Training Documentation

ZF Gearbox
10 AS 2301 Bus
12 AS 2301 Truck/Bus

AS TRONIC
Produced in December 2003 by
MAN Steyr AG
SERVICE AKADEMIE / VNSA
This documentation is intended solely for training
purposes. It is not subject to ongoing amendment
and updating.

2004 MAN Fahrzeuge Aktiengesellschaft

Reproduction, copying, dissemination, editing, translation,
microfilming and storage and/or processing in electronic
systems, including databases and online services, is prohibited
without the prior written approval of MAN.

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CONTENTS

CONTENTS .............................................................................. 3 PLANETARY GEAR CARRIER............................................... 56

DESCRIPTION OF AS TRONIC ............................................... 4 UNION PLATE FOR OIL PUMP AND BRAKE ........................ 64
SWITCH OPERATION.............................................................. 6 CASE I (BELL HOUSING)....................................................... 74
DESCRIPTION OF ELECTRICAL COMPONENTS................ 14 REMOVING MAIN SHAFT AND LAYSHAFTS........................ 82
CLUTCH RELEASE................................................................ 24 REMOVING INPUT SHAFT FROM MAIN SHAFT .................. 84
GEARBOX SELECTOR.......................................................... 26 DISASSEMBLING DRIVE SHAFT .......................................... 90
DISASSEMBLING AND ASSEMBLING SPLIT SYNC ........................................................................... 94
GEARBOX SELECTOR.......................................................... 30 ASSEMBLING DRIVE SHAFT ................................................ 98
MAIN SHAFT DRIVEN FLANGE ............................................ 32 MAIN SHAFT ........................................................................ 102
OUTPUT SPEED SENSOR.................................................... 34 LAYSHAFT............................................................................ 106
REPLACING COMPONENTS ON INTARDER....................... 36 GEARSHIFT LEVER SHAFT ................................................ 108
SETTING AXIAL CLEARANCE OF OUTPUT BEARING........ 40 CASE II GEARBOX MAIN PART .......................................... 110
GP CASE................................................................................ 44 CONSUMABLES................................................................... 114
SETTING MAIN SHAFT/PLANETARY GEAR CARRIER SETTING DATA .................................................................... 115
CLEARANCE.......................................................................... 46 SPECIAL TOOLS.................................................................. 116
ATTACHING GP CASE .......................................................... 50
DISASSEMBLING AND ASSEMBLING GP CASE ................. 54

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DESCRIPTION OF AS TRONIC

The AS Tronic (TipMatic) gearbox is a 12-speed gearbox with 1 Shift module cover

electropneumatic transmission control (shift module). The major 2 Intarder

part of the gearbox is a non-synchromesh 3-speed transmission 3 Intarder cooler

with two layshafts, each with a synchronized splitter box and 4 Range group

range group. All transmission functions and components are 5 3-speed transmission with splitter box

integrated in a single shift module, meaning that a large number 6 Clutch actuator

of electrical and pneumatic connections are done away with. In

addition to gear selection, the AS Tronic control unit operates the

clutch.

Note!

When the ignition is off, the gearbox is always in neutral.

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SWITCH OPERATION

The AS Tronic gearbox is operated by two function switches.

Drive/neutral/reverse switch A 434 Steering column switch A 429

When standing in neutral (N), the driver can use the The steering column switch A 429 enables correction of the
drive/neutral/reverse switch A 434 to select a drive-off gear (D1, drive-off gear (max. D5) when standing.
D3, D5, DM) or a reverse gear (R1, RM). The degree of automation can be determined while moving, or
DM and RM are maneuvering modes in which engine speed is selective intervention in the shift is possible.
limited to maximally 800 rpm and the clutch does not fully In manual mode a check is made, before a change of gear,
engage (maximally 80%). whether the selected gear can be engaged without operating the
While driving it is possible to change to neutral and then the engine in the wrong speed range.
appropriate gear can be engaged again. To change into higher gear push the steering column switch up
Preselection of the direction in which to drive is not possible (A), and to change into lower gear press it down (B).
while the vehicle is travelling. N ....................... Neutral
D1 ..................... Drive-off gear 1
D3 ..................... Drive-off gear 3
D5 ..................... Drive-off gear 5
DM .................... Maneuvering mode, forwards
R1 ..................... Reverse gear 1
RM .................... Maneuvering mode, reverse

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Driving program

Teaching of path sensors Driving off

When the ignition is turned on, the AS Tronic checks itself out When the accelerator is operated by more than 70%, the clutch
one time for absence of faults. To teach the path sensors, a begins to engage up to a defined point, after which there is
defined valve combination (neutral / 2/3 / fast group) is driven. controlled engagement until engine speed and gearbox input
The positions of the path sensors and actuating cylinders are speed are the same.
compared to plausibility ranges. If a learning process faults, this The EDC engine control is requested to limit the injected fuel
path sensor value is learnt while driving when the appropriate quantity. The requested limit is set as a function of clutch travel
change position is engaged. to enable smooth, powerful driving off.
At the same time the AS Tronic monitors the load on the clutch
and warns the driver in good time by a message on the display
and an acoustic tone. If the driver ignores this, the clutch is
disengaged.

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Changing up Changing down

At the beginning of the change operation the clutch is partly At the beginning of the change operation the clutch is partly
disengaged to make complete separation easier. At the same disengaged. At the same time the injected fuel quantity is
time the injected fuel quantity is reduced (by the EDC) to reduce reduced to reduce the load.
the load. The momentarily engaged gear is taken out when the load
The momentarily engaged gear is taken out when the load reduction is completed and the clutch is fully disengaged.
reduction is completed and the clutch is fully disengaged. The clutch is again partly engaged and, with an increase in
The transmission brake is activated to reduce the speed injected fuel quantity, the transmission at the clutch end
difference between the dog and the sliding sleeve. accelerates until the meshing speed for the new gear is reached.
The transmission brake is released and the new gear engaged at When equality of speed is reached, the clutch is again
a slight speed difference. disengaged and the new gear is engaged.
The clutch is engaged parallel to building up load. The clutch is then engaged parallel to building up load.

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Maneuvering If the driver does not react (by changing to a lower gear or
halting), the AS Tronic control unit ends the maneuvering mode
If the accelerator is operated less than 70%, and a low gear and fully engages the clutch.
(1,2,3,) is engaged, the maneuvering mode is activated and the
clutch softly partly engaged. In this way the entire engine torque Caution!
is not transmitted. The vehicle can accelerate.
At the same time the EDC holds the engine speed at If the engine is stalled and started again, no gear is engaged by
maneuvering level. the ECU until the clutch has properly cooled.
The vehicle starts to move away slowly or to crawl.
The driver can control the maneuvering mode direct with the DM Neutral
or RM setting of the switch. If neutral is requested with the drive/neutral/reverse switch, the
Here the driver has the full accelerator travel available to operate gearbox changes to neutral after reduction of load (reduced
the clutch. The more the accelerator is operated, the further the injected fuel quantity). Then the clutch engages.
clutch engages (the clutch is in a slipping mode).
Ignition off
Note! Turning the ignition off tells the EDC to shut down the engine. As
The clutch can be overloaded in this condition. The driver is soon as the AS Tronic control unit detects an engine speed of
warned in good time by a message on the display and an less than 300min-1, the gearbox is put into neutral and the clutch
acoustic tone. fully engaged.

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Automation levels Proceeding from engine power and consumption operating
maps, a primarily consumption-oriented gear changing strategy
The current state of the art does not yet allow all driving is used. The AS Tronic control unit recognizes the wish for a
situations to be covered by a fully automatic gear changing power-oriented driving manner from the preceding driving
strategy. The driver's visual advantage cannot be matched by an manner and matches the gear changing strategy appropriately.
automatic control that only reacts to events that have already In automatic mode the Manual symbol appears to the left of the
occurred. An automatic gear change cannot cover situations indication of the momentary gear.
where no conclusions can be drawn for a necessary change from
the vehicle's momentary behaviour. In these cases the driver By operating the control lever the driver can change to manual
must be able to intervene and correct. mode at any time and initiate a gear change. The AS Tronic
checks whether the selected gear is admissible, and then
Automatic mode performs the gear change.
In automatic mode the gear is specified by the AS Tronic control Arrow symbols pointing upwards V to the left of the indication of
unit, regardless of accelerator operation, engine speed and the momentary gear show the possible number of upward gear
driving speed. shifts, arrow symbols pointing downwards W on the right show
the possible number of downward gear shifts.

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Power takeoff Salvaging

One or two power takeoffs (PTOs) can be activated by the To allow salvaging, the drive shaft(s) must always be
vehicle management computer. The AS Tronic control unit disconnected (Fig. A).
receives the PTO request from the drive train data bus.
To switch the PTO, the clutch is disengaged, the large splitter Dragging
box is switched, the transmission brake is activated, and Dragging home the engine is not possible.
interlock requested by the EDC control unit. Shortly before the
layshaft comes to a halt, the valve for the PTO is cut off by the Chassis dynamometer test bed
vehicle management computer. After driving onto the rollers it is necessary to change to neutral
As soon as the AS Tronic control unit receives the message (Fig. B), otherwise the AS Tronic control unit will detect "moving
"PTO switched", the clutch is engaged under control and the vehicle" and engage the clutch.
interlock cancelled. The vehicle can move off the rollers under its own power.

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Fig. A

Fig. B

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DESCRIPTION OF ELECTRICAL COMPONENTS

Gearbox selector Control cylinders

The gearbox selector (shift module) is a compact unit seated on Four control cylinders in the gearbox selector are responsible for
gear selection.
the gearbox and containing the following parts:
They are only pressurized for the duration of a gear change.
After the gear engages they are ventilated.
The control cylinders for range group and splitter box act directly
• Integrated gearbox electronics
on the particular gear control fork.
• Electronic valves: shift, select, transmission brake In the main gearbox the selector cylinder connects the control
cylinder to one of the two gear control forks (1/R or 2/3).
• Control cylinders: shift, select
In this way it is possible to shift maximally 12 forward gears and
• Gearbox input speed sensor two reverse gears with four cylinders.
• Sensor for operating pressure Technical data
• Pressure limiting valve Operating voltage range 9 to 36 V
• Sensors for gearshift lever shaft position Quiescent current 5 mA
• Compressed-air terminal of circuit 4 braking system Max. current drain 10 A / 36 V (5% ED)
• Electrical connectors
A) ............ control cylinder range group
B) ............ control cylinder main gearbox
C) ............ control cylinder splitter box
D) ............ gearshift lever shaft splitter box
E) ............ gearbox selector (shift module with electronics)
F)............. selector cylinder main gearbox
G) ............ gearshift lever shaft range group
H) ............ gearshift lever shaft main gearbox

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Steering column switch DNR (drive/neutral/reverse) switch

The steering column switch has a total of seven functions that The seven switch settings are output as data signals.
are output as data signals. The vehicle management computer sends a clock signal (1 kHz)
The vehicle management computer sends a clock signal (1 kHz) as a synchronizing signal to which the switch responds with the
as a synchronizing signal to which the switch responds with the data signal.
appropriate data signal. If two adjacent switch settings overlap, that switch setting is
output that is closer to the N setting.
A) Rocker forwards........... Memory Errors like physically impossible switch statuses (e.g. two non-
B) Rocker backwards ....... Off
adjacent switch settings) are indicated as an error status.
C) Lever forwards ............. Set +
D) Lever backwards.......... Set -
E) End button ................... Manual/automatic mode
Measurement on A 434
F) Lever up....................... Higher gear
G) Lever down .................. Lower gear Clock signal FFR X1/8 60615 - X1/3 31000
Data signal FFR X2/7 60616 - X1/3 31000
Measurement on A 429
Plus supply A429 Pin 6 60028 - X1/3 31000
Clock signal FFR X1/7 60608 - X1/3 31000
Plus supply LED A434 Pin 3 58000 – ZE A1/17
Data signal FFR X2/8 60607 - X1/3 31000
Minus supply A434 Pin 8 31000 – X1644
Plus supply A429 Pin 6 60028 - X1/3 31000
LED FFR X2/17 60609 – X1/3 31000

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Clutch Wear

To drive the clutch module, the AS Tronic control unit uses In each clutch operation the point of application is newly
reference values based on clutch wear and the release determined and thus clutch wear. The actuation path of the next
mechanism. clutch operation is governed by the degree of wear.

Learning Caution!
Before disassembling and assembling, undo the venting screw A
When the ignition is turned on, AS Tronic checks clutch to relax the clutch cylinder.
operation. For this purpose all solenoid valves are cut out, the
clutch fully engages and the "Clutch engaged" position is stored. Note:
Then the clutch is disengaged 100% and engaged by a given In overrun conditions at speeds below 32 km/h the clutch is
amount of travel so that, with the engine running, the point of opened by a parametrised value.
application (the clutch plate is also turned) can be determined by If the brake is applied in these circumstances in overrun
comparison of engine speed with gearbox input speed. conditions the clutch is opened by a
further 20 %. It opens completely just before the vehicle comes
to a standstill.

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Output speed sensor
The gearbox output speed is obtained from a speed sensor A on A) Output speed sensor (black connector socket)
the output shaft and processed by the gearbox selector B) KITAS sensor (white connector socket)
electronics. If the speed sensor A fails, the TCO message of the
KITAS sensor on the drive train CAN is used as a reference The KITAS sensor has a longer case than the output speed
signal. In this case gear changing quality is poorer, and it is sensor.
consequently only possible to drive in manual mode.
Measurement A: output speed sensor B368
V voltage A330 B18 60613 – B6 31000 6.5 V
Output signal A330 B11 60613 – B6 31000 ⎦⎡⎤⎣
(8 pulses/flange turn)

Measurement B: KITAS sensor B406

V signal + KITAS pin 1 gr MTCO A408 Pin B1
GND signal - KITAS pin 2 gr/gn MTCO A408 Pin B2
Measured signal Pin 1-pin 2 max. 6.5 V

Realtime signal KITAS Pin 3 gr/br MTCO A408 Pin B3

Data signal KITAS Pin 4 gr/wh MTCO A408 Pin B4

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 A B

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Clutch actuator

Removal Attachment

• Remove the connector from the gearbox selector and output • Insert the push rod (68.210) in the pan of the release fork
speed sensor.
(68.060).
• Remove the cable harness from the cable clamps (68.300,
68.320, 68.330). • Ensure proper lay of the connections and correct seating of
• Remove the four M8 hex screws (68.154) and take off the
the push rod (68.210).
cover (68.150).
• Relax the clutch actuator by opening the screw plug (6). • Hex nuts M8 (/030) = 23 Nm
• Remove the four M8 hex nuts with washers (/030) and take Stud bolts M8 (/010) = 10 Nm
off the clutch actuator (68.010).
• Take the entire push rod (68.210) out of the release fork
(68.060). • Attach the cover (68.150) with the four M8 hex screws
Caution! (68.154).
Before disassembling the clutch actuator, open the screw Tightening torque M8 = 23 Nm
plug (6) and release initial pressure.
• Venting clutch actuator
Push rod Undo the M12x1.5 screw (6).
Length of push rod (68.210) according to parts list:
• Press the cable harness into the cable clamps.
ZF no. Length in mm • Replace the connectors on the gearbox selector and output
1328 368 003 127.1
speed sensor.

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CLUTCH RELEASE

Removal of release fork Note!

Wet the shaft sealing rings on the outer circumference, e.g. with
• Remove the two M12 hex screws (68.130) on the release spirit.
shaft (68.110).
• Take the release bearing (68.050) and release fork (68.060) • Press in the two shaft sealing rings (/140) with the stopper
1X56 138 215 for an axial match. Grease the sealing lip of
off the drive shaft. the shaft sealing rings (/140) with OLISTA LONGTIME 3EP
• Slide the release shaft (68.110) out of the release fork (ZF no. 0671 190 050).
(68.060). • Insert the release shaft (68.110) into the release fork
(68.060), being sure not to damage the shaft sealing rings.
• Disassemble the release fork (68.060).
• Position the release bearing (68.050) on the release flange.
Remove the shaft sealing rings (/140) and bushings (/130) Do not grease the sliding seat of the release
with a suitable tool. Renew the ball cup (/120) if it is damaged bearing/release flange.
or worn. • Grease the mating surface of the release fork (68.060) with
the release bearing (68.050) with OLISTA LONGTIME 3EP
(ZF no. 0671 190 050). Join the release fork (68.060) with the
Attachment of release fork release bearing (68.050). Ensure correct seating of the push
rod (68.210).
• Reassemble the release fork (68.060).
• Attach the release shaft (68.110) by two M12 hex screws
One stopper 1X56 138 215 is needed for the release fork. (68.130) to case I.
Tightening torque M12 = 79 Nm
Use another stopper 1X56 138 215 to press the two bushings
(/130) flush into the release fork (/110).

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GEARBOX SELECTOR

Removal Attachment
Caution! • Wet the thread of the knuckle bolt (06.080) with Loctite 262
Only work on the gearbox selector with the ignition off. and tighten the knuckle bolt with 23 Nm.
• Attach the device (11) 1X56 138 095. Engage the lever in the
• Remove the vent (74.120), angle piece (74.140) and socket
(74.130) on the gearbox selector (74.030). particular gearshift rail. Turn the drive shaft by hand and shift
the gears with the lever.
• Remove the 15 M8 hex screws (74.090; 74.070) on the
gearbox selector (74.030). • Shift the GV and GP rails in the direction of output. Move the
middle gearshift rail into neutral position.
• Take the gearbox selector (74.030) from the gearbox case.
• Remove the device (11) and place a new seal (74.010) on
Note!
the gearbox case.
Make sure the rubber seals (/170) do not fall into the gearbox
case. • On the gearbox selector shift the piston rod (4) into its middle
position (neutral). You know it is the right position when you
• Remove the pressure springs (06.050; 34.140 and 12.090)
and latch bolts (06.040; 34.130 and 12.080). feel slight resistance on pulling out the piston rod (4). Align
the two other piston rods (3 and 5) to the same level.
• Remove the seal (74.010) and clean the sealing faces on the
gearbox case and gearbox selector. • The selector gate (6) and the piston rod (4) must be aligned
one above the other. Make sure the rubber seals (/170) are
Note!
Do not shift the middle gearshift lever shaft in the middle inserted on the gearbox selector.
position in a longitudinal direction (the lock pin can drop into
the gearbox).

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Note! Note!
A tool (34) can be produced for setting the piston rods. Refer to If the gearbox selector is replaced or renewed, observe the
the drawing under Special Tools. following:
♦ The gearbox selector must be reprogrammed.
• Insert the latch bolts (06.040; 34.130 and 12.080) and ♦ Adopt the vehicle parameters from the removed gearbox
pressure springs (06.050; 34.140 and 12.090). selector or enter new ones.
• Set the knuckle bolt (06.080) vertical. The knuckle bolt
(06.080) engages with the selector gate (6) when seating the • Connect the air line to the pressure limiting valve of the
gearbox selector. gearbox selector.
• Seat the gearbox selector (74.030). The piston rods (3, 4 and
5) of the gearbox selector must engage in the gearshift rails Connect the cable harness, otherwise a performance check with
MAN-Cats will not be possible.
of the gearbox.
• Tighten the M8 hex screws (74.090 and 74.070) with 23 Nm.
• According to parts list:
Tighten the socket (74.130) with 18 Nm, attach the angle
piece (74.140), tighten the vent (74.120) with 10 Nm.

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DISASSEMBLING AND ASSEMBLING GEARBOX SELECTOR

Disassembly Assembly

• Remove both screws (/150-1). • Insert the seal (/150-3).

• Lift the top (/110) of the pressure limiting valve and carefully • Place the seal (/150-2) on the bottom (/130).
place it on its side with the two lugs (1) in the grooves (2). • Rejoin the connectors (7 and 8). Check that the connectors
Undo the connectors (7 and 8). are firmly in place.
• Remove the seals (/150-3 and /170). • Set the top (/110) on the bottom (/130) and tighten the two
• Remove the seal (/150-2) and clean the sealing faces. screws (/150) with 9.5 Nm.
• Insert the seals (/170).

Programming

If the gearbox selector or top part is replaced, customer

programming will be necessary (entry of EOL data).

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MAIN SHAFT DRIVEN FLANGE

Removal Attachment

• Heat the main shaft driven flange (32.510) to max. 70°C and
• Remove the two hex screws (32.550) and take off the disk
slide it onto the gearing of the planetary carrier for an axial
(32.540).
match. Make sure the screws (32.520) are in place for the
• Withdraw the main shaft driven flange (32.510) using a
intarder version.
conventional three-legged puller and remove the O-ring
(32.530).
Caution!
Wear gloves to handle the heated main shaft driven flange.
Note!
Place material in between to protect the main shaft driven
• Once the main shaft driven flange is cooled, insert the O-ring
flange.
(32.530) in the groove between the shaft and the main shaft
driven flange.
• Attach the disk (32.540) with two M12 hex screws (32.550).
Tightening torque M12 = 120 Nm

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OUTPUT SPEED SENSOR

Removal Connector replacement

• Withdraw the connector. If a connector needs to be replaced, use the standard AMP tool.
• Remove the pulse sensor (31.260).

Gearbox without intarder

Attachment Pulse sensor (DIN bayonet) length 90 mm

Caution!
- Fit the connector so that there is no strain on it and check that Gearbox with intarder

it is properly locked in place. Pulse sensor (DIN bayonet) length 19.8 mm

- There are different pulse sensors, so check the ZF no..

Note!

• Screw in the pulse sensor (31.260) (setting is not necessary). If the KITAS sensor is replaced, it has to be newly

Tightening torque = 45 Nm configured with VDO Kienzle ATC/MTC Tester.

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REPLACING COMPONENTS ON INTARDER

Caution!
Fit all connectors so that there is no strain on them, and check that they are properly locked in place.

Output speed sensor Solenoid valve

• Screw in the pulse sensor (1). • Lightly grease the O-ring (02.180), insert it in the solenoid
Tightening torque = 45 Nm valve (02.170) and fasten it with two M8x22 cylinder head
screws (02.190).
Tachograph sensor Tightening torque M8 = 23 Nm

• Screw in the KITAS sensor (2).

Tightening torque = 45 Nm Temperature sensor
• Screw in the temperature sensor (05.030) with sealing ring.
Note! Tightening torque = 40 Nm
The KITAS sensor must be calibrated and sealed.

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Removal of 3/2-way valve Removal of intarder cable harness
• Withdraw the connector from the 3/2-way valve (05.100) and • Remove the three cable ties (05.440).
remove the air connection (7).
• Remove the four M4 screws (05.430) and detach the
• Remove the two M8 hex screws (05.110). Take off the 3/2- connections.
way valve (05.100) with the O-ring (ZF no. 0634 313 028).

Attachment of intarder cable harness

Attachment of 3/2-way valve • Replace the angle (05.410) if it is damaged. Tighten the M8
• Attach a new O-ring (ZF no. 0634 313 028) and the 3/2-way hex screw (05.420) with 23 Nm.
valve (05.100) with two M8 hex screws (05.110).
Tightening torque M8 = 23 Nm • Fasten the cable harness – nose upwards – to the angle by
the four M4 screws (05.430).
• Refit the air connection (7). Tightening torque M4 = 2 Nm
Tightening torque:
Hollow screw M16X1.5 = 45 Nm • Fasten the cable harness to the intarder by the three cable
ties (05.440).

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SETTING AXIAL CLEARANCE OF OUTPUT BEARING

Removal Setting

• Remove the ten M10 hex screws (31.070) and lift the output • Determine thickness C of shim
bearing cover (31.050). Dimension A: measure the output bearing cover (31.050)
• Take off the shim (31.030). from the sealing face to the bearing seat.
• Remove the shaft sealing ring (31.080) with a suitable tool, Dimension B: measure from the ball bearing (31.020) to the
ensuring that the output bearing cover is not damaged. sealing face of the GP case (31.010).
• Remove the four M12 hex screws (31.120). Take off the
power takeoff blind cover (31.110) and seal (31.100). Example: A - B = C
Dimension A = 5.4 mm

Attachment - Dimension B = 5.0 mm

Shim without clearance = 0.4 mm
Axial clearance of ball bearing 0 to 0.1 mm
• Wet the shaft sealing ring (31.080) on the outer
Thickness of shim Dimension C = 0.3 to 0.4 mm
circumference with spirit, and press it into the output bearing
cover (31.050) for an axial match with the stopper 1X56 137
124 and ring 1X56 138 189. Lightly grease the sealing lip. • Select an appropriate shim (31.030) from the spare parts
catalog and keep it ready for insertion.

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• Coat the sealing face of the output bearing cover (31.050) Note!
with Loctite no. 574. Do not attach the power takeoff blind cover (31.110) until the GP
case is attached and the stopper (31.090) is in place.
Note!
Sealing faces must be clean, free of oil and grease. • Clean the sealing face on the GP case and the cover
(31.110).
• Place the output bearing cover (31.050) with the shim
(31.030). • Fit a new seal (31.100) and the cover (31.110).

• Tighten the ten M10 hex screws (31.070) with 46 Nm. • Tighten the four M12 hex screws (31.120) with 79 Nm.

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GP CASE

Removal

• The gearbox is upright with the output facing upwards (see • Slightly raise the gearshift rail (34.010) and remove the rocker
preparatory work). arm (34.020) and slide blocks (34.030).
• Remove the hex screws (34.080), retaining plates (34.070) • Take off the entire sliding sleeve (33.010) with the sync rings
and knuckle pins (34.050). Take the O-rings (34.060) off the (33.030).
knuckle pins.
• Remove the two cylindrical pins (31.390) – M12 extraction
thread – and the 22 hex screws (31.370). Caution!
Cover the sliding sleeve (33.010) with a cloth. Six bushings
Note! (33.050) and six pressure springs (33.070) eject when taking
Knock out the cylindrical pins with the 1X56 138 063 tool. off the sync rings.

• Attach two eyelets to the main shaft driven flange or planetary • Lift the plate (32.440) with two levers and remove the
gear carrier and hook up a chain. coupling member (32.430).
• Carefully raise the complete GP case with a crane. • Remove the sleeve (32.400) with the snap ring (32.390) and
• Remove the spray pipe (31.400). the shim (32.380).

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SETTING MAIN SHAFT/PLANETARY GEAR CARRIER CLEARANCE

• Requirement for measuring the shim: engage the snap ring in Measurement 2: dimension B2
the sleeve and set it on the main shaft. Measure from the rail to the sealing face of case II (e.g. 95 mm).

• Set up the instrument. Example for dimension B

The clearance from the snap ring to the sealing face of case II:
Measurement 1: dimension B1
Measure from the rail to the inner snap ring (e.g. 70 mm). B2 - B1 = B

B2 95 mm
B1 70 mm
B 25 mm

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 Dimension B1 Dimension B2

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Measurement 3: dimension A1 DETERMINATION OF ADJUSTING SHIM S
Measure from the plane to the sealing face of the GP case (e.g. S = (A - B) - axial clearance
55.1 mm).
Note!
Measurement 4: dimension A2 Axial clearance of 2 +0.1 mm is specified between the sun wheel
Measure from the plane to the sun wheel (e.g. 84.3 mm). and main shaft.

Example for dimension A Example:

S = (A - B) - 2 mm (clearance)
The clearance from the sun wheel to the sealing face of the GP S = (29.2 mm - 25 mm) - 2 mm
case. S = 4.2 mm - 2 mm
S = 2.2 mm
A2 - A1 = A

A2 84.3 mm
A1 55.1 mm
A 29.2 MM

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 Dimension A1 Dimension A2

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ATTACHING GP CASE

• Seat the shim (32.380) on the main shaft. • Insert the sync rings (33.030) in the sliding sleeve (33.010)
and remove the clips (8) 1X56 138 207.
Note!
Measurement of the shim (32.380), see Chapter 2.2. • Seat the complete sliding sleeve (33.010) with the sync rings
(33.030), bushings (33.050) and pressure springs (33.070)
• Insert the snap ring (32.390) in the sleeve (32.400). The snap on the coupling member (32.430).
ring must mate with the bottom of the groove of the sleeve.
Note!
• Seat the sleeve (32.400) on the main shaft. The snap ring The sealing faces on case II and the GP case must be clean,
(32.390) mates with the shim (32.380). free of oil and grease.

• Seat the coupling member (32.430) and plate (32.440) on • Coat the sealing face on case II with Loctite 574.
case II.

• Insert three pressure springs (33.070) and three bushings

(33.050) in each of the sync rings (33.030) and secure them
with a clip (8) 1X56 138 207.

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• Insert the spray pipe (31.400) with the longer side to the GP • Tighten the M10x1 screw plug (31.090) with 15 Nm.
case.
• Insert the two cylindrical pins (31.390). Insert the 22 hex
screws (31.370) and tighten with 50 Nm.
• Insert the slide blocks (34.030) in the rocker arm (34.020) and
position correctly in the sliding sleeve (33.010) and gearshift
• Insert new O-rings (34.060) on the knuckle pin (34.050).
rail (34.010).

Note!
• Screw two normal M10 guide bolts (1) into case II (01.400).
If the knuckle pin (34.050) is pushed too far into the GP case,
the case will have to be taken off again.
• Attach two eyelets to the main shaft driven flange or planetary
gear carrier and hook up a chain.
• Insert the knuckle pin with the aid of the retaining plate
(34.070) through the GP case borehole into the rocker arm
• Attach the chain to a crane and carefully set the GP case
(31.010) on case II. Use a tool (3) (e.g. pin) to insert the spray (34.020).
pipe (31.400) into the borehole of the screw plug (31.090).
Remove the two M10 guide bolts (1).
• Attach each of the retaining plates (34.070) with a hex screw
Caution!
(34.080) and tighten with 23 Nm.
Work with all due care when placing the GP case and
inserting the cylindrical pins – otherwise there is a
possibility of the case breaking.

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DISASSEMBLING AND ASSEMBLING GP CASE

Disassembly Assembly

• Remove the main shaft driven flange and output bearing • Insert the ball bearing (31.020) in the GP case (31.010).
cover.
• Heat the inner ring of the ball bearing (31.020) to max. 120°C
• Remove all screw plugs and pulse sensors from the GP case. and set the complete GP case on the planetary gear carrier
Remove the ball bearing (31.020) and GP case (31.010) from for an axial match.
the planetary gear carrier with an extractor (6) 1X56 122 314
Caution!
for ball bearings with 10 balls or 1X53 188 009 for ball
Wear gloves to handle heated parts.
bearings with 11 balls.

Note!
Do not fit the M10x1 screw plug (31.090) until the GP case is
attached to case II.

• Renew the sealing rings on the screw plugs.

Tightening torques:
Screw plug M24x1.5 (31.200) 60 Nm
Pulse sensor (31.230) 45 Nm
Pulse sensor (31.260) 45 Nm

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PLANETARY GEAR CARRIER

Disassembly (only for gearbox with intarder) Turn the planetary gear carrier 180° and knock the planet bolt
(32.050) out of the planetary gear carrier (32.010) with a
Remove the 10 hex screws (32.144) and take off the high wheel
(32.140) with a two-legged puller. punch.

• Place the planetary gear carrier sideways on the hollow • Take out the planet wheel set (32.100) (five planet wheels).
wheel. Take the disks (32.070, 32.080) and rollers (32.090) out of
the planet wheels.
• Remove the securing wire (32.240), e.g. with two small
screwdrivers. • This frees the sun wheel (32.190).

Caution!
• Turn the pressure washers (32.200 and 32.180) by half a
This frees the hollow wheel (32.130) and it can fall down.
tooth to free the dog pins (32.204 and 32.184).
Risk of injury!

• Remove the dog pins (32.204 and 32.184).

• Take off the hollow wheel carrier (32.230).

• Remove the inner ring of the bearing (32.310/1) with a puller

• Take the thrust ring (32.120) out of the hollow wheel (32.130).
1X56 138 087.

• Compress the snap ring (32.290) with pliers and take off the
coupling member (32.280).

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Preassembly of sun wheel Preassembly of planet wheel set

• Insert the dog pin (32.204) in the sun wheel (32.190). Note!
Planet wheels may only be replaced in whole sets.
• Slide the pressure washer (32.200) – with the shorter
shoulder pointing in the direction of the planet wheel – into • Oil all rollers (32.090) with gearbox oil.
the gearing of the sun wheel (32.190) and turn it. This
secures the dog pin (32.204). • Insert the thin disk (32.070) in the planet wheel (32.100) and
the 14 rollers (32.090) in the planet wheel.
• Slide the pressure washer (32.180) – with the shorter
shoulder pointing in the direction of the planet wheel – into • Insert the thick disk (32.080) and another 14 rollers (32.090)
the gearing of the sun wheel (32.190). in the planet wheel. Finally place a thin disk (32.070) on top.

• Insert the dog pin (32.184) in the borehole of the sun wheel. • Do the same for all five planet wheels.

• Shift the pressure washer (32.180) upwards and turn it to

secure the dog pin (32.184).

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Complete assembly of planetary gear carrier

• Heat the inner ring of the bearing (32.310/1) to max. 120°C • Insert the snap ring (32.290) in the planetary gear carrier
and push it onto the planetary gear carrier for an axial match. (32.010).

Caution!
• Seat the coupling member (32.280) on the planetary gear
Wear gloves to handle heated parts. carrier while compressing the snap ring (32.290) with pliers.
Let the snap ring spring into the coupling member groove.
• Insert the preassembled sun wheel in the planetary gear
carrier (32.010).
• Insert the thrust ring (32.120) in the hollow wheel (32.130)
with the ground side pointing in the direction of the input.
Extra caution!

Make sure your fingers are not caught.

• Push the hollow wheel (32.130) onto the planetary gear
carrier from the output end and the hollow wheel carrier
• Hold up the pressure washer (32.180) and insert the
(32.230) from the input end so that the securing wire (32.240)
preassembled planet wheels (32.100). Insert the planet bolt
can be inserted in the groove of the hollow wheel (32.130)
(32.050) and centre the planet wheels.
(e.g. with a small screwdriver).

• Use a plastic hammer to carefully knock the planet bolt

Note!
(32.050) into the planetary gear carrier borehole until it no
The securing wire (32.240) must mate with the bottom of the
longer projects.
groove of the hollow wheel.

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Only for intarder version

Assembly of high wheel

• Heat the high wheel (32.140) to between 120 and 130°C. • Remove the two M12 guide pins.

• Screw two M12 guide pins into the planetary gear carrier • Insert the ten M12 hex screws (32.144) and tighten them with
(32.010). 135 Nm.

• Seat the heated high wheel (32.140) on the planetary gear

carrier with the shoulder pointing to the output.

Caution!
Wear gloves to handle heated parts.

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UNION PLATE FOR OIL PUMP AND BRAKE

Removal

• Remove the 22 M10 hex screws (02.670). • Remove the brake cover (03.250) from the union plate and
take off the outer disks (03.270) and inner disks (03.280).
• Lift the union plate (02.500) with a suitable tool or use an M8
ejector thread (see arrows A, B). • Take out the brake plunger (02.610) and, when removing the
groove ring (02.630), remember how it is placed for replacing
Note! it later.
It is easier to lift the union plate if the release flange (02.520)
• Replace the cylindrical pins (03.260) if they are defective.
is not removed. Otherwise the union plate will tend to cant.

• The pump is disassembled for visual inspection of its parts

• Remove the shims (03.050, 02.100 and 03.150), latch bolt
and cleaning.
(03.210) and pressure spring (03.200).

• Remove the three Torx screws (02.580).

• Remove the four M8 hex screws (02.530) and lift the release
flange (02.520).
• Take out the pump cover (02.570), pump shaft (02.560) and
rotor (02.550).
• Remove the shaft sealing ring (02.510) from the release
flange (02.520) with a suitable tool.

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Gauging of union plate

• Turn the drive shaft B backwards and forwards a number of 1) Determine the space between the bearing outer ring and
times. This aligns the tapered rollers of the bearing so that the case sealing face:
they roll into the bearing outer rings. To set the specified
dimension of the layshafts of -0.05 to +0.05 mm it is first Layshafts
necessary to create "zero clearance". Oil pump C e.g. dimension c2 = 2.00
Transmission brake A e.g. dimension a2 = 1.95
• Use a punch to produce zero clearance between the bearing
outer rings and the tapered rollers. Drive shaft B e.g. dimension b2 = 3.90

• Use a pointed object to check whether the tapered rollers of

the bearing will move. 2) Gauge the union plate:.

Note! Space between sealing face union plate

Zero clearance is when the tapered rollers are firmly seated and oil pump cover C e.g. dimension c1 = 0.05
but there is no initial tension. and transmission brake cover A e.g. dimension a1 = 0.15
and mating face of shim (02.100)
drive shaft B e.g. dimension b1 = 5.50

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• Determine thickness of shims: • Observe the following when selecting the shims:
Pump:
c1 + c2 = c = shim (03.050) Layshafts:
2.00 + 0.05 = 2.05 mm = shim (03.050) Initial tension or clearance -0.05 to +0.05 mm

Transmission brake: Drive shaft:

a1 + a2 = a = shim (03.150) Clearance 0 to 0.10 mm
1.95 + 0.15 = 2.10 mm = shim (03.150) The clearance is deducted from the shim thickness.

Drive shaft: • Place the shims (03.050 and 03.150) on the bearing outer
b1 – b2 = b = shim (02.100) rings. Lightly grease the shim (02.100) (for easier assembly)
5.50 – 3.90 = 1.60 mm = shim (02.100) and place it in the union plate.

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Attachment

• Clean the sealing faces on the following parts: • Insert the three cylindrical pins (03.260), if removed, in case I.
union plate (02.500), release flange (02.520) and case I
(01.010). • Place the shims (03.150, 03.050 and 02.100) correctly on the
bearing outer rings. Lightly grease the shim (02.100).
Note!
All sealing faces and the M10 threaded boreholes in case I Note!
must be clean, free of oil and grease. Do not confuse the shims 03.150 and 03.050.

• Assemble the pump. • Place the brake cover (03.250) on the case sealing face. The
Insert the rotor (02.550), pump shaft (02.560) and pump collar of the brake cover (03.250) faces the disk packet.
cover (02.570). Tighten the three M6 screws (02.580) with 10
Nm. • Assemble the outer disks (03.270) and inner disks (03.280)
according to the parts list (number and size).
• Insert a new groove ring (02.630) in the plunger (02.610)
ensuring correct placement.

• Insert the plunger (02.610) in the union plate (02.500).

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• Press the shaft sealing ring (02.510) with tool 1X56 099 063 • Coat the sealing face of the union plate (02.500) with Loctite
for an axial match into the release flange (02.520). 574.

Note! • Carefully seat the union plate (02.500) over the drive shaft
Wet the shaft sealing ring on the outer circumference with onto the gearbox case. Align the dog of the pump (Z) so that
spirit. it engages in the groove (Y) in the layshaft.
The sealing lip must face the interior of the gearbox.
• Wet the 22 M10 hex screws (02.670) with Loctite 241 and
• Coat the sealing face on the release flange (02.520) with tighten with 50 Nm.
Loctite 574.

• Attach the release flange (02.520) by four M8 hex screws

(02.530) to the union plate (02.500).
Tightening torque M8 = 23 Nm

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CASE I (BELL HOUSING)

Removal
Caution!
Before removing case 1, secure the main shaft position
with the special tool (1X56 138 203).

• Remove the switch (06.260) and pin (06.250) or screw plug • Remove the 24 M10 hex screws (01.130). Remove the four
(6.270). cylindrical pins (01.140) – M12 extractor thread.

• Remove the snap ring (02.120). Note!

Knock out the cylindrical pins (01.140) with tool 1X56 138
• Remove the snap ring (02.080/1) on the ball bearing 063.
(02.080).
• Attach two eyelets 1X56 138 234 to case I. Do not damage
• Remove the filter (01.070). the case centering. Bridge the shoulder to the centering with
two or three washers (see arrow). Hook up the three-strand
• Set the intermediate piece 1X56 138 191 on the drive shaft. chain 1X56 137 795 and carefully lift case I (01.010).
The device (20) 1X56 138 195 engages in the ring groove of
the ball bearing. Attach the basic unit (5) 1X56 122 304 to the
device and withdraw the ball bearing (02.080).

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Disassembly Assembly

• Disassemble the following parts: • Insert the bearing outer rings (03.140, 03.040).
bearing outer rings (03.140, 03.040),
type label (01.150), • Insert the vents (01.100, 01.110) and attach the cover
M22x1.5 screw plugs (01.030, 01.040), (01.280) with the M8 hex screw (01.290).
hex screw M8 (01.290),
cover (01.280), • Tighten the M22x1.5 screw plugs (01.030, 01.040) and
vents (01.100, 01.110), sealing ring with 50 Nm.
spacer (06.200) and
two spring pins (06.210). • Insert the spacer (06.200) with two spring pins (06.210).

• Attach the type label (01.150) with four blind rivets (01.160).

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Attachment

• Clean the sealing faces. • Check that the spray pipes (01.420 and 01.430) are correctly
seated in case I.
Note!
The sealing faces on case I and case II must be clean, free of • Insert the cylindrical pins (01.140) (not fully) and tighten the
oil and grease. 24 M10 hex screws (01.130) with 50 Nm. Then drive in the
cylindrical pins (01.140) for an axial match.
• Coat the sealing face on case II with sealing compound
1215 (Three Bond). • Insert the snap ring (02.080/1) in the groove of the ball
bearing.
• Use tools 1X56 138 200 and 1X56 138 201 (see arrow) to
center the spray pipes (01.420 and 01.430) in case I (01.010) • Heat the inner ring of the ball bearing (02.080) to approx. 80
(see Chapter 13 for incorporation of spray pipes). to 90°C with a heating taper.

• Carefully set case I (01.010) on case II (01.400). Caution!

Wear gloves to handle heated parts.

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• Insert the ball bearing (02.080) until the snap ring (02.080/1) • Insert the pin (06.250) and tighten the switch (06.260) with 45
mates with case I, possibly opening it with the outer pipe of Nm and the screw plug (06.270) with 35 Nm.
the device (23) 1X56 138 216. Using the device 1X56 138
216 together with the fitting tool (24) 1X56 045 808, draw the • Insert the filter (01.070).
drive shaft into the ball bearing for an axial match.
• See Chapter 11.3 for attachment of the union plate.
• Remove the devices and measure the thickness of the snap
ring (02.120) with a feeler gauge.
When selecting the snap ring (02.120) allow for clearance of
0 to 0.10 mm.

• Insert the snap ring (02.120).

Note!
The snap ring (02.120) must mate with the bottom of the
groove of the drive shaft.

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REMOVING MAIN SHAFT AND LAYSHAFTS

• Remove the retaining bolt 1X56 138 208 and slide the Hook the three-strand chain 1X56 137 795 to the ring screw.
reverse gear intermediate gears (05.040 and 05.140) to one
side. • Use a crane to lift both the drive shaft and main shaft out of
case II.
• Remove the two spray pipes (01.420 and 01.430).
• Push up the sleeves (1 and 2) and take off the gearshift rails.
• Tip the layshafts (03.010 and 03.110) to one side and take On the 16-speed main shaft hold the sliding sleeve (04.060)
them out. and then take off the gearshift rails.

• Set the device (25) 1X56 138 197 on the drive shaft. Slide the • Hold the main shaft and drive shaft in a vice with protective
sleeves (1 and 2) over the gearshift rails. Then attach the jaws.
device (23) 1X56 138 216 to the drive shaft.

Note!
The device (23) 1X56 138 216 consists of two half shells, a
pipe and a threaded piece. On one end set the noses of the
two half shells in the groove of the drive shaft, and on the
other insert the threaded piece and stick the pipe over it.
Screw an M10 ring screw into the threaded piece of the
device 1X56 138 216.

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 Main shaft
10/12 gear

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REMOVING INPUT SHAFT FROM MAIN SHAFT

• Shift the sliding sleeve (04.350) in the direction of the output • Secure the guide plate (4) of the device 1X56 138 197 with
to show the snap ring (02.350). the snap ring (02.120).

• Compress the snap ring (02.350) with pointed flat pliers (3) • See Chapter 14.1 for disassembly of the drive shaft.
and lift the drive shaft from the main shaft.

• Take the device 1X56 138 216 and the sleeves (1 and 2) of
the device 1X56 138 197 off the drive shaft.

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Incorporation of main shaft and input shaft

• Attach the devices (25) 1X56 138 197 and (23) 1X56 138 216 • Insert the gear control forks of the completely assembled
to the drive shaft. gearshift lever shafts in the appropriate sliding sleeves. Push
the sleeves (1 and 2) of the device 1X56 138 197 over the
• Using a crane, set the drive shaft on the main shaft. Push the gearshift lever shafts. In the 16-speed version, hold up the
sliding sleeve (04.350) in the direction of the output. sliding sleeve (04.060) and insert the gear control fork.

• Use pointed flat pliers (3) to compress the snap ring (02.350) • Note: The reversing wheels (05.040 and 05.140) for the
and seat the drive shaft in the main shaft. reverse gear are seated in case II. Use a crane to seat the
drive shaft and main shaft in case II. Remove the devices
Caution! (25) 1X56 138 197 and (23) 1X56 138 216.
Make sure the snap ring engages in the main shaft. If the
snap ring is not correctly in place, the result will be a
complete write-off.

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Incorporation of layshaft

• Insert the layshafts (03.010 and 03.110) according to the • Change into reverse and engage the reversing wheels
marking. (05.040 and 05.140) with the layshafts. Fix the reversing
wheels (05.040 and 05.140) in place with the retaining bolt
Caution! 1X56 138 208.
The marking on the layshaft must be in the narrow window
of the counter disk (02.060) (see arrows). • Change to neutral (sliding sleeves in neutral) and turn
through the shaft packet.

• Insert the two spray pipes (01.420 and 01.430).

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DISASSEMBLING DRIVE SHAFT

Note! • Remove the following parts from the drive shaft::

• To disassemble the drive shaft, place it in a vice with split ring (02.380),
protective jaws. washer (02.370),
axial roller cage (02.360),
• Destroy the snap ring (02.390) of the split ring (02.380) with a bearing ring (02.330) with snap ring (02.350),
cutting tool and remove it. washer (02.320),
axial needle bearing retainer (02.310),
Caution! helical gear constant 2 (02.280),
Wear goggles when working with the cutting tool. axial needle bearing retainer (02.250),
washer (02.240).

• Disassemble the helical gear constant 2 (02.280):

remove the snap ring (02.290 and 02.260) and take out the
bearing disk (02.300).

• Take off the entire sync (02.200). See Chapter 14.2 for
disassembly of the sync.

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• Remove the snap ring (02.120) and guide plate (4). • Remove the bolt (02.020).

• Take the counter disk (02.060), thrust ring (2.050) and helical
gear constant 1 (02.040) off the drive shaft. Use a manual
press if necessary.

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SPLIT SYNC

Disassembly Assembly

• Place the sync (02.200) on the bench with the shoulder facing Note!
Part numbers on the sync ring (/220):
downwards. Cover with a cloth. Pull the sync ring K2 (/220)
Overdrive Underdrive
upwards to remove it. 1328 302 014 1328 302 013
1328 302 086 1328 302 085
1328 302 113 1328 302 112
Note!
• Press the three longer pins (/120) into the sync ring (/110)
and the three shorter pins (/210) into the sync ring (/220).
Three pressure springs (/240) and three cylindrical rollers
• Seat the plate (/180) on the operating sleeve (/150) and turn
(/250) jump out of the boreholes.
half a tooth.
• The borehole in the operating sleeve (/150) must align with
• Slide the bolt (/160) through the operating sleeve (/150). Turn
one of the three recesses of the plate (/180). Insert the bolt
the plate (/180) half a tooth and take it off the operating
(/160) through the borehole of the operating sleeve as far as
sleeve (/150).
it will go.
• Insert a pressure spring (/240) and a cylindrical roller (/250) in
• The pins (/120 and /210) can be pressed out of the sync rings
each of the three boreholes of the sync ring (/220) and secure
(/110 and /220) if necessary.
with the sleeves (17) 1X56 138 081.

Note! Incorporate the sync ring with springs in the

direction of the output.

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 Overdrive Underdrive

Overdrive Underdrive

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• Set the sync ring K1 (/110) and fully assembled operating • Remove the sleeves (17) while pressing the sync ring K2
sleeve (/150) with plate (/180) on the mounting plate (16) (/220) downwards.
1X56 138 097.
• Turn the sync. Center it by pulling up the plate (/180) with the
• Set the sync ring K2 (/220) with the three sleeves (17) on the operating sleeve (/150) and pressing the sync ring (/110)
coding bolts (/120) of the sync ring K1 (/110). down. Make sure the bolt (/160) has not fallen out.

• Press the sync rings evenly together.

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ASSEMBLING DRIVE SHAFT

• To assemble the drive shaft, place it in a vice with protective • Attach the guide plate (4) of the device 1X56 138 197 and
jaws. secure it with the snap ring (02.120).

• Set the bolt (02.020) in the drive shaft (02.010). • Turn the drive shaft 180° and place it in a vice with protective
jaws.
• Put on the helical gear constant 1 (02.040) and thrust ring
(02.050).

• Slide on the counter disk (02.060).

Note!
Clearance of up to 0.3 mm is admissible between the bolt
(02.020) and the counter disk (02.060).

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• Set the sync (02.200), washer (02.240) and axial needle • Seat the following parts one after the other on the drive shaft:
bearing retainer (02.250) on the drive shaft. axial needle bearing retainer (02.310),
washer (02.320),
• Insert the bearing disk (02.300) and the two snap rings bearing ring (02.330) with snap ring (02.350),
(02.260 and (02.290) in the helical gear constant 2 (02.280). axial roller cage (02.360),
washer (02.370),
• Seat the fully assembled helical gear constant 2 on the drive split ring (02.380),
shaft. snap ring (02.390).

• Secure the snap ring (02.390) by caulking it 3x120°.

• See Chapter 13.2 for incorporation of the drive shaft.

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MAIN SHAFT

Disassembly

• Place the main shaft in a vice with protective jaws. • Take off the helical gear (04.220). Take the washer (04.230)
and snap ring (04.240) out of the helical gear.
• Remove the oil pipe (04.040).
• Turn the washer (04.210) half a tooth and take it off.
• Press the wedge (04.030) out of the borehole, e.g. with a
small screw driver, and pull it downwards. Secure the last • Remove the sliding sleeve (04.200).
helical gear with the wedge.
• Remove the following parts from the main shaft (04.010):
• Take off the sliding sleeve (04.350). washer (04.160*),
helical gear (04.150*),
• Turn the washer (04.310) half a tooth and take it off.
washer (04.140*),
snap ring (04.240*),
• Take off the helical gear (04.300). Take the washer (04.290)
2* or 1 washers (04.110),
and snap ring (04.280) out of the helical gear.
snap ring (04.100),
• Turn the washers (04.270 and 04.250) half a tooth and take washer (04.090),
them off the main shaft. helical gear (04.080),
washer (04.070) and sliding sleeve (04.060*).

• Remove the oil pipe (04.020) if it is damaged.

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Main shaft 10- and 12 gear
Main shaft 10- and 12 gear

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Assembly

• Push the oil pipe (04.020) into the main shaft (04.010) with • Insert the snap ring (04.130) and washer (04.140) in the
the tool 1X56 138 205. Overshoot of oil pipe: 15-1 mm. helical gear (04.150). Push the assembled helical gear
(04.150) onto the main shaft.
• Place the main shaft in a vice with protective jaws.
• Locate the washer (04.160*) and turn half a tooth. Push up
• In the 16-speed version push the sliding sleeve (04.060*)
the wedge (04.030) and adjust the washer.
onto the main shaft so that the recess of the inner gearing
points to the wedge (04.030). • Push the sliding sleeve (04.200) onto the main shaft.
• Push the washer (04.070) onto the main shaft. In the groove • Locate the washer (04.210) and turn half a tooth. Push up the
of the main shaft turn the washer (04.070) half a tooth and wedge (04.030) and adjust the washer.
secure with the wedge (04.030).
• Insert the snap ring (04.240) and washer (04.230) in the
Note!
helical gear (04.220). Push the assembled helical gear
The wedge is in the gearing of the main shaft where the blind
(04.220) onto the main shaft.
hole borehole is located.
• Locate the washers (04.250 and 04.270) and turn half a
tooth. Push up the wedge (04.030) and adjust the washers.
Caution!
• Insert the snap ring (04.280) and washer (04.290) in the
When assembling the helical gears make sure the punched helical gear (04.300). Push the assembled helical gear
insert (see arrow in Fig. 17889 and 17890) of the washers (04.300) onto the main shaft.
(04.090, 04.230, 04.290, 04.140*) does not point to the snap
ring. • Locate the washer (04.310) and turn half a tooth. Push up the
wedge (04.030) and adjust the washer.
• Push the sliding sleeve (04.350) onto the main shaft with the
• Insert the snap ring (04.100) and washer (04.090) in the recess upwards. Align the recess of the sliding sleeve and of
helical gear (04.080). Push the assembled helical gear the main shaft with one another.
(04.080) onto the main shaft.
• Allow the nose of the wedge (04.030) to jump into the blind
• Locate the 2* or 1 washers (04.110) and turn half a tooth. hole borehole.
Push up the wedge (04.030) and adjust the washers.
• Insert the oil pipe (04.040).

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 Main shaft design 10-/12-Gear

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LAYSHAFT

Disassembly Assembly

• Take off the bearing inner rings (03.020, 03.040, 03.120 and Caution!
03.140) with the gripper 1X56 136 740 and basic unit 1X56 Check the tapered roller bearing and replace it if it is
122 304. damaged because the tapered rollers can be damaged by
extracting it.
Note!
Further disassembly of the layshaft is not possible, i.e. if • Heat the bearing inner rings (03.020, 03.040, 03.120 and
gearing is damaged, both layshafts will always have to be 03.140) to approx. 120°C and place them on the layshaft
replaced. without axial clearance.

Caution!
Wear gloves to handle heated parts.

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GEARSHIFT LEVER SHAFT

Disassembly Assembly

• Release and remove the gear control forks (06.100*, 06.120 • Insert the striker (06.010/120) in the gearshift lever shaft
and 06.160). (06.010/110).

• Take the interlock (06.140) and striker (06.010/120) off the • Place the interlock (06.140) on the gearshift lever shaft.
gearshift lever shaft (06.010/110).
• Place the gear control forks (06.100*, 06.120 and 06.160)
carefully in the interlock.

Caution!
Do not confuse gear control forks 06.120 and 06.160 (see
parts list).

• See Chapter 13.2 for incorporation of the gearshift lever

shaft.

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CASE II GEARBOX MAIN PART

Disassembly
Note! • Remove the snap ring (32.330).
The reverse spindles (05.010 and 05.110) are already removed.
• Heat case II evenly on the bearing bore with a hairdryer to
• Remove the reverse gear reversing wheels (05.040 and approx. 100°C and carefully withdraw the roller bearing
05.140) and take out the needle roller assembly (05.020 and (032.310).
05.120).
Caution!
• Remove the following parts on case II (01.400): Wear gloves to handle heated parts.
screw plug (01.460) M24x1.5,
screw plug (01.480) M24x1.5, • Only remove the bolt (01.440) if it is defective or if case II is
screw plug (01.490) M24x1.5. replaced. Heat case II to approx. 90°C and knock out the bolt.

• Remove the bearing outer rings of the tapered roller bearings

(03.020 and 03.120) if bearing inner rings on the layshaft are
replaced.

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Assembly

Caution! • Insert the reverse gear reversing wheels (05.040 and 05.140)
Wear gloves to handle heated parts. with the needle roller assembly (05.020 and 05.120).

• Heat the bearing seat in case II evenly with a hairdryer to • The reverse spindles (05.010 and 05.110) are incorporated
approx. 100°C and insert the bearing outer ring of the roller later.
bearing (32.310) in case II for an axial match.
• If bolts (01.440) are missing, heat case II to approx. 90°C,
• Allow the snap ring (32.330) to jump into place. grease the bolts lightly and carefully drive them in or press
them in with the manual press.
• Heat the bearing seats in case II evenly with a hairdryer to
approx. 100°C and insert the bearing outer rings of the Caution!
tapered roller bearings (03.020 and 03.120). Do not cant bolts when assembling otherwise there is a risk
of breaking the case.
• Tighten the M24x1.5 screw plugs (01.460, 01.480 and
01.490) with 60 Nm.

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CONSUMABLES

Designation
Name Approx. qty Use for Notes
ZF stock number
1 gram Shaft sealing ring (02.510)
Grease
e.g. Spectron FO 20 1 gram Pump shaft (02.560)
0750 199 019
2 gram Shaft sealing ring (31.080)
5 gram Shaft sealing rings (68.060/140)
Grease
Olista Longtime 3EP 5 gram Mating face release fork (68.060) /
0671 190 050
bearing (68.050)
Sealing compound
Three Bond 1215 grey 3 gram Sealing face case I / case II
0666 790 054
Sealing face
1 gram Release flange / union plate
Face seal 3 gram Union plate / case
No. 574
0666 790 033 0.5 gram Cover (31.050)
0.5 gram Sealing cover (32.010/050)
1 gram GP case / case II
Seating material
No. 241 0.5 gram Hex screw (02.670)
0666 690 017
Seating material
No. 262 0.5 gram Knuckle bolt (06.080)
0666 690 022
Anti-corrosion oil
e.g. MZK 150 1 ml Rotor (02.550)
0750 199 008
See ZF list of lubricants
Gearbox oil See type label Gearbox oil filling
TE-ML 02

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SETTING DATA

Item Dimension Instrument Notes

Move the tapered roller bearing into its zero
Axial clearance of layshaft (03.010) -0.05 to +0.05 mm Depth gauge position (no clearance) and measure; set
clearance with the shim (03.050).
Axial clearance of drive shaft / union
0 to 0.10 mm Depth gauge Set clearance with the shim (02.100).
plate

Axial clearance of intarder wheel 0 to 0.10 mm Depth gauge Set clearance with the shim.

Axial clearance of snap ring on drive

0 to 0.10 mm Feeler gauge / leaf gauge Set clearance with the snap ring (02.120).
shaft

Axial clearance of output bearing 0 to 0.10 mm Depth gauge Set clearance with the shim (31.030).

Axial clearance of gearshift lever

2 mm +0.1 Depth gauge Set clearance with the shim (32.380).
shaft / sun wheel
Sync rings splitter box 0.8 mm Feeler gauge / leaf gauge Determination of sync ring wear
Sync rings range group 1.2 mm Feeler gauge / leaf gauge Determination of sync ring wear
Screw plug (31.200, 31.190) 60 Nm Torque spanner
Screw plug (31.090) 15 Nm Torque spanner
Hex screw (32.550) 120 Nm Torque spanner
Hex screw (31.370) 50 Nm Torque spanner
Pulse sensor (31.230, 31260) 45 Nm Torque spanner

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SPECIAL TOOLS

Ordering code Ordering code

Illustration Qty Illustration Qty
Use Use

1X56 136 740

1X56 137 795 Gripper

for extracting tapered
1 1
3-strand chain roller bearing of
for lifting gearbox layshafts (with basic
unit
1X56 122 304)

1X56 122 304

1X56 138 234
Basic unit
1 in conjunction with 1
Eyelets M10
tool
for lifting case parts
1X56 136 740 and
1X56 138 195

1X56 122 314 for ball

bearing with 10 balls
1X56 137 836
1x53 188 009 for ball
bearing with 11 balls
Brace 1 1
for setting gearbox Puller for ball bearing
upright (31.020) of planetary
gear carrier

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 Ordering code Ordering code
Illustration Qty Illustration Qty
Use Use

1X56 138 087

1X56 138 203
Puller
1 Holding plate 1
for bearing inner ring
for holding and
(32.310/1) on
centering main shaft
planetary gear carrier

1X56 138 207

1X56 138 095
Bracket 6 1
Setting device
for assembly of GP
for gearshift rails
sync

1X56 138 215

1X56 138 208
Stopper
Retaining bolt 2 for assembling 2
for securing reverse bushings and shaft
gear reversing wheel sealing rings of
release fork

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 Ordering code Ordering code
Illustration Qty Illustration Qty
Use Use

1X56 138 205

1X56 138 063
1 Mounting device 1
Drill drift
for pipe (04.020) on
for removing set pins
main shaft

1X56 138 191

1X56 138 097
1 Bushing (thrust pad) 1
Mounting plate
to protect shaft when
for sync (02.200)
extracting

1X56 138 195

1X56 138 081
3 Puller 1
Sleeve
for ball bearing
for sync (02.200)
(02.080) on drive shaft

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 Ordering code Ordering code
Illustration Qty Illustration Qty
Use Use

1X56 045 808

1X56 138 200
Fitting device
Mounting tool 1 1
for drive shaft in
for centering oil pipe
conjunction with
(01.430)
1X56 138 216

1X56 138 201

1X56 138 197
Mounting tool 1 1
for centering oil pipe Mounting device
(01.420)

1X56 138 216

1X56 099 063
Device
lifting and fitting 1 Stopper 1
device for attachment for shaft sealing ring
and removal of drive in release flange
shaft

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 Ordering code
Illustration Qty
Use

1X56 137 124

Stopper
for fitting shaft sealing
1
ring on output bearing
cover (in conjunction
with spacer ring
1X56 138 139)

1X56 138 139

Spacer ring
for shaft sealing ring
105x125x12 on output 1
bearing cover (in
conjunction with
stopper 1X56 137
124)

Drawing

Setting aid 1
for plunger rods on
gearbox selector

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