Zf As Tronic Trucks 1327 751 103 2005 Repair Manual

Full download: http://manualplace.com/download/zf-as-tronic-trucks-1327-751-103-2005-repair-manual/

Repair Manual

Transmission Actuator and Clutch

Actuator

1327 751 103

This is the cut pages sample. Download all 40 page(s) at: ManualPlace.com
Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright. Any

reproduction or dissemination in whatever form
which does not comply fully with the intended pur-
pose of this documentation is prohibited without the
consent of ZF Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2005-09

Edition: 2005-09

1327 751 103

ZF-AS Tronic Table of Contents

Page

Preface ........................................................................................................................................................... 5
Safety Instructions ......................................................................................................................................... 6
General Information ...................................................................................................................................... 6
Instructions for Carrying out Repairs ............................................................................................................ 7
Overview of Amendments: 1327 751 003...................................................................................................... 9
Tightening Torques for Nuts and Bolts, Extract from ZFN 148 .................................................................... 10
Screw Plugs DIN 908, 910, and 7604 ............................................................................................................ 11
Union Screws DIN 7643 ................................................................................................................................ 11
Conversion from DIN to ISO Standards ........................................................................................................ 12
Special Tool..................................................................................................................................................... 14
Consumables .................................................................................................................................................. 15
ZF Repair Kits for Transmission/Clutch Actuator ........................................................................................ 16

Removing Transmission Actuator .................................................................................................................. 17

Fitting Transmission Actuator........................................................................................................................ 19

Removing Upper Section................................................................................................................................ 22

Replacing Travel Sensors (HG, GV, GP, and Gate)......................................................................................... 23

Replacing Solenoid Valve Unit ....................................................................................................................... 24

Replacing Cpl. Selector Cylinder ................................................................................................................... 25

Bracket for Temperature and Speed Sensor .................................................................................................. 26

Fitting Bracket for Temperature and Speed Sensor....................................................................................... 28

Removing Wiring Harness (Input Speed Sensor and Temperature Sensor) ................................................ 30

Fitting Wiring Harness (Input Speed Sensor and Temperature Sensor) ...................................................... 32

Replacing Pressure Relief Valve ..................................................................................................................... 34

Dismantling Lower Section of Transmission Actuator .................................................................................. 35

Assembling Lower Section of Transmission Actuator................................................................................... 37

Programming Transmission Actuator ............................................................................................................ 39

Programming Flash EPROMS with ZF Test Program.................................................................................... 40
Description of Test.......................................................................................................................................... 40
Outgoing Inspection ....................................................................................................................................... 40

Clutch Actuator .............................................................................................................................................. 41

1327 751 103 - 2005-09 3

Zf As Tronic Trucks 1327 751 103 2005 Repair Manual
Full download: http://manualplace.com/download/zf-as-tronic-trucks-1327-751-103-2005-repair-manual/

Preface

This manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.

This manual deals with a ZF product in accordance

with the state of development on the date of issue.

However, due to continuing development of the

product, repair work might require work practices
and test or adjustment data which are not contained
in this manual.
We therefore recommend that work done on your
ZF product is carried out only by skilled mechanics
and fitters who have had their practical and
theoretical knowledge updated on a regular basis at
our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG

all over the world offer you:

1. Well-trained personnel,

2. Specified equipment,
e.g.: Special tools

3. Genuine ZF spares, according to

our latest specifications

All work performed at these service locations is

carried out conscientiously and with care.

Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
the individual case.
ZF Friedrichshafen AG
Nutzfahrzeug- und Sonder-Antriebstechnik Damage resulting from work performed by non-ZF
Commercial Vehicle and personnel in an improper and unprofessional man-
Special Driveline Technology ner, together with follow-on costs caused by such
Service Werk 2 (Plant 2) work, is excluded from the contractual warranty
Phone: +49 (0)7541 77-0 agreement.
Fax: +49 (0)7541 77-908000 This also applies where genuine ZF spare parts have
Internet: www.zf.com not been used.

2003-08 5
This is the cut pages sample. Download all 40 page(s) at: ManualPlace.com