ZF Ecosplit 8S 16S 151 Repair Manual

®

16 S 151 8 S 151 1315 751 101d

16 S 151 / 8 S 151

Contents Page

Contents ...................................... ............................................................................. ............................................................................. ............................................................ ...................... Preface...................................................................................... Preface............................................... .............................................................................. ...................................................... ............... General information ....................................................................... .............................................................................................................. ................................................ ......... Safety instructions.............................................................. instructions.................................................................................................... ............................................................ ...................... Tightening torques for nuts and bolts............................................. bolts.................................................................................... ................................................ ......... Spring table ........................................................................ .............................................................................................................. ............................................................ ...................... Adjustment data ....................................... ............................................................................. ............................................................................. ................................................ ......... Special tools ...................................... ............................................................................. .............................................................................. ...................................................... ............... View of transmission.......................................................... transmission................................................................................................ ............................................................ ......................

1-01 1-03 1-04 1-06 1-07 1-08 1-09 1-14 1-16

1 1.1 1.1 1.2 1.2 1.3 1.4 1.4 1.5 1.5 1.6 1.6 1.7 1.7 1.8 1.8 1.9 1.9

Removing components/range-change ........................................................................................ Plast Plastic ic pipe pipess .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Outp Output ut flan flange ge .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Cove Coverr ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 5/25/2-wa way y valv valvee .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Shif Shiftt cylind cylinder er for rang rangee-ch chan ange ge ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Hous Housin ing/ g/ra rang ngee-ch chan ange ge .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Plane Planett gear gear train train with with sync synchr hron oniz izer. er... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Asse Assemb mbli ling ng plan planet et gear gear trai train n with with range range-c -cha hang ngee synch synchro roni nize zerr .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Assem Assembl blin ing g rang rangee-ch chan ange ge /hou /housin sing/ g/ou outp tput ut flan flange ge/p /pis isto ton n .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

2-01 2-01 2-01 2-01 2-01 2-01 2-01 2-02 2-02 2-02 2-02 2-03 2-03 2-04 2-04 2-06 2-06 2-09 2-09

2 2.1 2.1 2.2 2.2 2.3 2.3 2.4 2.4

Removing components from centre housing ............................................................................. Spli Splitte tterr (GV) (GV) cylin cylinde derr .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Shif Shiftt hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Shif Shiftt hou housin sing, g, fric frictio tionn-op optim timiz ized ed vers versio ion n .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Shif Shiftt mech mechan anism ism/s /sele elect ctor or pat patte terns rns .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

2-12 2-12 2-12 2-12 2-12 2-16 2-16 2-21 2-21

3 3.1 3.1 3.2 3.2 3.3 3.3

Removing components from clutch housing .............................................................................. Rele Release ase fork fork .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Conn Connec ecti tion on plat platee with with int integ egra rall pump... pump..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Clut Clutch ch hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

2-24 2-24 2-24 2-25 2-25 2-26 2-26

4 4.1 4.1 4.2 4.2 4.3 4.3 4.4 4.4 4.5 4.5 4.6 4.6 4.7 4.7 4.7.1 4.7.1 4.7.2 4.7.2 4.8

Removing components ........................................................................... ................................................................................................................. ...................................... Remo Removi ving ng comp compon onen ents/ ts/cl clut utch ch hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Spli Splitt tter er shif shiftt rail rail /cent /centre re hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Remo Removi ving ng shaf shafts.. ts.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Remo Removi ving ng comp compon onen ents ts/ce /cent ntre re housi housing ng .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Inpu Inputt shaf shaftt .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Main Mainsh shaf aftt .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Assem Assembl blin ing g sync synchr hron oniz izer... er..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Version ersion ZF-BK.... ZF-BK....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... Version ersion ZF-D ZF-D ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... Laysh Layshaft... aft...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...

2-26 2-26 2-26 2-26 2-26 2-27 2-27 2-27 2-27 2-28 2-28 2-30 2-30 2-37 2-37 2-37 2-37 2-38 2-38 2-39 2-39

1-01

Contents

16 S 151 / 8 S 151 Page

5 5.1 5.1 5.2 5.2

Installing components ......................................................................... ............................................................................................................... ......................................... ... 2-41 Cent Centre re hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2-41 2-41 Clut Clutch ch hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-41 2-41

6 6.1 6.1 6.2 6.2

Synchronizer/wear limits ..................................... ............................................................................ ........................................................................ ................................. 2-42 Determ Determin inin ing g wear ear limi limitt (exc (excep eptt 1st 1st and and 2nd 2nd gear gears) s) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-42 2-42 Determ Determin inin ing g wear wear limit limit (1st (1st and and 2nd 2nd gear gears). s)... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2-42 2-42

7 7.1 7.1 7.1 7.1

Adjusting mainshaft ........................................................................ ............................................................................................................... ............................................. ...... 2-43 Sele Select ctin ing g thrus thrustt wash washer er and and shim shim,, straig straight ht-c -cut ut vers versio ion... n..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-43 2-43 Sele Select ctin ing g thrus thrustt wash washer er and and shim shim,, heli helica call-cu cutt vers versio ion n .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-44 2-44

8 8.1 8.1

........................................................................... ............................................................................. ................................................. .......... 2-45 Installing shafts ..................................... Insta Install llin ing g inpu inputt shaf shaft, t, main mainsh shaf aft, t, lays laysha haft ft and and shif shiftt rail railss .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-45 2-45

9 9.1 9.1

.................................... ............................................................................. ................................................ ......... 2-46 Splitter shift fork .......................................................................... Adju Adjust stin ing g shif shiftt fork.... fork...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2-46 2-46

10 10.1 10.1

................................................................................................... ........................... 2-48 Clutch housing/centre housing ........................................................................ Fitt Fittin ing g clutch clutch hous housin ing g to centre centre hous housin ing g .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2-48 2-48

11 11.1 11.1 11.2 11.2

Adjusting shafts ........................................................................ .............................................................................................................. .................................................... .............. 2-49 Input Input shaft shaft ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 2-49 2-49 Laysh Layshaft... aft...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 2-50 2-50

12 12.1 12.1 12.2 12.2

Fitting clutch housing components ............................................................................................. 2-51 Conn Connec ectio tion n plat platee with with inte integra grall pump... pump..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2-52 2-52 Releas Releasee fork fork ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 2-53 2-53

13 13.1 13.1 13.2 13.2 13.3 13.3 13.4 13.4 13.5 13.5

Fitting centre housing components ............................................................................................. Rever Reverse se idler idler gear/r gear/rev evers ersee idler idler pin..... pin........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... Cylind Cylinder.. er..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 5/2-w 5/2-way ay valv valvee ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... Comp Compre resse ssed d air air test test for for pisto piston n and and split splitte terr cyli cylind nder. er... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Inject Injection ion pipe pipe ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..

14

Fitting complete range-change ........................................................................ ................................................................................................... ........................... 2-58

15 15.1 15.1 15.3 15.3

Fitting components......................................................................... ................................................................................................................ .............................................. ....... 2-60 Shift Shift housing housing ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 2-60 2-60 Plastic Plastic pipes pipes ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 2-60 2-60

16

Compressed air test on breather ................................................................................................ 2-61

1-02

2-55 2-55 2-55 2-55 2-55 2-56 2-56 2-56 2-56 2-57 2-57

16 S 151 / 8 S 151

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 t est or However, 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 Service Training Center. Center. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. specialized tools 3. Genuine ZF spares, to our latest specifications

All work performed in 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 personnel in an i mproper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies where genuine ZF spares have not been used.

ZF FRIEDRICHSHAFEN AG

Friedrichshafen Division Service

1-03

General Information

16 S 151 / 8 S 151

Description of transmission

The ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmissions have been developed for heavy goods vehicle applications (from 220 to 370 kW). 16 S 151 and 8 S 151 transmissions main components: - 4-sp 4-spee eed d secti section on wit with h reve revers rsee gear gear - rearrear-mou mounte nted d rangerange-cha change nge of of planet planetary ary desig design n - frontfront-mou mounte nted d integr integrate ated d splitter splitter grou group p (not (not in 8 S 151) ZF Friedrichshafen AG offers the following options with these transmiss ions: - NMV NMV 221, 221, eng engin inee-de depe pend nden entt PTO PTO - torq torque ue con conve verte rterr clut clutch ch (WS (WSK) K) - further further engine-dri engine-driven ven ZF PTO PTO (NMV) together together with the torqu torquee converter converter clutch - vario various us clutch clutch-de -depen penden dentt ZF PTOs PTOs - drive drive for for emerg emergenc ency y / dual-ci dual-circu rcuit it steeri steering ng pumps pumps - separat separatee heat heat exchan exchanger ger for for extre extreme me appli applicat cation ionss - ZF Intarder - ZF ES 2 shif shiftt sys syste tem m - silent kit

Repair manual NOTE: If clamping fixture 1X56 137 944 is used for dismantling dis mantling 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. CAUTION The transmission must not be suspended by the input shaft nor by the output flange when transporting, removing, installing and repairing.

!

ENVIR ENVIRONM ONMENT ENTAL AL HAZARD HAZARD ! Lubricants and cleaning agents must not be allowed allowed to enter the ground, the water table or t he sewage system. • Request safety information for the products concerned from from your local environmental environmental protection authority, and follow any instructions herein at all times. • Alway Alwayss collect used used oil in a suitably suitably large large containe containerr. • Always Always dispose of of used oil, clogged clogged filters, lubricants lubricants and cleaning cleaning agents in accordance with environmental protection laws. • Always Always observe observe manufacturer manufacturer instructions instructions when dealing with lubricants lubricants and cleaning cleaning agents.

NOTE: Additional removal removal and installation instructions 1315 754 007 are available for transmissions with silent kit.

1-04

16 S 151 / 8 S 151

General Information

General This repair manual shows how to repair a ZF ECOSPLIT 16 S 151 / 8 S 151 synchromesh transmission. Layout of repair manual:

Section 1 includes adjustment data, tightening torques, spring characteristics and a list of specified ZF special tools. Section 2 is a step-by-step guide to transmission repairs. Directions for removal and assembly, general work instructions

This repair manual is based on the steps necessary for the complete removal of transmission components and their subsequent reassembly. reassembly. When circumstances require, the assembly procedure for certain components is described immediately after the removal procedure. Such cases include the section on the “mainshaft and layshaft’’, layshaft’’, in which assembly instructions are given after removal instructions so as t o ensure that only fully repaired components proceed to the complete assembly assembly phase. This procedure reduces the risk of mixing up individual components and shortens the overall overall assembly phase. Always Always ensure cleanliness and appropriate high standard of work; therefore, clean all transmissions removed from vehicles before dismantling. Specified ZF special tools must be used. After dismantling, clean all transmission components. Particular attention should be paid to corners, recesses and protruding edges on housings and covers. covers. Carefully remove remove old sealing compound and gaskets. Check for blocked of lubrication oil bores, grooves grooves and pipes. There must be no build-up of deposits, foreign matter or preservatives. This is especially important in the case of new components. It is impossible to avoid damaging some components during dismantling; these must always always be renewed ; e.g.shaft seals, O-rings, grooved rings, flange packing, protective caps etc. Components such as roller bearings, thrust washers, synchronizer parts, etc., which are subject to normal wear during operation, must be checked by a specialist to determine whether they can be reused Gaskets must be fitted dry, i.e. free from oil and grease. Sealing faces without gaskets must be sealed using a plastic-type, heat- oil-resistant sealing compound (e.g. WEVO-L WEVO-L 100 A). During assembly, assembly, observe all adjustment values, test data and tightening torques. Fill the transmission with transmission oil after repair. Procedure for this and permitted oil types are given in the Operating Manual and List of Lubricants TE-ML 02. These documents may be obtained from all ZF After-Sales Service points. After filling with oil, tighten oil check plugs and oil drain plugs to specified torque.

1-05

Work Safety

16 S 151 / 8 S 151

Important work safety notice:

Companies who repair ZF units are responsible for their own work safety. safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. regulations.

Personnel required to carry out repairs on these ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that repair staff is properly trained.

The following safety instructions appear in this manual: NOTE

Refers to special processes, techniques, data, use of auxiliary equipment, etc.

CAUTION

This is used when incorrect, unprofessional working practices could damage the product.

!

DANGER

This is used when lack of care could lead to serious injury or death.

NOTE Read this manual carefully before star ting any tests or repair work. After completion of repair work and testing, skilled mechanics must satisfy themselves that the product is functioning correctly. correctly. CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings drawings and components are not to scale, and no information about size and weight should be inferred (even within a complete illustration). Always follow the working steps as described in the text.

1-06

16 S 151 / 8 S 151

Tightening Torques

Tightening torques for bolts and nuts from ZFN 148

This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934. This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12. Coating ZFB 811 Dacromet or coating ZFB 998 Deltatone - Deltaseal. Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, galvanized, chrome plated and oiled. NOTE: Tightening torques which differ from the values below are separately listed in the repair instructions.

Metric coarse pitch thread

Metric f ine pitch thread

Size

Size

Bolt Nut M 4 M 5 M 6

Tightening torque MA (Nm) for 8.8 10.9 8 10 2.8 5.5 9.5

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

Bolt Nut

12.9 12

4.1 8.1 14

4.8 9.5 16.5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

M 10 x 1.25 M 12 x 1.25 M 12 x 1.5

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

M 14 x 1.5 M 16 x 1.5 M 18 x 1.5

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

M 18 x 2 M 20 x 1.5 M 22 x 1.5

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

M 24 x 1.5 M 24 x 2 M 27 x 1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M 27 x 2 M 30 x 1.5 M 30 x 2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991

1-07

Spring Table

16 S 151 / 8 S 151

Part number

Installation point

0732 07 32 04 040 0 630 630

Shiftt mec Shif mecha hani nism sm:: on shift shaft (depending on version)

6.5

2.4

39.6

89.9

0732 07 32 04 040 0 985 985

Shiftt mec Shif mecha hani nism sm:: spherical roller for detent part or reverse gear interlock (depending on version)

6.5

2.0

14.8

23.4

0732 07 32 04 040 0 986 986

Shiftt mec Shif mecha hani nism sm: spherical roller for detent part or reverse gear interlock (depending on version)

5.5

2.25

14.8

21.6

0732 07 32 04 040 0 984 984

Shiftt mec Shif mecha hani nism sm:: reverse gear interlock (depending on version)

9.5

1.4

9.4

23.3

0732 07 32 04 040 0 736 736

Shiftt mec Shif mecha hani nism sm:: for detent pin and locking pin interlock

13.5

1.6

9.8

36.0

0732 07 32 04 040 0 40 409 9

Synchr Sync hron oniz izer erss input shaft and mainshaft

12.5

1.4

6.65

23.7

0732 07 32 04 042 2 12 126 6

Dete De tent nt pi piec ecee (compression spring)

9.5

1.0

9.4

25.0

0732 07 32 04 042 2 365 365


5.5

1.7

20.44

31.49

0732 07 32 04 042 2 366 366


4.5

1.5

15.03

15.6

0732 07 32 04 042 2 400 400


10.5

2.25

15.5

39.7

0732 07 32 04 042 2 401 401


12.5

1.5

10.1

36.0

1-08

No. of coils

Wire diam. in mm

Spring diam. Untensioned in mm length in mm

16 S 151 / 8 S 151

Adjustment Data

Description

Tolerance

Measuring device

01. Axial play play on layshaft layshaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on output end.

02. Combined Combined axial axial play play of mainshaft and input shaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on input shaft.

03. Axial play play / prestres prestresss of split ring on input shaft and mainshaft (only in older version)

- 0.05 to + 0.05 mm

Micrometer or feeler gauge

Always use correct tool.

04. Insertion Insertion depth depth for shaft shaft seal in output flange cover

12.5 + 1.0 mm

Depth gauge and/or drift 1X56 137 124

Measure depth of insertion between outside of cover and face of shaft seal. If drift is used with ring, depth is automatically given (must be flat).

05. Axial play play on ball ball bearing bearing in cover (range-change)

0 - 0.10 mm

Depth gauge/sliding caliper

Adjust using appropriate shims in cover.

06. Axial play play on helical helical gear gear Min. 0.20 mm on input shaft

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

07. Axial play play on helical helical gears on mainshaft

Min. 0.20 mm



08. Axial play play on 4th-speed 4th-speed helical gear

Min. 0.05 mm



09. Axial play play on circlips circlips on layshaft and mainshaft

0 - 0.05 mm

Micrometer or feeler gauge

Use appropriate circlip.

Feeler gauge


10. Axial play play of reverse reverse idler idler 0.4 - 1.15 mm gear

Remarks

1-09

Adjustment Data

16 S 151 / 8 S 151

Description

Tolerance

Measuring device

Remarks

11. Permitted Permitted axial axial play on planet gears in planet carrier

0.4 to 1.30 mm

Feeler gauge

Tolerance includes permitted wear on thrust washers. If wear limit exceeded exchange thrust washers

Feeler gauge

Exchange synchronizer ring and/or clutch body if dimension too small

12. Wear Wear limit limit for synchronizer ring and clutch body, measured between flat surfaces of ring and body with cones firmly nested together. 4-gear section and splitter Range-change

0.80 mm 1.20 mm

13. Wear limit limit for for 1st/2nd 1st/2nd gear synchronizer parts, measured between outer ring and clutch disc, measured with cones nested firmly together ) and force F = 50 N applied on the outer ring.

1.5 mm

Feeler gauge

Exchange intermediate ring and/or outer ring and inner ring if wear limit is excluded.

14. Max. Max. permi permitte tted d play play on on fulcrum pads in sliding sleeves

0.6 - 1.2 mm

Feeler gauge

Exchange if play is excessive

15. Adjustment Adjustment dimension dimension for 94.0 mm splitter shift fork

Depth gauge

Nominal dimension dimension between between piston and mid-housing mid-housing sealing face without gasket. Fulcrum pads must have play of of min. 0.10 mm mm upwards and downwards. Tightening torque for grub screw: 60Nm

16. Adjusting Adjusting mainshaf mainshaftt and determining thickness of shim and ring (in straightcut version)

Depth gauge

Measured between upper edge of clutch body with ring inserted and midhousing with gasket attached. Select appropriate ring to ensure nominal dimension (see table)

1-10

32.20 - 0.5 mm

16 S 151 / 8 S 151

Description

Adjustment Data

Tolerance

Selection of ring and shim

Measuring device

Remarks

Sliding caliper

Ring

Shim

3.6 mm

7.9 mm

4.0 mm

8.3 mm

Table shows which shim is correct for which ring 17. Adjusting mainshaft and determining thickness of ring and shim (in helicalcut version)

+ 0.07 to - 0.08 mm (Shim) 4.6-0.4 mm (Ring)

Depth gauge

Measure and determine thickness of shim first. Then, measure and select ring.

18. Temperature Temperature for shrinkshrinkfitting helical gears onto layshaft

160 - 180 °C

Temperature probe

Gears and shaft seats must be free of oil and grease during assembly

19. Tightening Tightening torque torque for breather

10 Nm

Torque wrench

20. Tightening Tightening torque torque for for M12 x 1.5 screws in housing

30 Nm

Torque wrench

Use new seal rings

21. Tightening Tightening torque torque of union screws for plastic pipes

35 Nm

Torque wrench

Use new seal rings

22. Tightening Tightening torque torque for detent plungers

50 Nm

Torque wrench

Use new seal rings

23. Tightening Tightening torque torque for pressure switch/impulse sensor

50 Nm

Torque wrench

Use new seal rings

24. Tightening Tightening torque torque of M12 M12 bolts for output flange

60 Nm/120 Nm (chap. 1.9.1)

Torque wrench

Fit new retaining plate. Use Loctite No. 262.

25. Tightening Tightening torque torque for shift fork grub screws

4-gear 4-gear secti section: on: 50 Nm Splitter: 60 Nm

Torque wrench

1-11

Adjustment Data

16 S 151 / 8 S 151

Description

Tolerance

Measuring device

Remarks

26. Tightening Tightening torque torque for for M38 x 1.5 magnetic screw

140 Nm

Torque wrench

Clean magnet and fit new seal ring

27. Tightening Tightening torque torque for locking bolts on reverse idler pin New version with slotted pin

86 Nm

Torque wrench

Use new bolt and washer.

28. Tightening Tightening torque torque for locking nuts on rangechange and splitter pistons

150 Nm

Torque wrench

Use new locking nut

29. Tightening Tightening torque torque for for hex bolts between clutch housing and mid-housing

50 Nm

Torque wrench

30. Tightening Tightening torque torque for M18 x 1.5 screw plugs on housing

35 Nm

Torque wrench

Use new seal rings


50 Nm

Torque wrench

Use new seal rings


60 Nm

Torque wrench

Use new seal rings

33. Heating Heating temperature temperature for for ring gear

60 °C

Temperature probe

Do not exceed temperature

34. Temperature Temperature of synchrosynchronizer hub, clutch body, bushes and counting disc

120 °C

Temperature probe


35. Temperature Temperature of of output output flange

Max. 70 °C

Temperature probe


36. Temperature Temperature of of input input shaft roller bearing

100 °C

Temperature probe


1-12

16 S 151 / 8 S 151

Adjustment Data

Description

Tolerance

Measuring device

Remarks

37. Temperature Temperature of of 4th-speed 4th-speed helical gear with needle cages on mainshaft

120 °C

Temperature probe


38. Rolling-in Rolling-in torque torque for injection pipe

5 - 6 Nm

Torque wrench

Rolling-in tool 1X56 155 653

39. Lifting Lifting device device for input input shaft/ mainshaft/ layshaft

85 Nm

Torque wrench

DANGER Fit lifting device carefully

40. Tightening Tightening torque torque for pivot bolts on shift fork

250 Nm

Torque wrench

Use Loctite No. 241

41. Tightening Tightening torque torque for for M8 hex bolts on shift cover

23 Nm

Torque wrench

42. Tightening Tightening torque torque for M10 hex bolts on shift lever

49 Nm

Torque wrench

43. Tightening Tightening torque torque for for M8 hex bolts on shift housing cover (with detent piece)

23 Nm

Torque wrench

44. Tightening Tightening torque torque for for M8 hex bolts on cutoff valve

23 Nm

Torque wrench


70 Nm

Torque wrench

Use new seal rings


150 Nm

Torque wrench

Use new seal rings

1-13

Special Tools

4 2 1 7 3 1 6 5 X 1

1 9 9 7 3 1 6 5 X 1

6 4 2 7 3 1 6 5 X 1

0 2 9 7 3 1 6 5 X 1

5 7 6 7 3 1 6 5 X 1

9 7 5 7 3 1 6 5 X 1

0 1 7 6 3 1 6 5 X 1

7 8 2 7 3 1 6 5 X 1

1 3 7 6 3 1 6 5 X 1

8 1 9 7 3 1 6 5 X 1

9 4 9 7 3 1 6 5 X 1

4 0 3 2 2 1 6 5 X 1

2 2 1 7 3 1 6 5 X 1

4 6 5 6 3 1 6 5 X 1

1-14

16 S 151 / 8 S 151

3 0 3 2 2 1 6 5 X 1

3 7 5 6 3 1 6 5 X 1

3 3 9 7 3 1 6 5 X 1

1 2 9 7 3 1 6 5 X 1

16 S 151 / 8 S 151

2 0 0 3 7 5 6 1 1 X

0 0 2 7 3 1 6 5 X 1

Special Tools

3 5 6 5 5 1 0 2 X 1

1 5 6 7 3 1 6 5 X 1

4 1 3 2 2 1 6 5 X 1

5 3 8 7 3 1 6 5 X 1

7 1 9 7 3 1 6 5 X 1

6 1 9 9 1 1 6 5 X 1

6 7 6 7 3 1 6 5 X 1

6 2 5 9 0 0

3 4 7 6 3 1 6 5 X 1

3 6 0 8 3 1 6 5 X 1

0 1 3 2 2 1 6 5 X 1

9 7 0 8 3 1 6 5 X 1

9 0 1 8 3 1 6 5 X 1

6 6 7 3 0 1 6 5 X 1

4 6 0 8 3 1 6 5 X 1

2 2 7 6 3 1 6 5 X 1

9 9 5 6 3 1 6 5 X 1

1-15

View of Transmission

16 S 151 / 8 S 151

00 795

1-16

16 S 151 / 8 S 151 1.

Remo Re movi ving ng co comp mpon onen ents ts/r /ran ang gee-ch chan ang ge

1.1

Plastic pi pipes

Removing Range-Change

3 6

NOTE: Label plastic pipes before removing to ensure correct cor rect re-assembly. re-assembly.

1

Unscre Unsc rew w uni nion on sc scre rews ws (1 an and d 2) fro rom m ran ange ge-change cylinder (3) and cutoff valve (4). Loosen pipe clip (5) on housing and remove remove complete together with plastic pipes (6).

5 2

6

1

2

4

1 001992

1.2

Output fl flange

1

Leve Le verr of offf re reta tain inin ing g pl plat atee (1 (1)) fr from om bo bolt ltss (2) (2)..

2

Secu Se cure re ou outp tput ut fl flan ange ge to pr preeve vent nt it fr from om tu turn rnin ing. g.

3

Unscre Unsc rew w hex hex bo bolt ltss (2) (2) an and d rem remo ove cla clamp mpin ing g dis discc (3).

4

Placee ad Plac adap apte terr on onto to pl plan anet et ca carr rrie ierr an and d re remo mov ve output flange (4) using 2- or 3-leg puller

5

Remove O-ring (5).

5

4

3

2

1

001902

1.3

Cover

1

Unscre Unsc rew w hex hex bo bolt ltss fro from m co cover (1 (1)) and and re remo move ve together with gasket (2).

2

Unscre Unsc rew w hex hex bo bolt ltss and and rem remo ove co cov ver (3 (3)) to toge geth ther er with gasket (4), shaft seal (5), shim (6) and ball bearing (7).

3

7

6

1

4

3

5

Using Usin g pla plast stic ic dr drif ift, t, dr driive out out ba ball ll be bear arin ing g fro from m cover. and remove loose shim. NOTE: For helical gear version, use extractor 1X56 122 314 to remove ball bearing from output shaft.

4

2

001903 001903

Usin Us ing g pla plast stic ic dri drift ft,, dri driv ve out out shaf shaftt seal seal fro from m cov cover er..

2-01

Removing Range-Change 1.4

5/2-way valve

1

Unsc Unscre rew w 5/2 5/2-w -waay val valv ve (1) (1) from from cent centre re hous housin ing. g.

2

Remove O-rings (2).

16 S 151 / 8 S 151

NOTE: Do not dismantle 5/2-way valve since it is a complete part. NOTE: 5/2-way valve valve is not included i n 8 S 151 transmission.

2

1

001904 001904

1.5 1.5

Shif Shiftt cyl cylin inde derr for for rang rangee-ch chan ange ge

1

Unsc Unscre rew w hex hex bolt bolts, s, loos loosen en cylin ylinde derr (1) (1) from from range-change housing and remove from piston (2).

2

Remo emove O-r O-rin ings gs (3 and and 4) 4) fro from m cy cylin linder der.

3

Remo Remov ve det deten entt plu plung nger er (5). (5). Scre Screw w fixi fixing ng devi device ce into threaded bore and position 1X56 137 579 fixing element on shift rail (6). Tighten fixing device. Tightening torque = 50 Nm.

4

Unsc Unscre rew w loc locki kin ng nu nut (7) (7) from from pist piston on (2) (2).

5

Remo Remov ve pis pisto ton n to togeth gether er with with guid guidee rin ring g (8) (8) and and grooved ring (9).

6

10 11

2

8

11

Remo Remov ve gui guide de ring ring and and gr groov ooved ring ringss fro from m piston.

8

Pull Pull out out fla flang ngee pac packi king ng (10) (10) from from rang rangee-ch chan ange ge housing.

1

3

10 2

9 9 8

7

Remo Remove ve groo groov ved ring ring (9) (9) and and seal seal ring ring (11, (11, new new version only) .

7

7 4

1

4

3

5

6 001905

2-02

16 S 151 / 8 S 151 1.6 1.6

Hous Housin ing/ g/ra rang ngee-ch chan ang ge

1

Remo Remov ve mec mecha han nical ical spee speedo dome mete terr or or imp impul ulse se sensor (15).

2

Remo Remov ve pi pivot bol bolts ts (1) (1) for for shif shiftt for fork k (2) (2)..

3

Remove f ix ixing device 1X56 137 579.

4

Unsc Unscre rew w hex hex bolt boltss from from rang rangee-ch chan ange ge hous housin ing g (3).

Removing Range-Change

1

12

4

15

!

DANGER Planet gear train is not secured on mainshaft. Secure this to prevent from falling.

5

6

Remo Remov ve shi shift ft fork fork (2) (2) to togeth gether er with with fulc fulcru rum m pad padss (6).

7

Remo Remov ve inte interm rmed edia iate te plat platee (7) (7) toge togeth ther er with with gaskets (8).

8

Remo Remov ve swi switc tch h (9) (9) toge togeth ther er with with seal seal ring ring and and pin pin (10). New version (13 and 14) also possible.

9

Pull Pull out out shif shiftt rail rail (11) (11) from from cent centre re hous housin ing. g.

10

Remo Remov ve inj injec ecti tio on pip pipee (12 (12). ).

3

4 2

Sepa Separa rate te rang rangee-ch chan ange ge hous housin ing g (3) (3) from from cent centre re housing (5) without tilting and remove. Use pins to ensure correct position (4).

6

4

1

8 7 8

13 5

14

11 9 10 001906

2-03

Removing Planet Gear Train 1.7 1.7

1

16 S 151 / 8 S 151

Plan Planet et gea gearr tra train in wit with h syn synch chrroniz onizer er NOTE: Prevent planet gear train from falling out when removing.

4

Remo Remov ve com compl plet etee pla plane nett gea gearr tr train ain fro from m mainshaft together with synchronizer. synchronizer.

5 3*

1.7. 1.7.1 1 Sync Synchr hron onize izerr

2

!

DANGER Pressure pieces are under spring pressure. pressure. Secure them to prevent them flying out.

1

Plac Placee ada adapt pter er onto onto plan planet et carr carrie ierr. Att Attac ach h tw two-or o-or three-leg puller underneath sliding sleeve sl eeve (1) and pull off together together with clutch body (2). Use a cloth to catch pressure pieces (4) and pressure springs (5) held by the sliding sleeve. s leeve.

7 8

6

1 10

9

11

NOTE: In the straight-cut version, pull off speedo worm or counting disc (3) with integrated bush together with clutch body (2). (2). 001907

NOTE: Parts marked * according to parts list.

2

Remove synchronizer ring (6).

3

Remove circlip (7).

4

Plac Placee ada adapt pter er onto onto plan planet et carr carrie ierr and and pull pull off off synchronizer hub (8) using 2- or 3-leg puller. puller.

5

Remo Remov ve syn synch chro roni nize zerr ring ring (9) (9) and and clut clutch ch body body (10) from planet carrier (11).

2-04

16 S 151 / 8 S 151

Removing Planet Carrier

1.7. 1.7.2 2 Ring Ring gear ear

1

Atta Attach ch circ circli lip p (7) (7) from from Sect Sectio ion n 1.7. 1.7.1 1 ont onto o rin ring g gear carrier. Place adapter onto planet carrier and fit using 2- or 3-leg puller underneath circlip.

2 1

Straight-cut version:

2

Pull Pull of off rin ring g gea gearr (1) (1),, rin ring g gea gearr carr carrie ierr (2) (2) and and bal balll bearing (5) together. together.

3

Deta Detach ch safe safety ty wire wire (4) (4) from from annu annula larr gro groo ove in ring gear.

4

Usin Using g pla plast stic ic hamm hammer er,, dri driv ve out out ring ring gear gear carr carrie ier r (2) from ring gear (1).

5

Deta Detach ch snap snapri ring ng (3) (3) from from ring ring gear gear carr carrie ierr and and remove remove ball ball bearing (5).

6

Remo Remove ve inte interm rmed edia iate te ring ring (6) (6) fro from m pla plane nett car carri rier er..

6

4

3

5

001908

Helical-cut version:

2

3

4

Pull Pull off off ring ring gear gear (1), (1), ring ring gear gear carr carrie ierr (2) (2),, intermediate ring (3) and axial needle bearing (5) together.

2 1

Deta Detach ch safe safety ty wire wire (4) (4) fro from m ann annul ular ar groo groove ve in ring gear.

3

5

009518

1.7. 1.7.3 3 Plan Planet et carr carrier ier

1

Dri Drive do dowels els (1) (1) full fully y int into o pla plane nett pin pin (2). (2).

2

Usin Using g pla plast stic ic drif drift, t, dri drive out out pla plane nett gea gearr pin pin from from planet carrier (3) towards towards “input’’. “input’’.

3

(5)

6 6 7

4

(5) 7 6

Rem Remove pla plan net gear gear (4) from rom pla plane nett car carri rier er together with thrust washers (5). 1

NOTE: Thrust washers (5) in straight-cut version only.

4

Remo Remov ve shi shims ms (6) (6) and and cylin ylinde derr rol rolle lers rs (7) (7) fro from m planet gear. gear.

5

Dri Drive out out dowels els (1) (1) from rom plan planet et pin. pin.

3 2

Repeat steps 1) to 5) for remaining planet gears. 009525

2-05

Assembling Planet Carrier 1.8 1.8

16 S 151 / 8 S 151

Asse Assemb mbli ling ng pla plane nett gear gear tra train in with with ran range ge-change synchronizer synchronizer

1.8. 1.8.1 1 Plan Planet et carr carrie ierr NOTE: Always Always exchange planet gears as complete sets.

1

Coat Coat face facess of of pla plane nett gea gears rs and and cyl cylin inde derr roll roller er raceways raceways with operating oil.

2

Stan Stand d pla plan net gear gear pin (1) (1) so so tha thatt col colla larr fac faces es downwards.

3

Slid Slidee thr thrus ustt was washe herr (2) (2) over plan planet et pin. pin. Ensu Ensure re coated side (bright side) faces towards planet gear.

(2)

3

5

4

3

5

3

(2)

1

009513

NOTE: Thrust washers (2) in straight-cut version only.

4

Slid Slidee shi shim m (3) (3) over ver pla plane nett gea gearr pin pin (eit (eithe herr wa way up).

5

Plac Placee pla plane nett gea gearr (4) (4) onto onto plan planet et pin pin (1) (1) and and ali align gn centrically.

6

Inse Insert rt 14 cylin ylinde derr rol rolle lers rs (5) (5) int into o pla plane nett gea gearr and and slide shim (6) over planet pin.

7

Coat Coat insi inside de of the the pla plane nett gea gearr wit with h ope opera rati ting ng oil oil and insert remaining 14 cylinder rollers.

8

Coat Coat cyli cylind nder er roll roller erss wit with h ope opera rati ting ng oil oil and and fit shim.

9

Fit Fit thr thrus ustt was washe herr on on pla plane nett gea gearr. Ens Ensur uree coa coate ted d side faces towards towards planet gear.

10

Stan Stand d pla plane nett carr carrie ierr (7) (7) on on shaft shaft secti section on..

11

Care Carefu full lly y remo remove ve pla plane nett gear gear and and thru thrust st wash washer erss from planet pin and slide into planet carrier.

12

Alig Align n pla plane nett gear gear wit with h bea beari ring ng bor boree (8) (8).. NOTE: Ensure “0” face of planet pin faces towards towards outside radius of planet carrier. (Oil bore must face towards the inner radius of planet carrier).

13

Radi Radiall ally y alig align n plan planet et pin pin and and inse insert rt int into o bea beari ring ng bore.

14

Using Using plas plastic tic hamm hammer er,, driv drivee in plan planet et pin pin.. Che Check ck for alignment with dowel dowel bore

10 9 8

7

(2) (2)

009505 009505

2-06

16 S 151 / 8 S 151 15

Driv Drivee new new dow dowel (9) (9) hal halfw fwaay into into hol hole. e. Dri Drive ve 2nd 2nd (new) dowel dowel (10) into 1st dowel with slot offset 180°. Drive both dowels approx. 0.5 mm into planet carrier (refer to Assembly Specification) .

16

Chec Check k axia axiall pla play on on pla plane nett gear gearss (0.4 (0.4 to to 1.3 1.3 mm) mm)..

Assembling Planet Carrier

Repeat steps 1) to 16) for remaining planet gears.

1.8. 1.8.2 2 Ring Ring gear gear

1

Plac Placee int inter erme medi diat atee rin ring g (2) (2) onto onto plan planet et carr carrie ierr (1) (1).. Ensure oil g rooves rooves face towards towards output end (only in straight-cut version).

2

Dri Drive rin ring g gea gearr car carri rier er (3) (3) flu flush sh into into ring ring gear gear (4). (4).

3

Inse Insert rt safe safety ty wire wire (5) (5) int into o ann annul ular ar groo groov ve in in rin ring g gear. Ensure entire safety wire is firmly seated.

2 1

6 5 3

Straight-cut version:

4

7

4

Inse Insert rt ball ball bear bearin ing g (6) (6) into into ring ring gear gear carr carrie ierr and and attach snapring (7). Select snapring so as to ensure ball bearing axial play of 0.0 to 0.1 mm. Snaprings are available in 0.1 mm thicknesses (0.1, 0.2, 0.3 etc.). 001912

Helical-cut version:

4

Slid Slidee int inter erme medi diat atee rin ring g (7) (7) and and ax axial ial nee needl dlee bearing (6) onto planet carrier. carrier.

1

!

DANGER Always wear protective gloves when handling heated ring gear. gear.

7 5

Heat Heat com compl plet etee ring ring gea gearr to 60° 60° C and and plac placee onto onto planet carrier. Rotate ring gear to bring bring teeth into mesh. Ensure bearing (6) is firmly seated.

6

5 3 4

009506

2-07

Assembling Planet Carrier

16 S 151 / 8 S 151

1.8. 1.8.3 3 Sync Synchr hron onize izerr

2 1

Chec Check k wea wearr lim limit it of syn synchro chron nizer izer part parts, s, see see Section 6.

2

Plac Placee clu clutc tch h bod body y (1) (1) and and syn synch chro roni nize zerr rin ring g (2) (2) onto planet carrier.

1

!

DANGER Always wear protective gloves when handling heated synchronizer hub.

3

Heat Heat sync synch hron ronizer izer hub hub (3) (3) to app approx. rox. 120 120° C and and push on until firmly seated. Ensure long hub side faces towards planet carrier. Synchronizer ring lugs must engage into recesses in the synchronizer hub.

4

Atta Attach ch circ circli lip p (4) (4) into into annu annula larr groo groove ve.. Axi Axial al pla play must be 0.0 to 0.1 mm. Circlips are available available in 0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).

5

Plac Placee sli slidi ding ng slee sleev ve (5) (5) onto onto sync synchr hron oniz izer er hub hub (3) (3) with collar side facing towards output end. NOTE: Recesses in sliding sleeve must be aligned with recesses in synchronizer hub.

6

Inse Insert rt new new com compr pres essi sion on spri spring ngss (6) (6) and and pre press ssur uree pieces (7) into synchronizer hub (3) and, and, using suitable tool, insert into sliding sleeve (5).

7

Plac Placee syn synch chro roni nize zerr rin ring g (8) (8) onto onto sync synchr hron oniz izer er hub hub (3). NOTE: Synchronizer ring lugs (8) must engage into recesses in the synchronizer hub (3).

8

Brin Bring g sli slidi ding ng slee sleev ve (5) (5) into into cent centre re posi positi tion on by pressing synchronizer ring against synchronizer hub. Engagement of presssure pieces can be clearly heard. !

DANGER Always wear protective gloves when handling heated clutch body and counting disc.

9

Heat Heat clu clutch tch bo body (9) to appr appro ox. 120° 20° C an and pus push h flush onto planet car rier.

10

Heat Heat spee speedo do worm/c orm/cou ount ntin ing g disc disc (10) (10) to to app appro rox. x. 120° C and push push onto planet carrier. Ensure sensor lugs face towards towards planet carrier. car rier. NOTE: Speedo worm and counting disc (10) in straight-cut version only.

2-08

9 5

7 3

6

10

8 4

001913

16 S 151 / 8 S 151 1.9

Assembling Range-Change

Assemb Assemblin ling g range range-ch -chang angee /housi /housing/ ng/ output output flange/piston

21

10 1

Plac Placee int inter erme medi diat atee pla plate te (1) (1) on onto plan planet et carrier/clutch body (2).

2

Inse Insert rt shif shiftt for fork k (3) (3) and and ful fulcr crum um pads pads (4) (4) int into o sliding sleeve (5).

22

1

7

6

WI 9

8 

3

Plac Placee ne new gas gaske kett (6) (6) onto onto inte interm rmed edia iate te plat platee (1) (1) and position.

4

Inse Insert rt shif shiftt rai raill (11 (11)) fro from m ins insid idee of of hou housi sing ng and and position roughly. roughly.

5

Inse Insert rt inje inject ctio ion n pipe pipe (2) into into hou housing sing..

6

Plac Placee hou housi sing ng (7) (7) ont onto o int inter erme medi diat atee pla plate te (1), (1), fit gasket and position. Check radial position of shift fork and engage.

W II 9

20

NOTE: When using a new housing (7), drive in ball (8) in accordance with selector pattern I or II.

7

10

Coat Coat piv pivot bolt boltss (10 (10)) wit with h Loct Loctit itee No. No. 241, 241, fit spring washers and insert. Position shift fork (3). NOTE: Pivot bolt tightening torque = 250 Nm. Tighten when range-change is fitted.

8

9

Coat Coat new new fla flang ngee pack packin ing g (12) (12) with with spir spirit it,, slid slidee over over shift rail (11) and, using soft drift, drive in until flush. Plac Placee pis pisto ton n (13 (13)) ont onto o shi shift ft rail rail the the cor corre rect ct way up together with guide ring (14) and new grooved grooved rings (15).

5 2

Tight ighten en new new loc locki king ng nut nut onc oncee ran range ge-c -cha hang ngee is is fitted. Tightening torque = 150 Nm. NOTE: Installation of range-change cylinder is only possible once range-change has been subassembled on centre housing. Thread must be absolutely free of oil and grease.

11

16

14

19

18

24

13 12 23

NOTE: in the new version, place seal ring (23), piston (13) with guide ring (14) and seal ring (24) onto shift rail.

10

3

4

17 19

18 15 14 12 13

15

16

17

Grea Grease se new new O-r O-rin ings gs (17 (17 and and 18) 18) and and inse insert rt int into o correct annular groov g rooves es (in cylinder and housing). NOTE: Mounting switches (21 and 22) if required, required, see page 2-59, work step 16.

12

Care Carefu full lly y slide slide cyl cylin inde derr (19) (19) ove overr pisto piston n toge togeth ther er with guide ring and piston gasket. Fix cylinder using two hex bolts.

11

NOTE: Align the compressed air bores. 009942

2-09


16 S 151 / 8 S 151

Measuring ball bearing axial play (nominal: 0 to 0.1 mm)

13

29 26

Fit new Fit new gask gasket et (25 (25)) ont onto o new new cov cover er (2 (26) 6) an and d measure insertion depth of cover together with gasket, e.g. 23.40 mm.

14

Measur Meas uree ext extra ract ctio ion n dep depth th be bear arin ing g sea seatt dep depth th of housing (7), (without gasket), e.g. 7.00 mm.

15

Measur Meas uree widt width h of of bal balll bea beari ring ng (2 (28) 8),, e.g. e.g. 30.00 mm.

25 27 28

Example

23.40 mm insertion depth - cover + 7.00 mm insertion depth - housing 30.40 mm

001915

– 30.00 mm width of ball bearing = 0.40 mm axial play without shim i.e. a 0.3 to 0.4 mm shim (27) is required to give axial play of 0 to 0.1 mm. !

DANGER Always wear protective gloves when handling heated cover.

16

Heat co Heat cove verr (26 (26)) to to app appro rox. x. 60 60°° C and and in inse sert rt correct shim (27) and ball bearing (28).

17

Drivee in Driv in sh shaf aftt sea seall (29 (29)) usin using g spe speci cial al to tool ol 1X56 137 124. NOTE: Only use special tool with 12.5 mm wide ring. Installation dimension = 12.5 + 1.0 mm between edge of cover and shaft seal. Thinly coat outside of shaft seal with sealing compound. Lubricate outside of shaft seal with rubber surround using soap wash.

18

Fit cov Fit cover er (2 (26) 6) wit with h new new ga gask sket et (2 (25) 5) an and d tig tight hten en using hex bolts and washers. Tightening torque = 49 Nm.

19

Fit cov Fit cover er (3 (30 0) wit with h new new ga gask sket et.. Tightening torque = 79 Nm.

30

26 25

001916

2-10

16 S 151 / 8 S 151


1.9. 1.9.1 1 Ou Outp tput ut flan flange ge

1

Lightly oil sha shaft sea seal in cover. !

DANGER Always wear protective gloves when handling heated output flange.

2

Heat output flange (1) to max. 70° C.

3

Push Push outp output ut flan flange ge flus flush h ont onto o pla plane nett car carri rier er shaf shaft. t.

4

Pull Pull on outp output ut flan flange ge unti untill flu flush sh usin using g dis discc (2) (2) and two standard M12x75 hex bolts.

5

Remove disc and bolts.

6

Ligh Lightl tly y oil oil new new O-ri O-ring ng (3) (3) and and inse insert rt into into gap gap between output flange and planet carrier shaft.

7

Inse Insert rt disc disc (2) (2) into into outp output ut flan flange ge and and atta attach ch to planet carrier using locking screws. Tightening torque (straight-cut version) = 60 Nm Tightening torque (helical-cut version) = 120 Nm. If required, use flange holder to prevent flange from turning. Insert locking screws with Loctite 262.

8

Using special tool 1X56 137 246 (straight-cut version) 1X56 137 651 (helical-cut version), drive new retaining plate (4) flush onto bolt heads.

1

3

2

4

001917

2-11

Removing Shift Housing 2

Rem Removin oving g co compon mponen entts ffro rom m cen centr tree hou houssing ing

2.1

Split litter ter (GV (GV)) cy cylin linder

1

Remove cylinder (1) by hand.

2

Remo Remove ve dete detent nt plun plunge gerr (9) (9) toge togeth ther er with with circ circli lip. p. Insert fixing device 1X56 137 579.

3

Remove locking nut (2 (2).

4

Remove spr spring (8) from housing.

5

Remov emovee pist piston on (3) (3) fro from shif shiftt rail rail (4) (4).

6

Remo Remove ve doub double le-g -gro roov oved ed ring ring (5) (5) from from pist piston on..

7

Remov emovee two two O-ri O-ring ngss (6 (6 and and 7) from rom cy cylin linder. der.

16 S 151 / 8 S 151

4 1

9 5

3

2

6

8 7 001918 001918

NOTE: There may be three O-rings in the cylinder.

2.2

Shift ho housing

14 1

Unsc Unscre rew w hex hex bolt boltss fro from shif shiftt hous housin ing. g.

2

Take Take off off comp comple lete te shif shiftt hou housi sing ng (1) (1) and and remo remove ve gasket (2).

3

Remo Remove ve swit switch ch (3) (3) toge togeth ther er with with seal seal ring ring and and pin.

4

Unsc Unscre rew w cov cover er (4) (4) tog toget eth her with with gask gasket et..

5

Rem Remove ove shi shift ft deten etentt (5) (5) and and was washe herr (6) (6) from rom detent piece (7). See Figure 001920.

6

Loos Loosen en shif shiftt lev lever er (8) (8) and and remo remove ve toge togeth ther er with with protective cap (9). Mark selector shaft for installation.

7

Remo Remove ve scre screw w plu plug g (10 (10)) tog toget ethe herr wit with h sea seall spr sprin ing g (11) and pin (12).

8

Unsc Unscre rew w cuto cutoff ff valv valvee (13) (13) and and remo remove ve toge togeth ther er with O-ring. NOTE: In new version, remove reverse gear switch (14) together with seal ring.

2-12

4

3 13

11

1

12 2

10

9

8 001919

16 S 151 / 8 S 151 9

Unsc Unscre rew w hex hex bolts olts from rom shi shift ft cove coverr (15 (15)) and and remove together with gasket.

10

Driv Drivee out out bush bush (16) (16),, wip wiper er (17) (17),, sha shaft ft seal seal (18 (18)) and bearing bush (19) from shift cover.

11

Driv Drivee pin pin (20 (20) tow towar ards ds cove cover. r.

12

Remo Remove ve cove coverr (21 (21)) fro from m shi shift ft hous housin ing g tog toget ethe her r with compression springs (22), detent piece (23) and O-ring (24).

13

Driv Drivee out out dowe dowels ls (25) (25) from from dete detent nt piec piecee and and remove compression springs (26) together with washers (27).

14

Driv Drivee out out dowe dowels ls (28) (28) from from driv driver erss (29 (29)) and and selector shaft (30).

15

By hand hand,, pull pull out out sele select ctor or shaf shaftt (30) (30) in dir direc ectio tion n of shift output.

16

Remo Remove ve loc locki king ng piec piecee (31 (31)) and and dri drive vers rs fro from m shif shiftt housing.

17

Remo Remove ve pin pins (32 (32)) if if nec neces essa sary ry.. NOTE: Clamp pins in vice using aluminium clamping jaws and remove by striking shift housing.

18

Removing Shift Housing

16 15 19 18 17

20

7 6

22 5

21

24

23

Driv Drivee out out need needle le slee sleeve ve (33) (33) from from shif shiftt hou housi sing ng.. 25 27

26 27

33 30

32

28 29 31

001920 001920

2-13

Assembling Shift Housing

16 S 151 / 8 S 151

2.2.1 2.2.1 Assemb Assemblin ling g shift housi housing ng

1

Using special tool 1X56 119 916, driv drivee new needle sleeve (1) into shift housing (2). Strike thicker coated side of needle sleeve.

2

Drive pins (3 (3) int into sh shift ho housin sing.

3

Inse Insert rt driv driver er (4) (4) and and lock lockin ing g pie piece ce (5) (5) int into o shi shift ft housing the correct way round.

4

Insert se selector sh shaft (6 (6).

5

Using special tool 1X56 119 916, drive new bearing bush (7) into shift cover.

6

Using special tool 1X56 119 916, drive shaft seal ring (8) into shift cover. Sealing lip must face towards cover.

7

Using special tool 1X56 119 916, drive scraper disc (9) into shift cover. Sealing lip must point outwards.

1 2 3

12

4

5

NOTE: Smear shaft seal and wiper with sealing compound and install. Fill the gap between shaft seal and wiper with grease.

8

Push Push bush bush (10) (10) into into shif shiftt hou housi sing ng (2) (2) and and slid slidee shift cover (11) and new gasket over selector shaft (6) until flush. Do not damage sealing lips.

9

Bolt olt sh shift ift cov cover er (11) (11) onto onto shif shiftt hou housi sing ng.. Tightening torque = 23 Nm.

10

Driv Drivee one one dowel dowel (12) (12) thro throug ugh h dri drive verr (4) (4) and and int into o selector shaft. Drive second dowel (12) into first, making sure slot is offset. (Refer to Assembly Specification)

11

7 8 9 2

6 10

001921

2-14

16 S 151 / 8 S 151

Assembling Shift Housing/Detent Piece

2.2.2 Detent Detent piece with compr compressio ession n springs springs

1

Plac Placee was washe herr (1) (1),, com compr pres essi sio on spr sprin ing g (2) (2) and and second washer (1) onto selector shaft (3). Drive in pins (8) if necessary.

2

Plac Placee shi shift ft dete detent nt (6) (6) wit with h was washe herr (7) (7) into into dete detent nt piece (4).

3

Plac Placee det deten entt pie piece ce (4), (4), shif shiftt det deten entt (6) (6) and and was washe her r (7) onto selector shaft against spring pressure and drive in dowels (5) offset. NOTE: Axial play between detent piece and pins must be 0.1 mm. Adjust if required using washer (7) of different thickness. Washers are available in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.). Grease shift detent (6) and pins (8).

4

4

2 1

6

7 18

14 8 11

17

15 10

3

13

16

12

Bolt Bolt on cove coverr (9) (9) toge togeth ther er with with new new gas gaske ket. t. Tightening torque = 23 Nm. NOTE: In the new version of the cover (a), screw in reverse gear switch (24) and new seal ring (25). In the old version, the reverse gear switch is on the centre housing (see page 2-59, items 20 and 21).

5

Inse Insert rt cove coverr (10 (10)) int into o shi shift ft hous housin ing g tog toget ethe herr wit with h compression springs (11), detent piece (12) and O-ring (13). Drive pin (14) into shift housing (countersink approx. 5 mm) and fit new cover (countersink approx. 2 mm).

6

Fit Fit pin pin (15) (15),, spr sprin ing g (16 (16)) and and scre screw w plu plug g (17 (17)) wit with h new sealing ring and screw into shift housing. Tightening torque = 60 Nm.

7

5 1

Fit Fit cut cutof offf val valve ve (18) (18) with with new new O-r O-rin ing g and and scre screw w onto shift housing. Tightening torque = 23 Nm.

8

Inse Insert rt pin pin (19 (19)) int into o cov cover er and and scr screw ew in swit switch ch (20) (20) together with new sealing ring (21). Tightening torque = 50 Nm.

9

Slid Slidee pro prote tect ctiv ivee cap cap (22) (22) onto onto sele select ctor or shaf shaftt (3) (3) and position shift lever (23) on selector shaft shaft depending on shift version. Tightening torque for hex bolt and nut on shift lever = 49 Nm. Protective cap must sit on selector shaft without play.

24

25 19

21

20

9

22 23

001922

2-15

Shift Mechanism 2.3

Removi Removing ng and disman dismantli tling ng fricti frictionon-opt optimi imized zed shift housing (illustrations show superimposed “H” shift pattern)

1

Loo Loosen sen hex hex bolt boltss (1) (1) and and rem remov ovee shi shift ft tur turret ret together with gasket (2).

2

Loos Loosen en shif shiftt lev lever er (3) (3) (de (depe pend ndin ing g on on par parts ts list list)) and remove together with protective cap.

3 4

16 S 151 / 8 S 151

Remov emovee det deten entt plu plun nger ger (4) (4) and and scr screw ew plug plug or switch (5).

12

14

1

6

5 8

7

4 9 13

11

15 2

Take Take out out cut cutof offf val valve ve and and remo remove ve toge togeth ther er with with O-ring (7).

3

NOTE: Cutoff valve is a complete component and is not dismantled. In the version with double “H” shift pattern, there are 2 ball rollers (8) in the cutoff valve.

5

Remo Remove ve scre screw w plu plug g (9) (9) toge togeth ther er with with seal seal ring ring,, spring (10) and bolt (11).

6

Remov emovee scr screw ew plugs lugs (12 (12 and and 13) 13) to togeth gether er with with seal rings.

7

Unsc Unscre rew w cov cover er (14) (14) toge togeth ther er with with pisto iston n an and remove together with gasket.

009684

21 19

18 20

NOTE: In the version with double “H” shift pattern, a cover and switch are installed here.

8

Loos Loosen en hous housin ing g (15) (15) and and remo remove ve toge togeth ther er with with gasket.

9

Remo Remove ve dete detent nt plat platee (16) (16) and and dete detent nt (17) (17) from from housing.

10 11

Unsc Unscre rew w hex hex bolts bolts from from shif shiftt cov cover er (18) (18) and and remove together with gasket. Driv Drivee out out shaf shaftt seal seal (19 (19), ), bear bearin ing g bus bush h (20) (20),, shaf shaftt seal (21) and wiper (22) from shift cover.

12

Deta Detach ch spli splitt rin ring g (23 (23)) and and remo remove ve dete detent nt (24) (24) from housing together with O-ring.

13

Driv Drivee out out dowe dowels ls (25) (25) from from driv driver er..

14

Remo Remove ve selec selecto torr sha shaft ft (26) (26),, dri drive verr (27 (27)) and and locking piece (28).

15

Remo Remove ve need needle le sle sleev evee (29) (29) from from hou housi sing ng..

16

Deta Detach ch spli splitt rin ring g (30 (30)) and and remo remove ve disc disc (31) (31),, spring (32) and disc (33) from selector shaft.

10

22 24 23 29 16

30

31 32

17 33

26

25

27

28 009685

2-16

16 S 151 / 8 S 151 17

Detac Detach h sna snapr prin ing g (34 (34)) fro from m cov cover er.. Rem Remov ovee pist piston on (35) together with O-rings (36).

Shift Mechanism

36 35 36 34

009893

2-17

Shift Mechanism

16 S 151 / 8 S 151

2.3.1 2.3.1 Assemb Assemblin ling g shift housi housing ng

1

1

10

Driv Drivee new new need needle le slee sleeve ve (1) (1) int into o shi shift ft hous housin ing g (2) (2) using special tool 1X56 119 916. Hit onto the side of the needle sleeve with the thicker surround.

2

Inse Insert rt driv driver er (3) (3) and and lock lockin ing g pie piece ce (4) (4) int into o shi shift ft housing.

3

Insert se selector sh shaft (5 (5).

8 7

2

NOTE: Engagement groove for detent and detent plate must face towards transmission

4

5

One One aft after er the the oth other er,, dri drive ve dowe dowell pin pinss (6) (6) thro throug ugh h driver (3) and into selector shaft (observe assembly specifications).

9

5

Inse Insert rt disc disc (7), (7), spri spring ng (8), (8), disc disc (9) (9) and and spli splitt rin ring g (10) according to selector pattern. 6

3

4 009900

6

Driv Drivee sha shaft ft seal seal (11) (11) into into shif shiftt cov cover er usin using g spe speci cial al tool 1X56 119 916. Sealing lip must face towards shift housing.

7

Driv Drivee new new bear bearin ing g bu bush (12 (12) int into o shi shift ft cove cover r using special tool 1X56 119 916.

8

Driv Drivee sha shaft ft seal seal (13) (13) into into shif shiftt cov cover er usin using g spe speci cial al tool 1X56 119 916. Sealing lip must face towards shift lever.

9

11

13

15 12

Driv Drivee wip wiper er (14) (14) into into shif shiftt cov cover er usin using g spe speci cial al tool 1X56 119 916. Sealing lip must face outwards.

14

NOTE: Lightly coat the outside of shaft seal and wiper with sealing compound. Fill gap between shaft seal and wiper with grease.

10

Slid Slidee shif shiftt cove coverr (15) (15) ove overr sele selecto ctorr shaf shaftt toge togeth ther er with new gasket and mount using bolts (16); Tightening torque = 23 Nm.

11

Inser Insertt det deten entt (17 (17)) tog toget ethe herr wit with h new new O-ri O-ring ng and and attach split ring (18).

2-18

16

18

17

009685

16 S 151 / 8 S 151 12

Inse Insert rt det deten entt (19) (19),, spri spring ng (20 (20)) and and scr screw ew plu plug g (21) (21) together with new seal ring and tighten; Tightening torque = 60 Nm.

13

Inse Insert rt cut cutof offf valv valvee (22) (22) int into o shif shiftt hous housin ing g toge togeth ther er with new O-ring, ensuring it is positioned the correct way round, and fix using hex bolts; Tightening torque = 23 Nm.

Shift Mechanism

22

23

NOTE: In the version with double “H” shift pattern, there are 2 ball rollers (23) in the cutoff valve.

14

Inse Insert rt scre screw w plu plugs gs (24 (24 and and 25) 25) int into o hou housin sing g (26 (26)) together with new seal ring and tighten; Tightening torque = 50 Nm.

15

Scre Screw w det deten entt plu plung nger er (27) (27) into into hous housin ing g tog togeth ether er with new seal ring.

16

Inse Insert rt gre grease ased d pin pin (28 (28)) into into bor bore. e. Clo Close se off off usin using g switch or screw plug (29) and new seal ring; Tightening torque = 35 Nm.

17

Inse Insert rt dete detent nt (30) (30) and and det deten entt pla plate te (31) (31) into into housing, ensuring they are positioned the correct way round.

21 20 19

26

25

29 28

27

24 30 31

009687

2-19

Shift Mechanism 18

Fit new gasket (32).

19

Slid Slidee shi shift ft housi housing ng over over dete detent nt plate plate and and dete detent nt together with selector shaft.

16 S 151 / 8 S 151

36

NOTE: Center housing and shift housing.

20

38

Inse Insert rt hex hex bol bolts ts (33) (33) and and tig tight hten en by hand hand..

34

NOTE: Check selector shaft for ease of movement by pushing against the spring force.

21

Tighten det deteent pl plunger; Tightening torque = 50 Nm.

22

Fit Fit O-r O-rin ings gs (34) (34) onto onto pist piston on (35) (35)..

23

Inse Insert rt pisto piston n int into o cov cover er (36) (36) and and sec secur uree usin using g snapring (37).

24

Fit Fit new new gask gasket et (38) (38) and and scr screw ew cove coverr ont onto o housing; Tightening torque = 23 Nm.

35 34

37

33 32

39

NOTE: In the version with double “H” shift pattern, a cover and switch are installed here.

25

2-20

Slid Slidee prot protec ectiv tivee cap cap (39 (39)) ont onto o sele select ctor or sha shaft ft and and position shift lever (40) on selector shaft (position depends on version). Tightening torque for hex bolt and hex nut on shift lever = 49 Nm. Ensure Ensure protective cap has no play when seated on selector shaft (according to parts list).

40

009688

16 S 151 / 8 S 151 2.4

Shift Mechanism

Shift Shift patter patterns/ ns/shi shift ft mechan mechanism ism left left or or righ rightt

Spring pack arrangement: Q 1 Selector pattern I Horizontal torque shaft left.

001923 001923


001924 001924


001925 001925

2-21

Shift Mechanism

16 S 151 / 8 S 151

Spring pack arrangement: Q 1 Selector pattern II Horizontal torque shaft left.

001926 001926


001927 001927


001928 001928

2-22

16 S 151 / 8 S 151

Shift Mechanism


001929

Anordnung des Federpaketes: Q 2 Wählbild I Waagrecht Drehwelle rechts

Anordnung des Federpaketes: Q 3 Wählbild I Waagrecht Drehwelle rechts

2-23

Removing Clutch Housing 3

Remo Re movi vin ng cl clut utch ch hou oussin ing g co comp mpon onen ents ts

3.1

Release fork Release fork (pulled)

1

16 S 151 / 8 S 151

3

8

6 7

1

2

Detach Deta ch ci circ rcli lips ps (1 (1). ). Re Remo move ve se seal alss (2) (2) an and d sea seall rings (3).

2

Pull Pu ll ou outt pin pin (4 (4)) and and re remo mov ve rel relea ease se for ork k (5) (5)..

3

Loosen Loos en he hex x bol bolts ts (6 (6)) and and re remo mov ve to toge geth ther er wi with th bearing block (7).

4

Detach Deta ch ci circ rcli lips ps (8 (8)) and and re remo mov ve pla plain in sp sphe heri rica call bearing (9) from bearing block. block.

9

8 3 2

5

1

4 009520

Release fork (pushed)

1 2

Remov Remo ve rel relea ease se fo fork rk (1 (1)) to toge geth ther er wi with th ba ball ll cu cup p (2).

2

3

4

1

Remo Re mov ve bal balll pin pin (3 (3)) to toge geth ther er wi with th was ashe herr (4 (4). ).

004484

004484

Release fork (pulled)

1

Loose Loo sen n scr screew (5) (5) an and d rem remo ove fr from sh shaf aftt (2) (2) together with clutch lever (3). NOTE: Mark position of clutch lever before removing.

2

Remo Re mov ve do dowel elss (4) (4) fro rom m rel relea ease se fo fork rk (1) 1)..

3

Rele Re leas asee and and lo loos osen en gr groo oov ved nu nutt (6) (6) an and d loo loose sen. n.

4

Remov Remo ve sha shaft ft (2 (2), ), re rele leas asee for fork k (1) (1),, gro groo oved nu nutt (6) and tab washer washer..

5

Remove bearing bush (8).

6

If ne nece cess ssar ary y, rem remo ove she sheet et (9 (9)) and and fo four ur sc scre rews ws (10).

2-24

9 10 1 2 3 6 4 5

8 7 004483

16 S 151 / 8 S 151 3.2 3.2

Removing Clutch Housing

Conn Connec ecti tion on plat platee wit with h int integ egra rall pum pump p

3

1 Single-piece version

1

Unsc Unscre rew w he hex bol bolts ts and and nu nuts from from conn connec ecti tion on plate (1) and pump cover cover (2).

2

Remo Remov ve conn connec ecti tion on plat platee (1) (1) toge togeth ther er with with pump/pump cover cover (2).

3

Remo Remov ve was washe herr (8) (8),, spa space cerr rin ring g (9) (9) and and was washe her r (10) from connection plate / input shaft.

4

Remove gasket (3).

5

Usin Using g plas plasti ticc dri drift ft,, dri drive out out sha shaft ft seal seal (4). (4).

6

Leve Leverr of off pum pump p co cover ver (2) (2) from from conn connec ecti tion on plat platee (1). Drive cylindrical pin (5) out of pump cover cover or connection plate.

7

Remo Remov ve pum pump p sha shaft ft,, int inter erna nall rot rotor or (6) (6) and and exte exterrnal rotor (7).

8

Remo Remov ve sh shim for for inp inpu ut sha shafft and and lay layshaf shaft. t.

10 2 4

8

9

5 2

6

7 001996

Split version

1

Loos Loosen en hex hex nut nuts, s, hex hex bol bolts ts and and was washe hers rs (1 and and 5). 5).

2

Remo emove pum pump p hous housin ing g (6 (6) to togeth ether with with pump/pump cover cover (2) and gasket (7). (7).

3

Remo Remov ve oute outerr roto rotorr (3) (3) and and inne innerr roto rotorr (4). (4).

4

Loos Loosen en hex hex nut nutss (8) (8) and and rem remo ove conn connec ecti tion on plat platee (9) from input shaft t ogether with gasket (10) and washer (11).

5

Remo Remov ve shi shim m fo for inp inpu ut sh shaft aft and and lay layshaf shaft. t.

6

2

3

7

4

11 9

5 10

1 8

009519

2-25

Removing Shift Rail / Centre Housing 3.3

16 S 151 / 8 S 151

Clutch housing

!

DANGER Ensure mounting brackets and rope are firmly secured.

1

Remo Remov ve 13 13 hex hex bolt boltss fro from m ins insid idee and and 9 he hex bol bolts ts from outside. Remove cylinder pins which are not easily accessible using special tool 1X56 138 063.

2

Fix two hooks 1X56 136 564 to clutch housing.

3

Exer Exertt tens tensio ion n on moun mounti ting ng brac brack kets. ets. Hint: The clutch housing is positioned on the centre housing using 4 cylindrical pins (1). Ensure clutch housing is level before separating from centre housing.

4

2

1

3

Hit Hit sid sideb ebar arss (2) (2) of cent centre re hous housin ing g and and clut clutch ch houhousing using plastic hammer.

CAUTION Do not use prybars on housing sealing faces.

5

Remo Remov ve clu clutc tch h hou housi sing ng and and tak takee of off gas gaske kett (3) (3)..

4

Removing components

4.1 4.1

Remo Removing ving com compo pone nent nts/ s/cl clut utch ch hou housi sing ng

1

Remo Remov ve all all scre screw w plu plugs gs and and sea seall rin rings gs if nece necesssary.

2

Remo Remov ve mag magn netic etic scre screw w plu plug g (1 (1) and and clea clean. n.

3

Renew sealing ing cap if necesary. ry.

4

Dri Drive out out tape taperr rol rolle lerr bea beari ring ng oute outerr rac races es for for inpu inputt shaft and layshaft from clutch housing if necessary.

4.2 4.2

Split Splitte terr shi shift ft rail rail / cent centre re hous housin ing g

1

Remo Remov ve grub grub scr screws (1) (1) fr from shif shiftt fo fork (2). 2).

2

Dri Drive shif shiftt rai raill (3) (3) out out of of shi shift ft fork fork (2) (2) in in dir direc ecti tion on of output end.

3

Remo Remove ve shif shiftt for fork k (2) (2) toge togeth ther er with with fulc fulcru rum m pad padss (4).

4

2

1

001931

1

001932

2 1

3

4

Remove shift rail (3). 1 009943

2-26

16 S 151 / 8 S 151 4.3

Removing shafts For Steps 1 - 6, see Section 4.4

1

Unsc Unscrrew co cover (9) (9) to togeth gether er with with gask asket. et.

2

Usin Using g dri drift ft,, dri driv ve out out reve revers rsee pin pin (3) (3) fro from m cen centr tree housing in direction of output. In older versions, loosen and remove fixing screw (3a) and fixingwasher.

Removing Centre Housing

!

DANGER Ensure mounting brackets and rope are firmly f irmly connected.

CAUTION Reverse idler gear may fall out.

3

Remo Remov ve re reverse erse idle idlerr gea gearr (4) (4) toge togeth ther er with with need need-le cage (5).

4

Remo Remove ve scre screw w plu plug g (6) (6) toge togeth ther er with with seal seal ring ring..

5

Screw in f ixture 1X56 137 287. Interlock locking pin (7) is pushed against spring pressure.

6

Bolt li lifting device (1 (17) 1X56 137 122 to centring bush 1X56 137 921 and place over input shaft (18) and shift rails (19) so that it lies on the layshaft (21). Place disc 1X56 137 933 between lifting device and layshaft. Place holder (20) 1X56 137 918 onto lifting device and insert into shift rail driver.

7

Bolt Bolt lay layshaf shaftt (21 (21)) to to lif lifti ting ng devi device ce;; tightening torque = 85 Nm.

8

Pull Pull out out sha shaft ftss and and shif shiftt rai rails ls from from cent centre re housing without tilting and place into device 1X56 137 675.

9

Remo Remove ve lift liftin ing g de device vice (17 (17)) and and acc acces esso sori ries es.. Tak Takee out shift rails, forks and fulcrum pads.

10

Remo Remove ve fulc fulcru rum m pad padss fro from m shi shift ft fork forks. s.

18 17 20 21

19

001995

NOTE: Do not dismantle shift rails any further. In this condition, they form a complete unit. 4.4 4.4

Remo Removi ving ng com compo pone nent nts/ s/ cent centrre hous housin ing g

1

Unscrew device 1X56 137 287 and remove locking pin (7) and compression spring (8).

2

Remo Remov ve all all scre screw w plu plugs gs,, sea seall rin rings gs,, pre press ssur uree swi swittches, pins, filler necks and gasket.

3 4 5

If nece necess ssar ary y, rem remo ove inje inject ctio ion n pip pipee (10 (10), ), type type plate (22) and roll pins (11). Remo Remov ve pac packi king ng (12) (12),, cir circl clip ip (13) (13) and and bea beari ring ng bush (14). Remo Remove ve roll roller er bear bearin ing g out outer er race racess for for main mainsh shaf aftt and layshaft from centre housing. Drive out towards towards inside of housing.

6

Renew f ilter (15).

7

Remove breather (16).

6

22

7

16

8 o

3a

10 15

5

4

14 13 12

11

3 9 001934

2-27

Removing Input Shaft 4.5

16 S 151 / 8 S 151

Input shaft

2

4.5.1 4.5.1 Disman Dismantli tling ng input input shaft shaft

1

Remo Remove ve comp comple lete te inpu inputt shaf shaftt unit unit from from main main-shaft.

2

Remo Remove ve clut clutch ch body body (1) (1) and and sync synchr hron oniz izer er ring ring (2) (2) from input shaft synchronizer. synchronizer.

3

Rem Remove rin ring g (6 (6) fr from insi inside de clut clutch ch body body..

6

1

3

4 5

17 !

DANGER Pressure pieces are under spring pressure. Prevent pressure pieces from flying out.

4

Pull Pull off off sli slidi ding ng slee sleev ve (3) (3) from from inpu inputt shaf shaft. t. Catc Catch h released pressure pieces (4) and compresion springs (5).

5

Detac tach circlip (7) and remove. NOTE: Detach and remove remove circlip (8). Remove Remove split ring (9) (in older version only).

6

7

Pull Pull off off rol rolle lerr bea beari ring ng inne innerr rac racee (10 (10)) fro from m inp input ut shaft using gripper 1X56 136 722, extension 1X56 122 310, threaded insert 1X56 122 303 and basic tool 1X56 122 304. To do this, slide gripper over roller bearing inner race until 1X56 136 722 over firmly seated against rollers and tighten using knurled ring. Remo Remov ve hel helic ical al gear gear (11) (11) fro from inp inpu ut sha shafft. NOTE: Remove Remove helical gear (11) from input shaft together with needle cages (12) (in older version only).

8

Remo Remov ve clu clutc tch h bod body y (13 (13)) and and sync synchr hron oniz izer er ring ring (14) from input shaft.

9

Remo Remov ve oil oil baf baffle fle pla plate te (17) (17),, det detac ach h cir circl clip ip (15) (15) and remove pipe (16) from input shaft.

2-28

16

15

14 11

(12)

13

(12) 10 7

(8)

(9)

009527

16 S 151 / 8 S 151

Assembling Input Shaft

4.5.2 4.5.2 Assemb Assemblin ling g input input shaft shaft

16 1

Chec Check k wear ear limi limits ts of sync synchr hron oniz izer er comp compon onen ents ts (see Section S ection 6, “Synchronizers/Wear “Synchronizers/Wear Limits’’).

2

Inse Insert rt pip pipee (1) (1) into into inpu inputt sha shaft ft and and att attac ach h cir circl clip ip (2) into annular groove. Press new oil baffle (16) into input shaft using drift 1X56 138 109.

3

1

2

4

3

Plac Placee syn synch chro roni nize zerr rin ring g (4) (4) and and clu clutc tch h bod body y (3) (3) onto input shaft. NOTE: Lugs of synchronizer ring must locate in recesses in synchronizer body on input shaft.

6

NOTE: In older version, lightly oil running areas for both needle cages (11) and slide onto input shaft. Slide helical gear (12) over needle cages.

4

10

8

7

5

9

Push Push heli helica call gea gearr (1 (12) over need needle le cage cages. s. NOTE: Engaging teeth of helical gear must face towards towards output end and mesh with inner spline s pline of clutch body. !

12

DANGER Always wear protective gloves when handling heated roller bearing inner race.

17 5

(15)

(14)

13

(11)

(11)

Heat Heat roll roller er bear bearin ing g inne innerr race race (13) (13) to appr appro ox. 100°C and slide onto input shaft. Once the roller bearing has cooled down, down, it must firmly fir mly abut against the input shaft collar. NOTE: In older version, insert split ring (14) into annular groove, ensuring it has axial play (prestress) of between -0.5 mm and + 0.5 mm (using special tool 1X56 136 573). Slide new circlip (15) onto split ring. The circlip must firmly abut against the ring. Secure circlip at three points (120° (120° apart). apart).

6

Attach circlip (17).

7

Plac Placee sli slidi ding ng slee sleeve ve (7) (7) ont onto o syn synch chro roni nize zerr bod body y (8) and locate correctly cor rectly.. Insert new compresion springs (9) and pressure pieces (10) into synchronizer body (8) and, using suitable tool, guide into sliding sleeve (7).

8

Plac Placee syn synch chro roni nize zerr rin ring g (5) (5) and and clu clutc tch h bod body y (6) (6) onto input shaft.

9

Move Move slid slidin ing g sle sleeeve int into o cen centr tree pos posit itio ion. n. To do do this, push against clutch body (6). The pressure pieces can be clearly heard clicking into place.

009528

2-29

Removing Mainshaft 4.6

16 S 151 / 8 S 151

Mainshaft

4.6.1 4.6.1 Disman Dismantlin tling g mainshaf mainshaftt CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device.

1

Clam Clamp p outp output ut end end of main mainsh shaf aftt in in vice vice.. Always Always use aluminium clamping jaws to protect mainshaft. Hint: Use special tool 1X56 137 200 to position and rotate mainshaft. Remove the oil pipe before doing this.

2

Rem Remove cir circl clip ip (1) and and spl split it ring ring (2). 2).

3

Slide gripper 1X56 136 743 over bearing inner race (3) and tighten firmly against bearing rollers using knurled ring. Screw on basic tool 1X56 122 304 and pull off bearing inner race.

4

Remove axial washer (4).

5

Clam Clamp p inpu inputt end end bear bearin ing g jour journa nall of of main mainsh shaf aftt in in vice. Always use aluminium clamping j aws.

6

Remove pr pressure di disc (5 (5).

1

2

3

4

6

NOTE: In straight-cut version, there is no pressure disc (5).

7

Deta Detach ch circ circli lip p (6) (6) from rom an annula nularr gr groov oove.

8

Atta Attach ch 2- or 3-le 3-leg g pul pulle lerr und under erne neat ath h hel helic ical al gear gear (7) and pull off gear together with roller bearing inner race (8). Use adapter.

9

Remove needle cage (9).

10

Atta Attach ch 2- or 3-arm 3-arm pulle pullerr und undern ernea eath th 1st1st-sp spee eed d helical gear (10) and pull off gear together with bush (11) and clutch body (12). (12). Use adapter.

11

5

8 7 9

10

Remove ne needle ca cage (1 (13).

12

11

13

009512 009512

2-30

16 S 151 / 8 S 151 12

Removing Mainshaft

Remo Remove ve clut clutch ch disc disc (14) (14) fro from m 1st/ 1st/5t 5th h gea gearr dua duallcone synchronizer. synchronizer.

13

Remove in inner ri ring (1 (15).

14

Remo Remov ve inte interm rmed edia iate te ring ring (16) (16)..

15

Remove ou outer ter ri ring (1 (17).

16

Pull Pull off off slid slidin ing g sle sleev evee (18 (18). ). Use Use clo cloth th to catc catch h released pressure pieces and compression springs.

17

Remove co coupling ings (1 (19).

18

Place Place 2- or 3-le 3-leg g pul pulle lerr ont onto o 2nd 2nd-s -spe peed ed heli helica call gear (21). Pull off helical gear together with bush (22), clutch disc (23), inner ring (24), intermediate ring (25), outer ring (26) and synchronizer hub (20). Use adapter. adapter.

19

Remove ne needle ca cage (2 (27).

20

Clam Clamp p out outpu putt en end of of mai mains nsha haft ft..

21

Attac Attach h 2- or 3-l 3-leg eg pulle pullerr unde underne rneat ath h slid slidin ing g slee sleeve ve (28) and pull off synchronizer ring (29), clutch body (30), roller bearing (31) and and helical gear (32). Use adapter. adapter.

17

18

Remo Remove ve pres pressu sure re pie piece cess and and spri spring ngs. s. Att Attach ach 2- or 3-leg puller underneath 3rd-speed helical gear (35) and pull off together with roller bearing (36), synchronizer hub (37), synchronizer ring (38) and clutch body (39). Use adapter.

CAUTION Do not attach puller to mainshaft collar (see arrow). arrow).

23

15

26

22

20

19

25

24 23

21 27

NOTE: Use cloth to catch released pressure pieces (33) and compression springs (34) when pulling off sliding sleeve.

22

16

14

36

32

30

31

33 29

37

28

38

34

Remo emove need needle le cage cage (40) (40)..

35

40

39

009511

2-31

Assembling Mainshaft

16 S 151 / 8 S 151

4.6.2 4.6 .2 Ass Assemb emblin ling g mainsha mainshaft ft

3 2

CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device

1

Clamp ma mainshaft (1 (1) at at ou output en end.

2

Lightl Ligh tly y oi oill nee needl dlee ca cage ge (2 (2)) and and sl slid idee ont onto o mai mainnshaft.

3

Push 2n Push 2nd d spe speed ed he heli lica call gea gearr (3) (3) on onto to ma main insh shaf aftt with clutch body engaging teeth facing the output end.

4

Che heck ck we wear ar li limi mitt of of sy sync nchr hron oniz izer er par arts ts (se seee Section 6).

5

Fit clu Fit clutc tch h dis discc (4) (4) on onto to en enga gagi ging ng te teet eth h of of hel helic ical al gear (3). Ensure the slightly raised internal spline in the clutch disc faces towards the output end.

6

Placee inn Plac inner er ri ring ng (5 (5)) ont onto o clu clutc tch h dis disc. c. En Ensu sure re lu lugs gs face towards the output end.

7

Fit int Fit inter erme medi diat atee rin ring g (6) (6).. Ens Ensur uree lug lugss loc locat atee in in recesses in clutch disc.

8

Fit out Fit outer er ri ring ng (7 (7). ). En Ensu sure re lu lugs gs fa face ce to towa ward rdss the the output end.

9

Align Alig n lug lugss on on out outer er ri ring ng (7 (7)) and and lu lugs gs on in inne nerr rin ring g (5) using 3 coupling (8). Position inner and outer ring lugs to cover coupling, so that the couplings will later locate in recesses in the synchronizer hub (9) and fit over the lugs. After adjustment, remove couplings. !


10

2-32

Heat He at syn synch chro roni nize zerr hub hub (9 (9)) to ap appr prox ox.. 120 120°° C and and push onto spline of mainshaft. Ensure lugs locate in recesses of the synchronizer hub. The outer ring tabs must engage in the synchronizer hub recessesd. Use plastic drift to drive on synchronizer hub.

1

7

8

9

6 4

5

001943 001943

16 S 151 / 8 S 151 11


Helic Helical al gear gear (3) (3) axia axiall pla play y must must be at least least 0.20 mm.

12

Inse Insert rt cou coupl plin ings gs (8) (8) into into syn synch chro roni nize zerr hub hub (9). (9).

13

Push Push slidi sliding ng sleev sleevee (10 (10)) ove overr syn synch chro roni nize zerr bod body y and outer ring and locate against clutch disc.

14

Inse Insert rt new new com compr pres esio ion n spr sprin ings gs (11) (11) and and pre pressu ssure re pieces (12) into the synchronizer hub, ensuring that they are the right way round.

8

Use suit suitab able le too tooll to guid guidee pre pressu ssure re piec pieces es int into o the the synchronizer hub and sliding sleeve.

16

Fit oute outerr rin ring g (13 (13). ). The The lug lugss mus mustt eng engag agee in in the the couplings and and the tabs must engage in the synchronizer hub recesses.

17

Fit inte interm rmed edia iate te ring ring (14) (14).. Lug Lugss mus mustt poi point nt towards the output end. Insert inner ring (15) and engage lugs into couplings.

18

Fit clut clutch ch disc disc (16 (16)) with with raise raised d inn inner er teeth teeth faci facing ng towards input end and engage with intermediate ring (14). Move sliding sleeve to neutral position, pressing against clutch disc. The pressure pieces can be heard clicking into place.

11

9

3

NOTE: Place “dual-cone synchronizer’’ pressure pieces in correct position in the synchronizer hub.

15

12

13

14

16

15

10

19 17

18

001944 001944

!

DANGER Always wear protective gloves when handling heated bush.

19

Heat Heat bush bush (17) (17) to 120 120 °C °C and and push push onto onto main mainsh shaf aftt until firmly seated. Use plastic drift to drive on if necessary.

20

Ligh Lightl tly y oil oil need needle le cage cage (18) (18) and and pus push h ove overr bush bush (17).

21

Place Place 1st 1st/5 /5th th spe speed ed helic helical al gea gearr (19) (19) ont onto o need needle le cage (18) so the engaging teeth mesh with clutch disc.

2-33


16 S 151 / 8 S 151

!

DANGER Always wear protective gloves when handling heated clutch body.

22

21

20

22

Heat Heat clut clutch ch body body (20) (20) to 120° 120° C and and push push onto onto mainshaft until firmly located. NOTE: Ensure clutch body collar faces towards output end.

23

Axia Axiall play play on 1st/5 1st/5th th speed speed heli helica call gear gear must must be at least 0.20 mm.

!

DANGER Always wear protective gloves when handling heated bush.

24

Heat Heat bush bush (21) (21) to 120° 120° C and and push push onto onto main mainsh shaf aftt until firmly seated.

25

Ligh Lightly tly oil oil nee needl dlee cag cagee (22 (22)) and and push push over over bush bush (21).

26

23

26 24

25

Push Push reve revers rsee speed speed heli helica call gea gearr (23 (23)) ont onto o mai mainnshaft and over needle cage. Ensure engaging teeth face towards input end. 009507

!

DANGER Always wear protective gloves when handling heated roller bearing.

27

Heat Heat roll roller er bear bearin ing g (24 (24)) to to app appro rox. x. 100° 100° C and and push onto mainshaft until firmly seated. Use plastic drift to drive on if necessary.

28

Atta Attach ch cir circl clip ip (25 (25)) into into ann annul ular ar gro groov ovee on on main main-shaft. NOTE: Axial play on circlip must be between 0 and 0.05 mm. Select correct circlip from spare parts catalogue.

29

Push Push pre press ssur uree dis discc (26 (26)) ont onto o mai mains nsha haft ft.. NOTE: There is no pressure disc (26) in the older version.

30

Clam lamp ou output tput end end of of mai main nshaf shaft. t.

CAUTION Do not damage mainshaft. Always use aluminium clamping jaws when clamping mainshaft in vice or similar device.

2-34

16 S 151 / 8 S 151 31

Oil Oil nee needl dlee cag cagee (27 (27)) and and push push onto onto main mainsh shaf aft. t.

32

Push Push 3rd 3rd speed speed heli helica call gear gear (28 (28)) ove overr nee needl dlee cage cage.. Engaging teeth of helical gear face towards output end.

33

Place Place clut clutch ch body body (29) (29) onto onto enga engagi ging ng teeth teeth of helical gear. Refer to Chapter 6, check wear limits.

34

Place Place sync synchr hron oniz izer er ring ring (30) (30) onto onto clut clutch ch body body..


34 32

35

30

33

28

!


31

27

29

Heat Heat sync synchr hron oniz izer er hub hub (31 (31)) to to 120 120°° C and and push push onto mainshaft splines until axially flush. Use plastic drift to drive on if necessary. NOTE: Synchronizer ring lugs must locate in recesses in synchronizer hub.

36

Fit Fit sl slidi iding sl sleeve (3 (32). NOTE: Recesses inside sliding sleeve must line up with recesses in synchronizer hub for compression springs (33) and pressure pieces (34).

37

001946

Inse Insert rt new new com compr pres essio sion n spri spring ngss and and pres pressu sure re pieces into holes in synchronizer hub and guide into sliding sleeve.

2-35

Assembling Mainshaft 38

Posit Positio ion n sync synchr hron oniz izer er rin ring g (35) (35) so so lugs lugs loca locate te in in recesses in synchronizer hub. Refer to Chapter 6, check wear limits.

39

Place Place clutch clutch body body (36) (36) onto onto sync synchr hron oniz izer er ring ring..

40

Move Move slidi sliding ng sleev sleevee into into neut neutra rall pos positi ition on,, pressing synchronizer ring (35) and clutch body body (36). The pressure pieces can be hear clicking into place.

41

16 S 151 / 8 S 151

43

42 41

40

37

39

36

35

38 37

Inser Insertt bot both h rol roller ler bear bearin ings gs (37) (37) into into 4th 4th spe speed ed helical gear (38). NOTE: Lubricating bores (see arrows) on roller bearings must face outwards.

!

DANGER Always wear protective gloves when handling heated roller bearing and helical gear.

42

Heat Heat roll roller er bear bearin ings gs and and hel helic ical al gear gear to 100° 100° C and push onto mainshaft until bearing pack is correctly seated.

001947 001947

NOTE: The helical engaging teeth on the helical gear must face towards the output end.

43

Axia Axiall play play of hel helic ical al gea gearr must must be be at leas leastt 0.05 mm.

37

37

NOTE: Hint: Axial washer (39), roller bearing (40), split ring (41), circlip (42) and ring (43) are only fitted in Section 11 “Adjusting shafts’’.

38 004915

2-36

16 S 151 / 8 S 151 4.7 4.7

Synchronizers

Asse Assemb mbli ling ng sync synchr hron oniz izer er

2

4.7. 4.7.1 1 Versi Version on ZFZF-BK BK

1 1

Chec Check k wea wearr lim limit itss acc accor ordi ding ng to Sect Sectio ion n 6. 6.

2

Rene Renew w com compr pres essi sion on spri spring ngss (5) (5).. Thi Thiss gua guara ran ntees tees prescribed prescribed shift shift force force for sliding sleeve (6). (6).

3

Sync Synchr hro onize nizers rs may may be be su subass bassem emb bled led fir first st or assembled on the mainshaft itself.

4

5

4

Push Push slid slidin ing g slee sleeve ve (6) (6) ont onto o syn synch chro roni nize zerr hub. hub. Insert new compression springs (5) and pressure pieces (4) into synchronizer hub (3). Hold drift drift against centre of pressure pieces and guide pressure pieces into sliding sleeve (6).

3

5

Posi Positi tion on clut clutch ch body body (1) (1) and and sync synchr hron oniz izer er ring ring (2) (2) and push sliding sleeve (6) into middle position. NOTE: Ensure correct position of pressure pieces.

1a 2a 6

009510 009510

4.7.1.1 Sectional view of synchronizer/ZF-BK

6

1 Clut lutch body 2 Sync Synchr hron oniz izer er ring ring 3 Sync Synchr hron oniz izer er hub hub

2

4 Pres Pressu sure re piec piecee

1

5 Comp Compre ress ssio ion n spri spring ng 6 Slid Slidin ing g slee sleeve ve

4

2a 5 1a

3 001940 001940

2-37

Synchronizers

16 S 151 / 8 S 151

4.7. 4.7.2 2 Vers Versio ion nZ ZFF-D D

2 1

7

Asse Assemb mbly ly proc proced edur uree bas basic ical ally ly simi simila larr to to ver versi sion on ZF-BK.

2

Teet Teeth h of of sli slidi ding ng slee sleeve ve (6) (6) hav havee 3 reces ecesse sess covering 3 teeth each. Align middle tooth with narrow recess in synchronizer hub (3) (pressure piece groove). Renew compression springs.

3

Inse Insert rt new new com compr pres essi sion on spri spring ngss (5) (5) and and pre press ssur uree pieces (4) into synchronizer hub. Fit pressure pieces so round head of pressure piece juts into recess in sliding sleeve teeth.

4

Insert couplings (9).

5

Inse Insert rt oute outerr rin ring g (2) (2),, int inter erme medi diat atee rin ring g (7) (7) and and inner ring (8).

6

Place cl clutch dis discc (1 (1) in in po positi ition.

8 1

4 5

3

9

NOTE: Ensure correct position of pressure pieces.

1a 7a

8a

2a 6

001941

4.7.2.1 Sectional view of synchronizer/ZF-D

6 1 Clutch di disc 2 Outer ring 3 Sync Synchr hron oniz izer er hub hub 4 Pres Pressu sure re piec piecee 5 Comp Compre ress ssio ion n spri spring ng 6 Slid Slidin ing g sle sleev evee

2 7 1 8

1a 2a 7a 8a 5

4

7 Inte Interm rmed edia iate te ring ring 8 Inner ring

3 001942 001942

2-38

16 S 151 / 8 S 151 4.8

Removing Layshaft

Layshaft

5 4

4.8.1 4.8.1 Disman Dismantli tling ng laysha layshaft ft CAUTION Do not damage layshaft. Always use aluminium clamping jaws when clamping layshaft .

1

Clam Clamp p out outpu putt en end of of lay laysh shaf aftt so so tha thatt ro roller ller bearing (6) cannot be damaged.

2

Deta Detach ch cir circlip clip (1) (1) fro from m ann annu ular lar gro groov ove. e.

3

On input end slide gripper 1X56 136 731 over roller bearing inner race (2) and tighten knurled ring to grip roller bearing firmly. Screw on basic tool 1X56 122 304 and pull off roller bearing (2).

4

Clamp layshaft at input end.

5

On ou output en end, sl slide gripper 1X56 136 731 over roller bearing inner race (6) and tighten knurled ring to grip roller bearing firmly. Place adapter on output end of layshaft. Screw on basic tool 1X56 122 304 and pull off roller bearing (6).

6

Pres Presss off off heli helica call gea gears rs (3, (3, 4 and and 5) 5) ind indiv ivid idua uall lly y and in sequence.

1

3

2

6

001948 001948

NOTE: The helical gear (3) is not included in the 8 S 151 transmission. In its place is a ring (7) (see figure 004477).

5 4 1

2

7

6

004477 004477

2-39

Assembling Layshaft

16 S 151 / 8 S 151

4.8.2 4.8.2 Assemb Assemblin ling g laysha layshaft ft

3 4

!

DANGER Always wear protective gloves when handling heated parts.

1

Ensu Ensurre bor bores es in heli helica call gea gears rs (3, (3, 4 and and 5) and and seats on layshaft are free of oil, grease and dust.

2

Heat Heat heli helica call gea gears rs to 160 - 180 180°° C and and push push onto onto layshaft in sequence (3, 4 and 5). Press helical gears on immediately. There must be no play whatsoever.

5 2

1

6

NOTE: In the 8 S 151 transmission, there is a ring (7) in place of the helical gear (5) {see figure 004477/1).

3

Heat Heat inne innerr rac racee of of rol rolle lerr bea beari ring ng (6) to 100 100° C an and push onto layshaft. Press roller bearing on until firmly seated, with no play on output end.

4

Heat Heat inne innerr rac racee of of rol rolle lerr bea beari ring ng (2) to 100 100° C an and push onto layshaft. Press roller bearing on until firmly seated, with no play on input end.

5

Atta Attach ch circ circli lip p (1) (1) into into annu annula larr groo groove ve on inpu inputt end of layshaft. Axial play on circlip must not exceed 0.1 mm. Select correct circlip from spare parts catalogue.

001948 001948

3 4 2

1

7

6

004477/1

NOTE:

a = Direct drive b = Overdrive

a

2-40

b

001949 001949

16 S 151 / 8 S 151

Assembling Clutch Housing / Centre Housing

5

Installing components

5.1

Centre ho housing

1

Fit Fit all all scre screw w plu plugs gs,, pre press ssur uree swi switc tche hess and and fill filler er necks with new seal rings or gaskets and insert. Tightening torques: see “Adjustment Data, Tightening torques’’section.

2

Inse Insert rt inje inject ctio ion n pip pipee (1) (1) if requ requir ired ed.. Rol Rolll end endss into into holes in housing using rolling tool 1X20 155 653 and insert O-ring (3). Rolling torque = 5 to 6 Nm.

3

Insert new filter (4).

4

If nece necess ssar ary, y, fit fit typ typee-p plate late (5) (5) usi using ng pins pins..

5

If nece necess ssar ary, y, inse insert rt new new cyl cylin indr dric ical al pins pins (6) (6) int into o housing.

6

Driv Drivee new new tape taperr roll roller er bear bearin ing g out outer er race racess for for mainshaft and layshaft into centre housing if necessary.

5

3

10 11

7 8

1

9

6 4 001950

NOTE: Heat bearing bore to approx. 60°C using hot air blower.

7

Inse Insert rt beari earing ng bush ush (7 (7), circ circli lip p (8 (8) and and new new packing using plastic drift (9). Ensure correct seating.

8

Inse Insert rt comp compre ress ssio ion n spr sprin ing g (11 (11)) wit with h loc locki king ng pin pin (10) and align . Screw in fixture 1X56 137 287.

5.2

Clutch housing

1

If nece necess ssar ary, y, inse insert rt tap taper er rol rolle lerr bea beari ring ng oute outerr rac races es for the input shaft and layshaft into bearing bores in the clutch housing. NOTE: Input shaft bearing outer race above. Layshaft bearing outer race below.

2

Fit Fit scre screw w plug plugss wit with h new new seal seal ring ringss and and inse insert rt.. Tightening torque: M18 x 1.5 = 35 Nm, M22 x 1.5 = 50 Nm, M24 x 1.5 = 60 Nm.

3

Scre Screw w in in cle clean aned ed oil oil dra drain in plug plug and and mag magne nett (1) (1).. Tightening torque = 140 Nm.

4

Fit cap (2).

1

2 001951 001951

2-41

Wear Limit/Synchronizer 6

16 S 151 / 8 S 151

Synchronizers/wear limit x

6.1

Determ Dete rmin inin ing g wea wearr lim limit it (except for 1st /2nd gear)

Check condition of synchronizer rings and clutch bodies before assembling synchronizers.

1

2

NOTE: Do not mix up synchronizer parts.

1

Placee syn Plac synch chro roni nize zerr rin ring g (1) (1) on onto to co corr rres espo pond ndin ing g clutch body (2). Turn synchronizer parts so cones nest evenly and parallel together. Wear limit for 3rd/4th gear and splitter synchronizer rings is 0.8 mm. Wear limit for range-change rings is 1.2 mm.

2

Using Usin g fee feele lerr gau gauge ge,, mea measu sure re di dist stan ance ce (X (X)) between clutch body and synchronizer ring at two opposing points. If wear limit is below 0.8 or 1.2 mm, exchange synchronizer ring and/or clutch body.

3

Check Chec k con condi diti tion on of sy sync nchr hron oniz izer er pa part rtss (vi (visu sual al check). Replace synchronizer parts if surface is not flat. Do not mix up parts which have been inspected together (mark parts accordingly). 001999

6.2 6. 2

Dete De term rmin inin ing g wear wear lim limit it (1s (1stt /2nd /2nd ge gear ar))

1

Placee inn Plac inner er ri ring ng (3 (3), ), in inte term rmed edia iate te ri ring ng (2 (2)) an and d outer ring (1) of 1st/2nd gear synchronizer onto clutch disc (4). Turn outer ring so cones nest evenly together. Evenly apply 50 Nm on outer ring.

2

Using Usin g a fe feel eler er ga gau uge ge,, mea measu sure re dis ista tanc ncee (s) (s) between clutch disc and outer ring at two opposing points. The wear limit is 1.5 mm. If distance (s) is below wear limit, use new intermediate and/or outer ring and inner ring.

F 50 N

s 1 2 3 4

001952 001952

2-42

16 S 151 / 8 S 151 7

Adjusting mainshaft

7.1 7.1

Deter Determi mini ning ng ring ring and and axia axiall was washe herr (straight-cut version)

Adjusting Mainshaft

2

1

Plac Placee mai mains nsha haft ft into into cent centre re hous housin ing g usi using ng lift liftin ing g device 1X56 137 200.

2

Plac Placee rin ring g (1) (1) into into clut clutch ch body body (2). (2). Fit Fit par parts ts onto onto 4th speed helical gear.

3

Take Take seve severa rall meas measur urem emen ents ts of dist distan ance ce betw betwee een n top edge of of clutch body and centre housing sealing face with gasket fitted. Calculate average distance.

4

Nominal dimension X of 32.2 -0.5 mm must be ensured. If the average distance is different, select ring to ensure nominal distance (see table in under 5).

5

1

001953

Sele Select ct thru thrust st wash washer er (3) (3) fro from m the the foll follow owin ing g tab table le.. If 3.6 mm ring is required, use 7.9 mm thrust washer. Ring (1): 3.6 / 4.0 Thrust washer (3): 7.9 / 8.3

6

Remo Remove ve main mainsh shaf aftt fro from m cen centr tree hous housin ing g and and pla place ce thrust washer onto mainshaft with raised collar facing towards helical gear.

1

3

X

!

DANGER Always wear protective gloves when handling heated bearing inner race.

7

8

Heat Heat new bear bearin ing g inne innerr race ace (4) (4) to 100° 100° C and and place onto bearing journal of main shaft ensuring it is firmly seated. Drive on using plastic drift.

001954 001954

Appl Apply y appr approx ox 4g of lubr lubric icat atin ing g grea grease se (Ara (Aralu lube be HL2 or Texando F020) bearing inner race (collar side) on face of bearing output end (see arrow). NOTE: Make sure no grease is applied to the outside of the bearing rollers. Grease applied here may block the input shaft lube bores.

9

10

Using drift 1X56 137 676, insert split ring (5) into annular groove on mainshaft to give axial play and prestress of - 0.05 mm to + 0.05 mm. Split rings are available in 0.1 mm thicknesses.

3 4 6

5

Slide Slide new new circ circli lip p (6) (6) over over spl split it rin ring g and and peen peen over over at 3 points (120° (120° apart) using using punch. punch.

001955

2-43

Adjusting Mainshaft 7.2 7.2

Dete Determ rmin inin ing g rin ring g and and axia axiall was washe herr (helical-cut version)

1

Meas Measur uree dis dista tanc ncee bet betwe ween en main mainsh shaf aftt and and bear bearin ing g inner race contact point using depth gauge (dimension „a“).

2

Inser nsertt axi axial al wash washer er (1) (1) and and measu easurre dis dista tan nce between mainshaft and axial washer using depth gauge (dimension „b“).

3

a – b mus mustt giv givee a play play of betwe etween en + 0.0 0.07 7 mm mm an and - 0.08 mm.

4

Afte Afterr sel selec ecti ting ng the the cor corre rect ct axia axiall was washe her, r, inse insert rt ring (2) into clutch body (3). Place parts onto 4thspeed helical gear.

5

Meas Measur uree dis dista tanc ncee bet betwe ween en axia axiall was washe herr and and clutch body at several points. Calculate mean value. Nominal dimension = 4.6 - 0.4mm (select ring (2) accordingly).

16 S 151 / 8 S 151

4.6 -0.4

2

1

+0.07 bis to -0.08 +0.07 -0.08 009521

009521

!

DANGER Always wear protective gloves when handling heated bearing inner race.

3 2

6

Heat Heat new new bea beari ring ng inne innerr rac racee (4) (4) to 100 100°C and and place onto mainshaft bearing journal until it is in firm contact. Fully drive home using plastic drift.

7

Appl Apply y app appro rox x 4g of lubr lubric icat atin ing g gre greas asee (Ar (Aral alub ubee HL2 or Texando F020) bearing inner race (collar side) on face of bearing output end (see arrow). NOTE: Make sure no grease is applied to the outside of the bearing rollers. Grease applied here may block the input shaft lube bores.

8

Use drift 1X56 137 676 to insert split ring (5) into annular groove in mainshaft to give axial play/prestress of between - 0.5 mm and + 0.05 mm. Split rings are available in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.).

9

Slid Slidee new new circ circli lip p (6) (6) over over spli splitt rin ring g and and peen peen over over in three places (120° (120° apart) using using punch.

001953

1 4 6

5

001955

2-44

16 S 151 / 8 S 151 8

Installing sh shafts

8.1 8.1

Inpu Inputt sha shaft ft,, main mainsh shaf aftt and and lays laysha haft ft

Installing Shafts

!

DANGER Ensure fixture and rope are firmly secured.

5

1

4

Place al alternating pin 1X56 137 920 onto the layshaft locator. Insert output end of mainshaft (1) into locator 1X56 137 675. Place clutch body, correct ring and synchronizer ring onto the teeth of the helical gear on the mainshaft. Place the complete input shaft onto the mainshaft. Position layshaft (2) with teeth at correct height for meshing. Push the layshaft against the mainshaft and bring the teeth into mesh.

2

Inse Insert rt shif shiftt rai rails ls (3) (3) and and fulc fulcru rum m pad padss int into o sli slidi ding ng sleeves on mainshaft.

3

Place centring bush 1X56 137 921 into lifting device 1X56 137 122 (4) and secure. Push lifting device over input shaft (5) and shift rails and push down onto layshaft.

4

Scre Screw w lif lifti ting ng devi device ce onto onto lays laysha haft ft usin using g disc disc 1X56 137 933 (6). Tightening torque = 85 Nm.

5

7 6

2

1

3

001995

Plac Placee hol holde derr (7) (7) in driv driver er rece recess sses es and and lif lifti ting ng device.

CAUTION Ensure holder (7) 1X56 137 918 is firmly located at both points. This guarantees safe lifting procedure.

6

Inse Insert rt main mainsh shaf aft, t, inpu inputt sha shaft ft and and lay laysh shaf aftt int into o taper roller bearing outer races in centre housing without tilting. NOTE: Ensure interlock is retracted and locked.

7

Remove all lifti iftin ng equipment.

8

Remove device 1X56 137 287 for interlock.

9

Turn Turn inpu inputt sha shafft to to cen centr tree bea beari ring ng rolle ollers rs..

.

2-45

Adjusting Shift Fork 9

Split litter shift fork / shift rail

9.1

Adju Adjust stin ing g shift ift fork fork

1

Guid Guidee in in sh shift ift rai raill (1) (1) from from insi insid de (in (in cent centre re housing). To protect packaging, slide correct size pin through packaging from outside outside to prevent damage to the packaging caused by shift rail threads.

16 S 151 / 8 S 151

6 3 4

CAUTION Do not damage flange packing when inserting shift rail.

1 2

Corr Correc ectl tly y pos posit itio ion n shi shift ft fork fork (3) (3) and and fulc fulcru rum m pad padss against sliding sleeve (4) and place onto shift rail. NOTE: Line up bores in shift rail with thread in shift fork.

3

Inser nsertt gru grub b scr screw ewss (6 (6) (d (do not not tig tighten hten yet) et).

4

Switch tch sli sliding slee leeve to output.

5

Scre Screw w pist piston on (2) (2) and and new new doub double le-g -gro roov oved ed ring ring onto shift rail. NOTE: Renew lock nut; Tightening torque = 150 Nm. Ensure the thread is absolutely free of grease.

6

Nomi Nomina nall dim dimen ensi sio on (X) (X) betw betwee een n pis pisto ton n and and centre housing (5) sealing face must be 94.0 mm. Use grub screws (6) to adjust shift. Measure without gasket on centre housing .

7

Fulc Fulcru rum m pad padss in in the the sli slidi ding ng slee sleeve ve must must have have the the same play above and below (check using feeler gauge).

8

Tighten grub screws evenly. Tightening torque = 60 Nm.

2-46

2 5

x 001956 001956

16 S 151 / 8 S 151 I

Adju Adjust st as foll follow owss if if usi usin ng sup supp port ort pla plate te 1X56 137 917:

9

Work Work step stepss 1) 1) to to 3) 3) and and 5). 5). Fit Fit spli splitt tter er cyli cylind nder er (7) (7) (see work steps 1) to 4) in Section 13.2). Screw support plate onto the housing sealing face. Switch the sliding sleeve to the output. Splitter piston must axially contact cylinder and cylinder must axially contact the supporting plate. This is the correct position. Then follow work steps 7) and 8).

Adjusting Shift Fork

5 8

7

001965

II

10

Adju Adjust st as foll follow owss (ne (new w ver versi sion on)) if if usi using ng centering device 1X56 138 079 and support plate 1X56 137 917:

8

Adju Adjust st as desc descri ribe bed d unde underr ste step p 9). 9). Attach the centering device 1X56 138 079 before performing steps 7) and 8).

3 1 9

009944

2-47

Assembling Clutch Housing / Centre Housing 10

16 S 151 / 8 S 151

Clut Cl utch ch ho hous usin ing g / ce cent ntrre hou housi sing ng

10.1 10 .1 Fi Fitt ttin ing g clut clutch ch hou housi sing ng

1

Fitt ne Fi new gas gaske kett to to cen centr tree hou housi sing ng se seal alin ing g fa face ce.. !

DANGER Ensure fixtures and rope are firmly secured.

2

1

Using hook 1X56 136 564, place clutch housing (1) flat onto centre housing.

CAUTION End of injection pipe must engage engage in clutch cl utch housing bores in funnel and shift rails. 001957

NOTE: Position all cylindrical pins between clutch housing and centre housing. If necessary, push shift rail drivers inwards inwards until clutch housing is fixed.

3

Screw Scre w in in 13 13 hex hex bo bolt ltss ins insid idee clu clutc tch h hou housi sing ng an and d9 hex bolts outside. Turn input shaft several times to centre bearing rollers. Tightening torque = 49 Nm.

4

Remove hook 1X56 136 564.

2-48

16 S 151 / 8 S 151 11

Adjusting Mainshaft

Adjusting shafts

11.1 11.1 Input Input shaf shaftt and and conne connecti ction on plat platee

1

To ach achie ieve ve corr correc ectt sett settin ing, g, the the inpu inputt shaf shaftt roll roller er- bearing must be play-free when measured. To To ensure this, the outer race (1) must touch the bearing rollers (2). Use plastic drift to push taper roller bearing outer race towards towards output end. Rotate input bearing several times to centre bearing rollers. 1

NOTE: Bearing rollers should not move and should not be prestressed.

2

a

Meas Measur uree dist distan ance ce betw betwee een n face face of bear bearin ing g out outer er race (1) and sealing face (3) using depth gauge. Note down dimension “a”.

2

NOTE: Measure at two opposite points and calculate the average value.

3

001958 001958

Meas Measur uree dist distan ance ce betw betwee een n seal sealin ing g face face (4) (4) and and locating face (5) for shim in connecting plate using depth gauge. Note down dimension “b”. Measure gasket (6) and note down dimension. NOTE: Measure at two opposite points and calculate the average value.

4

3

Calc Calcul ulat atee the the dif differe ferenc ncee “c” “c” and and not notee it it do down: wn: c = (b + gasket) – a

4

b

6 5

NOTE: Axial play on roller bearing: 0.0 to 0.1 mm.

5

Sele Select ct a shi shim m of of the the sam samee thi thick ckne ness ss as dime dimens nsio ion n “c” (max. 0 - 0.1 mm).

6

Plac Placee shi shim m in in th the con conn necti ectio on pla plate te.. Shi Shims ms are are available available in 0.05 mm thicknesses. NOTE: The same procedure is used for measuring split connection plates.

001959

2-49

Adjusting Layshaft

16 S 151 / 8 S 151

11.2 Layshaft

1

Ther Theree mus mustt be be no no pla play y on on the the lays laysha haft ft tape taperr rol rolle ler r bearing during measurement. Use plastic drift to push outer race (1) towards towards output until it is pressed firmly against the bearing rollers (2). Rotate input bearing several times to centre bearing rollers. NOTE: Bearing rollers should not move and should not be presetressed.

2

Meas Measur uree thic thickn knes esss of shim shim usin using g dept depth h gaug gauge. e. 1

NOTE: Measure at two opposing points.

3

Meas Measur uree dist distan ance ce betw betwee een n hous housin ing g sea seali ling ng face face and bearing outer race (1) face. Measure gasket and add to dimension “a”.

4

Use Use av averag eragee dim dimen ensi sion on “a” “a” ob obtain tained ed fro from measurements taken to select correct shim NOTE: Axial play 0.0 to 0.1 mm.

5

Thic Thickn knes esss of of shim shim must must corr corres espo pond nd to meas measur ureement “a” (max. minus 0.1 mm).

6

Plac Placee shi shim m ont onto o tap taper er roll roller er bear bearin ing g out outer er race race.. Shims are available in 0.05 mm thicknesses.

2-50

a

2 001960 001960

16 S 151 / 8 S 151

Assembling Connection Plate

12. Fitting clutch housing components 12.1 Connec Connectio tion n plate plate with with integr integral al pump pump

9

Single-piece version

7 1

Thin Thinlly coa coatt ou outsid tsidee of of sha shaft ft seal seal (1) (1) wit with h sealing compound and, using drift 1X56 103 766, insert into connection plate. NOTE: Sealing lip on shaft seal ring must face towards towards drift.

2

Plac Placee was washe herr (8) (8),, spa space cerr rin ring g (9) (9) and and was washe herr (10 (10)) onto input shaft.

3

Screw guide pin 1X56 137 949 into the threaded hole in the layshaft.

4

Fit Fit ne new gas gaske kett (11 (11)) to to con conne nect ctio ion n pla plate te (2), (2), plac placee over over input shaft and onto clutch housing. Tighten hex bolts and nuts. Tightening torque = 46 Nm.

5

Unsc Unscre rew w guid guidee pin pin from from the the lays laysha haft ft..

6

Plac Placee inn inner er roto rotorr (3 (3) int into o pum pump p hou housi sing ng (5) (5). Engage with layshaft.

7

Plac Placee out outer er rotor otor (4) into into pum pump ho housin using. g.

6

11

10

8 1

2

5

3

4

001993

NOTE: Ensure there is axial play on outer and inner rotors.

8

Thin Thinlly coa coatt co cover ver sea seali ling ng face face (6) (6) wit with h Loc Locti tite te No. 574 (from hole to hole) and place onto onto pump housing.

9

Dri Drive cylin ylindr dric ical al pin pinss (7) (7) into into pump pump cov cover. er. Rota Rotate te inout shaft to check.

10

Aff ix ix pump cover Tightening torque = 46 Nm.

2-51

Assembling Connection Plate

16 S 151 / 8 S 151

Split version

1

Plac lace wa washer (1) onto in input sh shaft.

2

Plac Placee con conne nect ctio ion n pla plate te (2) (2) ov over inpu inputt sha shaft ft and and onto clutch housing together with new gasket (3). Tighten hex nuts (4). Tightening torque = 46 Nm.

3

4

10

Inse Insert rt oute outerr rot rotor or (9) (9) in into pump pump housi ousing ng..

5

Ligh Lightl tly y coa coatt pum pump p co cover seal sealin ing g fac facee (10 (10)) wit with h Loctite 574 (from bore to bore) and place onto pump housing.

6

Firmly attach pump cover. Tightening torque = 46 Nm.

9

7

5

1 2

Fit Fit ne new gas gaske kett (7) (7).. Bri Bring ng pump pump hous housin ing g (6) (6) and and inner rotor into mesh with layshaft and tighten (8). Tightening torque = 46 Nm.

NOTE: Ensure that there is axial play on the outer and inner rotors.

2-52

6

8 3

11 4

009519

16 S 151 / 8 S 151

Assembling Release Fork

12.2 12.2 Rele Relea ase for fork k

7

Released fork (pulled)

1 2

Inse Insert rt plai plain n sphe spheri rica call bea beari ring ng (1) (1) into into bear bearin ing g block (2) and attach circlips (3).

9

3

4 2

8

Fix beari earing ng block lock usin using g hex hex bolt boltss (4) (4)..

1

Tightening torque = 115 Nm. 3

Slid Slidee rel relea ease se fork fork (5) (5) ove overr bea beari ring ng block lock and and insert pin (6).

4

Fit seal seal ring ringss (7) (7) and and sea seals ls (8) (8) ont onto o pin pin..

5

Attach circlips (9) to pin.

3 7 8

5

9

6 009520

Release fork (pushed)

1

Scr Screw in in ball ball bolt bolt (3) with with washe asherr (4). (4). Use Loctite no. 262. Tightening torque = 100 Nm

2

Plac Placee bal balll cup cup (2) in clu clutch tch lev lever (1). (1).

3

Plac Placee clu clutc tch h le lever (1) (1) ont onto o bal balll bol boltt (3) (3)..

2

3

4

1

004484

004484

2-53

Assembling Release Fork

16 S 151 / 8 S 151

Release fork (pulled)

1

Push Push shaf shaftt (2) (2) into into clut clutch ch bell bell hous housin ing. g. Fit Fit ne new tab washer (7) and grooved nut (6) onto shaft.

2

Guid Guidee sha shaft ft into into 1st 1st bea beari ring ng bore bore on conn connec ecti ting ng plate. Push release fork (1) onto shaft and guide this into 2nd bearing bore on the connecting plate.

3

Plac Placee bea beari ring ng bush bush (8) (8) ove overr sha shaft ft and and int into o clu clutc tch h housing.

4

Hit Hit slo slott tted ed pins pins (4) (4) int into o rel relea ease se fork fork (1) (1) and and shaf shaftt (refer to assembly specification).

5

Fit Fit tab tab washe asherr (7) (7) and and gro groo oved ved nut nut (6) (6) ont onto o bea bea-ring bush. Secure g rooved rooved nut. Tightening torque = 200 Nm

6

Fit Fit shi shift ft leve leverr (3) (3) onto onto shaf shaftt usi using ng scre screw w (5) (5) (observe position); Tightening torque = 120 Nm.

7

Mou Mount shee sheett (9) (9) usin using g fo four scre screws ws (10 (10); Tightening torque = 23 Nm

9 10 1 2

3 4

5

6

8

7

004483

004483

8

7 6 1

2

4

004 917

004917

5

3 004 918

004918

2-54

16 S 151 / 8 S 151 13

Assembling Reverse Idler Gear

Fitt Fittin ing g cen centr tree hou housi sing ng comp compon onen ents ts

3

13.1 Reverse Reverse idler gear/re gear/rever verse se idler pin

1

Inse Insert rt nee needl dlee cag cages es (1) (1) int into o re revers versee idl idler er gear gear..

2

Plac Placee reve revers rsee idle idlerr gear gear (2) (2) into into hous housin ing. g.

4 5

2

NOTE: Collar of reverse idler gear must face towards towards output end.

3

Push Push rev reverse erse idle idlerr pin pin (3) (3) into into cent centre re hous housin ing g from output side until firmly seated.

4

In “firs “firstt ver versi sion on’’’, scre screw w in in washe asherr (4) (4) and and locking bolt (5). Tightening torque = 86 Nm.

1

7 6

version’’, the reverse idler pin is NOTE: In “2nd version’’, secured using a centrally-mounted clamping pin (8) (figure 002000). 5

001962 001962

Fit Fit co cover (6) (6) and and new new gas gask ket (7) (7) onto onto cent centre re houhousing. Tightening torque = 49 Nm. 3

8

2 1 002000

13.2 Cylinder

1

Rem Remove sup supp porti ortin ng pla plate te and and cy cylin linder der.

2

Check locking nut on piston. Tightening torque = 150 Nm.

3

Fit sp spring ing wa washer (1 (1) on onto ho housing.

4

Fit cylin ylinde derr (2) (2) with with new new O-r O-rin ing gs (3 (3 and and 4). 4).

1

4

3

2

NOTE: If necessary, fit 3 O-rings. Hint: Lightly oil O-rings.

5

Inser nsertt cylin linder der onto nto cent centrre hou housing sing.. NOTE: Line up lug on cylinder with groove in centre housing.

001963 001963

2-55

Compressed Air Test

16 S 151 / 8 S 151

13.3 13.3 5/25/2-wa way y val valv ve

1

Inse Insert rt new new O-r O-rin ing g (1 (1) int into o 5/2 5/2-w -waay val valv ve.

2

Scre Screw w 5/2 5/2-w -waay val valv ve (2) (2) onto onto cent centre re hous housin ing. g. Tightening torque = 9.5 Nm. NOTE: There is no 5/2-way valve in the 8 S 151 transmission.

1

2 001964 001964

13.4 Compressed Compressed air test test for for piston piston and splitter splitter cylinder

1

Screw su support pl plate 1X56 137 917 (1) for splitter cylinder (2) onto centre housing (3).

2

Supp Supplly com compr pres esse sed d air air (max (max.. 6.8 6.8 bar) bar) to 5/25/2-w way valve and piston.

3

Wet oute outerr edg edgee of of spl split itte terr cyl cylin inde derr and and chec check k for for bubbles (leaks).

4

Supp Supplly com compr pres esse sed d air air to pist piston on in oppo opposi site te dire direcction and check if air escapes through 5/2-way valve.

5

If bubb bubble less for form, m, fit new new O-r O-rin ings gs if nece necess ssar ary y and and check correct location.

6

If air air esc escap apes es,, ren reneew dou doub ble-g le-gro roo oved ring ring on piston.

7

Remove su support pl plate (1 (1).

2-56

3 1

2

001965 001965

16 S 151 / 8 S 151

Installing Components

13.5 13.5 Inje Inject ctio ion n pip pipee

1

Using drift 1X56 137 835, drive injection pipe (1) into mainshaft until firmly located.

1

001966

2-57

Installing Range-Change Housing 14

Inst Instal alli ling ng com compl plet etee rang rangee-ch chan ang ge

1

Fit new new gas gask ket (1) (1) ont onto o cen centr tree ho housin using g (2 (2).

16 S 151 / 8 S 151

NOTE: There must 3 cylindrical pins in centre housing.

2

Fit Fit 2 hex hex bol bolts ts to rang rangee-ch chan ange ge hous housin ing g to to all allo ow range-change to be suspended from a rope and positioned horizontally against centre housing. housing.

1

CAUTION Secure hex bolts with nuts. Ensure rope is firmly secured.

2

Hint: Use threaded pins on centre housing to sim plify positioning of range-change. 3

Push Push rang rangee-ch chan ange ge agai agains nstt cen centr tree hous housin ing g (2). (2). Turn output flange to bring planet gear train and mainshaft teeth into mesh mes h if necessary.

4

Remo Remov ve hex hex bolt boltss and and rope rope when hen ran range ge-c -cha hang ngee is is held against centre housing.

5

Slid Slidee ran range ge-c -cha hang ngee (3) (3) para parall llel el to cent centre re hous housin ing g and bolt together. together. Tightening torque = 49 Nm.

6

Swit Switch ch pist piston on to end end pos posit itio ion n (hi (high gh or low low gro group up). ).

3 2

001967

2-58

16 S 151 / 8 S 151

Assembling Centre and Range-Change Housing

7

Screw f ixing device 1X56 137 579 into centre housing and into hole for detent plunger (6).

8

Screw ne new lo locking nut on onto pi piston Tightening torque = 150 Nm.

13 14 20 21

NOTE: Renew locking nut. Make sure the thread is absolutely free of grease.

9

Remove f ix ixing device.

10

Fit cy cylinder an and tig tigh hten. Tightening torque = 49 Nm.

6 7

11

8 10 9

NOTE: Carefully push cylinder over piston together with guide ring and piston gasket.

11

12

Scre Screw in dete detent nt plun plunge gerr (6) (6) toge togeth ther er with with new new seal ring (7). Tightening torque = 50 Nm. Inse Insert rt pin pin (8) (8) and and switc switch h (9) (9) toge togeth ther er with with new new seal ring (10). Tightening torque = 50 Nm. NOTE: In the new version, fit switch (9) onto the range-change housing.

13

Fit Fit scre screw w plu plug g (13 (13)) with with new new sea seall rin ring g (14 (14). ). Tightening torque = 50 Nm.

14

Inse Insert rt pin pin (15 (15)) and and swi switc tch h (16) (16) wit with h new new seal seal rin ring g (17). Tightening torque = 50 Nm.

15

Inse Insert rt dete detent nt plun plunge gerr (18) (18) wit with h new new seal seal rin ring g (19) (19);; Tightening torque = 50 Nm.

16

Screw Screw in rev rever erse se gea gearr pre pressu ssure re swit switch ch (20 (20)) with with new sealing ring (21). Tightening torque = 50 Nm.

22 19 18

23

15 17 16 001968 001968

NOTE: In the new version, the pressure switch (20) is mounted in the cover (shift housing).

17

Scre Screw w in scre screw w plug plug (23) (23) with with new new seal seal rin ring g (22 (22). ). Tightening torque = 35 Nm.

18

Screw Screw in mech mechan anic ical al speed speedom omet eter er and and ne new sea seall ring or impulse sensor. Tightening torque = 50 Nm.

19

Scre Screw w bre breat athe herr in into bore bore (11 (11). Tightening torque = 10 Nm.

2-59


15


15.1

Shift housing

1

Plac Placee ne new gas gaske kett (1) (1) onto onto clut clutch ch hous housin ing g (2) (2) and and sealing face.

2

Plac Placee com compl plet etee shi shift ft hous housin ing g (3) (3) in posi positi tion on.. Lin Linee up bores in shift housing with bores in gasket. Hint: Use threaded pins to simplify positioning of clutch housing, gasket and shift housing.

3

16 S 151 / 8 S 151

3 1

2

Shif Shiftt thr throu ough gh all all the the gear gears. s. Ther Theree mus mustt be be noticeable excess shift travel in each gear. If the shift angle is not within the specified tolerances, it must be adjusted using an angle measuring device. Finally, Finally, tighten all hex bolts. Tightening torque = 23 Nm.

CAUTION The shift turret housing must be centered on the transmission housing so that equal play (excess shift travel) is obtained on both sides and the resultant shift angle angle is 14° 14° 30’ +2° (see illustr illustration ation). ).

001969

0 +2° 1 4 ° 3 14° 3 30 0 '

1st, 3rd, 5th, 7th gear

'

+ 2

°

2nd, 4th, 6th, 8th gear

009894

15.2

1

2

Plastic pipes

2

Usin Using g uni unio on scr screews and and ne new sea seall rin ring gs, scre screw w plastic pipes (1) to cylinder (2) and shut-off shut-off valve (3) as marked. Tightening torque = 38 Nm. Fit Fit pip pipee bra brack cket et (4) (4) and and fixed fixed plas plasti ticc pip pipes es to houhousing. NOTE: Observe the following assembly sequence if renewing the pipe bracket or plastic pipes.

1. Place insert (5) into pipe bracket (4) 2. Draw plastic pipes (1) through the pipe bracket. 3. Press rings (6) into plastic pipes (1).

1

5

6

3

6

4

1

6

6

001992

2-60

16 S 151 / 8 S 151 16

Comp Comprresse essed d air air test test on brea breath ther er

1

If nece necess ssar ary y, rem remo ove brea breath ther er and and scre screw w pres pressu sure re gauge connection into bore (1).

Compressed Air Test

1

NOTE: Supply air to 5/2-way valve (2) over a long period (max. 6.8 bar) and check pressure gauge.

2

Reinsert breather Tightening torque = 10 Nm. NOTE: There is no 5/2-way valve in the 8 S 151 transmission. Therefore, this test is not required here.

2

001970 001970

2-61

ZF Ecosplit 8S 16S 151 Repair Manual

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