®

16 S 251

1316 751 102

Subject to alterations in design

Copyright by ZF
Reproduction in whole or in part, is only allowed with our written approval and authorization.
Printed in Germany

Edition: 11.98

1316 751 102

 16 S 251 Contents

Page

Preface........................................................................................................................................................ 5
Important information................................................................................................................................. 6
Instructions for carrying out repairs............................................................................................................ 7
Tightening torques ...................................................................................................................................... 9
Consumables ............................................................................................................................................... 11
Adjustment data .......................................................................................................................................... 12
Table of springs ........................................................................................................................................... 17
Special tools ................................................................................................................................................ 18

1 Components / range-change ..................................................................................................................... 1- 1

1.1 Plastic pipes ................................................................................................................................................ 1- 1
1.2 Output flange .............................................................................................................................................. 1- 2
1.3 Cover........................................................................................................................................................... 1- 3
1.4 5/2-way valve .............................................................................................................................................. 1- 5
1.5 Shift cylinder............................................................................................................................................... 1- 6
1.6 Housing....................................................................................................................................................... 1- 8
1.7 Planetary drive ............................................................................................................................................ 1-11

2 Servoshift ................................................................................................................................................... 2- 1
2.1 Non-integrated version................................................................................................................................ 2- 1
2.2 Integrated version........................................................................................................................................ 2- 2

3 Shift mechanism ........................................................................................................................................ 3- 1

3.1 Double “H” shift pattern ............................................................................................................................. 3- 1
3.2 Superimposed “H” shift pattern .................................................................................................................. 3- 4
3.3 Shift system for integrated Servoshift......................................................................................................... 3- 9
3.4 Shift pattern without Servoshift .................................................................................................................. 3-14
3.5 Shift pattern with Servoshift ....................................................................................................................... 3-18
3.6 Assembling complete shift housing ............................................................................................................ 3-22

4 Components / clutch housing ................................................................................................................... 4- 1

4.1 Release fork and connection plate............................................................................................................... 4- 1
4.2 Pump housing with integral pump .............................................................................................................. 4-10
4.3 Clutch housing ............................................................................................................................................ 4-11
4.4 Removing components................................................................................................................................ 4-13

5 Components / centre housing ................................................................................................................... 5- 1

5.1 Splitter (GV) cylinder ................................................................................................................................. 5- 1
5.2 Splitter shift rail .......................................................................................................................................... 5- 2
5.3 Removing shafts and components............................................................................................................... 5- 4
 16 S 251 Contents

Page

6 Input shaft.................................................................................................................................................. 6- 1

7 Mainshaft................................................................................................................................................... 7- 1

8 Layshaft...................................................................................................................................................... 8- 1

9 Synchronizer.............................................................................................................................................. 9- 1

10 Adjusting shafts......................................................................................................................................... 10-1

10.1 Mainshaft .................................................................................................................................................... 10-1
10.2 Input shaft and connection plate.................................................................................................................. 10-2
10.3 Layshaft....................................................................................................................................................... 10-3
10.4 Planetary drive ............................................................................................................................................ 10-4

11 Compressed air test................................................................................................................................... 11-1

11.1 Compressed air test for piston and splitter cylinder .................................................................................... 11-1
11.2 Compressed air test on breather .................................................................................................................. 11-1

Repair manual

NOTE: If clamping fixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover
before attaching the clamping fixture.
When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set.
Then install the reverse idler gear pin.
 Preface

This manual is intended for skilled personnel who have

been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.

This manual deals with the standard ZF product in

accordance with the state of development on the date
of issue.

However, due to continuing development of the product,

repair work might require work practices and 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
updated 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 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.

5
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