Order No. 5871 132 002
ZF – ERGOPOWER
2 WG-94 EC
ZF Passau GmbH
Donaustr. 25 - 71
D- 94 034 Passau
REPAIR MANUAL
for
ZF - ERGOPOWER
2 WG-94 EC
IMPORTANT INFORMATION:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a
current ZF production unit. Continuous technical upgrading of the ZF units and extensions
concerning design options may require differing steps, which can be carried out by qualified
specialists without greater difficulties by means of the perspective views included in the
corresponding spare parts lists.
This disassembly and reassembly manual is based on the design level of a ZF production unit at the
time of issue of the manual.
For information on operation, maintenance and for descriptions please refer to the relating Operation
Manual (ZF Order No.: 5872 136 001).
ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a
successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise
which edition is the latest one.
----------------------------------------------------------------------------------------------------------
ATTENTION:
Observe the vehicle manufacturer’s instructions and specifications for the
installation and commissioning of the unit!
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt. : ASDM / Division : ASDM
Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted!
Copyright ZF Passau GmbH! Toute reproduction, même partielle, est interdite!
Technische Änderungen vorbehalten!
Subject to technical modifications!
Sous réserve de modifications techniques!
Konstruktionsstand / Design Level / Niveau Technique 2006/06
1. Auflage / 1. Edition
2006/06
2. Auflage / 2. Edition
2006/11
TABLE OF CONTENTS
Chapt./Page
Preface
0/1
General
0/2 ... 3
Denomination of standard dimensions
0/4
Conversion table
0/5
Tightening torques for screws
0/6
Labeling of identification plate and information on spare parts ordering
0/7
Configuration of transmission
0/8 ... 9
Measuring points and connections
0/10
Notes on oil grade and oil fill quantity
0/11
SPECIAL TOOLS
COMMERCIAL TOOLS
WS/1 … 5
WH/1 … 5
1.
DISASSEMBLY
1/1 ... 2
1.1
Removal of filter
1/1
2.
DISASSEMBLY of proportional valves, inductive sensor, Hall sensor,
temperature sensor and breather
2/1 … 2
3.
DISASSEMBLY of PTO
3/1 ... 2
4.
DISASSEMBLY of output flange
4/1
5.
DISASSEMBLY of main pressure valve and converter safety valve
5/1
6.
DISASSEMBLY of engine connection
6/1 … 2
7.
REMOVAL of clutches and DISASSEMBLY of oil pressure pump
7/1 … 3
7.1
7.2
Removal of clutches
Disassembly of oil pressure pump
7/1
7/2 … 3
TABLE OF CONTENTS
Chapt./Page
8.
DISASSEMBLY of clutches
8.1/1 ... 8.4/1
8.1
8.2
8.3
8.4
KV clutch
KR clutch
KA clutch
KB clutch
9.
REASSEMBLY of clutches
9.1
9.2
9.3
9.4
KV clutch
KR clutch
KA clutch
KB clutch
9.1/1 … 6
9.2/1 … 6
9.3/1 … 6
9.4/1 … 6
10.
REINSTALLATION of clutches and REASSEMBLY of oil pressure
pump
10/1 … 6
10.1
Oil pressure pump
10/1
11.
REASSEMBLY of converter safety valve and main pressure valve
11/1
11.1
11.2
Reassembly of converter safety valve
Reassembly of main pressure valve (control pressure valve)
11/1
11/1
12.
REASSEMBLY of output flange
12/1 … 2
13.
Reassembly of PTO
13/1 … 2
14.
REASSEMBLY of engine connection
14/1 … 2
15.
REASSEMBLY of proportional valves, inductive sensor, Hall sensor,
temperature sensor, breather and screw plugs
15/1 … 2
16.
REASSEMBLY of filter, closing components for oil filler and oil drain
plug
16/1 … 2
8.1/1 … 4
8.2/1 … 4
8.3/1 … 4
8.4/1 … 4
9.1/1 … 9.4/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
PREFACE
This documentation has been developed for specialized staff trained by ZF Passau for repair and
maintenance work to be made on ZF units.
This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters and servicemen with the work on your ZF product
whose practical and theoretical training is constantly updated in our training school.
The Service Stations established by ZF Friedrichshafen all over the world offer you:
1. Permanently trained staff
2. Specified equipment, e.g. special tools
3. State-of-the-art genuine ZF spare parts
All work is done there with utmost care and reliability.
In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the
terms of the currently applicable contractual conditions.
Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred shall be excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.
ZF Passau GmbH
Service Department
5871 132 002
0/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
GENERAL
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the transmission, ensure utmost cleanliness and that the work is done in a professional
manner.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids
and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use
suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing
rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from
residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end
covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be
replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings,
thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with
worn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies
remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation.
NOTE :
Only a heating furnace or an electric drier is permitted to be used for heating up parts such
as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a perfect
contact.
CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual.
Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.
The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible
malfunction.
Never wash disks having organic friction linings (e.g. paper disks - adverse effect on lining adhesion).
Only dry cleaning is permitted (leather cloth).
DANGER
When using detergents, observe the manufacturer’s instructions regarding their handling.
5871 132 002
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Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Structure of the Service Manual
The structure of this repair manual reflects the sequence of the work steps for completely disassembling the
dismantled unit.
Tools required for carrying out the repair work are listed in the current text as well as in chapters "WS“
(special tools) and "WH" (commercial tools).
Important information on industrial safety
As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully
responsible for industrial safety.
The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding
any damage to persons and products during maintenance and repair work.
Repair workshops must familiarize themselves with these regulations prior to starting any work.
A suitably trained and skilled staff is required for a proper repair of these ZF products.
The repair workshop shall be responsible for the training.
The following safety references are used in this manual:
CAUTION
DANGER
This symbol serves as a reference to special working procedures,
methods, information, use of auxiliaries etc... indicated in this
repair manual.
This symbol identifies situations in which lacking care may lead to
personal injury or damage to the product.
NOTE:
Thoroughly study this manual before starting any tests or repair work.
NOTE:
Figures, drawings and parts in this manual do not always represent the original; they show
the working procedure.
Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on
size and weight (not even within one and the same illustration).
Carry out work according to the legend.
NOTE:
5871 132 002
After repair work and tests, the expert staff must verify that the product is perfectly
functioning again.
0/3
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Repair Manual
BEZEICHNUNG DER GESETZLICHEN EINHEITEN
DENOMINATION OF STANDARD DIMENSIONS
DÉNOMINATION DES DIMENSIONS STANDARDISÉES
Hinweis :
längenbezogene Masse in kg/m;
flächenbezogene Masse in t/m2
Note :
linear density in kg/m;
areal density in t/m2
Nota :
densité linéaire en kg/m;
densité superficielle en t/m2
Begriff
Unit
Unité
Masse
Density
Masse
Kraft
Force
Force
Arbeit
Work
Travail
Leistung
Power
Puissance
Drehmoment
Torque
Couple
Kraftmoment
Moment (Force)
Moment (Force)
Druck (Über-)
Pressure (Over-)
Pression (Sur-)
Drehzahl
Speed
Nombre de Tours
5871 132 002
Formelzeichen
Symbol
Symbole
m
Neu
New
Nouveau
kg (Kilogramm)
Alt
Old
Vieux
kg
Umrechnung
Conversion
Conversion
F
N (Newton)
kp
1 kp = 9.81 N
A
J (Joule)
kpm
0.102kpm = 1J = 1Nm
P
KW (Kilowatt)
HP (DIN)
1 HP = 0.7355 KW
1 KW = 1.36 HP
T
Nm (Newtonmeter)
kpm
1 kpm = 9.81 Nm
T (Nm) =
F (N) . r (m)
M
Nm (Newtonmeter)
kpm
1 kpm = 9.81 Nm
M (Nm) =
F (N) . r (m)
pü
bar
atü
1.02 atü = 1.02 kp/cm2
= 1 bar = 750 torr
n
min -1
rpm
tr/min
0/4
Bemerkungen
Note
Nota
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
VERGLEICHSTABELLE FÜR MASSEINHEITEN
CONVERSION TABLE
TABLEAU DE CONVERSION
25.40 mm
=
1 in ( inch)
1 kg ( Kilogramm )
=
2.205 lb ( pounds )
9.81 Nm ( 1 kpm )
=
7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm )
=
1 lbf x ft ( pound force foot )
1 kg / cm
=
5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 )
=
14.233 psi (pound force per square inch lbf/in2 )
0.070 bar ( 0.071 kp/cm2 )
=
1 psi ( lbf/in2 )
1 Liter
=
0.264 Gallon ( Imp. )
4.456 Liter
=
1 Liter
=
3.785 Liter
=
1609344 m
=
0° C ( Celsius )
=
+ 32° F ( Fahrenheit )
0 ° C ( Celsius )
=
273.15 Kelvin
5871 132 002
1 Gallon ( Imp. )
0.220 Gallon ( US )
1 Gallon ( US )
1 Mile ( land mile )
0/5
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148
Friction coefficient: µ tot.= 0.12 for screws and nuts without rework, as well as phosphated nuts. Tighten manually!
Take tightening torques from the following chart, unless otherwise specified:
Dimension
M4
M5
M6
M7
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
Metric ISO standard thread DIN 13, page 13
8.8
10.9
2.8
4.1
5.5
8.1
9.5
14
15
23
23
34
46
68
79
115
125
185
195
280
280
390
390
560
530
750
670
960
1000
1400
1350
1900
1850
2600
2350
3300
3000
4300
12.9
4.8
9.5
16.5
28
40
79
135
215
330
460
650
880
1100
1650
2250
3000
3900
5100
Metric ISO fine thread DIN 13, page 13
Dimension
M8x1
M9x1
M 10 x 1
M 10 x 1.25
M 12 x 1.25
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
M 18 x 1.5
M 18 x 2
M 20 x 1.5
M 22 x 1.5
M 24 x 1.5
M 24 x 2
M 27 x 1.5
M 27 x 2
M 30 x 1.5
M 30 x 2
M33 x 1.5
M 33 x 2
M 36 x 1.5
M 36 x 3
M 39 x 1.5
M 39 x 3
5871 132 002
8.8
24
36
52
49
87
83
135
205
310
290
430
580
760
730
1100
1050
1550
1500
2050
2000
2700
2500
3450
3200
10.9
36
53
76
72
125
120
200
300
440
420
620
820
1100
1050
1600
1500
2200
2100
2900
2800
3800
3500
4900
4600
0/6
12.9
43
62
89
84
150
145
235
360
520
490
720
960
1250
1200
1850
1800
2550
2500
3400
3300
4450
4100
5700
5300
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
LABELING OF IDENTIFICATION PLATE FOR ZF-POWERSHIFT
TRANSMISSIONS
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
Transmission type
Transmission number
ZF parts list number
Total transmission ratio
Oil filling (oil specification)
ZF List of Lubricants
Oil fill quantity
Customer number
1
2
3
4
5
6
7
8
INFORMATION ON SPARE PARTS ORDERING:
Please indicate the following information when ordering genuine ZF spare parts:
1.
2.
3.
4.
5.
6.
7.
=
=
=
=
=
=
=
Transmission type
Unit number
ZF parts list number
Make and type of spare part
Denomination of spare part
Spare part number
Shipping mode
You will find this information on the identification plate!
Please indicate all the a.m. details to avoid any mistakes in the delivery of the ordered spare
parts!
5871 132 002
0/7
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
CONFIGURATION 2 WG-94 EC
1 =
2 =
3 =
4 =
5 =
6 =
7 =
8 =
9 =
10 =
Converter
Flexplate for direct mount
Central shaft / input shaft, PTOs
Transmission pump
Clutch shaft
Output shaft / clutch shaft
Oil drain plug
Output flange
Input shaft / clutch shaft
PTO; coaxial, engine-dependent
(center distance 105 mm)
11 = Clutch shaft
„KA“
„KB“
„KV“
„KR“
11
1
10
2
3
9
4
8
5
7
6
5871 132 002
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Repair Manual
Transmission schematics
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Gear schematics
KR
PTO
AN
KR
KV
AN/KV
KA
KA
KB/AB
KB/AB
Legend:
AN/KV =
KR
=
KA
=
KB/AB =
PTO =
Input / KV clutch
- forwards
KR clutch
- reverse
KA clutch
- 1st gear
KB clutch / output
- 2nd gear
Power take-off; coaxial, engine-dependent
5871 132 002
0/9
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
MEASURING POINTS AND CONNECTIONS
2 WG-94 EC
Take measurements when the transmission has reached operating temperature (approx. 80° - 90° C)!
No.
Denomination of item
Connection
63
65
Measuring points for pressure oil and temperature:
Before the converter – opening pressure
11+2 bar
Forward clutch
KV
16+3 bar
= Reverse clutch
KR
16+3 bar
= Clutch
KA
16+3 bar
= Clutch
KB
16+3 bar
= Temperature after the converter 100° C; short-term 120° C
= System pressure
16+3 bar
10
=
51
53
55
56
57
=
=
M10x1
M10x1
M10x1
M10x1
M10x1
M14x1.5
9/16-18 UNF-2B
Valves and connections:
15
16
Breather
= Connection to heat exchanger
= Connection from heat exchanger
68
69
70
71
=
=
=
=
21
34
47
Inductive sensor and speed sensor:
= Induct. sensor
n turbine
= Speed sensor
n output
= Induct. sensor
n central gear chain
10x1
7/8“ 14 UNF
7/8“ 14 UNF
9/16-18 UNF-2B
7/8“ 14 UN 2A
Connection after ZF-filter
Connection before ZF-filter
Converter safety valve (WSV)
Main pressure valve (HDV)
M18x1.5
------M18x1.5
10
69
68
63
47
21
15
16
34
5871 132 002
0/10
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
34
34
15
71
52/63
49
55
70
53
51
65
56
Y4
57
Y5
NOTES ON THE REQUIRED OIL GRADE:
Approved oils for 2 WG-94 EC powershift transmissions see ZF List of Lubricants
TE-ML 03.
The list of lubricants is being continuously updated and can be obtained or viewed as
follows:
- at all ZF plants
- at all ZF service centers
- Internet http://www.zf.com
Informationen/Tech. Informationen
For information on operation, maintenance and for descriptions see relating operation
manual (ZF Order No. 5872 136 002).
5871 132 002
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Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure
No.
Denomination
Order No.
Qty
Assembly truck assy
with tilting device
1
5870 350 000
Chapter/Fig.
1/2
1
Holding fixtures
1/2
5870 350 063
2
1
Clamping angles
1/2
5870 350 136
3
1
Belt wrench
1/5
5870 105 005
4
1
Adjusting screws
6/6
14/2
5870 204 007
5
5871 132 002
1
WS/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure
No.
Denomination
Order No.
Qty
Eye bolt assortment
Chapter/Fig.
7/2
5870 204 002
6
1
Assembly aid
5870 345 114
7
1
Grab sleeve
8.1/10 _ 9.3/8
8.2/9 _ 9.4/6
8.3/9 _ 9.4/8
8.4/9
9.1/6
9.1/8
9.2/6
9.2/8
9.3/6
8.1/15
5873 001 026
8
1
Basic tool
8.1/15
5873 001 000
9
1
Grab sleeve
5873 000 029
10
5871 132 002
WS/2
8.2/14
8.3/2
1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure
No.
Denomination
Order No.
Qty
5873 000 000
Chapter/Fig.
8.2/14
8.3/2
Basic tool
11
1
Rapid grip
8.3/4
5873 011 011
12
1
Forcing device
8.3/4
5870 026 100
13
1
Grab sleeve
8.4/4
5873 002 035
14
1
Rapid grip
8.4/14
5873 012 011
15
5871 132 002
1
WS/3
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure
No.
Denomination
Order No.
Qty
Basic tool
Chapter/Fig.
8.4/14
5873 002 000
16
1
Driver tool
10/2
5870 048 219
17
1
Adjusting screws
10/8
5870 204 011
18
1
Drift
11/1
5870 705 012
19
1
Driver tool
12/1
5870 048 200
20
5871 132 002
1
WS/4
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure
No.
Denomination
Order No.
Qty
Driver tool
Chapter/Fig.
12/6
5870 057 009
21
1
Handle
12/6
5870 260 002
22
1
Assembly mandrel
13/3
13/6
5870 506 105
23
5871 132 002
1
WS/5
REPAIR MANUAL
Corporate Division
Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure
No.
Designation
Order No.
Qty
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
1
Universal
Magnetic stand
5870 200 055
1
Dial indicator
5870 200 057
2
Gauge blocks
3
5870 200 066
70 mm
5870 200 067
100 mm
Digital depth gauge
4
5870 200 072
200 mm
5870 200 114
300 mm
Digital caliper gauge
5870 200 109
5
5871 132 002
WH/1
150 mm
.
REPAIR MANUAL
Corporate Division
Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure
No.
Designation
Order No.
Qty
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
Torque wrench
6
5870 203 030
0.6 -6.0 Nm
5870 203 031
1.0 – 12 Nm
5870 203 032
3.0 – 23 Nm
5870 203 033
5.0 – 45 Nm
5870 203 034
10 – 90 Nm
5870 203 039
80 – 400 Nm
5870 203 016
140 – 750 Nm
5870 203 011
750 - 2000 Nm
Hot-air blower
7
5870 221 500
230 V
5870 221 501
115 V
Plastic hammer
5870 280 004
8
Ø 60 mm
Substitute nylon insert
5870 280 006
Lifting strap
5870 281 026
9
5871 132 002
WH/2
.
REPAIR MANUAL
Corporate Division
Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure
No.
Designation
Order No.
Qty
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
1
Universal
Lifting chain
5870 281 047
10
Pry bar
5870 345 071
11
Striker
5870 650 004
12
Set of internal pliers
I1-I2-I3-I4
13
5870 900 013
Set of internal pliers
I11-I21-I31-I41 90°
14
5871 132 002
5870 900 014
WH/3
.
REPAIR MANUAL
Corporate Division
Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure
No.
Designation
Order No.
Qty
Chapter/Fig
1
Universal
1
Universal
1
Universal
Set of external pliers
A1-A2-A3-A4
15
5870 900 015
Set of external pliers
A01-A02-A03-A04
16
90°
5870 900 016
Two-armed puller
17
5871 132 002
5870 970 001
Jaw width
Throat depth
5870 970 002
Jaw width
Throat depth
5870 970 003
Jaw width
Throat depth
5870 970 004
Jaw width
Throat depth
5870 970 006
Jaw width
Throat depth
5870 970 007
Jaw width
Throat depth
5870 970 026
Jaw width
Throat depth
5870 970 028
Jaw width
Throat depth
WH/4
80 mm
100 mm
120 mm
125 mm
170 mm
125 mm
200 mm
175 mm
350 mm
250 mm
520 mm
300 - 500 mm
250 mm
200 mm
380 mm
200 mm
.
REPAIR MANUAL
Corporate Division
Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure
No.
Designation
Order No.
Qty
Chapter/Fig
1
Universal
Three-armed puller
18
5871 132 002
5870 971 001
Jaw width
Throat depth
5870 971 002
Jaw width
Throat depth
5870 971 003
Jaw width
Throat depth
5870 971 004
Jaw width
Throat depth
5870 971 005
Jaw width
Throat depth
5870 971 006
Jaw width
Throat depth
WH/5
85 mm
65 mm
130 mm
105 mm
230 mm
150 mm
295 mm
235 mm
390 mm
270 mm
640 mm
300 mm
.
Repair Manual
1.
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY:
Transmission 2 WG-94 EC
Figure 1
Attach transmission to the assembly truck by means of holding
fixtures (1) and clamping angles (2).
1
1
2
(S) Assembly truck
(S) Holding fixtures
(S) Clamping angles
2
5870 350 000
5870 350 063
5870 350 136
Figure 2
1.1
Removal of filter
Drain oil prior to starting disassembly!
Remove screw plug (1).
Disposal of oil according to legal requirements!
1
Figure 3
The Figure shows the mounting provision for oil filler tube
with oil dipstick!
Loosen hexagon screw (1) and remove cover (2) and seal (3) .
2
1
3
If an oil filler tube with oil dipstick is installed instead of the
cover (2), these two parts are to be removed.
Figure 4
5871 132 002
1/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Separate ZF fine filter (1) from filter head by means of belt
wrench.
(S) Belt wrench
1
5870 105 005
Figure 5
Loosen cylindrical screws (2) and separate filter head (1) from
transmission housing.
2
1
Figure 6
1
Remove both O-rings (1) out of the annular groove of the filter
head.
Figure 7
5871 132 002
1/2
Repair Manual
2.
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of proportional valves,
inductive sensor, Hall sensor, temperature
sensor and breather
Loosen cylindrical screw (1) from the proportional valves (2).
2
1
Figure 1
Remove proportional valves.
1
Figure 2
4
Remove positioned parts.
3
1
2
3
4
1
2
Inductive sensor - n turbine
Inductive sensor - n gear chain
Temperature sensor, measuring point „63“ after converter
Breather
Remove O-rings!
Figure 3
5871 132 002
=
=
=
=
2/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Loosen cylindrical screw (1) and remove speed sensor (2).
2 = Speed sensor - n output (Hall sensor)
2
1
Remove O-rings!
Figure 4
5871 132 002
2/2
Repair Manual
3.
1
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of PTO
Loosen cylindrical screws (1).
Figure 1
Separate cover from the mounting face of the transmission
housing by means of slight hits with the plastic hammer.
Figure 2
Remove cover by means of assembly lever.
Difficult disassembly due to fixing by cylindrical pins !
Figure 3
Pull out gear (1) and central shaft (2).
If required, remove both cylindrical pins (3) .
1
3
2
The central shaft (2) cannot be disassembled!
It is supplied by the spare parts service only as a complete
assy which consists of:
• Shaft
• Tapered roller bearings (2 pcs)
• Helical gear
• Rectangular ring (available separately)
Figure 4
5871 132 002
3/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Pull needle cage out of the housing hole by means of a KUKKO
puller.
Figure 5
Use assembly levers to remove bearing outer ring from the
housing hole.
If the central shaft is not exchanged, the bearing assignment
(bearing outer ring to bearing inner ring) is to be marked!
Figure 6
Pull needle cage out of the cover hole by means of a KUKKO
puller.
Figure 7
Use assembly levers to remove bearing outer ring from the cover
hole.
If the central shaft is not exchanged, the bearing assignment
(bearing outer ring to bearing inner ring) is to be marked!
Figure 8
5871 132 002
3/2
Repair Manual
4.
3
2
1
4
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of output flange
Remove locking plate (1), loosen hexagon screws (2) and
remove disk and O-ring (3 and 4).
Figure 1
Pull output flange (1) off the output shaft by means of two-armed
puller.
1
Figure 2
Remove shaft seal (1) from the housing hole by means of
assembly lever.
1
Figure 3
5871 132 002
4/1
Repair Manual
5.
5
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of main pressure valve
and converter safety valve
Loosen screw plug (1) and remove main pressure valve (control
pressure valve):
4
Main pressure valve consists of:
2
1
2
3
4
5
3
=
=
=
=
=
Screw plug
O-ring
Piston
Spacer ring
Compression spring
1
Figure 1
Loosen screw plug (1) and remove converter safety valve.
3
Converter safety valve consists of:
2
1
2
3
-
=
=
=
=
Screw plug
O-ring
Pressure valves
Valve assy is installed in the housing – not visible (functional check of valve see Figure 3).
1
Figure 2
Functional check of valve.
Use a screwdriver to check the movability of the ball in the
valve.
If the valve is o.k., it does not need to be removed.
Figure 3
5871 132 002
5/1
Repair Manual
6.
1
2
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of engine connection
Loosen hexagon screws (1) and separate flexplate (2) from
converter (3).
3
Figure 1
Pull off converter (1) by hand.
1
Figure 2
1
Loosen bolted connection between converter bellhousing /
housing (1) and oil pressure pump / housing (2).
2
Figure 3
Press converter bellhousing off the housing equally by means of
hexagon screws M10 (1).
1
Figure 4
5871 132 002
6/1
Difficult disassembly due to fixing by cylindrical pins!
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
If required, remove both cylindrical pins (1).
1
Figure 5
1
Remove filter (1).
S
2
Oil pressure pump (2) cannot be separated from the housing
until the 4 cylindrical screws of the housing inner side have
been loosened.
Fit adjusting screws to ensure that the oil pressure pump is
centered at the housing after the 4 cylindrical screws have
been loosened!
(S) Adjusting screws (M10)
Figure 6
5871 132 002
6/2
5870 204 007
Repair Manual
3
2
1
Corporate Division
Off-Road Driveline Technology
and Axle Systems
7.
REMOVAL of clutches and
DISASSEMBLY of oil pressure pump
7.1
Removal of clutches
Force out cylindrical pin (1).
Cylindrical pin (2) is fitted into a blind hole and can
therefore not be forced out of the hole!
See Figure 3.
Loosen bolted connection (3) of housing front and rear part.
Figure 1
Separate housing front part by means of lifting device.
Support by means of assembly lever!
Difficult disassembly due to fixing by cylindrical pins!
(S) Eye bolt assortment
5870 204 002
Figure 2
Lift the clutches out of the housing in the following sequence:
KV
2
1
KB
KA
KR
KV
KB
2
KA
KR
=
=
=
=
=
1st gear clutch
Reverse clutch
Forward clutch and input
2nd gear clutch and output
Screen sheet
If required, remove cylindrical pin (1).
Figure 3
5871 132 002
7/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Use assembly levers to remove all bearing outer rings from the
housing rear part.
1
If, contrary to the ZF recommendation, the tapered roller
bearings of clutches are not replaced, it is imperative to
ensure the previous pairing (bearing outer ring/bearing inner
ring).
Bearing outer ring and bearing inner ring must be marked!
Remove O-ring (1).
Figure 4
Use assembly levers to remove all bearing outer rings from the
housing front part.
If, contrary to the ZF recommendation, the tapered roller
bearings of clutches and input are not replaced, it is
imperative to ensure the previous pairing (bearing outer
ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be marked!
Figure 5
Loosen cylindrical screws (1) and remove suction tube (2).
2
Loosen cylindrical screws (3 and 4) and remove oil pressure
pump.
1
3
Pay attention to the releasing oil pressure pump!
4
Figure 6
7.2
Disassembly of oil pressure pump
1
Remove oil pressure pump (1).
Figure 7
5871 132 002
7/2
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove O-ring (1).
1
Loosen cylindrical screws (2).
2
Figure 8
1
Check oil pressure pump :
In case of wear marks in the pump housing, stator hollow
shaft or on the inner and outer rotor, the complete oil
pressure pump is to be replaced.
2
1
2
3
4
3
=
=
=
=
Stator hollow shaft
Inner rotor
Outer rotor
Pump housing
4
Figure 9
Remove shaft seal (1) from the pump housing (2).
1
2
Figure 10
5871 132 002
7/3
Repair Manual
2
3
4
8.
Corporate Division
Off-Road Driveline Technology
and Axle Systems
DISASSEMBLY of clutches:
1
1
2
3
4
=
=
=
=
KB clutch (2nd gear clutch and output)
KV clutch (forward clutch and input)
KA clutch (1st gear clutch)
KR clutch (reverse clutch)
Figure 1
8.1
KV clutch/input
Snap out piston ring (1).
1
Figure 2
Pull off bearing inner ring with inner disk carrier (1).
1
Figure 3
1
Remove bearing inner ring (1), axial bearing assy (2) and idler
gear (3).
2
3
Figure 4
5871 132 002
8.1/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove needle cage (1).
1
Figure 5
Remove axial bearing assy (1).
1
Figure 6
Remove snap ring (1).
1
Figure 7
Remove end plate (1), disk package (2) and sheet – cpl. with cup
springs- (3) from the disk carrier.
3
2
1
Figure 8
5871 132 002
8.1/2
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove retaining ring (1) - contact position of axial bearing.
1
Figure 9
Preload compression spring and remove snap ring (1).
(S) Assembly aid
5870 345 114
1
Figure 10
Remove spring cup (1) and compression spring (2).
1
2
Figure 11
1
By means of compressed air (see arrow), press piston (1) off the
shaft/disk carrier and remove it.
Figure 12
5871 132 002
8.1/3
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove both O-rings (1 and 2).
1
2
Figure 13
Rechteckringe
Snap
out rectangular
(1) ausfedern.
rings (1).
1
Figure 14
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve
(S) Basic tool
5873 001 026
5873 001 000
Figure 15
The input shaft (1) cannot be disassembled!
It is supplied by the spare parts service only as a complete
assy which consists of:
1A
1B
1C
1D
1
1A
1B
1C
1D
Figure 16
5871 132 002
8.1/4
=
=
=
=
Ball
Helical gear
Disk carrier
Shaft
Repair Manual
8.2
1
Corporate Division
Off-Road Driveline Technology
and Axle Systems
KR clutch
Snap out piston ring (1).
Figure 1
Pull off bearing inner ring with idler gear (1).
1
Figure 2
Remove bearing inner ring (1), axial bearing assy (2) and idler
gear (3).
1
2
3
Figure 3
Remove needle cage (1).
1
Figure 4
5871 132 002
8.2/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove axial bearing assy (1).
1
Figure 5
Remove snap ring (1).
1
Figure 6
Remove end plate (1), disk package (2) and sheet – cpl. with cup
springs - (3) from the disk carrier.
3
2
1
Figure 7
Remove retaining ring (1) - contact position of axial bearing.
1
Figure 8
5871 132 002
8.2/2
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Preload compression spring and remove snap ring (1).
(S) Assembly aid
5870 345 114
1
Figure 9
Remove spring cup (1) and compression spring (2).
1
2
Figure 10
By means of compressed air (see arrow), press piston (1) off the
shaft/disk carrier and remove it.
1
Figure 11
Remove both O-rings (1 and 2).
1
2
Figure 12
5871 132 002
8.2/3
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Snap out piston ring (1).
1
Figure 13
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve
(S) Basic tool
5873 000 029
5873 000 000
Figure 14
1A
1B
1C
1A
1B
1C
1D
1
1D
Figure 15
5871 132 002
The clutch (1) cannot be disassembled!
It is supplied by the spare parts service only as a complete
assy which consists of:
8.2/4
=
=
=
=
Retaining ring
Helical gear
Disk carrier
Shaft
Repair Manual
8.3
1
Corporate Division
Off-Road Driveline Technology
and Axle Systems
KA clutch
Snap out piston ring (1).
Figure 1
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve
(S) Basic tool
5873 000 029
5873 000 000
Figure 2
Remove axial bearing assy (1) and idler gear (2).
1
2
Figure 3
Remove needle cage (1).
1
Figure 4
5871 132 002
8.3/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove axial bearing assy (1).
1
Figure 5
Remove snap ring (1).
1
Figure 6
Remove end plate (1), disk package (2) and cup spring (3) from
the disk carrier.
3
2
1
Figure 7
Remove retaining ring (1) - contact position of axial bearing.
1
Figure 8
5871 132 002
8.3/2
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Preload compression spring and remove snap ring (1).
(S) Assembly aid
5870 345 114
1
Figure 9
Remove spring cup (1) and compression spring (2).
1
2
Figure 10
By means of compressed air (see arrow), press piston (1) off the
shaft/disk carrier and remove it.
1
Figure 11
Remove both O-rings (1 and 2).
1
2
Figure 12
5871 132 002
8.3/3
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Snap out piston ring (1).
1
Figure 13
Pull tapered roller bearing (inner ring) off the shaft.
(S) Rapid grip
(S) Extractor set
5873 011 011
5870 026 100
Figure 14
The clutch (1) cannot be disassembled!
It is supplied by the spare parts service only as a complete
assy which consists of:
1A
1B
1C
1A
1B
1C
1D
1
1D
Figure 15
5871 132 002
8.3/4
=
=
=
=
Retaining ring
Helical gear
Disk carrier
Shaft
Repair Manual
8.4
1
Corporate Division
Off-Road Driveline Technology
and Axle Systems
KB clutch/output
Snap out piston ring (1).
Figure 1
Pull off bearing inner ring with idler gear (1).
1
Figure 2
Remove bearing inner ring (1), axial bearing assy (2) and idler
gear (3).
1
2
3
Figure 3
Remove needle cage (1).
1
Figure 4
5871 132 002
8.4/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Remove axial bearing assy (1).
1
Figure 5
Remove snap ring (1).
1
Figure 6
Remove end plate (1), disk package (2) and cup spring (3) from
the disk carrier.
3
2
1
Figure 7
1
Remove retaining ring (1) - contact position of axial bearing.
Figure 8
5871 132 002
8.4/2
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Preload compression spring and remove snap ring (1).
(S) Assembly aid
5870 345 114
1
Figure 9
Remove spring cup (1) and compression spring (2).
1
2
Figure 10
By means of compressed air (see arrow), press piston (1) off the
shaft/disk carrier and remove it.
1
Figure 11
Remove both O-rings (1 and 2).
1
2
Figure 12
5871 132 002
8.4/3
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Snap out rectangular rings (1).
1
Figure 13
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve
or
(S) Rapid grip
(S) Basic tool
5873 002 035
5873 012 011
5873 002 000
Figure 14
1A
1B
1C
1D
1
The clutch (1) cannot be disassembled!
It is supplied by the spare parts service only as a complete
assy which consists of:
1A
1B
1C
1D
1E
1E
Figure 15
5871 132 002
8.4/4
=
=
=
=
=
Ball
Retaining ring
Helical gar
Disk carrier
Shaft
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
1A
9.
REASSEMBLY of clutches:
1B
9.1
KV clutch/input
1C
1
The input shaft (1) is supplied by the spare parts service only
as a complete assy which consists of:
1A
1B
1C
1D
1D
=
=
=
=
Ball
Helical gear
Disk carrier
Shaft
Figure 1
Heat up bearing inner ring (approx. 120° C).
Figure 2
2
Mount bearing inner ring (1) until contact is obtained.
1
Fit rectangular rings 50x2.5 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Figure 3
Insert both O-rings (1 and 2) into the piston grooves and oil
them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002
9.1/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Insert piston (1) into the disk carrier.
1
Pay attention to the installation position, see Figure!
Figure 5
Use a hand-operated press to place piston into the disk carrier by
means of the assembly aid.
(S) Assembly aid
5870 345 114
Figure 6
Mount compression spring (1) and spring cup (2).
2
1
Figure 7
By means of the assembly aid, preload compression spring
under a hand-operated press until the retaining ring 40x1.75 (1)
can be snapped in.
1
(S) Assembly aid
Figure 8
5871 132 002
9.1/2
5870 345 114
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Sheet cpl. with cup spring (1) the open side the piston.
1
Installation position of sheet sees also Figure 10!
Figure 9
Install sheet (1) according to the sketch (see arrow).
1
2
Legend:
1
2
3
4
3
=
=
=
=
Sheet cpl. with cup spring
Compression spring with spring cup and retaining ring
Piston with O-rings
Input shaft ass.
4
Figure 10
Install outer and inner disks alternately into the disk carrier (3) as
shown in Figure 11,
Starting with an outer disk and ending with an inner disk.
2
Legend:
1
1 = Outer disks
(10 pcs)
2 = Inner disks
(10 pcs)
3 = Input shaft assy
3
Figure 11
Mount end plate (1) with the flat side showing towards the disk
package and fix it by means of snap ring (2) (e.g. thickness =
2.5 mm / recommended value).
2
1
Figure 12
5871 132 002
9.1/3
Pay attention to the installation position of the end plate!
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Equally press on end plate with F (approx. 100 N = 10 kg) and
set dial indicator to „zero“.
F
Figure 13
Then press end plate against the snap ring (upwards) and read the
disk clearance.
F
Disk clearance: 1.9 to 2.4 mm
In case of deviations, the disk clearance must be corrected
with an appropriate snap ring (optional thickness = 2.0 …...
3.5 mm/available in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1
Contact for axial bearing – see Figure 16!
Figure 15
Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3
(2) and axial washer 40x60x1 (3) and oil them.
3
2
1
Figure 16
5871 132 002
9.1/4
Mount running disk (1) with the chamfer showing towards
the axial needle cage!
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Mount needle cage 40x45x17 (1) and oil it.
1
Figure 17
Mount inner disk carrier until contact is obtained.
1
L
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
R
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
and running disk (3) 40x60x3.5 and oil them.
3
2
1
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Figure 19
Heat up bearing inner ring (approx. 120° C).
Figure 20
5871 132 002
9.1/5
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Mount bearing inner ring (1) until contact is obtained.
Fit rectangular ring 35x2 (2).
2
1
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Check closing and opening of the clutch by means of
compressed air at the hole (see arrow).
Closing and opening of the clutch must be clearly audible.
Figure 21
Figure 22
5871 132 002
9.1/6
Repair Manual
9.2
1A
1B
KR clutch
The clutch (1) is supplied by the spare parts service only as a
complete assy which consists of:
1A
1B
1C
1D
1
1C
Corporate Division
Off-Road Driveline Technology
and Axle Systems
=
=
=
=
Retaining ring
Helical gear
Disk carrier
Shaft
1D
Figure 1
Heat up bearing inner ring (approx. 120° C)
Figure 2
2
Mount bearing inner ring (1) until contact is obtained.
1
Fit rectangular ring 30x2 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Figure 3
Insert both O-rings (1 and 2) into the piston grooves and oil
them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002
9.2/1
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Insert piston (1) into the disk carrier.
1
Pay attention to the installation position, see Figure!
Figure 5
Use a hand-operated press to place piston into the disk carrier by
means of the assembly aid.
(S) Assembly aid
5870 345 114
Figure 6
Mount compression spring (1) and spring cup (2).
2
1
Figure 7
By means of the assembly aid, preload compression spring under
a hand-operated press until the retaining ring 40x1.75 (1) can be
snapped in.
1
(S) Assembly aid
Figure 8
5871 132 002
9.2/2
5870 345 114
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Sheet cpl. with cup spring (1) the open side the piston.
1
Installation position of sheet sees also Figure 10!
Figure 9
Install sheet (1) according to the sketch (see arrow).
1
2
Legend:
1
2
3
4
3
=
=
=
=
Sheet cpl. with cup spring
Compression spring with spring cup and retaining ring
Piston with O-rings
Input shaft ass.
4
Figure 10
Install outer and inner disks alternately into the disk carrier (3) as
shown in Figure 11,
starting with an outer disk and ending with an inner disk.
2
Legend:
1
1 = Outer disks
2 = Inner disks
3 = Clutch assy
3
(10 pcs)
(10 pcs)
Figure 11
Mount end plate (1) with the flat side showing towards the disk
package and fix it by means of snap ring (2) (e.g. thickness =
2.5 mm / recommended value).
2
1
Figure 12
5871 132 002
9.2/3
Pay attention to the installation position of the end plate!
Repair Manual
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Equally press on end plate with F (approx. 100 N = 10 kg) and
set dial indicator to „zero“.
F
Figure 13
Then press end plate against the snap ring (upwards) and read the
disk clearance.
F
Disk clearance: 1.9 to 2.4 mm
In case of deviations, the disk clearance must be corrected
with an appropriate snap ring (optional thickness = 2.0 …...
3.5 mm/available in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1
Contact for axial bearing - see Figure 16!
Figure 15
2
Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3
(2) and axial washer 40x60x1 (3) and oil them.
3
1
Figure 16
5871 132 002
9.2/4
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Repair Manual
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and Axle Systems
Mount needle cage 40x45x17 (1) and oil it.
1
Figure 17
Mount inner disk carrier until contact is obtained.
1
L
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
R
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
and running disk (3) 40x60x3.5 and oil them.
3
2
1
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Figure 19
Heat up bearing inner ring (approx. 120° C).
Figure 20
5871 132 002
9.2/5
Repair Manual
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and Axle Systems
Mount bearing inner ring (1) until contact is obtained.
2
1
Fit rectangular ring 30x2 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Check closing and opening of the clutch by means of
compressed air at the hole (see arrow).
Closing and opening of the clutch must be clearly audible.
Figure 21
Figure 22
5871 132 002
9.2/6
Repair Manual
9.3
1A
1B
1C
KA clutch
The clutch (1) is supplied by the spare parts service only as a
complete assy which consists of:
1A
1B
1C
1D
1
Corporate Division
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=
=
=
=
Retaining ring
Helical gear
Disk carrier
Shaft
1D
Figure 1
Heat up bearing inner ring (approx. 120° C).
Figure 2
Mount bearing inner ring (1) until contact is obtained.
2
1
Fit rectangular rings 30x2 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Figure 3
Insert both O-rings (1 and 2) into the piston grooves and oil
them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002
9.3/1
Repair Manual
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and Axle Systems
Insert piston (1) into the disk carrier.
1
Pay attention to the installation position, see Figure!
Figure 5
Use a hand-operated press to place piston into the disk carrier by
means of the assembly aid.
(S) Assembly aid
5870 345 114
Figure 6
Mount compression spring (1) and spring cup (2).
2
1
Figure 7
By means of the assembly aid, preload compression spring under
a hand-operated press until the retaining ring 40x1.75 (1) can be
snapped in.
(S) Assembly aid
1
Figure 8
5871 132 002
9.3/2
5870 345 114
Repair Manual
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and Axle Systems
Mount cup spring 112x75x2.55 (1) with the convex side showing
towards the piston.
1
Installation position of cup spring see also Figure 10!
Figure 9
Install cup springs (1) according to the sketch.
1
2
Legend:
1
2
3
4
3
=
=
=
=
Cup spring 112x75x2.55 (convex side towards the piston)
Compression spring with cup spring and retaining ring
Piston with O-rings
Clutch assy
4
Figure 10
Install outer and inner disks alternately into the disk carrier (3) as
shown in Figure 11,
starting with an outer disk and ending with an inner disk.
2
Legend:
1
1 = Outer disks
2 = Inner disks
3 = Clutch assy
3
(12 pcs)
(12 pcs)
Figure 11
Mount end plate (1) with the flat side showing towards the disk
package and fix it by means of snap ring (2) (e.g. thickness = 2.5
mm / recommended value).
2
1
Figure 12
5871 132 002
9.3/3
Pay attention to the installation position of the end plate!
Repair Manual
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and Axle Systems
Equally press on end plate with F (approx. 100 N = 10 kg) and
set dial indicator to „zero“.
F
Figure 13
Then press end plate against the snap ring (upwards) and read the
disk clearance.
F
Disk clearance: 2.1 to 2.6 mm
In case of deviations, the disk clearance must be corrected
with an appropriate snap ring (optional thickness = 2.0 …...
3.5 mm/available in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1
Contact for axial bearing - see Figure 16!
Figure 15
Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3
(2) and axial washer 40x60x1 (3) and oil them.
3
2
1
Figure 16
5871 132 002
9.3/4
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Repair Manual
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and Axle Systems
Mount needle cage 40x45x17 (1) and oil it.
1
Figure 17
Mount inner disk carrier until contact is obtained.
1
L
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
R
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
and running disk (3) 40x60x3.5 and oil them.
3
2
1
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Figure 19
Heat up bearing inner ring (approx. 120° C).
Figure 20
5871 132 002
9.3/5
Repair Manual
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and Axle Systems
Mount bearing inner ring (1) until contact is obtained.
2
1
Fit rectangular ring 30x2 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Check closing and opening of the clutch by means of
compressed air at the hole (see arrow).
Closing and opening of the clutch must be clearly audible.
Figure 21
Figure 22
5871 132 002
9.3/6
Repair Manual
9.4
1A
1B
1C
1D
1E
KB clutch/output
The clutch (1) is supplied by the spare parts service only as a
complete assy which consists of:
1A
1B
1C
1D
1E
1
Corporate Division
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=
=
=
=
=
Ball
Retaining ring
Helical gear
Disk carrier
Shaft
Figure 1
Heat up bearing inner ring (approx. 120° C).
Figure 2
Mount bearing inner ring (1) until contact is obtained.
2
Fit rectangular rings 55x3 (2).
1
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Figure 3
Insert both O-rings (1 and 2) into the piston grooves and oil
them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002
9.4/1
Repair Manual
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and Axle Systems
Insert piston (1) into the disk carrier.
1
Pay attention to the installation position, see Figure!
Figure 5
Use a hand-operated press to place piston into the disk carrier by
means of the assembly aid.
(S) Assembly aid
5870 345 114
Figure 6
Mount compression spring (1) and spring cup (2).
2
1
Figure 7
By means of the assembly aid, preload compression spring under
a hand-operated press until the retaining ring 40x1.75 (1) can be
snapped in.
(S) Assembly aid
1
Figure 8
5871 132 002
9.4/2
5870 345 114
Repair Manual
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and Axle Systems
Mount cup spring 112x75x2.55 (1) with the convex side showing
towards the piston.
1
Installation position of cup spring see also Figure 10!
Figure 9
2
Install cup spring (1) according to the sketch.
1
Legend:
1
2
3
4
3
=
=
=
=
Cup spring 112x75x2.55 (convex side towards the piston)
Compression spring with spring cup and retaining ring
Piston with O-rings
Clutch assy
4
Figure 10
Install outer and inner disks alternately into the disk carrier (3) as
shown in Figure 11,
starting with an outer disk and ending with an inner disk.
2
3
Legend:
1
1 = Outer disks
2 = Inner disks
3 = Clutch assy
(6 pcs)
(6 pcs)
Figure 11
Mount end plate (1) with the flat side showing towards the disk
package and fix it by means of snap ring (2) (e.g. thickness = 2.5
mm / recommended value).
2
1
Figure 12
5871 132 002
9.4/3
Pay attention to the installation position of the end plate!
Repair Manual
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and Axle Systems
Equally press on end plate with F (approx. 100 N = 10 kg) and
set dial indicator to „zero“.
F
Figure 13
Then press end plate against the snap ring (upwards) and read the
disk clearance.
F
Disk clearance: 1.1 to 1.6 mm
In case of deviations, the disk clearance must be corrected
with an appropriate snap ring (optional thickness = 2.0 …...
3.5 mm/available in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1
Contact for axial bearing - see Figure 16!
Figure 15
2
Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3
(2) and axial washer 40x60x1 (3) and oil them.
3
1
Figure 16
5871 132 002
9.4/4
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Repair Manual
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Mount needle cage 40x45x17 (1) and oil it.
1
Figure 17
Mount inner disk carrier until contact is obtained.
1
L
R
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
and running disk (3) 40x60x3.5 and oil them.
3
2
1
Mount running disk (1), with the chamfer showing towards
the axial needle cage!
Figure 19
Heat up bearing inner ring (approx. 120° C).
Figure 20
5871 132 002
9.4/5
Repair Manual
2
Corporate Division
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Mount bearing inner ring (1) until contact is obtained.
1
Fit rectangular ring 30x2 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down!
Check closing and opening of the clutch by means of
compressed air at the hole (see arrow).
Closing and opening of the clutch must be clearly audible.
Figure 21
Figure 22
5871 132 002
9.4/6
Repair Manual
10.
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REINSTALLATION of clutches and
REASSEMBLY of oil pressure pump
10.1 Oil pressure pump
1
In case of wear marks in the pump housing, stator hollow
shaft, inner rotor, outer rotor and on the sliding bearing, the
pump assy must be replaced.
2
Legend:
3
1
2
3
4
4
=
=
=
=
Stator hollow shaft
Inner rotor
Outer rotor
Pump housing with sliding bearing
Abbildung 1
With the sealing lip showing downwards, carefully insert the
shaft seal 55x75x8 (1) into the pump housing (2) until contact is
obtained.
S
1
2
Fill space between sealing lip and dust lip with grease!
Outer diameter:
if rubber-coated: wet with spirit
if made of metal: apply sealing agent Loctite No. 574!
(S) Driver tool
5870 048 219
Abbildung 2
Mount outer rotor (1) and inner rotor (2).
2
1
Abbildung 3
5871 132 002
10/1
The driver pins of the inner rotor (see arrows) are to be fitted
in upward direction.
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Fit stator hollow shaft (1).
1
Abbildung 4
Fix stator hollow shaft radially with two cylindrical screws (1).
1
Do not tighten the cylindrical screws – just turn them in until
contact is obtained and then turn them back by approx. ½
rotation!
Place O-ring (2) 135x3 into the annular groove and grease it.
2
Abbildung 5
Mount O-ring 30x3 (1) onto the suction tube (2) and grease it.
1
2
Abbildung 6
Fix suction tube (1) with cylindrical screws M8x16 (2).
Tightening torque M8/8.8x16................ MA = 23 Nm
2
1
Abbildung 7
5871 132 002
10/2
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Insert filter (1).
1
Abbildung 8
Fit two adjusting screws (S) and position converter bellhousing
(1) equally until contact is obtained.
S
1
Pay attention to the hole pattern!
Wet mounting face with Loctite (type No. 574)!
(S) Adjusting screws (M10)
5870 204 007
Abbildung 9
Force the cylindrical pins 12x24 (1) into the holes (blind holes)
until contact is obtained.
1
Abbildung 10
2
Fix converter bell housing (1) with cylindrical screws M10x30
(2).
1
Tightening torque (M10/8.8x30) ................ MA = 46 Nm
Abbildung 11
5871 132 002
10/3
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Repair Manual
Fit two adjusting screws (S) and mount preassembled pump (1).
1
S
Pay attention to the hole pattern!
(S) Adjusting screws (M8)
5870 204 011
Abbildung 12
Position transmission pump with 3 cylindrical screws (1)
M10x30 (3x120° offset position) equally until contact is
obtained.
1
ATTENTION: Do not damage (shear off) the O-ring!
Fix transmission pump with cylindrical screws M8x60 (1).
Tightening torque (M8/8.8x60) ...................MA = 23 Nm
Abbildung 13
Fix pump with cylindrical screws (1 and 2).
1
1 = M8x16
2 = M8x35
2
Tightening torque M8/8.8x16................ MA = 23 Nm
Tightening torque M8/8.8x35................ MA = 23 Nm
Abbildung 14
Insert all bearing outer rings into the bearing holes of both
housing parts (see Figures 15 and 16).
3
2
1
2
3
4
4
1
Abbildung 15
5871 132 002
10/4
=
=
=
=
„KB“ clutch „KV“ clutch „KR“ clutch „KA“ clutch -
2nd gear and outputs
forward and inputs
reverse
1st gear
Place bearing outer rings into the bearing holes using
assembly grease.
Repair Manual
3
2
Corporate Division
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and Axle Systems
If, contrary to the ZF recommendation, the tapered roller
bearings of clutches and input are not replaced, it is
imperative to ensure the previous pairing (bearing inner
ring/bearing outer ring) - see Chapter 7, Figures 4 and 5!
4
1
Abbildung 16
10.2
2
3
Align and grease rectangular rings 55x3 (1).
1
4
Reinstallation of clutches
Position KB clutch (2) together with screen sheet (3).
Bolts (4) of screen sheet must be fixed into the pilot holes!
Abbildung 17
Align and grease rectangular rings 50x2.5 (1).
2
Position KV clutch (2).
1
Abbildung 18
Align and grease rectangular ring 30x2 (1).
2
Position KR clutch (2).
1
Abbildung 19
5871 132 002
10/5
Repair Manual
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Align and grease rectangular ring 30x2 (1).
Position KA clutch (2).
2
1
Abbildung 20
2
Insert O-ring 24x2.5 (1) into the hole and grease it.
3
4
Align and grease rectangular rings (2, 3, 4 and 5).
5
1
Abbildung 21
Use the lifting device to carefully bring the transmission housing
front part into contact position.
The bolts (1) of the screen sheet must be fixed into the pilot
holes!
Wet mounting face with Loctite (type N. 586)!
1
Abbildung 22
5871 132 002
10/6
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Hand-tighten the transmission housings crosswise with 2
cylindrical screws (1).
1
Fit cylindrical pins 12x24 (2) centrically to the mounting face.
1
Abbildung 23
Force cylindrical pins 12x24 (1) into the transmission housing
until contact is obtained (blind hole).
1
Abbildung 24
3
Fix transmission housing front and rear part by means of
cylindrical screws (1 and 2).
1
2
Fit bracket (3).
Cylindrical screw (1)
Cylindrical screw (2)
M10x30 (13 pcs)
M10x50 (9 pcs)
Tightening torque M10/8.8x30 ..............................MA = 46 Nm
Tightening torque M10/8.8x50 ..............................MA = 46 Nm
Abbildung 25
5871 132 002
10/7
Repair Manual
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and Axle Systems
11.
REASSEMBLY of converter safety valve
and main pressure valve
11.1
Reassembly of converter safety valve
Insert valve (1) with drift (S) into the housing until contact is
obtained.
1
(S) Drift
S
5870 705 012
Figure 1
Place compression spring (1) into the transmission hole and fit
screw plug M38x1.5 (2) with O-ring 35x2 (3).
3
Tightening torque ..............................MA = 46 Nm
1
2
Figure 2
11.2
Reassembly of main pressure valve (control pressure
valve)
Main pressure valve consists of:
5
4
1
2
3
4
Screw plug M22x1.5
O-ring 19x2
Piston
Spacer ring (2 pcs)
recommended value 5 mm
5 = Compression spring
2
3
1
=
=
=
=
The main pressure 16 + 3 bar is determined by means of the
spacer rings!
Gradation of available spacer rings see spare parts list.
Figure 3
Tightening torque ..............................MA = 50 Nm
5871 132 002
11/1
Repair Manual
12.
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and Axle Systems
REASSEMBLY of output flange
Use driver tool to fit the shaft seal 60x90x8 (1) until contact
position, with the sealing lip showing towards the oil sump.
1
(S) Driver tool 5870 048 200
Figure 1
Fill space between sealing lip and dust lip with grease!
Outer diameter:
•
if rubber-coated: wet with spirit,
• if made of metal: apply sealing agent Loctite No.
574!
Press screen sheet (1) onto the flange (2) until contact is
obtained.
1
2
Use suitable pressure piece; screen sheet must not be
deformed!
Figure 2
Heat up output flange (approx. 120° C).
Figure 3
Mount output flange (1) until contact is obtained.
1
Wear protective gloves!
Figure 4
5871 132 002
12/1
Adjust output flange after cooling down!
Repair Manual
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Insert O-ring 38x4 into the space between output flange and
shaft.
2
1
Fix output flange by means of washer (1) and hexagon screws
(2).
Tightening torque (M8/10.9x25) ................ MA = 34 Nm
Figure 5
Fix locking plate by means of driver tool.
(S) Driver tool
(S) Handle
Figure 6
5871 132 002
12/2
5870 057 009
5870 260 002
Repair Manual
13.
Corporate Division
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and Axle Systems
REASSEMBLY of PTO
1
1B
The central shaft (1) is supplied by the spare parts service
only as a complete assy which consists of:
1D
1A
1B
1C
1D
1A
=
=
=
=
Shaft
Helical gear
Tapered roller bearing (bearing outer and inner ring)
Rectangular ring (available separately)
1C
Figure 1
Turn orifice M8 - orifice hole A=1.0 - (1) into the threaded hole
until contact is obtained.
1
Figure 2
Press in needle sleeve 40x47x20 (1) by means of the assembly
mandrel until contact is obtained and oil it.
1
2
Designation of the needle sleeve to show outwards to the
assembly mandrel!
(S) Assembly mandrel
5870 506 105
Place bearing outer ring (2) into the housing hole.
Figure 3
Place bearing outer rings into the bearing holes using
assembly grease.
Align and grease rectangular ring 50x2.5 (2).
Mount central shaft (1).
2
1
Figure 4
5871 132 002
13/1
Repair Manual
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Insert gear (1).
1
Splined shaft profile to show outwards (see arrow)!
Figure 5
Press in needle sleeve 40x47x20 (1) by means of the assembly
mandrel until contact is obtained and oil it.
1
Designation of the needle sleeve to show outwards to the
assembly mandrel!
(S) Assembly mandrel
2
5870 506 105
Insert bearing outer ring (2) into the cover hole.
Figure 6
2
Place bearing outer rings into the bearing holes using
assembly grease.
Hand-tighten the cover crosswise with 2 cylindrical screws
M10x30 (1).
1
2
Force the two cylindrical pins 12x24 (2) into the holes (blind
holes) until contact is obtained.
Wet mounting face with Loctite (type No. 574)!
Figure 7
Fix housing and cover by means of cylindrical screws M10x30
(1).
1
Tightening torque M10/8.8x30..............................MA = 46 Nm
Figure 8
5871 132 002
13/2
Repair Manual
14.
1
Corporate Division
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REASSEMBLY of engine connection
Mount converter (1) until contact is obtained.
Figure 1
Position 1 washer/each / thickness = 1.0 mm (4x) (1) onto the
flexplate mounting webs (4x).
4
3
Place flexplates (2).
2
1
Pay attention to the installation position ! Spot-welded
reinforcing disks of the flexplate to be arranged towards the
outside - see arrows !
Mount washer (3) onto the hexagon screw M10x16 (4) and fix
flexplates.
Figure 2
Tighten hexagon screws (1).
1
Tightening torque (M10/8.8x16) ................ MA = 46 Nm
Fix converter axially!
Risk of injury!
Figure 3
5871 132 002
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Repair Manual
15.
REASSEMBLY of proportional valves,
inductive sensor, Hall sensor, temperature
sensor, breather and screw plugs
Mount all screw plugs (1 and 3) with O-rings (2 and 4).
2
1
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Legend:
1 = Screw plug 9/16-18 UNF (6 pcs)
2 = O-ring 11.89x1.98 (6 pcs)
3 = Screw plug M10x1 (18 pcs)
4 = O-ring 8x1.5 (18 pcs)
3
4
Tightening torque (9/16-18 UNF) .................
MA = 15 Nm
Tightening torque (M10x1) ...........................
MA = 6 Nm
Figure 1
Mount O-ring 15.5x2.6 (2) onto the speed sensor -n output Hall
sensor- (1) and fix it with cylindrical screw M8x16 (3).
Tightening torque (M8/8.8x16)............. MA = 23 Nm
2
1
3
Figure 2
4
Fit positioned parts.
3
1 = Inductive sensor with O-ring 15x2 - n turbine
Tightening torque………… MA = 30 Nm
2 = Inductive sensor with O-ring 15x2 - n central gear
chain
Tightening torque………… MA = 30 Nm
3 = Temperature sensor with O-ring 11x2
(measuring point „63“ after the converter)
Tightening torque………… MA = 25 Nm
4 = Breather M10x1
Tightening torque………… MA =12 Nm
1
2
Figure 3
5871 132 002
15/1
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Insert proportional valves (1).
1
Figure 4
Fix proportional valves (1) with cylindrical screws M6x12 (2).
Tightening torque (M6/8.8x12)............. MA = 9.5 Nm
1
2
Figure 5
5871 132 002
15/2
Repair Manual
16.
Corporate Division
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and Axle Systems
REASSEMBLY of filter, closing
components for oil filler and oil drain plug
Place O-rings 34.2x3 (1) into the holes and grease them.
1
Figure 1
Attach filter head (1) with cylindrical screws M8x30 (2).
2
Tightening torque (M8/8.8X30) ...................... MA = 23 Nm
1
Figure 2
•
•
1
Figure 3
5871 132 002
The ZF filter (1) has to be fitted as follows:
16/1
Slightly oil the seal
Turn in the filter until contact with the sealing
surface is obtained, and then tighten it by hand with
approx. 1/3 to 1/2 rotation.
Repair Manual
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Fix closing cover (2) and seal (3) with hexagon screws (1).
Tightening torque (M8/8.8x18)................ MA = 34 Nm
2
1
3
Figure 4
Fit oil drain plug 7/8-14 UN 2A (1).
Tightening torque (7/8-14 UN 2A).............MA = 30 Nm
2
Fix identification plate (2) by means of 4 grooved pins 3x5.
1
Figure 5
Figure 6
5871 132 002
16/2
Before putting the transmission into operation, fill it with oil
according to Operation Manual (Order No. 5872 136 002)!