Transmission / Gearbox ZF AS Tronic Truck BUS 10 12 16 speed version without ZF Intarder Repair Manual PD

1327 751 102b Repair Manual Trucks and Buses 10-, 12- and 16-speed version without ZF-Intarder Repair Level 3

Subject to technical changes Copyright by ZF This documentation is protected by copyright. Any reproduction or dissemination in any form that does not comply exclusively with the intended purpose of this documentation is prohibited without the consent of ZF Friedrichshafen AG. Printed in Germany ZF Friedrichshafen AG, MC-C dept. / 2002-01 Edition: 2007-05 1327 751 102b

Overview of Amendments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Instructions for Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tightening Torques for Screws/Bolts and Nuts, Extract from ZFN 148 . . . . . . . . . . . . . . . . . . . . . . . 10 Screw Plugs DIN 908, 910, and 7604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Union Screws DIN 7643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Conversion from DIN to ISO Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Consumable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Diagnosis Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Preparatory Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clutch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removing Clutch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Mounting Clutch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removing Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mounting Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Output Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Removing Output Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Mounting Output Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 RC Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Dismounting the RC Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Play Setting of the Main Shaft – Planetary Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Mounting the RC Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Dismantling the RC Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Assembling the RC Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Planetary Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disassembling Planet Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Pre-Assembling the Sun Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Pre-Assembling the Planetary Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Completing the Planet Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Place Transmission Without RC (planetary range) in Horizontal Position . . . . . . . . . . . . . . . . . . . . 47 Transmission Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Removing Transmission Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Mounting Transmission Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Removing the Upper Section from the Lower Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Mounting the Upper Section to the Lower Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Replacing Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Programming Transmission Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Putting Transmission in Vertical Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Table of Contents ZF-AS Tronic 3 1327 751 102 - 2007-05

Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Removing Release Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Mounting the Release Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Removing Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Measure the Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Assembling Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Removing Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Dismantling Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Assembling Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Fitting Housing I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Shaft Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Removing Shaft Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Installing Shaft Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Disassembling the Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Disassembling the Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Assembling the Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Setting the Axial Play of the Bearing Disk in Constant Gear 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Assembling the Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Dismantling Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Assembling Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Set the Axial Play Gear to Wheel Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Set the Axial Play MS Disk to Wheel Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Disassembling the Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mounting the Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Selector Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Dismantling the Selector Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Assembling the Selector Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Dismantling Housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Assembling Housing II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Appendix Service Information No. 08_00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Service Information No. 02_04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Service Information No. 20_04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Service Information No. 02_05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Service Information No. 25_05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Table of Contents ZF-AS Tronic 4 1327 751 102 - 2007-05

ZF-AS Tronic Overview of Amendments: 1327 751 102 5 1327 751 102 - 2007-05 Index Date of issue Initiator Remark 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

6 ZF Friedrichshafen AG Nutzfahrzeug- und Sonder-Antriebstechnik Commercial Vehicle and Special Driveline Technology Service Werk 2 (Plant 2) Phone: +49 (0)7541 77-0 Fax: +49 (0)7541 77-908000 Internet: www.zf.com This documentation is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF products in accordance with the state of development on the date of issue. However, due to continuing technical development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge up- dated on a regular basis at our Customer Service / After Sales training center. Service Centers equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel, 2. Specified equipment, e.g. special tools, 3. Genuine ZF spares, according to our latest specifications. All work performed at these Service Centers is carried out conscientiously and with utmost care. Warranty: Repair work carried out at ZF Service Centers is subject to the contractual conditions prevailing in the individual case. Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used. Preface 0000_99D_010_en 2007-04

7 Safety Instructions In principal, companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained. The following safety instructions appear in this manual: NOTE Refers to special working procedures, methods, information, use of auxiliary equipment, etc. CAUTION This is used when incorrect, unprofessional working practices could damage the product. DANGER This is used when lack of care could lead to personal injury or death. General Information Read this manual carefully before starting any tests or repair work. CAUTION Pictures, drawings, and components shown do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings, and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text. After completion of repair work and testing, skilled staff must check whether the product is functioning correctly. THREATS TO THE ENVIRONMENT! Lubricants, consumables, and cleaning agents must not be allowed to enter the soil, ground water, or sewage system. • Ask your local environment agency for safety information on the relevant products and adhere to their requirements. • Collect used oil in a suitably large container. • Dispose of used oil, dirty filters, lubricants, and cleaning agents in accordance with environmental protection guidelines. • When working with lubricants and cleaning agents always refer to the manufacturer’s instructions. CAUTION The transmission must NOT be suspended by the input shaft NOR by the output flange. ! ! Important Information 0000_99D_020_en 2007-04

8 ZF Service Information must be observed. This information is available at all ZF Service Centers or via the ZF-ServiceLine. In case of doubt always turn to the relevant depart- ment within ZF Customer Service / After Sales Service for advice. All work on transmissions is to be performed by experts only and under clean conditions. Use specified tools to dismantle and assemble transmissions. After removing the transmission from the vehicle, clean it thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning. Parts joined with Loctite are easier to separate if warmed with a fan heater. Cleaning Parts Remove remains of old gaskets on all sealing surfaces. Carefully remove burrs or similar patches of roughness using an oilstone. Lube bores and grooves must be free of anti- corrosion agents and foreign matter; check for perfect passage. Carefully cover opened transmissions to prevent foreign matter from entering. Reusing Parts Parts such as roller bearings, disks, thrust washers etc., must be inspected by a competent person who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear. Gaskets, Locking Plates Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates). Shaft Seals Always change shaft seals with rough, ripped, or hardened sealing lips. Seal contact surfaces must be totally clean and in perfect condition. Reworking Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or scroll. If rework is needed on spacer disks, shims etc. because of clearance adjustment, ensure that the reworked areas contain no face runout and have the same surface quality. Transmission Assembly Find a clean work area to assemble the transmission. Gaskets are installed without sealing compound or grease. When measuring silicon- coated gaskets, do not include the silicon layer. During assembly, comply with all adjustment data and tightening torques in the Repair Manual. Instructions for Repairs 0000_99D_030_en 2007-04

9 Bearings If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at approx. 85 °C and must not exceed 120 °C. Each mounted bearing must be lubricated with operating oil. Sealing If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the parts are pressed together. Shaft Seals a) Apply a light coat of sealing agent* on circumference of shaft seals with “steel jacket”. b) Never apply sealing agent to shaft seals with “rubber jacket”, but apply a thin coat of Vaseline 8420 to the outer circumference or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber jackets should be treated on the outer circumference of the rubber jacket as described for shaft seal b). d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards. e) Fill the gap between the sealing lips so it is 60 % filled with grease (e.g. produced by Aral, such as Aralub HL2 or by DEA, such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press in shaft sealing ring with mounting or face plate until firmly home at relevant installation depth. Retaining Agents Retaining agents* may only be used where specified by the parts list. Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data, and tightening torques. Transmission Oil After completing repairs, fill transmissions with transmission oil. For the procedure and approved oil grades, refer to the transmission Operating Instruc- tions and TE-ML List of Lubricants (refer to identifi- cation plate) which can be obtained from all ZF Customer Service / After Sales Centers and on the Internet under www.zf.com. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil over- flow using the specified torques. * refer to expendable material X Instructions for Repairs 0000_99D_030_en 2007-04

10 Tightening Torques Regular screw thread Fine screw thread 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 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 M10x1.25 49 72 84 M8 23 34 40 M12x1.25 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 Tightening Torques for Bolts/Screws and Nuts Extract from ZFN 148 This standard applies to screws/bolts acc. 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 to nuts acc. to DIN 934 as well as ISO 4032, ISO 8673. This Standard contains data on tightening torques for screws/bolts and nuts in strength categories 8.8, 10.9, and 12.9, and nuts in strength categories 8, 10, and 12. Surface condition of bolts /screws and nuts: Ther- mally blackened and oiled or galvanized and oiled or galvanized, chromated, and oiled. Tighten screws/bolts with a calibrated ratchet dial torque or ratchet wrench. NOTE Deviating tightening torques are listed separately in the Repair Manual. Edition: August 1991 0000_99D_040_en 2007-04

Transmission / Gearbox ZF AS Tronic Truck BUS 10 12 16 speed version without ZF Intarder Repair Manual PD

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