ZF Ecosplit 12 Speed - 1325 - 751 - 101 - en 2009 PDF

Reparaturanleitung
Repair Manual
Manuel de Reparation
Manual de Reparaciones
Manuale di Riparazioni
ZF Synchromesh Transmissions
12-speed
1325 751 101_en
Subject to technical changes
Copyright by ZF
This documentation is protected by copyright. Any
reproduction or dissemination in any form that does
not fully agree with the intended purpose of this
documentation is prohibited without the consent of
ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG / 2009
Edition: 2009-03
1325 751 101
ZF-Ecosplit
Table of Contents
Page
Overview of Changes ........................................................................................................................

Preface ................................................................................................................................................
Safety Instructions..............................................................................................................................
Instructions for Repair .......................................................................................................................
Tightening Torques.............................................................................................................................
Consumables.......................................................................................................................................
Setting Data ........................................................................................................................................
ZF-Ecosplit Tightening Torques .........................................................................................................
Spring Table........................................................................................................................................
Special Tools .......................................................................................................................................
5
6
7
8
10
11
12
14
17
18
Polyamide tubes for range change group and valve ....................................................................... 1-1
Shift turret ........................................................................................................................................ 2-1
Range change group (R/C)................................................................................................................ 3-1
Planetary drive with synchronizer................................................................................................... 4-1
Splitter group piston and 5/2-way valve.......................................................................................... 5-1
Connection plate .............................................................................................................................
6-1
Clutch housing .................................................................................................................................
7-1
Shafts and selector rails .................................................................................................................
8-1
Transmission housing ....................................................................................................................
9-1
10
Input shaft ....................................................................................................................................... 10-1
11
Countershaft ................................................................................................................................... 11-1
12
Main shaft ....................................................................................................................................... 12-1
13
Bearing setting on main shaft, input shaft and countershaft ...................................................... 13-1
14
Synchronizers .................................................................................................................................. 14-1
1325 751 101 - 2009-03
ZF-Ecosplit
Transmission overview
The following transmissions and variants are

covered in this manual:
Transmission types:
12 S 2130 TD
12 S 2330 TD
12 S 2830 TD
1325 751 101 - 2009-03
ZF-Ecosplit
Index
Date of issue
1325 751 101 - 2009-03
Overview of changes: 1325 751 101
Chapter
Initiator
Comment
Preface
Preface
Warranty
This manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
The work described below may only be performed
by authorized, trained, and instructed staff. It is
the responsibility of the users company or repair
company to ensure that their repair staff is properly
trained.
Repair work carried out at ZF Service Points is

subject to the contractual conditions prevailing
in the individual case.
Direct and/or subsequent costs are not covered by
this contractual liability when:
work has been performed improperly or by
unskilled personnel, by non-ZF-personnel,
and/or
This manual deals with a ZF series product in

accordance with the state of development on the
date of issue.
use of non genuine ZF parts.

In case of failure it is mandatory to act immediately,
so to ensure the complete function of the ZF unit
and minimize the scope of damage.
However, due to continuing technical advancements

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
and fitters who have their practical and theoretical
knowledge updated on a regular basis at our Service
Training Center.
In case of proven unfounded delay in repair we

reserve the right of partial acceptance or even a
rejection of warranty claims.
Service points equipped by ZF Friedrichshafen AG

all over the world offer you:
1. Continuously trained personnel,
2. Specified equipment,
e.g.: special tools,
3. Genuine ZF spare parts in accordance
with the latest volume production
specifications.
All work performed at these service locations
is carried out conscientiously and with care.
ZF Friedrichshafen AG
Driveline and Chassis Technology
2008-06
Safety Instructions
The following safety instructions are used
in this repair manual:
DANGER to the health!

Ensure confident handling with supplies.
Manufacturers instructions must be observed.
NOTE
Refers to special working procedures, methods,
information, use of auxiliary equipment, etc.
DANGER 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 regulations.
When working with lubricants and cleaning agents
always refer to the manufacturers instructions.
CAUTION
Is used when the instructions are not complied
with or not followed precisely and could lead to
the product being damaged.
DANGER!
Is used when lack of care could result in personal
injury or danger to life.
CAUTION
The transmission must NOT be suspended by the
input shaft OR by the output flange/add-on parts.
Safety Instructions
As a rule, repair technicians for ZF units are
responsible for their own workplace 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 therefore
familiarize themselves with these regulations.
Incorrect
Personnel required to carry out repairs on ZF

products must receive appropriate training in
advance.
Compulsory training is the responsibility of the
repair staff.
Correct
! DANGER!
Do not walk under suspended load during parts
transportation with a hoist.
2008-06
Instructions for Repairs

General Information
Cleaning Parts
Read this manual carefully before starting tests or

repair work.
Remove old sealing compound residues from all

sealing faces. Carefully remove burrs or other
uneven patches using an oil stone.
Lube bores and grooves must be free from anticorrosion grease and foreign matter. Check that the
passage is free.
Carefully cover opened transmissions to prevent the
entry of foreign matter.
The ZF-Service Information details must be

observed. These are available from all ZF Service
Centers or from the ZF-ServiceLine.
In any cases of doubt, always contact the relevant
expert departments at ZF-Service.
Whenever working on the transmission, ensure
cleanliness and carry out the work as instructed.
Use specified tools to dismantle and assemble
transmissions.
Reusing Parts
Parts such as antifriction bearings, multidisks,
thrust washers etc., must be inspected by a
specialist, who should decide whether they can
be re-used or not.
Replace parts which are damaged or have suffered
from excessive wear.
CAUTION
The pictures, drawings, and components shown
do not always represent the original object, but are
used to illustrate working practices.
The pictures, drawings, and components are not to
scale and no conclusions must be drawn about size
and weight (not even within a complete illustration).
All work must be performed as described in the
text.
Gaskets, locking plates

Parts which cannot be removed without being
damaged must always be replaced with new
parts (e.g. gaskets and locking plates).
Gaskets are installed without the use of sealing
compound or grease. When measuring coated
gaskets/seals proceed as specified.
After repair work and tests performed, skilled

personnel must make sure that the product is
working properly again.
Shaft seals
Always replace shaft sealing rings with rough,
ripped, or hardened sealing lips. Seal contact
surfaces must be totally clean and in perfect
condition.
Conversions and modifications may impact the

transmissions operational safety. Therefore,
customer-specific deviations must be agreed with
ZF in writing.
After removing the transmission from the vehicle,
clean thoroughly with a suitable cleaning agent
before opening. Pay particular attention to the
recesses of housings and covers when cleaning.
2008-06
Reworking
If rework is needed on spacer washers and shims
etc. because of clearance settings, ensure that the
reworked areas contain no face runout and have
the same surface quality.
Instructions for Repairs

Shaft Sealing Rings
Press in shaft sealing ring with fixture or face
plate until firmly home at relevant installation
depth.
Transmission Assembly
Assemble the transmission in a clean workplace.
Adhere to all adjustment data and tightening
torques specified in the repair manual.
a) Apply a thin coat of sealing agent* to outer

circumference of shaft sealing rings with a
steel surround.
Bearings
If the bearings are fitted while warm, these
should be warmed up evenly (e.g. heating
cabinet).
The temperature should be approx. 85C and
must not exceed 120C. All bearings fitted must
be coated with operating oil after assembly.
b) Never apply sealing agent to shaft sealing

with a rubber surround but apply a thin
coat of Vaseline 8420 or spirit to the outer
circumference, or wet with a lubricant, e.g. a
water-soluble concentrated washing-up liquid.
c) Shaft sealing rings with steel and rubber
surrounds should be treated on the outer
circumference of the rubber surround as
described for shaft seal (b).
Sealing
If a sealant* is recommended for sealing, then
it is essential to adhere to the manufacturers
directions for use. A thin layer of sealing agent
should be applied to the surfaces and coat them
evenly. Do not allow sealing agent 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.
d) Duo shaft sealing rings have

two sealing lips. The dust
protection sealing lip (X)
must face outwards.
Fill the space between the
sealing lips up to 60% with
grease*.
Transmission Oil
After completing repairs, fill the transmission
with transmission oil. For the procedure and
approved oils, refer to the transmission operating
manual and the List of Lubricants TE-ML (refer
to type plate). These are available from all
ZF Service Centers or on the Internet at
www.zf.com. After filling the transmission with
oil, tighten the screw plugs at the oil filling point
and the oil overflow to the specified torques.
Retaining Agents
Retaining agents* may only be used where
specified by the parts list.
When using retaining agents (e.g. Loctite) always
comply with the manufacturers directions for
use.
During assembly, comply with all adjustment
data, inspection data, and tightening torques.
* refer to consumable material
2008-06
Tightening torques
Tightening torques for screws/bolts and nuts,
extract from ZFN 148
Surface condition of screws/bolts/ nuts:
Heat-treated blackened finish and oiled or
galvanized and oiled.
This standard applies to bolts according 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 for nuts according to DIN 934 and ISO 4032,
ISO 8673.
The bolts are tightened using a calibrated torque

wrench.
This standard contains data on tightening torques

for screws/bolts and nuts of strength categories 8.8,
10.9, and 12.9, as well as nuts of strength categories
8, 10, and 12.
NOTE
Differing tightening torques are listed separately
in the repair manual.
Coarse thread
Measurement
Screw/Bolt
Nut
M4
M5
M6
Fine thread
Tightening torque in Nm for
8.8
10.9
12.9
8
10
12
2,8
5,5
9,5
Measurement
Screw/Bolt
Nut
Tightening torque in Nm for

8.8
10.9
12.9
8
10
12
4,1
8,1
14
4,8
9,5
16,5
M8x1
M9x1
M10x1
24
36
52
36
53
76
43
62
89
M10x10.25
M12x10.25
M12x1.5
49
87
83
72
125
120
84
150
145
M7
M8
M10
15
23
46
23
34
68
28
40
79
M12
M14
M16
79
125
195
115
185
280
135
215
330
M14x1.5
M16x1.5
M18x1.5
135
205
310
200
300
440
235
360
520
M18
M20
M22
280
390
530
390
560
750
460
650
880
M18x2
M20x1.5
M22x1.5
290
430
580
420
620
820
490
720
960
M24
M27
M30
670
1000
1350
960
1400
1900
1100
1650
2250
M24x1.5
M24x2
M27x1.5
760
730
1100
1100
1050
1600
1250
1200
1850
M27x2
M30x1.5
M30x2
1050
1550
1500
1500
2200
2100
1800
2550
2500
Status: August 1991
2008-06
10
ZF-Ecosplit
Consumables
Grease
0750 199 001
For example
Spectron FO 20
General assembly aid
Grease
0671 190 016
Technical vaseline
8420
General assembly aid
Grease
0750 199 019
For example
Renolit CX-EP2
Jointing compound
0666 690 017
Loctite no. 241
Sealing compound
0666 790 033
Corrosion
protection oil
0750 199 008
Grease
0671 190 050
Loctite no. 574
For example
Renolin MR 40 Z
Olista Longtime 3EP
Quantity
approx.
5
3
1
2
1
3
2
1
1
grams
grams
gram
grams
gram
grams
grams
gram
gram
Comment
S/G cap seal

Double-lip seal
Detent plunger
Shaft sealing ring/pipe
R/C cap seal
R/C sealing rings
Shaft sealing ring
Tappet
Pin
Chapter 10
Chapter 10
Chapter 10
Chapter 7
Chapter 3
Chapter3
Chapter 3
Chapter 2
Chapter 2
300 mm3
Swivel screws
Chapter 3
1 cm3
hex head screws
Chapter 2
0.50 cm3
0.20 cm3
Oil pump rotor

Axial needle bearing
Chapter 7
Chapter 4
3 grams
Ball race release fork
Chapter 7
NOTE: Inquire about available package/container size before placing order!
1325 751 101 - 2009-03
Application
Loctite
Name
Loctite
Designation
ZF item number
11
ZF-Ecosplit
Setting data
Designation
Dimensions
Measurement device
Comment
01. Axial clearance of the

countershaft
0.01 to 0.10 mm
Depth gage
Rotate countershaft in order to

center the bearing rollers.
Set zero play.
Afterwards, adjust play with
suitably thick compensating
disk.
02. Axial clearance of the main 0.01 to 0.10 mm

and input shaft
Depth gage
Rotate input and main shaft in

order to center the bearing
rollers.
Set zero play.
Afterwards, adjust play with
suitably thick
compensating disk .

0.05 to + 0.05 mm
split ring on the main shaft
Feeler gage
Select suitable
ring.
04. Installation dimension of

the shaft sealing ring in
the bearing cover
Adapter
1X56 138 669
The installation dimension can

be determined by using an
adapter.
05. Installation dimension of

the oil pump rotor
23 mm
Depth gage
Do not separate/remove gear

set, only for check.
06. Axial clearance of the snap 0 to 0.1 mm

ring at deep groove ball
bearing in the ring gear
carrier
Feeler gage
Adjust with suitably thick snap

ring.

0 to 0.1 mm
retaining rings on the main
shaft and countershaft
Feeler gage
Adjust with suitably thick retaining ring.
1325 751 101 - 2009-03
0.1 mm
0.5 mm
12
ZF-Ecosplit
Setting data
Designation
Dimensions
Measurement device
Comment
08. Wear limit of synchronizer

rings and/or clutch body,
measured between end
faces, ring, and body at
centric, backlash-free
abutment of the tapers
of main transmission
0.80 mm
Feeler gage
If the dimension is below

specification, replace
synchronizer ring and/or
clutch body.
09. For information:

Synchronizer clearance
(axial)
> 0.60 mm
Feeler gage
Upper limit of the synchronizer

clearance is determined by the
wear limit of 0.80 and/or
1.20 mm.
10. Sliding pad clearance at

the splitter group shift
fork
0.1 + 0.2 mm
Feeler gage
Measured from the sliding

pads bottom side to the
sliding sleeve.
11. Control dimension A to

adjust splitter group shift
fork
short version:
93.70 mm
long version:
107.20 mm
Depth gage
See assembly instructions

0000 701 102
1325 751 101 - 2009-03
Range change group

1.20 mm
13
ZF-Ecosplit
Tightening torques
Designation
Dimensions
Measurement device
Comment
01. M24x1.5 screw plugs

on the transmission
housing
60 Nm
Torque wrench
Use new sealing ring.
02. Breather on the

transmission housing
10 Nm
Torque wrench
Breather must not be plugged.
03. M26x1.5 screw plug for

interlock
70 Nm
Torque wrench
04. M18x1.5 screw plug on

the clutch housing
35 Nm
Torque wrench
05. M10x60 hex head screws

on the clutch housing
50 Nm
Torque wrench
06. M8x22 screw and washer

assemblies on the guide
pipe
32 Nm
Torque wrench

on the connection plate
46 Nm
Torque wrench
08. M18x1.5 screw plugs on

the transmission housing
35 Nm
Torque wrench
09. M8x80
M8x25
screw plugs at the shift
turret
Torque wrench
23 Nm
23 Nm

for pneumatic servo unit
23 Nm
Torque wrench
11. Receptacle on the

pneumatic servo unit
24 Nm
Torque wrench
1325 751 101 - 2009-03
14
Use sealing compound at

position 71.180.
ZF-Ecosplit
Tightening torques
Designation
Dimensions
Measurement device

for cover at the shift
turret
23 Nm
Torque wrench

on the valve block
23 Nm
Torque wrench
14. Pressure switch at the

valve block
23 Nm
Torque wrench
15. Switch at the valve block
45 Nm
Torque wrench
16. Tappet switch at the valve

block
45 Nm
Torque wrench
17. M6x30 torx screws on the

pump cover
10 Nm
Torque wrench

on the range change
group housing
50 Nm
Torque wrench
19. Splitter group N/O contact

at the clutch housing
45 Nm
Torque wrench

on the 5/2-way valve
9.5 Nm
Torque wrench
21. M16x1.5 detent plunger at 50 Nm

the transmission housing
Torque wrench
22. M16x1.5 retaining nut on

150 Nm
the piston for splitter group
selector rail
Torque wrench
Use new retaining nut.
23. Impulse sensor at the

range change group
housing
45 Nm
Torque wrench
24. M24x1.5 screw plug on

the range change group
housing
60 Nm
Torque wrench
1325 751 101 - 2009-03
15
Comment
ZF-Ecosplit
Tightening torques
Designation
Dimensions
Measurement device
25. M10x40 hex head

screws on the output
cover
46 Nm
Torque wrench
26. M12x25 hex head

screws on the cover
for PTO
79 Nm
Torque wrench
27. M10x1 screw plug on the

range change group
housing
15 Nm
Torque wrench
28. M12x60 hex head

screws on the output
flange
120 Nm
Torque wrench
29. M24x1.5 swivel screws

on the range change
group housing
250 Nm
Torque wrench
Use sealing compound.
30. M16x1.5 retaining nut on

the piston for R/C selector
rail
150 Nm
Torque wrench
Use new retaining nut.

on the RC/ cylinder
46 Nm
Torque wrench
32. Detent plunger at the

transmission housing
50 Nm
Torque wrench
33. Switch at the R/C housing
45 Nm
Torque wrench
34. M6x25 screw and washer

assemblies on the valve
9.5 Nm
Torque wrench
35. M22x1.5 screw plugs

for heat exchanger
connection
50 Nm
Torque wrench

on the release shaft
115 Nm
Torque wrench
1325 751 101 - 2009-03
16
Comment
ZF-Ecosplit
Spring table
De
Spring diameter + tolerance in mm
Dh
Test sleeve diameter in mm
L0
Length of unloaded spring in mm
nt
Total number of coils
Wire diameter
nt
Lo
De
Dh
018325
Order no.
Installation blocation
Number of
coils
[nt]
Wire
in mm
[d]
Outer spring
in mm at L0
[De]
Free length
in mm
[L0]
0732 040 630
Shift turret of
superimposed H shift system
6.5
2.4
39.1
89.9
0732 040 985
Circuit
at detent
6.5
2.0
14.8
23.4
0732 040 984
Circuit
at detent
9.5
1.4
9.1
23.3
0732 040 385
Synchronizer
of range change group
18.5
1.25
6.35
34.2
0732 040 386
Synchronizer
of range change group
35.5
0.7
3.2
34.7
0732 040 409
Synchronizer
of main transmission
12.5
1.4
6.65
23.7
0732 040 736
Circuit
(interlock)
13.5
1.6
9.6
36.0
0732 040 983
Circuit
at detent
12.5
1.1
5.4
18.8
0732 040 986
Circuit
at detent
5.5
2.25
14.5
21.6
1325 751 101 - 2009-03
17
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X25 139 707
1325 751 101 - 2009-03
Chapter 2
Chapter 3
Chapter 7
Chapter 8
Pliers
for caulking the oil pipe
1X56 138 627
Chapter 2
Lifting device
for range change group
1X56 138 626
Impact adapter
to remove needle bush
on the valve lever
1X56 136 260
Remark
Adapter
for bush on the gearshift housing
1X25 139 783
No. of
pieces
Assembly aid
for interlock bolts
18
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 138 628
1325 751 101 - 2009-03
general
Chapter 8
Chapter 8
Chapter 8.3
Assembly aid
to support
S/G selector rail
1x56 138 633
10
Chapter 6
Assembly aid
to support main shaft and
countershaft
1X56 138 632
Assembly fixture
to clamp the transmission
1X56 138 631
Remark
Assembly aid
for connection plate
1X56 138 630
No. of
pieces
Assembly aid
for shift fork adjustment
19
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 138 635
11
1325 751 101 - 2009-03
Chapter 4
Chapter 4
Chapter 3
Chapter 5
Chapter 8
Press-in mandrel
for shaft sealing ring in the output
cover
1X56 138 673
15
Chapter 8
Locating bolt
d = 84.9 mm
to fix the plate to range change
group housing
(with Intarder)
1X56 138 669
14
Locating bolt
d = 89.9 mm
to fix the plate to range change
group housing
(without Intarder)
1X56 138 668
13
Remark
Centering device
for selector rails
1X56 138 664
12
No. of
pieces
Locating fixture
for leakage test
S/G cylinder and fork adjustment of
S/G selector rail
20
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 138 674
16
1325 751 101 - 2009-03
Chapter 3
general
Chapter 5
Chapter 6
Extractor
for clutch housing/transmission housing dowel pins
1X56 138 064
20
Chapter 3
Assembly block (stationary)

combined with
1X56 138 630
1X56 138 063
19
Locating fixture
for oil pipe (output end)
1P01 181 850
18
Remark
Heating device
for the output bearing
at the inner ring
1X56 138 675
17
No. of
pieces
Protective sleeve
for shaft sealing ring/connection
plate
21
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 137 122
21
1325 751 101 - 2009-03
Chapter 5
Chapter 8
Chapter 8
Chapter 8
Bolts
for shafts combined with
support 1X56 137 675
1X56 137 921
25
Chapter 8
Support
for shafts and selector rails
1X56 137 953
24
Locating fixture
for S/G selector rail
1X56 137 675
23
Remark
Lifting device
1X56 138 100
22
No. of
pieces
Centering ring
combined with
lifting device 1X56 137 122
22
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 137 933
26
1325 751 101 - 2009-03
Chapter 10
Chapter 10
Chapter 11
Chapter 11
Chapter 12
Gripper
for the tapered roller bearings
on the countershaft
1X56 138 596
30
Chapter 8
Basic tool
combined with
Gripper 1X56 136 722
1X56 136 756
29
Gripper
for tapered roller bearing(s)
at the input
1X56 122 304
28
Remark
Washer
combined with
1X56 136 722
27
No. of
pieces
Gripper
for tapered roller bearing(s)
on the main shaft
23
(if required)
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 122 306
31
1325 751 101 - 2009-03
(if required)
Chapter 8
Chapter 7
Chapter 3
Chapter 3
Heating device
for output bearing/bearing seat
of outer ring in the housing and
combined with threaded spindle
1X56 137 808
1X56 137 808
35
Chapter 12
Dowel pin
for clutch and transmission housing
1X56 138 696
34
Remark
Assembly aid
for S/G selector rail combined with
1X56 138 695
33
Basic tool
combined with
1X56 138 694
32
No. of
pieces
Threaded spindle
to insert output bearing
24
ZF-Ecosplit
Figure
no.
Depiction
Special tool
Order no.
Application
1X56 137 654
36
1325 751 101 - 2009-03
Threaded bolt
for output bearing combined with
threaded spindle 1X56 137 808
25
No. of
pieces
1
Remark
Chapter 3
26
ZF-Ecosplit
Range Change Group Shift Unit
1325 751 101 - 2009-03
Polyamide Tubes for Range Change Group and Valve
1.1
Removing polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1.2
Fitting polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-1
1-2
ZF-Ecosplit
Range Change Group Shift Unit
25
26
0510-0010
0480-0130
0510-0030
26
25
028566_1
Polyamide tubes for range change group

and valve
1.1
Removing polyamide tubes
NOTE
The connecting points are marked.
Tubes are reverse-mounted:
Pos. 0510-0010 (25),
Valve block at the top, R/C at the bottom.
Item 0510-0030 (26),
Valve block at top, R/C at bottom.
1
Unfasten polyamide tubes 0510-0010 /

0510-0030 and 0480-0130 on the plug
couplings (see sketch) and remove them.
1325 751 101 - 2009-03
1.2
Fitting polyamide tubes
Fit polyamide tubes 0510-0010 / 0510-0030

according to the designations.
Insert polyamide tubes into plug couplings at
the range change group cylinder and at the
shift unit and check whether the tubes are
fixed by pulling carefully.
Insert polyamide tube 0480-0130 into plug
couplings at Servoshift and valve.
NOTE
Maintain minimum distance of 5 mm between
polyamide tube and housing.
1-3
1-4
ZF-Ecosplit
Shift System
1325 751 101 - 2009-03
Shift Turret
2.1
Pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Removing pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Fitting pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-2
2-2
2.2
Gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Removing and dismantling gearshift housing . . . . . . . . . . . . .
2.2.2 Assembling gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2-3
2-6
2.3
Shift patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9
2.4
Fitting complete shift turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-1
ZF-Ecosplit
Shift System
71.180
71.170
71.170
Loctite
71.180
71.150
71.410
71.160
1
2
71.452
71.454
028567
Shift Turret
2.1.2 Fitting pneumatic servo unit
2.1
Pneumatic servo unit
Put in 71.452 receptacle, tighten elbow 71.454

and pipe 71.410.
Tightening torque: 24 Nm
2.1.1 Removing pneumatic servo unit

1
Unfasten hex head screws 71.170 / 71.180.
Place compression spring (1) in servo unit.
Remove the pneumatic servo unit 71.150 with

seal 71.160 and compression spring (1).
Fix pneumatic servo unit 71.150 together with

new seal 71.160 to shift turret.
Insert hex head screws 71.170 / 71.180 and

tighten.
NOTE
Compression spring (1) is loose in the pneumatic
servo unit.
Do not disassemble pneumatic servo unit any
further, sub-assembly.
3
Unfasten receptacle 71.452, remove together

with elbow 71.454 and pipe 71.410.
NOTE
Insert one hex head screw 71.170 and 71.180 each
using Loctite no. 574 as sealing compound.
Order no.: Compression spring (1) 0501 318 490
Detent (2)
0501 319 920
1325 751 101 - 2009-03
2-2
ZF-Ecosplit
Shift System
08.890
09.090
09.090
09.270
09.320
09.090
09.290
09.280
71.110
48.070
09.580
09.250
71.130
09.100
09.100
09.040
09.010
08.870
08.470
028568
2.2
Gearshift housing
If necessary, unfasten neutral switch 09.270

with sealing ring and pressure switch 09.580
and remove them.
Remove tappet 09.240 and pin 09.250 from

gearshift housing.
Unfasten tappet switch 09.320 with sealing

ring and them remove together with
compression spring 09.290 and detent 09.280.
Unfasten hex head screws 71.130 and remove

cover 71.110.
Remove V-shaped ring 49.070 from housing.
2.2.1 Removing and dismantling gearshift

housing
1
Unfasten hex head screws 08.890 and remove

shift turret with seal 08.87.
Remove roller 08.470 from valve lever.
NOTE
For Servoshift removal, refer to Chapter 2.1
2
Unfasten hex head screws 09.090 / 09.100 and

take them off together with valve block
09.010.
NOTE
seal may stick to gearshift housing; remove it from
housing and place it in the valve block. Do not
disassemble valve block further, sub-assembly.
1325 751 101 - 2009-03
2-3
ZF-Ecosplit
Shift System
08.830
08.830
08.830
08.440
08.430
08.810
08.530
08.540
08.450
08.560
08.410
08.490
08.100
08.130
08.800
08.470
08.010
08.300
08.370
08.380
08.350
08.080
08.360
028569
Unfasten hex head screws 08.830, remove

cover 08.810 and seal 08.800.
Remove locking pawl 08.540 and pin 08.530.
10
Slide pin 08.560 through gearshift housing

and remove.
CAUTION
Retaining rings 08.380 must not be overstretched
use adjustable pliers.
11
Unsnap retaining ring 08.380.
12
Remove cylindrical pin 08.370/110 and, if

necessary, remove retaining ring 08.370/120.
13
Push hollow shaft 08.300 towards sealing

cover.
14
Place impact adapter 1X25 139 783 on

needle bush 08.440 and drive valve lever
08.410 slightly downwards.
15
Remove needle bush 08.440.
1325 751 101 - 2009-03
16
Remove pin 08.430.
17
Remove gearshift shaft 08.150 from gearshift

housing in direction of arrow taking off valve
lever 08.410 and lever 08.490.
NOTE
Inspect gearshift shaft bores and level any raised
edges.
18
Remove pin 08.450 from valve lever; do not

remove lower needle bush. If the needle
bush is defective, replace valve lever and
needle bush as a complete set.
19
Fit plastic mandrel to hollow shaft 08.300

and use hollow shaft to drive bush 08.100
and shaft sealing ring 08.130 out of gearshift
housing. Push hollow shaft out of gearshift
housing and take off driver 08.350 and
blocking piece 08.360.
20
If necessary, remove cylindrical pin 08.080.
2-4
ZF-Ecosplit
21
22
Shift System
Use pliers to remove V-shaped ring 49.030

from gearshift shaft.
49.030
49.020
Remove washers 49.020 with compression

spring 49.010 from the gearshift shaft.
49.010
49.020
028571
1325 751 101 - 2009-03
2-5
ZF-Ecosplit
Shift System
2.2.2 Assembling gearshift housing

1
10
Mount washer 49.020, compression spring

49.010, and washer 49.020 onto gearshift
shaft.
Snap retaining ring 08.370/120 into pin

08.370/110 and insert in driver and gearshift
shaft. Insert retaining ring 08.380.
11
Insert pin 08.560 to stop in housing and lock

with pin 08.530. Insert locking pawl 08.540.
Use pliers to snap V-shaped ring 49.030 into

gearshift shaft.
12
Fit new seal 08.800 and cover 08.810.
13
Insert hex head screws 08.830 and tighten.

Slide driver 08.350 and blocking piece 08.360

into gearshift housing. Slide hollow shaft
08.300 in correct position into gearshift
housing, blocking piece, and driver.
Press bush 08.100 flush into housing using

mounting adapter 1X25 139 707.
Apply grease to shaft sealing ring 08.130 and

press firmly home.
Insert cylindrical pin 08.450 in valve lever

08.410.
If necessary, press in cylindrical pin 08.080.
Fit valve lever 08.410 and lever 08.490 on

hollow shaft in gearshift housing.
Insert gearshift shaft 08.150in hollow shaft

(in direction of arrow).
NOTE
Cylindrical pin 08.450 must mesh with the gearshift
shaft. Position gearshift shaft and hollow shaft.
9
Insert cylindrical pin 08.430 and drive in new

needle bush 08.440 until it is flush.
Check whether gearshift shaft is freely
moving.
CAUTION
Retaining rings 08.370/120 and 08.380 must not be
overstretched use adjustable pliers.
1325 751 101 - 2009-03
2-6
ZF-Ecosplit
Shift System
08.830
08.830
08.830
08.440
08.430
08.810
08.530
08.540
08.450
08.560
08.410
08.490
08.100
08.130
08.800
08.470
08.010
08.300
08.370
08.380
08.350
08.080
08.360
49.030
49.020
49.010
49.020
028571
028570
1325 751 101 - 2009-03
2-7
ZF-Ecosplit
Shift System
08.890
09.090
09.090
09.270
09.320
09.090
09.290
09.280
71.110
48.070
09.580
09.250
71.130
09.100
09.100
09.040
09.010
08.870
08.470
028568
14
15
16
Install detent 09.280, spring 09.290, and tappet

switch 09.320 with new sealing ring in gearshift housing and tighten.
19
Snap V-shaped ring 49.070 into gearshift

housing.
20
Mount cover 71.110 to housing using hex head

screws 71.130 and tighten.
21
Place greased roller 08.470 onto valve lever.
Insert tappet 09.040 and pin 09.250 in gearshift housing.

Mount valve block 09.010 with hex head
screws 09.090 / 09.100 on gearshift housing.
NOTE
To fit Servoshift, refer to Chapter 2.1
17
Screw in neutral switch 09.270 with new

sealing ring on valve block and tighten.
NOTE
To fit the entire shift unit to the transmission,
refer to Chapter 2.4.
18
Screw in pressure switch 09.580 on valve

block and tighten.
1325 751 101 - 2009-03
2-8
ZF-Ecosplit
2.3
Shift System
Shift patterns
Shift turret of superimposed H shift pattern
1325 173 008
Shift pattern I
Configuration of spring packages Q1
028572
Q1
028573
1325 751 101 - 2009-03
2-9
ZF-Ecosplit
2.4
Shift System
Fitting complete shift turret

08.890
Fit new seal 08.800 to clutch housing and/or

sealing face.
Fit complete gearshift housing 08.010.

Position bore holes in gearshift housing in line
with seal.
08.010
NOTE
Positioning between the clutch housing, seal, and
gearshift housing must be achieved by inserting 2
locating pins of 8.9 mm.
3
08.870
Insert all hex head screws 08.890 and tighten.

028694
15
80
shaft 8.9
110
15
M8
016 078_en
1325 751 101 - 2009-03
2-10
ZF-Ecosplit
Range Change Group
1325 751 101 - 2009-03
Range Change Group

3.1
Removing output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3.2
Fitting output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3.3
Removing cover and output bearing . . . . . . . . . . . . . . . . . . . . . . .
3-4
3.4
Fitting cover and output bearing . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3.5
Removing range change group . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3.6
Fitting range change group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
3.7
Dismantling range change group . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1 Removing range change group cylinder and piston . . . . . . . .
3.7.2 Fitting range change group cylinder and piston . . . . . . . . . . .
3-8
3-8
3-9
3-1
ZF-Ecosplit
Range Change Group
0360-0060-0630
0360-0060-0670
0360-0060-0640
0360-0060-0680
0360-0060-0660
0360-0060-0650
0360-0060-0600
0360-0060-0620
0360-0060-0610
028648_1
Range Change Group

2
NOTE
Please follow the work steps listed below when
repairing the range change group.
If the range change group is only to be removed for
further repair, please carefully remove washer
0360-0060-0660 and mount fixture 1X56 136 260.
For information on how to demount range change
group, refer to Chapter 3.5.
3.1
Removing output flange
Remove hex head screws 0360-0060-0670 and

0360-0060-0680 and take off washer
0360-0060-0660.
1325 751 101 - 2009-03
Use commercially available three-armed

extractor 0360-0060-0600 to pull off output
flange.
NOTE
Use intermediate piece to protect shaft during
pulling-off process.
3-2
Remove hex head screws 0360-0060-0610 to

0360-0060-0640 from output flange.
Remove O-ring 0360-0060-0650.
ZF-Ecosplit
3.2
Range Change Group
Fitting output flange
NOTE
Range change group is fitted to the transmission,
Output bearing and cover are fitted, refer to
Chapter 3.4.
1
Put hex head screws 0360-0060-0610 to

0360-0060-0640 into output flange.
DANGER
Only touch hot output flange when wearing
protective gloves.
Heat output flange 0360-0060-0600 to max.

100 C and slide onto spline of planet carrier
until firmly home (axial abutment).
NOTE
If necessary, pull on output flange by means of
washer 0360-0060-0660 and two assembly auxiliary
screws until it is firmly home (axial abutment).
Remove washer and assembly auxiliary screws
afterwards.
3
Lightly oil new O-ring 0360-0060-0650 and

insert it in the gap between output flange and
planet carrier shaft.
Fix washer 0360-0060-0660 with hex head

screws 0360-0060-0670 and 0360-0060-0680.
If required, secure the output flange against
twisting by means of a flange holder.
If necessary, fit protective caps on hex head

screws 0360-0060-0610 to 0360-0060-0640.
1325 751 101 - 2009-03
3-3
ZF-Ecosplit
Range Change Group
0360-0050-0320
0360-0050-0330
bis
0360-0050-0360
0360-0040-0400
0360-0040-0050
0360-0050-0310
0360-0040-0100
bis
0360-0040-0190
0360-0050-0300
0360-0040-0010
0360-0040-0050
0360-0040-0060
0360-0040-0020
0360-0040-0250
0370-0200-0210
bis
0370-0200-0250
028649_1
3.3
Removing cover and output bearing

0360-0050-0360.
Take off cover 0360-0050-0320 and seal 03600050-0310.
Unfasten cover 0360-0040-0050 by light blows

with a plastic hammer and take it off together
with seal 0360-0040-0060.
Drive shaft sealing ring 0360-0040-0070 out of

bearing cover by using plastic mandrel.
If necessary, remove screw plug

0360-0040-0250 .
Use commercially available extractor to pull

ball bearing 0360-0040-0020 out of housing.
If necessary, remove screw plug

0360-0050-0300 together with sealing ring.
Remove impulse sensor 0360-0040-0400.

0360-0040-0190 on the cover 0360-0040-0050.
1325 751 101 - 2009-03
3-4
ZF-Ecosplit
3.4
Range Change Group
Fitting cover and output bearing
NOTE
Range change group is fitted to the transmission,
1X56 138 669
DANGER
Only touch heated parts when wearing protective
gloves.
1
Heat housing around bearing bore up to

approx. 60C by using heating device
1X56 138 696.
Heat inner bearing ring up to approx. 60C by
using heating device 1X56 138 674.
Pull roller bearing 0360-0040-0020 with

heating device1X56 138 696, adapter
1X56 137 654 and spindle 1X56 137 808 into
housing via planet carrier; ensure axial
abutment.
028678_1
NOTE
Fitting dimension of shaft sealing ring is determined
by fitting driver.
Lightly oil the sealing lip of the shaft sealing ring.
Install new screw plug 0360-0040-0250 with

new sealing ring.
Clean sealing surface on R/C housing and

cover 0360-0050-0320.
Fit new seal 0360-0050-0310 and cover

0360-0050-0320.
Insert new hex head screws 0360-0050-0330

to 0360-0050-0360.
Install new screw plug 0360-0050-0300 with

new sealing ring.
Coat shaft sealing ring 0360-0040-0070 at the

outer circumference with spirit (ethanol) and
press it into bearing cover by means of fitting
driver 1X56 138 669 until firmly home.
1325 751 101 - 2009-03
3-5
Place new seal 0360-0040-0060 on housing.
10
Fit cover 0360-0040-0050 on housing and fix

with hex head screws 0360-0040-0100 to
0360-0040-0190.
11
Screw in impulse sensor 0360-0040-0400 .

ZF-Ecosplit
Range Change Group
0370-0200-0210
bis
0370-0200-0250
0110-0190
0480-0020
0360-0030-0240
0200-0020
0480-0030
0480-0010
0400-0300
0370-0300
bis
0370-0500
0370-0200
0130-0050
0360-0030-0250
0370-0240
028644_1
Mount fixture 1X56 136 260 on the planet

carrier. Use a crane and 2 pry bars to separate
the entire range change group from the basic
transmission and put it down.
Remove detent plunger 0400-0300.
Clean seal 0370-0240 and sealing faces.
Unfasten screw plug 0110-0190 and remove

together with sealing ring; then screw in
assembly aid 1X56 138 627.
Remove reverse shaft 0130-0050 from

transmission housing.
Pull oil pipe 0200-0020 out of transmission

housing.
10
Remove pressure disk 0370-0200 from the

main shaft.
3.5
Removing range change group
Unfasten both swivel screws 0360-0030-0240

and 0360-0030-0250, do not remove them yet.
2
3
Unfasten hex head screws 0480-0020 and

0480-0030 and remove them together with
valve 0480-0010.
Unfasten hex head screws 0370-0300 to
0370-0500 on range change group and remove
them.
1325 751 101 - 2009-03
NOTE
If necessary, remove cylindrical pins
0370-0200-0210 to 0370-0200-0250 from the
housing.
3-6
ZF-Ecosplit
3.6
Fitting range change group
If required, insert cylindrical pins

0370-0200-0210 to 0370-0200-0250 into
housing.
Put seal 0370-0240 on the transmission

housing.
Push thrust washer/pressure disk 0370-0200

on the main shaft with the collar facing the
input side.
Use locating fixture1X56 138 675 to insert oil

pipe 0200-0020 in the transmission housing
with the three oil bore holes facing the input
side (ensure abutment).
Slide reverse shaft 0130-0050 into reverse

gear.
Attach range change group to crane and

carefully move above transmission housing;
then lower until it abuts.
Range Change Group
NOTE
S/G cylinder must be installed.
Guide selector rail into support plate opening for
shift interlock.
Fix oil pipe from the outside and insert into plate
0360-0020-0020.
Make spline of main shaft and planetary gears
mesh by turning them.
7
Screw in hex head screws 0370-0300 to

0370-0500 and tighten.
Tighten swivel screws 0360-0030-0240 and

0360-0030-0250 fitted with Loctite no. 241.
Install detent plunger 0400-0300 together with

new sealing ring and tighten.
1325 751 101 - 2009-03
3-7
10
Fit valve 0480-0010 to transmission housing

using hex head screws 0480-0020 and
0480-0030.
Tightening torque: 9.5 Nm
11
Remove assembly aid 1X56 138 627, insert

new screw plug 0110-0190 together with new
sealing ring and fasten.
ZF-Ecosplit
Range Change Group
0360-0030-0070
0400-0520
0400-0400
0360-0030-0010
0360-0030-0240
0360-0030-0030
0360-0030-0040
0360-0030-0020
1
0360-0030-0120
0360-0030-0110
0360-0030-0090
0360-0030-0230
0360-0030-0050
Loctite
0360-0030-0250
0360-0030-0100
0360-0030-0230
0360-0030-0060
0510-0010
0510-0030
0360-0030-0080
028647_1
3.7
Dismantling range change group
Remove retaining nut 0360-0030-0070 from

piston 0360-0030-0030, take off piston, and
take sealing rings 0360-0030-0040,
0360-0030-0050, and guide ring
0360-0030-0060 out of the piston.
Use a suitable tool to lift cap seal

0360-0030-0020 out of range change group
housing.
3.7.1 Removing range change group cylinder and

piston
1
Remove unfastened swivel screws

0360-0030-0240 and 0360-0030-0250.
Unfasten switch 0400-0520 and remove
together with pin 0400-0400.
Unfasten hex head screws 0360-0030-0100

to 0360-0030-0120 and remove together with
washers.
Remove cylinder 0360-0030-0090 together

with seal 0360-0030-0080.
Detach selector rail 0360-0030-0010 from shift

fork 0360-0030-0230 and pull piston out of
housing bore.
1325 751 101 - 2009-03
CAUTION
Cap seal might be damaged. Therefore, it must
always be replaced with new one.
3-8
If necessary, unfasten and remove plug-in

couplings 0510-0010 and 0510-0030 on
cylinder 0360-0030-0090 .
Remove housing 0360-0040-0010 from the

planetary gear set.
ZF-Ecosplit
Range Change Group
3.7.2 Fitting range change group cylinder and

piston
Snap new seal 0360-0030-0080 into cylinder

0360-0030-0090 ensuring correct position.
Place cylinder with seal on range change

group and fix with hex head screws
0360-0030-0100 to 0360-0030-0120.
NOTE
Shift fork must be inserted, refer to Chapter 4.
10
Mesh lug (1) of gearshift fork 0360-0030-0230

with recess (2) of selector rail 0360-0030-0010.
Coat locating bore and new cap seal

0360-0030-0020 on the outside with ethyl
alcohol (spirit). Mount cap seal before ethyl
alcohol volatilizes.
11
Align shift fork with threaded holes in

housing in such a way that locating bores
of shift fork are aligned with the housings
threaded holes.
Use suitable tool to drive cap seal

0360-0030-0020 into range change group
housing until firmly home (axial abutment).
Grease the sealing lip of cap seal.
12
Screw in swivel screws 0360-0030-0240

and 0360-0030-0250, do not tighten.
Use locating pin 1X56 138 664 to place

housing on planetary gear set next to PTO
opening and support plate and ensure
abutment.
NOTE
Threads must be clean and free from oil and
grease.
Coat threads of swivel screws with
Loctite no. 241.
Equip piston 0360-0030-0030 with sealing

rings 0360-0030-0040, 0360-0030-0050 and
one guide ring 0360-0030-0060. Place
complete piston on the selector rail
0360-0030-0010.
CAUTION
Always use new retaining nut 0360-0030-0070.
Thread (Spiralock) of retaining nut must be
cleaned before screwing it on.
5
Tighten retaining nut 0360-0030-0070.

CAUTION
Do not damage the cap seals sealing lip.
6
Insert selector rail with piston into housing

bore through cap seal and ensure axial
abutment of piston.
Grease both sealing rings0360-0030-0040 and

0360-0030-0050 and the inner side of the
cylinder 0360-0030-0090.
1325 751 101 - 2009-03
3-9
13
Insert greased pin 0400-0400 and screw in

and tighten switch 0400-0520.
14
If necessary, install plug-in couplings

0510-0010 and 0510-0030 on the cylinder
0360-0030-0090 and tighten.
3-10
ZF-Ecosplit
Planetary Gear Set with Synchronizer
1325 751 101 - 2009-03
4.1
Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Disassembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Assembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
4-3
4.2
Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Disassembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Assembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
4-5
4-5
4.3
Planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Disassembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Assembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4-6
4-7
4-1
ZF-Ecosplit
4
4.1
Synchronizer
0360-0020-0200
4.1.1 Disassembling synchronizer

1
Take off shift fork 0360-0030-0230.
Remove sliding pads 0360-0030-0200 and

0360-0030-0210 from shift fork.
Fit intermediate piece onto planet carrier and

grip sliding sleeve 0360-0020-0050-0190 by
two or three-armed extractor.
0360-0010-0540
0360-0020-0050-0190
0360-0020-0250
0360-0030-0230
0360-0030-0200
0360-0030-0210
DANGER
Thrust pieces are under spring tension.
Use e.g. cloth to prevent the parts from jumping out.
0360-0020-0050-0150
0360-0020-0050-0160
Pull off sliding sleeve 0360-0020-0050-0190,

synchronizer ring 0360-0020-0050-0140, and
clutch body 0360-0020-0250. The thrust pieces
0360-0020-0050-0150, which are under
tension, and compression springs 0360-00200050-0160 and 0360-0020-0050-0170 are
stopped by the cloth.
0360-0020-0050-0170
0360-0020-0050-0140
0360-0020-0010
0360-0020-0200
Check axial bearing 0360-0010-0540 for

functioning, only remove from ring gear
carrier if it is defective.
Remove retaining ring 0360-0020-0200.
Grip clutch body 0360-0020-0010 with a

two-armed extractor and pull off.
Take synchronizer body 0360-0020-0050-0110

with synchronizer ring 0360-0020-0050-0140
off planet carrier 0360-0010-0010.
Remove plate 0360-0020-0020 from planet

carrier.
0360-0020-0050-0110
0360-0020-0020
0360-0010-0010
028621_1
1325 751 101 - 2009-03
4-2
ZF-Ecosplit
4.1.2 Assembling synchronizer

0360-0010-0540
NOTE
For more information about synchronizer wear test,
refer to Chapter 14.
0360-0020-0200
0360-0020-0050-0190
NOTE
Slightly oil the friction cones of the clutch bodies
and synchronizer rings.
1
0360-0020-0250
0360-0030-0230
Position plate 0360-0020-0020 correctly on

planet carrier 0360-0010-0010.
0360-0030-0200
0360-0030-0210
NOTE
Locating bore for oil pipe must be at top right, see
arrow.
2
Fit clutch body 0360-0020-0010 and

synchronizer ring 0360-0020-0050-0140
onto the planet carrier.
0360-0020-0050-0150
0360-0020-0050-0160
Slide on synchronizer body 0360-0020-00500110, with the long hub side facing the planet
carrier. The cams of the synchronizer ring
0360-0020-0050-0140 must engage with the
recesses of the synchronizer body.
0360-0020-0050-0170
0360-0020-0050-0140
0360-0020-0010
Snap in retaining ring 0360-0020-0200.

0360-0020-0200
NOTE
The retaining rings axial clearance must be between
0 and 0.10 mm. Try to have 0.0 mm. Select the
retaining ring in line with items offered in the spare
parts catalog.
5
0360-0020-0050-0110
0360-0020-0020
Put sliding sleeve 0360-0020-0050-0190 onto

synchronizer body and ensure axial contact.
NOTE
Recesses of the sliding sleeve must be congruent
with recesses of synchronizer body.
0360-0010-0010
028621_2
1325 751 101 - 2009-03
4-3
ZF-Ecosplit
6
Insert new compression springs 0360-00200050-0170 and 0360-0020-0050-0160 with

thrust pieces 0360-0020-0050-0150 in the
synchronizer body and use suitable tool to
locate them in sliding sleeve.
Fit synchronizer ring 0360-0020-0050-0200 to
synchronizer body. The cams of the synchronizer ring must engage with recesses of
synchronizer body.
0360-0010-0540
0360-0020-0200
0360-0020-0050-0190
0360-0020-0250
0360-0030-0230
If necessary, put new axial bearing

0360-0010-0540 onto ring gear carrier.
Push clutch body 0360-0020-0250 onto planet

carrier.
10
Press on clutch body and bring sliding sleeve

into central position. You will hear the thrust
pieces snap into place.
11
0360-0030-0200
0360-0030-0210
0360-0020-0050-0150
0360-0020-0050-0160
Insert sliding pads 0360-0030-0200 and

0360-0030-0210 in the shift fork
0360-0030-230.
12
Insert the shift fork into the sliding sleeve

0360-0020-0050-0190.
13
Slightly grease the locating bores (see arrow)

of the shift fork.
0360-0020-0050-0170
0360-0020-0050-0140
0360-0020-0010
0360-0020-0200
0360-0020-0050-0110
NOTE
To attach range change group, refer to Chapter 3.2.
0360-0020-0020
0360-0010-0010
028621_2
1325 751 101 - 2009-03
4-4
ZF-Ecosplit
4.2
Ring gear
4.2.1 Disassembling ring gear

1
Completely pull ring gear off planet carrier

0360-0010-0010.
Remove bush 0360-0010-0500 from planet

carrier.
Unsnap locking wire 0360-0010-0530 from

circular groove of the ring gear
0360-0010-0520 and remove it.
Drive ring gear carrier 0360-0010-0510
out of ring gear using plastic hammer.
0360-0010-0500
0360-0010-0530
4.2.2 Assembling ring gear

1
Put bush 0360-0010-0500 onto planet carrier.
Drive in ring gear carrier 0360-0010-0510 until

firmly home with ring gear 0360-0010-0520
(axial abutment).
0360-0010-0520
0360-0010-0510
028619_1
Snap locking wire 0360-0010-0530 into the

circular groove of the ring gear.
NOTE
Locking wire must make contact with the groove
base.
4
Put bush onto planet carrier. During the

process, turn the ring gear and ensure that the
gearings of the planetary gears mesh with the
ring gear.
012012
1325 751 101 - 2009-03
4-5
ZF-Ecosplit
4.3
Planet carrier
0360-0010-0380
0360-0010-0330
4.3.1 Disassembling planet carrier
0360-0010-0040
0360-0010-0310
NOTE
For reasons of simplification, only one gear set is
depicted. The process is identical for all five planet
carriers.
1
0360-0010-0160
0360-0010-0040
0360-0010-0130
Drive all dowel pins 0360-0010-0110,

0360-0010-0120 into the planetary bolts
0360-0010-0100 (full length).
0360-0010-0120
Use a hammer and plastic mandrel to drive all

five planetary bolts 0360-0010-0100 out of
planet carrier 0360-0010-0010 in drive/input
direction.
Take five planetary gears 0360-0010-0040
with intermediate disks 0360-0010-0130,
0360-0010-0310, 0360-0010-0330 and rollers
0360-0010-0160, 0360-0010-0380 out of planet
carrier.
0360-0010-0110
0360-0010-0100
0360-0010-0010
028618_1
Drive dowel pins 0360-0010-0110,

0360-0010-0120 out of planetary bolts
0360-0010-0100.
012006
1325 751 101 - 2009-03
4-6
ZF-Ecosplit
4.3.2 Assembling planet carrier

0360-0010-0380
0360-0010-0330
CAUTION
Do not replace planetary gears 0360-0010-0040
individually but always as a set.
0360-0010-0040
0360-0010-0310
0360-0010-0160
Lightly oil the planetary gears 0360-0010-0040

on the end faces and needle roller races.
Position planetary bolts 0360-0010-0100 with

collar facing downwards.
Pull intermediate disk 0360-0010-0130 over

the planetary bolt.
Mount planetary gear 0360-0010-0040 on

planetary bolt.
Insert 14 rollers 0360-0010-0160 in

planetary gear and pull intermediate disk
0360-0010-0310 over planetary bolt.
0360-0010-0130
0360-0010-0120
0360-0010-0110
0360-0010-0100
0360-0010-0010
028618_1
NOTE
Only use rollers of the same grade tolerance.
6
Insert another 14 rollers 0360-0010-0380,

lightly oil them and put on intermediate
disk 0360-0010-0330.
Position planet carrier 0360-0010-0010 on

the shaft part.
Carefully take the complete planetary gear

with intermediate disks off the planetary bolt
and insert into the planet carrier.
Align planetary gear with 0360-0010-0040

bearing bore hole.
NOTE
The 0 marking at the planetary bolt face must face
the outer radius of the planet carrier. The planetary
bolts bore for the dowel pins must align with planet
carriers bore.
1325 751 101 - 2009-03
0360-0010-0040
4-7
ZF-Ecosplit
10
11
12
13
Align planetary bolt 0360-0010-0100 in radial

direction and insert in bearing bore hole.
0360-0010-0380
0360-0010-0330
0360-0010-0040
Drive in planetary bolt by means of a plastic

hammer. Check the alignment of the dowel
pin bore.
0360-0010-0310
0360-0010-0160
Drive new dowel pin 0360-0010-0110 half

way in. Drive the second (new) dowel pin
0360-0010-0120 into first dowel pin, offset
by approx. 180 (gudgeon slots). Countersink
dowel pins together into planet carrier by
approx. 0.5 mm.
0360-0010-0040
0360-0010-0130
0360-0010-0120
0360-0010-0110
Repeat working steps 1 through 14 for the

other four planet carriers.
0360-0010-0100
0360-0010-0010
028618_1
1325 751 101 - 2009-03
4-8
ZF-Ecosplit
S/G Valve, 5/2-Way Valve
1325 751 101 - 2009-03
Splitter Group Piston and 5/2-Way Valve
5.1
Removing piston and valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
5.2
Fitting valve and piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
5.3
Compressed air test for piston and S/G cylinder . . . . . . . . . . . . . .
5-4
5-1
ZF-Ecosplit
0340-0110
0340-0140
0340-0110-0120
0340-0110-0110
01.500
0340-0150
0340-0170
0340-0160
0340-0130
0340-0100
01.520
0340-0310
0340-0320
0340-0330
01.530
0340-0180
01.510
0340-0300
0150-0050-0010
0340-0340
028660_1
Splitter Group Piston and 5/2-Way Valve
5.1
Removing piston and valve
Pull off cylinder 0340-0140 by hand.
Unfasten hex head screws 0340-0330 and

0340-0340 and remove together with 5/2-way
valve 0340-0320 from transmission housing.
Pick up O-rings 0340-0300 and 0340-0310.
NOTE
Do not disassemble 5/2-way valve, sub-assembly
(complete unit).
Remove entire piston 0340-0110 from selector

rail 0150-0050-0010.
Remove double-lip seal 0340-0110-0120 from

piston 0340-0110-0110.
Take O-rings 0340-0160 and 0340-0150 off the

cylinder.
NOTE
For information on how to remove cap seal
0340-0100, refer to Chapter 9.
For information on how to remove selector rail
0150-0050-0010, refer to Chapter 8.
10
Remove detent plunger 0340-0180, insert

locating fixture 1X56 138 100.
5
6
Remove retaining nut 0340-0130.

Unsnap spring 0340-0170 at the housing.
1325 751 101 - 2009-03
5-2
Use extraction tool 1X56 138 063 to drive

cylinder pins 0180-0500 to 0180-0530 in
drive/input direction and remove them.
ZF-Ecosplit
5.2
Fitting valve and piston
NOTE
Selector rail 0150-0050-0010 (refer to Chapter 8)
and cap seal 0340-0100 (refer to Chapter 9) must be
installed and greased.
1
Slip new O-rings 0340-0160 and 0340-0150

onto cylinder 0340-0140.
Mount double-lip seal 0340-0110-0120 on

piston 0340-0110-0110 and slightly grease.
Push the entire piston 0340-0110 onto selector

rail 0150-0050-0010.
Remove detent plunger 0340-0180, insert

locating fixture 1X56 138 100.
Screw new retaining nut 0340-0130 onto

selector rail and tighten.
Snap spring 0340-0170 into housing.
Remove locating fixture 1X56 138 100, screw

in detent plunger 0340-0180.
Insert cylinder 0340-0140 in the housing.
Insert new O-rings 0340-0300 and 0340-0310

in 5/2-way valve 0340-0320.
10
Screw 5/2-way valve 0340-0320 to

transmission housing using hex head screws
0340-0330 and 0340-0340.
Tightening torque: 9.5 Nm
1325 751 101 - 2009-03
5-3
ZF-Ecosplit
5.3
Compressed air test for piston and

S/G cylinder
Screw locating fixture 1X56 138 673 for

S/G cylinder 0340-0140 to transmission
housing.
Pressurize 5/2-way valve and/or piston with

compressed air (max. 6.8 bar).
Apply suitable liquid to outer diameter of S/G

cylinder and try to avoid formation of
blowholes.
1X56 138 673
0340-0140
Pressurize piston with compressed air in

opposite switching direction and check for air
leakage.
If necessary in the event of blistering, insert

new O-rings in the cylinder and check
cylinder for correct fit.
In the event of air leakage, replace

double-lip seal 0340-0110-0120 on piston
0340-0110-0110.
Remove locating fixture 1X56 138 673.
1325 751 101 - 2009-03
029010_1
5-4
ZF-Ecosplit
Release Unit, Connection Plate, and Pump
1325 751 101 - 2009-03
6.1
Release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Removing release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Fitting release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
6-2
6-2
6.2
Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Removing connection plate . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Fitting connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
6-3
6-4
6.3
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Fitting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6
6-6
6-6
6-1
ZF-Ecosplit
Release Unit
0260-0200
0260-0100
0260-0110
0260-0120
0260-0010
028574_1
6.1.2 Fitting release unit
6.1
Release unit
Slide release unit 0260-0200 over guide tube.
Insert release shaft 0260-0100 in release fork

0260-0010.
Insert release fork in release unit and attach

it to connection plate using hex head screws
0260-0110 and 0260-0120.
6.1.1 Removing release unit

1
Unfasten and remove screws 0260-0110 and

0260-0120.
Take off release fork 0260-0010 together with

release shaft 0260-0100. Remove release shaft.
Remove release unit 0260-0200 from guide

tube.
NOTE
Apply some grease on ball socket of release fork
0260-0010.
* depending on version
1325 751 101 - 2009-03
6-2
ZF-Ecosplit
6.2
Connection Plate
Connection plate
6.2.1 Removing connection plate

1
Unfasten screw and washer assemblies

0220-0910-0340 to 0220-0910-0370 and
remove by using guide tube 0220-0910-0320.
Unfasten hex head screws 0240-0500 to

0240-0670 and remove them.
Unfasten connection plate 0220-0910-0300

using pry bars and remove together with seal
0220-0910-0440.
0240-0420
0200-0010
NOTE
Use cast pockets as pry bar leverage points.
4
Remove washers 0200-0070, 0200-0080 and

spacer ring 0200-0090 from input shaft.
Remove compensation disk 0240-0420 from

countershaft and compensating disk
0240-0400 from input shaft.
Remove shaft sealing ring 0220-0910-0330

from connection plate.
0220-0910-0440
0240-0400
0200-0070
0200-0090
0200-0080
NOTE
Clean connecting surface, clean threaded holes;
possibly, thread is to be recut.
7
0220-0910-0300
0240-0500
0240-0670
Remove and clean strainer 0200-0010.
0220-0910-0330
0220-0910-0320
0220-0910-0370
0220-0910-0350
0220-0910-0360
0220-0910-0340
028590_1
1325 751 101 - 2009-03
6-3
ZF-Ecosplit
Connection Plate
6.2.2 Fitting connection plate

1
Insert strainer 0200-0010 in clutch housing.
Use assembly aid 1X56 138 628 to press shaft

sealing ring 0220-0910-0330 flush into
connection plate 0220-0910-0300.
0240-0420
NOTE
Coat the outer circumference of the shaft sealing
ring with spirits (ethanol).
Sealing lip of the shaft sealing ring faces the
output drive.
Coat shaft sealing ring with some grease.
3
Place specified washer 0240-0400 on input

shaft.
Place washers 0200-0070, 0200-0080 and

spacer ring 0200-0090 in correct position over
input shaft.
0200-0010
0220-0910-0440
0240-0400
0200-0070
0200-0090
0200-0080
0220-0910-0300
NOTE
Washer 0200-0070 = 88 mm
Washer 0200-0080 = 85 mm
5
0240-0500
0240-0670
0220-0910-0330
0220-0910-0320
Place specified compensation disk 0240-0420

on countershaft.
0220-0910-0370
NOTE
Washers 0240-0400 and 0240-0420 are specified in
Chapter 13.
6
0220-0910-0350
Place new seal 0220-0910-0440 on

transmission.
028590_2
0200-0080
0220-0910-0360
0220-0910-0340
Apply guide tube 0220-0910-0320 on

connection plate and fasten with screw and
washer assemblies 0220-0910-0340 to
0220-0910-0370.
0200-0090
0200-0070
0240-0400
0240-0420
028576_1
1325 751 101 - 2009-03
6-4
ZF-Ecosplit
8
Align countershaft groove and impeller

driver with each other.
Assembly suggestion: By turning countershaft align countershaft groove so that it
faces cast point (C) on the housing. Turn
impeller driver so that it faces recess (D)
of pump cover (see figure 031856).
Slide protective sleeve 1X56 138 064 over

input shaft to protect shaft sealing ring.
10
Insert connection plate 0220-0910-0300 in

clutch bell housing and use plastic hammer
to drive firmly home. Remove protective
sleeve.
Connection Plate
031856
NOTE
Threaded holes and connecting surfaces must be
clean.
11
7
5
Insert new hex head screws 0240-0500 to

0240-0670 and tighten.
NOTE
For better positioning of the connection plate at
pos. A and B, use dowel pin (3).
Tighten hex head screws in right sequence (1 - 16).
10
4
3
16
13
12
11
14
15
028675
15
15
80
shank 10.1
110
M10
028674_en
1325 751 101 - 2009-03
6-5
ZF-Ecosplit
6.3
Pump
Pump
6.3.1 Removing pump

1
0220-0920-0160
Unfasten and remove torx screws

0220-0920-0150 and 0220-0920-0160.
Remove pump cover 0220-0920-0140 from

connection plate.
Remove gear set 0220-0920-0120 and rotor

0220-0920-0110 from connection plate.
0220-0920-0120
0220-0920-0110
0220-0920-0150
0220-0920-0140
6.3.2 Fitting pump

1
Insert rotor 0220-0920-0110 and gear set

0220-0920-0120 in connection plate.
028577_1
NOTE
Check gear set 0220-0920-0120 for correct assembly.
/120
23-0.5
NOTE
Coat rotor 0220-920-0110 and gear set
0220-0920-0120 with corrosion protection oil.
2
Insert pump cover 0220-0920-0140 in connection plate.
Insert and tighten torx screws 0220-0920-0150

and 0220-0920-0160 in pump cover.
/110
Oberserve marking
0.5 max
Projection permitted
NOTE
Check whether rotor is free-moving.
1325 751 101 - 2009-03
028679_en
6-6
ZF-Ecosplit
Clutch Housing
1325 751 101 - 2009-03
Clutch Housing
7.1
Removing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7.2
Fitting clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
7.3
Pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4
7-1
ZF-Ecosplit
Clutch Housing
0180-0500
0180-0410
0180-0400
1
0180-0400-0120
0180-0530
0180-0400-0110
0180-0350
0180-0510
2
0180-0600
0180-0800
0110-0010
0180-0520
0380-0400
0380-0420
0320-0010
0320-0020
0260-0250
028625
Clutch Housing
7.1
Removing clutch housing
Unfasten switch 0380-0420 and remove

together with pin 0380-0400.
6
7
Unfasten screw plug 0180-0350 and take off

together with sealing ring.
Remove outer bearing ring (1) of tapered
roller bearing 0150-0020-0080 and outer
bearing ring (2) of tapered roller bearing
0150-0010-0230 from clutch housing.
Remove hex head screws 0180-0600 to

0180-0800 from clutch housing; do not use
impact wrench.
Lift the clutch housing 0180-0400.
If necessary, remove closure cap 0260-0250.
Remove the seal 0180-0410 from the

Unfasten screw plugs 0320-0010 and

0320-0020 and take them off together with
sealing rings.
If necessary, remove pipe 0180-0400-0120

from clutch housing.
1325 751 101 - 2009-03
7-2
ZF-Ecosplit
Clutch Housing
7.2
Fitting clutch housing
11
Screw in screw plugs 0320-0010 and

0320-0020 with new sealing rings and tighten.
Screw in screw plug 0180-0350 with new

sealing ring and tighten.
12
Insert greased pin 0380-0400, and screw in

and tighten switch 0380-0420.
Insert closure cap 0260-0250.
If necessary insert new pipe 0180-0400-0120

in clutch housing. For assembly instructions,
Insert outer bearing ring (1) of tapered

bearing ring (2) of tapered roller bearing
0150-0010-0230 in clutch housing.
Apply centering device 1X56 138 635 to

transmission housing 0110-0010 and use it
to position selector rails (see figure 029030).
Fit seal 0180-0410 and position it by using

2 centering pins 1X56 138 695.
Lower clutch housing 0180-0400 slowly over

centering pins onto transmission housing until
selector rails are centered in transmission
housing.
Remove centering device 1X56 138 635 and

lower clutch housing until it makes contact.
029030
NOTE
Measurement of axial roller bearing / main shaft
is done; refer to Chapter 13.
Selector rail is adjusted; refer to Chapter 5.1.
9
Drive cylindrical pins 0180-0500 to 0180-0530

into transmission housing.
10
Insert and tighten hex head screws 0180-0600

to 0180-0800.
1325 751 101 - 2009-03
7-3
ZF-Ecosplit
Insert new pipe 0180-0400-0120 in clutch housing in such a way that it protrudes by approx.
20 mm on the drive/input side.
BEFORE ASSEMBLY
NOTE
Ensure correct fit over the support rib in the
housing.
2
Use assembly pliers 1X56 138 626 to squeeze

in pipe end to actual cross section.
Press pipe into clutch housing for flush seat.
8+5
Pipe assembly
CA.20
7.3
Clutch Housing
3.5+1
NOTE
Housing and pipe are deformed.
END OF PIPE
7.2+0.8
028676_en
0.5-1
AFTER ASSEMBLY
PRESSED-IN
FLUSH
028677_en
1325 751 101 - 2009-03
7-4
ZF-Ecosplit
Shafts, Selector Rails
1325 751 101 - 2009-03
Shafts and Selector Rails
8.1
Removing shafts and selector rails . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8.2
Fitting shafts and selector rails . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4
8.3
Adjusting the S/G selector rail . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
8-1
ZF-Ecosplit
8
Shafts and Selector Rails
8.1
Removing shafts and selector rails
Push reverse gear 0130-0010 towards housing

wall (depiction without shafts and selector
rails).
Remove screw plug 0110-0190 and sealing

ring.
0130-0010
0110-0190
Screw in assembly aid 1X56 138 627. Locking

pin 0150-0040-0250 of interlock is pushed
against spring pressure.
DANGER
Make sure that assembly aid/device and rope are
fitted properly.
4
031016
0150-0010-0010
Screw lifting fixture 1X56 137 122 together

with centering ring 1X56 137 921 and position
over input shaft 0150-0010-0010, selector rails
and on top of countershaft 0150-0020-0010.
1X56 137 921
1X56 138 631

1X56 138 694
0150-0020-0010
1X56 137 122
1X56 137 933
Fit washer 1X56 137 933 between lifting

device and countershaft. Place support
1X56 138 631 on lifting device and insert in
selector rail driver.
Screw countershaft 0150-0020-0010 to lifting

device.
Insert assembly aid 1X56 138 694 via S/G

selector rail 0150-0050-0010 into the lifting
device 1X56 137 122 and fix selector rail with
screw.
0-0050-0010
029049_1
1325 751 101 - 2009-03
8-2
ZF-Ecosplit
8
Push spacer plate of support 1X56 138 631

between main shaft and countershaft (see
figure 029042) at the splitter groups
synchronizer.
Pull shaft pack with selector rails out of

transmission housing making sure they
are not jammed and put down on device
1X56 137 675.
10
Remove lifting device including accessories.

Remove selector rails with forks and sliding
pads.
11
Take sliding pads out of shift forks.
029042
NOTE
Do not disassemble selector rails further; in this
condition, they are sub-assembly.
0150-0050-0060
0150-0050-0050
S/G
0150-0050-0010
031017_1
1st/R gear
0150-0040-0160
0150-0040-0100
0150-0040-0170
0150-0040-0070
0150-0040-0010
0150-0040-0080
2nd/3rd gear
031017_2
1325 751 101 - 2009-03
8-3
ZF-Ecosplit
8.2
Fitting shafts and selector rails
0150-0010-0010
NOTE
Main shaft must be measured,
refer to Chapter 13.
Reverse gear must be inserted,
refer to Chapter 9.
Cap seal must be fitted,
see Chapter 9.
Bearing outer rings must be fitted,
refer to Chapter 9.
1X56 137 921
1X56 138 631

1X56 138 694
1X56 137 122
0150-0020-0010
1X56 137 933
DANGER
Make sure device and rope are are fitted properly.
1
Place replacement/turning bolt 1X56 137 953

on support for countershaft. Insert main shaft
(output-end) 0150-0030-0010 in receptacle
(support) 1X56 137 675. Mount complete
input shaft 0150-0010-0010 on main shaft.
Fit countershaft 0150-0020-0010 and position
it at the level where the gears mesh. Push
countershaft against main shaft and ensure
that gears are meshing.
029049_1
0150-0050-0060
0150-0050-0050
S/G
0150-0050-0010
Insert selector rails with sliding pads in main

shafts sliding sleeves.
031017_1
Place centering ring 1X56 137 921 in lifting

device 1X56 137 122 and fasten. Move lifting
device over input shaft and selector rails and
ensure contact with countershaft.
1st/R gear
0150-0040-0160
Screw lifting device with washer 1X56 137 933

to countershaft.
Tightening torque = 85 Nm
Place support 1X56 138 631 on lifting device

and insert in selector rail driver.
0150-0040-0100
0150-0040-0170
Insert assembly aid 1X56 138 694 via S/G

selector rail 0150-0050-0010 into the lifting
device 1X56 137 122 and fix selector rail with
screw.
0150-0040-0070
0150-0040-0010
0150-0040-0080
2nd/3rd gear
031017_2
1325 751 101 - 2009-03
8-4
ZF-Ecosplit
7
Push spacer plate of support 1X56 138 631

between main shaft and countershaft (see
figure 029042) at the splitter groups
synchronizer.
Attach support 1X56 138 632 for S/G selector

rail to transmission housing (see figure
029048).
CAUTION
Do not damage the cap seals sealing lip.
9
Slowly lower shafts and selector rails; support

is used to position S/G selector rail until it is
centered in cap seal.
10
Remove support 1X56 138 632.
11
Insert main shaft together with input shaft

and countershaft (making sure they are not
jammed) in tapered roller bearing outer rings
of transmission housing.
029042
NOTE
Retention (locking) by mechanical stop (interlock)
must be guaranteed.
Carefully slide S/G selector rail 0150-0050-0010
through cap seal.
Mesh gearing of reverse gear.
Shift transmission to Constant 2.
12
Remove all lifting devices.
13
Remove fixture 1X56 138 627 for mechanical

stop (interlock).
14
Turn input shaft so that bearing rollers are

centered.
1325 751 101 - 2009-03
029048
8-5
ZF-Ecosplit
8.3
Adjusting the S/G selector rail
NOTE
Only measure selector rail, if new parts have been
added.
For selector rail installation, refer to Chapter 8.2.
1
Screw adjusting device 1X56 138 633 to

transmission housing sealing surface (1).
Connect sliding sleeve 0150-0010-0100 facing
output. S/G selector rail must have axial
contact in adjusting device and is then in the
right position.
Sliding pads (2) must have downward

clearance in the sliding sleeve.
B = 0.1 + 0.2 mm (check with feeler gage).
Check dimension A:
Short version = 93.70 mm
Long version = 107.20 mm
1X56 138 633

1X56 138 634
0150-0050-0010
029010_2
2
4
NOTE
Also refer to assembly instructions 0000 701 102.
3
Evenly tighten setscrews (4) on the shift fork

(3).
0150-0010-0100
0150-0050-0010
1
0340-0110
031050
1325 751 101 - 2009-03
8-6
ZF-Ecosplit
Transmission Housing
1325 751 101 - 2009-03
9.1
Dismantling transmission housing
.......................
9-2
9.2
Assembling transmission housing . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-1
ZF-Ecosplit
0150-0040-0250
0160-0230
0150-0040-0260
0110-0200
0110-0010
0110-0180
0130-0040
0130-0020
0340-0100
0410-0340
0130-0010
0410-0320
0110-0150
0160-0240
028624_1
9.1
Dismantling Transmission Housing
Drive bearing outer ring (1) of the tapered

bearing ring (2) of the tapered roller bearing
0150-0030-0230 out of transmission housing,
in the direction of the input, by means of a
soft mandrel.
If necessary, unfasten and remove screw plugs

0410-0320 and switch 0410-0340.
If necessary, unfasten and remove screw plugs

0160-0230 and 0160-0240.
Unscrew fixture 1X56 138 627 and locking

bolt 0150-0040-0250 as well as compression
spring 0150-0040-0260.
Use a suitable to remove cap seal 0340-0100

from housing.
Take reverse gear 0130-0010 with needle

cages 0130-0020 and 0130-0040 out of the
housing and remove needle cages from the
reverse gear.
Remove breather 0110-0200 (*version

depends on parts list).
If necessary, unfasten screw plugs 0110-0150
und 0110-0180 and take off together with
sealing rings.
1325 751 101 - 2009-03
9-2
ZF-Ecosplit
9.2
Assembling Transmission Housing
Screw in new screw plugs 0160-0230 and

0160-0240 with new sealing ring.

0410-0340 with new sealing ring.

0110-0180 with new sealing rings.
Screw breather 0110-200 into housing.

DANGER
gloves.
5
Use hot air blower to heat housing to approx.

80 C in the area around bearing holes.
Insert bearing outer ring (1) of the tapered

roller bearing 0150-0020-0020 and bearing
outer ring (2) of the tapered roller bearing
0150-0030-0230 in the housing by means of a
plastic mandrel or suitable adapter until
firmly home (axial abutment).
Coat the outside of locating bore and new cap

seal 0340-0100 with ethyl alcohol (spirit).
Mount cap seal before ethyl alcohol volatilizes.
Use a suitable tool to drive cap seal 0340-0100

into the housing until firmly home (axial abutment). Grease the sealing lip of the cap seal.
Insert compression spring 0150-0040-0260

together with locking pins 0150-0040-0250
and align. Screw in assembly aid
1X56 138 627.
10
Insert reverse gear 0130-0010 with needle

cages 0130-0020 and 0130-0040 in the
housing.
1325 751 101 - 2009-03
9-3
9-4
ZF-Ecosplit
Input Shaft
10 Input Shaft
1325 751 101 - 2009-03
10.1
Disassembling input shaft
10.2
Assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
ZF-Ecosplit
Input Shaft
0150-0010-0090
0150-0010-0100
0150-0010-0116
0150-0010-0118
0150-0010-0112
0150-0010-0110
0150-0010-0080
0150-0010-0010
0150-0010-0124
0150-0010-0122
0150-0010-0130
0150-0010-0230
0150-0010-0240
0150-0010-0140
0150-0010-0200
028623_1
10
Input Shaft
0150-0010-0110, 0150-0010-0116,
0150-0010-0122 and compression springs
0150-0010-0112, 0150-0010-0118,
0150-0010-0124 which are released.
10.1 Disassembling input shaft

NOTE
Input shaft can only be removed after clutch housing
(refer to Chapter 7) and shafts have been removed
(refer to Chapter 8).
1
Completely remove input shaft 0150-0010-0010

from main shaft.
Take off clutch body 0150-0010-080 with

synchronizer ring 0150-0010-0090 from the
input shafts synchronizer.
DANGER
Thrust pieces are under spring tension. Prevent them
from jumping out.
3
Release and remove retaining ring

0150-0010-0240.
Pull off inner ring of roller bearing

0150-0010-0230 from the input shaft by using
gripper 1X56 136 722 and basic tool
1X56 122 304. To this end, position gripper
1X56 136 722 over roller bearing inner ring
and tighten by means of knurling ring until
fitted tightly on rollers.
Remove helical gear 0150-0010-0200 from

input shaft.
Remove clutch body 0150-0010-0140 and

synchronizer ring 0150-0010-0130 from input
shaft.
Pull sliding sleeve 0150-0010-0100 off the

input shaft. Catch thrust pieces
1325 751 101 - 2009-03
10-2
ZF-Ecosplit
10.2 Assembling input shaft
1
Input Shaft
8
Set sliding sleeve to center position. Apply

back-pressure on clutch body 0150-0010-0080.
You will hear the thrust pieces snap into place.
Place input shaft on main shaft.
Check synchronizer parts for wear limit, refer

to Chapter 14.
Put synchronizer ring 0150-0010-0130 and
clutch body 0150-0010-0140 on input shaft.
NOTE
For installation of input shaft, refer to Chapter 8.
NOTE
The cams of the synchronizer ring must engage with
recesses of the synchronizer body of the input shaft.
Push helical gear 0150-0010-0200 onto input
shaft.
NOTE
The driving spline of the helical gear faces output
and must engage with inner spline of clutch body.
DANGER
Only touch heated roller bearing inner ring when
wearing protective gloves.
4
Heat up roller bearing inner ring

0150-0010-0230 to approx. 100 C and push
onto input shaft. After roller bearing has
cooled down, there must be axial contact with
collar of input shaft.
Put sliding sleeve 0150-0010-0100 on input

shaft and ensure contact. Insert new compression springs 0150-0010-0112, 0150-0010-0118,
0150-0010-0124 together with thrust pieces
0150-0010-0110, 0150-0010-0116,
0150-0010-0122 in input shaft and use
suitable tool to located them in sliding sleeve.
Place synchronizer ring 0150-0010-0090 and

clutch body 0150-0010-0080 on input shaft.
1325 751 101 - 2009-03
10-3
10-4
ZF-Ecosplit
Countershaft
11 Countershaft
1325 751 101 - 2009-03
11.1
Disassembling countershaft
11.2
Assembling countershaft
11-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
ZF-Ecosplit
Countershaft
0150-0020-0020
0150-0020-0010
0150-0020-0030
0150-0020-0080
0150-0020-0040
0150-0020-0090
0150-0020-0050
028578_1
11
Countershaft
NOTE
For removal of countershaft, refer to Chapter 8.
Unsnap retaining ring 0150-0020-0090 and

remove it.
11.1 Disassembling countershaft
NOTE
In order to protect the countershaft, a thrust piece
must always be fitted between the extracting tool
and the countershaft 0150-0020-0010.
Fit gripper 1X56 136 756 to inner ring of

tapered roller bearing 0150-0020-0080. Turn
knurling ring on gripper, until gripping piece
locates firmly.
Screw 1X56 122 304 onto gripper and remove

bearing inner ring from countershaft.
Place gripper 1X56 136 756 on inner ring of

tapered roller bearing 0150-0020-0020. Turn
knurling ring on gripper, until gripping piece
locates firmly.
CAUTION
If necessary, replace tapered roller bearings
0150-0020-0020 / 0150-0020-0080; the bearing
rollers may be damaged by extraction process.
Screw basic tool 1X56 122 304 onto gripper

and pull bearing inner ring off the countershaft.
1325 751 101 - 2009-03
11-2
ZF-Ecosplit
6
Countershaft
Press helical gears 0150-0020-0050 and

0150-0020-0040 and the helical gear
0150-0020-0030 off individually using a
suitable hydraulic press due to high press-off
force force. The press-off force for each
helical gear can be as high as 500 kN.
Heat inner rings 0150-0020-0020 /

0150-0020-0080 up to 120 - 130 C for max.
15 min. and place on countershaft. Ensure
axial abutment, if necessary, drive in further
using a soft mandrel.
Snap in retaining ring 0150-0020-0090. Ensure

that retaining ring 0150-0020-0090 is firmly
home with the groove base of the countershaft.
NOTE
To prevent gear damage, catch countershaft or
helical gears on a soft surface.
NOTE
The retaining ring must feature axial clearance of
0.01 - 0.10 mm; select retaining ring in line with the
items listed in the spare parts catalog.
11.2 Assembling countershaft

!
DANGER
gloves.
NOTE
For installation of countershaft, refer to Chapter 8.
Bores in helical gears and countershaft snug

fits must be free of oil, grease, and dust.
Heat up helical gear 0150-0020-0030 and

helical gears 0150-0020-0040 /
0150-0020-0050 to max. 170 C.
Possibly cool down countershaft

0150-0020-0010, a temperature difference
of 150 C between the helical gears and the
countershaft is specified.
Put the heated helical gears 0150-0020-0030 /

0150-0020-0040 / 0150-0020-0050 on top of
each other on the hydraulic press and align
exactly.
Press countershaft into the bores of the helical

gears. Immediately repress helical gears until
axial abutment position is reached. Let
components cool down.
NOTE
The tapered roller bearings inner rings may be
damaged by the removal process. Therefore, carry
out exact inspection and, if necessary, use new
tapered roller bearings.
1325 751 101 - 2009-03
11-3
11-4
ZF-Ecosplit
Main Shaft
12 Main Shaft
1325 751 101 - 2009-03
12.1
Disassembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.2
Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
12-1
12-2
ZF-Ecosplit
Main Shaft
0150-0030-0490
0150-0030-0500
0150-0030-0510
0150-0030-0520
0150-0030-0530
029028_1
12
Main Shaft
12.1 Disassembling main shaft

NOTE
For removal of main shaft, refer to Chapter 8.
1
Position the main shaft (output-end) in the

receptacle (support) 1X56 137 675.
Remove axial roller bearing 0150-0030-0520

with baffle plate 0150-0030-0530.
Remove cylindrical roller bearing

0150-0030-0490 with washer 0150-0030-0500
and disk spring 0150-0030-0510.
Turn main shaft and position it in receptacle

(support) 1X56 137 675 (output-end).
1325 751 101 - 2009-03
12-3
ZF-Ecosplit
Main Shaft
0150-0030-0050
0150-0030-0030
0150-0030-0050-0050
0150-0030-0050-0060
0150-0030-0050-0110
0150-0030-0050-0020
0150-0030-0050-0120
0150-0030-0250
0150-0030-0050-0010
0150-0030-0050-0030
0150-0030-0240
00150-0030-0050-0080
0150-0030-0230
0150-0030-0040
0150-0030-0220
0150-0030-0210
0150-0030-0200
028662_1
Remove retaining ring 0150-0030-0240.
Place suitable washer on main shaft. Apply

commercial two-armed extractor to R gear
0150-0030-0220 and pull off together with
tapered roller bearing inner ring
0150-0030-0230.
Remove needle-roller assembly

0150-0030-0210 with inner ring
0150-0030-0200.
Use commercial two-armed extractor in

order to grip helical gear 0150-0030-0040
of 1st gear and pull off together with
synchronizer 0150-0030-0050.
Remove needle-roller assembly

0150-0030-0030 (2 parts).
1325 751 101 - 2009-03
10
Remove clutch body 0150-0030-0050-0080

and synchronizer ring 0150-0030-0050-0030
from synchronizer body
0150-0030-0050-0010.
DANGER
During the removal process, 3 thrust pieces
0150-0030-0050-0050 and 3 compression springs
0150-0030-0050-0060 are released. These parts are
under spring tension. Prevent parts from jumping out
(e.g. by using a cloth).
11
Remove sliding sleeve 0150-0030-0050-0020 ,

1st gear, from synchronizer body
0150-0030-0050-0010 .
12
Washer 0150-0030-0050-0120 and clutch body

0150-0030-0050-0110 are released.
13
Remove pipe 0150-0030-0250 if damaged.
12-4
ZF-Ecosplit
Main Shaft
0150-0030-0410
0150-0030-0270
0150-0030-0440
0150-0030-0420
0150-0030-0290
0150-0030-0390
0150-0030-0450
0150-0030-0280
0150-0030-0290-0030
0150-0030-0290-0020
0150-0030-0290-0060
0150-0030-0290-0050
0150-0030-0290-0010
0150-0030-0290-0030
0150-0030-0370
0150-0030-0010
0150-0030-0380
0150-0030-0400
0150-0030-0260
029029_1
14
Turn main shaft 0150-0030-0010 and position it in receptacle (support) 1X56 137 675
(output-end).
15
Remove split ring 0150-0030-0450.
16
Remove thrust washers 0150-0030-0390,

0150-0030-0380, helical gear 0150-0030-0440
3rd gear, roller rings 0150-0030-0420, 01500030-0410, and inner ring 0150-0030-0400.
17
Use commercial two-armed extractor in

order to grip helical gear 0150-0030-0270
of 2nd gear and pull off together with
synchronizer 0150-0030-0290.
20
Remove sliding sleeve 0150-0030-0290-0020 ,

2nd gear, from synchronizer body
0150-0030-0290-0010.
21
Synchronizer ring 0150-0030-0290-0030 and

clutch body 0150-0030-0280 are released.
18
Remove needle cage/needle-roller assembly

0150-0030-0260 (2 parts).
19
Remove clutch body 0150-0030-0370 and

synchronizer ring 0150-0030-0290-0030 from
synchronizer body 0150-0030-0290-0010.
1325 751 101 - 2009-03
DANGER
During the removal process, 3 thrust pieces
0150-0030-0290-0050 and 3 compression springs
0150-0030-0290-0060 are released. These parts are
under spring tension. Prevent the parts from jumping
out (e.g. by using a cloth).
12-5
ZF-Ecosplit
12.2 Assembling main shaft
1
Check main shaft for free passage of

lubrication oil bores. Pipe 0150-0030-0250
must be solidly seated on the main shaft.
Position main shaft into the receptacle

(support) 1X56 137 675 (input-end).
NOTE
Lightly oil the thrust faces and contact surfaces for
the needle-roller assemblies and helical gears with
oil.
3
Slide needle-roller assembly 0150-0030-0030

(2 parts) over the main shaft 0150-0030-0010.
Slide helical gear 0150-0030-0040, 1st gear,
over the needle-roller assembly of the main
shaft by means of light rotational motion.
Collar faces output.
CAUTION
Check wear limit of all synchronizer rings and/ or
clutch bodies as described in Chapter 14.
5
Slide sliding sleeve 0150-0030-0050-0020,

1st gear, over synchronizer body, synchronizer
ring, and clutch body, and fit to the helical
gear, 1st gear. In this context, make sure that
the recesses at the inner side of the sliding
sleeve are congruent with the fitting locations
of the synchronizer body (for compression
springs and thrust pieces).
Insert three compression springs

0150-0030-0050-0060 together with thrust
pieces 0150-0030-0050-0050 by means of a
suitable tool in the bores of the synchronizer
body and turn into the sliding sleeve.
NOTE
Use new compression springs and pull the sliding
sleeve into the center position (neutral position).
9
Insert washer 0150-0030-0050-0120 in

synchronizer body.
10
Fit clutch body 0150-0030-0050-0110 on the

main shaft. Flat side faces output.
11
Slide inner ring 0150-0030-0200 and needleroller assembly 0150-0030-0210 onto main
shaft shaft until it abuts against synchronizer
body.
12
Slide helical gear 0150-0030-0220, R gear, over

the needle-roller assembly by means of light
rotational motion. Driving spline points
towards the drive-end. In this context, make
sure that the clutch body lies on the driving
spline.
Place clutch body 0150-0030-0050-0080 with

synchronizer ring 0150-0030-0050-0030 onto
driving spline.
DANGER
Only touch heated synchronizer bodies when
6
Main Shaft
Heat up synchronizer body 0150-0030-00500010 to approx. 120 C and slide onto main
shaft gearing. Narrow sides faces output.
NOTE
The cams of the synchronizer ring must mesh with
the recesses of the synchronizer body.
1325 751 101 - 2009-03
DANGER
Only touch heated tapered roller bearings inner ring
when wearing protective gloves.
12-6
ZF-Ecosplit
Main Shaft
0150-0030-0050
0150-0030-0030
0150-0030-0050-0050
0150-0030-0050-0060
0150-0030-0050-0110
0150-0030-0050-0020
0150-0030-0050-0120
0150-0030-0250
0150-0030-0050-0010
0150-0030-0050-0030
0150-0030-0240
00150-0030-0050-0080
0150-0030-0230
0150-0030-0040
0150-0030-0220
0150-0030-0210
0150-0030-0200
028662_1
13
14
Heat up tapered roller bearing inner ring

0150-0030-030 to approx. 120 C and slide
onto main shaft; drive in further to ensure
axial abutment.
0150-0030-0050-0020
0150-0030-0050-0050
0150-0030-0050-0030
0150-0030-0050-0110
NOTE
The retaining rings axial clearance must be between
0.01 and 0.10 mm. Select the retaining ring in line
with items offered in the spare parts catalog.
15
Turn main shaft around and place it into the

receptacle (support) 1X56 137 675 (outputend).
0150-0030-0050-0080
0150-0030-0050-0120
0150-0030-0050-0060
0150-0030-0050-0010
028663_1
1325 751 101 - 2009-03
12-7
ZF-Ecosplit
Main Shaft
0150-0030-0440
0150-0030-0410
0150-0030-0270
0150-0030-0420
0150-0030-0390
0150-0030-0290
0150-0030-0450
0150-0030-0490
0150-0030-0500
0150-0030-0510
0150-0030-0280
0150-0030-0290-0030
0150-0030-0290-0020
0150-0030-0290-0060
0150-0030-0290-0050
0150-0030-0520
0150-0030-0530
0150-0030-0290-0010
0150-0030-0290-0030
0150-0030-0370
0150-0030-0380
0150-0030-0010
0150-0030-0400
0150-0030-0260
028661_1
16
Slide needle-roller assembly 0150-0030-0260

(2 parts) onto main shaft.
17
Slide helical gear 0150-0030-0270, 2nd gear,

over the needle-roller assembly by means of
light rotational motion. Driving spline points
towards the drive-end.
18
Place clutch body 0150-0030-0280 with

synchronizer ring 0150-0030-0290-0030
onto driving spline.
CAUTION
Check wear limit of all synchronizer rings and/or
clutch bodies as described in Chapter 14.
19
NOTE
The cams of the synchronizer ring must mesh with
the recesses of the synchronizer body.
20
DANGER
Only touch heated synchronizer body when wearing
protective gloves.
1325 751 101 - 2009-03
Heat up synchronizer body

0150-0030-0290-0010 to approx. 120 C and
slide onto main shaft gearing. The synchronizer body is symmetric and therefore can be
fit to the unit irrespective of its lateral
position. Drive in synchronizer body further
to ensure axial abutment.
12-8
Slide sliding sleeve 0150-0030-0290-0020,

1st/2nd gear, over synchronizer body, synchronizer ring, and clutch body, and fit to the
helical gear, 1st gear. In this context, make
sure that the recesses at the inner side of the
sliding sleeve are congruent with the fitting
locations of the synchronizer body (for
compression springs and thrust pieces).
ZF-Ecosplit
21
Main Shaft
Insert three compression springs

0150-0030-0290-0060 with thrust pieces
0150-0030-0290-0050 by means of a suitable
tool in the bores of the synchronizer body
and/or turn into the sliding sleeve.
23
Fit synchronizer ring 0150-0030-0290-0030.

The cams of the synchronizer ring must
mesh with the recesses of the synchronizer
body.
Place clutch body 0150-0030-0370 onto the
synchronizer ring and pull the sliding sleeve
into the center position (neutral position).
During the process, push the synchronizer
ring and clutch body tight.
24
Put on thrust washer 0150-0030-0380 and

inner ring 0150-0030-0400.
25
Insert roller rings 0150-0030-0410 and

0150-0030-0420 in helical gear
0150-0030-0440, 3rd gear.
26
Push helical gear 0150-0030-0440 with

collar facing the output into the clutch body
via the inner ring and fit thrust washer
0150-0030-0390 .
27
Insert split ring 0150-0030-0450 in the

groove of the main shaft and use retaining
ring to secure by 3x120 caulking.
Heat up cylindrical roller bearing

0150-0030-0490 to approx. 120 C and slide
onto main shaft until firmly home.
29
Fit washer 0150-0030-0500.
NOTE
Before fitting disk spring 0150-0030-0510, the input
and main shaft must be measured.
For measurement, refer to Chapter 13.
NOTE
Use new compression springs.
22
28
30
Fit disk spring 0150-0030-0510 and axial roller

bearing 0150-0030-0520.
31
Insert baffle plate 0150-0030-0530 in axial

roller bearing and main shaft.
NOTE
For installation of the main shaft, refer to
Chapter 8.
NOTE
The axial clearance of the split ring must be between 0.05 and + 0.05 mm. Select the retaining
ring in line with items offered in the spare parts
catalog.
DANGER
Only touch heated cylindrical roller bearing when
1325 751 101 - 2009-03
12-9
12-10
ZF-Ecosplit
Main Shaft, Input Shaft, and Countershaft
13 Bearing Setting on Main Shaft, Input Shaft, and

Countershaft
1325 751 101 - 2009-03
. . . . . . . . . . . . . . . . . . . . . . . . 13-2
13.1
Setting the main and input shaft
13.2
Setting the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
13-1
ZF-Ecosplit
13
Bearing Setting on Main Shaft, Input Shaft,

and Countershaft
13.1 Setting the main and input shaft
0150-0030-0530
0150-0030-0520
CAUTION
Set the main and input shaft with the respective
clearance.
Clearance is 0.01 - 0.10 mm
0150-0030-0510
0150-0030-0500
Assemble main shaft, as described in Chapter

12.2, until you get to disk spring. Do not
mount disk spring 0150-0030-0510.
Fit axial roller bearing 0150-0030-0520 and

insert baffle plate0150-0030-530 in axial roller bearing and the main shaft.
Insert main shaft in transmission housing

using lifting tool.
0150-0030-0490
NOTE
Bearing outer ring at the output-end must be fitted.
031051
Place input shaft on main shaft.
Use dowel pins to place clutch housing on

NOTE
Bearing outer ring at the input-end must be fitted.
6
Set the input bearing play to zero; to this end,

drive bearing outer ring with mandrel in the
direction of the main shaft.
CAUTION
Do not push or hammer close to oil ducts.
Otherwise, housing is damaged.
7
Rotate input and main shaft a few times in

order to center the bearing rollers at the
bearing points. Check by means of a pointed
device whether the bearing rollers can be
shifted.
NOTE
Constant 2 must be selected in the transmission.
031045
1325 751 101 - 2009-03
13-2
ZF-Ecosplit
NOTE
In the case of zero play, the bearing rollers must be
backlash-free, i.e. it should not be possible to shift
them to one or the other side. However, it must be
ensured that no preload is generated either.
8
Use depth gage to measure the distance

between the upper edge of the outer bearing
ring and the connecting surface of the clutch
bell housing; note down the dimension and
add thickness of seal/gasket 0240-0440. The
result is dimension A.
Example: A = 6.50 mm
+ 0.40 mm (seal/gasket)
1.00 mm (thickness of disk spring)
A = 5.90 mm
031049
NOTE
Perform measurement at two opposite locations and
calculate mean value.
9

between the connecting face and compensating disks contact surface, note down
dimension B.
Example:
B = 4.20 mm
NOTE
10
Determine difference C and note down.

Example:
C = A B = 5.90 mm 4.20 mm
C = 1.70 mm
11
031056
Calculate thickness D of compensating disk

0240-0400.
Example:
D = C clearance = 1.70 mm 0.10 mm
D = 1.60 to 1.70 mm
1325 751 101 - 2009-03
13-3
ZF-Ecosplit
12
Select compensating disk 0240-0400 in line

with items offered in the spare parts catalog.
NOTE
Installation of compensating disk 0240-0400 is described in Chapter 6.
13
Remove clutch housing.
14
Remove entire input shaft.
15
Use lifting device to take main shaft out of

the transmission housing and put it on
fixture.
16
Remove baffle plate and axial bearing.
17
Complete main shaft as described in

Chapter 12.2.
0240-0440
0240-0400
18
028626_1
For shaft installation, see Chapter 8.
1325 751 101 - 2009-03
13-4
ZF-Ecosplit
13.2 Setting the countershaft

NOTE
Shafts and selector rails must be completely
installed; refer to Chapter 8.
Main shaft must be measured;
CAUTION
Set countershaft with play.
Play is between 0.01 and 0.10 mm.
1
Transmission is in vertical position.
Set the countershafts roller bearing play to

zero; to this end, drive bearing outer ring with
mandrel in the direction of the countershaft.
031046
CAUTION
Do not push or hammer close to oil ducts.
Otherwise, housing is damaged.
3
Rotate countershaft a few times in order to

center the bearing rollers at the bearing
points. Check by means of a pointed device
whether the bearing rollers can be shifted.
NOTE
In the case of zero play, the bearing rollers must be
backlash-free, i.e. it must be impossible to shift them
to one or the other side. However, it must be
ensured that no preload is generated either.
031047

between the connecting surface of the clutch
bell housing and the upper edge of the outer
bearing ring; note down the dimension and
add thickness of seal 0240-0440. The result is
dimension a.
Example: a = 4.00 mm + 0.40 mm (seal)
a = 4.40 mm
NOTE
1325 751 101 - 2009-03
13-5
ZF-Ecosplit
5

between the pump and the contact surface
of the connection plate, note down
dimension b.
Example:
b = 1.40 mm
Determine difference c and note down.

Example:
c = a b = 4.40 mm 1.40 mm
c = 3.00 mm
Calculate thickness d of compensating

disk 0240-0420:
Example:
d = c clearance = 3.00 mm 0.10 mm
d = 2.90 to 3.00 mm
031048
Select compensating disk 0240-0420 in line

with items offered in spare parts catalog.
NOTE
Installation of compensating disk 0240-0420 is
described in Chapter 6.
0240-0420
0240-0440
a
028627_1
1325 751 101 - 2009-03
13-6
ZF-Ecosplit
Synchronizer
14 Synchronizers
14.1 Determining the wear limit of synchronizers . . . . . . . . . . . . . . . . . 14-2

14.2 Assembling synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
14.3 Cross section of a synchronizer / ZF-BK . . . . . . . . . . . . . . . . . . . . . 14-3
1325 751 101 - 2009-03
14-1
ZF-Ecosplit
14
Synchronizer
Synchronizers
X
14.1 Determining wear limit of synchronizers

The condition of the synchronizer rings and
clutch bodies must be checked before the
synchronizers are assembled.
NOTE
Do not mix up synchronizer parts.
1
Place synchronizer ring (2) on the corresponding clutch body (1). Turn the synchronizer
parts and thereby ensure even and parallel
contact of tapers.
The wear limit of synchronizer rings on the
synchronizers of the main transmission and
splitter group is 0.8 mm, and 1.2 mm for the
range change group.
Use feeler gage to measure distance (X)

between clutch body and synchronizer ring at
two opposite points. If the wear limit falls
below 0.8 or 1.2 mm respectively, the
synchronizer ring and/or clutch body must
be replaced.
001999
Also check the condition of the synchronizer

parts (visual check). If the surface is corrugated, replace synchronizer parts. Do not mix
up parts which were checked together (mark
them).
1325 751 101 - 2009-03
14-2
ZF-Ecosplit
Synchronizer
14.2 Assembling Synchronizer

ZF-BK version
1
Check the wear limit.
Replace compression springs (5) with new

ones. Thus, specified sliding force of sliding
sleeve (6) is ensured.
4
3
Synchronizers can be assembled as a complete

set or in a one assembly process directly on
the main shaft.
Push sliding sleeve (6) onto synchronizer body

(3).
Insert new compression springs (5) with thrust
pieces (4) into the synchronizer body (3).
Position the mandrel at the center of the thrust
pieces and guide thrust pieces into sliding
sleeve (6).
2a
1a
Put on clutch body (1) with synchronizer ring

(2) and push sliding sleeve (6) to center
position.
NOTE
Observe the correct position of the thrust pieces.
009510
14.3 Cross section of a synchronizer / ZF-BK

6
1/1a
2/2a
3
4
5
6
Clutch body
Synchronizer ring
Synchronizer body
Thrust piece
Compression spring
Sliding sleeve
2a
1a
3
001940
1325 751 101 - 2009-03
14-3
14-4

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Reparaturanleitung

Subject to technical changes

1325 751 101

Overview of Changes ........................................................................................................................

Shift turret ........................................................................................................................................ 2-1

Range change group (R/C)................................................................................................................ 3-1

Planetary drive with synchronizer................................................................................................... 4-1

Splitter group piston and 5/2-way valve.......................................................................................... 5-1

Connection plate .............................................................................................................................

Clutch housing .................................................................................................................................

Shafts and selector rails .................................................................................................................

Transmission housing ....................................................................................................................

Input shaft ....................................................................................................................................... 10-1

Countershaft ................................................................................................................................... 11-1

Main shaft ....................................................................................................................................... 12-1

Synchronizers .................................................................................................................................. 14-1

1325 751 101 - 2009-03

The following transmissions and variants are

1325 751 101 - 2009-03

1325 751 101 - 2009-03

Overview of changes: 1325 751 101

This manual is intended for skilled personnel

Repair work carried out at ZF Service Points is

This manual deals with a ZF series product in

use of non genuine ZF parts.

However, due to continuing technical advancements

In case of proven unfounded delay in repair we

Service points equipped by ZF Friedrichshafen AG

DANGER to the health!

DANGER to the environment!

Personnel required to carry out repairs on ZF

Instructions for Repairs

Read this manual carefully before starting tests or

Remove old sealing compound residues from all

The ZF-Service Information details must be

Gaskets, locking plates

After repair work and tests performed, skilled

Conversions and modifications may impact the

Instructions for Repairs

a) Apply a thin coat of sealing agent* to outer

b) Never apply sealing agent to shaft sealing

d) Duo shaft sealing rings have

* refer to consumable material

This standard applies to bolts according to DIN 912,

The bolts are tightened using a calibrated torque

This standard contains data on tightening torques

Tightening torque in Nm for

General assembly aid

General assembly aid

Loctite no. 574

Olista Longtime 3EP

S/G cap seal

hex head screws

Oil pump rotor

Ball race release fork

NOTE: Inquire about available package/container size before placing order!

1325 751 101 - 2009-03

01. Axial clearance of the

Rotate countershaft in order to

02. Axial clearance of the main 0.01 to 0.10 mm

Rotate input and main shaft in

03. Axial clearance of the

04. Installation dimension of