service information

Date: October/96 Distribution: I Substitues: Gr.: 26 Nr.: 03/94 Gr.: 26 Nr.: 03/96

Gear box ZF 8S-135

Vehicles L/LS 1625 and L/LB/LK 2325

In the above mentioned vehicles, as per the following indications, the gear box ZF 8S-135 is now being applied, in
replacement to the gear box ZF 4S-120 GP.

In consequence of applying the gear box ZF 8S-135, some modifications have been introduced also in the shifting
lever assembly, clutch system and transmission shaft, as per the indications which appear in the item “OTHER
MODIFICATIONS”.

INVOLVED PARTS
Assembly Nr. Assembly Nr.
Constr. Nr. Denomination Remark
Previous Present
718,053 386 260 05 00 =/= Gear box ZF 4S-120 GP
1
718,070 =/= 386 260 18 00 Gear box ZF 8S-135
718,080 386 260 09 00 =/= Gear box ZF 4S-120 GP+N 70-1B
2
718,071 =/= 386 260 19 00 Gear box ZF 8S-135+N 70-1B

APPLICATION ON SERIES
Remark Chassis constr. Nr. As of chassis final Nr. Type of vehicle
386,035 L 1625 (5,900 mm)
386,057 LS 1625 (4,500 mm)
1
386,384 ...988951 L 2325 (5,100 mm)
386,387 LB 2325 (4,200 mm)
2 386,389 LK 2325 (4,200 mm)

COMPLEMENTARY INFORMATIONS

• The gear box ZF 8S-135 consists of a basic box, with 4 forward speeds and 1 reverse speed, and of a reduc-
tion group (planetary), installed in the rear side of the same.

By means of the main box (basic) combination and of the reduction group (GP), 8 speeds result, engaged by
the “double H” system.

The reduction group (GP) actuates in the band of 1st. to 4th. speeds, remaining disactivated in the band of 5th.
to 8th. speeds.

Fundamentally derived from series of the gear box 16S-130/160/190 (except for the absence of the multipli-
cation group-GV), this box has a main housing equipped with front cover, for removing the drive shaft, main
shaft and counter shaft, and a housing of the reduction group.

MERCEDES-BENZ DO BRASIL S.A. IN WHOLE OR PARTIAL REPRODUCTION

DIVISÃO ASSISTÊNCIA TÉCNICA PROHIBITED WITHOUT PREVIOUS
WRITTEN AGREEMENT
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The reduction group (GP) operation is effected by means of an inner pneumatic cylinder, localized in the rear
region of the box. Due to its bigger diameter, the piston permits a greater efficiency for coupling the GP.

Posterior View Frontal View

• Inlet nominal torque - 1400 Nm
• Supply capacity - 14 l
• Relation of transmission
1st. - i = 11.64 4th. - i = 4.07 7th. - i = 1.41
2nd. - i = 8.00 5th. - i = 2.86 8th. - i = 1.00
3rd. - i = 5.73 6th. - i = 1.96 reverse - i = 9.41
Remark: For better information, consult the Workshop Manual B 09 923 140

OTHER MODIFICATIONS

A - SHIFTING LEVER ASSEMBLY

Assembly Nr. Assembly Nr.
Denomination Application
Previous Present
386 260 71 40 (a) 386 260 90 40 (c) L 1625
386 260 74 40 (a) 386 260 91 40 (c) Shifting lever L/LB/LK 2325
386 260 72 40 (b) 386 260 92 40 (d) Assembly
LS 1625
386 260 75 40 (b) 386 260 93 40 (d)
(a) - optional (c) - optional
(b) - optional (d) - optional

B - CLUTCH SYSTEM
With the application of the new gear box (8S-135), the servo-assisted clutch is now applied, in replacement to the
hydraulic operated mechanical clutch.

B.1 - CLUTCH HOUSING/FORK COMPONENTS/DISENGAGING SLEEVE/CYLINDER

Assembly Nr. Assembly Nr.
Denomination Quantity
Previous Present
386 251 01 01 388 251 01 01 Clutch housing 1
620 250 00 50 (a) =/= Bushing assembly 1
350 250 04 50 (a) =/= Bushing assembly 1
343 250 00 50 =/= Bushing assembly 1
345 293 01 11 =/= Fork 1
350 254 70 07 =/= Disengaging shaft 1
337 997 50 40 =/= Felt ring 2
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Assembly Nr. Assembly Nr. Denomination Quantity

Previous Present
000931 012283 =/= Screw M12 X 50 1
345 293 00 52 =/= Spacing washer 1
000471 024000 =/= Lock ring 1
364 290 01 34 =/= Lever assembly 1
000931 010395 =/= Screw M10 X 50 1
364 250 00 55 =/= Sealing cover assembly 1
385 295 17 40 =/= Cylinder support 1
000933 010267 =/= Screw M10 X 28 4
002 295 04 07 (a) =/= Cylinder 1
001 295 94 07 (a) =/= Cylinder 1
000933 010267 =/= Screw M10 X 28 2
=/= 388 254 01 06 Shaft 1
=/= 388 254 00 76 Washer 1
=/= 912009 030100 Lock ring 1
=/= 914112 010025 Screw M10 X 45 2
620 250 01 15 001 250 07 15 Disengaging sleeve 1
317 993 02 25 388 993 00 25 Spring clamp 1
=/= 388 250 01 13 Fork assembly, complete 1
385 997 05 82 (a) =/= Hose 1
350 997 71 82 (a) =/= Hose 1
003871 004102 =/= Screw A11 M8 X 1 2
003862 004001 =/= Cylindrical double ring 2
912004 014100 =/= Pressure washer A14 1
000493 014218 =/= Nut BM 14 X 1,5 1
071428 004100 =/= Threaded connection 1
620 997 01 88 =/= Greaser assembly 1
=/= 001 295 56 07 (*) Servo-clutch 1
=/= 000933 008268 Screw M8 X 16 4
=/= 350 251 00 80 Joint 1
(a) - Optional
(*) - Later on, as of chassis final Nr. ...054577, the cylinder Nr. 000 295 21 18, equipped with wearing out indica-
tor, started to be applied.

B.2 - COMPONENTS OF THE CLUTCH PEDAL ASSEMBLY

Assembly Nr. Assembly Nr.
Denomination Quantity
Previous Present
688 290 02 16 384 290 72 16 Pedal bracket assembly 1
388 291 00 74 388 291 70 74 Pin 1
386 291 70 86 688 291 75 86 Rubber stop 1
309 291 00 91 388 291 70 91 Spring seat 1
=/= 388 993 70 10 Return spring 1
386 993 70 01 388 993 70 01 Spring 1
001 295 53 06 (a) 001 295 59 06 (b) Master cylinder 1
384 295 70 06 (a) 001 295 52 06 (b) Master cylinder 1
=/= 001 295 24 06 (b) Master cylinder 1
=/= 688 290 04 39 Piston rod assembly 1
386 290 76 13 =/= Hydraulic piping assembly 1
386 290 75 13 388 290 70 13 Hydraulic piping assembly 1
=/= 388 290 71 13 Piping assembly 1
=/= 388 997 70 72 Threaded connection 1
=/= 007603 014405 Sealing ring D14 X 18 1
=/= 386 290 78 13 Piping assembly 1
(a) - Optional (b) - Optional
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B.3 - CLUTCH DISC

The new clutch disc GF420, with the pressure plate modified, is now being applied.
Assembly Nr. Assembly Nr.
Denomination
Previous Present
003 250 70 04 =/= Clutch disc GF 420
=/= 004 250 62 04 Clutch disc GF420 (with the pressure plate modified)
003 250 00 03 (a)
007 250 40 03 (a)
007 250 41 03 (a) Clutch disc 420GSZ
011 250 83 03 (a)
011 250 84 03 (a)
(a) - Optional

C - TRANSMISSION SHAFT (from gear box to intermediate bearing)

Assembly Nr. Assembly Nr. Denomination L Application
Previous Present (mm)
376 410 26 04 =/= 1428
L/LS 1625
=/= 376 410 11 04 1375
343 410 34 01 =/= Transmission 1717
L 2325
=/= 346 410 11 04 shaft 1686
346 410 12 04 =/= 1117
LB/LK 2325
=/= 350 410 04 04 1080

MERCEDES-BENZ DO BRASIL S.A.

Service