ZF ECOLITE Transmission Gearbox Workshop Repair Manual

6 S 850 6 S 890 1290 751 105a

Subject to alterations in design Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Printed in Germany Edition: 10.00 1290 751 105a

6 S 850 / 6 S 890 Contents Page Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Instructions for carrying out repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Table of springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Speedometer worm or pulse disc and radial sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Speedometer connection piece or pulse sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.4 Reversing lamp switch and pawl stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Removing and installing selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Removing and installing peripheral parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Dismantling and reassembling selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.4 Shift patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 3 Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 4 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Clutch housing, separate version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Clutch housing, integrated version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3 Thrust rods, selector clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4 Output bearing and radial sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5 Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 6 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Removing and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Assembling and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 7 Main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 8 Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Index a: 00-10-01

Contents 6 S 850 / 6 S 890 Page 9 Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 Checking wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 Version ZF-BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.3 Version ZF-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 10 Adjusting shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 Main shaft - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Index a: 00-10-01

ZF FRIEDRICHSHAFEN AG Division Comm. Vehicle/Special Transmissions Service Werk 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-8000 This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge upda- ted on a regular basis at our After-Sales Service training courses. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications All work performed at these service points is carried out conscientiously and with care. Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual conditions. Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies where genuine ZF spares have not been used. Preface 5 Index a: 00-10-01

SAFETY NOTICE Companies who repair 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 processes, techniques, data, 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 do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale and no information about size and weight should be inferred (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 satisfy themselves that the product is functioning correctly. THREATS TO THE ENVIRONMENT ! Lubricants 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 hung on the input shaft NOR on the output flange. ! ! Important information 6 Index: 98-01-12

7 Index: 98-01-12 In any cases of doubt always turn to the the relevant department within ZF After-Sales Services for advice. After removing the transmission from the vehicle clean thoroughly before opening. Pay particular attention to the corners and angles of housings and covers when cleaning. Parts held on with Loctite can be slightly loosened if warmed with a hot air blower. CLEANING PARTS Remove the old remains of gaskets on all gaskets. Carefully remove burrs or other similar patches of roughness using a oil-stone Lube bores and grooves must be free of anti-corrosion agents and foreign matter, check that they can move without encountering any problems. Carefully cover opened transmissions to prevent the entry of foreign matter.. REUSING PARTS Parts such as ball or roller bearings, multi-discs, 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 packing washers. Seal contact surfaces must be totally clean and in perfect condition. REWORKING Rework may only be carried out on the seal contact surfaces using plunge-cut grinding, never use an emery cloth. Ensure that there are no traces of grinding traces or rifling from grinding. If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality. TRANSMISSION ASSEMBLY Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measure- ment. During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual. Instructions for carrying out repairs

8 Index: 98-01-12 BEARINGS If the bearings are filled while hot, these should be warmed up accordingly (e.g. in a heating cabinet). The temperature should be approx. 85 °C and may not exceed 120 °C. All bearings must be coated with transmission oil after assembly. SEALING If a sealing agent* is to be used for carrying out 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 penetrates the oil feeds when the surfaces are sealed. SHAFT SEALS a) Apply a light coat of sealing agent on outer edge of shaft seals with “steel surround”. b) Never apply sealing agent to shaft seals with “rubber surround” but apply a thin coat of Vaseline 8420 to the outer edge 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 surrounds should be treated on the outer edge of the rubber surround as described above in section b). d) Duo shaft seals have two packing washers. The dust-proof packing washer (X) must face outwards. e) Fill the gap between the packing washers so it is 60% filled with grease (use a 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 (this makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installa- tion depth plan. RETAINING AGENTS Retaining agents* may only be used in places as specified in 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 the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques. * refer to expendable material Instructions for carrying out repairs X

Tightening torques 9 Index: 98-01-12 Tightening torques for nuts and bolts, extract from ZFN 148 This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. This Standard contains data on tightening torques (M A ) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12. Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome- plated and oiled. Tighten screws with a calibrated torque spanner. NOTE Irregular tightening torques are listed separately in the Repair Manual. Edition: August 1991 / checked 1997 Regular thread Fine screw thread Size Tightening torque Size Tightening torque M A (Nm) for M A (Nm) for Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9 Nut 8 10 12 Nut 8 10 12 M 4 2,8 4,1 4,8 M 8 x 1 24 36 43 M 5 5,5 8,1 9,5 M 9 x 1 36 53 62 M 6 9,5 14 16,5 M 10 x 1 52 76 89 M 7 15 23 28 M 10 x 1,25 49 72 84 M 8 23 34 40 M 12 x 1,25 87 125 150 M 10 46 68 79 M 12 x 1,5 83 122 145 M 12 79 115 135 M 14 x 1,5 135 200 235 M 14 125 185 215 M 16 x 1,5 205 300 360 M 16 195 280 330 M 18 x 1,5 310 440 520 M 18 280 390 460 M 18 x 2 290 420 490 M 20 390 560 650 M 20 x 1,5 430 620 720 M 22 530 750 880 M 22 x 1,5 580 820 960 M 24 670 960 1100 M 24 x 1,5 760 1100 1250 M 27 1000 1400 1650 M 24 x 2 730 1050 1200 M 30 1350 1900 2250 M 27 x 1,5 1100 1600 1850 M 27 x 2 1050 1500 1800 M 30 x 1,5 1550 2200 2550 M 30 x 2 1500 2100 2500

Tightening torques 10 Screw plugs DIN 908, 910 and 7604 The screw plug tightening torques M A were determined according to DIN 7604, for screwing into steel, grey cast, and aluminium alloys. The values are based on experience, and are intended as reference values for the designer. The values for the tightening torque M A shall also be used for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical. General rule: 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 Union screws DIN 7643 The tightening torques M A were determined for screwing into steel, grey cast and aluminium alloys. The values are based on experience and are intended as reference values for the designer. General rule: screw/bolt class 5, ZFN 148-1 Material 9SMnPb28K acc. to DIN 1651 Surface conditions: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled Status October 1995 Screw plugs (DIN 908, 910, 7604) Dimensions Tightening torque screwed into steel/grey cast Al alloy M 8 x 1 20 10 M 10 x 1 25 / 30* 15 / 20* M 12 x 1.5 35 25 M 14 x 1.5 35 25 M 16 x 1.5 40 30 M 18 x 1.5 50 35 M 20 x 1.5 55 45 M 22 x 1.5 60 / 80* 50 / 65* M 24 x 1.5 70 60 M 26 x 1.5 80 / 105* 70 / 90* M 27 x 2 80 70 M 30 x 1.5 100 / 130* 90 / 130* M 30 x 2 95 85 M 33 x 2 120 110 M 36 x 1.5 130 115 M 38 x 1.5 140 120 M 42 x 1.5 150 130 M 42 x 2 145 125 M 45 x 1.5 160 140 M 45 x 2 150 130 M 48 x 1.5 170 145 M 48 x 2 160 135 M 52 x 1.5 180 150 M 60 x 2 195 165 M 64 x 2 205 175 * DIN 7604 Form C Union screws (DIN7643) Pipe Thread Tightening- outer torque M A diameter in Nm 4 - 5 M 8 x 1 30 6 M 10 x 1 35 8 M 12 x 1.5 40 10 M 14 x 1.5 40 12 M 16 x 1.5 45 15 M 18 x 1.5 50 18 M 22 x 1.5 60 22 M 26 x 1.5 90 28 M 30 x 1.5 130 35 M 38 x 1.5 140

ZF ECOLITE Transmission Gearbox Workshop Repair Manual

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