual situation in our Training School.
The Service Stations, established by the ZF Friedrichshafen all over the world, offer you:
1. Constantly trained personnel
2. Prescribed installations, e.g. Special Tools
3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability.
Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the
actual contractual conditions, by the ZF-Warranty.
Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-
expenditures eventually arising from it, are excluded from this contractual responsibility.
This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH
Service Department
5871 042 002 0/1

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GENERAL
The Service Manual covers all works required for the dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
Parts fitted in heated state have to be installed subsequently after cooling down to ensure a
perfect contact!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
The use of Molykote is prohibited.
Lined plates with organic friction linings (e.g. paper linings) must not be washed (negative effect on lining
adhesion).
Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
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Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair work are listed in the text as well as in the
Chapters “W” (List of Special Tools) and “WB” (Illustrated Tables).
Important information on industrial safety
Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods,

! CAUTION information, the use of auxiliaries etc... in this repair manual.
Is used, if lacking care can lead to personal injury or damage the

DANGER product.
___________________________________________________
REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description.
REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again.
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Density lineaire en kg/m; Density superficielle en t/m2
Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Uniteo Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
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VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25,40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2,205 lb ( pounds )
9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)
1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5,560 lb / in ( pound per inch )
1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )
0,070 bar ( 0,071 kp/cm2 ) =

1 psi ( lbf/in2 )
1 Liter =
0,264 Gallon ( Imp. )
4,456 Liter =
1 Gallon ( Imp. )
1 Liter =
0,220 Gallon ( US )
3,785 Liter =
1 Gallon ( US )
1609,344 m =
1 Mile ( Landmeile )
0° C ( Celsius ) =
+ 32° F ( Fahrenheit )
0 ° C ( Celsius ) =
273,15 Kelvin
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TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARD 148
Friction value: µ total= 0.12 for screws and nuts without after-treatment, as well as phosphatized
nuts. Tightened by hand!
Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO-Standard Thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine Thread DIN 13, Page 13

Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
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
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
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INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

FOR ZF POWERSHIFT TRANSMISSIONS
VERSION "A"
1 = Model (Transmission Type)

2 = Serial No.
3 = ZF Parts List No.
4 = Total ratio of the transmission
5 = Oil filling (Oil specification)
6 = ZF List of Lubricants
7 = Oil capacity
8 = Customer Code
1 2
3 4
5 6
7
8
NOTES TO SPARE PARTS ORDERS:
When ordering genuine ZF Spare Parts please indicate as follows:
1. = Transmission Type
2. = Serial No. This data is indicated on the model identification plate!
3. = ZF Parts List No.
4. = Trade Mark and Type of the Spare Part
5. = Denomination of the Spare Part
6. = Spare Part No.
7. = Way of delivery
Please complete the above mentioned details in order to avoid mistakes in the delivery of the ordered
spare parts!
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INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

FOR ZF POWERSHIFT TRANSMISSIONS
VERSION "B"
1 = Customer Name (Vehicle Manufacturer)

2 = Type
3 = ZF Parts List No.
4 = Vehicle manufacturer Parts List Number
5 = Current Serial Number
6 = Oil filling (Oil specification)
1 KUNDE / CUSTOMER
TYPE SERIAL - NO.
2 5
PARTS LIST NO. LIST OF
LUBRICANTS
3 TE-ML
CUSTOMER PART NO. 6
4
MANUFACTURED BY
ZAHNRADFABRIK PASSAU GMBH
MADE IN GERMANY
NOTES TO SPARE PARTS ORDERS:
When ordering genuine ZF Spare Parts please indicate as follows:
1. = Transmission type
2. = Serial No. This data is indicated on the model identification plate!
3. = ZF Parts List No.
4. = Trade Mark and Type of the Spare Part
5. = Denomination of the Spare Part
6. = Spare Part No.
7. = Way of delivery
Please complete the above mentioned details in order to avoid mistakes in the delivery of the ordered
spare parts!
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NOTES TO THE REQUIRED

OIL QUALITY AND OIL FILLING CAPACITY:
Oil quality/Oil grade: Only oils according to the quality specified in the
ZF List of Lubricants TE - ML 07 are allowed to be used !
The ZF Lists of Lubricants will be updated every three (3) months and
can be requested or examined as follows:
-in all ZF Plants
-in all ZF After-Sales Service Stations
-Internet http://www.zf.com – Products for – Tech. Information – List of Lubricants .....
In the corresponding ZF Lists of Lubricants you will find information about:

Oil specification - Manufacturer - Product name
like e.g. ................... ........................................
transmission oils without and
with Limited-Slip-Additives etc. ....
grease for lubrication points ...
Oil filling capacity for Power Shift Transmissions (2 HL-250/270/290):

- vertical installation position: approx. 2.5 liters
- horizontal installation position: approx. 3.0 liters
oil sump volume – in the transmission to be filled initially (i.e. after dis- and reassembly).
The values indicated are approximate values !
Specifications – as to oil level check, oil and filter change – are indicated in the ZF Operating
Instructions!
ZF Operating Instructions  Order No.: 5872 014 002
For the version „AXLE ATTACHMENT“:

Oil level check and oil change for the ZF Axle see the respective
LUBRICATION AND MAINTENANCE INSTRUCTIONS
in the relating repair manuals!
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LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY
ZF – HYDROSTATIC POWERSHIFT TRANSMISSION

2 HL - 250 / 270 / 290
4143 020 030
Disassembly Reassembly Designation and Use Part No.
Chapter/Fig. Chapter/Fig.
1/01 Assembly truck cpl. with tilting device 5870 350 000
Supporting bracket 1 Set = 2 Pcs. 5870 350 106
Universal use.
To mount the complete axle onto the assembly truck.
1/02 8/01 Lifting chain 3-Strand 5870 281 047

1/17 8/02 or
Lifting strap 5870 281 026
Universal use.
To lift heavy loads when dis- and reassembling axle and
transmission parts.
2/01 Assembly truck cpl. with tilting device 5870 350 000
Holding fixture 5870 350 079
To mount the cpl. transmission 2 HL 250 / 2HL 270 / 2 HL 290
onto the assembly truck.
2/12 Set of external pliers A1-A2-A3-A4 5870 900 015

2/29 Universal use.
2/31 To unsnap and snap in externally clamping retaining rings.
2/40 To remove the piston 4143 201 021 from the housing bore.
3/11 To remove the output gear from the transmission housing.
2/17 Eyebolt assortment 5870 204 002

Lifting chain 3-Strand 5870 281 047
To lift out and in the piston 4143 351 054
2/21 Resetting device 2 pcs. required 5870 400 001

2/22 To lift the thrust ring 4143 351 056 from the transmission
2/41 housing. To separate the thrust ring 4143 351 056 from the
3/03 ring 4143 351 057 .
To press off the planetary gears from the planet carrier.
To press the shaft seal by means of lever action out of the
housing
2/25 5/23 Clamping pliers # 5870 900 021

2/33 5/32 Universal use.
To unsnap and to snap in the retaining ring 190 x 4 = 0630 502
056 / 115 x 4 = 0630 502 073 .
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2 HL - 250 / 270 / 290
4143 020 030
2/36 4/26 Fixture # 5870 240 025

3/01 4/35 Universal use.
5/20 To lock the output flange when detaching and tightening the bolt
connection.
2/37 Back-off device 5870 000 017

To press the planet carrier 4143 315 068 out of the transmission
housing.
2/38 Rapid grip # 5873 012 021

Basic tool # 5873 002 001
To pull the taper roller bearing – inner ring 0735 372 036 and
0735 372 036 respectively from the planet carrier.
2/42 Three-armed puller # 5870 971 003

Universal use.
To pull the bearing inner rings 0735 455 309 from the planet
carrier.
3/4 Parting tool # 5870 300 028

Pry bar set # 1 Set = 2 Pcs. 5870 345 036
Magnetic block 1 Set = 3 Pcs. 5870 450 003
Universal use.
To press the bevel pinion from the housing.
3/6 Gripping insert # 5873 001 037

To pull the bearing inner ring 0750 117 715 = HM807048
from the bearing pinion.
Used in combination with:
Basic tool Size I 5873 001 000
or hand lever press with magnetic block.
3/7 Internal extractor # 5870 300 019

Counter support # 5870 300 020
Universal use.
To pull the the bearing outer ring 0750 117 715=HM807010
out of the transmission housing.
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2 HL - 250 / 270 / 290
4143 020 030
4/1 Lever riveting tongs # 5870 320 016

Universal use.
To install the screw plug 0631 405 073 = LK950-070 into the
transmission housing.
Only required for new assembly!
4/3 Mounting tool 5870 058 073

To drive the bearing outer ring 0750 117 057 = 31310
into the transmission housing.
Handle 5870 260 002
4/7 Mounting tool 5870 048 281

4/8 To drive the shaft seal 0734 319 397 = 70x90x7
into the transmission housing.
4/10 Digital depth gauge # 5870 200 072

4/12 Straightedge # Length 195 mm 5870 200 108
4/13 Gauge blocks # 1 Set = 2 Pcs. 5870 200 066
4/36 Universal use.
To measure the bevel pinion and the transmission housing.
4/14 Mounting tool 5870 058 078

To drive the bearing outer ring 0750 117 515 = HM807010 into
the transmission housing.
Handle 5870 260 002
4/22 Clamping bar # 5870 654 049

5/16 To fasten the preassembled pinion in the transmission housing.
To fasten the preassembled planet carrier into the housing.
4/28 Torque spanner # 1 – 12 Nm 5870 203 031

Reducing # 1/2“-1/4“ 5870 656 056
Spanner # 5870 656 004
or
Spring balance # 0,5 – 10 Nm 5870 230 003
To check and to determine the rolling moment of the
pinion bearing.
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2 HL - 250 / 270 / 290
4143 020 030
4/30 Mounting tool # 5870 048 279

To insert the shaft seal 80 x 110 x 11 = 0734 319 718 into the
housing bore. Output flange.
4/33 Pressure piece # 5870 506 150

To press on the sheet 4143 303 085 onto the output flange
4143 303 082 .
5/01 Mounting tool 5870 058 051

5/02 To insert the bearing outer ring 0735 372 036 into the
transmission housing.
5/10 Mounting tool 5870 048 282

To install the cyl. roller bearings 0735 455 309 into the planetary
gear and bearing inner ring.
5/12 Mounting tool 5870 048 283

To install the planetary gear onto the planet carrier.
5/13 Set of external pliers A1 - A2 - A3 - A4 5870 900 015

5/15 Universal use.
5/22 To snap in and unsnap externally clamping retaining rings.
5/26 To locate and to position the preassembled planet carrier.
5/24 Hot-air blower # 230 V 5870 221 500

Hot-air blower # 115 V 5870 221 501
Universal use.
To heat the transmission and bearing parts.
5/42 Measuring cover # 5870 200 131

5/43 To determine the clearance in the clutch and brake .
5/44-47 Digital depth gauge # 5870 200 072

Straightedge # 5870 200 022
Universal use.
To determine the clearance in the clutch and brake .
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2 HL - 250 / 270 / 290
4143 020 030
5/51 Mounting tool 5870 506 161

5/53 To insert the ring.
5/61 To insert the pressure ring into the transmission housing.
To insert the piston.
5/70 Adjusting screws # (1 Set = 2 Pcs.) M 12 5870 204 021

Universal use.
To align and to position the cover of the housing .
5/79 Air connection 5870 505 012

For functional and leakage testing of the emergency release.
5/82-85 HP – Hand pump # 5870 287 007

Cpl. with shut-off valve, pressure gauge and HP-line for
functional and leakage testing of the multi-disc brake.
5/83 Spline mandrel # 5870 510 039

5/85 Torque spanner # 20 – 100 Nm 5870 203 037
To determine the breakaway torque in the multi-disc brake.
6/08 7/02 Set of internal pliers I11 – I21 – I31 – I41 5870 900 014
6/20 Universal use.
To unsnap and snap in of internally clamping retaining rings.
6/10 7/01 Set of external pliers A11 – A21 – A31 – A41 5870 900 016
6/22 Universal use.
To unsnap and snap in of internally clamping retaining rings.
6/11 Internal extractor 5870 300 012

6/23 Counter support 5870 300 011
Universal use.
To remove the needle sleeve HK1010 = 0635 303 036 from the
pump housing.
7/08 Mounting tool # 5870 705 003

To insert and to position the needle sleeve HK1010 = 0635 303
036 into the pump housing.
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2 HL - 250 / 270 / 290
4143 020 030
7/23 Mounting bush # 5870 651 055

Mounting-aid to widen and install the gasket 0501 320 242
upon the piston 4143 342 067
7/24 Calibrating pin # 5870 651 056

To calibrate the gasket 0501 320 242 upon the piston 4143
342 067
# Very important Special tools
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1. Separate the HL-TRANSMISSION from the AXLE CASING:

(only for the version „AXLE ATTACHMENT“)
Drain oil from the axle casing –
use a suitable collector.
(S) Assembly truck 5870 350 000

(S) Supporting bracket 5870 350 106
Figure 1
Pick-up the HL-Transmission by means of the lifting tackle,

loosen the bolt connection and the complete HL-Transmission
from the axle casing.
(S) Lifting chain 5870 281 047

or
(S) Lifting strap 5870 281 026
Figure 2
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2. DISASSEMBLY – BRAKE / CLUTCH / PLANET CARRIER

Mount the transmission to the assembly truck.
!
Illustration shows the HL-Version „AXLE ATTACHMENT“
(S) Assembly truck cpl. with 5870 350 000

tilting device
(S) Holding fixture 5870 350 079
Figure 1
Loosen the screw plug and drain the oil –

use a suitable collector.
Figure 2
2.1 LUBE OIL PUMP/DOWNSHIFT

INTERLOCK:
2.1.1 Version „Lube Oil Pump“:

Remove the lube oil pump or the downshift interlock (depending
on the version) (Illustration shows – Version „Lube Oil Pump).
! Cpl. disassembly of the lube oil pump/downshift interlock –

See CHAPTER 6.
Figure 3
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2.2 SPEED TRANSMITTER:

Loosen the screw and pull off the speed transmitter.
Figure 4
2.3 EMERGENCY RELEASE (Parking Brake):

(Illustration - Figure No. 5 … 8 – shows Version
„Transmission Installation Position VERTICAL“ )
! Position of the single connection or bleeder valves/lubrication

nipples etc. … as to the Version „Transmission Installation
Position HORIZONTAL“
- see Chapter 5, Page 5/22, Figure No. 81 !
Remove the bleeder.
Figure 5
Remove the compression spring and the ball.
Figure 6
Remove the threaded element (see Detail „X“) with O-Ring from
the bore.
„X“
Figure 7
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Remove the lubrication nipple, both screw plugs and the bleeder
valve – see arrow.
Figure 8
2.4 INPUT HOUSING and

MODULATION VALVE:
! Loosen the bolt connection of the input housing equally – the

input housing is subject to a cup spring and compression spring
preload !
Figure 9
Take off the input housing and remove the O-Ring (arrow).
Figure 10
Modulation valve:
Remove the compression spring and the O-Ring (arrow).
Figure 11
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Pull the complete piston out of the bore.
(S) Set of external pliers 5870 900 015
Figure 12
2.5 BRAKE / CLUTCH:

Remove the cup springs from the brake.
Figure 13
Remove the cup springs from the clutch.
Figure 14
Remove the piston.
Figure 15
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Pull off both cyl. pins (arrows).
Figure 16
Attach 2 (two) eyebolts and pull the piston cautiously out of the
housing – risk of damage!
(S) Eyebolts assortment 5870 204 002

Figure 17
Remove both seals (arrows) from the piston.
Figure 18
Remove the axial roller cage with both thrust washers.
Figure 19
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Remove the pressure piece and the compression spring.
Figure 20
Remove the pressure ring with ring – also see Fig. No. 22 –
cautiously by means of lever action – risk of damaging the
sealing surfaces !
! Ring can also remain in the housing – disassemble the ring

separately!
(S) Resetting device 5870 400 001
Figure 21
Remove the pressure ring from the ring cautiously by means of

lever action – risk of damaging the sealing surfaces !
Figure 22
Remove the gasket and O-Rings from the pressure ring / ring.
Figure 23
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Take the disc set of the brake with end shim(s) out of the
housing.
!
Illustration shows version/components of the 2 HL-290.
Figure 24
Unsnap the retaining ring.
(S) Clamping pliers 5870 900 021
Figure 25
Remove the snap ring and the shim.
Figure 26
Take the disc set of the clutch (with end shim/s) out of the
internal gear.
!
Illustration shows version/components of the 2 HL-290.
Figure 27
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Remove the cpl. input shaft with internal gear from

the housing.
Figure 28
Figure 29
Press the input shaft out of the ball bearing/internal gear.
Figure 30
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Figure 31
Press the centering disc from the input shaft.
! disassembly aid !
In case of an extremely fixed seat – heat the centering disc –
Figure 32
Unsnap the retaining ring and remove the ball bearing.
Figure 33
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2.6 PLANET CARRIER:
Remove the axial needle cage with both thrust washers.
Figure 34
If not yet disassembled before – remove the lube oil pump or the
downshift interlock (depending on the version) (illustration
shows - version - „Lube Oil Pump“).
! Chapter 6.
Cpl. disassembly of the lube oil pump/downshift interlock – see
Figure 35
Loosen the bolt connection and remove the washer – fasten the
output flange by means of the fixture.
(S) Fixture 5870 240 025
Figure 36
Press the cpl. planet carrier out of the roller bearing.
! ring !
Pay attention to the released planet carrier and the bearing inner
(S) Extractor 5870 000 017
Figure 37
5871 042 002 2/10

Division
Pull the second bearing inner ring from the planet carrier.
(S) Rapid grip 5873 012 021

(S) Basic tool 5873 002 001
Figure 38
If required – expel both bearing outer rings (arrow) from the

bearing bore.
! bearing
If the taper roller bearings are reused – pay attention to the
location, i.e. respective bearing inner ring to bearing
outer ring !
Figure 39
Figure 40
Remove the planetary gear by means of lever action – pay

attention to the released shim and the cylindrical rollers !
Figure 41
5871 042 002 2/11

Division
Pull off the bearing inner ring – in case of an extremely fixed

seat heat the bearing inner ring.
(S) Three-armed puller 5870 971 003
Figure 42
Remove both seals (1).
3 Remove both bleeder valves (2) and all screw plugs (3) with
sealing and O-Ring respectively.
(Illustration shows the positions for the transmission version
1
„Installation Position Vertical“) !
3
Figure 43
Only for the version

„Transmission Installation Position HORIZONTAL“:
(Figure No. 44 and 45)
Loosen the countersunk screws and remove the screen sheet.
! (Loctite) – heating for disassembly, if necessary !

Countersunk screws are installed with locking compound
Figure 44
Remove the screen sheet (2) from the planet carrier (1).
2
Figure 45
5871 042 002 2/12

Division
3. DISASSEMBLY - OUTPUT
3.1 VERSION – AXLE ATTACHMENT:
(HL-Transmission mounted directly to the axle)
Loosen the bolt connection, remove the cover and the O-Ring.
(S) Fixture 5870 240 025
Figure 1
Pull off the flange.
Figure 2
Remove the shaft seal by lever action.
Figure 3
Fasten the pinion by means of the device and press it off.
! adjusting ring (rolling moment/pinion bearing) behind it !

Pay attention to the released bearing inner ring and the
(S) Device 5870 300 028

(S) Pry bar set 5870 345 036
(S) Magnetic block 5870 450 003
Figure 4
5871 042 002 3/1

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Remove the O-Ring (arrow) and the bush from the pinion.
Figure 5
Pull off and press off respectively the bearing inner ring.
(S) Gripping insert 5873 001 037

(S) Magnetic block 5870 450 003
Figure 6
Pull the bearing outer ring out of the bearing cover.
!
Pay attention to the shim behind it (pinion gap setting) !
(S) Internal extractor 5870 300 008

(S) Counter support 5870 300 003
Figure 7
5871 042 002 3/2

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Pull off the bearing cover.
Figure 8
Remove the O-Rings (arrows).
Figure 9
Remove the shaft seal.
Figure 10
Lift the output gear with oil baffle plate out of the housing.
Remove the oil baffle plate from the output gear.
Figure 11
5871 042 002 3/3

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Remove the screen sheet.
Figure 12
Expel the bearing outer ring from the housing bore (arrow).
Figure 13
Remove the stud bolts, if necessary.
Figure 14
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3.2 VERSION - „SEPARATE

INSTALLATION“:
1 (HL-Transmission installed separately from the axle)
In case of the transmission version „SEPARATE
INSTALLATION“ it is possible, differently from the
transmission version „AXLE ATTACHMENT“, to remove
2 3 and to install the output – without the previous disassembly
of brake/clutch and planet carrier!
Legend to Sketch No. 15:

Figure 15 1 = Input
2 = Output – Front axle
3 = Output – Rear axle
Fasten the output flange by means of the fixture.

Loosen the bolt connection – pull off washer, O-Ring and
flange.
(S) Fixture 5870 240 025
Figure 16
Press off the shaft seal by lever action.
! Install the second output flange and the shaft seal

analogously !
Figure 17
Loosen the bolt connection.
Figure 18
5871 042 002 3/5

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By means of lifting tackle separate the output gear with cover

from the transmission housing.
Figure 19
Press the output gear out of the ball bearing/cover – remove the
released oil baffle plate.
Figure 20
Unsnap the retaining ring and expel the ball bearing from the
cover.
(S) Set of internal pliers 5870 900 013
Figure 21
Remove both O-Rings (arrows) from the cover.
Figure 22
5871 042 002 3/6

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Remove the screen sheet from the transmission housing.
Figure 23
Expel the ball bearing from the housing bore.
Figure 24
5871 042 002 3/7

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4. REASSEMBLY - OUTPUT
Only when a new housing is installed:
(Fig. No. 1)
Seal the finished holes (8x) of the oil supply bores with screw
plugs.
(S) Lever riveting tongs 5870 320 016
Figure 1
4.1 VERSION – AXLE ATTACHMENT:

(HL-Transmission directly attached to the axle)
Install the stud bolts.
! Observe the installation position – see Fig. Nr. 2 !

Tightening torque ....................... MA = 20 Nm
Figure 2
Insert the bearing outer ring until contact.
(S) Mounting tool 5870 058 073

(S) Handle 5870 260 002
Figure 3
Insert the slotted pin (arrow).
Figure 4
5871 042 002 4/1

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Position the screen sheet – with slotted pin (see Fig. No. 4) into
the fixing bore (arrow).
!
Observe the installation position – slotted pin = radial fixing of
the screen sheet !
Figure 5
Insert the output gear – Observe the installation position !
Figure 6 Contact face (external shell of the shaft seal) if:

- rubberized ! to be wet with spirit
- metal ! to be provided with sealing compound
(Loctite No. 586).
! Installation position of the shaft seal – Sealing lip showing to the

oil sump (see Sketch No. 8) !
! position (Dim. „X“ - see Sketch No. 8).

Install the shaft seal (1) considering the required installation
Grease the shaft seal in the area around the sealing and dust lip.
! (Grease „Renolit EP 2“ ZF Part No. 0671 190 079).
Figure 7 Exact installation position of the shaft seal is guaranteed by use
of the specified mounting tool !
1 Legend to the sketch:

„X“
1 = Shaft seal
2 = Bearing cover
2
„X“ = Installation dimension " 69.5 – 0.5 mm
Figure 8
5871 042 002 4/2
Division
4.1.1 Determine Adjusting Shim for Pinion Gap:

4
1 Legend to Sketch No. 9 ... Fig. No. 14:
X
A Z
1 = Pinion
2 = Roller bearing
C B 2 3 = Bearing cover
E 4 = Ball (Ø = 7 mm)
3
S D A = Auxiliary dimension
B = Bearing width
C = Reference dimension
D = Contact surface/bearing cover to contact/bearing bore
E = 73.0 mm (constant value)
X = Pinion dimension (engraved on the pinion)
Z = 189.0 mm (Contact surface/bearing cover to
center/axle casing)
For a correct installation and positioning

! of the pinion, the following steps are to be
carried out as exactly as possible !
Figure 9
Determine the auxiliary dimension „A“.
Position the ball (Ø = 7 mm) into the centering bore of the pinion
and determine Dim. „A“, from the contact surface/pinion
shoulder to the ball.
Auxiliary dimension „A“ = e.g. 42.56 mm
! Auxiliary dimension „A“ is obligatory to determine the

reference dimension „C“ – on the installed pinion (Fig. No.
36).
(S) Block gauges 5870 200 066

(S) Straightedge 5870 200 108
(S) Digital depth gauge 5870 200 072
Figure 10
Read pinion dim. „X“ on the pinion (see arrow) or measure it in

case of manufacturing-specific + or – deviation from the pinion
dim. (relating value is marked by hand on the pinion e.g. + 0.1).
Pinion dim. “X“ (without + or – deviation) = 116.0 mm

+ 0.1
Pinion dim. „X“ with an indicated deviation = 116.1 mm
Pinion dim. „X“ with an indicated deviation - 0.1 = 115.9 mm
+ 0,1
116
Figure 11
5871 042 002 4/3

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Determine Dim. „B“ bearing width, paying attention that the

rollers are seated without clearance (aligning of rollers – rotate
the bearing inner ring in both directions several times) !
! deducting an empirical value of

Since the installed roller bearing is subject to a preload,
– 0.1 mm is to be considered !
Dim. „B“ = e.g. 36.65 mm - 0.1 mm " 36.55 mm

(S) Block gauges 5870 200 066
Figure 12
Determine Dim. „D“ (contact surface/bearing cover to

contact/bearing bore ).
Dim. „D“ = e.g. 34.50 mm
(S) Block gauges (2 sets) 5870 200 066

EXAMPLE:
Figure 13 Dim. „Z“ .............................................. 189.00 mm

Dim. „X“ z.B. .................................... - 116.00 mm
Result " Dim. „E“ ............................ = 73.00 mm
Dim. „E“ ............................................... 73.00 mm

Dim. „B+D“ (e.g. 36.55 + 34.50) ....... - 71.05 mm
Result " required shim „S“ ............... = 1.95 mm
Insert the determined shim(s) „S“ = e.g. 1.95 mm and install

the bearing outer ring subsequently until contact is obtained.

(S) Handle 5870 260 002
Figure 14
Oil the O-Rings (arrows) and insert them into the ring grooves of
the bearing cover.
Figure 15
5871 042 002 4/4

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Bend the edges of the fixing straps of the oil baffle plate
slightly – assembly aid (sheet is fixed to the bearing cover –
see Fig. No. 17).
Figure 16
Mount the oil baffle plate on the bearing cover.
! baffle plate into the recess of the bearing cover (see arrow) !
Observe the installation position – locate the fixing lug of the oil
Figure 17
Oil the contact face/oil baffle plate/housing (assembly aid).
Mount the preassembled bearing cover and by means of hexagon

nuts (use washers) locate it equally until contact.
Then remove the hexagon nuts again.
Figure 18
Mount the heated bearing inner ring until contact and after
cooling-down install it subsequently until contact is obtained.
Figure 19
5871 042 002 4/5

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Mount the bush, oil the O-Ring (arrow) and put it into the ring
groove.
Figure 20
Mount the preassembled pinion.
Figure 21
Fasten the pinion by means of the clamping bar.
(S) Clamping bar 5870 654 049
Figure 22
5871 042 002 4/6

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4.1.2 Determine the Adjusting Ring for Rolling

Moment/Pinion Bearing:
Rotate the transmission by 180°.
Mount the adjusting ring (s = optional).
! Itmm)is recommended to reinstall the adjusting ring (e.g. s = 1.35

from the disassembly, if however the required rolling
moment of 1.5 ... 3.0 Nm (without shaft seal) is not obtained –
see bearing rolling moment check Fig. No. 28 – the bearing
rolling moment is to be corrected with an adequate adjusting
Figure 23 ring!
Mount the heated bearing inner ring and install it subsequently

until contact.
Figure 24
Mount the flange.
Figure 25
Put on the washer and fasten the flange with hexagon screws.
! Rotate the pinion – when tightening – in both directions

(aligning of rollers) several times !
Tightening torque (M 10/8.8) ................. MA = 46 Nm
(S) Fixture 5870 240 025
Figure 26
5871 042 002 4/7

Division
Turn back the pinion fastening and remove the clamping bar
respectively.
Figure 27
4.1.3 Check the Rolling Moment of the Pinion

Bearing:
Bearing rolling moment (without shaft seal) 1.5 ... 3.0 Nm
(When using new roller bearings – upper value should be
achieved)
! If the required rolling moment deviates, it is to be corrected with

an adequate adjusting ring (see Fig. No. 23) !
(S) Torque spanner ¼“ 5870 203 031

(S) Reducing ½“ -¼“ 5870 656 056
(S) Spanner 5870 656 004
or
(S) Spring balance 5870 230 006
Figure 28
Remove the flange again.
Figure 29
5871 042 002 4/8

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4.1.4 Shaft Seal/Output Flange:
Contact face (external shell of the shaft seal) if:

(Loctite No. 586).
! Installation position of the shaft seal – Sealing lip showing to the

oil sump (see Sketch No. 31) !

position (Dim. „M“ - see Sketch No. 31).
(Grease „Renolit EP 2“ ZF Part No. 0671 190 079).
Figure 30 Exact installation position of the shaft seal is guaranteed by use

Legend to the sketch:

4
1 = Shaft seal
N M 2 = Screen sheet
1
3 = Flange
2 5 4 = Roller bearing
5 = Bearing cover
3
„M“ = Installation dimension " 17.6 – 0.5 mm
Figure 31
„N“ = Installation dimension " 27.5 + 0.3 mm
Only for installation of a new flange or if stud bolts were

removed : (Fig. No. 32)
Install the stud bolts

Installation position –Stud bolts with short thread length into
flange!
Tightening torque (M10x1) ................. MA = 20 Nm
Figure 32
Only for installation of a new flange/screen sheet or if removed :

(Fig. No. 33)
Install the screen sheet (2), considering the required installation

position (Dim. „N“ - see Sketch No. 31).
Exact installation position of the screen sheet is guaranteed by

use of the specified mounting tool!
(S) Pressure piece 5870 506 150
Figure 33
5871 042 002 4/9

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Mount the preassembled flange and put the O-Ring into the
recess.
Figure 34
Place the washer and fasten it by means of hexagon screws.
Tightening torque (M 10/8.8) ................. MA = 46 Nm
(S) Fixture 5870 240 025
Figure 35 4.1.5 Check the Pinion Gap:
Position the ball [use Ø = 7 mm " ball Ø like for the

determination of auxiliary dimension „A“] into the centering
bore of the pinion and determine Dim. „C“ (see Sketch No.9),
from the contact surface/bearing cover to the ball.
EXAMPLE:
Reference dimension „C“ e.g. ....... 115.58 mm

Auxiliary dimension „A“ e.g. ...... - 42.56 mm (see Fig. No. 10)
Result (Dim. „E“) ........................ = 73.02 mm
If the constant value of Dim. „E“ = 73.00 ± 0.05 mm

is not achieved, it is to be corrected with an adequate
Figure 36 shim/pinion gap (see Fig. No. 14) !
For a correction of the shim/pinion gap, a counter-

correction of the adjusting ring of the rolling moment/
pinion gap – Fig. No. 23 is also to be considered !
(S) Block gauges (2 sets) 5870 200 066

5871 042 002 4/10

Division
4.2 VERSION SEPARATE INSTALLATION“:

(HL-Transmission installed separately from the axle) In case of the transmission version
„SEPARATE INSTALLATION“ it is
possible, differently from the
transmission version „AXLE
ATTACHMENT“, to remove and to
install the output – without the
2 10 previous disassembly of brake/clutch
and planet carrier!
11 13 11
Legend to Sketch No. 37 …. Fig. No. 55:
1 = Transmission housing
14 2 = Ball bearing
14
3 = Screen sheet
16 16 4 = Cover
5 = Ball bearing
6 = Retaining ring
15 15 7 = O-Ring
8 = Oil baffle plate
9 = Output gear
10 = Shaft seal
12 13 6 12 11 = Output flange
10 5 12 = Stud bolt
8 13 = Dirt deflector
14 = O-Ring
4 15 = Washer
1 16 = Hexagon screw
3 9 7
Figure 37
Insert ball bearing (2) until contact is obtained.
Figure 38
Insert the slotted pin (arrow).
Figure 39
5871 042 002 4/11

Division
Position the screen sheet – with slotted pin (see Fig. No. 39) into
the fixing bore (arrow).
! Observe the installation position – slotted pin = radial fixing of
the screen !
Figure 40
Insert the ball bearing into the cover and fasten it by means of
the retaining ring.
Figure 41
Oil both O-Rings (arrows) and put it into the ring grooves of the
planet carrier.
Figure 42
Bend the edges of the fixing straps of the oil baffle plate
slightly – assembly aid (sheet is fixed to the bearing cover –
see Fig. No. 44).
Figure 43
5871 042 002 4/12

Division
Mount the oil baffle plate on the bearing cover.
! into the recess of the bearing cover (radial fixing !.

Observe the installation position – locate the fixing lug (arrow)
Figure 44
Press the output gear into the ball bearing/bearing cover.
!
Rest the ball bearing against the bearing inner ring !
Figure 45
Heat the bearing inner ring of the ball bearing.
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 46 Attach two adjusting screws (M12) and mount the preassembled
bearing cover/output gear until contact is obtained.
(S) Adjusting screws (M12) 5870 204 021
!
Observe the installation position of the bearing cover (2) in
the transmission (1) – Transmission Installation
„VERTICAL“ or „HORIZONTAL“ - see detailed sketches
below:
„VERTICAL“ „HORIZONTAL“
1 1
Figure 47 2
2
5871 042 002 4/13

Division
Fasten the bearing cover by means of hexagon screws.
Tightening torque (M 12/8.8) ……. MA = 80 Nm
Figure 48
4.2.1 Shaft Seal/Output Flange:

N 3
M Legend to the sketch:
2 5
1 = Shaft seal
1 2 = Screen sheet
3 = Flange
4 4 = Ball bearing
5 = Bearing cover
„M“ = Installation dimension " 17.6 – 0.5 mm
Figure 49 „N“ = Installation dimension " 27.5 + 0.3 mm
Contact face (external shell of the shaft seal) if:

(Loctite No. 586).
! oil sump (see Sketch No. 49) !

Installation position of the shaft seal – Sealing lip showing to the

! position (Dim. „M“ - see Sketch No. 49).
Figure 50 (Grease „Renolit EP 2“ ZF Part No. 0671 190 079).
! Exact installation position of the shaft seal is guaranteed by use

Only for installation of a new flange or if stud bolts were

removed : (Fig. No. 51)
Install the stud bolts

! Installation position –Stud bolts with short thread length into
flange!
Figure 51 Tightening torque (M10x1) ................. MA = 20 Nm
5871 042 002 4/14

Division
Only for installation of a new flange/screen sheet or if removed :

(Fig. No. 52)
Install the screen sheet (2), considering the required installation

position (Dim. „N“ - see Sketch No. 50).
! use of the specified mounting tool!

Exact installation position of the screen sheet is guaranteed by
Figure 52
Mount the preassembled output flange.
Figure 53
Insert the O-Ring.
Figure 54
Position the washer and fasten the output flange by means of

hexagon screws.
!
Install the second shaft seal/output flange (front axle output)
analogously !
Figure 55
5871 042 002 4/15

Division
Prior to put the unit into operation the specifications and

regulations respectively as well as the instructions of the
ZF operating and maintenance instructions as well as the
specifications and instructions of the vehicle manufacturer
have to be observed !
5871 042 002 4/16

Division
5. REASSEMBLY - BRAKE / CLUTCH / PLANET CARRIER

5.1 PLANET CARRIER:
Illustration shows the HL-Version „AXLE ATTACHMENT“
Install the bearing outer ring until contact.
! Observe the bearing location – bearing inner ring to bearing

outer ring – also see instructions for disassembly Page 2/11, Fig.
No. 39 !

Handle 5870 260 002
Figure 1
Rotate transmission by 180°.
Install the second bearing outer ring until contact.
!
Observe the bearing location – bearing inner ring to bearing
outer ring – also see instructions for disassembly Page 2/11, Fig.
No. 39 !

Handle 5870 260 002
Figure 2
Only for the Version

„Transmission Installation Position
HORIZONTAL“
(Fig. No. 3 and 4)
Insert the screen sheet and fasten it with countersunk screws.

! Secure the countersunk screws with locking compound (Loctite
No. 243) !
Figure 3
DETAIL
Legend to detail sketch:
2 1
1 = Planet carrier
2 X 2 = Screen sheet
! 3 3 = Contact surface - Axial

needle cage/axial washer
X = Install. dim. 1.5 – 0.5 mm

3
1
Install the screen sheet (2) considering the installation dimension
„X“ (see detail sketch) onto the planet carrier (1).
Figure 4
5871 042 002 5/1

Division
Insert the slotted pins (6x), considering the installation

dimension „X“ = 28.0 – 1.0 mm and the installation position –
see Sketch No. 6 (slot is showing to the center).
!
Prior to installation grease the slotted pin – assembly aid !
Figure 5
Legend to the sketch:

1
1 = Planet carrier
2 2 = Slotted pins (6x)
3 = Center (Planet carrier)
Figure 6
Legend to Fig. No. 7 ... Fig. No. 13:
1a
1 = Bearing inner ring with cyl. rollers
1a = Packing sleeve + assembly aid
3a 2 = Planetary gear
3 = Cyl. rollers
1 3a = Packing sleeve + assembly aid
2 4 = Shim
3
4
Figure 7
Position the planetary gear (2) – with the marking showing

downwards.
Put the bearing inner ring (1) onto the planetary gear (2) and
press it until contact is obtained.
Then remove the loose packing sleeve (1a).
Keep the bearing inner ring to contact and rotate the

planetary gear by 180°.
Figure 8
5871 042 002 5/2

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Position the cyl. rollers (3) onto the planetary gear (2).
Figure 9
By means of the mounting tool press the cyl. rollers (2) into the
planetary gear (2).
Then remove the two loose packing sleeves (3a).
Figure 10
! and
Keep the bearing inner ring with cyl. rollers to contact –
mount the preassembled the planetary gear to the planet
carrier pin.
Figure 11
Press the planetary gear (bearing inner ring) until contact.
Figure 12
5871 042 002 5/3

Division
Mount the shim (4) – marking showing upwards – and snap in

the retaining ring.
! Install the retaining ring subsequently until contact at the groove

base is obtained.
Install the remaining planetary gears analogously.
Figure 13
Press the bearing inner ring onto the planet carrier until
contact ist obtained.
Figure 14
Insert the preassembled planet carrier.
Figure 15
5871 042 002 5/4

Division
Fasten the planet carrier by means of pressure plate and clamping

bar.
(S) Clamping bar 5870 654 049
Figure 16
Check locating of the bearing outer ring (arrow) – installation of

the bearing outer ring – see Fig. No. 1.
Figure 17
Mount the heated bearing inner ring until contact.
Figure 18
5871 042 002 5/5

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Position the shim and attach the hexagon screws by hand

(fixing of the planet carrier).
Then remove the clamping bar – see Fig. No. 16.
Figure 19
Fasten the fixture to the output flange.
! Tightening torque (M 10/8.8) ................... M = 46 Nm

Tighten the hexagon screws equally – risk of distortion !
When tightening the hexagon bolts rotate the planet carriers

– into both directions – several times (aligning of rollers) !
(S) Fixture 5870 240 025
Figure 20
5871 042 002 5/6

Division
5.2 BRAKE/CLUTCH:
Mount the heated centering disc and press it until contact is

obtained.
Figure 21
Fasten the centering disc by means of the retaining ring.
Figure 22
Insert the ball bearing into the internal gear and fasten it by
means of the retaining ring.
Figure 23
Heat the bearing inner ring of the ball bearing.
(S) Hot-air blower (230 V) 5870 221 500

(S) Hot-air blower (115 V) 5870 221 501
Figure 24
5871 042 002 5/7

Division
Mount the preassembled internal gear to the input shaft until

contact is obtained.
Figure 25
Snap in the retaining ring.
Figure 26
Position the axial needle cage with both thrust washers (1x each,
underneath and onto the axle needle cage resp. – see Figure).
! grease
Fix the axial needle cage and the thrust washers by means of
centrically – assembly aid !
Figure 27
Mount the preassembled input shaft (with internal gear).
Figure 28
5871 042 002 5/8

Division
Version „2 HL-290“ 5.2.1 DISC COMPONENTS BRAKE AND

8 7 CLUTCH:
Reassembly of both disc sets in the Version „2 HL-290“ –

see Sketch No. 29 and Fig. No. 32 .... Fig. No. 37 – is
4 shown below!
6 Reassembly as to the Versions „2 HL-270“ and
3 „2 HL-250“ is to be made as shown in the Sketches No. 30
5 and 31 respectively!
For information about number and arrangement of the discs
– also see the perspective illustration in the respective spare
B parts list!
A
5.2.1.1 VERSION „2 HL-290“:
2 1 Legend to Sketch No.29:

A = lower ring groove (2 HL-290, Item Retaining ring -1)
Figure 29 B = upper ring groove (2 HL-250/270, Item Retain. ring -1)
1 = Retaining ring
2 = End shim/Brake (1 Pc.)
Version „2 HL-270“ 3 = Outer disc/Brake (9 Pcs.)
9 8 4 = Inner disc/Brake (8 Pcs.)
5 = Inner disc/Clutch (12 Pcs.)
8 = Disc carrier/Internal gear
7 4
6 3 5.2.1.2 VERSION „2 HL-270“:
5 Legend to Sketch No. 30:

B A = lower ring groove (2 HL-290, Item Retaining ring -1)
B = upper ring groove (2 HL-250/270, Item Retain. ring -1)
A 1 = Retaining ring
2 = End shim/Brake (1 Pc.)
2 1 3 = Outer disc/Brake (6 Pcs.)
4 = Inner disc/Brake (6 Pcs.)
Figure 30 5 = End shim/Clutch (1 Pc.)
Version „2 HL-250“ 8 = Transmission housing
9 8 9 = Disc carrier/Internal gear
5.2.1.3 VERSION „2 HL-250“:

5 2
A = lower ring groove (2 HL-290, Item Retaining ring -1)
7 4 B = upper ring groove (2 HL-250/270, Item Retain. ring -1)
6 1 = Retaining ring
3 2 = End shim/Brake (2 Pcs.)
5 3 = Outer disc/Brake (5 Pcs.)
B 4 = Inner disc/Brake (4 Pcs.)
5 = End shim/Clutch (2 Pcs.)
A
2 1 8 = Transmission housing
9 = Disc carrier/Internal gear
Figure 31
5871 042 002 5/9

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Brake:
Snap the retaining ring (1) into the ring groove (A).
! groove (A) only for Version „2 HL-290“!

Observe the installation position of the retaining ring (1) – ring
Figure 32
Insert the end shim (2).
Figure 33
Insert the disc set (outer/inner discs) – beginning with an outer

disc - alternately.
! Position the outer disc (1 Pc.) s = variable 2.8 ..... 3.7 mm, in the
disc set on the top (piston-side) !
With outer disc s = variable, the disc clearance/piston stroke
will be adjusted – see Fig. 47 !
Figure 34
Clutch:
Insert the disc set (outer/inner discs) – beginning with an outer

disc - alternately.
! disc
Position the outer disc (1 Pc.) s = variable 1.2 ..... 1.6 mm, in the
set on the top (piston side) !
With outer disc s = variable, the disc clearance/piston stroke
will be adjusted – see Fig. 46 !
Figure 35
5871 042 002 5/10

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5.2.2 Adjust and check the DISC CLEARANCE/PISTON

STROKE of BRAKE and CLUTCH:
Mount the pressure piece (without compression spring).
Figure 36
Oil the axial roller cage and mount it with both thrust washers
(1x each, positioned underneath and onto the axial needle cage
respectively – see Figure).
Figure 37
Insert the piston (brake) – without sealing elements installed.
Figure 38
Insert the piston (clutch) – without sealing elements installed.
Figure 39
5871 042 002 5/11

Division
Insert both cup springs/clutch.

Fix the cup springs by means of grease and position them
centrically – assembly aid.
!
Observe the installation position – also see Sketch No. 42 !
Figure 40
Insert both cup springs/brake.

Fix the cup springs by means of grease and position them
centrically – assembly aid.
!
Observe the installation position – also see Sketch No. 42 !
Figure 41 Legend to Sketch No. 42 ... Fig. No. 47:

1 = Measuring fixture
2 = Piston/Clutch
3 = Cup springs/Clutch
I II 1 4 = Piston/Brake
5 = Cup springs/Brake
DC BA I = Measuring bore (Disc clearance/Clutch)
5
3 X
II = Measuring bore (Disc clearance/Brake)
Y A = Mounting face/Housing – Face/Piston
4 B = Mounting face/Housing – Piston contact/Housing
2 C = Mounting face/Housing – Face/Piston
6 D = Mounting face/Housing – Piston contact/Housing
Y = Disc clearance/Clutch ! 2.4 +0.3 mm

(Piston stroke)
X = Disc clearance/Brake ! 1.8 + 0.3 mm
Figure 42 (Piston stroke)
Locate the measuring fixture with hexagon screws equally (risk

of breakage) until contact is obtained.
Tightening torque (M 12/8.8) ................... MA = 80 Nm
(S) Measuring fixture 5870 200 131
Figure 43
5871 042 002 5/12

Division
Determine Dim. „A“ (Measuring bore „I“) from mounting

face/housing to the face/piston (clutch).
Dim. „A“ e.g. ................................. = 22.45 mm

Figure 44
Determine Dim. „C“ (Measuring bore „II“) from mounting

face/housing to the face/piston (brake).
Dim. „C“ e.g. ................................. = 11.85 mm
Figure 45
Determine Dim. „B“ from mounting face/housing to clutch
piston contact/housing.
Dim. „B“ e.g. ................................. = 19.95 mm
EXAMPLE:
Dim. „A“ e.g. .................................. 22.45 mm

Dim. „B“ e.g. ................................. - 19.95 mm
Result .............................................. = 2.50 mm
Clutch disc clearance (piston stroke) = 2.4 + 0.3 mm

If the required disc clearance (piston stroke) is not obtained,
Figure 46 this is to be corrected with a suitable outer disc – see Fig. No.
35!
Determine Dim. „D“ from mounting face/housing to brake

piston contact/housing.
Dim. „D“ e.g. ................................. = 9.95mm
EXAMPLE:
Dim. „C“ e.g. ................................... 11.85 mm

Dim. „D“ e.g. ................................. - 9.95 mm
Result .............................................. = 1.90 mm
Disc clearance(piston stroke) Brake = 1.8 + 0.3 mm

Figure 47 If the required disc clearance (piston stroke) is not obtained,
this is to be corrected with a suitable outer disc – see Fig. No.
34!
5871 042 002 5/13

Division
Remove the measuring fixture again – loosen the screws

equally .
Remove all cup springs, both pistons, axial roller cage with
thrust washers and pressure piece.
Figure 48
Insert the oil baffle plate into the disc carrier and fix it with the
snap ring.
Figure 49
Oil the sealing faces and the O-Ring.

Insert the O-Ring (arrow) into the groove and insert the ring.
! Observe the installation position – see Fig. No. 50!
Figure 50
By means of the mounting tool locate the ring until contact is

obtained.
Figure 51
5871 042 002 5/14

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Oil the sealing faces and the sealing elements.
Insert the seal (1) with the sealing lip showing to the oil
1 sump – also see detail sketch.
2 3
2
Put both O-Rings (2) into the ring grooves of the pressure ring
Figure 52 (3) and insert the preassembled pressure ring - observe the
installation position.
By means of the mounting tool locate the pressure ring until

contact.
Figure 53
Insert the compression spring.
Figure 54
Insert the pressure piece.
Figure 55
5871 042 002 5/15

Division
Oil the axial roller cage and mount it with both thrust washers
(1x each to be positioned underneath and onto the axial needle
cage respectively – see Figure).
Figure 56

2
Insert the seal (2, with the sealing lip showing to the oil sump)
3 and the seal (3) – see Sketch No. 58 - into the
housing (1).
Figure 57
Legend to Sketch No.58 as well as Fig. No. 57 and Fig. No. 59:
1
1 = Housing
2 2 = Seal (with sealing lip)
7 3 = Seal
4 4 = Piston/Brake
6 5 = Seal (with sealing lip)
3
6 = Seal (with sealing lip)
7 = Piston/Clutch
5
Figure 58

6
Insert the seals (5 and 6, see Sketch No. 58), with the sealing lip
5 showing to the oil sump, into the piston/brake (4).
Figure 59
5871 042 002 5/16

Division
Insert the preassembled piston/brake until contact is obtained.
! Piston is to be positioned that the oil supply bore (arrow) –

with the HL-Transmission installed into the vehicle – is at
12.00 o’clock position !
Observe the version as to the transmission installation
position „HORIZONTAL – VERTICAL“ !
Figure 60
By means of the mounting tool locate the piston until contact.
Figure 61
Insert both cyl. pins (arrow).
Figure 62
Insert the piston/clutch.
Figure 63
5871 042 002 5/17

Division
Press the piston axially, contrary to the compression spring

preload, and seal the pressure oil supply bore by means of screw
plug/sealing ring (arrow) – thus the piston is kept in axial
position – assembly aid for input housing assembly
(Fig. No. 70+71).
Figure 64
Insert both cup springs/clutch.
! Observe the installation position – see Fig. No. 65 and also

Sketch No. 42 respectively!
Figure 65
Insert both cup springs/brake.
! Sketch No. 42!

Observe the installation position - see Figure No. 66 and also the
Figure 66
5.3 Modulation Valve and Input housing:

Insert the modulation valve (cpl. – can only be replaced as unit).
Figure 67
5871 042 002 5/18

Division
Place the O-Ring (arrow) and insert the compression spring.
Figure 68
Input housing:
Oil the O-Ring and put it into the ring groove of the input
housing.
Figure 69
Position the cup springs centrically – assembly aid.
Insert two adjusting screws (M 12), mount the input housing and
fasten it with hexagon screws.
(S) Adjusting screws (M12) 5870 204 021
Figure 70
Locate the input housing with hexagon screws equally (risk of

breakage) until contact is obtained !
Tightening torque (M 12/8.8) ................... MA = 80 Nm
Figure 71
5871 042 002 5/19

Division
5.4 Emergency Release (Parking Brake):

8 7
Legend to Sketch No. 72 ... Bild-Nr. 75:
1 9
1 = Input housing
2 2 = Housing
6
5 3 = O-Ring
4 = Threaded element (orifice)
3 5 = Ball
4 6 = Compression spring
7 = O-Ring
8 = Bleeder
Figure 72 9 = Position of lubrication nipple for the version
„Transmission Installation Position VERTICAL“
- Position of lubrication nipple for the version
„Transmission Installation Position HORIZONTAL“
– see Sketch No. 77
Install the threaded element (4) with O-Ring (3).
Tightening torque (M 10x1)................... MA = 24 Nm
Figure 73
Insert the ball (5).
Figure 74
Insert the compression spring (6).
Figure 75
5871 042 002 5/20

Division
2 5.4.1 Check the Emergency Release for Leak

Tightness:
! Illustration shows the Version „Transmission Installation
Position VERTICAL“ (Fig. No. 76)
! HORIZONTAL“
1
For the version „Transmission Installation Position
the connection and positions respectively
of the bleeder valves/lubrication nipple etc. ... are to be
considered according to the illustration in Sketch No. 77 !
Install both bleeder valves (1), screw plugs (2) with sealing ring
3 and screw plugs (3) with O-Ring.
Tightening torque
3 Bleeder valve (M 10x1) ...................................... MA = 22 Nm
Figure 76 Screw plug (M 10x1 with sealing ring) .............. MA = 15 Nm
Screw plug (M 10x1 with O-Ring) ..................... MA = 25 Nm
5 6 Legend to Sketch No. 77:

7 8
1 = Bleeder/pressure-relief valve (Emerg. release – park. brake)
2 = Screw plug
1 3 = Bleeder valve (Emergency release – parking brake)
2 4 = Lubrication nipple (Emergency release - parking brake)
5 = Bleeder valve (Multi-disc clutch)
3 6 = Bleeder valve (Multi-disc brake)
7 = Pressure oil connection – Multi-disc brake
4 8 = Pressure oil connection – Multi-disc clutch
Figure 77
Install the bleeder valve (1), screw plugs (2) with O-Ring
screw plug (3) with O-Ring and compressed air connection
piece (4).
4
Tightening torque
Bleeder valve (M 10x1) .......................................... MA = 22 Nm
3 Screw plug (M 10x1 with O-Ring) ......................... MA = 25 Nm
Screw plug (M 18x1.5 with O-Ring) ...................... MA = 35 Nm
Compr.air connect. piece (M 10x1) w. seal. ring).... MA = 15 Nm
2
Figure 78
1
Pressurize the emergency release with compressed air p = 5 +

1bar and close the shut-off valve.
During a test duration of 3 minutes no pressure drop is allowed !
(S) Air connection 5870 505 012
Figure 79
5871 042 002 5/21

Division
Remove the screw plug and the compressed air connection

piece (see Fig. No. 78).
Install the bleeder (3) with O-Ring and lubrication nipple (4).
4 Tightening torque
3 Lubrication nipple (M 10x1) ............................. MA = 22 Nm
Bleeder (M 18x1.5) ............................................ MA = 22 Nm
Figure 80 5.4.2 Check the Multi-Disc Brake and Multi-Disc Clutch for
Leak Tightness as well as Closing Pressure:
AB AK EB
EK
2 = Input housing
1
2 AB = Pressure oil connection – Multi-disc brake
AK = Pressure oil connection – Multi-disc clutch
EB = Bleeder valve – Multi-disc brake

EK = Bleeder valve – Multi-disc clutch
! Illustration shows the version

„Transmission Installation Position VERTICAL“
! For the version „Transmission Installation Position

HORIZONTAL“ the connections and positions respectively
Figure 81 of the bleeder valves/lubrication nipple etc. ... are to be
considered according to the illustration in Sketch No. 77 !
Multi-disc brake:
Connect the HP-Pump (“AB“ – see Sketch No. 81 and

Sketch No. 77),
Build up a pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable pressure drop
is allowed !
(S) HP-Pump 5870 287 007

Figure 82
Test medium:
According to ZF List of Lubricants TE-ML 07
Closing pressure test (Cup spring preloading force):

When measuring the closing pressure the valve block is not
allowed to be attached to the transmission due to the by-pass
function between brake and clutch.
Connection „AK“ (see Sketch No. 81 and Sketch No. 77
respectively) open (not closed and tank connection respectively).
Reduce the pressure slowly, when pressure range 11 ... 9 bar

(closing pressure) is reached, the input shaft has to be locked at a
tightening torque of 50 ± 5 Nm!
Figure 83 (S) Spline mandrel 5870 510 039

Torque spanner 5870 203 037
5871 042 002 5/22

Division
Multi-disc clutch:
Connect the HP-Pump (“AK“ – see Sketch No. 81 and

Sketch No. 77),
Build up a pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable pressure drop
is allowed !
(S) HP-Pump 5870 287 007

Figure 84
Test medium:
Acc. to List of Lubricants TE-ML 07
Closing pressure test (Cup spring preloading force):
When measuring the closing pressure the valve block (only for
the version „with“ mounted electr. downshift interlock) is not
allowed to be attached to the transmission due to the by-pass
function between brake and clutch.
Connection „AB“ (see Sketch No. 81 and Sketch No. 77
respectively) open (not closed and tank connection respectively).
Reduce the pressure slowly, when pressure range 15.5 ... 13.5
Figure 85 bar (closing pressure) is reached, the input shaft has to be locked
at a tightening torque of 50 ± 5 Nm!
(S) Spline mandrel 5870 510 039
5.5 SPEED TRANSMITTER:
Install the speed transmitter with O-Ring.
Tightening torque (M 8/8.8)................... MA = 23 Nm
Figure 86
5.6 LUBE OIL PUMP/DOWNSHIFT INTERLOCK:
Install the lube oil pump (with O-Rings) or the downshift

interlock – depending on the version – (Illustration shows –
Version „Lube Oil Pump“).
! CHAPTER 7 !
Cpl. assembly of the lube oil pump/downshift interlock - see
Tightening torque (M 8/10.9)................. MA = 23 Nm
Figure 87
5871 042 002 5/23

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5871 042 002 5/24

Division
6. DISASSEMBLY - LUBE OIL PUMP/DOWNSHIFT INTERLOCK:
6.1 Version „with “ Lube Oil Pump:
Loosen the bolt connection and pull off the cpl. lube oil pump.
Figure 1
Loosen the cover bolt connection, remove the cover (1) with
gasket (2) and the filter (3) from the housing (4).
4
3
1 2
Figure 2
Remove the cpl. pressure limiting valve and both O-Rings

(arrows).
Figure 3
Loosen the pump cover bolt connection, keep the housing

in vertical position – disassembly aid (also see Fig. No. 5).
Figure 4
5871 042 002 6/1

Division
!
Keep pump to contact and rotate it by 180° – disassembly
aid!
Then pull the pump in vertical position out of the housing –

pay attention to possibly released balls/compression springs (see
Fig. No. 5 and 7).
Figure 5
Remove the outer (1) and internal rotor (2) and take the released
ball [(3) driver] out of the control housing (4).
4
! Outer, internal rotor and control housing = rotor set
3
1 2
Figure 6
Remove the control housing and the released balls and

compression springs (3 pcs. each).
Figure 7
Figure 8
5871 042 002 6/2

Division
Pull the cpl. pump shaft out of the pump cover.
Figure 9
Unsnap the retaining ring and press the ball bearing from the
shaft.
Figure 10
Pull the needle sleeve out of the housing bore.

Figure 11
5871 042 002 6/3

Division
6.2 Version „with“ hydr. Downshift Interlock:
Disassemble both oil tubes.
Figure 12
Loosen the bolt connection of the shift interlock (3 x cap screws)

and remove the cpl. shift interlock.
Figure 13
Loosen the cover bolt connection, remove the cover and flat
gasket (also see Fig. No. 15).
Figure 14
Take the filter out of the housing.
Figure 15
5871 042 002 6/4

Division
Loosen pump cover bolt connection.
Figure 16
!
Keep pump to contact and rotate it by 180° – disassembly
aid!
Then pull the pump in vertical position out of the housing –

pay attention to possibly released balls/compression springs (see
Fig. No. 18 and 19).
Figure 17
Remove the outer (1) and internal rotor (2) and take the released
ball [(3) driver] out of the control housing (4).
4 Outer, internal rotor and control housing = rotor set
3
2
1
Figure 18
Remove the control housing and the released balls and

compression springs (3 pcs. each).
Figure 19
5871 042 002 6/5

Division
Figure 20
Pull the cpl. pump shaft out of the pump cover.
Figure 21
Unsnap the retaining ring and press the ball bearing from the
shaft.
Figure 22
Pull the needle sleeve out of the housing bore.

Figure 23
5871 042 002 6/6

Division
Legend to the Sketch No. 24:

1 2
1 = Housing 2 = O-Rings
3 = Check valve (010) 4 = G.shift piston
5 = Check valve (009) 6 = Check valve (008)
7 = Pressure limiting valve
3 Remove the O-Rings and all single parts/valves.
7
5 6
4
Figure 24
6.3 Version „with“ electr. Downshift Interlock–

mounted to Transmission:
Loosen the fixing bolts and remove the cpl. downshift

interlock.
Figure 25
Remove both O-Rings (arrow).
! Make no further disassembly – electr. downshift interlock can

only be replaced as complete part!
Figure 26
5871 042 002 6/7

Division
7. REASSEMBLY – LUBE OIL PUMP/DOWNSHIFT INTERLOCK:

7.1 Version „with“ Lube Oil Pump:
Mount the ball bearing onto the shaft and fasten it by means of
the retaining ring.
Figure 1
Press the preassembled pump shaft into the pump cover and
fasten it by means of the retaining ring.
Figure 2
Insert the compression springs (1) and ball (2) into the bores
(see arrows - 3x).
Prior to installation oil single parts of the pump/rotor set

(control housing, internal and outer rotor) – use oil acc. to
2 the ZF List of Lubricants TE-ML 07 !
! Keep
1
the pump shaft/cover in „vertical“ position – pay attention
to the position of the inserted balls/compression springs
- see steps Fig. No. 3 .... Fig. No. 9) !
Figure 3
Mount the control housing.
Control housing/internal and outer rotor = rotor set
Figure 4
5871 042 002 7/1

Division
Position the ball – see arrow -(drive for internal rotor) with
grease (assembly aid) into the recess of the pump shaft.
Figure 5
Mount the internal rotor
! (see arrows)!
Place the groove of the internal rotor over the driving ball
Figure 6
Assemble the outer rotor.
Figure 7
! Check passage of the orifice/oil bore in the housing bottom !

Insert the needle sleeve to installation dimension „X“.
„X“ = 0.2 .... 0.7 mm below plane face/housing
! The exact installation position is ensured by use of the specified

mounting tool !
Figure 8 ! Insert the needle sleeve with marked face showing upwards!
5871 042 002 7/2

Division
Keep the preassembled pump in „vertical“ position (see Note

Fig. No. 3) and put on the housing.
Figure 9
! Rotate the housing by 180° and fasten the pump with hexagon
Keep the assembled pump to contact!
screws.
Figure 10
Fasten the pump finally.
Tightening torque (M6/8.8) .............. MA = 9.5 Nm
Figure 11
Functional test of the lube oil pump:
With counter-turning motions on the pump shaft, the

swivelling of the control housing (stop LH/RH in the pump
cover) is audible!
Figure 12
5871 042 002 7/3

Division
Oil both O-Rings (arrows) and put them into the ring groove of
the housing.
Figure 13
Check the O-Rings (arrows) of the pressure limiting valve and

replace them, if necessary.
Figure 14
Insert the pressure limiting valve.
Tightening torque ............................... MA = 20 Nm
Figure 15
Secure the pressure limiting valve by blows with the center

punch (2x).
Figure 16
5871 042 002 7/4

Division
Insert the filter – Observe the installation position!
Figure 17
Place the gasket.
Figure 18
Place the cover and fasten it with hexagon screws and washers.
Tightening torque (M8/8.8) .............. MA = 23 Nm
Figure 19
Insert the screw plug with O-Ring.
Tightening torque (M10x1) .............. MA = 15 Nm
Figure 20
5871 042 002 7/5

Division
Mount the cpl. lube oil pump and fasten it with cap screws and
washers.
Figure 21
4 5 2 7.2 Version „with“ hydr. Downshift Interlock:

3
6 1 = Housing 2 = G.shift piston
1 3 = Pressure limiting valve 4 = Check valve (008)
5 = Check valve (009) 6 = Check valve (010)
7 = Filter 8 = Lube oil pump
7
8
Figure 22
Install the gasket (consisting of plastic and O-Ring (Fig. No. 23

and 24):
Put the O-Ring (see arrow) into the ring groove of the piston.
Lead the plastic ring by means of the mounting bush (S) over the
piston and position it at the O-Ring.
(S) Mounting bush 5870 651 055
Figure 23
Calibrate the plastic ring by means of the bush.
(S) Calibrating pin 5870 651 056
Figure 24
5871 042 002 7/6

Division
Insert the compression spring, oil and mount the preassembled

piston.
Figure 25
2 Fix the piston with screw plug (1- with O-Ring).

Install the screw plug (2 – with sealing ring).
1
Tightening torque:
Screw plug (M24x1.5)..................... MA = 50 Nm
Screw plug (M10x1) ...................... MA = 15 Nm
Figure 26 Install the single parts according to the illustration on the left.
Observe the installation position of the different check valves!
! 1 = Pressure limiting valve (cpl.) .......... M = 10 Nm

Oil the single parts acc. to List of Lubricants TE-ML 07!
A
2 = Check valve (cpl.) ............................ MA = 10 Nm
ZF No.: 4143 242 008
3 = Check valve (cpl.) ............................ MA = 10 Nm
ZF No.: 4143 242 009
4 = Check valve (cpl.) ........................... MA = 10 Nm
ZF No.: 4143 242 010
4 1
Figure 27 3 2
Secure the check valves and the pressure limiting valve by two
blows each with the center punch.
Figure 28
5871 042 002 7/7

Division
Check passage of the orifice/oil bore in the housing bottom !
! Insert the needle sleeve to installation dimension „X“.

„X“ = 0.2 .... 0.7 mm below plane face/housing
! The exact installation position is ensured by use of the specified

mounting tool !
Figure 29 ! Insert the needle sleeve with marked face showing upwards!
Mount the ball bearing onto the shaft and fasten it with the
retaining ring.
Figure 30
Press the preassembled pump shaft into the pump cover and
fasten it with the retaining ring.
Figure 31
Insert the compression springs (1) and ball (2) into the bores
(see arrows - 3x).
Prior to installation oil single parts of the pump/rotor set

(control housing, internal and outer rotor) – use oil acc. to
2 the ZF List of Lubricants TE-ML 07 !
1
! Keep the pump shaft/cover in „vertical“ position – pay attention
to the position of the inserted balls/compression springs
- see steps Fig. No. 32 .... Fig. No. 37) !
Figure 32
5871 042 002 7/8

Division
Mount the control housing.
Control housing/internal and outer rotor
Figure 33
Position the ball – see arrow -(drive for internal rotor) with
grease (assembly aid) into the recess of the pump shaft.
Figure 34
Mount the internal rotor
! (see arrows)!
Place the groove of the internal rotor over the driving ball
Figure 35
Assemble the outer rotor.
Figure 36
5871 042 002 7/9

Division
Keep the preassembled pump in „vertical“ position (see

Instructions Fig. No. 32) and put on the housing.
Figure 37
! by 180° !
Keep the assembled pump to contact and rotate the housing
Fasten the pump with hexagon screws.
Tightening torque (M6/8.8) .............. MA = 9.5 Nm
Figure 38
Insert the screen filter – Observe the installation position!
Figure 39
Place the gasket.
Figure 40
5871 042 002 7/10

Division
Position the cover, fasten it with hexagon screws and washers.
!
Pay attention to different screw length !
Figure 41
Oil both O-Rings (arrows) and put them into the ring grooves of
the housing.
Figure 42
Mount the preassembled downshift interlock and fasten it with

cap screws and washers.
!
Pay attention to different screw length !
Tightening torque (M8/10.9).............. MA = 23 Nm
Figure 43
Install both screw-in sleeves and the screw plug (see arrows) –
with O-Rings.
Tightening torque:
Screw-in sleeve (M 16 x 1.5) ….... MA = 23 Nm
Screw plug (M 18 x 1.5) …............ MA = 35 Nm
Figure 44
5871 042 002 7/11

Division
Legend to Fig. No. 45:
1 = Oil tube
3 2 = Union screw (M 16 x 1.5)
5 3 = Sealing ring
4 = Union screw (M 14 x 1.5)
5 = Sealing ring
1
2 4
Figure 45
Install both oil tubes.
Tightening torque:
Union screw (M 14 x1.5)....................... MA = 25 Nm
Union screw (M 16 x1.5)....................... MA = 45 Nm
Figure 46
5871 042 002 7/12

Division
7.3 Version „with“ electr. Downshift Interlock –

mounted to the Transmission:
Position both O-Rings (arrows).
Figure 47
Fasten the cpl. downshift interlock with cap screws and washers.
Tightening torque (M8/10.9).............. MA = 23 Nm
Figure 48

5871 042 002 7/13

Division
8. Attach the HL-TRANSMISSION to the AXLE:

(only for the version „AXLE ATTACHMENT“)
Position the cpl. HL-Transmission to the axle.
(S) Lifting strap 5870 281 026

or
Figure 1
Fasten the HL-Transmission to the axle by means of hexagon

screws and nuts.
Tightening torque (M12/8.8) ............. MA = 79 NM
Figure 2

5871 042 002 8/1

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Order No.

: 5871 042 002

Abt.: ASTDM / Section : ASTDM

1. Constantly trained personnel

2. Prescribed installations, e.g. Special Tools

3. Genuine ZF-Spare Parts according to the latest phase of development

5871 042 002 0/1

5871 042 002 0/2

Structure of the Repair Manual

Important information on industrial safety

Serves as reference to special working procedures, methods,

Is used, if lacking care can lead to personal injury or damage the

5871 042 002 0/3

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Density lineaire en kg/m; Density superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

5871 042 002 0/4

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

0,070 bar ( 0,071 kp/cm2 ) =

5871 042 002 0/5

TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARD 148

Metric ISO-Standard Thread DIN 13, Page 13

Metric ISO-Fine Thread DIN 13, Page 13

5871 042 002 0/6

INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

1 = Model (Transmission Type)

NOTES TO SPARE PARTS ORDERS:

When ordering genuine ZF Spare Parts please indicate as follows:

5871 042 002 0/7

INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

1 = Customer Name (Vehicle Manufacturer)

NOTES TO SPARE PARTS ORDERS:

When ordering genuine ZF Spare Parts please indicate as follows:

5871 042 002 0/8

5871 042 002 0/9

5871 042 002 0/11

5871 042 002 0/12

5871 042 002 0/13

5871 042 002 0/14

NOTES TO THE REQUIRED

In the corresponding ZF Lists of Lubricants you will find information about:

Oil filling capacity for Power Shift Transmissions (2 HL-250/270/290):

For the version „AXLE ATTACHMENT“:

5871 042 002 0/15

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY

ZF – HYDROSTATIC POWERSHIFT TRANSMISSION

1/02 8/01 Lifting chain 3-Strand 5870 281 047

2/12 Set of external pliers A1-A2-A3-A4 5870 900 015

2/17 Eyebolt assortment 5870 204 002

2/21 Resetting device 2 pcs. required 5870 400 001

2/25 5/23 Clamping pliers # 5870 900 021

5871 042 002 W/01

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY

ZF – HYDROSTATIC POWERSHIFT TRANSMISSION

2/36 4/26 Fixture # 5870 240 025

2/37 Back-off device 5870 000 017

2/38 Rapid grip # 5873 012 021