Repair Instructions: Zf-Astronic 10-, 12-And 16-Speed Version Without ZF-Intarder Level 3

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REPAIR INSTRUCTIONS

ZF-ASTRONIC
10-, 12- and 16-speed version without ZF-Intarder
Level 3

TRUCK, BUSES
Copyright © ZF Friedrichshafen AG

This document is protected by copyright. Complete or partial reproduction


or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.

This document is a translation of the German original.


ZF-AS Tronic Table of Contents

Page

List of Changes .................................................................................................................................. 6


Preface............................................................................................................................................... 7
Product Designation................................................................................................................... 8
Transmission Overview .............................................................................................................. 9
Safety Instructions ............................................................................................................................. 10
General Safety Instructions ........................................................................................................ 10
Signal Words and Symbols......................................................................................................... 14
Instructions for Repair and Assembly ................................................................................................ 15
General Notes ............................................................................................................................ 15
Cleaning Parts ........................................................................................................................... 16
Reusing Parts............................................................................................................................. 16
Reworking Parts......................................................................................................................... 17
Disassembly............................................................................................................................... 17
Assembly ................................................................................................................................... 18
Tightening Torques ............................................................................................................................ 19
Consumable Material......................................................................................................................... 20
Setting Data ....................................................................................................................................... 21
Special Tool........................................................................................................................................ 23
Diagnosis Tool.................................................................................................................................... 30
Technical Data.................................................................................................................................... 31
Interfaces with the Vehicle ................................................................................................................ 32
ESD Protection ................................................................................................................................... 33

Preparatory Work............................................................................................................................... 34

Clutch Actuator .................................................................................................................................. 36


Removing clutch actuator........................................................................................................... 36
Pushrod ..................................................................................................................................... 37
Set pushrod ............................................................................................................................... 38
Bleeding clutch actuator ............................................................................................................ 39
Mounting clutch actuator ........................................................................................................... 40

Output Flange .................................................................................................................................... 42


Removing output flange ............................................................................................................. 42
Mounting output flange.............................................................................................................. 42
Removing the Yoke..................................................................................................................... 43
Mounting the Yoke ..................................................................................................................... 43

Output Cover ...................................................................................................................................... 44


Removing the output cover ........................................................................................................ 44
Fitting the output cover .............................................................................................................. 45

PTO Cover .......................................................................................................................................... 47


Removing the PTO cover ............................................................................................................ 47
Installing the PTO cover.............................................................................................................. 47

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

Place transmission without RC (planetary range) in horizontal position . . . . . . . . . . . . . . . . . . . . . 64

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

Putting transmission in vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73


Removing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Install clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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

Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100


Dismantling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Set axial play of the helical gear in relation to the wheel disk . . . . . . . . . . . . . . . . . . . . . . . . . 105
Set axial play of the washer in relation to the wheel disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Disassembling the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Mounting the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Selector Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109


Dismantling the selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Assembling the selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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

Index Date of issue Initiator Remark


- 2002-01 LKS-T dept. First edition
a 2004-02 LKS-T dept. The scope of validity of the ZF-AS Tronic transmission Repair Manual was
extended to 10-, 12-, and 16-speeds.

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

c 2010-11 LKS-T dept. New model pages, conversion factors,


List with tools: 1T66 154 240 replaced by 1T66 160 657.
Added in the screw-on adapter 1T66 160 650.
Tightening torque of screw (6) changed from 22 Nm to 35 Nm.
Tightening torque of screw 68.130 changed from 115 to 95 Nm.

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.

Object of documentation is a volume-produced ZF product. State of design acc. to date of issue.

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.

Type designation e. g. 12 AS 2130 TO

12 AS 21 3 0 T O

Application-specific extensions possible

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)

Torque limit in [Nm] = Factor x 100

Automatic transmission system

Number of gears

* In the event of a combination, the lowest digit is used

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.

Product family 3 Product family 4


12 AS 1630 TD 12 AS 2140 TD
12 AS 1930 TD 12 AS 2340 TD
12 AS 2130 TD 12 AS 2540 TD
12 AS 2330 TD 12 AS 2540 TO
16 AS 2230 TD 12 AS 2740 TO
12 AS 1930 TO 12 AS 2940 TO
12 AS 2130 TO 12 AS 3140 TO
12 AS 2330 TO
12 AS 2530 TO
16 AS 2630 TO

General instructions for these Repair Instructions:


▪ The ZF order numbers listed in the instructions apply to the ZF standard. For binding ZF order numbers,
please reference the spare parts catalog.
▪ The parts list [BoM] no. given on the transmission type plate is identical with the order number in the
spare parts catalog.

1327_50D_080_en
EN 1327.751.102d - 2014-11 9 2014-04
ZF-AS Tronic Safety Instructions

Safety Instructions

General safety instructions

Read all safety instructions. Failure to comply with safety instructions may lead to material damage, serio-
us injury, possibly even to death.

Intended use / liability / guarantee / warranty


The ZF product is exclusively designed for the purpose specified in the contract and agreed on at the
time of delivery. Any other or extended form of use does not comply with this definition of intended use.
ZF Friedrichshafen AG is not liable for any damage resulting from this. Instead, the user is fully liable for
this risk. The intended use includes compliance with this documentation and other applicable documents
in order to avoid malfunctions and damage in operation.

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

Handling operating fluids and consumables


Increased risk of injury at contact with heated, cooled down, or caustic operating fluids and consumables
(e. g. lubricants, cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources, do not smoke.

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

Signal words and symbols

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

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.

Cleaning the ZF product prior to disassembly

▪ 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

▪ Thoroughly clean all reusable components after disassembly.


▪ Thoroughly remove sealing compound residue on sealing faces or retaining agent residue, e. g. in
tapped holes or on splines.
▪ Thoroughly clean joining surfaces and check for damage.
▪ Thoroughly wash out blind holes and blind hole threads and remove contamination.
▪ Lubricating bores, oil clearance holes, oil ducts, bores for oil press fits, and lubricating grooves must be
free from dirt, preservative, and foreign matter. If possible, blow through with compressed air. Check
for free passage.
▪ Hose assemblies, oil tubes, and joining elements must be free from dirt, oil, and chafe marks. Dirty or
oily parts must be thoroughly cleaned and, if necessary, blown through with compressed air. Replace
damaged parts.
▪ Thoroughly clean all cavities and reliefs.
▪ All edges which can cause chip formation during assembly or represent a risk of injury for the fitter
must be deburred.
▪ Carefully remove burrs or other similar rough surfaces using a honing stone.
▪ Thoroughly remove preservative from new parts (e. g. on bearing).

Reusing parts

Authorized, specialized staff assess whether parts can be reused.


▪ Replace parts if they are damaged.
▪ Replace parts if they are worn, e. g. rolling bearings, multidisks, thrust washers, etc.
▪ Replace parts if they have a permanent deformation.
▪ Replace parts if they have been overheated during operation or during disassembly.

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

Authorized, specialized staff assess whether parts need to be reworked or replaced.


Minor damage on reusable components can be removed and reworked with suitable special tools if the
component’s function is not impaired.
Minor damage includes:
▪ Indentation marks on sealing faces
▪ Score marks or burrs caused by the disassembly of the ZF product
▪ Frictional corrosion
▪ Paint and rust damage

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.

* refer to Operating supplies and auxiliary materials

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.

Surface condition of screws/nuts:


Heat-treated blackened finish and oiled or galvanized and oiled.

The bolts are tightened using a calibrated torque wrench.

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

Coarse thread Fine thread

Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for


Screw 8.8 10.9 12.9 Screw 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12

M4 2.8 4.1 4.8 M8x1 24 36 43


M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14 16.5 M10x1 52 76 89

M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145

M12 79 115 135 M14x1.5 135 200 235


M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490


M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250


M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800


M30x1.5 1550 2200 2550
M30x2 1500 2100 2500

Status: August 1991

EN 1327.751.102d - 2014-11 19
ZF-AS Tronic Consumable Material

Designation Name Quantity Application Remarks


ZF part number approx.

Grease For example: 1 gram Shaft sealing ring 02.510


0750 199 019 Spectron FO 20 1 gram Grooved ring 02.630
2 grams Shaft sealing ring 31.080

Grease Olista Longtime 3EP 5 grams Shaft sealing rings 68.060/140


0671 190 050 3 grams Bush 68.130
5 grams Locating face Release fork 68.060
Release bearing 68.050
3 grams Ball cup 68.060/120

Sealing compound 1215 gray 3 grams Sealing surface housing I / housing II


0666 790 054 (depends upon the version, also refer to
chapter on “Mounting Housing I“)

Sealing compound No. 574 Sealing surface


0666 790 033 3 grams Connection plate / Housing I
0.5 grams Cover 31.050
0.5 grams Sealing cap 32.010/050
1 gram Range change housing / Housing II
(depends upon the version, also refer to
chapter on “Fitting the output cover“
and “Mounting RC Housing“)

Jointing compound No. 241 0.5 grams Hex-head screw 02.670


0666 690 017

Jointing compound No. 262 0.5 grams Ball bolt 06.080


0666 690 022

Anti-corrosion oil For example Pump shaft 02.560


0750 199 008 MZK 150 1 ml Rotor 02.550

Transmission oil according to ZF List refer to: Oil fill transmission


of Lubricants TE-ML 02 Type plate

NOTE: Inquire size of containers before placing any orders!

1327_92D_010_en
EN 1327.751.102d - 2014-11 20 2014-09
ZF-AS Tronic Setting Data

Designation Specification Measuring device Remarks

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.

Screw plug 31.200, 31.190 60 Nm Torque wrench

Remove screw plug 31.090 15 Nm Torque wrench

1327_92D_020_en
EN 1327.751.102d - 2014-11 21 2010-11
ZF-AS Tronic Setting Data

Designation Specification Measuring device Remarks

Hex-head screw 32.550 120 Nm Torque wrench

Hex-head screw 31.370 50 Nm Torque wrench

Hex-head screw 68.130 105 Nm Torque wrench

Impulse sensor 31.230, 31.260 45 Nm Torque wrench Assemble without Loctite

1327_92D_020_en
EN 1327.751.102d - 2014-11 22 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 137 795 Alternatively:


Order no.
1X56 137 391
3-strand chain
1 for lifting the transmission 1
ordinary

1T66 160 657 (M10) commercial


1T66 160 650 (M16x1,5) Eyebolt
1T66 160 494
2 Screw-on adapter 2 (M10) for
Only crack-inspected screws with through holes.
quality 10.9 and higher may be
used.

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)

1X56 136 740 Chapter


“Countershaft”
Gripper
4 Extract tapered roller bearing of 1
countershaft (in conjunction with
the basic device 1X56 122 304)
10_001726_01

1X56 122 304 Chapter


“Housing I“ and
Basic equipment “Countershaft”
5 combined with tool 1
1X56 136 740 and/or 1X56 138 195

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 23 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 122 314 for ball bearings with 10 balls


1X56 138 295 for ball bearings with 11 balls Chapter
“RC Housing”
hydr. variant
Extractor for ball bearings 31.020 upon request
6 from planet carrier (removal) 1
1X53 188 009
was replaced by
Caution: Both extractors are not 1X56 138 295
suitable for use with impact wrenches.

1X56 138 087 Chapter


“Planet Carrier“

Extractor
7 Bearing inner ring 32.310/1 1
at the planet carrier

1X56 138 207 Chapter


“RC Housing”
Bracket
8 Assembly of range change 6
synchronization

1X56 138 208 Chapter


“Putting
Fixing bolt transmission
9 R gear, secure reversing gear 2 without RC in
vertical position”

1X56 138 203 Chapter


“Putting
Fixing plate transmission
10 Fixing and centering the main shaft 1 without RC in
vertical position”

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 24 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

Version A Version B
1X56 138 095 Chapter
“Transmission
Actuator”
Setting fixture
11 for selector rails 1 Only variant B is
now available.

1X56 138 215 Chapter


“Clutch Release
Adapter Mechanism”
12 for assembly of bushes and shaft 2 (Version A)
sealing rings of release fork

1P01 181 850 Alternatively:


4 supports
1X56 138 443
Assembly block (stationary) (Refer to figure
13 in conjunction with basic plate 1 no. 3)
1X56 138 297 and clamping plate
1X56 139 608

1X56 137 450 Alternatively:


4 supports
(optional) 1X56 138 443
(Refer to figure
14 Transmission assembly stand 1 no. 3)
(mobile)
in conjunction with an adapter
1X56 138 232

1X56 138 063 Chapter


“RC Housing”
Drift key and “Housing I”
15 for driving out fitting pins 1

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 25 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 138 097 Chapter


“Input Shaft”

Mounting plate Assembly aid


16 Synchronization 02.200 1

1X56 138 081 Chapter


“Input Shaft”
Assembly sleeve
17 Synchronization 02.200 3

1X56 138 205 Chapter


“Main Shaft”
Assembly fixture
18 Pipe 04.020 on main shaft 1

1X56 138 191 Chapter


“Housing I“

Intermediate piece (thrust piece) commercial


19 For protecting the shaft when 1
removing it.

1X56 138 195 Chapter


“Housing I“
Extracting fixture
20 Tapered roller bearings 02.080 1
on the input shaft

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 26 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 138 200 Chapter


“Housing I“

Assembly tool Alternatively:


21 Centering oil tube 01.430 1 M4 dowel pin
with nut

1X56 138 201 Chapter


“Housing I“

Assembly tool Alternatively:


22 Centering oil tube 01.420 1 M8 dowel pin
with nut

1X56 138 216 Chapter


“Housing I“ and
Fixture “Shaft Pack”
23 Lifting and mounting fixture for 1
the assembly or disassembly of
the input shaft

1X56 045 808 Chapter


“Housing I“
Mounting fixture
24 Input shaft in conjunction 1
with 1X56 138 216

1X56 138 197 Chapter


“Shaft Pack“ and
Assembly fixture “Input Shaft“
25 1

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 27 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 099 063 Chapter


“Connection
Adapter Plate”
26 1
For shaft sealing ring with release
flange

1X56 137 124 Chapter


“Output Cover”
Adapter
27 For installing the shaft sealing ring 1
at the output cover (in conjunction
with a spacer ring 1X56 138 189)

1X56 138 189 Chapter


“Output Cover”
Spacer ring
28 For shaft sealing ring 105x125x12 1
at output cover (in connection with
adapter 1X56 137 124)

1X56 138 420 Chapter


“Planet Carrier“
Extracting fixture 1
29 Clutch body 32.280 at the planet
carrier in conjunction with the
pressure plate 1X56 138 424

1X56 138 424 Chapter


“Planet Carrier“
Pressure plate 1
30

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 28 2014-09
ZF-AS Tronic Special Tool

Fig. Figure Order no. Application Qty. Remarks


no.

1X56 138 426 Chapter


“Planet Carrier“
Fork 1
31 Compress the securing ring 32.290

1X56 138 546 Chapter


“Clutch Release
Press-in mandrel 1 Mechanism”
32 For assembly of cam rollers (Version B)
of the release fork

1X56 138 547 Chapter


“Clutch Release
Support 1 Mechanism”
33 For the release fork (Version B)

Chapter
240

Sketch:
“Transmission
M10

64
60.5

Actuator”
75

11

M10

112

Setting aid 1
74
15

34
ø9 H7 ø9H7

for piston rods on transmission


100.1

Assembly aid
200.1 14 2120.1
ø8.70.1

actuator
ø9r6

25

2x45 2x45
37.50.1

40

1X56 197 443 Chapter


“Output cover”

Adapter 1
35 for shaft sealing ring 0734 300 421

10_001212_01

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_040_en
EN 1327.751.102d - 2014-11 29 2014-09
ZF-AS Tronic Diagnosis Tool

Image Figure Order no. Application Qty. Comments


No.

6008 208 550 1 only for


ZF-TESTMAN Service Edition ZF Sales and
Service
Scope of supply: Organizations
1 - 6008 208 100 ZF-TESTMAN
with DPA05 + cable
- 6008 208 500 Software
(Service Edition)

6008 208 500 1 only for


ZF Sales and
Service
Software Organizations
2 (ZF-TESTMAN Service Edition with
license)

6008 208 450 1 Single-user


ZF-TESTMAN IAM edition for license,
all applications
ZF customers
3 Scope of supply:
- 6008 208 100 ZF-TESTMAN
with DPA05 + cable
- 6008 208 400 Software
(IAM edition)

6008 208 400 1 Single-user


license,
all applications
Software
4 (ZF-TESTMAN IAM edition with
license)

6008 207 003 1 Adapter cable for


programming and
configuration
Table mode adapter
purposes and for
5 ZF-AS Tronic 2 diagnosis outside
the vehicle

NOTE: Please inquire as to packaging unit before ordering.

1327_91D_050
EN 1327.751.102d - 2014-11 30 2014-03
ZF-AS Tronic Technical Data

Technical Data

10_000560_01

Fig.: Installation length (L)

Transmission type Installation Oil quantity Oil grade Weight


length (L) [mm] approx. liter acc. to (with oil fill and
ZF List of clutch release
Lubricants mechanism) approx. kg
TE-ML
AS Tronic with AS Tronic with
Intarder Intarder
Product family 3
910 12 22 see type plate 264 344
(12-speed)
Product family 3
953 13 23 see type plate 275 355
(16-speed)
Product family 4
953 13 23 see type plate 275 355
(12-speed)

1327_50D_060_en
EN 1327.751.102d - 2014-11 31 2014-03
ZF-AS Tronic Interfaces with the Vehicle

Interfaces with the Vehicle


1

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

Protect electronic components!

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

• To avoid damage to electronic components, the


workplace has to be grounded.
• Electronic components have to be packed in a
way that there will NOT be ANY static charging
during the parts installation, the transport, and
the parts removal.

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

In this Repair Manual, we provide a description


for the disassembly and/or assembly of the
ZF-ASTronic transmission (10-, 12-, and 16-speed)
without utilizing the mobile transmission swivel
stand 1X56 137 450.

1 For lifting or transport, the three-trace chain


1X56 137 795 is inserted into the eyes of the
transmission.

2 Prepare oil collecting basin.

3 Remove oil drain plug and drain oil.

In the case that you are repairing a transmis-


sion with an Intarder, you will need also the
Intarder Repair Manual e.g. 6085 751 122,
in this Repair Manual you will also find a
description of the disassembly/assembly of
the Intarder.

With transmission swivel stand*


015027

1 Secure adapter 1X56 138 232 to the mobile


transmission swivel stand 1X56 137 450.

Fasten transmission to the adapter


1X56 138 232.

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

Without transmission swivel stand M16x1,5

1 Prepare two squared timbers on level, solid


underground.

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".

2 Mount 2 screw-on adapters 1T66 160 650


(M16x1.5) to the R/C housing (see arrow).
Hook in the chain and lift up transmission
with a crane.
1T66 160 650
015181

3 Place transmission with the clutch bell


housing onto the squared timbers.

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

* depends on the parts list

028184

Removing clutch actuator

1 Disconnect plug connection from the NOTE


transmission actuator and from the output • For removal and fitting of release fork, refer to
speed sensor. the chapter “Clutch Release Mechanism”.

2 Remove cable harness from cable clamps


68.300, 68.320, 68.330, 68.400 and, if
necessary, remove the fixing devices 68.360,
68.370.

3 Remove 4 M8 hex-head screws 68.154 and


take off the cover 68.150.

4 Remove 4 M8 hex-head screws /030 with


shims and/or 4 M8 hex-head screws 68.020.

5 Take off clutch actuator 68.010.

6 Take push rod 68.210 completely out of the


release fork 68.060.

1327_68D_020_en
EN 1327.751.102d - 2014-11 36 2014-09
ZF-AS Tronic Pushrod

Pushrod

Length “A” of the pushrod 68.210 depending on


parts list version:
68.210

ZF item number Length “A” [mm]

1328 302 033 119.1

1328 368 008 123.1

1328 368 003 127.1 A

1328 368 007 130.1

1328 368 004 133.6

1328 368 015 138.1

1328 368 009 144.9 018485

68.210
Adjustable pushrod e.g. IVECO

ZF item number 68.220

1336 368 005 Ball pin 68.200

1328 368 043 Pushrod 68.210


68.200

0637 100 652 Hexagon nut 68.220

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

Set Pushrod (e.g. IVECO version) 2 Calculate dimension “A”:

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.

1 Determine dimension “B”: 3 Tighten hexagon nut 68.220 to 52 Nm.

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

Bleeding Clutch Actuator

Follow ZF Service Information No. 12_03.

1 Loosen screw (6) M12x1.5.


If sealing ring is worn at screw, replace
sealing ring.

018475

2 Push piston back.

018476

3 Hold piston pushed down and tighten


screw (6).
Tightening torque: 35 Nm

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

* depends on the parts list

028184

Mounting clutch actuator

NOTE 3 Fasten cover 68.150 with 4 M8 hex-head


The setting dimension (overall length) of the screws 68.154.
adjustable push rod* 68.210 can be taken from Tightening torque: 23 Nm
the parts list.
Tighten the hex-head screw /130 to 52 Nm. Vent clutch actuator
For venting the clutch actuator, loosen the
1 Insert push rod 68.210 into the recess of the screw (6) M12x1.5.
release fork 68.060. In the case that the sealing ring at the screw
is worn, replace the sealing ring.
2 When mounting the clutch actuator 68.010, Tighten the screw (6) to 35 Nm.
pay attention to correctly positioning the
connections and correctly seating the push
rod 68.210.

Mount clutch actuator – in relation to the


parts list version – by means of 4 hex-head
screws 68.020 and/or 4 hex-head nuts.
Tightening torque for the
M8 hex-head nuts /030: 23 Nm
M8 dowel pins /010: 10 Nm
Hex-head screws 68.020: 23 Nm

* depends on the parts list

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

* depends on the parts list

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.

4 If damaged, replace the cable clamps 68.300,


68.320, 68.330, 68.400 and, if necessary, the
fixing devices 68.360, 68.370.

5 Press cable harness into the cable clamps


and, if necessary, into the fixing devices.

6 Connect plug connection from the trans-


mission actuator and from the output speed
sensor.

1327_68D_030_en
EN 1327.751.102d - 2014-11 41 2014-09
ZF-AS Tronic Output Flange

Output Flange

Removing the output flange

1 Remove two hex-head bolts 32.550 and take


off washer 32.540.
32.550
32.540

2 Pull off the output flange 32.510 using a


32.530

standard three-armed puller and remove the


32.510

O-ring 32.530.

NOTE
The shaft must not be damaged during pull-off
process; therefore, use a thrust piece.

015171

Mounting the output flange


(06.260)
(06.250) 32.550
1 Heat output flange 32.510 to max. 70 °C and 32.540

slide onto spline of planetary carrier until


(06.220)
(06.200) 32.530

firmly home (axial abutment). Ensure that in


32.510

the case of the Intarder version, the screws


32.520 have been inserted.

DANGER
Only touch hot output flange when wearing
protective gloves.

(06.210)

2 Once the output flange has cooled down,


32.520 (with Intarder)

press the O-ring 32.530 into the groove


015169_1

between the shaft and the output flange.

3 Fasten washer 32.540 with 2 M12 hex-head


bolts 32.550.
Tightening torque: 120 Nm

1327_32D_010_en
EN 1327.751.102d - 2014-11 42 2009-09
ZF-AS Tronic Output Flange

Removing the Yoke

1 Remove two hex bolts 32.550 and take off 32.550

washer 32.540. 32.540

2 Use a suitable standard extractor to remove


yoke 32.510.

NOTE
When removing, use interim piece to protect the
shaft.

32.510

018733

Mounting the Yoke

1 Heat yoke 32.510 to max. 70 °C and slide


onto spline of planetary carrier until firmly
home.

DANGER
Always wear protective gloves when handling
heated output flange.

2 Once the yoke has cooled down, secure


washer 32.540 with two M12 hex-head
bolts 32.550.
Tightening torque M12: 120 Nm
018732

1327_32D_011_en
EN 1327.751.102d - 2014-11 43 2008-03
ZF-AS Tronic Output Cover

Output cover (cover)

Follow ZF Service Information No. 14_09c.


31.080
31.050

NOTE
In the case of transmissions equipped with a 31.030

ZF-Intarder, this chapter is superfluous since the


output cover is not used.

There are several generations for the output cover. 31.070

1st generation
Cover 1328 331 002
Loctite
574

Shim 0769 140 014


Sealing compound 0666 790 033
1st generation 015170

2nd generation
Cover 1314 331 014
Sealing compound 0666 790 033 31.080

3rd generation 31.050


Cover 1328 331 003
Paper seal 0501 315 956

4th generation
Cover 1328 331 004
Metal seal 0501 324 362
31.070

Remove the output cover


Loctite
574

1 Remove 10 hexagon screws M10 31.070 and


10_001765_01

2nd generation
lift off output cover 31.050.

2 If necessary, remove shim 31.030. 31.080


31.050

3 Remove seal/gasket 31.060.

4 Use a suitable tool to remove shaft sealing


31.060

ring 31.080; do not damage output cover in


the process.

31.070

10_001766_01

3rd and 4th generation

1327_31D_011_EN
EN 1327.751.102d - 2014-11 44 2014-09
ZF-AS Tronic Output Cover

Fitting the output cover


Version A Version B
1 Clean sealing faces on the R/C housing and
the output cover 31.110. 1X56 137 124

2 Coat the outer circumference of the shaft


1X56 197 443

sealing ring 31.080 with spirit (ethanol).

3 Version A
Press in the shaft sealing ring 0734 300 421
1X56 138 189

with adapter 1X56 197 443 into the output


cover 31.050 until it is firmly home.

Version B
Press in the shaft sealing ring 0734 319 459
with adapter 1X56 137 124 in connection
10_001218_01

with the ring 1X56 138 189 into output cover


31.050 until it is firmly home (axial abutment).
31.080
4 Slightly grease sealing lip. 31.050

5 1st generation
Version with shim
31.030*

Calculate thickness „C“ of shim.

Dimension A: Measure at the output cover 31.070


31.050 between sealing face and bearing
seat.

Dimension B: Measure from ball bearing * depending on the parts list


31.020 to sealing face of R/C housing 31.010.
1st generation 028256

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

Dimension C = 0.3 to 0.4 mm


31.020

6 Select the corresponding shim 31.030 by


using the spare parts catalog.
B

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

7 1st and 2nd generation


574

– Coat sealing face of the output cover 31.050 * depending on the parts list
with Loctite no. 574. 028255

– Fit output cover 31.050 – with shim


31.030 – if necessary.
31.080
3rd and 4th generation 31.050
– Fit seal/gasket 31.060 and output cover
31.050.
31.060

8 Fasten output cover 31.050 with 10 M10


hexagon screws 31.070.
Tightening torque: 46 Nm
31.070

10_001766_01

3rd and 4th generation

1327_31D_011_EN
EN 1327.751.102d - 2014-11 46 2014-09
ZF-AS Tronic PTO Cover

PTO Cover

Removing the PTO cover 31.090

1 Remove four M12 hexagon screws 31.120.

2 Take off PTO cover 31.110 and seal 31.100. 31.110

NOTE
For the installation of a PTO, the respective separate
installation instructions are binding.
31.100
31.120

015193

Installing the PTO cover

NOTE
31.090

Mount PTO cover 31.110 only once the R/C housing


and the screw plug 31.090 were installed as well.

1 Clean sealing faces on the R/C housing and


PTO cover 31.110.
31.110

2 Place new seal 31.100 on R/C housing. 31.100

3 Fasten PTO cover 31.110 using four M12 hexa-


gon screws 31.120.
Tightening torque: 79 Nm 31.120

018225

1327_31D_012_EN
EN 1327.751.102d - 2014-11 47 2014-09
ZF-AS Tronic R/C housing

R/C housing Version A

Dismounting the R/C housing 34.070 34.050


34.060
Transmission is in vertical position with
34.060

the output end pointing upwards (refer to


34.050 34.080

Preparatory Work).
31.390

34.080
Version A 34.070

1 Remove the two hex-head screws 34.080,


the holding plate 34.070 , and the pivot bolts
31.390

34.050. Take the O-rings 34.060 off the pivot


bolts. 31.370

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

2 Remove 2 cylindrical pins 31.390 – M12


extractor thread – and 22 hex-head screws
31.390

31.370.
34.090
34.050

NOTE
34.100

Push out the cylinder pins with the drift key


1X56 138 063.
34.090

3 Fix 2 screw-on adapters on output flange


31.390

and/or planet carrier and hook in chain. 31.370

4 Use a crane to lift complete range change


021762

housing.

5 If necessary, remove the seal 31.350. 31.400

6 Remove the spray pipe 31.400.


34.010
7 Lightly lift the selector rail 34.010 and remove
33.010

the gear shift fork 34.020 and the selector 34.030


pads 34.030.

8 Completely remove the synchronization


33.010.

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

6 bushes /150 and 6 pressure springs /170 are


/170

jumping out when taking off the synchronizer


/110

rings /130. 32.440


/130

9 Lift plate 32.440 with 2 rim levers and remove


32.430 /130

the clutch body 32.430. 32.400 /150


32.380 /170

10 Remove the sleeve 32.400 with the securing


ring 32.390 and the compensating disk 33.010
32.380.
32.390

021763

1327_31D_020_en
EN 1327.751.102d - 2014-11 49 2010-11
ZF-AS Tronic R/C housing

Play setting of the main shaft – Planetary carrier

01.400

32.390
04.010
32.400

Determine dimension B1
016660
Determine dimension B2 016661

Version with liquid sealing Version with solid sealing


(See ZF-Service Information No. 02_05 in the Annex.) (See ZF-Service Information No. 02_05 in the Annex.)

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

Without seal 31.350:

B = B2 – B1

With seal 31.350:

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

Determine dimension A1 016662


Determine dimension A2 016663

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

Mounting the R/C housing /150

1 Place compensating disk 32.380 on main


/170

shaft.
/110

32.440
NOTE
/130

For measuring of the compensating disk


32.430 /130

32.380 please refer to the chapter on “Play


32.400 /150
Setting of Main Shaft – Planetary Carrier”. 32.380 /170

2 Insert the securing ring 32.390 in the sleeve 33.010


32.400. Securing ring must rest firmly on base
of groove in the sleeve. 32.390

3 Fit sleeve 32.400 onto main shaft.


The securing ring 32.390 is flat on the 021763

compensating disk 32.380.

4 Put the clutch body 32.430 and the plate


32.440 on the housing II.

5 For the two synchronizer rings /130: Insert


3 pressure springs /170 and 3 bushes /150 in
each and secure with a bracket 1X56 138 207. 1X56 138 207

6 Insert both synchronizer rings /130 into the


sliding sleeve /110 and remove the bracket
1X56 138 207.

7 Put the complete synchronization with the


synchronizer rings /130, bushes /150, and
pressure springs /170 onto the clutch body
32.430.
015191

33.010 32.400 32.390

32.380

32.440 32.430 04.010

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

16 Tighten screw plug M10x1 31.090 to 15 Nm.

17 Insert two cylindrical pins 31.390. Screw in


22 hex-head screws 31.370 and tighten to
50 Nm.
31.090

CAUTION
31.390

Screws of an appropriate length must be used to


mounting the retaining plates.
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

into the R/C housing, then, you will have to


remove the R/C housing once again.
34.080
34.070

19 Insert the pivot bolts by means of the retai-


ning plate 34.070 via the R/C housing’s bore 31.390
into the gear shift fork 34.020.

20 Fasten the retaining plate 34.070 with a


31.370

hexagon screw 34.080 each and tighten to


23 Nm.
015167

Version B

Version B 34.050
34.100

18 Insert the snap ring 34.090 at the pivot bolts.


31.390
19 Cautiously insert the pivot bolts via the R/C 34.090
housing’s bore into the gear shift fork 34.020.
34.050

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

Disassembling the R/C housing

1 Remove the output flange (refer to the


corresponding chapter) and the output cover
(refer to the corresponding chapter).

2 Remove screw plugs 31.090 and 31.200.


6

3 Remove impulse sensor 31.230 and 31.260.

4 Use extractor (6) to remove ball bearing


31.020 and R/C housing 31.010 from planet
carrier.
– For ball bearing with 10 balls,
use extractor 1X56 122 314. 015189

– For ball bearing with 11 balls,


use extractor 1X56 138 295.
31.020
31.090

5 Use a manually operated press to press ball


bearing 31.020 out of the R/C housing.
31.260*

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

Assembling the R/C housing


Follow ZF Service Information no. 08_00 and no.
31.020

13_03.
31.090

1 Insert ball bearing 31.020 in the R/C housing


31.010. 31.260*

2 Heat up the bearing inner ring of the ball


bearing 31.020 to max. 120 °C and put on the 31.200
complete R/C housing until it axially abuts
with the planetary carrier.

DANGER
Only touch heated parts when wearing
protective gloves. 31.010 31.230*

* see parts list [BoM] 015173

NOTE
Mount screw plug M10x1 31.090 only once the R/C
housing was mounted to housing II.

3 Replace the sealing rings at the screw plugs


31.090 and 31.200.

4 Screw in screw plug M24x1.5 31.200.


Tightening torque: 60 Nm

5 Screw in impulse sensor 31.260 without using


Loctite.
Tightening torque: 45 Nm

6 Depending on parts list [BoM]*


‒ Screw in Kitas (speedometer) 31.230
without using Loctite.
Tightening torque: 45 Nm
or
‒ Screw in screw plug with new sealing ring.
Tightening torque: 35 Nm

7 Mount the output cover (refer to the


corresponding chapter „Output Cover“) and
the output flange (refer to the corresponding
chapter „Output Flange“).

1327_31D_050_EN
13271327.751.102d
EN 751 002 - 2004-04 - 2014-11 57 2014-09
ZF-AS Tronic Planet Carrier

Planet carrier

Disassembling the planet carrier

1 Use pliers to contract the securing ring


32.290.

2 Grip the clutch body 32.280 with two hooks


and lift it up.

3 Remove securing ring 32.290 from planet


carrier.

1 2

Optional
32.290
1 Place pressure plate (1) 1X56 138 424 onto
the planet carrier. 32.280

2 Use tool (2) 1X56 138 426 for contracting the


securing ring 32.290.

3 Take off the half-shells (3) from the tool


1X56 138 420 and push the small shoulder
underneath the clutch body 32.280.
023594

4 Push the ring (4) from the tool 1X56 138 420
onto the two half-shells (3) and tighten the
screw (5).
6

5 Pull off the clutch body 32.280 by means of a


commercial three-armed puller (6). 3

023595

1327_32D_020_en
EN 1327.751.102d - 2014-11 58 2014-10
ZF-AS Tronic Planet Carrier

NOTE for transmissions equipped with an Intarder 32.122*


Remove the 10 hex-head screws 32.144 and pull off
the step-up gear 32.140 by means of a two-arm 32.120

puller. 32.230
32.240
6 Position the planet carrier laterally on the ring
gear.

7 Remove the locking wire 32.240 (e. g. with


2 small screwdrivers).

DANGER
32.290

Ring gear 32.130 is free and can fall down.


32.130

– Risk of injury –

8 Take off the ring gear carrier 32.230.


32.280
32.144*

9 If necessary, remove the locking wire 32.122. 32.010

10 Take thrust ring 32.120 out of the ring gear


32.130. 32.310/1
32.200 /050 32.140*
11 Turn the planet carrier by 180° and use a 32.204
mandrel to drive the planetary bolt 32.050 out
32.184

of the planet carrier 32.010.

12 Take out the planetary gear set 32.100 (con-


32.190 32.090

tains 5 planetary gears). Take out the inter-


32.180 32.080

mediate washers 32.070, 32.080 and rollers


32.090

32.090 from the planetary gears.


32.070
32.050 32.070
32.100
13 The sun gear 32.190 is released. * depends on the parts list
028301

14 Offset pressure disks 32.200, 32.180 by 1/2 a


tooth so that the driving pins 32.204, 32.184
are released.

15 Remove the driving pins 32.204, 32.184.

1327_32D_020_en
EN 1327.751.102d - 2014-11 59 2014-10
ZF-AS Tronic Planet Carrier

16 Pull off bearing inner ring (5) 32.310/1 using


an extracting device 1X56 138 087. 1 2

The extracting device 1X56 138 087 consists


of:
‒ outer ring (1)
‒ split inner ring (2)
‒ split ring (3)
‒ plate (4)

4 3 10_002033_01

17 Place plate (4) on planet carrier.


2 4

18 Grip bearing inner ring (5) 32.310/1 with split


inner ring (2).

10_002034_01

19 Fit outer ring (1).

20 Insert split ring (3).

21 Place three-armed extractor at outer ring (1)


and pull off bearing inner ring (5) 32.310/1.

10_002035_01

44
1327_32D_020_en
EN 1327.751.102d - 2014-11 60 2014-10
ZF-AS Tronic Planet Carrier

Pre-Assembling the sun gear

1 Insert the driving pin 32.204 in the sun gear


32.190. 32.180

2 Slide the pressure disk 32.200 – the shorter


shoulder points towards the planetary gear –
32.190

into the spline of the sun gear 32.190 and off- 32.184
set the two. Thereby, the driving pin 32.204 is
secured.

3 Slide the pressure disk 32.180 – the shorter


shoulder points towards the planetary gear – 32.204
into the spline of the sun gear 32.190. 32.200

4 Insert the driving pin 32.184 into the bore of 015188

the sun gear.

5 Push the pressure disk 32.180 upwards and


offset it so that the driving pin 32.184 is
32.200

secured. 32.204
32.184

Pre-Assembling the planetary gear set 32.190

CAUTION
32.090
32.180
32.080
Planetary gears may not be replaced individually, 32.090
always replace the entire set. 32.070

1 Grease all needle rollers 32.090 with trans-


32.050 32.070
32.100

mission oil.
028362

2 Insert the thinner intermediate disk 32.070


in the planetary gear 32.100 and position the
14 rollers 32.090 in the planetary gear.

3 Insert the thicker intermediate disk 32.080


and, again, introduce 14 rollers 32.090 into
the planetary gear. Finally, add on top a thin
intermediate disk 32.070.

4 These work steps must be performed for all


5 planetary gears.

1327_32D_030_en
EN 1327.751.102d - 2014-11 61 2007-05
ZF-AS Tronic Planet Carrier

Completing the planet carrier 32.122*

DANGER
32.120

Always wear protective gloves when handling


32.230

heated parts.
32.240

1 Heat up the bearing inner ring 32.310/1 to


max. 120 °C and slide onto the planet carrier
until firmly home (axial abutment).

2 Insert the pre-assembled sun gear 32.190 in 32.290


the planet carrier 32.010. Ensure that the
driving pins cannot fall out.
32.130

DANGER 32.280
Fingers may get stuck/jammed!

3 Hold pressure disk at the sun gear upwards


32.010

and insert the pre-assembled planetary gears


32.100. Insert the planetary gear pins 32.050 32.310/1
and center the planetary gears.
32.190
4 Use a plastic hammer in order to cautiously
hammer in the planetary gear pins 32.050
into the planet carrier bore (until they no 32.050
longer protrude). * depends on the parts list

5 Insert the securing ring 32.290 into the planet 028363

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.

7 If necessary, use locking wire 32.122. NOTE


The locking wire 32.240 must make contact
8 Insert the thrust ring 32.120 – ground side with the ring gear’s groove base.
points towards the output – into the ring gear
32.130.

1327_32D_040_en
EN 1327.751.102d - 2014-11 62 2007-05
ZF-AS Tronic Planet Carrier

Only for the Intarder version

Assembly of Step-Up Gear


32.144*

1 Heat up the step-up gear 32.140 to 120 up to


130 °C.

2 Screw in two M12 guide pins into the planet


carrier 32.010.
32.140*
DANGER
Only touch heated parts when wearing
protective gloves.
* depends on the parts list

3 Put the hot step-up gear 32.140 – shoulder 028364

towards output – onto the planet carrier.

4 Remove M12 guide pins.

5 Screw in 10 M12 hex-head screws 32.144


and tighten to 135 Nm.

1327_32D_050_en
EN 1327.751.102d - 2014-11 63 2007-05
ZF-AS Tronic Place transmission is in stationary position

Place transmission without RC (planetary


range) in horizontal position
05.010 05.110

1 Replace the two reverse gear bolts 05.010, 1X56 138 208

05.110 by the tools (9) 1X56 138 208.

NOTE
The reverse gear’s reversing gears are secured
by means of a tool (9) 1X56 138 208.

018269

2 Fasten the holding plate (10) 1X56 138 203 to 10


the housing II.
9

3 Make oil collecting basin and skids available. 9

4 Mount two screw-on adapters (2)


1T66 160 657 to the housing II. 2
Hook in the chain and put transmission into
horizontal position using a hoist.

NOTE
Residual transmission oil may be drained; position
the oil collecting basin correspondingly.

015187

5 Remove the screw-on adapters.

6 For removing the transmission actuator,


please refer to the corresponding chapter.

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

plug 74.130 from the transmission actuator 74.090 74.070


74.030.

2 Remove 15 M8 hexagon screws 74.090,


74.070 and cable clamp 68.400 from the
transmission actuator 74.030.

3 Take off transmission actuator 74.030 from


the transmission housing.
Please pay attention to the fact that the rub-
ber seals (item /170, also refer to Fig. 017908
/ chapter “Mounting Transmission Actuator”)
are also removed otherwise they may fall into
the transmission housing.

10_000351_01

* depends on the parts list

4 Remove compression springs 06.050, 34.140,


12.090 and detent pins 06.040, 34.130,
12.080.
74.030

Replace the two cylinder pins 74.050 if they


are damaged.

5 Remove seal 74.010 and clean sealing


surfaces on transmission housing and
transmission actuator.
74.050
74.010

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

6 In the case that housing I 01.010, is


06.080

dismounted – refer to the corresponding


chapter – also remove the ball pins 06.080.

027850_2

1327_74D_030_en
EN 1327.751.102d - 2014-11 65 2014-09
ZF-AS Tronic Transmission Actuator

Removing the upper section from the lower


section 6009 274 069

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

1 Remove both screws /150-1.

2 Raise upper section /110 at the pressure


relief valve /180 and use both tabs (1) to
74.030

carefully move it sideways into the grooves*


/180

(2). Disconnect plug connections (7, 8).


/150-2
3 Remove seals /150-3 and /170. 2

4 Remove seal /150-2 and clean sealing /150-3


faces.
/130
* not possible with the 18-pin variant

/170

Reattaching the upper section to the lower


019352

section

1 Insert seal /150-3.

2 Place seal /150-2 on lower section /130.

3 Re-connect plug connections (7 and 8). 8


Again check fit of plug connection.
7

4 Place upper section /110 on lower section


/130. Ensure that the seal /150-2 does not
slip, fix if necessary. Tighten the two screws
/150-1 to 9.5 Nm.

5 Insert seals /170.


018205

1327_74D_005_en
EN 1327.751.102d - 2014-11 66 2007-05
ZF-AS Tronic Installing the Transmission Actuator

Installing the transmission actuator

NOTE
Mount the transmission actuator only once
06.080

the transmission is completely assembled.

1 Coat the threads of the ball pins 06.080 with


Loctite no. 262. Tighten ball pins to 23 Nm.
Loctite
262
017429

2 Fasten the fixture (11) 1X56 138 095. Hook in


the corresponding gearshift rails with the
lever. Manually turn the input shaft and use
lever to engage gears.

3 Engage S/G and R/C gearshift rails in the


transmission in output direction. Move the
11

central gearshift rail into neutral.

4 Remove fixture (11).

5 Move piston rod (4) on transmission actuator


into central position (neutral). The correct
position is reached when slight resistance can
be felt when pulling out the piston rod (4).
Align the two other piston rods (3 and 5) to
015183

the same level. 5 4 3


/170

6 Selector gate (6) and piston rod (4) must be


one above the other (flush). Ensure that the
rubber seals/gaskets /170 have been inserted
on the transmission actuator.

Legend
Piston rod (3) = shifts the splitter group (S/G)
Piston rod (4) = shifts the basic transmission
6

Piston rod (5) = shifts the range change group


(R/C)
Selector gate (6) = selects the shift gate

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

transmission, otherwise the gearshift finger could


fall into the transmission.

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

Upon request, the auxiliary tool (34) can also be


supplied by ZF with the following order number
1X56 138 244.

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

7 Place new seal 74.010 on transmission


housing.
74.070

8 Insert the detent bolts 06.040, 34.130, 12.080 74.140*


and the compression springs 06.050, 34.140,
68.400
74.130* 74.120*
12.090. 74.030

NOTE
74.090 74.070

The compression springs 06.050, 34.140, and


12.090 must be of the same length (approx. 50 mm).
If there are deviations, replace compression springs.

9 Align ball pins 06.080 vertically.


The ball pin 06.080 engages with the selector
gate (6) when putting on the transmission
74.050

actuator.
74.010

10 Attach transmission actuator 74.030 ensuring 74.050


12.090

that the piston rods (3, 4, 5) of the trans-


34.140 12.080
06.050
mission actuator fully engage with the
34.130
06.040

gearshift rails of the transmission. 06.080

11 Use a hexagon screw 74.070 to pin down the


cable clamp 68.400.
Loctite
262

12 Tighten hexagon screws M8 74.090, 74.070


10_000352_01

to 23 Nm. * depending on the parts list

13 In line with the parts list [BoM]:


Tighten cannon plug 74.130 to 18 Nm and
fasten the angle piece 74.140 and/or tighten
the breather 74.120 to 10 Nm.

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.

14 Connect airline to transmission actuator’s


pressure relief valve.

15 Connect the wiring harness otherwise


functional test with the diagnostic unit is not
possible.

1327_74D_040_EN
EN 1327.751.102d - 2014-11 69 2014-09
ZF-AS Tronic Replacing pressure relief valve

Replacing pressure relief valve


10
NOTE
Mark the installation position of the pressure relief
valve /180 for fitting later on.

1 Remove four nuts (10) and take off pressure


relief valve /180 and O-ring (12).

CAUTION
Do not use grease to fit O-ring (12).

2 Insert new O-ring (12), use four nuts (10)


to secure pressure relief valve /180 to
transmission actuator 74.030.
Tightening torque: 7 Nm 019251

/180 12 74.030

019252

1327_74D_011_en
EN 1327.751.102d - 2014-11 70 2014-03
ZF-AS Tronic Programming Transmission Actuator

Programming transmission actuator

When replacing the transmission actuator and/or 21


upper section, customer-specific programming
and/or parameter setting (entering EOL data) will
be required.
20

During parameter setting, the EOL data are


entered in the transmission actuator’s electronics
22

using ZF-TESTMAN and the corresponding


software.

Diagram of transmission actuator programming 23


Item
20.1

20 Table mode adapter


20.1 Power supply connection 028537

21 Cable from table mode adapter to the


DPA05
22 DPA05
23 Cable to laptop and/or PC

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

Putting transmission in vertical position

1 Mount 2 screw-on adapters 1T66 160 657 to


the housing I; ensure that with 2 to 3 washers
respectively, bridging the shoulder to the
centering diameter is possible (see arrow).

2 Hook in the chain and lift the transmission.

NOTE
Residual transmission oil may be drained; position
the oil collecting basin correspondingly.

015184

3 Screw in 4 supports (3) 1X56 138 443 into


the housing II.
3

3
015185

4 Lift transmission cautiously and position on


the four supports.

015186

1327_50D_030_en
EN 1327.751.102d - 2014-11 72 2010-11
ZF-AS Tronic Removing Clutch Release Mechanism

Clutch Release Mechanism

Removing Clutch Release Mechanism

68.060
68.130 68.110

/150
/160

/110

68.210

/120

68.050

68.050 68.130 68.060 68.130 68.110


10_001371_01

Clutch Release Mechanism: Version B

1 Remove 2 M12 hex-head bolts 68.130 from Version B:


release shaft 68.110. Release fork with track rollers

2 Take release bearing 68.050 and release fork CAUTION


68.060 off the input shaft. Do not wash the following parts:
- Release fork 68.060
3 Slide the release shaft 68.110 out of the - Release bearing 68.050
release fork 68.060. If necessary, take out the
pushrod 68.210 from the release fork. 4 Dismantling the release fork 68.060:
Drive track rollers /150 and /160 out of the
NOTE release fork 68.060 (e.g. by means of a
ZF recommends replacing version A with punch).
version B. Replace spherical shell /120 if damaged or
worn.

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

4 Disassemble the release fork 68.060:


68.060

Remove the bearing bush /130 with suitable


/140

tools.
/130 /110

Drive out cam rollers /150 and /160 from the 68.210

release fork 68.060 (e. g. with a punch).


Replace ball cups /120 if damaged or worn. /130

68.110

/120
68.050 /140
68.130
10_001383_01

Clutch Release Mechanism: Version A

1327_68D_010_en
EN 1327.751.102d - 2014-11 74 2014-04
ZF-AS Tronic Install Clutch Release Mechanism

Install clutch release mechanism (ZF-Service Information No. 14_07 note)

1X56 138 546

/150

1X56 138 547

/110
/160

10_001361_01

Clutch release fork: Version B

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

3 Where necessary, press in spherical shell


/120 and grease using OLISTA LONGTIME
3EP (ZF no. 0671 190 050).
68.060
68.110
68.130

4 Grease the front face of the release bearing /150


68.050 cams using OLISTA LONGTIME 3EP
/160

(ZF no. 0671 190 050).

CAUTION
/110

Do not grease the following parts: 68.210


- Track rollers /150 and /160
- Bearing fit "Clutch release bearing 68.050 –
release flange (guide tube)"
/120

- Release shaft 68.110


- Bearing bush in the release fork 68.060 68.050 10_001369_01

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.

5 Insert release shaft 68.110 into release fork


68.060.

NOTE
The release shaft has play with the release fork.

68.060
68.110 10_001396_01

6 Position release bearing 68.050 on the


release flange (guide tube) of the input shaft
02.010.
02.010 68.050

7 Engage release fork 68.060 with release


bearing 68.050. Ensure correct fit of pushrod
68.210.
68.110
8 Attach release shaft 68.110 to the clutch
housing with 2 M12 hex-head bolts 68.130.
Tightening torque: 105 Nm 68.130
68.130

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

Clutch Release Mechanism: Version A 028366

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

Removing connection plate

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.

4 Remove the brake cover 03.250 from the


connection plate as well as the outer
multidisks 03.270 and the lined multidisks
03.280.

1327_02D_010_en
EN 1327.751.102d - 2014-11 78 2010-11
ZF-AS Tronic Removing Connection Plate

10 Remove four M8 hex-head screws 02.530 and


lift off the release flange 02.520.
02.510
11 If necessary, remove the gasket 02.522.
02.522*

02.530
12 Use a suitable tool to remove shaft sealing
ring 02.510 from the release flange 02.520.

02.520

* depends on the parts list

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

Measuring connection plate

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.

Input shaft 8 Put the compensating disks 03.050, 03.150


b1 – b2 = b = disk 02.100 onto the bearing’s outer rings. Slightly grease
5.50–3.90 = 1.60 mm = disk 02.100 the compensating disks 02.100 (for improved
assembly) and place into connection plate.

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

Mounting connection plate

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

9 Press in shaft sealing ring 02.510 using tool


1X56 099 063 6 into the release flange
02.520 until it axially abuts. 02.510
02.522*

NOTE
• Coat the outer circumference of the shaft
02.530

sealing rings with spirits (ethanol).


• The sealing lip must point towards the
transmission’s interior.

10 Put on seal 02.522 and fasten the release


flange 02.520 by means of four M8 hex-head
screws 02.530 to the connection plate
02.520

02.500.
Tightening torque: 23 Nm * depends on the parts list

028302

11 Coat the sealing surface of the connection


plate 02.500 with Loctite no. 574.

12 Cautiously put the connection plate 02.500 on


the input shaft of the transmission housing.
Align the pump driver (Z) in such a way that it
meshes with the groove (Y) of the counter-
shaft.

Loctite
574

Z 02.500

014820

13 Coat 22 M10 hex-head screws 02.670 with


Loctite No. 241 or use new, micro-encapsu-
lated hex-head screws.
Tightening torque: 46 Nm

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

Removing housing I 06.260* 01.140


06.250*
1 Remove neutral switch 06.260 and pin 06.250
and/or screw plug 06.270. 01.010

2 Remove securing ring 02.120.


01.140
01.070

3 Remove snap ring 02.080/1 at the ball 01.130


bearing 02.080. 02.120

4 Remove filter 01.070.


02.080
02.080/1 * depending on the parts list

015176

5 Put the connecting piece 1X56 138 191on the


input shaft. Fixture (20) 1X56 138 195
meshes with the ball bearing’s annular
groove. The basic device (5) 1X56 122 304 1X56 138 191 5
must be fastened to the fixture. Pull off the
ball bearing 02.080.

6 Remove the 24 M10 hexagonal screws


01.130.
Remove the 4 cylinder pins 01.140 – M12
extractor thread.
20
NOTE
Push out the cylinder pins 01.140 with the
drift key 1X56 138 063.

015177

7 Mount 2 screw-on adapters 1T66 160 657 to


the housing I 01.010. Thereby, housing’s
centering must not be damaged. Bridge the
gap to the centering with 2 up to 3 washers
(see arrow).
Hook in 3 chains (string) 1X56 137 795 and
cautiously lift off the housing I 01.010.
01.010

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*

* depending on the parts list 01.030*


015175

Dismantling housing I Assembling housing I

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

4 Insert spacer 06.200 with two clamping pins


06.210 in housing I.

5 Mount type plate 01.150 with 4 blind rivets


01.160.

1327_01D_020_en
EN 1327.751.102d - 2014-11 85 2007-05
ZF-AS Tronic Fitting Housing I

Fitting housing I
01.400

1 Clean sealing surfaces.

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.

2 Determine dimension L of the housing II Dimension


Maß L L
Housing II II
01.400.
Gehäuse

3 Depending on the version: 028518

L = 184.5 -0.1 mm and/or 227.5 -0.1 mm:


Coat the sealing face at housing II with
sealing compound 1215 (company Three
Bond). 1X56 138 200 1X56 138 201

– OR –

L = 183.75 -0.13 mm and/or 226.75 -0.13 mm:


Put on seal 01.020.
4 Apply tools 1X56 138 200 and 1X56 138 201
(see arrows) for centering the spray pipes
01.420, 01.430 in the housing I 01.010 (for
the installation of the spray pipes see chapter
on “Shaft Package”).
5 Cautiously put on housing I 01.010 on 016664

housing II 01.400.
6 Check whether the spray pipes 01.420,
01.140

01.430 are correctly positioned in the 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

Then, subsequently drive in cylinder pins


01.140 until they axially abut. 01.020

CAUTION
02.080

Screws of an appropriate length must be used to


02.080/1

mounting the retaining plates. 028223

1327_01D_030_en
EN 1327.751.102d - 2014-11 86 2014-09
ZF-AS Tronic Fitting Housing I

9 Insert the snap ring 02.080/1 into the groove


of the ball bearing.

10 Heat up the inner ring of the ball bearing


02.080 with a heating arbor to approx.
80 - 90 °C.

DANGER
Only touch heated parts when wearing
24

protective gloves.

11 Insert the ball bearing 02.080 so that the snap


23

ring 02.080/1 is flat on housing I. If necessary,


push on with the outer tube with of the fixture
(23) 1X56 138 216. Push on the input shaft
until axial abutment with the fixture 016687

1X56 138 216 in combination of the mounting


fixture (24) 1X56 045 808 onto the ball 06.270*
bearing. 06.260*
06.250*
12 Remove the fixtures and use a feeler gage for
measuring the thickness of the securing ring
02.120.
Consider a play of 0 up to 0.10 mm for the 01.070
selection of the securing ring 02.120.

13 Insert the securing ring 02.120. 02.120

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

14 Insert the pin 06.250 and tighten the neutral


028224

switch 06.260 with 45 Nm and/or the screw


plug 06.270 with 35 Nm.

NOTE
Always renew the sealing ring at the neutral switch
and/or the screw plug.

15 Insert filter 01.070.

16 For removing the connection plate, please


refer to the corresponding chapter.

1327_01D_030_en
EN 1327.751.102d - 2014-11 87 2014-09
ZF-AS Tronic Removing Shaft Pack

Shaft pack

Removing shaft pack

1 For dismantling of housing I, refer to the


03.010

corresponding chapter.

2 Remove the fixing bolts 1X56 138 208 and


push the reverse gear’s intermediate gears 03.110

05.040, 05.140 to the side.


01.430
3 Remove the two spray pipes 01.420,
01.420

01.430.

4 Tilt the countershafts 03.010, 03.110 to the


side and take them out.
016665

5 Place fixture (25) 1X56 138 197 onto the


inputshaft. Slide sleeves (1 and 2) over gear
selector rails.
Mount the fixture (23) 1X56 138 216 to the
23

input shaft.
25
NOTE
The fixture (23) 1X56 138 216 consists of
two half-shells, a tube, and a threaded
1 2

coupling. At the one side, place the lugs of


the two half-shells into the groove of the
input shaft. At the other side, insert the
threaded coupling and put tube on top.
Screw in an M10 lug bolt at the threaded
05.140
05.040
coupling of the fixture 1X56 138 216.

6 Hang in the 3-strand chain 1X56 137 795 016666

at the lug bolt.


Main shaft, Main shaft,
10 and 12 speeds 16 speeds
7 Use a hoist to lift the input shaft and the
main shaft as one unit out of the housing II.

8 Slide bushes (1 and 2) upwards and remove


the selector rails.
In the case of a 16-gear main shaft, hold
onto the sliding sleeve 04.060 and remove
the selector rails.

9 Clamp main shaft and input shaft in a vise


with protective chucks.

04.060

018216

1327_05D_010_en
EN 1327.751.102d - 2014-11 88 2014-09
ZF-AS Tronic Removing Shaft Pack

10 Push sliding sleeve 04.350 in output


direction. Now, the securing ring 02.350
becomes visible.

11 Use sharp flat-nosed pliers (3) for


contracting the securing ring 02.350 and
lift off the input shaft from the main shaft. 02.350

3 04.350

016667

12 Take off the fixture 1X56 138 216 and


the bushes (1 and 2) of the fixture
1X56 138 197 from the input shaft.

13 Secure the guiding plate (4) of the fixture


1X56 138 197 with the securing ring
02.120.
02.120

14 For disassembling the input shaft, please


refer to the corresponding chapter.

016448

1327_05D_010_en
EN 1327.751.102d - 2014-11 89 2014-09
ZF-AS Tronic Installing Shaft Pack

Installing shaft pack Main shaft, Main shaft,


10 and 12 speeds 16 speeds
1 Position the fixtures (25) 1X56 138 197 and
(23) 1X56 138 216 at the input shaft.

2 Lift input shaft onto the main shaft by


means of a hoist. Push sliding sleeve
04.350 in output direction.

3 Use sharp flat-nosed pliers (3) for


contracting the securing ring 02.350 and
put the input shaft on the main shaft.

CAUTION
Check whether the securing ring has fully 04.060
engaged in the main shaft. If the securing ring 018216

is not correctly mounted, total loss (complete


breakdown) will be the consequence.

4 Put the shift forks of the completed gear


change shafts in the corresponding sliding
sleeves. Push the bushes (1 and 2) of the
fixture 1X56 138 197 on top of the gear
change shafts.
02.350

In the case of a 16-speed version, hold the


sliding sleeve 04.060 upwards and insert
3 04.350

the selector rail.

5 Assembly information: Insert the reversing


gears 05.040 and 05.140 for the reverse
gear in housing II.
Use a hoist to insert the input shaft and
main shaft in the housing II.
016667

Remove the fixtures (25) 1X56 138 197 and


(23) 1X56 138 216.
23

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

6 Insert in accordance with the respective


marks the countershafts 03.010, 03.110.

CAUTION
The respective marks on the countershaft must
be within the range of the small counting disk
02.060 window (see arrows).

7 Engage the reverse gear and ensure that


the reversing gears 05.040 and 05.140 are
meshing with the countershafts.

8 Fix the reversing gears 05.040 and 05.140


in position by means of a fixing bolt
1X56 138 208.
016449

9 Shift into neutral (sliding sleeves to be


brought into neutral position) and turn shaft
pack around one time.
03.010
10 Insert the two spray pipes 01.420 and
01.430.

11 For mounting the housing I, please refer to 03.110


the corresponding chapter.
01.430
01.420

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.

4 Completely remove the synchronization


02.200. For disassembling the synchroni-
zation, please refer to the corresponding
chapter.

1327_02D_040_en
EN 1327.751.102d - 2014-11 92 2007-05
ZF-AS Tronic Input Shaft

5 Remove the securing ring 02.120 and the


guide plate (4).

02.120

017926

6 Take off the counting disk 02.060, thrust


plate 02.050, and the helical gear constant 1
02.040 from the input shaft. If necessary,
use a manually operated press. 02.020

Remove bolts 02.020.


02.010
7
02.040

02.050

02.060

017893

1327_02D_040_en
EN 1327.751.102d - 2014-11 93 2007-05
ZF-AS Tronic Input Shaft

Disassembling synchronization Overdrive

1 Put synchronization 02.200 with the collar 02.200 /250


facing downwards onto a table. Cover with /240
a cloth. Pull off the K2 synchronizer ring /220 /220
17
in upward direction. /180

/160

DANGER
/150

There will be 3 pressure springs /240 and


/110 /210

3 cylindrical rollers /250 jumping out of the


bores.

2 Push bolts /160 through the gear shifting


/120

sleeve /150. Offset plate /180 by half a tooth 016691

and remove it from the gear shifting


sleeve /150. Direct drive

3 If necessary, the pins /120 and /210 can be 02.200

pressed out from the synchronizer rings /110


and /220.
/220
17
/180

/160
/150
/210
/110 /240
/250

/120

017892

Direct drive Overdrive


/160 /220 /210

/150 /180 /110 /120

018217

1327_02D_060_en
EN 1327.751.102d - 2014-11 94 2007-05
ZF-AS Tronic Input Shaft

Assembling the synchronization Overdrive

NOTE 02.200 /250


In the event of repairs, the synchronizer rings and /240
plate should always be replaced in complete sets. /220
17
Pleased pay attention to Service Information No.
20_04 in the Annex.
/180

/160

CAUTION
/150

Pay attention to the part number at the


/110 /210

synchronizer ring /220:


Overdrive Direct drive
1328 302 014 1328 302 013
1328 302 086 1328 302 085
1328 302 113 1328 302 112
/120

016691

1 Press in the longer 3 pins /120 in the


synchronizer ring /110 and the shorter 3 pins Direct drive
/210 in the synchronizer ring /220.
02.200

2 Put the plate /180 on the gear shifting sleeve


/150 and offset by half a tooth.
/220
17
/180
3 Align the bores of the gear shifting sleeve
/150 with one of the 3 recesses of the plate
/160
/150
/180.
/210
/110
Insert the bolts /160 via the gear shifting
/240
/250
sleeve’s bore until firmly home.

4 Insert a pressure spring /240 and a


cylindrical roller /250 into each of the three
bores of the synchronizer ring /220 and
/120

secure by means of assembly sleeves (17)


017892

1X56 138 081.

Direct drive Overdrive


/160 /220 /210

/150 /180 /110 /120

018217

1327_02D_070_en
EN 1327.751.102d - 2014-11 95 2007-05
ZF-AS Tronic Input Shaft

5 Onto the assembly plate (16) 1X56 138


097: Put on synchronizer ring K1 /110 and
the complete gear shifting sleeve /150 with
plate /180.

16

017894

6 Put the K2 synchronizer ring /220 with the


3 assembly sleeves (17) onto the locking
17

bolts /120 of the K1 synchronizer ring /110.

7 Evenly press synchronizer rings together.

8 Remove the assembly sleeves (17) and, in


parallel, press down the K2 synchronizer
ring /220.

017895

9 Turn synchronization around.


Position synchronization centrally by pulling
the plate /180 with the gear shifting sleeve
/150 upwards and, in parallel, pressing the
synchronizer ring /110 downwards.

Please check that the bolt /160 did not fall


out.

017896

1327_02D_070_en
EN 1327.751.102d - 2014-11 96 2007-05
ZF-AS Tronic Input Shaft

Setting the axial play of the bearing disk in


constant gear 2 Measurement 1
(See ZF-Service Information No. 25_05 in the
Annex.)

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

1 For the helical gear constant 2 02.280:


02.290

Insert the bearing disk (wheel disk) 02.300


and the two snap rings 02.260 and 02.290.

2 Measure from the rim of the helical gear 028248

constant 2 02.280 to the wheel disk


02.300; set depth gage to zero. Measurement 2

Measurement 2

3 Put the complete helical gear constant 2


02.280 onto a tube or something similar so

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.

5 If the measurement value is outside of the Tube


Rohr
tolerance range (0 up to 0.10 mm):
02.280

Disassemble the snap ring 02.290.


028249

6 Select and mount a new snap ring


(calculated) 02.290 from the OTK.

7 If necessary (at clearance 0), insert snap


ring 02.290 into the groove by applying soft
blows.

8 Check the axial play again.

9 Repeat the steps of action until the


measurement value resides within the
tolerance range.

1327_02D_080_en
EN 1327.751.102d - 2014-11 97 2007-05
ZF-AS Tronic Input Shaft

Assembling the input shaft

1 Clamp input shaft in a vise with protective


chucks for assembly.
02.020

02.010
2 Insert bolts 02.020 into input shaft 02.010.
02.040

3 Put on helical gear constant 1 02.040 and


thrust plate 02.050. 02.050

4 Push on counting disk 02.060.

NOTE
Play of up to 0.3 mm admissible between 02.060
bolts 02.020 and counting disk 02.060.

5 Put on the guiding plate (4) of the fixture 017893

1X56 138 197 and secure with securing ring


02.120.

6 Turn input shaft by 180° and clamp input


end in a vise with protective chucks.
02.120

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.

9 Subsequently put the parts - one after the


other - onto the input shaft:
- axial needle cage 02.310
- disk 02.320
- bearing ring 02.330 with securing ring
02.350
- axial roller cage 02.360
- disk 02.370
- split ring 02.380
- securing ring 02.390

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

Main shaft, 16 speeds 04.080


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
04.310
Snap ring 04.350 04.070

04.100 04.030
04.090
04.080
04.040

Main shaft, 10 and 12 speeds

017890

1327_04D_010_en
EN 1327.751.102d - 2014-11 100 2010-11
ZF-AS Tronic Main Shaft

Dismantling main shaft

1 Clamp main shaft in a vise with protective


chucks.

2 Remove oil pipe 04.040.

3 Press spline 04.030 out of the bore (e.g. with


a small screwdriver) and pull downwards.
Secure the last helical gear again with the
spline.

4 Pull off the sliding sleeve 04.350. 04.030

5 Offset the washer 04.310 by 1/2 a tooth and


take it off. Main shaft, 10 and 12 speeds 015207

6 Pull off the helical gear 04.300. Take the 04.200


wheel disk 04.290 and the snap ring 04.280 04.110

out of the helical gear.


04.210
04.220
04.230

7 Offset the washer 04.270 and the washer


04.240
04.250
04.250 by 1/2 a tooth and take them off.
04.270
04.280
04.290
8 Take off the helical gear 04.220. Remove the 04.300 04.020

wheel disk 04.230 and the snap ring 04.240


04.010
04.310
from the helical gear 04.350 04.070
04.100 04.030
04.090
9 Offset the washer 04.210 by 1/2 a tooth and
04.080
04.040
take it off.

10 Take off the sliding sleeve 04.200.


Main shaft, 10 and 12 speeds 015206

11 Remove the following parts from the main


shaft 04.010:
04.280 04.110

- washer 04.160*
04.290
04.300 04.130 04.110

- helical gear 04.150*


04.140
04.310 04.150
- wheel disk 04.140*
04.350
04.160
- snap ring 04.130* 04.200
- 2* and/or 1 washer 04.110
04.210
04.220
- snap ring 04.100
- wheel disk 04.090
04.230 04.020
04.240
- helical gear 04.080
04.010
04.250
04.270
- disk 04.070 and
04.060
04.030
- sliding sleeve 04.060* 04.080
04.040
04.090
12 If the oil pipe 04.020 is damaged, please
remove it. 04.100 04.070

Main shaft, 16 speeds 015205


* only for 16 speeds

1327_04D_010_en
EN 1327.751.102d - 2014-11 101 2010-11
ZF-AS Tronic Main Shaft

Assembling 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

Measure the snap rings


Main shaft, 16 speeds and select the OTK
04.080 (optional technical kit)

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

Measure these snap


rings and washers, then
Main shaft, 10 and 12 speeds select the OTK (optional
technical kit).

017890

1327_04D_020_en
EN 1327.751.102d - 2014-11 102 2010-11
Main Shaft

1 Drive in oil pipe 04.020 using tool


1X56 138 205 in the main shaft 04.010.
Control dimension: Oil pipe protrudes by
15-1 mm.
04.070
2 Clamp main shaft in a vise with protective
chucks.
3 For the 16-speed version, push the sliding
sleeve 04.060* onto the main shaft in such a
04.030
manner that the recesses of the inner gearing
point towards the spline 04.030.
4 Push the disk 04.070 onto the main shaft. In
the groove of the main shaft, offset the disk
04.070 by half a tooth and secure it with the
spline 04.030.
Main shaft, 10 and 12 speeds 016658

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

Measure these snap rings


and washers, then select the
OTK (optional technical kit).

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

Set axial play of the helical gear in relation to


the wheel disk Measurement 1
(Refer to ZF-Service Information No. 25_05 in the
Annex.)

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

04.300, and, if necessary, 04.150 (16-speed


04.090

version).

Measurement 1

1 Insert the wheel disk 04.090 and the snap 028247

ring 04.100 in the helical gear 04.080.


Measurement 2
2 Measure from the rim of the helical gear
04.080 to the wheel disk 04.090; set depth
gage to zero.

Measurement 2

0–0.10 mm
3 Put the complete helical gear 04.080 onto a
-0.03

tube or something similar (so that the

Spiel
Play
04.100

wheel disk and the snap ring are being


04.090

pushed upwards).

4 Measure from the rim of the helical gear


04.080 to the wheel disk 04.090. Tube
Rohr
04.080
5 If the measurement value is outside of the
tolerance range (0 up to 0.10 mm):
028246

Disassemble the snap ring 04.100.

6 Select and mount a new snap ring


(calculated) 04.100 from the OTK.

7 If necessary (at clearance 0), insert the


snap ring 04.100 into the groove by
applying soft blows.

8 Check the axial play again.

9 Repeat the steps of action until the


measurement value resides within the
tolerance range.

10 Set the axial play for the helical gears


04.220, 04.300, and, if necessary, 04.150
in the same way.
1327_04D_030_en
EN 1327.751.102d - 2014-11 105 2010-11
ZF-AS Tronic Main Shaft

Set axial play of the washer in relation to the wheel disk


(Refer to ZF-Service Information No. 25_05 in the Annex.)

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

0.15–0.25 mm 0.15–0.25 mm 0.15–0.25 mm

028194

Setting this type of axial play is a process which


Measurement 1
is only done with 12-speed transmissions. For
exceptions, see ZF-Service Information No.
0.00

25_05 in the Annex.


04.010
NOTE
For explanations on the setting of the required
axial play of 0.15 up to 0.25 mm, please refer to Bush
the example of the helical gear 04.080. The same
procedure applies for the helical gears 04.220
and 04.300.
04.080

Measurement 1
04.110
04.090 04.070

1 Mount the disk 04.070 onto the main shaft


04.100

04.010.
028227

2 Mount the helical gear 04.080 with the


securing ring 04.100 and the wheel disk
04.090 onto the main shaft.

3 Mount the washer 04.110 to the main shaft. CAUTION


The measurement must be effected directly on
4 Measure from the input-end of the main the wheel disk or by mains of a bush located on
shaft up to the bush; depth gage must be the wheel disk.
set to zero.

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

Take off the washer 04.110.


04.090

04.100

8 Select and mount a new washer (calculated)


04.110 from the OTK.
04.070

028234

9 Check the axial play again.

10 Repeat the steps of action until the


measurement value resides within the
tolerance range.

11 Set the axial play for the helical gears 04.220


and 04.300 in the same way.

1327_04D_040_en
EN 1327.751.102d - 2014-11 107 2010-11
ZF-AS Tronic Countershaft

Countershaft

Disassembling the countershaft


03.020

1 Pull off the bearing’s inner rings 03.020,


03.040, 03.120, 03.140 with the gripping 03.010

insert 1X56 136 740 and the basic tool


03.120

1X56 122 304. 03.040


03.110

NOTE
Further disassembly of the countershaft is not
possible, i.e. when the gearing is damaged, you
03.140

will always have to replace the complete counter-


shaft.

16-speed version 016668

Mounting the countershaft

CAUTION 03.020

Check the tapered roller bearings; if necessary,


replace them because the gripping process may 03.010

have damaged the bearing rollers. 03.120

1 Heat up the bearing’s inner rings 03.020,


03.040
03.110

03.040, 03.120, 03.140 to approx. 120 °C


and position axially, in a playfree manner on
the countershaft.
03.140

DANGER
10- and 12-speed version
Only touch heated parts when wearing protecti-
016669

ve gloves.

2 For installing the countershaft, please refer to


the chapter “Install Shaft Package”.

1327_03D_010_en
EN 1327.751.102d - 2014-11 108 2007-05
ZF-AS Tronic Selector Shaft

Selector Shaft

NOTE
06.100

Assembly and disassembly of the spacer 06.200 is 06.120


described in Chapter Housing I.
06.020

06.140 06.010
06.160

028241

Dismantling the selector shaft

1 Unlock the shift forks 06.100*, 06.120,


06.100

06.160 and take them out. 06.120

2 Remove interlock 06.140 from selector shaft


06.010.
06.020

06.140 06.010
06.160

16-speed version 028241

Assembling the selector shaft


06.120
1 Place interlock 06.140 on selector shaft.

2 Thread shift forks 06.100*, 06.120 and


06.160 into interlock in correct positional
06.020

arrangement. 06.010
06.140

CAUTION 06.160
Do not interchange shift forks 06.120 and 06.160;
refer to parts list.

3 For installing the selector shaft, please refer


to the chapter “Install Shaft Pack”.

12-speed version 028240


* only for 16-speed version

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

Dismantling housing II 3 Remove the bearing’s outer rings from the


tapered-roller bearings 03.020, 03.120 in
NOTE the case that the bearing’s inner rings at the
The idler shafts 05.010, 05.110 have already been countershaft are to be replaced.
removed.
Prior to the removal of the bearing’s outer
1 Remove the R gear’s reversing gears 05.040, rings, heat up the bearings’ seats to approx.
05.140 and take out the needle cages 80 °C.
05.020, 05.120.
4 Remove snap ring 32.330.
2 Remove the M24x1.5 screw plugs 01.460,
01.480, 01.490. 5 Heat up the bearings’ seat to approx. 100 °C
and cautiously remove the bearing’s outer
DANGER ring of the cylindrical roller bearing 32.310.
Only touch heated parts when wearing
protective gloves. 6 Only remove the bolts 01.440 if they are
defective or if the housing II is to be replaced.
Heat up the housing II to approx. 90 °C and
drive out bolts.

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

Assembling housing II 4 Tighten the M24x1.5 screw plugs 01.460,


01.480, 01.490 with 60 Nm.
DANGER
5 Insert the R gear’s reversing gears 05.040,
Only touch heated parts when wearing
05.140 together with the needle cages
protective gloves.
05.020, 05.120.
CAUTION
6 The idler shafts 05.010, 05.110 are installed
In order to avoid the generation of assembly
at a later point in time.
grooves, lightly coat the bearings’ seats with oil
prior to heating them up.
7 If the bolts 01.440 are missing, then heat up
1 Heat up the bearing seat of the cylindrical the housing II to approx. 90 °C, lightly grease
roller bearing 32.310 to approx. 100 °C and the bolts and drive them in cautiously or use
insert the bearing’s outer ring in the housing a manually operated press for pressing them
II (until it axially abuts). in.

2 Insert snap ring 32.330. CAUTION


Avoid canting/misalignment of bolts during
3 Heat up the bearings’ seats of the tapered- assembly danger of housing fracture!
roller bearings 03.020, 03.120 to
approx. 100 °C and insert the bearing’s outer 8 For the installation of shaft pack, please refer
rings. to the corresponding chapter.

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: --

Wiring Fastening for Clutch Actuator on ASTRONIC Transmissions

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:

Parts list modification for 1st stage

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

+) Mod = announcement number of parts list modification

Parts list modification for 2nd stage

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

+) Mod. = announcement number of parts list modification

Author: W. Ammann, Dept. LKS-T


07541 - 77 55 52
Fax 07541 - 77 90 55 52
E-mail: wolfgang.ammann@zf.com i.V. Venus i.A. Ammann
ZF Friedrichshafen AG, 88038 Friedrichshafen Kundendienst Technischer Service
© ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 113
SERVICE INFORMATION
Nr. 02_04 Page 2 of 5

Availability of parts in spare parts system:

Designation Item number Remark


Housing, OLD 1327 301 020 can no longer be supplied
Housing, OLD 1328 301 045 can no longer be supplied
Fixing device 1328 301 052 can still be supplied
Cable clip 0501 317 817 available
Fastening 0501 214 086 available, can only be fitted on new housing 2

Start data:

1st modification stage

The start of the parts list modification has been recorded as follows:

Transmission Model no. As of product number Mod. +)


12 AS 3001 1329 262.440 2239D
12 AS 3001 IT 1329 261.753 2237D
16 AS TD/TO IT 1328 262.655 2234D
16 AS TD/TO 1328 262.643 2231D
12 AS TD/TO 1327 263.843 2227D
12 AS TD/TO IT 1327 263.895 2223D

+) Mod. = announcement number of parts list modification

2nd modification stage

Only the start date of December 1, 2003 has been recorded for the modification.

EN 1327.751.102d - 2014-11 114


SERVICE INFORMATION
Nr. 02_04 Page 3 of 5

OLD fastening of wiring

Fixing device
1328 301 052

NEW fastening of wiring

Fastening
0501 214 086

EN 1327.751.102d - 2014-11 115


SERVICE INFORMATION
Nr. 02_04 Page 4 of 5

Fastening for wiring (underside of transmission, second modification stage)

OLD

Fixing device
1328 301 052

NEW

Cable clamp 0659 050 410

EN 1327.751.102d - 2014-11 116


SERVICE INFORMATION
Nr. 02_04 Page 5 of 5

Modified point on housing 2

EN 1327.751.102d - 2014-11 117


SERVICE INFORMATION
Nr. 02_05
Type: ASTRONIC Model: 1327,1328,1329,1337,1339 Date: 2005-01-20
CC list SSO: all 1348,1353,4231,4232,4240,4241 Page 1 of 5
CC list OEM: all Subassembly: Heat exchanger
CC list customer: --

New Housing Seals in ASTRONIC 2 Transmissions

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:

The new housings are being introduced in two steps:

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).

The following MUST be noted during repairs:

Old housings must be fitted with liquid gaskets,


New housings must be fitted with solid seals (2 metal gaskets).

Non-compliance with this procedure will result in transmission failure!

Author: W. Ammann, LKS-T dept.


07541 - 77 55 52
Fax 07541 - 77 90 55 52
Email: wolfgang.ammann@zf.com i.V. Stauber i.A. Ammann
ZF Friedrichshafen AG, 88038 Friedrichshafen Kundendienst Technischer Service
© ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 118
SERVICE INFORMATION
Nr. 02_05 Page 2 of 5

Components affected:

• Housing 2 (1st step)

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

Designation Item number Remark


Sealing compound 0666 791 001 Replacement part, 22 g tube
OLD
Gasket 0666 790 040 Replacement part, 7 g tube
Metal gasket,
Seal 0501 321 442
Clutch housing - housing 2
NEW
Metal gasket,
Seal 0501 321 443
Housing 2 - GP housing

Diagram of sealing face/GP thrust surface of housing 2:

• OLD Assembly with liquid gasket

Housing sealing face and thrust surface of GP plate at the same height

Figure 1

EN 1327.751.102d - 2014-11 119


SERVICE INFORMATION
Nr. 02_05 Page 3 of 5

• NEW, volume production introduction of 1st step

Assembly with solid seal


Shoulder can be felt when machining between housing’s sealing face and thrust surface of GP
plate.

Blue = Housing’s sealing face


Red = Thrust surface of GP plate
Date for introduction as of approx. January /February 2005

Figure 2

Step 1
Shoulder can be felt
by machining

• NEW, volume production introduction of 2nd step

Assembly with solid seal

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

Ribs are cast deeper

Ribs are cast deeper

EN 1327.751.102d - 2014-11 120


SERVICE INFORMATION
Nr. 02_05 Page 4 of 5

Diagram of ASTRONIC 2 transmission

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

Item number Dimension L, housing 2 Remark


1328 301 060 227.5 -0.1 Housing 2, long version
OLD
1327 301 023 184.5 -0.1 Housing 2, short version
1328 301 069 226.75 -0.13 Housing 2, long version
NEW
1327 301 026 183.75 -0.13 Housing 2, short version

Start data:

Parts list modification for 1st step

Parts list change notification Launch date Remark


9723D 15.06.2005 Housing 2, long new + 2 metal gaskets
1019E 15.06.2005 Housing 2, short new + 2 metal gaskets

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SERVICE INFORMATION
Nr. 02_05 Page 5 of 5

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

New ► • Housing 1327 298 002 consisting of:

Quantity Designation Order number Remark


1 Housing 1327 301 026 Short version
1 Seal 0501 321 442 Clutch housing - housing 2
1 Seal 0501 321 443 Housing 2 - GP housing

New ► • Housing 1328 298.003 consisting of:

Quantity Designation Order number Remark


1 Housing 1328 301 069 Long version
1 Seal 0501 321 442 Clutch housing - housing 2
1 Seal 0501 321 443 Housing 2 - GP housing

• Sealing kit 1327 298 001 consisting of:

Quantity Designation Order number Remark


4 Sealing ring 0730 008 637 A 24x29
2 Sealing ring 0730 009 515 A 22x27
1 Sealing ring 0634 801 013 A 10x14
1 Seal 0501 316 322
1 Shaft seal 0750 111 348 OTK 55x70x8
2 Shaft seal 0734 309 397
1 Shaft seal 0734 319 459 105x125x12/9.5
1 O-ring 0634 313 805 82x4
4 O-ring 0634 313 523 13x2
1 Grooved ring 0501 318 282 71.7x6.5
1 Compression spring 0732 040 385
2 Gasket 0666 790 040 7 g tube
1 Sealing compound 0666 791 001 22 g tube
1 Seal 1238 308 201
2 Sealing ring 0634 801 308 A20x24
New ► 1 Seal 0501 321 442 Metal gasket
New ► 1 Seal 0501 321 443 Metal gasket

EN 1327.751.102d - 2014-11 122


SERVICE INFORMATION
Nr. 08_00
Type: ECOLITE Model: 1304 cc: Date: 07-03-2000
ECOMID 1307 Page 1 of 4
ECOSPLIT 1315, 1316
ECOMAT 4139, 4149
ASTRONIC 1314, 1318, 1327

Impulse sensor and speed sensor (output sensor) in ZF transmissions

As requested by some customers, ZF transmission production series are delivered without


impulse sensor or speed sensor. The threaded hole is then sealed by a screw plug. If the im-
pulse sensor or speed sensor should go missing during a repair operation, it will not be possi-
ble to determine which impulse sensor or speed sensor is to be installed. Tables 1, 2 and 3 are
to assist in detecting the relevant components.

Transmissions affected

• ECOLITE: S 6-36, S 5-42, S 6-85, 6 S 850, 6 S 1600


• ECOMID: 9 S 75, 9 S 109, 16 S 109, 8 S 180
• ECOSPLIT: 8 S 151, 8 S 181; 8 S 221; 8 S 251; 16 S 151, 16 S 181; 16 S 221; 16 S 251
• ECOMAT: HP 500; HP 590; HP 600; HP 502; HP 592; HP 602
• ASTRONIC

Measures

Repair method for transmissions :


Assembly of new output sensor according to parts list and exchange of old component in ac-
cordance with the table.

Repair method for vehicles :


Replacement of output sensor in accordance with parts list, comparison of old component
with the contents of the table or inspection of the respective speed sensor in the vehicle.

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.

ZF Friedrichshafen AG Ersteller: Ammann


D-88038 Friedrichshafen
Telefon 07541 - 77 55 52
PC-Fax 07541 - 77 90 55 52 i.V. Schenk i.A. Schelkle
 ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 123
SERVICE INFORMATION
Nr. 08_00 Page 2 of 4

Variants of impulse sensors / speed sensors, mechanical transmissions

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

EN 1327.751.102d - 2014-11 124


SERVICE INFORMATION
Nr. 08_00 Page 3 of 4

Variants of impulse sensors / speed sensors, ECOMAT transmission

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.

EN 1327.751.102d - 2014-11 125


SERVICE INFORMATION
Nr. 08_00 Page 4 of 4

Variants of switches and impulse sensors /ASTRONIC transmissions

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

EN 1327.751.102d - 2014-11 126


SERVICE INFORMATION
Nr. 12_03 Datum: 2012-01-19 Seite1 of 4
Astronic Getriebe 1327, 1328, 1329, 1336, 1337, 1338,
1339, 1353, 1348 Kupplungssteller
Product,Transmission,Auxiliary Unit Model Assembly group

All DAF, IVECO, MAN, Irisbus, Van Hool, VDL


ZF Services OEM/Customer

Introduction of a new Plug Connection at the Clutch Actuator (CAU)

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:

Old (CAU 1 Service In- Old (CAU 2 Service In- New


formation 08_10) formation 08_10)
Designation Material number Material number Material number
Clutch actuator 0501.212.474 0501.215.260 0501.219.051
Clutch actuator 0501.213.233 0501.216.297 0501.219.052
Cable clamp none 0501.327.934

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.

EN 1327.751.102d - 2014-11 128


SERVICE INFORMATION
No. 12_03 Seite 3 of 4

Note:
• No preventive replacement of the clutch actuator.

• The clutch actuator is only to be replaced in case of complaint.

• Spare parts of the clutch actuator on stock with produced with the "macromelt casting"
method can be used up.

The following repair kits are available for repairs:

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.

• Repair kit for clutch actuator 1328.298.005 without pushrod

Item Quantity Designation Material number


10 1 CLUTCH ACTUATOR 0501.219.051
20 1 CABLE CLAMP 0659.050.410
30 4 STUD 0636.100.278
40 4 WASHER 0630.100.295
50 4 NUT 0637.006.280
400 1 CABLE CLAMP 0501.327.934

• Repair kit of the clutch actuator 1328.298.010 with push rod

Item Quantity Designation Material number


10 1 CLUTCH ACTUATOR 0501.219.051
20 1 CABLE CLAMP 0659.050.410
30 4 STUD 0636.100.278
40 4 WASHER 0630.100.295
50 4 NUT 0637.006.280
60 1 PUSHROD 1328.368.043
70 1 NUT 0637.100.652
400 1 CABLE CLAMP 0501.327.934

EN 1327.751.102d - 2014-11 129


SERVICE INFORMATION
No. 12_03 Seite 4 of 4

Introduction of modification

Model Transmission type As of product number Date


1327; 1328; 1329 ASTRONIC 2
1337;1338; 1339 722271 2011-12-13
1348;1353
1336 ASTRONIC MID 34664 2012-01-03

Transmissions on stock:

A retrofit of swing units on stock is not necessary.

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, ... ).

• Damaged part Damage *)


Poi
Designation Material number Place Type Cause
nt
0501.212.474
072 215
0501.215.260 013
1 Clutch actuator electrical con- electrically
0501.216.297 external effects
nection defective
0501.213.233
*) = in accordance with the damage coding catalog no. 1200.754.001 (German), no. 1200.754.101 (English), 2008 edition

Validity:

This service information is valid for an unlimited period from 2012-02-01.

EN 1327.751.102d - 2014-11 130


SERVICE INFORMATION
No. 13_03 Date:07-05-2013 Page 1 of 4
All all Housings
Product,Transmission,Auxiliary Unit Model Assembly group
All All
ZF Services OEM/Customer

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:

Successor Continental Predecessor


Kitas 2+/ 2+ Kitas 2
opt.
Order number Item
Designation Item number
number
Impulse sensor stat. L = 19.8 mm 0501.220.119 2171.20002110 0501.214.768
Impulse sensor stat. L = 90.0 mm 0501.220.120 2171.20002210 0501.214.769
Impulse sensor stat. L = 25.0 mm 0501.220.121 2171.20002310 0501.214.770 Standard
Impulse sensor stat. L = 63.2 mm 0501.220.122 2171.20002410 0501.214.771 version
Impulse sensor stat. L = 35.0 mm 0501.220.123 2171.20002510 0501.214.772
Impulse sensor stat. L = 136.8 mm 0501.220.124 2171.20002610 0501.214.773
Impulse sensor dyn. L = 90.0 mm 0501.220.125 2171.20502210 0501.214.774 for electric
Impulse sensor dyn. L = 35.0 mm 0501.220.126 2171.20502510 0501.214.775 retarder
Impulse sensor dyn. L = 115.0 mm 0501.220.127 2171.20502810 0501.214.776

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:

Identification of Kitas 2+ optimized

Serial no. Continental


no.

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).

EN 1327.751.102d - 2014-11 132


SERVICE INFORMATION
No. 13_03 Page 3 of 4

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

Transmission As of product Kitas 2+ types


model number Date Transmission type affected
1341 767908 2012-11-23 Ecosplit, Ford Otosan only 0501.220.119
0501.220.120
1353 797373 2012-12-12 AS Tronic, Ford Otosan only 0501.220.119
0501.220.120
1343 773900 2013-01-07 Ecosplit, all remaining 0501.220.119
0501.220.120
1353 801172 2013-01-08 AS Tronic, all remaining 0501.220.119
0501.220.120
1308 375956 2013-01-03 Ecomid 9 S 75 0501.220.119
1324 175887 2012-12-27 New Ecomid 0501.220.119
1336 040595 2013-01-02 AS Tronic mid 0501.220.119
1307 312823 2013-01-14 Ecolite S5-42 0501.220.121
0501.220.122
1346 178609 2013-01-10 Volume production entry of 0501.220.120
model 1346 0501.220.121
0501.220.125
1347 036101 2013-01-15 Volume production entry of 0501.220.121
model 1347
4181 337339 2013-01-07 EcoLife, model 4181 0501.220.123
1268 001898 2013-01-18 Classic Line 0501.220.119

Transmissions on stock.

• Existing transmissions should be retrofitted to the "Kitas 2+ optimized" version

EN 1327.751.102d - 2014-11 133


SERVICE INFORMATION
No. 13_03 Page 4 of 4

Damage coding:

Defective part Damage *)


Designation Item number Location Type Cause
0501.220.119
0501.220.120
0501.220.121
0501.220.122
072 157 212
Impulse sensor 0501.220.123
0501.220.124 Electrical connection broken Manufacturing defect
0501.220.125
0501.220.126
0501.220.127
*) = in accordance with the damage coding catalog no. 1200 754 001 (German), no. 1200 754 101 (English), 2008 edi-
tion

Validity:

This Service Information is valid for an unlimited period from 2013-03-01.

EN 1327.751.102d - 2014-11 134


SERVICE INFORMATION
No.14_07 Date: 27-03-2014 Page 1 of 6
AS Tronic 2 Alle Ausrückgabel
Product, Transmission, Auxiliary Unit Model Assembly group

Alle Alle
ZF Services OEM/Customer

New Release Fork for AS Tronic 2

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:

During installation of the fork, no grease must be applied to the bush.


The lateral contact surfaces with the clutch release bearing as well as the spherical shell are lubricat-
ed in the same way as before (see annex and/or lubrication instruction for clutch release mechanism
in the ZF-ServiceLine).

Release fork 1328.268.013 can replace the entire previous release fork 1328.268.012, component
parts are not compatible.

Presently, release fork 1328.268.012 continues to be installed in AS Tronic mid transmissions.

left: old bush, greased inside


right: new bush, without grease

Component part, new release fork: 1328.368.047 (can


only be obtained as complete component 1328.268.013)

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

Comparison complete release fork: left new, right old


Once the new fork has been installed, identification is only possible via the part number.

Components concerned:

NEW OLD
Designation Material number Material number
Release fork 1328.268.013 1328.268.012

Use of old parts:

Use up used parts

Transmissions on stock:

Not affected

Spare part kits:

Quantity Designation Material number


1 Repair kit 1328.298.008

Change data / Introduction data:

Transmission parts
list Product number Date Parts list amendment
Z000188991
1327.036.029 829218 2013-05-03
2013-05-02

EN 1327.751.102d - 2014-11 136


SERVICE INFORMATION
No. 14_07 Page 3 of 6

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:

Defective part Damage *)


Designation Material number Location Type Cause
048
Release fork 1328.268.012 035 (bush) 768 (worn)
(Design change)
*) = in accordance with the Damage Coding catalog no. 1200 754 001 (German), no. 1200 754 101 (English), 2008 edition

Validity:

This Service Information is valid for an unlimited period from 2014-03-15.

EN 1327.751.102d - 2014-11 137


SERVICE INFORMATION
No. 14_07 Page 4 of 6

Lubrication process for clutch release mechanism before transmission installation


Design: Release fork with cams (design until model year 06/2007)

Grease contact surface of


!! Attention !!
cams and release bearing
DO NOT Grease Release Bearing
to Input Cover Hub Surfaces. This
surface is coated with Teflon.

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.)

EN 1327.751.102d - 2014-11 138


SERVICE INFORMATION
No. 14_07 Page 5 of 6

Lubrication process for clutch release mechanism before transmission installation


Design: Release fork with rollers / repair kit 1328.298.008 (design from
07/2007 to 05/2013)

!! Attention !!
DO NOT Grease Release Bea-
ring to Input Cover Hub
Surfaces. This surface is coated
with Teflon.

 Grease Edges of the Re-


lease Bearing
 Grease heat treated
surface between roller
and fork
 Grease Push-Rod Pocket

!! Reminder!! Grease input


shaft as shown on page
one

!!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.)

EN 1327.751.102d - 2014-11 139


SERVICE INFORMATION
No. 14_07 Page 6 of 6

Lubrication process for clutch release mechanism before transmission installation


Design: Release fork with rollers / release fork 1328.268.013 (Design as of
06/2013)

On the new version there is no grease between sliding


and pivot shaft

No grease on the sliding bush!

The contact points to the release bearing and to the push


rod are greased same as before

EN 1327.751.102d - 2014-11 140


SERVICE INFORMATION
No.14_09c Date: 28-04-2014 Page 1 of 10
ECOMID, ASTRONIC MID, All Output
ECOSPLIT, ASTRONIC Model Assembly group
Product, Transmission, Auxiliary Unit
All All
ZF Services OEM/Customer

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.

Contents of the Service Information:

ECOMID Page 2-3


ECOSPLIT Page 4-5
ASTRONIC MID Page 6-7
ASTRONIC Page 8-9

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

Output flange Ø180 1304.338.097 1324.338.004


Output flange Ø180 1304.338.123 1324.338.005
Output flange Ø180 0501.325.822 1324.338.006
Output flange Ø180 0501.326.139 1324.338.006

Output flange Ø150 1304.238.002 1304.238.013


Output flange Ø150 1304.238.003 1304.238.014
Output flange Ø150 1304.238.004 1304.238.015
Output flange Ø150 1304.238.007 1304.238.016
Output flange Ø150 1304.238.008 1304.238.017
Output flange Ø150 1304.238.009 1304.238.018
Output flange Ø150 1304.238.010 1304.238.019
Output flange Ø150 1304.238.011 1304.238.020

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.

EN 1327.751.102d - 2014-11 142


SERVICE INFORMATION
No. 14_09c Page 3 of 10

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

Use of used parts:

Use up used parts

Transmissions on stock:

Not affected

Attention:

Do only press in with the above mentioned tools.


For geometrical reasons, the new shaft sealing ring has to be pressed in more accurately than the old
one (axial dimension). Therefore, the old tool must not be used for the new shaft sealing ring.

Introduction of modification:

Transmission parts list Product number Date Parts list change


1324.031.036 214907 2014-01-03 Z000219582

EN 1327.751.102d - 2014-11 143


SERVICE INFORMATION
No. 14_09c Page 4 of 10

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

Output flange 1325.332.027 1325.332.031


Output flange 1325.332.026 1325.332.032
Output flange 1327.332.007 1358.332.021
Output flange 1327.332.006 1358.332.226
Output flange 1348.332.004 1348.332.006
Output flange 1314.332.054 1358.332.210
Output flange 1348.332.002 1348.332.007
Output flange 1327.332.002 1358.332.020
Output flange 1325.332.012 1325.332.036
Output flange 1316.332.135 1316.332.146
Output flange 1325.332.029 1325.332.034
Output flange 1325.332.030 1325.332.035
Output flange 1316.338.002 1316.338.005
Output flange 1316.338.144 1316.338.148
Output flange 1316.338.003 1316.338.006
Output flange 1348.332.001 1348.332.008
Output flange 1315.338.002 1315.338.005
Output flange 1313.338.013 1315.338.007

Emergency steering
6091.315.008 6091.315.009
pump housing

EN 1327.751.102d - 2014-11 144


SERVICE INFORMATION
No. 14_09c Page 5 of 10

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

Use of used parts:

Use up used parts

Transmissions on stock:

Not affected

Attention:

Do only press in with the above mentioned tools.


For geometrical reasons, the new shaft sealing ring has to be pressed in more accurately than the old
one (axial dimension). Therefore, the old tool must not be used for the new shaft sealing ring.

Introduction of modification:

Transmission parts list Product number Date Parts list change


1356.002.064 825511 2013-11-05 Z000209288

EN 1327.751.102d - 2014-11 145


SERVICE INFORMATION
No. 14_09c Page 6 of 10

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

Output flange Ø180 1336.338.001 1336.338.015


Output flange Ø180 1336.338.007 1336.338.017
Output flange Ø180 1336.338.013 1336.338.017
Output flange Ø180 1336.338.005 1336.338.018
Output flange Ø180 1336.338.010 1336.338.019
Output flange Ø180 1336.338.011 1336.338.020
Output flange Ø180 1336.338.008 1336.338.022

Output flange Ø150 1336.238.005 1336.238.007


Output flange Ø150 1336.238.006 1336.238.008

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.

EN 1327.751.102d - 2014-11 146


SERVICE INFORMATION
No. 14_09c Page 7 of 10

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

Use of used parts:

Use up used parts

Transmissions on stock:

Not affected

Attention:

Do only press in with the above mentioned tools.


For geometrical reasons, the new shaft sealing ring has to be pressed in more accurately than the old
one (axial dimension). Therefore, the old tool must not be used for the new shaft sealing ring.

Introduction of modification:

Transmission parts list Product number Date Parts list change


1336.033.022 047928 2014-02-26 Z000219224

EN 1327.751.102d - 2014-11 147


SERVICE INFORMATION
No. 14_09c Page 8 of 10

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

Output flange 1325.332.027 1325.332.031


Output flange 1325.332.026 1325.332.032
Output flange 1327.332.007 1358.332.021
Output flange 1327.332.006 1358.332.226
Output flange 1348.332.004 1348.332.006
Output flange 1314.332.054 1358.332.210
Output flange 1348.332.002 1348.332.007
Output flange 1327.332.002 1358.332.020
Output flange 1325.332.012 1325.332.036
Output flange 1316.332.135 1316.332.146
Output flange 1325.332.029 1325.332.034
Output flange 1325.332.030 1325.332.035
Output flange 1316.338.002 1316.338.005
Output flange 1316.338.144 1316.338.148
Output flange 1316.338.003 1316.338.006
Output flange 1348.332.001 1348.332.008
Output flange 1315.338.002 1315.338.005
Output flange 1313.338.013 1315.338.007

Emergency steering
6091.315.008 6091.315.009
pump housing

EN 1327.751.102d - 2014-11 148


SERVICE INFORMATION
No. 14_09c Page 9 of 10

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

Use of used parts:

Use up used parts

Transmissions on stock:

Not affected

Attention:

Do only press in with the above mentioned tools.


For geometrical reasons, the new shaft sealing ring has to be pressed in more accurately than the old
one (axial dimension). Therefore, the old tool must not be used for the new shaft sealing ring.

Introduction of modification:

Transmission parts list Product number Date Parts list change


1353.041.042 877408 2013-11-13 Z000209360

EN 1327.751.102d - 2014-11 149


SERVICE INFORMATION
No. 14_09c Page 10 of 10

Tool overview:

Transmissions Tools Item number of tool


Ecomid solo / Ecomid IT3 Press-in mandrel 1X56 197 444
Ecomid IT2 Press-in mandrel 1X56 197 428
Ecosplit solo / Ecosplit IT3 Press-in mandrel 1X56 197 443
Ecosplit IT2 Press-in mandrel 1X56 197 428
AS Tronic mid solo Press-in mandrel 1X56 197 443
AS Tronic solo / AS Tronic IT3 Press-in mandrel 1X56 197 443
AS Tronic IT2 Press-in mandrel 1X56 197 428

Compensation in warranty case:

For the efforts invested, remuneration for 2 hour working time can be obtained via the standard war-
ranty claim (WC) filing process.

Damage coding:

Defective part Damage *)


Designation Item number Location Type Cause

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:

This Service Information is valid for an unlimited period as of 2014-04-01.

EN 1327.751.102d - 2014-11 150


SERVICE INFORMATION
Nr. 20_04
Type: ASTRONIC Model: 1314,1318,1327,1328,1329, Date: 2004-10-21
CC list VSO: all 1337,1338,1339, 1353 Page 1 of 4
CC list OEM: -- Subassembly: Synchronizer
CC list customer: --

New Splitter Group Synchronizer Unit in ASTRONIC Transmissions

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

o Synchronizer unit for DD version, direct gear

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

Ersteller: W. Ammann, Abt. LKS-T


07541 - 77 55 52
Fax 07541 - 77 90 55 52
Email: wolfgang.ammann@zf.com i.V. Stauber i.A. Reinfeld
ZF Friedrichshafen AG, 88038 Friedrichshafen Kundendienst Technischer Service
© ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 151
SERVICE INFORMATION
Nr. 20_04 Page 2 of 4

ASTRONIC 2

o Synchronizer unit for OD version, overdrive gear

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

o Synchronizer unit for DD version, direct gear

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.

EN 1327.751.102d - 2014-11 152


SERVICE INFORMATION
Nr. 20_04 Page 3 of 4

Spare parts:

If repairs are undertaken, 3 synchronizer kits are available and have to be ordered under the
relevant kit number.

Synchronizer kits available:

Kit order number Version Scope of parts identical to modular Transmission


system PL type
1314 298 007 DD (direct gear) 1314 202 089 ASTRONIC 1
1328 298 001 OD (overdrive) 1328 202 039 ASTRONIC 2
1328 298 002 DD (direct gear) 1328 202 040 ASTRONIC 2

Start data:

Modular system Model no. Serial number Date Bulletin number


parts list Change to parts list
1314 202 089 1314, 1318 -- 15-04-2004 3544D
1328 202 039 1327, 1329, 1337, -- 15-03-2004 3543D
1338, 1339
1327 276.490 17-03-2004 3545D
1328 276.492 17-03-2004
1328 202 040
1329 276.485 17-03-2004
1338 -- --
1353 301.120 27-09-2004

EN 1327.751.102d - 2014-11 153


SERVICE INFORMATION
Nr. 20_04 Page 4 of 4

Sample sketch of installation situation of splitter group synchronizer unit in ASTRONIC 2


transmissions

EN 1327.751.102d - 2014-11 154


SERVICE INFORMATION
No. 25_05
Type: ASTRONIC Model no: 1327,1328,1329,1337, Date: 2006-01-27
CC list SSO: All + USA 1338,1339,1348,1353 Page 1 of 8
CC list OEM: All Assembly: Gear set
Mailing list customer: --

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:

Clearance setting for

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.

Main shaft disks to wheel disks on the main shaft;


is only done with 12-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.

Implementation of the indicated measures only in the case of:

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.

Author: W. Ammann, LKS-T dept.


 07541 - 77 55 52
Fax 07541 - 77 90 55 52
E-mail: wolfgang.ammann@zf.com i.V. Leibinger i.V. Stauber i.A. Ammann
Technical After-Sales Service
ZF Friedrichshafen AG, TRUCK Driveline Technology 88038 Friedrichshafen/Germany
© ZF Friedrichshafen AG
EN 1327.751.102d - 2014-11 155
SERVICE INFORMATION
No. 25_05 Page 2 of 8

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

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SERVICE INFORMATION
No. 25_05 Page 3 of 8

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

OTK = optional technical kit

Start data:

The changes will be introduced into the parts list (PL) system as follows:

 o  about Interchange- As of prod-


Model no. Date Comment
the PL change ability uct number
1329 0878E in sets 11.08.05 343.201 MS disks
1327, 1337,
0879E in sets 11.08.05 342.936 MS disks
1348, 1353
1327, 1338 0880E single 24.08.05 344.117 Main shaft
1327, 1328,
K2 – snap
1337, 1348, 0881E in sets 11.08.05 342.936
ring
1353
1327, 1329,
1337, 1338, MS – snap
0882E in sets 11.08.05 342.936
1339, 1348, ring
1353

MS = main shaft, K2 = constant gear 2, PL = parts list

EN 1327.751.102d - 2014-11 157


SERVICE INFORMATION
No. 25_05 Page 4 of 8

Spare parts:

Available spare parts, standard

Designation Part number Technical information


Main shaft 1328 304 032 Replaces 1327 304 025
Main shaft 1329 304 012 Replaces 1329 304 009
OTK securing ring 0769 144 298 (2.50 to 2.80) constant gear 2
OTK securing ring 0769 144 299 (2.50 to 2.70) main shaft gears
OTK main shaft disk 0769 143 685 (7.00 to 7.20) main shaft disks

ZF Maxton, spare parts available (FreedomLine)

Designation Part number Technical information


Main shaft 1328 304 063 Old shaft, still to be used.
Main shaft 1327 304 032 Replaces 1327 304 025
Main shaft disk 1328 304 049 Nickel-coated disk, still to be used.

EN 1327.751.102d - 2014-11 158


SERVICE INFORMATION
No. 25_05 Page 5 of 8

Sketch on installation situation main shaft – gears, 12-speed version

Figure 1

04.242
04.282 04.252
04.112

04.102
04.312

= Standard main shaft


disk (7.0 mm)

Sketch on installation situation main shaft – gears, 16-speed version

Figure 2

xx.xxx created (yellow color) and established with * / those marked item numbers do include information on
clearance setting in the parts list

EN 1327.751.102d - 2014-11 159


SERVICE INFORMATION
No. 25_05 Page 6 of 8

Sketch on installation situation input shaft constant gear 2, 12-speed version

Figure 3

K1K1
K2

= Standard snap ring (2.5 mm)


02.292

Sketch on installation situation input shaft constant gear 2, 16-speed version

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

EN 1327.751.102d - 2014-11 160


SERVICE INFORMATION
No. 25_05 Page 7 of 8

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.

NEW 7.25 mm NEW 7.25 mm NEW 7.25 mm


OLD 7.05 mm OLD 7.05 mm OLD 7.05 mm

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

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SERVICE INFORMATION
No. 25_05 Page 8 of 8

Clearance settings:

Components OLD: NEW: Comment


Gear to no setting with OTK no.: 0769 144 298
0 to 0.10 mm
wheel disk (0.05 to 0.30 mm) with OTK no.: 0769 144 299
Main shaft disks no setting Lubricating film required
0.15 to 0.25 mm
to wheel disk (0.20 to 0.45 mm) with OTK no. 0769 143 685

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

Setting disk Main shaft disk in the OTK Standard disk

Standard disk Setting disk

Validity:

The present Service Information is valid for an unlimited period as of February 01, 2006.

EN 1327.751.102d - 2014-11 162


ZF Friedrichshafen AG
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-908 000
www.zf.com

EN 1327.751.102d - 2014-11

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