ZF Ecosplit 12 Speed_1325_751_101_en 2009.pdf

Reparaturanleitung Repair Manual Manuel de Reparation Manual de Reparaciones Manuale di Riparazioni

ZF Synchromesh Transmissions 12-speed 1325 751 751 101_e 101_en n

Subject to technical changes

Copyright by ZF This documentation is protected by copyright. Any reproduction or dissemination in any form that does not fully agree with the intended purpose of this documentation is prohibited without the consent of ZF Friedrichshafen AG. Printed in Germany ZF Friedrichshafen AG / 2009

Edition: 2009-03

1325 751 101

ZF-Ecosplit

Table of Contents

Page Overview of Changes .............. ............................. ............................. ............................. .............................. .............................. .............................. ................................ ................. Preface ............. ............................ .............................. ............................. ............................. .............................. .............................. .............................. ................................. ........................... ......... Safety Instructions..................... Instructions.................................... .............................. ............................. ............................. .............................. ................................ ............................... .............. Instructions for Repair ............. ............................ .............................. .............................. ............................. ............................. .............................. ................................ ................. Tightening Torques.................. orques.................................. ............................... .............................. .............................. .............................. ................................ ............................... .............. Consumables......................... Consumables.......... .............................. .............................. .............................. ............................. ............................. .............................. ................................... ...................... Setting Data .............. ............................ ............................. .............................. .............................. .............................. ............................. ................................ ................................. ................. ZF-Ecosplit Tightening Torques .............. ............................. .............................. .............................. .............................. .............................. ............................... ................ Spring Table...................... able..................................... .............................. .............................. .............................. ............................. ............................. .................................. ......................... ...... Special Tools ools.............. ............................. .............................. ............................. ............................. .............................. .............................. ................................. ................................ ..............

5 6 7 8 10 11 12 14 17 18

1

............................. ............................. ............................. ............................ ............. 1-1 Pol olya yami mide de tu tube bess for ran rang ge cha chang ngee gro group up an and d val valvve ..............

2

............................ .............................. ............................. ............................. .............................. .............................. ............................. ................................. ..................... 2-1 Shif t turret .............

3

............................. .............................. .............................. ............................. ............................. .............................. ........................ ......... 3-1 Range change group (R/C) ..............

4

............................. ............................. ............................. .............................. .............................. .......................... ........... 4-1 Planetary dri rivve with synchronizer ..............

5

.............................. .............................. ............................. ............................. .............................. ................. 5-1 Spl plit ittter gr gro oup piston and 5/22-w way valve ...............

6

............................. ............................. .............................. .............................. .............................. ............................. ............................. ...................... ....... Connection plate ...............

6-1

7

............................ ............................. .............................. .............................. .............................. ............................. ............................. ........................... ............ Clutch housing ..............

7-1

8

.............................. .............................. .............................. ............................. ............................. .............................. ........................ ......... Shaf ts and selector rails ...............

8-1

9

............................ .............................. .............................. ............................. ............................. .............................. ............................. .............. Transmission housing .............

9-1

10

............................. .............................. .............................. .............................. ............................. ............................. .............................. ................................ ................. 10-1 Input shaft ..............

11

........................................ .............................. .............................. .............................. ............................. ............................. ................................ ................. 11-1 Countershaf t .........................

12

............................. .............................. .............................. .............................. ............................. ............................. .............................. ................................ ................. 12-1 Main shaft ..............

13

.............................. ............................. ........................ .......... 13-1 Beari Be aring ng se sett tting ing on mai main n sha shaft, ft, in inpu putt sha shaft ft and and co coun unte ters rsha haft ft ...............

14

........................ ............................. .............................. .............................. .............................. ............................. ............................. ................................ ................. 14-1 Synchronizers ..........

1325 751 101 - 2009-03

3

ZF-Ecosplit

Transmission overview

The following transmissions and variants are covered in this manual: Transmission types : 12 S 2130 TD 12 S 2330 TD 12 S 2830 TD

1325 751 101 - 2009-03

4

ZF-Ecosplit

Index

Date of issue

1325 751 101 - 2009-03

Overview of changes: 1325 751 101

Chapter

Initiator

Comment

5

Preface

Preface

Warranty

This manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. The work described below may only be performed by authorized, trained, and instructed staff. It is the responsibility of the t he user’s company or repair company to ensure that their repair staff is properly trained.

Repair work carried out at ZF Service Points is subject to the contractual conditions prevailing in the individual case. Direct and/or subsequent costs are not covered by this contractual liability when: • work has been performed improperly improperly or by unskilled personnel, by non-ZF-personnel, and/or

This manual deals with a ZF series product in accordance with the state of development on the date of issue.

• use of “non” genuine genuine ZF parts. In case of failure it is mandatory to act immediately, so to ensure the complete function of the ZF unit and minimize the scope of damage.

However, due to continuing technical advancements However, of the product, repair work might require work practices and test or adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics and fitters who have their practical and theoretical knowledge updated on a regular basis at our Service Training Center.

In case of proven unfounded delay in repair we reserve the right of partial acceptance or even a rejection of warranty claims.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continuously trained personnel, 2. Specified equipment, e.g.: special tools, 3. Genuine ZF spare parts in accordance with the latest volume production specifications. All work performed at these service locations is carried out conscientiously and with care.

ZF Friedrichshafen AG Driveline and Chassis Technology

2008-06

6

Safety Instructions

The following safety instructions are used in this repair manual:

!

DANGER to the health!

Ensure confident handling with supplies. Manufacturer’s instructions must be observed.

NOTE Refers to special working procedures, methods, information, use of auxiliary equipment, etc.

!

DANGER to the environment!

Lubricants, consumables, and cleaning agents must

CAUTION Is used when the instructions are not complied with or not followed precisely and could lead to the product being damaged.

not be allowed to enter the soil, ground water, or sewage system. • Ask your local environment agency for safety information on the relevant products and adhere to their requirements. • Collect used oil in a suitably large container.

!

• Dispose of used oil, dirty filters, lubricants, and

DANGER!

cleaning agents in accordance with environmental

Is used when lack of care could result in personal

protection regulations.

injury or danger to life.

• When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

CAUTION The transmission must NOT be suspended by the input shaft OR by the output flange/add-on parts.

Safety Instructions

As a rule, repair technicians for ZF units are responsible for their own workplace 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 therefore familiarize themselves with these regulations.

Incorrect

Personnel required to carry out repairs on ZF products must receive appropriate training in advance. Compulsory training is the responsibility of the repair staff.

Correct

!

DANGER!

Do not walk under suspended load during parts transportation with a hoist.

2008-06

7

Instructions for Repairs

General Information

Cleaning Parts

Read this manual carefully before starting tests or repair work.

Remove old sealing compound residues from all sealing faces. Carefully remove burrs or other uneven patches using an oil stone . Lube bores and grooves must be free from anticorrosion grease and foreign matter. Check that the passage is free. Carefully cover opened transmissions to prevent the entry of foreign matter.

The ZF-Service Information details must be observed. These are available from all ZF Service Centers or from the ZF-ServiceLine. In any cases of doubt, always contact the relevant expert departments at ZF-Service. Whenever working on the transmission, ensure cleanliness and carry out the work as instructed. Use specified tools to dismantle and assemble transmissions.

Reusing Parts

Parts such as antifriction bearings, multidisks, thrust washers etc., must be inspected by a specialist, who should decide whether they can be re-used or not. Replace parts which are damaged or have suffered from excessive wear.

CAUTION The pictures, drawings, and components shown do not always represent the original object, but are used to illustrate working practices. The pictures, drawings, and components are not to scale and no conclusions must be drawn about size and weight (not even within a complete illustration). All work must be performed as described in the text.

• Gaskets, locking plates Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates). Gaskets are installed without the use of sealing compound or grease. When measuring coated gaskets/seals proceed as specified.

After repair work and tests performed, skilled personnel must make sure that the product is working properly again.

• Shaft seals Always replace shaft sealing rings with rough, ripped, or hardened sealing lips. Seal contact surfaces must be totally clean and in perfect condition.

Conversions and modifications may impact the transmission’s operational safety. Therefore, customer-specific deviations must be agreed with ZF in writing. After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the recesses of housings and covers when cleaning.

2008-06

Reworking

If rework is needed on spacer washers and shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.

8

Instructions for Repairs

• Shaft Sealing Rings Press in shaft sealing ring with fixture or face plate until firmly home at relevant installation depth.

Transmission Assembly

Assemble the transmission in a clean workplace. Adhere to all adjustment data and tightening torques specified in the repair manual.

a) Apply a thin coat of sealing agent* to outer circumference of shaft sealing rings with a «steel surround».

• Bearings If the bearings are fitted while warm, these should be warmed up evenly (e.g. heating cabinet). The temperature should be approx. 85°C and must not exceed 120°C. All bearings fitted must be coated with operating oil after assembly.

b) Never apply sealing agent to shaft sealing with a « rubber surround» but apply a thin coat of Vaseline 8420 or spirit to the outer circumference, or wet with a lubricant, e.g. a water-soluble concentrated washing-up liquid. c) Shaft sealing rings with steel and rubber surrounds should be treated on the outer circumference of the rubber surround as described for shaft seal (b).

• Sealing If a sealant* is recommended for sealing, then it is essential to adhere to the manufacturer’s directions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly. Do not allow sealing agent to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the parts are pressed together.

d) Duo shaft sealing rings have two sealing lips. The dust protection sealing lip (X) must face outwards. Fill the space between the sealing lips up to 60% with grease*.

X

• Transmission Oil After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and the List of Lubricants TE-ML (refer to type plate). These are available from all ZF Service Centers or on the Internet at www.zf.com. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.

• Retaining Agents Retaining agents* may only be used where specified by the parts list. When using retaining agents (e.g. Loctite) always comply with the manufacturer’s directions for use. During assembly, comply with all adjustment data, inspection data, and tightening torques.

* refer to consumable material

2008-06

9

Tightening torques

Tightening torques for screws/bolts and nuts, extract from ZFN 148

Surface condition of screws/bolts/ nuts: Heat-treated blackened finish and oiled or galvanized and oiled.

This standard applies to bolts according to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and for nuts according to DIN 934 and ISO 4032, ISO 8673.

The bolts are tightened using a calibrated torque wrench.

This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8, 10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.

NOTE Differing tightening torques are listed separately in the repair manual.

Coarse thread Measurement

Fine thread Tightening torque in Nm for

Measurement

Tightening torque in Nm for

Screw/Bolt

8.8

10.9

12.9

Screw/Bolt

8.8

10.9

12.9

Nut

8

10

12

Nut

8

10

12

M4

2,8

4,1

4,8

M8x1

24

36

43

M5

5,5

8,1

9,5

M9x1

36

53

62

M6

9,5

14

16,5

M10x1

52

76

89

M7

15

23

28

M10x10.25

49

72

84

M8

23

34

40

M12x10.25

87

125

150

M10

46

68

79

M12x1.5

83

120

145

M12

79

115

135

M14x1.5

135

200

235

M14

125

185

215

M16x1.5

205

300

360

M16

195

280

330

M18x1.5

310

440

520

M18

280

390

460

M18x2

290

420

490

M20

390

560

650

M20x1.5

430

620

720

M22

530

750

880

M22x1.5

580

820

960

M24

670

960

1100

M24x1.5

760

1100

1250

M27

1000

1400

1650

M24x2

730

1050

1200

M30

1350

1900

2250

M27x1.5

1100

1600

1850

M27x2

1050

1500

1800

M30x1.5

1550

2200

2550

M30x2

1500

2100

2500 Status: August 1991

2008-06

10

ZF-Ecosplit

Consumables

Designation ZF item number

Name

Grease

For example

0750 199 001

Spectron FO 20

Grease

Technical vaseline

0671 190 016

8420

Grease

For example

0750 199 019

Renolit CX-EP2

Quantity approx.

Application

Comment

General assembly aid

General assembly aid

5 grams

S/G cap seal

Chapter 10

3 grams

Double-lip seal

Chapter 10

1 gram

Detent plunger

Chapter 10

2 grams

Shaft sealing ring/pipe

Chapter 7

1 gram

R/C cap seal

Chapter 3

3 grams

R/C sealing rings

Chapter3

2 grams

Shaft sealing ring

Chapter 3

1 gram

Tappet

Chapter 2

1 gram

Pin

Chapter 2

e t i t c o L

300 mm 3

Swivel screws

Chapter 3

e t i t c o L

1 cm3

hex head screws

Chapter 2

0.50 cm3

Oil pump rotor

Chapter 7

Axial needle bearing

Chapter 4

Ball race release fork

Chapter 7

Jointing compound 0666 690 017

Loctite no. 241

Sealing compound 0666 790 033

Loctite no. 574

Corrosion

For example

protection oil

Renolin MR 40 Z

0750 199 008

0.20

cm 3

Grease 0671 190 050

Olista Longtime 3EP

3 grams

NOTE: Inquire about available package/container size before placing order!

1325 751 101 - 2009-03

11

ZF-Ecosplit

Setting data

Designation

Dimensions

Measurement device

Comment

01. Axial clearance of the

0.01 to 0.10 mm

Depth gage

Rotate countershaft in order to

countershaft

center the bearing rollers. Set zero play. Afterwards, adjust play with suitably thick compensating disk.

02. Axial clearance of the main 0.01 to 0.10 mm

Depth gage

and input shaft

Rotate input and main shaft in order to center the bearing rollers. Set zero play. Afterwards, adjust play with suitably thick compensating disk .


– 0.05 to + 0.05 mm

Feeler gage

split ring on the main shaft

04. Installation dimension of

ring.

9 ± 0.1 mm

the shaft sealing ring in

Adapter

The installation dimension can

1X56 138 669

be determined by using an

the bearing cover

05. Installation dimension of

Select suitable

adapter.

23 mm

Depth gage

–0.5 mm

the oil pump rotor

Do not separate/remove gear set, only for check.

06. Axial clearance of the snap 0 to 0.1 mm

Feeler gage

ring at deep groove ball

Adjust with suitably thick snap ring.

bearing in the ring gear carrier


0 to 0.1 mm

Feeler gage

retaining rings on the main

ning ring.

shaft and countershaft

1325 751 101 - 2009-03

Adjust with suitably thick retai-

12

ZF-Ecosplit

Setting data

Designation

Dimensions

Measurement device

Comment

08. Wear limit of synchronizer

of main transmission

Feeler gage

If the dimension is below

rings and/or clutch body,

0.80 mm

specification, replace

measured between end

synchronizer ring and/or

faces, ring, and body at

Range change group

centric, backlash-free

1.20 mm

clutch body.

abutment of the tapers

09. For information:

> 0.60 mm

Feeler gage

Upper limit of the synchronizer

Synchronizer clearance

clearance is determined by the

(axial)

wear limit of 0.80 and/or 1.20 mm.

10. Sliding pad clearance at

0.1 + 0.2 mm

Feeler gage

Measured from the sliding

the splitter group shift

pad’s bottom side to the

fork

sliding sleeve.

11. Control dimension A to adjust splitter group shift fork

short version:

Depth gage

0000 701 102

93.70 mm long version: 107.20 mm

1325 751 101 - 2009-03

See assembly instructions

13

ZF-Ecosplit

Tightening torques

Designation

Dimensions

Measurement device

Comment

01. M24x1.5 screw plugs

60 Nm

Torque wrench

Use new sealing ring.

10 Nm

Torque wrench

Breather must not be plugged.

70 Nm

Torque wrench


35 Nm

Torque wrench


50 Nm

Torque wrench

32 Nm

Torque wrench

46 Nm

Torque wrench

35 Nm

Torque wrench

on the transmission housing 02. Breather on the transmission housing 03. M26x1.5 screw plug for interlock 04. M18x1.5 screw plug on the clutch housing 05. M10x60 hex head screws on the clutch housing 06. M8x22 screw and washer assemblies on the guide pipe 07. M10x60 hex head screws on the connection plate 08. M18x1.5 screw plugs on


the transmission housing 09. M8x80

Torque wrench

M8x25 screw plugs at the shift

23 Nm

turret

23 Nm

10. M8x80 hex head screws

23 Nm

Torque wrench

position 71.180.

for pneumatic servo unit 11. Receptacle on the

24 Nm

Torque wrench

pneumatic servo unit

1325 751 101 - 2009-03

Use sealing compound at

14

ZF-Ecosplit

Tightening torques

Designation

Dimensions

Measurement device

Comment

12. M8x20 hex head screws

23 Nm

Torque wrench

23 Nm

Torque wrench

23 Nm

Torque wrench

15. Switch at the valve block

45 Nm

Torque wrench


16. Tappet switch at the valve

45 Nm

Torque wrench


10 Nm

Torque wrench

50 Nm

Torque wrench

45 Nm

Torque wrench

9.5 Nm

Torque wrench

50 Nm

Torque wrench


150 Nm

Torque wrench

Use new retaining nut.

45 Nm

Torque wrench

60 Nm

Torque wrench

for cover at the shift turret 13. M8x70 hex head screws on the valve block 14. Pressure switch at the valve block

block 17. M6x30 torx screws on the pump cover 18. M10x60 hex head screws on the range change group housing 19. Splitter group N/O contact at the clutch housing 20. M6x40 hex head screws on the 5/2-way valve 21. M16x1.5 detent plunger at the transmission housing 22. M16x1.5 retaining nut on the piston for splitter group selector rail 23. Impulse sensor at the range change group housing 24. M24x1.5 screw plug on the range change group housing

1325 751 101 - 2009-03

15


ZF-Ecosplit

Tightening torques

Designation

Dimensions

Measurement device

Comment

25. M10x40 hex head

46 Nm

Torque wrench

79 Nm

Torque wrench

15 Nm

Torque wrench

120 Nm

Torque wrench

250 Nm

Torque wrench

Use sealing compound.

150 Nm

Torque wrench

Use new retaining nut.

46 Nm

Torque wrench

50 Nm

Torque wrench


33. Switch at the R/C housing

45 Nm

Torque wrench


34. M6x25 screw and washer

9.5 Nm

Torque wrench

50 Nm

Torque wrench

115 Nm

Torque wrench

screws on the output cover 26. M12x25 hex head screws on the cover for PTO 27. M10x1 screw plug on the range change group housing 28. M12x60 hex head screws on the output flange 29. M24x1.5 swivel screws on the range change group housing 30. M16x1.5 retaining nut on the piston for R/C selector rail 31. M10x90 hex head screws on the RC/ cylinder 32. Detent plunger at the transmission housing

assemblies on the valve 35. M22x1.5 screw plugs for heat exchanger connection 36. M12x50 hex head screws on the release shaft

1325 751 101 - 2009-03

16


ZF-Ecosplit

Spring table

De

d t o n L

D

De

Spring diameter + tolerance in mm

Dh

Test sleeve diameter in mm

L0

Length of unloaded spring in mm

nt

Total number of coils

d

Wire diameter

018325

Dh

Order no.

Installation blocation

Number of coils [nt]

Wire Ø in mm [d]

Outer spring Ø in mm at L0 [De]

Free length in mm [L0]

0732 040 630

Shift turret of

6.5

2.4

39.1

89.9

6.5

2.0

14.8

23.4

9.5

1.4

9.1

23.3

18.5

1.25

6.35

34.2

35.5

0.7

3.2

34.7

12.5

1.4

6.65

23.7

13.5

1.6

9.6

36.0

12.5

1.1

5.4

18.8

5.5

2.25

14.5

21.6

superimposed H shift system 0732 040 985

Circuit at detent

0732 040 984

Circuit at detent

0732 040 385

Synchronizer of range change group

0732 040 386

Synchronizer of range change group

0732 040 409

Synchronizer of main transmission

0732 040 736

Circuit (interlock)

0732 040 983

Circuit at detent

0732 040 986

Circuit at detent

1325 751 101 - 2009-03

17

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X25 139 707

1

Chapter 2

1

Chapter 2

1

Chapter 3

1

Chapter 7

1

Chapter 8

Adapter 1

for bush on the gearshift housing

1X25 139 783 Impact adapter 2

to remove needle bush on the valve lever

1X56 136 260 Lifting device 3

for range change group

1X56 138 626 Pliers 4

for caulking the oil pipe

1X56 138 627 Assembly aid 5

1325 751 101 - 2009-03

for interlock bolts

18

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X56 138 628

1

Chapter 6

1

general

1

Chapter 8

1

Chapter 8

1

Chapter 8.3

Assembly aid 6

for connection plate

1X56 138 630 Assembly fixture 7

to clamp the transmission


to support main shaft and countershaft


to support S/G selector rail

1x56 138 633 Assembly aid 10

1325 751 101 - 2009-03

for shift fork adjustment

19

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X56 138 635

1

Chapter 8

1

Chapter 4

1

Chapter 4

1

Chapter 3

1

Chapter 5

Centering device 11

for selector rails

1X56 138 664 Locating bolt 12

d = 89.9 mm to fix the plate to range change group housing (without Intarder)

1X56 138 668 Locating bolt 13

d = 84.9 mm to fix the plate to range change group housing (with Intarder)

1X56 138 669 Press-in mandrel 14

for shaft sealing ring in the output cover

1X56 138 673

Chapter 8

Locating fixture 15

for leakage test S/G cylinder and fork adjustment of S/G selector rail

1325 751 101 - 2009-03

20

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X56 138 674

1

Chapter 3

1

Chapter 3

1

general

1

Chapter 5

1

Chapter 6

Heating device 16

for the output bearing at the inner ring

1X56 138 675 Locating fixture 17

for oil pipe (output end)

1P01 181 850 Assembly block (stationary) 18

combined with 1X56 138 630

1X56 138 063 Extractor 19

for clutch housing/transmission housing dowel pins

1X56 138 064 Protective sleeve 20

for shaft sealing ring/connection plate

1325 751 101 - 2009-03

21

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X56 137 122

1

Chapter 8

1

Chapter 5

1

Chapter 8

1

Chapter 8

1

Chapter 8

Lifting device 21

for shafts and selector rails

1X56 138 100 Locating fixture 22

for S/G selector rail

1X56 137 675 Support 23

for shafts and selector rails

1X56 137 953 Bolts 24

for shafts combined with support 1X56 137 675

1X56 137 921 Centering ring 25

for shafts and selector rails combined with lifting device 1X56 137 122

1325 751 101 - 2009-03

22

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of

Remark

pieces 1X56 137 933

1

Chapter 8

1

Chapter 10

1

Chapter 10

Washer 26

for shafts and selector rails combined with lifting device 1X56 137 122

1X56 136 722 Gripper 27

for tapered roller bearing(s) at the input

1X56 122 304

Chapter 11

Basic tool 28

combined with Gripper 1X56 136 722 Gripper 1X56 136 756

1X56 136 756

1

Chapter 11

1

Chapter 12

Gripper 29

for the tapered roller bearings on the countershaft

1X56 138 596 Gripper 30

for tapered roller bearing(s) on the main shaft

1325 751 101 - 2009-03

23

(if required)

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

No. of pieces

1X56 122 306

1

Basic tool 31

Remark

Chapter 12 (if required)

combined with Gripper 1X56 138 596

1X56 138 694

1

Chapter 8

2

Chapter 7

1

Chapter 3

1

Chapter 3

Assembly aid 32

for S/G selector rail combined with lifting device 1X56 137 122

1X56 138 695 Dowel pin 33

for clutch and transmission housing

1X56 138 696 Heating device 34

for output bearing/bearing seat of outer ring in the housing and combined with threaded spindle 1X56 137 808

1X56 137 808 Threaded spindle 35

1325 751 101 - 2009-03

to insert output bearing

24

ZF-Ecosplit

Figure

Depiction

Special tool

Order no.

Application

no.

Threaded bolt for output bearing combined with threaded spindle 1X56 137 808

1325 751 101 - 2009-03

Remark

pieces 1X56 137 654

36

No. of

25

1

Chapter 3

26

ZF-Ecosplit

Range Change Group Shift Unit

1

1325 751 101 - 2009-03

Polyamide Tubes for Range Change Group and Valve

1.1

Removing polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

1.2

Fitting polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

1-1

1-2

ZF-Ecosplit

Range Change Group Shift Unit

25

26

0510-0010

0480-0130

0510-0030

26 25

028566_1

1

Polyamide tubes for range change group and valve

1.1

Removing polyamide tubes

NOTE

1.2

Fitting polyamide tubes

1

Fit polyamide tubes 0510-0010 / 0510-0030 according to the designations. Insert polyamide tubes into plug couplings at the range change group cylinder and at the shift unit and check whether the tubes are fixed by pulling carefully. Insert polyamide tube 0480-0130 into plug couplings at Servoshift and valve.

The connecting points are marked. Tubes are reverse-mounted: • Pos. 0510-0010 (25), Valve block at the top, R/C at the bottom. • Item 0510-0030 (26), Valve block at top, R/C at bottom. 1

Unfasten polyamide tubes 0510-0010 / 0510-0030 and 0480-0130 on the plug couplings (see sketch) and remove them.

1325 751 101 - 2009-03

NOTE

Maintain minimum distance of 5 mm between polyamide tube and housing.

1-3

1-4

ZF-Ecosplit

Shift System

2

1325 751 101 - 2009-03

Shift Turret

2.1

Pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Removing pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Fitting pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2.1 Removing and dismantling gearshift housing . . . . . . . . . . . . . 2-3 2.2.2 Assembling gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.3

Shift patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Fitting complete shift turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-1

2-2 2-2 2-2

2-9

ZF-Ecosplit

Shift System

71.180 71.170 71.170

71.180

e t i t c o L

71.150

71.410

71.160

1 71.452 71.454 2

028567

2

Shift Turret

2.1.2 Fitting pneumatic servo unit

2.1

Pneumatic servo unit

1

Put in 71.452 receptacle, tighten elbow 71.454 and pipe 71.410 . Tightening torque: 24 Nm

2.1.1 Removing pneumatic servo unit

1

Unfasten hex head screws 71.170 / 71.180 .

2

Place compression spring (1) in servo unit.

2

Remove the pneumatic servo unit 71.150 with seal 71.160 and compression spring (1).

3

Fix pneumatic servo unit 71.150 together with new seal 71.160 to shift turret.

4

Insert hex head screws 71.170 / 71.180 and tighten. Tightening torque: 23 Nm

NOTE Compression spring (1) is loose in the pneumatic servo unit. Do not disassemble pneumatic servo unit any further, sub-assembly. 3

Unfasten receptacle 71.452 , remove together with elbow 71.454 and pipe 71.410 .

NOTE Insert one hex head screw 71.170 and 71.180 each using Loctite no. 574 as sealing compound. Order no.: Compression spring (1) 0501 318 490 Detent (2) 0501 319 920

1325 751 101 - 2009-03

2-2

ZF-Ecosplit

Shift System

08.890

09.090 09.090 09.270

09.320

09.090

09.290 09.280 71.110 48.070 09.580

09.100

09.250

71.130

09.100 09.040 09.010

08.870 08.470

028568

2.2

Gearshift housing

3

If necessary, unfasten neutral switch 09.270 with sealing ring and pressure switch 09.580 and remove them.

4

Remove tappet 09.240 and pin 09.250 from gearshift housing.

5

Unfasten tappet switch 09.320 with sealing ring and them remove together with compression spring 09.290 and detent 09.280 .

6

Unfasten hex head screws 71.130 and remove cover 71.110 .

7

Remove V-shaped ring 49.070 from housing.

2.2.1 Removing and dismantling gearshift housing

1

Unfasten hex head screws 08.890 and remove shift turret with seal 08.87. Remove roller 08.470 from valve lever.

NOTE For Servoshift removal, refer to Chapter 2.1 2

Unfasten hex head screws 09.090 / 09.100 and take them off together with valve block 09.010 .

NOTE seal may stick to gearshift housing; remove it from housing and place it in the valve block. Do not disassemble valve block further, sub-assembly.

1325 751 101 - 2009-03

2-3

ZF-Ecosplit

Shift System

08.830

08.830

08.830

08.440

08.810 08.530 08.540

08.430 08.450

08.560 08.410

08.490 08.100

08.800

08.130

08.470

08.010

08.300 08.370 08.380 08.350

08.080

08.360

028569

8

Unfasten hex head screws 08.830 , remove cover 08.810 and seal 08.800 .

9

Remove locking pawl 08.540 and pin 08.530 .

10

Slide pin 08.560 through gearshift housing and remove.

CAUTION Retaining rings 08.380 must not be overstretched – use adjustable pliers. 11

Unsnap retaining ring 08.380 .

12

Remove cylindrical pin 08.370/110 and, if necessary, remove retaining ring 08.370/120 .

13

Push hollow shaft 08.300 towards sealing cover.

14

Place impact adapter 1X25 139 783 on needle bush 08.440 and drive valve lever 08.410 slightly downwards.

15

Remove needle bush 08.440 .

1325 751 101 - 2009-03

16

Remove pin 08.430 .

17

Remove gearshift shaft 08.150 from gearshift housing in direction of arrow taking off valve lever 08.410 and lever 08.490 .

NOTE Inspect gearshift shaft bores and level any raised edges. 18

Remove pin 08.450 from valve lever; do not remove lower needle bush. If the needle bush is defective, replace valve lever and needle bush as a complete set.

19

Fit plastic mandrel to hollow shaft 08.300 and use hollow shaft to drive bush 08.100 and shaft sealing ring 08.130 out of gearshift housing. Push hollow shaft out of gearshift housing and take off driver 08.350 and blocking piece 08.360 .

20

If necessary, remove cylindrical pin 08.080 .

2-4

ZF-Ecosplit

21

Shift System

Use pliers to remove V-shaped ring 49.030 from gearshift shaft.

49.030 49.020

22

Remove washers 49.020 with compression spring 49.010 from the gearshift shaft.

49.010 49.020

028571

1325 751 101 - 2009-03

2-5

ZF-Ecosplit

Shift System

10

Mount washer 49.020 , compression spring 49.010 , and washer 49.020 onto gearshift shaft.

Snap retaining ring 08.370/120 into pin 08.370/110 and insert in driver and gearshift shaft. Insert retaining ring 08.380 .

11

Insert pin 08.560 to stop in housing and lock with pin 08.530 . Insert locking pawl 08.540 .

Use pliers to snap V-shaped ring 49.030 into gearshift shaft.

12

Fit new seal 08.800 and cover 08.810 .

13

Insert hex head screws 08.830 and tighten. Tightening torque: 23 Nm

2.2.2 Assembling gearshift housing

1

2

3

Slide driver 08.350 and blocking piece 08.360 into gearshift housing. Slide hollow shaft 08.300 in correct position into gearshift housing, blocking piece, and driver.

4

Press bush 08.100 flush into housing using mounting adapter 1X25 139 707 .

5

Apply grease to shaft sealing ring 08.130 and press firmly home.

6

Insert cylindrical pin 08.450 in valve lever 08.410 . If necessary, press in cylindrical pin 08.080 .

7

Fit valve lever 08.410 and lever 08.490 on hollow shaft in gearshift housing.

8

Insert gearshift shaft 08.150 in hollow shaft (in direction of arrow).

NOTE Cylindrical pin 08.450 must mesh with the gearshift shaft. Position gearshift shaft and hollow shaft.

9

Insert cylindrical pin 08.430 and drive in new needle bush 08.440 until it is flush. Check whether gearshift shaft is freely moving.

CAUTION Retaining rings 08.370/120 and 08.380 must not be overstretched – use adjustable pliers.

1325 751 101 - 2009-03

2-6

ZF-Ecosplit

Shift System

08.830

08.830

08.830

08.440

08.810 08.530 08.540

08.430 08.450

08.560 08.410

08.490 08.100

08.800

08.130

08.470

08.010

08.300 08.370 08.380 08.350

08.080

08.360

49.030 49.020 49.010 49.020

028571

028570

1325 751 101 - 2009-03

2-7

ZF-Ecosplit

Shift System

08.890

09.090 09.090 09.270

09.320

09.090

09.290 09.280 71.110 48.070 09.580

09.100

09.250

71.130

09.100 09.040 09.010

08.870 08.470

028568

14

15

Install detent 09.280 , spring 09.290 , and tappet switch 09.320 with new sealing ring in gearshift housing and tighten. Tightening torque: 45 Nm

19

Snap V-shaped ring 49.070 into gearshift housing.

20

Mount cover 71.110 to housing using hex head screws 71.130 and tighten. Tightening torque: 23 Nm

21

Place greased roller 08.470 onto valve lever.

Insert tappet 09.040 and pin 09.250 in gearshift housing. Mount valve block 09.010 with hex head screws 09.090 / 09.100 on gearshift housing. Tightening torque: 23 Nm

NOTE To fit Servoshift, refer to Chapter 2.1

17

Screw in neutral switch 09.270 with new sealing ring on valve block and tighten. Tightening torque: 45 Nm

NOTE To fit the entire shift unit to the transmission, refer to Chapter 2.4.

18

Screw in pressure switch 09.580 on valve block and tighten. Tightening torque: 23 Nm

16

1325 751 101 - 2009-03

2-8

ZF-Ecosplit

2.3

Shift System

Shift patterns Shift turret of superimposed H shift pattern 1325 173 008 Shift pattern I

Configuration of spring packages Q1

028572

Q1

028573

1325 751 101 - 2009-03

2-9

ZF-Ecosplit

2.4

Fitting complete shift turret

1

Fit new seal 08.800 to clutch housing and/or sealing face.

2

Fit complete gearshift housing 08.010 . Position bore holes in gearshift housing in line with seal.

Shift System

08.890

08.010

NOTE Positioning between the clutch housing, seal, and gearshift housing must be achieved by inserting 2 locating pins of Ø 8.9 mm. 3

08.870

Insert all hex head screws 08.890 and tighten. Tightening torque: 23 Nm

028694

Ø 15

shaft Ø 8.9

0 8

0 1 1

5 1

M8

016 078_en

1325 751 101 - 2009-03

2-10

ZF-Ecosplit

Range Change Group

3

1325 751 101 - 2009-03

Range Change Group 3.1

Removing output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

3.2

Fitting output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

3.3

Removing cover and output bearing . . . . . . . . . . . . . . . . . . . . . . .

3-4

3.4

Fitting cover and output bearing . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

3.5

Removing range change group . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6

3.6

Fitting range change group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7

3.7

Dismantling range change group . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Removing range change group cylinder and piston . . . . . . . . 3.7.2 Fitting range change group cylinder and piston . . . . . . . . . . .

3-8 3-8 3-9

3-1

ZF-Ecosplit

Range Change Group

0360-0060-0630

0360-0060-0670 0360-0060-0640

0360-0060-0680

0360-0060-0660 0360-0060-0650 0360-0060-0600

0360-0060-0620

0360-0060-0610

028648_1

3

Range Change Group

2

NOTE Please follow the work steps listed below when repairing the range change group. If the range change group is only to be removed for further repair, please carefully remove washer 0360-0060-0660 and mount fixture 1X56 136 260. For information on how to demount range change group, refer to Chapter 3.5.

3.1

Removing output flange

1

Remove hex head screws 0360-0060-0670 and 0360-0060-0680 and take off washer 0360-0060-0660.

1325 751 101 - 2009-03

Use commercially available three-armed extractor 0360-0060-0600 to pull off output flange.

NOTE Use intermediate piece to protect shaft during pulling-off process.

3-2

3

Remove hex head screws 0360-0060-0610 to 0360-0060-0640 from output flange.

4

Remove O-ring 0360-0060-0650.

ZF-Ecosplit

3.2

Range Change Group

Fitting output flange

NOTE • Range change group is fitted to the transmission, refer to Chapter 3.6. • Output bearing and cover are fitted, refer to Chapter 3.4. 1

Put hex head screws 0360-0060-0610 to 0360-0060-0640 into output flange.

!

DANGER

Only touch hot output flange when wearing protective gloves.

2

Heat output flange 0360-0060-0600 to max. 100 °C and slide onto spline of planet carrier until firmly home (axial abutment).

NOTE If necessary, pull on output flange by means of washer 0360-0060-0660 and two assembly auxiliary screws until it is firmly home (axial abutment). Remove washer and assembly auxiliary screws afterwards. 3

Lightly oil new O-ring 0360-0060-0650 and insert it in the gap between output flange and planet carrier shaft.

4

Fix washer 0360-0060-0660 with hex head screws 0360-0060-0670 and 0360-0060-0680. If required, secure the output flange against twisting by means of a flange holder. Tightening torque: 120 Nm

5

If necessary, fit protective caps on hex head screws 0360-0060-0610 to 0360-0060-0640.

1325 751 101 - 2009-03

3-3

ZF-Ecosplit

Range Change Group

0360-0050-0320

0360-0040-0400

0360-0050-0330 bis 0360-0050-0360 0360-0040-0050

0360-0050-0310 0360-0040-0100 bis 0360-0040-0190

0360-0050-0300 0360-0040-0010

0360-0040-0050

0360-0040-0060

0360-0040-0020

0360-0040-0250 0370-0200-0210 bis 0370-0200-0250

028649_1

3.3

Removing cover and output bearing

1

Remove hex head screws 0360-0050-0330 to 0360-0050-0360. Take off cover 0360-0050-0320 and seal 03600050-0310.

2

5

Unfasten cover 0360-0040-0050 by light blows with a plastic hammer and take it off together with seal 0360-0040-0060.

6

Drive shaft sealing ring 0360-0040-0070 out of bearing cover by using plastic mandrel.

7

If necessary, remove screw plug 0360-0040-0250 .

8

Use commercially available extractor to pull ball bearing 0360-0040-0020 out of housing.

If necessary, remove screw plug 0360-0050-0300 together with sealing ring.

3

Remove impulse sensor 0360-0040-0400.

4

Remove hex head screws 0360-0040-0100 to 0360-0040-0190 on the cover 0360-0040-0050.

1325 751 101 - 2009-03

3-4

ZF-Ecosplit

3.4

Range Change Group

Fitting cover and output bearing

NOTE • Range change group is fitted to the transmission, refer to Chapter 3.6. !

1X56 138 669

DANGER

Only touch heated parts when wearing protective gloves.

1

Heat housing around bearing bore up to approx. 60°C by using heating device 1X56 138 696. Heat inner bearing ring up to approx. 60°C by using heating device 1X56 138 674. 028678_1

2

3

Pull roller bearing 0360-0040-0020 with heating device1X56 138 696, adapter 1X56 137 654 and spindle 1X56 137 808 into housing via planet carrier; ensure axial abutment.

NOTE Fitting dimension of shaft sealing ring is determined by fitting driver. Lightly oil the sealing lip of the shaft sealing ring.

Install new screw plug 0360-0040-0250 with new sealing ring. Tightening torque: 60 Nm

4

Clean sealing surface on R/C housing and cover 0360-0050-0320.

5

Fit new seal 0360-0050-0310 and cover 0360-0050-0320.

6

Insert new hex head screws 0360-0050-0330 to 0360-0050-0360. Tightening torque: 79 Nm

7

Install new screw plug 0360-0050-0300 with new sealing ring. Tightening torque: 15 Nm

8

Coat shaft sealing ring 0360-0040-0070 at the outer circumference with spirit (ethanol) and press it into bearing cover by means of fitting driver 1X56 138 669 until firmly home.

1325 751 101 - 2009-03

3-5

9

Place new seal 0360-0040-0060 on housing.

10

Fit cover 0360-0040-0050 on housing and fix with hex head screws 0360-0040-0100 to 0360-0040-0190. Tightening torque: 46 Nm

11

Screw in impulse sensor 0360-0040-0400 . Tightening torque: 45 Nm

ZF-Ecosplit

Range Change Group

0370-0200-0210 bis 0370-0200-0250

0110-0190

0480-0020

0360-0030-0240

0200-0020

0480-0030 0480-0010

0370-0300 bis 0370-0500

0400-0300 0370-0200 0130-0050

0360-0030-0250

0370-0240

028644_1

6

Mount fixture 1X56 136 260 on the planet carrier. Use a crane and 2 pry bars to separate the entire range change group from the basic transmission and put it down.

Remove detent plunger 0400-0300.

7

Clean seal 0370-0240 and sealing faces.

Unfasten screw plug 0110-0190 and remove together with sealing ring; then screw in assembly aid 1X56 138 627.

8

Remove reverse shaft 0130-0050 from transmission housing.

9

Pull oil pipe 0200-0020 out of transmission housing.

10

Remove pressure disk 0370-0200 from the main shaft.

3.5

Removing range change group

1

Unfasten both swivel screws 0360-0030-0240 and 0360-0030-0250, do not remove them yet.

2 3

4

5

Unfasten hex head screws 0480-0020 and 0480-0030 and remove them together with valve 0480-0010. Unfasten hex head screws 0370-0300 to 0370-0500 on range change group and remove them.

1325 751 101 - 2009-03

NOTE If necessary, remove cylindrical pins 0370-0200-0210 to 0370-0200-0250 from the housing.

3-6

ZF-Ecosplit

3.6

Fitting range change group

1

If required, insert cylindrical pins 0370-0200-0210 to 0370-0200-0250 into housing.

2

Put seal 0370-0240 on the transmission housing.

3

Push thrust washer/pressure disk 0370-0200 on the main shaft with the collar facing the input side.

4

Use locating fixture1X56 138 675 to insert oil pipe 0200-0020 in the transmission housing with the three oil bore holes facing the input side (ensure abutment).

5

Slide reverse shaft 0130-0050 into reverse gear.

6

Attach range change group to crane and carefully move above transmission housing; then lower until it abuts.

Range Change Group

NOTE • S/G cylinder must be installed. • Guide selector rail into support plate opening for shift interlock. • Fix oil pipe from the outside and insert into plate 0360-0020-0020. • Make spline of main shaft and planetary gears mesh by turning them. 7

Screw in hex head screws 0370-0300 to 0370-0500 and tighten. Tightening torque: 50 Nm

8

Tighten swivel screws 0360-0030-0240 and 0360-0030-0250 fitted with Loctite no. 241. Tightening torque: 250 Nm

9

Install detent plunger 0400-0300 together with new sealing ring and tighten. Tightening torque: 50 Nm

1325 751 101 - 2009-03

3-7

10

Fit valve 0480-0010 to transmission housing using hex head screws 0480-0020 and 0480-0030. Tightening torque: 9.5 Nm

11

Remove assembly aid 1X56 138 627, insert new screw plug 0110-0190 together with new sealing ring and fasten. Tightening torque: 70 Nm

ZF-Ecosplit

Range Change Group

0360-0030-0070 0400-0520 0400-0400 0360-0030-0010

0360-0030-0240

0360-0030-0030 0360-0030-0040 0360-0030-0020

2

1 0360-0030-0120 0360-0030-0110 0360-0030-0090 0360-0030-0230 0360-0030-0050 0360-0030-0250 e t i t c o L

0360-0030-0100

0360-0030-0230

0510-0010 0510-0030 0360-0030-0060

0360-0030-0080

028647_1

3.7

Dismantling range change group

6

Remove retaining nut 0360-0030-0070 from piston 0360-0030-0030, take off piston, and take sealing rings 0360-0030-0040, 0360-0030-0050, and guide ring 0360-0030-0060 out of the piston.

7

Use a suitable tool to lift cap seal 0360-0030-0020 out of range change group housing.

3.7.1 Removing range change group cylinder and piston

1

2

3

Remove unfastened swivel screws 0360-0030-0240 and 0360-0030-0250. Unfasten switch 0400-0520 and remove together with pin 0400-0400.

CAUTION Cap seal might be damaged. Therefore, it must always be replaced with new one.

Unfasten hex head screws 0360-0030-0100 to 0360-0030-0120 and remove together with washers.

4

Remove cylinder 0360-0030-0090 together with seal 0360-0030-0080.

5

Detach selector rail 0360-0030-0010 from shift fork 0360-0030-0230 and pull piston out of housing bore.

1325 751 101 - 2009-03

3-8

8

If necessary, unfasten and remove plug-in couplings 0510-0010 and 0510-0030 on cylinder 0360-0030-0090 .

9

Remove housing 0360-0040-0010 from the planetary gear set.

ZF-Ecosplit

Range Change Group

3.7.2 Fitting range change group cylinder and piston

8

Snap new seal 0360-0030-0080 into cylinder 0360-0030-0090 ensuring correct position.

1

9

Place cylinder with seal on range change group and fix with hex head screws 0360-0030-0100 to 0360-0030-0120. Tightening torque: 46 Nm

NOTE • Shift fork must be inserted, refer to Chapter 4.

10

Mesh lug (1) of gearshift fork 0360-0030-0230 with recess (2) of selector rail 0360-0030-0010.

2

Coat locating bore and new cap seal 0360-0030-0020 on the outside with ethyl alcohol (spirit). Mount cap seal before ethyl alcohol volatilizes.

11

Align shift fork with threaded holes in housing in such a way that locating bores of shift fork are aligned with the housing’s threaded holes.

3

Use suitable tool to drive cap seal 0360-0030-0020 into range change group housing until firmly home (axial abutment). Grease the sealing lip of cap seal.

12

Screw in swivel screws 0360-0030-0240 and 0360-0030-0250, do not tighten.

4

Use locating pin 1X56 138 664 to place housing on planetary gear set next to PTO opening and support plate and ensure abutment.

NOTE • Threads must be clean and free from oil and grease. • Coat threads of swivel screws with Loctite no. 241.

Equip piston 0360-0030-0030 with sealing rings 0360-0030-0040, 0360-0030-0050 and one guide ring 0360-0030-0060. Place complete piston on the selector rail 0360-0030-0010.

CAUTION • Always use new retaining nut 0360-0030-0070. • Thread (Spiralock) of retaining nut must be cleaned before screwing it on. 5

Tighten retaining nut 0360-0030-0070. Tightening torque: 150 Nm

CAUTION Do not damage the cap seal’s sealing lip. 6

Insert selector rail with piston into housing bore through cap seal and ensure axial abutment of piston.

7

Grease both sealing rings0360-0030-0040 and 0360-0030-0050 and the inner side of the cylinder 0360-0030-0090.

1325 751 101 - 2009-03

3-9

13

Insert greased pin 0400-0400 and screw in and tighten switch 0400-0520. Tightening torque: 45 Nm

14

If necessary, install plug-in couplings 0510-0010 and 0510-0030 on the cylinder 0360-0030-0090 and tighten. Tightening torque: 10 Nm

3-10

ZF-Ecosplit

Planetary Gear Set with Synchronizer

4

1325 751 101 - 2009-03


4.1

Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Disassembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Assembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-2 4-3

4.2

Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Disassembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Assembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5 4-5 4-5

4.3

Planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Disassembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Assembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6 4-6 4-7

4-1

ZF-Ecosplit


4


4.1

Synchronizer

0360-0020-0200

4.1.1 Disassembling synchronizer

1

Take off shift fork

0360-0010-0540

0360-0020-0050-0190

0360-0030-0230 . 0360-0020-0250

2

Remove sliding pads 0360-0030-0200 and 0360-0030-0210 from shift fork.

3

Fit intermediate piece onto planet carrier and grip sliding sleeve 0360-0020-0050-0190 by two or three-armed extractor.

!

0360-0030-0230

0360-0030-0200 0360-0030-0210

DANGER

Thrust pieces are under spring tension. Use e.g. cloth to prevent the parts from jumping out. 0360-0020-0050-0150 0360-0020-0050-0160

4

Pull off sliding sleeve 0360-0020-0050-0190 , synchronizer ring 0360-0020-0050-0140 , and clutch body 0360-0020-0250 . The thrust pieces 0360-0020-0050-0150 , which are under tension, and compression springs 0360-00200050-0160 and 0360-0020-0050-0170 are stopped by the cloth.

0360-0020-0050-0170

0360-0020-0050-0140 0360-0020-0010

0360-0020-0200

5

Check axial bearing 0360-0010-0540 for functioning, only remove from ring gear carrier if it is defective.

6

Remove retaining ring

7

Grip clutch body 0360-0020-0010 with a two-armed extractor and pull off.

8

Take synchronizer body 0360-0020-0050-0110 with synchronizer ring 0360-0020-0050-0140 off planet carrier 0360-0010-0010 .

9

Remove plate carrier.

0360-0020-0050-0110

0360-0020-0200 .

0360-0020-0020

0360-0020-0020

from planet 0360-0010-0010

028621_1

1325 751 101 - 2009-03

4-2

ZF-Ecosplit


4.1.2 Assembling synchronizer 0360-0010-0540

NOTE For more information about synchronizer wear test, refer to Chapter 14 .

0360-0020-0200

0360-0020-0050-0190

NOTE Slightly oil the friction cones of the clutch bodies and synchronizer rings.

1

0360-0020-0250

0360-0030-0230

Position plate 0360-0020-0020 correctly on planet carrier 0360-0010-0010. 0360-0030-0200 0360-0030-0210

NOTE Locating bore for oil pipe must be at top right, see arrow.

2

Fit clutch body 0360-0020-0010 and synchronizer ring 0360-0020-0050-0140 onto the planet carrier.

0360-0020-0050-0150 0360-0020-0050-0160

3

4

Slide on synchronizer body 0360-0020-00500110, with the long hub side facing the planet carrier. The cams of the synchronizer ring 0360-0020-0050-0140 must engage with the recesses of the synchronizer body.

0360-0020-0050-0170

0360-0020-0050-0140 0360-0020-0010

Snap in retaining ring 0360-0020-0200. 0360-0020-0200

NOTE The retaining ring’s axial clearance must be between 0 and 0.10 mm. Try to have 0.0 mm. Select the retaining ring in line with items offered in the spare parts catalog.

5

0360-0020-0050-0110

0360-0020-0020

Put sliding sleeve 0360-0020-0050-0190 onto synchronizer body and ensure axial contact.

NOTE Recesses of the sliding sleeve must be congruent with recesses of synchronizer body.

0360-0010-0010

028621_2

1325 751 101 - 2009-03

4-3

ZF-Ecosplit

6


Insert new compression springs 0360-00200050-0170 and 0360-0020-0050-0160 with thrust pieces 0360-0020-0050-0150 in the synchronizer body and use suitable tool to locate them in sliding sleeve.

0360-0010-0540

0360-0020-0200

0360-0020-0050-0190

7

8

Fit synchronizer ring 0360-0020-0050-0200 to synchronizer body. The cams of the synchronizer ring must engage with recesses of synchronizer body.

0360-0020-0250

0360-0030-0230

If necessary, put new axial bearing 0360-0010-0540 onto ring gear carrier.

9

Push clutch body 0360-0020-0250 onto planet carrier.

10

Press on clutch body and bring sliding sleeve into central position. You will hear the thrust pieces snap into place.

0360-0030-0200 0360-0030-0210

0360-0020-0050-0150

11

0360-0020-0050-0160

Insert sliding pads 0360-0030-0200 and 0360-0030-0210 in the shift fork 0360-0030-230.

12

Insert the shift fork into the sliding sleeve 0360-0020-0050-0190.

13

Slightly grease the locating bores (see arrow) of the shift fork.

0360-0020-0050-0170

0360-0020-0050-0140 0360-0020-0010

0360-0020-0200 0360-0020-0050-0110

NOTE To attach range change group, refer to Chapter 3.2. 0360-0020-0020

0360-0010-0010 028621_2

1325 751 101 - 2009-03

4-4

ZF-Ecosplit

4.2


Ring gear

4.2.1 Disassembling ring gear

1

Completely pull ring gear off planet carrier 0360-0010-0010.

2

Remove bush 0360-0010-0500 from planet carrier.

3

Unsnap locking wire 0360-0010-0530 from circular groove of the ring gear 0360-0010-0520 and remove it. Drive ring gear carrier 0360-0010-0510 out of ring gear using plastic hammer.

0360-0010-0500

0360-0010-0530

4.2.2 Assembling ring gear

1

Put bush 0360-0010-0500 onto planet carrier.

2

Drive in ring gear carrier 0360-0010-0510 until firmly home with ring gear 0360-0010-0520 (axial abutment).

3

0360-0010-0520

0360-0010-0510

028619_1

Snap locking wire 0360-0010-0530 into the circular groove of the ring gear.

NOTE Locking wire must make contact with the groove base.

4

Put bush onto planet carrier. During the process, turn the ring gear and ensure that the gearings of the planetary gears mesh with the ring gear.

012012

1325 751 101 - 2009-03

4-5

ZF-Ecosplit

4.3


Planet carrier 0360-0010-0380 0360-0010-0330

4.3.1 Disassembling planet carrier

0360-0010-0040 0360-0010-0310

NOTE For reasons of simplification, only one gear set is depicted. The process is identical for all five planet carriers.

0360-0010-0160

0360-0010-0040

0360-0010-0130

1

2

3

4

Drive all dowel pins 0360-0010-0110, 0360-0010-0120 into the planetary bolts 0360-0010-0100 (full length).

0360-0010-0120 0360-0010-0110

Use a hammer and plastic mandrel to drive all five planetary bolts 0360-0010-0100 out of planet carrier 0360-0010-0010 in drive/input direction.

0360-0010-0100

Take five planetary gears 0360-0010-0040 with intermediate disks 0360-0010-0130, 0360-0010-0310, 0360-0010-0330 and rollers 0360-0010-0160, 0360-0010-0380 out of planet carrier.

0360-0010-0010

028618_1

Drive dowel pins 0360-0010-0110, 0360-0010-0120 out of planetary bolts 0360-0010-0100.

012006

1325 751 101 - 2009-03

4-6

ZF-Ecosplit


4.3.2 Assembling planet carrier 0360-0010-0380 0360-0010-0330

CAUTION Do not replace planetary gears 0360-0010-0040 individually but always as a set.

0360-0010-0040 0360-0010-0310 0360-0010-0160

1

Lightly oil the planetary gears 0360-0010-0040 on the end faces and needle roller races.

2

Position planetary bolts 0360-0010-0100 with collar facing downwards.

3

Pull intermediate disk 0360-0010-0130 over the planetary bolt.

4

Mount planetary gear 0360-0010-0040 on planetary bolt.

5

Insert 14 rollers 0360-0010-0160 in planetary gear and pull intermediate disk 0360-0010-0310 over planetary bolt.

0360-0010-0040

0360-0010-0130

0360-0010-0120 0360-0010-0110

0360-0010-0100

0360-0010-0010

028618_1

NOTE Only use rollers of the same grade tolerance.

6

Insert another 14 rollers 0360-0010-0380, lightly oil them and put on intermediate disk 0360-0010-0330.

7

Position planet carrier 0360-0010-0010 on the shaft part.

8

Carefully take the complete planetary gear with intermediate disks off the planetary bolt and insert into the planet carrier.

9

Align planetary gear with 0360-0010-0040 bearing bore hole.

NOTE The “0” marking at the planetary bolt face must face the outer radius of the planet carrier. The planetary bolt’s bore for the dowel pins must align with planet carrier’s bore.

1325 751 101 - 2009-03

4-7

ZF-Ecosplit

10


Align planetary bolt 0360-0010-0100 in radial direction and insert in bearing bore hole.

0360-0010-0380 0360-0010-0330

11

12

13

0360-0010-0040

Drive in planetary bolt by means of a plastic hammer. Check the alignment of the dowel pin bore.

0360-0010-0310 0360-0010-0160

Drive new dowel pin 0360-0010-0110 half way in. Drive the second (new) dowel pin 0360-0010-0120 into first dowel pin, offset by approx. 180° (gudgeon slots). Countersink dowel pins together into planet carrier by approx. 0.5 mm.

0360-0010-0040

0360-0010-0130

0360-0010-0120 0360-0010-0110

Repeat working steps 1 through 14 for the other four planet carriers.

0360-0010-0100

0360-0010-0010

028618_1

1325 751 101 - 2009-03

4-8

ZF-Ecosplit

S/G Valve, 5/2-Way Valve

5

1325 751 101 - 2009-03

Splitter Group Piston and 5/2-Way Valve

5.1

Removing piston and valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

5.2

Fitting valve and piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

5.3

Compressed air test for piston and S/G cylinder . . . . . . . . . . . . . .

5-4

5-1

ZF-Ecosplit


0340-0110

0340-0140

0340-0110-0120 0340-0110-0110

01.500

0340-0150 0340-0170 0340-0160 0340-0130 0340-0100 01.520

0340-0310 0340-0320 0340-0330

01.530

0340-0180 01.510

0340-0300 0340-0340

0150-0050-0010

028660_1

5

Splitter Group Piston and 5/2-Way Valve

5.1

Removing piston and valve

1

Pull off cylinder 0340-0140 by hand.

2

Unfasten hex head screws 0340-0330 and 0340-0340 and remove together with 5/2-way valve 0340-0320 from transmission housing.

3

Pick up O-rings 0340-0300 and 0340-0310 .

NOTE Do not disassemble 5/2-way valve, sub-assembly (complete unit).

7

Remove entire piston 0340-0110 from selector rail 0150-0050-0010 .

8

Remove double-lip seal 0340-0110-0120 from piston 0340-0110-0110 .

9

Take O-rings 0340-0160 and 0340-0150 off the cylinder.

NOTE • For information on how to remove cap seal 0340-0100 , refer to Chapter 9. • For information on how to remove selector rail 0150-0050-0010 , refer to Chapter 8.

10 4

Remove detent plunger 0340-0180 , insert locating fixture 1X56 138 100 .

5 6

Remove retaining nut 0340-0130 . Unsnap spring 0340-0170 at the housing.

1325 751 101 - 2009-03

5-2

Use extraction tool 1X56 138 063 to drive cylinder pins 0180-0500 to 0180-0530 in drive/input direction and remove them.

ZF-Ecosplit

5.2


Fitting valve and piston

NOTE Selector rail 0150-0050-0010 (refer to Chapter 8) and cap seal 0340-0100 (refer to Chapter 9) must be installed and greased.

1

Slip new O-rings 0340-0160 and 0340-0150 onto cylinder 0340-0140 .

2

Mount double-lip seal 0340-0110-0120 on piston 0340-0110-0110 and slightly grease.

3

Push the entire piston 0340-0110 onto selector rail 0150-0050-0010 .

4

Remove detent plunger 0340-0180 , insert locating fixture 1X56 138 100.

5

Screw new retaining nut 0340-0130 onto selector rail and tighten. Tightening torque: 150 Nm

6

Snap spring 0340-0170 into housing.

7

Remove locating fixture 1X56 138 100 , screw in detent plunger 0340-0180 . Tightening torque: 50 Nm

8

Insert cylinder 0340-0140 in the housing.

9

Insert new O-rings 0340-0300 and 0340-0310 in 5/2-way valve 0340-0320 .

10

Screw 5/2-way valve 0340-0320 to transmission housing using hex head screws 0340-0330 and 0340-0340 . Tightening torque: 9.5 Nm

1325 751 101 - 2009-03

5-3

ZF-Ecosplit

5.3

Compressed air test for piston and S/G cylinder

1

Screw locating fixture 1X56 138 673 for S/G cylinder 0340-0140 to transmission housing.

2

Pressurize 5/2-way valve and/or piston with compressed air (max. 6.8 bar).

3

Apply suitable liquid to outer diameter of S/G cylinder and try to avoid formation of blowholes.

4


1X56 138 673

0340-0140

Pressurize piston with compressed air in opposite switching direction and check for air leakage.

5

If necessary in the event of blistering, insert new O-rings in the cylinder and check cylinder for correct fit.

6

In the event of air leakage, replace double-lip seal 0340-0110-0120 on piston 0340-0110-0110 .

7

Remove locating fixture 1X56 138 673 .

1325 751 101 - 2009-03

029010_1

5-4

ZF-Ecosplit

Release Unit, Connection Plate, and Pump

6

1325 751 101 - 2009-03


6.1

Release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Removing release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Fitting release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-2 6-2

6.2

Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Removing connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 Fitting connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-4

6.3

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Fitting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6 6-6 6-6

6-1

ZF-Ecosplit

Release Unit

*

0260-0200

0260-0100

0260-0110

0260-0120

0260-0010

028574_1

6


6.1.2 Fitting release unit

6.1

Release unit

1

Slide release unit 0260-0200 over guide tube.

2

Insert release shaft 0260-0100 in release fork 0260-0010.

3

Insert release fork in release unit and attach it to connection plate using hex head screws 0260-0110 and 0260-0120. Tightening torque: 115 Nm

6.1.1 Removing release unit

1

Unfasten and remove screws 0260-0110 and 0260-0120.

2

Take off release fork 0260-0010 together with release shaft 0260-0100. Remove release shaft.

3

Remove release unit 0260-0200 from guide tube.

NOTE Apply some grease on ball socket of release fork 0260-0010.

* depending on version

1325 751 101 - 2009-03

6-2

ZF-Ecosplit

6.2

Connection Plate

Connection plate

6.2.1 Removing connection plate

1

Unfasten screw and washer assemblies 0220-0910-0340 to 0220-0910-0370 and remove by using guide tube 0220-0910-0320.

2

Unfasten hex head screws 0240-0500 to 0240-0670 and remove them.

3

Unfasten connection plate 0220-0910-0300 using pry bars and remove together with seal 0220-0910-0440.

0240-0420

0200-0010

NOTE Use cast pockets as pry bar leverage points. 0220-0910-0440

4

Remove washers 0200-0070, 0200-0080 and spacer ring 0200-0090 from input shaft.

5

Remove compensation disk 0240-0420 from countershaft and compensating disk 0240-0400 from input shaft.

6

0240-0400 0200-0070 0200-0090 0200-0080

Remove shaft sealing ring 0220-0910-0330 from connection plate.

NOTE Clean connecting surface, clean threaded holes; possibly, thread is to be recut. 7

0220-0910-0300

0240-0500 — 0240-0670

Remove and clean strainer 0200-0010.

0220-0910-0330 0220-0910-0320

0220-0910-0370

0220-0910-0360 0220-0910-0340 0220-0910-0350 028590_1

1325 751 101 - 2009-03

6-3

ZF-Ecosplit

Connection Plate

6.2.2 Fitting connection plate

1

Insert strainer 0200-0010 in clutch housing.

2

Use assembly aid 1X56 138 628 to press shaft sealing ring 0220-0910-0330 flush into connection plate 0220-0910-0300.

0240-0420

NOTE • Coat the outer circumference of the shaft sealing ring with spirits (ethanol). • Sealing lip of the shaft sealing ring faces the output drive. • Coat shaft sealing ring with some grease. 3

4

0200-0010

0220-0910-0440

0240-0400 0200-0070 0200-0090

Place specified washer 0240-0400 on input shaft.

0200-0080

Place washers 0200-0070, 0200-0080 and spacer ring 0200-0090 in correct position over input shaft.

0220-0910-0300

NOTE Washer 0200-0070 = Ø 88 mm Washer 0200-0080 = Ø 85 mm

0240-0500 — 0240-0670 0220-0910-0330 0220-0910-0320

5

Place specified compensation disk 0240-0420 on countershaft.

0220-0910-0370

NOTE Washers 0240-0400 and 0240-0420 are specified in Chapter 13. 6

0220-0910-0360 0220-0910-0340 0220-0910-0350

Place new seal 0220-0910-0440 on transmission.

028590_2

0200-0080

7

0200-0090

0200-0070 0240-0400

Apply guide tube 0220-0910-0320 on connection plate and fasten with screw and washer assemblies 0220-0910-0340 to 0220-0910-0370. Tightening torque: 32 Nm

0240-0420 028576_1

1325 751 101 - 2009-03

6-4

ZF-Ecosplit

8

Connection Plate

Align countershaft groove and impeller driver with each other. Assembly suggestion: By turning countershaft align countershaft groove so that it faces cast point (C) on the housing. Turn impeller driver so that it faces recess (D) of pump cover (see figure 031856).

9

Slide protective sleeve 1X56 138 064 over input shaft to protect shaft sealing ring.

10

Insert connection plate 0220-0910-0300 in clutch bell housing and use plastic hammer to drive firmly home. Remove protective sleeve.

D

C

031856

NOTE Threaded holes and connecting surfaces must be clean. 11

7 5

Insert new hex head screws 0240-0500 to 0240-0670 and tighten. Tightening torque: 46 Nm

8

6

A

NOTE • For better positioning of the connection plate at pos. A and B, use dowel pin (3). • Tighten hex head screws in right sequence (1 - 16).

9

1

10

2 B

4

3

16

13

12

11

14

15

028675

Ø 15

3

shank Ø 10.1

0 8

0 1 1

5 1

M10

028674_en

1325 751 101 - 2009-03

6-5

ZF-Ecosplit

6.3

Pump

Pump

6.3.1 Removing pump

1

0220-0920-0160

Unfasten and remove torx screws 0220-0920-0150 and 0220-0920-0160.

0220-0920-0120 0220-0920-0110

2

0220-0920-0150

Remove pump cover 0220-0920-0140 from connection plate.

0220-0920-0140

3

Remove gear set

and rotor 0220-0920-0110 from connection plate. 0220-0920-0120

6.3.2 Fitting pump

1

Insert rotor

and gear set 0220-0920-0120 in connection plate. 0220-0920-0110

028577_1

NOTE

Check gear set

0220-0920-0120

23-0.5

for correct assembly.

/120

NOTE

Coat rotor

and gear set 0220-0920-0120 with corrosion protection oil. 2

0220-920-0110

Insert pump cover nection plate.

0220-0920-0140

in con/110

3

Insert and tighten torx screws 0220-0920-0150 and 0220-0920-0160 in pump cover. Tightening torque: 10 Nm

Oberserve marking

0.5 max Projection permitted

NOTE

Check whether rotor is free-moving.

1325 751 101 - 2009-03

028679_en

6-6

ZF-Ecosplit

Clutch Housing

7

1325 751 101 - 2009-03

Clutch Housing

7.1

Removing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

7.2

Fitting clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3

7.3

Pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4

7-1

ZF-Ecosplit

Clutch Housing

0180-0410 0180-0500

0180-0400 1 0180-0530 0180-0400-0120 0180-0400-0110

0180-0350

0180-0510

0110-0010

2 0180-0520

0180-0600 – 0180-0800

0380-0400 0380-0420 0320-0020

0320-0010

0260-0250

028625

7

Clutch Housing

7.1

Removing clutch housing

1

Unfasten switch 0380-0420 and remove together with pin 0380-0400.

6 7

Unfasten screw plug 0180-0350 and take off together with sealing ring. Remove outer bearing ring (1) of tapered roller bearing 0150-0020-0080 and outer bearing ring (2) of tapered roller bearing 0150-0010-0230 from clutch housing.

2

Remove hex head screws 0180-0600 to 0180-0800 from clutch housing; do not use impact wrench.

3

Lift the clutch housing 0180-0400.

8

If necessary, remove closure cap 0260-0250.

4

Remove the seal 0180-0410 from the transmission housing.

9

Unfasten screw plugs 0320-0010 and 0320-0020 and take them off together with sealing rings.

5

If necessary, remove pipe 0180-0400-0120 from clutch housing.

1325 751 101 - 2009-03

7-2

ZF-Ecosplit

Clutch Housing

7.2

Fitting clutch housing

11

1

Screw in screw plugs 0320-0010 and 0320-0020 with new sealing rings and tighten. Tightening torque: 50 Nm

Screw in screw plug 0180-0350 with new sealing ring and tighten. Tightening torque: 35 Nm

12

Insert greased pin 0380-0400, and screw in and tighten switch 0380-0420. Tightening torque: 45 Nm

2

Insert closure cap 0260-0250.

3

If necessary insert new pipe 0180-0400-0120 in clutch housing. For assembly instructions, refer to Chapter 7.3.

4

Insert outer bearing ring (1) of tapered roller bearing 0150-0020-0080 and outer bearing ring (2) of tapered roller bearing 0150-0010-0230 in clutch housing.

5

Apply centering device 1X56 138 635 to transmission housing 0110-0010 and use it to position selector rails (see figure 029030).

6

Fit seal 0180-0410 and position it by using 2 centering pins 1X56 138 695.

7

Lower clutch housing 0180-0400 slowly over centering pins onto transmission housing until selector rails are centered in transmission housing.

8

029030

Remove centering device 1X56 138 635 and lower clutch housing until it makes contact.

NOTE • Measurement of axial roller bearing / main shaft is done; refer to Chapter 13. • Selector rail is adjusted; refer to Chapter 5.1. 9

Drive cylindrical pins 0180-0500 to 0180-0530 into transmission housing.

10

Insert and tighten hex head screws 0180-0600 to 0180-0800. Tightening torque: 50 Nm

1325 751 101 - 2009-03

7-3

ZF-Ecosplit

7.3

Pipe assembly

1

Insert new pipe 0180-0400-0120 in clutch housing in such a way that it protrudes by approx. 20 mm on the drive/input side.

Clutch Housing

BEFORE ASSEMBLY

5 +

0 2 . A C

NOTE

8

END OF PIPE

Ensure correct fit over the support rib in the housing. 2

Use assembly pliers 1X56 138 626 to squeeze in pipe end to actual cross section.

3

Press pipe into clutch housing for flush seat.

NOTE 1 +

Housing and pipe are deformed.

5 . 3

7.2+0.8

028676_en

AFTER ASSEMBLY

1 -

5 . 0 PRESSED-IN

FLUSH

028677_en

1325 751 101 - 2009-03

7-4

ZF-Ecosplit

Shafts, Selector Rails

8

1325 751 101 - 2009-03

Shafts and Selector Rails

8.1

Removing shafts and selector rails . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.2

Fitting shafts and selector rails . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4

8.3

Adjusting the S/G selector rail . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6

8-1

ZF-Ecosplit

8

Shafts and Selector Rails

8.1

Removing shafts and selector rails

1

Push reverse gear 0130-0010 towards housing wall (depiction without shafts and selector rails).

2

Remove screw plug 0110-0190 and sealing ring.


0130-0010

0110-0190

Screw in assembly aid 1X56 138 627. Locking pin 0150-0040-0250 of interlock is pushed against spring pressure.

3

!

DANGER

031016

Make sure that assembly aid/device and rope are 0150-0010-0010

fitted properly.

4

Screw lifting fixture 1X56 137 122 together with centering ring 1X56 137 921 and position over input shaft 0150-0010-0010, selector rails and on top of countershaft 0150-0020-0010 .

1X56 137 921

1X56 138 631 1X56 138 694

0150-0020-0010

1X56 137 122

1X56 137 933

5

Fit washer 1X56 137 933 between lifting device and countershaft. Place support 1X56 138 631 on lifting device and insert in selector rail driver.

6

Screw countershaft 0150-0020-0010 to lifting device. Tightening torque: 85 Nm

7

Insert assembly aid 1X56 138 694 via S/G selector rail 0150-0050-0010 into the lifting device 1X56 137 122 and fix selector rail with screw.

-0050-0010

029049_1

1325 751 101 - 2009-03

8-2

ZF-Ecosplit

8

Push spacer plate of support 1X56 138 631 between main shaft and countershaft (see figure 029042) at the splitter group’s synchronizer.

9

Pull shaft pack with selector rails out of transmission housing making sure they are not jammed and put down on device 1X56 137 675.

10

Remove lifting device including accessories. Remove selector rails with forks and sliding pads.

11

Take sliding pads out of shift forks.


029042

NOTE Do not disassemble selector rails further; in this condition, they are sub-assembly.

0150-0050-0050 0150-0050-0060

S/G 0150-0050-0010

031017_1

1st/R gear 0150-0040-0160

0150-0040-0100

0150-0040-0170

0150-0040-0070

0150-0040-0010 0150-0040-0080

2nd/3rd gear

031017_2

1325 751 101 - 2009-03

8-3

ZF-Ecosplit

8.2


Fitting shafts and selector rails

0150-0010-0010

NOTE • Main shaft must be measured, refer to Chapter 13. • Reverse gear must be inserted, refer to Chapter 9. • Cap seal must be fitted, see Chapter 9. • Bearing outer rings must be fitted, refer to Chapter 9. !

1X56 137 921

1X56 138 631 1X56 138 694 1X56 137 122

0150-0020-0010 1X56 137 933

DANGER

Make sure device and rope are are fitted properly.

1

Place replacement/turning bolt 1X56 137 953 on support for countershaft. Insert main shaft (output-end) 0150-0030-0010 in receptacle (support) 1X56 137 675. Mount complete input shaft 0150-0010-0010 on main shaft. Fit countershaft 0150-0020-0010 and position it at the level where the gears mesh. Push countershaft against main shaft and ensure that gears are meshing.

029049_1

0150-0050-0050 0150-0050-0060

S/G 0150-0050-0010

2

Insert selector rails with sliding pads in main shaft’s sliding sleeves. 031017_1

3

Place centering ring 1X56 137 921 in lifting device 1X56 137 122 and fasten. Move lifting device over input shaft and selector rails and ensure contact with countershaft.

4

Screw lifting device with washer 1X56 137 933 to countershaft. Tightening torque = 85 Nm

5

Place support 1X56 138 631 on lifting device and insert in selector rail driver.

6

1st/R gear 0150-0040-0160

0150-0040-0100

0150-0040-0170

Insert assembly aid 1X56 138 694 via S/G selector rail 0150-0050-0010 into the lifting device 1X56 137 122 and fix selector rail with screw.

0150-0040-0070

0150-0040-0010 0150-0040-0080

2nd/3rd gear

031017_2

1325 751 101 - 2009-03

8-4

ZF-Ecosplit

7

Push spacer plate of support 1X56 138 631 between main shaft and countershaft (see figure 029042) at the splitter group’s synchronizer.

8

Attach support 1X56 138 632 for S/G selector rail to transmission housing (see figure 029048).


CAUTION Do not damage the cap seal’s sealing lip. 9

Slowly lower shafts and selector rails; support is used to position S/G selector rail until it is centered in cap seal. 029042

10

Remove support 1X56 138 632.

11

Insert main shaft together with input shaft and countershaft (making sure they are not jammed) in tapered roller bearing outer rings of transmission housing.

NOTE • Retention (locking) by mechanical stop (interlock) must be guaranteed. • Carefully slide S/G selector rail 0150-0050-0010 through cap seal. • Mesh gearing of reverse gear. • Shift transmission to Constant 2. 12

Remove all lifting devices. 029048

13

Remove fixture 1X56 138 627 for mechanical stop (interlock).

14

Turn input shaft so that bearing rollers are centered.

1325 751 101 - 2009-03

8-5

ZF-Ecosplit

8.3


Adjusting the S/G selector rail

NOTE Only measure selector rail, if new parts have been added. For selector rail installation, refer to Chapter 8.2. 1

Screw adjusting device 1X56 138 633 to transmission housing sealing surface (1). Connect sliding sleeve 0150-0010-0100 facing output. S/G selector rail must have axial contact in adjusting device and is then in the right position.

2

Sliding pads (2) must have downward clearance in the sliding sleeve. B = 0.1 + 0.2 mm (check with feeler gage). Check dimension A: Short version = 93.70 mm Long version = 107.20 mm

1X56 138 633 1X56 138 634

0150-0050-0010 029010_2

2

4

NOTE Also refer to assembly instructions 0000 701 102. 3

B 3

Evenly tighten setscrews (4) on the shift fork (3). Tightening torque: 60 Nm

0150-0010-0100

0150-0050-0010

A

1

0340-0110 031050

1325 751 101 - 2009-03

8-6

ZF-Ecosplit

Transmission Housing

9

1325 751 101 - 2009-03

Transmission Housing 9.1

Dismantling transmission housing . . . . . . . . . . . . . . . . . . . . . . .

9-2

9.2

Assembling transmission housing . . . . . . . . . . . . . . . . . . . . . . . .

9-3

9-1

ZF-Ecosplit


0150-0040-0250 0160-0230

0150-0040-0260 0110-0200

0110-0010

0110-0180

0130-0040 0130-0020

1

0340-0100 0410-0340

0130-0010 2 0410-0320 0110-0150 0160-0240

028624_1

9


9.1

Dismantling Transmission Housing

1

2

3

Drive bearing outer ring (1) of the tapered roller bearing 0150-0020-0020 and outer bearing ring (2) of the tapered roller bearing 0150-0030-0230 out of transmission housing, in the direction of the input, by means of a soft mandrel.

4

If necessary, unfasten and remove screw plugs 0410-0320 and switch 0410-0340.

5

If necessary, unfasten and remove screw plugs 0160-0230 and 0160-0240.

6

Unscrew fixture 1X56 138 627 and locking bolt 0150-0040-0250 as well as compression spring 0150-0040-0260.

7

Use a suitable to remove cap seal 0340-0100 from housing.

8

Take reverse gear 0130-0010 with needle cages 0130-0020 and 0130-0040 out of the housing and remove needle cages from the reverse gear.

Remove breather 0110-0200 (*version depends on parts list). If necessary, unfasten screw plugs 0110-0150 und 0110-0180 and take off together with sealing rings.

1325 751 101 - 2009-03

9-2

ZF-Ecosplit

9.2

Assembling Transmission Housing

1

Screw in new screw plugs 0160-0230 and 0160-0240 with new sealing ring. Tightening torque: 35 Nm

2

Screw in screw plugs 0410-0320 and 0410-0340 with new sealing ring. Tightening torque: 35 Nm

3

Screw in screw plugs 0110-0150 and 0110-0180 with new sealing rings. Tightening torque: 60 Nm

4

Screw breather 0110-200 into housing. Tightening torque: 10 Nm !


DANGER


5

Use hot air blower to heat housing to approx. 80 °C in the area around bearing holes.

6

Insert bearing outer ring (1) of the tapered roller bearing 0150-0020-0020 and bearing outer ring (2) of the tapered roller bearing 0150-0030-0230 in the housing by means of a plastic mandrel or suitable adapter until firmly home (axial abutment).

7

Coat the outside of locating bore and new cap seal 0340-0100 with ethyl alcohol (spirit). Mount cap seal before et hyl alcohol volatilizes.

8

Use a suitable tool to drive cap seal 0340-0100 into the housing until firmly home (axial abutment). Grease the sealing lip of the cap seal.

9

Insert compression spring 0150-0040-0260 together with locking pins 0150-0040-0250 and align. Screw in assembly aid 1X56 138 627.

10

Insert reverse gear 0130-0010 with needle cages 0130-0020 and 0130-0040 in the housing.

1325 751 101 - 2009-03

9-3

9-4

ZF-Ecosplit

Input Shaft

10 Input Shaft

1325 751 101 - 2009-03

10.1

Disassembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.2

Assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-1

ZF-Ecosplit

Input Shaft

0150-0010-0090 0150-0010-0100 0150-0010-0116 0150-0010-0118 0150-0010-0112

0150-0010-0080

0150-0010-0110

0150-0010-0010 0150-0010-0124 0150-0010-0122

0150-0010-0130

0150-0010-0230

0150-0010-0240

0150-0010-0140 0150-0010-0200

028623_1

10

0150-0010-0110 , 0150-0010-0116 , 0150-0010-0122 and compression springs 0150-0010-0112 , 0150-0010-0118 , 0150-0010-0124 which are released.

Input Shaft

10.1 Disassembling input shaft

NOTE Input shaft can only be removed after clutch housing (refer to Chapter 7) and shafts have been removed (refer to Chapter 8).

1

Completely remove input shaft 0150-0010-0010 from main shaft.

2

Take off clutch body 0150-0010-080 with synchronizer ring 0150-0010-0090 from the input shaft’s synchronizer. !

DANGER

4

Release and remove retaining ring 0150-0010-0240 .

5

Pull off inner ring of roller bearing 0150-0010-0230 from the input shaft by using gripper 1X56 136 722 and basic tool 1X56 122 304 . To this end, position gripper 1X56 136 722 over roller bearing inner ring and tighten by means of knurling ring until fitted tightly on rollers.

6

Remove helical gear 0150-0010-0200 from input shaft.

7

Remove clutch body 0150-0010-0140 and synchronizer ring 0150-0010-0130 from input shaft.

Thrust pieces are under spring tension. Prevent them from jumping out.

3

Pull sliding sleeve 0150-0010-0100 off the input shaft. Catch thrust pieces

1325 751 101 - 2009-03

10-2

ZF-Ecosplit

10.2 Assembling input shaft

1

Input Shaft

8

Set sliding sleeve to center position. Apply back-pressure on clutch body 0150-0010-0080 . You will hear the thrust pieces snap into place.

9

Place input shaft on main shaft.

Check synchronizer parts for wear limit, refer to Chapter 14.

2

Put synchronizer ring 0150-0010-0130 and clutch body 0150-0010-0140 on input shaft.

NOTE For installation of input shaft, refer to Chapter 8.

NOTE The cams of the synchronizer ring must engage with recesses of the synchronizer body of the input shaft.

3

Push helical gear 0150-0010-0200 onto input shaft.

NOTE The driving spline of the helical gear faces output and must engage with inner spline of clutch body.

!

DANGER

Only touch heated roller bearing inner ring when wearing protective gloves.

4

Heat up roller bearing inner ring 0150-0010-0230 to approx. 100 °C and push onto input shaft. After roller bearing has cooled down, there must be axial contact with collar of input shaft.

5

Snap in retaining ring 0150-0010-0240 .

6

Put sliding sleeve 0150-0010-0100 on input shaft and ensure contact. Insert new compression springs 0150-0010-0112, 0150-0010-0118, 0150-0010-0124 together with thrust pieces 0150-0010-0110, 0150-0010-0116, 0150-0010-0122 in input shaft and use suitable tool to located them in sliding sleeve.

7

Place synchronizer ring 0150-0010-0090 and clutch body 0150-0010-0080 on input shaft.

1325 751 101 - 2009-03

10-3

10-4

ZF-Ecosplit

Countershaft

11 Countershaft

1325 751 101 - 2009-03

11.1

Disassembling countershaft

11.2

Assembling countershaft

11-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

ZF-Ecosplit

Countershaft

0150-0020-0020

0150-0020-0010

0150-0020-0030

0150-0020-0080 0150-0020-0040 0150-0020-0090

0150-0020-0050

028578_1

11

Countershaft

NOTE For removal of countershaft, refer to Chapter 8.

3

Unsnap retaining ring 0150-0020-0090 and remove it.

11.1 Disassembling countershaft

4

NOTE In order to protect the countershaft, a thrust piece must always be fitted between the extracting tool and the countershaft 0150-0020-0010.

Fit gripper 1X56 136 756 to inner ring of tapered roller bearing 0150-0020-0080. Turn knurling ring on gripper, until gripping piece locates firmly.

5

Screw 1X56 122 304 onto gripper and remove bearing inner ring from countershaft.

1

2

Place gripper 1X56 136 756 on inner ring of tapered roller bearing 0150-0020-0020. Turn knurling ring on gripper, until gripping piece locates firmly.

CAUTION If necessary, replace tapered roller bearings 0150-0020-0020 / 0150-0020-0080; the bearing rollers may be damaged by extraction process.

Screw basic tool 1X56 122 304 onto gripper and pull bearing inner ring off the countershaft.

1325 751 101 - 2009-03

11-2

ZF-Ecosplit

6

Countershaft

Press helical gears 0150-0020-0050 and 0150-0020-0040 and the helical gear 0150-0020-0030 off individually using a suitable hydraulic press due to high press-off force force. The press-off force for each helical gear can be as high as 500 kN.

6

Heat inner rings 0150-0020-0020 / 0150-0020-0080 up to 120 - 130 °C for max. 15 min. and place on countershaft. Ensure axial abutment, if necessary, drive in further using a soft mandrel.

7

Snap in retaining ring 0150-0020-0090. Ensure that retaining ring 0150-0020-0090 is firmly home with the groove base of the counter shaft.

NOTE To prevent gear damage, catch countershaft or helical gears on a soft surface.

NOTE The retaining ring must feature axial clearance of 0.01 - 0.10 mm; select retaining ring in line with the items listed in the spare parts catalog.

11.2 Assembling countershaft !

DANGER

NOTE For installation of countershaft, refer to Chapter 8.


1

Bores in helical gears and countershaft snug fits must be free of oil, grease, and dust.

2

Heat up helical gear 0150-0020-0030 and helical gears 0150-0020-0040 / 0150-0020-0050 to max. 170 °C.

3

Possibly cool down countershaft 0150-0020-0010, a temperature difference of 150 °C between the helical gears and the countershaft is specified.

4

Put the heated helical gears 0150-0020-0030 / 0150-0020-0040 / 0150-0020-0050 on top of each other on the hydraulic press and align exactly.

5

Press countershaft into the bores of the helical gears. Immediately repress helical gears until axial abutment position is reached. Let components cool down.

NOTE The tapered roller bearing’s inner rings may be damaged by the removal process. Therefore, carry out exact inspection and, if necessary, use new tapered roller bearings.

1325 751 101 - 2009-03

11-3

11-4

ZF-Ecosplit

Main Shaft

12 Main Shaft

1325 751 101 - 2009-03

12.1

Disassembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.2

Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12-1

12-2

ZF-Ecosplit

Main Shaft

0150-0030-0490 0150-0030-0500 0150-0030-0510 0150-0030-0520

0150-0030-0530

029028_1

12

Main Shaft

12.1 Disassembling main shaft

NOTE For removal of main shaft, refer to Chapter 8.

1

Position the main shaft (output-end) in the receptacle (support) 1X56 137 675.

2

Remove axial roller bearing 0150-0030-0520 with baffle plate 0150-0030-0530.

3

Remove cylindrical roller bearing 0150-0030-0490 with washer 0150-0030-0500 and disk spring 0150-0030-0510.

4

Turn main shaft and position it in receptacle (support) 1X56 137 675 (output-end).

1325 751 101 - 2009-03

12-3

ZF-Ecosplit

Main Shaft

0150-0030-0050

0150-0030-0030

0150-0030-0050-0050 0150-0030-0050-0060 0150-0030-0050-0110 0150-0030-0050-0020 0150-0030-0050-0120 0150-0030-0250

0150-0030-0050-0010 0150-0030-0050-0030 0150-0030-0240

00150-0030-0050-0080

0150-0030-0230

0150-0030-0040

0150-0030-0220 0150-0030-0210 0150-0030-0200 028662_1

5

Remove retaining ring 0150-0030-0240.

6

Place suitable washer on main shaft. Apply commercial two-armed extractor to R gear 0150-0030-0220 and pull off together with tapered roller bearing inner ring 0150-0030-0230.

10

!

Remove clutch body 0150-0030-0050-0080 and synchronizer ring 0150-0030-0050-0030 from synchronizer body 0150-0030-0050-0010. DANGER

During the removal process, 3 thrust pieces 0150-0030-0050-0050 and 3 compression springs

7

8

9

Remove needle-roller assembly 0150-0030-0210 with inner ring 0150-0030-0200.

0150-0030-0050-0060 are released. These parts are

Use commercial two-armed extractor in order to grip helical gear 0150-0030-0040 of 1st gear and pull off together with synchronizer 0150-0030-0050.

11

Remove sliding sleeve 0150-0030-0050-0020 , 1st gear, from synchronizer body 0150-0030-0050-0010 .

12

Washer 0150-0030-0050-0120 and clutch body 0150-0030-0050-0110 are released.

13

Remove pipe 0150-0030-0250 if damaged.

under spring tension. Prevent parts from jumping out (e.g. by using a cloth).

Remove needle-roller assembly 0150-0030-0030 (2 parts).

1325 751 101 - 2009-03

12-4

ZF-Ecosplit

Main Shaft

0150-0030-0410

0150-0030-0270

0150-0030-0440 0150-0030-0420 0150-0030-0290

0150-0030-0390 0150-0030-0450

0150-0030-0280

0150-0030-0290-0030

0150-0030-0290-0020 0150-0030-0290-0060 0150-0030-0290-0050 0150-0030-0290-0010 0150-0030-0290-0030

0150-0030-0370

0150-0030-0010

0150-0030-0380 0150-0030-0400

0150-0030-0260

029029_1

14

Turn main shaft 0150-0030-0010 and position it in receptacle (support) 1X56 137 675 (output-end).

!

During the removal process, 3 thrust pieces 0150-0030-0290-0050 and 3 compression springs 0150-0030-0290-0060 are released. These parts are

15

Remove split ring 0150-0030-0450.

16

Remove thrust washers 0150-0030-0390, 0150-0030-0380, helical gear 0150-0030-0440 3rd gear, roller rings 0150-0030-0420, 01500030-0410, and inner ring 0150-0030-0400.

17

under spring tension. Prevent the parts from jumping

Use commercial two-armed extractor in order to grip helical gear 0150-0030-0270 of 2nd gear and pull off together with synchronizer 0150-0030-0290.

out (e.g. by using a cloth).

20

Remove sliding sleeve 0150-0030-0290-0020 , 2nd gear, from synchronizer body 0150-0030-0290-0010.

21

Synchronizer ring 0150-0030-0290-0030 and clutch body 0150-0030-0280 are released.

S

18

Remove needle cage/needle-roller assembly 0150-0030-0260 (2 parts).

19

Remove clutch body 0150-0030-0370 and synchronizer ring 0150-0030-0290-0030 from synchronizer body 0150-0030-0290-0010.

1325 751 101 - 2009-03

DANGER

12-5

ZF-Ecosplit

12.2 Assembling main shaft

1

Check main shaft for free passage of lubrication oil bores. Pipe 0150-0030-0250 must be solidly seated on the main shaft.

2

Position main shaft into the receptacle (support) 1X56 137 675 (input-end).

NOTE Lightly oil the thrust faces and contact surfaces for the needle-roller assemblies and helical gears with oil.

Slide needle-roller assembly 0150-0030-0030 (2 parts) over the main shaft 0150-0030-0010.

3

Slide helical gear 0150-0030-0040, 1st gear, over the needle-roller assembly of the main shaft by means of light rotational motion. Collar faces output.

4

CAUTION Check wear limit of all synchronizer rings and/ or clutch bodies as described in Chapter 14.

5

Main Shaft

7

Slide sliding sleeve 0150-0030-0050-0020, 1st gear, over synchronizer body, synchronizer ring, and clutch body, and fit to the helical gear, 1st gear. In this context, make sure that the recesses at the inner side of the sliding sleeve are congruent with the fitting locations of the synchronizer body (for compression springs and thrust pieces).

8

Insert three compression springs 0150-0030-0050-0060 together with thrust pieces 0150-0030-0050-0050 by means of a suitable tool in the bores of the synchronizer body and turn into the sliding sleeve.

NOTE Use new compression springs and pull the sliding sleeve into the center position (neutral position).

9

Insert washer 0150-0030-0050-0120 in synchronizer body.

10

Fit clutch body 0150-0030-0050-0110 on the main shaft. Flat side faces output.

11

Slide inner ring 0150-0030-0200 and needleroller assembly 0150-0030-0210 onto main shaft shaft until it abuts against synchronizer body.

12

Slide helical gear 0150-0030-0220, R gear, over the needle-roller assembly by means of light rotational motion. Driving spline points towards the drive-end. In this context, make sure that the clutch body lies on the driving spline.

Place clutch body 0150-0030-0050-0080 with synchronizer ring 0150-0030-0050-0030 onto driving spline. !

DANGER

Only touch heated synchronizer bodies when wearing protective gloves.

6

Heat up synchronizer body 0150-0030-00500010 to approx. 120 °C and slide onto main shaft gearing. Narrow sides faces output. !

NOTE The cams of the synchronizer ring must mesh with the recesses of the synchronizer body.

1325 751 101 - 2009-03

DANGER

Only touch heated tapered roller bearing’s inner ring when wearing protective gloves.

12-6

ZF-Ecosplit

Main Shaft

0150-0030-0050

0150-0030-0030

0150-0030-0050-0050 0150-0030-0050-0060 0150-0030-0050-0110 0150-0030-0050-0020 0150-0030-0050-0120 0150-0030-0250

0150-0030-0050-0010 0150-0030-0050-0030 0150-0030-0240

00150-0030-0050-0080

0150-0030-0230

0150-0030-0040

0150-0030-0220 0150-0030-0210 0150-0030-0200

028662_1

13

14

Heat up tapered roller bearing inner ring 0150-0030-030 to approx. 120 °C and slide onto main shaft; drive in further to ensure axial abutment.

0150-0030-0050-0020 0150-0030-0050-0050 0150-0030-0050-0030 0150-0030-0050-0110

Snap in retaining ring 0150-0030-0240.

NOTE The retaining ring’s axial clearance must be between 0.01 and 0.10 mm. Select the retaining ring in line with items offered in the spare parts catalog.

15

Turn main shaft around and place it into the receptacle (support) 1X56 137 675 (outputend).

0150-0030-0050-0080

0150-0030-0050-0120

0150-0030-0050-0060 0150-0030-0050-0010

028663_1

1325 751 101 - 2009-03

12-7

ZF-Ecosplit

Main Shaft

0150-0030-0440

0150-0030-0410

0150-0030-0270

0150-0030-0420 0150-0030-0390 0150-0030-0290 0150-0030-0450 0150-0030-0490 0150-0030-0500 0150-0030-0510 0150-0030-0280 0150-0030-0290-0030

0150-0030-0290-0020

0150-0030-0520

0150-0030-0290-0060 0150-0030-0530

0150-0030-0290-0050 0150-0030-0290-0010 0150-0030-0290-0030 0150-0030-0370 0150-0030-0380

0150-0030-0010

0150-0030-0400 0150-0030-0260

028661_1

16

Slide needle-roller assembly 0150-0030-0260 (2 parts) onto main shaft.

17

Slide helical gear 0150-0030-0270, 2nd gear, over the needle-roller assembly by means of light rotational motion. Driving spline points towards the drive-end.

18

Place clutch body 0150-0030-0280 with synchronizer ring 0150-0030-0290-0030 onto driving spline.

CAUTION Check wear limit of all synchronizer rings and/or clutch bodies as described in Chapter 14. !

19

NOTE The cams of the synchronizer ring must mesh with the recesses of the synchronizer body.

20

DANGER

Only touch heated synchronizer body when wearing protective gloves.

1325 751 101 - 2009-03

Heat up synchronizer body 0150-0030-0290-0010 to approx. 120 °C and slide onto main shaft gearing. The synchronizer body is symmetric and therefore can be fit to the unit irrespective of its lateral position. Drive in synchronizer body further to ensure axial abutment.

12-8

Slide sliding sleeve 0150-0030-0290-0020, 1st /2nd gear, over synchronizer body, synchronizer ring, and clutch body, and fit to the helical gear, 1st gear. In t his context, make sure that the recesses at the inner side of the sliding sleeve are congruent with the fitting locations of the synchronizer body (for compression springs and thrust pieces).

ZF-Ecosplit

21

Main Shaft

Insert three compression springs 0150-0030-0290-0060 with thrust pieces 0150-0030-0290-0050 by means of a suitable tool in the bores of the synchronizer body and/or turn into the sliding sleeve.

NOTE Use new compression springs.

22

23

Place clutch body 0150-0030-0370 onto the synchronizer ring and pull the sliding sleeve into the center position (neutral position). During the process, push the synchronizer ring and clutch body tight. Put on thrust washer 0150-0030-0380 and inner ring 0150-0030-0400.

25

Insert roller rings 0150-0030-0410 and 0150-0030-0420 in helical gear 0150-0030-0440, 3rd gear.

26

Push helical gear 0150-0030-0440 with collar facing the output into the clutch body via the inner ring and fit thrust washer 0150-0030-0390 .

27

Insert split ring 0150-0030-0450 in the groove of the main shaft and use retaining ring to secure by 3x120° caulking.

Heat up cylindrical roller bearing 0150-0030-0490 to approx. 120 °C and slide onto main shaft until firmly home.

29

Fit washer 0150-0030-0500.

NOTE Before fitting disk spring 0150-0030-0510, the input and main shaft must be measured. For measurement, refer to Chapter 13.

Fit synchronizer ring 0150-0030-0290-0030. The cams of the synchronizer ring must mesh with the recesses of the synchronizer body.

24

28

30

Fit disk spring 0150-0030-0510 and axial roller bearing 0150-0030-0520.

31

Insert baffle plate 0150-0030-0530 in axial roller bearing and main shaft.

NOTE For installation of the main shaft, refer to Chapter 8.

NOTE The axial clearance of the split ring must be between – 0.05 and + 0.05 mm. Select the retaining ring in line with items offered in the spare parts catalog. !

DANGER

Only touch heated cylindrical roller bearing when wearing protective gloves.

1325 751 101 - 2009-03

12-9

12-10

ZF-Ecosplit

Main Shaft, Input Shaft, and Countershaft

13 Bearing Setting on Main Shaft, Input Shaft, and Countershaft

1325 751 101 - 2009-03

13.1

Setting the main and input shaft . . . . . . . . . . . . . . . . . . . . . . . . 13-2

13.2

Setting the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

13-1

ZF-Ecosplit

13


Bearing Setting on Main Shaft, Input Shaft, and Countershaft

13.1 Setting the main and input shaft

0150-0030-0530

0150-0030-0520

CAUTION Set the main and input shaft with the respective clearance. Clearance is 0.01 - 0.10 mm

0150-0030-0510

0150-0030-0500

1

Assemble main shaft, as described in Chapter 12.2, until you get to disk spring. Do not mount disk spring 0150-0030-0510 .

2

Fit axial roller bearing 0150-0030-0520 and insert baffle plate0150-0030-530 in axial roller bearing and the main shaft.

3

Insert main shaft in transmission housing using lifting tool.

0150-0030-0490

NOTE Bearing outer ring at the output-end must be fitted. 031051

4

Place input shaft on main shaft.

5

Use dowel pins to place clutch housing on transmission housing.

NOTE Bearing outer ring at the input-end must be fitted. 6

Set the input bearing play to zero; to this end, drive bearing outer ring with mandrel in the direction of the main shaft.

CAUTION Do not push or hammer close to oil ducts . Otherwise, housing is damaged. 7

Rotate input and main shaft a few times in order to center the bearing rollers at the bearing points. Check by means of a pointed device whether the bearing rollers can be shifted.

NOTE Constant 2 must be selected in the transmission. 031045

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NOTE In the case of zero play, the bearing rollers must be backlash-free, i.e. it should not be possible to shift them to one or the other side. However, it must be ensured that no preload is generated either. 8

Use de dept pth h gag agee to mea eassur uree th thee di dist stan ance ce between the upper edge of the outer bearing ring and the connecting surface of the clutch bell housing; note down the dimension and add thickness of seal/gasket 0240-0440 0240-0440.. The result is dimension “A” A”.. Exampl Exa mple: e: A = 6.5 6.50 0 mm + 0.40 mm (seal/gasket) – 1.00 1.00 mm (thickn (thickness ess of dis disk k spr sprin ing) g) A = 5.90 mm

031049

NOTE Perform measurement at two opposite locations and calculate mean value. 9

Use de dept pth h gag agee to mea eassur uree th thee di dist stan ance ce between the connecting face and compencompensating disk’s contact surface, note down dimension “B” “B”.. Example: B = 4.20 mm

NOTE Perform measurement at two opposite locations and calculate mean value. value. 10

Determ rmiine di diff ffeerence “C” and note down. Example: C = A – B = 5.90 mm – 4.20 mm C = 1.70 mm

11

031056

Calculate th thiick ckn ness “D” of compensating disk 0240-0400.. 0240-0400 Example: D = C – clearance = 1.70 mm – 0.10 mm D = 1.60 to 1.70 mm

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12


Select compensating disk 0240-0400 in line with items offered in the spare parts catalog.

NOTE Installation of compensating disk 0240-0400 is described in Chapter 6. 6. 13

B

0240-0440

Remove cl clutch ho housing.

0240-0400

14

Remove entire input shaft.

15

Use lif Use lifti tin ng de devi vice ce to ta tak ke mai main n sha shaft ft out of the transmission housing and put it on fixture.

16

Rem Re move ba baff ffle le pl plat atee an and d axi xia al be bear arin ing. g. A

17

18

Complete ma main sh shaft as de descri rib bed in in Chapter 12.2. 12.2 .

028626_1

For shaft installation, see Chapter 8. 8.

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13.2 Sett Setting ing the coun counter tershaft shaft

NOTE • Shafts and selector rails must be completely installed; refer to Chapter 8. • Main shaft must be measured; refer to Chapter 13.1. CAUTION Set countershaft with play play.. Play is between 0.01 and 0.10 mm. 1

Tra rans nsm mis issi sion on is in ve vert rtic ical al po possit itiion on..

2

Set the Set the co coun unte ters rsha haft ft’’s ro roll ller er be bear arin ingg pla play y to zero; to this end, drive bearing outer ring with mandrel in the direction of the countershaft.

031046

CAUTION Do not push or hammer close to oil ducts . Otherwise, housing is damaged. 3

Rotate Rota te co coun unte ters rsha haft ft a few few ti time mess in in or orde derr to center the bearing rollers at the bearing points. Check by means of a pointed device whether the bearing rollers can be shifted.

NOTE In the case of zero play, the bearing rollers must be backlash-free, i.e. it must be impossible to shift them to one or the other side. However, it must be ensured that no preload is generated either. 031047

4

Use de dept pth h gag agee to mea eassur uree th thee di dist stan ance ce between the connecting surface of the clutch bell housing and the upper edge of the outer bearing ring; note down the dimension and add thickness of seal 0240-0440 0240-0440.. The result is dimension “a” “a”.. Example: a = 4.00 mm + 0.40 mm (seal) a = 4.40 mm

NOTE Perform measurement at two opposite locations and calculate mean value.

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5


Use depth gage to measure the distance between the pump and the contact surface of the connection plate, note down dimension “b”. Example: b = 1.40 mm

6

Determine difference “c” and note down. Example: c = a – b = 4.40 mm – 1.40 mm c = 3.00 mm

7

Calculate thickness “d” of compensating disk 0240-0420: Example: d = c – clearance = 3.00 mm – 0.10 mm d = 2.90 to 3.00 mm

8

031048

Select compensating disk 0240-0420 in line with items offered in spare parts catalog.

NOTE Installation of compensating disk 0240-0420 is described in Chapter 6.

b

0240-0420

0240-0440

a 028627_1

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Synchronizer

14 Synchronizers

14.1 Determining the wear limit of synchronizers . . . . . . . . . . . . . . . . . 14-2 14.2 Assembling synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 14.3 Cross section of a synchronizer / ZF-BK . . . . . . . . . . . . . . . . . . . . . 14-3

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14

Synchronizer

Synchronizers X

14.1 Determining wear limit of synchronizers

The condition of the synchronizer rings and clutch bodies must be checked before the synchronizers are assembled.

1

2

NOTE

Do not mix up synchronizer parts. 1

Place synchronizer ring (2) on the corresponding clutch body (1). Turn the synchronizer parts and thereby ensure even and parallel contact of tapers. The wear limit of synchronizer rings on the synchronizers of the main transmission and splitter group is 0.8 mm, and 1.2 mm for the range change group.

2

Use feeler gage to measure distance (X) between clutch body and synchronizer ring at two opposite points. If the wear limit falls below 0.8 or 1.2 mm respectively, the synchronizer ring and/or clutch body must be replaced.

3

001999

Also check the condition of the synchronizer parts (visual check). If t he surface is corrugated, replace synchronizer parts. Do not mix up parts which were checked together (mark them).

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Synchronizer

14.2 Assembling Synchronizer 2 1

ZF-BK version

1

Check the wear limit.

2

Replace compression springs (5) with new ones. Thus, specified sliding force of sliding sleeve (6) is ensured. 4

3

4

5

Synchronizers can be assembled as a complete set or in a one assembly process directly on the main shaft.

5

Push sliding sleeve (6) onto synchronizer body (3). Insert new compression springs (5) with thrust pieces (4) into the synchronizer body (3). Position the mandrel at the center of the thrust pieces and guide thrust pieces into sliding sleeve (6).

3

1a 6

2a

Put on clutch body (1) with synchronizer ring (2) and push sliding sleeve (6) to center position.

NOTE

Observe the correct position of the thrust pieces. 009510

14.3 Cross section of a synchronizer / ZF-BK 6

1/1a

Clutch body

2/2a

Synchronizer ring

3

Synchronizer body

4

Thrust piece

5

Compression spring

6

Sliding sleeve

2

2a

1

5

4

1a

3

001940

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ZF Ecosplit 12 Speed_1325_751_101_en 2009.pdf

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