Professional Documents
Culture Documents
Copyright by ZF
Printed in Germany
Edition: 2005-09
Copyright by ZF
Printed in Germany
Edition: 2005-09
Page
Preface ...............
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Safety
Safety Instruc
Instructions
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General
Gener al Inf
Informati
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Instruction
Instructionss for Carrying out Repai Repairs rs ....
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Overview
Overvie w of Amendments:
Amendments: 1327 751 003..... 003.................
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Tightening Torques for for Nuts and Bolts, Bolts, Extract
Extract from ZFN ZFN 148 ....................
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Screw Plugs DIN 908, 910, and 7604 .......................................
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Union Screws DIN 7643 ........................
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Conversion from DIN to ISO Standards .............. .............................
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Special Tool..............
ool.............................
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Consumables .............
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ZF Repair Kits for Tran Transmission/Clutch
smission/Clutch Actuator ...................................
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Removing Trans
Transmission
mission Actuator ...............
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Fitting Trans
Transmission
mission Actuator.........................
Actuator.........................................
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Removing Upper Section................
Section...............................
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Replacing Tra
Travel
vel Sensors
Sensors (HG, GV,
GV, GP,
GP, and
and Gate)...................
Gate)..................................
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Replacing Solenoid Valve Unit...........................
Unit..........................................
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Replacing Cpl. Selector Cylinder .............
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Bracket for Temperature and Speed Sensor ...............
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Fitting Bracket for Temperature and Speed Sensor.....................
Sensor....................................
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Removing
Removing Wiring
Wiring Harness (Input
(Input Speed Sensor
Sensor and Tempera
Temperature
ture Sensor)
Sensor) .....
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Fitting Wiring Harness (Input Speed Sensor and Temperature Sensor) .....................................
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Replacing Pressure Relief Valve
alve...............
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Dismantling Lower Section of Tran
Transmission
smission Actuator ..............
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Assembling Lower Section of Transmi
Transmission
ssion Actuator...........................
Actuator..........................................
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Programming Trans
Transmission
mission Actuator ..............
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Programming Flash EPROMS with ZF Test Program...............Program..............................
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Description of Test
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Outgoing Inspection ...............
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Clutch Actuator ...............
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1. Well-trained
Well-trai ned personne
personnel,
l,
2. Specified equipment,
e.g.: Special tools
3. Genuine ZF spares,
spares, according to
our latest specifications
Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
the individual case.
ZF Friedrichshafen AG
Nutzfahrzeug- und Sonder-Antriebstechnik Damage resulting from work performed by non-ZF
Commercial Vehicle and personnel in an improper and unprofessional man-
Special Driveline Technology ner, together with follow-on costs caused by such
Service Werk 2 (Plant 2) work, is excluded from the contractual warranty
Phone: +49 (0)7541 77-0 agreement.
Fax: +49 (0)754
(0)7541
1 77-908000
77- 908000 This also applies where genuine ZF spare parts have
h ave
Internet: www.zf
ww w.zf.com
.com not been used.
2003-08 5
Safety Instructions
Companies repairing ZF units are responsible for Read this manual carefully before starting any tests
their own work safety. or repair work.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
2005-04 6
Instructions for Repairs
Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
2005-04 7
Instructions for Repairs
2003-08 8
Overview of Amendments: 1327 751 103
This standard applies to screws/bolts acc. to Surface condition of bolts / nuts: Thermally
DIN 912, DIN 931, DIN 933, DIN 960, DIN 961, as blackened and oiled or galvanized and oiled or
well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, galvanized, chrome-plated, and oiled.
ISO 8676, and to nuts acc. to DIN 934 as well as
ISO 4032, ISO 8673. Tighten screws with a calibrated ratchet dial torque
or ratchet wrench.
This Standard contains data on tightening torques
(MA) for screws/bolts and nuts in strength categories NOTE
8.8, 10.9, and 12.9, and nuts in strength categories 8, Deviating tightening torques are listed separately in
10, and 12. the Repair Manual.
Size Tightening torque (Nm) for Size Tightening torque (Nm) for
Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M7 15 23 28 M10x1.25 49 72 84
M8 23 34 40 M12x1.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
2003-08 10
Tightening Torques
Screw Plugs DIN 908, 910, and 7604 Union Screws DIN 7643
The screw plug tightening torques were determined The tightening torques were determined for screw-
according to DIN 7604 for screwing into steel, gray ing into steel, gray cast, and aluminum alloys.
cast, and aluminum alloys. The values are based on experience and are
The values are based on experience and are intended as reference values for the fitter.
intended as reference values for the fitter.
The values for the tightening torque apply General rule:
analogously to screw plugs according to DIN 908 Screw/Bolt class 5, ZFN 148-1
and DIN 910, as the thread geometries are almost Material: 9SMnPb28K acc. to DIN 1651
identical. Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
General rule: chromated, and lightly oiled.
Screw/Bolt class 5, ZFN 148-1
Screw/ Bolt material: Steel acc. to DIN 7604.
Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)
DIN 1 Tapered pins ISO 2339 - some can be replaced → changed to ISO 2339
- parts which cannot be replaced (e.g. where 1 = 36 mm)
documented as DIN 1 OLD
DIN 7 Cylindrical ISO 2338 - some can be replaced → changed to ISO 2338
pins - parts which cannot be replaced (e.g. diameter 13 and 14 and/or
where 1 = 36 mm) documented as DIN 7 OLD
DIN 84 Cylindrical ISO 1207 - some can be replaced → changed to ISO 1207
screws - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD
DIN 85 Flat head bolts ISO 1580 - can be replaced → changed to ISO 1580
DIN 94 Split pins ISO 1234 - can be replaced → changed to ISO 1234
DIN 417 Threaded pins ISO 7435 - can be replaced → changed to ISO 7435
DIN 439-1 Hex nuts ISO 4036 - cannot be replaced → documented as DIN 439 OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675
DIN 551 Threaded pins ISO 4766 - can be replaced → changed to ISO 4766
DIN 553 Threaded pins ISO 7434 - can be replaced → changed to ISO 7434
DIN 555 Hex nuts ISO 4034 - cannot be replaced → documented as DIN 555 OLD
DIN 558 Hex bolts ISO 4018 - some can be replaced → changed to ISO 4018
- parts which cannot be replaced (e.g. M12, with new SW) documented as
DIN 558 OLD
DIN 601 Hex bolts ISO 4016 - some can be replaced → changed to ISO 4016
- parts which cannot be replaced (e.g. M10 and M12, with new SW)
documented as DIN 601 OLD
DIN 912 Cylindrical ISO 4762 - some can be replaced → changed to ISO 4762
screws - parts which cannot be replaced (e.g. M18, M22, M27, and M33)
documented as DIN 912 OLD
DIN 931-1 Hex bolts ISO 4014 - some can be replaced → changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 931 OLD
DIN 933 Hex bolts ISO 4017 - some can be replaced → changed to ISO 4017
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 933 OLD
DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for
ISO 8673 M10, M12, M14, and M22 with new SW.
DIN 960 Hex bolts ISO 8765 - some can be replaced → changed to ISO8765
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 960 OLD
DIN 961 Hex bolts ISO 8676 - some can be replaced → changed to ISO 8676
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 961 OLD
DIN 963 Countersunk ISO 2009 - cannot be replaced as a result of modif ied head dimensions → documented
bolts as DIN 963 OLD
DIN 964 Countersunk ISO 2010 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 964 OLD
2003-08 12
Conversion from DIN to ISO Standards
DIN 965 Countersunk ISO7046 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 965 OLD
DIN 980 Locking nuts ISO 7042 - cannot be replaced → documented as DIN 980 OLD
ISO 10513
DIN 985 Locking nuts ISO 10511 - cannot be replaced → documented as DIN 985 OLD
DIN 1440 Washers ISO 8738 - some can be replaced → changed to ISO 8738
- parts which cannot be replaced documented as DIN 1440 OLD
DIN 1443 Bolts ISO 2340 - can be replaced → changed to ISO 2340
DIN 1444 Bolts ISO 2341 - can be replaced → changed to ISO 2340
DIN 1471 Grooved pins ISO 8744 - some can be replaced → changed to ISO 8744
- parts which cannot be replaced (e.g. 1 = 6 mm) documented as
DIN 1471 OLD
DIN 1472 Grooved pins ISO 8745 - some can be replaced → changed to ISO 8745
- parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as
DIN 1472 OLD
DIN 1473 Grooved pins ISO 8740 - some can be replaced → changed to ISO 8740
- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25, and 50 mm)
documented as DIN 1473 OLD
DIN 1474 Grooved pins ISO 8741 - can be replaced → changed to ISO 8741
DIN 1475 Grooved pins ISO 8742 - can be replaced → changed to ISO 8742
DIN 1476 Grooved stud ISO 8746 - can be replaced → changed to ISO 8746
DIN 1477 Grooved stud ISO 8747 - can be replaced → changed to ISO 8747
DIN 1481 Clamping pins ISO 8752 - some can be replaced → changed to ISO 8752
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD
DIN 6325 Cylindrical pins ISO 8734 - some can be replaced → changed to ISO 8734
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD
DIN 7346 Clamping pins ISO 13337 - some can be replaced → changed to ISO 13337
Flange - parts which cannot be replaced (∅ 7, 11, and 23 mm) documented as
DIN 6325 OLD
DIN 7976 Self-tapping ISO 1479 - can be replaced → changed to ISO 1479
screws
DIN 7978 Tapered pins ISO 8736 - some can be replaced → changed to ISO 8736
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD
DIN 7979 Cylindrical pins ISO 8733 - some can be replaced → changed to ISO 8733/8735
ISO 8735 - parts which cannot be replaced documented as DIN 7979 OLD
DIN 7981 Self-tapping ISO 7049 - can be replaced → changed to ISO 1479
screws
DIN 7982 Self-tapping ISO 7050 - cannot be replaced → documented as DIN 7982 OLD
screws
DIN 7985 Cheese-head ISO 7045 - can be replaced → changed to ISO 7045
screws
2003-08 13
ZF-AS Tronic Special Tool
240
5
0
1 64 1
Sketch
7 5
. M 1 0
0 112 1
6 M
74
5
1
017912
CAUTION
If the transmission actuator or upper section 74.140*
74.010
! DANGER
Only work on the transmission actuator if the igni-
tion is off. 12.090
12.080
06.050
1 Switch off ignition
06.040
34.140
CAUTION
34.130
If vehicle-specific parts (e.g. fuel pump, coolant
pipe, exhaust pipe, or steering pump) have to be
removed, please contact the vehicle manufacturer.
06.080
transmission actuator.
! DANGER
Protective glasses must be worn when removing
the compressed air line from the transmission
actuator.
Compressed air will escape!
Risk of injury from particles of dirt.
CAUTION
The profile seals (/170) and compression springs
(06.050; 34.140 and 12.090) may fall into the trans-
mission housing.
/170
NOTE
Both profile seals (/170) are contained in sealing kit
0501 319 864.
a b
NOTE 74.140*
Cover transmission opening, otherwise dirt may 74.130* 74.120*
fall into the transmission. 74.030
74.070
8 Remove seal (74.010) and clean sealing 74.090
surfaces on transmission housing and
transmission actuator.
12.090
12.080
06.050
06.040
34.140
34.130
06.080
Loctite
262
Legend
Piston rod (3) = shifts the splitter group (GV) 6
Piston rod (4) = shifts the basic transmission
017908
Piston rod (5) = shifts the range change group
(GP)
Selector gate (6) = selects the shift gate
34.010 06.080 06.010 12.010
NOTE
With the 12-speed version, do not slide the
central shift rail (06.010) too far into the
transmission, otherwise t he gearshift finger
may fall into the transmission.
Legend
12.010 Shift rail (GV)
06.010 Shift rail for basic transmission
34.010 Shift rail (GP)
06.080 Ball bolt
015019
017907
NOTE
The compression springs (06.050; 34.140
and 12.090) must be of the same length
(around 50 mm). If deviances are found,
replace compression springs.
74.010
CAUTION 34.140
NOTE
Ensure that the connectors are snapped into
place and fitted without traction relief.
Caution
Record the data on the type plate. 1
/150-1
This is needed for ordering spare parts and for
correspondence.
/130
Fitting Upper Section
018205
NOTE
The repair kit 0501 321 148 contains two screws
(22), one retaining plate (23), one travel sensor
(24), and one O-ring (25).
24
Removal 23
22
NOTE
The sensors for GP, GV main transmission, and
gate cylinder are identical.
Installation
NOTE 21 24
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.
021 794
NOTE
The repair kit 0501 321 147 contains t hree Torx
screws (19), one solenoid valve unit (18), and one
profile seal (20).
The solenoid valve unit (18) contains 10 solenoid
valves as a fully checked unit.
18
Removal
Installation
021 785
NOTE
Repair kit 0501 321 182 contains the selector 26
/130
Removal
27
Installation
NOTE 29
27
NOTE
The repair kit 0501 322 661 contains three hex- 47
52
head bolts (27), one profile seal (29), two Torx
48
screws (47), one Torx screw (48), retaining plate 29
(52), O-ring (49), and the cylinder cover (58). 58
49
Removal
024 559
021 786
48
021 790
50
7 Remove Torx screws (47).
58
47
021 791
50
1 Insert new O-ring on cylinder cover (58) and
on travel sensor (51).
NOTE 51
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces. 49
(58).
021 790
29
28
26
021 787
27
10 Fit upper section.
(See page 22)
021 786
47
021 789
NOTE
Screw head (47) T40
Screw head (48) T25
021 792
58
024 738
024 534
024 668
024 560
49
58
47
021 791
021 792
021 793
26
021 789
21 24
021 794
NOTE
- Repair kit 0501 320 849 contains 4 nuts (10), one
O-ring (12) , and the pressure relief valve (/180).
- Before removing, mark the installation position
of the pressure relief valve (/180) for fitting later
on.
CAUTION
Do not use grease to fit O-ring (12).
74.030
/180
12
019252
NOTE
- The main transmission piston (62) is exchanged
as a complete unit. Repair kit 0501 322 388.
- Seal kit for GP/GV gear shift cylinders
0501 321 149.
CAUTION
The cylinder covers are numbered. They have to
be refitted in the same positions.
021 796
62
58
021 797
58
70 63
021 798
70 63
NOTE
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.
021 798
60
4 Insert pistons (59, 60, and 62) and bush (61)
in transmission actuator’s lower section.
62
58
021 797
55
56 57
021 796
Assembly check
24
The cylinder covers are numbered (see arrow).
For installation position, see Fig.
1
1
3 1
2
021 799
021 800
CAUTION
When programming a new transmission actuator,
transfer the vehicle parameters from the
transmission actuator removed or re-enter them.
NOTE
If using costly peripheral attachments, such as
flatbeds, crossbars etc. we would advise checking
the transmission with ZF-Testman pro test soft-
ware once removed from the vehicle.
After checking with ZF-Testman pro, load the
volume production program (can be downloaded
via ZF-ServiceLine).