Reparo Servo Shifting.pdf

Repair Manual

Shift system with PSU (Pneumatic Servo Unit) 1315 751 110b

Subject to alterations in design

Copyright by ZF The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Printed in Germany ZF Friedrichshafen AG / 2000 / 2005-06

Edition: 2005-06

1315 751 110b

ZF-Ecosplit

Table of Contents Page

Preface .................................................................................................................................................. Safety Instructions................................................................................................................................ Instructions for Repairs........................................................................................................................ Overview of Amendments ................................................................................................................... Tightening Torques............................................................................................................................... Recoding from DIN to ISO Standards ................................................................................................. Consumables......................................................................................................................................... Spare Parts............................................................................................................................................ Adjustment Data ................................................................................................................................... Table of Springs .................................................................................................................................... Special Tools .........................................................................................................................................

5 6 7 9 10 12 14 15 16 18 19

1 1.1 1.2 1.3 1.4

Removal and installation of the PSU.................................................................................................. Shift turret with left and right shifting outputs................................................................................... Shift turret with HTC (hydrostatic control)......................................................................................... Super H shift turret with HTC (superimosed H shift system) ............................................................ Shift turret with superimposed H shift system with control cable ....................................................

1-1 1-1 1-2 1-3 1-5

2

Removal and installation of selector and shift cylinder ................................................................... 2-1

3 3.1

Shift turret with left shifting output, disassembly and assembly .................................................... 3-1 Shift patterns, shift turret with left shifting output............................................................................. 3-6

4 4.1

Shift turret with right shifting output, disassembly and assembly.................................................. 4-1 Shit patterns, shift turret with right shifting output............................................................................ 4-9

5 5.1

Shift turret with HTC, disassembly and assembly ............................................................................ 5-1 Shift patterns, shift turret with HTC ................................................................................................... 5-7

6 6.1

Super H shift turret with HTC (superimosed H shift system), disassembly and assembly............ 6-1 Shift patterns, Super H shift turret (superimosed H shift system) .................................................... 6-5

7 7.1

Shift turret with superimposed H shift system with control cable, disassembly and assembly.... 7-1 Shift patterns, shift turret with superimposed H shift system............................................................ 7-7

8

Functional test, shift turret with HTC ............................................................................................... 8-1

9

Mounting of shift turret ...................................................................................................................... 9-1

1315 751 110b - 2005-03

3

4

Preface This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF products in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data 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 trained personnel, 2. Specified equipment, e.g. special tools, 3. Genuine ZF spares, according to our latest specifications. All work performed at these Service Points is carried out conscientiously and with utmost care. Warranty: Repair work carried out at ZF Service Points is subject to the contractual conditions prevailing in the individual case.

ZF Friedrichshafen AG Nutzfahrzeug- und Sonder-Antriebstechnik Commercial Vehicle and Special Driveline Technology Service Werk 2 (Plant 2) Phone: +49 (0)7541 77-0 Fax: +49 (0)7541 77-908000 Internet: www.zf.com

2003-08

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.

5

Safety instructions Safety Instructions

General Information

Companies repairing ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.

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.

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 staff is properly trained.

After completion of repair work and testing, skilled staff must check whether the product is functioning correctly.

The following safety instructions appear in this manual:

!

THREATS TO THE ENVIRONMENT ! Lubricants, consumables, 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 in a suitably large container. • Dispose of used oil, 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.

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

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

!

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

CAUTION The transmission must NOT be suspended by the input shaft NOR by the output flange.

2003-08

6

Instructions for Repairs Gaskets, Locking plates

ZF Service Information must be observed. This information is available at all ZF Service Centers or via the ZF-ServiceLine.

Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

In case of doubt always turn to the relevant department within ZF After-Sales Services for advice. All work on transmissions is to be performed by experts only and under clean conditions. Use specified tools to dismantle and assemble transmissions.

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

After removing the transmission from the vehicle, clean it thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning.

Reworking

Parts joined with Loctite are easier to separate if warmed with a fan heater.

Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or scroll.

Cleaning parts

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

Remove remains of old gaskets on all sealing surfaces. Carefully remove burrs or similar patches of roughness using an oilstone. Lube bores and grooves must be free of anticorrosion agents and foreign matter; check for perfect passage.

Transmission Assembly Find a clean work area to assemble the transmission. Gaskets are installed without sealing compound or grease. When measuring siliconcoated gaskets, do not include the silicon layer. During assembly, comply with all adjustment data and tightening torques in the Repair Manual.

Carefully cover opened transmissions to prevent foreign matter from entering.

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

2003-08

7

Instructions for Repairs d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.

Bearings If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at approx. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

X

e) Fill the gap between the sealing lips so it is 60 % filled with grease (e.g. produced by Aral, such as Aralub HL2 or by DEA, such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

Sealing If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing 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 surfaces are sealed.

Retaining Agents Retaining agents* may only be used in places as specified in the parts list. Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data, and tightening torques.

Shaft Seals a) Apply a light coat of sealing agent* on circumference of shaft seals with “steel jacket”.

Transmission Oil After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and TE-ML List of Lubricants (refer to identification plate) which are available from any ZF After-Sales Service Point and on the Internet under www.zf.com. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow using the specified torques.

b) Never apply sealing agent to shaft seals with “rubber jacket”, but apply a thin coat of Vaseline 8420 to the circumference or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber jackets should be treated on the circumference of the rubber jacket as described above in section b).

* refer to expendable material

2003-08

8

Overview of Amendments: 1315 751 110

Index

Date of issue

Chapter

Initiator

Comment

a

2002-05

1, 2, 6, 8

LKS-T

Supplement: Super H shift turret (superimposed H shift system)

b

2005-03

1, 7

LKS-T

Supplement: Shift turret with superimposed H shift system with control cable

1315 751 110b - 2005-03

9

Tightening Torques Tightening Torques for Nuts and Bolts, Extract from ZFN 148 Surface condition of bolts / nuts: Thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated, and oiled.

This standard applies to screws/bolts acc. 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 to nuts acc. to DIN 934 as well as ISO 4032, ISO 8673.

Tighten screws with a calibrated ratchet dial torque or ratchet wrench.

This Standard contains data on tightening torques (MA) for screws/bolts and nuts in strength categories 8.8, 10.9, and 12.9, and nuts in strength categories 8, 10, and 12.

NOTE Deviating tightening torques are listed separately in the Repair Manual.

Regular screw thread Size Screw/Bolt Nut M4 M5 M6

Fine screw thread Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12 2.8 5.5 9.5

Size Screw/Bolt Nut

Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12

4.1 8.1 14

4.8 9.5 16.5

M8x1 M9x1 M10x1

24 36 52

36 53 76

43 62 89

M7 M8 M10

15 23 46

23 34 68

28 40 79

M10x1.25 M12x1.25 M12x1.5

49 87 83

72 125 120

84 150 145

M12 M14 M16

79 125 195

115 185 280

135 215 330

M14x1.5 M16x1.5 M18x1.5

135 205 310

200 300 440

235 360 520

M18 M20 M22

280 390 530

390 560 750

460 650 880

M18x2 M20x1.5 M22x1.5

290 430 580

420 620 820

490 720 960

M24 M27 M30

670 1000 1350

960 1400 1900

1100 1650 2250

M24x1.5 M24x2 M27x1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M27x2 M30x1.5 M30x2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 2003-08

10

Tightening Torques Screw Plugs DIN 908, 910, and 7604

Union Screws DIN 7643

The screw plug tightening torques were determined according to DIN 7604 for screwing into steel, gray cast, and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque apply analogously to screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

The tightening torques were determined for screwing into steel, gray cast, and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. General rule: Screw/ Bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: As manufactured (without surface protection) and lightly oiled or galvanized, chromated, and lightly oiled.

General rule: Screw/ Bolt class 5, ZFN 148-1 Screw/ Bolt material: Steel acc. to DIN 7604. Surface condition: As manufactured (without surface protection) and lightly oiled or galvanized, chromated, and lightly oiled.

Union screws (DIN 7643)

Screw plugs (DIN 908, 910, 7604) Dimensions

M8x1 M10x 1 M12x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M22x1,5 M24x1,5 M26x1,5 M27x2 M30x1,5 M30x2 M33x2 M36x1,5 M38x1,5 M42x1,5 M42x2 M45x1,5 M45x2 M48x1,5 M48x2 M52x1,5 M60x2 M64x2

Tightening torque in Nm screwed into steel / gray cast Al alloy 20* 10* 25 / 30* 15 / 20* 35 25 35 25 40 30 50 35 55 45 60 / 80* 50 / 65* 70 60 80 / 105* 70 / 90* 80 70 100 / 130* 90 / 130* 95 85 120 110 130 115 140 120 150 130 145 125 160 140 150 130 170 145 160 135 180 150 195 165 205 175

* DIN 7604 Form C

Thread

Tightening torque in Nm

4-5

M8x1

20 - 25

6

M10x1

25 - 35

8

M12x1.5

30 - 40

10

M14x1.5

35 - 40

12

M16x1.5

45

15

M18x1.5

50

18

M22x1.5

60

22

M26x1.5

90

28

M30x1.5

130

35

M38x1.5

140

Edition: October 1995

11 2003-08

Pipe outer diameter

Conversion from DIN to ISO Standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 1

Tapered pins

ISO 2339

- some can be replaced ∅ changed to ISO 2339 - parts which cannot be replaced (e.g. where 1 = 36 mm) documented as DIN 1 OLD

DIN 7

Cylindrical pins

ISO 2338

- some can be replaced ∅ changed to ISO 2338 - parts which cannot be replaced (e.g. diameter 13 and 14 and/or where 1 = 36 mm) documented as DIN 7 OLD

DIN 84

Cylindrical screws

ISO 1207

- some can be replaced ∅ changed to ISO 1207 - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD

DIN 85

Flat head bolts

ISO 1580

- can be replaced ∅ changed to ISO 1580

DIN 94

Split pins

ISO 1234

- can be replaced ∅ changed to ISO 1234

DIN 417

Threaded pins

ISO 7435

- can be replaced ∅ changed to ISO 7435

DIN 439-1 DIN 439-2

Hex nuts Hex nuts

ISO 4036 ISO 4035 ISO 8675

- cannot be replaced ∅ documented as DIN 439 OLD

DIN 551

Threaded pins

ISO 4766

- can be replaced ∅ changed to ISO 4766

DIN 553

Threaded pins

ISO 7434

- can be replaced ∅ changed to ISO 7434

DIN 555

Hex nuts

ISO 4034

- cannot be replaced ∅ documented as DIN 555 OLD

DIN 558

Hex bolts

ISO 4018

- some can be replaced ∅ changed to ISO 4018 - parts which cannot be replaced (e.g. M12, with new SW) documented as DIN 558 OLD

DIN 601

Hex bolts

ISO 4016

- some can be replaced ∅ changed to ISO 4016 - parts which cannot be replaced (e.g. M10 and M12, with new SW) documented as DIN 601 OLD

DIN 912

Cylindrical screws

ISO 4762

- some can be replaced ∅ changed to ISO 4762 - parts which cannot be replaced (e.g. M18, M22, M27, and M33) documented as DIN 912 OLD

DIN 931-1

Hex bolts

ISO 4014

- some can be replaced ∅ changed to ISO 4014 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 931 OLD

DIN 933

Hex bolts

ISO 4017

- some can be replaced ∅ changed to ISO 4017 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 933 OLD

DIN 934

Hex nuts

ISO 4032 ISO 8673

- cannot be replaced replaced as a result of uneven nut height and for M10, M12, M14, and M22 with new SW.

DIN 960

Hex bolts

ISO 8765

- some can be replaced ∅ changed to ISO8765 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 960 OLD

DIN 961

Hex bolts

ISO 8676

- some can be replaced ∅ changed to ISO 8676 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 961 OLD

DIN 963

Countersunk bolts

ISO 2009

- cannot be replaced as a result of modified head dimensions ∅ documented as DIN 963 OLD

DIN 964

Countersunk bolts

ISO 2010

- cannot be replaced as a result of modified head dimensions ∅ documented as DIN 964 OLD

1) with reference to productive parts numbered at ZF 2003-08

12

Conversion from DIN to ISO Standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 965

Countersunk bolts

ISO7046

- cannot be replaced as a result of modified head dimensions ∅ documented as DIN 965 OLD

DIN 980

Locking nuts

ISO 7042 ISO 10513

- cannot be replaced ∅ documented as DIN 980 OLD

DIN 985

Locking nuts

ISO 10511

- cannot be replaced ∅ documented as DIN 985 OLD

DIN 1440

Washers

ISO 8738

- some can be replaced ∅ changed to ISO 8738 - parts which cannot be replaced documented as DIN 1440 OLD

DIN 1443

Bolts

ISO 2340

- can be replaced ∅ changed to ISO 2340

DIN 1444

Bolts

ISO 2341

- can be replaced ∅ changed to ISO 2340

DIN 1471

Grooved pins

ISO 8744

- some can be replaced ∅ changed to ISO 8744 - parts which cannot be replaced (e.g. 1 = 6 mm) documented as DIN 1471 OLD

DIN 1472

Grooved pins

ISO 8745

- some can be replaced ∅ changed to ISO 8745 - parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as DIN 1472 OLD

DIN 1473

Grooved pins

ISO 8740

- some can be replaced ∅ changed to ISO 8740 - parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25 and 50 mm) documented as DIN 1473 OLD

DIN 1474

Grooved pins

ISO 8741

- can be replaced ∅ changed to ISO 8741

DIN 1475

Grooved pins

ISO 8742

- can be replaced ∅ changed to ISO 8742

DIN 1476

Grooved stud

ISO 8746

- can be replaced ∅ changed to ISO 8746

DIN 1477

Grooved stud

ISO 8747

- can be replaced ∅ changed to ISO 8747

DIN 1481

Clamping pins

ISO 8752

- some can be replaced ∅ changed to ISO 8752 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD

DIN 6325

Cylindrical pins

ISO 8734

- some can be replaced ∅ changed to ISO 8734 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD

DIN 7346

Clamping pins Flange

ISO 13337

- some can be replaced ∅ changed to ISO 13337 - parts which cannot be replaced (≥ 7, 11, and 23 mm) documented as DIN 6325 OLD

DIN 7976

Self-tapping screws

ISO 1479

- can be replaced ∅ changed to ISO 1479

DIN 7978

Tapered pins

ISO 8736

- some can be replaced ∅ changed to ISO 8736 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD

DIN 7979

Cylindrical pins

ISO 8733 ISO 8735

- some can be replaced ∅ changed to ISO 8733/8735 - parts which cannot be replaced documented as DIN 7979 OLD

DIN 7981

Self-tapping screws

ISO 7049

- can be replaced ∅ changed to ISO 1479

DIN 7982

Self-tapping screws

ISO 7050

- cannot be replaced ∅ documented as DIN 7982 OLD

DIN 7985

Cheese-head screws

ISO 7045

- can be replaced ∅ changed to ISO 7045

1) refers to the productive components numbered at ZF 2003-08

13

ZF-Ecosplit

Description ZF item number

Consumables

Designation

Approx. Quantity

Application

Comments

Sealing compound 0666 690 017

Loctite Nr. 241

5 mm3

breather

Section 3, 4, 5

Grease 0750 199 001

for example: Aralub HL2

1g

pin o-ring roller

Section 3, 4

0634 316 057

o-ring

1 part

detent

Section 3, 4, 5

1g

tappet pin

Section 6, 7

Grease 0750 199 019

NOTE: Inquire as to size of containers before placing any orders.

1315 751 110b - 2005-03

14

ZF-Ecosplit

Spare Parts

Description ZF item number

Name

Approx. Quantity

Application

Comments

0501 318 490

spring (Ø12.4 x 43.4)

1

pneumatic servo unit

Section 1

0501 319 920

catch

1

pneumatic servo unit

Section 1

1315 751 110b - 2005-03

15

ZF-Ecosplit

Adjustment Data

Description

Dimension

Measurement device

01.

Tightenig torque screw plugs M22x1.5

60 Nm

Torque wrench

02.

Tightenig torque hexagon head screws M8x30 on cover

23 Nm

Torque wrench

03.

Tightenig torque hexagon head screws M8x65 on cover

23 Nm

Torque wrench

04.

Tightenig torque switch

45 Nm

Torque wrench

05.

Tightenig torque hex nut M10 on shift lever

49 Nm

Torque wrench

06.

Tightenig torque hexagon head screw M8x65 on cutoff valve

23 Nm

Torque wrench

07.

Tightenig torque hexagon head screw M8x30 on cover

23 Nm

Torque wrench

08.

Tightenig torque screw plugs M18x1.5

35 Nm

Torque wrench

09.

Tightenig torque hexagon head screw M8x32 on cover

23 Nm

Torque wrench

1315 751 110b - 2005-03

16

Comments

Screw plug or switch depend on parts list

Screw plug or switch depend on parts list

ZF-Ecosplit

Adjustment Data

Description

Dimension

Measurement device

10.

Tightenig torque hexagon head screw M8x28 on selector and shift cylinder

23 Nm

Torque wrench

11.

Tightenig torque hexagon head screw M8x25 and M8x80 on cover

23 Nm

Torque wrench

12.

Tightenig torque tappet switch and neutral switch

45 Nm

Torque wrench

13.

Tightenig torque hollow bolt on pipe

20 Nm

Torque wrench

14.

Tightenig torque hexagon head screw M8x70 and M8x95 on Super H valve block

23 Nm

Torque wrench

15.

Tightenig torque plug-in connector on Super H valve block

24 Nm

Torque wrench

1315 751 110b - 2005-03

17

Comments

Use new sealing ring

DANGER Use SW 22

ZF-Ecosplit

Spring Table

De

Spring diameter + tolerance in mm

Dh

Testing sleeve diameter in mm

L0

Untensioned spring length in mm

nt

Total of coils

d

Wire diameter in mm

nt Lo

d

De

D

Dh

Part number

018325

Total of coils [nt ]

Wire diam. in mm [d]

Spring diam. in mm at L0 [Dh] [De]

6.5

2.0

14.4

23.4

0732 042 126

9.5

1.0

9.2

25.0

0732 042 684

5.16

2.1

39.0

70.0

6.5

1.8

29.3

80.0

0732 041 612

6.5

1.7

13.9

25.8

0732 042 126

9.5

1.0

9.2

25.0

0732 042 207

7.5

1.5

14.2

30.6

6.5

2.4

39.1

89.9

6.5

2.0

14.4

23.4

5.16

2.1

39.0

70.0

0732 042 106

4.5

2.25

30.2

41.3

0732 041 500

6.5

2.1

14.4

23.6

5.5

2.25

14.5

21.6

4.5

2.0

30.5

50.1

0732 040 985

0732 040 728

0730 040 630

Installation point

Shifting output, left

Shifting output, right

Shift turret with HTC

0732 040 985 0732 042 684

0732 040 986 0732 041 011

1315 751 110b - 2005-03

Shift turret superimosed H shift system

Shift turret Superimposed H shift system with control cable

18

Untensioned length in mm [L0]

ZF-Ecosplit

Fig. no.

Special tools

Special Tools

Order no.

Application

1X25 139 707

1

1315 751 110b - 2005-03

Section 3 Section 4

1

Section 3 Section 4 Section 7

1

Section 3 Section 4 Section 7

1

Section 8

Handle for 1X25 139 707 and 1X25 139 783

1X56 138 229

4

2

Adaptor for bush on selector housing

1X56 138 107

3

Comments

Adaptor for bush on selector housing

1X25 139 707

2

Qty.

Function test device for shift turret with HTC

19

Servoshift

ZF-Ecosplit

3 1 2

4

5

6 7

012319

1

Pneumatic Servo Unit (PSU)

1.1

Shift turret with left and right shifting output Assembly

Disassembly 1

Loosen hollow screws (1 and 2) and remove together with sealing rings and pipe (3).

1

Place spring (7) inside servo-unit.

2

Re-place servo-unit (5) together with new gasket (6) on shift turret.

2

Loosen hexagon head screw (4).

3

Remove pneumatic servo-unit (5) together with gasket (6) and spring (7).

3

Insert and tighten hexagon head screw (4). Tightening torque = 23 Nm.

NOTE Spring (7) is placed loosely inside pneumatic servo-unit. Pneumatic servo-unit is a complete component - do not disassemble.

4

Fix pipe (3) together with new sealing rings to shift turret using a hollow screw (1). Tightening torque = 20 Nm.

5

Fix pipe together with new sealing rings to pneumatic servo-unit using a hollow screw (2). Tightening torque = 20 Nm.

1315 751 110b - 2005-06

1-1

Servoshift

ZF-Ecosplit

8

3 2 1 4

9

6 7

5

015984

1.2

1

Shift turret with HTC (hydrostatic control) Removal Unfasten union screws (1 and 2) and take off with sealing rings and pipe (3).

2

Unfasten hexagon head screw (4).

3

Take off pneumatic servo unit (5) with gasket (6) and spring (7). NOTE Spring (7) lies loosely in the pneumatic servo unit. Do not dismantle pneumatic servo unit any further. It is a complete part. NOTE The selector cylinder (8) and the shift cylinder (9) are only listed here for your information. They remain in the vehicle when the transmission and/or shift turret are removed.

1315 751 110b - 2005-06

For dismounting and mounting on shift turret see Chapter 2.

Installation 1

Place spring (7) in servo unit.

2

Attach pneumatic servo unit (5) and new gasket (6) on shift turret.

3

Insert hexagon head screw (4) and tighten. Tightening torque = 23 Nm.

4

Fasten pipe (3) on valve block with union screw (1) and new sealing rings. Tightening torque = 20 Nm.

5

Attach pipe with union screw (2) and new sealing rings on the pneumatic servo unit. Tightening torque = 20 Nm.

1-2

Servoshift

ZF-Ecosplit

3 3 7 3 3

2

1 8

2

5

4

6 018645

1.3

Super H shift turret with HTC (superimosed H shift system) NOTE Spring (6) is loosely placed in pneumatic servo unit. Do not disassemble servo unit further - complete component!

Removal 1

Loosen pipe (2) on plug-in connector (see drawing).

2

Loosen hollow bolt (1) and remove together with sealing rings and pipe (2).

3

Loosen hexagon head screws (3).

4

Remove servo unit (4) together with gasket (5) and spring (6).

1315 751 110b - 2005-06

NOTE Selector cylinder (7) and shifting cylinder (8) are mentioned here for information only. They remain in the vehicle during removal of the transmission or the shift turret. For dismounting and mounting on shift turret see Chapter 2.

1-3

Servoshift

ZF-Ecosplit

3 3 7 3 3

2

1 8

2

5

4

6 018645

Installation 1

Place spring (6) in servo unit.

2

Mount pneumatic servo unit (4) together with new gasket (5) on shift turret.

3

Put hexagon head screws (3) in place and tighten Tightening torque = 23 Nm.

4

Mount pipe (2) together with hollow bolt (1) and new sealing rings on servo unit. Tightening torque = 20 Nm.

5

Insert pipe (2) on Super H valve block, connection A5

1315 751 110b - 2005-06

1-4

Servoshift

ZF-Ecosplit

1

1

3

2

4

024463

1.4

Shift turret with superimposed H shift system with control cable Installation

Removal 1

Loosen 4 hexagon head screws (1).

1

Place spring (4) in servo unit.

2

Remove pneumatic servo unit (4) together with gasket (3) and spring (6).

2

Mount pneumatic servo unit (2) together with new gasket (3) on shift turret.

NOTE Spring (4) is loosely placed in pneumatic servo unit. Do not disassemble servo unit further - complete component!

3

Insert hexagon head screws (1) and tighten. Tightening torque = 23 Nm.

1315 751 110b - 2005-06

1-5

1315 751 110b - 2005-06

1-6

Servoshift

ZF-Ecosplit

2

1 4

3 5

018646

2

Selector cylinder/shift cylinder Shift turret with HTC NOTE The selector cylinder (2) and the shift cylinder (4) are connected to a separate hydraulic circuit and remain in the vehicle when the transmission and/or shift turret are removed.

Removal 1

Unfasten two hexagon head screw (1) and washers.

2

Pull off selector cylinder (2) with O-ring, remove piston rods of selector cylinder from driver groove in selector shaft. NOTE Move shift lever into the gate so that the selector cylinder can be pulled out.

3

Unfasten two hexagon head screw (3) and washers.

4

Pull off shift cylinder (4), remove piston rods of shift cylinder from driver groove of shaft in pneumatic servo unit (5).

1315 751 110b - 2005-06

2-1

Servoshift

ZF-Ecosplit

2

1 4

3 5

018646

Installation 1

4

Suspend piston rods of shift cylinders (4) in driver groove of shaft on pneumatic servo unit (5). NOTE Move shift lever in shift direction so that the piston rods move out.

2

Attach shift cylinder (4) the right way round (direction depends on installation conditions in the vehicle) on the pneumatic servo unit.

3

Screw in two M8x28 hexagon head screw and washers (3) and tighten. Tightening torque = 23 Nm.

NOTE Push shift lever in selector direction for piston rod travel. 5

Attach selector cylinder with O-ring on shift turret.

6

Screw in two M8x28 hexagon head screw and washers (1) and tighten. Tightening torque = 23 Nm.

NOTE Check O-ring on selector cylinder and replace if necessary.

1315 751 110b - 2005-06

Suspend piston rods of selector cylinders (2) in driver groove of selector shaft. A housing notch on the selector cylinder allows the rods to only be suspended in the correct assembly position.

2-2

Shift mechanism

ZF-Ecosplit

7

6

4

5 22 21 20 1 3

10 9 8

11

48

12 13

2

18 14 19

15 16 17

012330

3

Shift turret with left shifting output

4

Loosen switch (6 and 7) and remove together with sealing rings and pins. Depending on parts list, there may be screw plugs.

5

Unsnap V-ring (8) and remove detent (9) together with O-ring from shift housing.

Removing and dismantling of shift housing 1

Loosen hexagon head screws (1) and remove shift turret together with gasket (2). Remove roller (48) from valve lever.

NOTE Check O-ring and replace if necessary (cf. consumables).

NOTE For removal of the Servoshift see Section 1.1 2

3

Loosen shift lever (3, depending on parts list) and remove together with protective cap.

6

Loosen hexagon head screws (10) and remove cover (11) together with sealing.

NOTE Mark selector lever position.

7

Unsnap V-ring (12) and locking ring (13) and remove disk (14), spring (15), disk (16), V-ring (17), spring (18) and disk (19).

Disassemble cutoff valve (4) and remove together with O-ring (5). NOTE Cutoff valve is a complete part - do not dismantle.

1315 751 110b - 2005-06

NOTE Arrangement and sequence of parts in step 7 depend on parts list. 8

3-1

Loosen screw (20) and remove together with sealing ring, spring (21) and detent (22).

Shift mechanism

ZF-Ecosplit

29

27

24

23

38

40

28

25

26 39

35

42 43

36

32

33 34

46

31 30

37

44

41 45 47

012331

9

Loosen hexagon head screws (23) and remove cover (24) together with sealing (25).

10

Loosen screw plugs (26 and 27) and remove together with sealing rings, spacing washers and springs.

11

Remove detent lever (28 and 29) from shift housing. If necessary, remove cylindrical pins.

CAUTION Locking rings (30 and 32) must not be overstrained - use adjustable pliers. 12

Unsnap locking rings (30).

13

Remove cylindrical pins (31). If necessary, remove locking rings (32).

14

Remove pin (38) and slide hollow shaft (39) towards cover.

15

Place impact adaptor 1X25 139 783 on needle bush (33) and drive valve lever (37) downwards.

1315 751 110b - 2005-06

16

Remove needle bush (33).

17

Remove pin (34).

18

Dismantle shift shaft (40) from shift housing together with valve lever (37) and lever (41). NOTE Inspect selector shaft bores and level any revised edges.

19

Remove pin (35) from valve lever. Do not remove lower needle bush (36). Replace any damaged needle bush (36) together with valve lever.

20

Place plastic arbor on hollow shaft and drive it out of the shift housing together with the shaft bush (42) and the shaft seal (43). Slide hollow shaft out of shift housing and in the process remove dog (44) and blocking piece (45).

21

If necessary, remove cylindrical pins (46 and 47).

3-2

Shift mechanism

ZF-Ecosplit Assembly of shift housing 38

1

Insert dog (44) and blocking piece (45) in shift housing. Position hollow shaft (39) properly in shift housing, blocking piece and dog.

2

Use adaptor 1X25 139 707 to press in bush (42) for flush seat in housing.

3

Snugly fit greased shaft seal ring (43) in its support.

4

Insert cylindrical pin (35) into valve lever (37). If necessary, press in cylindrical pins (46 and 47).

5

Mount valve lever (37) and lever (41) in shift housing onto hollow shaft.

6

Introduce shift shaft (40) into hollow shaft.

32

46 31 30

44

NOTE Cylindrical pin (35) must engage with shift shaft. Position shift shaft and hollow shaft properly.

45

CAUTION Secure only hollow shaft with the cylindrical pin (38). Only insert by hand until detent is reached never drive in.

39

35 36 33 34

7

Insert cylindrical pin (38). Check ease of movement of the shift shaft.

8

Insert cylindrical pin (34) and drive in new needle bush (33) until it is flush. Check ease of movement of the shift shaft.

37 41

47

CAUTION Locking rings (32 and 30) must not be overstrained - use adjustable pliers. 9

40 42

Snap in locking rings (32) on pins (31) and insert in dog and shift shaft. Insert locking rings (30).

43

012332

1315 751 110b - 2005-06

3-3

Shift mechanism

ZF-Ecosplit 10

Place detent levers (28 and 29) in shift housing. If necessary, insert cylindrical pins.

24

23

NOTE Arrangement of detent levers depends on parts list (see Fig.12334). 11

Insert screw plugs (26 and 27) together with springs, spacing washers and new sealings and tighten. Tightening torque = 60 Nm.

12

Place new sealing (25) and cover (24).

13

Insert hexagon head screws (23) and tighten. Tightening torque = 23 Nm.

25 29

27

NOTE Version Standard "A"

28 26

012333

Version Standard "B"

Version Alternative "C"

012334

1315 751 110b - 2005-06

3-4

Shift mechanism

ZF-Ecosplit

7

6

4

5 22 21 20 1 3

10 9 8

11

48

12 13

2

18 14 19

15 16 17

012330

14

Place disk (19), spring (18), V-ring (17), disk (16), spring (15), disk (14), and snap in locking ring (13) and V-ring (12).

18

Place switches (6 and 7) together with pins and new sealing rings in shift housing and tighten. Tightening torque = 45 Nm. Depending on parts list, there may be screw plugs. Tightening torque = 35 Nm.

19

Mount cutoff valve (4) together with greased O-ring (5) with hexagon head screws to shift housing. Tightening torque = 23 Nm.

20

Mount shift lever (3) together with protective cap on shift shaft. Tightening torque = 49 Nm.

21

Place greased roller (48) on valve lever.

NOTE Arrangement and sequence of parts in step 14 depend on parts list. 15

Place cover (11) together with new sealing and tighten with hexagon head screws (10). Tightening torque =23 Nm.

16

Place detent (22), spring (21) and screw plug (20) with new sealing ring and tighten. Tightening torque = 60 Nm.

17

Place detent (9) together with greased O-ring and V-ring (8) in shift housing. For new O-ring, cf. consumables.

NOTE For assembling of the Servoshift see Section 1.1

1315 751 110b - 2005-06

3-5

Shift mechanism

ZF-Ecosplit 3.1

Shift patterns Shift turret with left shifting output

3.1.1 Horizontal torque shaft left / Selector pattern I

Spring pack arrangements Q1 - Q6

012338

Q1

Q2

012335

Q3

012336

Q4

012337

Q5

Q6

012340

1315 751 110b - 2005-06

012339

3-6

012341

Shift mechanism

ZF-Ecosplit 3.1.2 Horizontal torque shaft left / Selector pattern II

Spring pack arrangements Q1 - Q6

012345

Q1

Q2

012342

Q3

012343

Q4

012346

012344

Q5

Q6

012347

1315 751 110b - 2005-06

3-7

012348

1315 751 110b - 2005-06

3-8

Shift mechanism

ZF-Ecosplit

3

10 6 19 18 17 27 7

4

11 5 21

22

20

26 1 2

48 014992

4

3

Shift turret with right shifting output Removing and dismantling gear shift housing

1

Unfasten hexagon head screws (1) and take off shift turret with gasket (2). Take roller (48) off valve lever.

NOTE Do not dismantle cut-off valve further. It is a complete part. 4

Unfasten switches (6 and 7) and take off with seals and pins. Depending on parts list, there may be screw plugs.

5

Unfasten hexagon head screws (10) and take off cover (11) with gasket.

6

If necessary, press bearing bush (17), shaft seal (18) and scraper (19) out of cover.

Unfasten shift lever (3, depending on parts list) and remove with protective cap.

7

Unfasten screw (20) with seal, remove spring (21) and bolt (22).

NOTE Mark selector lever position.

8

Unfasten screw plugs (26 and 27) and remove with seals, spacing washers and springs.

NOTE For removal of servoshift, refer to section 1.1 NOTE Depending on version, an angled plate (not shown here) is screwed onto the housing cover using the screws of the servoshift mounting. 2

Remove cut-off valve (4) and take off with O-ring (5).

1315 751 110b - 2005-06

4-1

Shift mechanism

ZF-Ecosplit

29

24

23

38

28

40

39 9

25

35 36 33 34

46

8

37

32 31

41 30 44 47 45

014993

9

Unfasten hexagon head screws (23), take off cover (24) and gasket (25).

10

Snap out V-ring (8) and remove. Press detent (9) and O-ring out of gear shift housing. Press from inside to outside. NOTE Check O-ring and replace if necessary (cf. consumables).

11

Note down position of detent levers (28 and 29). Take detent lever out of gear shift housing. If necessary, remove cylindrical pins.

14

Remove pin (38).

15

Slide quill shaft (39) towards the shift lever until it engages.

16

Fix impact adaptor 1X25 139 783 above the needle bush (33) and drive valve lever (37) downwards.

17

Use gripper pliers to remove needle bush (33).

18

Remove pin (34).

19

Remove gear shift shaft (40) in the direction indicated by the arrow and in so doing take out the valve lever (37) and lever (41).

CAUTION Circlips (30 and 32) must not be overstretched - use adjustable pliers. 12

Snap out circlips (30).

13

Remove cylindrical pins (31) and if necessary remove circlips (32).

1315 751 110b - 2005-06

4-2

Shift mechanism

ZF-Ecosplit

29

24

23

38

28

40

39 9

25

35 36 33 34

46

8

37

32 31

41 30 44 47 45

014993

NOTE If the bores on the gear shift shaft show signs of raised edges after long operating hours, the gear shift shaft cannot be removed as described above. In such instances, the spring package (step 22) must be removed with the gear shift shaft still installed and the gear shift shaft then removed in the opposite direction to that indicated by the arrow. The raised edges should be levelled before the gear shift shaft is refitted. 20

Take pin (35) out of valve lever, do not remove lower needle bush (36). If the needle bush is faulty, replace the entire valve lever and needle bush.

21

If necessary, remove cylindrical pin (47).

1315 751 110b - 2005-06

4-3

Shift mechanism

ZF-Ecosplit 22

With the shaft removed, snap out V-ring (12) and circlip (13). Remove washer (14), spring (15) and washer (16).

23

NOTE Number, arrangement and sequence of parts in step 22 depend on the parts list.

24

Place plastic mandrel on quill shaft and drive out of gear shift housing with quill shaft (39), bush (42) and cover (43). Slide quill shaft off gear shift housing and in so doing take off driver (44) and blocking piece (45).

46

If necessary, remove cylindrical pin (46).

44

25

45

39

12 13 14 15 16

42 43

014994

1315 751 110b - 2005-06

4-4

Shift mechanism

ZF-Ecosplit Assembling gear shift housing 38

1

Guide driver (44) and blocking piece (45) into gear shift housing. Align quill shaft (39) correctly and slide into gear shift housing, blocking piece and driver.

2

Press new bush (42) with adaptor 1X25 139 707 into housing until flush.

3

Press new cover (43) onto system. NOTE Housing bores an cover must be free from greese.

4

5

32

46 31 30

44

Insert cylindrical pin (35) in valve lever (37). If necessary, press in cylindrical pins (46 and 47). Position valve lever and lever in housing.

45

With the shaft removed, fit V-ring (12), circlip (13), washer (14), spring (15) and washer (16). NOTE Number, arrangement and sequence of parts in step 5 depend on the parts list.

6

39

33 34

Guide gear shift shaft (40) (in direction indicated by arrow) into housing and quill shaft. NOTE Cylindrical pin (35) must engage with gear shift shaft. Position gear shift shaft and quill shaft accordingly.

7

35 36 37 41

12 47

13 14

Press valve lever (37) and lever (41) upwards. Slide quill shaft towards cover (43).

15 16

CAUTION Only the quill shaft is secured with cylindrical pin (38). Only insert by hand until detent is reached never drive in.

40 42 43

014995

1315 751 110b - 2005-06

4-5

Shift mechanism

ZF-Ecosplit 8

Use grease to insert cylindrical pin (38). Check ease of movement of gear shift shaft.

9

Use an appropriate attachment to fix valve lever and lever or support in a suitable manner.

10

Use grease to insert cylindrical pin (34) in new needle sleeve (33) and drive firmly together. Check ease of movement of gear shift shaft.

38

32

46 31 30

44

45

39

35 36 33 34 37 41

12 47

13 14 15 16 40

42 43

014995

1315 751 110b - 2005-06

4-6

Shift mechanism

ZF-Ecosplit CAUTION Circlips (30 and 32) must not be overstretched - use adjustable pliers. 11

Snap circlips (32) onto pins (31) and insert in driver and gear shift shaft. Insert circlips (30).

12

Insert detent levers (28 and 29) in gear shift housing as noted down. If necessary, insert cylindrical pins.

24

23

NOTE Arrangement of detent levers depends on parts list. For possible arrangements, refer to diagram 012334.

25 29

13

Attach new gasket (25) and cover (24).

14

Insert hexagon head screws (23) and tighten. Tightening torque = 23 Nm

15

Insert screw plugs (26 and 27) with springs, spacing washers and new seals and tighten. Tightening torque = 60 Nm.

27

28 26 NOTE Standard "A" version 014996

Standard "B" version

Standard "C" version

012334

1315 751 110b - 2005-06

4-7

Shift mechanism

ZF-Ecosplit

3

10 6 19 18 17 7

4

11 5 21

22

20 1 8 9 48 2 014997

16

17

21

NOTE Use gasket as specified in parts list (0.5 mm thick).

Use hexagon head screws to fit cut-off valve (4) and greased O-ring (5) to gear shift housing. Tightening torque = 23 Nm.

22

Attach cover (11) with new gasket and use hexagon head screws (10) to tighten into place. Tightening torque = 23 Nm.

Attach gear shift lever (3) with cover cap to gear shift shaft. Tightening torque = 49 Nm.

23

Use grease to attach roller (48) to valve lever.

Press new bearing bush (17), new shaft seal (18) and new scraper (19) into cover (11).

18

Insert bolt (22), spring (21) and screw plug (20) with new seal and tighten. Tightening torque = 60 Nm.

NOTE If necessary, fasten angled plate (not shown) to servoshift retaining screws.

19

Insert detent (9) with greased O-ring and Vring (8) in gear shift housing. For new O-ring, cf. consumables.

20

Insert switches (6 and 7) with pins and new seals in gear shift housing and tighten. Tightening torque = 45 Nm. Depending on parts list, there may be screw plugs. Tightening torque = 35 Nm.

NOTE The valve lever and lever must be flush if the servoshift to be fitted. The servoshift must be in its neutral position (central position).

1315 751 110b - 2005-06

24

4-8

Attach servoshift refer to section 1.1.

Shift mechanism

ZF-Ecosplit 4.1

Shift patterns Shift turret with right shifting output

4.1.1 Horizontal torque shaft right / Selector pattern I Spring pack arrangements Q1 - Q6

012362

012352

Q1

Q2

012350

012349

Q3

Q4

012351

Q5

Q6

012354

1315 751 110b - 2005-06

012353

4-9

012355

Shift mechanism

ZF-Ecosplit 4.1.2 Horizontal torque shaft right / Selector pattern II Spring pack arrangements Q1 - Q6

012362

012362

Q1

Q2

012356

Q3

012357

Q4

012358

Q5

Q6

012360

1315 751 110b - 2005-06

012359

4-10

012 012361

Shift mechanism

ZF-Ecosplit

3 4

6 23 11 7 10

18 17 16 5 1

22

2

015986

5

1

Shift turret with hydrostatic control (HTC) Removing and dismantling shift housing

3

Unfasten hexagon head screws (1) and take off shift turret and gasket (2).

Unfasten switches (6 and 7), take off with sealing rings and pins.

4

Unfasten screw (16) and remove with sealing ring, spring (17) and bolt (18).

5

Unfasten screw plugs (22 and 23) and remove with sealing rings.

NOTE For removal of the Servoshift, refer to Chapter 1.2. NOTE The selector cylinder (3) with O-ring (11) and hexagon head screws (10) is only listed here for your information. It remains in the vehicle when the transmission and/or shift turret are removed. 2

Remove valve block (4) and take out with O-ring (5). NOTE Do not dismantle valve block any further. It is a complete part.

1315 751 110b - 2005-06

5-1

Shift mechanism

ZF-Ecosplit

20

19

27

29 21 30

9

34

8 28 26 25 24

32

33

015987

6

Loosen hexagon head screws (19), remove cover (20) and gasket (21).

7

Snap out V-ring (8) and remove. Push out detent (9) and O-ring from the inside of the shift housing.

10

Remove pin (27).

11

Remove selector shaft (29) from shift housing in direction indicated by the arrow and take off lever (30) at the same time. NOTE If the edges of the selector shaft bores are raised after longer operating periods, the selector shaft can no longer be removed as is described above. In such instances, the spring pack (step 12) must be removed when the selector shaft is still installed and the selector shaft then removed in the direction opposite to that indicated by the arrow. The raised edges should be levelled out before the selector shaft is re-installed.

NOTE Alternatively, the detent can be pushed out from the inside as the last disassembly step. NOTE Check O-ring and replace if necessary (refer to consumables). CAUTION Circlips (24 and 26) must not be overstretched - use adjustable tongs. 8

Snap out circlips (24).

9

Remove cylindrical pins (25) and remove circlips (26) if necessary.

1315 751 110b - 2005-06

5-2

Shift mechanism

ZF-Ecosplit 12

Snap out V-ring (12) from the removed shaft, remove washer (13), spring (14) and washer (15).

13

Place plastic mandrel on quill shaft and use quill shaft (28) to drive cover (31) out of shift housing. Slide quill shaft out of shift housing and in so doing, lift off driver (32) and blocking piece (33).

14

If necessary, remove cylindrical pin (34).

34

32

33

28 12 13 14 15

31 015988

1315 751 110b - 2005-06

5-3

Shift mechanism

ZF-Ecosplit Assembling shift housing 1

Guide driver (32) and blocking piece (33) into shift housing. Slide quill shaft (28) the right way round into shift housing, blocking piece and driver.

2

Press on new cover (31) until firmly fitted.

27

NOTE Housing bore and cover must be free of grease. 3

If necessary, press in cylindrical pin (34). Position lever (30) in housing.

4

Attach V-ring (12), washer (13), spring (14) and washer (15) to removed shaft.

34 26

5 6

25 24

32

Guide selector shaft (29) (in direction indicated by arrow) into housing and quill shaft.

33

Press lever (30) upwards, slide quill shaft in direction of cover (31).

CAUTION Only the quill shaft is secured by the cylindrical pin (27), only insert by hand until the stop is reached do not drive in.

28

30

12 7

Use grease to insert cylindrical pin (27). Check selector shaft for ease of movement.

13 14 15

CAUTION Circlips (24 and 26) must not be overstretched - use adjustable tongs. 8

Snap circlips (26) onto pins (25) and insert in driver and selector shaft. Insert circlips (24). 29

31 015989

1315 751 110b - 2005-06

5-4

Shift mechanism

ZF-Ecosplit 9

Attach new gasket (21) and cover (20).

10

Insert hexagon head screws (19) and tighten. Tightening torque = 23 Nm.

11

Insert screw plugs (22 and 23) with new sealing rings and tighten. Tightening torque = 60 Nm.

20

19

21

23

22

015990

1315 751 110b - 2005-06

5-5

Shift mechanism

ZF-Ecosplit

4 6 7

5 18 17 16

1

8

9

2

015991

12

Insert bolt (18), spring (17) and screw plug (16) with new sealing ring and tighten. Tightening torque = 60 Nm.

13

Insert stop (9) with greased O-ring and V-ring (8) in shift housing. If using new O-ring, refer to consumables. NOTE Both switches (6 and 7) and the associated pins are different. Do not mix them up.

14

15

NOTE Mounting of the pneumatic servo unit (PSU) requires the shift turret to be in neutral position (center position). 16

Insert switches (6 and 7) with pins and new sealing rings in shift housing and tighten. Tightening torque = 45 Nm.

1315 751 110b - 2005-06

Fit valve block (4) and greased O-ring (5) with hexagon head screws on shift housing. Tightening torque = 23 Nm.

5-6

Install Servoshift refer to Chapter 1.2

Shift mechanism

ZF-Ecosplit 5.1 Shift patterns Shift turret with HTC 5.1.1 Horizontal torque shaft right / Selector pattern I Spring pack arrangements Q1

015992

Q1

015993

1315 751 110b - 2005-06

5-7

1315 751 110b - 2005-06

5-8

Shift mechanism

ZF-Ecosplit

7

9

13 3

14 15

4 6

5 12 11

1

8 10

2

018647

6

3

Super H shift turret with HTC (superimosed H shift system) Removal and disassembly of the shift housing

1

Loosen hexagon head screws (1) and remove shift turret together with gasket (2).

CAUTION Do not loosen plug-in connector (10) on front but on rear hex connection - SW 22. 4

NOTE For dismounting the servo shift, see Chapter 1.3. NOTE Selector cylinder (3) with O-ring (4) and hexagon head screws (5) are mentioned only for information. They remain in the vehicle during removal of the transmission or the shift turret. See Chapter 2. 2

If necessary, remove plug-in connector (10). O-ring might stick to housing - remove it. NOTE Do not disassemble super H valve block further - complete part!

5

Remove tappet (11) and pin (12) from shift housing.

6

Loosen tappet switch (13) together with sealing ring and remove together with pressure spring (14) and lock (15).

Loosen hexagon head screws (6 and 7) and remove Super H valve block (8). NOTE Gasket may stick to shift housing. Remove and place in valve block.

1315751 010b - 2005-06

If necessary, loosen neutral switch (9) together with sealing ring and remove.

6-1

Shift mechanism

ZF-Ecosplit

16

17

24 23 22

18 21

26 25

32

35 27 20 19

28

33

29 30 34 31

018648

7

Loosen hexagon head screws (16), remove cover (17) and gasket (18).

CAUTION Snap rings (19) must not be stretched too much use adjustable pliers. 8

Remove snap ring (19).

9

Remove cylindrical pin (20) and remove second snap ring if necessary.

10

Remove shift shaft (21) from shift housing in the direction of the arrow.

11

Remove catch (22) and pin (23).

12

Push pin (24) through shift housing and remove.

13

Push hollow shaft (25) in the direction of the arrow and remove lever (26).

1315751 010b - 2005-06

14

Remove V-ring (27) on removed shaft and remove disk (28), springs (29 and 30) and disk (31).

15

Place plastic mandrel on hollow shaft and drive hollow shaft (25) and cover (32) out of shift housing. Push hollow shaft out of shift housing and in the process remove driver (33) and blocking piece (34).

16

Remove cylindrical pin (35) if necessary.

6-2

Shift mechanism

ZF-Ecosplit

16

17

24 23 22

18 21

26 25

32

35 27 20 19

28

33

29 30 34 31

018648

1

2

Assembling shift housing

6

Insert driver (33) and blocking piece (34) into shift housing. Insert hollow shaft (25) in correct position in shift housing, blocking piece and driver.

CAUTION Snap rings (19) must not be stretched too much use adjustable pliers.

Press on new cover (32).

7

If necessary, snap upper snap ring onto pin (20) and place in driver and shift shaft. Put snap ring (19) in place.

8

Push pin (24) to stop in housing and lock with pin (23). Put catch (22) in place.

9

Put new gasket (18) and cover (17) in place.

10

Insert hexagon head screws (16) and tighten. Tightening torque = 23 Nm.

NOTE Housing bore and cover must not be greasy. 3

Press in cylindrical pin (35) if necessary. Position lever (26) in housing.

4

Mount disk (31), springs (29 and 30), disk (28) and V-ring (27) on removed shaft.

5

Insert shift shaft (21) (in the direction of the arrow) in housing and hollow shaft.

1315751 010b - 2005-06

6-3

Push lever (26) upward and push hollow shaft towards the cover (32).

Shift mechanism

ZF-Ecosplit

7

9

13 3

14 15

4 6

5 12 11

1

8 10

2

018647

11

Install lock (15), spring (14) and tappet switch (13) together with new sealing ring in shift housing and tighten. Tightening torque = 45 Nm.

12

Place tappet (11) and pin (12) in shift housing.

13

Mount valve block (8) with hexagon head screws (6 and 7) to shift housing. Tightening torque = 23 Nm.

14

Screw in neutral switch (9) together with new sealing ring on valve block and tighten. Tightening torque = 45 Nm.

NOTE Mounting of the pneumatic servo unit (PSU) requires the shift turret to be in neutral position (center position). 16

CAUTION Do not loosen plug-in connector (10) on front but on rear hex connection - SW 22. 15

Insert plug-in connectors (10) and tighten. Tightening torque = 24 Nm.

1315751 010b - 2005-06

6-4

For mounting servo shift see Chapter 1.3

Shift mechanism

ZF-Ecosplit 6.1 Shift patterns Super H shift turret (superimosed H shift system) 6.1.1 Shift patterns I Arrangement of spring packages Q5

018649

Q5

018650

1315751 010b - 2005-06

6-5

1315751 010b - 2005-06

6-6

Shift mechanism

ZF-Ecosplit

17 16

4

6

18 1 14 10 11

15

7

12

4

13 9 8 5 3

2 49

024464

7

Shift turret with superimposed H shift system with control cable 4

Removal and disassembly of the shift system housing 1

2

NOTE Gasket may stick to shift housing. Remove it and place it in the valve block. Do not disassemble valve block further - complete component!

Loosen hexagon head screws (16), remove selector lever (17) with protective cap (18). NOTE The selector lever covers a hex screw; for this reason, first remove selector lever to be able to remove the shift system.

5

Loosen hexagon head screws (1) and remove shift turret together with gasket (2). Remove roller (49) from valve lever.

If necessary, loosen neutral switch (6) together with sealing ring and pressure switch (7) and remove.

6

Remove tappet (8) and pin (9) from shift housing.

7

Loosen shift lever (3, depending on parts list) and remove together with protective cap.

Loosen tappet switch (10) together with sealing ring and remove together with pressure spring (11) and interlock (12).

8

NOTE Mark selector lever position.

Loosen hexagon head screws (13) and remove cover (14) together with gasket.

9

Remove V-ring (15) from housing.

NOTE For removal of the Servoshift, refer to Chapter 1.4. 3

Loosen hexagon head screws (4) and remove together with valve block (5).

1315751 010b - 2005-06

7-1

Shift mechanism

ZF-Ecosplit

19

20 32 23 22

29 31

24

33 30 21

34 35 36

28 39 26

37

27 25

38

024465

10

Loosen hexagon head screws (19), remove cover (20) and gasket (21).

11

Remove locking pawl (22) and pin (23).

12

Push pin (24) through shift housing and remove it.

CAUTION Locking rings (25 and 26) must not be overstrained - use adjustable pliers. 13

Remove locking ring (25).

14

Remove cylindrical pins (27). If necessary, remove locking rings (26).

15

Push hollow shaft (28) towards sealing cap.

16

Place impact adaptor 1X25 139 783 on needle bush (29) and drive valve lever (30) slightly downwards.

17

Remove needle bush (29).

18

Remove pin (31).

1315751 010b - 2005-06

19

Dismantle shift shaft (32) from shift housing (as indicated by the arrow) together with valve lever (30) and lever (34). NOTE Inspect selector shaft bores and level any raised edges.

20

Remove pin (33) from valve lever. Do not remove lower needle bush. Replace any damaged needle bush as complete unit together with valve lever.

21

Place plastic arbor on hollow shaft (28) and push through the shift housing together with the shaft bush (35) and the shaft seal (36). Push hollow shaft out of shift housing and in the process, remove driver (37) and blocking piece (38).

22

Remove cylindrical pin (39) if necessary.

7-2

Shift mechanism

ZF-Ecosplit 23

Use pliers to remove V-ring (40) from shift shaft.

24

Use compression spring (42) to lift discs (41 and 43) from shift shaft.

40 41 42 43

024466

25

Remove V-ring (44) from selector shaft (45).

26

Push out shift shaft (45) (in the direction of the arrow) from housing and remove rotary shaft seal (48).

27

Remove selector lever (46) from housing cover.

28

Remove needle sleeve (47) from housing cover if necessary.

48 47

45 46 44 024467

1315751 010b - 2005-06

7-3

Shift mechanism

ZF-Ecosplit Assembling Selector Housing

48 47

1

Insert needle sleeve (47) into housing cover (until it is flush) if necessary.

2

Insert selector lever (46) into housing cover.

3

Insert shift shaft (45) (in the direction of the arrow) into housing cover and selector lever.

4

Insert V-ring (44) into selector shaft.

5

Insert greased rotary shaft seal ring (48) in correct position in its support.

45 46 44 024467

6

Mount disc (43), compression spring (42), and disc (41) onto shift shaft.

7

Use pliers to snap V-ring (40) onto shift shaft.

40 41 42 43

024466

1315751 010b - 2005-06

7-4

Shift mechanism

ZF-Ecosplit

19

20 32 23 22

29 31

24

33 30 21

34 35 36

28 39 26

37

27 25

38

024465

8

9

Use adaptor 1X25 139 707 to press in bush (35) for flush seat in housing.

10

Snugly fit greased rotary shaft seal ring (36) in its support.

11 12 13

14

Insert driver (37) and blocking piece (38) into shift housing. Place hollow shaft (28) in correct position in shift housing, insert blocking piece and driver.

Insert cylindrical pin (31) and drive in new needle bush (29) until it is flush. Check ease of movement of the shift shaft.

CAUTION Locking rings (26 and 25) must not be overstrained - use adjustable pliers. 15

Insert cylindrical pin (33) into valve lever (30). Press in cylindrical pin (39) if necessary.

Snap in locking ring (26) on pin (27) and insert in driver and shift shaft. Put locking ring (25) in place.

16

Mount valve lever (30) and lever (34) in shift housing onto hollow shaft.

Push pin (24) to stop in housing and lock with pin (23). Put locking pawl (22) in place.

17

Insert shift shaft (32) into hollow shaft (as indicated by the arrow).

Put new gasket (21) and preassembled cover (20) in place.

18

Insert hexagon head screws (19) and tighten. Tightening torque = 23 Nm.

NOTE Cylindrical pin (33) must engage with shift shaft. Position shift shaft and hollow shaft properly.

1315751 010b - 2005-06

7-5

Shift mechanism

ZF-Ecosplit

17 16

4

6

18 1 14 10 11

15

7

12

4

13 9 8 5 3

2 49

024464

19

Install interlock (12), spring (11), and tappet switch (10) together with new sealing ring in shift housing and tighten. Tightening torque = 45 Nm.

25

Fit cover (14) together with new sealing onto housing using hex-head screw (13) and tighten. Tightening torque = 23 Nm.

20

Place tappet (8) and pin (9) in shift housing.

26

21

Mount valve block (5) with hexagon head screws (6) to shift housing. Tightening torque = 23 Nm.

Mount shift lever (3) together with protective cap on shift shaft. Tightening torque = 49 Nm.

27

Place greased roller (49) on valve lever.

22

Screw in neutral switch (6) together with new sealing ring on valve block and tighten. Tightening torque = 45 Nm.

23

Insert pressure switch (7) at valve block and tighten. Tightening torque = 23 Nm.

24

NOTE For Servoshift assembly, refer to Chapter 1.4. NOTE Refer to Chapter 9 for mounting of complete shift system on transmission. 28

Snap V-ring (15) in selector shaft.

1315751 010b - 2005-06

7-6

Fit protective cap (18) together with selector lever (17) onto shift shaft and tighten using hexagon nut (16). Tightening torque = 23 Nm.

Shift mechanism

ZF-Ecosplit 7.1

Shift patterns Shift turret with superimposed H shift system.

7.1.1 Shift patterns I Allocation of spring packages Q4.

024461

Q4

024462

1315751 010b - 2005-06

7-7

1315751 010b - 2005-06

7-8

Shift mechanism

ZF-Ecosplit

1

2

1X56 138 229

015997

8

Function test Shift turret with HTC

1

Suspend test device 1X56 138 229 in driver groove of selector shaft (1). Screw in 2 hexagon head screws (2) and tighten. Tightening torque = 23 Nm.

2

The individual gears can be shifted through using a box spanner or hex nut.

3

Remove test device 1X56 138 229.

1315751 010b - 2005-06

8-1

1315751 010b - 2005-06

8-2

Shift mechanism

ZF-Ecosplit 9

Assembling complete shift turret

1

Place new gasket (1) onto clutch housing (2) and sealing face.

2

Place complete shift housing (3) in position. Line up bores in shift housing with bores in gasket.

3

1

NOTE Positioning between clutch housing, gasket and selector housing must be effected by insertion of 2 fixing ping Ø 8,9 mm.

2

NOTE When placing the selector mechanism make sure the roller on the valve lever does not come off. Assembly suggestion: Use grease to place roller on valve lever. Insert all hexagon head screws and tighten them. Tightening torque = 23 Nm. NOTE - version with HTC Once the transmission has been installed in the vehicle, the selector cylinder and shift cylinder remaining in the vehicle should be flange-mounted to the shift turret or the pneumatic servo unit. Installation of the two cylinders is described in Chapter 2.

015070

Ø 15

15

80

Schaft Ø 8.9

110

3

M8

016078

1315751 010b - 2005-06

9-1

1315751 010b - 2005-06

9-2