Gearbox PDF

Component manual 12S2130 TD
12S2330 TD
ZF-Ecosplit 4, 12-speed 12S2830 TD
©201051 DAF Trucks N.V., Eindhoven,
The Netherlands.
In the interest of continuing product development,

DAF reserves the right to change specifications
or products at any time without prior notice.
ZF-Ecosplit
No part of this publication may be reproduced
Edition 2009-03
and/or published by printing, by photocopying, on
1325 751 101 microfilm or in any way whatsoever without the
prior consent in writing of DAF Trucks N.V.
©
201051 DW43280501
ZF-Ecosplit 4, 12-speed
SAFETY PRECAUTIONS
Warning symbol
When text is accompanied by the warning symbol
shown here, this indicates that the information
provided is essential for the health and personal
safety of the mechanic.
In addition, this warning symbol is also shown if
there are conditions in which damage can be
caused to the component or parts thereof.
Safety instructions
To ensure that the mechanic's health is not

endangered, the following safety instructions
must be strictly observed.
- Comply with all the warnings and safety

instructions given in this component manual.
First read the instructions and warnings on
the labels and stickers which are affixed to
various components on the vehicle and
follow them! They have been put there for
your health and safety, so do not ignore
them!
- Wear clean, fitted clothes and apply

protective cream to unprotected parts of your
body, as necessary.
- Ensure proper extraction of dangerous

materials from the work area.
- Maintain a safe distance from rotating and/or

moving parts.
- Avoid unnecessary contact with drained oil.

Frequent contact damages the skin.
- Various sorts of oil and other lubricants used

on the vehicle may constitute a health
hazard. So avoid both inhaling and direct
contact with these.
- Exercise caution when working with springs

under pressure. Inadvertently released
springs may cause serious injuries. Small
springs and circlips may also cause injuries
when inadvertently released (wear goggles).
©
201051
ZF-Ecosplit 4, 12-speed
- If necessary, support the component

suitably.
- Always use the appropriate lifting gear

(gearbox jack) or approved lifting gear or
hoists for the removal and installation of
heavy components. Attach the component
securely to the lifting or hoisting gear.
- After a fire it is possible that hazardous

residues may remain from the plastics used
in some oil seals and sealing rings. Wear
protective, acid-resistant clothing and PVC
gloves when removing such fire residues.
Submerge such fire residues in, or sprinkle
them amply with, a calcium hydroxide
solution (slaked lime and water). Thoroughly
clean the protective clothing after use. Treat
the gloves as chemical waste.
©
201051
ZF-Ecosplit Table of Contents
Page
Overview of Changes ........................................................................................................................ 5

Preface ................................................................................................................................................ 6
Safety Instructions.............................................................................................................................. 7
Instructions for Repair ....................................................................................................................... 8
Tightening Torques............................................................................................................................. 10
Consumables....................................................................................................................................... 11
Setting Data ........................................................................................................................................ 12
ZF-Ecosplit Tightening Torques ......................................................................................................... 14
Spring Table........................................................................................................................................ 17
Special Tools ....................................................................................................................................... 18
1 Polyamide tubes for range change group and valve ....................................................................... 1-1
2 Shift turret ........................................................................................................................................ 2-1
3 Range change group (R/C)................................................................................................................ 3-1
4 Planetary drive with synchronizer................................................................................................... 4-1
5 Splitter group piston and 5/2-way valve.......................................................................................... 5-1
6 Connection plate ............................................................................................................................. 6-1
7 Clutch housing ................................................................................................................................. 7-1
8 Shafts and selector rails ................................................................................................................. 8-1
9 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 3

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 4

ZF-Ecosplit Overview of changes: 1325 751 101
Index Date of issue Chapter Initiator Comment
1325 751 101 - 2009-03 5

Preface
Preface Warranty
This manual is intended for skilled personnel Repair work carried out at ZF Service Points is
trained by ZF Friedrichshafen AG to carry out subject to the contractual conditions prevailing
maintenance and repair work on ZF products. in the individual case.
The work described below may only be performed
by authorized, trained, and instructed staff. It is Direct and/or subsequent costs are not covered by
the responsibility of the user’s company or repair this contractual liability when:
company to ensure that their repair staff is properly
• work has been performed improperly or by
trained.
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 • use of “non” genuine ZF parts.
date of issue.
In case of failure it is mandatory to act immediately,
However, due to continuing technical advancements so to ensure the complete function of the ZF unit
of the product, repair work might require work and minimize the scope of damage.
practices and test or adjustment data which are not
contained in this manual. In case of proven unfounded delay in repair we
We therefore recommend that work done on your reserve the right of partial acceptance or even a
ZF product is carried out only by skilled mechanics rejection of warranty claims.
and fitters who have their practical and theoretical
knowledge updated on a regular basis at our Service
Training Center.
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 6
Safety Instructions
The following safety instructions are used ! DANGER to the health!

in this repair manual:
Ensure confident handling with supplies.
Manufacturer’s 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
CAUTION
not be allowed to enter the soil, ground water, or
Is used when the instructions are not complied
sewage system.
with or not followed precisely and could lead to
• Ask your local environment agency for safety
the product being damaged.
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
DANGER!
cleaning agents in accordance with environmental
Is used when lack of care could result in personal
protection regulations.
injury or danger to life.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
CAUTION
Safety Instructions
The transmission must NOT be suspended by the
input shaft OR by the output flange/add-on parts.
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
Incorrect
requirements which apply to repair and
maintenance work must be adhered to.
Before starting work, mechanics must therefore
familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF

Correct
products must receive appropriate training in
advance.
Compulsory training is the responsibility of the
repair staff.
! DANGER!
Do not walk under suspended load during parts
transportation with a hoist.
2008-06 7
Instructions for Repairs
General Information Cleaning Parts
Read this manual carefully before starting tests or Remove old sealing compound residues from all
repair work. sealing faces. Carefully remove burrs or other
uneven patches using an oil stone.
The ZF-Service Information details must be Lube bores and grooves must be free from anti-
observed. These are available from all ZF Service corrosion grease and foreign matter. Check that the
Centers or from the ZF-ServiceLine. passage is free.
Carefully cover opened transmissions to prevent the
In any cases of doubt, always contact the relevant entry of foreign matter.
expert departments at ZF-Service.
Whenever working on the transmission, ensure
cleanliness and carry out the work as instructed. Reusing Parts
Use specified tools to dismantle and assemble
transmissions. Parts such as antifriction bearings, multidisks,
thrust washers etc., must be inspected by a
specialist, who should decide whether they can
CAUTION be re-used or not.
The pictures, drawings, and components shown Replace parts which are damaged or have suffered
do not always represent the original object, but are from excessive wear.
used to illustrate working practices.
The pictures, drawings, and components are not to • Gaskets, locking plates
scale and no conclusions must be drawn about size Parts which cannot be removed without being
and weight (not even within a complete illustration). damaged must always be replaced with new
All work must be performed as described in the parts (e.g. gaskets and locking plates).
text. Gaskets are installed without the use of sealing
compound or grease. When measuring coated
After repair work and tests performed, skilled gaskets/seals proceed as specified.
personnel must make sure that the product is
working properly again. • Shaft seals
Always replace shaft sealing rings with rough,
Conversions and modifications may impact the ripped, or hardened sealing lips. Seal contact
transmission’s operational safety. Therefore, surfaces must be totally clean and in perfect
customer-specific deviations must be agreed with condition.
ZF in writing.
After removing the transmission from the vehicle, Reworking

clean thoroughly with a suitable cleaning agent
before opening. Pay particular attention to the If rework is needed on spacer washers and shims
recesses of housings and covers when cleaning. etc. because of clearance settings, ensure that the
reworked areas contain no face runout and have
the same surface quality.
2008-06 8
Instructions for Repairs
Transmission Assembly • Shaft Sealing Rings

Press in shaft sealing ring with fixture or face
Assemble the transmission in a clean workplace. plate until firmly home at relevant installation
Adhere to all adjustment data and tightening depth.
torques specified in the repair manual.
a) Apply a thin coat of sealing agent* to outer
circumference of shaft sealing rings with a
• Bearings
«steel surround».
If the bearings are fitted while warm, these
should be warmed up evenly (e.g. heating b) Never apply sealing agent to shaft sealing
cabinet). with a «rubber surround» but apply a thin
The temperature should be approx. 85°C and coat of Vaseline 8420 or spirit to the outer
must not exceed 120°C. All bearings fitted must circumference, or wet with a lubricant, e.g. a
be coated with operating oil after assembly. water-soluble concentrated washing-up liquid.
c) Shaft sealing rings with steel and rubber

• Sealing
surrounds should be treated on the outer
If a sealant* is recommended for sealing, then
circumference of the rubber surround as
it is essential to adhere to the manufacturer’s
described for shaft seal (b).
directions for use. A thin layer of sealing agent
should be applied to the surfaces and coat them d) Duo shaft sealing rings have
evenly. Do not allow sealing agent to enter oil two sealing lips. The dust
ducts and bores. On oil-carrying ducts and bores, protection sealing lip (X)
wipe off the sealing agent on the surfaces to be must face outwards.
sealed near apertures to ensure that no sealing Fill the space between the X
agent enters the oil feeds when the parts are sealing lips up to 60% with
pressed together. grease*.
• Retaining Agents • Transmission Oil

Retaining agents* may only be used where After completing repairs, fill the transmission
specified by the parts list. with transmission oil. For the procedure and
When using retaining agents (e.g. Loctite) always approved oils, refer to the transmission operating
comply with the manufacturer’s directions for manual and the List of Lubricants TE-ML (refer
use. to type plate). These are available from all
During assembly, comply with all adjustment ZF Service Centers or on the Internet at
data, inspection data, and tightening torques. 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.
* refer to consumable material
2008-06 9
Tightening torques
Tightening torques for screws/bolts and nuts,

extract from ZFN 148
This standard applies to bolts according to DIN 912, Surface condition of screws/bolts/ nuts:
DIN 931, DIN 933, DIN 960, DIN 961 as well as Heat-treated blackened finish and oiled or
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, galvanized and oiled.
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, NOTE
10.9, and 12.9, as well as nuts of strength categories Differing tightening torques are listed separately
8, 10, and 12. in the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89
M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960
M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850
M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500
Status: August 1991
2008-06 10
ZF-Ecosplit Consumables
Designation Name Quantity Application Comment

ZF item number approx.
Grease For example General assembly aid

0750 199 001 Spectron FO 20
Grease Technical vaseline General assembly aid

0671 190 016 8420
Grease For example

0750 199 019 Renolit CX-EP2 5 grams S/G cap seal Chapter 10
3 grams Double-lip seal Chapter 10
1 gram Detent plunger Chapter 10
2 grams Shaft sealing ring/pipe Chapter 7
1 gram R/C cap seal Chapter 3
3 grams R/C sealing rings Chapter3
2 grams Shaft sealing ring Chapter 3
1 gram Tappet Chapter 2
1 gram Pin Chapter 2
Jointing compound
Loctite
0666 690 017 Loctite no. 241 300 mm3 Swivel screws Chapter 3
Sealing compound
Loctite
0666 790 033 Loctite no. 574 1 cm3 hex head screws Chapter 2
Corrosion For example

protection oil Renolin MR 40 Z 0.50 cm3 Oil pump rotor Chapter 7
0750 199 008 0.20 cm3 Axial needle bearing Chapter 4
Grease
0671 190 050 Olista Longtime 3EP 3 grams Ball race release fork Chapter 7
NOTE: Inquire about available package/container size before placing order!
1325 751 101 - 2009-03 11

ZF-Ecosplit Setting data
Designation Dimensions Measurement device Comment
01. Axial clearance of the 0.01 to 0.10 mm Depth gage Rotate countershaft in order to
countershaft 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 Depth gage Rotate input and main shaft in
and input shaft order to center the bearing
rollers.
Set zero play.
Afterwards, adjust play with
suitably thick
compensating disk .
03. Axial clearance of the – 0.05 to + 0.05 mm Feeler gage Select suitable
split ring on the main shaft ring.
04. Installation dimension of 9 ± 0.1 mm Adapter The installation dimension can

the shaft sealing ring in 1X56 138 669 be determined by using an
the bearing cover adapter.
05. Installation dimension of 23 mm –0.5 mm Depth gage Do not separate/remove gear

the oil pump rotor set, only for check.
06. Axial clearance of the snap 0 to 0.1 mm Feeler gage Adjust with suitably thick snap
ring at deep groove ball ring.
bearing in the ring gear
carrier
07. Axial clearance of the 0 to 0.1 mm Feeler gage Adjust with suitably thick retai-
retaining rings on the main ning ring.
shaft and countershaft
1325 751 101 - 2009-03 12

ZF-Ecosplit Setting data
08. Wear limit of synchronizer of main transmission Feeler gage If the dimension is below
rings and/or clutch body, 0.80 mm specification, replace
measured between end synchronizer ring and/or
faces, ring, and body at Range change group clutch body.
centric, backlash-free 1.20 mm
abutment of the tapers
09. For information: > 0.60 mm Feeler gage Upper limit of the synchronizer
Synchronizer clearance clearance is determined by the
(axial) wear limit of 0.80 and/or
1.20 mm.
10. Sliding pad clearance at 0.1 + 0.2 mm Feeler gage Measured from the sliding
the splitter group shift pad’s bottom side to the
fork sliding sleeve.
11. Control dimension A to short version: Depth gage See assembly instructions
adjust splitter group shift 93.70 mm 0000 701 102
fork long version:
107.20 mm
1325 751 101 - 2009-03 13

ZF-Ecosplit Tightening torques
01. M24x1.5 screw plugs 60 Nm Torque wrench Use new sealing ring.
on the transmission
housing
02. Breather on the 10 Nm Torque wrench Breather must not be plugged.

transmission housing
03. M26x1.5 screw plug for 70 Nm Torque wrench Use new sealing ring.
interlock
04. M18x1.5 screw plug on 35 Nm Torque wrench Use new sealing ring.
the clutch housing
05. M10x60 hex head screws 50 Nm Torque wrench

on the clutch housing
06. M8x22 screw and washer 32 Nm Torque wrench

assemblies on the guide
pipe

on the connection plate
08. M18x1.5 screw plugs on 35 Nm Torque wrench Use new sealing ring.
the transmission housing
09. M8x80 Torque wrench

M8x25
screw plugs at the shift 23 Nm
turret 23 Nm
10. M8x80 hex head screws 23 Nm Torque wrench Use sealing compound at
for pneumatic servo unit position 71.180.
11. Receptacle on the 24 Nm Torque wrench

pneumatic servo unit
1325 751 101 - 2009-03 14


for cover at the shift
turret

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

valve block
15. Switch at the valve block 45 Nm Torque wrench Use new sealing ring.
16. Tappet switch at the valve 45 Nm Torque wrench Use new sealing ring.
block
17. M6x30 torx screws on the 10 Nm Torque wrench

pump cover

on the range change
group housing
19. Splitter group N/O contact 45 Nm Torque wrench

at the clutch housing
20. M6x40 hex head screws 9.5 Nm Torque wrench

on the 5/2-way valve
21. M16x1.5 detent plunger at 50 Nm Torque wrench Use new sealing ring.
the transmission housing
22. M16x1.5 retaining nut on 150 Nm Torque wrench Use new retaining nut.
the piston for splitter group
selector rail
23. Impulse sensor at the 45 Nm Torque wrench

range change group
housing
24. M24x1.5 screw plug on 60 Nm Torque wrench Use new sealing ring.
the range change group
housing
1325 751 101 - 2009-03 15

25. M10x40 hex head 46 Nm Torque wrench

screws on the output
cover

screws on the cover
for PTO
27. M10x1 screw plug on the 15 Nm Torque wrench

range change group
housing

screws on the output
flange
29. M24x1.5 swivel screws 250 Nm Torque wrench Use sealing compound.
on the range change
group housing
30. M16x1.5 retaining nut on 150 Nm Torque wrench Use new retaining nut.
the piston for R/C selector
rail

on the RC/ cylinder
32. Detent plunger at the 50 Nm Torque wrench Use new sealing ring.
transmission housing
33. Switch at the R/C housing 45 Nm Torque wrench Use new sealing ring.
34. M6x25 screw and washer 9.5 Nm Torque wrench

assemblies on the valve
35. M22x1.5 screw plugs 50 Nm Torque wrench Use new sealing ring.
for heat exchanger
connection

on the release shaft
1325 751 101 - 2009-03 16

ZF-Ecosplit Spring table
De
De Spring diameter + tolerance in mm
d Dh Test sleeve diameter in mm
Lo
nt
D L0 Length of unloaded spring in mm
nt Total number of coils
d Wire diameter
018325
Dh
Order no. Installation blocation Number of Wire Ø Outer spring Ø Free length
coils in mm in mm at L0 in mm
[nt] [d] [De] [L0]
0732 040 630 Shift turret of 6.5 2.4 39.1 89.9

superimposed H shift system
0732 040 985 Circuit 6.5 2.0 14.8 23.4

at detent
0732 040 984 Circuit 9.5 1.4 9.1 23.3

at detent
0732 040 385 Synchronizer 18.5 1.25 6.35 34.2

of range change group
0732 040 386 Synchronizer 35.5 0.7 3.2 34.7

of range change group
0732 040 409 Synchronizer 12.5 1.4 6.65 23.7

of main transmission
0732 040 736 Circuit 13.5 1.6 9.6 36.0

(interlock)
0732 040 983 Circuit 12.5 1.1 5.4 18.8

at detent
0732 040 986 Circuit 5.5 2.25 14.5 21.6

at detent
1325 751 101 - 2009-03 17

ZF-Ecosplit Special tool
Figure Depiction Order no. Application No. of Remark

no. pieces
1X25 139 707 1 Chapter 2
Adapter
1 for bush on the gearshift housing
1X25 139 783 1 Chapter 2
Impact adapter
2 to remove needle bush
on the valve lever
1X56 136 260 1 Chapter 3
Lifting device
3 for range change group
1X56 138 626 1 Chapter 7
Pliers
4 for caulking the oil pipe
1X56 138 627 1 Chapter 8
Assembly aid
5 for interlock bolts
1325 751 101 - 2009-03 18


no. pieces
1X56 138 628 1 Chapter 6
Assembly aid
6 for connection plate
1X56 138 630 1 general
Assembly fixture
7 to clamp the transmission
1X56 138 631 1 Chapter 8
Assembly aid
8 to support main shaft and
countershaft
1X56 138 632 1 Chapter 8
Assembly aid
9 to support
S/G selector rail
1x56 138 633 1 Chapter 8.3
Assembly aid
10 for shift fork adjustment
1325 751 101 - 2009-03 19


no. pieces
1X56 138 635 1 Chapter 8
Centering device
11 for selector rails
1X56 138 664 1 Chapter 4
Locating bolt
12 d = 89.9 mm
to fix the plate to range change
group housing
(without Intarder)
1X56 138 668 1 Chapter 4
Locating bolt
13 d = 84.9 mm
to fix the plate to range change
group housing
(with Intarder)
1X56 138 669 1 Chapter 3
Press-in mandrel
14 for shaft sealing ring in the output
cover
1X56 138 673 1 Chapter 5

Chapter 8
Locating fixture
15 for leakage test
S/G cylinder and fork adjustment of
S/G selector rail
1325 751 101 - 2009-03 20


no. pieces
1X56 138 674 1 Chapter 3
Heating device
16 for the output bearing
at the inner ring
1X56 138 675 1 Chapter 3
Locating fixture
17 for oil pipe (output end)
1P01 181 850 1 general
Assembly block (stationary)

18 combined with
1X56 138 630
1X56 138 063 1 Chapter 5
Extractor
19 for clutch housing/transmission hou-
sing dowel pins
1X56 138 064 1 Chapter 6
Protective sleeve
20 for shaft sealing ring/connection
plate
1325 751 101 - 2009-03 21


no. pieces
1X56 137 122 1 Chapter 8
Lifting device
21 for shafts and selector rails
1X56 138 100 1 Chapter 5
Locating fixture
22 for S/G selector rail
1X56 137 675 1 Chapter 8
Support
1X56 137 953 1 Chapter 8
Bolts
24 for shafts combined with
support 1X56 137 675
1X56 137 921 1 Chapter 8
Centering ring
combined with
lifting device 1X56 137 122
1325 751 101 - 2009-03 22


no. pieces
1X56 137 933 1 Chapter 8
Washer
combined with
1X56 136 722 1 Chapter 10
Gripper
27 for tapered roller bearing(s)
at the input
1X56 122 304 1 Chapter 10

Chapter 11
Basic tool
28 combined with
Gripper 1X56 136 722
1X56 136 756 1 Chapter 11
Gripper
29 for the tapered roller bearings
on the countershaft
1X56 138 596 1 Chapter 12
Gripper (if required)

30 for tapered roller bearing(s)
on the main shaft
1325 751 101 - 2009-03 23


no. pieces
1X56 122 306 1 Chapter 12
Basic tool (if required)

31 combined with
1X56 138 694 1 Chapter 8
Assembly aid
32 for S/G selector rail combined with
1X56 138 695 2 Chapter 7
Dowel pin
33 for clutch and transmission housing
1X56 138 696 1 Chapter 3
Heating device
34 for output bearing/bearing seat
of outer ring in the housing and
combined with threaded spindle
1X56 137 808
1X56 137 808 1 Chapter 3
Threaded spindle
35 to insert output bearing
1325 751 101 - 2009-03 24


no. pieces
1X56 137 654 1 Chapter 3
Threaded bolt
36 for output bearing combined with
threaded spindle 1X56 137 808
1325 751 101 - 2009-03 25

26
ZF-Ecosplit Range Change Group Shift Unit
1 Polyamide Tubes for Range Change Group and Valve
1.1 Removing polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Fitting polyamide tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1325 751 101 - 2009-03 1-1

1-2
ZF-Ecosplit Range Change Group Shift Unit
25
26
0510-0010
0480-0130
0510-0030
26
25
028566_1
1 Polyamide tubes for range change group

and valve
1.1 Removing polyamide tubes 1.2 Fitting polyamide tubes
NOTE 1 Fit polyamide tubes 0510-0010 / 0510-0030

The connecting points are marked. according to the designations.
Tubes are reverse-mounted: Insert polyamide tubes into plug couplings at
• Pos. 0510-0010 (25), the range change group cylinder and at the
Valve block at the top, R/C at the bottom. shift unit and check whether the tubes are
• Item 0510-0030 (26), fixed by pulling carefully.
Valve block at top, R/C at bottom. Insert polyamide tube 0480-0130 into plug
couplings at Servoshift and valve.
1 Unfasten polyamide tubes 0510-0010 /
0510-0030 and 0480-0130 on the plug NOTE
couplings (see sketch) and remove them. Maintain minimum distance of 5 mm between
polyamide tube and housing.
1325 751 101 - 2009-03 1-3

1-4
ZF-Ecosplit Shift System
2 Shift Turret
2.1 Pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.1.1 Removing pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.2 Fitting pneumatic servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 Removing and dismantling gearshift housing . . . . . . . . . . . . . 2-3
2.2.2 Assembling gearshift housing . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Shift patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4 Fitting complete shift turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
1325 751 101 - 2009-03 2-1

71.180
71.170
71.170
71.180
Loctite
71.150
71.410
71.160
1
71.452
71.454
2
028567
2 Shift Turret 2.1.2 Fitting pneumatic servo unit
2.1 Pneumatic servo unit 1 Put in 71.452 receptacle, tighten elbow 71.454
and pipe 71.410.
2.1.1 Removing pneumatic servo unit Tightening torque: 24 Nm
1 Unfasten hex head screws 71.170 / 71.180. 2 Place compression spring (1) in servo unit.
2 Remove the pneumatic servo unit 71.150 with 3 Fix pneumatic servo unit 71.150 together with
seal 71.160 and compression spring (1). new seal 71.160 to shift turret.
NOTE 4 Insert hex head screws 71.170 / 71.180 and

Compression spring (1) is loose in the pneumatic tighten.
servo unit. Tightening torque: 23 Nm
Do not disassemble pneumatic servo unit any
further, sub-assembly. NOTE
Insert one hex head screw 71.170 and 71.180 each
3 Unfasten receptacle 71.452, remove together using Loctite no. 574 as sealing compound.
with elbow 71.454 and pipe 71.410.
Order no.: Compression spring (1) 0501 318 490
Detent (2) 0501 319 920
1325 751 101 - 2009-03 2-2

09.090
08.890
09.090
09.270
09.320
09.090
09.290
09.280
71.110
48.070
09.580 09.100
71.130 09.250
09.100
09.040
09.010
08.870
08.470
028568
2.2 Gearshift housing 3 If necessary, unfasten neutral switch 09.270

with sealing ring and pressure switch 09.580
2.2.1 Removing and dismantling gearshift and remove them.
housing
4 Remove tappet 09.240 and pin 09.250 from
1 Unfasten hex head screws 08.890 and remove gearshift housing.
shift turret with seal 08.87.
Remove roller 08.470 from valve lever. 5 Unfasten tappet switch 09.320 with sealing
ring and them remove together with
NOTE compression spring 09.290 and detent 09.280.
For Servoshift removal, refer to Chapter 2.1
6 Unfasten hex head screws 71.130 and remove
2 Unfasten hex head screws 09.090 / 09.100 and cover 71.110.
take them off together with valve block
09.010. 7 Remove V-shaped ring 49.070 from housing.
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

08.830
08.830
08.830
08.810 08.440
08.530 08.430
08.540 08.450
08.560
08.410
08.490
08.800 08.100
08.130
08.470
08.010
08.300
08.370
08.380
08.350 08.080
08.360
028569
8 Unfasten hex head screws 08.830, remove 16 Remove pin 08.430.

cover 08.810 and seal 08.800.
17 Remove gearshift shaft 08.150 from gearshift
9 Remove locking pawl 08.540 and pin 08.530. housing in direction of arrow taking off valve
lever 08.410 and lever 08.490.
10 Slide pin 08.560 through gearshift housing
and remove. NOTE
Inspect gearshift shaft bores and level any raised
CAUTION
edges.
Retaining rings 08.380 must not be overstretched –
use adjustable pliers. 18 Remove pin 08.450 from valve lever; do not
remove lower needle bush. If the needle
11 Unsnap retaining ring 08.380.
bush is defective, replace valve lever and
12 Remove cylindrical pin 08.370/110 and, if needle bush as a complete set.
necessary, remove retaining ring 08.370/120.
19 Fit plastic mandrel to hollow shaft 08.300
13 Push hollow shaft 08.300 towards sealing and use hollow shaft to drive bush 08.100
cover. and shaft sealing ring 08.130 out of gearshift
housing. Push hollow shaft out of gearshift
14 Place impact adapter 1X25 139 783 on
housing and take off driver 08.350 and
needle bush 08.440 and drive valve lever
blocking piece 08.360.
08.410 slightly downwards.
20 If necessary, remove cylindrical pin 08.080.
15 Remove needle bush 08.440.
1325 751 101 - 2009-03 2-4

21 Use pliers to remove V-shaped ring 49.030

from gearshift shaft. 49.030
49.020
22 Remove washers 49.020 with compression 49.010
spring 49.010 from the gearshift shaft.
49.020
028571
1325 751 101 - 2009-03 2-5

2.2.2 Assembling gearshift housing 10 Snap retaining ring 08.370/120 into pin
08.370/110 and insert in driver and gearshift
1 Mount washer 49.020, compression spring shaft. Insert retaining ring 08.380.
49.010, and washer 49.020 onto gearshift
shaft. 11 Insert pin 08.560 to stop in housing and lock
with pin 08.530. Insert locking pawl 08.540.
2 Use pliers to snap V-shaped ring 49.030 into
gearshift shaft. 12 Fit new seal 08.800 and cover 08.810.
3 Slide driver 08.350 and blocking piece 08.360 13 Insert hex head screws 08.830 and tighten.
into gearshift housing. Slide hollow shaft Tightening torque: 23 Nm
08.300 in correct position into gearshift
housing, blocking piece, and driver.
4 Press bush 08.100 flush into housing using

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

press firmly home.
6 Insert cylindrical pin 08.450 in valve lever

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

hollow shaft in gearshift housing.
8 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

08.830
08.830
08.830
08.810 08.440
08.530 08.430
08.540 08.450
08.560
08.410
08.490
08.800 08.100
08.130
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

09.090
08.890
09.090
09.270
09.320
09.090
09.290
09.280
71.110
48.070
09.580 09.100
71.130 09.250
09.100
09.040
09.010
08.870
08.470
028568
14 Install detent 09.280, spring 09.290, and tappet 19 Snap V-shaped ring 49.070 into gearshift
switch 09.320 with new sealing ring in gear- housing.
shift housing and tighten.
Tightening torque: 45 Nm 20 Mount cover 71.110 to housing using hex head
screws 71.130 and tighten.
15 Insert tappet 09.040 and pin 09.250 in gear- Tightening torque: 23 Nm
shift housing.
21 Place greased roller 08.470 onto valve lever.
16 Mount valve block 09.010 with hex head
screws 09.090 / 09.100 on gearshift housing. NOTE
Tightening torque: 23 Nm To fit Servoshift, refer to Chapter 2.1
17 Screw in neutral switch 09.270 with new NOTE

sealing ring on valve block and tighten. To fit the entire shift unit to the transmission,
Tightening torque: 45 Nm refer to Chapter 2.4.
18 Screw in pressure switch 09.580 on valve

block and tighten.
Tightening torque: 23 Nm
1325 751 101 - 2009-03 2-8

2.3 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

2.4 Fitting complete shift turret

08.890
1 Fit new seal 08.800 to clutch housing and/or

sealing face.
2 Fit complete gearshift housing 08.010.

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

028694
Ø 15
110
shaft Ø 8.9
80
15
M8
016 078_en
1325 751 101 - 2009-03 2-10

ZF-Ecosplit Range Change Group
3 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.7.1 Removing range change group cylinder and piston . . . . . . . . 3-8
3.7.2 Fitting range change group cylinder and piston . . . . . . . . . . . 3-9
1325 751 101 - 2009-03 3-1

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
3 Range Change Group
NOTE 2 Use commercially available three-armed

Please follow the work steps listed below when extractor 0360-0060-0600 to pull off output
repairing the range change group. flange.
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. NOTE
For information on how to demount range change Use intermediate piece to protect shaft during
group, refer to Chapter 3.5. pulling-off process.
3 Remove hex head screws 0360-0060-0610 to

3.1 Removing output flange 0360-0060-0640 from output flange.
1 Remove hex head screws 0360-0060-0670 and 4 Remove O-ring 0360-0060-0650.

0360-0060-0680 and take off washer
0360-0060-0660.
1325 751 101 - 2009-03 3-2

3.2 Fitting output flange
NOTE
• Range change group is fitted to the transmission,
refer to Chapter 3.6.
• 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.
2 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.
4 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.
5 If necessary, fit protective caps on hex head

screws 0360-0060-0610 to 0360-0060-0640.
1325 751 101 - 2009-03 3-3

0360-0050-0320 0360-0050-0330
bis
0360-0040-0400 0360-0050-0360
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
1 Remove hex head screws 0360-0050-0330 to 5 Unfasten cover 0360-0040-0050 by light blows
0360-0050-0360. with a plastic hammer and take it off together
Take off cover 0360-0050-0320 and seal 0360- with seal 0360-0040-0060.
0050-0310.
6 Drive shaft sealing ring 0360-0040-0070 out of
2 If necessary, remove screw plug bearing cover by using plastic mandrel.
0360-0050-0300 together with sealing ring.
7 If necessary, remove screw plug
3 Remove impulse sensor 0360-0040-0400. 0360-0040-0250 .
4 Remove hex head screws 0360-0040-0100 to 8 Use commercially available extractor to pull
0360-0040-0190 on the cover 0360-0040-0050. ball bearing 0360-0040-0020 out of housing.
1325 751 101 - 2009-03 3-4

3.4 Fitting cover and output bearing
NOTE
• Range change group is fitted to the transmission,
refer to Chapter 3.6. 1X56 138 669
!DANGER
Only touch heated parts when wearing protective
gloves.
1 Heat housing around bearing bore up to

approx. 60°C by using heating device
1X56 138 696.
Heat inner bearing ring up to approx. 60°C by
using heating device 1X56 138 674.
028678_1
2 Pull roller bearing 0360-0040-0020 with
heating device1X56 138 696, adapter NOTE
1X56 137 654 and spindle 1X56 137 808 into Fitting dimension of shaft sealing ring is determined
housing via planet carrier; ensure axial by fitting driver.
abutment. Lightly oil the sealing lip of the shaft sealing ring.
3 Install new screw plug 0360-0040-0250 with 9 Place new seal 0360-0040-0060 on housing.
new sealing ring.
Tightening torque: 60 Nm 10 Fit cover 0360-0040-0050 on housing and fix
with hex head screws 0360-0040-0100 to
4 Clean sealing surface on R/C housing and 0360-0040-0190.
cover 0360-0050-0320. Tightening torque: 46 Nm
5 Fit new seal 0360-0050-0310 and cover 11 Screw in impulse sensor 0360-0040-0400 .
0360-0050-0320. Tightening torque: 45 Nm
6 Insert new hex head screws 0360-0050-0330

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

new sealing ring.
8 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

0370-0200-0210 0360-0030-0240
bis
0370-0200-0250
0200-0020
0480-0020
0110-0190
0480-0030
0480-0010
0370-0300
0400-0300 bis
0370-0500
0370-0200
0130-0050 0360-0030-0250
0370-0240
028644_1
3.5 Removing range change group 6 Mount fixture 1X56 136 260 on the planet
carrier. Use a crane and 2 pry bars to separate
1 Unfasten both swivel screws 0360-0030-0240 the entire range change group from the basic
and 0360-0030-0250, do not remove them yet. transmission and put it down.
2 Remove detent plunger 0400-0300. 7 Clean seal 0370-0240 and sealing faces.
3 Unfasten screw plug 0110-0190 and remove 8 Remove reverse shaft 0130-0050 from
together with sealing ring; then screw in transmission housing.
assembly aid 1X56 138 627.
9 Pull oil pipe 0200-0020 out of transmission
4 Unfasten hex head screws 0480-0020 and housing.
0480-0030 and remove them together with
valve 0480-0010. 10 Remove pressure disk 0370-0200 from the
main shaft.
5 Unfasten hex head screws 0370-0300 to
0370-0500 on range change group and remove NOTE
them. If necessary, remove cylindrical pins
0370-0200-0210 to 0370-0200-0250 from the
housing.
1325 751 101 - 2009-03 3-6

3.6 Fitting range change group 10 Fit valve 0480-0010 to transmission housing
using hex head screws 0480-0020 and
1 If required, insert cylindrical pins 0480-0030.
0370-0200-0210 to 0370-0200-0250 into Tightening torque: 9.5 Nm
housing.
11 Remove assembly aid 1X56 138 627, insert
2 Put seal 0370-0240 on the transmission new screw plug 0110-0190 together with new
housing. sealing ring and fasten.
3 Push thrust washer/pressure disk 0370-0200
on the main shaft with the collar facing the
input side.
4 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).
5 Slide reverse shaft 0130-0050 into reverse

gear.
6 Attach range change group to crane and

carefully move above transmission housing;
then lower until it abuts.
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.
8 Tighten swivel screws 0360-0030-0240 and

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

new sealing ring and tighten.
1325 751 101 - 2009-03 3-7

0360-0030-0070
0400-0520
0400-0400
0360-0030-0240 0360-0030-0010 0360-0030-0030
0360-0030-0040
0360-0030-0020
2
1
0360-0030-0120
0360-0030-0110
0360-0030-0090
0360-0030-0230
0360-0030-0050
0360-0030-0250
Loctite
0360-0030-0100
0360-0030-0230 0510-0010
0510-0030
0360-0030-0080
0360-0030-0060
028647_1
3.7 Dismantling range change group 6 Remove retaining nut 0360-0030-0070 from
piston 0360-0030-0030, take off piston, and
3.7.1 Removing range change group cylinder and take sealing rings 0360-0030-0040,
piston 0360-0030-0050, and guide ring
0360-0030-0060 out of the piston.
1 Remove unfastened swivel screws
0360-0030-0240 and 0360-0030-0250. 7 Use a suitable tool to lift cap seal
0360-0030-0020 out of range change group
2 Unfasten switch 0400-0520 and remove housing.
together with pin 0400-0400.
CAUTION
3 Unfasten hex head screws 0360-0030-0100 Cap seal might be damaged. Therefore, it must
to 0360-0030-0120 and remove together with always be replaced with new one.
washers.
8 If necessary, unfasten and remove plug-in
4 Remove cylinder 0360-0030-0090 together couplings 0510-0010 and 0510-0030 on
with seal 0360-0030-0080. cylinder 0360-0030-0090 .
5 Detach selector rail 0360-0030-0010 from shift 9 Remove housing 0360-0040-0010 from the
fork 0360-0030-0230 and pull piston out of planetary gear set.
housing bore.
1325 751 101 - 2009-03 3-8

3.7.2 Fitting range change group cylinder and 8 Snap new seal 0360-0030-0080 into cylinder
piston 0360-0030-0090 ensuring correct position.
1 Use locating pin 1X56 138 664 to place 9 Place cylinder with seal on range change
housing on planetary gear set next to PTO group and fix with hex head screws
opening and support plate and ensure 0360-0030-0100 to 0360-0030-0120.
abutment. Tightening torque: 46 Nm
NOTE 10 Mesh lug (1) of gearshift fork 0360-0030-0230

• Shift fork must be inserted, refer to Chapter 4. with recess (2) of selector rail 0360-0030-0010.
2 Coat locating bore and new cap seal 11 Align shift fork with threaded holes in
0360-0030-0020 on the outside with ethyl housing in such a way that locating bores
alcohol (spirit). Mount cap seal before ethyl of shift fork are aligned with the housing’s
alcohol volatilizes. threaded holes.
3 Use suitable tool to drive cap seal 12 Screw in swivel screws 0360-0030-0240
0360-0030-0020 into range change group and 0360-0030-0250, do not tighten.
housing until firmly home (axial abutment).
Grease the sealing lip of cap seal. NOTE
• Threads must be clean and free from oil and
4 Equip piston 0360-0030-0030 with sealing grease.
rings 0360-0030-0040, 0360-0030-0050 and • Coat threads of swivel screws with
one guide ring 0360-0030-0060. Place Loctite no. 241.
complete piston on the selector rail
0360-0030-0010. 13 Insert greased pin 0400-0400 and screw in
and tighten switch 0400-0520.
CAUTION Tightening torque: 45 Nm
• Always use new retaining nut 0360-0030-0070.
• Thread (Spiralock) of retaining nut must be 14 If necessary, install plug-in couplings
cleaned before screwing it on. 0510-0010 and 0510-0030 on the cylinder
0360-0030-0090 and tighten.
5 Tighten retaining nut 0360-0030-0070. Tightening torque: 10 Nm
CAUTION
Do not damage the cap seal’s sealing lip.
6 Insert selector rail with piston into housing

bore through cap seal and ensure axial
abutment of piston.
7 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

3-10
ZF-Ecosplit Planetary Gear Set with Synchronizer
4 Planetary Gear Set with Synchronizer
4.1 Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 Disassembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Assembling synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2.1 Disassembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 Assembling ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.1 Disassembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.2 Assembling planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
1325 751 101 - 2009-03 4-1

4 Planetary Gear Set with Synchronizer
4.1 Synchronizer 0360-0020-0200

0360-0010-0540
4.1.1 Disassembling synchronizer

0360-0020-0050-0190
1 Take off shift fork 0360-0030-0230.

0360-0020-0250
2 Remove sliding pads 0360-0030-0200 and 0360-0030-0230
0360-0030-0210 from shift fork.
3 Fit intermediate piece onto planet carrier and

grip sliding sleeve 0360-0020-0050-0190 by 0360-0030-0200
two or three-armed extractor. 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
4 Pull off sliding sleeve 0360-0020-0050-0190, 0360-0020-0050-0170
synchronizer ring 0360-0020-0050-0140, and
clutch body 0360-0020-0250. The thrust pieces 0360-0020-0050-0140
0360-0020-0050-0150, which are under 0360-0020-0010
tension, and compression springs 0360-0020-
0050-0160 and 0360-0020-0050-0170 are
stopped by the cloth.
0360-0020-0200
5 Check axial bearing 0360-0010-0540 for 0360-0020-0050-0110

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

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

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

carrier. 0360-0010-0010
028621_1
1325 751 101 - 2009-03 4-2

4.1.2 Assembling synchronizer

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

planet carrier 0360-0010-0010.
0360-0030-0200
NOTE 0360-0030-0210
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
3 Slide on synchronizer body 0360-0020-0050- 0360-0020-0050-0170
0110, with the long hub side facing the planet
carrier. The cams of the synchronizer ring 0360-0020-0050-0140
0360-0020-0050-0140 must engage with the 0360-0020-0010
recesses of the synchronizer body.
4 Snap in retaining ring 0360-0020-0200.

0360-0020-0200
NOTE 0360-0020-0050-0110
The retaining ring’s 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. 0360-0020-0020
5 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

6 Insert new compression springs 0360-0020-

0050-0170 and 0360-0020-0050-0160 with
0360-0010-0540
thrust pieces 0360-0020-0050-0150 in the
synchronizer body and use suitable tool to 0360-0020-0200
locate them in sliding sleeve.
0360-0020-0050-0190
7 Fit synchronizer ring 0360-0020-0050-0200 to
synchronizer body. The cams of the synchro- 0360-0020-0250
nizer ring must engage with recesses of

synchronizer body. 0360-0030-0230
8 If necessary, put new axial bearing

0360-0010-0540 onto ring gear carrier.
0360-0030-0200
0360-0030-0210
9 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.
0360-0020-0050-0150
0360-0020-0050-0160
11 Insert sliding pads 0360-0030-0200 and
0360-0030-0210 in the shift fork 0360-0020-0050-0170
0360-0030-230.
0360-0020-0050-0140
12 Insert the shift fork into the sliding sleeve 0360-0020-0010
0360-0020-0050-0190.
13 Slightly grease the locating bores (see arrow) 0360-0020-0200

of the shift fork.
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

4.2 Ring gear
4.2.1 Disassembling ring gear
1 Completely pull ring gear off planet carrier

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

carrier.
0360-0010-0530
3 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.
4.2.2 Assembling ring gear
1 Put bush 0360-0010-0500 onto planet carrier. 0360-0010-0520
2 Drive in ring gear carrier 0360-0010-0510 until 0360-0010-0510

firmly home with ring gear 0360-0010-0520
028619_1
(axial abutment).
3 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

4.3 Planet carrier

0360-0010-0380
0360-0010-0330
4.3.1 Disassembling planet carrier
0360-0010-0040
0360-0010-0310
NOTE
0360-0010-0160 0360-0010-0040
For reasons of simplification, only one gear set is
depicted. The process is identical for all five planet
carriers.
0360-0010-0130
1 Drive all dowel pins 0360-0010-0110,
0360-0010-0120 into the planetary bolts
0360-0010-0100 (full length).
0360-0010-0120
0360-0010-0110
2 Use a hammer and plastic mandrel to drive all
five planetary bolts 0360-0010-0100 out of 0360-0010-0100
planet carrier 0360-0010-0010 in drive/input
direction.
3 Take five planetary gears 0360-0010-0040

with intermediate disks 0360-0010-0130, 0360-0010-0010
0360-0010-0310, 0360-0010-0330 and rollers
028618_1
0360-0010-0160, 0360-0010-0380 out of planet
carrier.
4 Drive dowel pins 0360-0010-0110,

0360-0010-0120 out of planetary bolts
0360-0010-0100.
012006
1325 751 101 - 2009-03 4-6

4.3.2 Assembling planet carrier

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

on the end faces and needle roller races.
0360-0010-0130
2 Position planetary bolts 0360-0010-0100 with
collar facing downwards.
0360-0010-0120
3 Pull intermediate disk 0360-0010-0130 over
0360-0010-0110
the planetary bolt.
0360-0010-0100
4 Mount planetary gear 0360-0010-0040 on
planetary bolt.
5 Insert 14 rollers 0360-0010-0160 in

planetary gear and pull intermediate disk 0360-0010-0010
0360-0010-0310 over planetary bolt.
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.
7 Position planet carrier 0360-0010-0010 on

the shaft part.
8 Carefully take the complete planetary gear

with intermediate disks off the planetary bolt
and insert into the planet carrier.
9 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
bolt’s bore for the dowel pins must align with planet
carrier’s bore.
1325 751 101 - 2009-03 4-7

10 Align planetary bolt 0360-0010-0100 in radial

direction and insert in bearing bore hole. 0360-0010-0380
0360-0010-0330
0360-0010-0040
11 Drive in planetary bolt by means of a plastic
hammer. Check the alignment of the dowel 0360-0010-0310
pin bore. 0360-0010-0160 0360-0010-0040
12 Drive new dowel pin 0360-0010-0110 half

way in. Drive the second (new) dowel pin
0360-0010-0130
0360-0010-0120 into first dowel pin, offset
by approx. 180° (gudgeon slots). Countersink
dowel pins together into planet carrier by
0360-0010-0120
approx. 0.5 mm.
0360-0010-0110
13 Repeat working steps 1 through 14 for the 0360-0010-0100

other four planet carriers.
0360-0010-0010
028618_1
1325 751 101 - 2009-03 4-8

ZF-Ecosplit S/G Valve, 5/2-Way Valve
5 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
1325 751 101 - 2009-03 5-1

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
5 Splitter Group Piston and 5/2-Way Valve 7 Remove entire piston 0340-0110 from selector
rail 0150-0050-0010.
5.1 Removing piston and valve
8 Remove double-lip seal 0340-0110-0120 from
1 Pull off cylinder 0340-0140 by hand. piston 0340-0110-0110.
2 Unfasten hex head screws 0340-0330 and 9 Take O-rings 0340-0160 and 0340-0150 off the
0340-0340 and remove together with 5/2-way cylinder.
valve 0340-0320 from transmission housing.
NOTE
3 Pick up O-rings 0340-0300 and 0340-0310. • For information on how to remove cap seal
0340-0100, refer to Chapter 9.
NOTE • For information on how to remove selector rail
Do not disassemble 5/2-way valve, sub-assembly 0150-0050-0010, refer to Chapter 8.
(complete unit).
10 Use extraction tool 1X56 138 063 to drive
4 Remove detent plunger 0340-0180, insert cylinder pins 0180-0500 to 0180-0530 in
locating fixture 1X56 138 100. drive/input direction and remove them.
5 Remove retaining nut 0340-0130.

6 Unsnap spring 0340-0170 at the housing.
1325 751 101 - 2009-03 5-2

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.
2 Mount double-lip seal 0340-0110-0120 on

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

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

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

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

in detent plunger 0340-0180.
8 Insert cylinder 0340-0140 in the housing.
9 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

5.3 Compressed air test for piston and

S/G cylinder
1 Screw locating fixture 1X56 138 673 for 1X56 138 673
S/G cylinder 0340-0140 to transmission
housing.
2 Pressurize 5/2-way valve and/or piston with

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

cylinder and try to avoid formation of
0340-0140
blowholes.
4 Pressurize piston with compressed air in

opposite switching direction and check for air 029010_1
leakage.
5 If necessary in the event of blistering, insert

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

double-lip seal 0340-0110-0120 on piston
0340-0110-0110.
7 Remove locating fixture 1X56 138 673.
1325 751 101 - 2009-03 5-4

ZF-Ecosplit Release Unit, Connection Plate, and Pump
6 Release Unit, Connection Plate, and Pump
6.1 Release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.1.1 Removing release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.2 Fitting release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2.1 Removing connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2 Fitting connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.1 Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.2 Fitting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
1325 751 101 - 2009-03 6-1

ZF-Ecosplit Release Unit
0260-0200 *
0260-0100
0260-0110
0260-0120
0260-0010
028574_1
6 Release Unit, Connection Plate, and Pump 6.1.2 Fitting release unit
6.1 Release unit 1 Slide release unit 0260-0200 over guide tube.
6.1.1 Removing release unit 2 Insert release shaft 0260-0100 in release fork
0260-0010.
1 Unfasten and remove screws 0260-0110 and
0260-0120. 3 Insert release fork in release unit and attach
it to connection plate using hex head screws
2 Take off release fork 0260-0010 together with 0260-0110 and 0260-0120.
release shaft 0260-0100. Remove release shaft. Tightening torque: 115 Nm
3 Remove release unit 0260-0200 from guide NOTE

tube. Apply some grease on ball socket of release fork
0260-0010.
* depending on version
1325 751 101 - 2009-03 6-2

ZF-Ecosplit Connection Plate
6.2 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.
0240-0420
2 Unfasten hex head screws 0240-0500 to

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

using pry bars and remove together with seal
0220-0910-0440.
0200-0010
NOTE
Use cast pockets as pry bar leverage points.
0220-0910-0440
4 Remove washers 0200-0070, 0200-0080 and
spacer ring 0200-0090 from input shaft.
5 Remove compensation disk 0240-0420 from 0240-0400

countershaft and compensating disk 0200-0070
0200-0090
0240-0400 from input shaft.
0200-0080
6 Remove shaft sealing ring 0220-0910-0330

from connection plate.
NOTE 0220-0910-0300
Clean connecting surface, clean threaded holes;
possibly, thread is to be recut.
0240-0500
—
7 Remove and clean strainer 0200-0010. 0240-0670
0220-0910-0330
0220-0910-0320
0220-0910-0370
0220-0910-0360
0220-0910-0340
0220-0910-0350
028590_1
1325 751 101 - 2009-03 6-3

6.2.2 Fitting connection plate
1 Insert strainer 0200-0010 in clutch housing.

0240-0420
2 Use assembly aid 1X56 138 628 to press shaft

sealing ring 0220-0910-0330 flush into
connection plate 0220-0910-0300.
NOTE
0200-0010
• Coat the outer circumference of the shaft sealing
ring with spirits (ethanol).
• Sealing lip of the shaft sealing ring faces the 0220-0910-0440
output drive.
• Coat shaft sealing ring with some grease.
0240-0400
3 Place specified washer 0240-0400 on input 0200-0070
0200-0090
shaft. 0200-0080
4 Place washers 0200-0070, 0200-0080 and

spacer ring 0200-0090 in correct position over
input shaft. 0220-0910-0300
NOTE 0240-0500
Washer 0200-0070 = Ø 88 mm —
0240-0670
Washer 0200-0080 = Ø 85 mm 0220-0910-0330
0220-0910-0320
5 Place specified compensation disk 0240-0420
0220-0910-0370
on countershaft.
NOTE
Washers 0240-0400 and 0240-0420 are specified in 0220-0910-0360
0220-0910-0340
Chapter 13. 0220-0910-0350
6 Place new seal 0220-0910-0440 on 028590_2
transmission.
0200-0080 0200-0070
0200-0090
7 Apply guide tube 0220-0910-0320 on 0240-0400
connection plate and fasten with screw and

washer assemblies 0220-0910-0340 to
0220-0910-0370.
0240-0420
028576_1
1325 751 101 - 2009-03 6-4

8 Align countershaft groove and impeller

D
driver with each other.
Assembly suggestion: By turning counter-
shaft 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).
9 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
C
to drive firmly home. Remove protective
sleeve.
031856
NOTE
Threaded holes and connecting surfaces must be 7
8
5 9
clean. 6
11 Insert new hex head screws 0240-0500 to

0240-0670 and tighten. A 1 10
2
NOTE B
4
• For better positioning of the connection plate at
pos. A and B, use dowel pin (3).
16 3
• Tighten hex head screws in right sequence (1 - 16).
13 12 11
14
15
028675
Ø 15
3
110
shank Ø 10.1
80
15
M10
028674_en
1325 751 101 - 2009-03 6-5

ZF-Ecosplit Pump
6.3 Pump
6.3.1 Removing pump 0220-0920-0160
1 Unfasten and remove torx screws

0220-0920-0120
0220-0920-0150 and 0220-0920-0160.
0220-0920-0110
0220-0920-0150
2 Remove pump cover 0220-0920-0140 from
connection plate.
0220-0920-0140
3 Remove gear set 0220-0920-0120 and rotor
0220-0920-0110 from connection plate.
6.3.2 Fitting pump
1 Insert rotor 0220-0920-0110 and gear set 028577_1
0220-0920-0120 in connection plate.
NOTE
23-0.5
Check gear set 0220-0920-0120 for correct assembly. /120
NOTE
Coat rotor 0220-920-0110 and gear set
0220-0920-0120 with corrosion protection oil.
2 Insert pump cover 0220-0920-0140 in con-

nection plate.
/110
3 Insert and tighten torx screws 0220-0920-0150 Oberserve marking
and 0220-0920-0160 in pump cover.
0.5 max
Projection permitted
NOTE
Check whether rotor is free-moving. 028679_en
1325 751 101 - 2009-03 6-6

ZF-Ecosplit Clutch Housing
7 Clutch Housing
7.1 Removing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Fitting clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
1325 751 101 - 2009-03 7-1

0180-0410
0180-0500
0180-0400
1
0180-0530
0180-0400-0120
0180-0350 0180-0400-0110
0180-0510 0110-0010
2
0180-0520
0180-0600
–
0180-0800 0380-0400
0380-0420
0320-0020
0320-0010
0260-0250
028625
7 Clutch Housing
7.1 Removing clutch housing
1 Unfasten switch 0380-0420 and remove 6 Unfasten screw plug 0180-0350 and take off
together with pin 0380-0400. together with sealing ring.
7 Remove outer bearing ring (1) of tapered
2 Remove hex head screws 0180-0600 to roller bearing 0150-0020-0080 and outer
0180-0800 from clutch housing; do not use bearing ring (2) of tapered roller bearing
impact wrench. 0150-0010-0230 from clutch housing.
3 Lift the clutch housing 0180-0400. 8 If necessary, remove closure cap 0260-0250.
4 Remove the seal 0180-0410 from the 9 Unfasten screw plugs 0320-0010 and
transmission housing. 0320-0020 and take them off together with
sealing rings.
5 If necessary, remove pipe 0180-0400-0120
from clutch housing.
1325 751 101 - 2009-03 7-2

7.2 Fitting clutch housing 11 Screw in screw plug 0180-0350 with new
sealing ring and tighten.
1 Screw in screw plugs 0320-0010 and Tightening torque: 35 Nm
0320-0020 with new sealing rings and tighten.
Tightening torque: 50 Nm 12 Insert greased pin 0380-0400, and screw in
and tighten switch 0380-0420.
2 Insert closure cap 0260-0250. Tightening torque: 45 Nm
3 If necessary insert new pipe 0180-0400-0120

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

roller bearing 0150-0020-0080 and outer
bearing ring (2) of tapered roller bearing
0150-0010-0230 in clutch housing.
5 Apply centering device 1X56 138 635 to

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

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

029030
centering pins onto transmission housing until
selector rails are centered in transmission
housing.
8 Remove centering device 1X56 138 635 and

lower clutch housing until it makes contact.
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

7.3 Pipe assembly

BEFORE ASSEMBLY
1 Insert new pipe 0180-0400-0120 in clutch hou-

sing in such a way that it protrudes by approx.
20 mm on the drive/input side.
8+5
END OF PIPE
CA.20
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.
3 Press pipe into clutch housing for flush seat.
NOTE
Housing and pipe are deformed.
3.5+1
7.2+0.8
028676_en
AFTER ASSEMBLY
0.5-1
PRESSED-IN
FLUSH
028677_en
1325 751 101 - 2009-03 7-4

ZF-Ecosplit Shafts, Selector Rails
8 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
1325 751 101 - 2009-03 8-1

8 Shafts and Selector Rails
8.1 Removing shafts and selector rails 0130-0010
1 Push reverse gear 0130-0010 towards housing

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

ring.
0110-0190
3 Screw in assembly aid 1X56 138 627. Locking
pin 0150-0040-0250 of interlock is pushed
against spring pressure.
! DANGER 031016
Make sure that assembly aid/device and rope are

fitted properly. 0150-0010-0010
4 Screw lifting fixture 1X56 137 122 together

1X56 137 921 1X56 138 631
with centering ring 1X56 137 921 and position
1X56 138 694
over input shaft 0150-0010-0010, selector rails
and on top of countershaft 0150-0020-0010. 0150-0020-0010 1X56 137 122
1X56 137 933

5 Fit washer 1X56 137 933 between lifting
device and countershaft. Place support
1X56 138 631 on lifting device and insert in
selector rail driver.
6 Screw countershaft 0150-0020-0010 to lifting

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

0-0050-0010
selector rail 0150-0050-0010 into the lifting
device 1X56 137 122 and fix selector rail with
screw.
029049_1
1325 751 101 - 2009-03 8-2

8 Push spacer plate of support 1X56 138 631

between main shaft and countershaft (see
figure 029042) at the splitter group’s
synchronizer.
9 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 0150-0050-0050
condition, they are sub-assembly. 0150-0050-0060
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

8.2 Fitting shafts and selector rails 0150-0010-0010
NOTE
• Main shaft must be measured, 1X56 137 921 1X56 138 631
refer to Chapter 13. 1X56 138 694
• Reverse gear must be inserted, 0150-0020-0010 1X56 137 122
refer to Chapter 9.
1X56 137 933
• Cap seal must be fitted,
see Chapter 9.
• Bearing outer rings must be fitted,
refer to Chapter 9.
!
DANGER
Make sure device and rope are are fitted properly.
1 Place replacement/turning bolt 1X56 137 953 029049_1
on support for countershaft. Insert main shaft

(output-end) 0150-0030-0010 in receptacle
0150-0050-0050
(support) 1X56 137 675. Mount complete 0150-0050-0060
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
S/G
that gears are meshing.
0150-0050-0010
2 Insert selector rails with sliding pads in main
shaft’s sliding sleeves.
031017_1
3 Place centering ring 1X56 137 921 in lifting

device 1X56 137 122 and fasten. Move lifting
device over input shaft and selector rails and 1st/R gear
ensure contact with countershaft. 0150-0040-0160
4 Screw lifting device with washer 1X56 137 933 0150-0040-0100

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

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

0150-0040-0070
selector rail 0150-0050-0010 into the lifting
device 1X56 137 122 and fix selector rail with
screw. 0150-0040-0010
0150-0040-0080
2nd/3rd gear
031017_2
1325 751 101 - 2009-03 8-4

7 Push spacer plate of support 1X56 138 631

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

rail to transmission housing (see figure
029048).
CAUTION
Do not damage the cap seal’s 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.
029042
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.
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.

029048
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 8-5

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 1X56 138 633

1X56 138 634
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.
2 Sliding pads (2) must have downward 0150-0050-0010

clearance in the sliding sleeve. 029010_2
B = 0.1 + 0.2 mm (check with feeler gage).

Check dimension A:
Short version = 93.70 mm 2
Long version = 107.20 mm
4
NOTE
Also refer to assembly instructions 0000 701 102. B
3
3 Evenly tighten setscrews (4) on the shift fork 0150-0010-0100

(3).
0150-0050-0010
A
0340-0110
031050
1325 751 101 - 2009-03 8-6

ZF-Ecosplit Transmission Housing
9 Transmission Housing
9.1 Dismantling transmission housing ....................... 9-2
9.2 Assembling transmission housing . . . . . . . . . . . . . . . . . . . . . . . . 9-3
1325 751 101 - 2009-03 9-1

0150-0040-0250
0160-0230
0150-0040-0260
0110-0200
0110-0010
0110-0180
0130-0040
0130-0020
1 0340-0100
0410-0340
0130-0010
2
0410-0320
0110-0150
0160-0240
028624_1
9 Transmission Housing 4 If necessary, unfasten and remove screw plugs

0410-0320 and switch 0410-0340.
9.1 Dismantling Transmission Housing
5 If necessary, unfasten and remove screw plugs
1 Drive bearing outer ring (1) of the tapered 0160-0230 and 0160-0240.
roller bearing 0150-0020-0020 and outer
bearing ring (2) of the tapered roller bearing 6 Unscrew fixture 1X56 138 627 and locking
0150-0030-0230 out of transmission housing, bolt 0150-0040-0250 as well as compression
in the direction of the input, by means of a spring 0150-0040-0260.
soft mandrel.
7 Use a suitable to remove cap seal 0340-0100
2 Remove breather 0110-0200 (*version from housing.
depends on parts list).
8 Take reverse gear 0130-0010 with needle
3 If necessary, unfasten screw plugs 0110-0150 cages 0130-0020 and 0130-0040 out of the
und 0110-0180 and take off together with housing and remove needle cages from the
sealing rings. reverse gear.
1325 751 101 - 2009-03 9-2

9.2 Assembling Transmission Housing
1 Screw in new screw plugs 0160-0230 and

0160-0240 with new sealing ring.
2 Screw in screw plugs 0410-0320 and

0410-0340 with new sealing ring.
3 Screw in screw plugs 0110-0150 and

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

!DANGER
Only touch heated parts when wearing protective
gloves.
5 Use hot air blower to heat housing to approx.

80 °C in the area around bearing holes.
6 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).
7 Coat the outside of locating bore and new cap

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

into the housing until firmly home (axial abut-
ment). Grease the sealing lip of the cap seal.
9 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
10.1 Disassembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
1325 751 101 - 2009-03 10-1

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
0150-0010-0230 0150-0010-0130
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
10.1 Disassembling input shaft 0150-0010-0112, 0150-0010-0118,
0150-0010-0124 which are released.
NOTE
Input shaft can only be removed after clutch housing 4 Release and remove retaining ring
(refer to Chapter 7) and shafts have been removed 0150-0010-0240.
(refer to Chapter 8).
5 Pull off inner ring of roller bearing
1 Completely remove input shaft 0150-0010-0010 0150-0010-0230 from the input shaft by using
from main shaft. gripper 1X56 136 722 and basic tool
1X56 122 304. To this end, position gripper
2 Take off clutch body 0150-0010-080 with 1X56 136 722 over roller bearing inner ring
synchronizer ring 0150-0010-0090 from the and tighten by means of knurling ring until
input shaft’s synchronizer. fitted tightly on rollers.
!
DANGER 6 Remove helical gear 0150-0010-0200 from
Thrust pieces are under spring tension. Prevent them input shaft.
from jumping out.
7 Remove clutch body 0150-0010-0140 and
3 Pull sliding sleeve 0150-0010-0100 off the synchronizer ring 0150-0010-0130 from input
input shaft. Catch thrust pieces shaft.
1325 751 101 - 2009-03 10-2

10.2 Assembling input shaft 8 Set sliding sleeve to center position. Apply
back-pressure on clutch body 0150-0010-0080.
1 Check synchronizer parts for wear limit, refer You will hear the thrust pieces snap into place.
to Chapter 14.
9 Place input shaft on main shaft.
2 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.
3 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.
6 Put sliding sleeve 0150-0010-0100 on input

shaft and ensure contact. Insert new compres-
sion 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.
7 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
11.1 Disassembling countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2 Assembling countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
1325 751 101 - 2009-03 11-1

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 3 Unsnap retaining ring 0150-0020-0090 and

For removal of countershaft, refer to Chapter 8. remove it.
11.1 Disassembling countershaft 4 Fit gripper 1X56 136 756 to inner ring of
tapered roller bearing 0150-0020-0080. Turn
NOTE knurling ring on gripper, until gripping piece
In order to protect the countershaft, a thrust piece locates firmly.
must always be fitted between the extracting tool
and the countershaft 0150-0020-0010. 5 Screw 1X56 122 304 onto gripper and remove
bearing inner ring from countershaft.
1 Place gripper 1X56 136 756 on inner ring of
tapered roller bearing 0150-0020-0020. Turn CAUTION
knurling ring on gripper, until gripping piece If necessary, replace tapered roller bearings
locates firmly. 0150-0020-0020 / 0150-0020-0080; the bearing
rollers may be damaged by extraction process.
2 Screw basic tool 1X56 122 304 onto gripper
and pull bearing inner ring off the counter-
shaft.
1325 751 101 - 2009-03 11-2

6 Press helical gears 0150-0020-0050 and 6 Heat inner rings 0150-0020-0020 /

0150-0020-0040 and the helical gear 0150-0020-0080 up to 120 - 130 °C for max.
0150-0020-0030 off individually using a 15 min. and place on countershaft. Ensure
suitable hydraulic press due to high press-off axial abutment, if necessary, drive in further
force force. The press-off force for each using a soft mandrel.
helical gear can be as high as 500 kN.
7 Snap in retaining ring 0150-0020-0090. Ensure
NOTE that retaining ring 0150-0020-0090 is firmly
To prevent gear damage, catch countershaft or home with the groove base of the counter-
helical gears on a soft surface. shaft.
NOTE
The retaining ring must feature axial clearance of
11.2 Assembling countershaft 0.01 - 0.10 mm; select retaining ring in line with the
items listed in the spare parts catalog.
!DANGER
Only touch heated parts when wearing protective NOTE
gloves. For installation of countershaft, refer to Chapter 8.
1 Bores in helical gears and countershaft snug

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

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

0150-0020-0010, a temperature difference
of 150 °C between the helical gears and the
countershaft is specified.
4 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.
5 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 bearing’s 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
12.1 Disassembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.2 Assembling main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
1325 751 101 - 2009-03 12-1

12-2
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.
2 Remove axial roller bearing 0150-0030-0520

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

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

(support) 1X56 137 675 (output-end).
1325 751 101 - 2009-03 12-3

0150-0030-0030 0150-0030-0050
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
5 Remove retaining ring 0150-0030-0240. 10 Remove clutch body 0150-0030-0050-0080

and synchronizer ring 0150-0030-0050-0030
6 Place suitable washer on main shaft. Apply from synchronizer body
commercial two-armed extractor to R gear 0150-0030-0050-0010.
0150-0030-0220 and pull off together with
tapered roller bearing inner ring ! DANGER
0150-0030-0230. During the removal process, 3 thrust pieces
0150-0030-0050-0050 and 3 compression springs
7 Remove needle-roller assembly 0150-0030-0050-0060 are released. These parts are
0150-0030-0210 with inner ring under spring tension. Prevent parts from jumping out
0150-0030-0200. (e.g. by using a cloth).
8 Use commercial two-armed extractor in 11 Remove sliding sleeve 0150-0030-0050-0020 ,

order to grip helical gear 0150-0030-0040 1st gear, from synchronizer body
of 1st gear and pull off together with 0150-0030-0050-0010 .
synchronizer 0150-0030-0050.
12 Washer 0150-0030-0050-0120 and clutch body
9 Remove needle-roller assembly 0150-0030-0050-0110 are released.
0150-0030-0030 (2 parts).
13 Remove pipe 0150-0030-0250 if damaged.
1325 751 101 - 2009-03 12-4

0150-0030-0410 0150-0030-0270
0150-0030-0440
0150-0030-0420
0150-0030-0390 0150-0030-0290
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 positi-

!DANGER
on it in receptacle (support) 1X56 137 675
During the removal process, 3 thrust pieces
(output-end).
0150-0030-0290-0050 and 3 compression springs
0150-0030-0290-0060 are released. These parts are
15 Remove split ring 0150-0030-0450.
under spring tension. Prevent the parts from jumping
out (e.g. by using a cloth).
16 Remove thrust washers 0150-0030-0390,
0150-0030-0380, helical gear 0150-0030-0440
3rd gear, roller rings 0150-0030-0420, 0150-
20 Remove sliding sleeve 0150-0030-0290-0020 ,
0030-0410, and inner ring 0150-0030-0400.
2nd gear, from synchronizer body
0150-0030-0290-0010.
17 Use commercial two-armed extractor in
order to grip helical gear 0150-0030-0270
21 Synchronizer ring 0150-0030-0290-0030 and
of 2nd gear and pull off together with
clutch body 0150-0030-0280 are released.
synchronizer 0150-0030-0290.
S
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 12-5

12.2 Assembling main shaft 7 Slide sliding sleeve 0150-0030-0050-0020,

1st gear, over synchronizer body, synchronizer
1 Check main shaft for free passage of ring, and clutch body, and fit to the helical
lubrication oil bores. Pipe 0150-0030-0250 gear, 1st gear. In this context, make sure that
must be solidly seated on the main shaft. the recesses at the inner side of the sliding
sleeve are congruent with the fitting locations
2 Position main shaft into the receptacle of the synchronizer body (for compression
(support) 1X56 137 675 (input-end). springs and thrust pieces).
NOTE 8 Insert three compression springs

Lightly oil the thrust faces and contact surfaces for 0150-0030-0050-0060 together with thrust
the needle-roller assemblies and helical gears with pieces 0150-0030-0050-0050 by means of a
oil. suitable tool in the bores of the synchronizer
body and turn into the sliding sleeve.
3 Slide needle-roller assembly 0150-0030-0030
(2 parts) over the main shaft 0150-0030-0010. NOTE
Use new compression springs and pull the sliding
4 Slide helical gear 0150-0030-0040, 1st gear, sleeve into the center position (neutral position).
over the needle-roller assembly of the main
shaft by means of light rotational motion. 9 Insert washer 0150-0030-0050-0120 in
Collar faces output. synchronizer body.
CAUTION 10 Fit clutch body 0150-0030-0050-0110 on the

Check wear limit of all synchronizer rings and/ or main shaft. Flat side faces output.
clutch bodies as described in Chapter 14.
11 Slide inner ring 0150-0030-0200 and needle-
5 Place clutch body 0150-0030-0050-0080 with roller assembly 0150-0030-0210 onto main
synchronizer ring 0150-0030-0050-0030 onto shaft shaft until it abuts against synchronizer
driving spline. body.
!DANGER 12 Slide helical gear 0150-0030-0220, R gear, over

Only touch heated synchronizer bodies when the needle-roller assembly by means of light
wearing protective gloves. rotational motion. Driving spline points
towards the drive-end. In this context, make
6 Heat up synchronizer body 0150-0030-0050- sure that the clutch body lies on the driving
0010 to approx. 120 °C and slide onto main spline.
shaft gearing. Narrow sides faces output.
!DANGER
NOTE Only touch heated tapered roller bearing’s inner ring
The cams of the synchronizer ring must mesh with when wearing protective gloves.
the recesses of the synchronizer body.
1325 751 101 - 2009-03 12-6

0150-0030-0030 0150-0030-0050
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 Heat up tapered roller bearing inner ring

0150-0030-030 to approx. 120 °C and slide 0150-0030-0050-0020
0150-0030-0050-0050
onto main shaft; drive in further to ensure
0150-0030-0050-0030
axial abutment. 0150-0030-0050-0110
NOTE
The retaining ring’s 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. 0150-0030-0050-0080 0150-0030-0050-0120
15 Turn main shaft around and place it into the

0150-0030-0050-0060
receptacle (support) 1X56 137 675 (output-
0150-0030-0050-0010
end).
028663_1
1325 751 101 - 2009-03 12-7

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
0150-0030-0520 0150-0030-0290-0020
0150-0030-0290-0060
0150-0030-0530 0150-0030-0290-0050
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 19 Heat up synchronizer body

(2 parts) onto main shaft. 0150-0030-0290-0010 to approx. 120 °C and
slide onto main shaft gearing. The synchro-
17 Slide helical gear 0150-0030-0270, 2nd gear, nizer body is symmetric and therefore can be
over the needle-roller assembly by means of fit to the unit irrespective of its lateral
light rotational motion. Driving spline points position. Drive in synchronizer body further
towards the drive-end. to ensure axial abutment.
18 Place clutch body 0150-0030-0280 with NOTE

synchronizer ring 0150-0030-0290-0030 The cams of the synchronizer ring must mesh with
onto driving spline. the recesses of the synchronizer body.
CAUTION 20 Slide sliding sleeve 0150-0030-0290-0020,

Check wear limit of all synchronizer rings and/or 1st/2nd gear, over synchronizer body, syn-
clutch bodies as described in Chapter 14. chronizer ring, and clutch body, and fit to the
helical gear, 1st gear. In this context, make
! DANGER sure that the recesses at the inner side of the
Only touch heated synchronizer body when wearing sliding sleeve are congruent with the fitting
protective gloves. locations of the synchronizer body (for
compression springs and thrust pieces).
1325 751 101 - 2009-03 12-8

21 Insert three compression springs 28 Heat up cylindrical roller bearing

0150-0030-0290-0060 with thrust pieces 0150-0030-0490 to approx. 120 °C and slide
0150-0030-0290-0050 by means of a suitable onto main shaft until firmly home.
tool in the bores of the synchronizer body
and/or turn into the sliding sleeve. 29 Fit washer 0150-0030-0500.
NOTE NOTE
Use new compression springs. Before fitting disk spring 0150-0030-0510, the input
and main shaft must be measured.
22 Fit synchronizer ring 0150-0030-0290-0030. For measurement, refer to Chapter 13.
The cams of the synchronizer ring must
mesh with the recesses of the synchronizer 30 Fit disk spring 0150-0030-0510 and axial roller
body. bearing 0150-0030-0520.
23 Place clutch body 0150-0030-0370 onto the 31 Insert baffle plate 0150-0030-0530 in axial
synchronizer ring and pull the sliding sleeve roller bearing and main shaft.
into the center position (neutral position).
During the process, push the synchronizer NOTE
ring and clutch body tight. For installation of the main shaft, refer to
Chapter 8.
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.
NOTE
The axial clearance of the split ring must be bet-
ween – 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
wearing protective gloves.
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
13.1 Setting the main and input shaft . . . . . . . . . . . . . . . . . . . . . . . . 13-2
13.2 Setting the countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
1325 751 101 - 2009-03 13-1

13 Bearing Setting on Main Shaft, Input Shaft,

and Countershaft 0150-0030-0530
13.1 Setting the main and input shaft

0150-0030-0520
CAUTION
Set the main and input shaft with the respective 0150-0030-0510
clearance.
0150-0030-0500
Clearance is 0.01 - 0.10 mm
0150-0030-0490
1 Assemble main shaft, as described in Chapter
12.2, until you get to disk spring. Do not
mount disk spring 0150-0030-0510.
2 Fit axial roller bearing 0150-0030-0520 and

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

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

transmission housing.
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

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)
031049
A = 5.90 mm
NOTE
Perform measurement at two opposite locations and
calculate mean value.

between the connecting face and compen-
sating disk’s contact surface, note down
dimension “B”.
Example:
B = 4.20 mm
NOTE
10 Determine difference “C” and note down.
Example: 031056
C = A – B = 5.90 mm – 4.20 mm
C = 1.70 mm
11 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

12 Select compensating disk 0240-0400 in line

with items offered in the spare parts catalog.
NOTE
Installation of compensating disk 0240-0400 is des- B
cribed in Chapter 6.
0240-0440
13 Remove clutch housing.
0240-0400
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.

A
17 Complete main shaft as described in
Chapter 12.2. 028626_1
18 For shaft installation, see Chapter 8.
1325 751 101 - 2009-03 13-4

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.
2 Set the countershaft’s roller bearing play to

zero; to this end, drive bearing outer ring with 031046
mandrel in the direction of the countershaft.
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


between the pump and the contact surface
of the connection plate, note down
dimension “b”.
Example:
b = 1.40 mm
6 Determine difference “c” and note down.
Example:
c = a – b = 4.40 mm – 1.40 mm
c = 3.00 mm
7 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
8 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

14 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. 1
NOTE 2
Do not mix up synchronizer parts.
1 Place synchronizer ring (2) on the correspon-

ding 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.
2 Use feeler gage to measure distance (X)

between clutch body and synchronizer ring at
two opposite points. If the wear limit falls 001999
below 0.8 or 1.2 mm respectively, the

synchronizer ring and/or clutch body must
be replaced.
3 Also check the condition of the synchronizer

parts (visual check). If the surface is corru-
gated, replace synchronizer parts. Do not mix
up parts which were checked together (mark
them).
1325 751 101 - 2009-03 14-2

14.2 Assembling Synchronizer

2
ZF-BK version 1
1 Check the wear limit.
2 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 5
the main shaft.
4 Push sliding sleeve (6) onto synchronizer body

(3).
Insert new compression springs (5) with thrust 3
pieces (4) into the synchronizer body (3).
Position the mandrel at the center of the thrust 1a
pieces and guide thrust pieces into sliding 6 2a
sleeve (6).
5 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 Clutch body
2/2a Synchronizer ring
2 2a
3 Synchronizer body
4 Thrust piece 1 5
5 Compression spring
6 Sliding sleeve 4 1a
001940
1325 751 101 - 2009-03 14-3

14-4
English
Printed in the Netherlands DW43280501

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Component manual 12S2130 TD

In the interest of continuing product development,

To ensure that the mechanic's health is not

- Comply with all the warnings and safety

- Wear clean, fitted clothes and apply

- Ensure proper extraction of dangerous

- Maintain a safe distance from rotating and/or

- Avoid unnecessary contact with drained oil.

- Various sorts of oil and other lubricants used

- Exercise caution when working with springs

- If necessary, support the component

- Always use the appropriate lifting gear

- After a fire it is possible that hazardous

Overview of Changes ........................................................................................................................ 5

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

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

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

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

6 Connection plate ............................................................................................................................. 6-1

7 Clutch housing ................................................................................................................................. 7-1

8 Shafts and selector rails ................................................................................................................. 8-1

9 Transmission housing .................................................................................................................... 9-1

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

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

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

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

1325 751 101 - 2009-03 3

The following transmissions and variants are

1325 751 101 - 2009-03 4

Index Date of issue Chapter Initiator Comment

1325 751 101 - 2009-03 5

Service points equipped by ZF Friedrichshafen AG

1. Continuously trained personnel,

3. Genuine ZF spare parts in accordance

All work performed at these service locations

The following safety instructions are used ! DANGER to the health!

To avoid injury to personnel and damage to

Personnel required to carry out repairs on ZF

General Information Cleaning Parts

After removing the transmission from the vehicle, Reworking

Transmission Assembly • Shaft Sealing Rings

c) Shaft sealing rings with steel and rubber

• Retaining Agents • Transmission Oil

* refer to consumable material

Tightening torques for screws/bolts and nuts,

Coarse thread Fine thread

Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

M4 2,8 4,1 4,8 M8x1 24 36 43

M12 79 115 135 M14x1.5 135 200 235

M18 280 390 460 M18x2 290 420 490

M24 670 960 1100 M24x1.5 760 1100 1250

M27x2 1050 1500 1800

Status: August 1991

Designation Name Quantity Application Comment

Grease For example General assembly aid

Grease Technical vaseline General assembly aid

Grease For example

Corrosion For example

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

1325 751 101 - 2009-03 11

Designation Dimensions Measurement device Comment

04. Installation dimension of 9 ± 0.1 mm Adapter The installation dimension can

05. Installation dimension of 23 mm –0.5 mm Depth gage Do not separate/remove gear