ZF Ecomid Manual 9S109 - 1304 - 751 - 102 - A 1998

9 S 109
1304 751 102a

9 S 109 Contents
Page
Preface .................................................................................................................................................................. 5
General information .............................................................................................................................................. 6
Safety notice.......................................................................................................................................................... 9
Tightening torques................................................................................................................................................. 10
Adjustment data..................................................................................................................................................... 12
Spring table ........................................................................................................................................................... 16
Special tools .......................................................................................................................................................... 18
Sequences of removal and installation................................................................................................................... 23
1 Tecalan pipes for range-change group..................................................................................................... 1-1

1.1 Removal ...................................................................................................................................................... 1-1
1.2 Assembly..................................................................................................................................................... 1-1
2 Output ........................................................................................................................................................ 2-1

2.1 Removal of output flange and cover............................................................................................................ 2-1
2.2 Removal of bearing cover............................................................................................................................ 2-2
2.3 Mounting of bearing cover .......................................................................................................................... 2-2
2.4 Mounting of output flange and cover .......................................................................................................... 2-4
3 Range-change group ................................................................................................................................. 3-1

3.1 Removal of range-change group ................................................................................................................. 3-1
3.2 Mounting of range-change group................................................................................................................ 3-3
3.3 Dismantling range-change group................................................................................................................ 3-7
3.4 Assembling range-change group................................................................................................................. 3-9
4 Planetary gear with synchronizer ............................................................................................................ 4-1

4.1 Dismantling synchronizer ........................................................................................................................... 4-1
4.2 Dismantling ring gear.................................................................................................................................. 4-2
4.3 Dismantling planet carrier........................................................................................................................... 4-2
4.4 Assembling planet carrier ........................................................................................................................... 4-3
4.5 Assembling ring gear .................................................................................................................................. 4-4
4.6 Assembling synchronizer............................................................................................................................ 4-4
5 Sun gear ..................................................................................................................................................... 5-1

5.1 Removal of sun gear.................................................................................................................................... 5-1
5.2 Mounting of sun gear .................................................................................................................................. 5-2
6 Shift mechanism ........................................................................................................................................ 6-1

6.1 Removal of shift mechanism ....................................................................................................................... 6-1
6.2 Mounting of shift mechanism ..................................................................................................................... 6-2
6.3 Dismantling shift mechanism...................................................................................................................... 6-4
6.4 Shift mechanism assembly - summary of shift mechanism types ............................................................... 6-10
6.4.1 Driver arrangement ..................................................................................................................................... 6-11
6.4.2 Compression spring arrangement (spring packs) in acc. with parts list
(spare parts catalogue) ................................................................................................................................ 6-16
6.5 Assembling shift mechanism ...................................................................................................................... 6-19
Contents 9 S 109
Page
7 Connection plate - lubricating oil pump ................................................................................................. 7-1

7.1 Removal of connection plate ....................................................................................................................... 7-1
7.2 Removal and dismantling of lubricating oil pump ...................................................................................... 7-1
7.3 Assembly and mounting of lubricating oil pump ........................................................................................ 7-3
7.4 Assembly and mounting of connection plate .............................................................................................. 7-5
8 Adjusting bearings on mainshaft, input shaft and layshaft ................................................................... 8-1

8.1 Adjusting mainshaft and input shaft............................................................................................................ 8-1
8.2 Adjusting layshaft ....................................................................................................................................... 8-3
9 Shift rails and reverse gear ....................................................................................................................... 9-1

9.1 Removal of shift rails .................................................................................................................................. 9-1
9.2 Removal of reverse gear .............................................................................................................................. 9-5
9.3 Installation of shift rails .............................................................................................................................. 9-6
9.4 Installation of reverse gear .......................................................................................................................... 9-11
10 Input shaft, mainshaft and layshaft ......................................................................................................... 10-1

10.1 Removal of the shafts .................................................................................................................................. 10-1
10.2 Installation of the shafts .............................................................................................................................. 10-4
11 Input shaft.................................................................................................................................................. 11-1

11.1 Dismantling the input shaft ......................................................................................................................... 11-1
11.2 Assembly of the input shaft......................................................................................................................... 11-2
12 Mainshaft................................................................................................................................................... 12-1
12.1 Dismantling the mainshaft .......................................................................................................................... 12-1
12.2 Assembly of the mainshaft .......................................................................................................................... 12-4
13 Layshaft...................................................................................................................................................... 13-1
13.1 Dismantling the layshaft ............................................................................................................................. 13-1
13.2 Assembly of the layshaft ............................................................................................................................. 13-2
14 Housing ...................................................................................................................................................... 14-1

14.1 Dismantling the housing ............................................................................................................................. 14-1
14.2 Assembly of the housing ............................................................................................................................. 14-2
15 Clutch housing........................................................................................................................................... 15-1

15.1 Removal ...................................................................................................................................................... 15-1
15.2 Installation .................................................................................................................................................. 15-1
9 S 109 Preface
This manual is intended for skilled personnel trained by

ZF Friedrichshafen AG to carry out maintenance and
repair work on ZF products.
This manual deals with the standard ZF product in

accordance with the state of development on the date
of issue.
However, due to continuing development of the product,

repair work might require work practices and test or
adjustment data which are not contained in this manual.
We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who
have had their practical and theoretical knowledge upda-
ted on a regular basis at our After-Sales Service training
courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out

conscientiously and with utmost 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

ZF FRIEDRICHSHAFEN AG personnel in an improper and unprofessional manner,
Division Comm. Vehicle/Special Transmissions together with follow-on costs caused by such work, is
Service Werk 2 excluded from the contractual guarantee agreement.
Tel.: (0 75 41) 77-0 This also applies where genuine ZF spares have not
Fax: (0 75 41) 77-5726 been used.
Index: 98-01-12 5
General information 9 S 109
TRANSMISSION DESCRIPTION SERVICE MANUAL AND FUNCTION
The ZF 9 S 109 synchronous transmission of the Eco- This service manual describes how to overhaul a ZF 9 S
mid construction range has been specially developed for 109 synchronous transmission of the Ecomid range.
use in commercial vehicles of the upper medium duty
class.
The contents of this manual are arranged as follows:
9 S 109 transmissions basically consist of: Part 1: Adjustment data, tightening torques, spring
characteristics and an illustrated list of pre-
– a fully synchronized four gear component scribed ZF special tools.
– an integrated crawler and reverse gear
Part 2: A step-by-step description of transmission
– a rear-mounted range-change group built overhaul, divided by Section and steps to be
into the planet followed.
In addition to the above, ZF Friedrichshafen AG

offers the following additional equipment as optional
attachments:
– an engine-dependent ZF power take-off

– various clutch-dependent ZF power take-offs
– an input for an emergency or dual-circuit
steering pump
– or a separate heat exchanger for use in extre-
me conditions.
6
9 S 109 Instructions for carrying out repairs
In any case of doubt always turn to the relevant GASKETS, LOCKING PLATES
department within ZF After-Sales Service for
advice. Parts which cannot be removed without being damaged
All work on transmissions needs to be done expertly must always be replaced with new parts (e.g. gaskets
and under clean conditions. and locking plates).
Proper tools are to be used for disassembly and
assembly of transmissions.
SHAFT SEALS
The removed transmission is to be cleaned thoroughly
with a suitable agent before opening. Always change shaft seals with rough, ripped or
Pay particular attention to the corners and angles of hardened sealing lips. Seal contact surfaces must be
housings and covers when cleaning. absolutely clean and in perfect condition.
Loctite-joined parts are easier to seperate if warmed
with a hot-air blower.
REWORKING
CLEANING OF PARTS Rework may only be carried out on the seal contact
surfaces using plunge-cut grinding, never use an emery
Remove remains of gaskets on all seal faces. Carefully cloth. Ensure that there are no grinding or scrolling
remove burrs or similar patches of roughness using traces.
oil-stone.
If rework is needed on distance washers, shims etc.
Lube bores and grooves must be free of anti-corrosion because of clearance settings, ensure that the reworked
agents and foreign matter; check for perfect passage. areas contain no face runout and have the same surface
quality.
Carefully cover opened transmissions to prevent foreign
matter from entering.
TRANSMISSION ASSEMBLY
RE-USE OF PARTS Find a clean site to assemble the transmission. Gaskets

are installed without the use of sealing compound or
Parts such as ball or roller bearings, multi-discs, thrust grease. When measuring silicon-coated gaskets, take
washers etc., must be inspected by a competent person, care not to include the silicon layer in the measure-
who should decide whether or not they can be re-used. ment.
Replace parts which are damaged or have suffered from During assembly, comply with all adjustment data,
excessive wear. checking data and tightening torques in the Repair
Manual.
Index: 98-10-02 7
Instructions for carrying out repairs 9 S 109
BEARINGS d) Duo shaft seals have two sealing

lips. The dust-proof sealing lips
If the bearings are filled while hot, these should be (X) must face outwards.
warmed up evenly (e.g. in a heating cabinet). X
The temperature should be approx. 85 °C and may not e) Fill the gap between the sealing
exceed 120 °C. All bearings must be coated with trans- lips so it is 60% filled with grease* (use a grease e.g.
mission oil after assembly. produced by Aral such as Aralub HL2 or by DEA
such as Spectron FO 20).
f) If possible, heat shaft seal bores to between 40° and

50° C (this makes fitting easier). Press the seal shaft
SEALING with mounting or faceplate onto the relevant installa-
tion depth plan.
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing to enter oil ducts RETAINING AGENTS
and bores. On oil-carrying ducts and bores wipe off the
sealing agent on the surfaces to be sealed near apertures Retaining agents* may only be used in places as
to ensure that no sealing agent penetrates the oil feeds specified in the parts list.
when the surfaces are sealed. Always comply with manufacturer’s directions for use
when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAFT SEALS
a) Apply a light coat of sealing agent* on outer edge of TRANSMISSION OIL

shaft seals with “steel surround”.
After repair, fill the transmission with transmission oil.
b) Never apply sealing agent to shaft seals with For the procedure and approved oils, refer to the trans-
“rubber surround” but apply a thin coat of Vaseline mission operating manual and List of Lubricants TE-
8420 to the outer edge or wet with a lubricant, e.g. a ML (refer to identification plate) which are available
water-soluble, concentrated washing-up liquid (e.g. from any ZF After-Sales Service Point. After filling the
Pril, Coin, Palmolive). transmission with oil, tighten the screw plugs at the oil
filling point and the oil overflow to the specified tor-
c) Shaft seals with steel and rubber surrounds should be ques.
treated on the outer edge of the rubber surround as
described above in section b).
* refer to expendable material
8 Index: 98-10-02
9 S 109 Important information
SAFETY NOTICE GENERAL INFORMATION
Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale
and no information about size and weight should be
Personnel required to carry out repairs on ZF products inferred (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
! DANGER agents always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.
CAUTION
The transmission must NOT be hung on the
input shaft NOR on the output flange.
Index: 98-10-02 9
Tightening torques 9 S 109
Tightening torques for nuts and bolts, extract from

ZFN 148
This Standard applies to bolts acc. to DIN 912, DIN Surface condition of bolts: thermaly blackened
931, DIN 933, DIN 960, DIN 961 and for nuts acc. to finish and oiled or galvanized and oiled or galvanized,
DIN 934. chrome-plated and oiled.
This Standard contains data on tightening torques (MA)
for bolts in strength categories 8.8, 10.9 and 12.9 and Tightening of screws is done with calibrated torque
nuts in strength categories 8, 10 and 12. wrench.
NOTE
Divergent tightening torques are listed separately in the
Repair Manual.
Regular thread Fine screw
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 / checked 1997
10 Index: 98-10-02
9 S109 Tightening torques
Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643
The screw plug tightening torques MA were determined The tightening torques MA were determined for
according to DIN 7604 for screwing into steel, grey screwing into steel, grey cast and aluminium alloys.
cast, and aluminium alloys. The values are based on experience and are intended as
The values are based on experience, and are reference values for the fitter.
intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1
The values for the tightening torque MA are to be used Material: 9SMnPb28K acc. to DIN 1651
analogously for screw plugs according to DIN 908 and Surface conditions: as manufactured
DIN 910, as the thread geometries are almost identical. (without surface protection) and lightly
General rule: Screw/bolt class 5, ZFN 148-1 oiled or galvanized, chromated and
Screw/bolt material: steel acc. to lightly oiled
DIN 7604. Surface condition: as manu-
factured (without surface protection) and
lightly oiled or galvanized, chromated
and lightly oiled
Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)
Dimensions Tightening torque Pipe Thread Tightening-

MA in Nm screwed into outer torque MA
steel/grey cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 30
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 40
M 22 x 1.5 60 / 80* 50 / 65*
M 24 x 1.5 70 60 12 M 16 x 1.5 45
M 26 x 1.5 80 / 105* 70 / 90*
M 27 x 2 80 70 15 M 18 x 1.5 50
M 30 x 1.5 100 / 130* 90 / 130*
M 30 x 2 95 85 18 M 22 x 1.5 60
M 33 x 2 120 110
M 36 x 1.5 130 115 22 M 26 x 1.5 90
M 38 x 1.5 140 120
M 42 x 1.5 150 130 28 M 30 x 1.5 130
M 42 x 2 145 125
M 45 x 1.5 160 140 35 M 38 x 1.5 140
M 45 x 2 150 130
M 48 x 1.5 170 145
M 48 x 2 160 135
M 52 x 1.5 180 150
M 60 x 2 195 165
M 64 x 2 205 175
* DIN 7604 Form C
Edition: October 1995
Index: 98-10-02 11
Adjustment data 9 S 109
Description Dimension Measuring device Remarks
01. Axial preload of layshaft 0.18 to Depth gauge Turn layshaft and thereby
0.30 mm centre bearing rollers.
Adjust zero play.
Then aim to set preload
(0.25 mm) using a shim of
appropriate thickness.
02. Axial preload of mains- 0.18 to Depth gauge Turn input shaft and main-
haft and input shaft 0.30 mm shaft and thereby centre bea-
ring rollers. Adjust zero play.
Then aim to set preload
(0.25 mm) using a shim of
appropriate thickness
03. Axial play of grooved ball 0 to Depth gauge Up to 0.1 mm play is permit-
bearing situated on output 0.10 mm ted.
(range-change group) Adjust using shim washer
04. Installation dimension for 8 + 0.5 mm Drift 1X56 126 467 If drift and ring are used, the
shaft seal in bearing cover and ring 1X56 137 484 installation dimension is
automatically given
05. Axial play of circlip on 0 to Feeler gauge Adjust using circlip of

sun gear 0.05 mm appropriate thickness
06. Axial play of snap ring for 0 to Depth gauge Adjust using circlip of
grooved ball bearing in 0.1 mm appropriate thickness
ring gear carrier
07. Axial play of circlip on 0 to Feeler gauge Adjust using circlip of

main shaft and layshaft 0.1 mm appropriate thickness
08. Axial play of reverse gear 0.40 to Depth gauge Play is given by correct
0.75 mm or feeler gauge assembly. Check to confirm
09. Axial play of crawler and 0.20 to Depth gauge Play is given by correct
first gear 0.45 mm or feeler gauge assembly. Check to confirm
10. Axial play of 2nd speed 0.20 to Depth gauge Play is given by correct
helical gear 0.40 mm or feeler gauge assembly. Check to confirm
12
9 S 109 Adjustment data
11. Axial play of 3rd or 4th 0.20 to Depth gauge Play is given by correct
speed helical gear 0.45 mm or feeler gauge assembly. Check to confirm
12. Axial play of reverse gear 0.20 to 0.60 mm Feeler gauge Play is given by correct
situated on the idler shaft assembly. Check to confirm
13. Permitted axial play of 0.10 to Feeler gauge Dimension data contains per-
planetary gears in planet 0.70 mm mitted level of wear for thrust
carrier washer. Minimum thickness
per thrust washer = 1.20 mm
14. Limit of wear of synchro- Main transmission Feeler gauge If gap is smaller, replace
nizer rings and/or clutch 0.80 mm synchronizer ring and/or
bodies, measured between clutch body
flat surfaces of ring and Range-change group
body with cones nested 1.20 mm
firmly together
0.60 mm Feeler gauge Upper limit of synchronous

15. Information on synchro- play is given by limit of wear
nous play (axial) of between 0.80 and 1.20 mm
Shift transmission Replace all spring packs of

16. Information on shifting 270 bis 310 N the synchronizer. This ensu-
force of synchronizer’s res that the specified shifting
shift sleeves Range-change group force is present.
850 bis 950 N
17. Axial play on speedo min. 0.10 mm Depth gauge Check by hand that play can
pinion shaft be felt
18. Backlash on pinion shaft 0.10 to Backlash play is given by cor-

0.20 mm rect assembly. Check by hand
19. Temperature for shrink- Heating up temperatu- Temperature probe or Seating surfaces of gears and
fitting helical gears onto re max. 170 °C thermometer shaft must be free of oil and
layshaft Temperature difference grease during assembly. Do
between joined parts not exceed maximum tempe-
150 °C rature and only remain at this
for 15 min at the most
20. Temperature for “assemb- max. 170 °C Temperature probe or Do not exceed maximum
ly of sun gear” thermometer temperature and only remain
at this for 15 min at the most
13
Adjustment data 9 S 109
21. Delivery rate of lubrica- 5.15 to 6.45 l/min and Graduated vessel and Measured when pump speed
ting oil pump during sepa- 0.155 bar stop watch n=725/min. Oil type Shell
rate check Spirex SAE 80 W at 100 °C
Tightening torques
01. Breather in transmission 10 Nm Torque wrench Breather must not be

housing or shift mechanism stopped
02. Restrictor in shut-off 20 Nm Torque wrench Use new sealing ring

valve (some versions)
03. Pressure switch in trans- 45 Nm Torque wrench Use new sealing ring
mission housing and
covers
04. M10x1 lock nut on reac- 46 Nm Torque wrench

tion links and ball joint
05. M12 hex nuts on reaction 50 Nm Torque wrench

links
06. Pawl stop on transmission 50 Nm Torque wrench Use new sealing ring
and shift mechanism
housing
07. M24x1.5 screw plug 50 Nm Torque wrench Do not overtighten

(conical) on transmission
housing
08. Impulse sensor 50 Nm Torque wrench Do not overtighten
09. Tightening torque for M12 60 Nm Torque wrench Secure with locking plate
hex screws on output
flange
10. Speedo connecting piece 100 Nm Torque wrench Use new sealing ring
11. Pivot bolt in transmission 130 Nm Torque wrench Use sealing compound and
housing on swinger (over- sealing washers
drive version)
14
9 S 109 Adjustment data
12. Screw plug with M38x1.5 120 Nm Torque wrench Use new sealing ring
magnet on transmission
housing
13. Pivot bolts on transmissi- 160 Nm Torque wrench Use sealing compound and
on housing sealing washers
14. M16x1.5 lock nut on 150 Nm Torque wrench Use new lock nut
piston for range-change
group shift mechanism
15. Pivot bolts on range- 180 Nm Torque wrench Use sealing compound and
change group housing sealing washers
15
Spring table 9 S 109
Part number Where fitted No. of Wire Ø Spring Unloaded

turns in mm outer length
Ø in mm in mm
0732 040 765 Shift mechanism 6.5 2.8 39.9 81.7
(on selector shaft,
some versions)
0732 040 728 Shift mechanism 6.5 1.8 28.9 80.0

(on selector shaft,
some versions)
0732 040 630 Shift mechanism 6.5 28.9 39.6 89.9

(on selector shaft,
some versions)
1204 307 334 Shift mechanism 5.5 2.0 27.2 45.3

(on selector shaft,
some versions)
1204 318 011 Shift mechanism 5.0 2.1 30.9 38.0

(on selector shaft,
some versions)
0732 040 237 Shift mechanism 7.5 2.5 39.4 76.9

(on selector shaft,
some versions)
0732 041 499 Shift mechanism 6.5 2.25 28.7 55.5

(on selector shaft,
some versions)
0732 040 986 Shift mechanism 5.5 2.25 14.8 21.6

(near detent levers,
some versions)
0732 040 985 Shift mechanism 6.5 2.0 14.8 23.4

some versions)
0732 040 819 Shift mechanism 10.5 2.25 13.55+0.2 40.4

(near ball roller for
detent segment)
0732 042 156 Shift mechanism 4.0 2.5 25.3 30.7

(near ball roller for
detent segment)
0732 040 385 Synchronisierung 18.5 1.25 6.35 34.2

range-change group
16
9 S 109 Spring table
Part number Where fitted No. of Wire Ø Spring Unloaded

turns in mm outer length
Ø in mm in mm
0732 041 500 Shift mechanism 6.5 2.1 14.8 23.6
some versions)
0732 040 409 Synchronizer 12.5 1.4 6.65 23.7

Main transmission
0732 041 374 Shift mechanism 13.5 1.3 10.7 37.8

(interlock)
17
Special tools 9 S 109
Fig. no Illustration Order no. Application Qty. Comments
1X56 100 632
Drift with conical sleeve for inser-

1 ting shaft seal 10x15x3 into speedo 1 Section 3
connecting piece
1X56 103 768
Drift for fitting shaft seal 48x65x10

2 on input 1 3/4ý 1 Section 7
1X56 119 916
Drift for fitting shaft seal and scra-

3 per 25x35x7 in shift housing 1 Section 6
1X56 122 304
Basic puller M65x2 for use with

Sections 11,
4 grippers 1
12 and 13
1X56 122 310
Extension M65x2 only for taper rol-

5 ler bearings on input 1 Section 11
18
9 S 109 Special tools
1X56 122 317
Adapter of M95x2 and M65x2 for

6 use with grippers 1 Section 11
1X56 126 467
Drift for fitting shaft seal 95x115x10

7 on input, for use with ring 1 Section 2
1X56 137 484
1X56 136 599
Hook M12 for lifting layshaft

Sections 3
8 1
and 10
1X56 136 708

Section 13
Gripper M95x2 for layshaft taper
(only use tools as
9 roller bearings on input side 1
of Jan. 1991, old
tools are not sui-
table)
1X56 136 711
Gripper M65x2 for layshaft taper

10 roller bearings on output side 1 Section 11
19
1X56 136 719
Gripper M95x2 for taper roller bea-

11 rings on input 1 Section 11
1X56 136 737
Gripper M65x2 for taper roller bea-

12 rings on mainshaft journal bearing 1 Section 12
1X56 137 135
Drift for bearing bush 25x32x20 in

13 shift housing 1 Section 6
1X56 137 200
Lifting rod for mainshaft

14 1 Section 10
1X5
6 13
7 20
0
1X56 137 451
Hook for guiding shift forks

Sections 9
15 1
and 10
20
9 S 109 Special tools
1X56 137 452
Drift for lock plate 4132 304 015 on

16 output flange 1 Section 2
1X56 137 456 30,0 mm

1X56 138 101 40,5 mm
1 each
17 Drift for oil pipe, mainshaft Section 5
on output side
1X56 137 457
Puller, split, for mainshaft synchro-

18 nizer hubs 1 Section12
1X56 137 484
Ring for distancing shaft seal

19 95x115x10 on output, for use with 1 Section 2
drift 1X56 126 467
1X56 137 579

Fixing attachment for radial fixing
of GP shift rail
20 1 Section 3
1X56 138 100
ISUZU version
Isuzu
21
1X56 137 648
Divided ring for extracting output

21 side clutch body of range-change 1 Section 3
group
1X56 137 134
Protective sleeve
22 Assembly aid for assembling shift 1 Section 6
cover on selector shaft
1X56 138 026
Drift for assembling baffle plate in

23 input shaft 1 Section 11
1X56 138 065
Protective sleeve
24 Assembly aid for fitting connection 1 Section 7
plate
1X56 137 450
Assembly stands 1
25 for use with adapters 1X56 136 998
and 1X56 137 459
22
9 S 109 Sequences of removal and installation
When performing a basic overhaul of the transmission, the sequence for removal (steps 01 to 14) and the sequence
for installation (steps 14 to 01), as shown below, should be strictly followed.
02, 03,
02, 03,
01
01 04, 05,
04
05
06 06
07
09 12
07 10 13
11
08 10
08 11 14
006 808
01 Tecalan pipe 07, 08 Connection plate, shift rails and oil sieve,
02, 03, 04 Output, range-change group, planet carrier bearing adjustment of shafts
05 Sun gear 09, 10, 11 Input shaft, reverse gear and pivot
06 Shift mechanism 12,13,14 Shafts with clamps, housings
23
9 S 109 Range-change and splitter group
1 Tecalan pipes for range-change group
NOTE
Mark the Tecalan pipes at connection points
before removal.
1.1 Removal
1 Remove union screws on range-change group

cylinder and shut-off valve. Take off Tecalan
pipes.
2 Remove cable *.
006 809
1.2 Assembly
1 Screw Tecalan pipes onto shut-off valve and

range-change group cylinder with union screws.
Use new sealing rings on the union screws. Fit
Tecalan pipes in accordance with marks 1/A
Tightening torque for union screws:

- M14x1,5 tightening torque = 35 Nm
2 Attach cable*. 3
CAUTION
Tecalan pipes can be incorrectly connected. If they 2
were not marked during removal, proceed as follows:
Use selector shaft to select R gear position. Pressurize
entry to main shut-off valve with compressed air - not 2
higher than operating pressure - (refer to arrow in dia-
3
gram 006 809).
Air for low-ratio group will exit from valve exit.
Connect Tecalan pipe at this exit and on cylinder
connection “2” (diagram 006 810). This provides the
connection for the second Tecalan pipe.
NOTE
Ensure that minimum distance between Tecalan pipe and
housing is 5 mm
1/B
1 = Cylinder A or B
2 = Connection for low-ratio group
* depending on parts list version
3 = Connection for high-ratio group006 810
006 810
1-1
9 S 109 Output
2 Output
8
2.1 Removal of output flange and cover 1
9 7
2
1 Remove retaining plate (1). 3
4
2 Secure output flange to stop it rotating using stan- 5
dard flange holder.
3 Remove two hex bolts (2) and take off washer (3).
4 Place intermediate part on planet carrier and pull

off output flange (5) using standard two-leg or 6
three-leg puller.
5 If necessary, remove flange bolts (6).

008 002
6 Remove O-ring (4).
7 Remove four hex bolts (7). Lift off cover (8) and
seal (9).
2-1
Output 9 S 109
2.2 Removal of bearing cover
1 Unscrew eight hex bolts on bearing cover.
2 Release bearing cover by hitting it gently with pla-

stic hammer
006 816
3 Lift off bearing cover with seal and washer.
4 Use plastic mandrel to drive shaft seal out of

bearing cover.
006 817
2.3 Mounting of bearing cover

A
NOTE
To avoid measurement errors, tap bearing cover home
onto collar of housing III by gently hitting it with plastic
mandrel hammer.
1 Adjust axial play of ball bearing with washer, aim

for play of 0.0 mm.
- Permitted axial play: 0 - 0.1 mm
2 Measure dimension “A” from the bearing cover

face end to the housing sealing face.
009 311
2-2
9 S 109 Output
3 Measure dimension “B” from bearing cover with

seal added to contact face of ball bearing.
B
4 Determine the washer thickness “C”
C = B -A
C = washer thickness when axial play is 0
006 819
5 Apply lubricant to outer diameter of shaft seal;

e.g. fluid soap
6 Use drift 1X56 126 467 and ring 1X56 137 484 to
drive shaft seal into bearing cover. This gives an
installation diameter of 8.0 + 0.5 mm.
NOTE
Lightly grease sealing lip of shaft seal.
009 312
7 Place washer in recess of bearing cover.
8 Add new seal to bearing cover.
9 Screw in eight M8 hex bolts with spring washers.

- tightening torque = 23 Nm.
006 817
2-3
Output 9 S 109
2.4 Mounting of output flange and cover

8
1 Add new seal (9) to cover (8), screw in four M12 1
9 7
hex bolts (7). 2
- tightening torque = 79 Nm 3
4
2 If necessary, add and/or press in flange bolts (6). 5
3 Push output flange (5) onto planet carrier shaft.
4 Use washer (3) and two assembly aid bolts to pull

up output flange until it is fully home.
6
5 Remove washer and assembly aid bolts.
6 Lightly oil new O-ring (4) and insert in gap bet-

008 002
ween output flange and planet carrier shaft.
7 Insert washer (3) in output flange, screw in two

bolts (2) and tighten to 60 Nm.
If possible, secure output flange to stop it rotating
using standard flange holder.
8 Fully drive on new retaining plate (1) over bolt

heads using drift 1X56 136 452.
2-4
9 S 109 Range-change group
3 Range-change group
NOTE
If the range-change group is not dismantled
and only cap collar and/or piston are to be repla-
ced on the cylinder, proceed as follows:
Screw fixing attachment** into threaded bore of 2
pawl stop and tighten to 50 Nm. In so doing, set
the fixing piece so that the shift rail is fixed radi-
ally. Remove cylinder (refer to Section 3.3).
Remove locking nut from piston, lift off piston 3 1
and take grooved ring from piston. Press cap
collar out of housing, e.g. using screwdriver.
006 825
3.1 Removal of range-change group
1 Remove pawl stop (1) for range-change group and 2

range-change group display switch* (3) or screw 2
plug*.
1
2 Screw out R gear display switch* (2) or plug 3 3

screw* and use magnet to take ball out of bore.
1
006 826
3 Screw out speedo input* or impulse sensor*.
NOTE
Speedo input is a single component and is not
dismantled.
* parts in accordance with parts list

** depending on version 1X56 137 579 or 1X56 138 100
006 827
3-1
Range-change group 9 S 109
4 Remove hex bolts at edge of housing.
006 828
5 Screw hook 1X56 136 599 into housing.
6 Suspend range-change group on hook.
CAUTION
If output flange has been removed, secure planet car-
rier in housing. Place suitable bush on shaft of planet
carrier. Fasten bush with previously removed washer
and two hex bolts
7 Use two mounting levers to separate housing parts.
8 Remove seal and clean sealing faces.
006 829
3.2 Mounting of range-change group
CAUTION
If output flange has been removed, secure planet
carrier in housing. Place suitable bush on shaft of
planet carrier. Fasten bush with previously removed
washer and two hex bolts.
1 Carefully insert two cylinder pins (refer to arrow).
2 Screw standard M10 guiding bolts into housing.
006 830
3-2
3 Slide new seal over guiding bolts and place on

housing.
4 Suspend range-change group on crane and

carefully drive onto transmission housing
NOTE
Drive shift rail into bearing plate opening for shift
locking (interlock).
5 Use guiding bolts to drive range-change group

fully home.
NOTE
Engage gear teeth on sun gear and planetary
gears.
006 831
6 Screw in hex bolts in accordance with parts list.

- M10 tightening torque = 50 Nm
NOTE
Screw hex bolts with bore into head of speedo
input (wire lock).
NOTE
If the range-change group is not dismantled
and cap collar and/or piston, locking nut and
cylinder are to be replaced on the cylinder, pro-
ceed as follows before screwing in the pawl stop:
Screw fixing attachment* into threaded bore of
pawl stop (1) and tighten to 50 Nm. In so doing,
set the fixing piece so that the shift rail is fixed
006 832
radially. Spray new cap collar on outer edge with
spirits. With sealing ring facing housing, slide it
over shift rail and place on housing bore. Use sui-
table tool to drive cap collar fully home. (Assemb- 3
ly of following parts is described in Section 3.4).
Assemble shim, piston and locking nut. Assembly
double-grooved ring, O-ring and cylinder. 2
Unscrew fixing attachment*.
2
3 1
1
* depending on version 1X56 137 579 or 1X56 138 100

006 833
3-3
7 Screw in pawl stop (1) for range-change group with

new sealing ring.
- M16x1.5 tightening torque = 50 Nm 2
2
8 Use ohmmeter to check that range-change group
1
display switch * (3) is functioning correctly and
screw in with new sealing ring.
- tightening torque = 50 Nm 3 3
or screw in screw plug* (3) with new sealing ring.
- tightening torque = 35 Nm. 1
9 Insert ball in housing bore, use ohmmeter to check

that R gear display switch* (2) is functioning cor-
rectly and screw in with new sealing ring.
- tightening torque = 50 Nm
or screw in screw plug* (2) with new sealing ring.
006 826
- tightening torque = 35 Nm.
3-4
3.3 Dismantling range-change group
1 Screw both pivot bolts out of housing.
006 834
2 Lift housing from planet carrier.
006 835
NOTE
If the range-change group is not dismantled,
cylinder, locking nut, piston with grooved rings,
guiding rings and cap collar are disassembled as is
described below.
3 Remove four hex bolts from cylinder.
006 836
3-5
4 Use O-ring to carefully lift cylinder.
5 Take guiding ring out of piston groove (refer to

arrow).
6 Use piston to take out shift rail.
CAUTION
The cap collar may be damaged. It should therefore
ALWAYS be replaced
006 837
7 Press cap collar out of housing, e.g. using

screwdriver.
006 838
8 Clamp shift rail in vice and place square material

in recess.
CAUTION
Protect shift rail with aluminium wedges.
006 840
3-6
9 Unscrew locking nut and take off piston.
10 Take both grooved rings out of piston groove.
006 839
11 Use mandrel to drive ball bearing out of housing

and then place housing on two wooden blocks in
reverse order.
12 Screw out screw plugs in housing.
006 841
3.4 Assembling range-change group
1 Screw screw plugs into housing and use new

sealing ring.
- M18x1.5 tightening torque = 35 Nm
NOTE
Use hot air blower to heat bearing seat in housing
to max. 70° C.
2 Use plastic mandrel to drive ball bearing into

housing and ensure that it is driven home.
3 Use sealing compound to slide sealing cover

(refer to arrow) onto sealing face and – use suita-
ble tool – to drive in flush to the housing bore.
006 842
3-7
4 Clamp shift rail in vice and place square material

in recess.
CAUTION
Protect shift rail with aluminium wedges.
006 843
NOTE
If the range-change group is not dismantled,
cap collar, piston with grooved rings, guiding ring,
locking nut and cylinder are disassembled as is
described below.
NOTE
Spray cap collar on outer edge with spirits.
5 Use suitable tool to drive new cap collar into

housing.
006 844
6 Insert new grooved ring in piston. Version

Standard Dampened stop
CAUTION
The grooved sides of the ring should face outwards.
7 Apply thin coat of grease ZF no. 0750 199 001

(e.g. ARALUB HL2) to sealing lips of grooved
ring
009 767
3-8
8 Place piston on shift rail.
NOTE
Recess in piston faces upwards.
9 Screw in new locking nut.

10 Insert shift rail and piston into housing bore and in

so doing turn shift rail.
006 846
11 Insert guiding ring into middle piston ring groove.
006 847
12 Apply thin coat of grease ZF no. 0750 199 001
(e.g. ARALUB HL2) to sealing lips of grooved
ring.
13 Coat new O-ring with grease and place in ring

groove of cylinder.
14 Carefully push cylinder over piston.
NOTE
During this process, the guiding ring must be at
the base of the piston ring groove.
CAUTION
Try to avoid damaging O-ring, groove and guiding
rings.
006 848
3-9
15 Rotate cylinder into position.
16 Screw in four hex bolts with spring disks.

17 Radially position shift rail so that both detents

face upwards for the fitting of the range-change
group (3.2).
006 849
NOTE
The recesses in the shift rail for shift fork engage-
ment can be found in the installation position.
006 850
18 Use group synchronizer to place range-change

group housing on planet carrier and drive firmly
home.
NOTE
The shift rail is located in one of the two recesses
in the clutch body and the second recess is located
below the prepared selector cylinder fitting point.
(for splitter group in 16 gear version).
19 Engage shift fork nose with recess in shift rail.
NOTE
Clutch body journals must engage in housing
recesses.
006 835
3-10
20 Align shift fork to threaded bores in housing so

that guiding bores of shift fork are flush with
threaded bores of housing.
006 851
NOTE
• Threads must be clean and free of oil and grease.
• Spray pivot bolt threads with Loctite no. 241.
21 Screw in pivot bolts with spring washers.

Depending on version:
22 Fit cover as described in Section 2.3.
23 Fit output flange as described in Section 2.4.
24 Screw in speedo shaft* or screw plug* with new

sealing ring.
- tightening torque = 100 Nm
006 834
NOTE
Do not disassemble defective shaft seals but use
drift 1X56 100 632 to drive new shaft seal firmly
home.
25 Check axial play and backlash of speedo shaft by

hand.
- axial play = min. 0.1 mm
- backlash = min. 0.1 to 0.2 mm
26 Tighten impulse sensor* to 50 Nm or screw plug*

to 35 Nm.

006 852
3-11
9 S 109 Planetary gear with synchronizer
4 Planetary gear with synchronizer
4.1 Dismantling synchronizer
1 Remove shift fork.
2 Take fulcrum pad out of shift fork.
3 Place intermediate part on planet carrier.
006 876
4 Insert split ring (3) 1X56 137 648 between clutch

1*
body (2) and synchronizer ring (4). Grip bottom of 2
sliding sleeve (5) with two-leg or three-leg puller
and pull off synchronizer ring (4), clutch body (2) 3
and impulse washer (1) or speedo worm. The pres- 4
sure pieces (7) and compression springs (8) retai-
ned by the sliding sleeve can be caught in a cloth. 5
! DANGER
Pressure pieces are under spring-load. Secure them to
ensure that they do not spring out. 7
8 6
9
5 Spring out circlip (6). 10
11
6 Grip bottom of synchronizer hubs (9) with two-leg
puller and pull off.
7 Remove synchronizer ring (10) and clutch bodies

(11) from planet carrier
12

010 610
4-1
Planetary gear with synchronizer 9 S 109
4.2 Dismantling ring gear
1 Pull ring gear completely off planet carrier (18).
2 Remove snap ring (12) from ring groove of ring 18

gear carrier (14) and remove ball bearing (13).
3 Remove safety wire (15) from ring groove in ring

gear (11) and use plastic hammer to drive ring
gear carrier (14) out of ring gear.
15
14
11 13
12
4.3 Dismantling planet carrier 010 611
1 Drive the full length of each clamping pin (16) 19

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

(17).
010 612
4-2
4.4 Assembling planet carrier

19
21 20
CAUTION 20
Do not replace planet gears individually but always as 21
a set. 16 20
19
1 Lightly oil front face of planet gear (22) and the 17
cylinder roller race. 18 22
2 Assemble planetary bolt (17) with collar facing

downwards.
3 Slide washer (19) over planetary bolt with marked

side facing planet carrier.
4 Slide an intermediate washer (20) over planetary

010 612
bolt.
5 Place planetary gear (22) on planetary bolt.
6 Insert 20 needle rollers (21) in planetary gear and

slide intermediate washer (20) over planetary bolt.
NOTE
Only use needle rollers of the same dimensions.
7 Insert the remaining 20 needle rollers, slightly oil

and add intermediate washer (20).
8 Slide washer (19) over planetary bolt with marked

side facing planet carrier. 12 Align planetary bolt (17) radially and insert in
bearing bore.
9 Place planet carrier (18) on front face of shaft.
13 Use plastic hammer to drive in planetary bolt.
10 Carefully take planetary gear (22) and washers Check that clamping pin bore is flush.
(19) off planetary bolt (17) and insert in planet
carrier. 14 Drive new clamping pin (16) into planet carrier.
11 Align planetary gear (22) and washers (19) to bea- NOTE

ring bore. Countersink clamping pin approx. 0.5 mm into the
planet carrier.
NOTE
The “0” mark on the front face of the planetary 15 Check axial play of planetary gears (0.1 to 0.7
bolt must face the outer radius of the planet carrier mm).
(oil bore must face inner radius of planet carrier).
16 Repeat steps 1 to 15 on the other three planetary
gears.
4-3
4.5 Assembling ring gear 18

1 Drive ring gear carrier (14) firmly home in the
ring gear (11).
2 Insert safety wire (15) into groove ring of ring

gear.
NOTE
The safety wire must lie on the groove base.
3 Insert ball bearing (13) in ring gear carrier and

insert snap ring (12). Use suitable snap ring to 15
adjust ball bearing axial play to 0 to 0.1 mm. 14
4 Heat ball bearing (13) to approx. 60 °C and place

on planet carrier with ring gear. In so doing, turn
ring gear and engage gear teeth. Ball bearing must 11 13
lie axially on planet carrier. 12
! DANGER
Always wear protective gloves when handling heated
parts.
4.6 Assembling synchronizer

010 611
NOTE
Use synchronizer parts in accordance with
brochure 1297 754 101 “ZF locking synchronizers 1
component inspection”.
CAUTION
Check, mark and store parts IN PAIRS. Do not mix
up parts.
1 = Synchronizer ring
1 Place synchronizer ring on centre of clutch body. 2
2 = Clutch body
Move the cones by turning the parts.
006 867
2 Use feeler gauge to measure distance between NOTE

clutch body and synchronizer ring. Compare dimension found with permitted limits
of wear. These are:
- main transmission = 0.8 mm
- range-change group = 1.2 mm
NOTE
If your dimension is below these, install new syn-
chronizer ring and / or clutch body.
4-4
3 Place clutch body (11) and synchronizer ring (10)

on planet carrier.
4 Push on clutch body (11) with long hub side 1*

2
facing planet carrier. The cams of the synchroni-
zer ring (10) must reach into the recesses of the 4
synchronizer hub.
5
5 Insert circlip (6) in ring groove with axial play of
0 to 0.1 mm
NOTE 7
Select a circlip of suitable strength from the spare
parts catalogue. 8 6
9
6 Place sliding sleeve (5) on synchronizer hub (9) 10

11
and drive home.
NOTE
Sliding sleeve recesses must cover the same area
as the synchronizer hub recesses.
7 Insert new compression springs (8) with pressure

pieces in synchronizer hub and guide into sliding
sleeve with suitable tool.
12
8 Place synchronizer ring (4) on synchronizer hub.
The cams of the synchronizer ring (10) must reach
into the recesses of the synchronizer hub.
9 Press on synchronizer ring (4) and bring sliding

sleeve into middle position. You will clearly be
able to hear the pressure pieces snapping in.
10 Heat clutch bodies (2) to approx. 120° C and push

onto planet carrier.
! DANGER * parts in accordance with parts list

010 675
parts.
11 Heat speedo worm or impulse washer (1) to

approx. 80° C and push onto planet carrier.
4-5
12 Insert fulcrum pad into shift fork.
13 Insert shift fork into sliding sleeve.
NOTE
Shift fork nose should be located in the appro-
priate recess in clutch body.
006 876
4-6
9 S 109 Sun gear
5 Sun gear
5.1 Removal of sun gear
1 Remove circlip.
006 885
2 Push drift 1X56 137 456 over pipe used for

pressurized oil lubrication.
3 Use standard two-leg puller to pull sun gear off

mainshaft.
006 886
5-1
Sun gear 9 S 109
5.2 Mounting of sun gear
1 Evenly heat sun gear to max. 170 °C so that it can

be pushed on with one manual tug
CAUTION
Do not exceed maximum temperature of 170 °C
and do not maintain this temperature for more than
15 mins.
! DANGER
sun gears.
006 887
2 Push sun gear onto mainshaft and drive firmly
home.
CAUTION
Only mount sun gear when it has been heated. Never
drive the sun gear onto the mainshaft as the taper
roller bearing on the journal bearing of the mainshaft
can be destroyed or damaged if hit or pushed too
hard.
NOTE
Collar and bore face input shaft.
3 Insert circlip.
NOTE
Circlip axial play is 0 to 0.5 mm. Select circlip in
006 888
accordance with spare parts catalogue.
4 Use drift 1X56 137 456 to drive oil pipe firmly

home in the mainshaft.
5-2
9 S 109 Shift mechanism
6 Shift mechanism
6.1 Removal of shift mechanisms 21
1 Remove the four hex bolts (16 and 21) from the 20
shift housing and cover (20). 19
16
18
CAUTION
Cover (20) is spring-loaded. 17
2 Take off cover (20) seal (19) and the three com-
pression springs (18) and shift detents (17).
NOTE
Cover is a single part and is not dismantled.
011 024
3 Take off shift mechanism.
006 891
4 Remove sealing ring (9).
5 Remove pipe (8).

(only in horizontal shift mechanisms)
8 9
010 988
6-1
Shift mechanism 9 S 109
6.2 Mounting of shift mechanism
1 Switch shift mechanism to “neutral”, place new

sealing ring (9) on housing sealing faces.
NOTE
Insert pipe (8) in horizontal shift mechanisms
only.
2 Add shift mechanism and in so doing engage it

with driver (refer to arrow).
8 9
010 988
3 Place new sealing ring (19) on shift housing. In

sert three shift detents (17) and three compression
springs (18) and add cover (20). 21
4 Screw in hex bolts (16 and 21) on shift housing 20
and cover and temporarily only tighten them 19
slightly. 16
18
NOTE 17
The shift housing must be centred to the shift
components in the transmission. For this, proceed
as follows:
5 Engage a gear by activating the shift lever (refer to

arrow).
011 024
6 Engage opposite gear.
7 Compare shift travel/excess shift travel with the

central position.
8 If the shift travel/excess shift travel are not of the

same size, loosen the hex bolts slightly and dis-
place the shift housing by gently tapping it with a
plastic hammer.
NOTE
Repeat procedure until the shift travel/excess shift
travel are of the same size.
006 892
6-2
9 Tighten all hex bolts on the shift mechanism

006 889
6-3
6.3 Dismantling shift mechanism
NOTE
The following diagrams show the version “shift
mechanism horizontal left”. It will depend on the
type of shift mechanism as to whether the arrange-
ment of shift parts and pressure springs (refer to
Section 6.4) are visible or not.
1 Clamp shift mechanism in vice.
CAUTION
Protect shift housing from damage with aluminium
wedges
006 896
NOTE
Depending on transmission version, the reaction
linkage may be fitted.
2 Remove locking nut from ball joint.
3 Remove ball joint from shift lever and take off

reaction linkage.
NOTE
Do not dismantle reaction linkage because other-
wise it will have to be readjusted to fit the vehicle
properly.
006 897
4 Mark the position of the shift lever on the selector

shaft.
5 Remove hex bolt and screw from shift lever.
6 Use standard two-leg puller to pull shift lever off

selector shaft.
006 898
6-4
7 Take protective cap off selector shaft.
006 900
8 Remove hex bolts (1) from shift cover (2).
9 Lift shift cover off selector shaft.
10 Remove seal (3) and bush (4).
4*
3
2
1 *parts in accordance with parts list
007 993
11 Remove scraper (1), shaft seals (2) and (5) from

shift cover (4). 5
12 Use drift 1X56 137 135 to drive bearing bush (3) 4

out of shift cover.
3
2
1
007 997
6-5
7* 3
5 2 1
6*
9 8* 4
13
14* 10
15* 11 19
16
17 12 20
18

007 996
13 Remove four cylinder bolts (1). 16 Take off cover (17) with compression spring(s)
(15/14) and sealing ring (16).
14 Take off shut-off valve (2) and O-ring (4).
17 Take out insert (12) with O-ring (11), sealing ring
NOTE (10) and tapered roller (13).
Shut-off valve is a single part and is not
dismantled. 18 Remove detent plunger (7) for reverse gear.
NOTE 19 Remove plug screws (5/9) and compression

Unscrew throttle screw (3) on shut-off valve. springs (6/8) from both sides of the shift housing.
15 Remove two screws (18) from cover (17).

! DANGER
Screw plugs are spring-loaded.
DANGER
Cover (17) is spring-loaded.
20 Take bolts (20) and detent lever (19) out of shift
housing.
6-6
21 Remove four hex bolts (1).
22 Take off cover (2) and sealing ring (4).

Depending on version, check needle bearing (3) in
cover (2) and replace if necessary
1
2 3*
4
007 994
23 Remove O-ring (1), four hex bolts (2), cover (3)

and sealing ring (4) from version with gate
interlock*.
24 Remove snap ring (8) from cover (3) and take out
1*
piston (6) and O-ring (7/5).
NOTE
Mark site of circlips and washers to allow for easy
future assembly.
2*
25 Remove circlip from ring groove of selector shaft. 3* 8*
4* 5*
6*
! DANGER 7*
007 995
Circlip is spring-loaded. Hold back washer on circlip
against spring pressure.
26 Take washer and compression spring(s) off selec-

tor shaft.
27 Depending on shift version and arrangement of

compression springs, remove circlip, washer and
second compression spring.

006 916
6-7
28 Use a suitable amount of force to drive double

clamping pin in detent bush out through the open
threaded bore onto the upper side of the shift
housing.
NOTE
Bring selector shaft into proper position.
006 919
29 Mark position of detent bush. Pull detent bush off

selector shaft.
006 920
30 Use an appropriate amount of force to drive detent

piece clamping pin out through insert aperture.
NOTE
Position selector shaft correspondingly.
006 921
6-8
31 Pull selector shaft out of shift housing.
32 Take detent piece and driver out of shift housing.
NOTE
Driver could fall out, secure appropriately.
006 922
33 Take rollers out of selector shaft (refer to arrow).
006 923
34 Use drift 1X56 137 135 to drive needle sleeve out

of shift housing.
006 924
6-9
6.4 Shift mechanism assembly

Selector pattern and spring arrangement (refer to Technical Cover Sheet in spare parts catalogue)
Summary of shift mechanism types, parts according to parts list
Transm. install. position Shift mecha- Shift Driver Spring pack arrangement
horizontal left nism type output arrangement Q1 to Q7
Selector pattern
I and II
horizontal left Section 6.4.1 Section 6.4.2
006925
horizontal right Section 6.4.1 Section 6.4.2
006926
vertical top Section 6.4.1 Section 6.4.2
006927
vertical below Section 6.4.1 Section 6.4.2
006928
Transm. install. position

horizontal right
vertical top Section 6.4.1 Section 6.4.2
006929
6-10
6.4.1 Driver arrangement
Transmission installation position: horizontal left

Shift mechanism type: horizontal
Shift output: left
Selector pattern: I Side position of detent bush (2)
1 2 3 4 5
R/C 3/4 1/2 006 930
Selector pattern: II Side position of detent bush (2)
1 2 3 4 5
006 931
R/C 1/2 3/4
1 = Driver * NOTE
The spring arrangement is only displayed as an
2 = Detent bush
example.
3 = Compression spring(s) Springs should be arranged in accordance with Sec-
tion 6.4.2
4= Selector shaft
5 = Shift housing
6-11
Driver arrangement

Shift mechanism type: horizontal
Shift output: right
Selector pattern: I Side position of detent bush (2)
1 2 3 4 5
R/C 3/4 1/2 006 932
Selector pattern: II Side position of detent bush (2)
1 2 3 4 5
R/C 1/2 3/4 006 933
1 = Driver * NOTE
The spring arrangement is only displayed as an
2 = Detent bush
example.
3 = Compression spring(s) Springs should be arranged in accordance with Sec-
tion 6.4.2
4= Selector shaft
5 = Shift housing
6-12
Driver arrangement

Shift mechanism type: vertical
Shift output: top
Selector pattern: I Selector pattern: II
1/2 3/4
1 1
3/4 1/2
R/C R/C
Side position of Side position of

detent bush (2) detent bush (2)
2 2
3 3
006 934 006 935
4 4
5 5
1 = Driver * NOTE
2 = Detent bush The spring arrangement is only displayed as an
example.
3 = Compression spring(s)
Springs should be arranged in accordance with Sec-
4= Selector shaft tion 6.4.
5 = Shift housing
6-13
Driver arrangement

Shift output: top
1/2 3/4
1 1
3/4 1/2
R/C R/C

2 2
3 3
006 936 006 937
4 4
5 5
1 = Driver * NOTE
example.
Springs should be arranged in accordance with
4= Selector shaft Section 6.4.2
5 = Shift housing
6-14
DRIVER ARRANGEMENT

Shift output: top

5
5
4 4
3 3
2 2
R/C
1 3/4 R/C
R
1/2 1 1/2
1/2
3/4 3/4
006 938 006 939
1 = Driver * NOTE
example.
Springs should be arranged in accordance with
4= Selector shaft Section 6.4.2
5 = Shift housing
6-15
6.4.2 Compression spring arrangement (spring packs) in acc. with parts list (spare parts catalogue)
6.4.2.1 Transmission installation position: horizontal left / shift output: vertical top
Q1 Q5
009746 009750
Q2 Q6
009747 009751
Q3 Q7
009748 009752
Q4
009749
6-16
6.4.2.2 Transmission installation position: horizontal left / shift output: horizontal left
Q1 Q5
009753
Q2 Q6
009754 009758
Q3 Q7
009755 009759
Q4
009756
6-17
6.4.2.3 Transmission installation position: horizontal left / shift output: horizontal right
Q1 Q5
009760
009764
Q2 Q6
009761 009765
Q3 Q7
009762 009766
Q4
6-18
6.5 Assembling shift mechanism
NOTE
The following diagrams show the version “shift
mechanism horizontal left”. It will depend on the
type of shift mechanism as to whether the arrange-
ment of shift parts and pressure springs (refer to
Section 6.4) is visible or not.
1 Use drift 1X56 137 135 to drive needle sleeve into

ridge of shift housing. (Side of needle sleeve
which is written on should be facing drift).
NOTE
The needle sleeve is positioned opposite the ridge
faces, on the detent piece, back approx. 1 mm.
006 949
2 Insert six rollers in bores of selector shaft and

slightly grease bores for this (refer to arrow).
NOTE
Three more rollers need to be inserted for the ver-
sion “shift mechanism vertical”. These three rol-
lers have milled faces. Insert rollers radially so
that each of the faces is facing the bush when the
selector shaft is installed.
3 Assemble suitable driver for shift mechanism type

as is shown in Section 6.4.
006 950
4 Hold driver in installation point of shift housing.
5 Use selector shaft to slide on the driver.
006 951
6-19
Shift mechanisms 9 S 109
6 Slide detent piece onto selector shaft.
NOTE
Detent level (refer to arrow) of detent piece faces
installation point for shut-off valve.
006 952
7 Slide detent bush, depending on version, onto

selector shaft (as marked during disassembly).
NOTE
Move bores for clamp pins on licking unit and
detent bush up until flush.
006 953
6-20
NOTE Shift output horizontal or on top

Apply light coat of sealing compound to outer
edge of shaft seals with steel surround.
Apply coat of Vaseline or water-soluble concentra-
ted washing-up liquid (e.g. Pril) to outer edge of 1
shaft seals with rubber surround. 2
B
3
Shift output version horizontal or top
4
A
1a Drive shaft seal (7) into shift cover (5) using drift
1X56 137 135 to dimension “A”. 5
6
2a Drive bush bearing (4) into shift cover (5) using
7
drift 1X56 137 135 to dimension “B”.
Dimension “A” = 40+0,5 mm Dimension “B” = 18+0,5 mm

006 139
Shift output version below Shift output below*
1b Drive shaft seal (7) into shift cover (5) using drift
1X56 137 135 to dimension “A”.
2 Drive bush bearing (4) into shift cover (5) using

drift 1X56 137 135 to dimension “B”.
3 Fully drive in shaft seal (2) using drift

1X56 119 916.
NOTE
The sealing lips of the shaft seals (7) and (2) must
face towards the bearing bush (4).
4 Fully drive in scraper (1) using drift 1X56 119 916, Dimension “A” = 22+0,5 mm Dimension “B”‚ = 17+0,5 mm
009 496
until it is flush with the shift cover.
5 Fill the pockets (3) and (6) with grease (ZF order
number 0750 199 001).
6 Depending on version, insert bush (4)
7 Place shift cover (2) and new sealing ring (3) on

shift housing.
CAUTION
Do not damage shaft seal and scraper when sliding
onto selector shaft. Use protective sleeve 1X56 137 134. 4*
8 Tighten four M8 hex bolts (1) to 23 Nm. 3

2
1 * parts in accordance with parts list
007 993
6-21
9 Drive both clamping pins and mandrel into detent

piece and detent bush.
CAUTION
Do not confuse clamping pins.
Clamping pin for detent piece: = 36 mm
Clamping pin for detent bush: = 30 or 28 mm
NOTE
Assemble circlips and washers as marked.
10 Place washer on selector shaft.
11 Depending on version, insert circlip in appropriate

ring groove.
006 958
12 Depending on version, place small washer on sel-
ector shaft.
13 Depending on version, place compression spring

(small) on selector shaft.
14 Depending on version, place washer (small) on

selector shaft.
15 Depending on version, insert circlip (small) and

circlip tongs in ring groove and in so doing push
back compression spring.
16 Place compression spring (large) on selector shaft.
17 Add washer (large), push back compression

spring.
009 328
18 Insert circlip (large) and circlip tongs in outer ring

groove.
NOTE
Position selector shaft as far as is possible in the
direction of compression springs.
CAUTION
Washer is spring-loaded.
009 329
6-22
19 Bring shift mechanism into neutral position.
20 Depending on version, use drift 1X56 137 135 to

drive needle bearing (3) into cover (2). (Side of
needle sleeve written on should be facing drift).
21 Add cover (2) and new sealing ring (3). Screw in

four hex bolts (1) and spring washers and tighten
to 23 Nm.
1
2 3*
* parts in accordance with parts list 4

010 613
Version with gate interlock*
◆ Slightly grease O-ring (5 and 7) and insert on

piston (6). Apply approx. 2 grams of grease
(ZF# 0750 199 001) to piston.
◆ Insert piston (6) in cover (3) and insert snap

1*
ring (8).
◆ Tighten down cover (3) and new sealing ring

(4) with four hex bolts (2).
Tightening torque = 23 Nm.
2*
◆ Insert O-ring (1) on cover (3). 3* 8*
4* 5*
CAUTION 6*
* parts in accordance with parts list 7*
You must be able to move selector shaft easily in both
010 614
directions
6-23
7* 3
5 2 1
6*
9 8* 4
13
14* 10
15* 11 19
16
17 12 20
18

010 615
22 Insert both detent levers (19) in shift housing. 29 Insert O-ring (4) on shut-off valve (2).
23 Insert bolts (20) through detent lever bore into 30 Fit shut-off valve (2) and in so doing note position
shift housing. of pneumatic connections.
24 Insert compression springs (6/8) and tighten screw 31 Tighten screws (1) to 23 Nm.
plugs (5/9) to 35 Nm.
32 Screw in throttle screw (3) and new sealing ring.
25 Insert O-ring (11) in insert (12). Tightening torque = 50 Nm.
26 Grease ball rollers (13). 33 Screw in pawl stop (7) and new sealing ring.
Tightening torque = 50 Nm.
27 Fit items 10 to 18.
28 Tighten screw (18) to 23 Nm
6-24
34 Place protective cap on selector shaft.
006 900
35 Push shift lever onto selector shaft as marked and

in so doing fix protective cap.
36 Insert hex bolt and nut and tighten

006 898
37 Place ball pivot in shift lever and tighten
with hex nut.
- M10x1 tightening torque = 46 Nm
006 896
6-25
9 S 109 Connection plate / lubricating oil pump
7 Connection plate - lubricating oil pump
7.1 Removal of connection plate
1 Depending on version, spring out circlip (1) and

remove sealing cap (2).
2 Remove six hex bolts (3), take off connection

plate (4) and shim (7) and sealing ring (6).
3 Remove shaft seal (5) from connection plate (4)

and in so doing ensure you do not damage sealing
faces of connection plate.
7
6
4 5
3
2*
1*

007992
7.2 Removal and dismantling of lubricating oil
pump
1 Remove eight hex bolts and compression washers.
006975
7-1
Connection plate / lubricating oil pump 9 S 109
2 Use mounting levers to press lubricating oil pump

out of housing, remove sealing ring.
NOTE
Add mounting lever to cast pockets.
CAUTION
Do not damage pump and housing.
3 Take shim from outer bearing ring of layshaft.
NOTE
Lubricating oil pump is a single component, only
dismantle for visual checks and cleaning
purposes.
006976
4 Remove screws from lubricating oil pump.
006977
5 Press pump housing off pump cover.

Do not damage sealing face in the process.
006978
7-2
6 Take out inner and outer rotors from pump cover.
NOTE
First mark installation point of outer rotor
7 If necessary, extract cylinder pin.
006979
7.3 Assembly and mounting of lubricating oil

pump
1 Clean and visually check pump parts.
2 If necessary, insert cylinder pin in bores of pump

cover.
3 Insert outer rotor in marked installation point and

insert inner rotor in pump cover, add some oil.
006979
4 Add pump housing and drive firmly home.
5 Screw screws into lubricating oil pump.

006977
7-3
Connection plate / lubricating oil pump 9 S 109
6 Check that the lubricating oil pump moves easily,

if necessary, loosen screws and retighten again.
7 Place new sealing ring on sealing faces for lubri-

cating oil pump.
NOTE
When adjusting the layshaft, the shim used must
lie on the roller bearing outer race.
CAUTION
Before fitting the lubricating oil pump and connec-
tion plate, layshaft, mainshaft and input shaft must
be adjusted (refer to Section 8).
006980
8 Use hot-air blower to heat housing slightly around

bearing bore, add lubricating oil pump and drive
fully home.
NOTE
Engage pump driver with layshaft recess.
9 Screw in eight hex bolts and compression

washers.
006975
7-4
7.4 Assembly and mounting of connection plate
1 Coat outer edge of shaft seal (5), e.g. with soap.
2 Use drift 1X56 103 768 to drive shaft seal (5) fully
home into connection plate (4).
NOTE
Sealing lip of shaft seal must face drift.
3 Lightly grease sealing lip. 7

6
NOTE
The shim (7) used during the adjustment of the
mainshaft and input shaft must be lying in connec-
tion plate.
4 Place connection plate (4) and new sealing ring

(6) on transmission.
4 5
5 Use protective sleeve 1X56 138 065 as assembly
aid.
3
CAUTION 2*
Do not damage shaft seal when adding connection
1*
plate
6 Tighten six hex bolts (3) to 23 Nm.
7 To check bearing setting, engage 1st gear and fully * parts in accordance with parts list
rotate transmission on input shaft. You must be 007992
able to feel an appropriate amount of resistance.
8 Depending on version, place sealing cap (2) on

connection plate and inset circlip (1) in ring
groove.
7-5
9 S 109 Mainshaft, input shaft and layshaft
8 Adjusting bearings on mainshaft, input shaft

and layshaft
8.1 Adjusting mainshaft and input shaft
CAUTION
Adjust mainshaft and layshaft with preload. Preload
is 0.18 to 0.30 mm.
1 Bring transmission into vertical position.
NOTE
Cool housing before adjusting bearings.
2 Adjust input bearing to zero play. To do this, use

mandrel to drive outer bearing ring in direction of
009 330
mainshaft.
CAUTION
Do not press or hit anything near the oil ducts. Other-
wise housing will be damaged.
a
3 Rotate input shaft and mainshaft several times to
centre bearing rollers and bearing points. Use a
sharp object to test whether the bearing rollers can
be moved.
NOTE
When there is zero play, the bearing rollers must
have no play, i.e. they must not be able to move.
However no preload should be present.
4 Use depth gauge to measure distance between 006 985

upper edge of outer bearing ring and housing,
adhere to dimension “a”.
Example: a = 5.40 mm
NOTE
Make measurements at two opposite points and
take the mean value.
8-1
Mainshaft, input shaft and layshaft 9 S 109
5 Place new sealing ring on connection plate.

b
6 Use depth gauge to measure distance between
sealing ring and face for shim. Adhere to dimensi-
on “b”.
Example: b = 7.80 mm
NOTE
7 Determine and adhere to difference “c”.

Example:
c = b – a (7.80 mm – 5.40 mm)
c = 2.40 mm
006 986
NOTE
You should aim at a preload of 0.25 mm (dimensi-
on “e”).
8 Calculate thickness “d” of shim:

Example:
d = c + e (2.40 mm + 0.25 mm)
d = 2.65 mm
9 Select shim from spare parts catalogue, grind to

correct dimension
NOTE
Experience shows that later tightening of the hex
bolts on the connection plate causes the sealing to
settle by 0.03 to 0.05 mm. This should be taken
into consideration when selecting the shim.
006 987
10 Insert shim in connection plate.
8-2
9 S 109 Mainshaft, input shaft and layshaft
8.2 Adjusting layshaft
NOTE
Adjust layshaft with preload. Preload is 0.18 to
0.30 mm.
1 Transmission should be in vertical position.
2 Adjust layshaft roller bearing to zero play. To do

this, use mandrel to drive outer bearing ring in
direction of layshaft.
CAUTION
006 988
3 Rotate layshaft several times to centre bearing rol-
lers and bearing points. Use a sharp object to test
whether the bearing rollers can be moved.
NOTE
When there is zero play, the bearing rollers must A
have no play, i.e. they must not be able to move.
However no preload should be present.

upper edge of outer bearing ring and housing,
adhere to dimension “A”.
Example: a = 17.80 mm
NOTE
006 989
8-3
Mainshaft, input shaft and layshaft 9 S 109
5 Place new sealing ring on pump.

sealing ring and face for shim. Adhere to
dimension “B”.
Example: B = 15.50 mm B
7 Determine and adhere to difference “C”.
Example:
C = A – B (17.80mm – 15.50mm)
C = 2.30 mm
NOTE
You should aim at a preload of 0.25 mm (dimensi-
on “E”).
009 331
8 Calculate thickness “D” of shim:
Example:
D = C + E (2.30mm + 0.25mm)
D = 2.55 mm
9 Select shim from spare parts catalogue, grind to

correct dimension.
NOTE
Experience shows that later tightening of the hex
bolts on the pump causes the sealing to settle by
0.03 to 0.05 mm. This should be taken into consi-
deration when selecting the shim.
10 Insert shim layshaft bearing outer race.
006 990
8-4
9 S 109 Shift rails and reverse gear
9 Shift rails and reverse gear
9.1 Removal of shift rails
1 Remove ring in mechanical shift lock (interlock)

from ring groove.
006 992
2 Take out bearing plate.
006 993
9-1
Shift rails and reverse gear 9 S 109
3 Unscrew screw plug for interlock compression

spring.
In versions without screw plug, secure com-
pression spring with a wire to ensure it does not
fall out.
4 Take out compression spring and locking lever.
006 994
5 Remove circlip from reverse gear bolts.
006994
6 Bring transmission into vertical shaft position.

Transmission should be facing upwards.
7 Remove seven M10 hex bolts from housing.
006995
9-2
8 Separate housing by gently tapping the housing

recesses.
NOTE
Use plastic mandrel.
9 Remove screw plugs, oil-carrying pipe and if

necessary cylinder pins from housing.
006 996
10 Use plastic mandrel to drive bearing outer race

from housing.
11 Remove seal and clean sealing faces.
006 997
12 Take filter out of housing.
006 998
9-3
13 Take off blocking piece. Slightly press down shift

rails to do this.
Depress indented side of blocking piece, pull
opposite side over shift rail edge.
14 Take off bearing plate.
006 999
15 Unscrew neutral position switch* or screw plug*
from plate.
16 Unscrew hex bolts on plate for neutral position

switch.
17 Remove plate and seal.
009339
18 Take bolts out of housing.
19 Remove pivot bolts and separate shift rails from

selector forks and remove individually from
housing.
! DANGER
Shift rails could fall out of transmission.
* depending on parts list
009340
9-4
9.2 Removal of reverse gear
1 Circlip (1) was removed in Section 9.1.
009 682
2 Use a rod (5) to drive reverse gear bolts (2) in

direction of output.
3 Push reverse gear (4) towards housing wall.

5
4 Lift mainshaft and layshaft out of housing, as
described in Section 10.
5 Take reverse gear (4) and 2 roller rings (3) out of

housing.
007 003
6 Remove hex bolts.
7 Take off cover, remove seal and clean sealing

faces.
007 002
9-5
9.3 Installation of shift rails
1 Bring transmission into vertical shaft position.

Transmission should face upwards.
2 Individually insert shift rails into housing, engage

selector fork noses with recesses in shift rails. To
do this, use hook 1X56 137 451 to guide selector
forks.
Order of installation:
1st = 1st - 2nd or 5th - 6th speed
2nd = 3rd - 4th or 7th - 8th speed
3rd = R gear/crawler
007005
NOTE
Compare shift rail part numbers, shift rail with
different number must be placed in centre.
3 Slide bearing plate (refer to parts list) over shift

rails, recessed side is placed alongside housing
sealing face.
007006
4 Slip on blocking piece. To do this, slightly depress

central shift rail.
Lower blocking piece over shift rail edge.
NOTE
Studs on blocking piece reach into bearing
plate bore.
007007
9-6
5 Insert cleaned or new filter in housing.
6 Depending on parts list version.
• Version A
Place new seal on housing.
• Version B
Coat sealing faces with sealing compound
ZF no. 0769 170 769.
CAUTION
No other sealing compounds are permitted.
7 Insert two cylinder pins in transmission housing.
8 Insert bearing outer race in housing. 006998
9 Insert oil-carrying pipe in housing. Bores in pipe

must not be blocked.
10 Add housing and use plastic hammer to gently hit

housing and drive it home.
CAUTION
006 996
11 Screw in seventeen M10 hex bolts.

006 995
9-7
12 Screw screw plug and new sealing ring into

housing.
009 344
13 Insert bolts in transmission housing.
007 012
14 Depending on version
Fit plate with new seal and screw plug or switch
(for neutral display).
M8 screws tightening torque = 23 Nm
M18x1.5 screw plugs tightening torque = 35 Nm
M18x1.5 switch tightening torque = 50 Nm
007 013
9-8
NOTE
Bring transmission into vertical shaft position.
Output side should be on top.
15 Push locking lever over shift rails.
16 Push bearing plate over shift rails.
17 Insert compression spring in housing bore and

engage with locking lever.
NOTE
In versions without screw plug, secure compres-
sion spring with a wire to ensure it does not fall
out.
006 994
18 Insert ring to secure bearing plate in ring groove.
NOTE
Ring must not be located near the area where the
range-change group shift rail is to be inserted.
19 Screw in screw plugs for interlock compression

007 014
spring with new sealing ring.
- M14x1.5 tightening torques = 35 Nm
007 016
9-9
9.4 Installation of reverse gear
1 Insert roller rings (3) in reverse gear (4).
2 Insert reverse gear and roller rings in housing and

push towards housing wall
NOTE
The larger recess should face the output.
3 Install mainshaft and layshaft as is described in

Section 10.2.
NOTE
Transmission is completely assembled on input
side.
009 682
4 Align reverse gear to bearing bores.
5 Use hot-air blower to slightly heat housing bores.
6 Drive in bolt until ring groove in circlip is fully in

housing.
7 Insert circlip and circlip tongs in ring groove,

check that it is seated correctly.
8 Use feeler gauge to check axial play on reverse

gear
- Axial play 0.20 - 0.60 mm
NOTE
Cover with sealing web may only be used once.
006 991
9 Place new cover with new seal on sealing face.
10 Screw in six M10x22 hex bolts.

007002
9-10
9 S 109 Input shaft, mainshaft and layshaft
10 Input shaft, mainshaft and layshaft
10.1 Removal of the shafts
1 Lift input shaft off mainshaft.
NOTE
For instructions on how to dismantle input shaft,
refer to Section 11.1.
007 019
2 Remove six pivot bolts from housing.
NOTE
In overdrive versions, there is a shift lever for the
3rd/4th speed selector fork and this is stored with
the seventh pivot bolt.
007 020
3 Take 3rd/4th speed selector fork (if necessary,

with shift lever) out of sliding sleeve. Lift it up
and out of transmission housing.
007 020
10-1
Input shaft, mainshaft and layshaft 9 S 109
4 Take fulcrum pad out of 3rd/4th speed selector

fork.
007 022
5 Use hook 1X56 137 451 to take 1st/2nd speed sel-

ector fork out of sliding sleeve. Lift it up and out
of transmission housing.
6 Take fulcrum pad out of 1st/2nd speed selector

fork.
007 023
NOTE
Remove reverse gear bolt and push reverse gear
towards housing wall (refer to Section 9.2).
7 Screw hook 1X56 136 599 in layshaft.
8 Lift layshaft out of housing and in so doing press

mainshaft to one side.
007 024
10-2
9 Push lifting rod 1X56 137 200 into mainshaft

central bore and in so doing push oil pipe out of
mainshaft. Secure lifting rod on output side
with associated hex nut.
10 Use lifting rod to lift mainshaft out of transmission

housing. In so doing, secure R gear/crawler
selector fork with hook 1X56 137 451.
11 Take R gear/crawler selector fork out of

mainshaft.
12 Take fulcrum pad out of selector fork.
007 026
10-3
10.2 Installation of the shafts
1 Use lifting rod 1X56 137 200 to push mainshaft

into central bore and secure on output side with
associated hex nut.
2 Use lifting rod to guide mainshaft over transmissi-

on housing.
NOTE
Insert reverse gear and roller rings in housing and
push towards housing wall.
007 025
3 Insert fulcrum pad in crawler/R gear selector fork.
4 Place selector fork in crawler/R gear sliding sleeve

and secure with hook 1X56 137 451. Once the
mainshaft has been installed, selector fork nose
must engage with shift mechanism housing ope-
ning.
007 027
5 Guide mainshaft into bearing point of trans-

mission housing.
6 Take lifting fork 1X56 137 200 out of mainshaft.
007 026
10-4
7 Screw hook 1X56 136 599 into layshaft.
8 Place layshaft in bearing point in transmission

housing, in so doing, press mainshaft to one side.
9 Engage mainshaft and layshaft gear teeth, unscrew

hook 1X56 136 599 out of layshaft.
10 Align crawler/R gear selector fork with hook

1X56 137 451 so that you can see the selector fork
guiding bores in the threaded bores of the trans-
mission housing.
11 Insert fulcrum pads in 1st/2nd speed selector fork

and 3rd/4th speed selector fork.
007 024
12 Insert selector forks in sliding sleeve so that selec-
tor fork nose faces shift mechanism housing ope-
ning.
13 Align selector forks with hook 1X56 137 451 so

that you can see the selector fork guiding bores in
the threaded bores of the transmission housing.
14 Coat threads of pivot bolt with Loctite no. 241.

Screw pivot bolts and compression washers into
each side of the transmission housing.
- M18x1.5 tightening torque 160 Nm.
NOTE
Overdrive version: Screw the two longer pivot
bolts into the swing fork. The shorter one is for the
toggle.
007 021
Coat threads of pivot bolt with Loctite no. 241.
- M18x1.5 tightening torque 160 Nm.
007030
10-5
NOTE
For input shaft assembly, refer to Section 11.2.
15 Carefully place input shaft on mainshaft.

Do not damage sealing lip of baffle plate.
16 Engage input shaft gear teeth with those of clutch

body.
007 019
10-6
9 S 109 Input shaft
11 Input shaft
5
11.1 Dismantling the input shaft 4
3
1 Place gripper 1X56 136 719 on inner race of input
shaft tapered roller bearing. Turn knurled ring
until gripper is firmly secured. 2
2 Screw extension 1X56 122 310 and adapter

1
1X56 122 317 onto basic puller 1X56 122 304.
3 Screw extension 1X56 122 310 onto gripper

1X56 136 719.
4 Pull inner race (1) of taper roller bearing off input

shaft (2).
010 617
5 Use suitable tool to remove baffle plate (5).

Remove circlip (4) and cover (3) from
input shaft (2).
11-1
Input shaft 9 S 109
11.2 Assembly of the input shaft

5
4
1 Insert cover (3) in input shaft (2) and insert circlip 3
(4).
2 Use tool 1X56 138 026 to press in baffle plate (5)

until it is flush with input shaft. 2
1
3 Heat tapered roller bearing inner race (1) to
approx. 120 °C and place on input shaft (2).
Ensure that it is firmly driven home.
! DANGER
parts. 2 3 4 5
010 616
11-2
9 S 109 Mainshaft
12 Mainshaft
7 11 27
26
8 10
9 25
22
5 6 24
23
4 21
20
3
19
2 36
1 18 35
17
34
33
16 32
15
14 31
30
13
12
29
28
010 618
12.1 Dismantling the mainshaft
NOTE 4 Place gripper 1X56 136 737 on inner race of taper

Instructions for removing mainshaft are described roller bearing. Turn knurled ring until gripper is
in Section 10.1. firmly secured. Screw basic puller 1X56 122 304
onto gripper and pull off bearing inner race (1).
1 Clamp output end of mainshaft in a vice with soft
jaws. 5 Remove circlip (2).
2 Remove clutch body (3) and synchronizer ring (4) 6 Insert puller 1X56 137 457 between synchronizer
from mainshaft. ring (10) and 3rd speed clutch body (11). Place
appropriate intermediate part on mainshaft. Place
3 Pull off 3rd/4th speed sliding sleeve (5). standard two-leg puller on puller and pull-off syn-
chronizer hub (6) and synchronizer ring (10).
! DANGER
Pressure pieces (7), ball pin (8) and compression
springs (9) will be released during extraction process.
These parts are spring-loaded. Secure pieces to pre-
vent them flying out (e.g. with a cloth).
12-1
Mainshaft 9 S 109
7 11 27
26
8 10
9 25
22
5 6 24
23
4 21
20
3
19
2 36
1 18 35
17
34
33
16 32
15
14 31
30
13
12
29
28
010 618
7 Remove 3rd speed helical gear (12) with clutch 12 Place suitable intermediate part on mainshaft.
body (11) and two needle cages (13) from Place standard two-leg puller on crawler helical
mainshaft (28). gear (30).
8 Turn mainshaft over and clamp input end in vice 13 Pull off crawler (30) an sleeve carrier (31).
with soft jaws.
14 Remove needle cage (29).
9 Place appropriate intermediate part on mainshaft.
Attach standard 2-leg puller to R gear spur gear 15 Turn mainshaft over again and clamp input end in
(35) and pull off gear and inner race of taper roller vice with soft jaws.
bearing (36).
16 Remove circlip (14).
10 Remove needle cage (34) and circlip (33).
17 Place suitable intermediate piece on mainshaft.
11 Lift off crawler/R gear sliding sleeve (32).
12-2
9 S 109 Mainshaft
18 Use standard two-leg puller to grip the rear of 1st

speed helical gear (26) and pull off entire pack
(items 15 to 26).
NOTE
Ensure that the puller’s teeth do not grip the shaft
collar.
19 Take bearing bush (15) and needle cage (16) out

of 2nd speed helical gear (17).
20 Take clutch body (18) and synchronizer ring (19)

off synchronizer hub (21).
21 Lift 1st/2nd speed sliding sleeve (20) off synchro-

nizer hub (21).
007 048
! DANGER
Pressure pieces (3) and compression springs (9) will
be released during extraction process. These parts are
spring-loaded. Secure pieces to prevent them flying
out (e.g. with a cloth).
22 Remove 1st speed helical gear (26), clutch body

(25), synchronizer ring (24) and synchronizer hub
(21) from mainshaft (28).
23 Remove two needle cages (29).
12-3
Mainshaft 9 S 109
7 11 27
26
8 10
9 25
22
5 6 24
23
4 21
20
3
19
2 36
1 18 35
17
34
33
16 32
15
14 31
30
13
12
29
28
010 618
12.2 Assembly of the mainshaft 5 Heat sleeve carrier (31) to approx. 120° C and
push onto mainshaft (hub facing crawler). If
1 Check that the lubricating oil bores can be freely necessary, drive fully home.
accessed on the mainshaft
! DANGER
2 Clamp output end of mainshaft in a vice with soft Always wear protective gloves when handling heated
jaws. sleeve carriers.
NOTE 6 Check axial play of crawler helical gear.

Lightly grease running face and bearing race of - Axial play 0.20 to 0.45 mm
needle cages and helical gears with operating oil.
3 Slide needle cage (29) onto mainshaft.
4 Push crawler helical gear (30) over needle cage CAUTION

onto mainshaft by gently twisting it. Driver teeth Ensure circlip remains absolutely free of burrs as it
should face output. serves as a running surface for the needle cage.
12-4
9 S 109 Mainshaft
NOTE 17 Heat synchronizer hub (21) to approx. 120° C and

Circlip must have axial play of 0 - 0.1 mm. Select place on mainshaft gear teeth. Synchronizer hub is
suitable circlip in accordance with spare parts symmetrical and can therefore be placed on either
catalogue. side of mainshaft. Drive synchronizer hub firmly
home.
8 Place crawler/R gear sliding sleeve (32) on sleeve
carrier. Sliding sleeve is symmetrical and can ! DANGER
therefore be placed on either side of carrier. Always wear protective gloves when handling heated
synchronizer hubs.
9 Slide needle cage (34) onto mainshaft.
NOTE
10 Push R speed helical gear (35) over needle cage Synchronizer ring noses must engage in recesses
onto mainshaft by gently twisting it. Driver teeth of synchronizer hub.
should face output.
18 Check axial play of 1st speed helical gear.
11 Heat inner race of taper roller bearing (36) to - Axial play 0.20 to 0.45 mm
approx. 120° C and slide onto main shaft and
drive firmly home. 19 Slide 1st/2nd speed sliding sleeve (20) over syn-
chronizer hub, synchronizer ring and clutch body
and place on 1st speed helical gear. Ensure that
! DANGER recesses in sliding sleeve interior cover the same
Always wear protective gloves when handling heated areas of the synchronizer hub locating points (for
inner races of taper roller bearings. compression springs and compression pieces).
12 Check axial play of R speed helical gear. 20 Use suitable tool to insert three compression
- Axial play 0.40 to 0.75 mm springs (23) and compression pieces (22) in syn-
chronizer hub bores or to guide them into sliding
13 Turn over mainshaft and clamp output end in vice sleeve.
with soft jaws.
14 Slide both needle cages (27) onto mainshaft. NOTE

Use new compression springs.
15 Push 1st speed helical gear (26) over needle cage
onto mainshaft by gently twisting it. Driver teeth 21 Add synchronizer ring (19). The synchronizer ring
should face output. noses must engage in recesses of synchronizer hub.
16 Place clutch body (25) and synchronizer ring (24) 22 Place clutch body (18) on synchronizer ring (19)
on driver gear teeth. and pull sliding sleeve into central position (neu-
tral position). In so doing, press synchronizer ring
and clutch body.
CAUTION
Check limits of wear for all synchronizer rings or
clutch bodies as described in Section 4.6. For all syn-
chronizers, use parts in accordance with the brochure
1297 754 101 “ZF locking synchronizers component
inspection”. Lightly oil bearing races of all synchroni-
zer rings.
12-5
Mainshaft 9 S 109
7 11 27
26
8 10
9 25
22
5 6 24
23
4 21
20
3
19
2 36
1 18 35
17
34
33
16 32
15
14 31
30
13
12
29
28
010 618
23 Push needle cage (16) and 2nd speed helical

gear (17) onto bush (15) and heat it all to 27 Slide both needle cages (13) onto mainshaft.
approx. 120° C.
28 Push 3rd speed helical gear (12) over needle cage
! DANGER onto mainshaft by gently twisting it. Driver teeth
Always wear protective gloves when handling heated should face output.
parts.
29 Place clutch body (11) on 3rd speed helical gear
24 Place parts together on mainshaft and drive home (12).
bush (15) without any play. Bush collar should
face input (Photo 007 060). 30 Add synchronizer ring (10).
25 Check axial play of 2nd speed helical gear. 31 Heat synchronizer ring (6) to approx. 120° C and
- Axial play 0.20 to 0.40 mm place on mainshaft with the longer nose facing
output. If necessary, drove fully home.
CAUTION DANGER
Ensure circlip remains absolutely free of burrs as it Always wear protective gloves when handling heated
serves as a running surface for the needle cage. synchronizer hubs.
12-6
9 S 109 Mainshaft
NOTE
Synchronizer ring noses must engage in recesses
of synchronizer hub.
32 Insert circlip (2).
NOTE
Circlip must have axial play of 0 - 0.1 mm. Select
circlip in accordance with spare parts catalogue.
33 Check axial play of 3rd speed helical gear.

- Axial play 0.20 to 0.45 mm
34 Slide 3rd/4th speed sliding sleeve (5) (nose on

upper side) over synchronizer hub, synchronizer
ring (10) and clutch body (11) and place on 3rd
007 060
speed helical gear. Ensure that recesses in sliding
sleeve interior cover the same areas of the syn-
chronizer hub locating points (for compression
1
springs, ball pins and compression pieces).
35 Use suitable tool to insert three compression

springs (9) with ball pins (8) and compression pie-
ces (7) in synchronizer hub bores or to guide them
into sliding sleeve.
NOTE
Use new compression springs.
36 Add synchronizer ring (4). The synchronizer ring

noses must engage in recesses of synchronizer
hub (6).
007 076
37 Place clutch body (3) on synchronizer ring (4) and
pull sliding sleeve (5) into central position (neutral
position). In so doing, press synchronizer ring and ! DANGER
clutch body. Always wear protective gloves when handling heated
taper roller bearing inner races.
NOTE
Do not reuse the inner race of taper roller bearing 39 Grease bottom of inner race of taper roller
which is removed when mainshaft is dismantled. bearing (1) between inner race and cage with grease
ZF# 0750 199 001. (refer to arrow in Photo
38 Heat new inner race of taper roller bearing (1) to 007 076) It is not permitted to apply grease on the
approx. 120° C and push onto journal bearing of outside on the roller bearing itself since this
mainshaft. Drive inner race of taper roller bearing could block the lubricating bores in the input shaft.
fully home.
NOTE
For instructions on installation of the mainshaft,
12-7
9 S 109 Layshaft
13 Layshaft
NOTE
For instructions on the removal of the layshaft,
13.1 Dismantling the layshaft
1 Place gripper 1X56 136 708 on inner race (1) of

taper roller bearing. Turn knurled ring until grip-
per is firmly secured.
2 Place suitable intermediate part on layshaft.
3 Screw basic puller 1X56 122 304 on gripper.

007 080
4 Pull inner race of taper roller bearing off
layshaft (2).
1
5 Remove circlips (7).
6 Place gripper 1X56 136 711 on inner race (6) of 2

taper roller bearing. Turn knurled ring until grip-
per is firmly secured.
7 Screw basic puller 1X56 122 304 on gripper.
8 Pull inner race (6) of taper roller bearing off

layshaft.
9 Because of the large force required, the helical

gears (5, 4) and double helical gear (3) should be 3
pressed off the layshaft singly using a suitable
hydraulic press. 4
5
6
7
010 619
13-1
Layshaft 9 S 109
13.2 Assembly of the layshaft

1
! DANGER
2
parts.
1 Clean bores in helical gears and shrink-fit seats on

layshaft.
2 Heat double helical gear (3) and helical gears

(4, 5) to max. 170° C. Keep at a temperature diffe-
rence of 150° C to the parts to be added.
3 Stack up the heated helical gears (5, 4 and 3) on a

hydraulic press and align them accurately. 3
4
Depending on version
I 4th / 3rd speed helical gear - hub upwards
5
II 3rd / 4th speed helical gear - hub downwards
III 1st / 2nd speed double helical gear 6
7
4 Press layshaft into bores in helical gears. Press
gears into firm end contact immediately. Let parts
cool down
NOTE 010 619
Press layshaft into bores in helical gears. Press

gears into firm end contact immediately. Let parts
Direct drive Overdrive
cool down
5 Heat inner races of taper roller bearings (1 and 6)

to max. 120° C and slide onto layshaft. Drive
inner races fully home.
6 Insert circlip (7) in layshaft groove.

III
NOTE
Circlip play must be between 0 and 0.1 mm, select
circlip in accordance with spare parts catalogue. II
001 949
13-2
9 S 109 Housing
*17
15
*16 *18
*12
*14
20
L
SE
CH
*13
WE 30
OL SAE BI
S
EN
LL F
UE AU
NF RL
EI BE
UE RT
AH R
EF TA
OB RE
PR NE
OH N
LE
EL AU
FU RL
CH BE
NA S UE
BI
11
4*
*8 3
2
10 6
5
9 7
1
010 620
14 Housing 14.2 Assembly of the housing
14.1 Dismantling the housing 1 Carefully drive in two cylinder pins (11).
1 Use soft mandrel to drive taper roller bearing 2 Insert screw plug (13) and sealing covers (6 and
outer races (9, 10) out of housing. 15) with sealing compound.
2 Remove breather (18). 3 Screw in screw plugs.

M18x1.5 (14, 16) tightening torque = 35 Nm
3 Remove four hex bolts (1) and take off cover (20) M24x1.5 (4, 5, 12, 13) tightening torque = 50 Nm
and seal (3). M38x1.5 (7) tightening torque = 120 Nm
Inductive sensor (17) tightening torque = 50 Nm
4 Oil spray bores on pipe (8) must not be blocked.
4 Insert pipe (8). (Refer to Section 6.2)
When changing the housing 5 Fasten cover (2) and new seal (3) with four hex
bolts (1).
5 Take two cylinder pins (11) out of housing and - M8 tightening torque = 23 Nm
remove all screw plugs.
6 Screw breather (18) into housing.
tightening torque = 10 Nm
14-1
Housing 9 S 109
*17
15
*16 *18
*12
*14
20
L
SE
CH
*13
WE 30
OL SAE BI
S
EN
LL F
UE AU
NF RL
EI BE
UE RT
AH R
EF TA
OB RE
PR NE
OH N
LE
EL AU
FU RL
CH BE
NA S UE
BI
11
4*
*8 3
2
10 6
5
9 7
1

010 620
7 Use hot-air blower to heat housing around bearing

bores to approx. 80° C.
! DANGER
parts.
8 Use plastic mandrel or suitable tool to insert taper

roller bearing outer races (9, 10) of mainshaft and
layshaft into housing and drive firmly home.
NOTE
If a new taper roller bearing outer race (20) is
installed for fitting an auxiliary output, fully drive
home taper roller bearing outer race in the housing
bearing bore and secure by peening 4 x 90°.
In new housings, the taper roller bearing outer race
(20) is preinstalled as part of volume production.
14-2
9 S 109 Clutch housing
15 Clutch housing
15.1 Removal
1 Remove 10 M18x1.5 hex bolts (1) from clutch

housing and do not use screwdriver to do so.
1
2 Lift off clutch housing.
3 Depending on parts list version:

remove screw plugs
15.1 Installation
010 983
1 Depending on parts list version:

Seal bores and housing apertures with screw
plugs.
2 Set up clutch housing in correct position.
3 Tighten 10 M18x1.5 hex bolts (1) on clutch

housing to 280 Nm and do not use screwdriver to
do so.
15-1 15-1

ZF Ecomid Manual 9S109 - 1304 - 751 - 102 - A 1998

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ZF Ecomid Manual 9S109 - 1304 - 751 - 102 - A 1998

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Available Formats

9 S 109

1304 751 102a

1 Tecalan pipes for range-change group..................................................................................................... 1-1

2 Output ........................................................................................................................................................ 2-1

3 Range-change group ................................................................................................................................. 3-1

4 Planetary gear with synchronizer ............................................................................................................ 4-1

5 Sun gear ..................................................................................................................................................... 5-1

6 Shift mechanism ........................................................................................................................................ 6-1

7 Connection plate - lubricating oil pump ................................................................................................. 7-1

8 Adjusting bearings on mainshaft, input shaft and layshaft ................................................................... 8-1

9 Shift rails and reverse gear ....................................................................................................................... 9-1

10 Input shaft, mainshaft and layshaft ......................................................................................................... 10-1

11 Input shaft.................................................................................................................................................. 11-1

14 Housing ...................................................................................................................................................... 14-1

15 Clutch housing........................................................................................................................................... 15-1

This manual is intended for skilled personnel trained by

This manual deals with the standard ZF product in

However, due to continuing development of the product,

Service points equipped by ZF Friedrichshafen AG all

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out

Repair work carried out at ZF service points is

Damage resulting from work performed by non-ZF

TRANSMISSION DESCRIPTION SERVICE MANUAL AND FUNCTION

In addition to the above, ZF Friedrichshafen AG

– an engine-dependent ZF power take-off

RE-USE OF PARTS Find a clean site to assemble the transmission. Gaskets

BEARINGS d) Duo shaft seals have two sealing

f) If possible, heat shaft seal bores to between 40° and

a) Apply a light coat of sealing agent* on outer edge of TRANSMISSION OIL

* refer to expendable material

SAFETY NOTICE GENERAL INFORMATION

To avoid injury to personnel and damage to pro-

After completion of repair work and testing, skilled staff

! THREATS TO THE ENVIRONMENT !

Tightening torques for nuts and bolts, extract from

Regular thread Fine screw

Size Tightening torque Size Tightening torque

M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1,5 135 200 235

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

M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991 / checked 1997

Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)

Dimensions Tightening torque Pipe Thread Tightening-

Edition: October 1995

Description Dimension Measuring device Remarks

05. Axial play of circlip on 0 to Feeler gauge Adjust using circlip of

07. Axial play of circlip on 0 to Feeler gauge Adjust using circlip of

Description Dimension Measuring device Remarks

0.60 mm Feeler gauge Upper limit of synchronous

Shift transmission Replace all spring packs of

18. Backlash on pinion shaft 0.10 to Backlash play is given by cor-

Description Dimension Measuring device Remarks

01. Breather in transmission 10 Nm Torque wrench Breather must not be

02. Restrictor in shut-off 20 Nm Torque wrench Use new sealing ring

04. M10x1 lock nut on reac- 46 Nm Torque wrench

05. M12 hex nuts on reaction 50 Nm Torque wrench

07. M24x1.5 screw plug 50 Nm Torque wrench Do not overtighten

08. Impulse sensor 50 Nm Torque wrench Do not overtighten

Description Dimension Measuring device Remarks