Repair Instructions: Zf-Astronic 10-, 12-And 16-Speed Version Without ZF-Intarder Level 3
Repair Instructions: Zf-Astronic 10-, 12-And 16-Speed Version Without ZF-Intarder Level 3
Repair Instructions: Zf-Astronic 10-, 12-And 16-Speed Version Without ZF-Intarder Level 3
ZF-ASTRONIC
10-, 12- and 16-speed version without ZF-Intarder
Level 3
TRUCK, BUSES
Copyright © ZF Friedrichshafen AG
Page
Preparatory Work............................................................................................................................... 34
EN 1327.751.102d - 2014-11 3
ZF-AS Tronic Table of Contents
Page
R/C housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Dismounting the R/C housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Play setting of the main shaft – Planetary carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Mounting the R/C housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembling the R/C housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Assembling the R/C housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassembling the planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Pre-Assembling the sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pre-Assembling the planetary gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Completing the planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly of Step-Up Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removing transmission actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removing the upper section from the lower section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Reattaching the upper section to the lower section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installing the transmission actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacing pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Programming transmission actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Removing connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Measuring connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Mounting connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Removing housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Dismantling housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Assembling housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Fitting housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Shaft Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Removing shaft pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installing shaft pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
EN 1327.751.102d - 2014-11 4
ZF-AS Tronic Table of Contents
Page
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Disassembling the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Disassembling synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Assembling the synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Setting the axial play of the bearing disk in constant gear 2 . . . . . . . . . . . . . . . . . . . . . . . . . 97
Assembling the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Disassembling the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Mounting the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Dismantling housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Assembling housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Annex
Service Information no. 02_04 ............................................... 113
Service Information no. 02_05 ............................................... 118
Service Information no. 08_00 ............................................... 123
Service Information no. 12_03 ............................................... 127
Service Information no. 13_03 ............................................... 131
Service Information no. 14_07 ............................................... 135
Service Information no. 14_09 ............................................... 141
Service Information no. 20_04 ............................................... 151
Service Information no. 25_05 ............................................... 155
EN 1327.751.102d - 2014-11 5
List of Changes: 1327 751 102
List of Changes
b 2007-05 LKS-T dept. Complete revision of text, i.a. the following items were added:
- Solid sealings
- Measuring disks in helical gears and on the main shaft.
- Service Information No. 08_00, 02_04, 02_05, 20_04, 25_05.
- New clutch release mechanism
d 2014-11 TTCT dept. New: ESD protection; Technical data; Product designation; Transmission
overview; Pushrod measurements; Bleeding of clutch actuator;
Updated: Diagnosis tool;
New tool for new shaft sealing ring at the output side included.
Output cover;
Clutch release mechanism (completely revised; screw tightening torque
68.130 old 95 Nm, new 105 Nm);
impulse sensor;
EN 1327.751.102d - 2014-11 6
ZF-AS Tronic Preface
Preface
This documentation was developed for specialized staff trained in the operation of ZF products by
ZF Friedrichshafen AG (hereinafter referred to as "ZF").
The work described below may be performed by authorized, trained, and instructed staff only. It is the
responsibility of the user's company or service company to ensure that their specialized staff is properly
trained and that current documents are made available.
The images illustrate the work sequence and do not always represent the original. Illustrations and figures
are not drawn to scale; no conclusions about size and weight can be drawn.
The repair or assembly of the ZF product available to you may require different work steps as well as
different settings and test data as a result of technical further developments. We therefore recommend
that work done on your ZF product be carried out only by skilled mechanics and fitters who have had their
practical and theoretical knowledge updated on a regular basis at ZF.
The ZF service locations which have been put in place for you worldwide by ZF offer the following
services:
▪ Well-trained specialized personnel
▪ Specified workshop equipment, e. g. special tools, diagnostic software, etc.
▪ Genuine ZF spare parts in accordance with the latest volume production specifications
ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 7
ZF-AS Tronic Preface
Product Designation
The ZF-AS Tronic product designation is based on the following type key.
12 AS 21 3 0 T O
Ratio
O = Overdrive
Ratio top gear lower than 1.0 (e. g. 0.78)
D = Direct drive
Ratio top gear = 1.0
Application
T = Truck
B = Bus
S = Special application
D = Dust-protected
W = Fordable
Variant
0 = Standard (solo)
1* = with Intarder
5* = With clutch-dependent PTO or other accessories/units
Product family
3 = 12-speed (short) and 16-speed
4 = 12-speed (long)
Number of gears
1327_50D_050_en
EN 1327.751.102d - 2014-11 8 2014-03
ZF-AS Tronic Preface
Transmission Overview
The repair instructions are valid for the transmission types of product family 3 and 4 described here, also in
conjunction with Intarder.
1327_50D_080_en
EN 1327.751.102d - 2014-11 9 2014-04
ZF-AS Tronic Safety Instructions
Safety Instructions
Read all safety instructions. Failure to comply with safety instructions may lead to material damage, serio-
us injury, possibly even to death.
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate.
However, this product may cause hazardous situations if used incorrectly by unauthorized, untrained, and
uninstructed specialized staff or if not used for its intended purpose.
This version of the document complies with the relevant standards and regulations as well as with Europe-
an product liability law.
We offer guarantee for the ZF product in accordance with our Terms and Conditions. Warranty claims
cease to apply if damage and secondary damage result from incorrect and unprofessionally performed
work. Work that is performed by unauthorized, untrained, and uninstructed specialized staff leads to cea-
sing of all warranty claims.
We offer warranty for the ZF product in accordance with our Terms and Conditions.
Damage, secondary damage, defects, and possibly resulting costs are excluded from contractual liability
or warranty in the event of non-compliance with one of the following points:
▪ All work must be performed in a professional manner.
▪ Work must only be performed by trained, instructed and authorized specialized staff.
▪ Only genuine ZF spare parts may be used which have been tested and released by ZF.
▪ Only genuine ZF accessories may be used which have been tested and released by ZF.
▪ Only genuine ZF special tools may be used which have been tested and released by ZF.
▪ Revisions and modifications on the ZF product must be approved by ZF.
EN 1327.751.102d - 2014-11 10
ZF-AS Tronic Safety Instructions
In case of damage, immediate action is mandatory in order to restore full functionality and safety / opera-
tional safety of the ZF product and to minimize the extent of damage. In the event of non-compliance, ZF
will not accept liability or warranty claims.
In case of damage, contact ZF Services and have the following data available:
▪ Product type, product parts list number, and serial number
▪ Total mileage
▪ Damage history
▪ Damage pattern
Specialized staff
Work must only be performed by trained and instructed specialized staff. As a result of specialized training
and practical experience, the specialized staff must be capable of detecting risks and avoiding possible
dangers which may be caused by the operation, maintenance, and repair of the ZF product.
To avoid injury to personnel and damage to ZF products, all safety regulations and legal requirements must
be adhered to. The specialized staff must have read and understood these regulations prior to beginning
work.
Country-specific safety, accident prevention, and environmental regulations apply irrespective of the
instructions provided in this document.
Safety-relevant workwear is to be used for all work. Depending on the type of work, additional protection,
e. g. protective goggles, protective gloves, a hard hat, and a skirt, is to be used. The workwear must fit pro-
perly and be tight so that it cannot get caught in turning or protruding parts.
After completion of repair work and inspections, the specialized staff must ensure that the ZF product is
again functioning perfectly and is safe to operate.
The user/operator is responsible for assigning the corresponding section of the documentation to the cor-
rect target group. The former must ensure that the respective section of the documentation is stored
in the immediate vicinity of the ZF product and that the relevant target group has access to it.
EN 1327.751.102d - 2014-11 11
ZF-AS Tronic Safety Instructions
Handling of ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the
ZF product’s operational safety and are only permitted with the approval of ZF Friedrichshafen AG.
Unless explicitly permitted, no work may be performed while the engine is running.
Secure the engine against unintentional setting off and the vehicle against moving.
Attach a “Do not operate” sign which is visible for everyone!
Keep uninvolved parties away.
Always secure the ZF product before starting work according to specification and using suitable means.
Do not work on ZF products which are only held by a lifting device or a hoist.
Risk of injury from tilting or falling parts and/or tools.
▪ Do not walk under suspended loads.
▪ Keep distance.
Lifting and moving heavy parts without tools may lead to health damage or serious injury.
▪ Only use permitted means of transport, lifting equipment with sufficient load capacity, and suitable
chain hoist.
▪ Observe safety regulations.
Increased risk of injury at contact with cooled down or heated parts. Only touch parts when wearing suit-
able protective gloves.
Noise
Wear suitable ear protection at all workplaces with a sound pressure level above 85 dB(A).
Country-specific safety and accident prevention regulations apply regardless of this.
Noise can mean a higher risk of accidents if the noise affects the perception of acoustic signals, warning
calls, or other sounds alerting to danger.
EN 1327.751.102d - 2014-11 12
ZF-AS Tronic Safety Instructions
Store operating fluids and consumables in suitable and correctly labeled containers.
Use suitable protective clothing, protective gloves, and protective goggles/face protection.
Pay attention to manufacturer’s and accident prevention regulations.
Immediately seek medical assistance after contact with heated, cooled down, or caustic operating fluids
and consumables.
Environment
Operating fluids and consumables must not be allowed to enter the soil, groundwater, or sewage system.
▪ Ask your local environmental protection agency for the safety data sheets of the relevant ZF products
and observe these requirements.
▪ Collect operating fluids and consumables in a sufficiently large container.
▪ Dispose of operating fluids and consumables, waste, containers, soaked cleaning cloths, contaminated
filters etc. in accordance with the regulations of the environmental protection laws.
▪ Pay attention to manufacturer’s and accident prevention regulations.
When selecting operating fluids and consumables, bear in mind health risks, environmental compatibility,
disposal regulations, and country-specific possibilities for approved disposal.
EN 1327.751.102d - 2014-11 13
ZF-AS Tronic Safety Instructions
This document contains particularly highlighted safety instructions which start with one of the following
signal words depending on the danger’s severity.
DANGER!
Is used when lack of care could result in personal injury or danger to life.
CAUTION
Is used when the instructions are not complied with or not followed precisely and could lead to the
product being damaged.
NOTE
Refers to special working procedures, methods, information, use of auxiliary equipment, etc.
EN 1327.751.102d - 2014-11 14
ZF-AS Tronic Instructions for Repair and Assembly
General notes
▪ Please read carefully through this documentation prior to starting repair or assembly work.
▪ Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF
product is available. ZF Service Information can contain tests, supplements to the product or to repair
processes which may not yet be included in this documentation. The ZF Service Information details are
available from all ZF Service Centers or from the ZF-ServiceLine.
▪ In cases of doubt, always contact the relevant expert departments of the ZF Customer Service.
▪ All work on the ZF product must be performed expertly and under clean conditions.
▪ Use the specified special tools and equipment intended for the described working procedures.
▪ All work must be performed according to the described working procedure.
▪ Carefully cover opened ZF products to prevent the entry of foreign matter.
▪ Cover all parts that have been removed and that are reusable and protect them against dirt and
damage.
▪ After completion of work and inspections, the specialized staff must ensure that the ZF product is again
functioning perfectly and is safe to operate.
▪ Use an appropriate cleaning agent to thoroughly clean the ZF product prior to repair or assembly work.
Thoroughly clean the angles and recesses of housing and cover.
CAUTION
Be careful when using a high-pressure cleaner on the ZF product.
Penetrating water might lead to operational disruption and damage to the ZF product.
EN 1327.751.102d - 2014-11 15
ZF-AS Tronic Instructions for Repair and Assembly
Cleaning parts
Reusing parts
Always replace:
▪ Bolts with reduced shank, seals, etc., and parts that are intended for single use only
▪ Sealing rings
▪ Safety plates
▪ Shaft sealing rings
The parts must be replaced with genuine ZF parts or parts released by ZF. Please refer to the spare parts
catalog for the ZF product.
EN 1327.751.102d - 2014-11 16
ZF-AS Tronic Instructions for Repair and Assembly
Reworking parts
If rework is needed on spacer washers or shims because of clearance settings, ensure that the reworked
surface is level with the starting face and has the same surface quality.
Disassembly
▪ To avoid mixing up parts, the parts must be clearly assigned to the disassembled ZF product. In
particular, this applies to gear parts, reusable spacer washers or shims, electronic components, etc.
▪ Assemblies which must not be disassembled or are only available as spare parts assembly are
described accordingly. Please refer to the spare parts catalog for the ZF product.
▪ Inspect the parts during disassembly in order to find a potential cause of damage.
EN 1327.751.102d - 2014-11 17
ZF-AS Tronic Instructions for Repair and Assembly
Assembly
Assemble the ZF product at a clean workplace. The order, settings, and tightening torques must be
observed.
Bearings
The bearings’ assembly specifications are described in the corresponding work step. After assembly, each
mounted bearing must be lubricated with transmission oil.
Sealing
If a sealing agent* is recommended for sealing, then it is essential to adhere to the manufacturer’s direc-
tions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly. Do not
allow sealing agent to enter oil ducts and oil bores. In the case of oil transfer channels and/or oil transfer
bores in the sealing face areas, the sealing agent should be scraped off around the openings so that no
sealing agent gets into the oil supply lines when the parts are pressed together.
Retaining agents
Only use retaining agents* if specified in the work step. Follow the safety instructions and the processing
instructions of the manufacturer.
Transmission oil
Prior to initial operation, fill the transmission with transmission oil. For the procedure and approved oil
grades, refer to the technical manual, the operating instructions, the type plate, and/or the latest List of
Lubricants TE-ML. These documents are available from the ZF Service Centers and at www.zf.com.
EN 1327.751.102d - 2014-11 18
ZF-AS Tronic Tightening Torques
Tightening torques for screws and nuts, extract from ZFN 148
This standard applies to bolts according to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and for nuts according to DIN 934 and ISO 4032,
ISO 8673.
This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8,
10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.
NOTE
Differing tightening torques are listed separately in the repair manual.
M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
EN 1327.751.102d - 2014-11 19
ZF-AS Tronic Consumable Material
1327_92D_010_en
EN 1327.751.102d - 2014-11 20 2014-09
ZF-AS Tronic Setting Data
Axial clearance of the –0.05 to +0.05 mm Depth gage Get tapered roller bearing
countershaft 03.010 micrometer into zero position (backlash-
free) and measure. Adjust
play with the compensating
disk 03.050.
Axial clearance of the –0.05 to +0.05 mm Depth gage Get tapered roller bearing
countershaft 03.110 micrometer into zero position (backlash-
free) and measure. Adjust
play with the compensating
disk 03.150.
Axial clearance input shaft / 0 to 0.10 mm Depth gage Adjust play with the
connection plate micrometer compensating disk 02.100.
Axial clearance securing ring 0 to 0.10 mm Feeler gage Adjust play with the
on input shaft compensating disk 02.120.
Axial clearance output bearing 0 to 0.10 mm Depth gage If necessary, adjust play
micrometer with the compensating disk
31.030.
Axial clearance main shaft / 2 mm ±0.1 Depth gage Adjust play with the
sun gear micrometer compensating disk 32.380.
Axial clearance gear to 0 to 0.10 mm Depth gage Use the snap ring to adjust
wheel disk on main shaft micrometer the play.
Axial clearance constant 0 to 0.10 mm Depth gage Adjust play with the snap
gear 2 to wheel disk on micrometer ring 02.290.
input shaft
Axial clearance disk to wheel 0.15 to 0.25 mm Depth gage Use the disk to adjust the
disk on main shaft micrometer play.
1327_92D_020_en
EN 1327.751.102d - 2014-11 21 2010-11
ZF-AS Tronic Setting Data
1327_92D_020_en
EN 1327.751.102d - 2014-11 22 2014-09
ZF-AS Tronic Special Tool
Chapter “Putting
1X56 138 443
Transmission in
Vertical Position”
Support
3 Alternatively:
for vertical positioning of the 4 Mobile or
transmission stationary
assembly stand
(refer to fig.
13 and 14)
1327_91D_040_en
EN 1327.751.102d - 2014-11 23 2014-09
ZF-AS Tronic Special Tool
Extractor
7 Bearing inner ring 32.310/1 1
at the planet carrier
1327_91D_040_en
EN 1327.751.102d - 2014-11 24 2014-09
ZF-AS Tronic Special Tool
Version A Version B
1X56 138 095 Chapter
“Transmission
Actuator”
Setting fixture
11 for selector rails 1 Only variant B is
now available.
1327_91D_040_en
EN 1327.751.102d - 2014-11 25 2014-09
ZF-AS Tronic Special Tool
1327_91D_040_en
EN 1327.751.102d - 2014-11 26 2014-09
ZF-AS Tronic Special Tool
1327_91D_040_en
EN 1327.751.102d - 2014-11 27 2014-09
ZF-AS Tronic Special Tool
1327_91D_040_en
EN 1327.751.102d - 2014-11 28 2014-09
ZF-AS Tronic Special Tool
Chapter
240
Sketch:
“Transmission
M10
64
60.5
Actuator”
75
11
M10
112
Setting aid 1
74
15
34
ø9 H7 ø9H7
Assembly aid
200.1 14 2120.1
ø8.70.1
actuator
ø9r6
25
2x45 2x45
37.50.1
40
Adapter 1
35 for shaft sealing ring 0734 300 421
10_001212_01
1327_91D_040_en
EN 1327.751.102d - 2014-11 29 2014-09
ZF-AS Tronic Diagnosis Tool
1327_91D_050
EN 1327.751.102d - 2014-11 30 2014-03
ZF-AS Tronic Technical Data
Technical Data
10_000560_01
1327_50D_060_en
EN 1327.751.102d - 2014-11 31 2014-03
ZF-AS Tronic Interfaces with the Vehicle
Legend:
1 Transmission actuator’s compressed-air
connection
2 Tachograph connection (optional)
4
3 Type plate
4 Engine connection
5 Neutral switch connection (optional)
6 Connection for vehicle-end wiring harness
7 Heat exchanger connection
8 Clutch actuator’s compressed-air connection
2
9 PTO connection 3
10 Propshaft connection
10_000561_01
5 6
8 7 10_000563_01
10
9
10_000565_01
1327_50D_070_en
EN 1327.751.102d - 2014-11 32 2014-03
ESD Protection
CAUTION
Electronic components are highly sensitive to
electrostatic discharge; therefore, strictly adhere
to EDS protection measures for all works
performed. If the ESD protection is not observed,
damage due to overvoltage may occur.
Technical terms and their abbreviations! ElectroStatic discharge sensitive devices are marked
ESD: ElectroStatic Discharge with this symbol.
EPA: Electrostatic Protected Area
ESDS/EGB: ElectroStatic Discharge Sensitive Device
034389
ESD
Products protecting against ESD, e.g. electrically
conductive safety footwear, protective coverings,
clothing, mats, trolleys, etc. are marked with this
symbol.
034390
0000_50D_010_EN
EN 1327.751.102d - 2014-11 33 2012-05
ZF-AS Tronic Preparatory Work
Preparatory Work
CAUTION
After every repair, the transmission must be
tested for function and leakage on a test bench.
General
NOTE*
We recommend the stationary assembly
stand 1P01 181 850 in connection with basic
plate 1X56 138 297 and the clamping plate
1X56 139 608 for specialized workshops.
For further information, please contact
ZF Friedrichshafen AG, MKS-IP department
(Customer Service).
* Option
1327_50D_010_EN
EN 1327.751.102d - 2014-11 34 2010-11
ZF-AS Tronic Preparatory Work
CAUTION
Do not use the cast lug at the R/C housing! M16x1,5
The cast lug is too weak for overall transmission
weight: "Risk of housing fracture".
CAUTION
Transmission must not stand on input shaft.
015018
1327_50D_010_EN
EN 1327.751.102d - 2014-11 35 2010-11
ZF-AS Tronic Removing Clutch Actuator
Clutch actuator
68.360* 68.010
68.210* 6
68.320
68.300
68.020*
68.370*
/120
68.330 /130 /030
/020
/110 /010
68.020*
68.210*
68.400
68.150
68.060
68.154
028184
1327_68D_020_en
EN 1327.751.102d - 2014-11 36 2014-09
ZF-AS Tronic Pushrod
Pushrod
68.210
Adjustable pushrod e.g. IVECO
10_000376_01
1327_68D_080_en
EN 1327.751.102d - 2014-11 37 2014-04
ZF-AS Tronic Set Pushrod
68.020
68.060
B 68.200 68.220 68.210
A 10_000377_01
The old pushrod dimension is adopted when the Dimension “B” + 19 mm = Dimension “A”
clutch actuator only is replaced.
Example:
If the driver disk or pressure plate is replaced, the 57 mm + 19 mm = 76 mm (dimension “ A”)
pushrod 68.210 must be reset.
Set pushrod to dimension “A”
CAUTION
In vehicles with an AS Tronic transmission, the 1 Loosen hexagon nut 68.220.
release travel is set and not the wear dimension
(as is usually the case). If not set correctly, the 2 Screw in ball pin 68.200 until desired
pressure plate is damaged. dimension is attained.
Press release fork 68.060 forward and 4 For control purposes, check set dimension
measure dimension “B” (e. g. 57 mm). “A”.
1327_68D_090_en
EN 1327.751.102d - 2014-11 38 2014-04
ZF-AS Tronic Bleeding Clutch Actuator
018475
018476
018477
1327_68D_033_en
EN 1327.751.102d - 2014-11 39 2014-09
ZF-AS Tronic Mounting Clutch Actuator
68.360* 68.010
68.210* 6
68.320
68.300
68.020*
68.370*
/120
68.330 /130 /030
/020
/110 /010
68.020*
68.210*
68.400
68.150
68.060
68.154
028184
1327_68D_030_en
EN 1327.751.102d - 2014-11 40 2014-09
ZF-AS Tronic Mounting Clutch Actuator
68.360* 68.010
68.210* 6
68.320
68.300
68.020*
68.370*
/120
68.330 /130 /030
/020
/110 /010
68.020*
68.210*
68.400
68.150
68.060
68.154
028184
CAUTION NOTE
• Do not bend cable or tighten hard. • For fastening the wiring of the transmission
• Avoid chafing points. actuator, also refer to the Service Information
• Fit connectors with traction relief and check No. 02_04 in the Annex.
detent.
1327_68D_030_en
EN 1327.751.102d - 2014-11 41 2014-09
ZF-AS Tronic Output Flange
Output Flange
O-ring 32.530.
NOTE
The shaft must not be damaged during pull-off
process; therefore, use a thrust piece.
015171
DANGER
Only touch hot output flange when wearing
protective gloves.
(06.210)
1327_32D_010_en
EN 1327.751.102d - 2014-11 42 2009-09
ZF-AS Tronic Output Flange
NOTE
When removing, use interim piece to protect the
shaft.
32.510
018733
DANGER
Always wear protective gloves when handling
heated output flange.
1327_32D_011_en
EN 1327.751.102d - 2014-11 43 2008-03
ZF-AS Tronic Output Cover
NOTE
In the case of transmissions equipped with a 31.030
1st generation
Cover 1328 331 002
Loctite
574
2nd generation
Cover 1314 331 014
Sealing compound 0666 790 033 31.080
4th generation
Cover 1328 331 004
Metal seal 0501 324 362
31.070
2nd generation
lift off output cover 31.050.
31.070
10_001766_01
1327_31D_011_EN
EN 1327.751.102d - 2014-11 44 2014-09
ZF-AS Tronic Output Cover
3 Version A
Press in the shaft sealing ring 0734 300 421
1X56 138 189
Version B
Press in the shaft sealing ring 0734 319 459
with adapter 1X56 137 124 in connection
10_001218_01
5 1st generation
Version with shim
31.030*
Calculation example: A – B = C
Shaft
Dimension A = 5.4 mm A
– Dimension B = 5.0 mm
Shim without play = 0.4 mm
Axial play of the ball bearing 0 to 0.1 mm
Thickness of the shim
31.050
31.010
015194
1327_31D_011_EN
EN 1327.751.102d - 2014-11 45 2014-09
ZF-AS Tronic Output Cover
NOTE
The shim 31.030 is no longer needed for genera-
tions 2, 3, and 4 since the output cover 31.050 was 31.080
modified accordingly. 31.050
31.030*
NOTE
Sealing faces must be clean and free from oil and 31.070
grease.
Loctite
– Coat sealing face of the output cover 31.050 * depending on the parts list
with Loctite no. 574. 028255
10_001766_01
1327_31D_011_EN
EN 1327.751.102d - 2014-11 46 2014-09
ZF-AS Tronic PTO Cover
PTO Cover
NOTE
For the installation of a PTO, the respective separate
installation instructions are binding.
31.100
31.120
015193
NOTE
31.090
018225
1327_31D_012_EN
EN 1327.751.102d - 2014-11 47 2014-09
ZF-AS Tronic R/C housing
Preparatory Work).
31.390
34.080
Version A 34.070
Version B 015167
Version B
Remove the two screw plugs 34.100.
Dismount the pivot bolts 34.050 – M8 extrac-
tor thread – and remove the snap ring 34.090.
34.050
34.100
31.370.
34.090
34.050
NOTE
34.100
housing.
34.020
31.350
028225
1327_31D_020_en
EN 1327.751.102d - 2014-11 48 2010-11
ZF-AS Tronic R/C housing
CAUTION
Cover the synchronization 33.010 with a cloth.
/150
021763
1327_31D_020_en
EN 1327.751.102d - 2014-11 49 2010-11
ZF-AS Tronic R/C housing
01.400
32.390
04.010
32.400
Determine dimension B1
016660
Determine dimension B2 016661
1 Prerequisite for measuring the compensating 1 Prerequisite for measuring the compensating
disk. disk.
Snap in securing ring 32.390 in the sleeve Snap in securing ring 32.390 in the sleeve
32.400 and put onto the main shaft 04.010. 32.400 and put onto the main shaft 04.010.
2 Install the measuring plane. 2 Install the measuring plane.
3 Dimension B 1: Measure from the measuring 3 Dimension B 1: Measure from the measuring
plane to the securing ring 32.390. plane to the securing ring 32.390.
4 Dimension B 2: Measure from the measuring 4 Dimension B 2: Measure from the measuring
plane to the sealing face at the housing II plane to the sealing face at the housing II
01.400. 01.400 (without the seal 31.350).
5 Dimension B: Determine the distance from 5 Dimension B: Determine the distance from
the securing ring 32.390 to the sealing face at the securing ring 32.390 to the sealing face
the housing II 01.400. at the housing II 01.400.
NOTE
Example:
The thickness of the seal must be measured
B = B2 – B1
without taking the seam/crimp into account!
B = 100 mm – 74.7 mm
B = 25.3 mm Example:
B = (B 2 – B 1) – seal
B = (100 mm – 74.35 mm) – 0.35 mm
B = 25.65 mm – 0.35 mm
B = 25.30 mm
1327_31D_040_en
EN 1327.751.102d - 2014-11 50 2007-05
ZF-AS Tronic R/C housing
Determine dimension B
32.400 B1
B2 B1 B2 32.390
B
B
04.010
B = B2 – B1
B = (B 2 – B 1) – seal
Determine dimension A
A1
A2
A2 A1
A
A
32.190
31.010
A = A2 – A1
015200
1327_31D_040_en
EN 1327.751.102d - 2014-11 51 2007-05
ZF-AS Tronic R/C housing
6 Dimension A 1: Measure from the measuring 6 Dimension A 1: Measure from the measuring
plane to the sealing face at the R/C housing plane to the sealing face at the R/C housing
31.010. 31.010 (without the seal 31.350).
7 Dimension A 2: Measure from the measuring 7 Dimension A 2: Measure from the measuring
plane to the sun gear 32.190. plane to the sun gear 32.190.
8 Dimension A: Determine the distance from 8 Dimension A: Determine the distance from
the sun gear 32.190 to the sealing face at the the sun gear 32.190 to the sealing face at the
R/C housing 31.010. R/C housing 31.010.
Example: Example:
A = A2 – A1 A = A2 – A1
A = 129.3 mm – 100 mm A = 129.3 mm – 100 mm
A = 29.3 mm A = 29.3 mm
9 Calculate the thickness (S) of the compensa- 9 Calculate the thickness (S) of the compensa-
ting disk 32.380. ting disk 32.380.
S = (A – B) – play S = (A – B) – play
NOTE NOTE
A play or clearance of 2 ±0.1 mm between the sun A play or clearance of 2 ±0.1 mm between the sun
gear 32.190 and the main shaft 04.010 gear 32.190 and the main shaft 04.010
must be considered mandatory. must be considered mandatory.
Example: Example:
S = (A – B) – 2 mm (play) S = (A – B) – 2 mm (play)
S = (29.3 mm – 25.3 mm) – 2 mm S = (29.3 mm – 25.3 mm) – 2 mm
S = 4.0 mm – 2 mm S = 4.0 mm – 2 mm
S = 2.0 mm S = 2.0 mm
10 Select compensating disk 32.380 using spare 10 Select compensating disk 32.380 using spare
parts catalog. parts catalog.
1327_31D_040_en
EN 1327.751.102d - 2014-11 52 2007-05
ZF-AS Tronic R/C housing
shaft.
/110
32.440
NOTE
/130
32.380
018085
1327_31D_030_en
EN 1327.751.102d - 2014-11 53 2010-11
ZF-AS Tronic R/C housing
01.400
31.010
34.010
1
31.400
33.010
31.350*
* 34.020
Loctite
574
Maß L
34.030
Gehäuse II
* depends upon the dimension L of the housing II / in accordance with Service Information No. 02_05 in the Annex
028226
8 Clean sealing surfaces. 11 Insert the spray pipe 31.400 – longer end
towards the R/C housing.
NOTE
The sealing faces on the housing I and the 12 Insert the selector pads 34.030 in the gear
R/C housing must be clean and free of oil and shift fork 34.020 and ensure correct
grease. positioning in the sliding sleeve 33.010 and
the selector rail 34.010.
CAUTION
The correct seal must be used in accordance with 13 Screw in two commercial M10 guide bolts (1)
Service Information No. 02_05 (also see Annex) into the housing II 01.400.
otherwise, the transmission may be damaged.
14 Fix 2 screw-on adapters on output flange
9 Determine dimension L of the housing II and/or planet carrier and hook in chain.
01.400.
15 Hook in chain at hoist and cautiously lower
10 Depending on the version: the R/C housing 31.010 onto housing II.
L = 184.5 -0.1 mm and/or 227.5 -0.1 mm: Use an auxiliary tool (3) (e. g. pin) in order to
Coat the sealing face at housing II with insert the spray pipe 31.400 into the bore of
Loctite no. 574. the screw plug 31.090.
Remove the two M10 guide bolts (1).
– OR –
CAUTION
L = 183.75 -0.13 mm and/or 226.75 -0.13 mm: Appropriate handling is essential when positio-
Put on seal 31.350. ning the R/C housing and when driving in the
cylindrical pins – danger of housing fracture.
1327_31D_030_en
EN 1327.751.102d - 2014-11 54 2010-11
ZF-AS Tronic R/C housing
CAUTION
31.390
31.370
018224
Version A
Version A
18 Insert new O-rings 34.060 at the pivot bolts
34.050.
34.070 34.050
34.060
34.060
NOTE 34.050 34.080
If the pivot bolts 34.050 are inserted too far 31.390
Version B
Version B 34.050
34.100
34.100
20 Tighten screw plug with sealing ring 34.100 to
40 Nm.
34.090
31.390
31.370
021762
1327_31D_030_en
EN 1327.751.102d - 2014-11 55 2010-11
ZF-AS Tronic R/C Housing
31.200
31.010 31.230*
015173
1327_31D_050_EN
EN 1327.751.102d - 2014-11 56 2014-09
ZF-AS Tronic R/C Housing
13_03.
31.090
DANGER
Only touch heated parts when wearing
protective gloves. 31.010 31.230*
NOTE
Mount screw plug M10x1 31.090 only once the R/C
housing was mounted to housing II.
1327_31D_050_EN
13271327.751.102d
EN 751 002 - 2004-04 - 2014-11 57 2014-09
ZF-AS Tronic Planet Carrier
Planet carrier
1 2
Optional
32.290
1 Place pressure plate (1) 1X56 138 424 onto
the planet carrier. 32.280
4 Push the ring (4) from the tool 1X56 138 420
onto the two half-shells (3) and tighten the
screw (5).
6
023595
1327_32D_020_en
EN 1327.751.102d - 2014-11 58 2014-10
ZF-AS Tronic Planet Carrier
puller. 32.230
32.240
6 Position the planet carrier laterally on the ring
gear.
DANGER
32.290
– Risk of injury –
1327_32D_020_en
EN 1327.751.102d - 2014-11 59 2014-10
ZF-AS Tronic Planet Carrier
4 3 10_002033_01
10_002034_01
10_002035_01
44
1327_32D_020_en
EN 1327.751.102d - 2014-11 60 2014-10
ZF-AS Tronic Planet Carrier
into the spline of the sun gear 32.190 and off- 32.184
set the two. Thereby, the driving pin 32.204 is
secured.
secured. 32.204
32.184
CAUTION
32.090
32.180
32.080
Planetary gears may not be replaced individually, 32.090
always replace the entire set. 32.070
mission oil.
028362
1327_32D_030_en
EN 1327.751.102d - 2014-11 61 2007-05
ZF-AS Tronic Planet Carrier
DANGER
32.120
heated parts.
32.240
DANGER 32.280
Fingers may get stuck/jammed!
carrier 32.010.
DANGER
Always wear protective gloves when handling
heated parts.
6 Heat up the clutch body 32.280 to max. 9 Slide the ring gear 32.130 (output-end) and
120 °C and slide onto the planet carrier until the ring gear carrier 32.230 (input-end) onto
firmly home (axial abutment). Use pliers here the planet carrier so that the locking wire
in order to help contracting the securing ring 32.240 (e. g. by means of a small screw-
32.290. The securing ring snaps into the driver) can be put into the groove of the ring
groove of the clutch body. gear 32.130.
1327_32D_040_en
EN 1327.751.102d - 2014-11 62 2007-05
ZF-AS Tronic Planet Carrier
1327_32D_050_en
EN 1327.751.102d - 2014-11 63 2007-05
ZF-AS Tronic Place transmission is in stationary position
1 Replace the two reverse gear bolts 05.010, 1X56 138 208
NOTE
The reverse gear’s reversing gears are secured
by means of a tool (9) 1X56 138 208.
018269
NOTE
Residual transmission oil may be drained; position
the oil collecting basin correspondingly.
015187
015192
1327_50D_020_en
EN 1327.751.102d - 2014-11 64 2010-11
ZF-AS Tronic Transmission Actuator
Transmission Actuator
74.140*
Removing transmission actuator 74.130* 74.120*
74.070
74.030
1 Depending on parts list: Remove breather
74.120 and/or angle piece 74.140 and cannon
68.400
10_000351_01
NOTE
A transmission actuator kit is available. 12.090
It consists of transmission actuator 74.030,
74.050
34.140 12.080
seal 74.010, and breather 74.120. 34.130 06.050
06.040
027850_2
1327_74D_030_en
EN 1327.751.102d - 2014-11 65 2014-09
ZF-AS Tronic Transmission Actuator
NOTE 09 03 43872
Seal kit 0501 319 863 contains both screws 4213 550 110
/150-1, the flat seal /150-2, and the profile
seal /150-3. 024361
CAUTION 1
/150-1
Note down the data on the type plate.
You will need them for ordering spare parts
and for correspondence.
/110
/170
section
1327_74D_005_en
EN 1327.751.102d - 2014-11 66 2007-05
ZF-AS Tronic Installing the Transmission Actuator
NOTE
Mount the transmission actuator only once
06.080
Legend
Piston rod (3) = shifts the splitter group (S/G)
Piston rod (4) = shifts the basic transmission
6
017908
1327_74D_040_EN
EN 1327.751.102d - 2014-11 67 2014-09
ZF-AS Tronic Installing the Transmission Actuator
NOTE
With the 12-speed version, do not slide the
gearshift rail 06.010 in the middle too far into the
34.010 06.080 06.010 12.010
Legend
12.010 Splitter group (S/G) gearshift rail
06.010 Gearshift rail for basic transmission
34.010 Range change group (R/C) gearshift rail
06.080 Ball pin
015019
NOTE
An auxiliary tool (34) can be manufactured for
setting the piston rods.
For special tool sketch refer to Figure 34. 34
017907
1327_74D_040_EN
1327 751 102 - 2004-04
EN 1327.751.102d - 2014-11 68 2014-09
ZF-AS Tronic Installing the Transmission Actuator
NOTE
74.090 74.070
actuator.
74.010
CAUTION
Pay attention to the following instructions if the
transmission actuator was replaced or renewed:
• Reprogram transmission actuator
• Transfer vehicle parameters from removed
transmission or re-enter.
1327_74D_040_EN
EN 1327.751.102d - 2014-11 69 2014-09
ZF-AS Tronic Replacing pressure relief valve
CAUTION
Do not use grease to fit O-ring (12).
/180 12 74.030
019252
1327_74D_011_en
EN 1327.751.102d - 2014-11 70 2014-03
ZF-AS Tronic Programming Transmission Actuator
CAUTION
• When reprogramming a transmission
actuator, transfer the vehicle parameters
from the removed transmission actuator or
re-enter them.
• Make sure that the number of gears of the
software matches that of the transmission.
1327_74D_012_en
EN 1327.751.102d - 2014-11 71 2014-03
ZF-AS Tronic Putting transmission in vertical position
NOTE
Residual transmission oil may be drained; position
the oil collecting basin correspondingly.
015184
3
015185
015186
1327_50D_030_en
EN 1327.751.102d - 2014-11 72 2010-11
ZF-AS Tronic Removing Clutch Release Mechanism
68.060
68.130 68.110
/150
/160
/110
68.210
/120
68.050
1327_68D_010_en
EN 1327.751.102d - 2014-11 73 2014-04
ZF-AS Tronic Remove Clutch Release Mechanism
Version A:
Release fork with cam rollers
tools.
/130 /110
Drive out cam rollers /150 and /160 from the 68.210
68.110
/120
68.050 /140
68.130
10_001383_01
1327_68D_010_en
EN 1327.751.102d - 2014-11 74 2014-04
ZF-AS Tronic Install Clutch Release Mechanism
/150
/110
/160
10_001361_01
NOTE Version B:
ZF recommends replacing version A with Clutch release fork with track roller
version B.
1 Assemble the release fork /110 using
CAUTION assembly fixture 1X56 138 547 as a
The release fork 68.060 and the clutch release support.
bearing 68.050 of versions A and B cannot be
combined. The release shaft 68.110 however is 2 Use the press-in mandrel 1X56 138 546 in
identical for both versions. order to press in the cam rollers /150 and
/160 until firmly home in the release fork
/110.
1327_68D_100_en
EN 1327.751.102d - 2014-11 75 2014-04
ZF-AS Tronic Install Clutch Release Mechanism
CAUTION
/110
NOTE
"Release shaft must not be greased" applies to new 68.050
components as they are already factory-greased.
However, maintenance should include a lubrication
check followed by greasing if necessary.
NOTE
The release shaft has play with the release fork.
68.060
68.110 10_001396_01
68.060
10_001370_01
1327_68D_100_en
EN 1327.751.102d - 2014-11 76 2014-04
ZF-AS Tronic Install Clutch Release Mechanism
Version A:
Release fork with cam rollers
/110
/140 /130
68.050 68.060
68.110
/140
/130 /110
68.130
68.130 68.210
/120
/130
68.060 68.050
68.110
/140
1 Assembling the release fork 68.060. 5 Position release bearing 68.050 on release
An adapter 1X56 138 215 is needed as flange (guide tube).
support for the release fork /110. Another
adapter 1X56 138 215 is used to press in the NOTE
two bushes /130 and shaft sealing rings /140 Do not grease the bearing fit
(pay attention to the installation position) one “release bearing – release flange”.
after the other.
6 Apply OLISTA LONGTIME 3EP (ZF no.
2 Fill the shaft sealing rings /140 with grease 0671 190 050) grease to contact face to the
between the sealing lips. release bearing 68.050 at the release fork
Grease bearing bushes /130 with OLISTA 68.060. Engage release fork 68.060 with
LONGTIME 3EP (ZF no. 0671 190 050). release bearing 68.050.
3 Press in ball cup /120 and grease with 7 Fasten the release shaft 68.110 with 2 M12
OLISTA LONGTIME 3EP (ZF no. hex-head bolts 68.130 to the connection
0671 190 050). plate.
Tightening torque: 105 Nm
4 Guide release shaft 68.110 into release fork
68.060, do not damage shaft sealing rings in
the process.
1327_68D_100_en
EN 1327.751.102d - 2014-11 77 2014-04
ZF-AS Tronic Removing Connection Plate
Connection plate
03.050
03.150
03.200*
02.570
03.250
02.100 03.270
02.560
02.550 03.210*
03.270
02.580
02.500
03.260
02.630* 03.280
A*
03.280
02.670
03.270
02.610
02.530
02.520
B* * depends on the parts list
028303
1 Remove the 22 M10 hex-head screws 5 Take out the brake piston 02.610 and, when
02.670. removing the groove ring 02.630, pay
attention to the installation position
2 Lift the connection plate 02.500 with a suita- (important for subsequent re-installation).
ble tool or, if necessary, use the M8 thread for
pressing off (refer to arrows A, B). 6 Exchange the cylindrical pins 03.260 if they
are defective.
NOTE
In order to lift off the connection plate, it is 7 Disassemble the pump for parts inspection
much easier if the release flange 02.520 has (visual) and cleaning.
not been removed. Otherwise, the connection
plate tends to cant/misalign. 8 Remove three Torx screws 02.580.
3 Remove the compensating disks 03.050, 9 Remove the pump cover 02.570, pump shaft
02.100, 03.150, detent pin 03.210, and the 02.560, and rotor 02.550.
pressure spring 03.200.
1327_02D_010_en
EN 1327.751.102d - 2014-11 78 2010-11
ZF-AS Tronic Removing Connection Plate
02.530
12 Use a suitable tool to remove shaft sealing
ring 02.510 from the release flange 02.520.
02.520
028302
1327_02D_010_en
EN 1327.751.102d - 2014-11 79 2010-11
ZF-AS Tronic Measuring Connection Plate
b2
b1
b
02.100
03.150 03.050
a1
c1
a2
c2
a
015199
1 Turn input shaft several times back and forth. 4 Determine the distance of the bearing’s outer
Thereby, the taper rollers of the bearings are ring to the housing’s sealing face:
aligned and bearing outer races are rolled in. Pump e.g. dimension c2 = 2.00
To set the specified countershaft setting Transm. brake e.g. dimension a2 = 1.95
dimension of –0.05 to +0.05 mm, you first Input shaft e.g. dimension b2 = 3.90
need to reach “Zero Clearance”
2 Use a drift to place the outer bearing rings on 5 Measure connection plate.
taper rollers free of clearance. Distance of sealing face connection plate
to pump cover e.g. dimension c1 = 0.05
3 Use sharp object to check whether taper to brake cover e.g. dimension a1 = 0.15
rollers of bearing can be moved. to abutment face of disk 02.100
Input shaft e.g. dimension b1 = 5.50
NOTE
Zero clearance is attained when the taper rollers
are solidly fixed but there is no preload reached.
1327_02D_020_en
EN 1327.751.102d - 2014-11 80 2014-09
ZF-AS Tronic Measuring Connection Plate
b2
b1
b
02.100
03.150 03.050
a1
c1
a2
c2
a
015199
6 Determine thickness of disks: 7 Pay attention to the following aspects for the
selection of the disks:
Calculation example
Countershafts:
Pump: Preload and/or play
c1 + c2 = c = disk 03.050 –0.05 mm up to +0.05 mm
0.05 + 2.00 = 2.05 mm = disk 03.050
Input shaft:
Transmission brake: Play
a1 + a2 = a = disk 03.150 0 up to 0.10 mm
0.15 +1.95 = 2.10 mm = disk 03.150 Deduct the play from the thickness of the disk.
1327_02D_020_en
EN 1327.751.102d - 2014-11 81 2014-09
ZF-AS Tronic Mounting Connection Plate
03.050
03.150
03.200*
02.570
03.250
02.100 03.270
02.560
02.550 03.210*
03.270
02.580
02.500
03.260
02.630* 03.280
03.280
02.670
03.270
02.610
574 e
Loctite
tit
Loc
241
02.530
02.520
* depends on the parts list
028304
1 Clean the sealing faces of the following 6 Put the compensating disks 03.150 and
components: 03.050 correctly onto the bearing’s outer
Connection plate 02.500, release flange rings. Slightly grease the compensating disks
02.520, and housing I 01.010. 02.100 and insert in the connection plate.
NOTE CAUTION
All sealing faces and the M10 threaded holes Do not mix up the compensating disks 03.150 and
on housing I must be clean and free of oil and 03.050.
grease.
7 Position the brake cover 03.250 on the
2 Mount the pump. housing’s sealing face. The collar of the brake
Insert the rotor 02.550, pump shaft 02.560, cover 03.250 points in the direction of the
and pump cover 02.570. multidisk package.
Tighten 3 M6 screws 02.580 with 10 Nm.
8 Mount the outer multidisks 03.270 and the
3 Insert a new grooved ring 02.630 in the piston lined multidisks 03.280 in accordance with
02.610; pay attention to its installation the respective parts list.
position. In the case of 4 outer multidisks, then, in
between the two lined multidisks, there must
4 Insert the piston 02.610 in the connection always be 2 outer multidisks.
plate 02.500. (Number and size of the multidisks depends
upon the parts list).
5 If the three cylindrical pins 03.260 were
removed, then insert them in the housing I.
1327_02D_030_en
EN 1327.751.102d - 2014-11 82 2014-09
ZF-AS Tronic Mounting Connection Plate
NOTE
• Coat the outer circumference of the shaft
02.530
02.500.
Tightening torque: 23 Nm * depends on the parts list
028302
Loctite
574
Z 02.500
014820
014819
1327_02D_030_en
EN 1327.751.102d - 2014-11 83 2014-09
ZF-AS Tronic Removing Housing I
Housing I
06.270* 01.140
015176
015177
016690
1327_01D_010_en
EN 1327.751.102d - 2014-11 84 2014-09
ZF-AS Tronic Housing I
06.200
06.210
01.010
06.210
03.140
01.150
01.160
03.040
01.100
01.280
01.110*
01.290
01.040*
Remove the following parts: 1 Insert the bearing’s outer rings 03.140,
- bearing’s outer rings 03.140, 03.040 03.040 in the housing I 01.010.
- type plate 01.150
- screw plugs M22x1.5 01.030, 01.040 2 Insert the vent 01.100, 01.110 and the cover
- M8 hex-head screw 01.290 01.280 with an M8 hex-head screw 01.290.
- cover 01.280 Tightening torque: 23 Nm
- vent 01.100, 01.110
- spacer 06.200 and 3 Screw in screw plugs M22x1.5
- two clamping pins 06.210 01.030/01.040 with sealing ring.
Tightening torque: 50 Nm
1327_01D_020_en
EN 1327.751.102d - 2014-11 85 2007-05
ZF-AS Tronic Fitting Housing I
Fitting housing I
01.400
NOTE
The sealing faces on housing I and housing II
must be clean and free of oil and grease.
CAUTION
The correct seal must be used in accordance with
Service Information No. 02_05 (also see Annex)
otherwise, the transmission may be damaged.
– OR –
housing II 01.400.
6 Check whether the spray pipes 01.420,
01.140
housing I.
01.010 01.400
7 Remove tools 1X56 138 200 and
1X56 138 201.
01.140
8 Insert the cylinder pins 01.140 (do not fully
push in) and tighten 24 M10 hex-head screws
01.130 with 50 Nm.
01.130
CAUTION
02.080
1327_01D_030_en
EN 1327.751.102d - 2014-11 86 2014-09
ZF-AS Tronic Fitting Housing I
DANGER
Only touch heated parts when wearing
24
protective gloves.
NOTE
The securing ring 02.120 must make contact with 02.080
the input shaft’s groove base. 02.080/1
* depends on the parts list
NOTE
Always renew the sealing ring at the neutral switch
and/or the screw plug.
1327_01D_030_en
EN 1327.751.102d - 2014-11 87 2014-09
ZF-AS Tronic Removing Shaft Pack
Shaft pack
corresponding chapter.
01.430.
input shaft.
25
NOTE
The fixture (23) 1X56 138 216 consists of
two half-shells, a tube, and a threaded
1 2
04.060
018216
1327_05D_010_en
EN 1327.751.102d - 2014-11 88 2014-09
ZF-AS Tronic Removing Shaft Pack
3 04.350
016667
016448
1327_05D_010_en
EN 1327.751.102d - 2014-11 89 2014-09
ZF-AS Tronic Installing Shaft Pack
CAUTION
Check whether the securing ring has fully 04.060
engaged in the main shaft. If the securing ring 018216
25
1 2
05.140
05.040
016666
1327_05D_020_en
EN 1327.751.102d - 2014-11 90 2014-09
ZF-AS Tronic Installing Shaft Pack
CAUTION
The respective marks on the countershaft must
be within the range of the small counting disk
02.060 window (see arrows).
016665
1327_05D_020_en
EN 1327.751.102d - 2014-11 91 2014-09
ZF-AS Tronic Input shaft
Input shaft
02.390
02.380
02.370
02.360
02.350
02.330
02.320
02.310
02.290
02.280
02.300
02.260
02.250
02.240
02.200
017891
Disassembling the input shaft 2 Remove the following parts from the
input shaft:
NOTE - split ring 02.380
Clamp input shaft in a vise with protective chucks - disk 02.370
for disassembly. - axial roller cage 02.360
- bearing ring 02.330 with securing ring
1 Destroy the securing ring 02.390 of the split 02.350
ring 02.380 with a chisel and remove it. - disk 02.320
- axial needle cage 02.310
- helical gear constant 2 02.280
DANGER
- axial needle cage 02.250
Always wear protective glasses when working
- disk 02.240
with a chisel.
3 For the disassembly of the helical gear
constant 2 02.280:
Remove the snap ring 02.290 and 02.260
and take out the bearing disk 02.300.
1327_02D_040_en
EN 1327.751.102d - 2014-11 92 2007-05
ZF-AS Tronic Input Shaft
02.120
017926
02.050
02.060
017893
1327_02D_040_en
EN 1327.751.102d - 2014-11 93 2007-05
ZF-AS Tronic Input Shaft
/160
DANGER
/150
/160
/150
/210
/110 /240
/250
/120
017892
018217
1327_02D_060_en
EN 1327.751.102d - 2014-11 94 2007-05
ZF-AS Tronic Input Shaft
/160
CAUTION
/150
016691
018217
1327_02D_070_en
EN 1327.751.102d - 2014-11 95 2007-05
ZF-AS Tronic Input Shaft
16
017894
017895
017896
1327_02D_070_en
EN 1327.751.102d - 2014-11 96 2007-05
ZF-AS Tronic Input Shaft
NOTE
The necessary axial play of 0 up to 0.10 mm is
set by means of the snap rings.
0.00
Measurement 1
02.260 02.280
02.300
Measurement 2
0–0.10 mm
that the wheel disk is pushed upwards. -0.03
Spiel
Play
02.260
4 Measure from the rim of the helical gear 02.300
constant 2 02.280 to the wheel disk 02.290
02.300.
1327_02D_080_en
EN 1327.751.102d - 2014-11 97 2007-05
ZF-AS Tronic Input Shaft
02.010
2 Insert bolts 02.020 into input shaft 02.010.
02.040
NOTE
Play of up to 0.3 mm admissible between 02.060
bolts 02.020 and counting disk 02.060.
017926
1327_02D_050_en
EN 1327.751.102d - 2014-11 98 2007-05
ZF-AS Tronic Input Shaft
02.390
02.380
02.370
02.360
02.350
02.330
02.320
02.310
02.290
02.280
02.300
02.260
02.250
02.240
02.200
017891
7 Insert the synchronization 02.200, the disk 10 Secure securing ring 02.390 by staking
02.240, and the axial needle cage 02.250 3x120°.
onto the input shaft.
11 For installing the input shaft, please refer to
8 Put the complete helical gear constant 2 onto the chapter “Install Shaft Package”.
the input shaft.
1327_02D_050_en
EN 1327.751.102d - 2014-11 99 2007-05
ZF-AS Tronic Main Shaft
Main Shaft
NOTE
In the figure: All disks and snap rings that are marked with « » feature a label so that during assembly they
can be assigned to the correct assembly location. Thus, the measurement process is implemented for
control purposes only.
04.280
04.290
04.300 04.110
04.130 04.110
04.310 04.140
04.350 04.150
04.160
04.200
04.210
04.220
04.230 04.020
04.240
Snap ring
04.010
04.250
04.270 04.060
04.070 04.030
04.040
04.090
04.100
04.200 04.110
04.210
04.220
04.230
04.240
04.250
04.270
04.280
04.290
04.300 04.020
04.010
04.310
Snap ring 04.350 04.070
04.100 04.030
04.090
04.080
04.040
017890
1327_04D_010_en
EN 1327.751.102d - 2014-11 100 2010-11
ZF-AS Tronic Main Shaft
- washer 04.160*
04.290
04.300 04.130 04.110
1327_04D_010_en
EN 1327.751.102d - 2014-11 101 2010-11
ZF-AS Tronic Main Shaft
04.280
04.290
04.300 04.110
04.130 04.110
04.310 04.140
04.350 04.150
04.160
04.200
04.210
04.220
04.230 04.020
04.240
Snap ring 04.250
04.010
04.270 04.060
04.070 04.030
04.040
04.090
04.100
017889
04.200 04.110
04.210
04.220
04.230
04.240
04.250
04.270
04.280
04.290
04.300 04.020
04.010
Snap ring
04.310
04.350 04.070
04.100 04.030
04.090
04.080
04.040
017890
1327_04D_020_en
EN 1327.751.102d - 2014-11 102 2010-11
Main Shaft
NOTE
The spline is located in the main shaft’s gearing
where you can also find the blind hole’s bore. 11 Insert the wheel disk 04.140*and the snap
ring 04.130* in the helical gear 04.150*.
CAUTION
When completing the helical gear set ensure that 12 Set axial play of the helical gear 04.150* in
the stamping reduction (see arrow on Fig. 017889 relation to the wheel disk 04.140*, in
and 017890) of the wheel disks 04.090, 04.230, accordance with the instructions given in the
04.290, 04.140* does not point towards the snap respective chapter on the 'axial play of the
ring. helical gear - wheel disk'.
5 Insert the wheel disk 04.090 and the snap 13 Push the complete helical gear 04.150* onto
ring 04.100 in the helical gear 04.080. the main shaft.
6 Set axial play of the helical gear 04.080 in 14 Put on the disk 04.160* and offset by half a
relation to the wheel disk 04.090, in tooth. Push the spline 04.030 upwards and
accordance with the instructions given in the adjust the disk.
respective chapter on the 'axial play of the 15 Push the sliding sleeve 04.200 onto the main
helical gear – wheel disk'. shaft.
7 Push the complete helical gear 04.080 onto 16 Put on the disk 04.210 and offset by half a
the main shaft. tooth. Push the spline 04.030 upwards and
8 Put on the washer 04.110 and offset by half a adjust the disk.
tooth. Push the spline 04.030 upwards and 17 Insert the wheel disk 04.230 and the snap
adjust the washer(s). ring 04.240 in the helical gear 04.220.
9 Set axial play of the washer 04.110 in relation 18 Set axial play of the helical gear 04.220 in
to the wheel disk 04.090, in accordance with relation to the wheel disk 04.230, in
the instructions given in the respective accordance with the instructions given in the
chapter on the 'axial play of the washer – respective chapter on the 'axial play of the
wheel disk'. helical gear – wheel disk'.
10 For the 16-speed version, put on the 2nd. disk 19 Push the complete helical gear 04.220 onto
04.110* and offset by half a tooth. Push the the main shaft.
spline 04.030 upwards and adjust the disk.
* only for 16 speeds
1327_04D_020_en
EN 1327.751.102d - 2014-11 103 2010-11
ZF-AS Tronic Main Shaft
04.200 04.110
04.210
04.220
04.230
04.240
04.250
04.270
04.280
04.290
04.300 04.020
04.010
04.310
04.350 04.070
04.100 04.030
04.090
04.080
04.040
017890
20 Put on the washer 04.250 and offset by half a 26 Put on the washer 04.310 and offset by half a
tooth. Push the spline 04.030 upwards and tooth. Push the spline 04.030 upwards and
adjust the washer(s). adjust the washer(s).
21 Set axial play of the washer 04.250 in relation 27 Set axial play of the washer 04.310 in relation
to the wheel disk 04.230, in accordance with to the wheel disk 04.290, in accordance with
the instructions given in the respective the instructions given in the respective
chapter on the 'axial play of the washer – chapter on the 'axial play of the washer –
wheel disk'. wheel disk'.
22 Put on the disk 04.270 and offset by half a 28 Push the sliding sleeve 04.3500 onto the main
tooth. Push the spline 04.030 upwards and shaft with the recess upwards. Align the
adjust the disk(s). recess of the sliding sleeve and the main shaft
with one another.
23 Insert the wheel disk 04.290 and the snap
ring 04.280 in the helical gear 04.300. 29 Snap the spline’s 04.340 lug into the blind
hole’s bore.
24 Set axial play of the helical gear 04.300 in
relation to the wheel disk 04.290, in 30 Insert the oil pipe 04.040.
accordance with the instructions given in the
31 For the installation of main shaft, please refer
respective chapter on the 'axial play of the
to the corresponding chapter.
helical gear – wheel disk'.
25 Push the complete helical gear 04.300 onto the
main shaft.
1327_04D_020_en
EN 1327.751.102d - 2014-11 104 2010-11
ZF-AS Tronic Main Shaft
NOTE
For explanations on the setting of the required
axial play of 0 up to 0.10 mm, please refer to the
example of the helical gear 04.080. The same
0.00
procedure applies for the helical gears 04.220,
04.100 04.080
version).
Measurement 1
Measurement 2
0–0.10 mm
3 Put the complete helical gear 04.080 onto a
-0.03
Spiel
Play
04.100
pushed upwards).
04.250
04.270
04.310 04.070
04.090
04.100
04.290
04.210
04.280
04.230 04.110
04.240
04.300 04.080
04.220
028194
Measurement 1
04.110
04.090 04.070
04.010.
028227
1327_04D_040_en
EN 1327.751.102d - 2014-11 106 2010-11
ZF-AS Tronic Main Shaft
Measurement 2
Measurement 2
5 Raise the helical gear 04.080.
NOTE
-0.20
Two rim levers or something similar is
necessitated for raising the helical gear
04.300. 04.010
Bush
6 Measure from the input-end of the main
shaft up to the bush.
mm
Play 0.20Spiel
7 If the measurement value is outside of the
04.080
0,20mm
tolerance range (0.15 up to -0.25mm):
04.110
04.100
028234
1327_04D_040_en
EN 1327.751.102d - 2014-11 107 2010-11
ZF-AS Tronic Countershaft
Countershaft
NOTE
Further disassembly of the countershaft is not
possible, i.e. when the gearing is damaged, you
03.140
CAUTION 03.020
DANGER
10- and 12-speed version
Only touch heated parts when wearing protecti-
016669
ve gloves.
1327_03D_010_en
EN 1327.751.102d - 2014-11 108 2007-05
ZF-AS Tronic Selector Shaft
Selector Shaft
NOTE
06.100
06.140 06.010
06.160
028241
06.140 06.010
06.160
arrangement. 06.010
06.140
CAUTION 06.160
Do not interchange shift forks 06.120 and 06.160;
refer to parts list.
1327_06D_010_en
EN 1327.751.102d - 2014-11 109 2014-09
ZF-AS Tronic Housing II
Housing II
05.010
32.330
32.310
01.400
01.440
01.490
05.110
01.440
03.020
05.040
05.020 03.120
01.480
05.140
05.120
01.460
028197
1327_01D_040_en
EN 1327.751.102d - 2014-11 110 2007-05
ZF-AS Tronic Housing II
05.010
32.330
32.310
01.400
01.440
01.490
05.110
01.440
03.020
05.040
05.020 03.120
01.480
05.140
05.120
01.460
028196
1327_01D_050_en
EN 1327.751.102d - 2014-11 111 2007-05
EN 1327.751.102d - 2014-11 112
SERVICE INFORMATION
Nr. 02_04
Type: ASTRONIC Model: 1327, 1328, 1329, 1337 Date: 2004-02-03
CC list SSO: All Subassembly: Electrics Page 1 of 5
CC list OEM: DAF
CC list customer: --
During the course of further development work, the wiring fastening for the clutch actuator was
modified. The two retaining plates, to which the cable harness was previously attached by means
of cable clips, were discarded in two modification stages. They have been replaced by cable
clamps. A modification related to this has also been undertaken on housing section 2. The new
housing section 2 has been introduced to volume production by modifying the parts list and using
new item numbers.
Components affected:
NEW OLD
Designation Item number Item number Model no. Mod. +)
Housing, short 1327 301 023 1327 301 020 1327 2223D
Fixing device no longer used 1328 301 052 (1x) 1327 2227D
Cable clip 0501 317 817 (1x) 0501 317 817 (2x)
Housing, long 1328 301 060 1328 301 045 1328 2231D
Fixing device no longer used 1328 301 052 (1x) 1328 2234D
1329 2237D
Cable clip 0501 317 817 (1x) 0501 317 817 (2x) 1329 2239D
NEW OLD
Designation Item number Item number Model no. Mod. +)
Fixing device no longer used 1328 301 052 (1x) 1327
Cable clip no longer used 0501 317 817 (1x) 1328 2250D
1329
Fastening 0501 214 086 (1x) --- 1337
Start data:
The start of the parts list modification has been recorded as follows:
Only the start date of December 1, 2003 has been recorded for the modification.
Fixing device
1328 301 052
Fastening
0501 214 086
OLD
Fixing device
1328 301 052
NEW
In the past, the housing seals used on ASTRONIC 2 transmissions have involved a liquid
gasketing agent. Solid seals (metal gaskets) are to be used instead in the future. The thicknesses
of the metal gaskets must be taken into account in the housing assembly. New housings 2 with a
reduced total length have been introduced for this purpose. There are two versions of housing 2,
with different lengths.
The new components, housings and metal gaskets are being launched into volume production
through parts list changes.
Measures:
1st step: Introduction of housing with reduced total length, (raw part as before, see Figure 2).
2nd step: Introduction of housing with reduced total length with optimized raw part (new
pressure die cast part, see Fig. 3).
Components affected:
OLD NEW
Designation Item number Item number Remark
Housing 1328 301 060 1328 301 069 Housing 2, long version
Housing 1327 301 023 1327 301 026 Housing 2, short version
• Seals
Housing sealing face and thrust surface of GP plate at the same height
Figure 1
Figure 2
Step 1
Shoulder can be felt
by machining
Interruption of webbing, visual division of housing’s sealing face from thrust surface of GP plate.
Conversion into new pressure die cast shape.
Date of introduction approx. 3rd quarter of 2005
Figure 3
OLD OLD
Sealing face with Sealing face with
sealing compound gasket
0666 790 054 0666 790 033
Clutch housing GP housing
NEW NEW
Metal gasket Metal gasket
0501 321 442 0501 321 443
Figure 4
Length
dimension L
Gehäuse 2
Start data:
Spare parts:
Liquid gaskets are still available for repairs. The metal gaskets are included in the current sealing
kit 1327 298 001. Old housings 2 will be used up and replaced by kits (each containing one
housing 2 and two metal gaskets). Any old housings 2 still available can be used.
Kits available
Transmissions affected
Measures
Replacement transmissions :
Depending on the parts list, output sensor is either installed on the replacement transmission
or bore hole is sealed with a screw. In this case, the vehicle manufacturer is responsible for
the correct installation of the output sensor.
Table 1
sensor types Í impulse sensor impulse sensor impulse sensor KITAS I KITAS I
"Inductive" "Hall" "Hall" "Hall" Inductive
(standard) (for Telma)
plug connection Í Renk Renk Bajonett Bajonett Bajonett sensor distance
DIN 72585 DIN 72585 DIN 72585 (mm)
Part No. Part No. Part No. Part No. Part No. application according to transmission
type
0501 208 791 0501 209 399 0501 210 855 0501 211 731 --- 19,8 6 S 1600 with/without Intarder,
S 6-85;
9 S 109, 16S 109, 8 S 180 Model
maintenance package;
9 S 75, 9 S 109, 16S 109, 8 S 180
with Intarder,
ECOSPLIT 3 with Intarder
0501 208 792 0501 209 400 0501 210 856 0501 211 732 --- 25 S 5-42, S 6-36, 6 S 850
0501 208 793 --- --- --- 0501 211 842 35 8 S 180 with Telma
0501 208 794 0501 209 402 0501 210 858 0501 211 734 --- 63,2 S 5-42 implemented by Daimler-
Chrysler Wörth
0501 208 795 0501 209 403 0501 210 859 0501 211 735 --- 90 9 S 109, 16S 109, 8 S 180
ECOSPLIT 3 without Intarder
0501 208 796 --- 0501 210 860 --- 0501 211 843 115 6 S 1600, S 6-85
Voith + Telma Voith Telma
0501 208 796 --- --- --- 0501 211 843 115 8 S 180 + Telma Model maintenance
package
--- --- 0501 210 991 --- --- 136,8 8 S 180 + Voith Model maintenance
package
Table 2
Sensor type Í impulse sensor impulse sensor impulse sensor KITAS I KITAS I
"inductive" "Hall" "Hall" "Hall" inductive
(standard) (for Telma)
plug connection Í Renk Renk Bajonett Bajonett Bajonett sensor distance
DIN 72585 DIN 72585 DIN 72585 (mm)
Part No. Part No. Part No. Part No. Part No. Observation
0501 208 793 --- 0501 210 857 --- 0501 211 842 35 applied to ECOMAT 1/2,
with co-axial transmission type and
angle drive with thread bolt
M18x1,5. Co-axial transmission type
depends on the output cover version.
0501 208 794 0501 209 402 0501 210 858 0501 211 734 --- 63,2 applied to ECOMAT 1/2,
with co-axial transmission version
and thread bolt M18x1,5. Not possi-
ble if angle drive applied. Co- axial
transmission type depends on the type
of output cover.
Table 3
sensor type Í impulse sensor impulse sensor KITAS I Neutral
"Hall" "Hall" "Hall" position
(standard) switch
plug connection Í Renk Bajonett Bajonett sensor distance
DIN 72585 DIN 72585 (mm)
Part No. Part No. Part No. Part No. Observation
0501 209 399 0501 201 855 0501 211 731 --- 19,5 with
Intarder threaded bolt sealed with
0501 209 403 0501 210 859 0501 211 735 --- 90 without Screw plug 0768 406 235
Intarder consists of: ×
0501 210 059 --- Screw plug 0636 302 021
(M18x1,5)
+ sealing 0634 801 055
Within the context of technical further development, the "macromelt casting" method was re-
placed by the introduction of a plastic cap with a heat shrink tubing for traction relief and an addi-
tional fastening of the cable with a cable clamp, namely for the plug connection of the clutch ac-
tuator (CA) to the transmission actuator (TA).
Components affected:
Author: D. Bentele verantwortlich: i.A. Niessen Approved: i.V. Stauber Checked: i.V. Thollot
Dept. TTC-T +49 7541 - 77 3767 Fax +49 7541 - 77 90 3767 Email: dieter.bentele@zf.com
Customer Service / After Sales Technical Service for Truck and Bus Driveline Technology
Delivery Address: ZF Friedrichshafen AG, Zeppelin-Werftgelände 70, 88045 Friedrichshafen, Germa-
ny
© ZF Friedrichshafen AG e
EN 1327.751.102d - 2014-11 127
SERVICE INFORMATION
No. 12_03 Seite 2 of 4
Measure:
• Introduction of a cap (plastic folding part with heat shrink tubing for traction relief), conse-
quently, "macromelt casting" can be dispensed with.
Foldable connector
with heat shrink
tubing
• Introduction of a cable catch with a cable clamp to reduce the vibration-induced loads.
The original screw is used as fastening screw (same screw length).
In conjunction with a new clutch actuator, the new cable clamp must
be installed!!!
When ordering the clutch actuator, the cable clamp has to be ordered as well.
Note:
• No preventive replacement of the clutch actuator.
• Spare parts of the clutch actuator on stock with produced with the "macromelt casting"
method can be used up.
Note:
If a new clutch actuator is installed on a transmission for which no 0501.327.934 cable clamp is
available, the following repair kits must essentially be used.
Due to missing cable clamps, electric contact problems may occur in conjunction with the new
clutch actuator because a traction relief is not available.
Introduction of modification
Transmissions on stock:
Damage coding:
Use the damage coding stated below only in the case of diagnosis code 119.
For the warranty claim, please present the corresponding verification regarding the diagnosis
code 119 (e.g. diagnosis extract, .STA file, ... ).
Validity:
Optimizations Kitas 2+
Within the framework of new legal requirements, the "Kitas 2" impulse sensor was changed to "Ki-
tas 2+". The introduction was implemented transmission-specifically in the course of 2012 (see
Table 1). With the introduction of Kitas 2+, we partly had field complaints regarding sporadic faults
of the speedometer signal. This led to optimizations at the impulse sensor and to the introduction
of "Kitas 2+ optimized" as a consequence (see Table 2 for launch data). The introduction of the
production-related improvements was carried out under the same part number.
Author: D.Bentele i.A.. Bentele Approved: i.V. Stauber Checked: i.V. Thollot
Dept. LKS-T +49 7541 - 77 3767 Fax +49 7541 - 77 90 3767 Email: dieter.bentele@zf.com
Customer Service / After Sales Technical Service for Truck and Bus Driveline Technology
Delivery Address: ZF Friedrichshafen AG, Zeppelin-Werftgelände 70, 88045 Friedrichshafen, Germany
© ZF Friedrichshafen AG e
EN 1327.751.102d - 2014-11 131
SERVICE INFORMATION
No. 13_03 Page 2 of 4
Components concerned:
Measure:
In case of complaint, the impulse sensor has to be checked and in the field, only spare parts of the
"Kitas 2+ optimized" design may be installed. Identification of the design or differences between
"Kitas 2+" and "Kitas 2+ optimized" can be made according to the following characteristics:
The "Kitas 2+" has a serial no. starting from 1000 0000
(see picture).
The "Kitas 2+ optimized" has a serial no. starting from 1046 2061
(see picture).
Change/Launch data:
Kitas 2+
Model As of product
Transmissions number Date Transmission type
1346 156227 CW 19/2012 Ecolite (6 (A)S800/1000
1347 030521 CW 19/2012 Ecolite (6(A)S700
1307 308922 CW 19/2012 Ecolite S5-42
1341 730457 CW 22/2012 Ecosplit 16 S 1820
1343 727149 CW 19/2012 Ecosplit 16 S 2520
1355 726058 CW 19/2012 Ecosplit 16 S 1830
1356 725812 CW 19/2012 Ecosplit 16 S 2330
1367 725817 CW 19/2012 Ecosplit 16 S 2230
1353 752550 CW 19/2012 AS Tronic 12AS2330
1353 750968 CW 19/2012 AS Tronic 12AS2331
1324 157912 CW 26/2012 New Ecomid 9S110, 9S1310
1336 37651 CW 26/2012 AS Tronic mid 12AS1220 – 12AS1620
Kitas 2+ optimized
Transmissions on stock.
Damage coding:
Validity:
Alle Alle
ZF Services OEM/Customer
As part of technical further development, a new release fork with an optimized plastic bush has been
developed for AS Tronic transmissions and introduced into volume production.
Thanks to this innovation, jolting during gear engagement or maneuvering can be reduced, if neces-
sary. The new bush differs from the one previously in use in terms of material and shape.
Note:
Release fork 1328.268.013 can replace the entire previous release fork 1328.268.012, component
parts are not compatible.
Author: K.Dillmann i.A.. Rothhaas Approved: i.V. Stauber Checked: i.V. Thollot
Dept. TTCT2 +49 7541 - 77 4089 Fax +49 7541 - 77 90 4089 Email: klaus.dillmann@zf.com
Customer Service / After Sales Technical Service for Truck and Bus Driveline Technology
Delivery Address: ZF Friedrichshafen AG, Leutholdstr. / Tor 4, D-88045 Friedrichshafen
© ZF Friedrichshafen AG d
EN 1327.751.102d - 2014-11 135
SERVICE INFORMATION
No. 14_07 Page 2 of 6
Components concerned:
NEW OLD
Designation Material number Material number
Release fork 1328.268.013 1328.268.012
Transmissions on stock:
Not affected
Transmission parts
list Product number Date Parts list amendment
Z000188991
1327.036.029 829218 2013-05-03
2013-05-02
Actions:
After verification of complaints such as "engagement jolt" or "clutch judder", it should first be exam-
ined whether cleaning and lubricating the clutch release mechanism can remedy the problem. Ob-
serve instructions on pages 4 to 6, depending on the design.
Should these measures not help to remedy the problem, the costs for installation of the new release
fork can be covered by the warranty.
For this purpose, use a data logger to record the complaint and obtain a confirmation via the ticket
system. The signals to be recorded are
n_mot
n_sek
sensor(0).messwert
sensor(3).messwert
s_kup
s_kup_abs
z_sys_status_2_ufb
z_kupp_berech_fall
sollgang_ufb
Damage coding:
Validity:
Grease Input
Grease Clutch
Shaft Splines
Fork Pivot Shaft
(Light Coat)
Grease Push-Rod
Pocket and both
ends of Push-Rod
Approved ZF Lubricant
Optimol Olista Longtime
ZF no. 0671 190 165
(100 gr.)
!! Attention !!
DO NOT Grease Release Bea-
ring to Input Cover Hub
Surfaces. This surface is coated
with Teflon.
!!Cleaning process!!
Please, do not wash
!! Attention!! pregreased components
The pivot shaft has clearance (Bush, roller bearings,
when it is mounted inside the release bearing)
pregreased bush of the roller
fork. Additional greasing is not Approved ZF Lubricant
necessary of the bush and the Optimol Olista Longtime
roller surfaces ZF no. 0671 190 165
(100 gr.)
Introduction of New Shaft Sealing Ring at the Output With Additional Axial Dust Lip
In the course of technical further development and in order to increase the robustness against con-
taminations from outside at the output end, a shaft sealing ring with an additional axial dust lip was
introduced. This axial dust lip in combination with a geometrically adapted output flange generates a
labyrinth effect that can reduce the risk of leakage due to dust entering from outside.
The introduction includes the Ecomid, AS Tronic mid, Ecosplit, and AS Tronic product families.
Note:
For all products, the outer circumference of the new shaft sealing ring has to be coated with spirit
(ethanol) during the repair process. The sealing lip has to be greased slightly.
The assembly dimension of the shaft sealing ring is preset by the punch.
The shaft sealing ring has to be exchanged in case of leakage. The output flange has to be ex-
changed only in case of damage.
Author: K.Dillmann i.A. H.Hölz Approved: i.V. Stauber Checked: i.V. Thollot
Dept. TTCT1 +49 7541 - 77 4089 Fax +49 7541 - 77 90 4089 Email: klaus.dillmann@zf.com
Customer Service / After Sales Technical Service for Truck and Bus Driveline Technology
Delivery Address: ZF Friedrichshafen AG, Leutholdstr. / Tor 4, D-88045 Friedrichshafen
© ZF Friedrichshafen AG d
EN 1327.751.102d - 2014-11 141
SERVICE INFORMATION
No. 14_09c Page 2 of 10
ECOMID:
Fig. 1: Section of new shaft sealing ring in Ecomid Fig. 2: Comparison of tool old-new (Ecomid solo)
Components concerned:
OLD NEW
Designation Item number Item number
Shaft sealing ring 0734.319.459 0734.300.421
Comment:
The output flange Ø150 is a completion consisting of output flange and protecting plate. The output
flange is not changed, however, the protection plate is changed from 1324.338.001 to 1324.338.002.
Interchangeability:
Combination
new flange + old shaft sealing ring possible (1)
old flange + new shaft sealing ring possible (2)
Comment:
The interchange combinations are possible, however, they only make sense to a limited extent in
practice.
(1) The labyrinth effect can only be achieved in combination with a new shaft sealing ring.
(2) Functioning of the axial dust lip for new shaft sealing ring can only be guaranteed in combi-
nation with labyrinth of new flange.
Tool:
Tool new
Press-in mandrel 1X56 197 444 (1)
Press-in mandrel 1X56 197 428 (2)
(1) Tool for non-Intarder transmissions and for transmissions with IT3
(2) Tool for transmissions with IT2
Transmissions on stock:
Not affected
Attention:
Introduction of modification:
ECOSPLIT:
Fig. 3: Section of new shaft sealing ring in Ecosplit Fig. 4: Comparison of tool old-new (Ecosplit solo)
Components concerned:
OLD NEW
Designation Item number Item number
Shaft sealing ring 0734.319.459 0734.300.421
Emergency steering
6091.315.008 6091.315.009
pump housing
Interchangeability:
Combination
new flange + old shaft sealing ring not possible
old flange + new shaft sealing ring not possible
Tool:
Tool new
Press-in mandrel 1X56 197 443 (1)
Press-in mandrel 1X56 197 428 (2)
(1) Tool for non-Intarder transmissions and for transmissions with IT3
(2) Tool for transmissions with IT2
Transmissions on stock:
Not affected
Attention:
Introduction of modification:
ASTRONIC MID:
Fig. 5: Section of new shaft sealing ring in AS Tronic mid Fig. 6: Comparison of tool old-new (AS Tronic mid)
Components concerned:
OLD NEW
Designation Item number Item number
Shaft sealing ring 0734.319.459 0734.300.421
Comment:
The output flange Ø150 is a completion consisting of output flange and protecting plate. The output
flange is not changed, however, the protection plate is changed from 1324.338.001 to 1324.338.002.
Interchangeability:
Combination
new flange + old shaft sealing ring possible (1)
old flange + new shaft sealing ring possible (2)
Comment:
The interchange combinations are possible, however, they only make sense to a limited extent in
practice.
(1) The labyrinth effect can only be achieved in combination with a new shaft sealing ring.
(2) Functioning of the axial dust lip can only be guaranteed for the new shaft sealing ring in
combination with the labyrinth of the new flange.
Tool:
Tool new
Press-in mandrel 1X56 197 443
Transmissions on stock:
Not affected
Attention:
Introduction of modification:
ASTRONIC:
Fig. 7: Section of new shaft sealing ring in AS Tronic Fig. 8: Comparison of tool old-new (AS Tronic solo)
Components concerned:
OLD NEW
Designation Item number Item number
Shaft sealing ring 0734.319.459 0734.300.421
Emergency steering
6091.315.008 6091.315.009
pump housing
Interchangeability:
Combination
new flange + old shaft sealing ring not possible
old flange + new shaft sealing ring not possible
Tool:
Tool new
Press-in mandrel 1X56 197 443 (1)
Press-in mandrel 1X56 197 428 (2)
(1) Tool for non-Intarder transmissions and for transmissions with IT3
(2) Tool for transmissions with IT2
Transmissions on stock:
Not affected
Attention:
Introduction of modification:
Tool overview:
For the efforts invested, remuneration for 2 hour working time can be obtained via the standard war-
ranty claim (WC) filing process.
Damage coding:
294
Shaft sealing ring 0734.300.421 049 (sealing lip) 800 (leaking)
(contamination)
*) = in accordance with the Damage Coding catalog no. 1200 754 001 (German), no. 1200 754 101 (English), 2008 edition
Validity:
During the course of further development work, the splitter group synchronizer unit in the
ASTRONIC 2 transmission has been further optimized. The design of the synchronizer rings and
plate has been changed. To ensure uniformity, the synchronizer rings and plate of the
synchronizer unit in the ASTRONIC 1 transmission have also been modified.
Components affected:
ASTRONIC 1
NEW OLD
Scope of parts Modular system PL 1314 202 Modular system PL 1314 202
089 082
consisting of: consisting of:
Pos. Designation Qty. Item number Item number
110 Synchronizer ring 1 1328 302 084 1328 302 111
120 Pin 3 0731 201 698 0731 201 698
150 Gear shift sleeve 1 1314 302 188 1314 302 188
160 Bolt 3 1328 302 016 1328 302 016
180 Plate 1 1328 302 109 1328 302 015
190 Circlip 1 0730 505 158 0730 505 158
210 Pin 3 0731 201 699 0731 201 699
220 Synchronizer ring 1 1328 302 085 1328 302 112
240 Compression spring 3 0732 040 385 0732 040 385
250 Cylinder roller 3 0635 470 046 0635 470 046
ASTRONIC 2
NEW OLD
Scope of parts Modular system PL 1328 202 Modular system PL 1328 202
039 016
consisting of: consisting of:
Pos. Designation Qty. Item number Item number
110 Synchronizer ring 1 1328 302 084 1328 302 111
120 Pin 3 0731 201 698 0731 201 698
150 Gear shift sleeve 1 1328 302 064 1328 302 064
160 Bolt 1 1328 302 072 1328 302 072
180 Plate 1 1328 302 109 1328 302 015
210 Pin 3 0731 201 699 0731 201 699
220 Synchronizer ring 1 1328 302 086 1328 302 113
240 Compression spring 3 0732 040 385 0732 040 385
250 Cylinder roller 3 0635 470 046 0635 470 046
NEW OLD
Scope of parts Modular system PL 1328 202 Modular system PL 1328 202
040 017
consisting of: consisting of:
Pos. Designation Qty. Item number Item number
110 Synchronizer ring 1 1328 302 084 1328 302 111
120 Pin 3 0731 201 698 0731 201 698
150 Gear shift sleeve 1 1328 302 064 1328 302 064
160 Bolt 1 1328 302 072 1328 302 072
180 Plate 1 1328 302 109 1328 302 015
210 Pin 3 0731 201 699 0731 201 699
220 Synchronizer ring 1 1328 302 085 1328 302 112
240 Compression spring 3 0732 040 385 0732 040 385
250 Cylinder roller 3 0635 470 046 0635 470 046
Measures:
In the event of repairs, the synchronizer rings and plate should always be replaced in complete
sets. Old and new components must not be combined with one another. Old parts may be used
up.
Spare parts:
If repairs are undertaken, 3 synchronizer kits are available and have to be ordered under the
relevant kit number.
Start data:
Noise reduction through axial setting of clearance for disks/shims and gears in AS Tronic
transmissions
Within the context of noise reduction, we will, in the near future, enable the following settings:
Constant gear 2 to wheel disk on the input shaft (via the OTK securing ring);
Gears to wheel disks on the main shaft (via OTK securing ring);
Main shaft disks to wheel disks on the main shaft (via OTK main shaft disks).
For selection purposes, technical kits (OTKs) for securing rings and main shaft disks have been
introduced.
Measures:
Constant gear 2 to wheel disk on the input shaft (via the OTK securing ring);
is done with 12-speed and 16-speed transmissions.
Gears to wheel disks on the main shaft (via OTK securing ring);
is done with 12-speed and 16-speed transmissions.
Exception:
In the case of transmissions belonging to the model ZF Maxton (FreedomLine: 1338, 1339, and
1327 with nickel-coated disks) no setting of the main shaft disks to the wheel disks on the main
shaft is done; no OTKs have yet been set up. The nickel-coated disks used so far will still be in-
stalled.
a) Transmissions to be repaired -> where the wheel disks and the main shaft disks have
already been set;
b) Exceptional cases where noise-related complaints have been filed -> upon prior
agreement with Friedrichshafen After-Sales Service, Technical Customer Service,
LKS-T dept.
Note:
The main shaft disks (item no.: 04.070, 04.210, 04.270) will not be replaced by the OTK mains
haft disks. The snap ring (circlip) of the constant gear 2 on the input shaft, item no. 02.260, will
not be replaced by an OTK securing ring but with the previously used snap ring no. 0730 513
973 (thickness: 2.50) (also refer to Figures 3 and 4, Page 6).
For proceedings relating to clearance setting, please refer to illustrations in the documentation.
“Technical Annual Seminar 2005, no. 04, ZF_AS Tronic in the Truck, Charts 16 to 21.”
Components affected:
Main Shaft
NEW: OLD:
Designation Part number Part number Comment
12-speed, standard,
Main Shaft 1327 304 032 1327 304 025
ZF Maxton (FreedomLine)
Main shaft 1329 304 012 1329 304 009 12-speed, 1329 model
OTK securing ring gears for wheel disks on the main shaft, for all 12-speed and 16-speed
transmissions
NEW: OLD:
Item Designation Part number Part number Comment
Securing ring -- OTK (2.50 up to 2.70)
0769 144 299
consisting of Drawing no.: 0730 514 005
04.100 Snap ring 0730 513 973 0730 513 973 2.5
04.240 Snap ring 0730 514 006 -- 2.55
04.280 Snap ring 0730 514 007 -- 2.60
Snap ring 0730 514 008 -- 2.65
Snap ring 0730 514 009 -- 2.70
OTK securing ring for constant gear 2 to the wheel disk, for all 12-speed and 16-speed
transmissions
NEW: OLD:
Item Designation Part number Part number Comment
Securing ring (2.50 to 2.80)
0769 144 298 --
consisting of Drawing no.: 0730 514 005
Snap ring 0730 513 973 0730 513 973 2.50
Snap ring 0730 514 006 2.55
02.290 Snap ring 0730 514 007 2.60
Snap ring 0730 514 008 2.65
Snap ring 0730 514 009 2.70
Snap ring 0730 514 010 2.75
Snap ring 0730 514 011 2.80
OTK main shaft disks to wheel disks on the main shaft, only for 12-speed transmissions
(not the ZF Maxton model no.: 1338, 1339, and 1327 with nickel-coated disks)
NEW: OLD:
Item Designation Part number Part number Comment
Disk -- (7.00 to 7.20)
04.070 0769 143 685
consisting of Drawing no. 1314 304 014
04.110
04.210 Disk 1314 304 008 1314 304 008 7.00
04.250 Disk 1327 304 033 -- 7.05
04.270 Disk 1327 304 034 -- 7.10
04.310 Disk 1327 304 035 -- 7.15
Disk 1327 304 036 -- 7.20
Start data:
The changes will be introduced into the parts list (PL) system as follows:
Spare parts:
Figure 1
04.242
04.282 04.252
04.112
04.102
04.312
Figure 2
xx.xxx created (yellow color) and established with * / those marked item numbers do include information on
clearance setting in the parts list
Figure 3
K1K1
K2
Figure 4
02.292
K1
K2
xx.xxx created (yellow color) and established with * / those marked item numbers do include information on
clearance setting in the parts list
Note:
The OTKs for the main shaft disks on the main shaft are not downward compatible since the re-
cess for the setting had to be enlarged respectively on the main shaft.
Old main shaft disks can be mounted to the new main shaft.
New main shaft disks (OTK) cannot be mounted to the old main shaft.
Changes in the nominal dimension of the groove’s thickness on the main shaft no. 1327 304 032
and 1329 304 012.
Figure 5
Main shaft disk in the OTK no. 0769 143 685. Securing ring in the OTK no. 0769 144 298 /
299.
Figure 6 Figure 7
Clearance settings:
Clearance of main shaft disk to wheel disk Clearance of gear to wheel disk
Figure 8
Securing ring of the OTK
Wheel disk
Wheel disk
Validity:
The present Service Information is valid for an unlimited period as of February 01, 2006.
EN 1327.751.102d - 2014-11
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