ZF ECOMID 16 S 109 Transmission Gearbox Workshop Manual

16 S 109 1304 751 103a 1304 751 003 D 1304 751 203 F 1304 751 303 E 1304 751 403 I

Subject to alterations in design Copyright by ZF Reproduction, in whole or in part, is only allowed with our written approval and authorization. Printed in Germany Printed: November 1997 Edition: August 1997 1304 751 103a

16 S 109 Contents Page Preface .................................................................................................................................................................. 5 General notes ......................................................................................................................................................... 6 Safety instructions ................................................................................................................................................. 8 Tightening torques ................................................................................................................................................. 9 Adjustment data..................................................................................................................................................... 11 Spring table ........................................................................................................................................................... 15 Special tools .......................................................................................................................................................... 17 Removal / installation summary ............................................................................................................................ 22 1 Pneumatic range-change and splitter shift mechanism ......................................................................... 1-1 1.1 Disassembly ................................................................................................................................................ 1-1 1.2 Assembly..................................................................................................................................................... 1-1 2 Output ....................................................................................................................................................... 2-1 2.1 Removing output flange and cover .............................................................................................................. 2-1 2.2 Removing bearing cover.............................................................................................................................. 2-2 2.3 Fitting bearing cover ................................................................................................................................... 2-2 2.4 Fitting output flange and cover.................................................................................................................... 2-4 3 Range-change ............................................................................................................................................ 3-1 3.1 Removing range-change / splitter operating cylinder.................................................................................. 3-1 3.2 Fitting range-change / splitter operating cylinder ....................................................................................... 3-3 3.3 Dismantling range-change .......................................................................................................................... 3-7 3.4 Assembling range-change ........................................................................................................................... 3-9 4 Planetary mechanism with synchronizer ................................................................................................ 4-1 4.1 Dismantling synchronizer .......................................................................................................................... 4-1 4.2 Dismantling ring gear.................................................................................................................................. 4-2 4.3 Dismantling planet carrier........................................................................................................................... 4-2 4.4 Assembling planet carrier .......................................................................................................................... 4-3 4.5 Assembling ring gear .................................................................................................................................. 4-4 4.6 Assembling synchronizer ............................................................................................................................ 4-4 5. Sun gear ..................................................................................................................................................... 5-1 5.1 Removing sun gear ...................................................................................................................................... 5-1 5.2 Fitting sun gear............................................................................................................................................ 5-2 6. Shift mechanism ........................................................................................................................................ 6-1 6.1 Removing shift mechanism ......................................................................................................................... 6-1 6.2 Fitting shift mechanism............................................................................................................................... 6-2 6.3 Dismantling shift mechanism...................................................................................................................... 6-4 6.4 Assembling shift mechanism - summary of shift mechanism types ........................................................... 6-10 6.4.1 Driver arrangement ..................................................................................................................................... 6-11 6.4.2 Compression spring arrangement (spring pack) in accordance with parts list (spare parts catalogue) ....... 6-16 6.5 Assembling shift mechanism ...................................................................................................................... 6-19

Contents 16 S 109 Seite 7 Connection plate - lube oil pump ............................................................................................................. 7-1 7.1 Removing connection plate ......................................................................................................................... 7-1 7.2 Removing and dismantling lube oil pump................................................................................................... 7-1 7.3 Assembling and fitting lube oil pump ......................................................................................................... 7-3 7.4 Assembling and fitting connection plate ..................................................................................................... 7-5 8 Adjusting bearings on mainshaft, input shaft and layshaft ................................................................... 8-1 8.1 Adjusting mainshaft and input shaft ........................................................................................................... 8-1 8.2 Adjusting layshaft ....................................................................................................................................... 8-3 9 Shift rails and reverse idler gear .............................................................................................................. 9-1 9.1 Removing shift rails ................................................................................................................................... 9-1 9.2 Removing reverse idler gear ........................................................................................................................ 9-5 9.3 Installing shift rails ..................................................................................................................................... 9-6 9.4 Installing reverse idler gear ........................................................................................................................ 9-11 10 Input shaft, mainshaft and layshaft ......................................................................................................... 10-1 10.1 Removing shafts .......................................................................................................................................... 10-1 10.2 Installing shafts ........................................................................................................................................... 10-4 11 Input shaft ................................................................................................................................................. 11-1 11.1 Dismantling input shaft ............................................................................................................................... 11-1 11.2 Assembling input shaft ............................................................................................................................... 11-2 12 Mainshaft .................................................................................................................................................. 12-1 12.1 Dismantling mainshaft ................................................................................................................................ 12-1 12.2 Assembling mainshaft ................................................................................................................................. 12-4 13 Layshaft ..................................................................................................................................................... 13-1 13.1 Dismantling layshaft ................................................................................................................................... 13-1 13.2 Assembling layshaft .................................................................................................................................... 13-2 14 Housing ..................................................................................................................................................... 14-1 14.1 Dismantling housing ................................................................................................................................... 14-1 14.2 Assembling housing .................................................................................................................................... 14-2

5 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 adjust- ment 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 updated on a regular basis at our 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. ZF FRIEDRICHSHAFEN AG Friedrichshafen Division Service 16 S 109 Preface

6 TRANSMISSION DESCRIPTION AND FUNCTION ZF-Ecomid 16 S 109 synchromesh transmissions have been especially developed for use in upper mid-range commercial vehicles. 16 S 109 transmissions mainly comprise: – a fully-synchromesh four-gear section – an integrated reverse gear – a rear-mounted planetary range-change mechanism – an integrated front-mounted splitter In addition ZF Friedrichshafen AG can offer the following optional add-ons for these transmissions – a ZF engine-dependent PTO – various ZF clutch-dependent PTOs, – a drive for an emergency steering pump or dual-circuit steering pump – or a separate heat exchanger for extreme applications. REPAIR MANUAL The Repair Manual shows how to repair ZF-Ecomid 16 S 109 synchromesh transmissions. Structure of the Repair Manual: Section 1: adjustment data, tightening torques, spring characteristics and an illustrated list of specified ZF special tools. Section 2: description of transmission repair procedure, broken down into work steps. General Work Instructions Maintain cleanliness in all work, and carry out all work to a proper professional standard. After removing a transmis- sion from the vehicle, clean the outside thoroughly before opening the housing. Always use the tools specified by ZF. Clean all components after dismantling. Pay particular attention to corners, recesses and angles of housings and covers. Carefully remove all traces of old sealing compound and gaskets. Check that lube oil feed bores, grooves and pipes are clear. They must be free of deposits, foreign matter and anti- corrosion agents. Take special care to remove anti-corrosion agents from new parts. General Notes 16 S 109

7 All parts which cannot be removed without being damaged must always be replaced with new parts (e.g. shaft seals, O-rings, piston sealing rings, flange packing, protective caps, etc.). Parts such as ball or roller bearings, thrust wash- ers, synchronizer parts, etc., which are subject to wear during normal operation, must be inspected by a competent person, who should decide whether or not they can be re-used. Fit gaskets dry, i.e. free from oil and grease. Joints without gaskets should be sealed with an oil and heat resistant mastic sealing compound (e.g. WEVO-L 100 A). During assembly, comply with all adjustment data, checking data and tightening torques. After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, see the transmission operating manual and List of Lubricants TE-ML 02, which are available from any ZF After-Sales Ser- vice point. After filling the transmission with oil, tighten the oil level check plug and oil drain plug to the specified torques. ENVIRONMENTAL HAZARD ! Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system. • Request safety information for the products concerned from your local environmental protection authority, and follow any instructions herein at all times. • Always collect used oil in a suitably large container. • Always dispose of used oil, clogged filters, lubricants and cleaning agents in accordance with environmental protection laws. • Always observe manufacturer instructions when dealing with lubricants and cleaning agents. ! 16 S 109 General Notes

8 Important work 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 these ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that 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 serious injury or death. NOTE 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. NOTE After completion of repair work and testing, skilled mechanics must satisfy themselves that the product is functioning correctly. ! Work safety 16 S 109

9 Tightening torques for bolts and nuts from ZFN 148 This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934. This Standard contains data on tightening torques (MA) 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: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome- plated and oiled. Tighten screws using a calibrated signal or pointer-type torque wrench. Edition: August 1991 Metric coarse pitch thread Metric fine pitch thread Size Tightening torque Size Tightening torque MA (Nm) for MA (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 16 S 109 Tighteining torques

Tightening torques 16 S 109 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 manu- factured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled Union screws DIN 7643 The tightening torques M A were determined for scr- ewing 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 n acc. to DIN 1651 Surface conditions: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and light- ly 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