Component Manual ZF IntarderContents 14 12 13 14 15 16 17 18 Foreword .. General : Safety instructions . . Dipped bots. . Use of locking compounds . Tightening torques... ‘Addition . Use of seals... Fitting on bearings... - Spring table... Adjustment data Tightening torques. Special tools ‘Transmission view Transmission section. . Disassembly Oilfiter removal ..... Heat exchanger removal, solenoid valve, reservoir, ‘epee sensor Removal of Intarder from main transmission il pump removal Control unit housing and vaive removal Stator and rotor removal Input spur gear removal. Stator removal ......-+ SSLSSesBy Assembly Stator and rotor assembly . - Stator and rotor installation . Fiting of taper roller bearing to rotor and taper roller bearing auton « Valve assembly and fiting of control unit housing . ll pump assembly and mounting . : ‘xia play measurement stato and grooved bal bearing on min wansmission) Fitting of intarder .......- Fiting of reservoir and temperature ‘sensor to heat averages : Fiting of heat exchanger Fitting of ol fter to Intarder Fitting of solenoid valve to reservoir &ESBBSForeword Foreword ‘This component overhaul book is intended to help well-trained and experienced workshop staff overhaul ‘components and carry out setting procedures and repair operations. This book therefore includes a list of special tools, technical data, instructions for the removal and installation of components, and setting procedures. Furthermore, you will find safety instructions, which should be strictly adhered to.General General Tris book is based on the component and its parts as originally fitted in DAF vehicles. There may be different types and versions of the ‘components described in this book, because every vehicle is constructed in accordance with the legal regulations of the country where itis sold and in accordance with the expected operating conditions. AS ‘a result, the component you are overhauling may be slightly different from the descriptions and illustrations in this book. The technical data and setting data shown in this ‘component overhaul book have been compiled with the ‘greatest care and they only refer to the components. described in this book. The information given in this book was up-to-date at the date of issue. The date of issue is stated at the bottom of the page. DAF reserves the right to make, if necessary, changes to the procedures specified and to the setting data without prior notice. Important changes to the information given in this ‘component overhaul book will be published in the Technical Information (T.,) bulletins. These bulletins can be ‘obtained through your contact person. ‘To be able to carry out the operations correctly and, safely, the mechanic should have the experience required and he should have followed the necessary ‘raining courses. * Always use the special tools specified in this book. ‘These tools not only make the work easier and. ‘quicker but also safer, and they avoid irreparable ‘damage to the component or part. * Only use genuine DAF parts and components. They are carefuly matched, which is one ofthe factors determining the original DAF quality. This quality is best guaranteed if genuine DAF parts and ‘components are used when replacement is. necessary. ‘= When draining oils or other fluids, collect them in a suitable container and ensure that they are properly disposed of and/or processed. + NOTE ‘The intarder may only be repaired if itis, ‘guaranteed that following repair a purchase check can be carried out on the test bench,Safety instructions Safety instructions ‘When text is accompanied by the waming symbol shown here, this indicates that the information in question is very important for the machanic's health and safety. The instructions given with the warning symbol should therefore be strictly adhered to. ‘+ Follow out the instructions given on stickers and labels attached to the component. '* Avoid unnecessary contact with drained oil or other fluids. + Be careful when working on springs under tension. ‘Aspring jumping off may cause serious inury. Even ‘small springs and circlips jumping off may cause injury (protect your eyes). © When removing or installing heavy components, always use approved iting and/or hoisting tools ‘and attach them securely to the component ‘concerned. ‘= Some plastics used for oll seals and other sealing rings may leave dangerous residues after they have been exposed to high temperatures. When removing these residues, wear acid resistant clothes and PVC gloves. The residues should be dipped in or ‘generously sprayed with a calcium hydroxide solution (slaked lime in water) Protective clothing should be thoroughly cleaned after use. The gloves should be treated as chemical waste.Dipped bolts Dipped botts Vehicles and components may be fitted with dipped ruts and bots. In production, zinc-coated nuts and bolts are wax-dipped, whereas blackened and phosphated nuts and bolts are ol-dipped. The advantage of the use of dipped nuts and bolts is reduced friction during tightening, so that the specified pre-tension can be accurately obtained (smaller pre- tension range). ‘Asa consequence, the tolerance range of the tightening torques has also become smaller, which means that the specified tightening torques should be accurately adhered to, So always use a reliable torque spanner. NOTE Have torque spanners calibrated regulary. Instructions with respect to threaded connections ‘+ To obtain the correct pre-tension for nuts and bolts ‘which are being re-used, the screw thread should be thoroughly cleaned. After the cleaning, apply one % 1" 1 z F Cre 13Tightening torques ‘Screw plugs on control unit housing Intarder housing, items 35 to 47 47 46 a f— 37 4s A 5 38 4“ S 39 ay “0 a om item No. Description Tight. torque | Dimension | Remarks 35, 96, 37 ‘Sorew plug 25Nm MI2K0.5 38,39 ‘Sorew plug 70Nm 261.5 40 ‘Sorew plug 150Nm Maat 5 a2 Sorew plug 60Nm Meat 5 4 Control valve 70Nm M26x1.5, 45 Screw plug 400Nm M30x1.5 46,47 Cyling. screw 23Nm Max22 4Tightening torques Retaining screws on contro! unit housing Control unit housing, item 1 to 33 tem No. Tight. torque | Dimension | Remarks 2 62Nm Mi2xt15 1.34 62Nm M12x120 5 23Nm Maxt15 6,7,8,9,10 23NNm Max30 n 50Nm M0215 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 | 23 Nm Mexa0 25, 26, 27, 28, 29, 30, 31 23Nm Maxt05 32, 33 23Nm ‘Max30Tightening torques Ecomid Intarder housing, item 11, and 49 to 66 54055 BEE 66 67 538 59 83 0 52. 61 51. 2 Q ~ 63 49: 66 65 64 s7* item No, Description Tight-torque | Dimension | Remarks " Hex screw 50Nm Mi0x215 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 81, 62, 63, 64, 65,66 | Hex screw 50Nm (10x60, 87 Verschlufschraube 50.Nm Miox60 | with bore in head 87 Preload valve 1 BaeTightening torques Ecosplit Intarder housing, tems. 11, and 49 to 73, tem No. Description Tight.torque | Dimension | Remarks 1" Hex screw 50Nm Mi0x215 49, 50, 51, 58, 54, 55, 56, 64, 65, 66, 67, 69, 70, 71, 72,73 Hex screw 5ONm 10x60 58, 59, 60, 61 Hex screw 50Nm M10x75 62, 63, Hex screw 50.Nm 10x35 with washer 6 Hex screw SONm Mt10x180 52 Hex screw 50Nm ‘M10x60 ‘with bore in head “87 Preload valveIS ® | = a (0694780 (Ecos) "10488 Eos)Special tools Fig. | ttlustration Order No. ‘Application | ty. | Remarks No. * 4310459 1 | possible to use Hydraulic spindle M40 spindle for pressing out rotor and stator from flange (in conjunction with 1310462) extractor 1 ‘Workshops with hydraulic tools refer of main to tool appendix, page 7.8" do not transmission. require hydraulic spindle. * 1310460 7 Centring disc Use as guide when installing stator 2 and rotor. + 1310461 1 Adjustment fixture for taper roller bearing on stator and 3 rotor. + 1310462 1 | absolutely necessary if Extraction fixture 15ton for pressing out stator and rotor hydraulictspindle 4 press is not (with 1310459 or with universal available. hydraulic too, refer to appendix). 1910463 1 Ring for iting spur gear when assembling 5 inner race of taper roller bearing. 19Special tools Fig. | titustration Order No. ‘Application Remarks No. (0694780 Tefer to tool for basic Tool transmission, for shaft seal 105x130 possibly already available (refer 6 (used with too! 1310467) to Ecospiit) 310464 Too! for driving in inner race of 7 taper roller bearing Tat0465 Tool for instaling needle sleeve in control e housing and pump housing Ta10866 refer to tool for basic Tool transmission, for shaft seal 105x130 possibly already ° available (refer (used with too! 0694780) ‘0 Ecospiit) 7310867 required i 1310462 not Ring used for pressing out stator and rotor with 10 spindle press or hydraulic press 20 paseSpecial tools Fig. | tilustration ‘Order No. Application | Qty. | Remarks No. 1 | refer to basic transmission ‘Tool for tool for driving retaining plate into output " flange 1 | standard unit, ‘expansion Three-leg puller width approx. for removing spur gear and stator dia. 140 mm 12 1310468 1 | only on Ecomid e.g. 8S 180 Too! for shaft seal 90x110xt0 on 13 ‘output flange 1310496 1 Calibration mandrel for bore - pressure relief valve / 14 ccontrol valve 1310497 1 Calibration mandrel for bore - pressure increase valve 15 21Special tools a | tusation oa. joo ne 1310498 Calibration mandrel for bore - cooler changeover valve 8 1310499 Cation mani fervoe peer ” TO a. i ates | toasurhg plugs —. (M24X1.5 x M12X1.5) 18 \\ used on Intarder housing / control » cae ee nea sere Cimaeeenaae 19 Py L Ea parTransmission view ZF-Ecomid bus transmission with ZF-Intarder 8 S 140 und 8 $ 180 (figure shows 8 S 180) ‘ZF-Ecomid truck transmission with ZF-Intarder 9 $ 109 und 16 $ 109 (figure shows 16 S 109) 23Transmission view 88 140/88 180 98 109/165 109 24 RaeTransmission viewTransmission section 16S 151 X= depending on version 26Disassembly 1 Disassembly 1.1 Remove oil filter 1 = Oil fiter (1) on Intarder 1 Remove M8x20 retaining screw and washer from oil iter. 2 Pull fiter from fiter neck using pliers. Remove oll fiter from Intarder housing. Beware of escaping oil. Catch escaping oll in suitable container.Disassembly 3 Remove filter cover from oil filter. 2 = Remove fiter cover from oi iter. 3 = O-ring fiter ‘Magnetic disc CAUTION Always renew filter. Cleaning old fiter is not sufficient. NOTE: Take magnetic disc (4) from removed fiter cartridge (I fitted) and keep to one side for subsequent fitting to new fer cartridge. itDisassembly 1 = Nut (M12) (wat 16) TA=62Nm | 2= O-ring ‘Stud bolt TA = 18 Nm 4 = Hex screw (M8x115) TA=23Nm ‘Screw plug TA=35Nm 6 = O-ring Hex screw (M8) TA=23Nm 8 = Line connection - solenoid valve 9 = Sorew plug 1.2 Remove heat exchanger, solenoid valve, reservoir, and temperature sensor ‘CAUTION In the following procedure, oil will flow out of heat ‘exchanger. Catch oil as it emerges. Support heat exchanger to prevent from falling. 4. Unfasten nuts (1) (waf 18) on stud bolts and unscrew. Unscrew and remove on M&x115 (4) hex nut from oil connection flange on heat exchanger. Remove heat exchanger and reservoir. Femove two O-rings (2) from heat exchanger oil ducts in control unit housing. TA=23Nm TA=23Nm TA=23Nm 16 = Screw plug TA=35Nm 17 = Temperature sensor (M18x1.5) TA= 40 Nm 10 ‘Angie plate Unscrew and remove retaining screws (12) from solenoid valve, remove valve from reservoir. Unscrew and remove retaining screws (14 or 15) from angle plate and on reservoir connection flange (), remove reservoir. Remove O-ring (6) from annular groove in reservoir. Unscrew and remove temperature sensor (17) from heat exchanger.Disassembly 1 = Retaining plate 13 = Hex sorew (M10x275) TA 50m Hex screw (TA = 60 Nm depen. on version, 120Nm) 14 = Hex screws for cardan shaft | 3= Washer 15" Hex screw Ta=50Nn | | 4= o-ng (65x4) (head with bore for wire retainer) | = Output flange 16 = Hex screw TA=50Nm | Ring 17 = Hex screw TA=50Nm 7 = Shaft seal 18 = Shim (thickness 1.6 0 0.9 mm, 0.1 mm steps) = Hex screw (M10x5/8.8) —‘TA=46Nm 19 = Shim (thickness 06, 0.5, 04,03, 02mm) Hex screw 20 Gasket 10= Hex screw ‘A = Sealing face of Intarder housing 11 = Hex screw £8 = Contact face for output shat bal bearing 12 Hex screw TA=60Nm C= Contact face for stator 13 Removal of Intarder from main transmission 11 Release output flange (6), remove shim (3) and (O-ring (4), extract flange with tworleg pul. 12 Remove ring (6) or, instead of ring (6), remove ring gear (not shown in drawing) from output flange. NOTE: Depending on version, screw (13) can have screw-in thread in housing 3 as well asa through-hread in the Intarder housing. CAUTION In the following procedure, the intarder becomes free and may fall. Secure intarder to prevent it from falling. 18 Remove hex screws (8, 9, 10, 11, 12, 13, 15, 16 and 17) from Intarder, remove Intarder. 14 Remove gasket (20) and shims (18 and 19).Disassembly 1= O-ring 2 Ring gear 3= Shaft 4=V-ring Needle sleeve 6 = Oring 7 = Pump housing 8 = Hex screw, (x4) (MBx80) TA = 23 Nm 9 = Hex screw, (x1) (M&x30) TA = 23 Nm 10 = Dowel pins (x2) 11 = Mark on ring gear (ease of assembly) 1.4 Oil pump removal 15 Unscrew and remove screws (8 and 9). 16 Remove pump, pressing off with pry lever if necessary until dowel pin (10) comes tree. 17 Remove O-rings (1 and 6) from control unit housing. 18 Remove shatt (2) and ring gear (2) from pump. housing. Check the following ‘Axial play on ring gear: 0.03 - 0.05 mm No scoring permitted on ring gear, shaft and ring gear bore in housing. ‘Check that pump pinion (3) is fimiy located on shat. pes 31DisassemblyDisassembly 1 = Cooler changeover valve 1.1. = Screw plug (M48) with seal 1.2 = Compression spring, e.g. 0732 042 402 13 = Piston | 2. = Pressure relief valve (12 bar) 2.1 = Screw plug (M26) with seal 22 = Piston 2.3 = Compression spring, e.g. 0732 042 470 2.4 = Compression spring, ¢.9. 0782 042 471 25 = Piston 3 sfety valve (14,5 bar) 3.1 = Sorew plug M12x1.5 with seal 3.2 = Compression spring, e.g. 0732 041 247 3.3 = Ball 4 = Screw plug M26 M 26 with seal 5 = Screw plug M12 (pump pressure) with seal 6 = Screw plug M12 (control pressure) with seal 7 = Cover 8 = Proportional solenoid with control valve &1 = Cylindrical screw 8.2 = Orring 83 = Piston (control valve) 9 = Hex screw (M10x215) 10 = Pressure valve 10.1 = Screw plug (M30x1,5) 10.2 = Compression spring, e.g. 0732 042 348 10.3 = Piston 11° = Control valve 11.1 = Sealing cover 11.2 = Adjusting screw 11.3 = Piston 14 5 ‘Compression spring Piston 12, = Hex screws 13 = Screw plug (M24x1,5) with seal (entry to heat exchanger, ol temperature) 14 = Gasket (on sheet metal version, do not bend). 15 = Preload valve (1.5 bar) 18.1 = Screw plug (1.5 bar) M26x1.5 with seal and recess for compression spring. 182 = Compression spring, e.g. 0732 042 403, 15.3 = Piston 16 = Drain valve (not on all versions) 16.1 = Screw plug (M22xt,5) with seal 16.2 = Compression spring, e.g. 0732 042 406 163 = Piston 17 = Needle sleeve and V-ring (for pump shatt). 4.5 Control unit housing and valve removal 19 Remove Intarder control unt. 20 Remove gasket (14). NOTE: When removing the valves, ensure that the removed pistons and piston guides are not damaged. 21 Remove the valves shown in this diagram, Clean Loctite residue trom thread on screw plugs and threads for screw plugs. CAUTION Proportional solenoid (8) must not be subjected to 24V power source. Check solenoid using terminal tester only. ‘Technical data - proportional solenoid (8) [Stroke mm 242 imi eare A 0s Resistance at20°C | a 2502 6% [Ralvaion time % 700 | Rear 33Disassembly @= Rotor 72 Stator 8 = Baseplate or ring (ring 1310467 when using press) 9= Shaft sea! reer to tools, item 15) 1.6 ‘Stator and rotor removal 22 Release retaining ring (1) and remove NOTE: When using fixture (4) with spindle (2), an (strike with chisel. appropriate height of baseplate can be inserted instead of item 8 (ring). 23 Remove circlips (2). When using a press, item 8 (ring) 1X56 198 049 must 24 Fitpressing-out fixture (4) with pressure plece (5). be used 25. Heat housing at points around circumference tno baseplate is used, housing may become distorted ‘marked with arrows to between 90 and 100°C using ia hot a blower 25 Press out shaft with stator an rotor rom housing. 27. Press out shaft seal (9) from housingDisassembly 12 " H 3 4 5 6 7 8 9 3 ‘Special hex screw 2= Shim 3 = Spur gear 4 = Inner race of taper roller bearing ‘Outer race of taper roller bearing = Stator 7 = Ring (not fitted to all versions) 8= Rotor ‘9 = Rectangular ring (piston ring) 1.7 Input spur gear removal 28 Clamp shaft in vice using soft chucks. 29 Remove hex screw (1) and shim (2). 30 Remove spur gear (3) using three-leg puller and pressure piece.Disassembly m (C) © 1 1 2 3 vy) . 1 5 | 6 7 8 9 \y 10 T= Three-teg puller “= Stator housing pocket 120) @ = Rotor 2 = Pressure piece 5= Oring 9 = Rectangular ring 3 Inner race of taper roller 6 = Stator 10 = Ring (or baseplate) bearing 7 = Ring (not fitted to all versions) 11 = Impulse sensor 18. Stator removal 381. Place rotor (8) or ring on baseplate, remove stator using three-leg puller. Remove inner race of taper roller bearing. Remove ring (7) (not fitted to all versions). 34 Remove O-ring (6) from stator. 35 Remove outer race of taper roller bearing from stator (6). 86 Remove rectangular tings (9) from rotor (8). ‘ BB 37 Remove impulse sensor (11). ‘Technical data - impulse sensor (17 Operating voltage Us max 6-15V Current intake max. 1 mA “Tightening torque 40Nm ‘Air gap sensor/impulse wheel 4mm ZF operating voltage BV 36 BarAssembly 1 = Hex screw M12x80 Powerlock (95 Nm) 2= Shim 3= Spur gear ‘4 = Inner race of taper roller bearing 5 = Outer race of taper roller bearing 6 = Stator 7= O-ring 8 = Ring (not fitted to all versions) ‘9 = Rectangular ring (piston ring) 10 = Rotor 2. Assembly 2.1 Stator and rotor assembly NOTE: Clean all parts. Lightly coat all moving parts with oll. 1 Coat rectangular rings (9) with ol, insert in annular grooves of rotor. 2 Heat stator bore for outer race of taper roller bearing (6) to approx. 80°C, install outer race of bearing in stator, facing in correct direction. Slide ring (8) onto stator (6). 4 Place rotor on bench (end of shaft) as shown in diagram. 5 Fitstator with ring onto rotor. 6 Heat inner race of taper roller bearing (4) to approx. 100°C, slide correctly onto rotor shaft (contact face for inner race of taper roller bearing protrudes, Le. inner race of bearing faces rotor). Apply ight coat of cil to inner race of taper roller bearing, 7 Heat spur gear (3) to approx. 85°C, place correctly on rotor. 8 Fitshim 2). @ Screw in special hex screw (1), tighten provisionally. ‘When cooled down, tighten to 95 Nm. 10 Place O-ring (7) in Stator and coat lightly using grease. 37Assembly 1 5 2 6 7 3 # 4 t 8 1 = Stator ‘= Rotor 2= O-ring 6 = Shaft seal (3 = Rectangular ring (piston ring) 7 = Plate (in-house manufacture, refer to tools, item 16) 4 Intarder housing 8 = Centrng disc 1310460 2.2 Stator and rotor installation NOTE: If shaft seal has been fitted, this must be protected by a battle plate (7) when the housing is heated (it anything other than a heating chamber is used). 11. Apply light coat of oil to rectangular ring (piston ring) and align centrally. 12 Fit centring disc (8) to Intarder housing. 13 Heat Intarder housing (4) to approx. 90 to 100°C {in heating chamber at 100°C for approx. 15 mins, if possible) NOTE: Carry out following procedure using manual housing when fitting. Housing must be heated to between 90 and 100°C. 14 Firmly install stator (1) and rotor (6) in Intarder housing until tips of arrows on cam surface of Intarder housing and stator are precisely aligned ‘with one another. Maximum tolerance 1 mm. Using manual press lever, apply pressure to stator ‘and rotor for approx. 5 minutes until stator locates firmly in housing recess. NOTE: When correctly installed, stator must be located lower than the groove on the Sealing face (corresponds to plate (7) supporting face. 15 Press shaft seal (depending on version) to correct depth using suitable too! (refer to list of tools). 16 Screw 1.5 bar preload valve (refer to control unit), ‘spring, seal plug (with recess for spring) and seal into Intarder housing.Assembly a —= 3. 7 4 6 7 6 ' | ze 10 | 5: ‘8 = Feeler gauge 9 Spurgear 1910461 10= Rotor shat 4 = Inner race of taper roller bearing A= Gap (measure at spin torque 2 +/- 0.5 Nm. ting (for assembly of item 4) 1310463 ‘Taper roller bearing must have preload of 0.05 to 6 = Baseplate 0.1mm). "ightening torque to spin point 2*2.5Nm 2.3. Fitting of taper roller bearing to rotor and taper roller bearing adjustment 17 Fit Intarder and spur gear to ring 1X56 138 050 as shown in diagram. 18 Heat inner race of taper roller bearing (4) 10 approx. 85°C, fit correctly on rotor shatt. 19° Apply light coat of oil o inner race (4) of taper roller bearing, 20. Allow bearing to cool. Remove ring (5). Place Intarder housing on baseplates (6). This enables spur gear (9) to rotate freely. 21 Fit adjusting fixture (8), preload inner race of taper roller bearing until spin torque reaches 20.5 Nm. 22. Using feeler gauge (8), measure gap A“ and note dimension. Circlip is supplied in 0.05 mm grades from 2.910 3.7 mm. Taper roller bearing must have pressure of 0.05 to 0.1 mm, This is assured if a circlip with thickness ‘equivalent to gap .A is fitted. At a spin torque of 2.Nm, circip with next possible dimension can be installed. 23. Fit retaining ring (1) and peen onto baseplate at 3 points (120° apart). Bar %Assembly 2.4 Valve assembly and fitting of control unit housing “0 BarAssembly Cooler changeover valve 1_= Control valve ‘Sorew plug (M48) with seal 111 = Seating cover Compression spring, e.g. 0732 042 402 112 = Adjusting sorew Piston 113 = Piston 11:4 = Compression spring Pressure rlit valve (12 bar) 115 = Piston 21 = Screw pug (M26) wih sea! 22 = Piston 12 = Hexsorews 23 = Compression spring, e.g. 0732 042 470 24 = Compression soring, eg. 0732 042 471 13. = Screw plug (M24x1.5) with seal 25 = Piston (entry to heat exchanger, ol temperature) Safety valve (14.5 bar) 14. = Gasket (on sheet metal version, donot Sorew plg M12x1.5 with seal ben). Compression spring, e.g. 0732 041 247 Bal 15. = Pretension vaive (1-5 bar) 1841 = Sorew pug (1.5 bar) M26x7.5 with seal and 4 = Verschludschraube M26 mit Dichtring recess for compression spring. 162 = Compression spring, eg, 0732 042 408 5 = Screw plug M12 (pump pressure) with seal 15.3 = Piston 6 = Screw plug M12(control pressure) wih seal 16 = Drain valve (not on all versions) 161 = Sorew pug (M22x1.5) wih seal 7 = Cover 162 = Compression spring, eg. 0732 042 406 71 = Gasket 163 = Piston 72 = Hexscrew 73 = Hex serew 17 = Needle sleeve and V-ring (or pump shaft) {instal needle sleeve so that thie collar 8 = Proportional solenoid with contol valve faces pressing side) 81 = Cylindrical screw a2 = Oring &3 = Piston (contro vate) 9 = Hox sorew Mi0x215 10 = Pressure vaive {01 = Sorew plug (M0x1.5) with seal Technical data proportional solenoid (@) 102= Gompression sprig, e.g. 0732 042 348 Stoke mm 232 103= Piston Lim earent A Resistance at20°C | 2 Aetvation tne % Irtarder housing Rems. 35 to 47 (lightening torques) Ttem no. | Tightening torque | Dim. | Pos. ne. | Ratenngoraue | Dim. o 25Nm Mia (2 @0Nm Monts | 96 | 25Nm Mi2K15 “ 70Nm Maexi 5 37 25Nm Mizxis | 6 100 Nm a1 5 38 70Nm M 26x15 4% 23Nm Maze 2 70Nm M 26x15 a7 Mexze 0 150m Maer 5 | 23Nm 41Assembly NOTE: Check compression springs against spring table. ‘Apply ight coat of oil to moving parts. Calibrate bores for valve pistons using calibration mandrel (if available) (refer to calibration tools in lst of too). Inall cases, check piston for ease of movement in piston bore. 24 Install appropriate piston and compression springs in control housing. ‘Apply light coat of Loctite 574 to seal plug threads and screw in with new sealing ring. Tighten to required torque. 25 Fit proportional solenoid (8) with O-ring (8.2) and piston (8.3) 26 Fit control unit with gasket (14). Tighten retaining screws to required torque. 2 BarAssembly ‘Mounting bolts on contro! housing Control housing Items 1 to 33 1 i. MY ‘ m ie tem no. Tight. torque | Dim. Remarks. 2 62Nm Mi2x115, 1,3,4 e2Nm ‘Mex120 5 23Nm Max115 6,7,8,9,10 23Nm Max30 " 50.Nm M10x215 42,18, 14, 18, 16, 17, 18, 19, 20, 21, 22, 23, 24 | 23Nm Mgx80 25, 26, 27, 28, 29, 90, 31 23Nm Mexto5 32,33 23Nm Max30 Dae 43Assembly 00428 8 = Hex screws, (x4) (MBX80) TA=23Nm 9 = Hex sorew, (x1) (MBxS0) TA=23Nm 10 = Dowel pins (x2) 11 = Mark on ring gear (for ease of assembly) 25 Oil pump assembly and mounting NOTE: Apply light coat ofc to moving parts. 27 Install shaft (8) with internal rotor and ring gear (2) (Once needle sleeve and V-ring have been removed in pump housing. from pump housing or control unit housing, heat Incoreol un housing ® approx 40°C and instal needs slosve 28 Install O-ring (6 and 1) in control unit housing. Correctly using tool 1310465 (thick collar facing 29° Fitpump housing, avoiding damage to drive spigot pressing-on side). on shaft (9) Drive in dowel pins (10). Tighten Note that mark (dot) on ring gear (11) points upwards. sorews to required torque. This ensures that the lug on the ring gear external diameter points towards pump housing.Assembly 2.6 Axial play measurement (stator and grooved ball bearing on main transmission) 1 = Retaining plate 2 = Hex screw (depending on version) 3 = Shim 4= O-ring (68x4) 5 = Output flange 6 = Ring (ring or ring gear) 7 = Shaft seal (possibly already fitted) 8 = Hex screw (M10x35/8.8) 9 = Hex screw 10= Hex screw 11 = Hex screw 12 = Hex screw 13 = * Hex screw (M10x215) TA = 50 Nm 14 = Hex screw for universal shaft 15 = * Hex screw (head with bore for wire retainer to secure with impulse sensor) 16 = Hex screw 17 = Hex screw 18 = Shim (thickness 1.6 to 0.9 mm, available in 0.1 mm steps) 19 = Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm) 20= Gasket ‘A= Sealing face of Intarder housing B = Contact face for ball bearing on output shaft housing (refer to Page 50) GapA-C eg. 11mm GapA-B eg. 10,5 mm Gap D (refer to page 50) e.g. 10,0 mm ‘Axial play: ‘Axial play of stator must be 0 + 0.05 mm ‘Axial play of output flange bearing must be 0 to 0.1 mm.| * Depending on version, item 13 may have a through-thread in the intarder housing. 45Assembly ale 5 ‘Dap between sealing face of basic transmission and face end of grooved ball bearing. ‘AB = gap between sealing face of Intarder housing {and face end of grooved ball bearing - must be to 0.1 mm larger than dimension .D*. ‘A-C = gap between sealing face of Intarder housing and face end of stator must be 00,05 mm — | E = Impuisgeber NOTE: Various versions of the gasket between Intarder and main transmission are in circulation. 1. Paper gasket. 2. Paper gasket and gasket bead. 8. Steel plate gasket (with corrugated strip). When measuring this part, do not include gasket bead ( comrugated strip. When being measured, the paper gaskets are placed on the Intarder housing. The steel plate gasket is measured separately. 30 Measure shim (19) (refer to Page 10.9). ‘Shim must have play of 0 to 0.1 mm. Measure dimension ,A-B" from sealing face (A) with paper gasket fitted to contact face (B), note dimension, 6.9. 10.5 mm. (On version with steel plate gasket, dimension A-B* is thinner by the thickness of the gasket. In this case, thickness of steel plate gasket without corrugated strip must be added to dimension .A-B"). ,A-B". ‘Measure dimension ,D* from outer race of ball bearing to sealing face of main transmission, note dimension, e.g. 10.0 mm. EG. Dimension A-B 10.5 mm —GapD 10.0 mm Gap= 0.5 mm —Axial play 0.1 mm Thickness of shim (19) 0.4mmAssembly 2.7. Fitting of Intarder 81 Measure shim (18) (refer to Page 10.9). Shim must bbe adjusted to 0.05 mm pressure and 0.05 mm play. Measure dimension ,A-C' from sealing face (A) with fited paper gasket to contact face (0), rote dimension, e.g. 1-1 mm. (On version with stee! plate gasket, dimension .A-C is thinner by the thickness of the gasket. In this case, the thickness of the stee! plate gasket without ‘corrugated strip must be added to dimension A-C’). Eg. Dimension A-C 410mm “ + Pressure 0,05 mm kness of shim (18) 1,15 mm ‘Seoure the gasket by inserting as many hex ‘screws as possible to the basic transmission and by screwing in long enough stud bolts. Fit stud bolts at the points where through bores exist on the Intarder housing. The stud bolts also serve as dowels when fing the Intarder. NOTE: Depending on version, screw (11) M10x215 may have through-bore in Intarder housing. 34 Carefully fit intarder to basic transmission and screw down. Note tightening torques. 385 Slide ring (6) (depending on version) onto output flange. owas 1 =Mi0215 = 50Nm 43,50, 51, "52, 53, 54, 55, 56, 64,65, 66, 67, 69, 70, 71, 72, 73=M10x60 =50Nm | 58, 59, 60, 61 ‘= M10x75. = 50 Nm 62, 63 (with shim) =M10x35 = 50Nm 68 = M10x180 = 50 Nm “| with bore in head 1 =Mi0x215 = 50Nm “with bore in head 32. Attach corrected shims (18 and 19) to contact faces .C* and ,B" with grease. 33. Fit gasket (20) to basic transmission. On version with gasket bead or corrugated strip, raised portion of bead (corrugated strip) points towards Intarder housing. 36 Correctly install retaining screws for cardan shaft in ‘output flange. (screws cannot be inserted when flange is fitted). 37 Fit output flange (5) without heating, a7Assembly 38 Fit O-ing (4) and shim (3) 89 Screw in hex screws (2), tighten to correct torque and secure with retaining plate (1) using tool (refer to basic transmission). 40. Screw in impulse sensor, tightening torque 40 Nm. ‘Technical data - impulse sensor (11) Operating vohage Oe | aE TST ‘Curentintake | “max, 18 mA surrent “Tightening torque “Kir gap between sensorimpulse gear | 1.4 mm TF eaing hag |Assembly 28 Fitting of reservoir and temperature sensor to heat exchanger ‘41 Install O-ring (3) in annular groove of reservoir. Fitreservoir to heat exchanger. 42. Screw temperature sensor (1) into heat ‘exchanger, tighten. Max. tightening torque (M 18x1.5) 40 Nm. {Technical data - Temperature sensor (0501 311 232) at+ 20°C ‘approx. 5000.0 ate oC approx. 2380 0 at 00S approx. 1630 Tat TC, approx. 1340. at aS | aprox. 878Assembly 1 = Retaining nut (wat 18) ("coat with Loctite 574) | 2= Hex screw (Ma) | 3=0-ing 29 Fitting of heat exchanger 43 Install new O-rings (8) in annular grooves of control unit housing. 44 Screw stud bolts (1) into heat exchanger with Loctite 574 (18 Nm) 45 Apply thin coat of Loctite 574 to designated surfaces (*) of heat exchanger. Fit heat exchanger to control unit housing, insert and tighten hex nuts using Loctite 574. Tightening torque 62 Nm 46 Screw in one MB hex screw (2) and tighten.Assembly 2.10 Fitting of oil filter to Intarder 47 Install new O-rings in fiter cover and fiter cartridge. Fit fiter cartridge to fiter cover. Fit magnet from old ter cartridge to face of new cartridge. If magnet disc is missing, obtain a new fone and fit. 48 49 Install fiter cover with cartridge in housing, secure with hex screw and washer. 2 = O-ring in filter cover 3 = O-ring in fiter cartridge 4 = Magnet disc 2.11 Fitting of solenoid valve to reservoir 51 Slide retaining screws (2) into solenoid valve. Install O-ring (4) in groove. Fit solenoid valve. Tightening torque for screws (2) is 23 Nm. Technical data Solenoid valve ( 3/2-way valve 0501 207 251) Operating voltage: 24 “Coilresistance approx: ‘85.6. bei + 23°C Mechanical test: Subject vaive alternately to 0 and 24 V and check. acoustic limit stop of piston (piston must not jam).Component Manual S 6-36/2 DAEContents Chapter 14 12 24 22 at 32 33 4a 42 5A et 7A at a2 eos Contents Foreword General Transmission cross-section Safety instructiones Dipped bolts. Use of locking compounds Tightening torques Use of seals Fiting on bearings, Spring table . Agjustment data Special tools ‘Output flange, speedometer worm and radial sealing ring Removing and installing output flange Installing speedometer worm and radial sealing ring ‘Speedometer connection piece, reversing lamp switch, pawl stop .. Removing and installing speedometer connection piece Removing and installing reversing lamp switch and pawl stop Selector Removing and instaliing selector Removing and installing peripheral parts Dismanting and reassembling selector Adjusting input bearing and layshaft ‘Measuring and adjusting input bearing, instaling connection plate Measuring and adjusting layshatt Connection housing Removing and instaling connection housing Reverse gear Removing and installing reverse gear ‘Adjusting spacer ring / main shaft/ input shaft Measuring and agusing axl clearance of Spacer ng ied betwoon input shal and clutch body . Input shaft Removing and dismantling input shaft ‘Assembling and installing input shaft 19 a 21 23 B BR 8B at at 32. 8 8 Se 5 @Contents Page 9 ‘Thrust rods, selector clamp 36 on Removing and installing thrust rods and selector clamp 36 10 Main shaft and layshaft 38 10.1 Removing and installing main shaft and layshaft 38 102 Dismanting and assembling main shaft 39 103 Dismanting and assembling layshaft 42 1" ‘Output bearing, radial sealing ring 44 na Removing and installing output bearng and radial sealing ring 44 12 Synchronizers / Wear limit .. : : . 45 rea ZF-B lock synchronizer - General .......... . 45 12.2 ‘Assembling synchronizers : cee a7 123 Checking wear limit 48 ear ©9811Foreword Foreword ‘This component overhaul book is intended to help well-trained and experienced workshop staff overhaul ‘components and carry out setting procedures and repair operations, This book therefore includes a list of special tools, technical data, instructions for the removal and installation of components, and setting procedures. Furthermore, you wil find safety instructions, which ‘should be strictly adhered to. ©9411 Bae 1General General ‘This book is based on the component and its parts as. originally fitted in DAF vehicies, ‘There may be different types and versions of the ‘components described in this book, because every vehicle is constructed in accordance with the legal regulations of the country where it is sold and in accordance with the expected operating conditions. As a result, the component you are overhauling may be slightly different from the descriptions and illustrations in this book, The technical data and setting data shown in this component overhaul book have been compiled with the ‘greatest care and they only refer to the components described in this book. The information given in this book was up-to-date at the date of issue. The date of issue is stated at the bottom of the page. DAF reserves the right to make, if necessary, changes to the procedures specified and to the setting data without prior notice, Important changes to the information given in this ‘component overhaul book will be published in the Technical Information (T..) bulletins. These bulletins can be ‘obtained through your contact person. To be able to carry out the operations correctly and safely, the mechanic should have the experience required and he should have followed the necessary training courses. + Always use the special tools specified in this book ‘These tools not only make the work easier and Quicker but also safer, and they avoid irreparable damage to the component or part. *+ Only use genuine DAF parts and components. They are carefully matched, which is one ofthe factors determining the original DAF quality. This quality is best guaranteed if genuine DAF parts and ‘components are used when replacement is necessary. + When draining oils or other fluids, collect them in a ‘suitable container and ensure that they are properly disposed of and/or processed. oatTransmission cross-section esa Rae 3Safety instructions Safety instructions When text is accompanied by the waming symbol shown here, this indicates that the information in ‘question is very important for the machanic’s health and safety. The instructions given with the warning symbol should therefore be strictly adhered to, * Follow out the instructions given on stickers and labels attached to the component. * Avoid unnecessary contact with drained oil or other fluids. ‘= Be careful when working on springs under tension. ‘A spring jumping off may cause serious injury. Even ‘small springs and circlips jumping off may cause injury (protect your eyes). * When removing or installing heavy components, always use approved lifting and/or hoisting tools and attach them securely to the component concerned, ‘Some plastics used for oil seals and other sealing rings may leave dangerous residues after they have been exposed to high temperatures. When removing these residues, wear acid resistant Clothes and PVC gloves. The residues should be dipped in or generously sprayed with a calcium hydroxide solution (slaked lime in water). Protective clothing should be thoroughly cleaned after use. The gloves should be treated as chemical waste. oatDipped bolts Dipped bolts Vehicles and components may be fitted with dipped ruts and bolts. In production, zinc-coated nuts and bolts are wax-dipped, whereas blackened and pphosphated nuts and bolts are oildipped. The ‘advantage of the use of dipped nuts and bolts is reduced friction during tightening, so that the specified pre-tension can be accurately obtained (smaller pre- ‘tension range). ‘Asa consequence, the tolerance range of the tightening torques has also become smaller, which ‘means that the specified tightening torques should be accurately adhered to. So always use a reliable torque ‘spanner. NOTE Have torque spanners calibrated regularly oat Instructions with respect to threaded connections, ‘+ To obtain the correct pre-tension for nuts and bolts Which are being re-used, the screw thread should bbe thoroughly cleaned. After the cleaning, apply one drop of lubricant to the first tum of the screw thread and one drop to the bearing face of the nut or bolt. The only lubricant permitted for re-used nuts and bolts is engine oil. It is on no account permitted to use other lubricants than engine oil and the lubricant applied in production. “The use of locking compounds on dipped nuts and bolts gives no problems. The locking compound ‘should be applied to the screw thread before the lubricant. '* Standard threaded connections: apply the lubricant bbefore fitting the fastener, and tightervretorque in ‘accordance with the standard for dipped bolts (see Under "Tightening torques”). ‘© Special threaded connections: apply the lubricant before fitting the fastener, and tightervretorque to the torques specified in the workshop manual. ‘= The instructions for thé use of a lubricant also apply ‘to new bolts supplied from the warehouse. Dry ‘threaded fasteners are no longer permitted because Of their highly variable friction coefficients. ‘+ If alocking compound is specified, the use of a lubricant is not necessary.Use of locking compounds Use of locking compounds This component overhaul book indicates when the use ‘of a locking compound is required and it also gives information about the type of locking compound to be used. The locking compounds specified are mainly the following: + Alocking compound for medium-strength locking of threaded fasteners. These threaded fasteners can be unscrewed with normal tools. ‘The locking compound specified is Loctite 243 or an ‘equivalent product. ‘Allocking compound for high-strength locking of threaded fasteners, mainly studs and such like. ‘These threaded fasteners are difficult to unscrew. The lacking compound specified is Loctite 270 or an equivalent product. ‘The method of application is the same for the two locking compounds. *+ Clean the internal and external screw threads. + Degrease the screw thread, using a good degreasing agent which does not leave residues which would reduce the effectiveness of the locking compound, NOTE ‘Some cleaning agents have a negative influence on the effectiveness of the locking compound. ‘The general rule is therefore that threaded fasteners ‘and components which have been cleaned with a cleaning agent, should be given after-treatment with @ ‘cleaning fuid which guarantees the effectiveness of the locking compound (see the manufacturer's instructions) + Depending on the screw thread diameter, apply one ‘or more drops of locking compound to the screw thread. ‘+ Apply one drop to the underside of the bolt head. As the locking compound reduces frictional resistance, the use of a lubricant is not necessary. + Tighten the fastener to the tightening torque specified. ©9411Tightening torques Tightening torques ‘Table of standard tightening torques, DAF standard (00804-203 ‘The tightening torques in the table below are the ‘standard tightening torques and they only apply to oil- dipped or wax-dipped nuts and bolts, which should be fitted in accordance with the instructions given in this ook. q Tightening torques for dipped nuts and bolts (Nm) Property class Property class Bolt 8.8 Bott 10.9 nut 88 nut 10.9 M4 25 £02 M5 81 £04 M6 86 207 Ma oat + 2 MB 7 M10 42 + 3 M10 55 Mi2 75 + 5 M12 95 Mia 116 #10 M14 150 M16 180 #15 M16 225 M18 250 + 20 M18 320 M20 350 + 30 M20 440 M22 480 40 M22 615, M24 600 = 50 M2470 M27 890 = 70 M27 1110 M30 1200 +100 ‘Clamping flange bolts (property class 12.9) M12 180 + 15 M14 275 + 20 M16 425 = 35, MiB 550 = 45 Have torque spanners calibrated regularly! oan C&W “The property class code is stamped on the nut or bolt, except on the clamping flange bolt. A clamping flange bolt can be recognised by the waist between the hexagon head and the flange, which an ordinary flange bolt does not have (see the drawings below), © © Property class Bolt 12.9 nut 12.9 +2 MB 32 + 3 +5 M10 65 + 5 +10 M12 115 + 10 215 M14 180 = 15 +220 M16 275 + 20 225 M18 385 + 30 235 M20 550 + 45 +250 M22 740 + 60 +360 M24 925 + 75 +290 M27 1370 2110Use of seals Use of seals ‘This component overhaul book indicates when the use of a seal is required and it also gives information about the type of seal to be used. Gaskets ‘+ Remove the old gaskets before fiting new ones. Clean the contact surfaces and check them for damage. ‘+ Apply some grease to paper gaskets before fitting them. In most cases, these gaskets are graphitised. They are used for the sealing of flat parts and they are resistant to oll, water and heat. ‘+ There are special instructions for cylinder head gaskets. Liquid gaskets The liquid gaskets mainly used are Loctite 510 or an equivalent seaiant. ‘These liquid gaskets, which have replaced conventional gaskets, are designed for the sealing of fat surfaces, and they are resistant to oil and temperatures up to approx. 200°C. To appl the sels, flow the instructions gen bow Remove any remain ofthe old gasket and clean the surfaces tobe sealed * Sparingly apply the specified sealant to one of the surfaces to be sealed. Ensure proper sealing around studs, bores and such like. * Put the surfaces to be sealed against each other and evenly tighten the attachment botts. © If there is sealant in an (ol) bore, it should be removed with caution, Oil seals * Anoil seals fitted into a housing by applying a steady pressure with a driving tool. ‘+ Pay attention to any markings indicating the outside Of the oil seal and the direction of shaft rotation. Once a unitised seal has been removed, it must not be used againt When an oil seal without sheathing is fitted, itis usually given a liquid gasket on the circumference. ‘An oil seal with rubber sheathing is fitted with oll or liquid soap (except when itis a unitised seal) * Lightly oil or grease the sealing edge of the oil seal and the bearing surface (do not do this wth united seal). attFitting on bearings Fitting of bearings General Bearings should be replaced: ‘Ifthe bearing surface is pitted. ‘= If there has been excessive tieat generation (blue patches) Instructions for installation ‘© Ensure the bearing is property cleaned. ‘© Avoid ditt getting into the bearing while itis being fitted. Press-fitting bearings into a bearing housing Use the correct size of driving tool. ‘Centre the driving tool accurately on the outer bearing race. ‘© Preferably press the bearing into the housing. Fitting bearings to an axle ‘+ Use the correct size of driving tool ‘= Centre the driving tool accurately on the inner bearing race. ‘+ Preferably press the bearing onto the axle. Heating of bearings + Ifthe instructions specify that the bearing should be heated before itis fitted, avoid local heating and ‘excessively high temperatures, ‘= Warm the bearing evenly by dipping it in a special oil bath or use a boiling plate. ©9411 pasSpring table | Order no. Installation position Number of | Wire Spring | Untensioned coils inmm inmm Jength in mm 0782.040 400 | Synchronizers 12.5, 14 6,65 23,7 Input shaft and mainshatt 0732040983 | Shift mechanism 125 1 57 188 (with R gear detent , according to version) 0732. 040.984 | Shift mechanism 95 14 94 23,3 0732 040985 | Shift mechanism 65. 20 148 23,4 0782 040986 | Shift mechanism 55 2.28 148 216 10 RAE ©oattAdjustment data Name Dimension Measuring device | Remarks (1. Input bearing axial play | Omm Depth gauge Up 100.1 mm play (bearing outer race) permitted. Adjust using shims. 02, Output bearing axial play | 0mm Feeler gauge Up to 0.1 mm piay (bearing outer race) permitted. Adjust using | correct retaining rings 03. Retaining ring axial play on_| 0 + 0,1 mm. Feeler gauge Adjust using correct ‘synchronizer bodies for tst! retaining rings. 2nd gear +5/6th gear and | bearing bush for ath gear (04, Spit ring axial preload, on | 0 + 0,05 mm Micrometer Use tool. input shat and feoler gauge 05. Helical gear axial play 6th | 0,25 + 0,65 mm Feeler gauge Only overdrive version ‘gear mainshaft Not adjustable. Measure as check only. 06, Helical gear axial play th | 0,25 + 0,65 mm Fesler gauge Only direct drive version. gear mainshatt Not adjustable. Measure 28 check only. 07. Helical gear axial play 4th | 0,2 + 0,6 mm Feeler gauge Not adjustable. Measure gear mainshaft 2s check only 08. Helical gear axial play 3rd | 0.2 + 0.45 mm Foster gauge Not adjustable. Measure gear mainshatt as check only. 09. Helical gear axial play | 0.2 + 0,45 mm Feeler gauge Not adjustable, Measure 2nd gear mainshatt as check only. 410. Spur gear axial play tst_ | 0,15 + 0,50mm Feeler gauge Not adjustable. Measure ‘gear mainshatt as check only. 11. Reserseidler gear axial | 0,9 + 1.8mm Feeler gauge Not adjustable. Measure play on reverseidler shaft as check only. 412. Layshaft axial play 0+ 0,1 mm Dial gauge Fit bearing in zer0 position and check play. Adjust using shims. (2). 13. Retaining tng axial play | 0 + 0,05 mm Fooler gauge ‘Adjust using correct on layshat input side retaining rings oat Bee "Adjustment data Name | Dimension Measuring device | Remarks 18, Axial clearance of circip | 0 + 0.05 mm Feeler gauge ‘Adjustment with circlips of on layshaft input end various thicknesses 14, Clearance of fulcrum 0.4+0.7 mm Feeler gauge Larger clearance denotes ads in guide grooves or ‘wear on fulorum pads or sliding sleeves (new sliding sleeve condition) 15. Max. possible clearance | approx. 1.2 mm Feeler gauge If value is exceeded, of fulcrum pads in sliding determine amount of wear sleeve or guide grooves and exchange respective pari(s) (visual test) 16. Clearance of selector fork | 0.2 + 0.5 mm Feeler gauge Larger clearance denotes in guide grooves. Reverse wear on shifting fork or ‘gear (new condition) guide grooves 17. Max. permissible approx. 1 mm | Feeler gauge If value is exceeded clearance of shifting fork | determine amount of wear in guide grooves reverse | and exchange respective gear | part or parts (visual test) 18. Axial clearance of > 0.4 mm. Depth gauge Value given, check by hand speedometer shat (perceptible) 19. Backlash of speedometer Experience Value given, check by hand pinion (perceptible) 20. Wear limit of synchonizer | 0.8 mm Feeler gauge if measurement is below rings or clutch body, specified value, exchange ‘measured between plain synchronizer rings or faces of ring and body; possibly clutch body friction cones of both ‘must be centrally in contact with no play 21. For information: 20.6 mm Feeler gauge Upper limit of synchronizer ‘Synchronizer clearance ‘clearance is given by wear ‘st - 5th gear (axial) limit of 0.8 mm 2 Dae ©9411Adjustment data Name Measuring device | Remarks | 22. Axial clearance of spacer Depth gauge Use apoer ring of ring installed between appropriate thickness. When input shaft and clutch ‘measuring, remove input body and output bearing slack in direction of transmission exterior 23, For information: 270+310N All compression springs in ‘Synchronizer pressure of synchronizers must be three sliding sleeves in of replaced by new ones; this synchronizer system will guarantee specified ‘synchronizer pressure 24. Distance from housing | 7 mm (Depth gauge) (Measure installation size ‘edge to face of shaft seal Adapter 1X86 137 133 | from cast edge to sealing ‘on output end ting). The installation size is ‘obtained when using the adapter 25. Temperature for shrink ft | 120°C Temperature Ensure axial abutment (of thrust bushing for measuring probe or helical gear 4th gear and thermometer inner ring on the bearing stud of main shaft 28. Temperature for shrink fit | 120°C Temperature Ensure axial abutment Of thrust bushing for spur ‘measuring probe or (gear. Reverse gear on thermometer main shatt 27. Temperature for shrink ft | 120°C Temperature Ensure axial abutment of inner ring on bearing measuring probe stud or thermometer 28. Temperature for pushing | 100 + 120°C. Temperature Use lube oil on sealing ring ‘on input flange measuring probe or | race thermometer 29. Temperature for shrink fit | 160 + 180°C ‘Temperature Mating surfaces of gears of layshaft gears measuring probe or _| and shaft must be free of oil thermometer and grease 30. Tightening torque for | 360 Nm Torque wrench Coat hexagon nut on face hexagon nut on output and thread with sealing ‘compound and secure with locking plate oan par 18Adjustment data f Name Dimension Measuring device | Remarks 31. Tightening torque of 160 Nm Torque wrench Fit spring washers, coat hinged botts| thread with sealing M 18x15 in housing compound 32. Tightening torque for 100 Nm Torque wrench Fit seating ring ‘speedo connection M30x1.5 33, Tightening torque for approx. 60 Nm Torque wrench Fit sealing ring. Do not use sorew plug M 24 x 1.5 (ol tapered screw plugs filer and oil control plugs) in housing 34. Tightening torque for __—_| approx. 50. Nm Torque wrench Fit sealing ring ‘screw plug M 20 x 1.5 of detent element on selector housing 35. Screw plug (tapered) 45 +50Nm Torque wrench Coat screw plugs with tightening torque ‘sealing compound. Do not M24 x 1.5 (oil fil, oi Use screw plugs with collar overflow and oll drain ‘screw plugs) in housing 36, Tightening torque for | approx. 45 Nm Torque wrench Fit spacer ring reversing light switch M18 x15 87. Tightening torque for approx. 45 Nm Torque wrench Fit seating ring neutral position switch M18x15 38. Tightening torque for paw! | approx. 40. Nm Torque wrench Coat pawl stop thread with stop M16 x 1.5 in sealing compound, Secure selector and gearbox with locking plate housings 39. Tightening torque for 30 + 35 Nm Torque wrench Coat with sealing compound screw plugs (tapered) M 18 x 1.5 inhousing 40. Tightening torque for 10m Torque wrench Do not exceed specitied breather M 10x 1 value “4 Dae e941Special tools Fig. Special tools Order no. Application | Qty. 1X56 099.070 ‘Adaptor for radial sealing ring (42 x 62) on output 1X56 100 632 Adaptor with conical extension for radial sealing ring in speedo connecting piece 0535659 ‘Adaptor for radial sealing ring (25 x 35 x7) and scraper (25 x 35 x7 x 10) of selector 0535662 Too! used in conjunction with gripping device 1X56 136 724 and 1X56 136 725 for tapered roller bearings on layshaft 0694814 Gripping device Used in conjunction with tool 1X56 122 304 for tapered roller bearing on layshaft mounted on input side. 16 ©oa1Special tools Fig. | Item | Order no. Remarks 0694815, Gripping device used in conjunction with tool (0535662 for tapered roller bearing (on fayshaft mounted on output side 1X56 136 822 Too! for split ring on input shaft 0192536 Ss Socket spanner 8 for reversing light switch C) ) 1X56 137 054 ‘Socket spanner for hexagon nut on output 1X56 137 133 on output ‘Adaptor 10 {or radial sealing ring (60 x 74) oat 7Special tools Special tools. Order no. Application u" 1X56 137 134 Protective sleeve Used in conjunction with adaptor (0535659 for radial sealing ring ‘and scraper of selector n oss4s18 ‘Adaptor for bearing bush on selector 13 1X56 137 138 Litting device {for mainshatt and layshaft 4 1X56 137 181 Guide bush {for output of mainshatt during installation of main and layshafts 1s 1X56 137 584 Puller ‘general for joints 8 ootOutput flange, speedometer worm and radial sealing ring 1 Output flange, speedometer worm and radial sealing ring 1.1. Removing and installing output flange REMOVAL 01 Remove tab washer (3), 02 Prevent output flange (1 oF 4) from turning with ‘commercial flange holder. (03 Unscrew hexagon nut (2) with socket wrench 1X56 137 054. 04 Remove output flange (1 or 4) with commercial ‘two or three-leg puller. INSTALLATION (01 Install bearing collar washer, speedometer worm and radial sealing ring in acc. with Section 1.2 02 Heat output flange (1 oF 4) to 100 - 120°C A dancer Ensure protective gloves are used when handling heated input flange (03 Coat sealing ring friction surface of flange with, lubricating oil and slide flange onto main shaft. 04 Prevent flange from turing with commercial flange holder. (05 Screw on hexagon nut with socket wrench. 11X56 137 054 and tighten to 360 Nm 06 Push on tab washer (9) as far as it will go and ‘secure hexagon nut. NOTE: Parts marked * as per parts list. Output flange (4) with safety bore. oon Bae 19Output flange, speedometer worm and radial sealing ring 1.2 Installing speedometer worm and radial i sealing ring INSTALLATION 01 Fitcollar washer of output bearing (5) to inner race of bearing. The plane face of the washer without radius points to the bearing. 03 Insert radial sealing ring (3) with adapter 1X56 137 133 (1) as follows and grease sealing lip. NoTE: 2) Apply a thin coat of sealing compound to outer diameter of radial sealing ring with steel coat. ) Moisten outer diameter of radial sealing ring with rubber coat using a lubricant such as water-soluble liquid dishwashing detergent (e.g. Fairy Liquid). | 02 Slide on speedometer worm (4). 04 Fit output flange in ace. with Section 1.1 20 1 = Adapter 1X56 137 133 2= Main shaft 3 = Radial sealing ring 4 = Speedometer worm 5 = Collar washer of output bearing 6 = Output bearing 7=Circlip 8 = Housing eeeSpeedometer connection piece, reversing lamp switch, pawl stop 2 Speedometer connection piece, reversing lamp switch, paw! stop 2.1 Removing and installing speedometer connection piece REMOVAL, 01 Unscrew speedometer connection piece (1). Do rot dismantle further as this is complete unit. INSTALLATION 01 If radial sealing ring (2) in speedometer ‘connection piece (1) is defective, replace it possible or insert new radial sealing ring on top of defective one. Installation tool 1X56 100 632. (02 Screw in speedometer connection piece with ‘sealing ring (2) and tighten to 100 Nm (03 Perform manual check of speedometer pinion for ooat ‘existing axial play > 0.1 mm and backlash 0.1 10 0.2 mm, 2Speedometer connection piece, reversing lamp switch, pawl stop 2.2 Removing and installing reversing lamp ‘switch and paw! stop REMOVAL 01 Unscrew reversing lamp switch (4) with socket wrench 0192536 and paw! stop (1) for reverse gear. 4 | | INSTALLATION ot Installation note Tightening torque Remarks Pawi stop (1) 40Nm Coat thread with seating ‘compound. Fit ab washer (2) and secure. Reversing lamp switch (4) 45Nm Fit adjusting ring (3) 22 Dae ©oattSelector 3 Selector 3.1. Removing and installing selector REMOVAL (01 Unscrew hexagon bolts (1) of selector and remove selector (2). INSTALLATION 01 Set thrust rods in gear and drivers of selector to neutral position. 02 _ Fi gasket (8) to installation face for selector. (03 Mount selector (2). Fit hexagon bolts (1) with spring washers and tighten to 25 Nm. att 23,Selector 32 Removing and installing peripheral parts NOTE: The operations described below apply by to all types of selector. Detent 1st - 6th speed Feather Pawil stop, gate reverse Neutral poston switch Sealing plug Ff coins = Selector Interock DISMANTLING 01 Mark position of selector lever relative to rotary selector mechanism and remove selector lever and protective cap. 02 Remove detent, breather, pawi stop and, if fitted, neutral positon switch or selector interlock. 24 Bae eatSelector ASSEMBLY o1 Installation note Tightening torque Remarks Pawi stop 40.Nm Coat thread with sealing ‘compound. Fit tab washer and secure Neutral position switch 45Nm Fit sealing ring Detent 1st - 6th speed 50.Nm Fit seating ring Breather 10Nm 02 For RH drive version, coat inside of gearshift tube 05 (2) with grease e.9. ARALUB HL2 belore bearing bush (3) is installed. 03 Fit protective sleeve 1X56 137 134 (6) to selector output. (04 First drive in radial sealing ring (4) and then scraper ring (5) using adapter 0595659 (7) as, follows and grease sealing lips: NoTE: 2) Apply @ thin coat of sealing compound to outer diameter of radial sealing rings with steel coat. b) Moisten outer ameter of racial sealing rings with rubber coat with a lubricant such as water-soluble liquid dishwashing detergent (e.g Fait Liquid. eos ‘Slide on protective cap and fit selector lever (Gismantiing mark). Tightening torque of hexagon rut 49 Nm, 1= Rotary selector mechanism Gearshift tube Bearing bush Radial sealing ring ‘Seraper ring Protective sleeve 1X56 137 134 7 = Adapter 0535659 25Selector 3.3 Dismantling and reassembling selector REMOVAL 01 Drive two pairs of roll pins each out of selector finger and rotary selector mechanism by positioning selector mechanism in such a way that the roll pins Point into the recess (removal path Fig. 003180) in the selector housing. Left hand selector output version (Fig. 003178) 02 Release circiip (1, Fig. 003181) opposite selector output. 03 Move rotary selector mechanism (9) toward ‘selector output and knock out cover (2) and/or bush (3) or (17) IW fitted with spring "B* only (04 Remove compression spring (16) and washer (15) Remove snap ring (14). IW fitted with springs “A* and "B" 05 Release circlip (4) from rotary selector mechanism. 06 Collect bush (5), compression spring (6) and ‘washer (7) 07 Pull out rotary selector toward selector output and remove selector finger (12) with blocking plate (13). 08 Remove scraper ring (11) and radial sealing ring (10), Right hand selector output version (Fig. 003182) (09 Remove cover (11). 10 Remove V-ring (9). 11 Move rotary selector (4) toward selector output and remove sleeve (8), compression spring (7), washer (6) and intermediate tube (5). 12 Pull out rotary selector fully and remove selector finger (14) with block plate (15). 13. Remove scraper ring (1) and radial sealing ring (2). 14 Remove bearing bushes (2) and (3) (Fig. 003184) it necessary using suitable drift. 26 Dae eosSelector 11817 1615144 5 Selector housing Rotary selector mechanism raper = dial sealing ring 12 = Hexagon bolt fector housing 13 = Spring washer jotary selector mechanism 14= Selector finger Intermediate tube 15 = Blocking plate 27Selector INSTALLATION o1 03 28 First ft a bearing bush (2) or (3) (Fig. 003184) into long neck, then second bearing bush into short Neck using adaptor 0694618. Place selector finger with blocking plate in installation position (see Fig. 003181 and 003182) and push in rotary selector mechanism. The detent of the rotary selector points towards the threaded bore for paw! stop. Align holes for roll pins in selector finger and rotary selector ‘mechanism. Drive in two pairs of roll pins each (see Fig. 003176 and 003177), Install the springs fitted in the reverse order to that described under .Removal". Fit cover (2, Fig. 003181) with sealing compound, 941Adjus' 4 Adjusting input bearing and layshaft 4.1 Measuring and adjusting input bearing, installing connection plate 01 Measure distance “A” from joint face to contact surface for bearing outer race at connection plate. 02 Place snap ring (2) in circular groove of bearing outer race. (03 Measure distance "B” from edge of bearing outer race to snap ring. “The adjusting snap ring thickness is calculated as follows: Example: Distance ‘A with gasket 8.50 mm minus distance “B” 5.60 mm Difference is snap ring thickness 290mm e.g. = 1.50 mm and 1.40 mm 290 mm Various snap rings are available as per parts list. NOTE: Take “A” and “B" measurements at two directly ‘opposite points and calculate average value. (04 Insert radial sealing ring into connection plate as. follows using too! 1X56 099 070 and grease sealing lip. NOTE: a) Apply a thin coat of sealing compound to outer diameter of radial sealing ring with steel coat. ) Moisten outer diameter of radial sealing ring with. rubber coat with lubricant such as water-soluble liquid dishwashing detergent (e.g. Fairy Liquid). 05 Fit the measured shims to bearing outer races centrally. Gasket must be in installation position. 06 Carefully slide connection plate over input shaft Until it abuts against housing. 07 Screw in fixing bolts with spring washers and tighten to 25 Nm. 9a BeeAdjusting input bearing and layshaft 4.2 Measuring and adjusting tayshaft 01 Position the gear vertically with the input end upward for measuring. 02 Drive back bearing outer race of layshatt evenly using a soft drift until bearing is free of play (perceptibie). When doing this, constantly rotate layshatt over input shaft so that rollers of taper roller bearings line up. (03 Fit gasket to connection housing. Measure distance “A from gasket to bearing outer race. ‘The size of the correct shims (2 pieces) is calculated as follows: Example: Distance “AY ‘minus average of clearance 0-1.0 mm, ‘mean value Difference is size of correct shims. 30 a2er e9attConnection housing 5 Connection housing 5.1. Removing and installing connection housing REMOVAL (01 Unscrew hexagon bolts around circumference of connection housing, 02 Drive out both fixing pins (1). (03 Liftoff connection housing parallel from joint face. (04 Slide roller cage off inner ring of bearing pinion of ‘main shaft. NOTE: if the connection housing cannot be removed, the clutch body on the input shaft is twisted. Should this ‘occur, proceed as follows: Repeatably turn input shaft until clutch body becomes loose. INSTALLATION 01 Slide roller cage onto inner ring of bearing pinion ‘of main shaft. 02 Using two guide pins, fit gasket to pot housing. (03 Install input shaft in connection housing in ace. with Section 8.2. (04 Mount connection housing with input shat in parallel wth pot housing. 05 Drive both fixing pins (1) into installation position. 06 Screw in hexagon bolts with spring washers. around circumference of connection housing and tighten to 50 Nm, ost pak 31Reverse gear 61 REMOVAL o1 02 04 INSTALLATION o1 03, 05, 06 o7 Reverse gear Removing and installing reverse gear Unscrew hexagon bott (1), remove washer (3) and. spring washer (2). Unscrew bolts (6), remove sealing cover (5) and gasket (4) Drive out reverse bolt (9) toward output using drift ®. Remove reverse gear (10) with needle cages (11), Insert O-ring (12) in annular groove of reverse bolt ©). ‘Set reverse gear (10) with needle cages (11) to installation position. Drive in reverse bolt until the lower edge of the Circular groove is level with the recess of the threaded bore. Check axial play of reverse goar. It must be 0. 1.3mm Insert washer (3) into the circular groove in the reverse bolt. Screw in hexagon bolt (1) with spring washer (2) and tighten to 25 Nm. Fit sealing cover (5) with gasket (4). ‘Screw in hexagon botts (6) with spring washers (7) and tighten to 25 Nm,Adjusting spacer ring / main shaft / input shaft TA a 02 03, 04 05, 06 07 09, ‘Adjusting spacer ring / main shaft / input shaft Measuring and adjusting axial clearance of ‘spacer ring fitted between input shatt and clutch body Install input shaft in connection housing in ace. with Section 8.2 and clamp bearing output ring, ‘Support connection housing in such a way that the input shaft hangs free and therefore the bearing slack towards the outside is removed. ‘The snap ring in the input bearing must rest against connection housing free of play. Measure distance “A” from joint face of connection housing to face of ring gear of input shaft. Install main shaft and layshaft in pot housing in ace. with Section 10.1. Insert existing spacer ring into clutch body. ‘Support pot housing in such a way that the main shaft hangs free and therefore the bearing siack towards the outside is removed. Fit gasket to pot housing. Measure distance “B* {rom spacer ring to gasket. “The correct size of spacer ring has been used if the following calculations result in the specified Clearance of 0.9 to 1.2 mm. In this example the existing spacer ring must be replaced by one which is 0.3 to 0.6 mm thicker. NOTE: The setting of the gasket is of no significance for this adjustment operation. ooatt Example: Distance “A” minus distance “ Difference is existing clearance ‘Specified clearance 7.5mm 6.0mm 1.5mm 0.910 1.2mm 33Input shaft aa a1 02 Input shaft Removing and dismantling input shaft Fig. 003269 Disconnect connection plate (1) and remove together with gasket (2), collect loosened adjustment washers (5). Press complete input shaft (4) out of connection housing (7). Remove racial sealing ring (3) from connection plate and bearing outer race (6) from connection housing 04 07 Fig. 003270 Lit off cirtip (1). Fomove split ring (2). Collect loosened snap ring (3) and ajustment rings (6) from roller bearing. ‘Take off collar washer and bearing outer race on cylinder roller bearing (4). Drive bearing inner race off input shaft only if wor, oonInput shaft ‘Assembling and installing input shaft NOTE: Do not instal the input shaft i an angle drive is ited, Fig. 003270 Fig, 009269 (01 Heat bearing inner race of eylinder roller bearing 07 Before inserting the bearing outer races into the (4) to approx. 85 °C and slide onto input shaft (6). connection housing (7), itis of advantage to heat Drive on inner race further until it abuts free of Up the bearing bores to approx. 60 °C play and cool 08 Insert input shaft wth bearing unt it rests against vancer snap ring. Ensure protective gloves are always worn when handling heated bearing inner race. NOTE: Fit connection plate only after measuring in acc. with Section 4.1 02 Slide on bearing outer race and collar washer. 09 Insert outer race of taper roller bearing (6) flush. 03 Slide on 2 adjustment snap rings (6). For ‘measurements see Section 4.1 (04 Insert split ring (2) with 0 - 0.5 mm pre-load using tool 1X56 136 822. 05 Slide on circlip (1) and secure at three points (x 120%). (06 Insert snap ring (3) into annular groove of bearing ‘outer race, ©9411 Bee 35Thrust rods, selector clamp 9 Thrust rods, selector clamp 8.1 Removing and installing thrust rods and NOTE: Do not remove selector clamp 1s¥2nd speed selector clamp and selector bar, reverse (6) with selector fork (7) until the main shaft and layshaft have been removed in acc. REMOVAL with Section 10.1 (01 Unscrew three hinged bolts (8) from both sides of ‘or through-drive version ppot housing 02 Remove thrust ods and selector clamps in the following order: ‘Thrust rod (8) and solector.clamp Sthv6th speed Thrust rod (4) and selector clamp StWvath speed Thrust rod (5) 1sv2nd speed bar by 2 clamping pins) 36 Bae ©oattThrust rods, selector clamp INSTALLATION NOTE: Selector bar reverse (6) with selector fork (7) ‘and thrust rod 1st’2nd speed (5) with selector clamp were already installed in ace. with Section 10.1 when the main shaft and layshaft were fitted. 01 ,f Coat the thread ofthe hinged botts with sealing ‘compound. First, slide hinged bot 1sv2nd speed wth spring washers into housing and serew in selector fork tsV2nd speed. (02 Fit remaining selector clamps and thrust rods 03 Screw in raining hinged bots with spring ‘washers as described above and tighten each to 160 Nm," 9411 en =Main shaft and layshaft 10 Main shaft and layshaft 10.1 Removing and installing main shaft and layshatt REMOVAL 01 Position pot housing vertically. CAUTION Reverse gear must be removed in acc. with Section 6.1. 02 _Lift main shaft and layshaft together out of pot housing using iting device 1X56 137 136. (03 Remove selector clamp 1st/2nd speed and selector bar, reverse with selector fork. 04 Lay aside shafts and remove lifting device. INSTALLATION 01 Slide guide bush 1X56 137 181 at output of main shaft onto shatt. (02 Roll main shaft cpl. and layshaft cp. together on ‘work bench and position so that they mesh 03 Fitting device 1X56 137 136 and raise shafts. 04 Insert selector clamp 1st/2nd speed and selector bar reverse with selector fork in main shaft. 05 Carefully insert gear shafts into pot housing. 38 Bar ©9811Main shaft and layshaft 102 ismantling and assembling main shaft DISMANTLING NOTE: The illustrations shows the through-drive version. In the overdrive version, item 1 is the helical 05 ‘gear 6th speed. The main shaft is dismantled on a press 06 ‘or using a three-leg puller. 01 Release circlip (13) in front of Sth/éth speed synchronizer. 07 02 Clamp puller on Sth/6th speed synchronizer (9) of 08 ‘clutch body from behind and pul off. Remove helical gear (1). 03 Grip 1st speed spur gear (5) from behind and pull off. I excessive force is used, pull off reverse ‘speed spur gear (6) separately beforehand. ose cave | Release circlip (14) in front of 1sv2nd speed ‘synchronizer. Grip 2nd speed helical gear (4) from behind and pull off. Release circip (15) in front of 4th speed bearing bush (16). Grip 3rd speed helical gear (3) from behind and pull off. Ifthe inner ring (17) on the bearing stud (8) is ‘damaged, loosen the snap ring (18) and remove the inner ring. NOTE: Position main shaft vertically and remove inner ring by heating. 39Main shaft and layshaft ASSEMBLY NOTE: The illustration shows the through-drive version. 03 Inthe overdrive version, item 1 is the helical gear 6th speed. (01 Assembly of the main shaft should start from the output end (02 The assembly sequence for the parts is shown in the Figs. 003197 and 003198, The assembly ‘temperature for the two bearing bushes and for the inner ring on the bearing stud amounts to 120 *C. The remaining tight-seated parts are heated to ‘approx. 85 °C. A DaNceR Ensure protective gloves are worn when handling heated parts. 40 Rae The axial clearance of the circips specified in the table is achieved by fitting the appropriate. size of Circlip. The axial clearance of the gears is given and only requires to be checked for conformity with the value specified in the table. 1 = Helical gear Sth speed 2 = Helical gear 4th speed 3 = Helical gear 3rd speed 4= Helical gear 2nd speed 5 = Spur gear ist speed 6 = Spur gear reverse 7 = Main shatt 8 = Bearing journal with inner ring ‘9 = Synchronizer Sth / 6th speed 10 = Synchronizer 3rd / 4th speed 11 = Synchronizer 1st / 2nd speed 12 = Bearing inner race, output bearing oatMain shaft and layshaft 04 [Axial clearance of gears | ist speed 2nd speed |rdspeed | 4th speed | 5th speed | 6th speed (in mm) 0.15 +0.50 | 02+045 |02+0.45 |0.2+0.60 |0.25+0.65] 0.25+0.65 [Axial clearance of circlips iam) or04 — oz01 “CAUTION ‘The plane face of the circlip pointing toward the needle bearing must be absolutely free of burrs. oan poe aMain shaft and layshaft reversed. DISMANTLING 8 10.3 Dismantling and assembling layshatt NOTE: Fig. 003204 shows the through-drive version. In the overdrive version the helical gears Items 3 and 4 are 01 Release circlip (1) 02 Open arip with cord ring, guide over taper roller bearing inner race (2 and 8) and re-close with cord ring unti it sits tight on the rollers. Screw on basic tool and extract inner races. 03 Press off helical gears individually from the layshaft (7) in view of the high force required (up to 300 kN). 42 Rae ostMain shaft and layshaft ASSEMBLY 01 Ensure bores of helical gears and seats of layshaft are free of grease and dust. Heat helical gears to 160 + 180 °C and ft on layshatt. Immediately atter assembiing helical gears, press (on further until they rest with no play. 4 DANGER Ensure protective gloves are worn when handling heated helical gears. (02 Heat taper roller bearing inner races to approx. 85°C and push on unt they rest with no play. dA vaNcer Ensure protective gloves are worn when handling heated taper roller bearing inner race. 03. Fitcirciip in front of input end taper roller bearing inner race with 0 + 0.05 mm axial play. oven faper roller bearing inner race 2.= Grip 0694814 (input end, Item 2) Grip 0694815 (output end, Item 8) 3 = Basic tool 0535662 43Output beai g, radial sealing ring 11 Output bearing, radial sealing ring 11.1. Removing and installing output bearing and radial sealing ring REMOVAL | 01 Remove radial sealing ring (5) from pot housing (1), take off collar washer of cylinder roller bearing. 02 Release circip (3). 03 Drive out cylinder roller bearing outer race (4) and taper roller bearing outer race (2) without twisting. INSTALLATION 01 To insert the bearing outer races, i is of ‘advantage to heat the housing around the bearing bores to approx. 60 °C. (02 Insert bearing outer races (2 and 4), drive on until they abut with no play. 03. Insert circlip (3) with 0 0.1 mm clearance. 04 Install radial sealing ring (5) as described in Section 1.2, NOTE: Only on upright version (parts lists 1290 062 (002/003 and 1290 052 018) and during housing ‘exchange (end-loaded housing). 05 Both sealing caps (3) must be affixed with jointing ‘compound (Loctite) no. 262. 06 Secure the oil bale plate (1) with 2 bolts (2). Tightening torque for bolts = 28 Nm. oeSynchronizers / Wear limit 12 Synchronizers / Wear limit 12.1 ZF-B lock synchronizer - General Fig. 003199 shows the construction of a ZF-B lock synchronizer. Using a ZF-B lock synchronizer, itis possible to obtain a quick, perfect and silent gear change without the necessity of double de-clutching even on inclines and in difficut situations. The easier (gear change achieved with a lock synchronizer frees the river of any inhibitions regarding changing gear. He will ‘change gear more frequently and drive more smoothly, adding to road safely in modern-day dense trafic. s 13 4 = Synchronizer body 5= Sliding sleeve —_ A B ©9411 pas -Synchronizers / Wear limit Fig. 003200 shows the operation and section of the ZF-B lock synchronizer. The section drawing and section A of the illustration show the idle position of the synchronizer. If sliding sleeve is moved out of the idle position to the right or left (Fig. shows right), the ‘corresponding synchronizer ring is pushed via the pressure pieces onto friction cone of the clutch body. Due to the difference in rotational speed, the synchronizer ring immediately rotates as far as a stop Con the synchronizer body not shown in the Figure, Preventing the sling sleeve from being pushed further (ection B). Due to the pressure exerted on the sliding sleeve, the synchronizer ring is tured back via the cchamifers on the selector teeth at the same rotational ‘speed when friction no longer exists. The sliding sleeve ‘can now be pushed further fully meshed with the clutch body (Section C). The appropriate gear is thus engaged. Fig. 003201 shows the components of the ZF-B lock synchronizer. The components may vary in shape and design from those shown in the illustration. Subject to technical modifications, 48 eosSynchronizers / Wear limit \ 122 Assembling synchronizers 01 Check wear limit in ace. with Section 12.3. The illustration shows the Sth/6th speed and ‘Srd/4th speed synchronizers. Replace compression springs (7) with new ones. ‘This ensures the specified overthrust of the stiding sleeves. This does not require checking. 270 +10 N. This value applies to ‘each of the three synchronizers. 03. Synchronizer body (3), sliding sieeve (4) and synchronizer rings (2) must be correctly positioned relative to each other in the peripheral direction {during 9/4 and 5/6 synchronization . The Figure ‘shows the correct position. ose (04 The synchronizers can either be assembled ‘separately or after they are installed on the main shaft. NOTE: The sliding sleeve of the 1s’2nd synchronizer ‘can very easily slide along the synchronizer body. It is therefore good practice to assemble it on the main shaft. In this case, the synchronizer body and sliding ‘sleeve do not require to be in a fixed position. However, the lugs of the synchronizer rings are in front of the ball bolts (refer to Section 10.2, 10.2, Fig. 003197, Item 11). ‘Synchronizer body sliding sleeve 7 = Compression spring 47Synchronizers / Wear limit 123 Checking wear limit NOTE: Goo sntnting the ein, ctckthe o1 02 Position synchronizer ring (1) centrally on relevant clutch body (2). By turning the parts, ensure both ‘cones are uniform and parallel, The wear limit of the synchronizer rings is 0.8 mm. Check wear limit as follows: Measure distance between clutch body and synchronizer ring with feeler gauge (3) at two ‘opposite points. If distance measured is less than 0.8 mm, replace synchronizer ring andlor clutch body with a new one. Inspect parts visually for ‘wear (wavy surface). Do not mix up parts inspected together (use marking for identification). ©oatComponent Manual ZF Servoshift \ eX ZN DAServoshift SAFETY PRECAUTIONS Warning symbol When text is accompanied by the warming symbol shown here, this indicates that the information provided is essential for the health and personal safety of the mechanic. In addition, this waming symbol is also shown if there are conditions in which damage can be caused to the component or parts thereof. Safety instructions To ensure that the mechanic's health is not endangered, the following safety instructions must be strictly observed. - Comply with all the wamings and safety instructions given in this component manual. First read the instructions and wamings on the labels and stickers which are affixed to various components on the vehicle and follow them! They have been put there for your health and safety, so do not ignore them! - Wear clean, fitted clothes and apply protective cream to unprotected parts of your body, as necessary. + Ensure proper extraction of dangerous materials from the work area. - Maintain a safe distance from rotating and/or moving parts = Avoid unnecessary contact with drained oil Frequent contact damages the skin. Various sorts of oil and other lubricants used on the vehicle may constitute a health hazard. So avoid both inhaling and direct contact with these, - Exercise caution when working with springs: under pressure. Inadvertently released springs may cause serious injuries. Small springs and circlips may also cause injuries when inadvertently released (wear goggles). F 0104Servoshift Hf necessary, support the component suitably. ‘Always use the appropriate lifting gear (gearbox jack) or approved lifting gear or hoists for the removal and installation of heavy components. Attach the component securely to the lifting or hoisting gear. After a fire itis possible that hazardous residues may remain from the plastics used in some oil seals and sealing rings. Wear protective, acid-resistant clothing and PVC gloves when removing such fire residues. ‘Submerge such fire residues in, or sprinkle them amply with, a calcium hydroxide solution (slaked lime and water). Thoroughly clean the protective clothing after use. Treat the gloves as chemical waste. 010416 S 151, 16 S 181, 16 S 221, 16S 251 Contents Preface. : Important information... Instructions for repair.. Tightening torques Consumables... Adjustment data... ‘Table of springs Servoshift, disassembly and assembly. Left-hand and right-hand version HGS version Left-hand gear shift system, dismantling and assembly Shift patterns, shift mechanism lef. Right-hand gear shift system, dismantling and assembly Shift patterns, shift mechanism right. Right-hand gearshift system, HGS version, dismantling and assembly .. Function test . Shift patterns, shift mechanism right Assembling complete shift housing.Preface ZF FRIEDRICHSHAFE! C.V/Special Transmissions Service Plant 2 Tel: (07541) 77-0 Fax: (075 41) 77-5726 AG This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out mainte- nance and repair work on ZF products. ‘This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, tepair work might require work practices and test or adjustment data not contained in this manual, ‘We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a ‘regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually tained personnel 2. Specified equipment, eg. special tools 3. Genuine ZF spares, to our latest specifications All work performed at these service points is carried out conscientiously and with utmost care. Repair work carried out at ZF service points subject to the contractual conditions prevailing in the individual case. Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used,Important information SAFETY NOTICE ‘Companies repairing ZF units are responsible for their ‘own work safety. ‘To avoid injury to personnel and damage to pro- ‘which apply to repair and maintenance work must be adhered to, Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products ‘must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staffis properly trained. ‘The following safety instructions appear in this manual: NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc. ‘CAUTION This is used when incorrect, unprofessional working practices could damage the product. AXDANGER This is used when lack of care could lead to personal injury or death. GENERAL INFORMATION Read this manual carefully before starting any tests or repair work. CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text. After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning, correctly. AX THREATS TO THE ENVIRONMENT! Lubricants and cleaning agents must 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 ina suitably large container. spose of used ol, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines. + When working with lubricants and cleaning agents always refer to the manufacturer's instructions. CAUTION ‘The transmission must NOT be hung by the input shaft NOR by the output flange.