ZF 6wg310

Part No.
: 5871 179 002 E
ZF – ERGOPOWER
6 WG-310 (4) RPC
Version: With Retarder and Lock-up Clutch

With power shiftable Differential Lock
ZF Passau GmbH
Donaustr. 25 – 71
D – 94 034 Passau
REPAIR INSTRUCTIONS
ZF – ERGOPOWER
6 WG-310 (4) RPC
Version: With Retarder and Lock-up Clutch

With power shiftable Differential Lock
NOTE:
The described repair instructions are based on the design level of the
ZF – Unit at the time of preparation of the Repair Manual.
Technical development of the product as well as extensions concerning the
design possibilities may require differing steps, which can be carried out by qualified
Specialists without greater difficulties with the help of the Perspective Illustrations
in the corresponding Spare Parts Lists.
For information about the Description, Installation Instructions, Operation and Maintenance,
refer to the corresponding operating instructions.
The present Disassembly and Reassembly Manual is losing ist legal obligation with
the publication of a new successional Edition.
The ZF Passau GmbH is in this connection not responsible for the
positive knowledge at the User of the Manual.
ZF Passau GmbH
Donaustr. 25 – 71
D – 94034 Passau
Dept.: ASDM
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Subject to technical modifications!
Design level: 2003/10
2. Edition: 2005/10
3. Edition: 2007/01
TABLE OF CONTENTS Chap./Page
Preface .............................................................................................................................. 0/1

General ....................................................................................................................... 0/2 ... 0/3
Designation of the Legal Units ........................................................................... 0/4
Conversion Table for Dimensional Units........................................................................ 0/5
Torque Limits for Screws ................................................................................... 0/6
SPECIAL TOOLS
LIST OF TOOLS W/1...W/11

ILLUSTRATED TABLES WB1...WB15
1. ELECTRO-HYDRAULIC CONTROL 1/1 ... 1/12
1.1 DISASSEMBLY – CONTROL UNIT 1/2 ... 1/4

1.2 REASSEMBLY – CONTROL UNIT 1/5 ... 1/11
1.2.1 Mounting of the Control Unit 1/10 ... 1/11
1.3 LOCK-UP VALVE 1/11 ... 1/12

1.3.1 DISASSEMBLY 1/11
1.3.2 REASSEMBLY 1/12
2. RETARDER 2/1 ... 2/20
2.1 DISASSEMBLY 2/1 ... 2/5

2.2 REASSEMBLY 2/6 ... 2/20
2.2.1 Preassembly and Installation of the Retarder Valve 2/18 ... 2/20
TRANSMISSION 3/1 ... 4/96
3. DISASSEMBLY 3/1 ... 3/28
3.1. Engine Connection – Converter 3/1 ... 3/2

3.1.1 Version with Retarder
3.1.2 Version without Retarder
3/3 ... 3/4
3.2 Input
3.3 Input Shaft (Transmission Pump/Power Take-Off) 3/5
3.4 Transmission Pump 3/6 ... 3/7
3.5 Emergency Steering Pump 3/7
3.6 Coarse Filter 3/7
3.7 Layshaft 3/7 ...3/8
3.8 Removal of the Inductive and Speed Transmitters 3/8
3.9 Removal of the Housing Cover 3/9 ... 3/10
TABLE OF CONTENTS Chap./Page
3.10 Interaxle differential 3/10 ... 3/17

Version: Differential lock power shiftable
3.10.1 Differential
3.10.2 Powershift Group
3.11 Removal of the Multi-Disc Clutches 3/18
3.12 Dismantling of the Multi-Disc Clutches – K3/K4 3/19 ... 3/21
3.13 Dismantling of the Multi-Disc Clutches – KR/K2 3/22 ... 3/24
3.14 Dismantling of the Multi-Disc Clutches – KV/K1 3/25 ... 3/28
4. REASSEMBLY 4/1 ... 4/96
4.1 Interaxle differential 4/1 ... 4/18

4.1.1 Mounting of the Clutch Housing 4/1 ... 4/2
4.1.2 Assembly of the Powershift Group 4/2 ... 4/12
4.1.3 Installation of the Powershift Group 4/12 ... 4/13
4.1.4 Assembly of the Differential 4/14 ... 4/18
4.2 Assembly of the Multi-Disc Clutches – K4/K3 4/19 ... 4/30

4.2.1 Disc Components – K4 4/23
4.3 Assembly of the Multi-Disc Clutches – KR/K2 4/31 ... 4/41

4.3.1 Disc Components – KR 4/33
4.4 Assembly of the Multi-Disc Clutches – KV/K1 4/42 ... 4/53

4.4.1 Disc Components – KV 4/44
4.5 Installation of the Layshaft Gear and the Multi-Disc Clutches 4/53 ... 4/56
4.6 Installation of the Differential 4/57 ... 4/58
4.7 Preassembly and Installation of the Housing Cover 4/59 ... 4/73
4.8 Installation of the Idler Shaft 4/74 ... 4/75
4.9 Transmission Pump 4/76 ... 4/78
Version in connection with only the 1st power take-off
4.10 Input Shaft (Transmission Pump/Power Take-Off) 4/78 ... 4/79
4.11 Input – Converter Bell 4/80 ... 4/85
4.12 Engine Connection – Converter ( with Lock-up Clutch) 4/86 ... 4/88
Version without Retarder
4.13 Coarse Filter 4/89 ... 4/90
4.14 Mounting of the Emergency Steering Pump 4/91
4.15 Inductive and Speed Transmitters 4/92 ... 4/96
Off-Road Transmissions
Repair Manual and Axle Systems
Division
PREFACE
This documentation has been developed for skilled staff trained by the ZF Passau GmbH for the repair and
maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the ZF Friedrichshafen AG are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by an adequate warranty within the scope of
the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
and Axle Systems
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0/1
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GENERAL
The Service Manual covers all works required for the dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
The use of Molykote is prohibited.
Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
0/2
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Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc.
CAUTION Is used, if a deviating and improper working procedure can

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

DANGER life.
___________________________________________________
REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description.
REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again.
0/3
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

Unit New old Conversion Note
Unité Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Masse
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
0/4
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VERGLEICHSTABELLE FÜR MASSEINHEITEN

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

1 psi ( lbf/in2 )
1 Liter = 0,264 Gallon ( Imp. )
4,456 Liter =
1 Gallon ( Imp. )
1 Liter =
0,220 Gallon ( US )
3,785 Liter =
1 Gallon ( US )
1609,344 m =
1 Mile ( Landmeile )
0° C ( Celsius ) = + 32° F ( Fahrenheit )
0 ° C ( Celsius ) =
273,15 Kelvin
0/5
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TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARD 148
Friction value: µ tot.= 0.12 for screws and nuts without after-treatment, as well as phophatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO-Standard thread DIN 13, Page 13

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

Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
0/6
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Heat the bearing inner ring.
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501
Figure 47
Insert the flange shaft until contact.
Figure 48
Grease the O-ring (arrow) and insert it into the annular groove of
the intermediate ring.
Figure 49
Fasten the intermediate ring by means of hexagon screws.
 Screw locking – use Loctite 648!

Tightening torque (M10/10.9) ........... MA = 46 Nm
Figure 50
5871 179 002 2/14

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TRANSMISSION
4. REASSEMBLY
4.1 Interaxle Differential
4.1.1 Mounting of the Clutch Housing

Provide the mounting face with sealing compound.
Product name – sealing compound:
Figure 1 Three Bond Type 1215, ZF Part No.: 0666 790 054.
Position the clutch housing.
Figure 2
Flush-mount both cylindrical pins (arrows) to the housing face.
Figure 3
Fasten the clutch housing by means of cap screws.
Figure 4
5871 179 002 4/1

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Insert the screen sheet and fasten it with cap screws.
Figure 5
4.1.2 Assembly of the Powershift Group
The following sketch shows sectioning of the powershiftable

interaxle differential.
1 2
3
4
VA HA
8
7
6 5
Figure 6
Legend to Figure 6 :
VA = Output – Front axle (converter side)
HA = Output – Rear axle
1 = Powershift group (differential lock)
2 = Differential
3 = Spacer bush
4 = Output shaft to rear shaft
5 = Output shaft to front axle
6 = Bush (driver)
7 = Washer
8 = Hexagon screw
Pay attention to the installation position of the single

components for the following assembly!
5871 179 002 4/2

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The following sketch shows the installation position of the single components and disc components of the
powershift group.
7 8 9 10 11 12 11
17
16
13 14 15
6 5 4 3 2 1
Figure 7
Pos. Description Quantity s (mm) Remarks

1 Retaining ring 1
2 Shim 1 2.5
3 Cup spring 1
4 Disc carrier 1
5 Shim 1 5.0
6 Retaining ring 1
7 Cup spring set 1 consisting of 3 cup springs
8 Piston 1
9 Cylindrical roller 6
10 Pressure plate 1
11 Outer clutch disc 2 coated on one side
12 Outer clutch disc 9 coated on both sides
13 Inner clutch disc 1 4.0
15 Inner clutch disc 3 2.5 ... 4.0 optional
16 End shim 1
17 Snap ring 1 2.3 or 2.5 optional
Note: Install the outer clutch discs Item 11, with the uncoated side showing to the pressure plate
and the end shim respectively!
5871 179 002 4/3

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Adjustment of disc clearance (Figure 8 ... 16).
Piston side:
Put the piston into the disc carrier.
Install the piston without O-rings first!

Observe the installation position – plane face shows
downwards, also see Figure 7, Page 4/3!
Figure 8
Insert the spacer (special tool).
For determination of the clearance it is absolutely necessary

to use the spacer
(S) Spacer 5870 200 128
Figure 9
Fasten the single components by means of shim s = 5.0 mm and

retaining ring.
Figure 10
Disc set side:

Insert the cylindrical rollers (6 pcs.) into the boreholes (arrows).
Figure 11
5871 179 002 4/4

Division
Put the pressure plate over the cylindrical rollers.
Pay attention to the installation position, also see Fig. 7,

Page 4/3!
Figure 12
Mount the cup spring.
Pay attention to the installation position, also see Fig. 7,

Page 4/3!
Figure 13
Fasten the single components by means of shim s = 2.5 mm and

retaining ring.
Figure 14
Mount the disc set in accordance with the sketch and table
respectively, Page 4/3.
In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!
Figure 15
5871 179 002 4/5

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Press on the outer clutch disc with approx. 100 N (10 kg) and
+0.2
check the adjusting dimension = 15.2 mm, from the front-
end/disc carrier to the outer clutch disc!
Correct clearance of the multi-disc clutch is determined by

means of the adjusting dimension = 15.2
+0.2
mm!
If the required adjusting dimension differs, it has to be
corrected with the corresponding inner clutch discs, see
table/Page 4/3, Item 15!
(S) Digital depth gauge 5870 200 072

Figure 16
Upon adjusting of the disc clearance, remove the disc set, oil the
clutch discs according to ZF list of lubricants TE-ML 03 and
reinstall them.
Following to this put in the end shim and fasten it by means of
the snap ring (Fig. 17).
Figure 17
Remove the spacer and the piston again.
Figure 18
Align the disc set radially and centrically and install the
cup spring set (Figure 19 ... 29):
Locate the disc carrier over the output shaft.
Figure 19
5871 179 002 4/6

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Fasten the disc carrier on the output shaft preliminarily

6 (Figure 20 and 21).
Use the following single components for fastening:

3 Item Description
3 Spacer bush
6 Bush (driver)
7 Washer
8 Hexagon screw
Figure 20 Note: The single components to be used are

shown in sketch/page 4/2 !
Figure 21
Mount the quill shaft until all inner clutch discs are aligned
radially and centrically (Figure 22 and 23).
At a control dimension of > 107 mm (Figure 23), it is ensured

that all inner clutch discs are centered!
Figure 22
Figure 23
5871 179 002 4/7

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Keep the quill shaft to contact and position the preassembled disc
carrier to the assembly press.
Support is given by the quill shaft (arrow)!

Figure 24
Install the cylindrical rollers (6x), see arrows!
Figure 25
Put both O-rings scroll free into the annular grooves of

the piston, see arrows!
Figure 26
Oil the O-rings and the piston contact faces.

Install the piston evenly until contact.
Observe the installation position – plane face shows

downwards, also see Figure 7, Page 4/3!
Figure 27
5871 179 002 4/8

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Insert the cup spring set with the concave face showing to the
piston.
For installation of a new cup spring set remove the anti-

corrosive!
Figure 28
Preload the cup spring set and fasten it by means of the shim
(Item 5) and retaining ring (Item 6).
Installation position
sketch/Page 4/3!
of the single components, see
(S) Pressure piece 5870 345 072
Figure 29
Remove the disc carrier fastening again and separate the

quill shaft as well as the output shaft from the disc carrier.
Figure 30
Fix the output shaft in the vice.
Use protective jaws!
Mount the preassembled disc carrier.
Figure 31
5871 179 002 4/9

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Install connection pipe 1 and solenoid valve 2.
1
Figure 32
Put in the ball bearing until contact and fasten it by means of the
retaining ring.
Figure 33
Snap both rectangular rings (arrows) into the annular grooves

of the oil feed bush.
Figure 34
Insert the oil feed bush until contact.
Figure 35
5871 179 002 4/10

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1 Seal the finished bore (arrow 1) by means of plug (König).

Insert the O-ring (arrow 2) into the annular groove and oil it.
2
Figure 36
Heat the ball bearing (Figure 37) and mount the cover
until contact (Figure 38).
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 37
Figure 38
Fasten the cover by means of driver bush, washer and

hexagon screws.
Figure 39
5871 179 002 4/11

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Fasten the hexagon screw by means of tab washer.
(S) Mounting tool 5870 057 009

(S) Handle 5870 260 002
Figure 40
Install the shaft seal with the sealing lip showing to the oil sump.
Using of the specified mounting tool (S) results in the exact

installation position!
Wet the outer diameter with spirit!
Figure 41
4.1.3 Installation of the Powershift Group
Assemble the quill shaft until all inner clutch discs are located
(Figure 42 and 43).
At a control dimension of > 107 mm, the exact installation

position is ensured (Figure 43) !
Figure 42
Figure 43
5871 179 002 4/12

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Install two adjusting screws.

Insert the preassembled powershift clutch by means of lifting
equipment (arrow) until contact (from the bottom to the top).
Pay attention to the radial location of the cover!
Then fasten the cover and powershift clutch respectively by

means of cap screws.
(S) Adjusting screws 5870 204 007

Figure 44 (S) Eyebolts assortment 5870 204 002
(S) Lifting chain 5870 281 047
5871 179 002 4/13

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4.1.4 Assembly of the Differential

The following sketch shows the sectioning of the differential.
9 10 11 12
8 13
8
7
14
6
15
VA HA
5 16
17
18
4
3 2 1
Figure 45
To Figure 45:
VA = Output-front axle (converter side) 11 = Planet gear

HA = Output-rear axle 12 = Planet shaft
1 = Ring gear 13 = Washer
2 = Ring gear carrier 14 = Rectangular rings
3 = Snap ring 15 = Plug (König)
4 = Planet carrier 16 = Snap ring
5 = Needle sleeve 17 = Retaining ring
6 = Snap ring 18 = Snap ring
7 = Sun gear
8 = Thrust washer Note: Pay attention to the mounting position
9 = Slotted pin of the single components for the following assembly!
10 = Roller set
5871 179 002 4/14

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For installation of a new planet carrier the finished bores

(6x, see arrows) are to be sealed with plugs (König)!
(S) Lever riveting tongs 5870 320 016
Figure 46
Press the needle sleeve with the reinforced coating showing

towards the press-in tool until contact and fasten it by means of
snap ring.
(S) Pressing bush 5870 506 131
Figure 47
Engage the snap ring (arrow) into the annular groove of the
sun gear.
Figure 48
Position the sun gear in the planet carrier.
Observe the installation position – snap ring shows

downwards, also see sketch/Page 4/14!
Figure 49
5871 179 002 4/15

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11 The opposite figure shows the single components of the planet

gear:
8 = Thrust washer
10 = Roller set (roll body 2x30 pcs. and washer 1 piece)
11 = Planet gear
12 = Planet shaft
12
Put the roller set into the planet gear and install the thrust
8 washers!
10 Use assembly grease!
8
Figure 50
Position the planet gear, align it centrically and fasten it by

means of planet shaft.
Pay attention to axial and radial installation position of the

planet shaft – central oil bore (arrow) shows to the front!
Figure 51
Fasten the planet shaft by means of slotted pin.
Mount the slotted pin up to the planet shaft center,

see arrow resp. sketch/Page 4/14!
Install the remaining planet gears (5x) analogously.
Figure 52
Put the preassembled planet carrier into the ring gear.
Figure 53
5871 179 002 4/16

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Place the bearing outer ring (arrow) into the ring gear carrier
until contact.
Figure 54
Heat the ring gear (Figure 55), undercool the ring gear carrier
and insert it until contact (Figure 56).
Wear safety gloves!
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 55
Figure 56
Fasten the ring gear carrier by means of the snap ring.
Figure 57
5871 179 002 4/17

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Heat the bearing inner ring and install it until contact.
Wear safety gloves!
Figure 58
Snap-in and lock both rectangular rings (see arrows).
Figure 59
5871 179 002 4/18

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4.2 Assembly of the Multi-Disc Clutch-K4/K3
The following sketch shows the sectioning of the clutch !
1
3
K4 K3
9
7 6 5 4
Figure 60
To Figure 60:
1 = Disc carrier (cpl.)

2 = Spur gear-K4
3 = Spur gear-K3
K4 = Multi-disc clutch-K4
4 = Piston
5 = Cup spring (2x)
6 = Baffle plate
7 = Snap ring
8 = Plug 2x (König)
Note: Pay attention to the installation position of the single components for the following assembly!
5871 179 002 4/19

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Note:
For installing a new disc carrier the finished bores of the
clutch shaft have to be sealed by plugs (König)!
Installation position, see arrows/Fig. 61 and 62 resp. sketch,
Page 4/19!
(S) Hand inserting tool 5870 320 014

(S) Ratchet spanner 5870 320 018
Figure 61
Figure 62
K4-side:
Place both O-rings scroll free into the annular grooves of the
piston, see arrows!
Figure 63
Oil the O-rings as well as the piston contact surfaces and mount
the piston.
Observe the installation position, see figure resp. sketch/Page

4/19!
Figure 64
5871 179 002 4/20

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Press in the piston evenly until contact.
(S) Assembly fixture 5870 345 102

Figure 65
Put in the cup springs (2x).
Observe the installation position, also see sketch/Page 4/19!
Figure 66
Put the O-ring (arrow) scroll free into the annular groove of the
baffle plate.
Figure 67
Oil the O-ring as well as the cylinder contact face and install the
baffle plate into the piston evenly.
Observe the installation position, see Figure 68

resp. sketch/Page 4/19!
Figure 68
5871 179 002 4/21

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Mount the snap ring.
Figure 69
Cautiously press the baffle plate into the piston and fasten it by
engaging the snap ring (arrow).
Installation position
sketch/Page 4/19!
of single components, also see
(S) Assembly fixture 5870 345 102

K3-side to be preassembled analogously (Figure 63 to 70)!
Figure 70
5871 179 002 4/22

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4.2.1 Disc Components-K4
Following sketch and table resp. shows the standard version for the installation position of the
single components! The respective spare parts list is binding!
6 7 6 5 2 1
12
K4 K3
11 10 9 8
Figure 71
Item Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4.0
6 Outer clutch disc 2 1.85 coated on one side
7 Outer clutch disc 5 2.5 coated on both sides
8 Inner clutch disc 2 3,5
11 End shim 1
12 Snap ring 1 2.1 ... 3.1 optional
Number of friction surfaces : 12
Disc clearance : 2.4 ... 2.8 mm
Note: Install the outer clutch discs Item 6, with the lining side showing to the inner clutch disc!
5871 179 002 4/23

Division
Install disc set-K4 and check disc clearance = 2.4 ... 2.8 mm
(Figure 72 and 73)
Put the preassembled disc carrier into the clamping ring (S) and
fasten it.
(S) Clamping ring 5870 654 033
Install the disc set (Item 5 to 12).
Figure 72
Installation position of the single components, see sketch
resp. table/Page 4/23!
Press on the end shim with approx. 100 N (10 kg) and set the
dial indicator to „Zero“.
Then press the end shim against the snap ring (upwards) and
read the disc clearance on the dial indicator.
If the required disc clearance differs, it has to be corrected

with the adequate inner clutch discs or/and snap ring, see
table/Item 10 and 12!
reinstall them.
Figure 73
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
5871 179 002 4/24

Division
Preassemble and install spur gear-K4 (Figure 74 ... 78)

2 1
4 The opposite figure shows the single components of spur gear-
1 2 3 K4.
1 = Bearing inner ring

2 = Bearing outer ring
3 = Ring
4 = Spur gear
Put in both bearing outer rings (2) until contact.
Figure 74
Figure 75
Mount the ring (3).
Figure 76
Assemble the spur gear until all inner clutch discs are located.
Figure 77
5871 179 002 4/25

Division
Heat the bearing inner ring (spur gear bearing) and locate it until
contact.
Wear safety gloves!
Figure 78
Heat the bearing inner ring (clutch bearing) and install it until
contact.
Wear safety gloves!
Figure 79
5871 179 002 4/26

Division
1 2 5 6 7 6
12
K4 K3
8 9 8 9 10 11
Figure 80

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4.0
11 End shim 1
Disc clearance : 2.8 ... 3,0 mm
5871 179 002 4/27

Division
Install disc set-K3 and check disc clearance = 2.8 ... 3,0 mm
(Figure 81 and 82)

Figure 81

reinstall them.
Figure 82
5871 179 002 4/28

Division
Wear safety gloves!
Figure 83
Lift the disc carrier out of the clamping ring (S).
To ensure an exact contact of the single components preload the

bearing with 100 000 N (10 t) (Figure 84).
Support on the lower and upper bearing inner ring!

Use pressure pieces (S)!
Figure 84
Put the disc carrier into the clamping ring (S) and fasten it.
Install the slotted nut.
Pay attention to the installation position of the slotted nut!

Collar (Ø 60 mm), must show to the bearing inner ring, also
see sketch/Page 4/19! Oil the thread!
Tightening torque ..... ........... MA = 550 Nm

(S) Slotted nut wrench 5870 401 118
Figure 85 (S) Slotted nut wrench 5870 401 115
Check function of clutch-K3 and –K4 with compressed air.
Closing or opening of the clutches is clearly audible when the

single components have been installed adequately!
Figure 86
5871 179 002 4/29

Division
Snap-in and lock the rectangular rings (3x, see arrows).
Spur gear-K3 is installed after placing of the clutch into the

housing!
Figure 87
5871 179 002 4/30

Division
4.3 Assembly of the Multi-Disc Clutch-KR/K2.
2 1 3
KR K2
9
7 6 5 4
Figure 88
To Figure 88:
1 = Disc carrier
2 = Spur gear-KR
3 = Spur gear-K2
KR = Multi-disc clutch-KR
4 = Piston
5 = Cup spring (2x)
6 = Baffle plate
7 = Snap ring
5871 179 002 4/31

Division
Note:
Installation position, see arrow/Figure 89 and 90 resp. sketch,
Page 4/31!

Figure 89
Figure 90
5871 179 002 4/32

Division
4.3.1 Disc Components-KR

Following sketch and table resp. shows the standard version for the installation position of the single
components.
12 5 2 1
7
6 6
KR K2
11 9 9 8
10 10
4
Figure 91

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4.0
11 End shim 1
5871 179 002 4/33

Division
Note:
Prior to the installation of the disc sets mount piston, cup
springs and baffle plate on both clutch sides.
Observe installation sequence, Page 4/20 ... 4/22!
Then put the disc carrier into the clamping ring (S) and fasten it.
Figure 92
Install disc set-KR and check disc clearance = 2.8 ... 3.0 mm
(Figure 93 and 94)

Figure 93
dial indicator to „Zero“..

reinstall them!
Figure 94
5871 179 002 4/34

Division
Preassemble and install spur gear-KR (Figure 95 ... 99)
The opposite figure shows the single components of spur gear-

KR.
1
1 = Bearing inner ring (75 x 41 mm)
2 = Ring
3 = Spur gear
4 4 = Bearing inner ring (75 x 37 mm)
3
2
Figure 95
Heat the bearing inner ring (75 x 37 mm) and install it until
contact.
Wear safety gloves!
Figure 96
Figure 97
Mount the ring.
Figure 98
5871 179 002 4/35

Division
Heat the bearing inner ring (75 x 41) and locate it until contact.
Wear safety gloves!
Figure 99
Heat the bearing inner ring (clutch bearing) and locate it until
contact.
Wear safety gloves!
Figure 100
5871 179 002 4/36

Division
1 2 5 12
7
6 6
KR K2
8 9 8 9 10 11
4
Figure 101

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4.0
11 End shim 1
Number of the friction surfaces : 18
Disc clearance : 2.8 ... 3,0 mm
5871 179 002 4/37

Division
Install disc set-K2 and check disc clearance = 2.2 ... 2.4 (Figure
102 and 103)

Figure 102

reinstall them.
Figure 103
5871 179 002 4/38

Division
Preassemble and install spur gear-K2 (Figure 104 ... 108)
1 Undercool gear 1 (approx. - 80° C) and heat gear 2

2 (approx. + 120° C).
Engage the snap ring (arrow), preload it and join both parts by
means of hydr. press until the snap ring engages into the annular
groove of gear 2.
Figure 104
The opposite figure shows the single components of the

spur gear bearing.
3 1 = Bearing inner ring

2 = Spur gear (cpl.)
3 = Bearing inner ring
1
2
Figure 105
Wear safety gloves!
Figure 106
Figure 107
5871 179 002 4/39

Division
Heat the bearing inner ring (spur gear bearing) and install it until
contact.
Wear safety gloves!
Figure 108
Heat the bearing inner ring (clutch bearing) and locate it until
contact.
Wear safety gloves!
Figure 109


(S) Pressure pieces 5870 506 096
Figure 110
5871 179 002 4/40

Division
Lift the disc carrier into the clamping ring (S) and fasten it.
K2-side:

Chamfer must show to the bearing inner ring, also see
sketch/Page 4/31! Oil the thread!
Tightening torque ........... MA = 800 Nm

Figure 111 (S) Reduction sleeve 5870 654 048
KR-side:

Collar (Ø 76 mm), must show to the bearing inner ring, also
Tightening torque ........... MA = 800 Nm

Figure 112
Check function of clutch-KR and –K2 with compressed air.

Figure 113
Figure 114
5871 179 002 4/41

Division
4.4 Assembly of the Multi-Disc Clutch-KV/K1.
2 1
KV K1
7 6 5 4
Figure 115
To Figure 115:
1 = Disc carrier
2 = Spur gear-KV
3 = Spur gear-K1
KV = Multi-disc clutch-KV
4 = Piston
5 = Cup spring (2x)
6 = Baffle plate
7 = Snap ring
5871 179 002 4/42

Division
Note:
Installation position, see arrows/Figure 116 and 117 resp.
sketch/Page 4/42!

Figure 116
Figure 117
5871 179 002 4/43

Division
4.4.1 Disc Components-KV

Following sketch and table resp. shows the standard version for the installation position of the single components!
The respective spare parts list is binding!
6 7 6 5 2 1
11
KV
KV
K1
10 8 8
9 9
4
Figure 118

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4.0
10 End shim 1
5871 179 002 4/44

Division
Note:
Prior to the installation of the disc sets mount piston, cup
springs and baffle plate on both clutch sides.
Observe installation sequence, Page 4/20 ... 4/22!
Then put the disc carrier into the clamping ring (S) and fasten it.
Install disc set-KV and check disc clearance = 2.8 ... 3.0 mm
(Figure 119 and 120):
Install disc set (Item 5 to 12).

Figure 119

reinstall them.
Figure 120
5871 179 002 4/45

Division
Preassemble and install spur gear-KV (Figure 121 ... 125)
1 The opposite figure shows the single components of spur gear-

2 KV.
2 3
1 1 = Bearing inner ring
2 = Bearing outer ring
3 = Ring
4 = Spur gear
4 Put in both bearing outer rings (2) until contact.
Figure 121
Heat the bearing inner ring and locate it until contact.
Wear safety gloves!
Figure 122
Figure 123
Mount the ring.
Figure 124
5871 179 002 4/46

Division
Heat the bearing inner ring (spur gear bearing) and locate it until
contact.
Wear safety gloves!
Figure 125
Heat the bearing inner ring (clutch bearing) and install it until
contact.
Wear safety gloves!
Figure 126
5871 179 002 4/47

Division

Following sketch and table resp. shows the standard version for the installation position of the single
components! The respective spare parts list is binding!
1 2 5
6 7 6
11
KV
KV
K1
8 9 10
4
3
Figure 127

1 Disc carrier 1
2 Piston 1
3 Cup spring 2
4 Baffle plate 1
5 Washer 1 4,0
6 Outer clutch disc 2 2,0 coated on one side
7 Outer clutch disc 8 2,5 coated on both sides
9 Inner clutch disc 2 2,5 ... 4,0 optional
10 End shim 1
11 Snap ring 1 2,1 ... 2,5 optional
Disc clearance : 2,8 ... 3,0 mm
5871 179 002 4/48

Division
Install disc set-K1 and check disc clearance = 2.2 ... 2.4 mm
(Figure 128 and 129)

Figure 128

reinstall them.
Figure 129
5871 179 002 4/49

Division
1 Preassemble and install spur gear-K1 (Figure 130 ... 137):
The opposite figure shows the single components of spur gear-

K1.
1 = Ball bearing (cpl.)

2 = Snap ring
3 = Spur gear
2
3 Prior to installation of the single components align the disc
set radially and center it by means of the spur gear, see Fig.
131!
Figure 130
Figure 131
Mount the snap ring.
Figure 132
Assemble the bush with front-end collar (arrow) showing to the

snap ring.
Figure 133
5871 179 002 4/50

Division
Press in the ball bearing until contact.
Install the ball bearing with the lubrication groove (arrow)

showing downwards!
Put the press-in tool only to the bearing outer ring!
Figure 134
Heat the second ball bearing and install it until contact.
Lubrication groove (arrow) must show upwards!
Wear safety gloves!
Figure 135
Mount the bush.
Figure 136
Heat the spur gear to approx. 120° C and mount it until all inner
clutch discs are located.
Wear safety gloves!
Figure 137
5871 179 002 4/51

Division
Mount the shim s = 1.2 mm.
Figure 138
Wear safety gloves!
Figure 139


(S) Pressure pieces 5870 506 096
Figure 140
Fasten the disc carrier by means of clamping ring (S).

Collar (Ø 60 mm), must show to the taper roller bearing. also
Tightening torque ..................... MA = 550 Nm
(S) Slotted nut wrench (KV-side) 5870 401 118

(S) Slotted nut wrench (KV-side) 5870 401 115
Install the opposite slotted nut (K1-side) analogously.

Figure 141
5871 179 002 4/52

Division
Check function of clutch-KV and –K1 with compressed air.

Figure 142
Figure 143
4.5 Installation of the Layshaft Gear and the Multi-Disc

Clutches
The opposite figure shows the single components of the layshaft

gear bearing.
1 = Bearing inner ring (2x)

2 = Ring
1 3 = Layshaft gear
3
1 2
Figure 144
Position the layshaft gear (cpl.) in the housing.
Only when the clutches are installed, the idler shaft can be
mounted!
Figure 145
5871 179 002 4/53

Division
Insert the bearing outer rings-KV/K1, -KR/K2 and K4/K3 until

contact into the housing bores, see arrows!
Figure 146
The opposite figure shows the preassembled clutches.
K2 K3
K1
KV KR K4
Figure 147
Position clutch-KV/K1 by means of lifting equipment.
(S) Eyebolts assortment 5870 204 002

Figure 148
Position clutch-KR/K2.

Figure 149
5871 179 002 4/54

Division
Lift clutch-KR/K2 slightly and position clutch-K4/K3 by means

of lifting equipment.

Figure 150
Install spur gear-K3 (Figure 151 ... 153):
Insert the bearing outer ring (arrow) until contact.
Figure 151
Insert the spur gear-K3 by means of lifting equipment until all

inner clutch discs are located.
Only an exact alignment of both spur gears (see

arrow/Figure 153) ensures that all inner clutch discs are
located!

Figure 152
Figure 153
5871 179 002 4/55

Division
Install the roller bearing (K3-bearing) (Figure 154 and 155)
Bearing inner ring and bearing rollers are fastened by means

of snap ring (arrow). At following installation of the roller
bearing, the snap ring must show downwards!
Figure 154
Heat the roller bearing and install it until contact.
Figure 155
5871 179 002 4/56

Division
4.6 Installation of the Interaxle Differential
Position the oil baffle.
Figure 156
Figure 157
Insert the preassembled differential by means of the

lifting equipment.
(S) Lifting bracket 5873 004 008

(S) Gripping insert 5873 004 026
Figure 158
Fasten the sun gear by means of the retaining ring (arrow).
Installation position of the retaining ring, also see

sketch/Page 4/14, Item 17!
Figure 159
5871 179 002 4/57

Division
Mount the output shaft.
Figure 160
Fasten the output shaft axially by means of the snap ring.
Installation position of the snap ring, also see

sketch/page 4/14, Item 16!
Figure 161
Mount the bush.
Figure 162
Position the upper oil baffle and fasten both plates by means of
cap screws (5x) and hexagon nut (1x).
Install the washers!

Insert the cap screw (installation position, see arrow) with
Loctite 243!
Figure 163
5871 179 002 4/58

Division
1 4.7 Preassembly and Installation of the Housing Cover

3 Version: Interaxle differential
2 Install the single components.
1 = Sealing cover (use Loctite, Type No. 262)

2 = Connection piece (install new sealing ring)
4 3 = Cover plate (install new gasket)
4 = Sealing cover (use Loctite, Type No. 262)
Depending on the transmission version, differences as to the
Figure 164
single components and their installation positions are
possible! See the corresponding parts list!
Flush-mount the slotted pin (2 x 8 mm) see arrow 1!

Provide the screw plug with a new O-ring and install it, see
2 arrow 2.
Figure 165
Install the input gear-emergency steering pump (Figure 166 ...

170)
2 3 4 The opposite sketch shows the installation position of the single

1 5 components.
1 = Housing cover
2 = Snap rings (2x)
3 = Input gear
4 = Retaining ring
5 = Ball bearing
Figure 166
Engage both snap rings (arrow) into the recess.
Figure 167
5871 179 002 4/59

Division
Expand both snap rings and insert the ball bearing until the upper
snap ring engages into the groove of the ball bearing.
Pay attention to the installation position, see Fig. 166!
(S) Clamping pliers 5870 900 026
Figure 168
Insert the input gear until contact.
(S) Hammer 5870 280 004
Figure 169
Fasten the input gear by means of the retaining ring.
(S) Set of external pliers 5870 900 015
Figure 170
Adjust bearing preload of differential bearing = 0.0 ... 0.1 mm

(Figure 171 ... 175)
Determine Dim. I from the mounting face to the locating face of

the bearing outer ring.
Dim. I e.g. ...................................... 66.30 mm
Figure 171
5871 179 002 4/60

Division
Place the bearing outer ring.
Figure 172
Put on the measuring disc (S) and center it.
(S) Measuring disc 5870 200 129
Figure 173
Measure Dim. II from the shoulder of the bearing outer ring to

the mounting face of the housing.
Dim. II e.g. ....................................... 64.40 mm
Take several measuring points and determine the mean!

Then remove the measuring disc again.
(S) Gauge blocks 5870 200 067

(S) Straightedge 5870 200 022
Figure 174
Example
Dim. I ............................................... 66.35 mm

Dim. II .............................................. - 64.40 mm
Difference ......................................... 1.95 mm
required bearing preload e.g. ................ + 0.05 mm
results in shim e.g. .......................... s = 2.00 mm
Insert the shim.
Figure 175
5871 179 002 4/61

Division
Install the bearing outer ring.
Figure 176
Grease both rectangular rings (arrow) and align them

centrically.
Figure 177
Provide mounting face with sealing compound (Loctite, No.

574). By means of the lifting equipment locate the housing cover
cautiously to the transmission housing.
Meshing surface of the gearing (emergency steering pump –

differential) is required, see figure !
Figure 178
Install both cylindrical pins (arrow 1 and 2) as well as the slotted

2 pin (arrow 3).
Fasten the housing cover.

4 1
Wet the thread of the hexagon screw (arrow 4) with Loctite,
3
Type No. 574 (through hole)!
Figure 179
5871 179 002 4/62

Division
Assemble the ball bearing (Figure 180) and locate it until contact
with aid of the output flange (Figure 181).
Then remove the output flange again.
Figure 180
Figure 181
Fasten the ball bearing by means of a retaining ring.
Figure 182
Install the shaft seal with the sealing lip showing to the oil sump.
Wet the rubberized outer diameter with spirit!

Using of the specified mounting tool (S) results in the exact
installation position!
Figure 183
5871 179 002 4/63

Division
Press the screen sheet (arrow) until contact.
(S) Pressing bush 5870 506 138
Figure 184
Mount the output flange.

Put the O-ring (arrow) into the gap between output flange and
shaft.
Figure 185
Put on the washer and fasten the output flange with hexagon
screws.
Figure 186
Fasten the hexagon screws by means of tab washer.

(S) Handle 5870 260 002
Figure 187
5871 179 002 4/64

Division
1 Adjust bearing preload of clutch K4/K3 = 0.0 ... 0.05 mm

(Figure 188 ... 192)
For the installation of a new bearing cover both finished

bores have to be sealed by means of plugs (König)!
The finished bores are opposed (180°) to each other, also see
2 arrows/Figure 188 and 189!
To Figure 188 and 189:

(S)
1 = Bearing cover-K4/K3
Figure 188 2 = Plug (König)
(S) = Special tool

1 (S) Ratchet spanner 5870 320 018
(S)
Figure 189
Housing dimension:
Place the bearing inner ring and center it (rotate it in both
directions).
Press on the bearing inner ring evenly and determine Dim. I
from the mounting face to the bearing inner ring.
Dim. I e.g. .......................................... 43.65 mm
Then remove the bearing inner ring again.
Figure 190 (S) Measuring shaft 5870 200 022

Cover dimension:
Determine Dim. II from the mounting face to contact/bearing
inner ring.
Dim. II e.g. .......................................... 42.12 mm
(S) Straightedge 5870 200 022

Figure 191
5871 179 002 4/65

Division
Example
Dim. I ............................................... 43.65 mm

Dim. II .............................................. - 42.12 mm
Difference ......................................... 1.53 mm
required bearing preload e.g. ............... + 0.02 mm
results in shim(s) s = 1.55 mm
Insert the shim.
Figure 192
Wear safety gloves!
After cooling down install the bearing inner ring subsequently

until contact (press)!
Figure 193
Grease the rectangular rings (3x, arrows) and align

them centrically.
Figure 194
Install the O-ring (arrow) and grease it.

Heat the inner diameter of the bearing cover (bearing seat).
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 195
5871 179 002 4/66

Division

Mount the bearing cover and by means of hexagon screws pull it
evenly until contact.
Observe the radial installation position!
Figure 196
Check function of both clutches by means of compressed air!
In case of a high pressure loss, the possible cause is the

failure of one or several rectangular rings (Figure 194)!
If necessary, replace the rectangular ring(s)!
Figure 197
5871 179 002 4/67

Division
Adjust bearing preload of clutch-KR/K2 = 0.0 ... 0.05 mm

1 (Figure 198 ... 204):

The finished bores are opposed (180°) to each other, also see
2 arrows/Figure 198 and 199!
To Figure 198 and 199:

(S) 1 = Bearing cover-KR/K2
2 = Plug (König)
Figure 198 (S) = Special tool

1 (S) Ratchet spanner 5870 300 018
(S)
Figure 199
Install both stud bolts (arrows).
Wet the thread with Loctite (Type No. 243)!
Tightening torque (M10) ........... MA = 13 Nm
Figure 200
Insert the bearing outer ring until contact.
Pay attention to exact location!
Figure 201
5871 179 002 4/68

Division
Housing dimension:
Determine Dim. I from the bearing outer ring to the mounting

face.
Dim. I e.g. ........................................... 16.13 mm
Figure 202
Cover dimension:
Determine Dim. II from the mounting face to the contact/bearing

outer ring.
Dim. II e.g. ......................................... 17.75 mm
Figure 203
Example
Dim. I ............................................... 17.75 mm

Dim. II .............................................. - 16.13 mm
Difference ......................................... 1.62 mm
required bearing preload e.g. ................ + 0.03 mm
Fix the shim with assembly grease into the cover.

Install the O-ring (arrow).
Figure 204
Grease the rectangular rings (3x, arrows) and align

them centrically.
Figure 205
5871 179 002 4/69

Division
Pull the bearing cover evenly until contact.
Figure 206

Figure 207
5871 179 002 4/70

Division
Adjust bearing preload of clutch-KV/K1 = 0.0 ... 0.05 mm

1 (Figure 208 ... 212)

Installation position see arrows/Figure 208!
2 To Figure 208:
1 = Bearing cover-KV/K1
(S) 2 = Plug (König)
(S) = Special tool
Figure 208
Put the bearing outer ring over the bearing inner ring and center
it (rotate it in both directions).
Housing dimension:
Press on the bearing outer ring evenly and determine Dim. I from
the mounting face to the bearing outer ring.
Dim. I e.g. ......................................... 52.67 mm
Figure 209
Put the ring with the chamfer showing downward into the
bearing cover.
Figure 210
5871 179 002 4/71

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Cover dimension:
Determine Dim. II from the mounting face to the ring.
Dim. II e.g. .......................................... 50.75 mm

Figure 211
Example
Dim. I ..................................................... 52.67 mm
Dim. II .................................................. - 50.75 mm
Difference ............................................. = 1.92 mm
required bearing preload e.g. ... ............. + 0.03 mm
Insert the shim.
Figure 212

Install the O-ring (arrow) and grease it.
Figure 213
Grease the rectangular rings (arrows) and align them

centrically.
Figure 214
5871 179 002 4/72

Division
Heat the bearing bore.
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 215
Insert the bearing cover until contact and fasten it with hexagon
screws.
Observe the radial installation position, see figure!

Figure 216

Figure 217
5871 179 002 4/73

Division
4.8 Installation of the Idler Shaft
Align the layshaft gear and the single components centrically.

Heat the layshaft bearing (Figure 218).
Make the following steps (Figure 218 ... 220) in direct time
sequence!
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 218
Install the adjusting screw.
Figure 219
Undercool the idler shaft and mount it until contact.
Figure 220
Remove the adjusting screw and fasten the shaft by means of

hexagon screw.
Wet thread of the hexagon screw with Loctite

(Type No. 243)!
Figure 221
5871 179 002 4/74

Division
Flush-mount the sealing covers (arrows) with the concave side

showing downwards, to the housing surface.
Wet the contact surface with Loctite (Type No. 262) !
Figure 222
5871 179 002 4/75

Division
4.9 Transmission Pump

Press the needle sleeve (arrow) with the reinforced coating

showing towards the press-in tool until contact.

(S) Handle 5870 260 002
Figure 223
Snap the V-rings (3x) into the recess of the driver

(internal gearing).
Install the key (arrow).
Figure 224
Press the ball bearing over the collar of the driver until contact.
Figure 225
Mount the ball bearing resp. the driver and press it until
contact.
Pay attention to contact of key and keyway!
Figure 226
5871 179 002 4/76

Division
Fasten the ball bearing by means of the retaining ring.
(S) Set of internal pliers 5870 900 013
Figure 227
Mount and grease the O-ring (arrow).
Figure 228
Heat the housing bore.
(S) Preheating bush 5870 801 006

(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501
Figure 229
Install two adjusting screws and mount the pump until contact.
Pay attention to the radial installation position!

Figure 230
5871 179 002 4/77

Division
Put the O-ring (arrow) into the annular groove of the pump
flange.
Depending on the transmission version there can be

differences as to the version and fastening of the pump
flange!
The corresponding spare parts lists is binding!
Figure 231
Fasten the pump flange resp. the pump by means of cap screws.
Wet the thread of both cap screws (Position, see arrows) with
Loctite, Type No. 574 (through holes) !
Then rotate the transmission housing by 90°.
Figure 232
4.10 Input Shaft (Transmission Pump/Power Take-Off)

Snap-in and lock the rectangular ring (arrow).
Figure 233
Mount both shims (2.0 mm thickness each).
Use assembly grease!
Figure 234
5871 179 002 4/78

Division
Heat the ball bearing inner ring.
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 235
Mount the input shaft until contact.
Figure 236
Fasten the input shaft by means of clamping plate and cap screw
(arrow).
Tightening torque (M10/8.8, DIN 6912) ........ MA = 32 Nm
Wet the thread of the cap screw with Loctite (Type No. 243)!

Figure 237
5871 179 002 4/79

Division
4.11 Input – Converter Bell
To install a new converter bell the finished bores (3x) have to

be sealed with plugs (König)!
Installation position, see arrows!
Figure 238
Locate the bearing outer ring into the housing bore until contact
and install the bearing inner ring, see arrow!
Figure 239
Install the spur gear (arrow) laterally with the long collar
showing upwards and position it.
Figure 240
Heat the spur gear bore (arrow).
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 241
5871 179 002 4/80

Division
Mount the input shaft until contact.
Figure 242
Wear safety gloves!
Figure 243
Figure 244
Snap both rectangular rings (arrow) into annular grooves of the

input shaft and lock them.
Then grease the rectangular rings and align them centrically.
Figure 245
5871 179 002 4/81

Division
Install the converter safety valve (arrow 1) and fasten it by

means of slotted pin (arrow 2).
1
Flush-mount slotted pin to recess!
Put the O-Ring (arrow 3) into the annular groove.
3 2
Figure 246
Press the needle sleeve with the reinforced coating showing

towards the press-in tool into the bore of the bearing cover until
contact.

(S) Handle 5870 260 002
Figure 247
Flush-mount the shaft seal (arrow), with the sealing lip showing
to the oil sump (downwards).
Wet the outer diameter with spirit!

For the version with retarder the installation of the shaft seal
is omitted!
Figure 248
Make the following steps (Figure 249 ... 252) in direct time
sequence to ensure the exact location of the oil feed flange!
Heat the housing bore.
(S) Preheating bush 5870 801 006

(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501
Figure 249
5871 179 002 4/82

Division
Install two adjusting screws and insert the oil feed flange until
contact.
Observe the radial installation position!
Figure 250
Insert the O-ring (arrow) with assembly grease into the annular
groove of the bearing cover.
Figure 251
Put on the bearing cover and fasten it by means of

hexagon screws.
Figure 252
Note to Fig. 253:

Depending on the transmission version there can be
4 differences as to the single components and their installation
2 position!
1 The respective spare parts list is binding!
Install the single components:
1 = Screw neck
2 = Screw plug
3 = Screw plug
4 = Screw neck
3
Figure 253
Wet thread of the screw necks (Item 1 and 4) with Loctite,
Type No. 262! Provide screw plugs (Item 2 and 3) with new O-
rings!
5871 179 002 4/83

Division
Converter pressure back-up valve (Figure 254 ... 255):
Insert slotted pin (6 x 50 mm) until contact.
Figure 254
Assemble the piston and the compression spring.
Provide screw plug with new O-ring and install it.
Tightening torque (M36x1.5) ........... MA = 130 Nm
Figure 255
If required, (depending on the version) fasten the gasket and

cover plate by means of hexagon screws and washers.
Tightening torque (M6/8.8) ........... MA = 9.5 Nm
Figure 256
Insert the sealing disc (arrow), with the concave side showing
downwards, into the housing bore until contact.
Wet the contact face with Loctite/Type No. 262!
Figure 257
5871 179 002 4/84

Division
Install two adjusting screws and put on the flat gasket (arrow 1).
Put the O-ring (arrow 2) into the annular groove.
1
2
Figure 258
Mount the converter bell by means of the lifting equipment until

contact.

Figure 259
Fasten the converter bell by means of hexagon screw.
Tightening torque (M8/10.9) ............ MA = 34 Nm

Figure 260
5871 179 002 4/85

Division
4.12 Engine Connection–Converter (with Lock-up Clutch)

Version without Retarder
Assembly as well as the installation of the version with
retarder, are described in Chapter 2!
To Figure 261:
To install a new converter the finished bore has to be sealed with
a plug (König)!
Installation position, see arrow!
Figure 261 Sealing of the bore ist only required for the version without
retarder!
Clean the threaded bores from Loctite residues.
Figure 262
Fasten the flange shaft by means of hexagon screws.
Screw locking – use Loctite 243!
Figure 263
Snap the rectangular ring (arrow) into the annular groove and
lock it.
Figure 264
5871 179 002 4/86

Division
Insert the ball bearing until contact and fasten it with

retaining ring.
(S) Set of internal pliers 5870 900 013
Figure 265
If required, insert hexagon screws (depending on the version)

into the bores of the input flange and fasten them preliminarily).
Figure 266
Assemble the housing cover and with aid of the input flange
locate it on the converter until contact.
Figure 267
Finally fasten the input flange by means of washer and

hexagon screws.
Figure 268
5871 179 002 4/87

Division
Fasten the hexagon screws by means of tab washer.

(S) Handle 5870 260 002
Figure 269
Grease and align the rectangular ring (arrow) centrically.
Figure 270
Mount the converter by means of the lifting equipment

until contact.
Observe the radial installation position! Data of the vehicle

manufacturer resp. markings made at disassembly are
binding!
Figure 271
Fasten cover to the converter bell with screws.
Figure 272
5871 179 002 4/88

Division
4.13 Coarse Filter
Install the filter (cpl.) into the housing bore.
Oil the sealing ring (arrow)!

Figure 273
Fasten the cover by means of hexagon screws (install the

washers).
Install the new O-Ring (arrow)!
Figure 274
Note:
The following pictures describe the installation of various
peripheral components!
1 2 Depending on the transmission version there can be
differences as to the single components and their installation
position!
1 = Screw plug (M12x1.5) ........... MA = 35 Nm

2 = Cover plate (M 8/8.8) .............. MA = 23 Nm
3 = Screw plug (M 38x1.5) ........... MA = 80 Nm
3 Always install new sealing elements!

Figure 275
Insert the breather cup flush to the housing half.
Pay attention to the radial installation position – opening of

the angle tube shows 90° to the input axle resp. housing
external wall!
Wet the sealing surface (arrow) with Loctite 262!
Figure 276
5871 179 002 4/89

Division
Install the breather (arrow).
Figure 277
Install the single components.
1 = Bolt connection (Use sealing compound-Loctite 262)

2 = Fixing plates
3 = Screw plugs (install new O-rings)
Figure 278
Provide screw plug with new O-ring and install it.
Tightening torque (M26x1.5) ........... MA = 80 Nm
Mounting of the control unit is described in Chapter 1!
Figure 279
5871 179 002 4/90

Division
4.14 Mounting of the Emergency Steering Pump
Put the O-ring (arrow) into the annular groove and grease it.
Figure 280
Insert the emergency steering pump until contact and fasten it

with hexagon screws.
Screw locking - use Loctite 243!

Pay attention to the radial installation position - Data of the
vehicle manufacturer resp. markings made at disassembly
are binding!
Figure 281
5871 179 002 4/91

Division
4.15 Inductive and Speed Transmitters

14
The following sketches show the installation
position of the single inductive and speed
transmitters.
6 = Inductive transmitter n – Turbine

14 = Inductive transmitter n – Engine
39 = Induct.trans. n – internal speed input
31 = Speed transmitter n – Output
39
Figure 282
31
Figure 283
5871 179 002 4/92

Division
The following pictures describe the installation resp.

adjusting of the inductive transmitter n – Engine (14)!
Installation of the inductive transmitter n-Turbine (6) and n-
internal speed input (39), is to be made analogously !
Observe the different adjusting dimensions „X“ !
+ 0.3
"S"
Inductive transmitter n-Engine (14) ...... X = 0.5 mm
"A"
I
+ 0.3
Inductive transmitter n-Turbine (6) ....... X = 0.5 mm
Induct.trans. n-intern. speed input (39) X = 0.3 + 0.1 mm
X
Figure 284
Adjust Dim. X by means of shim ring(s) (Figure 285 .. 290):
Measure Dim. I on the inductive transmitter from the contact

face to the screw-in face.
Dim. I e.g. ......................................... 30.00 mm
Figure 285
Turn in the counting disc radially until one tooth tip is centrically
to the inductive transmitter bore.
Screw in the plug gauge until contact.

Locate anvil at the tooth tip and lock it by means of threaded pin
(Figure 286 and 287).
(S) Plug gauge 5870 200 104
Figure 286
(S) Plug gauge 5870 200 104

II
Figure 287
5871 179 002 4/93

Division
Remove the plug gauge and determine Dim. II,

(also see Figure 287).
Dim. II e.g. ......................................... 30.10 mm
(S) Plug gauge 5870 200 104

Figure 288
Example “ M1“:
Dim. II e.g. ....................................... 30.10 mm
+ 0.3
Dim. X (0.5 mm) e.g. .............. - 0.60 mm
results in installation dimension A = 29.50 mm
Example “ M2“:
Dim. I e.g. ........................................ 30.00 mm
Installation dimension A e.g. ............. - 29.50 mm
results in shim ring(s) s = 0.50 mm
Mount the corresponding shim ring(s) and wet the thread (arrow)
with Loctite (Type No. 574).
Figure 289
Install the inductive transmitter n - Engine (14), see arrow!
Tightening torque .................... MA = 30 Nm
Adjust and install the inductive transmitter n – Turbine (6)

and n-internal speed input (39) analogously!
Observe the different adjusting dimensions!
Installation position of the single inductive transmitters, also
see page 4/92!
Figure 290
5871 179 002 4/94

Division
Install the speed transmitter n-output/speedo (31)

X (Figure 291 ... 296):
2
31 To Figure 291:
1 1 = Housing
2 = Spur gear-K3
3 3 = Disc carrier
31 = Speed transmitter (Hall sensor)
X = Adjusting dimension = 1.0 + 0.5 mm
Figure 291
The opposite figure shows the speed transmitter (Hall sensor).
Figure 292
Determine Dim. I from the housing surface to the spur gear-K3.
Dim. I e.g. ......................................... 39.70 mm
Figure 293
Measure Dim. II from the contact face to the mounting face.
Dim. II e.g. ........................................ 40.00 mm
Figure 294
5871 179 002 4/95

Division
Example „B1“:
Dim. I ............................................... 39.70 mm
Dim. X (1.0 + 0.5 mm) ............... e.g. - 1.20 mm
results in installation dimension = 38.50 mm
Example „B2“:
Dim. II ............................................... 40.00 mm
Installation dimension ...................... - 38.50 mm
results in shim(s) s= 1.50 mm
Assemble the shims (3x, s = 0.50 mm) and grease the O-ring
Figure 295 (arrow).
Fasten the speed transmitter with a cap screw.
Tightening torque (M8/8.8) ................. MA = 23 Nm
Installation position of the speed transmitter, also see

Page 4/92!
Figure 296
Install all oil lines.
Depending on the transmission version the routing is

different! Pay attention to the perspective illustration in the
corresponding parts list!
Prior to commissioning of the transmission fill up oil
according to the data in the operating instructions!
5871 179 002 4/96

ZF 6wg310

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Part No.

: 5871 179 002 E

Version: With Retarder and Lock-up Clutch

Version: With Retarder and Lock-up Clutch

Preface .............................................................................................................................. 0/1

LIST OF TOOLS W/1...W/11

1. ELECTRO-HYDRAULIC CONTROL 1/1 ... 1/12

1.1 DISASSEMBLY – CONTROL UNIT 1/2 ... 1/4

1.3 LOCK-UP VALVE 1/11 ... 1/12

2. RETARDER 2/1 ... 2/20

2.1 DISASSEMBLY 2/1 ... 2/5

TRANSMISSION 3/1 ... 4/96

3. DISASSEMBLY 3/1 ... 3/28

3.1. Engine Connection – Converter 3/1 ... 3/2

3.10 Interaxle differential 3/10 ... 3/17

4. REASSEMBLY 4/1 ... 4/96

4.1 Interaxle differential 4/1 ... 4/18

4.2 Assembly of the Multi-Disc Clutches – K4/K3 4/19 ... 4/30

4.3 Assembly of the Multi-Disc Clutches – KR/K2 4/31 ... 4/41

4.4 Assembly of the Multi-Disc Clutches – KV/K1 4/42 ... 4/53

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

Structure of the Repair Manual

Important information on industrial safety

Serves as reference to special working procedures, methods,

CAUTION Is used, if a deviating and improper working procedure can

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

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

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

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

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

VERGLEICHSTABELLE FÜR MASSEINHEITEN

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

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

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

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

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

1 Liter = 0,264 Gallon ( Imp. )

0° C ( Celsius ) = + 32° F ( Fahrenheit )

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

Metric ISO-Standard thread DIN 13, Page 13

Metric ISO-Fine thread DIN 13, Page 13

Heat the bearing inner ring.

(S) Hot-air blower 230V 5870 221 500

Insert the flange shaft until contact.

Fasten the intermediate ring by means of hexagon screws.

 Screw locking – use Loctite 648!

5871 179 002 2/14

4.1.1 Mounting of the Clutch Housing

Position the clutch housing.

Flush-mount both cylindrical pins (arrows) to the housing face.

Fasten the clutch housing by means of cap screws.

Tightening torque (M10/10.9) ........... MA = 68 Nm

5871 179 002 4/1

Insert the screen sheet and fasten it with cap screws.

Tightening torque (M8/8.8) ........... MA = 23 Nm

4.1.2 Assembly of the Powershift Group

The following sketch shows sectioning of the powershiftable

Pay attention to the installation position of the single

5871 179 002 4/2

Pos. Description Quantity s (mm) Remarks