DW 33367604

Component manual
ZF AS Tronic Mid
©201128 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 AS Tronic Mid
No part of this publication may be reproduced
Edition 2011-04
and/or published by printing, by photocopying, on
1336 751 102c microfilm or in any way whatsoever without the
prior consent in writing of DAF Trucks N.V.
©
201128 DW33367604
ZF AS Tronic Mid
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).
©
201128
ZF AS Tronic Mid
- 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.
©
201128
ZF-AS Tronic mid Table of Contents
Page
Overview of Revisions 1336 751 102 ......................................................................................... 5
Preface ...................................................................................................................................... 6
Safety Instructions...................................................................................................................... 7
Instructions for Repair ............................................................................................................... 8
Tightening torques for screws/bolts and nuts, extract from ZFN 148........................................... 10
Overview Transmission Family/Types .......................................................................................... 11
Consumables ............................................................................................................................. 12
Setting Data............................................................................................................................... 13
Special Tools.............................................................................................................................. 14
Diagnosis Tools .......................................................................................................................... 23
Preparatory Work...................................................................................................................... 24
Clutch Release Mechanism....................................................................................................... 25
Removing the release fork .......................................................................................................... 25
Mounting the release fork........................................................................................................... 26
Transmission Actuator .............................................................................................................. 28
Removing transmission actuator................................................................................................. 28
Removing the upper section from the lower section ................................................................... 29
Reattaching the upper section to the lower section .................................................................... 29
Installing the transmission actuator ............................................................................................ 30
Replacing pressure relief valve ................................................................................................... 32
Programming transmission actuator ........................................................................................... 33
Programming EPROMS flash with ZF test program ..................................................................... 34
Putting Transmission in Vertical Position (Output at Top) ......................................................... 35
Clutch Actuator ......................................................................................................................... 36
Removing clutch actuator........................................................................................................... 36
Setting of pushrod...................................................................................................................... 37
Bleeding and assembling clutch actuator ................................................................................... 38
Speed Sensor / KITAS ............................................................................................................... 40
Removing speed sensor and KITAS............................................................................................. 40
Installing speed sensor and KITAS .............................................................................................. 40
Connector replacement.............................................................................................................. 40
Replacing Neutral Switch ......................................................................................................... 41
Removing neutral switch ............................................................................................................ 41
Fitting neutral switch.................................................................................................................. 41
Range Change Group (R/C)....................................................................................................... 42
Removing range change group .................................................................................................. 42
Installing range change group .................................................................................................... 44
Output Flange .......................................................................................................................... 46
Removing output flange ............................................................................................................. 46
Fitting output flange .................................................................................................................. 46
1336 751 102 - 2011-04 3

ZF-AS Tronic mid Table of Contents
Output Cover............................................................................................................................. 47
Removing output cover ............................................................................................................. 47
Fitting output cover .................................................................................................................... 48
Range Change Group ............................................................................................................... 50
Dismantling range change group ............................................................................................... 50
Completing and installing range change group........................................................................... 54
Planet Carrier ............................................................................................................................ 58
Dismantling planet carrier .......................................................................................................... 60
Assembling planet carrier........................................................................................................... 64
Removing Reverse Idler Gear Bolt ............................................................................................ 67
Connection Plate ...................................................................................................................... 69
Removing connection plate ........................................................................................................ 71
Bearing setting on input shaft and countershaft ......................................................................... 73
Installing connection plate ......................................................................................................... 77
Clutch Housing ......................................................................................................................... 80
Removing clutch housing ........................................................................................................... 80
Installing clutch housing............................................................................................................. 82
Shaft Package ........................................................................................................................... 84
Removing shaft package ............................................................................................................ 84
Installing shaft package ............................................................................................................. 86
Input Shaft ............................................................................................................................... 87
Dismantling input shaft .............................................................................................................. 87
Assembling input shaft............................................................................................................... 88
Countershaft ............................................................................................................................ 91
Dismantling countershaft ........................................................................................................... 91
Assembling countershaft............................................................................................................ 92
Main shaft ................................................................................................................................ 94
Dismantling main shaft .............................................................................................................. 95
Assembling main shaft............................................................................................................... 97
Shift System ............................................................................................................................. 101
Dismantling shift system ............................................................................................................ 101
Assembling shift system............................................................................................................. 101
Clutch Housing ......................................................................................................................... 102
Dismantling clutch housing ........................................................................................................ 102
Assembling clutch housing ........................................................................................................ 103
Transmission Housing .............................................................................................................. 104
Dismantling transmission housing .............................................................................................. 104
Assembling transmission housing .............................................................................................. 105
Additional Cooling (Heat Exchanger) ........................................................................................ 106
Removing the additional cooling ............................................................................................... 106
Installing the additional cooling.................................................................................................. 107
1336 751 102 - 2011-04 4

ZF-AS Tronic mid Overview of Revisions: 1336 751 102
Index Date of issue Chapter Initiator Comment
a 2006-08 13.3 LKS-T - Put transmission in vertical position for assembly

Transmission brake
1 MC-C - Observe ZF Service Information
b 2010-01 MC-C - Tightening torque of clutch release mechanism has been

changed from 115 Nm to 95 Nm.
- Housing sealing: Loctite no. 574 replaced with flat seal.
- Completing and installing of range change group has
been redefined.
- Axial needle bearing at planet carrier replaced by plain
bearing segments.
- Secure sealing cover of breather by means of securing
ring.
- Additional cooling: “Version B” added.
c 2011-04 MC-C - Overview transmission family/types newly included.

LPE1-A - Reduction of the preload to 0.10 - 0.20 mm, for the input shaft:
0.25 - 0.35 mm and for the countershaft: 0.15 - 0.25 mm.
- Tightening torque of bolt (6) changed at the clutch actuator
from 22 Nm to 35 Nm.
- Planet carrier bolts changed over from loose fit to press fit.
1336 751 102 - 2011-04 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 advance- so to ensure the complete function of the ZF unit
ments of the product, repair work might require and minimize the scope of damage.
work 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
Commercial Vehicle and
Special Driveline Technology
D-88038 Friedrichshafen
Phone: +49 7541 77-0
Fax: +49 7541 77-908000
www.zf.com
2010-09 6
Safety Instructions
The following safety instructions are used in this ! DANGER to the health!
repair manual:
Ensure confident handling with supplies. Manu-
facturer’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
CAUTION
must not be allowed to enter the soil, ground
Is used when the instructions are not complied
water, or 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,
DANGER!
and cleaning agents in accordance with
Is used when lack of care could result in perso-
environmental protection regulations.
nal injury or danger to life.
• When working with lubricants and cleaning
agents always refer to the manufacturer’s
instructions.
Safety Instructions
CAUTION
The transmission must NOT be suspended by the
As a rule, repair technicians for ZF units are
input shaft OR by the output flange/add-on parts.
responsible for their own workplace safety.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal require-
ments which apply to repair and maintenance
Incorrect
work must be adhered to.
Before starting work, mechanics must therefore
familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF pro-

ducts must receive appropriate training in advance.
Correct
Compulsory training is the responsibility of the
repair staff.
! DANGER!
Do not walk under suspended load during parts
transportation with a hoist.
2010-09 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
Centers or from the ZF-ServiceLine. the passage is free.
Carefully cover opened transmissions to prevent
In any cases of doubt, always contact the rele- the entry of foreign matter.
vant 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
CAUTION specialist, who should decide whether they can
The pictures, drawings, and components shown be re-used or not.
do not always represent the original object, but Replace parts which are damaged or have suffered
are used to illustrate working practices. from excessive wear.
The pictures, drawings, and components are
not to scale and no conclusions must be drawn • Gaskets, locking plates
about size and weight (not even within a Parts which cannot be removed without being
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 per- gaskets/seals proceed as specified.
sonnel 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.
2010-09 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.
• Sealing c) Shaft sealing rings with steel and rubber sur-
If a sealant* is recommended for sealing, then rounds should be treated on the outer cir-
it is essential to adhere to the manufacturer’s cumference of the rubber surround as descri-
directions for use. A thin layer of sealing agent bed for shaft seal (b).
should be applied to the surfaces and coat
them evenly. Do not allow sealing agent to enter d) Duo shaft sealing rings have
oil ducts and bores. On oil-carrying ducts and two sealing lips. The dust
bores, wipe off the sealing agent on the surfa- protection sealing lip (X)
ces to be sealed near apertures to ensure that must face outwards. X
no sealing agent enters the oil feeds when the Fill the space between the
parts are pressed together. sealing lips up to 60% with
grease*.
• Retaining Agents
Retaining agents* may only be used where • Transmission Oil
specified by the parts list. After completing repairs, fill the transmission
When using retaining agents (e.g. Loctite) with transmission oil. For the procedure and
always comply with the manufacturer’s direc- approved oils, refer to the transmission opera-
tions for use. ting manual and the List of Lubricants TE-ML
During assembly, comply with all adjustment (refer to type plate). These are available from all
data, inspection data, and tightening torques. ZF Service Centers or on the Internet at
www.zf.com. After filling the transmission with
oil, tighten the screw plugs at the oil filling point
and the oil overflow to the specified torques.
* refer to consumable material
2010-09 9
Tightening Torques
Tightening torques for screws and nuts,

extract from ZFN 148
This standard applies to bolts according to Surface condition of screws/nuts:

DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as Heat-treated blackened finish and oiled or
well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, galvanized and oiled.
ISO 8676, and for nuts according to DIN 934 and
ISO 4032, ISO 8673. The bolts are tightened using a calibrated torque
wrench.
This standard contains data on tightening torques
for screws/bolts and nuts of strength categories NOTE
8.8, 10.9, and 12.9, as well as nuts of strength Differing tightening torques are listed separately in
categories 8, 10, and 12. the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw 8.8 10.9 12.9 Screw 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
2010-09 10
ZF-AS Tronic mid Overview Transmission Family/Types
Type plate
The following data should always be provided

when making inquiries or
in the case of repairs:
• Parts list [BoM] no. of the transmission
• Transmission type
• Serial no. of the transmission Legend
1 Transmission family
ZF FRIEDRICHSHAFEN AG 2 Transmission type
MADE IN FRANCE
3 Parts list [BoM] no.
1 AS Tronic mid 12 AS 1210 TO 2 4 Serial no.
PARTS LIST NO. MODEL SERIAL NO.
3 1336 036 001 002 010 4
5 Customer order/reference no.
CUSTOMER XXXX 6 Transmission ratio
5
SPEC. NO. 7 Speedometer ratio (impulses/revolutions)
TOTAL 6 10.37 - 0.81 SPEEDO XXXX 7
RATIO 8 Type of PTO (power take-off)
RATIO
P.T.O. N 8 XXX n= XXX 9 xn
ENGINE 9 PTO/Power take-off ratio
OIL CAPACIT OIL GRADE SEE
IN LITERS 10 7.8 LUBRIC. LIST TE-ML 02 11 10 Oil quantity
026814 11 List of Lubricants
Type plate (example)
Overview Transmission Family/Types

L
The ZF-AS Tronic mid transmission family is made up by two product
families:
• PF1 Short version L = 840 mm

• PF2 Long version L = 900 mm (standard)
L = 910 mm (with extended output flange) 034178
The repair instructions are valid for the following transmission types:
Transmission type Product family Oil quantity Oil grade according to Weight
(PF) in liters, approx. ZF List of Lubricants, in kg, approx.
TE-ML
12 AS 1010 TD
1 7.8 02 183 2001)
12 AS 1010 TO
12 AS 1210 TO 02
1 7.8 183 2001)
12 AS 1210 SO 13
12 AS 1220 TD 2 9.3 02 201 2201)
12 AS 1420 TD
2 9.3 02 201 2201)
12 AS 1420 TO
12 AS 1620 TO 02
2 9.3 13 201 2201)
12 AS 1620 SO
1) including transmission oil and clutch release mechanism, without PTO
1336_50D_030_en
1336 751 102 - 2011-04 11 2011-03
ZF-AS Tronic mid Consumables
Description Name Quantity Application Comment

ZF item no. approx.
Grease for example:

0750 199 019 RENOLIT CX-EP2 2 grams Shaft sealing ring 02.300/140
0.5 gram Shaft sealing ring 31.090
Grease Olista Longtime 3EP 3 grams Shaft sealing rings 68.100/140

0671 190 050 3 grams Bush 68.100/130
3 grams Contact surface of release fork 68.100
and release bearing 68.200
Sealing compound No. 574 Sealing face

Loctite company
0666 790 033 500 mm³ Sealing face of clutch housing /
transmission housing Pos. 01.410
Cover 31.080
R/C housing / Transmission housing Pos. 28.100
Jointing compound No. 262 90 mm³ Ball pin 06.080

0666 690 022 Loctite company
Transmission oil ZF ECOFLUID M Refer to Transmission oil fill

0750 198 017 according ZF List of type plate
Lubricants TE-ML 02
NOTE: Inquire as to size of containers before ordering!
1336_92D_010_en
1336 751 102 - 2011-04 12 2011-04
ZF-AS Tronic mid Setting Data
Description Dimension Measuring device Comment
Setting countershaft Preload Digital depth gage Move tapered roller bearing
0.10 to 0.20 mm into zero position (zero back-
lash) and measure. Adjust
preload by means of the
compensating disk 02.260.
Setting input shaft Preload Digital depth gage Move tapered roller bearing
0.10 to 0.20 mm to zero position (zero back-
lash) and measure. Adjust
preload by means of the
compensating disk 02.250.
Securing ring on input shaft Axial clearance Feeler gage Select suitable securing ring
0 to 0.10 mm 02.240.
Screw plug M24x1.5 10.100 / 60 Nm Torque wrench 10.100 on transm. housing

10.110 10.110 on clutch housing
Screw plug M10x1 31.030 / 15 Nm Torque wrench

31.040
M10 hex head screws 50 Nm Torque wrench R/C housing to transmission

Quality: 10.9 housing/ clutch housing to
transmission housing
M10 hex head screws 46 Nm Torque wrench Connection plate to

Quality: 10.9 clutch housing
Impulse sensor 31.150/31.200 45 Nm Torque wrench
Ball pin 06.080 23 Nm Torque wrench Insert using Loctite no. 262
Securing ring at main shaft, Axial clearance Feeler gage Select suitable securing ring
output-end 0 to 0.10 mm 02.150.
Securing ring at the main Axial clearance Feeler gage Select suitable securing ring
shaft, input-end 0 to 0.10 mm 02.350.
Screw plug M18x1.5 35 Nm Torque wrench

06.300 / 31.210
Switch 06.220 45 Nm Torque wrench Neutral switch
Cannon plug 74.130 18 Nm Torque wrench At transmission actuator
1336_92D_020_en
1336 751 102 - 2011-04 13 2011-04
ZF-AS Tronic mid Special Tools
Figure Depiction Order no. Application Quantity Comment

no.
1X56 137 795 Alternatively:

Order no.
1X56 137 391
1 3-strand chain
for lifting the transmission 1
commercially
available
1T66 160 650 “Putting trans-

mission in verti-
cal position”
2 Screw-on adapter and “Removing
M16x1.5 2 reverse idler gear
for lifting housing parts bolt” chapters
commercially
available
1X56 138 443 “Removing reverse

idler gear bolt”
chapter
3 Support
for vertical positioning of the 4 Alternatively:
transmission Stationary
assembly stand
(1P01 181 850)
“Range change
1X56 138 447 group” chapter
Hydraulic variant
4 Extractor for ball bearing with 11 balls upon request
Remove ball bearing 31.070 from 1 ———————————-
For bearing
planet carrier.
with 10 balls,
use extractor
Note: Extractor is not suitable for impact 1X56 122 256
wrench use.
1X56 122 304 Chapters

“Countershaft”
and “Main shaft”
5 Basic device
in conjunction with tool 1
1X56 138 601 and/or 1X56 138 597
Note: Basic device is not suitable for impact

wrench use.
NOTE: Please inquire as to packaging unit before ordering.
1336_91D_030_en
1336 751 102 - 2011-04 14 2010-01

no.
1X56 138 444 “Shaft package”

chapter
Fixture
6
for main shaft and countershaft 1

chapter
7 Fixture
Insert shaft package into transmission 1
housing
1X56 138 207 “Range change

group” chapter
8 U-bolt
R/C synchronizer assembly 6

chapter
9 Retaining bolt
Fix reverse idler gear 05.010 in the 1
transmission housing
Chapter
1X56 138 449 “Main shaft”
(optional) in conjunction
10 with
Thrust piece 1 1X56 122 304
Shaft protection for removing tapered and
1X56 138 597
roller bearing on main shaft
1336_91D_030_en
1336 751 102 - 2011-04 15 2010-01

no.
Version A Version B
1X56 138 095 “Transmission
actuator” chapter
11 Setting fixture Only version B is

for selector rails 1 still available
1X56 138 215 “Clutch release

mechanism”
chapter
12 Adapter (version A)
for assembly of bushes and 2
shaft sealing rings of release fork
1P01 181 850 Alternatively:

4 supports
(optional) 1X56 138 443
13
Assembly stand (stationary) 1
1X56 138 621 Clamping plate

1X56 138 621 is
(optional) fitted to
14 assembly stand
Clamping plate 1 1P01 181 850
for AS Tronic mid
1X56 138 063 “Removing

reverse idler gear
bolt” and “clutch
15 Extractor housing” chapters
for pushing dowel pins out of trans- 1
mission housing
1336_91D_030_en
1336 751 102 - 2011-04 16 2010-01

no.
1X56 138 065 “Connection

plate” chapter
16 Protective sleeve Assembly aid

Place on input shaft 1
when fitting connection plate
1X56 138 445 “Input shaft”

chapter
17 Extracting fixture consists of

for removal of input shaft 1 split ring and
bush

reverse idler gear
Bolt” chapter
18 Retaining fixture
for oil pipe 10.060 in the transmission 1
housing
1X56 138 543 “Planet carrier”

chapter
19 Clamping fixture
Preload disk spring 32.026 at planet 2
carrier

group” chapter
20 Heating mandrel
for ball bearing at R/C 1
1336_91D_030_en
1336 751 102 - 2011-04 17 2010-01

no.

chapter
21 Assembly tool
for centering oil pipe 10.060 1

chapter
22 Assembly tool
for centering oil pipe 10.030 1

plate” chapter
23 Adapter
for shaft sealing ring 55x70x10 1
pipe, connection plate

plate” chapter
24 Assembly fixture
Press in pipe, 1
measure connection plate

chapter
25 Adapter
for fitting baffle plate 02.010/160 in 1
input shaft
1336_91D_030_en
1336 751 102 - 2011-04 18 2010-01

no.

plate” chapter
26 Pressure plate
for fitting pipe in connection plate 1

chapter
27 Bolt
for centering and fitting of needle 1
rollers in planetary gears
Length: 37 mm

chapter
28 Bolt
for centering and fitting of needle 1
rollers in planetary gears
Length: 51 mm

reverse idler gear
bolt” chapter
Solenoid
29
for removing reverse shaft idler gear 1
bolt 05.050
1X56 138 463 “Clutch housing”

chapter
30 Adapter
for input shaft bearing shell 1
in clutch housing
1336_91D_030_en
1336 751 102 - 2011-04 19 2010-01

no.

housing” chapter
31 Adapter
for PTO bearing shell 1
in transmission housing
1X56 138 465 “Clutch housing”

and “Transmission
housing” chapters
32 Adapter
for countershaft bearing shell 1
in clutch housing and transmission
housing

housing” chapter
33 Adapter
for main shaft bearing shell 1
at output-end in transmission housing
1X56 138 601 “Countershaft”

chapter
34 Gripper
for extracting the tapered roller 1
bearing from the countershaft
1X56 137 124 “Output cover”

chapter
35 Adapter
for fitting shaft sealing ring 31.090 to 1
the output cover (in conjunction with
spacer ring 1X56 138 189)
1336_91D_030_en
1336 751 102 - 2011-04 20 2010-01

no.
1X56 138 189 “Output cover”

chapter
36 Spacer ring
for shaft sealing ring 105x125x12 1
at output cover (in conjunction
with adapter 1X56 137 124)
1X56 138 487 “Countershaft”

and “Range
change group”
37 Adapter (optional) chapters
Use: 1
- Fitting tapered roller bearing Assembly aid
of input shaft
- As pressure pad for planet carrier

chapter
38 Adapter Assembly aid

for fitting tapered roller bearing 1
02.230

chapter
39 Gripper
for extracting tapered roller bearing 1
04.340

chapter

For fitting tapered roller bearing 1
04.340
1336_91D_030_en
1336 751 102 - 2011-04 21 2010-01

no.

chapter

for bush 04.100 and 1
tapered roller bearing 04.140

chapter

for fitting of bush04.260 1
240
actuator” chapter
M10
64
75
11
60.5
M10
112
74
Setting aid 1
15
43 100.1 ø9H7 ø9H7

Assembly aid
200.1 14
2120.1 for piston rods on
ø8.70.1
transmission actuator
ø9r6
25
2x45 2x45
37.50.1
40

group” chapter
Lifting device
44
for planet carrier 1

group” chapter
45 Pull-on fixture 1 Assembly aid

for bearing at output
1336_91D_030_en
1336 751 102 - 2011-04 22 2010-01
ZF-AS Tronic mid Diagnosis Tool

no.
6008 208 503 only for

ZF-Testman pro complete ZF Sales
and Service
Organizations
Scope of supply:
1
- 6008 208 100 ZF-Testman pro with DPA05
1
- 6008 208 015 Application CD
- 6008 208 016 License
- 6008 207 025 Adapter
- 6008 208 009 Diagnosis software
only for
6008 208 501 ZF Sales
and Service
Diagnosis software ZF-Testman pro Organizations
2
Scope of supply: 1
- 6008 208 011 Diagnosis software
- 6008 208 015 Application CD
- 6008 208 016 License
following agree-
6008 208 003 ment with
ZF Friedrichs-
ZF-Testman pro for ZF customers hafen AG
3
Scope of supply: 1
- 6008 208 100 Diagnosis tool (complete)
- 6008 208 900 Testman pro
software for user interface
(CD basic installation)
Application software for Single user

license
ZF-AS Tronic mid
4
upon prior consultation with ZF 1
Adapter cable for

6008 207 003 programming and
configuration
purposes and for
5 AS Tronic table mode adapter diagnosis outside
1 the vehicle.
1336_91D_040_en
1336 751 102 - 2011-04 23 2010-01
ZF-AS Tronic mid Preparatory Work
Preparatory Work
CAUTION
After each repair, the transmission must be tested
for function and leakage on a test bench.
General
• Transmission sectional drawing 1336 005 013 is
used as the basis of this Repair Manual.
• This Repair Manual describes the complete
dismantling and (re-)assembly of the ZF-
AS Tronic mid model range; in addition, also
observe ZF Service Information.
026737
1 For lifting or transporting, hook 3-strand

chain 1X56 137 795 into 3 eyes on the trans-
mission.
2 Make oil collector available.
3 Remove oil drain plug and drain oil.
NOTE
For specialized workshops we recommend
using the stationary assembly stand*
1P01 181 850 in conjunction with the
clamping plate* 1X56 138 621.
For further information, please refer to
ZF Friedrichshafen AG, MKS-IP dept.
(Customer Service/After Sales).
* option
1336_50D_010_en
1336 751 102 - 2011-04 24 2010-01
ZF-AS Tronic mid Clutch Release Mechanism
Clutch Release Mechanism
Removing the release fork
1 Remove 2 M12 hex head screws 68.160 and

68.170 take off from the release shaft 68.150.
2 Take release bearing 68.200 and release fork

68.100 off the input shaft.
68.200 68.160 68.100 68.170

026831
3 Take pushrod 68.050 out of release fork

68.100.
4 Push release shaft 68.150 out of the release

fork 68.100. 68.100
CAUTION 68.150
Do not wash the release fork 68.100 and the
68.170
release bearing 68.200.
68.160 68.050
026966
5 Dismantle the release fork 68.100. 68.100

Remove the bearing bush /130 by means of a
suitable tool.
Drive out the cam rollers /150 and /160 from /150
/160
the release fork 68.100 e.g. by means of pus-
hing them through.
Replace ball race /120 if they are damaged or /130 /110
worn.
/120
68.200
028231_1
1336_68D_032_en
1336 751 102 - 2011-04 25 2010-01
1X56 138 546
1X56 138 547
/110 /130
028244
Mounting the release fork
CAUTION NOTE
Always press in the bearing bush /130 first, then Press in the bearing bush - rim facing the
the cam rollers /150 and /160. press-in mandrel.
1 Assemble the release fork 68.060. Use the press-in mandrel 1X56 138 546 for
While doing that, use the assembly fixture pressing in the bearing bush /130 until firmly
1X56 138 547 as a support. home in the release fork /110 so that the
bush’s rim fully engages in the groove of the
release fork.
2 Use the press-in mandrel 1X56 138 546 in

order to press in the cam rollers /150 and
/160 until firmly home in the release fork
/110.
1336_68D_042_en
1336 751 102 - 2011-04 26 2011-04
CAUTION
Do not grease the following parts: 68.200
- Cam rollers /150 and /160
- Sliding seat “Release bearing ‒ release flange”
- Release shaft 68.150
- Bearing bush /130 (greased ex works)
NOTE
Within the context of maintenance works, the
existing lubrication of the release shaft 68.150 is to
be checked and, if necessary, to be lightly greased. 68.150
68.100
028239_1
3 If necessary, press in ball cup /120 and

grease with OLISTA LONGTIME 3EP 68.100
(ZF no. 0671 190 050).
68.150
4 Slide release shaft 68.150 into release fork
/150
68.100. /160
68.160
68.170
NOTE
The release shaft in the bearing bush has play. /130 /110
68.050
5 Grease the front end of the cams of the
release bearing with OLISTA LONGTIME 3EP
(ZF no. 0671 190 050). /120
68.200
6 Position release bearing 68.200 on release
flange (guide tube). 028233_1
Sliding seat face of release bearing –

release flange must not be greased.
7 Engage release fork 68.100 with release

bearing 68.200. Ensure correct fit of pushrod
68.050.
8 Mount release shaft 68.150 with 2 M12 hex

head screws 68.160; 68.170 to the clutch
housing.
Tightening torque: 95 Nm
68.200 68.160 68.100 68.170
026831
1336_68D_042_en
1336 751 102 - 2011-04 27 2011-04
ZF-AS Tronic mid Transmission Actuator
Transmission Actuator
74.140*
74.130* 74.120* 74.030 74.070
Removing transmission actuator
74.090
1 Detach breather 74.120 and/or angle piece

74.140 and cannon plug 74.130 at trans-
mission actuator 74.030 if these parts are
being replaced.
2 Remove 15 M8 hex head screws 74.090 and

74.070 from the transmission actuator
74.050
74.030.
74.010
CAUTION
74.050
The rubber seals /170 may fall into the trans- 12.090
mission housing. 12.080
06.050
3 Remove transmission actuator 74.030 from 06.040
34.140
transmission housing and ensure that you
34.130
take note of dimensions “a” and “b” for
subsequent installation. 06.080
4 Remove the compression springs 06.050 / Loctite
34.140 / 12.090 and detent pins 06.040 /

262
34.130 / 12.080. Replace the two cylindrical

pins 74.050 if they are damaged.
5 Remove seal 74.010 and clean sealing faces

on transmission housing and transmission
actuator. * depending on parts list 024324
NOTE
A transmission actuator kit is available.
It consists of the transmission actuator
74.030, seal 74.010 and breather 74.120.
/170
6 Remove ball pin 06.080 if damaged or if the
clutch bell housing is removed in the further
course of action.
b
a
018774
1336_74D_011_en
1336 751 102 - 2011-04 28 2010-01
Removing the upper section from the lower

section 6009 274 069
NOTE 09 03 43872
Seal kit 0501 319 863 contains both screws /150- 4213 550 110
1, the flat seal /150-2, and the profile seal /150-3.
024361
CAUTION
1
Note down the data on the type plate. You will /150-1
need them for ordering spare parts and for cor-
respondence.
/110
1 Remove both screws /150-1.
2 Raise upper section /110 at the pressure

relief valve /180 and use both tabs (1) to
74.030
carefully move it sideways into the /180
grooves* (2).
Disconnect plug connections (7, 8).
/150-2
3 Remove seals /150-3 and /170. 2
4 Remove seal /150-2 and clean sealing /150-3

faces.
/130
* not possible with the 18-pin variant
Reattaching the upper section to the lower /170

section
019352
1 Insert seal /150-3.
2 Place seal /150-2 on the lower section

/130.
3 Re-connect plug connections (7 and 8).

Again check fit of plug connection. 8
7
4 Place upper section /110 on lower section
/130.
Ensure that the seal /150-2 does not slip, fix
if necessary. Tighten the two screws /150-1
to 9.5 Nm.
5 Insert seal /170.

018205
1336_74D_050_en
1336 751 102 - 2011-04 29 2010-01
Installing the transmission actuator
1 Move piston rod (4) at transmission actuator

into central position (Neutral). The correct /170
position is reached when slight resistance can
be felt when pulling piston rod (4) out.
2 Copy dimensions “a” and “b” from removed

transmission actuator to the piston rods
b
a
(3 and 5).
3 Selector gate (6) and piston rod (4) must be

one above the other (flush). Ensure that the
rubber seals /170 have been inserted at the
transmission actuator.
018774
/170
NOTE 5 4 3
Piston rod (3) = shifts the splitter group (S/G)
Piston rod (4) = shifts the basic transmission
Piston rod (5) = shifts the range-change group
(R/C)
Selector gate (6) = selects the shift gate
017908
Alternatively: If dimensions “a” and “b” can no
longer be determined, the transmission actuator
can be fitted using setting aid (34) 1X56 138 244.
In-house production according to sketch; refer to 34
Special Tools. On request, tool 1X56 138 244 can
also be supplied by ZF.
Adjust the transmission actuator’s piston rods (3, 4,
and 5) so that they are in contact with the setting
aid (34). Engage S/G and R/C selector rails in the
transmission
in output direction. Move the central selector rail to
Neutral. Selector gate (6) and piston rod (4) must
be one above the other (flush). Ensure that the
rubber seals /170 have been inserted at the trans-
mission actuator.
017907
1336_74D_021_en
1336 751 102 - 2011-04 30 2010-01
4 If the ball pin is being replaced, coat the thread

74.140*
of the ball pin 06.080 with Loctite no. 262.
74.130* 74.120* 74.030 74.070
Tighten ball pin to 23 Nm.
74.090
5 Place new seal 74.010 on the transmission

housing.
6 Insert detent pins 06.040, 34.130 and 12.080

and compression springs 06.050, 34.140 and
12.090.
74.050
NOTE
The compression springs 06.050, 34.140 and
74.010
12.090 must be of the same length (approx. 74.050
50 mm). If there are deviations, replace com- 12.090
pression springs. 12.080
06.050
06.040
7 Attach transmission actuator 74.030,
34.140
ensuring that the piston rods of transmission 34.130
actuator engage with transmission’s selector
rails. The vertically positioned ball pin 06.080 06.080
engages with the selector gate.
Loctite
262
8 Tighten M8 hex head screws 74.090 and
74.070 to 23 Nm.
9 Depending on parts list:

Tighten cannon plug 74.130 to 18 Nm and * depending on parts list 024324
secure angle piece 74.140 and/or tighten

breather 74.120 to 10 Nm.
CAUTION
If the transmission actuator is replaced, the
following should be noted:
• Reprogram the transmission actuator!
• Copy vehicle parameters of removed trans-
mission actuator or reenter them.
10 Connect airline to transmission actuator’s

pressure relief valve.
Tightening torque: 34 Nm
11 Re-connect cable harness at transmission and

vehicle end, otherwise functional test cannot
be performed.
NOTE
Connectors must be fitted so that they are
strain-relieved. Check lock-in position.
1336_74D_021_en
1336 751 102 - 2011-04 31 2010-01
Replacing pressure relief valve
NOTE
Mark the installation position of the pressure relief
valve /180 for subsequent fitting.
1 Remove 4 nuts (10) and take off the pressure

relief valve /180 and the O-ring (12).
10
10
/180
024327
CAUTION
Do not use grease to fit O-ring (12).
2 Insert new O-ring (12), and fit pressure relief

valve /180 to the transmission actuator
74.030 using 4 nuts. Tighten 4 nuts (10) to
7 Nm.
/180 12 74.030
019252
1336_74D_031_en
1336 751 102 - 2011-04 32 2010-01
Programming transmission actuator
21
Illustration of transmission actuator programming
Pos.
20 Table mode adapter
20.1 Power supply connection
20
21 Cable to DPA
22 DPA 22
23 Cable to Laptop or PC respectively
When replacing the transmission actuator and/or

upper section, customer specific programming
and/or parameter setting (entering EOL data) will 20.1 23
be required.
During parameter setting, the EOL data are entered 028537
in the transmission actuator’s electronics using

ZF-Testman pro and the corresponding software.
CAUTION
In the case of a newly programmed transmission
actuator, the vehicle parameters from the
removed transmission actuator are to be copied
or reentered.
Final check:
Has the transmission actuator been reprogrammed?
Refit vehicle-specific parts as far as possible. The

diagnosis unit can only be used to test the trans-
mission actuator once the engine is running and if
a sufficient air reserve is made available. Then, the
system carries out a number of calibration processes.
This may take up to 5 minutes. Afterwards, the
following faults might for example be indicated:
piston rod not connected, fault 132, 134 etc., or
teaching faultof sensors in gear, gate, R/G, S/G,
when ignition is on.
1336_74D_041_en
1336 751 102 - 2011-04 33 2010-01
Programming EPROMS flash with ZF test

program
Required equipment: Test description:

• Laptop with latest Testman pro software • Connect air supply, at least 7 bar, to the pressure
• Test software: GS_test_07_2005_gb.exe reducing valve at the transmission actuator.
(download from ServiceLine)
• Testman pro application: • Connect table mode adapter to the transmission
(download from ServiceLine) actuator (vehicle-end) and connect 24 V voltage
• Table mode adapter cable: supply and DPA05 with laptop via connecting
– ZF no. 6008 207 003 cables.
DPA05 interface adapter:
– ZF no. 6008 208 017 • Start Testman pro
USB connection cable: Select main menu/AS Tronic/assembly test AS2.
– ZF no. 6008 207 026
Diagnosis interface cable: NOTE
– ZF no. 6008 207 024 This test must not be performed in the vehicle with
24 V voltage supply the engine running!
• Select test bench functional run.

Process:
• Download installation routine • Shift through the different ranges by the
GS_test_07_2005.zip from ZF-ServiceLine, unzip numerical key function 1 - 0 on the laptop
by using following password: astronic keyboard or using the mouse:
1 = upshift gears 1 - 12
• Start installation routine: Double-click file: 2 = downshift gears 12 - 1
GS_test_07_2005.exe 3 = Neutral
4 = 1st R gear
• Download Mont_as2.app application from Service- 5 = 2nd R gear
Line, save it, unzipby using following password:
testman • Menu item 6, dynamic transmission actuator,
shows the latest sensor positions.
• Extract Mont_as2.app file under the following
path: C:\Gds3000\apps • Menu item 9 shows the currently engaged gear.
• Start Testman pro, NOTE

possibly copy customer-specific data in the The test software shifts the gears 1 - 12 and the
transmission actuator (e.g. iHa; Intarder etc.) and reverse gears.
subsequently program test program Testman pro /
flash programming / loading parts list.
Open GS_test_07_2005.txt file and program Output check:
(processor 1, 2 and E2 data are programmed and • After functional/leakage test, correct software
previously set drive program is deleted). must be programmed according to vehicle appli-
cation, engine/transmission/software correlation
(source: ServiceLine)
1336_74D_012_en
1336 751 102 - 2011-04 34 2010-01
ZF-AS Tronic mid Putting Transmission in Vertical Position
Putting Transmission in Vertical Position
1 Place two squared timbers on firm, level

ground.
1T66 160 650
CAUTION
Do not use eye on R/C housing to lift transmission!
The eye is too weak for overall transmission
weight: “Risk of housing fracture”.
2 Attach two lifting lugs M16x1.5 1T66 160 650

to transmission housing. Hook in chain and lift
transmission by means of a crane.
026717
3 Place transmission with the clutch bell

housing on the squared timbers.
CAUTION
Do not position transmission on input shaft.
026718_1
1336_50D_020_en
1336 751 102 - 2011-04 35 2010-01
ZF-AS Tronic mid Clutch Actuator
68.320
68.300
68.240
68.310
68.034
68.030 6
68.034
68.010
68.330* 68.030
68.020
68.024
68.050*
68.024
/120 68.020
/130
/110
68.050*
Variant
* depending on parts list
031727
Clutch Actuator
Removing clutch actuator
1 Disconnect plug connection (7) from trans- 5 Take pushrod 68.050 out of release fork
mission actuator and (8) from output speed 68.100.
sensor.
NOTE
2 Detach wiring harness from cable clamps For removal and fitting of release fork, refer
68.300, 68.310, 68.320 and 68.330. to “Clutch Release Mechanism” chapter.
Bleed clutch actuator by unscrewing screw
(6).
3 Loosen M8 screw connection (68.020,

68.024, 68.030 and 68.034).
Remove hex head nuts and washers first
before taking off clutch actuator 68.010 and
hex head screws.
4 Remove protection cap 68.240.
1336_68D_011_en
1336 751 102 - 2011-04 36 2011-04
6
68.050
68.010
68.100 B C
024433
Setting of pushrod
The old pushrod dimension is kept if the clutch 2 Calculate dimension “C”:
actuator is the only part that is replaced.
Dimension “B” + 33 mm = dimension “C”
If the driver disk or pressure plate is replaced, the
pushrod 68.050 must be reset. Example:
Dimension “B” = 57 mm
CAUTION 57 mm + 33 mm = 90 mm (dimension “C”)
In vehicles with an AS Tronic transmission,
the release travel is set instead of the wear
dimension (as is usually the case). If not set 3 Set dimension “C”:
correctly, the pressure plate will be damaged.
Insert pushrod 68.050 in clutch actuator
68.010. Loosen screw (6) on clutch actuator
1 Dimension “B” 68.010 until cylinder moves out.
Measure dimension “C” between the ball
Press release fork 68.100 forward and head of pushrod and contact surface of clutch
measure dimension “B”. actuator.
Set pushrod accordingly until dimension “C”
is reached.
1336_68D_016_en
1336 751 102 - 2011-04 37 2010-01
Bleeding and assembling clutch actuator
1 Loosen screw (6) M12x1.5.

If sealing ring is worn at screw,
replace sealing ring.
018475
2 Push piston back.
018476
3 Hold piston pushed down and tighten

screw (6).
018477
1336_68D_020_en
1336 751 102 - 2011-04 38 2011-04
68.320
68.300
68.240
68.310
68.034
68.030 6
68.034
68.010
68.330* 68.030
68.020
68.024
68.050*
68.024
/120 68.020
/130
/110
68.050*
Variant * depending on parts list
031727
4 Place pushrod 68.050 in the socket of the 7 Insert the protection cap 68.240 in the
release fork. transmission housing.
5 Assemble the clutch actuator 68.010 in CAUTION

accordance with the instructions. In the Do not bend cable or put under tensile load.
process, ensure correct positioning of Avoid chafing points.
connections. Fit connectors with traction relief and check
Plug in 4 combination screws to the clutch detent.
actuator and tighten the 4 hexagon nuts with
shim to 23 Nm. 8 Replace cable clamps 68.300, 68.310,
68.320, and 68.330 if damaged.
NOTE
The positions 68.020, 68.024, 68.030, and 9 Press wiring harness into cable clips.
68.034 are made respectively up by one:
- combination screw 10 Connect the 18 or 20-pin connector (7) to
- shim the transmission actuator and then attach the
- hexagon nut connector (8) to the output speed sensor.
6 Loosen the screw (6) and wait until piston 11 Connect compressed air line to clutch
has extended. In doing so, ensure that the actuator 68.010.
pushrod 68.050 is seated correctly in the
release fork and the clutch actuator.
Tighten screw (6) to 35 Nm.
1336_68D_020_en
1336 751 102 - 2011-04 39 2011-04
ZF-AS Tronic mid Speed Sensor / Kitas
Speed Sensor / Kitas

31.150
31.200
Output speed sensor (impulse sensor) depending
on vehicle manufacturer.
CAUTION
When Kitas sensor 31.200 is replaced, the new
sensor must be parameterized (or taught in),
otherwise, the speedometer function will no
longer be available.
Removing speed sensor and Kitas
1 Unplug connector.
026809
2 Remove impulse sensor 31.150.
3 Remove Kitas 31.200.
Fitting speed sensor and Kitas
CAUTION
• Connector must be fitted so that it is strain-
relieved. Connector must snap in.
• Impulse sensor may be mixed up.
Always check ZF number.
Impulse sensor for operating voltage

Hall 31.150 0501 210 855 ZF 6.5 - 30 V
Kitas 31.200 0501 214 768 Vehicle-end 6.5 - 9 V
NOTE
The Kitas is the longer of the two sensors.
1 Screw in impulse sensor 31.150.

Screw in Kitas 31.200.
(Setting is not required)
Tightening torque: always 45 Nm
2 Make sure that the connector snaps in during

assembly.
Connector replacement
If a connector has to be replaced, please use the
AMP standard tool (for wiring diagram, refer to
parts list).
1336_31D_011_en
1336 751 102 - 2011-04 40 2010-01
ZF-AS Tronic mid Neutral Switch
Replacing neutral switch*

06.200* 06.220*
Removing neutral switch
06.210
Depending on parts list version:
1 Remove neutral switch 06.220 with sealing

ring or screw plug 06.200.
2 Take out pin 06.210.
* depending on parts list
027404
Fitting neutral switch
Depending on parts list version:
1 Insert pin 06.210 .
2 Slightly grease neutral switch tappet.

Screw in neutral switch 06.220 with sealing
ring and tighten to 45 Nm
or screw in screw plug 06.200 and tighten to
35 Nm.
* Option (refer to parts list)
1336_06D_011_en
1336 751 102 - 2011-04 41 2010-01
ZF-AS Tronic mid Range Change Group
Range Change Group (R/C)*
Removing range change group
NOTE
- The transmission actuator must be removed
beforehand (refer to “Removing transmission
actuator” chapter).
- Neutral switch with pin must have been removed
already.
- Transmission is in vertical position with the output
at the top (refer to “Putting Transmission in Vertical
Position” chapter).
1 Drive out 2 cylindrical pins 31.050 and

31.060 – with drawing thread M12 – using 024762
tool 1X56 138 063.
2 Remove 19 hex head screws, from 28.120 to

28.300.
3 Fix 2 lifting eyes on output flange and/or pla-

net carrier and hook in chain.
024763
4 Carefully lift complete R/C housing by means

of a crane. Hold selector rail 34.010 during
the process.
CAUTION
Selector rail 34.010 is put loosely on the gearshift
fork, it may fall down if not held. 34.010
5 Take selector rail 34.010 out of gearshift fork.
* R/C = planetary group
024764
1336_31D_020_en
1336 751 102 - 2011-04 42 2010-01
6 Remove pressure disk 04.160.
7 Remove and clean solenoid 28.110.

04.160
28.110
024765
1336_31D_020_en
1336 751 102 - 2011-04 43 2010-01
Installing range change group
CAUTION
04.160 10.060
If a transmission housing* of the 1st generation
(e.g. 1336 301 037 or 1336 301 038) is installed,
it must be sealed with Loctite no. 574.
If a transmission housing* of the 2nd generation
flat seal 28.100 must be used.
1 Clean the sealing faces on the R/C housing

31.010 and transmission housing 01.400.
28.110
NOTE
The sealing faces on the R/C housing and
transmission housing must be free from oil 024766
and grease.
Sealing for Sealing for
2 Depending on the transmission housing transmission housing of the transmission housing of the
1st generation 2nd generation
generation:
Fit flat seal 28.100 or apply Loctite no. 574 to
sealing faces (surface sealing) of R/C housing
31.010 and transmission housing 01.400.
3 Fit thrust disk 04.160 (small offset facing

downwards); insert solenoid 28.110 into the
transmission housing basket.
Loctite
574
4 Fix 2 lifting eyes on output flange and/or

planet carrier and hook in chain.
28.100
5 Lift R/C housing using a crane and insert
032420
selector rail 34.010 into gearshift fork.
CAUTION
Selector rail 34.010 is put loosely on the gearshift
fork, it may fall down.
6 Screw two dowel pins (1) into transmission 31.010

housing 01.400 as assembly aid. Insert tool
1X56 138 467 into the R/C housing and use it 1X56 138 467
34.010
to center injection tube 10.060.
01.400 1 10.060
1
7 Use the crane to carefully lower the pre-
assembled R/C housing, insert selector rail
34.010 into the transmission housing.
* also refer to “Transmission Housing” Chapter 024767
1336_31D_030_en
1336 751 102 - 2011-04 44 2010-01
8 Carefully place R/C housing 31.010 onto the

transmission housing 01.400.
9 Remove tool 1X56 138 467 and the two

dowel pins (1).
10 Unhook chain and remove the lifting eyes

from the output flange and/or planet carrier.
024768
11 Carefully drive in 2 cylindrical pins 31.050 and

31.060 with M12 extractor thread pointing
towards output flange.
CAUTION
If the cylindrical pins 31.050 and 31.060 are not
driven in correctly, the housing can break.
12 Screw in 19 hex head screws 28.120 through

28.300 and tighten to 50 Nm.
024762
1336_31D_030_en
1336 751 102 - 2011-04 45 2010-01
ZF-AS Tronic mid Output Flange
Output Flange
Removing output flange
1 Remove 2 hex head screws 32.230 and

32.240 and take off washer 32.220. 32.230
32.210 32.220
/010
2 Use commercially available hydraulic extractor
to remove output flange 32.510.
/040* 32.240
NOTE
When removing, use spacer to protect the
shaft.
024769
32.210/040*
Fitting output flange
1 If a new protective plate* 32.210/040 is

installed, press it onto the output flange
until firmly home. Use suitable tool to caulk
protective plate* (4x90°).
! DANGER 32.210/010
Only touch hot output flange when wearing
protective gloves.
2 Heat output flange 32.210 to max. 160 °C

024770
and slide onto planet carrier until firmly home
(axial abutment).
3 Secure washer 32.220 with 2 M12 hex head

screws 32.230 and 32.240.
Tightening torque: M12 = 79 Nm
* depending on parts list version
1336_32D_011_en
1336 751 102 - 2011-04 46 2010-01
ZF-AS Tronic mid Output Cover
Output Cover
31.100 31.136
31.132
Removing output cover
31.104
1 Unscrew 10 M10 hex head screws 31.100 / 31.108 31.030
31.104 / 31.108 / 31.112 / 31.116 / 31.120 / 31.278
31.282
31.124 / 31.128 / 31.132 / 31.136. Remove
31.270
output cover 31.080 and possibly flat seal 31.274
31.082. 31.112
31.116
31.128
31.120 31.124
026689
2 Use a suitable tool to remove shaft sealing

ring 31.090; make sure you do not damage
31.090
output cover. 31.108 31.104
31.128
31.100
31.124
31.136
31.132
31.120
31.112
31.116
31.082 31.080
032415
3 Unscrew 4 M12 hex head screws 31.270 /

31.274 / 31.278 / 31.282. 31.282
31.278
Remove cover 31.260 and seal 31.250. 31.260
31.040 31.250
4 Remove 2 M10x1 screw plugs 31.030 and 31.274
31.030 31.270
31.040 if needed.
31.010
032416
1336_31D_040_en
1336 751 102 - 2011-04 47 2010-01
ZF-AS Tronic Output Cover
Fitting output cover
1 Coat the outer circumference of shaft sealing 1X56 137 124

ring 31.090 with Vaseline 8420 and, using
mounting adapter 1X56 137 124, press it
into output cover 31.080 together with ring
1X56 138 189 until firmly home (axial abut-
ment). Slightly grease sealing lip. 1X56 138 189
31.090
31.080
026716
CAUTION
To determine whether a flat seal or Loctite no. 574
is used for sealing, measure dimension “X” (from
the sealing face to the bearing seat).
Output cover 31.082 is fitted with flat seal, if
X
dimension “X” is 4.6 +0.05.

If dimension “X” is 5.0 +0.05 mm Loctite no. 574
must be used.
NOTE
Sealing faces must be clean and free from oil and
grease.
Assembly aid
Screw 2 studs into R/C housing. 032419
2 Depending on output cover: Fit flat seal

31.082 or apply Loctite no. 574 on sealing
face of output cover 31.080.
31.090
31.108 31.104
3 Fit output cover 31.080 in such a way that 31.128
31.100
KITAS and speedometer output is at the top. 31.124
31.136
31.132
4 Tighten 10 M10 hex head screws 31.100 / 31.120
31.104 / 31.108 / 31.112 / 31.116 / 31.120 / 31.112
31.124 / 31.128 / 31.132 / 31.136 to 46 Nm. 31.116
31.082 31.080
032415
1336_31D_050_en
1336 751 102 - 2011-04 48 2010-01
ZF-AS Tronic Output Cover
5 Clean sealing face at R/C housing 31.010 and

cover 31.260. 31.282
31.278
31.260
NOTE
31.040 31.250
Mount cover 31.260 and screw plug 31.030 31.274
only once R/C housing has been fitted. For 31.030 31.270
centering the injection tube ‒ when fitting R/C
housing ‒ tool 1X56 138 467 is inserted
through the hole of the screw plug plug
31.030 (also refer to “Fitting range-change
group” chapter).
6 Fit new seal 31.250 and cover 31.260.

31.010
7 Tighten 4 M12 hex head screws 31.270 /
31.274 / 31.278 / 31.282 to 79 Nm. 032416
8 Tighten M10x1 hex head screws 31.030 /

31.040 to 15 Nm.
1336_31D_050_en
1336 751 102 - 2011-04 49 2010-01
Range Change Group
NOTE
Output flange, output cover, and impulse sensor are described in individual chapters.
31.070
34.060
34.020 34.040 34.044
28.100
31.010
31.050
34.030 34.034
31.360
31.350
31.370
33.034 33.100
33.030
33.060 33.074
33.064
33.080
33.070
04.160 28.110 33.050
33.084
33.054
33.090 33.110
33.040
33.044
026691_1
Fig. Range Change Group
1336_31D_060_en
1336 751 102 - 2011-04 50 2010-01
Dismantling range change group
1 Use extractor 1X56 138 447 to extract ball

bearing 31.070 including R/C housing from
planet carrier.
1X56 138 447
026692
2 Remove extractor 1X56 138 447 and turn R/C 34.044 33.090
housing.
3 Push sliding sleeve 33.110 and synchronizer

ring 33.090 down (in neutral position).
! DANGER
Bushes and compression springs may jump out
when pushing them down.
33.110
026693
4 Put a squared timber on the R/C housing

31.010. It serves as a dolly or counter-support 34.040 31.010
for the pry bar.
5 Use a pry bar to lever the bearing blocks

34.040 and 34.044 out of the R/C housing.
026694
1336_31D_060_en
1336 751 102 - 2011-04 51 2010-01
6 Drive sliding pads 34.030 / 34.034 out of

sliding sleeve 33.110.
Take off gearshift fork 34.020 and mounts
34.040 and 34.044.
026695
34.040 34.044
7 Take sliding pads 34.030 / 34.034 out of
gearshift fork 34.020.
34.020
34.030 34.034
026696
8 Take plate 31.350 and clutch body 31.360 out

of R/C housing.
Unsnap securing ring 31.370 between plate 31.350
31.350 and clutch body 31.360 and remove it.
31.360
026697
1336_31D_060_en
1336 751 102 - 2011-04 52 2010-01
9 Use a hand-operated press to press ball

bearing out of the R/C housing.
026698
10 Cover sliding sleeve and synchronizer rings

with cloth.
! DANGER
Bushes and compression springs jump out when
removing the synchronizer rings.
026699
11 Take synchronizer rings 33.090 / 33.100 out

of sliding sleeve33.110; during this process, 33.034 33.100
bushes 33.034 / 33.044 / 33.054 / 33.064 / 33.030
33.074 / 33.084 and compression springs 33.064 33.110 33.074
33.030 / 33.040 / 33.050 / 33.060 / 33.070 / 33.060
33.080 will jump out.
33.070
33.080
33.090
33.050
33.084 33.054
33.044
33.040
026700
1336_31D_060_en
1336 751 102 - 2011-04 53 2010-01
Completing and installing range change group

01.400
1 Clean the sealing faces on the R/C housing 04.160

and transmission housing 01.400; they must
be free from oil and grease.
28.110
2 Fit thrust disk 04.160 (small offset facing
downwards), insert solenoid 28.110 into the
transmission housing pocket.
032448_1
3 Attach lifting device 1X56 136 260 to planet

carrier. Use crane to lift the planet carrier and
place it into the transmission housing.
Remove lifting device 1X56 136 260.
032449_1
4 Insert compression springs 33.030 / 33.050 /

33.070 and bushes 33.034 / 33.054 / 33.074 33.034 33.100
into synchronizer ring 33.100 and secure by 33.030
1X56 138 207
means of one U-bolt 1X56 138 207 each.
33.064 33.110 33.074
33.060
5 Insert compression springs 33.040 / 33.060 /
33.080 and bushes 33.044 / 33.064 / 33.084 33.070
33.080
into synchronizer ring 33.090 and secure by 33.090
means of one U-bolt 1X56 138 207 each. 33.050
33.084 33.054
33.044
33.040
026700
1336_31D_071_en
1336 751 102 - 2011-04 54 2010-01
6 Insert both synchronizer rings into sliding

sleeve 33.110 and remove all U-bolts
1X56 138 207.
1X56 138 207
015191
7 Apply thin coat of oil to synchronizer cones.

Place synchronizer fully assembled with
synchronizer rings, bushes, and compression
springs onto planet carrier.
032463
8 Insert bearing blocks 34.040 / 34.044 and 34.040 34.030

sliding pads 34.030 / 34.034 into the gear-
shift fork 34.020.
9 Drive sliding pads 34.030 / 34.034 into sliding

sleeve 33.110; ensure that lug of gearshift fork
34.020 points towards output.
10 Insert the bearing blocks 34.040 / 34.044 into

the transmission housing.
34.044 34.034 33.110

34.020
032450_1
1336_31D_071_en
1336 751 102 - 2011-04 55 2010-01
11 Insert gearshift fork 34.020 into selector rail

34.010.
34.010
34.020
032455_1
12 Insert clutch body 31.360 and plate 31.350

with securing ring (31.370) into R/C housing.
Secure plate 31.350 from falling out by 4 to
31.350
6 center-punched recesses in the housing.
31.360
CAUTION
If a transmission housing* of the 1st generation
032452_1
it must be sealed with Loctite no. 574. Sealing for Sealing for
If a transmission housing* of the 2nd generation transmission housings transmission housings
(e.g. 1336 301 008 or 1336 301 009) is installed, of the of the
1st generation 2nd generation
flat seal 28.100 must be used.
13 Depending on the transmission housing

generation:
Fit flat seal or apply Loctite no. 574 to sealing
faces (surface sealing) of R/C housing and
Loctite
transmission housing.
574
*also refer to “Transmission Housing” chapter

28.100
032420
1336_31D_071_en
1336 751 102 - 2011-04 56 2010-01
14 Screw two dowel pins (as assembly aid) into

the transmission housing.
Carefully place R/C housing onto transmission
1X56 138 467
housing and use tool 1X56 138 467 to center
injection tube. (Also refer to figure in
“Completed range change group” chapter.)
15 Remove tool 1X56 138 467 and two dowel

pins.
032461
16 Carefully drive in two cylindrical pins 31.050

and (31.060 in opposite position), with M12
extractor thread pointing towards output flange.
CAUTION 31.050
If the cylindrical pins are not driven in correctly,
the housing can break.
17 Screw in 19 hex head screws (28.120

through 28.300) and tighten to 50 Nm.
18 Use a heating mandrel 1X56 138 460 to heat

up ball bearing inner ring to approx. 120 °C.
032451_1
19 Pull on ball bearing using fixture 1X56 138 712.
Reinstall the following components as described in

the corresponding chapters:
- Output cover
- Output flange
- Impulse sensor
032462
1336_31D_071_en
1336 751 102 - 2011-04 57 2010-01
ZF-AS Tronic mid Planet Carrier
Planet Carrier
1X56 138 446 1X56 138 543
1X56 138 486
32.050
33.010
32.150 32.110 33.020
32.010
32.310
32.320
32.370
32.290
32.380 32.330
32.290 32.340
32.390 32.350
32.400
32.410
32.360
32.300 /120
32.490
32.430
32.500
32.440
32.290
32.290
32.420 32.510
32.450
32.480 32.520
32.460
32.530
32.470
026655_1
Fig. Planet Carrier
1336_32D_020_en
1336 751 102 - 2011-04 58 2011-04
There are three different versions of the planet

Version A
carrier: 32.010
Version A 32.026
- Planet carrier 32.010 with loose fit for planetary 32.024
bolts
32.030
- Disk spring 32.026
- Axial needle bearing 32.024
- Thrust ring 32.030
Loose fit
032430
Version B
- Planet carrier 32.010 with loose fit for planetary Version B
32.010
bolts
- 3 plain bearing segments 32.014, 32.016, 32.018
- Thrust ring 32.030 32.014
NOTE
32.030
If a transmission is overhauled, the planet carrier
should be converted to Version C.
32.016 Loose fit

Conversion from Version A to C
The planet carrier 32.010, disk spring 32.026, and

32.018
axial needle bearing 32.024 are replaced with a
new planet carrier* 32.010 and 3 sliding bearing
032431_1
segments 32.014, 32.016, 32.018. The remaining
parts can be re-used. Version C
For dismantling and reassembling of planet carrier, 32.010
refer to the following pages.
32.014
Version C
- Planet carrier 32.010 with press fit for planetary 32.030
bolts
- 3 plain bearing segments 32.014, 32.016, 32.018
- Thrust ring 32.030 Press fit
32.016
32.018
*Planet carrier has 3 bore holes for fixture of plain bearing segments.
032431_1
1336_32D_020_en
1336 751 102 - 2011-04 59 2011-04
Disassembling planet carrier
1 Remove locking wire 32.050 , e.g. by using

two small screwdrivers, and take off ring gear
32.150.
!DANGER
The ring gear 32.150 is released and may fall
32.050
down.
- Risk of injury -
32.150
026707
2 Push ring gear 33.020 together using tongs 33.010

and remove clutch body 33.010.
33.020
3 Remove securing ring 32.110.
32.010
32.110
026708
Only Version A Version A

Preload the thrust ring 32.030, the axial needle
bearing 32.024, and the disk spring 32.026 using
two clamps 1X56 138 543 and turning the parts
with 180 degree offset.
1X56 138 543
026709_1
1336_32D_020_en
1336 751 102 - 2011-04 60 2011-04
4 Versions A and B
Versions A and B
Slide out the planetary bolts 32.300 / 32.360 /
32.360 32.300
32.420 / 32.480 by means of the assembly
bolts 1X56 138 486 (short version) and/or
1X56 138 446 (long version) and fix the planet 32.010 32.480
gears’ needles.
1X56 138 486
1X56 138 446
32.420
026710
4 Version C Version C 1
Knock out the planetary bolts 32.300 / 32.360 /
32.420 / 32.480 by means of a plastic punch
(1) in the drive direction of the planet carrier
32.010. 32.010
32.360
32.480
32.300 1X56 138 486

1X56 138 446
32.420
026710_1
5 Fix the planet gears’ needles by means of

assembly bolts 1X56 138 486 (short version) 32.350
and/or 1X56 138 446 (long version) and push 32.410
32.470
the intermediate disks 32.350, 32.410, 32.530
32.470 and 32.530 towards the inside by 1X56 138 446
means of a spring steel strip (1); then, take out. 1X56 138 486
026711
1336_32D_020_en
1336 751 102 - 2011-04 61 2011-04
6 Lift up the intermediate disk e.g. 32.490 with

the spring steel strip (1) and push in beneath
the planetary gear. Carefully take out the
planetary gear together with assembly bolts
and needles.
NOTE
Take one after the other planet gear out of the
planet carrier.
026712
7 Take the intermediate disks 32.310 / 32.330 / Long version

AS Tronic mid
32.370 / 32.390 / 32.430 / 32.450 / 32.490 /
32.510 / and the needle rollers 32.320 / 32.490
32.340 / 32.380 / 32.400 / 32.440 / 32.460 /
32.500
32.500 / 32.520 out of the planet gears.
32.290
CAUTION 32.510
There is a short and a long version of the 32.520
32.490
ZF-AS Tronic mid; accordingly, also the planet 32.530
32.500
carriers, the intermediate disks 32.330 / 32.390 /
32.450 / 32.510 and the planet gears 32.290 are 32.290
different in their lengths. 32.510
32.520
Short version of
32.530 AS Tronic mid
032433
8 Version A Version A
Take off the two clamps 1X56 138 543, the
1X56 138 543
thrust ring 32.030, the axial needle bearing
32.024, and the disk spring 32.026 from the 32.026
planet carrier. 32.024
32.030
1X56 138 543
032434
1336_32D_020_en
1336 751 102 - 2011-04 62 2011-04
9 Versions B and C
Versions B and C
Take off the thrust ring 32.030 and the 32.010
3 sliding bearing segments 32.014, 32.016,
32.018 from the planet carrier 32.010. 32.014
32.030
32.016
32.018
032431
1336_32D_020_en
1336 751 102 - 2011-04 63 2011-04
Assembling planet carrier
CAUTION
- Planet gears may not be replaced individually,
only as entire set.
- There is a short and long version of the
ZF-AS Tronic mid; accordingly, also the planet
carriers, the intermediate disks 32.330 / 32.390 /
32.450 / 32.510, and the planet gears 32.290 are
different in their lengths.
1 Replace oil tube /120 with new one if

damaged.
33.010
2 Insert the securing ring 33.020 in the groove

at the planet carrier. Use pliers in order to 33.020
contract the securing ring and put the clutch
body 33.010 onto the planet carrier.
The securing ring must be firmly home with
the clutch body’s groove base. The clutch
body is used as mounting face for the
planetary bolts.
/120
032432
3 Version A Version A
Place the disk spring 32.026, the axial needle
bearing 32.024, and the thrust ring 32.030 1X56 138 543
onto the planet carrier and preload by means
of two clamps 1X56 138 543. 32.026
32.024
32.030
1X56 138 543
032434
1336_32D_030_en
1336 751 102 - 2011-04 64 2011-04
3 Versions B and C
Versions B and C 32.010
Insert the tabs of the 3 plain bearing
segments 32.014, 32.016 und 32.018 in
the planet carrier’s outer bore holes. 32.014
Fit the thrust ring 32.030 with smaller
diameter [Ø] facing the output.
32.030
4 Complete the set of the 4 planet gears 32.290

with intermediate disks 32.310 / 32.330 /
32.350 / 32.370 / 32.390 / 32.410 / 32.430 / 32.016
32.450 / 32.470 / 32.490 / 32.510 / 32.530
and needle rollers 32.320 / 32.340 / 32.380 /
32.400 / 32.440 / 32.460 / 32.500 / 32.520.
32.018
5 Oil the needle rollers and running surface of 032431_2
the planet gears with operating oil.

Long version
AS Tronic mid
NOTE
1X56 138 446
• Only use needle rollers from the same type
32.490 1X56 138 486
tolerance (grades).
32.500
• Use the assembly bolts 1X56 138 486 for
the short version and the assembly bolts 32.290
1X56 138 446 for the long version. 32.510
32.520
32.490
6 Assembly process: 32.530
- Slide the planetary gear and the intermediate 32.500
disk over the assembly bolt 32.290
- Insert 17 needle rollers in the planetary gear 32.510
and slide the intermediate disk over the 32.520 Short version
assembly bolt. 32.530 AS Tronic mid
- Insert another 17 needle rollers; lightly oil
032433
these and put them on the intermediate disk.
7 Position the planet carrier on the shaft part.
NOTE
First, insert the pre-assembled planet gears
without the upper intermediate disk in the
planet carrier.
8 Carefully insert the preassembled planet

gears 32.290 (4 planet gears make one set),
completely with the assembly bolt, into the
planet carrier by using a spring steel strip (1).
1
026712
1336_32D_030_en
1336 751 102 - 2011-04 65 2011-04
9 Cautiously slide the upper intermediate disks

(1) from the inside over the planet gears.
1X56 138 446
1
1X56 138 486
10 Cautiously remove the assembly bolts

1X56 138 446 and/or 1X56 138 486 one after
the other and insert the planetary bolts.
NOTE
In the case of the versions A and B, the
planetary bolts feature a loose fit in the planet
carrier; in the case of the version C, the planet
carrier has a press fit.
026712_3
11 Versions A and B
Cautiously slide the planetary bolts 32.300 /
32.480 32.300
32.360 / 32.420 / 32.480 into the planet
1X56 138 543
carrier bores until they protrude no longer. 32.420 32.360
Version C
Cautiously slide the planetary bolts 32.300 /
32.360 / 32.420 / 32.480 into the planet
carrier bores until they abut.
32.010
Use a plastic hammer in order to cautiously
hammer in the planetary bolts into the planet
carrier bore until they protrude no longer.
Version A
Take off the clamps 1X56 138 543.
026712_2
12 Insert the securing ring 32.110 in the planet
carrier 32.010.
NOTE
The securing ring 32.110 must make contact 32.010
with the planet carrier’s groove base.
32.150 32.110
13 Slide the ring gear 32.150 over the planet
32.050
gears and secure by means of locking wire
32.050.
NOTE
- For easier fitting of the locking wire, use ring
gear as support.
- Locking wire 32.050 must make contact
with the ring gear’s groove base.
026708_1
1336_32D_030_en
1336 751 102 - 2011-04 66 2011-04
ZF-AS Tronic mid Reverse Idler Gear Bolt
Removing Reverse Idler Gear Bolt

05.060
1 Remove securing ring 05.060. 10.060
026719
2 Use solenoid 1X56 138 459 to pull out reverse

idler gear bolt 05.050. 1X56 138 459 1X56 138 450
05.050
3 Use retaining fixture 1X56 138 450 to fix oil

pipe 10.060.
026720
4 Remove solenoid 28.110. 1X56 138 443
5 Screw four supports 1X56 138 443 into the

28.110
transmission housing.
6 Screw two screw-on adapters 1T66 160 650

onto the transmission housing and hook in
chain.
1T66 160 650
026721
1336_05D_030_en
1336 751 102 - 2011-04 67 2010-01
ZF-AS Tronic mid Reverse Idler Gear Bolt
NOTE
If the clutch housing is detached, it is possible to
remove the bolted assembly of clutch housing and
transmission housing completely except for
4 screws and cylindrical pins 01.600 / 01.610 /
01.620 using tool 1X56 138 063; however, this
must be done before the transmission is put into a
vertical position (also refer to the chapter “Removing
clutch housing”).
CAUTION
Do not remove all screws, otherwise the clutch
housing will come off when putting the trans-
mission into a vertical position.
NOTE
Make oil collector and squared timber 1T66 160 650
available.
Position oil collector accordingly, residual
transmission oil may leak.
7 Use a crane to bring the transmission into a

horizontal position.
8 Remove screw-on adapter 1T66 160 650.
026723
9 Fix two lifting eyes on clutch housing and

hook in chain. Use a crane to place trans-
mission on the four supports 1X56 138 443
1X56 138 443
in a vertical transmission.
026724
1336_05D_030_en
1336 751 102 - 2011-04 68 2010-01
ZF-AS Tronic mid Connection Plate
Connection Plate
02.760 02.740 02.730 02.720
02.770
02.750
02.630 02.700 02.710

02.640
02.650
09.100
02.660
09.090
02.670
02.690 09.080
09.070
02.680
09.060 09.090
09.050 09.080
09.040 09.070
09.060
09.140
09.050
09.040
09.030
02.610 09.120
02.780 09.130
02.620
02.790
026846
Fig. Connection Plate, Transmission brake
1336_02D_010_en
1336 751 102 - 2011-04 69 2010-01
02.310 02.260 02.250
10.090
10.080
10.070
09.010
/140
10.120 02.300 /130

10.130
/110 /120
09.020
02.300
026847
Fig. Connection Plate, Pump
1336_02D_010_en
1336 751 102 - 2011-04 70 2010-01
Removing connection plate
1 Remove 2 hex head screws (M10x120)

02.610 / 02.620 and 17 hex head screws
(M10x60)
02.630 / 02.640 / 02.650 / 02.660 / 02.670 /
02.680 / 02.690 / 02.700 / 02.710 / 02.720 /
02.730 / 02.740 / 02.750 / 02.760 / 02.770 /
02.780 / 02.790.
NOTE
Use a screw tap to re-cut threaded holes in
housing as threads might be dirty and show
traces of Loctite or micro encapsulation.
2 Remove brake cover 09.140 and diaphragm 026730
09.130.
02.260 02.250
3 Lift and remove connection plate 02.300 by
means of a suitable tool. 02.310
02.300
4 Remove washers 02.260 / 02.250.
09.130
09.140
5 Remove seal 02.310.
026725
6 Take pump cover 10.090, pump shaft 10.080, 10.090

and rotor 10.070 out off connection plate.
10.080
7 Take baffle plates 10.120 and 10.130 off the 10.070
input shaft.
09.010
8 Remove cylindrical pins 09.010 / 09.020 if

they are damaged.
10.120
10.130
09.020
026726
1336_02D_010_en
1336 751 102 - 2011-04 71 2010-01
9 Take brake piston 09.120, outer multidisks

and inner multidisks – for arrangement and 09.*
number, refer to parts list – 09.030 / 09.040 / 100
090
09.050 / 09.060 / 09.070 / 09.080 / 09.090 / 080
070
09.100 /out 060 090
050
of the connection plate. 040 080
070
060
050
040
09.030
09.120
09.130
09.140
*je nach Stücklisten-

* depending on
ausführung
parts list version
026727
10 Support connection plate 02.300 by 2 squared

timbers using a hand-operated press and
place a plate on pipe 02.300/130.
11 Push pipe 02.300/130 out of connection plate

02.300.
026728
12 Take O-ring 02.300/120 out of connection

plate 02.300/110.
/130 /140
13 Remove shaft sealing ring 02.300/140 from
pipe 02.300/130.
/ 110 / 120
02.300
026766
1336_02D_010_en
1336 751 102 - 2011-04 72 2010-01
Bearing setting on input shaft and countershaft
02.300 10.090
02.300/130
02.310 02.260
02.310
02.250
03.020
02.230
026775
1 Turn input shaft several times. This helps 3 Use sharp object to check whether tapered
align the bearings’ tapered rollers and makes rollers of bearing can be moved.
them roll into the bearing outer rings.
To set the specified setting dimension, “zero NOTE
clearance” must be reached first. Zero clearance is attained when the tapered
rollers are fixed securely but have no preload.
2 Fit the bearing outer rings to the tapered
rollers with zero clearance by using a
mandrel.
1336_02D_050_en
1336 751 102 - 2011-04 73 2011-04
Setting of input shaft

Dimension: A
CAUTION
The tapered roller bearing of the input shaft is set
with a preload of 0.10 to 0.20 mm.
Dimension A:
Use depth gage to measure the distance
between the housing sealing face and the
bearing outer ring’s upper edge 02.250:
e.g. = 2.00 mm
026780
Dimension B:
Use depth gage to measure offset depth of Dimension: B
the connection plate 02.300:
e.g. = 2.20 mm
Dimension C:
Measure thickness of seal 02.310:
e.g. = 0.35 mm
Dimension D:
Measure sheet thickness of release bearing
pipe 02.300/130:
e.g. = 2.50 mm
Theoretical thickness “X”of the washer

02.250 at a clearance of 0.00 mm
026779
Example:
A + B + C – D = X Dimension: D Dimension: C
2.00 + 2.20 + 0.35 – 2.50 = 2.05 mm
min. preload:
2.05 mm + 0.10 mm = 2.15 mm
max. preload:
2.05 mm + 0.20 mm = 2.25 mm
Considering the preload (0.10 to 0.20 mm),

a washer with a thickness between 2.15 mm
and 2.25 mm is to be selected from the spare
parts catalog.
026781
1336_02D_050_en
1336 751 102 - 2011-04 74 2011-04
Setting of countershaft
Dimension: E
CAUTION
The countershaft’s tapered roller bearing 03.020
is set with a preload of 0.10 to 0.20 mm.
Dimension E:
Use a depth gage to measure the distance
between the bearing outer ring’s upper edge
03.020 and the housing sealing face:
e.g. = 6.80 mm
026776
Dimension F:
Measure from the pump cover’s upper edge to Dimension: F Dimension: G
the connection plate’s sealing face:
e.g. = 0.20 mm
Dimension G:
Measure from the pump cover’s upper edge to
the first offset:
e.g. = 7.55 mm
Dimension C:
026777
Measure thickness of seal 02.310:
e.g. = 0.35 mm Dimension: C
Calculation example:
Theoretical thickness “Y“ of washer 02.260 at
a clearance of 0.00 mm
G – F + C – E = Y
7.55 – 0.20 + 0.35 – 6.80 = 0.90 mm
min. preload:
0.90 mm + 0.10 mm = 1.00 mm
max. preload:
0.90 mm + 0.20 mm = 1.10 mm
026778
1336_02D_050_en
1336 751 102 - 2011-04 75 2011-04
Considering the preload (0.10 to 0.20 mm), select

a washer with a thickness between 1.00 mm and
1.10 mm from the spare parts catalog.
4 Place the shims 02.250 on the input shaft’s

bearing outer ring.
Lightly grease shim 02.260 (for easier
assembly) and put it into pump cover.
1336_02D_050_en
1336 751 102 - 2011-04 76 2011-04
Installing connection plate
1 Apply thin coat of grease to O-ring /130 /140

02.300/120 and insert it into the connection
plate 02.300/110.
/ 110 / 120
02.300
026766
2 Press shaft sealing ring 02.300/140 into the

pipe 02.300/130 using tool 1X56 138 462.
Observe installation dimension of
0,3
31.50 mm ± 0.30 mm. 31,50 +
-
NOTE 1X56 138 462

• Coat the outer circumference of the shaft 02.300/140
sealing ring with Vaseline 8420. 02.300/130
• Sealing lip of the shaft sealing ring faces the
output drive.
• Apply thin coat of grease to the sealing lip of
the shaft sealing ring.
3 Drive in cylindrical pins 09.010 / 09.020 until

026767
firmly home (axial abutment).
10.090
NOTE
Insert rotor 10.070 in such that marking pointfaces 10.080
connection plate. 10.070
Slightly grease rotor 10.070 and pump shaft 10.080
09.010
with operating oil before assembly.
4 Insert rotor 10.070, pump shaft 10.080, and

pump cover 10.090 into the connection plate. 10.120
10.130
5 Place baffle plates 10.120 and 10.130 on the
input shaft.
09.020
026726
1336_02D_020_en
1336 751 102 - 2011-04 77 2010-01
6 Place connection plate 02.300/110 on fixture

1X56 138 469 and press in pipe 02.300/130
until firmly home using pressure plate
1X56 138 485.
1X56 138 485
02.300
1X56 138 469
026774
7 Clean sealing faces of the connection plate

02.300 and the clutch housing.
1X56 138 065 02.260 02.250
NOTE
02.310
All sealing faces and the M10 threaded holes
must be clean and free from oil and grease.
02.300
8 Place seal 02.310 on the clutch housing.
9 Put protective sleeve 1X56 138 065 on the

input shaft to protect shaft sealing ring in the
connection plate.
10 Insert measured disks 02.250 and 02.260.

027852
11 Align pump shaft square with countershaft.
Carefully place connection plate 02.300 on
the clutch housing.
027853
1336_02D_020_en
1336 751 102 - 2011-04 78 2010-01
CAUTION 02.780 02.750 02.740 02.730 02.720

Use new micro-encapsulated screws or grease
02.760
screws with Loctite no. 241 for fitting connection
plate. 02.770 02.710
02.790 02.700
02.610
12 Tighten the 15 hex head screws (M10x60)
02.620
02.630 / 02.640 / 02.650 / 02.660 / 02.670 /
02.680 / 02.690 / 02.700 / 02.710 / 02.720 /
02.730 / 02.740 / 02.750 / 02.760 / 02.770 to
46 Nm.
02.630
02.640
02.650 02.660 02.670 02.680 02.690

026730
CAUTION
Transmission should be in vertical position for 09.*
fitting transmission brake; otherwise, diaphragm 100
09.130 can get out of place. 090
080
070
060 090
13 Insert outer multidisks and inner multidisks – 050
040 080
for arrangement and number refer to parts list 070
060
– 09.030 / 09.040 / 09.050 / 09.060 / 09.070 050
040
/ 09.080 / 09.090 / 09.100. 09.030
09.120
14 Fit brake piston 09.120, diaphragm 09.130, 09.130
and brake cover 09.140. 09.140
*je nach Stücklisten-

* depending on
ausführung
parts list version
026727
15 Screw in remaining 4 screws at the brake
cover:
Tighten screws 02.610 / 02.620 and 02.780 /
02.790 to 46 Nm.
027854
1336_02D_020_en
1336 751 102 - 2011-04 79 2010-01
ZF-AS Tronic mid Clutch Housing
Clutch Housing
01.010
1X56 138 063
01.410
01.640
01.650
01.660 01.630
01.810
01.800
01.670
01.680 01.790
01.600 01.690
01.700 01.780
01.710 01.770
01.720 01.760
01.620 01.750
01.740
01.730
01.400
01.610
032422
Removing clutch housing
1 Remove cylindrical pins 01.600 / 01.610 / 2 Remove all hex head screws
01.620. 01.630 / 01.640 / 01.650 / 01.660 / 01.670 /
01.680 / 01.690 / 01.700 / 01.710 / 01.720 /
NOTE 01.730 / 01.740 / 01.750 / 01.760 / 01.770 /
Pull out cylindrical pins – M12 extractor thread – 01.780 / 01.790 / 01.800 / 01.810 from the
with the tool 1X56 138 063. clutch housing 01.010 / transmission housing
01.400 bolted assembly.
1336_01D_010_en
1336 751 102 - 2011-04 80 2011-04
3 Lift clutch housing from transmission housing

by means of a hoist.
NOTE
Transmission housings from the 1st generation are
installed with Loctite no. 574 and transmission
housings from the 2nd generation with flat seals
01.410.
026959
NOTE
Once the shaft package is removed, the flat seal
01.410 can also be removed afterwards and the
sealing surfaces can be cleaned.
026960
4 Remove the tube 10.030 and the screen insert

10.010.
10.030 10.010
026740
1336_01D_010_en
1336 751 102 - 2011-04 81 2011-04
Installing clutch housing 10.050
10.030
1 Insert O-rings 10.040 / 10.050 at pipe 10.030.
Properly grease the two O-rings and the
corresponding bore holes in the clutch
housing and housing II.
2 Insert pipe 10.030 into the transmission

housing.
3 Put tools 1X56 138 467 and 1X56 138 468 on

the pipes as insertion aid.
4 Clean sealing faces.

10.040
CAUTION 026747
If the clutch housing is fitted to transmission

housing of 1st generation e.g. 1336 301 037
(210 mm)* or 1336 301 038 (270 mm)*, it must
be sealed with Loctite no. 574. 1X56 138 468
If a transmission housing of the 2nd generation
1336 301 008 (209.2 mm)* or 1336 301 009
(269.2 mm)* is installed, flat seal 01.410 must 1X56 138 467
be used.
10.030
NOTE
The sealing faces on the clutch housing and trans-
mission housing must be clean and free from oil and 10.060
grease. 01.400
5 Depending on the transmission housing

generation:
026748
Fit new flat seal 01.410 or apply Loctite no.
574 to the sealing face of the transmission
housing (surface sealing).
6 Carefully place clutch housing 01.010 onto

1X56 138 468
7 Check whether pipes 01.060 and 01.030 1X56 138 467

have correct fit in clutch housing (flush with
housing face).
8 Remove tools 1X56 138 467 and

1X56 138 468.
* For length of transmission housing, refer to “Transmission Housing”

chapter
026749
1336_01D_020_en
1336 751 102 - 2011-04 82 2011-04
ZF-AS Tronic Clutch Housing
01.010
01.410
01.640
01.650
01.660 01.630
01.810
01.800
01.670
01.680 01.790
01.600 01.690
01.700 01.780
01.710 01.770
01.720 01.760
01.620 01.750
01.740
01.730
01.400
01.610
032422
9 Insert cylindrical pins 01.600 / 01.620 /

01.620 (do not drive in fully yet) and tighten
19 M10 hex head screws 01.630 through
01.810 to 50 Nm.
Subsequently drive in cylindrical pins 01.600 /
01.610 / 01.620 until firmly home (axial abut-
ment).
1336_01D_020
1336 751 102 - 2011-04 83 2011-04
ZF-AS Tronic mid Shaft Package
Shaft Package
1X56 137 795
Removing shaft package
1X56 138 442
1 To remove clutch package, refer to “Clutch
Package” chapter. 1
2
2 Push reverse idler gear 05.010 aside. 3
3 Remove baffle plates from the input shaft.

(Refer to “Connection Plate” chapter),
4 Place fixture 1X56 138 442 onto the input

shaft. Slide sleeves (1 and 2) over the selector 05.010
rails. Tighten hex head screw (3). Shift 3rd
gear (sliding sleeve facing upwards) and 026750
tighten knurled thumb screw (4).
5 Hook 3-strand chain 1X56 137 795 to eye

bolts and lift shaft package out of trans-
mission 3
housing.
6 Place shaft package on fixture 1X56 138 444 4

and unhook 3-strand chain.
NOTE
12.010
For 12 AS 1010 and 12 AS 1210, place disk
(approx. 10 mm thick) into the fixture.
7 Loosen knurled thumb screw (4) and hex

head screw (3).
026751
8 Push sleeve (1) upwards and take off S/G

selector rail 12.010.
9 Push sleeve (2) upwards and take off gearshift

shaft 06.010 of the main transmission shift
system.
1X56 138 444
10 Remove fixture 1X56 138 442 from shaft 06.010

package.
11 Remove input shaft from main shaft.
NOTE
The input shaft and the shift system are
described in individual chapters.
026752
1336_05D_010_en
1336 751 102 - 2011-04 84 2010-01
ZF-AS Tronic Shaft Package
12 Take reverse idler gear 05.010 with roller

rings 05.020 / 05.040 and spacer ring
05.030 out of transmission housing.
10.060
05.010
05.040
05.030
05.020
026753
1336_05D_010_en
1336 751 102 - 2011-04 85 2010-01
ZF-AS Tronic mid Shaft Package
Installing shaft package
1 Insert spacer ring 05.030 and roller rings

05.020 / 05.040 into the reverse idler gear
05.010.
2 Insert completed reverse idler gear ‒ with

collar facing output-end ‒ into the trans- 10.060
mission housing and slightly push to the side.
NOTE
Injection tube 10.060 must be installed in the 05.010
transmission housing. 05.040
05.030
05.020
3 Place main shaft and countershaft on fixture
1X56 138 444. Put input shaft onto main 026753
shaft. Push countershaft towards main shaft

so that the gears of main shaft and counter-
shaft are meshing.
4 Place fixture 1X56 138 442 onto the shaft

package. Slide S/G selector rail 12.010 into 4
the main shaft and secure by means of sleeve
(1).
Slide the two shift forks of the gearshift shaft 12.010
06.010 into the main shaft and secure by
means of sleeve (2).
5 Tighten hex head screw (3).
6 Shift 3rd gear and tighten knurled thumb 06.010

screw (4).
026970
7 Hook 3-strand chain 1X56 137 795 to eye

bolts.
1X56 137 795
8 Lift shaft package into the transmission 1X56 138 442 1X56 138 483
housing by means of a crane.
1
9 Remove fixture 1X56 138 442. 2
3
10 Make reverse idler gear 05.010 engage with
main shaft and countershaft. 10.010
Use tool 1X56 138 483 to fix reverse idler
gear from below.
11 Insert strainer 10.010. 05.010
026983
1336_05D_020_en
1336 751 102 - 2011-04 86 2010-01
ZF-AS Tronic mid Input Shaft
Input Shaft 02.110 02.100

02.112
Dismantling input shaft 02.124
02.122
1 Three thrust pieces 02.110 / 02.116 / 02.122
with one compression spring each 02.112 / 02.090
02.118 / 02.124 are released, therefore, cover 02.140
02.118
synchronizer with cloth. 02.200
02.010 02.116
02.210
2 Pull off sliding sleeve 02.100.
02.230
02.240
3 Collect three thrust pieces 02.110 / 02.116 /
02.122 with one compression spring each
02.112 / 02.118 / 02.124.
Remove securing ring 02.240.

026755
4
5 Insert tool 1X56 138 445 between clutch

body 02.140 and synchronizer ring 02.090.
026756
6 Use hand-operated press to remove input

shaft from tapered roller bearing by pressure.
Remove tapered roller bearing 02.230,
counting disk 02.210, helical gear constant 1
02.200, clutch body 02.140, and synchronizer
ring 02.090 from the input shaft 02.010.
026757
1336_02D_030_en
1336 751 102 - 2011-04 87 2010-01
7 Check the rubber lip of the baffle plate

02.010/160 at the input shaft for hardening 02.010
(brittleness) and damage. Should it be har- / 170 / 140 / 150 / 160
dened or damaged, remove baffle plate by
means of a suitable tool.
8 If necessary, remove securing ring

02.010/150, cover 02.010/140.
9 The dowel pin 02.010/170 is used for oil

supply. Check whether supply is free.
026758
1336_02D_030_en
1336 751 102 - 2011-04 88 2010-01
Assembling input shaft

02.010
1 Check whether dowel pin /170 has been fitted.
/ 170 / 140 / 150 / 160
1X56 138 474
2 Insert cover /140 in the input shaft 02.010
and snap in securing ring /150.
3 Press in baffle plate /160 using tool

1X56 138 474 until firmly home (axial abut-
ment).
4 Place synchronizer ring 02.090 and clutch

body 02.140 on input shaft. The synchronizer
ring’s tabs face downwards and must engage
with the recesses of the synchronizer body
part. 026978
5 Apply a thin coat of grease on the contact sur- 02.110 02.100

face of the helical gear 02.200. 02.112
02.124
6 Slide helical gear 02.200 over the input shaft. 02.122
The driving spline faces downwards and
engages with inner spline of the clutch body. 02.090
02.140
02.118
7 Fit counting disk 02.210. 02.010 02.116 02.200
02.210
! DANGER 02.230
Only touch heated parts when wearing protec- 02.240
tive gloves.
8 Heat up the inner ring of the tapered roller

026755
bearing 02.230 to approx. 120 °C and place it
onto input shaft; ensure axial abutment! Use
tool 1X56 138 473 to push in further until
firmly home (axial abutment).
9 Measure thickness of the securing ring 02.240

using a feeler gage.
Make sure to consider axial clearance of 0 to
0.1 mm when selecting the securing ring
02.240.
10 Select securing ring 02.240 according to

spare parts catalog and snap it in with input
shaft.
1336_02D_040_en
1336 751 102 - 2011-04 89 2010-01
11 Put sliding sleeve 02.100 onto input shaft 04.370

and attach. Insert thrust pieces 02.110 / 02.130
02.110
02.116 / 02.122 with new compression 02.100
02.112
springs 02.112 / 02.118 / 02.124 into input
shaft and use suitable tool to locate them in
02.124
sliding sleeve.
02.122
12 Place synchronizer ring 02.130 and clutch

body 04.370 on input shaft. Move sliding
sleeve into center position. To do so, apply
back-pressure on clutch body 04.370. 02.118
You will clearly hear the thrust pieces snap
into place. 02.116
10.120
13 Place baffle plates 10.120 and 10.130 on 10.130
the input shaft. 026842
For installation of input shaft, refer to “Shaft

Package” chapter.
1336_02D_040_en
1336 751 102 - 2011-04 90 2010-01
ZF-AS Tronic mid Countershaft
Countershaft
03.090
Dismantling countershaft
1X56 138 601 1X56 122 304 03.010
1 In order to protect countershaft 03.010, a
thrust piece must be inserted between the 03.030
extracting tool and the countershaft.
03.040
2 Screw basic device 1X56 122 304 onto grip- 03.080

per 1X56 138 601. 03.020
3 Use gripper 1X56 138 601 to grip output-end

tapered roller bearing inner ring 03.090 from
behind and pull it off.
Overdrive
4 Take tapered roller bearing inner ring 03.090 026759
out of gripper.
03.090
5 Insert thrust piece, grip tapered roller bearing
inner ring 03.020 from behind using gripper 1X56 138 601 1X56 122 304 03.010
1X56 138 601 and pull it off.
03.030
6 Take tapered roller bearing inner ring 03.020
03.040
out of gripper.
03.080
CAUTION 03.020
If necessary, replace tapered roller bearings
03.020 / 03.090; the bearing rollers may be
damaged when extracted.
7 Remove securing ring 03.080. Direct Drive
026760
8 Use suitable hydraulic press to remove sliding
gear wheel 03.040 and helical gear 03.030
by pressure force but remove them individual-
ly due to high press-off forces. The press-off
force for each helical gear is 500 kN.
NOTE
To prevent damage to the gears, support
countershaft and/or helical gears on a soft
base.
1336_03D_010_en
1336 751 102 - 2011-04 91 2010-01
Assembling countershaft
Direct drive (DD) Overdrive (OD)
1 Bores in helical gears and countershaft snug
fits must be free from oil, grease, and dust.
!DANGER
Only touch heated helical gears and tapered
roller bearings when wearing protective gloves. II
2 Heat helical gears to max. 170 °C.

I
3 Cool down countershaft 03.010 to reach
specified temperature difference of 150 °C
between helical gears and countershaft.
026761
4 Put the heated helical gears on top of each

other on a hydraulic press and align them
03.090
exactly.
03.010
Depending on version, DD or OD:
I Sliding gear wheel constant of 1st and 3rd
03.030
gear
II Helical gear of 2nd gear – hub pointing 03.040
downwards 03.080
03.020
NOTE
The helical gearing of the 1st and R gear is an
essential part of the countershaft.
5 Insert cooled countershaft 03.010 in OD - Overdrive

heated helical gears 03.040 / 03.030 and
026759
immediately repress until firmly home (axial
abutment).
03.090
6 Snap in securing ring 03.080.
03.010
Ensure that securing ring 03.080 is firmly
home with the groove base of the counter-
shaft. 03.030
03.040
03.080
03.020
DD - Direct Drive
026760
1336_03D_020_en
1336 751 102 - 2011-04 92 2010-01
NOTE
Wait until countershaft has cooled down
before fitting tapered roller bearing inner 03.090
rings. 1X56 138 487
03.010
7 Heat inner rings of tapered roller bearings

03.020 / 03.090 for 15 min. to 120 - 130 °C
max. and then place them on countershaft
03.010. Ensure axial abutment, if necessary, 03.020
drive in further using a soft mandrel and/or
tool 1X56 138 487.
For installation of countershaft, refer to

“Shaft Package” chapter.
026793
1336_03D_020_en
1336 751 102 - 2011-04 93 2010-01
ZF-AS Tronic mid Main Shaft
Main Shaft
04.200
04.210
04.220 04.160
1X56 138 444 1X56 138 597 1X56 122 304 1X56 138 470 1X56 138 472
04.230 04.150
04.250
04.140
04.260
04.282 04.120
04.290 04.110
04.280
04.100
04.370
04.080
02.130
04.330 04.070
04.340 04.060
04.350
04.050
04.010
027481
Detailed diagram of main shaft
1336_04D_010_en
1336 751 102 - 2011-04 94 2010-01
Dismantling main shaft
CAUTION
When using an adapter, always use spacer to pro-
tect the shaft.
04.370
Always apply extractor spindle to the spacer
02.130
(intermediate piece), never directly to the shaft.
04.340
04.350
1 Clamp main shaft at output end in a vise

with protective chucks or place into fixture
1X56 138 444.
2 Remove securing ring 04.350 and clutch

body 04.370 with synchronizer ring 02.130.
026786
3 Grip tapered roller bearing inner ring 04.340

from behind using gripper 1X56 138 597.
4 Screw basic device 1X56 122 304 onto

gripper and remove tapered roller bearing’s
inner ring 04.340.
026773
5 Remove thrust ring 04.330, helical gear

04.290 with roller ring 04.280 / 04.282 and
sliding sleeve 04.230.
04.230
04.280
04.290
04.280
04.330
026787
1336_04D_010_en
1336 751 102 - 2011-04 95 2010-01
6 Turn main shaft and clamp its output end in a

vise with protective chucks or place it into 04.140 04.150
fixture 1X56 138 444. 04.120
04.110
7 Remove securing ring 04.150.
04.080
8 Use two or three-armed extractor to pull off R

gear helical gear 04.120.
The inner ring of the tapered roller bearing
04.120 is also pulled off during this process.
9 Remove needle cage 04.110 and sliding

sleeve 04.080.
026788
10 Use two or three-armed extractor to pull off

helical gear of 1st gear 04.060. 04.100
04.080
11 Take off bearing bush 04.100, sleeve carrier 04.070
04.070, helical gear of 1st gear 04.060, and 04.060
needle cage 04.050 of the main shaft 04.050
04.010.
026789
12 Turn main shaft and clamp its output end in

a vise with protective chucks or place into
04.010
fixture 1X56 138 444.
13 Use two or three-armed extractor, and 04.200

possibly hydraulic press to pull of helical gear 04.210
04.220
of 2nd gear 04.210.
04.250
04.260
14 Take off bearing bush 04.260, washer
04.250, sleeve carrier 04.220, helical gear of
2nd gear 04.210 and needle cage 04.200 of
the main shaft 04.010.
026815
1336_04D_010_en
1336 751 102 - 2011-04 96 2010-01
Assembling main shaft
! DANGER
Only touch heated parts when wearing protec-
tive gloves.
1 Clamp main shaft 04.010 at the input end in

a vise with protective chucks.
NOTE
The main shaft can also be placed into fixture
1X56 138 444. To do so, put matching insert
into pipe section of support and engage main
shaft and bearing journal.
2 Apply thin coat of oil to needle cage 04.050

and slide onto main shaft.
04.100
3 Slide helical gear of 1st gear 04.060 onto
main shaft with spline pointing towards out- 04.070
put. 04.060
04.050
! DANGER
Only touch heated parts when wearing protecti- 04.010
ve gloves.
4 Heat up sleeve carrier 04.070 to approx.

120 °C and slide onto spline of main shaft
04.010.
Ensure axial abutment; if necessary, drive in
further using tool 1X56 138 470.
026832
5 Heat up bush 04.100 to approx. 120 °C and

04.150
slide onto main shaft. Ensure axial abutment;
04.140
if necessary drive in further using tool 04.120
1X56 138 470. 04.110
6 Slip sliding sleeve 04.080 over sleeve carrier 04.080

04.070.

and slide over bush 04.100.
8 Slide helical gear of R gear 04.120 over

needle cage onto main shaft. Driving spline
must point towards sleeve carrier 04.070.
026833
1336_04D_020_en
1336 751 102 - 2011-04 97 2010-01
! DANGER
04.150
Only touch heated tapered roller bearing inner
04.140
ring when wearing protective gloves. 04.120
04.110
9 Heat up tapered roller bearing inner ring 04.080

04.140 to 120 - 130 °C for 15 minutes max.
and place onto main shaft. Ensure axial abut-
ment; if necessary, drive in further using tool
1X56 138 470.
CAUTION
Securing ring 04.150 must be completely free of
burrs, because it is used as thrust face for thrust
washer 04.160.
028833
10 Measure thickness of securing ring 04.150

11 Select securing ring 04.150 so that axial

clearance is between 0 and 0.1 mm.
Aim for 0.0 mm.
12 Snap in selected securing ring 04.150. Ensure

that securing ring 04.150 is firmly home with
the groove base of the main shaft.
13 Turn main shaft by 180°.
1336_04D_020_en
1336 751 102 - 2011-04 98 2010-01

and slide onto main shaft.
15 Slide helical gear of 2nd gear 04.210 onto

04.200
main shaft.
04.210
04.220
! DANGER 04.250
Only touch heated parts when wearing protec- 04.260
tive gloves.
16 Heat up sleeve carrier 04.220 to approx.

120 °C and slide onto spline of main shaft.
further using a soft mandrel. 026834
17 Heat up washer 04.250 and bush 04.260 to

approx. 120 °C and slide onto main shaft.
further using a soft mandrel.
04.230
18 Slip sliding sleeve 04.230 over sleeve carrier
04.280
04.220.
04.290
19 Apply thin coat of oil to roller rings 04.280 / 04.280

04.282, insert into helical gear 04.290, and 04.330
slide over bush 04.260.
20 Place thrust ring 04.330 onto main shaft.
! DANGER 026787
Only touch heated tapered roller bearing inner

ring when wearing protective gloves.
21 Heat up tapered roller bearing inner ring 04.370

04.340 to 120 - 130 °C for 15 minutes max. 02.130
and place onto main shaft. Ensure axial abut- 04.340
ment; if necessary, drive in further using tool 04.350
1X56 138 472.
026786
1336_04D_020_en
1336 751 102 - 2011-04 99 2010-01
22 Measure thickness of securing ring 04.350

23 When selecting securing ring 04.350,

consider axial clearance of 0 to 0.1 mm.
04.370
24 Snap in selected securing ring 04.350. 02.130
Ensure that securing ring 04.350 is firmly 04.340
home with the groove base of the main shaft. 04.350
25 Place clutch body 04.370 and synchronizer

ring 02.130 onto main shaft.
For installing main shaft, refer to “Shaft

Package” chapter.
026786
1336_04D_020_en
1336 751 102 - 2011-04 100 2010-01
ZF-AS Tronic mid Shift System
Shift System
06.010 06.120
Dismantling shift system
1 Unlock shift forks 06.120 and 06.160 and take

06.140
them off.
2 Remove locking mechanism 06.140 from 06.160
gearshift shaft 06.010.
3 Take sliding pads 12.020 and 12.030 out of

shift fork. Further dismantling of the S/G
selector rail 12.010 is not possible.
026848
Assembling shift system
12.010
1 Place locking mechanism 06.140 on the
gearshift shaft.
2 Fit gearshift forks 06.120 and 06.160 in the

right position in locking mechanism.
CAUTION
Do not interchange shift forks 06.120 and 06.160;
12.020
if necessary, refer to parts list.
3 Insert sliding pads 12.020 and 12.030 into 12.030

the shift fork of the S/G selector rail 12.010.
027439
For installing gearshift shaft and S/G selector
rail, refer to “Shaft Package” chapter.
1336_06D_020_en
1336 751 102 - 2011-04 101 2010-01
Clutch Housing
01.170
01.180
01.160
01.190
01.150
01.010
03.020
01.120* 01.110 10.110

02.230
01.100
032417
Dismantling clutch housing
1 Remove screw plug 10.110. 3 Take off blind rivets 01.160 / 01.170 / 01.180 /
01.190 and remove type plate 01.150.
2 Remove securing ring* 01.120, sealing
washer 01.110, and breather 01.100. 4 Take off bearing outer rings 03.020 and
02.230,
NOTE if the tapered roller bearings are being
If necessary, destroy sealing washer 01.110 replaced.
during disassembly process.
1336_01D_030_en
1336 751 102 - 2011-04 102 2010-01
74.050
01.170
1X56 138 463 1X56 138 465 01.180
01.160
1x56 138 463 1x56 138 465
01.190
01.150
03.020
01.120* 01.110
10.110
01.100 02.230 01.010

0.2
4.5±
01.010/120
032418
Assembling clutch housing
1 Mount type plate 01.150 with 4 blind rivets 3 Depending on parts list version:
01.160 / 01.170 / 01.180 / 01.190. Secure sealing washer 01.110 by using
securing ring 01.120 or by caulking (3x120°).
NOTE
The installation position – convexity of sealing 4 Screw in M24x1.5 screw plug 10.110 with
washer – depends on the securing method. new sealing ring and tighten to 60 Nm.
• The sealing washer 01.110 is mounted with the
convex side facing the output when a securing 5 Heat up the two bearing seats to approx.
ring 01.120 is used. 100 °C using a hot air blower.
• If there is no groove for the securing ring in the
clutch housing, the sealing washer is fitted and 6 Insert bearing outer ring 03.020 using tool
caulked with the convex side facing the input. 1X56 138 465.
• Always use new breather 01.100 and sealing
washer 01.110. 7 Insert bearing outer ring 02.230 using tool
1X56 138 463.
2 Insert breather 01.100 and sealing washer
01.110 into clutch housing01.010. 8 Insert cylindrical pins 01.010/120 and 74.050
if they are not there already.
1336_01D_040_en
1336 751 102 - 2011-04 103 2010-01
ZF-AS Tronic mid Transmission Housing
Transmission Housing
01.400/120 10.060
X
47.010
01.400
47.010
03.090
47.030
10.100
04.140
026844_1
Detailed diagram of transmission housing 4 If the bearing outer ring 01.400/120

Dimension “X” Type of seal of the PTO shaft is damaged, use tool
1st generation 210.0 mm Loctite 574 1X56 138 475 to drive it out.
2nd generation 209.2 mm Flat seal
1st generation 270.0 mm Loctite 574 5 Demount injection tube 10.060 moving it in
2nd generation 269.2 mm Flat seal direction of output.
NOTE
Dismantling transmission housing Cover 47.010 is destroyed during demounting
process; thus, only demount if absolutely
1 Remove screw plug 01.100 M24x1.5. necessary. Wear protective goggles!
2 Use commercially available internal extractor 6 Remove securing ring 47.030.

to remove bearing outer ring 03.090 from the
! DANGER
3 Use soft mandrel to drive bearing outer ring When removing cover 47.010 it is absolutely
out of 04.140 housing. necessary to wear protective goggles. Chips or
splinters might otherwise injure eyes.
1336_01D_050_en
1336 751 102 - 2011-04 104 2010-01
ZF-AS Tronic mid Transmission Housing
1X56 138 466 1X56 138 465 1X56 138 464 1X56 138 450
01.400/120 10.060
01.400
03.090
47.010
10.100
47.030
04.140
026982_1
Assembling transmission housing
! DANGER Secure bearing outer ring 01.400/120 by

Only touch heated parts when wearing protec- caulking (4x90°).
tive gloves.
5 Install injection tube 10.060 from input side
1 Use blow-dryer to evenly heat up bearing and use tool1X56 138 450 to fix it.
seats of tapered roller bearings 03.090 and
04.140 in the transmission housing 01.400 to 6 Screw in screw plug 10.100 M24x1.5 and
approx. 100 °C. new sealing ring and tighten to 60 Nm.
2 Press in bearing outer ring 03.090 until 7 Clean sealing faces on housing 01.400 and
firmly home (axial abutment) by using tool cover 47.010.
1X56 138 465.
8 Insert cover 47.010 and securing ring 47.030.
3 Press in bearing outer ring 04.140 until Ensure that securing ring is firmly home with
firmly home (axial abutment) by using tool the groove base.
1X56 138 466.
Install reverse idler gear (refer to “Shaft
4 Evenly heat up bearing seat of PTO shaft in Package” chapter).
the transmission housing to approx. 100 °C
and press in bearing outer ring 01.400/120
until firmly home (axial abutment) by using
tool 1X56 138 464.
1336_01D_060_en
1336 751 102 - 2011-04 105 2010-01
ZF-AS Tronic mid Additional Cooling
Additional cooling (heat exchanger)

(option)
Version A Version B
47.090 47.090
47.070 47.070
47.060
47.060
47.050 /010
47.050
47.020 /020
/030
47.040
47.040
47.030
47.030
031724
Removing the additional cooling
Version A Version B
1 Remove the securing ring 47.030. 1 Remove the securing ring 47.030.
2 Use a screwdriver or tip lever (pry bar) to lift 2 Use a screwdriver or tip lever (pry bar) to lift
heat exchanger 47.040 out of transmission. heat exchanger 47.040 out of transmission.
3 Take off tube 47.050 and remove the O-ring 3 Remove the snap ring 47.040/030 and take
47.020. off the seal 47.040/020.
4 Remove securing ring 47.090, piston 47.070, 4 Remove securing ring 47.090, piston 47.070,
and compression spring 47.060 from the and compression spring 47.060 from the
heat exchanger. heat exchanger.
5 Clean heat exchanger 47.040. 5 Clean heat exchanger 47.040/010.
NOTE
“Version A” was replaced by “Version B”.
1336_47D_010_en
1336 751 102 - 2011-04 106 2010-01
ZF-AS Tronic mid Additional Cooling
Version A Version B
47.090 47.090
47.070 47.070
47.060
47.060
47.050 /010
47.050
47.020 /020
/030
47.040
47.040
47.030
47.030
031724
Installing the additional cooling
Version A Version B
1 Slide compression spring 47.060 and piston NOTE

47.070 onto heat exchanger 47.040 and Always use new sealing ring 47.040/020.
snap in securing ring 47.090.
1 Slide new sealing ring 47.040/020 onto the
2 Insert new O-ring 47.020 and slide tube heat exchanger. Snap the snap ring
47.050 onto heat exchanger 47.040. 47.040/030 into the groove; make sure that
the snap ring is firmly home with the groove
3 Insert the complete heat exchanger unit. base.
4 Insert the securing ring 47.030 and make 2 Slide tube 47.050 onto the heat exchanger
sure that the securing ring 47.030 is firmly 47.040.
home with the groove base.
3 Slide compression spring 47.060 and piston
47.070 onto heat exchanger 47.040 and
snap in securing ring 47.090.
4 Insert complete heat exchanger unit.
5 Insert the securing ring 47.030 and make

sure that the securing ring 47.030 is firmly
home with the groove base.
1336_47D_010_en
1336 751 102 - 2011-04 107 2010-01
English
Printed in the Netherlands DW33367604

DW 33367604

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DW 33367604

Uploaded by

Copyright:

Available Formats

Component manual

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

1336 751 102 - 2011-04 3

1336 751 102 - 2011-04 4

Index Date of issue Chapter Initiator Comment

a 2006-08 13.3 LKS-T - Put transmission in vertical position for assembly

b 2010-01 MC-C - Tightening torque of clutch release mechanism has been

c 2011-04 MC-C - Overview transmission family/types newly included.

1336 751 102 - 2011-04 5

Service points equipped by ZF Friedrichshafen AG

To avoid injury to personnel and damage to pro-

Personnel required to carry out repairs on ZF pro-

General Information Cleaning Parts

After removing the transmission from the vehicle, Reworking

Transmission Assembly • Shaft Sealing Rings

* refer to consumable material

Tightening torques for screws and nuts,

This standard applies to bolts according to Surface condition of screws/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

The following data should always be provided

Overview Transmission Family/Types

• PF1 Short version L = 840 mm

Description Name Quantity Application Comment

Grease for example:

Grease Olista Longtime 3EP 3 grams Shaft sealing rings 68.100/140

Sealing compound No. 574 Sealing face

Jointing compound No. 262 90 mm³ Ball pin 06.080

Transmission oil ZF ECOFLUID M Refer to Transmission oil fill

NOTE: Inquire as to size of containers before ordering!

Description Dimension Measuring device Comment

Screw plug M24x1.5 10.100 / 60 Nm Torque wrench 10.100 on transm. housing

Screw plug M10x1 31.030 / 15 Nm Torque wrench

M10 hex head screws 50 Nm Torque wrench R/C housing to transmission

M10 hex head screws 46 Nm Torque wrench Connection plate to

Impulse sensor 31.150/31.200 45 Nm Torque wrench

Screw plug M18x1.5 35 Nm Torque wrench

Switch 06.220 45 Nm Torque wrench Neutral switch

Cannon plug 74.130 18 Nm Torque wrench At transmission actuator

Figure Depiction Order no. Application Quantity Comment

1X56 137 795 Alternatively:

1T66 160 650 “Putting trans-

1X56 138 443 “Removing reverse

1X56 122 304 Chapters

Note: Basic device is not suitable for impact

NOTE: Please inquire as to packaging unit before ordering.