Checklist for the removal of synchro transmission

Driveline & Chassis Technology

Vehicle owner: ............................................................................................................................

hiu

Customer address: ......................................................................................................................

Clutch:

Shift turret interface:

clutch functions
clutch release system
hydraulic connection

remote shifting system (linkage, cable, ball joints,)

nominal air pressure & air connection
electrical connections e.g. switch
safety features (range and gate group interlock)

Contact person with number:......................................................................................................

Vehicle data: ...............................................................................................................................
Vehicle manufacturer: .................................................................................................................

Main transmission:

Vehicle type: ...............................................................................................................................

quantity & quality of oil

presence of oil leakage
transmission breather
presence of gear noise
rattling or hammering

Chassis-no./VIN:..........................................................................................................................
Registration number:...................................................................................................................

Propshaft:
connection

Type of operation: .......................................................................................................................

Investigation to be run before removal

Engine type:................................................................................................................................
Engine performance:...................................................................................................................

Transmission data

Date of registration: ....................................................................................................................

Transmission type:.......................................................................................................................

Current kilometers:......................................................................................................................

Spec. no.: ...................................................................................................................................

Current engine hours: .................................................................................................................

Serial-no.: ...................................................................................................................................

Load carried: ...............................................................................................................................

Is the transmission mounted on the vehicle?

iRear axle: .....................................................................................................................................

Date of failure: ............................................................................................................................

Additional notes: .........................................................................................................................

Description of complaint: ............................................................................................................

...................................................................................................................................................

...................................................................................................................................................

...................................................................................................................................................

Failure history: ............................................................................................................................

Date of preparation: ....................................................................................................................

...................................................................................................................................................

ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C

1238 755 102a - 2010-03

yes

no

Page 1 of 3

Checklist for the removal of synchro transmission

Description of action
1

Clutch & engine interface

1.1

Check the clutch release behavior

Driveline & Chassis Technology

Reference value

Result

Operating temperature, idling speed, press

okay

Measures in case of not okay or no

not okay

Improve clutch release behavior:

clutch, after max. 20 sec engage the R-gear,

Correct clutch function is essential to avoid

during engagement no noise from the t/m

failures of the transmission

1.2

Check the clutch fluid (air bubbles etc.)

Bleeding procedure

okay

not okay

Improve clutch fluid system

1.3

Check the hydraulic connection to the

Is the connection in good shape?

yes

no

Repair hydraulic connections

Is there high clearance and/or wear?

okay

not okay

Repair/correct shift linkages and ball joints

Are the ball joints free to move?

yes

no

Are the ball joints broken or damaged?

yes

no

Are the link rods touching the body or frame?

yes

no

Are there marks on the link rods?

yes

no

General check of cable shifting

Is the cable damaged or blocked into the socket?

yes

no

Change the cable shifting

Check pneumatic connections at the

Are there oil or air leaks?

okay

not okay

Repair pneumatic connections

Is the pressure higher than 10 bar?

okay

not okay

Make sure the air pressure is not too high

Is the pressure lower than 6.2 bar?

okay

not okay

Make sure the air pressure is not too low

Is the connection secured?

okay

not okay

clutch booster

Shift turret interface

2.1

General check of shift linkage & ball joints

2.2

Check ball joints

2.3
2.4

Check of the linkage

2.5
2.6
2.7

Repair shift linkage and ball joints

Repair shift linkage and link rods

transmission
2.8

Check air pressure

2.9

Propshaft interface

3.1

Check the output connection

ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C

1238 755 102a - 2010-03

Page 2 of 3

Checklist for the removal of synchro transmission

Description of action
4

Check the oil level

4.1

Check the oil level

4.2
Check the oil quality
4.3

Driveline & Chassis Technology

Reference value

Result

Measures in case of not okay or no

Oil should come out through the oil filler in plug.

okay

not okay

Correct oil level

Does the oil comply with the ZF list of lubricants

yes

no

Only use the oil released by ZF

yes

no

Make sure the oil change intervals correspond

TE-ML 02?
Was the last oil change interval as specified?

to requirements
4.4

Check the oil status into the transmission

Not burned, no intense blackening,

okay

not okay

no water-in-oil emulsion, no metal particles

4.5
4.6

Check the transmission breather

Change oil and make sure that no further negative

influences are there

Clean and not covered with mud etc

okay

not okay

Clean/change the breather

Breather with pipes should be clean and no

okay

not okay

Clean/change the pipe

okay

not okay

Change the shift turret gasket without removing the

water leaking from the pipe.

4.7

On shift turret housing?

transmission (first repair level)

Check of oil leakage

4.8

Between shift turret & transmission main housing?

okay

not okay

Change the gasket between shift turret & transmission main housing (first repair level)

4.9

Noise check

Hammering or rattling noise?

okay

not okay

Ensure that the noise does not come from engine

or clutch

Further proceeding
1

If there are no further findings and if all checks from number 1.1 to 4.9 have been carried out and answered with okay or yes, the transmission can be released
by ZF for removal. Please contact ZF Hotline. 1.800.209.093

After removal, the following package has to be sent to an authorized ZF dealer for warranty investigation & repair:
1. The complete failed unit (still assembled)
2. The completed checklist for removal of transmission. Warranty can not be handled with an incomplete checklist.
3. Oil sample from the failed transmission

ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C

1238 755 102a - 2010-03

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