Escolar Documentos
Profissional Documentos
Cultura Documentos
Copyright by ZF
Printed in Germany
Edition: 2005-06
Page
Preface .................................................................................................................................................. 5
Safety Instructions................................................................................................................................ 6
Instructions for Repairs........................................................................................................................ 7
Overview of Amendments ................................................................................................................... 9
Tightening Torques............................................................................................................................... 10
Recoding from DIN to ISO Standards ................................................................................................. 12
Consumables......................................................................................................................................... 14
Spare Parts............................................................................................................................................ 15
Adjustment Data ................................................................................................................................... 16
Table of Springs .................................................................................................................................... 18
Special Tools ......................................................................................................................................... 19
3 Shift turret with left shifting output, disassembly and assembly .................................................... 3-1
3.1 Shift patterns, shift turret with left shifting output............................................................................. 3-6
4 Shift turret with right shifting output, disassembly and assembly.................................................. 4-1
4.1 Shit patterns, shift turret with right shifting output............................................................................ 4-9
6 Super H shift turret with HTC (superimosed H shift system), disassembly and assembly............ 6-1
6.1 Shift patterns, Super H shift turret (superimosed H shift system) .................................................... 6-5
7 Shift turret with superimposed H shift system with control cable, disassembly and assembly.... 7-1
7.1 Shift patterns, shift turret with superimposed H shift system............................................................ 7-7
Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
ZF Friedrichshafen AG the individual case.
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Damage resulting from work performed by non-ZF
Special Driveline Technology personnel in an improper and unprofessional
Service Werk 2 (Plant 2) manner and any consequential costs are excluded
Phone: +49 (0)7541 77-0 from the contractual liability agreement. Exclusion
Fax: +49 (0)7541 77-908000 of liability also applies if genuine ZF spares are
Internet: www.zf.com not used.
2003-08 5
Safety instructions
Companies repairing ZF units are responsible for Read this manual carefully before starting any tests
their own work safety. or repair work.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
2003-08 6
Instructions for Repairs
Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
2003-08 7
Instructions for Repairs
b) Never apply sealing agent to shaft seals with After completing repairs, fill transmissions with
“rubber jacket”, but apply a thin coat of transmission oil. For the procedure and approved
Vaseline 8420 to the circumference or wet with oils, refer to the transmission operating manual and
a lubricant, e.g. a water-soluble, concentrated TE-ML List of Lubricants (refer to identification
washing-up liquid (e.g. Pril, Coin, Palmolive). plate) which are available from any ZF After-Sales
Service Point and on the Internet under
c) Shaft seals with steel and rubber jackets should www.zf.com.
be treated on the circumference of the rubber After filling the transmission with oil, tighten the
jacket as described above in section b). screw plugs at the oil filling point and the oil over-
flow using the specified torques.
2003-08 8
Overview of Amendments: 1315 751 110
This standard applies to screws/bolts acc. to Surface condition of bolts / nuts: Thermally
DIN 912, DIN 931, DIN 933, DIN 960, DIN 961, as blackened and oiled or galvanized and oiled or
well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, galvanized, chrome-plated, and oiled.
ISO 8676, and to nuts acc. to DIN 934 as well as
ISO 4032, ISO 8673. Tighten screws with a calibrated ratchet dial torque
or ratchet wrench.
This Standard contains data on tightening torques
(MA) for screws/bolts and nuts in strength cate- NOTE
gories 8.8, 10.9, and 12.9, and nuts in strength cate- Deviating tightening torques are listed separately in
gories 8, 10, and 12. the Repair Manual.
Size Tightening torque (Nm) for Size Tightening torque (Nm) for
Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M7 15 23 28 M10x1.25 49 72 84
M8 23 34 40 M12x1.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
2003-08 10
Tightening Torques
Screw Plugs DIN 908, 910, and 7604 Union Screws DIN 7643
The screw plug tightening torques were determined The tightening torques were determined for screw-
according to DIN 7604 for screwing into steel, gray ing into steel, gray cast, and aluminum alloys.
cast, and aluminum alloys. The values are based on experience and are
The values are based on experience and are intended as reference values for the fitter.
intended as reference values for the fitter.
The values for the tightening torque apply General rule:
analogously to screw plugs according to DIN 908 Screw/ Bolt class 5, ZFN 148-1
and DIN 910, as the thread geometries are almost Material: 9SMnPb28K acc. to DIN 1651
identical. Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
General rule: chromated, and lightly oiled.
Screw/ Bolt class 5, ZFN 148-1
Screw/ Bolt material: Steel acc. to DIN 7604.
Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)
DIN 1 Tapered pins ISO 2339 - some can be replaced ∅ changed to ISO 2339
- parts which cannot be replaced (e.g. where 1 = 36 mm)
documented as DIN 1 OLD
DIN 7 Cylindrical ISO 2338 - some can be replaced ∅ changed to ISO 2338
pins - parts which cannot be replaced (e.g. diameter 13 and 14 and/or
where 1 = 36 mm) documented as DIN 7 OLD
DIN 84 Cylindrical ISO 1207 - some can be replaced ∅ changed to ISO 1207
screws - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD
DIN 85 Flat head bolts ISO 1580 - can be replaced ∅ changed to ISO 1580
DIN 94 Split pins ISO 1234 - can be replaced ∅ changed to ISO 1234
DIN 417 Threaded pins ISO 7435 - can be replaced ∅ changed to ISO 7435
DIN 439-1 Hex nuts ISO 4036 - cannot be replaced ∅ documented as DIN 439 OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675
DIN 551 Threaded pins ISO 4766 - can be replaced ∅ changed to ISO 4766
DIN 553 Threaded pins ISO 7434 - can be replaced ∅ changed to ISO 7434
DIN 555 Hex nuts ISO 4034 - cannot be replaced ∅ documented as DIN 555 OLD
DIN 558 Hex bolts ISO 4018 - some can be replaced ∅ changed to ISO 4018
- parts which cannot be replaced (e.g. M12, with new SW) documented as
DIN 558 OLD
DIN 601 Hex bolts ISO 4016 - some can be replaced ∅ changed to ISO 4016
- parts which cannot be replaced (e.g. M10 and M12, with new SW)
documented as DIN 601 OLD
DIN 912 Cylindrical ISO 4762 - some can be replaced ∅ changed to ISO 4762
screws - parts which cannot be replaced (e.g. M18, M22, M27, and M33)
documented as DIN 912 OLD
DIN 931-1 Hex bolts ISO 4014 - some can be replaced ∅ changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 931 OLD
DIN 933 Hex bolts ISO 4017 - some can be replaced ∅ changed to ISO 4017
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 933 OLD
DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for
ISO 8673 M10, M12, M14, and M22 with new SW.
DIN 960 Hex bolts ISO 8765 - some can be replaced ∅ changed to ISO8765
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 960 OLD
DIN 961 Hex bolts ISO 8676 - some can be replaced ∅ changed to ISO 8676
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 961 OLD
DIN 963 Countersunk ISO 2009 - cannot be replaced as a result of modified head dimensions ∅ documented
bolts as DIN 963 OLD
DIN 964 Countersunk ISO 2010 - cannot be replaced as a result of modified head dimensions ∅ documented
bolts as DIN 964 OLD
2003-08 12
Conversion from DIN to ISO Standards
DIN 965 Countersunk ISO7046 - cannot be replaced as a result of modified head dimensions ∅ documented
bolts as DIN 965 OLD
DIN 980 Locking nuts ISO 7042 - cannot be replaced ∅ documented as DIN 980 OLD
ISO 10513
DIN 985 Locking nuts ISO 10511 - cannot be replaced ∅ documented as DIN 985 OLD
DIN 1440 Washers ISO 8738 - some can be replaced ∅ changed to ISO 8738
- parts which cannot be replaced documented as DIN 1440 OLD
DIN 1443 Bolts ISO 2340 - can be replaced ∅ changed to ISO 2340
DIN 1444 Bolts ISO 2341 - can be replaced ∅ changed to ISO 2340
DIN 1471 Grooved pins ISO 8744 - some can be replaced ∅ changed to ISO 8744
- parts which cannot be replaced (e.g. 1 = 6 mm) documented as
DIN 1471 OLD
DIN 1472 Grooved pins ISO 8745 - some can be replaced ∅ changed to ISO 8745
- parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as
DIN 1472 OLD
DIN 1473 Grooved pins ISO 8740 - some can be replaced ∅ changed to ISO 8740
- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25 and 50 mm)
documented as DIN 1473 OLD
DIN 1474 Grooved pins ISO 8741 - can be replaced ∅ changed to ISO 8741
DIN 1475 Grooved pins ISO 8742 - can be replaced ∅ changed to ISO 8742
DIN 1476 Grooved stud ISO 8746 - can be replaced ∅ changed to ISO 8746
DIN 1477 Grooved stud ISO 8747 - can be replaced ∅ changed to ISO 8747
DIN 1481 Clamping pins ISO 8752 - some can be replaced ∅ changed to ISO 8752
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD
DIN 6325 Cylindrical pins ISO 8734 - some can be replaced ∅ changed to ISO 8734
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD
DIN 7346 Clamping pins ISO 13337 - some can be replaced ∅ changed to ISO 13337
Flange - parts which cannot be replaced (≥ 7, 11, and 23 mm) documented as
DIN 6325 OLD
DIN 7976 Self-tapping ISO 1479 - can be replaced ∅ changed to ISO 1479
screws
DIN 7978 Tapered pins ISO 8736 - some can be replaced ∅ changed to ISO 8736
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD
DIN 7979 Cylindrical pins ISO 8733 - some can be replaced ∅ changed to ISO 8733/8735
ISO 8735 - parts which cannot be replaced documented as DIN 7979 OLD
DIN 7981 Self-tapping ISO 7049 - can be replaced ∅ changed to ISO 1479
screws
DIN 7982 Self-tapping ISO 7050 - cannot be replaced ∅ documented as DIN 7982 OLD
screws
DIN 7985 Cheese-head ISO 7045 - can be replaced ∅ changed to ISO 7045
screws
2003-08 13
ZF-Ecosplit Consumables
Sealing compound
0666 690 017 Loctite Nr. 241 5 mm3 breather Section 3, 4, 5
Grease
0750 199 019 1g tappet Section 6, 7
pin
De
d
Dh Testing sleeve diameter in mm
Lo
nt
D
L0 Untensioned spring length in mm
nt Total of coils
d Wire diameter in mm
018325
Dh
Part number Installation point Total Wire diam. Spring diam. Untensioned
of in mm in mm length
coils at L0 in mm
[nt ] [d] [Dh] [De] [L0]
0732 040 985 Shifting output, left 6.5 2.0 14.4 23.4
0732 040 728 Shifting output, right 6.5 1.8 29.3 80.0
0730 040 630 Shift turret with HTC 6.5 2.4 39.1 89.9
1
2
6 5
7
012319
Disassembly Assembly
1 Loosen hollow screws (1 and 2) and remove 1 Place spring (7) inside servo-unit.
together with sealing rings and pipe (3).
2 Re-place servo-unit (5) together with new gas-
2 Loosen hexagon head screw (4). ket (6) on shift turret.
3 Remove pneumatic servo-unit (5) together 3 Insert and tighten hexagon head screw (4).
with gasket (6) and spring (7). Tightening torque = 23 Nm.
3
2
1
4
6
5
7
015984
1.2 Shift turret with HTC For dismounting and mounting on shift turret see
(hydrostatic control) Chapter 2.
Removal
1 Unfasten union screws (1 and 2) and take off Installation
with sealing rings and pipe (3).
1 Place spring (7) in servo unit.
2 Unfasten hexagon head screw (4).
2 Attach pneumatic servo unit (5) and new gas-
3 Take off pneumatic servo unit (5) with gasket ket (6) on shift turret.
(6) and spring (7).
3 Insert hexagon head screw (4) and tighten.
NOTE Tightening torque = 23 Nm.
Spring (7) lies loosely in the pneumatic servo
4 Fasten pipe (3) on valve block with union
unit.
screw (1) and new sealing rings.
Do not dismantle pneumatic servo unit any
Tightening torque = 20 Nm.
further. It is a complete part.
5 Attach pipe with union screw (2) and new
NOTE
sealing rings on the pneumatic servo unit.
The selector cylinder (8) and the shift cylinder
Tightening torque = 20 Nm.
(9) are only listed here for your information.
They remain in the vehicle when the transmis-
sion and/or shift turret are removed.
3
3
7
3
3 2
2 5
4
018645
Removal NOTE
Spring (6) is loosely placed in pneumatic servo
1 Loosen pipe (2) on plug-in connector (see
unit.
drawing).
Do not disassemble servo unit further - com-
2 Loosen hollow bolt (1) and remove together plete component!
with sealing rings and pipe (2).
NOTE
3 Loosen hexagon head screws (3). Selector cylinder (7) and shifting cylinder (8)
are mentioned here for information only. They
4 Remove servo unit (4) together with gasket (5)
remain in the vehicle during removal of the
and spring (6).
transmission or the shift turret. For dismount-
ing and mounting on shift turret see Chapter 2.
3
3
7
3
3 2
2 5
4
018645
Installation
2 4
024463
Removal Installation
1 Loosen 4 hexagon head screws (1). 1 Place spring (4) in servo unit.
2 Remove pneumatic servo unit (4) together 2 Mount pneumatic servo unit (2) together with
with gasket (3) and spring (6). new gasket (3) on shift turret.
1
4
018646
Removal NOTE
The selector cylinder (2) and the shift cylinder
1 Unfasten two hexagon head screw (1) and
(4) are connected to a separate hydraulic
washers.
circuit and remain in the vehicle when the
2 Pull off selector cylinder (2) with O-ring, transmission and/or shift turret are removed.
remove piston rods of selector cylinder from
driver groove in selector shaft.
NOTE
Move shift lever into the gate so that the
selector cylinder can be pulled out.
1
4
018646
NOTE
Check O-ring on selector cylinder and replace
if necessary.
6 7 4
5
22
21
20
1
3
10
9
11 8
48 2
12
13
18
14
15 19
16 17
012330
3 Shift turret with left shifting output 4 Loosen switch (6 and 7) and remove together
with sealing rings and pins. Depending on
Removing and dismantling of shift housing parts list, there may be screw plugs.
1 Loosen hexagon head screws (1) and remove 5 Unsnap V-ring (8) and remove detent (9)
shift turret together with gasket (2). Remove together with O-ring from shift housing.
roller (48) from valve lever.
NOTE
NOTE Check O-ring and replace if necessary (cf. con-
For removal of the Servoshift see Section 1.1 sumables).
2 Loosen shift lever (3, depending on parts list) 6 Loosen hexagon head screws (10) and remove
and remove together with protective cap. cover (11) together with sealing.
29 27 23 24
38
28 40 25
26
39 35 42 43
32 36
46 33
31
34
30 37
44
41
45
47
012331
9 Loosen hexagon head screws (23) and remove 16 Remove needle bush (33).
cover (24) together with sealing (25).
17 Remove pin (34).
10 Loosen screw plugs (26 and 27) and remove
18 Dismantle shift shaft (40) from shift housing
together with sealing rings, spacing washers
together with valve lever (37) and lever (41).
and springs.
NOTE
11 Remove detent lever (28 and 29) from shift
Inspect selector shaft bores and level any
housing. If necessary, remove cylindrical pins.
revised edges.
CAUTION
19 Remove pin (35) from valve lever. Do not
Locking rings (30 and 32) must not be overstrained
remove lower needle bush (36). Replace any
- use adjustable pliers.
damaged needle bush (36) together with valve
12 Unsnap locking rings (30). lever.
13 Remove cylindrical pins (31). If necessary, 20 Place plastic arbor on hollow shaft and drive it
remove locking rings (32). out of the shift housing together with the shaft
bush (42) and the shaft seal (43). Slide hollow
14 Remove pin (38) and slide hollow shaft (39)
shaft out of shift housing and in the process
towards cover.
remove dog (44) and blocking piece (45).
15 Place impact adaptor 1X25 139 783 on needle
21 If necessary, remove cylindrical pins (46 and
bush (33) and drive valve lever (37) down-
47).
wards.
NOTE 45
Cylindrical pin (35) must engage with shift
shaft. Position shift shaft and hollow shaft
properly.
CAUTION
Secure only hollow shaft with the cylindrical pin 39 35
(38). Only insert by hand until detent is reached - 36
33
never drive in.
34
7 Insert cylindrical pin (38). Check ease of 37
movement of the shift shaft.
41
8 Insert cylindrical pin (34) and drive in new
needle bush (33) until it is flush. Check ease of
movement of the shift shaft.
47
CAUTION
Locking rings (32 and 30) must not be overstrained 40
- use adjustable pliers.
42 43
9 Snap in locking rings (32) on pins (31) and
insert in dog and shift shaft. Insert locking
rings (30).
012332
NOTE
Version
Standard "A"
28
26
012333
Version
Standard "B"
Version
Alternative "C"
012334
6 7 4
5
22
21
20
1
3
10
9
11 8
48 2
12
13
18
14
15 19
16 17
012330
14 Place disk (19), spring (18), V-ring (17), disk 18 Place switches (6 and 7) together with pins
(16), spring (15), disk (14), and snap in locking and new sealing rings in shift housing and
ring (13) and V-ring (12). tighten.
Tightening torque = 45 Nm.
NOTE
Depending on parts list, there may be screw
Arrangement and sequence of parts in step 14
plugs.
depend on parts list.
Tightening torque = 35 Nm.
15 Place cover (11) together with new sealing and
19 Mount cutoff valve (4) together with greased
tighten with hexagon head screws (10).
O-ring (5) with hexagon head screws to shift
Tightening torque =23 Nm.
housing.
16 Place detent (22), spring (21) and screw plug Tightening torque = 23 Nm.
(20) with new sealing ring and tighten.
20 Mount shift lever (3) together with protective
Tightening torque = 60 Nm.
cap on shift shaft.
17 Place detent (9) together with greased O-ring Tightening torque = 49 Nm.
and V-ring (8) in shift housing. For new O-ring,
21 Place greased roller (48) on valve lever.
cf. consumables.
NOTE
For assembling of the Servoshift see
Section 1.1
012338
Q1 Q2
012335 012336
Q3 Q4
012337 012339
Q5 Q6
012340 012341
012345
Q1 Q2
012342 012343
Q3 Q4
012344 012346
Q5 Q6
012347 012348
10
6
19
18
17
27
7 4
11
5
22
21
20
26
1
48
014992
4 Shift turret with right shifting output 3 Remove cut-off valve (4) and take off with
O-ring (5).
Removing and dismantling gear shift housing
NOTE
1 Unfasten hexagon head screws (1) and take off Do not dismantle cut-off valve further.
shift turret with gasket (2). Take roller (48) off It is a complete part.
valve lever.
4 Unfasten switches (6 and 7) and take off with
NOTE seals and pins. Depending on parts list, there
For removal of servoshift, refer to section 1.1 may be screw plugs.
29 23 24
38
28 40 25
39 35
36
9 46 33
8 34
37
32
31
41
30
44
47
45
014993
9 Unfasten hexagon head screws (23), take off 14 Remove pin (38).
cover (24) and gasket (25).
15 Slide quill shaft (39) towards the shift lever
10 Snap out V-ring (8) and remove. Press detent until it engages.
(9) and O-ring out of gear shift housing. Press
16 Fix impact adaptor 1X25 139 783 above the
from inside to outside.
needle bush (33) and drive valve lever (37)
NOTE downwards.
Check O-ring and replace if necessary (cf. con-
17 Use gripper pliers to remove needle bush (33).
sumables).
18 Remove pin (34).
11 Note down position of detent levers (28 and
29). Take detent lever out of gear shift housing. 19 Remove gear shift shaft (40) in the direction
If necessary, remove cylindrical pins. indicated by the arrow and in so doing take
out the valve lever (37) and lever (41).
CAUTION
Circlips (30 and 32) must not be overstretched - use
adjustable pliers.
29 23 24
38
28 40 25
39 35
36
9 46 33
8 34
37
32
31
41
30
44
47
45
014993
NOTE
If the bores on the gear shift shaft show signs
of raised edges after long operating hours, the
gear shift shaft cannot be removed as
described above. In such instances, the spring
package (step 22) must be removed with the
gear shift shaft still installed and the gear shift
shaft then removed in the opposite direction to
that indicated by the arrow. The raised edges
should be levelled before the gear shift shaft is
refitted.
23 NOTE
Number, arrangement and sequence of parts
in step 22 depend on the parts list.
45
39
12
13
14
15
16
42 43
014994
NOTE 32 46
Housing bores an cover must be free from 31
greese. 30 44
NOTE
Number, arrangement and sequence of parts
in step 5 depend on the parts list. 39 35
36
6 Guide gear shift shaft (40) (in direction indicat- 33
34
ed by arrow) into housing and quill shaft.
37
NOTE
41
Cylindrical pin (35) must engage with gear
shift shaft. Position gear shift shaft and quill
shaft accordingly. 12
13 47
7 Press valve lever (37) and lever (41) upwards. 14
15
Slide quill shaft towards cover (43).
16
CAUTION 40
Only the quill shaft is secured with cylindrical pin
42 43
(38). Only insert by hand until detent is reached -
never drive in.
014995
32 46
31
30 44
45
39 35
36
33
34
37
41
12
13 47
14
15
16
40
42 43
014995
CAUTION
Circlips (30 and 32) must not be overstretched - use
adjustable pliers. 24
23
11 Snap circlips (32) onto pins (31) and insert in
driver and gear shift shaft. Insert circlips (30).
NOTE
Arrangement of detent levers depends on parts
list. For possible arrangements, refer to dia- 25
gram 012334.
29 27
13 Attach new gasket (25) and cover (24).
28
26
NOTE
Standard "A"
version
014996
Standard "B"
version
Standard "C"
version
012334
10
6
19
18
17
7 4
11
5
22
21
20
1
48
2
014997
16 Press new bearing bush (17), new shaft seal 21 Use hexagon head screws to fit cut-off valve
(18) and new scraper (19) into cover (11). (4) and greased O-ring (5) to gear shift hous-
ing.
NOTE
Tightening torque = 23 Nm.
Use gasket as specified in parts list (0.5 mm
thick). 22 Attach gear shift lever (3) with cover cap to
gear shift shaft.
17 Attach cover (11) with new gasket and use
Tightening torque = 49 Nm.
hexagon head screws (10) to tighten into place.
Tightening torque = 23 Nm. 23 Use grease to attach roller (48) to valve lever.
18 Insert bolt (22), spring (21) and screw plug (20) NOTE
with new seal and tighten. If necessary, fasten angled plate (not shown) to
Tightening torque = 60 Nm. servoshift retaining screws.
012362
012352
Q1 Q2
012349 012350
Q3 Q4
012351 012353
Q5 Q6
012354 012355
012362
012362
Q1 Q2
012356 012357
Q3 Q4
012358 012359
Q5 Q6
012360 012
012361
6 4
23
11
7
10
18
17
16
5
1
22
015986
Removing and dismantling shift housing 3 Unfasten switches (6 and 7), take off with seal-
ing rings and pins.
1 Unfasten hexagon head screws (1) and take off
shift turret and gasket (2). 4 Unfasten screw (16) and remove with sealing
ring, spring (17) and bolt (18).
NOTE
For removal of the Servoshift, refer to Chapter 5 Unfasten screw plugs (22 and 23) and remove
1.2. with sealing rings.
NOTE
The selector cylinder (3) with O-ring (11) and
hexagon head screws (10) is only listed here
for your information. It remains in the vehicle
when the transmission and/or shift turret are
removed.
NOTE
Do not dismantle valve block any further. It is
a complete part.
19 20
27
29
21
30
9 34
8
28
26
25
24 32
33
015987
6 Loosen hexagon head screws (19), remove cov- 10 Remove pin (27).
er (20) and gasket (21).
11 Remove selector shaft (29) from shift housing
7 Snap out V-ring (8) and remove. Push out in direction indicated by the arrow and take
detent (9) and O-ring from the inside of the off lever (30) at the same time.
shift housing.
NOTE
NOTE If the edges of the selector shaft bores are
Alternatively, the detent can be pushed out raised after longer operating periods, the selec-
from the inside as the last disassembly step. tor shaft can no longer be removed as is
described above.
NOTE
In such instances, the spring pack (step 12)
Check O-ring and replace if necessary (refer to
must be removed when the selector shaft is
consumables).
still installed and the selector shaft then
CAUTION removed in the direction opposite to that indi-
Circlips (24 and 26) must not be overstretched - use cated by the arrow.
adjustable tongs. The raised edges should be levelled out before
the selector shaft is re-installed.
8 Snap out circlips (24).
34
32
33
28
12
13
14
15
31
015988
NOTE
Housing bore and cover must be free of grease.
CAUTION
Only the quill shaft is secured by the cylindrical pin 28
(27), only insert by hand until the stop is reached -
do not drive in.
12 30
7 Use grease to insert cylindrical pin (27). Check 13
selector shaft for ease of movement. 14
CAUTION 15
Circlips (24 and 26) must not be overstretched - use
adjustable tongs.
29
31
015989
21
23
22
015990
4
6
18
17
16
8 1
015991
12 Insert bolt (18), spring (17) and screw plug (16) 15 Fit valve block (4) and greased O-ring (5) with
with new sealing ring and tighten. hexagon head screws on shift housing.
Tightening torque = 60 Nm. Tightening torque = 23 Nm.
015992
Q1
015993
7 9
13
3 14
15
5 6
12
1 11
8
10
018647
6 Super H shift turret with HTC 3 If necessary, loosen neutral switch (9) together
(superimosed H shift system) with sealing ring and remove.
CAUTION
Removal and disassembly of the shift housing
Do not loosen plug-in connector (10) on front but on
1 Loosen hexagon head screws (1) and remove rear hex connection - SW 22.
shift turret together with gasket (2).
4 If necessary, remove plug-in connector (10).
NOTE O-ring might stick to housing - remove it.
For dismounting the servo shift, see Chapter
NOTE
1.3.
Do not disassemble super H valve block furt-
NOTE her - complete part!
Selector cylinder (3) with O-ring (4) and hexa-
5 Remove tappet (11) and pin (12) from shift
gon head screws (5) are mentioned only for
housing.
information. They remain in the vehicle
during removal of the transmission or the shift 6 Loosen tappet switch (13) together with seal-
turret. See Chapter 2. ing ring and remove together with pressure
spring (14) and lock (15).
2 Loosen hexagon head screws (6 and 7) and
remove Super H valve block (8).
NOTE
Gasket may stick to shift housing. Remove and
place in valve block.
16
24 17
23
22
18
21
26
25 32
35
27
20 33 28
19 29
30
34
31
018648
7 Loosen hexagon head screws (16), remove 14 Remove V-ring (27) on removed shaft and
cover (17) and gasket (18). remove disk (28), springs (29 and 30) and disk
(31).
CAUTION
Snap rings (19) must not be stretched too much - 15 Place plastic mandrel on hollow shaft and
use adjustable pliers. drive hollow shaft (25) and cover (32) out of
shift housing. Push hollow shaft out of shift
8 Remove snap ring (19).
housing and in the process remove driver (33)
9 Remove cylindrical pin (20) and remove and blocking piece (34).
second snap ring if necessary.
16 Remove cylindrical pin (35) if necessary.
10 Remove shift shaft (21) from shift housing in
the direction of the arrow.
16
24 17
23
22
18
21
26
25 32
35
27
20 33 28
19 29
30
34
31
018648
Assembling shift housing 6 Push lever (26) upward and push hollow shaft
towards the cover (32).
1 Insert driver (33) and blocking piece (34) into
shift housing. Insert hollow shaft (25) in cor- CAUTION
rect position in shift housing, blocking piece Snap rings (19) must not be stretched too much -
and driver. use adjustable pliers.
2 Press on new cover (32). 7 If necessary, snap upper snap ring onto pin
(20) and place in driver and shift shaft. Put
NOTE
snap ring (19) in place.
Housing bore and cover must not be greasy.
8 Push pin (24) to stop in housing and lock with
3 Press in cylindrical pin (35) if necessary.
pin (23). Put catch (22) in place.
Position lever (26) in housing.
9 Put new gasket (18) and cover (17) in place.
4 Mount disk (31), springs (29 and 30), disk (28)
and V-ring (27) on removed shaft. 10 Insert hexagon head screws (16) and tighten.
Tightening torque = 23 Nm.
5 Insert shift shaft (21) (in the direction of the
arrow) in housing and hollow shaft.
7 9
13
3 14
15
5 6
12
1 11
8
10
018647
12 Place tappet (11) and pin (12) in shift housing. 16 For mounting servo shift see Chapter 1.3
CAUTION
Do not loosen plug-in connector (10) on front but on
rear hex connection - SW 22.
018649
Q5
018650
17
16 4
6
18
1
14
10
15 11
12 7
13 4
9
8
5
3
2
49
024464
19
20
32 29
23 31
24
22
33
30
21 34
35
36
28
39
26 27 37
25
38
024465
10 Loosen hexagon head screws (19), remove 19 Dismantle shift shaft (32) from shift housing
cover (20) and gasket (21). (as indicated by the arrow) together with valve
lever (30) and lever (34).
11 Remove locking pawl (22) and pin (23).
NOTE
12 Push pin (24) through shift housing and remo-
Inspect selector shaft bores and level any rai-
ve it.
sed edges.
CAUTION
20 Remove pin (33) from valve lever. Do not
Locking rings (25 and 26) must not be overstrained
remove lower needle bush. Replace any dama-
- use adjustable pliers.
ged needle bush as complete unit together
13 Remove locking ring (25). with valve lever.
14 Remove cylindrical pins (27). If necessary, 21 Place plastic arbor on hollow shaft (28) and
remove locking rings (26). push through the shift housing together with
the shaft bush (35) and the shaft seal (36).
15 Push hollow shaft (28) towards sealing cap.
Push hollow shaft out of shift housing and in
16 Place impact adaptor 1X25 139 783 on needle the process, remove driver (37) and blocking
bush (29) and drive valve lever (30) slightly piece (38).
downwards.
22 Remove cylindrical pin (39) if necessary.
17 Remove needle bush (29).
024466
45
46
44
024467
46
44
024467
024466
19
20
32 29
23 31
24
22
33
30
21 34
35
36
28
39
26 27 37
25
38
024465
8 Insert driver (37) and blocking piece (38) into 14 Insert cylindrical pin (31) and drive in new
shift housing. Place hollow shaft (28) in cor- needle bush (29) until it is flush. Check ease of
rect position in shift housing, insert blocking movement of the shift shaft.
piece and driver.
CAUTION
9 Use adaptor 1X25 139 707 to press in bush Locking rings (26 and 25) must not be overstrained
(35) for flush seat in housing. - use adjustable pliers.
10 Snugly fit greased rotary shaft seal ring (36) in 15 Snap in locking ring (26) on pin (27) and insert
its support. in driver and shift shaft. Put locking ring (25)
in place.
11 Insert cylindrical pin (33) into valve lever (30).
Press in cylindrical pin (39) if necessary. 16 Push pin (24) to stop in housing and lock with
pin (23). Put locking pawl (22) in place.
12 Mount valve lever (30) and lever (34) in shift
housing onto hollow shaft. 17 Put new gasket (21) and preassembled cover
(20) in place.
13 Insert shift shaft (32) into hollow shaft (as indi-
cated by the arrow). 18 Insert hexagon head screws (19) and tighten.
Tightening torque = 23 Nm.
NOTE
Cylindrical pin (33) must engage with shift
shaft. Position shift shaft and hollow shaft pro-
perly.
17
16 4
6
18
1
14
10
15 11
12 7
13 4
9
8
5
3
2
49
024464
19 Install interlock (12), spring (11), and tappet 25 Fit cover (14) together with new sealing onto
switch (10) together with new sealing ring in housing using hex-head screw (13) and
shift housing and tighten. tighten.
Tightening torque = 45 Nm. Tightening torque = 23 Nm.
20 Place tappet (8) and pin (9) in shift housing. 26 Mount shift lever (3) together with protective
cap on shift shaft.
21 Mount valve block (5) with hexagon head
Tightening torque = 49 Nm.
screws (6) to shift housing.
Tightening torque = 23 Nm. 27 Place greased roller (49) on valve lever.
024461
Q4
024462
1 2
015997
8 Function test
NOTE
Positioning between clutch housing, gasket
and selector housing must be effected by inser- 2
tion of 2 fixing ping Ø 8,9 mm.
NOTE
When placing the selector mechanism make
sure the roller on the valve lever does not
come off. Assembly suggestion: Use grease to
place roller on valve lever.
110
Schaft Ø 8.9
80
15
M8
016078