B - ZF - Transmission - 4 WG-98 TS

Transmission
Supplemental Repair Manual
Models
MMV
&
EIRV
JLG
8990418
Component Manufacturer
5871 139 002
Revised
September 24, 2009
An Oshkosh Corporation Company

DISCLAIMER: Information provided within is supplied directly from the component manufacturer. The
information has not been altered in any way and is the sole property of the component manufacturer. Due
to continuous improvements, the component manufacturer reserves the right to make changes without
prior notification. Contact the component manufacturer for the latest information.
Order-No.: 5871 139 002
ZF – REVERSING TRANSMISSION
4 WG-98 TS
(TeleHandler SideMount)
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
EDITION: 1999/06
REPAIR MANUAL
for
ZF – REVERSING TRANSMISSIONS
4 WG-98 TS
INSTRUCTIONS CONCERNING THE REPAIR MANUAL
The described Disassembly and Assembly Manual is based on the design level of the ZF-Unit at the
time of preparation of the Repair Manual.
Technical development of the product as well as extensions concerning the design possibilities may
require differing steps, which can be carried out by qualified Specialists without greater difficulties
with the help of the Perspective Illustrations in the respective Spare Parts Lists.
The present Disassembly and Assembly Manual is loosing its legal obligation with the publication of a
new successional Edition.
The ZF Passau GmbH is in this connection not responsible for the positive knowledge at the User of
the Manual.
-----------------------------------------------------------------------------------------------------------------
ATTENTION:
Specifications concerning Operation, Maintenance and Description – see the

ZF-Operating Instructions ZF-Order-No. 5872 132 002
For the installation as well as for the commissioning of the unit, the Instructions and Specifications of
the Vehicle Manufacturer have to be observed !
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZAHNRADFABRIK PASSAU GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction meme par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous reserve de modification techniques!
1.Auflage / 1.Edition
Geschäftsbereich
Repair Manual Arbeitsmaschinen-
Antriebe
und Achssysteme
PREFACE
This documentation has been developed for the skilled Serviceman, trained by the Zahnradfabrik Passau for
the Repair and Maintenance operations on ZF-Units.
Treated is a ZF-Serial product according to the design stage of the date of Edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require differents steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Service-men, whose practical and
theoretical training is constantly completed to the actual situation in our Training School.
The Service Stations, established by the Zahnradfabrik Friedrichshafen all over the world, offer you:
1. Constantly trained personnel
2. Prescribed installations, e.g. Special Tools
3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and realibity.
Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual
contractual conditions, by the ZF-Warranty.
Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-
expenditures eventually arising from it, are excluded from this contractual responsibility.
This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH
Service Department
0.1
Geschäftsbereich
Antriebe
und Achssysteme
GENERAL WORKING INSTRUCTIONS

During all operations, pay attention to cleanliness and skilled working.
Therefore, Transmissions, removed from the vehicle, must be cleaned prior to open them.
We assume that the Special Tools, specified by ZF, will be used.
The Special Tools have a 10-digit Subject-No. and are availabe from ZF-Passau.
After the disassembly, all components must be cleaned, especially corners, cavities and recesses of housing
and covers.
The old sealing compound must be carefully removed.
Check lubricating holes, grooves and pipes for free passage. They must be free of residues, foreign material
or protective compounds.
The latter refers expecially to new parts.
Parts which have been inevitably damaged in a disassembly operation, must be generally replaced by new
ones, e.g. : rotary seal rings, O-Rings, U-Section rings, cap boots, protective caps etc..
Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to normal
wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in a vessel
filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
Ball bearings, covers, flanges and parts like that must be heated to about 90o to 100o C.
Hot-mounted parts must be reset after cooling in order to assure a proper contact.
Before pressing shafts, bearings etc. in position, both parts must be lubricated.
During the reassembly, all specified adjustment values, testing specifications and torque limits must be
respected.
After the repair, ZF-Units are filled up with oil.
The procedure and the permitted oil qualities can be taken from the Operator's Manual, resp. from the
Lubrication Instructions and the corresponding List of Lubricants.
The Lists of Lubricants are available at all ZF-Service Stations.
After the oil filling, the oil level plugs and oil drain plugs must be tightened to th specified torque limits.
0.2
Geschäftsbereich
Antriebe
und Achssysteme
CONCERNING THE LABOUR SAFETY
In principle, Repairers of ZF-Units are themselves responsible for the labour safety.
The observance of all valid Safety Regulations and Legal Rules is a precondition to prevent damage to
individuals and products during the Maintenance and Repair operations.
Before starting the work, the Repairers have to make themselves familiar with these Regulatisons.
The proper Repair of these ZF-Products requires especially trained personnel.
The Repairer himself is obliged to provide for the training.
0.3
Geschäftsbereich
Antriebe
und Achssysteme
SYMBOL EXPLICATION
ATTENTION
You will find this Symbol in this Repair Manual on passages, which require your
special attention !

NOTE
You will find this Symbol in this Repair Manual on passages, which include aNote
concerning the Disassembly and Assembly sequence !
0.4
Geschäftsbereich
Antriebe
und Achssysteme
BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Density lineaire en kg/m; Density superficielle en t/m2
Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Uniteo Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
0.5
Geschäftsbereich
Antriebe
und Achssysteme
VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25,40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2,205 lb ( pounds )
9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)
1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5,560 lb / in ( pound per inch )
1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per squar inch lbf/in2 )
=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )
=
3,785 Liter 1 Gallon ( US )
=
1609,344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273,15 Kelvin
0.6
Geschäftsbereich
Antriebe
und Achssysteme
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148
Coefficient of friction: µ total = 0,12 for screws and nuts without aftertreatments as well
as for phosphates nuts. Tighten by hand!
Torque limits, of not exspecially, can be taken from the following list:
Metric ISO-Standard Thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15,5 23 27
M8 23 34 40
M10 46 68 79
M12 79 117 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1120
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine Tread DIN 13, Page 13

Size 8.8 10.9 12.9
M8x1 24,5 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 122 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1090 1270
M 24 x 2 730 1040 1220
M 27 x 1,5 1110 1580 1850
M 27 x 2 1070 1500 1800
M 30 x 1,5 1540 2190 2560
M 30 x 2 1490 2120 2480
M33 x 1,5 2050 2920 3420
M 33 x 2 2000 2800 3300
M 36 x 1,5 2680 3820 4470
M 36 x 3 2500 3500 4100
M 39 x 1,5 3430 4890 5720
0.7
Geschäftsbereich
Antriebe
und Achssysteme
INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

ZF –REVERSING TRANSMISSION 4 WG-98 TS
1 WG-98 TS
2
3 4660 023 002
1 = Transmission Type (e.g.. WG-98 TS)
2 = Serial number (e.g. PS00002)
3 = ZF-Parts List number (e.g. 4660 023 002)
Specfications concerning Spare Parts Orders
When ordering Original ZF-Spare Parts, please consider the following indications:
}
1. Transmission Type
2. Serial number These Indications can be seen on the

Model identification plate !
3. ZF-Parts List number
4. Make und Type of the vehicle
5. Denomination of the Spare Part
6. Spare Part number
7. Way of delivery
If all above-mentioned Specifications are considered,

wrong deliveries of Spare Parts Orders will be avoided !
0.8
LAYOUT
AUFBAU 4WG-98
4WG-98 TSTS
1 = WANDLER
1 = CONVERTER ANTRIEBSWELLE
2 = MOTORABHÄNGIGE
3 = KUPPLUNGSWELLE
2 = K4
ENGINE-DEPENDENT INPUT SHAFT
4 = GETRIEBEPUMPE
3 = CLUTCH SHAFT K4
5 = ANBAUMÖGLICHLKEIT
4 = NEBENABTRIEB
TRANSMISSION PUMP
5 = ATTACHMENT POSSIBILITY POWER TAKE-OFF
Repair Manual
6 = KUPPLUNGSWELLE KR
6 = CLUTCH SHAFT KR
7 = KUPPLUNGSWELLE KV
7 = CLUTCH SHAFT KV
8 = KUPPLUNGSWELLE
8 = K1K1
CLUTCH SHAFT
9 = KUPPLUNGSWELLE
9 = K3K3
CLUTCH SHAFT
10 = KUPPLUNGSWELLE
10 = K2K2
CLUTCH SHAFT
0.9
11 = ABTRIEB
11 = OUTPUT
12 = OUTPUT
12 = ABTRIEBSFLANSCHFLANGE
Arbeitsmaschinen-
und Achssysteme
Geschäftsbereich
Antriebe
INSTALLATION VIEW 4WG-98 TS
FRONT VIEW SIDE VIEW
1 = CONVERTER 1 = CONVERTER
2 = DIAPHRAGM 2 = DIAPHRAGM
3 = CONVERTER BELL FOR ENGINE CONNECTION 3 = CONVERTER BELL FOR ENGINE CONNECTION
4 = OUTPUT 4 = OUTPUT
5 = CONVERTER-SIDE CONNECTION POSSIBILITY 5 = OIL FILLER TUBE WITH OIL DIPSTICK
Repair Manual
FOR OIL FILLER TUBE WITH OIL DIPSTICK 6 = SHIFT CONTROL COMPONENT „II“
7 = SHIFT CONTROL COMPONENT „I“
0.10
7
1
1
2
6
Arbeitsmaschinen-
und Achssysteme
Geschäftsbereich
3 2
Antriebe
5 3
4 4
5
INSTALLATION VIEW 4WG-98 TS
Repair Manual
EINBAUÜBERSICHT
REAR VIEW 4 WG 98 TS
1= SHIFT CONTROL COMPONENT „I“
(DIRECTIONAL CLUTCHES AND PRESSURE CONTROL)
2 = SHIFT CONTROL COMPONENT „II“
0.11
(SPEED CLUTCHES)
RÜCKANSICHT
3 = OIL DRAIN (7/8“ 14 UNF)
4 = MODEL IDENTIFICATION PLATE
SCHALTUNGSKOMPONENTE
1 5= = "I"
OIL FILLER TUBE WITH OIL DIPSTICK
6 (RICHTUNGSKUPPLUNGEN
= FILTER UND DRUCKSTEUERUNG)
2 7= SCHALTUNGSKOMPONENTE
= TRANSMISSION PUMP "II"
8 (GANGKUPPLUNGEN)
= DUCT PLATE
3 = ÖLABLASS (7/8" 14 UNF)
4 = TYPENSCHILD
5 = ÖLEINFÜLLROHR MIT ÖLMESS-STAB
Arbeitsmaschinen-
6 = FILTER
und Achssysteme
Geschäftsbereich
7 = GETRIEBEPUMPE
8 = KANALPLATTE
Antriebe
SCHEDULE
MESSPLAN OF MEASURING POINTS AND CONNECTIONS
UND ANSCHLÜSSE 4WG-98 4WG-98
TS TS
DIE MESSUNGEN
THE MEASUREMENTS SIND BEI
HAVEWARMEN GETRIEBEN
TO BE CARRIED OUT - 95°)TRANSMISSION
80°HOT
(ca.AT VORZUNEHMEN !
ERFORDERLICHE
(ca 80° - 95° C) ! MEßWERTE - SIEHE ZF-PRÜFPROTOKOLL !
REQUIRED MEASURING VALUES – SEE ZF-TEST REPORT !
EINBAUPOSITIONEN
1 = KANALPLATTE
POSITIONS"I"
SCHALTUNGSKOMPONENTE
2 = INSTALLATION
3 = SCHALTUNGSKOMPONENTE "II"
1 = DUCT PLATE
4 = GETRIEBEPUMPE
25 == SHIFT CONTROL COMPONENT „I“
ENTLÜFTER
3 = SHIFT CONTROL COMPONENT „II“
NUR BEI AUSFÜHRUNG
4 = TRANSMISSION PUMP "MIT" - (POSITION DER DIVERSEN MAGNETVENTILE)
7 = "Y7"
5 = BREATHER DIFERENTIALSPERRE
8 = "Y8" PARKBREMSE
ONLY AT VERSION „WITH“ (POSITION OF THE VARIOUS SOLENOID VALVES)
Repair Manual
9 = "Y9" VORDERACHSABSCHALTUNG
7 = „Y7“ DIFFERENTIAL LOCK
8 = „Y8“ PARKING BRAKE
ANSCHLÜSSE/VERSCHLUSSSCHRAUBEN ANZIEHDREHMOMENTE
915 == „Y9“ FRONT AXLE
ANSCHLUSS ZUMDISCONNECTION
WÄRMETAUSCHER 7/8“ - 14 UNF 35 Nm
16 = CONNECTIONS
ANSCHLUSS VOM/ WÄRMETAUSCHER
SCREW PLUGS 7/8“ - 14 UNF TORQUE
35 Nm LIMITS
15
17 == CONNECTION TO HEAT
DRUCKANSCHLUSS EXCHANGER
FESTSTELLBREMSE 7/8“ – 14 UNF 35 Nm
7/8“ - 14 UNF 35 Nm
16 = CONNECTION FROM HEAT EXCHANGER 7/8“ – 14 UNF 35 Nm
18 = DRUCKANSCHLUSS DIFFERENTIALSPERRE 3/4“ - 16 UNF 28 Nm
17 = PRESSURE PORT PARKING BRAKE 7/8“ – 14 UNF 35 Nm
0.12
19 = DRUCKANSCHLUSS BETRIEBSBREMSE 9/16“ - 18 UNF 15 Nm

18 = PRESSURE PORT DIFFERENTIAL LOCK ¾“ - 16 UNF 28 Nm
20
19 == STECKANSCHLUSS
PRESSURE AN DER
PORT SERVICE ELEKTRO-HYDRAULISCHEN
BRAKE 1/2“ - 20 UNF 11 Nm
9/16“ – 18 UNF 15 Nm
20 = STEUERUNG (STEUERUNGSKREISLAUF I)
PLUG CONNECTION ON THE ELEECTROHYDRAULIC ½“ - 20 UNF 11 Nm
21 = STECKANSCHLUSS
SHIFT CONTROL (CONTROL ELEKTRO-HYDRAULISCHEN
AN DERCIRCUIT „I“)
21 = STEUERUNG
PLUG (STEUERUNGSKREISLAUF
CONNECTION II )
ON THE ELECTROHYDRAULIC
SHIFT CONTROL (CONTROL CIRCUIT „II“)
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE
MESS-STELLEN FÜR DRUCKÖL UND TEMPERATUR
50 = ATTACHMENT POSSIBILITY FOR 16+3 bar M10x1 6 Nm 5
50 = ANSCHLUSSMÖGLICHKEIT
PRESSURE FÜR
PORT AXLE DISCONNECTION 16+3 bar M10x1 6 Nm
51 = DRUCKANSCHLUSS ACHSABSCHALTUNG
PRESSURE IN FRONT OF THE CONVERTER 8+2 bar M10x1 6 Nm
51
53 == VORWANDLERDRUCK
CLUTCH FORWARD KV 8+2 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
53
55 == KUPPLUNG
CLUTCH VORWÄRTS KR
REVERSE KV 16+3 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
63
55
56 == KUPPLUNG RÜCKWÄRTS K1
CLUTCH KR 16+3 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
56
57 == KUPPLUNG
CLUTCH K1
K2 16+3 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
Arbeitsmaschinen-
und Achssysteme
Geschäftsbereich
58
57 == CLUTCH
KUPPLUNG K3
K2 16+3 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm 15
60
58 == CLUTCH
KUPPLUNG K4
K3 16+3 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
63 == PRESSURE BEHIND THE CONVERTER ¾“ – 16 6UNF 28 Nm
Antriebe
60 KUPPLUNG K4 16+3 bar M10x1 Nm
65
63 == SYSTEM PRESSURE
NACHWANDLERDRUCK – MODULATED 16+3 bar 3/4“ - 16 UNF 628Nm
M10x1 Nm 16
66
65 == REDUCING PRESSURE
SYSTEMDRUCK - MODULIERT 16+3 bar10 bar M10x1 M10x1
6 Nm 6 Nm
67
66 == SYSTEM PRESSURE
REDUZIERTERDRUCK 10 bar 16+3 bar M10x1 M10x1 6 Nm 6 Nm
67 = SYSTEMDRUCK 16+3 bar M10x1 6 Nm
VIEW X
GEARBOX DIAGRAM
CONVERTER TRANSMISSION PUMP
INPUT POWER TAKE-OFF
Repair Manual
0.13
OUTPUT
CODING
• SOLENOID VALVES UNDER SHIFTED
VOLTAGE CLUTCHES
Arbeitsmaschinen-
und Achssysteme
Geschäftsbereich
DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6
FORWARD 1 • • • • KV K1
2 • • • • KV K2
• • • •
Antriebe
3 KV K3
4 • • • K4 K3
RESERVE 1 • • • • KR K1
2 • • • • KR K2
3 • • • • KR K3
NEUTRAL
Geschäftsbereich
Antriebe
und Achssysteme
INSTRUCTION CONCERNING THE REQUIRED

QUALITY AND OIL FILLING CAPACITY:
Oil quality/oil grade: Permited for the ZF-Reversing transmission WG-98 Powershift are oils
according to the Specifications in the ZF-List of lubricants TE ML-03 (see
document below). This ZF-List of lubricants can requested from all ZF-Service
Stations !
Oil filling capacity: about 16 liters (sump capacity), extternal oil capacity (e. g. radiator, lines etc.)
are depending on the vehicle.
------------------------------------------------------------------------------------------------------------------------------
Off-Road
Transmissions Division
Torque converter transmissions for off-road vehicles and machinery
(construction plant, special vehicles, lift trucks) List of Lubricants TE-ML 03
Version Approved lubricants Recommended

for service fills alternatives
Engine oils Automatic Transmission Fluid (ATF)
WG 80, 81, 83, 85, 86 - API CD / CE / CF / SF / SG - Dexron -IID / -III
WG 100, 120, 121, 150, 151 - MIL-L-2104C / -D / -E - Mercon -M
WG 180, 181 - MIL-L-46152C / -D / -E
WG 200, 201, 250, 251 - SAE 10W / 10W-30 / 10W-40 / Automatic Transmission Fluids (ATF) only at ambient
WG 65 15W-40 / 20W-20 temperatures below
HN 500 Approved commercial products: Page 2 –10 °C (+14°F)
PW 45H Oil as per specification
- Caterpillar TO-4 (SAE 10W / 30) or Approved commercial products: Page 4
John Deere JDM J20C (SAE 10W-30)
Approved commercial products: Page 3
Automatic Transmission Fluid (ATF) Engine oils
WG 98 - Dexron -IID / -III - API CD / CE / CF / SF / SG
WG 110, 130, 160, 190, 210 - Mercon -M - MIL-L-2104C / -D / -E
WG 260, 261 Approved commercial products: Page 4 - MIL-L-46152C / -D / -E
WG 310, 311 Oil as per specification - SAE 10W / 10W-30 / 10W-40 /
- Caterpillar TO-4 (SAE 10W / 30) or 15W-40 / 20W-20
John Deere JDM J20C (SAE 10W-30) Approved commercial products: Page 2
Approved commercial products: Page 3
Engine oils none
WG 92 S4 - API CD / CE / CF / SF / SG
- MIL-L-2104C / -D / -E
- MIL-L-46152C / -D / -E
- SAE 10W / 10W-30 / 10W-40 /
15W-40 / 20W-20
Approved commercial products:
marked (+) Page 2
Oil as per specification
- John Deere JDM J20C (SAE 10W-30)
Approved commercial products:
marked (+) Page 3
Temperature application range:
Viscosity class Operation at outside temperatures
- ATF -30°C to +30°C (-22 °F to 86 °F)
- SAE 10W -20°C to +30°C ( - 4 °F to 86 °F)
- SAE 10W-30, 10W-40 -20°C to +40°C (- 4 °F to 104 °F)
- SAE 15W-40 -15°C to +40°C ( 5 °F to 104 °F)
- SAE 20W-20 -10°C to +40°C (14 °F to 104 °F)
- SAE 30 -5°C to +50°C (23 °F to 122 °F)
Use multi-purpose, lithium-saponified grease (NLGI class 2) on lubricating points.
Note to lubricant suppliers: Please inform ZF immediately of any changes to the composition or trade names of approved products, and of differences in quality between Germany
and other countries.
This list can be obtained through any ZF ZF Passau GmbH Telephone (0851) 494-0
After-Sales Service point. D-94030 Passau Telefax (0851) 44394
1205 75103c / 1296
0.14
Geschäftsbereich
Repair Manual Arbeitsmaschinen-Antriebe
und Achssysteme
LIST OF SPECIAL TOOLS FOR THE DISASSEMBLY AND ASSEMBLY
TRANSMISSION 4 WG 98 TS
DISASSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO.
Figure 1.01 Assembly car 5870 350 000

Figure 3.01 Clamping bracket Set of 2 5870 350 092
To clamp and tilt the compl.transmission on the assembly
car.
Figure 3.02 Ribbon spanner 5870 105 005

Universal use.
To screw off the filter cartridge from the pump housing.
Figure 1.05 Figure 2.04 Adjusting screws Set of 2 5870 204 049
Figure 1.12 Figure 2.16 To screw off and on the cover on the control unit block.
Univeral use.
Figure 3.06 Crow bar 2 pieces needed 5870 345 071

Figure 3.17 Universal use.
To separate the pump housing as well as different trans-
mission components.
Figure 3.13 Figure 4.118 Insert TX 40 / 1/2“ 5873 042 004

To tighten the duct plate screw connection (M 8 x 30)
- 0736 101 312 .
Figure 3.20 Figure 4.98 Set of eye bolts 5870 204 002
Figure 3.29 Figure 4.104 Universal use.
Combined with:
Lifting device 5870 281 047
For various lifting operating of transmission components.
Figure 3.23 Hot-air blower 230 V 5870 221 500

Hot-air blower 115 V 5870 221 501
Universal use.
To heat transmission parts at disassembly resp. assembly.
Figure 3.24 Internal puller # 5870 300 007

Figure 3.27 To pull off the bearing bush out of the stator shaft.
To pull off the bearing bush out of the converter bell.
To be used combined with:
Counter support 5870 300 003
Magnetic holder Set of 3 5870 450 003
Figure 3.26 Plastic mallet ∅ 60 mm 5870 280 004

Universal use.
To separate and unite transmission components.
5871 139 001 W.1

Geschäftsbereich
und Achssysteme
DISASSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO.
Figure 3.30 Three-leg puller # 5870 971 002

Figure 3.65 To pull off various transmission parts, shafts, bearings and
flanges etc.
Figure 3.32 Set of external pliers # A1-A2-A3-A4

Figure 3.35 Figure 4.26 Universal use. 5870 900 015
Figure 3.43 To squeeze external-locking circlips out and in.
Figure 3.57
Figure 3.35 Figure 4.38 Pressing sleeve # 5870 506 128
To preload the cup springs in the clutch pack K1 - K2 and
K4.
Figure 3.39 Grab sleeve # 5873 001 036

Figure 3.47 To pull off the tapered roller bearing inner race 4660 251
Figure 3.51 007= LM 48 510 from the clutch shaft K1/KR.
012 from the clutch shaft KR and KV.
To be used combined with :
Basic tool # 5873 001 000

Figure 3.63 009-010-019 from the clutch shaft K3 .
To pull off the tapered roller bearing inner race 4660 251
081 from the clutch shaft KR. 5873 000 001
To be used c ombined with:
Basic tool # 5873 000 000

Universal use.
To pull off various transmission parts, shafts, bearings.
Figure 3.51 Quick-acting grip # 5873 011 011

To pull off the tapered roller bearing innner race 4660 274
001 from the clutch shaft KV .
Basic tool # 5873 001 000
Figure 3.60 Figure 4.26 Set of external pliers # A1-A2-A3-A4 5870 900 015
Figure 3.67 Figure 4.38 Universal use.
Figure 3.91 Figure 4.61 To squeeze external-locking circlips out and in.
Figure 3.95 Figure 4.82
5871 139 001 W.2

Geschäftsbereich
und Achssysteme
DISASSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO..

To pull off various transmission parts such as shafts,
bearings etc.

008 from the clutch shaft K3 .
Basic tool # 5873 001 000

004 from the output shaft.
Basic tool # 5873 001 000
Sleeve short # 5873 001 005
Figure 3.38 Figure 4.19 Pressure piece # 5870 506 128

Figure 3.87 Figure 4.26 To preload the cup springs in the clutch pack K1 FA .
Figure 4.30
Figure 4.65
Figure 4.20 Digital Depth gauge # 5870 200 072
Figure 4.102 For various measuring operations, plate clearance etc.
Figure 4.96 Driver # 5870 048 219

To insert the shaft seal 55 x 75 x 8 = 0734 310 386 into the
converter bell.
Figure 4.97 To insert the bearing bush 0501 316 494 into the converter
bell.
Figure 4.98 Adjusting screws M 10 5870 204 007

For the easier assembly of the converter bell upon the
gear-box housing Part I.
Figure 4.100 For the easier assembly of the stator shaft into the gearbox
housing Part I.
Figure 4.135 Driver # 5870 048 199

To drive the shaft seal 40 x 63 x 7 = 0734 309 364 into the
housing bore.
Figure 4.136 To mount the sealing cap 0730 361 200 upon the output
shaft.
5871 139 001 W.3

Geschäftsbereich
und Achssysteme
DISASSSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO.
Figure 4.108 Driver # 5870 048 200

To drive the shaft seal 60 x 90 x8 = 0734 309 363 into the
housing bore.
Installation dimension = 6 ± 0,2 mm stop on end face
housing.
Figure 4.112 Driver #

To press on the lock plate 4644 324 012 upon the output 5870 057 012
flange screw connection.
To be used only combined with:
Handle 5870 260 002
Figure 4.115 Adjusting screws M8 5870 204 011

Assembly aid at the mounting of the flat gaskets and the
duct plate on the gearbox housing.
Figure 4.124 Adjusting screws M6 5870 204 063

Figure 4.130 Assembly aid at the mounting of the flat gaskets, the inter-
mediate plate as well as of the compl. control block on the
duct plate.
Figure 4.151 Straightedge # 5870 200 022

Combined with::
Digital Depth gauge # 5870 200 072
Universal use.
To determine the installation dimension on the pre-assem-
bled converter along with diaphragm.
Parts List-No. 4660 023 002
5871 139 001 W.4

Geschäftsbereich
und Achssysteme
1. DISASSEMBLY - ELECTROHYDRAULIC SHIFT CONTROL
General Remarks:
In case of malfunctions of the transmission due to a defective shift control, we recommend to replace the complete
shift control within the replacement program.
ZF-Order-No. – for the respective shift control component – see Indication in the corresponding Spare Parts List.
An adequate Workshop equipment of our Service Stations (gearshift systems, resp. transmission test rigs) as well as
continuously trained personnel ensure a competent repair.
The following Disassembly and Assembly description (Page 1.1 ... 2.9) is therefore serving only as an Information of
the ZF-Service Stations and of the Vehicle Manufacturer which are disposing of a corresponding Workshop equip-
ment and espsecially drained Specialists.
LEGEND
1 = Shift control component (Control circuit „I“)
2 = Shift control component (Control circuit „II“)
3 = Duct plate
4 = Hydraulic pump
View of the Measuring points and Connections – see Pages 0.11 ... 0.13, resp. in the ZF-Operating
Instructions (with indication of the required pressures and pressure denomination).
ZF-Operating Instructions Order-No.: 5872 132 002!
1.1
Geschäftsbereich
und Achssysteme
Unscrew filter.
Loosen screw connection of the hydraulic pump and remove the
complete hydraulic pump.
(S) Ribbon spanner 5870 105 005
Figure 1
1.1 Gearhift system component -

Control circuit „I“:
Loosen screw connection.
Figure 2
Remove complete control unit along with released flat gaskets

(2x) and intermediate plate.
Figure 3
1 = Control unit (Control circuit I)

2 = Flat gasket (under valve block)
3 = Intermediate plate
3 4 4 = Flat gasket (on duct plate)
1 2
Figure 4
1.2
Geschäftsbereich
und Achssysteme
Replace 2 screws of the cover screw connection by adjusting

screws (M6), (Pos. see Arrows), loosen remaining screws.
Now, loosen nuts of adjusting screws uniformly.
Cover is spring-loaded !
(S) Adjusting screws (M6) 5870 204 049

(with nuts)
Figure 5
Remove cover.
Loosen plug connections of cable harness/solenoid valves.

Remove flat gasket (Arrow).
Figure 6
If necessary, disassemble cable harness.
Pull off retaining plate (Arrow) and remove subsequently cable

harness out of the cover.
Figure 7
Disassemble compression springs (2 pieces), shim(s) and spool

of the modulation valve (DMV), as well as compression spring,
shim and spool of the converter safety valve (WSV).
Figure 8
1.3
Geschäftsbereich
und Achssysteme
Remove solenoid valves.
Solenoid valve (Y3) is spring-loaded.
Figure 9
Take compression spring and spool of the shift valve/Neutral

(SN) and the complete shift valve – Forward/Reverse/Clutch K4
(S-F/R/K4) out of the valve housing.
Figure 10
Pull retaining plate out (Arrow).
Now, remove plug, spacer sleeve, compression spring and spool

of the reducing valve (RDV) out of the bore.
Plug has only short guide faces and can therefore (during the
pulling out) easily be caught on the control edges !
Do not exert force – danger of damage !
Figure 11
Replace 2 screws of the cover screw connection by adjusting

screws (M6), remove remaining screws.
Loosen nuts of adjusting screws uniformly (cover is spring-

loaded).
Remove cover and flat gasket.

(with nuts)
Figure 12
1.4
Geschäftsbereich
und Achssysteme
Take compression springs, shim and spool of the control pres-

sure valve (SDV) as well as spool (along with lock washer) of
the modulation valve (DMV) out of the valve housing.
Figure 13
Remove all screw plugs (along with O-ring).
Figure 14
Check passage of orifice C-2 (set screw M5), resp. disassemble if

necessary.
The orifice can be also demounted, resp. inserted through the

aperture (screw plug M10) in the cover, on the non-disassemb-
led control unit !
Torque limit (M5) .................................. 2,5 Nm
Figure 15
1.2 Gearhift system component -

Control circuit „II“:
Loosen screw connection, remove complete control unit with the
released flat gaskets (2x) and the intermediate plate.
Figure 16
1.5
Geschäftsbereich
und Achssysteme
Loosen screw connection, remove cover and flat gasket.
Figure 17
Separate plug connection of solenoid valve/cable harness.
Figure 18
If necessary, disassemble cable harness.
Pull off retaining plate (Arrow) and remove subsequently cable

harness out of the housing.
Figure 19
Disassemble solenoid valves.
Solenoid valves are spring-loaded !
Figure 20
1.6
Geschäftsbereich
und Achssysteme
Remove spools and compression springs out of the housing.
Figure 21
Remove all screw plugs (along with O-ring).
Figure 22
Legend ref. Figure-No. 23:
1 = Valve block/Control unit compl. (Control cicuit „I“)

1 2 = Gasket (under valve block)
4 = Gasket (on duct plate)
2 3 4
Figure 23
1.7
Geschäftsbereich
und Achssysteme
2. ASSEMBLY - ELECTROHYDRAULIC SHIFT CONTROL:
Check all components for damaged, resp. wear and renew if necessary !
Prior to the installation, check the free travel of the movable components in the housing !
Oil components prior to the assembly !
Oil according to the ZF-List of lubricants TE-ML 03 !
2.1 Shift control component - Control circuit „I“:
1 = Cable harness
2 = Reducing valve (RDV) 9
(10 bar)
8 7
3 = Shift valve (S-N/K4)
(neutral/K4) Y1 Y3 Y2
4 = Shift valve (S-F/R)
(Forward/Reverse)
5 = Modulation valve (DMV)
(3 - 12 bar) 1
6 = Control pressure valve
(SDV) (16 + 3 bar)
7 = Converter safety valve
(WSV) (8 + 2 bar)
8 = Orifice (C2) for (DMV)
9 = Solenoid valves
(Y1, Y2, Y3) 2
4 5 6
Figure 1
.
2.1
Geschäftsbereich
und Achssysteme
Draft + Legend ref. Figure No. 3 ... No. 7:
1 = Compression spring 10 = Compression spring

2 = Shim 11 = Spool
3 = Spool 12 = Lock washer
4 = Spool 13 = Orifice C-2 (Set screw M5)
5 = Shim
6 = Compression spring
7 = Spool
8 = Shim
Figure 2
Control pressure valve (SDV):

Insert spool (3), shim (2, S = optional)
and compression spring (1).
Modulation valve (DMV):

Insert spool (11) along with lock washer (12).
Valve position - see Figure-No. 1 !

Valve components - see Figure-No. 2 !
Figure 3
Screw in 2 adjusting screws (M6), line up flat gasket (Arrow) –

pay attention to the installation location !
Position cover by means of adjusting screws and nuts uniformly

against shoulder.

(with nuts))
Figure 4
Fasten cover by means of hex. head screws (equipped with disk).
At this step, replace adjusting screws.
Torque limit (M6/8.8) ............................. 9,5 Nm
Figure 5
2.2
Geschäftsbereich
und Achssysteme
Insert orifice C-2 (13).
Check passage of orifice !
Torque limit ............................................ 2,5 Nm.
Figure 6
Converter safety valve (WSV):

Insert spool (4), shim (5, S = optional) and compression spring
(6).
Modulation valve (DMV):

Insert compression spring (10), compression spring (9), shim(s)
(8), S = optional) and spool (7).
Valve position - see Figure-No. 1!

Valve components - see Figure-No. 2!
Figure 7
Draft + Legend ref. Figure-No. 9 ... No. 10:
1 = Valve (control spool compl.)

3 = Spool
4 = Spacer sleeve
5 = Spool
7 = Plug
8 = Retaining plate
Figure 8
Shift valve (S-F/R):

Insert valve (1), (control spool compl.).
Shift valve (SN/K4):

Insert compression spring (2) and spool (3).
Reducing valve (RDV):

Insert spool (5), compression spring (6), spacer sleeve (4) and
plug (7).
Valve position - see Figure-No. 1!

Valve components - see Figure-No. 8!
Figure 9
2.3
Geschäftsbereich
und Achssysteme
Reducing valve (RDV):

Press plug (7) into position (spring-preload) until retaining plate
(8) (installation position - see Draft-No. 8) can be inserted into
the plug groove.
Valve position - see Draft-No. 1 !

Valve components - see Draft-No. 8 !
Because of short guide faces, the plug (6) can easily can t during
the introduction – do not exert force !
Figure 10
Insert solenoid valve (3x), fasten it with retaining plate, flat

washer (installation position – see Figure) and socket head
screw.
Pay attention to the installation location of the solenoid valves

(position of the cable harness connections – see Figure) !
Install retaining plate, with the claw (Arrow) facing the valve
body !
Torque limit (M5/8.8) ................................. 6 Nm
Figure 11
Draft + Legend ref. Figure 13:
2 4 1 = Cable harness
2 = Retaining plate
3 = Sealing rings
6 4 = Position/Double locking
5 = Plug (3x)
6 = Cover
1 3 5
Bild 12
Pre-assemble cover:
Insert cable harness (1) and fix it with retaining plate (2).
Pay attention to the installation location of retaining plate (2) and

cable harness locking (4) – see Figure-No. 12 !
Figure 13
2.4
Geschäftsbereich
und Achssysteme
Mount flat gasket.
Figure 14
Connect cable harness with solenoid valves (plug connection).
Figure 15
Position cover.
Screw in 2 adjusting screws (M6) and position cover by means of

adjusting screws and nuts uniformly against shoulder.
Pay attention to the flat gasket !

(with nuts)
Figure 16
Fasten cover with hex. head screws (equipped with disk).

At this step, remove adjusting screws.
Torque limit (M6/8.8) ............................... 9,5 Nm
Figure 17
2.5
Geschäftsbereich
und Achssysteme
Screw in the screw plugs (M10 x 1, C-2 orifice – assembly

aperture) along with O-ring.
Torque limit (M10 x 1) ................................ 6 Nm
Figure 18
Install screw plugs (along with O-ring).
Torque limit (M10x1) ................................ 6 Nm
Figure 19
Legend ref. Figure-No. 20:
1 = Valve block/Control unit compl. (Control circuit „I“)

1
3 4 = Gasket (on duct plate)
Figure 20
Mount Control unit on the transmission – see

Section 4.14.2 / Page 4.36... 4.37 !
2.6
Geschäftsbereich
und Achssysteme
2.2 Shift control component - Control circuit „II“:
1 = Valve block
2 = Shift valve 7
3 = Shift valve
4
5
=
=
Shift valve
Solenoid valves (Y4, Y5, Y6) Y6 Y5 Y4 6
6 = Flat gasket
7 = Cover 1 5
2
3 4
Figure 21
Insert compression spring and spool of the shift valves (Pos. 2, 3

and. 4) - see Figure-No. 21).
Figure 22
Draft + Legend ref. Figure-No. 23 ... Nr. 27:
1 = Cover
2 = Solenoid valves
3 = Cable harness
4 = Cable harness locking
Figure 23
2.7
Geschäftsbereich
und Achssysteme
Insert solenoid valve (3x) and fasten with retaining plate and
socket head screw.
Pay attention to the installation location of the solenoid valves

(2) (position of the cable harness connections – see Figure-No.
23) !
Install retaining plate, with the claw (Arrow) facing the valve
body !
Figure 24
Torque limit (M5/8.8) ............................... 6 Nm
Figure 25
Insert the cable harness (3) along with sealing rings (Arrows).
Pay attention to the installation location of the cable harness

locking (4) – see Figure-No. 23 !
Figure 26
Fix cable harness (3) with retaining plate (pay attention to the
installation location – tongue in direction of Arrow).
Connect cable harness with solenoid valves (plug connection).
Figure 27
2.8
Geschäftsbereich
und Achssysteme
Mount flat gasket.
Figure 28
Fasten cover with hex. head screws (equipped with disk).
Torque limit (M5/10.9) .......................... 5,5 Nm
Figure 29
Mount screw plugs (along with O-ring).
Torque limit (M10x1) ........................... 6 Nm
Figure 30
Legend ref. Figure-No.. 31:
1 = Valve block/Control unit compl. (Control circuit „II“)

4 = Gasket (on duct plate)
2 3 4
Mount Control unit on the transmission – see

Section 4.14.1 / Page 4.35 ... 4.36 !
Figure 31
2.9
Geschäftsbereich
und Achssysteme
3. DISASSEMBLY - TRANSMISSION:
Drain oil (use suitable pan).
Fasten unit on the assembly car.
(S) Assembly car 5870 350 000

(S) Support 5870 350 092
Figure 1
3.1 Hydraulic pump:
Unscrew oil filter.
(S) Ribbon spanner 5870 105 005
Figure 2
Loosen socket head screws and remove complete pump.
The central shaft can remain in the input shaft – see Illustration
Figure-No. 4 – or in the hydraulic pump, if necessary, the central
shaft has to be pulled out of the pump !
Figure 3
Pull central shaft out of the input shaft.
Figure 4
3.1
Geschäftsbereich
und Achssysteme
Disassemble components:
6 7
Remove spacer sleeve (1), O-ring (2), angle disk (3), axial needle
cage (4), axial disk (5), O-ring (6) and O-rings (7).
5
3
1
4
2 7
Figure 5
Remove both socket head screws (Arrows).

Separate pump halves.
(S) Crow bar 5870 345 071
Figure 6
Mark installation location of the pump gears (assembly aid).
Carry out visual inspection on liners and pump gears as well as

on the pump housing (traces of running-in).
In case of serious traces of wear which are affecting the required

pump pressure, resp. the delivery rate, the hydraulic pump has to
be replaced !
Components are not exchangeable !
Figure 7
3.2 Demount complete Gearshift system component:
The total disassembly of the Shift control is illustrated in the

Section 1. Electrohydraulic shift control – Page 1.1 ... 1.7 –
the total assembly of the Shift control in the Section 2.
Electrohydraulic shift control – Page 2.1 ... 2.9 - .
Loosen screw connection of the gearshift system component –

Control circuit „I“.
Figure 8
3.2
Geschäftsbereich
und Achssysteme
Remove complete gearshift system component – Control circuit

„I“ with flat gaskets (2x) and intermediate plate.
Figure 9
1 = Shift control (Control circuit „I“)

2 = Flat gasket (under valve block))
4 3 = Intermediate plate
3 4 = Flat gasket (on duct plate)
1 2
Figure 10
Loosen screw connection of the gearshift system component –

Control circuit „II“.
Remove complete gearshift system component with flat gaskets
(2x) and intermediate plate.
Figure 11
1 = Control unit (Control circuit „II“)

1 3 = Intermediate plate
4 = Flat gasket (on duct plate)
2
3 4
Figure 12
3.3
Geschäftsbereich
und Achssysteme
3.3 Duct plate:
Loosen screw connection and remove duct plate along with flat
gasket.
Figure 13
3.4 Converter:
Pull off the complete converter.
If necessary, loosen screw connection and remove diaphragm

(pay attention to released disks).
Shaft seal from the converter bell – see Figure-No. 21/Page 3.6 –
can be also exchanged without previous housing separation.
Figure 14
3.5 Flange/Shaft seal (Output):
Remove lock plate and loosen both hex. head screws.
Figure 15
Pull off flange (along with disk and O-ring).
Figure 16
3.4
Geschäftsbereich
und Achssysteme
Remove shaft seal.
(S) Crow bar 5870 345 071
Figure 17
3.6 Gearbox housing:
Drive out both cylindrical pins.
Figure 18
Loosen housing screw connection.
Mark positions and installation location of the retaining bracket

(to make the assembly easier).
Figure 19
Screw in 2 eye bolts and separate the gearbox housing/Part I

carefully from Part II..
(S) Set of eye bolts 5870 204 002

(S) Lifting device 5870 281 047
Figure 20
3.5
Geschäftsbereich
und Achssysteme
Remove shaft seal.
Figure 21
Loosen screw connection of the converter bell.
The converter bell cannot yet be removed, the stator shaft screw
connection – see Figure-No. 23 – has also still to be loosened !
Figure 22
Loosen stator shaft screw connection and pull out the stator shaft.
Screws are inserted with locking compound – aggravated disas-

sembly !
(S) Hot-air blower 230 V 5870 221 500

115 V5870 221 501
Figure 23
Pull bearing bush out of the stator shaft.
(S) Internal puller 5870 300 007

(S) Counter support 5870 300 003
(S) Magnetic block 5870 450 003
Figure 24
3.6
Geschäftsbereich
und Achssysteme
Remove bearing outer races out of the gearbox housing (Part I),
at this step, pay attention to the mounting chamfer for rect-
angular rings – danger of damage !
For roller bearings which will not be exchanged, pay atten-

tion to the following !
Record (mark) the installation position (shaft) as well as the

single bearing coordination (bearing outer race to bearing
inner race !
Figure 25
Separate gearbox housing (Part I) from the converter bell.
(S) Plastic mallet 5870 280 004
Figure 26
Pull bearing bush out of the converter bell.
(S) Internal puller 5870 300 007

(S) Counter support 5870 300 003
Figure 27
3.7 Clutches, Input and Output shafts:
3.7.1 Clutch „K1“:
Lift the complete Clutch pack „K1“ out of the gearbox housing
(Part II).
Figure 28
3.7
Geschäftsbereich
und Achssysteme
Squeeze out and remove both rectangular rings (Arrows).
Figure 29
Pull off bearing inner race with inner plate carrier.


inner race) !
(S) Three-leg puller 5870 971 002
Figure 30
Remove roller cage half (along with collar washer) from the
inner plate carrier and outer plate carrier.
Figure 31
Squeeze circlip out.
(S) Set of external pliers 5870 900 015
Figure 32
3.8
Geschäftsbereich
und Achssysteme
Squeeze snap ring out.
Figure 33
Take end shim and plate pack out of the plate carrier.
Figure 34
Equalize preload of the cup spring pack by means of press and

pressing sleeve.
Now, squeeze circlip out.
(S) Pressing sleeve 5870 506 128

Figure 35
Remove shim and cup spring pack.
Figure 36
3.9
Geschäftsbereich
und Achssysteme
Press piston by means of compressed air from the shaft, resp. out
of the plate carrier.
Figure 37
Take both O-rings out of the piston.
Check function of the vent valve (ball) (crimped in the piston –

however freely movable in the bore) (Arrow) !
Figure 38
Pull off bearing inner race.

inner race) !
Do not carry out further disassembly – shaft (with helical gear
and plate carrier) is only exchangeable as a complete part !
(S) Grab sleeve „Super“

Clutch (K1/K2) 5873 001 036
Figure 39 Clutch (K4) 5873 011 011
(S) Basic tool 5873 001 000
3.7.2 Clutch „KR“:
Lift the complete Clutch pack „KR“ out of the gearbox housing
(Part II).
Figure 40
3.10
Geschäftsbereich
und Achssysteme
Unhook and remove both rectangular rings (Arrows).
Figure 41


inner race) !
(S) Grab sleeve „Super“ 5873 000 029

(S) Basic tool 5873 000 000
Figure 42
Figure 43
Pull off plate carrier (inner plates) with roller bearing.
If necessary, remove both bearing outer races out of the plate

carrier.
Figure 44
3.11
Geschäftsbereich
und Achssysteme
Figure 45
Figure 46


inner race) !

(S) Basic tool 5873 001 000
Figure 47
Remove shim and cup spring pack.
Figure 48
3.12
Geschäftsbereich
und Achssysteme
Figure 49
Check function of the vent valve (ball) (jammed in the piston,

however freely movable in the bore) (Arrow) !
Figure 50

inner race) !
Do not carry out further disassembly – shaft (with helical gear
and plate carrier) is only as a complete part exchangeable !
(S) Grab sleeve „Super“

Clutch (KR) 5873 001 036
Figure 51 Clutch (KV) 5873 011 011
(S) Basic tool 5873 001 000
3.7.3 Clutch „KV“:
Lift the complete Clutch pack „KV“ out of the gearbox housing
(Part II).
Carry out the further disassembly of the Clutch „KV“ in the

same way as shown in the Illustration 3.7.2 Clutch „KR“ –
see Figure-No. 41/Page 3.11 ... Figure-No. 51/Page 3.13 !
Figure 52
3.13
Geschäftsbereich
und Achssysteme
3.7.4 Clutch „K4“:
(Part II).
Carry out the further disassembly of the Clutch „K4“ in the

same way as shown in the Illustration 3.7.1 Clutch „K1“ - see
Figure-No. 29/Page 3.8 ... Figure-No. 39/Page 3.10 !
Figure 53
3.7.5 Input shaft:
Squeeze circlip (duct plate-side) out of the ball bearing groove.
Figure 54
Remove the complete input shaft out of the gearbox housing

(Part II), for this step, lift the Clutch pack K2 slightly – disas-
sembly aid.
Figure 55
Unhook and remove both rectangular rings (position of the

second rectangular ring – see Arrow).
Figure 56
3.14
Geschäftsbereich
und Achssysteme
Figure 57
Pull off ball bearing.
Figure 58
Loosen screw connection and remove oil tube with O-ring.
Figure 59
3.7.6 Clutch „K2“:
(Part II).
Carry out the further disassembly of Clutch „K2“ in the

same way as shown in the Illustration 3.7.1 Clutch „K1“ –
see Figure-No. 29/Page 3.8 ... Figure-No. 39/Page 3.10 !
Figure 60
3.15
Geschäftsbereich
und Achssysteme
3.7.7 Clutch „K3“:
(Part II).
Figure 61
Unhook and remove rectangular rings (Position – see Arrows).
Figure 62


inner race) !

(S) Basic tool 5873 000 000
Figure 63
Figure 64
3.16
Geschäftsbereich
und Achssysteme
Pull off plate carrier (inner plates) with roller bearing.
Figure 65
Figure 66
Figure 67


inner race) !

(S) Basic tool 5873 001 000
Figure 68
3.17
Geschäftsbereich
und Achssysteme
Remove support shim and cup spring pack.
Figure 69
Figure 70
Check function of the vent valve (ball) (jammed in the piston,

however freely moavable in the bore) (Arrow) !
Figure 71


inner race) !

(S) Basic tool 5873 002 001
Figure 72 Do not carry out further disassembly – shaft and plate carrier can
be exchanged only as a complete part !
3.18
Geschäftsbereich
und Achssysteme
3.7.8 Output:
Loosen socket head screws and remove screening plate/Part I.
Figure 73
Lift complete output shaft out of the gearbox housing (Part II).
Figure 74
Pull off both bearing inner races.


inner race) !
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 001
(S) Bush (short) 5873 001 005
Figure 75
Loosen screw connection and remove screening plate/Part II.
Figure 76
3.19
Geschäftsbereich
und Achssysteme
Remove bearing outer races out of the gearbox housing (Part II).


inner race) !
Figure 77
Loosen screw connections and remove oil tubes.
Figure 78
3.20
Geschäftsbereich
und Achssysteme
4. ASSEMBLY - GEARBOX:
4.1 Oil tubes:

4
3 Pre-assemble oil tubes.
Grease O-ring (2) and insert it into the annular groove of the oil
2 1 tube (1).
1 = Oil tube
2 2 = O-ring
3 = Retaining plate
4 = Socket head screw
3 4
Figure 1
Insert all oil tubes (pre-assembled) and fasten by means of the

retaining plate (3) and socket head screw (4).
Torque limit (M8/8.8) ............................. 23 Nm
Figure 2
Installation location of the various oil tubes in the gearbox

housing/Part II – see Illustration.
Torque limit (M16x1,5) ........................ 45 Nm
Figure 3
4.2 Output:
Legend ref. Figure:

1 = Gearbox housing
2 = Output shaft
3 = Flange
4 = Clutch „K3“
Figure 4
4.1
Geschäftsbereich
und Achssysteme
Position bearing outer races (output shaft FA) into the bore until
contact is obtained.
Pay attention to the installation position and bearing coordi-

nation !
See also disassembly Note - Page 3.25/Figure-No. 98 !
Figure 5
Mount screening plate/Part II.
Insert socket head screws with locking compound (Loctite-No.

262) !
Torque limit (M8/8.8) .............................. 23 Nm
Figure 6
Pre-assemble output shaft:
Press both bearing inner races against shoulder.
Pay attention to the installation position and bearing coordi-

naion !
See also disassembly Note - Page 3.19/Figure-No. 75 !
Figure 7
Insert pre-assembled output shaft.
Figure 8
4.2
Geschäftsbereich
und Achssysteme
Mount the screening plate/Part I and fasten with socket head

screws.
Insert socket head screws with locking compound (Loctite-No.

262).
Torque limit (M6/8.8) .............................. 9,5 Nm
Figure 9

As to the assembly of the shaft seal and the flange - see
Section 4.11/Page 4.31 !
4.3
Geschäftsbereich
und Achssysteme
4.3 Clutch „K3“:
Legend ref. Draft-No. 10 ... Figure-No. 31
6 5 4 1 = Shaft compl. (with plate carrier and

circlip)
2 = Piston compl. (with ball)
2 3 = O-ring
4 = O-ring
14 3 5 = Cup spring pack
16 6 = Support shim
7 = Plate pack
1 8 = End shim
9 = Snap ring(S = optional)
10 = Roller bearing
11 = Plate carrier (inner)
12 = Roller bearing
13 = Circlip (S = optional)
14 = Roller bearing (bearing inner race)
15 = Roller bearing (bearing inner race)
16 = Rectangular rings
13 12 16
11 15
10
9 8 7
Figure 10
Check passage of pressure oil supply and lubricating oil supply

holes (by means of compressed air) !
Figure 11
Insert both O-rings (3 and 4) into the piston (2) and oil.
Check the function of the vent valve (Arrow) (assembly hole

jammed – however ball is freely movable in the piston) !
Figure 12
4.4
Geschäftsbereich
und Achssysteme
Oil sealing surface of shaft and plate carrier.
Insert pre-assembled piston (2) until contact is obtained (pay

attention to the installation location – see Illustration) !
Figure 13
Line up cup spring pack (5) – stacking and installation location

of the single cup springs – see Draft-No. 10.
Position the upper cup spring centrally – with grease – (assem-

bly aid) !
Figure 14
Line up support shim (6).
Figure 15
Press bearing inner race (10) against shoulder.
Check central position of the upper cup spring – see Note of

Figure-No. 14 !
Figure 16
4.5
Geschäftsbereich
und Achssysteme
Immerse lined plates (inner plates) 30 minutes in oil, prior to the

assembly – oil according to ZF-List of lubricants TE-ML 03!
Insert plates of plate pack (7) alternately – starting with one outer
plate.
Figure 17
Mount end shim (8) and squeeze in snap ring (9) (S = optional).
Figure 18
4.3.1 Adjust/check Plate clearance:

x = Plate clearance
F = 40 Nm
1 = Shaft (with plate carrier – see Draft-No. 10)
7 = Plate pack
8 = End shim
K3 Plate clearance per friction surface = 0,10 ... 0,15 mm

e.g. 8 lined plates = 16 friction surfaces
gives Total Plate clearance 1,6 ......2,4 mm
Figure 19
Press plate pack against shoulder (F = about 40 N).
Determine Dimension I from the end face of the plate carrier to

the end shim.
Dimension I e.g....................................... 9,30 m
(S) Digital Depth gauge 5870 200 072
Figure 20
4.6
Geschäftsbereich
und Achssysteme
Position end shim (8) and snap ring (9) on the outer face of the
recess/plate carrier until contact is obtained – see Figure.
Determine Dimension II from the end face of the plate carrier to

the end shim.
Dimension II e.g. ...................................... 7,40 mm
Figure 21
EXAMPLE:
Dimension I e.g. .................................... 9,30 mm

Dimension II e.g. .............................. - 7,40 mm
gives Dimension X (Plate clearance) = 1.90 mm
If the required Total Plate clearance e.g. (1,6 ... 2,4 mm) should
not be obtained, correct it with one corresponding snap ring (9)
(S = optional) !
If disassembled –
insert both bearing outer races of the roller bearings (10 and 12)
into the plate carrier until contact is obtained.
Figure 22

Align plates radially and centrally (assembly aid).
Introduce plate carrier (11) until all inner plates are lined up.
Figure 23
4.7
Geschäftsbereich
und Achssysteme
Press on the bearing inner race (12) until the rollers of the roller
bearings (10 and 12) have a playfree contact, however no pre-
leoad is achieved.
At this step, the plate carrier has to be rotated several times in
both directions, to ensure the settling of the single rollers.
Figure 24
Determine the thickness of the Circlip for the Plate carrier

bearing fixing:
Determine thickness of the required circlip (13) by means of

feeler gauge (from end face/bearing inner race to outer locating
face/groove).
The base for an exact determination of the required circlip, is the

correct roller bearing positioning !
Figure 25
Select thickness of the circlip (S = optional) so that a playfree

fixing of the plate carrier bearing will be achieved !
Squeeze in the determined circlip (13).
Reset the circlip until contact on the groove base is obtained !
Figure 26
Pay attention to the installation position and bearing coordina-

tion – see also disassembly Note Page 3.16/Figure-No. 63 !
Figure 27
4.8
Geschäftsbereich
und Achssysteme
Figure 28
Squeeze in and hook in rectangular rings (16).
Figure 29
Insert bearing outer race into the gearbox housing/Part II.

Figure 30
Insert complete Clutch „K3“.
Figure 31
4.9
Geschäftsbereich
und Achssysteme
4.4 Clutch „K1“:
Legend ref. Draft-No. 32 ... Figure-No. 51:
1 = Shaft compl. (with spur gear, plate

carrier and circlip)
2 = Piston
3 = O-ring
4 = O-ring
5 = Cup spring pack
6 = Support shim
7 = Circlip
8 = Plate pack
9 = End shim
10 = Snap ring (S = optional)
11 = Circlip
12 = Collar washer
13 = Roller cage
15 = Roller bearing
16 = Roller bearing
17 = Rectangular ring
Figure 32
Check passage of presure oil supply and lubricating oil supply

holes (by means of compressed air).
Figure 33
Insert both O-rings (3 and 4) into the piston and oil.
Check the function of the vent valve (Arrow) (assembly bore

jammed, however ball is freely movable in the piston) !
Figure 34
4.10
Geschäftsbereich
und Achssysteme

attention to the installation location – see Illustration) !
Figure 35

Position the upper cup spring centrally - with grease - (assembly

aid) !
Figure 36
Figure 37
Preload cup spring pack (5) - by means of sleeve - until the

circlip (7) can be squeezed in.
(S) Pressure piece 5870 506 128
Figure 38
4.11
Geschäftsbereich
und Achssysteme

Insert plates of plate pack (8) alternately – starting with one outer
plate.
Figure 39
Mount the end shim (9) and squeeze in the snap ring (10) (S =
optional).
Figure 40

x = Plate clearance
F = 40 Nm
8 = Plate pack
9 = End shim

gives Total Plate clearance 2,4 ... 3,6 mm
Figure 41


4.12
Geschäftsbereich
und Achssysteme

the end shim.
Dimension I e.g. ...................................... 7,30 mm
Figure 42
recess/plate carrier until contact is obtained – see Illustration.

the end shim.
Dimension II e.g. ................................... 4,30 mm
Figure 43
EXAMPLE:
Dimension I e.g. .................................... 7,30 mm
Dimension II e.g. ................................ - 4,30 mm
gives Dimension X (Plate clearance) = 3,00 mm
If the required Total Plate clearance e.g.
K1 2,4 ... 3,6 mm
K2 1,6 ... 2,4 mm
K4 1,6 ... 2,4 mm
Should not be obtained, correct it with a corresponding snap ring
(10) (S = optional) !
Squeeze in circlip (11).
Figure 44
4.13
Geschäftsbereich
und Achssysteme
Line up one collar washer (12).
Figure 45
Make one roller cage (13) adhere with grease in the inner plate
carrier (assembly aid).
Pay attention to the installation location of the roller cage –

great/small roller cage diameter – see in this connection Draft-
No. 32 !
Figure 46

Figure 47
Insert outer roller cage (13) and line up second collar washer
(12).
At a correct assembly (all plates lined up, correct installation

location of the two roller cages), the collar washer must not pro-
trude beyond the locating face of the bearing inner race (15)
- to be checked !
Figure 48
4.14
Geschäftsbereich
und Achssysteme
Figure 49
Figure 50
Squeeze in and hoook in rectangular rings (17 and 18).
The installation of the compl. Clutch „K1“ – see Page 4.27/

Figure-No. 92 and 93 !
Figure 51
4.15
Geschäftsbereich
und Achssysteme
4.5 Clutch „K2“ and „K4“:
Legend ref. Draft-No. 52:
1 = Shaft compl. (with spur gear, plate

carrier and circlip)
2 = Piston
3 = O-ring
4 = O-ring
5 = Cup spring pack
6 = Support shim
7 = Circlip
8 = Plate pack
9 = End shim
11 = Circlip
12 = Collar washer
13 = Roller cage
15 = Roller bearing
16 = Roller bearing
Figure 52
The assembly of the Clutches „K2“ and „K4“ has to be carried out in the same way as
that of the Clutch „K1“ – see Section 4.4 Figure-No. 33/Page 4.10 ... Figure-No. 51/Page
4.15.
However, the differing number of the plates, and with it the modified plate clearance –
see Indication Page 4.12 – has to be considered !
Pre-assembled Clutches „K1“ - „K2“ - „K4“.

K2 K1
K4
Figure 53
4.16
Geschäftsbereich
und Achssysteme
Insert bearing outer race („K2“) into gearbox housing/Part II.

Figure 54
The installation of the compl. Clutch „K4“ – see Page 4.19/

Figure-No. 64 and 65 !
Figure 55
4.6 Oil suction tube:
Lay O-ring (Arrow) into the groove of the oil suction tube and
oil.
Figure 56
Insert pre-assembled oil suction tube.
Torque limit (M8/8.8) ........................... 23 Nm
Figure 57
4.17
Geschäftsbereich
und Achssysteme
4.7 Input shaft:

7 6
1 = Input shaft
2 = Turbine shaft
3 = Snap ring
4 = Ball bearing
5 = Circlip
6 = Snap ring
2 3 1 4 5 7 = Rectangular ring
Figure 58

Install turbine shaft (2) (Figure-No. 59) – only required in case of
a new part assembly !
Insert snap ring (3) into the groove of the turbine shaft (2), now,
introduce turbine shaft (2) into the profile of the input shaft (1)
until the snap ring (3) snaps into the groove of input shaft (1).
(In this connection, see also Draft-No. 58) !
Figure 59
Press ball bearing (4) upon the input shaft (1) until contact is
obtained.
Pay attention to the installation location of the ball bearing – see

Figure – groove for snap ring (6) on top !
Figure 60
Squeeze in circlip (5).
Figure 61
4.18
Geschäftsbereich
und Achssysteme
Insert the pre-assembled input shaft into the gearbox housing/

Part II.
Figure 62
Squeeze snap ring (6) into the groove of the ball bearing (4).
Figure 63
Insert the bearing outer race („K4“) into the gearbox housing/
Part II.

Figure 64
Figure 65
4.19
Geschäftsbereich
und Achssysteme
4.8 Clutch „KR“:
1 = Shaft compl. (with plate carrier,

helical gear and circlip)
2 = Piston compl. (with ball)
3 = O-ring
4 = O-ring
5 = Cup spring pack
6 = Support shim
7 = Plate pack
8 = End shim
9 = Snap ring(S = optional)
10 = Roller bearing
12 = Roller bearing
14 = Roller bearing
15 = Roller bearing
Figure 66
Check passage of pressure oil supply and lubricating oil supply

holes (by means of compressed air) !
Figure 67
Lay both O-rings (3 and 4) into the piston (2) and oil.
Check the function of the vent valve (Arrow) (assembly bore

jammed, however the ball is freely movable in the piston) !
Figure 68
4.20
Geschäftsbereich
und Achssysteme

attention of the installation position – see Illustration) !
Figure 69

Position upper cup spring centrally – with grease – (assembly

aid) !
Figure 70
Figure 71

Insert plates of plate pack (7) alternately– starting with one outer
plate.
Figure 72
4.21
Geschäftsbereich
und Achssysteme
Mount end shim (8) and squeeze in snap ring (9) (S = optional).
Figure 73

8 F F 9 X x = Plate clearance
F = 40 Nm
7 7 = Plate pack
8 = End shim
KR Plate clearance per friction surface = 0,10 ... 0,15 mm

1 gives Total Plate clearance 2,2 ... 3,3 mm
Figure 74 KV Plate clearance per friction surface = 0,10 ... 0,15 mm
gives Total Plate clearance 2,2 ..... 3,3 mm

the end shim.
Dimension I e.g. ...................................... 9,9 mm
Figure 75
recess/plate carrier against shoulder – see Figure.

the end shim.
Dimension II e.g. ............................... 7,10 mm
Figure 76
4.22
Geschäftsbereich
und Achssysteme
EXAMPLE:
Dimension I e.g..................................... 9,90 mm

Dimension II e.g.................................. - 7,10 mm
gives Dimension X (Plate clearance) = 2,80 mm
If the required Total Plate clearance e.g. (2,2 ... 3,3 mm)
should not be obtained, correct it with one corresponding
snapring (9) (S = optional) !
Check central position of the upper cup spring – see Note of

Figure-No. 70 !

Figure 77
If disassembled -
insert both bearing outer races of the roller bearings (10 and 12)
into the plate carrier until contact is obtained.
Figure 78

Figure 79
4.23
Geschäftsbereich
und Achssysteme
Press bearing inner race (12) on until the rollers of the roller
bearings (10 and 12) have a playfree contact, however no pre-
load is achieved.
At this step, the plate carrier has to be rotated several times in
both directions to ensure the settling of the single rollers.

Figure 80
Determine thickness of the Circlip for the Plate carrier

bearing fixing:
Determine thickness of the required circlip (13) by means of

feeler gauge (from end face/bearing inner race to outer locating
face/groove).
The base for an exact determination of the required circlip is the

correct roller bearing positioning !
Figure 81
Select thickness of the circlip (S = optional) so that a playfree

fixing of the plate carrier bearing will be achieved !
Squeeze in the determined circlip (13).
Reset circlip until contact on the groove base is obtained !
Figure 82

Figure 83
4.24
Geschäftsbereich
und Achssysteme
Pay attention to the installation position and bearing coor-

dination – see also disassembly Note Page 3.13/Figure-No.
51 !
Figure 84
Squeeze in and hook in rectangular rings (16 and 17).
The installation of the compl. Clutch „KR“ – see Page

4.26/Figure-No. 50 and 51 !
Figure 85
4.9 Clutch „KV“:
Legend ref. Draft-No. 86:
7 8 9 10 1 = Shaft compl. (with helical gears,

plate carrier and circlip)
2 = Piston
11 3 = O-ring
15 4 = O-ring
12 5 = Cup spring pack
16 13 6 = Support shim
17 7 = Circlip
8 = Plate pack
9 = End shim
11 = Circlip
12 = Collar washer
1 13 = Roller cage
14 15 = Roller bearing
3 16 = Roller bearing
2 18 = Rectangular ring
4 5 6
Figure 86 Pre-assemble Clutch „KV“ as Clutch „KR“
- see Section 4.8 Figure-No. 67/Page 4.20 ... Figure-No. 85/Seite 4.25 !
4.25
Geschäftsbereich
und Achssysteme
Pre-assembled Clutches „KR“ - „KV“ and „K1“
K1 KV KR
Figure 87
Insert the bearing outer race („KV“) into the gearbox housing/
Part II.

Figure 88
Insert complete Clutch „KV“.
Figure 89
Insert the bearing outer race („KR“) into the gearbox housing/
Part II.

Figure 90
4.26
Geschäftsbereich
und Achssysteme
Insert complete Clutch („KR“).
Figure 91
Insert the bearing outer race („K1“) into the gearbox housing/
Part II.

Figure 92
Insert complete Clutch („K1“).
Figure 93
1 Total view of the clutches in the gearbox housing/Part II.
Clutch arrangement:
7 1 = Output 5 = K4
6 2 = K1 6 = K2
2 3 = KV 7 = K3
4 = KR
5
3
4
Figure 94
4.27
Geschäftsbereich
und Achssysteme
4.10 Gearbox housing/Converter bell:

1 2
1 = Converter bell
2 = Shaft seal
3 = Bearing bush
3
Figure 95
Install shaft seal (2) into the converter bell (1).
Shaft seal installation position – sealing lip facing the oil cham-
ber – (see Draft).
Outer shell of the shaft seal
- if metal cover with sealing compound Loctite (Type- No.
574).
- if rubber-coated wet with spirit.
(S) Driver 5870 048 219
Figure 96
Insert bearing bush (3) against shoulder, using sealing com-

pound (Loctite Type-No. 574).
Now, oil the bearing bush.
(S) Driver 5870 048 219
Figure 97
Screw in 2 adjusting screws (M10) into the gearbox housing/

Part I (outer hole circle/converter bell screw connection).
Cover mounting face (contact face – Arrow) of converter bell/
gearbox housing/Part I with sealing compound (Loctite Type-No.

574).
Unite gearbox housing/Part I with converter bell.
(S) Set of eye bolts 5870 204 002
Figure 98
4.28
Geschäftsbereich
und Achssysteme
Install bearing bush – with sealing compound (Loctite Type-No.

574) – into the stator shaft.
Now, oil the bearing bush.
Figure 99
Screw in 2 adjusting screws (M10).
Insert pre-assembled stator shaft.
Figure 100
Fasten stator shaft with socket head screws.
Torque limit (M10/8.8) ...................... 46 Nm
Figure 101
Insert all bearing outer races into the gearbox housing/Part I

(make adhere with grease – assembly aid).
6 1
5 Clutch arrangement:
1 = Output 5 = K4
7 2 = K1 6 = K2
4 3 = KV 7 = K3
4 = KR
3 2

Figure 102
4.29
Geschäftsbereich
und Achssysteme
Remove adjusting screws and screw in hex. head screws of the

converter bell screw connection.
Pay attention to the different screw lengths !

Torque limit (M10/8.8) ......................... 46 Nm
Figure 103
Cover mounting face (contact face) of the two gearbox housing

halves with sealing compound (Loctite Type-No. 574).
Check the centrical position of the rectangular rings on the

different shafts (assembly aid) !
Unite gearbox housing halves carefully !
Figure 104
Screw hex. head screws in – do not tighten.

Position retaining bracket – position, see disassembly Note Page
3.5/Figure-No. 19.
Insert both cylindrical pins (Arrows) (fixing of gearbox housing

halves).
Pay attention to the different screw lengths !
Figure 105
Tighten hex. head screws finally.
Torque limit (M10/8.8) ....................... 46 Nm
Figure 106
4.30
Geschäftsbereich
und Achssysteme
4.11 Install Shaft seal and Output flange:

7 6 3 Legend ref. Draft-No. 107 ... Figure-No. 112:
1 = Gearbox housing
2 = Output shaft
3 = Shaft seal
8 4 = Screening plate
9 5 = Flange
6 = O-ring
2 7 = Disk
5 8 = Hex. head screws
4 1 9 = Lock plate
Figure 107
Shaft seal (3), if:

- Outer shell/rubber-coated wetr with spirit.
- Outer shell/metall cover with sealing compound
(Loctite Type-No. 574)
and install with the sealing lip facing the oil chamber.
Grease area of sealing lip/dust lip !

At application of the prescribed driver, the exact installation
location will be obtained – see also Draft-No. 107 !
(S) Driver 5870 048 200
Figure 108
Mount screening plate (4) upon flange (5).
Pay attention to the installation location – see Draft-No. 107 !
Line up the pre-assembled flange.
Figure 109
Insert O-ring (6) and disk (7).
Figure 110
4.31
Geschäftsbereich
und Achssysteme
Fasten flange by means of hex. head screws (8).
Torque limit (M8/10.9) .................. 34 Nm
Figure 111
Fix hex. head screws by means of lock plate (9).
(S) Driver 5870 057 012

(S) Handle 5870 260 002
Figure 112
4.12 Duct plate:
Position input shaft against shoulder.
Figure 113
Line up and hook in rectangular ring.
Position rectangular ring centrally – with grease – (assembly aid)

!
Figure 114
4.32
Geschäftsbereich
und Achssysteme
Screw in 2 adjusting screws (M8) (Arrows).
Line up flat gasket and make it adhere with grease (assembly

aid).
(S) Adjusting screws 5870 204 011
Figure 115
Insert orifice.
Torque limit (M5) ............................ 2,5 Nm
Figure 116
Insert ball and compression spring (check valve).
Figure 117
Line up duct plate until contact is obtained and fasten with socket
head screws (Torxform).
Tightening sequence of the screw – inside screws at first – and

going on toward outward !
Torque limit (M8/Torxform) ................ 23 Nm

(S) Insert TX 40 5873 042 004
Figure 118
4.33
Geschäftsbereich
und Achssysteme
4.13 . Version with Solenoid valves for

Differential lock and Parking brake:
1 = Solenoid valve/Differential lock
2 = Solenoid valve/Parking brake
3 = Installation position (Solenoid valve) for Version with
front axle disconnection
4 = Duct plate
5 = Control unit (Control circuit II)
6 = Control unit (Control circuit I)
Figure 119
Solenoid valve components:
1 = Screw cap
6 2 = Coil
2 4 3 = O-ring
7 4 = Valve body
1 5 5 = O-ring
3 6 = O-ring
7 = O-ring
3
Figure 120
Screw in valve body (4) along with O-rings (5, 6, 7).
Torque limit (3/4-16 UNF-2B) .......... 27 Nm

At the Version „without“ solenoid valves, the mounting holes
have to be closed with screw plugs (along with O-ring) !
Torque limit (3/4-16 UNF-2B) ......... 27 Nm
Figure 121
Line up coil (2) along with O-rings (3) (installation location – see
Draft-No. 119), and fix with screw cap (1).
Torque limit ..................................... 6 Nm
Figure 122
4.34
Geschäftsbereich
und Achssysteme
4.14 Install compl. Control unit:

Total assembly of the Control unit – see Section
1 2. ASSEMBLY – ELECTROHYDRAULIC SHIFT
CONTROL – Page 2.1 ... 2.9 !
4.14.1 – Component – Control circuit II:
2 3 4
Legend ref. Figure-No. 123 ... Figure-No. 128:
1 = Control unit (Control circuit II)
Figure 123
Insert 2 adjusting screws (M6) – see Arrows – and line up flat

gasket (4).
(S) Adjusting screws (M6) .................. 5870 204 063
Figure 124
Line up intermediate plate (3).
Figure 125
Line up flat gasket (2).
Figure 126
4.35
Geschäftsbereich
und Achssysteme
Line up compl. Control unit/Control circuit II (1).
Figure 127
Fasten complete Control unit/Control circuit II with hex. head

screws (along with disk).
Torque limit (M6/10.9) ......................... 9,5 Nm
Figure 128
4.14.2 Component – Control circuit I:

Legend ref. Figure-No. 129 ...Figure-No. 134:
4
3 1 = Control unit (Control circuit I)
1 2
Figure 129
Insert 2 adjusting screws (M6) – see Arrows – and line up flat

gasket (4).
Figure 130
4.36
Geschäftsbereich
und Achssysteme
Line up intermediate plate (3).
Figure 131
Line up flat gasket (2).
Figure 132
Line up compl. Control unit/Control circuit I (1).
Figure 133
Fasten complete Control unit/Control circuit I with hex. head

screws (along with disk).
Torque limit (M6/10.9) ......................... 9,5 Nm
Figure 134
4.37
Geschäftsbereich
und Achssysteme
4.15 Hydraulic pump:

3 4
2 Oil components of the pump and place them into the pump
housing (1).
5 Legend ref. Figure-No. 135 ... Figure-No. 137:
5 1 = Pump housing 4 = Pump gear II
2 = O-ring 5 = Cylindrical pins
3 = Pump gear I
Pay attention to the installation location of the pump gears –
1 insert pump gears with the chamfered tooth side showing down-
ward – see also disassembly Note Page 3.2/Figure-No. 7 !
Figure 135
Mount pump cover and fasten with socket head screws.
Torque limit (M8/12.9) 40 Nm
Figure 136
Lay in the O-rings (see Arrows).
Fix O-rings with grease (assembly aid) !
Figure 137
Legend ref. Draft-No. 138 ... Figure-No. 143)
1 = Pump gear II
2 = O-ring
3 = Pump housing
4 = Axial disk
5 = Axial needle cage
6 = Angle disk
7 = Spacer sleeve
8 = Central shaft
Figure 138
4.38
Geschäftsbereich
und Achssysteme
Line up axial disk (4) and axial needle cage (5).
Figure 139

Mount angle disk (6).
Pay attention to the installation location – see Draft-No. 138 !
Figure 140
Insert O-ring (2).
Grease O-ring (assembly aid) !
Figure 141
Line up spacer sleeve (7).
Spacer sleeve has to be mounted on the pump (as illustrated)

and not to be lined up on the central shaft –
to ensure the function !
Figure 142
4.39
Geschäftsbereich
und Achssysteme
Insert central shaft (8) until contact is obtained.
Installation position – see Draft-No. 138 !
Figure 143
Mount pre-assembled pump.
Figure 144
Position pump with socket head screws uniformly against shoul-

der and fasten it.
Torque limit (M12/10.9) ......................... 115 Nm
Figure 145
Mount filter.
Carry out filter assembly – according to Instructions/see filter

shell (ZF-Original filter) !
Figure 146
4.40
Geschäftsbereich
und Achssysteme
4.16 Converter:
Position 1 disk each (s = 1,00 mm) upon the diaphragm moun-

ting webs (4x).
Figure 147
Mount diaphragm (2 pieces).
Pay attention to the installation location !

Spot-welded reinforced disks of the diaphragm always on the
outside – see Arrows !
Figure 148
Fasten diaphragm with hex. head screws (equipped with disk) !
Pay attention to the disks which are under the diaphragm – see
Figure-No. 147 !
Insert hex. head screws with Loctite (Type-No. 262) !
Torque limit (M10/8.8) ............................. 46 Nm
Figure 149
Introduce complete converter until the gear splines of central

shaft, turbine shaft and stator shaft are accommodated.
Figure 150
4.41
Geschäftsbereich
und Achssysteme
Control dimension for the lined up converter – from the

diaphragm on top to the mounting face/converter bell (see
Figure)
L = about 59 mm.
The indicated control dimension serves only for the converter

assembly, however not for the mounting engine/transmission !
(S) Straightedge 5870 200 022

Figure 151
Secure converter by means of quick hardener (transport protec-

tion).
Figure 152
Mount breather (Arrow).
Torque limit (M10 x 1) ............................. 6 Nm
Figure 153
4.17 Oil drain plug:

Screw in oil drain plug and the remaining screw plugs (along
with O-ring).
Position – see also various Illustrated Tables Page 0.10 ... 0.13!
Torque limit (1/2-20 UNF) MA = 11 Nm
Figure 154 Prior to the commissioning of the unit, the Indications, resp.
Specifications and Notes of the ZF-Operating Instructions as
well as the Specifications and Notes of the Vehicle Manufac-
turer have to be observed !
4.42
8990418
An Oshkosh Corporation Company
JLG Industries, Inc.

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USA
Phone: +1-717-485-5161
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Fax: +1-717-485-6417
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Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Sverige AB

UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
Phone: +48 (0)914 320 245 Scotland 08755Castellbisbal, Barcelona Sweden
Fax: +48 (0)914 358 200 Phone: +44 (0)141 781 6700 Spain Phone: +46 (0)850 659 500
Fax: +44 (0)141 773 1907 Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762
www.jlg.com

B - ZF - Transmission - 4 WG-98 TS

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Supplemental Repair Manual

An Oshkosh Corporation Company

INSTRUCTIONS CONCERNING THE REPAIR MANUAL

Specifications concerning Operation, Maintenance and Description – see the

Abt.: ASTDM / Section : ASTDM

1. Constantly trained personnel

2. Prescribed installations, e.g. Special Tools

3. Genuine ZF-Spare Parts according to the latest phase of development

This applies also in case of a renouncement of Genuine ZF-Spare Parts.

GENERAL WORKING INSTRUCTIONS

We assume that the Special Tools, specified by ZF, will be used.

The old sealing compound must be carefully removed.

The latter refers expecially to new parts.

After the repair, ZF-Units are filled up with oil.

The Lists of Lubricants are available at all ZF-Service Stations.

CONCERNING THE LABOUR SAFETY

The proper Repair of these ZF-Products requires especially trained personnel.

The Repairer himself is obliged to provide for the training.

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Density lineaire en kg/m; Density superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148

Metric ISO-Standard Thread DIN 13, Page 13

Metric ISO-Fine Tread DIN 13, Page 13

INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

3 4660 023 002

1 = Transmission Type (e.g.. WG-98 TS)

2 = Serial number (e.g. PS00002)

3 = ZF-Parts List number (e.g. 4660 023 002)

Specfications concerning Spare Parts Orders

2. Serial number These Indications can be seen on the

4. Make und Type of the vehicle

5. Denomination of the Spare Part

6. Spare Part number

If all above-mentioned Specifications are considered,

19 = DRUCKANSCHLUSS BETRIEBSBREMSE 9/16“ - 18 UNF 15 Nm

CONVERTER TRANSMISSION PUMP

INPUT POWER TAKE-OFF

INSTRUCTION CONCERNING THE REQUIRED

Version Approved lubricants Recommended

1205 75103c / 1296

LIST OF SPECIAL TOOLS FOR THE DISASSEMBLY AND ASSEMBLY

DISASSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO.

Figure 1.01 Assembly car 5870 350 000

Figure 3.02 Ribbon spanner 5870 105 005

Figure 3.06 Crow bar 2 pieces needed 5870 345 071

Figure 3.13 Figure 4.118 Insert TX 40 / 1/2“ 5873 042 004

Figure 3.23 Hot-air blower 230 V 5870 221 500

Figure 3.24 Internal puller # 5870 300 007

Figure 3.26 Plastic mallet ∅ 60 mm 5870 280 004

5871 139 001 W.1

LIST OF SPECIAL TOOLS FOR THE DISASSEMBLY AND ASSEMBLY

DISASSEMBLY ASSEMBLY DENOMINATION/APPLICATION SPECIAL TOOLS PART-NO.

Figure 3.30 Three-leg puller # 5870 971 002

Figure 3.32 Set of external pliers # A1-A2-A3-A4