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ZF 9S 109 PDF
ZF 9S 109 PDF
ZF 9S 109 PDF
Service Manual
ZF 9 S 109 Gear Box
27.02 ZF 9 S 109 GEAR BOX
CONTENTS
GROUP - 27
CONTENTS
CHAPTER - 27
The ZF 9 S 109 synchronous transmission of The 4-speed section with reverse gear and
the Ecomid construction range has been rear-mounted range-change group is
specially developed for use in commercial operated mechanically by a double-H
vehicles of the upper medium duty class control.
9 S 109 transmissions is basically consist of: With this type of control, each of the
forward gears and the reverse gear is
- a fully synchronized four gear component
allocated its own position in the gear shift
- an integrated crawler and reverse gear pattern. A range of spring detents of
- a rear-mounted range-change group different loads ensures perfect orientation
built into the planet. through the shift pattern, i.e. accurate
location of individual gears.
27.0.1 Description
The shifting process of the range-
Design change group is carried out automatically
The synchromesh transmission with range- under pneumatic control while the gate 3/4
change group is being shifted to 5/6 or while 5/6 is
being shifted back to 3/4 . The control
(ZF 9 S 109) consists of a 4-speed section system for shifting the range-change group
(with dog clutch operated crawler and consists of a shift valve and a double
reverse gear) of countershaft type together acting shift cylinder integrated in the
with a rear-mounted range-change group of transmission. The shift valve is controlled by
planetary design. The range-change group the turning shaft of the 4-speed section
doubles the number of gears available in and only releases the air pressure to the
the 4-speed section, thereby increasing the shift cylinder in neutral position.
number of consecutively selectable forward
gears to 9, including the crawler,
No of Gears 9
Fig - 1
N N
The selector lever springs back to the
neutral position if released in the central
C 2 4 6 8
area. In order to select gears 1/2 or 7/8,
move the selector lever against the spring
force in the required direction and hold the
lever against this force when making the
engagement stroke. Fig. 1
Gates 3/4 and 5/6 are separated by a
stronger spring detent. The range-change
group is changed over automatically when
the selector lever is moved between these
gates. A range of spring detents of different
loads ensures perfect orientation through the
shift pattern, i.e. accurate location of
individual gears. The reverse gate is fitted
with a spring loaded stop which must be
overcome by deliberate effort.
Changing gear
Move between gate 3/4 and 5/6 (or vice
versa) by knocking the selector lever with
the palm of your hand and briskly moving
the selector lever into the required gear.
You must move the selector lever quickly,
but you do not have to move it particularly
forcefully. We recommend keeping your hand
open when selecting gears.
Fig - 2
NOTE: - When engaging a gear, hold the selector
lever against the end stop until the
synchronizer unit has completed the gearshift.
Fig. 2
- Change gears quickly to reduce shift effort.
This is particularly important when the
transmission is cold. If the transmission is
below operating temperature, the driver
has to work harder to change gear. If the
range-change group does not change over
when changing down from gate 5/6 into
gate 3/4, slow your vehicle and engage the
appropriate gear at a lower speed.
CAUTION: Never change down a gear unless the
vehicle and engine speeds are below
the maximum values for the gear you
are going to engage. Failure to comply
can lead to transmission or engine
damage. The maximum transmission
input and output speed is 2500 rpm.
27.06 ZF 9 S 109 GEAR BOX
03. Axial play of grooved ball bearing situated on output (range-change group) 0 - 0.10 mm
06. Axial play of snap ring for grooved ball bearing in ring gear carrier 0 - 0.1 mm
11. Axial play of 3rd or 4th speed helical gear 0.20 - 0.45 mm
12. Axial play of reverse gear situated on the idler shaft 0.20 - 0.60 mm
13. Permitted axial play of planetary gears in planet carrier 0.10 - 0.70 mm
14. Limit of wear of synchronizer rings and/or clutch bodies, measured between
flat surfaces of ring and body with cones nested firmly together
Main transmission 0.80 mm
Range-change group 1.20 mm
21. Delivery rate of lubricating oil pump during separate check 5.15 - 6.45 l/min.
and 0.155 bar
27.08 ZF 9 S 109 GEAR BOX
Setting Dimensions"
Connection Flange : B = 93 mm
Connection Flange
Pitch (Top Hole) : C = 47 mm
Fig - 1 & 2
Fig 3
ZF 9 S 109 GEAR BOX 27.09
Connection plate, shift rails Input Shaft, reverse gear Shafts with clamps, housings
and oil sieve, bearing and pivot
adjustment of shafts.
27.010 ZF 9 S 109 GEAR BOX
27.1.0 Removal
27.1.1 Assembly
2. Attach cable
Fig - 1
27.2 OUTPUT
Fig - 1
Fig - 2
Fig - 3
Fig. 3
27.2.2 Mounting of Bearing Cover
Fig - 5
Fig - 6
Fig - 7
Fig. 6
Fig - 8
Fig. 8
ZF 9 S 109 GEAR BOX 27.13
Fig. 5 Fig. 4
27.14 ZF 9 S 109 GEAR BOX
Fig - 6 Fig. 6
Fig - 7
Fig. 7
NOTE: Engage gear teeth on sun gear and planetary
gears.
Fig - 8
Fig - 9
Fig. 9
ZF 9 S 109 GEAR BOX 27.15
Fig - 10
Fig - 11
Fig - 12
Fig - 14
Fig. 12
Fig. 14 Fig. 13
27.16 ZF 9 S 109 GEAR BOX
Fig - 15
Fig. 15
Fig - 16
Fig. 16
Fig - 17
Fig. 17
Fig - 18
Fig. 18
ZF 9 S 109 GEAR BOX 27.17
Fig - 19
Fig - 20
Fig - 22
Fig. 22
27.18 ZF 9 S 109 GEAR BOX
Fig. 25
Fig. 27 Fig. 26
ZF 9 S 109 GEAR BOX 27.19
Fig - 28
Fig - 30
Fig - 31
Fig. 31
27.20 ZF 9 S 109 GEAR BOX
Fig - 1
Fig. 1
Fig - 2
Fig - 3
Fig. 3
ZF 9 S 109 GEAR BOX 27.21
Fig - 5
Fig - 6
ZF 9 S 109 GEAR BOX 27.23
Fig - 7
Fig - 8
Fig. 8
27.24 ZF 9 S 109 GEAR BOX
1. Remove circlip.
Fig - 1
Fig - 2
Fig - 3
3. Insert circlip.
Fig - 4
Fig - 1
Fig. 1
NOTE: Cover is a single part and is not dismantled.
Fig - 2
Fig - 3
Fig - 4
Fig. 4
27.26 ZF 9 S 109 GEAR BOX
Fig - 5
Fig. 5
Fig - 6
Fig. 6
Fig - 7
Fig. 7
Fig - 8
Fig. 8
ZF 9 S 109 GEAR BOX 27.27
Fig - 9
Fig. 9
Fig - 10
Fig. 10
Fig - 11
Fig. 11
Fig - 12
Fig. 12
27.28 ZF 9 S 109 GEAR BOX
Fig. 13
Fig - 13
Fig - 14
Fig. 14
ZF 9 S 109 GEAR BOX 27.29
Fig - 15
Fig - 16
Fig. 16
Fig - 17
Fig. 17
Fig - 18
Fig. 18
27.30 ZF 9 S 109 GEAR BOX
Fig - 19
Fig. 19
Fig - 20
Fig. 20
Fig - 21
Fig. 21
Fig - 22
Fig. 22
ZF 9 S 109 GEAR BOX 27.31
Fig - 23 & 24
Driver Arrangement
Driver arrangement install position is
horizontal right.
Fig - 25 Fig. 23
Fig. 24
Fig. 25
1. Driver
2. Detent bush
3. Compression spring(s)
4. Selector shaft
5. Shift housing
27.32 ZF 9 S 109 GEAR BOX
Fig - 1
Fig - 2
Fig. 2
Fig - 3
Fig. 3
Fig - 4
Fig. 4
ZF 9 S 109 GEAR BOX 27.33
Fig - 5
Fig - 6
Fig - 7
Fig - 8
Fig. 8
27.34 ZF 9 S 109 GEAR BOX
Fig - 9
Fig - 10
Fig - 11
Fig. 11
NOTE: Position selector shaft as far as is possible
in the direction of compression springs.
Fig - 12
Fig. 12
ZF 9 S 109 GEAR BOX 27.35
Fig. 13
26. Grease ball rollers (13).
Fig - 13
Fig - 14
Tightening torque = 46 Nm
Fig - 15
Fig - 16
Fig 16
27.36 ZF 9 S 109 GEAR BOX
Fig - 1
Fig - 2
Fig - 4
Fig. 2
Fig 4
Fig. 3
ZF 9 S 109 GEAR BOX 27.37
Fig - 5
Fig. 5
Fig - 6
Fig - 7
Fig 7
27.38 ZF 9 S 109 GEAR BOX
Fig - 10
Fig. 10
ZF 9 S 109 GEAR BOX 27.39
Fig - 1
Example: a = 5.40 mm
Fig - 2
Fig - 3
Example:
c = 2.40 mm
Fig - 4
Fig - 5
Example: A = 17.80 mm
Fig - 6
Fig - 7
Fig. 7
Example :
C = 2.30 mm
D = 2.55 mm
Fig. 8
Fig - 8
27.42 ZF 9 S 109 GEAR BOX
Fig - 1
Fig - 2 Fig 1
Fig - 3
Fig - 4
Fig. 2
Fig - 5
Fig. 3
Fig. 5 Fig. 4
ZF 9 S 109 GEAR BOX 27.43
Fig - 6
Fig - 7
Fig - 8
Fig. 7
14. Take off bearing plate.
Fig - 9
Fig - 10
Fig. 8
Fig. 10 Fig. 9
27.44 ZF 9 S 109 GEAR BOX
Fig. 13
Fig 15 Fig. 14
ZF 9 S 109 GEAR BOX 27.45
Fig - 16
Fig - 17
Fig - 18
Coat sealing faces with sealing compound.
Fig - 19
Fig - 20
Fig. 18
Fig. 20 Fig. 19
27.46 ZF 9 S 109 GEAR BOX
Fig - 21
Fig - 22
Fig - 23
Fig - 24
Fig - 25
Fig. 23
Fig. 25 Fig. 24
ZF 9 S 109 GEAR BOX 27.47
Fig - 26
Fig - 27
Fig - 29
Fig 29
27.48 ZF 9 S 109 GEAR BOX
Fig - 1
Fig - 2
Fig - 3
Fig - 4
Fig - 5
Fig. 3
Fig 5 Fig 4
ZF 9 S 109 GEAR BOX 27.49
Fig - 6
Fig - 8
Fig 8
NOTE: Insert reverse gear and roller rings in housing
and push towards housing wall.
Fig - 9
Fig. 9
27.50 ZF 9 S 109 GEAR BOX
Fig - 10
Fig - 11
Fig - 12
Fig - 13
Fig. 13
ZF 9 S 109 GEAR BOX 27.51
Fig - 14
Fig. 14
27.52 ZF 9 S 109 GEAR BOX
Fig - 1
Fig - 2
ZF 9 S 109 GEAR BOX 27.53
27.12 MAINSHAFT
Fig. 1
27.12.0 Dismantling the Mainshaft 7. Remove 3rd speed helical gear (12) with
clutch body (11) and two needle cages
Fig - 1 (13) from mainshaft (28).
NOTE: Instructions for removing mainshaft are 8. Turn mainshaft over and clamp input end in
described in section 27.10.0. vice with soft jaws.
Fig - 2
8. Place crawler/R gear sliding sleeve (32) on 20. Use suitable tool to insert three
sleeve carrier. Sliding sleeve is symmetrical compression springs (23) and compression
and can therefore be placed on either side pieces (22) in synchronizer hub bores or to
of the carrier. guide them into sliding sleeve.
9. Slide needle cage (34) onto mainshaft. NOTE: Use new compression springs.
10. Push R speed helical gear (35) over needle 21. Add synchronizer ring (19). The
cage onto mainshaft by gently twisting it. synchronizer ring noses must engage in
Drive teeth should face output. recesses of synchronizer hub.
11. Heat inner race of taper roller bearing (36) 22. Place clutch body (18) on synchronizer ring
to approx. 120°C and slide onto mainshaft (19) and pull sliding sleeve into central
and drive firmly home. position (neutral position). In so doing,
press synchronizer ring and clutch body.
12. Check axial play of R speed helical gear.
Axial play 0.40 to 0.75mm. 23. Push needle cage (16) and 2nd speed
helical gear (17) onto bush (15) and heat
13. Turn over mainshaft and clamp output end it all to approx. 120°C.
in vice with soft jaws.
24. Place parts together on mainshaft and drive
14. Slide both needle cages (27) onto mainshaft. home bush (15) without any play. Bush
collar should face input. (Fig - 2).
15. Push 1st speed helical gear (26) over needle
cage onto mainshaft by gently twisting it. 25. Check axial play of 2nd speed helical gear.
Drive teeth should face output.
- Axial play to 0.20 to 0.40mm
16. Place clutch body (25) and synchronizer ring
(24) on driver gear teeth. 26. Insert circlip (14).
CAUTION: Check limits of wear for all CAUTION: Ensure circlip remains absolutely free
synchronizer rings or clutch bodies as of burrs as it serves as a running
described in Section 27.4.5. Lightly oil surface for the needle cage.
bearing races of all synchronizer rings.
27. Slide both needle cages (13) onto
17. Heat synchronizer hub (21) to approx. 120°C mainshaft.
and place on mainshaft gear teeth.
Synchronizer hub is symmetrical and can 28. Push 3rd speed helical gear (12) over
therefore be placed on either side of needle cage onto mainshaft by gently
mainshaft. Drive synchronizer hub firmly home. twisting it. Driver teeth should face output.
NOTE Synchronizer ring noses must engage in 29. Place clutch body (11) on 3rd speed helical
recesses of synchronizer hub. gear (12).
18. Check axial play of 1st speed helical gear 30. Add synchronizer ring (10).
Axial play 0.20 to 0.45mm
31. Heat synchronizer ring (6) to approx.
120°C and place on mainshaft with the
19. Slide 1st/2nd speed sliding sleeve (20) over
longer nose facing output. If necessary,
synchronizer hub, synchronizer ring and clutch
drove fully home.
body and place on 1st speed helical gear.
Ensure that recesses in sliding sleeve interior
NOTE: Synchronizer ring noses must engage in
cover the same areas of the synchronizer
recesses of synchronizer hub.
hub locating points (for compression springs
and compression pieces).
27.56 ZF 9 S 109 GEAR BOX
Fig - 2
Fig - 3
Fig 3
ZF 9 S 109 GEAR BOX 27.57
27.13 LAYSHAFT
Fig - 1
Fig - 2
Fig. 2
27.13.1 Assembly of the Layshaft
Fig - 2
27.58 ZF 9 S 109 GEAR BOX
Fig - 3 Fig. 3
27.14 HOUSING
Fig. 1
27.14.0 Dismantling the Housing 4. Insert pipe (8) (Refer to Section 27.6.1)
Fig - 1
5. Fasten cover (2) and new seal (3) with
1. Use soft mandrel to drive taper roller four hex bolts (1)
bearing outer races (9,10) out of housing.
M8 tightening torque = 23 Nm
2. Remove breather (18).
6. Screw breather (18) into housing: tightening
3. Remove four hex bolts (1) and take off torque= 10Nm
cover (20) and seal (3).
7. Use hot-air blower to heat housing around
4. Oil spray bores on pipe (8) must not be bearing bores to approx. 80°C.
blocked.
8. Use plastic mandrel or suitable tool to
When changing the housing insert taper roller bearing outer races
(9,10) of mainshaft and layshaft into
5. Take two cylinder pins (11) out of housing housing and drive firmly home.
and remove screw plugs.
27.15.0 Removal
27.15.1 Installation
Fig. 1
1. Set up the clutch housing in correct position.
Fig - 1
ZF 9 S 109 GEAR BOX 27.61
1X56 100 632 Drift with conical sleeve for inserting shaft seat 10 x 15 x 3 into
speedo connecting piece 1
1X56 103 768 Drift for fitting shaft seal 48 x 65 x 10 on input 1¾" 1
1X56 119 916 Drift for fitting shaft seal and scraper 25 X 35 X 7 in shift housing 1
1X56 122 304 Basic puller M65 X 2 for use with grippers 1
1X56 122 310 Extension M65 X 2 only for taper roller bearings on input 1
1X56 122 317 Adapter of M95 X 2 and M65 X 2 for use with grippers 1
1X56 126 467 Drift for fitting shaft seal 95 X 115 X 10 on input, for use with ring 1X56 137 484 1
1X56 136 708 Gripper M95 X 2 for layshaft taper roller bearings on input side 1
1X56 136 711 Gripper M65 X 2 for layshaft taper roller bearings on output side 1
1X56 136 719 Gripper M95 X 2 for taper roller bearings on input 1
1X56 136 737 Gripper M65 X 2 for taper roller bearings on mainshaft journal bearing 1
1X56 137 452 Drift for lock plate 4132 304 015 on output flange 1
1X56 137 456 30.0 mm Drift for oil pipe mainshaft on output side 1
1X56 138 101 40.5 mm Drift for oil pipe, mainshaft on output side 1
1X56 137 484 Ring for distancing shaft seal 95 X 115 X 10 on output, for use with
drift 1X56 126 467 1
1X56 137 579 Fixing attachment for radial fixing of GP shift rail 1
1X56 137 648 Divided ring for extracting output side clutch body of range-change group 1
1X56 137 134 Protective sleeve assembly aid for assembling shift cover on selector shaft 1
1X56 138 026 Drift for assembling baffle plate in input shaft 1
1X56 138 065 Protective sleeve assembly aid for fitting connection plate 1
1X56 137 450 Assembly stands for use with adapters 1X56 136 998 and 1X56 137 459 1
27.62 ZF 9 S 109 GEAR BOX
$ - Castrol LMM Grease to be used for lubricating Gear shift linkage ball joints 10.02.2004
16000 km
8000 km
Weekly
Remarks
No. of
points
Every
Every
Every
Daily
PDI
A. Lubrication
1. Lubricate gear shift lever fulcrum joint G 1 ✓ ✓
2. Check oil level and top up O 1 ✓
3. Change oil when hot. Refill upto correct level O 1 ✓ 80
B. Maintenance
1. Check for correct operation of gear shift
linkage and setting ✓
2. Check and clean transmission breather
provided on selector housing ✓
3. Check tightness of clutch housing mounting bolts ✓