ZF CV Manuala 16S-1620 Participant Handout Manual Reparatie

FORD TRAINING
After Sales Technical Training
ZF 16 S 1620 Transmission
Ecosplit 3
Participant Handout
Subject to technical changes
Copyright by ZF
This documentation is protected by copyright. Any

reproduction or dissemination in any form that does
not fully agree with the intended purpose of this
documentation is prohibited without the consent of
ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG / 2010-05
Edition: 2010-05
1315 751 103

ZF-Ecosplit Table of Contents
Page
Transmission Overview.................................................................................................................. 4
Overview of Amendments ............................................................................................................. 5
Preface ............................................................................................................................................ 6
Safety Instructions.......................................................................................................................... 7
Instructions for Repairs.................................................................................................................. 8
Tightening Torques......................................................................................................................... 10
Consumables................................................................................................................................... 11
Spring Table.................................................................................................................................... 12
Setting Data..................................................................................................................................... 13
Transmission Tightening Torques.................................................................................................. 16
Special Tools ................................................................................................................................... 21
1 Plastic Tubes ...................................................................................................................................... 1-1
2 Shift Turret......................................................................................................................................... 2-1
3 Range Change Group......................................................................................................................... 3-1
4 Planetary Gearset with Synchronizers............................................................................................. 4-1
5 Splitter Group Piston and 5/2-Way Valve......................................................................................... 5-1
6 Release Unit, Connection Plate, and Pump.................................................................................... 6-1
7 Clutch Housing ................................................................................................................................ 7-1
8 Shaft and Selector Rails .................................................................................................................. 8-1
9 Intermediate Housing...................................................................................................................... 9-1
10 Input Shaft ....................................................................................................................................... 10-1
11 Counter shaft ................................................................................................................................... 11-1
12 Main Shaft........................................................................................................................................ 12-1
13 Bearing Setting on Main Shaft, Input Shaft, and Countershaft ................................................... 13-1
14 Synchronizers .................................................................................................................................. 14-1
1315 751 103 - 2010-05 3

ZF-Ecosplit Transmission Overview
NOTE Planet carrier:

This manual replaces the following manuals – straight-toothed version
– 1315 751 101 (8/16 S 151, 16 S 221)
– 1315 751 110
– helical-toothed version
– 1316 751 101
– standard
– 1316 751 102
– reinforced version
(16 S 251, 16 S 2720 TO)
This manual contains information about the following
transmissions and versions: Release fork:
– pull-type clutch version
• Transmission types – push-type clutch version
(contained in models 1315, 1316, 1341, 1342,
1343, 1344, and 1345) Connection plate and pump:
16 S 1511) / 8 S 1511) / 16 S 181 / 8 S 181 / – split version
16 S 221 / 16 S 222 / 16 S 2512) – single-piece version
16 S 1620 TD1) / 16 S 1820 TO1)
16 S 1920 TD / 16 S 2220 TO Input shaft:
16 S 2220 TD / 16 S 2520 TO – for axial roller bearings (standard)3)
16 S 2320 TD / 16 S 2720 TO2) – for axial roller bearings with ring (16 S 222)3)
– for tapered roller bearings (standard)
– for tapered roller bearings with ring
• Variants
– for helical gear with needle ring (needle roller and
Shift turret:
cage assembly)
– without servo unit
– Disintegrated servo unit (add on)
Main shaft:
– with integrated servo unit
– with axial roller bearings3)
– with gate-dependent servo unit
– with tapered roller bearings
– H-H (double-H)
– UE-H (Superimposed H) Synchronizer:
– MGS (Manual Gearshift) – ZF-BK
– HGS (Hydraulic Gearshift) For transmissions with servo unit
– CGS (Cable Gearshift) (all gears)
– ZF-D
Range change group: For transmissions without servo unit
– Standard (only 1st/2nd gear)
– reinforced version – Synchronizers with molybdenum
(16 S 251, 16 S 2720 TO) (all gears)
– Synchronizers with carbon
(only 1st/2nd and 3rd/4th gear for transmissions
with servo unit)
1) compact version
2) reinforced version
3) 100 % overrun (with auxiliary brake in engine)
1315 751 103 - 2010-05 4

Overview of Amendments: 1315 751 103
Index Date of Issue Chapter Initiator Comment
2010-05 All LKS-T Summary of all Ecosplit 3 Repair Manuals
1315 751 103 - 2010-05 5

Preface
Preface Warranty
This manual is intended for skilled personnel Repair work carried out at ZF Service Points is
trained by ZF Friedrichshafen AG to carry out subject to the contractual conditions prevailing
maintenance and repair work on ZF products. in the individual case.
The work described below may only be performed
by authorized, trained, and instructed staff. It is Direct and/or subsequent costs are not covered by
the responsibility of the user’s company or repair this contractual liability when:
company to ensure that their repair staff is properly
• work has been performed improperly or by
trained.
unskilled personnel, by non-ZF-personnel,
and/or
This manual deals with a ZF series product in
accordance with the state of development on the • use of “non” genuine ZF parts.
date of issue.
In case of failure it is mandatory to act immediately,
However, due to continuing technical advancements so to ensure the complete function of the ZF unit
of the product, repair work might require work and minimize the scope of damage.
practices and test or adjustment data which are not
contained in this manual. In case of proven unfounded delay in repair we
We therefore recommend that work done on your reserve the right of partial acceptance or even a
ZF product is carried out only by skilled mechanics rejection of warranty claims.
and fitters who have their practical and theoretical
knowledge updated on a regular basis at our Service
Training Center.
Service points equipped by ZF Friedrichshafen AG

all over the world offer you:
1. Continuously trained personnel,
2. Specified equipment,
e.g.: special tools,
3. Genuine ZF spare parts in accordance

with the latest volume production
specifications.
All work performed at these service locations

is carried out conscientiously and with care.
ZF Friedrichshafen AG
Driveline and Chassis Technology
2008-06 6
Safety Instructions
The following safety instructions are used ! DANGER to the health!

in this repair manual:
Ensure confident handling with supplies.
Manufacturer’s instructions must be observed.
NOTE
Refers to special working procedures, methods,
information, use of auxiliary equipment, etc. ! DANGER to the environment!
Lubricants, consumables, and cleaning agents must
CAUTION
not be allowed to enter the soil, ground water, or
Is used when the instructions are not complied
sewage system.
with or not followed precisely and could lead to
• Ask your local environment agency for safety
the product being damaged.
information on the relevant products and adhere
to their requirements.
• Collect used oil in a suitably large container.
! • Dispose of used oil, dirty filters, lubricants, and
DANGER!
cleaning agents in accordance with environmental
Is used when lack of care could result in personal
protection regulations.
injury or danger to life.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
CAUTION
Safety Instructions
The transmission must NOT be suspended by the
input shaft OR by the output flange/add-on parts.
As a rule, repair technicians for ZF units are
responsible for their own workplace safety.
To avoid injury to personnel and damage to

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

Correct
products must receive appropriate training in
advance.
Compulsory training is the responsibility of the
repair staff.
! DANGER!
Do not walk under suspended load during parts
transportation with a hoist.
2008-06 7
Instructions for Repairs
General Information Cleaning Parts
Read this manual carefully before starting tests or Remove old sealing compound residues from all
repair work. sealing faces. Carefully remove burrs or other
uneven patches using an oil stone.
The ZF-Service Information details must be Lube bores and grooves must be free from anti-
observed. These are available from all ZF Service corrosion grease and foreign matter. Check that the
Centers or from the ZF-ServiceLine. passage is free.
Carefully cover opened transmissions to prevent the
In any cases of doubt, always contact the relevant entry of foreign matter.
expert departments at ZF-Service.
Whenever working on the transmission, ensure
cleanliness and carry out the work as instructed. Reusing Parts
Use specified tools to dismantle and assemble
transmissions. Parts such as antifriction bearings, multidisks,
thrust washers etc., must be inspected by a
specialist, who should decide whether they can
CAUTION be re-used or not.
The pictures, drawings, and components shown Replace parts which are damaged or have suffered
do not always represent the original object, but are from excessive wear.
used to illustrate working practices.
The pictures, drawings, and components are not to • Gaskets, locking plates
scale and no conclusions must be drawn about size Parts which cannot be removed without being
and weight (not even within a complete illustration). damaged must always be replaced with new
All work must be performed as described in the parts (e.g. gaskets and locking plates).
text. Gaskets are installed without the use of sealing
compound or grease. When measuring coated
After repair work and tests performed, skilled gaskets/seals proceed as specified.
personnel must make sure that the product is
working properly again. • Shaft seals
Always replace shaft sealing rings with rough,
Conversions and modifications may impact the ripped, or hardened sealing lips. Seal contact
transmission’s operational safety. Therefore, surfaces must be totally clean and in perfect
customer-specific deviations must be agreed with condition.
ZF in writing.
After removing the transmission from the vehicle, Reworking

clean thoroughly with a suitable cleaning agent
before opening. Pay particular attention to the If rework is needed on spacer washers and shims
recesses of housings and covers when cleaning. etc. because of clearance settings, ensure that the
reworked areas contain no face runout and have
the same surface quality.
2008-06 8
Instructions for Repairs
Transmission Assembly • Shaft Sealing Rings

Press in shaft sealing ring with fixture or face
Assemble the transmission in a clean workplace. plate until firmly home at relevant installation
Adhere to all adjustment data and tightening depth.
torques specified in the repair manual.
a) Apply a thin coat of sealing agent* to outer
circumference of shaft sealing rings with a
• Bearings
«steel surround».
If the bearings are fitted while warm, these
should be warmed up evenly (e.g. heating b) Never apply sealing agent to shaft sealing
cabinet). with a «rubber surround» but apply a thin
The temperature should be approx. 85°C and coat of Vaseline 8420 or spirit to the outer
must not exceed 120°C. All bearings fitted must circumference, or wet with a lubricant, e.g. a
be coated with operating oil after assembly. water-soluble concentrated washing-up liquid.
c) Shaft sealing rings with steel and rubber

• Sealing
surrounds should be treated on the outer
If a sealant* is recommended for sealing, then
circumference of the rubber surround as
it is essential to adhere to the manufacturer’s
described for shaft seal (b).
directions for use. A thin layer of sealing agent
should be applied to the surfaces and coat them d) Duo shaft sealing rings have
evenly. Do not allow sealing agent to enter oil two sealing lips. The dust
ducts and bores. On oil-carrying ducts and bores, protection sealing lip (X)
wipe off the sealing agent on the surfaces to be must face outwards.
sealed near apertures to ensure that no sealing Fill the space between the X
agent enters the oil feeds when the parts are sealing lips up to 60% with
pressed together. grease*.
• Retaining Agents • Transmission Oil

Retaining agents* may only be used where After completing repairs, fill the transmission
specified by the parts list. with transmission oil. For the procedure and
When using retaining agents (e.g. Loctite) always approved oils, refer to the transmission operating
comply with the manufacturer’s directions for manual and the List of Lubricants TE-ML (refer
use. to type plate). These are available from all
During assembly, comply with all adjustment ZF Service Centers or on the Internet at
data, inspection data, and tightening torques. www.zf.com. After filling the transmission with
oil, tighten the screw plugs at the oil filling point
and the oil overflow to the specified torques.
* refer to consumable material
2008-06 9
Tightening torques
Tightening torques for screws/bolts and nuts,

extract from ZFN 148
This standard applies to bolts according to DIN 912, Surface condition of screws/bolts/ nuts:
DIN 931, DIN 933, DIN 960, DIN 961 as well as Heat-treated blackened finish and oiled or
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, galvanized and oiled.
and for nuts according to DIN 934 and ISO 4032,
ISO 8673. The bolts are tightened using a calibrated torque
wrench.
This standard contains data on tightening torques
for screws/bolts and nuts of strength categories 8.8, NOTE
10.9, and 12.9, as well as nuts of strength categories Differing tightening torques are listed separately
8, 10, and 12. in the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89
M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960
M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850
M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500
Status: August 1991
2008-06 10
ZF-Ecosplit Consumables
Description Name Quantity Application Comment

ZF item number approx.
Compression spring 1 piece Compression spring in servo unit Chapter 2

0501 318 490 (Ø12,4 x 43,4) (in the event of loss)
Ball roller 1 piece Roller in servo unit Chapter 2

0501 319 920 (in the event of loss)
O-ring 1 piece Detent Chapter 2.4

0634 316 057 Chapter 2.5
Grease For example: 1g Pin Chapter 2

0750 199 001 Aralub HL2 O-ring
Roller
Grease For example: 1g Tappet Chapter 2

0750 199 019 Spectron FO 20 Pin
Sealing compound Loctite no. 241 5 mm3 Breather Chapter 2

0666 690 017 300 mm3 Swivel screws Chapter 3.3
Sealing compound Loctite no. 262 Hex head screws/output flange Chapter 3.1
0666 690 022 Ball pin/clutch housing chapter 6.1.3
Sealing compound Loctite no. 574 Pump cover Chapter 6.3

0666 790 033
NOTE: Inquire about package/container size before placing an order!
1315 751 103 - 2010-05 11

ZF-Ecosplit Spring Table
Order no. Installation location Number of Wire Ø Spring outer Ø Non-loaded

coils in mm in mm length in mm
0732 040 630 Shift system (2-piece) 6.50 2.40 39.60 89.90
0732 042 126 Detent unit 9.50 1.00 9.40 25.00

0732 042 365 (shift system 2-piece) 5.50 1.70 20.44 31.49
0732 042 366 4.50 1.50 15.03 15.60
0732 042 400 10.50 2.25 15.50 39.70
0732 042 401 12.50 1.50 10.10 36.00
0732 040 985 Shifting output, left side 6.50 2.00 14.40 23.40
0732 042 126 Double-H shift system 9.50 1.00 9.20 25.00
0732 042 684 5.16 2.10 39.00 70.00
0732 040 728 Shifting output, right side 6.50 1.80 29.30 80.00
0732 041 612 Double-H shift system 6.50 1.70 13.90 25.80
0732 042 126 9.50 1.00 9.20 25.00
0732 042 207 7.50 1.50 14.20 30.60
0730 040 630 Shift turret with HGS 6.50 2.40 39.10 89.90
0732 040 985 6.50 2.00 14.40 23.40
0732 042 684 Shift turret 5.16 2.10 39.00 70.00

0732 042 106 Superimposed H shift system 4.50 2.25 30.20 41.30
0732 041 500 6.50 2.10 14.40 23.60
0732 040 986 Shift turret 5.50 2.25 14.50 21.60

0732 041 011 Superimposed H shift system 4.50 2.00 30.50 50.10
with cable control
0732 040 385 Synchronizer/ 18.50 1.25 6.25 34.20

0732 040 386 Planet carrier 35.50 0.70 3.20 34.70
0732 040 736 Locking pin/interlock 13.50 1.60 9.80 36.00
1315 751 103 - 2010-05 12

ZF-Ecosplit Setting Data
Designation Dimensional details Measurement device Comment
01. Axial clearance of detent 0.10 mm Depth gage Select suitable washer
unit on shift turret
(2-piece)
02. Axial clearance of output 0 to 0.1 mm Depth gage Select suitable shim
bearing
03. Installation dimension of 12.5 +1.0 mm Depth gage Installation dimension is defined
shaft sealing ring/output by adapter 1X56 137 124
04. Axial clearance of main + 0.05 mm Test socket Select suitable shim
shaft/planetary gear set 1X56 138 158
(only 16 S 251 and
16 S 2720)
05. Test pressure for piston max. 6.8 bar Locating device Use new O-rings and new
and S/G cylinder 1X56 138 673 double-lip seal
06. Permissible clearance of 0.1 +0.2 mm Feeler gage

sliding pads in S/G sliding
sleeve
07. Control dimension for S/G Depth gage Setting done by adjusting shift
selector rail fork by centering aid
Short transmission version 93.70 mm 1X56 138 079
Long transmission version 107.20 mm
08. Axial clearance of split –0.05 to +0.05 mm Feeler gage Select suitable ring
ring on main shaft (8/16 S 151, 8/16 S 181,
16 S 221, 16 S 251)
09. Axial clearance of securing 0.01 to 0.10 mm Feeler gage Select suitable securing ring
ring on countershaft
1315 751 103 - 2010-05 13

10. Axial clearance of securing 0.01 to 0.10 mm Feeler gage Select suitable securing rings
rings on the main shaft
11. Axial clearance of 0.01 to 0.10 mm Depth gage Rotate countershaft in order to
countershaft center bearing rollers.
Set to zero clearance.
Afterwards, adjust clearance
by suitably thick washer.
12. Axial clearance of main 0.01 to 0.10 mm Depth gage Rotate input and main shaft in
and input shaft order to center bearing rollers.
Set to zero clearance.
Afterwards, adjust clearance
by suitably thick washer.
13. Determine setting of main 19,20 –0.5 mm Depth gage Measurement of distance bet-
shaft and thickness of ring (8/16 S 181, 16 S 221) ween clutch body upper edge
and axial washer (for with inserted ring and interme-
straight-toothed version) 32.20 –0.5 mm diate housing with fitted seal.
(8/16 S 151) Reach target dimension by
using suitable ring.
14. Determine setting of main +0.07 to –0.08 mm Depth gage First, measurement is done
shaft and thickness of ring (axial washer) and axial washer determined.
and axial washer (for heli- Afterwards, measurement and
cal-toothed version) 4.6 –0.4 mm selection of ring.
(ring)
15. Axial clearance of axial +0.07 to –0.08 mm Depth gage Only for versions with tapered
washer on the main shaft roller bearings. Select suitable
axial washer.
1315 751 103 - 2010-05 14

16. Permissible axial tolerance ±0.05 mm Test socket Only for transmission types
of main shaft/planetary 1X56 138 158 16 S 251, 16 S 2720.
gear set Setting is done by using
suitable shim.
Also refer to assembly
instructions 1316 700 017
17. ZF-BK Main transmission and Feeler gage If the dimension is below
Wear limit of synchronizer splitter group the specified value, replace
rings and/or clutch bodies, 0.80mm synchronizer ring and clutch
measured between moun- body.
ting faces, ring and body Range-change group
at centric, backlash-free 1.20 mm
abutment of the tapers.
18. ZF-D 1.50 mm Feeler gage If the dimension is below the

(For transmission versions specified value, replace inter-
without servo unit) mediate ring, outer ring, and
Wear limit of synchronizer inner ring.
parts, 1st/2nd gear, bet-
ween outer ring and clutch
disk, measured with back-
lash-free abutment of the
tapers and load of F = 50 N
on outer ring
19. For information > 0.60 mm Feeler gage Upper limit of the synchronizer
Synchronizer clearance (molybdenum) clearance is determined by the
(axial) > 0.70 mm wear limit of 0.80 and/or
(carbon) 1.20 mm.
1315 751 103 - 2010-05 15

ZF-Ecosplit Tightening torques
01. Hollow screws for plastic 38 Nm Torque wrench Use new sealing rings
pipes
02. M8 hex head screws on 23 Nm Torque wrench

the gearshift cover
(2-piece)

the shift system/cover
(2-piece)
03. Screw plug on the shift 60 Nm Torque wrench Use new sealing ring
system/detent

shut-off valve
05. Switch on the shift system 50 Nm Torque wrench Use new sealing ring
(2-piece)
06. M10 hexagon nut at the 49 Nm Torque wrench

shift lever
07. Switch on the shift system 35 Nm Torque wrench

(2-piece, superimposed H)
08. Screw plugs on the shift 50 Nm Torque wrench Use new sealing rings
system
09. Detent plunger on the 50 Nm Torque wrench Use new sealing ring
shift system
1315 751 103 - 2010-05 16

10. Hex head screws on the 205 Nm Torque wrench

console/servo unit
11. Hex nuts on the shift 40 Nm Torque wrench

cylinder
12. Hex nut on the 40 Nm Torque wrench

valve/servo unit
13. Hollow screws for 35 Nm Torque wrench

PA pipes/servo unit

servo unit
15. Hollow screws for 20 Nm Torque wrench

PA pipes/servo unit
16. M22x1.5 screw plugs on 60 Nm Torque wrench Use new sealing rings
the shift system

housing cover/shift turret
18. Switch on the shift system 45 Nm Torque wrench Use new sealing rings
and/or screw plugs 35 Nm

valve block/shift system
20. Neutral-position switch 45 Nm Torque wrench Use new sealing ring

on the shift turret
(superimposed H)
1315 751 103 - 2010-05 17

21. Plug-in coupling at 24 Nm Torque wrench

the shift turret
(superimposed H)
22. M8x28 hex head screws 23 Nm Torque wrench

on the shift and selector
cylinder (HGS)
23. Hex head screws for 23 Nm Torque wrench

testing device (HGS)
24. Pressure switch at the 23 Nm Torque wrench

valve block

shift turret/transmission

the output flange
27. Hex head screws on the 49 Nm Torque wrench Use new safety plate
cover/output
28. Hex head screws on PTO 79 Nm Torque wrench

cover
29. Locknut on the 150 Nm Torque wrench Use new securing rings
R/C piston and S/G piston

R/C cylinder
31. Swivel screws on the range 250 Nm Torque wrench Use Loctite no. 241
change group
1315 751 103 - 2010-05 18


range change group /
intermediate housing
33. Mechanical speedometer 50 Nm Torque wrench

and/or impulse sensor on
the range change group
34. M24x1.5 screw plug on 60 Nm Torque wrench Use new sealing ring
the R/C housing
35. M18x1.5 screw plug on 35 Nm Torque wrench Use new sealing ring
the R/C housing
36. Hex head screws on the 9.5 Nm Torque wrench

5/2 way valve
37. Detent plunger on the 50 Nm Torque wrench Use new sealing ring
intermediate housing (R/C
and S/G)
38. M10 hex nuts and/or M10 46 Nm Torque wrench

hex head screws on the
connection plate and the
pump

clutch release fork

bearing block
41. Ball pins in the clutch bell 100 Nm Torque wrench

housing
1315 751 103 - 2010-05 19

the clutch housing (oil
cooler connections)
43. M24x1.5 screw plugs on 60 Nm Torque wrench Use new sealing ring
the clutch housing (with
solenoid)

the clutch housing

the R gear cover
46. M12x1 threaded pins on 60 Nm Torque wrench

the S/G shift fork
the intermediate housing
48. Breather at the inter- 10 Nm Torque wrench

mediate housing
49. M26x1.5 screw plugs 70 Nm Torque wrench Use new sealing ring
1315 751 103 - 2010-05 20

ZF-Ecosplit Special Tools
Figure Illustration Order no. Application Item Comment

No. pieces
1X56 119 916 1 Chapter 2.1,

Chapter 2.2
Mounting adapter
1 for bush, shaft sealing ring, scraper
on gearshift housing
1X25 139 783 1 Chapter 2.4

Chapter 2.8
Impact adapter
2 to remove needle bush on the valve
lever
1X25 139 707 1 Chapter 2.4

Chapter 2.8
Adapter
3 for bush on gearshift housing
1X56 138 229 1 Chapter 2.7
Testing device
4 for gearshift housing with HGS
1X46 183 298 1 Chapter 2.9
Locating pins
5 to attach the shift turret
(2 pins are required)
1315 751 103 - 2010-05 21


No. pieces
1X56 136 260 1 Chapter 3.1

Chapter 3.3
Lifting device
6 for range-change group
1X56 137 651 1 Chapter 3.1
Adapter
7 for safety plate at output flange
1X56 137 246 1 Chapter 3.1

(only for
Adapter straight-toothed
8 for safety plate at output flange version)
1X56 122 314 (for 10 balls) 1 Chapter 3.2

1X56 122 295 (for 11 balls)
9 Rillex extractor
for output bearing
1X56 137 124 1 Chapter 3.2
Adapter
10 for shaft sealing ring in the output
cover (with ring of 12.5 mm
thickness)
1315 751 103 - 2010-05 22


No. pieces
1X56 138 100 1 Chapter 3.3

Chapter 5
Locating device
11 for R/C and S/G selector rail
on the detent plunger
1X56 138 158 1 Chapter 3.3

(only 16 S 251
Measuring bush and 16 S 2720)
12 for setting and/or measurement of
main shaft/planetary gear set
1X56 137 917 1 Chapter 5.1

Chapter 8.1
Locating device
13 for S/G cylinder (air pressure test)
1X56 103 766 1 Chapter 6
Adapter
14 for shaft sealing ring in the
connection plate
1X56 138 064 1 Chapter 6
Protective sleeve
15 for shaft sealing ring/connection
plate
1315 751 103 - 2010-05 23


No. pieces
1X56 137 949 1 Chapter 6.3
Guide pins
16 for single-piece connection plate
1X56 138 063 1 Chapter 7
Extractor
17 for cylindrical pins on clutch housing/
intermediate housing
1X56 136 564 2 Chapter 7
M10 hook
18 for clutch housing
1X56 136 599 1 Chapter 7
M12 hook
19 for clutch housing
1X56 138 695 2 Chapter 7
Centering/dowel pins
20 for clutch housing/intermediate
housing
1315 751 103 - 2010-05 24


No. pieces
1X56 137 287 1 Chapter 8
Locating screw
21 for fixing locking pin at interlock
1X56 137 122 1 Chapter 8
Lifting device
22 for shaft package
1X56 137 921 1 Chapter 8
Centering ring
1X56 137 933 1 Chapter 8
Washer/Shim
1X56 137 918 1 Chapter 8
Bracket
1315 751 103 - 2010-05 25


No. pieces
1X56 137 675 1 Chapter 8

Chapter 12
Support
26 for shafts and selector rails
1X56 137 920 1 Chapter 8
Pins 8/16 S 151

27 for shafts in conjunction with 16 S 1620
support 1X56 137 675 16 S 1820
1X56 137 953 1 Chapter 8
Pins 8/16 S 181

support 1X56 137 675 16 S 1920
16 S 2220
16 S 2320
16 S 2520
1X56 138 257 1 Chapter 8
Pins 16 S 251
support 1X56 137 675
1X56 138 079 1 Chapter 8.2
Centering aid
30 for S/G selector rail
1315 751 103 - 2010-05 26


No. pieces
1X20 155 653 1 Chapter 9
Rolling-in roll
31 for oil pipe
1X56 136 722 1 Chapter 10
Gripping device
32 for roller bearings/input shaft
1X56 122 304 1 Chapter 10
Basic device
33 in conjunction with
gripping devices 1X56 136 722
1X56 136 710, 1X56 136 756
1X56 136 731, 1X56 136 743
1X56 136 573 1 Chapter 10.3
Adapter
34 for split ring
1X56 136 710 1 Chapter 11
Gripping device
35 for roller bearings/countershaft
1315 751 103 - 2010-05 27


No. pieces
1X56 136 756 1 Chapter 11
Gripping device
1X56 136 731 1 Chapter 11

(16 S 151 only)
Gripping device
1X56 136 743 1 Chapter 12
Gripping device
38 for roller bearings/main shaft
1X56 137 835 1 Chapter 12
Adapter
39 for injection tube/main shaft
1X56 137 676 1 Chapter 13
Adapter
40 for split ring
1315 751 103 - 2010-05 28


No. pieces
1X56 138 320 1 Ecosplit 3
Assembly fixture
41 for clamping of transmission
1P01 181 850 1 General
Assembly stand (stationary)

42 in conjunction with 1X56 138 320
1315 751 103 - 2010-05 29

30
ZF-Ecosplit Tubes
1 Plastic Tubes
Removal ....................................................................................................... 1-3

Installation ..................................................................................................... 1-3
1315 751 103 - 2010-05 1-1

1-2
ZF-Ecosplit Tubes
1 Plastic Tubes
Removal 57
3
NOTE
Mark plastic tubes prior to removal in line with their 2
respective connections.
6
Different variants possible.
1 Remove the hollow screws(1 ad 2) from the 2

1
range change group cylinder (3) as well as the
cutoff valve (4).
Loosen the cable clip (5) and/or hose clamp (7) 4
at the housing and take off as a complete set 1
with the plastic tubes (6).
032524
Installation
2
1 Screw the plastic tubes (6) down to the range 5 3
change group cylinder (3) and the cutoff valve
(4) in accordance with the markings at the
hollow screws (1 and 2) and the new sealing 2
6
rings. 1
Tightening torque = 38 Nm
2 Secure the hose clamp (7) and/or cable clips 4

(5) with drawn-in plastic tubes at the housing. 1
032523
1315 751 103 - 2010-05 1-3

1-4
ZF-Ecosplit Shift system
2 Shift Turret
2.1 Double-H shift system (2-piece).................................................................... 2-2
Removal and disassembly............................................................................... 2-2
Assembling .................................................................................................... 2-4
2.2 Superimposed H shift system (2-piece) ........................................................ 2-6
Removal and disassembly............................................................................... 2-6
Assembling .................................................................................................... 2-8
Selector patterns for 2.1 and 2.2..................................................................... 2-11
2.3 Servo unit, disintegrated version (add-on) .................................................... 2-14
Removal and installation................................................................................. 2-14
2.4 Double-H shift system with pneumatic servo unit (PSU) .............................. 2-15
2.4.1 Shift turret with shifting output on the left and right side ..................... 2-15
Removal and installation of servo unit.................................................. 2-15
2.4.2 Shift turret with shifting output, left side.............................................. 2-16
Removing, disassembling, and assembling gearshift housing.............. 2-16
Selector patterns ................................................................................. 2-21
2.4.3 Shift turret with shifting output, right side ........................................... 2-23
Removing, disassembling, and assembling gearshift housing.............. 2-23
Selector patterns ................................................................................. 2-31
2.5 Shift turret with HGS (Hydraulic gearshift System)....................................... 2-33
Removal and installation of servo unit............................................................. 2-33
Removing, disassembling, and assembling gearshift housing......................... 2-34
Selector patterns ............................................................................................ 2-40
2.6 Superimposed H shift system shift turret with HGS .................................... 2-41
2.7 Selector and shift cylinder, shift turret with HGS.......................................... 2-47
Disconnecting, connecting, functional check.................................................. 2-47
2.8 Superimposed H shift system with cable control ......................................... 2-51
2.9 Superimposed H shift system with gate-dependent servo unit ................... 2-59
2.10 Complete fitting of shift turret....................................................................... 2-69
2.10.1 Versions without servo unit.................................................................. 2-69
2.10.2 Versions with servo unit....................................................................... 2-70
1315 751 103 - 2010-05 2-1

3
4
34
14
13
10
1 11
12
9
2
001919_1
2 Shift Turret 6 Loosen shift lever (8) and remove with

protective cap (9). Mark gearshift shaft for
2.1 Double-H shift system (2-piece) installation.
(8/16 S 151, 8/16 S 181, 16 S 221)
7 Remove screw plug (10) with sealing ring,
Removal and disassembly spring (11), and bolt (12).
1 Unscrew hex head screws from gearshift 8 Unscrew shut-off valve (13) and remove
housing. together with O-ring.
2 Take off complete gearshift housing (1) and NOTE

remove gasket (2). Depending on the version, remove R gear switch (14)
together with sealing ring.
3 Remove switch (3) with sealing ring and pin
(34).
4 Unscrew cover (4) and remove with gasket.
5 Take shift detent (5) with washer (6) out of

detent component (7) (refer to Fig. 001920).
1315 751 103 - 2010-05 2-2

9 Unscrew hex head screws on gearshift cover

(15) and remove together with gasket.
10 Drive bush (16), scraper (17), shaft sealing ring

(18), and bearing bush (19) out of gearshift
16
cover.
15
19
11 Push pin (20) towards sealing cap.
18
17
12 Take cover (21) with compression springs (22)
and detent component (23) and O-ring (24) out
of gearshift housing.
13 Drive dowel pins (25) out of detent component

and remove compression spring (26) together 20
with washers (27). 7
6
5
14 Drive dowel pins out of (28) driver (29) and

gearshift shaft (30).
22
15 Extract gearshift shaft (30) manually pulling it

in the direction of shifting output. 21
24
16 Take blocking piece (31) and driver out of

23
gearshift housing.
25
17 Remove pins (32) if necessary.
27
NOTE 26
Clamp pins in vice with aluminum clamping jaws 27
33
and release them by blow against the gearshift
housing. 30
18 Drive needle bush (33) out of gearshift

32
housing.
28
29
31
001920_1
1315 751 103 - 2010-05 2-3

Assembling
33
1 Drive new needle bush (33) into gearshift 1

housing (1) using adapter 1X56 119 916. The
thicker side of needle bush is the impact side.
32
2 Drive pins (32) into gearshift housing.
3 Insert driver (29) and blocking piece (31) in

correct position into the gearshift housing.
4 Insert gearshift shaft (30).

28
5 Drive new bearing bush (19) into gearshift 29

cover using adapter 1X56 119 916.
6 Drive shaft sealing ring (18) into gearshift

cover using adapter 1X56 119 916. Sealing lip 31
must point towards the cover.
7 Drive scraper (17) into the gearshift cover

using adapter 1X56 119 916. Sealing lip must
point towards the outside.
NOTE 15
Install shaft sealing ring and scraper with sealing
compound. Fill space between the shaft sealing ring
and the scraper with grease.
8 Insert bush (16) into gearshift housing (1) and

slide gearshift cover (15) with new gasket over
19
the gearshift shaft (30) until it is firmly home
18
(axial abutment). Do not damage sealing lips.
17
9 Screw gearshift cover (15) to gearshift housing.

10 Drive dowel pins (28) through driver (29), one

after the other and offset from one another,
and into the gearshift shaft (note assembly 30
instructions 1315 700 004).
16
1X56 119 916
001921_1
1315 751 103 - 2010-05 2-4

11 Fit washer (27), compression spring (26), and

second washer (27) onto gearshift shaft (30). 25
If necessary, drive in pins (32). 27
26
27
12 Insert shift detent (5) and washer (6) into 7
5 6
detent component (7).
20
13
13 Place detent component (7), shift detent (5), 32
and washer (6) on gearshift shaft pressing it
against spring pressure and drive dowel pins 22
(25) in, offset from one another. 11 10
12
21 24 30
NOTE
There must be an axial clearance between the detent 23
component and the pins of 0.1 mm. If necessary,
adjust clearance by using suitably thick washers (6).
Washers are available at 0.1 mm stepped thickness
levels. Apply grease to shift detent (5) and pins (32). 14
3
34
14 Fit cover (4) with new gasket.
NOTE
Depending on the cover design (4), screw in reverse 4
gear switch (14) with new sealing ring. 9
Depending on the version, the R gear switch is on
the intermediate housing.
15 Insert cover (21) with compression springs (22),

detent component (23), and O-ring (24) into
8
gearshift housing. Drive pin (20) into gearshift
housing (countersinking it by approx. 5 mm)
001922_1
and fit new sealing cap, countersinking it by
approx. 2 mm. 19 Slide protective cap (9) onto gearshift shaft
(30) and position shift lever (8), depending
16 Screw bolt (12), spring (11), and screw plug (10) on the shift system version, on gearshift
with new sealing ring into gearshift housing. shaft.
Tightening torque = 60 Nm Tightening torque for hex nut on the shift
lever = 49 Nm
17 Screw shut-off valve (13) with new O-ring to Protective cap must be fitted on gearshift
gearshift housing. shaft without clearance.
NOTE
18 Insert pin (34) in cover and screw in switch (3) For fitting the entire shift unit to the transmission,
with new sealing ring. refer to Chapter 2.10.1
1315 751 103 - 2010-05 2-5

14
5
12
6
1
7
4
8
9
13
15 10
11
009684_2
2.2 Superimposed H shift system (2-piece) NOTE

(8/16 S 151, 8/16 S 181, 16 S 221) Do not dismantle shut-off valve, complete part.
In the case of the double-H shift system, there are 2
Removal and disassembly ball rollers (8) fitted in the shut-off valve.
1 Loosen hex head screws (1) and remove shift 5 Remove screw plug (9) with sealing ring,
turret with gasket (2). spring (10), and bolt (11).
2 Loosen shift lever (3, depending on parts list) 6 Remove screw plugs (12 and 13) with sealing
and remove with protective cap. rings.
3 Remove detent plunger (4) and screw plug or 7 Unscrew cover (14) with piston and remove
switch (5). together with gasket.
4 Remove shut-off valve (6) and take off with NOTE

O-ring (7). In the case of the double-H shift system, a sealing
cover with switch is fitted in this place.
1315 751 103 - 2010-05 2-6

8 Loosen housing (15) and remove together

with gasket. 19
9 Remove detent plate (16) and detent (17)

from the housing. 21
10 Unscrew hex head screws from gearshift 18

cover (18) and remove together with gasket.
20
22
11 Drive shaft sealing ring (19), bearing bush
(20), shaft sealing ring (21), and scraper (22)
out of gearshift cover.
24
12 Unsnap V-ring (23) and remove detent (24) 23
with O-ring from the housing.
13 Drive dowel pins (25) out of driver.

16 32
17
14 Remove gearshift shaft (26), driver (27), and 29
30
blocking piece (28). 31 33
15 Remove needle bush (29) from the housing.

26
16 Unsnap V-ring (30), remove washer (31),
spring (32), and washer (33) from the gear-
shift shaft.
17 Unsnap snap ring (34) from the cover, remove 25 27

the piston (35) together with O-rings (36).
28
009685_4
36
35
36
34
009893_1
1315 751 103 - 2010-05 2-7

Assembling 29
30
31
1 Drive new needle bush (29) into gearshift
housing using adapter 1X56 119 916. 32
The thicker side of needle bush is the impact
side.
33
2 Insert driver (27) and blocking piece (28) into

gearshift housing and install gearshift shaft
(26).
NOTE 26
Driving groove for detent and detent plate must face
towards transmission.
3 Drive dowel pins (25) through driver (27), one

after the other and offset from one another, 27
and into gearshift shaft (note assembly 25
instructions 1315 700 004).
28
4 Insert washer (33), spring (32), washer (31),
and V-ring (30) according to the selector
pattern.
1X56 119 916

cover using adapter 1X56 119 916. Sealing lip 009900_2
must point towards the gearshift housing.
6 Drive new bearing bush (20) into gearshift

cover using adapter 1X56 119 916.

cover using adapter 1X56 119 916. Sealing lip 19
must point towards the shift lever.
8 Drive scraper (22) into the gearshift cover 21

using adapter 1X56 119 916. Sealing lip must
point towards the outside. 18
20
NOTE 22
Apply thin coat of sealant to shaft sealing ring and
scraper. Fill space between the shaft sealing ring and
the scraper with grease.
24
9 Position gearshift cover (18) with new gasket 23
over gearshift shaft and fit with screws/bolts.
1X56 119 916
009685_3
1315 751 103 - 2010-05 2-8

10 Insert detent (24) with new O-ring and snap

in V-ring (23).
11 Insert detent (11), spring (10), and screw plug

(9) with new sealing ring and tighten. 6
8
12 Insert shut-off valve (6) with new O-ring in
correct position into gearshift housing and
9
tighten using hex head screws.
Tightening torque = 23 Nm 10
11
NOTE
In the case of the double-H shift system, there are 2
ball rollers (8) fitted in the shut-off valve.
13 Insert screw plugs (12 and 13) with new sea-

ling ring into the housing (15) and tighten.
5
Tightening torque = 50 Nm 15 12
37
14 Screw detent plunger (4) with new sealing

ring into housing.
4
15 Insert grease-coated pin (37) into bore.
Fit switch and/or screw plug (5) and new
sealing ring and tighten. 13
17
16 Insert detent (16) and detent plate (17) in
correct position into housing.
009687_2
1315 751 103 - 2010-05 2-9

17 Fit new gasket (38).

14
18 Position gearshift housing with gearshift shaft 40
over detent plate and detent. 36
35
NOTE
36
Center housing and gearshift housing. 34
19 Insert hex head screws (39) and tighten

manually.
39
NOTE
Check ease of movement of the gearshift shaft by 38 41
pressing it against spring force.
20 Tighten detent plunger (4).

21 Mount O-rings (36) on piston (35). 009688_2
22 Insert piston in cover (14) and secure by

means of snap ring (34).
23 Fit new gasket (38) and screw cover to hou-

sing.
NOTE
In the case of the double-H shift system, a sealing
cover with switch is fitted in this place.
24 Slide protective cap (41) on gearshift shaft and

position shift lever (3) on gearshift shaft,
depending on shift system version.
Tightening torque for hex nut on shift lever
= 49 Nm
Protective cap must be fitted on gearshift shaft
without clearance (depending on parts list).
NOTE
For fitting the entire shift unit to the transmission,
refer to Chapter 2.10.1
1315 751 103 - 2010-05 2-10

Selector patterns for 2.1 and 2.2

Shift system, left or right
Turning shaft, horizontal, left / selector pattern I
Arrangement of spring assembly: Q1
001923
001924
001925
1315 751 103 - 2010-05 2-11

Turning shaft, horizontal, left / selector pattern II
001926
001927
001928
1315 751 103 - 2010-05 2-12

Turning shaft, horizontal, right / selector pattern I
001929
1315 751 103 - 2010-05 2-13

4
3
6
1 7
9 8
5
2
10
13 15
12
14
16
11
011394
2.3 Servo unit, disintegrated version (add-on)
Removal Installation
1 Remove cable clip (16) and hollow screws 1 Attach bracket (4) with hex head screws (3).
(6, 7, 9, 11 and 15). Tightening torque = 205 Nm
NOTE 2 Attach shift cylinder (1) – with bellows facing

Mark installation position of PA pipes. towards shift lever – with locknut (2 and 12).
Tightening = 40 Nm
2 Remove PA pipe (5, 8 and 10).
3 Attach valve (14) with locknut (13) to the shift
3 Remove locknuts (2, 12 and 13). lever.
4 Remove shift cylinder (1) and valve (14).
4 Attach PA pipes (5, 8, and 10) as marked.
NOTE Tighten hollow screws (6, 7, 9, 11 , and 15).
If the supporting linkage is attached to the valve Tightening torque = 35 Nm
(14), do not disassemble it because the setting is
vehicle-specific. 5 Attach cable clip (16).
5 Remove hex head screws (3) and take off

bracket (4).
1315 751 103 - 2010-05 2-14

ZF-Ecosplit Servoshift
1
2
6 5
7
012319
2.4 Double-H shift system with pneumatic Installation of servo unit

servo unit (PSU)
1 Insert spring (7) into servo unit.
2.4.1 Shift turret with shifting output on the left
and right side 2 Attach pneumatic servo unit (5) with new
gasket (6) to the shift turret.
Removal of servo unit
3 Insert hex head screws (4) and tighten.
1 Loosen hollow screws (1 and 2) and take them Tightening torque= 23 Nm
off with sealing rings and pipe (3).
4 Attach pipe (3) to shift turret with hollow
2 Loosen hex head screws (4). screw (1) and new sealing rings.
3 Remove pneumatic servo unit (5) with gasket
(6) and spring (7). 5 Fit pipe to the pneumatic servo unit with
hollow screw (2) and new sealing rings.
NOTE Tightening torque = 20 Nm
• Spring (7) is placed loosely in the pneumatic servo
unit.
• Do not disassemble pneumatic servo unit further,
complete component.
1315 751 103 - 2010-05 2-15

6 7 4
5
22
21
20
1
3
10
9
11 8
48 2
12
13
18
14
15 19
16 17
012330
2.4.2 Shift turret with shifting output, left side 5 Unsnap V-ring (8) and remove detent (9) with
O-ring from the gearshift housing.
Removing and dismantling gearshift
NOTE
housing
Check O-ring and replace it if necessary (refer to
chapter on consumables).
1 Loosen hex head screws (1) and remove shift
turret with gasket (2). 6 Loosen hex head screws (10) and remove
Remove roller (48) from valve lever. cover (11) with gasket.
2 Loosen shift lever (3, depending on parts list) 7 Unsnap V-ring (12) and securing ring (13),
and remove with protective cap. remove washer (14), spring (15), washer (16),
V-ring (17), spring (18), and washer (19).
NOTE
Mark shift lever position. NOTE
Arrangement and installation sequence of parts in
3 Remove shut-off valve (4) and take off with
working step 7 depend on parts list.
O-ring (5).
8 Loosen screw/bolt (20) and remove with
NOTE
sealing ring, spring (21), and detent (22).
Do not disassemble shut-off valve further, complete
part.
4 Loosen switch (6 and 7), and remove with

sealing rings and pins. Depending on the parts
list, screw plugs may be fitted instead.
1315 751 103 - 2010-05 2-16

29 27 24
23
38
28 40 25
26
39 35 42 43
32 36
46 33
31
34
30 37
44
41
45
1X25 139 783 47
012331
9 Loosen hex head screws (23), remove cover 16 Remove needle bush (33).
(24) and gasket (25).
17 Remove pin (34).
10 Loosen screw plugs (26 and 27) and remove
18 Remove gearshift shaft (40) from gearshift
together with sealing rings, spacers, and
housing and take off valve lever (37) and lever
springs.
(41).
11 Take detent lever (28 and 29) out of gearshift
NOTE
housing. If necessary, remove cylindrical pins.
Check gearshift shaft bores and level any raised
CAUTION edges.
Securing rings (30 and 32) must not be over-
19 Take pin (35) out of valve lever; do not remove
stretched – use adjustable pliers.
lower needle bush (36). If the needle bush (36)
12 Unsnap securing rings (30). is defective, replace valve lever and needle
bush as complete set.
13 Remove cylindrical pins (31) and detach secu-
ring rings if necessary (32). 20 Apply plastic punch to hollow shaft and use
hollow shaft to drive bush (42) and shaft
14 Remove pin (38) and push hollow shaft (39)
sealing ring (43) out of gearshift housing.
towards sealing cap.
Then slide hollow shaft out of gearshift
15 Place impact adapter 1X25 139 783 on needle housing and take off driver (44) and blocking
bush (33) and drive valve lever (37) slightly piece (45).
downwards.
21 If necessary, remove cylindrical pins (46 and
47).
1315 751 103 - 2010-05 2-17

Assembling gearshift housing

38
gearshift housing. Slide hollow shaft (39) in
correct position into the gearshift housing,
blocking piece, and driver.
2 Press bush (42) flush into housing using

adapter 1X25 139 707.
3 Apply grease to shaft sealing ring (43) and

press firmly home.
4 Insert cylindrical pin (35) in valve lever (37). If

necessary, press cylindrical pin (46 and 47) in. 32 46
31
5 Fit valve lever (37) and lever (41) on hollow 30 44
shaft in gearshift housing.
6 Insert gearshift shaft (40) into hollow shaft.
NOTE 45
Cylindrical pin (35) must mesh with the gearshift
shaft. Position gearshift shaft and hollow shaft.
CAUTION
Cylindrical pin (38) secures hollow shaft only; only
push in by hand, do not drive in. 39 35
36
7 Insert cylindrical pin (38). Check ease of 33
movement of the gearshift shaft. 34
37
8 Insert cylindrical pin (34) and drive in new
needle bush (33) until it is flush. Check ease 41
of movement of the gearshift shaft.
CAUTION
Securing rings (32 and 30) must not be overstret- 47
ched – use adjustable pliers.
9 Snap in securing rings (32) on pins (31) and 40

insert in driver and gearshift shaft. Insert
42 43
securing rings (30).
1X25 139 707
012332
1315 751 103 - 2010-05 2-18

10 Place detent lever (28 and 29) in gearshift

housing. If necessary, use cylindrical pins.
23 24
NOTE
Arrangement of detent levers depends on parts list
(refer to Fig. 012334).
11 Insert screw plugs (26 and 27) with spacing

washers, springs, and new sealing rings and
tighten.
12 Fit new gasket (25) and cover (24).

25
Tightening torque = 23 Nm 29 27
NOTE
Version
standard “A”
28
26
012333
Version
standard “B”
Version
optional “C”
012334
1315 751 103 - 2010-05 2-19

6 7 4
5
22
21
20
1
3
10
9
11 8
48 2
12
13
18
14
15 19
16 17
012330
14 Insert washer (19), spring (18), V-ring (17), Depending on parts list, screw plugs are fitted.
washer (16), spring (15), washer (14) and snap Tightening torque = 35 Nm
in securing ring (13) and V-ring (12).
19 Fit shut-off valve (4) and greased O-ring (5)
NOTE with hex head screws to gearshift housing.
Arrangement and installation sequence of parts in Tightening torque = 23 Nm
working step 14 depend on parts list.
20 Fit shift lever (3) with cover cap to gearshift
15 Fit cover (11) with new gasket and tighten shaft.
with hex head screws (10). Tightening torque = 49 Nm
21 Place greased roller (48) on valve lever.
16 Insert lever (22), spring (21), and screw plug
NOTE
(20) with new sealing ring and tighten.
• For fitting/installation of servo unit, refer to
beginning of the chapter.
17 Insert detent (9) with greased O-ring and • For fitting/installation of shift system to
V-ring (8) into gearshift housing. transmission, refer to Chapter 2.10.2.
With new O-ring, refer to chapter on
consumables.
18 Insert switch (6 and 7) with pins and new

sealing rings into gearshift housing and
tighten.
1315 751 103 - 2010-05 2-20

Selector patterns
Shift turret with shifting output, left side
Turning shaft, horizontal, left / selector pattern I
Arrangement of spring assemblies Q1 - Q6
012338
Q1 Q2
012335 012336
Q3 Q4
012337 012339
Q5 Q6
012340 012341
1315 751 103 - 2010-05 2-21

Turning shaft, horizontal, left / selector pattern II
012345
Q1 Q2
012342 012343
Q3 Q4
012344 012346
Q5 Q6
012347 012348
1315 751 103 - 2010-05 2-22

10
6
19
18
17
27
7 4
11
5
22
21
20
26
1
48
014992
2.4.3 Shift turret with shifting output, right side 4 Loosen switches (6 and 7), remove with
sealing rings and pins. Depending on the
Removing and dismantling gearshift parts list, screw plugs may be fitted instead.
housing
5 Loosen hex head screws (10) and remove
cover (11) with gasket.
turret with gasket (2). 6 Push bearing bush (17), shaft sealing ring (18),
Remove roller (48) from valve lever. and scraper (19) out of cover.
NOTE 7 Loosen screw/bolt (20) and remove with

Depending on the version, an angular metal sheet sealing ring, spring (21), and detent (22).
(not depicted here) is bolted to the housing cover
with the screws of the servoshift fixing.
together with sealing rings, spacers, and
2 Loosen shift lever (3, depending on parts list) springs.
and remove with protective cap.
NOTE
Mark shift lever position.
3 Remove shut-off valve (4) and take off with

O-ring (5).
NOTE
Do not disassemble shut-off valve further, complete
part.
1315 751 103 - 2010-05 2-23

29 23 24
38
28 40 25
39 35
36
9 46 33
8 34
37
32
31
41
30
44
47
45
1X25 139 783
014993
9 Loosen hex head screws (23), remove cover 15 Push hollow shaft (39) towards selector lever
(24) and gasket (25). until stop.
10 Unsnap V-ring (8) and remove it. Push detent 16 Place impact adapter 1X25 139 783 over needle
(9) and O-ring from the inside out of gearshift bush (33) and drive valve lever (37) slightly
housing. downwards.
NOTE 17 Remove needle bush (33) with locking pliers.

Check O-ring and replace it if necessary (refer to
18 Remove pin (34).
19 Dismantle gearshift shaft (40) from gearshift
11 Note down position of detent levers (28 and 29).
housing in direction of arrow and take off
Take detent levers of out gearshift housing.
valve lever (37) and lever (41).
If necessary, remove cylindrical pins.
CAUTION
stretched – use adjustable pliers.
12 Unsnap securing rings (30).
13 Remove cylindrical pins (31) and detach

securing rings if necessary (32).
14 Remove pin (38).
1315 751 103 - 2010-05 2-24

29 23 24
38
28 40 25
39 35
36
9 46 33
8 34
37
32
31
41
30
44
47
45
014993
NOTE
If the boreholes of the gearshift shaft show raised
edges after a long operating time, the gearshift shaft
cannot be removed as described above. In that case,
the spring assembly (working step 22) must be dis-
mantled with the gearshift shaft installed, and the
gearshift shaft must be removed in the counter-
direction of the arrow. Before reinstalling the gear-
shift shaft, the raised edges must be leveled.
20 Take pin (35) out of valve lever, do not remove

lower needle bush (36). If the needle bush is
defective, replace valve lever and needle bush
as a complete set.
21 If necessary, remove cylindrical pin (47).
1315 751 103 - 2010-05 2-25

22 Unsnap V-ring (12) and securing ring (13) on

the removed shaft and remove washer (14),
spring (15) and washer (16).
NOTE
Number, arrangement, and installation sequence of
parts in working step 22 depend on parts list.
23 Apply plastic punch to hollow shaft and use

hollow shaft (39) to drive bush (42) and cover
(43) out of gearshift housing. Then slide
hollow shaft out of gearshift housing and take
off driver (44) and blocking piece (45). 46
24 If necessary, remove cylindrical pin (46). 44
45
39
12
13
14
15
16
42 43
014994
1315 751 103 - 2010-05 2-26


38
2 Press new bush (42) into housing until firmly

home (axial abutment) using adapter
1X25 139 707.
3 Press in new cover (43) until firmly home

(axial abutment). 32 46
31
NOTE 30 44
Housing bore and cover must be free from grease.
4 Insert cylindrical pin (35) in valve lever (37). If

45
necessary, press cylindrical pin(46 and 47) in.
Position valve lever and lever in the housing.
5 Fit V-ring (12), securing ring (13), washer (14),

spring (15), and washer (16) onto the removed
shaft.
NOTE 39 35
Number, arrangement, and installation sequence of 36
33
parts in working step 5 depend on parts list. 34
37
6 Insert gearshift shaft (40), into the housing and
hollow shaft in direction of arrow. 41
NOTE
Cylindrical pin (35) must mesh with gearshift shaft. 12
13 47
Position gearshift shaft and hollow shaft correspon- 14
dingly. 15
16
7 Push valve lever (37) and lever (41) upwards,
40
slide hollow shaft towards cover (43).
42 43
CAUTION
Cylindrical pin (38) secures hollow shaft only;
only push by hand, do not drive in.
1X25 139 707
014995
1315 751 103 - 2010-05 2-27

8 Insert greased cylindrical pin (38).

38
Check ease of movement of the gearshift shaft.
9 Secure valve lever and lever with one another

using suitable adapter or support.
10 Insert greased cylindrical pin (34) into new

needle bush (33) and drive together until they
are flush. Check ease of movement of the gear-
shift shaft.
32 46
31
30 44
45
39 35
36
33
34
37
41
12
13 47
14
15
16
40
42 43
014995
1315 751 103 - 2010-05 2-28

CAUTION
stretched - use adjustable pliers. 24
23
11 Snap in securing rings (32) on pins (31) and
12 Insert detent lever (28 and 29) into gearshift

housing as noted down. If necessary, use
cylindrical pins.
NOTE
Arrangement of detent levers depends on parts list. 25
For possible arrangements, refer to Fig. 012334.
29 27

15 Insert screw plugs (26 and 27) with spacing

washers, springs, and new sealing rings and
tighten.
28
26
NOTE
Version
standard “A”
014996
Version
standard “B”
Version
optional “C”
012334
1315 751 103 - 2010-05 2-29

10
6
19
18
17
7 4
11
5
22
21
20
1
48
2
014997
16 Press new bearing bush (17), new shaft 21 Fit shut-off valve (4) and greased O-ring (5)
sealing ring (18), and new scraper (19) into with hex head screws to gearshift housing.
cover (11). Tightening torque = 23 Nm
NOTE 22 Fit shift lever (3) with cover cap to gearshift

Use gasket according to parts list (0.5 mm thick). shaft.
17 Fit cover (11) with new gasket and tighten
with hex head screws (10). 23 Place greased roller (48) on valve lever.
NOTE
18 Insert detent (22), spring (21), and screw plug • Possibly fit angular metal sheet (not depicted in
(20) with new sealing ring and tighten. the drawing) to the servo unit – use fastening
Tightening torque = 60 Nm screws.
• For fitting/installation of the servo unit, valve
19 Insert detent (9) with greased O-ring and
lever and lever must be aligned. The servo unit
V-ring (8) into gearshift housing. In the case of
must be in neutral position (center position).
new O-ring, refer to chapter on consumables.
20 Insert switch (6 and 7) with pins and new sea- beginning of the chapter.
ling rings into gearshift housing and tighten. • For fitting the complete shift system to the
Tightening torque = 45 Nm transmission, refer to Chapter 2.10.2
Depending on the parts list, screw plugs are
fitted.
1315 751 103 - 2010-05 2-30

Selector patterns
Shift turret with shifting output, right side
Turning shaft, horizontal, right / selector pattern I
012352
Q1 Q2
012349 012350
Q3 Q4
012351 012353
Q5 Q6
012354 012355
1315 751 103 - 2010-05 2-31

Turning shaft, horizontal, right / selector pattern II
012362
Q1 Q2
012356 012357
Q3 Q4
012358 012359
Q5 Q6
012360 012361
1315 751 103 - 2010-05 2-32

3
2
4
1
6
5
7
015984
2.5 Shift turret with HGS Installation of servo unit

(Hydraulic gearshift System)
1 Insert spring (7) into servo unit.
Removal of servo unit
2 Attach pneumatic servo unit (5) with new
1 Loosen hollow screws (1 and 2) and take them
off with sealing rings and pipe (3). 3 Insert hex head screws (4) and tighten.
Tightening torque= 23 Nm
2 Loosen hex head screws (4).
4 Attach pipe (3) to valve block with hollow
3 Take off pneumatic servo unit (5) with gasket
screw (1) and new sealing rings.
(6) and spring (7).
NOTE
5 Fit pipe to the pneumatic servo unit with
• Spring (7) is placed loosely in the pneumatic servo
hollow screw (2) and new sealing rings.
unit.
complete component.
NOTE
The selector cylinder (8) and the shift cylinder (9)
are listed here only for information purposes. They
remain in the vehicle when the transmission and/or
the shift turret is removed.
For its removal and fitting to the shift turret, refer to
Chapter 2.7
1315 751 103 - 2010-05 2-33

6 4
23
11
7
10
18
17
16
5
1
22
015986
Removing and dismantling gearshift housing

turret with gasket (2).
NOTE
The selector cylinder (3) with O-ring (11) and hex
head screws (10) is listed here only for information
purposes. It remains in the vehicle when the trans-
mission and/or shift turret is removed.
2 Remove valve block (4) and take it off with

O-ring (5).
NOTE
Do not dismantle valve block further, complete part.
3 Loosen switches (6 and 7), remove with

sealing rings and pins.
4 Loosen bolt (16) and remove with sealing ring,

spring (17), and detent (18).

with sealing rings.
1315 751 103 - 2010-05 2-34

19 20
27
29
21
30
9 34
8
28
26
25
24 32
33
015987
6 Loosen hex head screws (19), remove cover 11 Remove gearshift shaft (29) from gearshift
(20) and gasket (21). housing in direction of arrow and take off
lever (30).
7 Unsnap V-ring (8) and remove it. Push detent
(9) and O-ring from the inside out of gearshift NOTE
housing. If the boreholes of the gearshift shaft show raised
edges after a long operating time, the gearshift shaft
NOTE
cannot be removed as described above. In that case,
Alternatively, in a last disassembly step, the detent
the spring assembly (working step 12) must be
can be pushed out of housing also towards the
removed with the gearshift shaft installed and the
inside.
gearshift shaft must be removed in the counter-
NOTE direction of the arrow. Before reinstalling the gear-
Check O-ring and replace it if necessary (refer to shift shaft, the raised edges must be leveled.
CAUTION
stretched - use adjustable pliers.
8 Unsnap securing rings (24).
9 Remove cylindrical pins (25) and detach

securing rings if necessary (26).
10 Remove pin (27).
1315 751 103 - 2010-05 2-35

12 Unsnap V-ring (12) on the removed shaft and

remove washer (13), spring (14), and washer
(15).
13 Apply plastic punch to the hollow shaft and

use hollow shaft (28) to drive cover (31) out of
gearshift housing. Then slide hollow shaft out
of gearshift housing and take off driver (32)
and blocking piece (33).
34
32
33
28
12
13
14
15
31
015988
1315 751 103 - 2010-05 2-36

1 Insert driver (32) and blocking piece (33) into 27

2 Press in new cover (31) until firmly home

(axial abutment).
NOTE
Housing bore and cover must be free from grease.
34
3 If necessary, press in cylindrical pin (34).
26
Position lever (30) in the housing. 25
24 32
4 Fit V-ring (12), washer (13), spring (14) and
washer (15) onto the removed shaft.
5 Insert gearshift shaft (29), into the housing and 33

hollow shaft in direction of arrow.
6 Push lever (30) upwards, slide hollow shaft

towards cover (31).
CAUTION 28
Cylindrical pin (27) secures hollow shaft only; only

push by hand, do not drive in.
12 30
7 Insert greased cylindrical pin (27). 13
Check ease of movement of the gearshift shaft. 14
15
CAUTION
Securing rings (24 and 26) must not be overstret-
ched – use adjustable pliers.
8 Snap in securing rings (26) on pins (25) and

29
31
015989
1315 751 103 - 2010-05 2-37

10 Insert hex head screws (19) and tighten. 19 20

Tightening torque = 23 Nm.
11 Insert screw plugs (22 and 23) with new

sealing rings and tighten.
21
23
22
015990
1315 751 103 - 2010-05 2-38

18
17
16
8 1
015991
12 Insert detent (18), spring (17) and screw plug NOTE

(16) with new sealing ring and tighten. • For fitting/installation of the pneumatic servo unit
Tightening torque = 60 Nm (PSU), shift turret must be in neutral position
(center position).
13 Insert detent (9) with greased O-ring and
V-ring (8) into gearshift housing. In the
case of new O-ring, refer to chapter on
• For fitting the complete shift system to the trans-
consumables.
mission, refer to Chapter 2.10.2
NOTE
Both the switches (6 and 7) and the corresponding
pins are different. Do not interchange them.
14 Insert switches (6 and 7) with pins and new

sealing rings into gearshift housing and
tighten.
15 Fit valve block (4) and greased O-ring (5) with

hex head screws to gearshift housing.
1315 751 103 - 2010-05 2-39

Selector patterns of shift turret with HGS
Selector pattern I
Arrangement of spring assemblies Q1
015992
Q1
015993
1315 751 103 - 2010-05 2-40

3
3
7
3 2
2
5
4
018645
2.6 Superimposed H shift system shift turret They remain in the vehicle when the transmission
with HGS and/or shift turret is removed.
For its removal and fitting to shift turret, refer to
Removal of servo unit Chapter 2.7
1 Loosen pipe (2) on the plug-in coupling (refer

to sketch).
Installation of servo unit
2 Loosen hollow screw (1) and take it off with
sealing rings and pipe (2). 1 Insert spring (6) into servo unit.
3 Loosen hex head screws (3). 2 Attach pneumatic servo unit (4) with new
4 Take off pneumatic servo unit (4) with gasket
(5) and spring (6). 3 Insert hex head screws (3) and tighten.
Tightening torque= 23 Nm
NOTE
• Spring (6) is placed loosely in the pneumatic servo 4 Fit pipe (2) to the pneumatic servo unit with
unit. hollow screw (1) and new sealing rings.
• Do not disassemble pneumatic servo unit further, Tightening torque = 20 Nm
complete component.
5 Slide in pipe (2) at superimposed H shift
NOTE system valve block, connection A5.
are listed here only for information purposes.
1315 751 103 - 2010-05 2-41

7 9
13
3 14
15
5 6
12
1 11
8
10
018647
Removing and dismantling gearshift housing CAUTION

Do not loosen plug-in coupling (10) at the front hex
1 Loosen hex head screws (1) and remove shift drive. Use back hex drive – SW 22.
4 If necessary, remove plug-in coupling (10).
NOTE The corresponding O-ring may stick to the
The selector cylinder (3) with O-ring (4) and hex housing – remove O-ring.
head screws (5) is listed here only for information
NOTE
purposes.
Do not disassemble superimposed H shift system
It remains in the vehicle when the transmission
further, complete part.
and/or the shift turret is removed; refer to Chapter
2.7. 5 Remove tappet (11) and pin (12) from the
gearshift housing.
2 Loosen hex head screws (6 and 7) and take off
valve block of superimposed H shift system 6 Loosen tappet switch (13) with sealing ring
(8). and take them off together with compression
spring (14) and detent (15).
NOTE
Gasket may stick to gearshift housing. Remove it
from the housing and place it in the valve block.
3 If necessary, loosen neutral switch (9) with

sealing ring and remove them.
1315 751 103 - 2010-05 2-42

16
24 17
23
22
18
21
26
25 32
35
27
20 33 28
19 29
30
34
31
018648
7 Loosen hex head screws (16), remove cover 14 Unsnap V-ring (27) on the removed shaft and
(17) and gasket (18). remove washer (28), springs (29 and 30), and
washer (31).
CAUTION
Securing rings (19) must not be overstretched – use 15 Apply plastic punch to the hollow shaft and
adjustable pliers. use hollow shaft (25) to drive cover (32) out of
gearshift housing. Then slide hollow shaft out
8 Unsnap securing ring (19).
of gearshift housing and take off driver (33)
9 Remove cylindrical pin (20) and, if necessary, and blocking piece (34).
remove second securing ring.
10 Remove gearshift shaft (21) from gearshift
housing in direction of arrow.
11 Remove locking pawl (22) and pin (23).
12 Slide pin (24) through gearshift housing and

remove it.
13 Push hollow shaft (25) in direction of arrow

and remove lever (26).
1315 751 103 - 2010-05 2-43

16
24 17
23
22
18
21
26
25 32
35
27
20 33 28
19 29
30
34
31
018648
Assembling gearshift housing 6 Push lever (26) upwards, slide hollow shaft
towards cover (32).
gearshift housing. Slide hollow shaft (25) in CAUTION
correct position into the gearshift housing, Securing rings (19) must not be overstretched – use
blocking piece, and driver. adjustable pliers.
2 Press in new cover (32) until firmly home 7 If necessary, snap upper securing ring into pin
(axial abutment). (20) and insert in driver and gearshift shaft.
Insert securing ring (19).
NOTE
Housing bore and cover must be free from grease. 8 Insert pin (24) until stop in housing and lock
with pin (23). Insert locking pawl (22).
3 If necessary, press in cylindrical pin (35).
Position lever (26) in the housing. 9 Fit new gasket (18) and cover (17).
4 Fit washer (31), springs (29 and 30), washer 10 Insert hex head screws (16) and tighten.
(28), and V-ring (27) onto the removed shaft. Tightening torque = 23 Nm
5 Insert gearshift shaft (21) into the housing and

hollow shaft (in direction of arrow).
1315 751 103 - 2010-05 2-44

7 9
13
3 14
15
5 6
12
1 11
8
10
018647
11 Install detent (15), spring (14), and tappet NOTE

switch (13) with new sealing ring in the gear- • For fitting/installation of the pneumatic servo unit
shift housing and tighten. (PSU), shift turret must be in neutral position
Tightening torque = 45 Nm (center position).
• For fitting/installation of servo unit refer to
12 Insert tappet (11) and pin (12) into gearshift
housing.
• For fitting the complete shift system to the trans-
13 Fit valve block (8) to gearshift housing with mission, refer to Chapter 2.10.2
hex head screws (6 and 7).
14 Screw neutral switch (9) with new sealing

ring to valve block and tighten.
CAUTION
Do not tighten plug-in coupling (10) at the front
hex drive. Use back hex drive – SW 22.
15 Screw in plug-in couplings (10) and tighten.

1315 751 103 - 2010-05 2-45

Selector patterns of superimposed H shift system

shift turret
Selector pattern I
Arrange of spring assemblies Q5
018649
Q5
018650
1315 751 103 - 2010-05 2-46

ZF-Ecosplit HGS cylinder
1
4
018646
2.7 Selector and shift cylinder Separating

Shift turret with HGS
1 Loosen two hex head screws (1) with washers.
NOTE
2 Pull off selector cylinder (2) with O-ring;
uncouple selector cylinder’s piston rod from
are connected to a separate hydraulic circuit and
driver groove of gearshift shaft.
remain in the vehicle when the transmission and/or
shift turret is removed. NOTE
Move shift lever in the gate to be able to extract
selector cylinder.
3 Loosen two hex head screws (3) with washers.
4 Extract shift cylinder (4), uncouple shift cylin-

der’s piston rod from driver groove of shaft in
the pneumatic servo unit (5).
1315 751 103 - 2010-05 2-47

1
4
018646
Connecting
1 Connect shift cylinder’s piston rod (4) with 4 Connect selector cylinder’s piston rod (2) with
driver groove of shaft in the pneumatic servo driver groove of the gearshift shaft.
unit (5). A housing cutout close to the selector cylinder
allows for connection in correct assembly
NOTE
position only.
Operate shift lever in shifting direction so that
piston rod extends. NOTE
Operate shift lever in selecting direction so that
2 Place shift cylinder (4) in correct position
piston rod extends.
(depends on the installation conditions in the
vehicle) onto the pneumatic servo unit. 5 Place selector cylinder with O-ring on shift
turret.
3 Screw in two M8x28 hex head screws (3) with
washers and tighten. 6 Screw in two M8x28 hex head screws (1) with
Tightening torque = 23 Nm washers and tighten.
NOTE
Check O-ring on selector cylinder and replace if
necessary.
1315 751 103 - 2010-05 2-48

1 2
1X56 138 229
015997
Functional test
NOTE
Also refer to inspection instructions 6008 756 003.
1 Connect testing device 1X56 138 229 to driver

groove of gearshift shaft (1).
2 Screw in hex head screws (2) and tighten.

3 The individual gears can be shifted by using a

box wrench or hex head wrench socket.
4 Remove testing device 1X56 138 229.
1315 751 103 - 2010-05 2-49

2-50
2 4
024463
2.8 Superimposed H shift system with cable

control
Removal of servo unit Installation of servo unit
1 Loosen 4 hex head screws (1). 1 Insert spring (4) into servo unit.
2 Take off pneumatic servo unit (2) with gasket 2 Attach pneumatic servo unit (2) with new
(3) and spring (4). gasket (3) to the shift turret.
NOTE 3 Insert hex head screws (1) and tighten.

• Spring (4) is placed loosely in the pneumatic servo Tightening torque = 23 Nm
unit.
complete component.
1315 751 103 - 2010-05 2-51

17
16 4
6
18
1
14
10
15 11
12 7
13 4
9
8
5
3
2
49
024464
Removing and dismantling gearshift housing NOTE

Gasket may stick to the gearshift housing. Remove it
1 Loosen hex nut (16) and take off selector lever
(17) with protective cap (18).
Do not disassemble valve block further, complete
NOTE part.
Selector lever conceals a hex head screw; therefore,
shift system cannot be detached before selector
sealing ring and pressure switch (7) and
lever is removed.
remove them.
6 Remove tappet (8) and pin (9) from the gear-
shift housing.
Remove roller (49) from valve lever.
7 Loosen tappet switch (10) with sealing ring
3 Loosen shift lever (3, depending on parts list)
and take them off together with compression
and remove with protective cap.
NOTE
cover (14) with gasket.
4 Loosen hex head screws (4) and take off with
9 Remove V-ring (15) from the housing.
valve block (5).
1315 751 103 - 2010-05 2-52

19
20
32 29
23 31
24
22
33
30
21 34
35
36
28
39
26 27 37
25
38
1X25 139 783
024465
10 Loosen hex head screws (19), remove cover 18 Remove pin (31).
(20) and gasket (21).
11 Remove locking pawl (22) and pin (23). housing in direction of arrow and take off
12 Slide pin (24) through gearshift housing and
remove it. NOTE
CAUTION
edges.
stretched – use adjustable pliers. 20 Take pin (33) out of valve lever; do not remove
lower needle bush. If the needle bush is
14 Remove cylindrical pin (27) and, if necessary, as a complete set.
detach securing ring (26).
21 Apply plastic punch to hollow shaft (28) and
15 Push hollow shaft (28) in towards sealing cap. use hollow shaft to drive bush (35) and shaft
16 Place impact adapter 1X25 139 783 over
Then slide hollow shaft out of gearshift
needle bush (29) and drive valve lever (30)
housing and take off driver (37) and blocking
slightly downwards.
piece (38).
17 Remove needle bush (29).
1315 751 103 - 2010-05 2-53

23 Use pliers to remove V-ring (40) from gearshift

shaft.
40
24 Remove washers (41 and 43) with com- 41
42
pression springs (42) from the gearshift shaft. 43
024466
25 Remove V-ring (44) from selector shaft (45).

48
26 Push out selector shaft (45) (in the direction of 47
the arrow) from housing cover and in doing
so, remove shaft sealing ring (48).
27 Remove selector lever (46) from housing cover.
28 Remove needle bush (47) from housing cover

if necessary.
45
46
44
024467
1315 751 103 - 2010-05 2-54


48
1 If necessary, insert needle bush (47) into hou- 47

sing cover until it is flush.
2 Insert selector lever (46) into housing cover.
3 Insert selector shaft (45) (in the direction of

the arrow) into housing cover and selector
lever.
4 Insert V-ring (44) into selector shaft.

45
5 Insert greased shaft sealing ring (48) in correct
position, until firmly home.
46
44
024467
6 Mount washer (43), compression spring (42),

and washer (41) onto gearshift shaft.
40
7 Use pliers to snap V-ring (40) into gearshift 41
42
shaft. 43
024466
1315 751 103 - 2010-05 2-55

19
20
32 29
23 31
24
22
33
30
21 34
35
36
28
39
26 27 37
25
38
1X25 139 707
024465
8 Insert driver (37) and blocking piece (38) into 14 Insert cylindrical pin (31) and drive in new
gearshift housing. Slide hollow shaft (28) in needle bush (29) until it is flush. Check ease
correct position into the gearshift housing, of movement of the gearshift shaft.
CAUTION
9 Press bush (35) flush into housing using adap- Securing rings (26 and 25) must not be over-
ter 1X25 139 707. stretched – use adjustable pliers.
10 Apply grease to shaft sealing ring (36) and 15 Snap securing ring (26) in with pin (27) and
press firmly home. insert it into driver and gearshift shaft. Insert
securing ring (25).
11 Insert cylindrical pin (33) in valve lever (30).
If necessary, press in cylindrical pin (39). 16 Insert pin (24) until stop in housing and lock
12 Fit valve lever (30) and lever (34) on hollow
shaft in gearshift housing. 17 Fit new gasket (21) and preassembled cover
(20).
13 Insert gearshift shaft (32) into hollow shaft in
direction of arrow. 18 Insert hex head screws (19) and tighten.
NOTE
Cylindrical pin (33) must mesh with gearshift shaft.
Position gearshift shaft and hollow shaft.
1315 751 103 - 2010-05 2-56

17
16 4
6
18
1
14
10
15 11
12 7
13 4
9
8
5
3
2
49
024464
19 Install detent (12), spring (11), and tappet 25 Fit cover (14) with new gasket to housing
switch (10) with new sealing ring in the with hex head screws (13) and tighten.
gearshift housing and tighten. Tightening torque = 23 Nm
26 Fit shift lever (3) with cover cap to gearshift
20 Insert tapped (8) and pin (9) into gearshift shaft.
housing. Tightening torque = 49 Nm
21 Fit valve block (5) with hex head screws (6) 27 Place greased roller (49) onto valve lever.
to gearshift housing.
NOTE
• For fitting/installation of the servo unit, refer to
22 Screw neutral switch (6) with new sealing beginning of the chapter.
ring to valve block and tighten. • For fitting the complete shift system to the trans-
Tightening torque = 45 Nm mission, refer to Chapter 2.10.2
23 Screw pressure switch (7) to valve block and 28 Place protective cap (18) and selector lever
tighten. (17) on selector shaft and tighten with hex
Tightening torque = 23 Nm nut (16).
24 Snap V-ring (15) into gearshift housing.
1315 751 103 - 2010-05 2-57

Selector patterns
Superimposed shift system shift turret
Selector pattern I
Arrange of spring assemblies Q4
024461
Q4
024462
1315 751 103 - 2010-05 2-58

2
1
031770_1
2.9 Superimposed H shift system with gate-

dependent servo unit
Removal of servo unit Installation of servo unit
1 Loosen hex head screws (1 and 2). 1 Place compression spring (6) in servo unit.
2 Remove pneumatic servo unit (4) with gasket 2 Attach pneumatic servo unit (4) with new
(3) and compression spring (6). gasket (3) to the shift turret.
NOTE 3 Insert hex head screws (1 and 2) and tighten.

• Compression spring (6) is placed loosely in Tightening torque: 23 Nm
pneumatic servo unit.
• Do not disassemble pneumatic servo unit further, NOTE
complete component. Insert hex head screws (2) with sealing compound
Loctite no. 574.
Order no.: Compression spring (6) 0501 318 490

Detent (5) 0501 319 920
1315 751 103 - 2010-05 2-59

Removing and dismantling gearshift housing
1 Loosen hex nut (1) and take off selector lever

(2) with protective cap (3).
NOTE
Selector lever conceals a hex head screw; therefore,
shift system cannot be detached before selector
lever is removed.

Remove roller (6) from valve lever.
3 Loosen hex head screw (7) and remove shift

lever (8) with protective cap (9).
NOTE
4 Loosen hex head screws (10 and 11) and take

off with valve block (12).
NOTE
Gasket may stick to gearshift housing. Remove it
Do not disassemble valve block further, complete
component!

sealing ring and pressure switch (14) and
remove them.
6 Remove tappet (15) and pin (16) from the

gearshift housing.
7 Loosen tappet switch (17) with sealing ring

and take them off together with compression

cover (21).
9 Remove V-ring (22) from the housing.
1315 751 103 - 2010-05 2-60

2
1
3
11
4
17
13
18
19
21
22
14
10
20 16
15
12
9 8
5
6
7
031800_1
1315 751 103 - 2010-05 2-61

10 Loosen hex head screws (23), remove cover 22 Apply plastic punch to hollow shaft (32) and
(24) and gasket (25). use hollow shaft to drive bush (39) and shaft
11 Remove locking pawl (26) and pin (27). Then slide hollow shaft out of gearshift
housing and take off driver (41) and blocking
12 Slide pin (28) through gearshift housing and piece (42).
remove it.
CAUTION
Securing rings (29) must not be overstretched – use 24 Use pliers to remove V-ring (44) from gearshift
adjustable pliers. shaft.
13 Unsnap securing ring (29). 25 Remove washers (45) with compression

spring (46) from the gearshift shaft.
14 Remove cylindrical pin (30) and, if necessary,
remove upper securing ring. 26 Remove V-ring (47) from selector shaft (48).
15 Remove pin (31). 27 Push selector shaft (48) out of the housing
cover in direction of arrow and remove shaft
16 Push hollow shaft (32) in towards sealing cap. sealing ring (49).
17 Position impact adapter 1X25 139 783 over 28 Remove selector lever (51) from housing
needle bush (33) and drive valve lever (36) cover.
slightly downwards.
29 If needed, remove needle bush (50) from
18 Remove needle bush (33). housing cover.
19 Remove pin (34).

housing in direction of arrow and take off
NOTE
edges.
21 Take pin (35) out of valve lever; do not remove

lower needle bush. If the needle bush is
as a complete set.
1315 751 103 - 2010-05 2-62

44 49
45
50
46
45
48
51
47
028571_2 031802_1
23 23
23
31 24
37
33
27 34
26 28 35
36
38
25 39
40
52
32
30
29
41 43
42
1X25 139 783
031801_2
1315 751 103 - 2010-05 2-63

Assembling gearshift housing 14 Insert cylindrical pin (34) and drive in new
needle bush (33) until it is flush. Check ease
1 If necessary, insert needle bush (50) into of movement of the gearshift shaft.
housing cover until it is flush.
CAUTION
2 Insert selector lever (50) into housing cover. Securing rings (29) must not be overstretched – use
adjustable pliers.
3 Insert selector shaft (48) into the housing
cover in direction of arrow and the selector 15 Snap securing ring (29) in with pin (30) and
lever. insert it into driver and gearshift shaft. If
necessary, insert upper securing ring.
4 Insert V-ring (47) into selector shaft.
16 Insert pin (31) into hollow and gearshift shaft.
5 Insert greased shaft sealing ring (49) in
correct position, until firmly home. 17 Insert pin (28) until stop into housing and lock
6 Mount washer (45), compression spring (46),
and washer (45) onto gearshift shaft. 18 Fit new gasket (25) and cover (24).
7 Use pliers to snap V-ring (44) into gearshift 19 Insert hex head screws (23) and tighten.
shaft. Tightening torque = 23 Nm

9 Press bush (39) flush into housing using

adapter 1X25 139 707.
10 Apply grease to shaft sealing ring (40) and

press firmly home.
11 Insert cylindrical pin (35) in valve lever (36).

If necessary, press in cylindrical pin (43).
12 Fit valve lever (36) and lever (38) onto hollow

shaft in gearshift housing.
13 Insert gearshift shaft (37) into hollow shaft in

direction of arrow.
NOTE
Cylindrical pin (35) must mesh with gearshift shaft.
Position gearshift shaft and hollow shaft.
1315 751 103 - 2010-05 2-64

44 49
45
50
46
45
48
51
47
028571_2 031802_1
23 23
23
31 24
37
33
27 34
26 28 35
36
38
25 39
40
52
32
30
29
41 43
42
1X25 139 707
031801_2
1315 751 103 - 2010-05 2-65

20 Install detent (19), spring (18), and tappet

switch (17) with new sealing rings in the gear-
shift housing and tighten.
21 Insert tapped (15) and pin (16) into gearshift

housing.
22 Fit valve block (12) to gearshift housing with

hex head screws (11 and 10).
23 Screw neutral switch (13) with new sealing

ring to valve block and tighten.
24 Screw pressure switch (14) to valve block and

tighten.
25 Snap V-ring (22) into gearshift housing.
26 Fit cover (21) to housing with hex head

screws (20) and tighten.
27 Place protective cap (9) and selector lever (8)

on gearshift shaft and tighten with hex head
screw (7).
28 Place greased roller (6) onto valve lever.
NOTE
• For fitting/installation of the servo unit, refer to
• For fitting the complete shift system to the
transmission, refer to Chapter 2.10.2.
29 Place protective cap (3) and selector lever (2)

on selector shaft and tighten with hex nut (1).
NOTE
If the shift unit is fitted to the transmission at a later
date, a bolt (see arrow) must be inserted in the shift
unit before the selector lever is fitted.
1315 751 103 - 2010-05 2-66

2
1
3
11
4
17
13
18
19
21
22
14
10
20 16
15
12
9 8
5
6
7
03180_1
1315 751 103 - 2010-05 2-67

Selector patterns for shift turret of superimposed

shift system with gate-dependent servo unit
Selector pattern I
Arrangement of spring assemblies Q1
031791_1
Q1
031792
1315 751 103 - 2010-05 2-68

2.10 Complete fitting of shift turret
2.10.1 Versions without servo unit

(8/16 S 151, 8/16 S 181, 16 S 221) 3
1 Fit new gasket (1) to clutch housing (2) and/or

sealing face.
1
2 Fit complete gearshift housing (3). Align

boreholes in gearshift housing with gasket.
Assembly recommendation
2
Positioning between clutch housing, gasket, and
gearshift housing can be facilitated by using
threaded pins; refer to Chapter 2.10.2.
3 Engage all gears. There must be a noticeable

excess shift travel for each gear.
Should the shifting angle not correspond to
the specified tolerances, it must be set using
an angle measuring equipment.
Finally tighten all hex head screws. 001969
CAUTION
The shift turret housing must be centered on the
transmission housing so that the play (excess shift
travel) is identical on both side and that a shifting
angle of 14°30” +2° is reached (refer to image).
1st, 3rd, 5th, 7th gear

2st, 4rd, 6th, 8th gear
009894
1315 751 103 - 2010-05 2-69

2.10.2 Versions with servo unit
1 Fit new gasket (1) to clutch housing (2) and/or

3
sealing face.
2 Fit complete gearshift housing (3). Align

boreholes in gearshift housing with gasket.
1
NOTE
Positioning between clutch housing, gasket, and
gearshift housing must be achieved by using two
locating pins 1X46 183 298. Alternatively, pins can
be manufactured in-house. For drawing, refer to Fig.
016078. 2
NOTE
When fitting the shift system, ensure that the roller
in the valve lever does not fall out.
Place roller with grease onto valve lever.
3 Insert all hex head screws and tighten. 1X46 183 298
NOTE – HGS version

After installing the transmission in the vehicle, the
selector and shift cylinders remaining in the vehicle Ø 15
need to be flange-mounted to the shift turret and/or
pneumatic servo unit.
The installation of both cylinders is described in
Chapter 2.7.
110
Shaft Ø
Schaft ø 8.9
8.9
80
15
M8
016078
1315 751 103 - 2010-05 2-70

ZF-Ecosplit Range-Change Group
3 Range-Change Group
3.1 Output flange ................................................................................................ 3-2

Removing output flange ................................................................................. 3-2
Installing the output flange............................................................................. 3-3
3.2 Cover and output bearing ............................................................................. 3-4

Removing cover and output bearing ............................................................... 3-4
Installing cover and output flange................................................................... 3-4
3.3 Range change group ..................................................................................... 3-6

Removing and dismantling range change group............................................. 3-6
Assembling and installing range change group .............................................. 3-9
Measurement of main shaft and planetary gear set (16 S 251, 16 S 2720)..... 3-11
Completely fitting range change group ........................................................... 3-12
1315 751 103 - 2010-05 3-1

3 Range Change Group
NOTE
When repairing the range change group, proceed
according to the following sequence of operations. 2 1
If the range change group is only being removed for
further repair work, only remove washer (3) and 3
attach fixture 1X56 136 260. For removal of range 5
change group, refer to Chapter 3.3.
4
3.1 Output flange
Removing output flange

1X56 136 260
1 Pry safety plate (1) off the screws/bolts (2). 011374
NOTE
Whether/which safety plate is installed depends on
the transmission version.
2 Secure output flange so that it cannot be

twisted.
3 Remove hex head screws (2) and take off

conical spring washer (3).
4 Fit interim piece onto planet carrier and

extract output flange (4) with two- or three-
armed extractor.
5 Remove O-ring (5).
1315 751 103 - 2010-05 3-2

Installing the output flange
NOTE 2
• Range change group is fitted to the transmission;
refer to Chapter 3.3.
• Output bearing and cover are fitted; refer to 1
Chapter 3.2. 3
5
1 Lightly oil shaft sealing ring in the cover.
4
! DANGER
Only touch heated output flange wearing protective
gloves.
1X56 137 651

2 Heat output flange (4) to max. 100 °C and slide
it onto spline of planet carrier until firmly 001917_1
home (axial abutment).
2
NOTE
If necessary, pull on output flange by means of
washer (3) and two assembly auxiliary screws until
1
it is firmly home (axial abutment). Remove washer
and assembly auxiliary screws afterwards. 3
5
3 Lightly oil new O-ring (5) and insert it in the
gap between output flange and planet carrier 4
shaft.
4 Fix washer (3) with hex-head screws (2).

If required, secure the output flange against
1X56 137 651
twisting by means of a flange holder. Hex
head screws are fitted with Loctite no. 262. 011375_1
5 Fit new safety plate (1) using adapter

1X56 137 651 and/or 1X56 137 246.
NOTE
Which safety plate (1) is installed depends on the
transmission version.
1315 751 103 - 2010-05 3-3

3.2 Cover and output bearing

2
3 1 8
Removing cover and output bearing 5
6
1 Remove hex head screws (1). Take off cover (2) 7
and seal (3). 9
2 Remove hex head screws (4) from the cover (5).

4
3 Loosen cover (5) by slight blows with a plastic

hammer and take it off together with seal (6)
and, depending on the transmission version,
also with shim (7).
4 Drive shaft sealing ring (8) out of bearing

cover using a plastic punch. 1X56 122 314
1X56 122 295
5 Use extractor 1X56 122 314 (for 10 balls) to 011376_1
pull ball bearing (9) out of housing and/or

extractor 1X56 122 295 (for 11 balls).
Installing cover and output flange
NOTE
Range change group is fitted to the transmission; 8
refer to Chapter 3.3. 5
! DANGER 6
Only touch heated parts when wearing protective
gloves. 7
9
Measurement of ball bearing’s axial clearance
(target: 0 to 0.1 mm):
1 Place new seal (6) on cover (5) and measure

cover’s screw-in length together with seal, e.g.
23.40 mm.
011377_1
2 Measure screw-out length and/or bearing seat

depth of housing (without seal), e.g. 7.00 mm.
3 Measure width of ball bearing (9), e.g.

30.00 mm.
1315 751 103 - 2010-05 3-4

Example of calculation:
23.40 mm screw-in depth of cover
+) 7.00 mm screw-in depth of housing
30.40mm 1X56 137 124
–) 30.00 mm width of ball bearing
0.40 mm axial clearance without shim
that means a shim (7) of 0.3 – 0.4 mm is

required and the resulting axial clearance
Ring
is 0 to 0.1 mm.
NOTE
For transmission versions without a shim (7), the
measurements explained above don’t have to be
considered.
028678_2
4 Heat cover (5) to approx. 60 °C and insert

determined shim (7) and ball bearing (9). 2
3 1
5 Drive shaft sealing ring (8) into cover using
adapter 1X56 137 124.
NOTE
Use adapter only together with 12.5 mm ring.
Installation dimension = 12.5 + 1.0 mm from the 4
cover edge to the shaft sealing ring.
5
Apply thin coat of sealant to shaft sealing ring.
Apply lubricant, e.g. soapsuds, to the outside of 6
rubber sleeve.
6 Fit cover (5) with new seal (6) and tighten hex
head screws (4) and washers.
011378_1
7 Fit cover (2) with new seal (3) to the housing

and screw on with hex head screws (1).
1315 751 103 - 2010-05 3-5

3.3 Range change group

2
Removing and dismantling range change
group 5 1
8
11
Shift cylinder for range change group 9
3
11 4
1 Unscrew hex head screws (1), loosen cylinder 12
(2) on the range change group housing and 2
pull it off piston (3).
5 1
a
8
2 Take O-rings (4 and 5) out of cylinder. 10
9
10
4
3 Remove detent plunger (6), screw locating 3
fixture 1X56 138 100 into the same threaded 12
hole, position fixture on selector rail (7), and
tighten locating fixture.
b
4 Unscrew securing nut (8) from the piston (3). 6
5 Remove piston with guide ring (9).
6 Take off grooved rings (10) and/or sealing

rings (11). 7
1X56 138 100

NOTE
Depending on the transmission version, variant a or 009942_1
b is possible.
7 Remove guide ring and grooved rings from the

piston.
8 Pull sleeve (12) of out range change group

housing.
1315 751 103 - 2010-05 3-6

Housing/Range change group 17

26
1 Remove mechanical speedo and/or impulse 19
sensor (13).
27
2 Remove switch (14) with sealing ring and pin
(15), depending on parts list possibly also (16).
13
3 Loosen swivel screws (17) for gearshift fork
(18), do not remove yet. 20
4 Remove locating fixture 1X56 138 100 again. 34

23 17
5 Unscrew hex head screws (19) of the range
change housing (20). 25
18
6 Fit fixture 1X56 136 260 to planet carrier (21

and/or 21a) and remove range change group 24
from intermediate housing (22) avoiding
canting and using a hoist.
1X56 136 260
7 Remove swivel screws (17) and take range

change group housing off planet carrier.
8 Take off gearshift fork (18) and sliding pads

(23). 25a
9 Remove intermediate plate (24) together with

24a
seals (25) and/or 24a and 25a for 16 S 251,
21
16 S 2720) from the planet carrier.
10 Pull selector rail (7) out of intermediate

housing.
11 Remove injection tube (26).
12 If necessary, remove cylindrical pins (27).
22 16
21a
7 14
15
011382_1
1315 751 103 - 2010-05 3-7

13 Remove seal (28) and/or (28a) for 16 S 251

and 16 S 2720) from intermediate housing.
29
14 Remove thrust washer (29) from the main 30
shaft.
NOTE
The 16 S 251 and 16 S 2720 versions have an
additional shim (30) in this place.
28
22 28a
011384_2
1315 751 103 - 2010-05 3-8

Assembling and installing range change

group
17
Housing/Range change group 33
20 W
25
1 Place intermediate plate (24 and/or 24a) on
24 W
planet carrier (21 and/or 21a).
2 Insert gearshift fork (18) and sliding pads (23) 26

into sliding sleeve.
3 Place and position new seal (25 and/or 25a) 7

on intermediate plate.
17
4 Insert injection tube (26) in the housing.
18
21
5 Place housing (20) over planet carrier onto
seal and position it. Ensure radial position of
23
gearshift fork.
6 Introduce gearshift fork (7) from housing

inner side, position it roughly and make it
mesh with gearshift fork.
009942_2
7 Coat swivel screw threads (17) with Loctite

17
no. 241, fit spring washers, screw in, do not
tighten. 20
33
25a W
NOTE 24a
When using a new housing (20), drive ball (33) into
housing in accordance with selector pattern I or II. W
26
7
17
23
13
21a
011383_1
1315 751 103 - 2010-05 3-9

Shift cylinder for the range change group

2
1 Coat new sleeve (12) with spirit (7), slide it
over selector rail, and drive it in with soft 5 1
8
punch until it is firmly home (axial abutment). 11
9
3
2 Place sealing ring (11) and/or grooved rings
11 4
(10), piston (3) with guide ring (9), and sealing 12
ring (11) on selector rail (7). 2
5 1
3 Tighten new locknut (8) when range change a
8
group is completely installed. 10
10
4
3
NOTE 12
Fitting of range change group cylinder can only be
done once R/C has been fully assembled with inter-
mediate housing. Thread must be absolutely free b
from oil and grease. Locating fixture 1X56 138 100
must be fitted in place of detent plunger (6). 6
4 Grease new O-rings (4 and 5) and insert them

into corresponding annular grooves (cylinder
and housing).
7
5 Carefully slide cylinder (2) over the piston
with guide pin and piston seal. Fix cylinder
using two hex head screws (1). 009942_1
NOTE
Align compressed-air boreholes.
1315 751 103 - 2010-05 3-10

6 Slide thrust washer (29) over gearing onto

main shaft.
32
Measurement of main shaft and planetary
gear set (16 S 251, 16 S 2720)
a Place test socket (31) 1X56 138 158 on thrust
washer (29) and set dial gage (32) to zero.
b Push test socket 1X56 138 158 vertically 31

upwards until stop and read off value on the
test gage.
29
NOTE
• The support points for the test socket must be
clean.
• Perform measurement at two opposite locations 012669_2
and calculate mean value.
c Reading value corresponds to the thickness of

32
the shim (30).
A permissible tolerance of ± 0,05 mm is to be
observed.
Example 1:
Measured value = 1.97 mm
In the case of a permitted tolerance of ± 0.05 mm,
a shim of 2.00 mm is to be selected. 31
Example 2:
Measured value = 1.93 mm
In the case of a permitted tolerance of ± 0.05 mm,
a shim of 1.90 mm is to be selected.
012670_2
NOTE
1316 700 017
Also refer to assembly instructions 1316 700 017.
d Remove test socket and thrust washer from

68.75 + 0.05
main shaft. Fit determined shim (30) and slide

thrust washer (29) over gearing onto main
shaft.
29
30
012672_2
1315 751 103 - 2010-05 3-11

Completely fitting range change group
NOTE
Before fitting range change group, main shaft/plane-
tary gear set must be measured (only 16 S 251,
16 S 2720).
1 Fit new seal (28 and/or 28a) to the intermediate

28
housing (22).
22
NOTE 28a
Three cylindrical pins (27) must be fitted on the
intermediate housing. If needed, drive in.
2 Attach lifting device 1X56 136 260 to planetary

19
body so that range change group can be posi-
tioned horizontally over intermediate housing
using the hoist. 1
Positioning the range change group over the inter-
mediate housing is facilitated by fitting threaded
pins to the intermediate housing.
3 Possibly turn lifting gear so that planetary gear 27

set and main shaft mesh.

NOTE 1X56 138 100 1X56 136 260

• Ensure that snap ring snaps in audibly.
011384_1
• Move piston to final position (high or low range
group).
• Screw in locating fixture 1X56 138 100.
• Tighten new locknut (8) and assemble R/C cylinder.
5 Remove lifting gear 1X56 136 260.
6 Tighten hex head screws (1) on R/C cylinder.

1315 751 103 - 2010-05 3-12

7 Remove locating fixture 1X56 138 100 and

insert detent plunger (6) with new sealing ring 6
and tighten. 16
8 Insert mechanical speedo and/or impulse

sensor (13) with new sealing ring and tighten.
9 Screw in screw plug (34) and new sealing ring

on housing and tighten.
10 Screw in screw plug (16) and new sealing ring

on housing and tighten.
1315 751 103 - 2010-05 3-13

3-14
ZF-Ecosplit Planetary Gearset with Synchronizers
4 Planetary Gearset with Synchronizers
4.1 Synchronizers ................................................................................................ 4-3

Disassembling synchronizers .......................................................................... 4-3
Assembling synchronizers .............................................................................. 4-4
4.2 Ring gear ....................................................................................................... 4-6

Dismantling ring gear ..................................................................................... 4-6
Assembling ring gear ..................................................................................... 4-7
4.3 Planet carrier................................................................................................. 4-9

4.3.1 Planet carrier (standard) ...................................................................... 4-9
Disassembling planet carrier ............................................................... 4-9
Assembling planet carrier.................................................................... 4-10
4.3.2 Planet carrier (reinforced version 16 S 251, 16 S 2720 TO) ................. 4-12
Disassembling planet carrier ............................................................... 4-12
Assembling planet carrier.................................................................... 4-13
1315 751 103 - 2010-05 4-1

4-2
4 Planetary Gearset with Synchronizers 3*

2
4.1 Synchronizers 1
Disassembling synchronizers 4 6
!
DANGER 5
7
Thrust pieces are under spring tension.
Use e.g. cloth to prevent the parts from jumping out.
8
1 Fit thrust piece to planet carrier. Grip sliding

sleeve (1) with two or three-armed extractor
and extract it together with clutch body (2).
The thrust pieces (4) held back by the sliding
sleeve and the compression springs (5) can be
caught by a cloth. 9
NOTE
10
For the straight-toothed version, extract speedo
worm and/or counting disk (3) with integrated bush
together with clutch body (2). 001907_1
2 Remove synchronizer ring (6).
4 Fit thrust piece to planet carrier and grip and 2

extract synchronizer body (8) with two or
three-armed extractor. 13*
1
5 Remove synchronizer ring (9) and clutch body 4 6
(10) from planet carrier.
5
7
8
Reinforced version (16 S 251, 16 S 2720):
9
6 Remove clutch disk from (11) planet carrier. 10
12
11
7 Unsnap snap ring (12) on clutch body (10).
8 Check axial bearing for functioning (13) and

only remove from planet carrier if it is
defective.
* in place depending on parts list
011385_1
1315 751 103 - 2010-05 4-3

ZF-Ecosplit Planetary Gear Set with Synchronizer
Assembling synchronizers
2
NOTE
13*
For synchronizer wear test, refer to Chapter 14.1 1
NOTE 4 6
Lightly oil the friction cones of the clutch bodies 5
7
and synchronizer rings.
8
Reinforced version, working steps 1 to 2 9

(16 S 251, 16 S 2720):
10
1 Fit clutch disk (11) to planet carrier.
12
11
2 Insert snap ring (12) into clutch body (10).
3 Slide clutch body (10) onto clutch disk (11)

and/or planet carrier.
4 Fit synchronizer ring (9) to planet carrier.
! DANGER
Only touch heated synchronizer body when
wearing protective gloves. 011385_1
5 Heat synchronizer body (8) to approx. 120 °C

and push on until it is firmly home (axial abut-
ment). The long hub side must face towards
planet carrier. The synchronizer ring’s lugs
must mesh with the synchronizer body’s 3*
2
recesses.
1
6 Snap securing ring (7) with axial clearance
4 6
between 0.0 and 0.1 mm into annular groove.
Securing rings are available at 0.1 mm stepped 7
5
thickness levels.
7 Fit sliding sleeve (1) to synchronizer body (8) 8

with collar facing towards output.
NOTE
The sliding sleeve’s recesses must line up with
synchronizer body’s recesses.
10
001907_1
1315 751 103 - 2010-05 4-4

8 Insert new compression springs (5) with trust

pieces (4) in synchronizer body (8) and guide
into sliding sleeve (1) with suitable tool.
9 Place synchronizer ring (6) on synchronizer

body (8).
NOTE
Lugs of synchronizer ring (6) must mesh with reces-
ses of synchronizer body (8).
10 Depending on the transmission version, insert

axial bearing (13) in clutch body (2)
(only for 16 S 251, 16 S 2720).
!
DANGER
Only touch heated clutch body when wearing
protective gloves.
11 Heat clutch body (2) to approx. 120 °C and

slide onto planet carrier until it is firmly home
(axial abutment).
12 Press synchronizer ring (6) against synchroni-

zer body (2) and set sliding sleeve (1) to center
position. You will clearly hear the thrust
pieces snap into place.
13 Heat speedo worm and/or counting disk (3) to

approx. 120 °C and slide onto planet carrier.
Sensor lugs must face towards planet carrier.
NOTE
Speedo worm and/or counting disk (3) are only
installed in straight-toothed version, that is
8/16 S 151, 8/16 S 181, 16 S 221.
1315 751 103 - 2010-05 4-5

4.2 Ring gear

5
Dismantling ring gear
4
3 9
1 Snap securing ring (7) described in Chapter
4.1 into ring gear carrier. Fit thrust piece onto 2
planet carrier and grip securing ring with two
or three-armed extractor. 1
Straight-toothed version
(8/16 S 151, 8/16 S 181, 16 S 221):
2 Ring gear (1), ring gear carrier (2), and ball
bearing (5) are extracted together.
3 Unsnap locking wire (3) from annular groove

of the ring gear. 005390_1
4 Drive ring gear carrier (2) out of ring gear (1)

using a plastic hammer. 7
6
5 Unsnap snap ring (4) from ring gear carrier 3
and take out ball bearing (5).
2
6 Remove intermediate ring (9) from planet
1
carrier (only 16 S 151).
Helical-toothed version (standard):

2 Ring gear (1), ring gear carrier (2), interme-
diate ring (6), and axial needle bearing (7) are
extracted together.
3 Unsnap locking wire (3) from annular groove

of the ring gear. 009518_1
Reinforced version (16 S 251, 16 S 2720):

6
1 Unsnap locking wire (3) from annular groove 3
of the ring gear.
2
2 Snap securing ring (7) described in Chapter
8
4.1 into ring gear carrier; refer to work step 1.
1
3 Remove ring gear (1) and thrust ring (8) from
planet carrier.
4 Remove thrust ring (8) from ring gear.
5 Remove intermediate ring (6) from planet

carrier.
011387_2
1315 751 103 - 2010-05 4-6

Assembling ring gear
1 Drive ring gear carrier (2) into the ring gear

(1) until it is firmly home (axial abutment). 5
4
2 Snap the locking wire (3) into the annular 3 9
groove of the ring gear and countersink (fit) it
2
along the entire breadth.
1
Straight-toothed version
(8/16 S 151, 8/16 S 181, 16 S 221):
3 Place intermediate ring (9) onto planet carrier.
Lubricating grooves must face towards output
(only 16 S 151).
004411_1
4 Insert ball bearing (5) in ring gear carrier and
snap in snap ring (4). Set axial clearance of
ball bearing to 0.0 - 0.1 mm using suitable
snap ring. Snap rings are available at 0.1 mm
stepped thickness levels.
5 Place ring gear with ring gear carrier on

planet carrier and make them engage by
rotating them.
Helical-toothed version (standard):

3 Place ring gear with ring gear carrier on 7
planet carrier and make them engage by
rotating them. 6
3
4 Slide intermediate ring (6) and axial needle 2

bearing (7) on planet carrier until firmly home
(axial abutment). 1
009506_1
1315 751 103 - 2010-05 4-7

Reinforced version (16 S 251, 16 S 2720): 8

1 Insert thrust ring (8) into ring gear (1) until it
1
is firmly home (axial abutment).
6
!DANGER 3
Only touch heated ring gear when wearing protective
gloves. 2
2 Heat ring gear to 60 °C and insert planet

6
carrier in ring gear. During the process, rotate
planet carrier and ensure that the gears mesh.
3 Slide intermediate ring (6) onto planet carrier.
4 Drive ring gear carrier (2) into ring gear until

it is firmly home (axial abutment). 011388_2
5 Snap the locking wire (3) into the annular

groove of the ring gear and countersink (fit) it
along the entire breadth.
1315 751 103 - 2010-05 4-8

4.3 Planet carrier
NOTE
5
For reasons of simplification, only one gearset is 6
7
depicted. The process is identical for all five 4
planetary gears. 6
7
6
5
4.3.1 Planet carrier (standard)
Disassembling planet carrier

1a
1 Drive all dowel pins (1 and 1a), into the plane- 1
tary bolts (2) (at full length).
2
2 Use a hammer and plastic punch to drive all
five planetary bolts (2) out of planet carrier (3) 3
towards the input.
3 Take the five planetary gears (4) with thrust

washers (5), intermediate washers (6), and 009525_1
rollers (7) out of planet carrier.
NOTE
Thrust washers (5) are only installed in straight-too-
thed version.
4 Drive dowel pins (1 and 1a) out of planetary

bolts (2).
012006
1315 751 103 - 2010-05 4-9

Assembling planet carrier

5
CAUTION 6
7
Do not replace planetary gears individually, but
4
always as full set.
6
7
1 Lightly oil planetary gears (4) at the end faces 6
5
and needle roller races.
2
2 Position planetary bolts (2) with collar facing
downwards.
3 Slide thrust washer (5) over planetary bolt.

009513_1
Coated side (bright side) must face towards
planetary gear.
NOTE
Thrust washers (5) are only installed in straight-toot-
hed version.
4 Slide shim (6) over planetary bolt.
5 Fit planetary gear (4) to planetary bolt.
6 Insert 14 rollers (7) in planetary gear and slide

shim (6) over planetary bolt.
NOTE
Only use rollers of the same type tolerance (grades).
1a
1
7 Insert another 14 rollers (7), lightly oil them,
and put on shim (6).
8 If needed, fit thrust washer (5). Coated side 3 5

(bright side) must face towards planetary gear.
9 Position planet carrier (3) on the shaft part. 5

5
10 Carefully remove complete planetary gear and
shims from the planetary bolt and insert them
in the planet carrier.
009505_1
1315 751 103 - 2010-05 4-10

11 Align the planetary gear (4) with the bearing

bore.
5
NOTE 6
7
The “0” marking at the planetary bolt front side 4
must face towards the outer radius of the planet 6
7
6
carrier. The planetary bolt’s bore for the dowel pins 5
must be in line with the bore in the planet carrier.
12 Align planetary bolt(s) (2) in radial direction

and insert in bearing bore. 1a
1
13 Drive in planetary bolt(s) by means of a plastic
hammer. Check alignment of dowel pin bore. 2
3
14 Drive new dowel pin (1) half way in. Drive the
second (new) dowel pin (1a) at an approx.
180° offset position (gudgeon slots) into the
first dowel pin. Countersink all dowel pins 009525_1
together into the planet carrier by approx.
0.5 mm.
15 Repeat working steps 1 through 14 for the

other four planetary gears.
1315 751 103 - 2010-05 4-11

4.3.2 Planet carrier

(reinforced version 16 S 251, 16 S 2720 TO)
6
Disassembling planet carrier 7
4
5
NOTE 7
6
For reasons of simplification, only one gearset is
depicted. The process is identical for all five
planetary gears.
1 Drive all dowel pins (1 and 1a), into the 1a

planetary bolts (2) at full length. 3 1
2 Use a hammer and plastic punch to drive all 2

five planetary bolts (2) out of planet carrier (3)
towards the input.
3 Take the five planetary gears (4) with shims

(6), bush (5), and rollers (7) out of the planet
carrier. 011389_1
4 Drive dowel pins (1 and 1a) out of planetary

bolts (2).
5 Remove thrust washer (8) from planet carrier.
6 Unsnap snap rings (9 and 10) and remove the

with cover (11).
7 Remove axial ball bearing(s) (13) and 4 disk

springs (12).
012006
12
13
11
10
9
8
011390_2
1315 751 103 - 2010-05 4-12

Output
12
13
11
Input 012318
10
012317
011390_2
Assembling planet carrier

Inner Ø 30 mm
1 Insert 4 disk springs (12) in planet carrier.
NOTE
Refer to Figure 012317 for arrangement of 4 disk 13
springs.
2 Insert axial ball bearing(s) (13) in planet

carrier.
CAUTION
Ensure that thrust ring with inner Ø of 32 mm is
inserted facing towards the output and thrust ring
with inner Ø of 30 mm is inserted facing towards Inner Ø 32 mm
the input; for arrangement, refer to Fig. 032254.
032259_1
3 Insert cover (11), snap rings (10 and 9).
NOTE
For correct installation position of snap ring (10),
refer to Fig. 012318.
4 Put on thrust washer (8).
1315 751 103 - 2010-05 4-13

CAUTION
Do not replace planetary gears individually, but
always as full set. 6
7
5 Lightly oil planetary gears (4) at the end faces 4
and needle roller races.
5
7
6 Position planetary bolts (2) with collar facing
6
downwards.
2
7 Slide shim (6) over planetary bolt.
8 Fit planetary gear (4) on planetary bolt.
9 Insert 14 rollers (7) in planetary gear and slide

bush (5) over planetary bolt. 011391_1
NOTE
Only use rollers of the same type tolerance (grades).
10 Insert another 14 rollers (7), lightly oil them

and put on shim (6).
11 Position planet carrier (3) on the shaft part.
12 Carefully remove complete planetary gear and

shims from the planetary bolt and insert them
into the planet carrier.
13 Align the planetary gear (4) with the bearing

bore.
1a
1
NOTE
The “0” marking at the planetary bolt front side 6
must face towards the outer radius of the planet
carrier. The planetary bolt’s bore for the dowel pins
must be in line with the bore in the planet carrier.
011392_1
1315 751 103 - 2010-05 4-14

14 Align planetary bolt(s) (2) in radial direction

and insert in bearing bore.
6
15 Drive in planetary bolt(s) by means of a 7
4
plastic hammer. Check alignment of dowel
5
pin bore. 7
6
16 Drive new dowel pin (1) half way in. Drive

the second (new) dowel pin (1a) at an
approx. 180° offset position (gudgeon slots)
into the first dowel pin. Countersink all 1a
dowel pins together into the planet carrier 3 1
by approx. 0.5 mm.
2
17 Repeat working steps 5 through 16 for the
other four planetary gears.
011389_1
1315 751 103 - 2010-05 4-15

4-16
ZF-Ecosplit Splitter Group Piston and 5/2-Way Valve
5 Splitter Group Piston and 5/2-Way Valve
Removing the S/G piston and the 5/2-way valve ............................................. 5-2
Installing the S/G piston and the 5/2-way valve............................................... 5-3
5.1 Compressed air test for piston and splitter group cylinder ........................... 5-4
1315 751 103 - 2010-05 5-1

5 Splitter Group Piston and 5/2-Way Valve
Removing the S/G piston and the 5/2-way

valve
1 Unfasten the hex head screws (1) and remove

from transmission housing together with
5/2-way valve (2).
3
NOTE
In line with the respective transmission design, the
5/2-way valve (2) may be installed with the connec-
2
tions up- or downward. 1
2 Remove the O-rings (3).

011379_1
NOTE
• Do not dismantle 5/2-way valve, complete part.
• There is no directional-control valve for the trans-
mission designs with the 8 speeds. 13
3 Remove the detent plunger (4) and install the

locating fixture 1X56 138 100. 5
9
4 Manually pull off the cylinder (5).
5 Loosen and remove the counternut (6). 12

7
11
6 Unsnap the spring (7) at the housing. 4 6
10
8
7 Remove the complete piston (8) from the
selector rail (9).
1X56 138 100

8 Remove the double-lip seal (10) from the
piston (8). 011401_1
9 Remove the O-rings (11 and 12) from the

cylinder.
NOTE
• For information on how to remove the cap seal
(13), refer to Chapter 9.
• For information on how to remove the selector rail
(9), refer to Chapter 8.
1315 751 103 - 2010-05 5-2

Installing the S/G piston and the 5/2-way

valve
13
NOTE
The selector rail (9) (refer to Chapter 8) and the cap
seal (13) (refer to Chapter 9) must be installed and
5
greased. 9
1 Slide on new O-rings (11 and 12) at the

cylinder (5).
12
7
2 Mount the double-lip seal (10) to the piston (8) 11
4 6
and slightly grease. 10
8
3 Slide the complete piston (8) onto the selector

rail (9). 011401_1
4 Remove the detent plunger (4) and install the

locating fixture 1X56 138 100.
5 Screw new counternut (6) onto the selector

rail and tighten down.
6 Snap in the spring (7) at the housing. 3
7 Remove the locating fixture 1X56 138 100;

screw in the detent plunger (4).
1
8 Insert the cylinder (5) in the housing.
011379_1
9 Insert the new O-rings (3) in the 5/2-way valve
(2).
10 Screw the 5/2-way valve (2) down to the

transmission housing using the hex head
screws (1).
Tightening torque = 9.5 Nm
1315 751 103 - 2010-05 5-3

5.1 Compressed air test for piston and splitter

group cylinder 1X56 137 917
1 Screw the locating fixture 1X56 137 917 for

the splitter group cylinder (5) down to the
transmission housing.
2 Apply compressed air (at max. 6.8 bar) to

5/2-way valve and/or piston.
2 5
3 Coat outer circumference of splitter group
cylinder with a suitable fluid and watch out
for bubbling action.
4 Pressurize piston with compressed air in

opposite switching direction and check for 029010_1
air leakage.
5 If necessary in the event of blistering, insert

new O-rings (11 and 12) in the cylinder and
check cylinder for correct fit.
6 In the event of air leakage, replace the double-

lip seal (10) on the piston (8).
7 Remove the locating fixture 1X56 137 917.
1315 751 103 - 2010-05 5-4

ZF-Ecosplit Release Unit, Connection Plate, and Pump
6 Release Unit, Connection Plate, and Pump
6.1 Release fork, release unit, and connection plate .......................................... 6-2
6.1.1 Pull-type clutch version I...................................................................... 6-2
Removal of release fork and release unit.............................................. 6-2
Removal of connection plate ............................................................... 6-2
Installation of connection plate and release fork .................................. 6-3
6.1.2 Pull-type clutch version II ..................................................................... 6-4
Removal of release fork and release unit.............................................. 6-4
6.1.3 Push-type clutch version...................................................................... 6-6
Removal of release fork ....................................................................... 6-6
6.1.4 Pull-type clutch version III .................................................................... 6-8
Removal of release fork ....................................................................... 6-8
Installation of connection plate ............................................................ 6-9
Installation of release fork .................................................................... 6-10
6.2 Pump housing with integrated pump ............................................................ 6-11

Removal ......................................................................................................... 6-11
Installation...................................................................................................... 6-11
6.3 Connection plate with integrated pump, single-piece version...................... 6-12

Removal ......................................................................................................... 6-12
Installation...................................................................................................... 6-13
1315 751 103 - 2010-05 6-1

6 Release Unit, Connection Plate, and Pump
6.1 Release fork, release unit, and connection

plate
NOTE
Depending on the transmission version, connection
plate and pump can either be fitted by hex head
screws or by threaded bolts and hex nuts.
This chapter presents the version with threaded
bolts – the tightening torques for hex head screws
are identical.
6.1.1 Pull-type clutch version I
Removal of release fork and release unit
1 Loosen hex head screws (1) and remove toget- 14

12
her with washers (2). 13
12 7 8
2 Pull shafts (3) out sideways and take off
6
release fork (4).
11 5
3 Take off release unit (15).
9
Removal of connection plate 10
10
11
1 Loosen hex nuts (5), take off connection plate 9
(6) with seal (7). 5
2 Remove shaft sealing ring (8) from the

connection plate.
3 Remove sealing rings (9 and 10) and bushes

(11) from the connection plate.
15
*
4 Remove washers (12) and spacer ring (13) 4
from the input shaft. 3
2
5 Remove shim (14) from the input shaft.
3
2
011305_1
1315 751 103 - 2010-05 6-2

Installation of connection plate and release

fork
NOTE
Before fitting connection plate, install pump housing
with integrated pump.
1 Press in shaft sealing ring (8) until firmly

home with connection plate (6) (axial abut-
ment) using adapter 1X56 103 766. Shaft sea-
ling ring’s sealing lip faces towards adapter.
2 Place determined washer (14) on input shaft;

for measurement, refer to Chapter 13, Input
and Main Shaft.
3 Place washers (12) and spacer ring (13) over

input shaft.
14
12
13
4 Grease sealing rings (10) and bushes (11) and 12 8
7
insert them.
6
5 Insert sealing rings (9). 5
11
6 Place connection plate (6) with new seal (7)

over the input shaft on the clutch housing. 9
10
NOTE 10
Put protective sleeve 1X56 138 064 on the input 11
9
shaft to protect shaft sealing ring. 5
7 Screw on connection plate using hex nuts (5).

8 Slide release unit (15) over input shaft onto

connection plate.
15
*
9 Insert shafts (3) into connection plate, fix 4
release fork (4) to connection plate, slide shafts
3
in until firmly home (axial abutment).
2
10 Insert washers (2) and hex head screws (1) in
release fork and tighten. 1X56 103 766
3
2
1X56 138 064
011305_1
1315 751 103 - 2010-05 6-3

6.1.2 Pull-type clutch version II
Removal of release fork and release unit
1 Unsnap securing rings (1), remove sealing

washers (2) and sealing rings (3).
2 Pull out bolts (4) and remove release fork (5).

together with bearing block (7).
4 Unsnap securing rings (8) and take swing

bearing(s) (9) out of the bearing block.
5 Remove release unit (17).
Removal of connection plate 14

16
15
14
1 Loosen hex nuts (10).
17
*
2 Remove connection plate (11) with seal (12).
3 Remove shaft sealing ring (13) from the

12
connection plate.
13
11
4 Remove washers (14) and spacer ring (15)
from the input shaft. 10
5 Remove shim (16) from the input shaft.
10
2
8 6
1 7
3
9
5 3
1
8
4
2
011306_1
1315 751 103 - 2010-05 6-4


fork


and Main Shaft.

input shaft.

over the input shaft on the clutch housing.
16
NOTE 14
15
shaft to protect shaft sealing ring.
*
17
5 Fix connection plate using hex nuts (10).

12
6 Insert swing bearing (9) in bearing block (7) 13
11
and snap in securing rings (8).
10
7 Fix bearing block with hex head screws (6).
8 Slide release unit (17) over input shaft onto

connection plate.
10
9 Position release fork (5) over bearing block
and insert bolts (4). 1X56 103 766
10 Fit sealing rings (3) and sealing washers (2) 2

onto bolts. 8 6
1 7
1X56 138 064
11 Snap in securing rings (1) with bolts. 3
9
5 3
1
8
4
2
011306_1
1315 751 103 - 2010-05 6-5

6.1.3 Push-type clutch version
Removal of release fork
1 Take off release fork (1) and ball socket (2).
2 Remove ball pin (3) and washer (4).
3 Take off release unit (12).
Removal of connection plate
1 Loosen hex nuts (5).
2 Take off connection plate (6) and sealing ring

(7).
11
3 Remove shaft sealing ring (8) from connection 9
10
plate. 9
4 Remove washers (9) and spacer ring (10) from

12
*
the input shaft.
5 Remove shim (11) from the input shaft. 7

8
6
4
3
2
1
011307_1
1315 751 103 - 2010-05 6-6


fork


and Main Shaft.

input shaft.

11
NOTE 9
10
shaft to protect shaft sealing ring. 12
*
7
6 Screw in ball pin (3) with washer (4). 8
6
Use Loctite no. 262.
7 Slide release unit (12) over input shaft on the

connection plate.
8 Insert ball socket (2) into clutch lever (1).

5
9 Place clutch lever (1) on ball pin (3).
4
3
2
1
1X56 103 766
1X56 138 064
011307_1
1315 751 103 - 2010-05 6-7

6.1.4 Pull-type clutch version III
Removal of release fork
10
1 Loosen screw/bolt (1) and remove from the
shaft (3) together with clutch lever (2).
NOTE
Mark clutch lever position before taking it off.
9
2 Remove dowel pins (4) from release fork (5).
6
7
3 Slacken and remove slotted nut (6).
8
4 Remove shaft (3), release fork (5), slotted nut
(6), and safety plate (7).
5 Remove bearing bush (8).

13
6 If necessary, remove plate (9) and four 20
18
screws/bolts (10). 19
18
14
7 Remove release unit (21).
Removal of connection plate
1 Loosen hex nuts (11), take off connection plate

21
*
(12) with seal (13).
2 Remove shaft sealing ring (14) from connection

plate.
12
16 11
3 Remove sealing rings (15 and 16) and bushes 17
15
(17) from the connection plate.
4 Remove washers (18) and spacer ring (19)

from the input shaft.
11
5 Remove shim (20) from the input shaft. 15
17
16
5 1
2
4
3
011308_1
1315 751 103 - 2010-05 6-8

Installation of connection plate
NOTE
Before fitting connection plate, pump housing with
10
integrated pump must already be installed.

9
6
2 Grease sealing rings (15) and bushes (17) and
7
insert them.
8
3 Insert sealing rings (16).

and Main Shaft. 13
20
18
5 Place washers (18) and spacer ring (19) over 19
input shaft. 18
14
6 Place connection plate (12) and new seal (13)

NOTE
Put protective sleeve 1X56 138 064 on the input
21
* 1X56 103 766

1X56 138 064
12
16 11
8 Slide release unit (21) over input shaft on the 17
15
connection plate.
11
15
17
16
5 1
2
4
3
011308_1
1315 751 103 - 2010-05 6-9

Installation of release fork
1 Slide shaft (3) into clutch bell housing, place

new safety plate (7) and slotted nut (6) onto
shaft.
8
2 Guide shaft into first bearing bore of the con-
nection plate, slide release fork (5) onto shaft
and guide shaft into second bearing bore of
the connection plate.
7
3 Slide bearing bush (8) over shaft and insert it 6
into the clutch bell housing.
5 3
4
4 Drive dowel pins (4) into release fork (5) and
shaft (observe assembly instructions). 004917
5 Fit safety plate (7) and slotted nut (6) to

bearing bush, fasten slotted nut.
6 Fit shift lever (2) to shaft (observe position)

with a screw/bolt (1).
1
7 Fit plate (9) using four screws/bolts (10).
004918
1315 751 103 - 2010-05 6-10

6.2 Pump housing with integrated pump
Removal
1 Loosen hex head screws (1) and hex nuts (2),

remove entire pump housing (3) with seal (4).
2 Remove pump cover (5), rotor (6), and pump

shaft (7) from pump housing.
3 Remove shim (8).
Installation 8
4
3
for measurement, refer to Chapter 13, 7
Countershaft. 6
5
2 Place new seal (4) onto clutch housing and fit 2
pump housing (3) to clutch housing.
1 2
3 Insert rotor (6), insert pump shaft (7) lubricated
with corrosion oil into pump housing, and
make sure it meshes with countershaft.
011398_1
4 Apply sealing compound Loctite no. 574 to

pump cover (5) and fit it.
Fix with hex head screws (1) and hex nuts (2).
1315 751 103 - 2010-05 6-11

2
13
9
12
5
6
11 5
10 8
4
2
7
1 3
001993_1
6.3 Connection plate with integrated pump

Single-piece version
Removal
1 Loosen hex head screws (1) and nuts (2) on 6 Pry off pump cover (4) from connection plate
the connection plate (3) and pump cover (4) (3).
and remove them.
7 Drive cylindrical pin (9) out of pump cover or
2 Take off connection plate (3) and pump/pump connection plate.
cover (4).
8 Remove pump shaft and/or inner rotor (10)
3 Remove washers (5) and spacer ring (6) from and outer rotor (11).
connection plate and/or input shaft.
9 Remove shim (12) from input shaft and
4 Take off the seal (7). washer (13) from countershaft.
5 Drive out shaft sealing ring (8) using plastic

punch.
1315 751 103 - 2010-05 6-12

2
13
9
12
5
6
11 5
10 8
4
2
7
1X56 103 766
1 3
1X56 137 949 1X56 138 064
001993_1
Installation 5 Screw guide pin(s) 1X56 137 949 into

threaded bore of countershaft.
1 Press shaft sealing ring (8) into connection
plate using adapter 1X56 103 766. Shaft sea- 6 Remove guide pin(s) from countershaft.
7 Insert inner rotor (10) into pump housing and
2 Place washers (5) and spacer ring (6) onto make sure it meshes with countershaft.
input shaft.
8 Insert outer rotor (11) into pump housing.
3 Insert determined shim (12) onto input shaft
and determined shim (13) onto countershaft. NOTE
Outer and inner rotor must have axial clearance.
NOTE
For measurement of shim (12), refer to Chapter 13, 9 Apply thin coat of Loctite no. 574 to sealing
Input and Main Shaft. face of pump cover (4) (from bore to bore) and
For measurement of shim (13), refer to Chapter 13, place onto pump housing.
Countershaft.
10 Drive cylindrical pins (9) into pump cover.
4 Place connection plate (3) with new seal (7) Rotate input shaft to check correct assembly.
over input shaft on the clutch housing.
Tighten hex nuts (2). 11 Screw on pump cover with hex head screws (1).
Tightening torque = 46 Nm Tightening torque = 46 Nm
NOTE
Put protective sleeve 1X56 138 064 on the input
1315 751 103 - 2010-05 6-13

6-14
ZF-Ecosplit Clutch Housing
7 Clutch Housing
Removing clutch housing ............................................................................... 7-2

Installing clutch housing................................................................................. 7-3
1315 751 103 - 2010-05 7-1

7 Clutch Housing
Removing clutch housing
1 Remove hex head screws (1) from clutch 3

housing (2), but do not use impact wrench. 5
Use extraction tool 1X56 138 063 to remove
cylinder pins with difficult access (3).
2 Attach 2 hooks 1X56 136 564 (M10) and/or

1X56 136 599 (M12) to the opposite clutch
housing. 3
4
Assembly suggestion
The clutch housing is positioned on the inter- 8
mediate housing by four cylinder pins (3), i.e. 9
6
the clutch housing must be lifted off straight
from the intermediate housing (4).
CAUTION
Do not use and/or pry off pry bars on the housing 1 2
sealing surfaces.
3 Lift the clutch housing and remove gasket

from intermediate housing (5).
4 If necessary, remove pipe (6) from clutch hou- 12

7
sing. 11
5 Unfasten screw plug (7) and take off with sea- 10

ling ring.
6 Remove outer bearing ring (8) of taper roller

bearing countershaft, and outer bearing ring 1X56 136 564
1X56 138 063 1X56 138 695 1X56 136 599
(9) of taper roller bearing input shaft from
clutch housing . 011399
7 If necessary, remove closure cap (10).
8 Unfasten screw plugs (11 and 12) and take off

together with sealing rings.
1315 751 103 - 2010-05 7-2

Installing clutch housing
1 Screw in screw plugs (11 and 12) with new

sealing rings and tighten.
Screw in screw plug (7) with new sealing ring

and tighten.
2 Insert closure cap (10).
3 If necessary, insert new pipe (6) in clutch

housing.
4 Insert outer bearing ring (8) of taper roller

bearing countershaft, and outer bearing ring
(9) of taper roller bearing input shaft in clutch
housing.
5 Fit gasket (5) and position using 2 centering

pins 1X56 138 695.
6 Lower clutch housing (2) slowly over centering

pins onto intermediate housing until selector
rails and pipe are centered in intermediate
housing.
NOTE
• Measurement of axial roller bearing/main shaft
has been carried out, see Chapter 13.
• Selector rail is adjusted; refer to Chapter 8.1.
7 Drive cylinder pins (4) into intermediate

housing.

1315 751 103 - 2010-05 7-3

7-4
ZF-Ecosplit Shafts and Selector Rails
8 Shaft and Selector Rails
Removing shafts and selector rails ................................................................. 8-2

Installing shafts and selector rails................................................................... 8-4
8.1 Adjusting the S/G selector rail ...................................................................... 8-6

Installation and measurement of changed parts............................................. 8-6
1315 751 103 - 2010-05 8-1

8 Shafts and Selector Rails
Removing shafts and selector rails

1
1 Unfasten hex head screws (1) and remove 2

cover (2) with seal (3).
2 Drive R gear wheel bolt (4) with mandrel from

intermediate housing towards input direction.
3 7
NOTE
Depending on the transmission version, there can 6
be a locking screw and a locking washer instead of
the clamping pin (5). Loosen and remove them.
4
8
3 Take off reverse idler gear (6) with needle
5
cages (7) laterally from transmission.
4 Remove screw plug (8) and sealing ring. 1X56 137 284
011404_1
5 Screw in the assembly adapter 1X56 137 287
instead of screw plug (8). Locking pin of inter-
lock is pushed against spring pressure.
!
DANGER
Secure fixture and rope conscientiously. 9
1X56 137 122

6 Screw lifting fixture 1X56 137 122 together 1X56 137 921
with centering ring 1X56 137 921 and position
1X56 137 918
over input shaft (9) and selector rails, on top 1X56 137 933
of countershaft (10).
7 Fit washer 1X56 137 933 between lifting

device and countershaft. Place support
1X56 137 918 on lifting device and insert in
selector rail driver. 10
8 Screw countershaft (10) firmly to lifting

11
device.
12
031796_1
1315 751 103 - 2010-05 8-2

CAUTION
Hold S/G selector rail (12) when removing the
shaft pack. The selector rail is unsecured on the
sliding sleeve. 12b 12
9 Pull shaft pack with selector rails out of 12a

transmission housing, remove selector
rail (12) once it is released, and put down S/G
shaft pack with selector rails on support
1X56 137 675.
032740
NOTE
Replacement/turning bolt (depending on the trans-
mission version) 13
1X56 137 920, (8/16 S 151, 16 S 1620, 16 S 1820)
1X56 137 953, (8/16 S 181, 16 S 221, 16 S 1920,
16 S 2220, 16 S 2320, 16 S 2520)
Reverse gear
Place 1X56 138 257, (16 S 251, and 16 S 2720)
on support 1X56 137 675 for countershaft. 14
10 Remove lifting device including accessories. 14a

Remove selector rails (13, 14, and 15) with
forks and sliding pads.
First/Second 14b
11 Take sliding pads out of shift forks. gear
15
NOTE
Do not disassemble selector rails further; in this
condition, they are sub-assembly. 15a
3th/4th gear 15b
032741
1X56 137 920
1X56 137 953
1X56 137 675
1X56 138 257
1315 751 103 - 2010-05 8-3

Installing shafts and selector rails 9
1X56 137 122

NOTE 1X56 137 921
• Main shaft must be measured, refer to Chapter 13.
1X56 137 918
• Cap seal must be fitted, refer to Chapter 9. 1X56 137 933
• Bearing outer rings must be fitted, refer to

Chapter 9.
! DANGER
Secure fixture and rope conscientiously. 10
11
1 Place replacement/turning bolt (1X56 13x xxx,
refer to tool overview) on support for counter-
shaft. Insert main shaft (11) (output-end) in 12
support 1X56 137 675. Fit complete input 031796_1
shaft (9) to main shaft. Fit countershaft (10)

and position it at the level where the gears
mesh. Push countershaft against main shaft 13
and ensure that gears are meshing.
Reverse gear
2 Insert selector rails (13, 14, and 15) with
slidingpads in main shaft´s sliding sleeves.
14
3 Place centering ring 1X56 137 921 in lifting
device 1X56 137 122 and fasten. Slide lifting 14a
device over input shaft and selector rails (13,
14, and 15) and ensure contact with counter-
shaft. First/Second 14b
gear
15
4 Screw lifting device with washer 1X56 137 933
to countershaft.
15a
5 Place support 1X56 137 618 on lifting device
and insert in selector rail driver. 3th/4th gear 15b
6 Guide complete shaft pack over intermediate 032741
housing using a crane. Insert selector rail (12)

in sliding sleeve and secure.
12b 12
12a
S/G
032740
1315 751 103 - 2010-05 8-4

CAUTION
• Selector rail (12) is unsecured in the sliding
sleeve; hold it when inserting the shaft pack.
1
• Do not damage the cap seal´s sealing lip.
2
7 Slowly lower shafts and selector rails; at the
same time, carefully guide the S/G selector
rail (12) by hand through the cap seal until it
is centered in the cap seal.
3 7
8 8 Without tilting, install the main shaft with
input shaft and countershaft in the outerrings 6
of the taper roller bearings of the interme-
diate housing. 4
8
NOTE 5
• Retention (locking) by mechanical stop (interlock)
must be guaranteed.
• Shift transmission to Constant 2.
011404_1
9 Remove all lifting devices.

15 Screw on cover (2) with new seal (3) on
10 Remove assembly adapter 1X56 137 287 for intermediatehousing using hex head screws
mechanical stop (interlock). (1).
11 Turn input shaft until bearing rollers are
centered.
12 Insert needle rings (7) into reverse idler (6).
13 Insert reverse idler (6) into housing and make

sure meshes with countershaft (10).
14 Insert reverse gear pin (4) from the drive end

into intermediate housing until stop is
reached.
NOTE
• The axial protection of the reverse gear pin is
performed by a central inserted dowel pin (5).
• Depending on the transmission version, there can
be a locking screw and a locking washer instead
of the dowel pin (5). Insert washer and fasten
with hex head screw.
1315 751 103 - 2010-05 8-5

8.1 Adjusting the S/G selector rail
NOTE
Only measure selector rail, if new parts have been 12
added. 12b
For complete installation of the selector rails, refer
12a
to Chapter 8.1.
Installation and measurement of changed

parts 032740_1
1 Insert selector rail (12) from the inside (into

intermediate housing).
12a+b
18 18a
CAUTION
Do not damage the cap seal when inserting the
selector rail.
B
2 Fit shift fork (16) with sliding pads (12a and
12b) in correct position in sliding sleeve (17)
and insert selector rail. 17 16
NOTE
Position bores in selector rail with screw threads
into shift fork.
12
3 Preliminary screw in both set screws (18
and/or 18a) and secure them hand-tight.
4 Screw piston (19) with new double-lip seal to

selector rail.
A
NOTE 24
Use new check nut.
Thread must be absolutely free from grease. 19
031794_1
5 Place snap ring (20) on housing.
6 Fix new O-rings (21 und 22) to S/G cylinder

(23) and apply thin coat of oil.
23
7 Insert S/G cylinder into intermediate housing;
22
in doing so be careful with the cylinder´s hub 21
and the groove at the housing.
20
001963_1
1315 751 103 - 2010-05 8-6

8 Sliding pads (12 a and 12b) must have

downward clearance in the sliding sleeve.
B = 0.1 +0.2 mm (check with feeler gage). 1X56 137 917
Control dimension A:
Short version = 93.70 mm
(8/16 S 151, 16 S 1620, 16 S 1820)
Long version = 107.20 mm

(8/16 S 181, 16 S 221, 16 S 251, 16 S 1920,
16 S 2220, 16 S 2320, 16 S 2520, 16 S 2720)
NOTE
Also refer to assembly instructions 0000 701 102.
9 Evenly tighten setscrews (18 and/or 18a) on 001965_1

the shift fork (16).
1X56 137 917
Adjustment with supporting plate

1X56 137 917 is to be performed like this: 1X56 138 079
10 Working steps 1 to 7. Screw supporting plate

1X56 137 917 to housing sealing surface (24). 18 12
16
Shift sliding sleeve into output. S/G selector
rail must have axial contact in adjusting 12b
12a
device and is then in the right position. After
that, working steps 8 and 9.
Adjustment with centering aid 1X56 138 079

009944_1
and supporting plate 1X56 137 917 is perfor-
med like this:
11 Adjustment is performed as described in wor-

king step 10. Before performing working steps
8 and 9, insert centering aid 1X56 138 079.
1315 751 103 - 2010-05 8-7

8-8
ZF-Ecosplit Intermediate Housing
9 Intermediate Housing
Disassembling intermediate housing .............................................................. 9-2

Assembling intermediate housing .................................................................. 9-3
1315 751 103 - 2010-05 9-1

ZF-Ecosplit Transmission Housing
7 3
1X56 137 287

8
14
4
1X20 155 653
9
11
10
5
13
12
6
2
032691
9 Intermediate Housing 5 Unscrew fixture 1X56 137 287 and remove

locking bolt (7) as well as compression spring
Disassembling intermediate housing (8).
1 Remove outer bearing ring (1) of the tapered 6 Use a suitable tool to remove cap seal (9)
roller bearing countershaft and outer bearing from housing.
ring (2) of the tapered roller bearing main
shaft from the intermediate housing by 7 Depending on the transmission version, there
means of a soft mandrel and drive towards can be a bearing bush (10) and a securing
input direction. ring (11); remove, if necessary.
2 Remove breather (3) (*version depends on 8 Remove filter (12).

parts list).
9 Remove oil pipe (13) and O-ring (14) from
3 Unfasten screw plugs (4 and 5) if necessary, intermediate housing.
and take off together with sealing rings.
4 If required, unfasten screw plug (6) and

remove.
1315 751 103 - 2010-05 9-2

ZF-Ecosplit Intermediate Housing
Assembling intermediate housing
1 Screw in screw plugs (4, 5, and 6) with new

sealing rings.
2 Screw in breather (3) into the housing.

! DANGER
gloves.
3 Use hot air blower to heat housing to approx.

80 °C in the area around bearing holes.
4 Push in bearing outer ring (1) of the tapered

roller bearing countershaft and bearing outer
ring (2) of the tapered roller bearing main
shaft by means of a plastic mandrel or a
suitable adapter until firmly home (axial abut-
ment) in housing.
5 Depending on the transmission version, insert

bearing bush (10) with securing ring (11).
NOTE
Heat bearing bore of the bearing bush (10) up to
60 °C.
6 Coat locating bore and new capseal (9) on the

outside with ethanol (spirit). Mount cap seal
before ethanol volatilizes.
7 Use a suitable tool to drive in cap seal (9) into

housing until firmly home (axial abutment).
Grease the sealing lip of the cap seal.
8 Install compression spring (8) and lockingpins

(7) and align. Screw in the assembly adapter
1X56 137 287.
9 Insert new filter (12).
10 Insert oil pipe (13) with new O-ring (14) into

intermediate housing.
Clinch ends with rolling-in roll 1X20 155 653
into housing bore.
Rolling torque = 5 to 6 Nm
1315 751 103 - 2010-05 9-3

9-4
ZF-Ecosplit Input Shaft
10 Input Shaft
10.1 Version for axial roller bearing....................................................................... 10-2

Input shaft disassembly .................................................................................. 10-2
Assembling the input shaft ............................................................................. 10-3
10.2 Version for tapered roller bearing.................................................................. 10-4

Input shaft disassembly .................................................................................. 10-4
Assembling the input shaft ............................................................................. 10-5
10.3 Version: helical gear with needle rings ......................................................... 10-6

Removal ......................................................................................................... 10-6
Installation...................................................................................................... 10-6
1315 751 103 - 2010-05 10-1

10
9
1X56 136 722 7

12
8
11
1X56 122 304

6
2 5
1
4
3
028623_1
10 Input Shaft ! DANGER

Thrust pieces are under spring tension. Prevent them
10.1 Version for axial roller bearing from jumping out.
Input shaft disassembly

3 Pull sliding sleeve (9) off input shaft. Catch
NOTE thrust pieces (7) and compression springs (8)
Input shaft can only be removed after clutch housing which are released.
(refer to Chapter 7) and shafts have been removed
(refer to Chapter 8). 4 Release and remove securing ring (1).
1 Completely remove input shaft (6) from main 5 Pull inner ring of roller bearing (2) with grip-
shaft. per 1X56 136 722 and basic unit 1X56 122 304
off input shaft. To this end, position gripper
2 Remove ring (12), clutch body (11) , and over roller bearing inner ring and tighten by
synchronizer ring (10) from the input shaft´s means of knurling ring until fitted tightly on
synchronizers. rollers.
NOTE 6 Remove helical gear (3) from input shaft.

Ring (12) is only available at 16 S 222 transmission.
For measurement and installation, refer to Chapter 7 Remove clutch body (4) and synchronizer ring
13.2. (5) from input shaft.
1315 751 103 - 2010-05 10-2

Assembling the input shaft
1 Check synchronizer parts for wear limit, refer

to Chapter 14.1.
2 Place synchronizer ring (5) and clutch body (4)

on input shaft.
NOTE
Synchronizer ring lugs must engage with the
synchronizer body recesses of the input shaft.
3 Slide helical gear (3) onto input shaft.
NOTE
The driving spline of the helical gear faces output
and must engage with inner spline of clutch body.
! DANGER
Always wear protective gloves when handling the
heated inner ring.
4 Heat roller bearing inner ring (2) to approx.

100 °C and slide onto input shaft. After roller
bearing has cooled down, there must be axial
contact with collar of input shaft.
5 Snap in securing ring (1).
6 Position the sliding sleeve (9) onto the input

shaft and ensure contact. Insert new compres-
sion springs (8) with thrust pieces (7) in the
input shaft and, by means of a suitable tool, fit
to sliding sleeve.
7 Place synchronizer ring (10) and clutch body

(11) on input shaft.
8 Move sliding sleeve into center position.

To do so, apply back-pressure on clutch body
04.370. You will clearly hear the thrust pieces
snap into place.
9 Place input shaft on main shaft.
NOTE
For installation of the input shaft, refer to Chapter 8.
1315 751 103 - 2010-05 10-3

7 12
8 10
9
1X56 136 722
11
1X56 122 304
5
3
6
2
16
15
14
1 13
031774
10.2 Version for tapered roller bearing 3 Pull sliding sleeve (13) off input shaft. Catch
thrust pieces (7) and compression springs (8)
Input shaft disassembly which are released.
4 Release and remove securing ring (1).

NOTE
Input shaft can only be removed after clutch housing 5 Pull inner ring of roller bearing (2) with grip-
(refer to Chapter 7) and shafts have been removed per 1X56 136 722 and basic unit 1X56 122 304
(refer to Chapter 8). off input shaft. To this end, position gripper
over roller bearing inner ring and tighten by
1 Completely remove input shaft (6) from main
means of knurling ring until fitted tightly on
shaft.
rollers.
2 Remove ring (16), clutch body (15) and
6 Remove helical gear (3) from input shaft.
synchronizer ring (14) from the input shaft´s
synchronizers. 7 Remove clutch body (4) and synchronizer ring
(5) from input shaft.
NOTE
8 Release and remove securing ring (11).
Ring (16) is only available in transmissions
8/16 S 151, 8/16 S 181, 16 S 221, and 16 S 251. 9 Remove pipe (10).
For measurement and installation, refer to
10 Remove baffle plate (12) from input shaft.
Chapter 13.4 and 13.5.
11 Depending on the version, remove pin (9).
! DANGER
Thrust pieces are under spring tension. Prevent them
from jumping out.
1315 751 103 - 2010-05 10-4

Assembling the input shaft 12 Move sliding sleeve to middle position.

To do so, apply back-pressure on clutch body
1 Depending on the version, insert pin (9). 04.370.
You will clearly hear the thrust pieces snap
2 Insert baffle plate (12) by means of a suitable
into place.
tool in the correct position until firmly home
with the input shaft (see Fig. 031775_1). 13 Place input shaft on main shaft.
3 Insert pipe (10) in correct position in input NOTE

shaft (see Fig. 031775_1). For installation of the input shaft, refer to Chapter 8.
4 Snap in securing ring (11) (see Fig. 031775_1).
5 Check synchronizer parts for wear limit, refer 11

to Chapter 14.1.

(4) on input shaft.
NOTE
The synchronizer ring´s lugs must mesh with the
synchronizer body´s recesses of the input shaft.
7 Slide helical gear (3) onto input shaft.
NOTE
The driving spline of the helical gear faces output 10
and must engage with inner spline of clutch body.
12
! DANGER 031775_1
Always wear protective gloves when handling the
heated inner ring.
8 Heat roller bearing inner ring (2) to approx.

100 °C and slide onto input shaft. After roller
bearing has cooled down, there must be axial
contact with collar of input shaft.
10 Position the sliding sleeve (13) onto the input

shaft and ensure contact. Insert new compres-
sion springs (8) with thrust pieces (7) in the
input shaft and, by means of a suitable tool,
fit to sliding sleeve.

(15) on input shaft.
1315 751 103 - 2010-05 10-5

10.3 Version: helical gear with needle rings

(needle roller and cage assemblies)
19
NOTE 1X56 136 573 3
There can be, in addition, 2 needle rings (needle
roller and cage assemblies) at the helical gear (3) for 18
2
transmissions 8/16 S 151, 8/16 S 181, 16 S 221, and
16 S 251. 17
1
Removal
1 Remove securing ring (1).
2 Remove split ring (17).

032659
3 Remove bearing inner ring (2) as described in
Chapter 10.1 and 10.2.
4 Take off the helical gear (3) with needle rings

(needle roller and cage assemblies) (18 and 19).
Installation
1 Slide helical gear (3) with needle rings (18 and

19) onto input shaft.
2 Slide heated bearing inner ring (2), as descri-

bed in Chapter 10.1 and 10.2, onto input shaft.
3 Insert split ring (17) with axial clearance

between – 0.05 mm and +0.05 mm into groove
of the input shaft, using adapter 1X56 136 573,
and secure with securing ring by caulking 3
times at 120°.
1315 751 103 - 2010-05 10-6

ZF-Ecosplit Countershaft
11 Counter shaft
Dismantling counter shaft............................................................................... 11-3

Assembling Counter shaft............................................................................... 11-4
1315 751 103 - 2010-05 11-1

11-2
11 Countershaft
NOTE
For the removal of the countershaft, refer to Chapter 8.
1
Dismantling countershaft
NOTE
In order to protect the countershaft (7) a thrust piece
7
must always be fitted between the extracting tool
and the countershaft.
1 Fit gripping 1X56 136 710 to tapered roller

bearing´s inner ring (1). Turn knurling ring of
gripper until gripping piece locates firmly.
6
2 Screw basic tool 1X56 122 304 onto gripping 3

device and extract bearing´s inner ring from
5
the countershaft. 2
3 Remove and unsnap securing ring (2). 4
4 Fit gripping 1X56 136 756 (1X56 136 731 for

the version 16 S 151) to tapered roller
bearing´s inner ring (3). Turn knurling ring of
gripper until gripping piece locates firmly.
5 Screw 1X56 122 304 onto gripper and remove 1X56 136 710 1X56 136 756 1X56 136 731
bearing inner ring from countershaft.
CAUTION
If necessary, replace tapered roller bearings (3); the 1X56 122 304
bearing rollers may be damaged when extracted.
031762_1
6 Use a suitable hydraulic press to remove the

helical gears (4), (5) and (6) one at a time, due
to the high extraction force required.
The press-off force for each gear accounts for
up to 500 kN.
NOTE
In the case of the 8-speed versions, there´s a ring
instead of the helical gear (4).
NOTE
To prevent damage to the gears, support counter-
shaft and/or helical gears on a soft base.
1315 751 103 - 2010-05 11-3

Assembling Countershaft
! DANGER
1
gloves.
1 Bores in helical gears and snug fits for counter-

shaft must be free from oil, grease, and dust. 7
2 Heat up the helical gears (6), (5), and (4) to at

max. 170 °C.
NOTE
In the case of the 8-speed versions, there´s a ring
6
instead of the helical gear (4).
3
5
3 Possibly cool down countershaft (7); a tempera- 2
ture difference of 150 °C between the helical
gears and the countershaft is specified. 4
031762_1
4 Put the heated helical gears (6), (5), and (4)
onto each other on the hydraulic press and
exactly align these.
5 Press countershaft into the bores of the

helicalgears. Immediately repress helical gears
until axial abutment position is reached. Let
components cool down.
NOTE
The inner rings on the taper roller bearings may be
damaged during the removal process. Therefore,
carry out an exact inspection and, if necessary, use
new tapered roller bearings.
6 Heat inner rings of tapered roller bearings

(1) and (3) to between 120 and 130 °C
max. 15 min. and place on countershaft.
Ensure axial abutment, if necessary, drive in
further using a soft mandrel.
7 Snap in securing ring (2). Ensure that the

securing ring is firmly home with the groove
base of the countershaft.
1315 751 103 - 2010-05 11-4

NOTE
a
The securing ring must feature an axial clearance of
K1 K2 3 2 1 R GP
0.01 - 0.10 mm; select securing ring in line with the
items listed in the spare parts catalog.
NOTE
a = Direct drive / TD
b = Overdrive / TO
NOTE
For the installation of the countershaft, refer to
011422
Chapter 8.
b
K1 K2 3 2 1 R GP
011423
1315 751 103 - 2010-05 11-5

11-6
ZF-Ecosplit Main Shaft
12 Main Shaft
12.1 Version with axial roller bearing............................................................... 12-3

Dismantling Main Shaft ............................................................................. 12-3
Assembling Main Shaft.............................................................................. 12-8
12.1.1 Version with roller bearing on 4th gear ........................................... 12-14
Removal.......................................................................................... 12-14
Installation ...................................................................................... 12-14
12.2 Version with tapered roller bearing.......................................................... 12-15

Dismantling Main Shaft ............................................................................. 12-15
Assembling Main Shaft.............................................................................. 12-20
12.2.1 Version with roller bearing on 4th gear ........................................... 12-26
Removal.......................................................................................... 12-26
Installation ...................................................................................... 12-26
1315 751 103 - 2010-05 12-1

1315 751 103 - 2010-05 12-2
1X56 137 675
5
4
3
2
031781_1
12 Main Shaft 1 Place main shaft at output-side into the

receptacle (support) 1X56 137 675.
12.1 Version with axial roller bearing
2 Remove axial roller bearing (2) and baffle
Dismantling Main Shaft plate (1).
NOTE 3 Remove cylindrical roller bearing (5) with

• For removal of main shaft, refer to Chapter 8. washer (4) and disk spring (3).
• For the synchronizers (ZF-BK) of the 1st/2nd gear
and the 3rd/4th gear, the synchronizer rings may 4 Turn main shaft and place input-side into
be coated with carbon or molybdenum; also refer receptacle (support) 1X56 137 675.
to Chapter 14.
CAUTION
- Carbon synchronizer rings require clutch bodies
with a smooth conical surface.
- Molybdenum synchronizer rings require clutch
bodies with curved grooves and possibly oil bores
with corresponding flattening on the conical
surface.
- The synchronizers must be matched according to
those requirements.
- By all means consider this for reassembly!
1315 751 103 - 2010-05 12-3

5 Remove securing ring (6). 12a ZF-D version

a Remove clutch disk (42), inner ring (43),
6 Place suitable washer on main shaft. Apply intermediate ring (44), and outer ring (45)
standard two-armed extractor to R gear (7) from the synchronizer body (47).
and extract it together with tapered roller
bearing inner ring (8). !DANGER
During the extraction process, 3 thrust pieces (48)
7 Remove needle ring (needle roller and cage and 3 compression springs (49) are released. These
assembly) (9) together with inner ring (10). parts are under spring tension. Prevent parts from
jumping out (e.g. by using a cloth).
8 Use standard two-armed extractor to grip the
helical gear (11), 1st gear, from behind and b Remove sliding sleeve (46), 1st/2nd gear,
extract it together with clutch body (12). thrust pieces (48), and compression springs
(49) from the synchronizer body (47).
9 Remove needle ring (needle roller and cage
assembly) (13) together with inner ring (14). c Remove clutch components (50).
10 Use standard two-armed extractor to grip d Outer ring (51), intermediate ring (52), inner
helical gear (15), 2nd gear, from behind and ring (53), and clutch disk (54) are released.
extract it together with synchronizer (16
and/or 55). 13 Remove tube (23) if damaged.
NOTE regarding synchronizer of 1st/2nd gear 14 Turn main shaft and place output-side into
Synchronizer ZF-BK (16) is installed in the version receptacle (support) 1X56 137 675.
with servo unit.
Synchronizer ZF-D (55) is installed in the version
without servo unit.
11 Remove needle ring (17) (2-piece: needle

roller and cage assembly).
12 ZF-BK version
a Remove clutch body (18) and synchronizer
ring (19) from synchronizer body (20).
! DANGER
and 3 compression springs (23) are released. These
parts are under spring tension. Prevent parts from
b Remove sliding sleeve (21), 1st/2nd gear,

thrust pieces (22), and compression springs
c Synchronizer ring (19a) and clutch body

(18a) are released.
1315 751 103 - 2010-05 12-4

1X56 137 675

17
12
16 (ZF-BK) 11
13
14
22
23
18
6
19
21
20
23
19a
8
18a 7
9
15 10
031779_1
55 (ZF-D)
42
48 43
44
49
45
50 46
47
51
52
53
54
032522
1315 751 103 - 2010-05 12-5

15 Remove split ring (24).
NOTE
The following dismantling (working step 16) is
inapplicable for the following transmissions:
8/16 S 151, 8/16 S 181, 16 S 221, and 16 S 251.
There are no thrust washers, roller rings, and inner
ring installed, only helical gear and 2 roller
bearings; for removal, refer to Chapter 12.1.3.
16 Remove thrust washers (25 and 26), helical

gear (27), 4th gear, roller rings (28 and 29),
and inner ring (30).
17 Use standard two-armed extractor to grip

helical gear (31), 3rd gear, from behind and
extract it together with synchronizer (32).

19 Remove clutch body (34) and synchronizer

ring (35) from the synchronizer body (36).
! DANGER
During the removal process, 3 thrust pieces (37) and
3 compression springs (38) are released. These
parts are under spring tension. Prevent parts from
20 Remove sliding sleeve (39), 3rd/4th gear, from

the synchronizer body (36).
21 Synchronizer ring (40) and clutch body (41)

are released.
1315 751 103 - 2010-05 12-6

29
27
28
25
24 32 (ZF-BK)
37 31
38
41
40
39
36
35
33
34
26
30
031776_2
031776_2
1315 751 103 - 2010-05 12-7

Assembling Main Shaft NOTE

The synchronizer ring’s lugs must mesh with
1 Check main shaft for free passage of synchronizer body’s recesses.
lubrication oil bores. Tube (23) must be
solidly seated on the main shaft. c Slide sliding sleeve (21), 1st/2nd gear over
If required, drive in until firmly home (axial synchronizer body, synchronizer ring and
abutment) using adapter 1X56 137 835. clutch body and see to axial abutment with
helical gear, 2nd gear. Make sure that the
2 Place main shaft at the input-side into the recesses at the inner side of the sliding sleeve
receptacle (support) 1X56 137 675. line up with the fitting points (for compres-
sion springs and thrust pieces) of the syn-
NOTE chronizer body.
Lightly lubricate the thrust faces and contact sur-
faces for needle rings (needle roller and cage d Insert three compression springs (23) with
assemblies) and helical gears with operating oil. thrust pieces (22) into the synchronizer body
bores using a suitable tool and guide them
3 Slide needle ring (17) (2-piece: needle roller into sliding sleeve.
and cage assembly) onto main shaft.
NOTE
4 Slide helical gear (15), 2nd gear, over the Use new compression springs and pull the sliding
needle ring (needle roller and cage assembly) sleeve into center position (neutral position).
onto the main shaft through careful rotational
motion. Collar faces towards output. e Fit synchronizer ring (19). The synchronizer
ring’s lugs must mesh with the synchronizer
NOTE regarding synchronizer of 1st/2nd gear body’s recesses.
Synchronizer ZF-BK (16) is installed in the version
with servo unit. f Place the clutch body (18) onto the synchro-
Synchronizer ZF-D (55) is installed in the version nizer ring and pull the sliding sleeve into cen-
without servo unit. ter position (neutral position). During the pro-
cess, press on synchronizer ring and clutch
CAUTION body.
Check wear limit of all synchronizer rings and/or
clutch bodies as described in Chapter 14.1 (ZF-BK) NOTE
and Chapter 14.2 (ZF-D). For ZF-D version, refer to page 12-10; working steps
are described under 5a.
5 ZF-BK version
a Place clutch body (18a) and synchronizer ring !DANGER
(19a) onto synchronizer gear tooth system. Only touch heated inner ring when wearing
protective gloves.
!DANGER
Only touch heated synchronizer body when wearing
6 Heat inner ring (14) to 120 °C. Slide inner
protective gloves.
ring and needle ring (13) (2-piece: needle rol-
ler and cage assembly) onto the main shaft.
b Heat synchronizer body (20) to approx. 120 °C
and place onto main shaft gearing. Narrow 7 Slide helical gear (11), 1st gear, over the
side faces towards output. needle ring (needle roller and cage assembly)
onto the main shaft under careful rotational
motion. Collar faces towards output.
1315 751 103 - 2010-05 12-8

1X56 137 675 17
12
16 (ZF-BK) 11
13
14
22
23
18
6
19
21
20
23
19a
8
18a 7
9
15 10 1X56 137 835
03177_19
!
DANGER ! DANGER
Only touch heated clutch body and inner ring when Only touch heated tapered roller bearing inner ring
wearing protective gloves. when wearing protective gloves.
8 Heat clutch body (12) to 120 °C and slide 11 Heat tapered roller bearing inner ring (8) to
onto the main shaft. Narrow side faces approx. 120 °C and slide onto main shaft;
towards output. drive in further to ensure axial abutment.
9 Heat inner ring (10) to 120 °C. Slide inner 12 Snap in securing ring (6).
ring and needle ring (needle roller and cage
assembly) (9) onto main shaft until it is firmly NOTE
home with synchronizer body (axial abut- The securing ring’s axial clearance must be
ment). between 0.01 and 0.10 mm. Select suitable securing
ring from the spare parts catalog.
10 Slide helical gear (7), R gear, over needle ring
(needle roller and cage assembly) through 13 Turn main shaft and place output-side into
careful rotational motion. Synchronized gear the receptacle (support) 1X56 137 675.
tooth system faces towards input. Ensure that
clutch body rests on the synchronized gear
tooth system.
1315 751 103 - 2010-05 12-9

5a ZF-D version i Insert new compression springs (49) and the

a Place clutch disk (54) onto the synchronized thrust pieces in place (48) into the synchroni-
gear tooth system of the helical gear, 2nd zer body ensuring correct position and guide
gear. The clutch disk’s slightly raised inter- them into synchronizer body and sliding
nal gearing faces towards output. sleeve using suitable tool.
b Fit inner ring (53) on clutch disk. The tabs k Fit outer ring (45). The tabs must mesh with
must face towards output. clutch components and the lugs with syn-
chronizer body’s recesses.
c Fit intermediate ring (52) in such a way that
the tabs mesh with the clutch disk’s recesses. l Insert intermediate ring (44). The tabs must
face towards output. Insert inner ring (43)
d Fit outer ring (51). The tabs must face and ensure that tabs mesh with clutch com-
towards output. ponents.
e Align tabs on outer ring with tabs on inner m Fit clutch disk (42) with raised internal
ring by means of three clutch components gearing facing towards input and ensure it
(50). Align tabs of inner and outer ring so meshes with intermediate ring (44). Set sli-
that they line up with clutch components ding sleeve into neutral position and press
and that clutch components later fit into against clutch disk. You will clearly hear the
recesses of synchronizer body (47) and over thrust pieces snap into place.
the tabs. After alignment, remove clutch
components again.
!DANGER
protective gloves.
f Heat synchronizer body (47) to approx. 120 °C

and slide onto main shaft gearing. The posi-
tioned tabs must be in the synchronizer
body’s recesses. The lugs of the outer ring
must mesh with the recesses of the synchro-
nizer body. The synchronizer body can be
driven in further using a plastic punch.
g Insert the clutch components (50) into the

synchronizer body (47).
h Slide the sliding sleeve (46) over the synchro-

nizer body and outer ring and see to axial
abutment with clutch disk.
1315 751 103 - 2010-05 12-10

55 (ZF-D)
42
48 43
44
49
45
50 46
47
51
52
53
54
032522
1315 751 103 - 2010-05 12-11

14 Slide needle ring (33) (2-piece: needle roller NOTE

and cage assembly) onto main shaft. Use new compression springs.
15 Slide helical gear (31), 3rd gear, over needle 20 Fit synchronizer ring (35). The synchronizer
ringunder careful rotational motion. Syn- ring’s lugs must mesh with the synchronizer
chronized gear tooth system faces towards body’s recesses.
input.
21 Place clutch body (34) on synchronizer ring
CAUTION and pull the sliding sleeve into center position
Check wear limit of all synchronizer rings and/or (neutral position). During the process, press
clutch bodies as described in Chapter 14.1 (ZF-BK). on synchronizer ring and clutch body.
16 Place clutch body (41) with synchronizer NOTE

ring (40) onto synchronized gear tooth The following fitting (working steps 22 - 25) is
system. inapplicable for the following transmissions:
8/16 S 151, 8/16 S 181, 16 S 221, and 16 S 251.
! DANGER For fitting of version with roller bearings, refer to
Only touch heated synchronizer body when wearing Chapter 12.1.3.
protectivegloves.
!DANGER
Only touch heated inner ring when wearing pro-
tective gloves.
and slide onto main shaft gearing. The syn-
chronizer body is symmetric and can there-
fore be fitted irrespective of lateral position. 22 Heat inner ring (30) to 120 °C.
Drive synchronizer body further in to ensure
axial abutment. 23 Fit thrust washer (26) and inner ring (30).
NOTE 24 Insert roller rings (29) and (28) in helical gear

The synchronizer ring’s lugs must mesh with (27), 4th gear.
synchronizer body’s recesses.
25 Push helical gear (27) over inner ring into
18 Slide sliding sleeve (39), 3rd/4th gear over the clutch body with collar facing towards output
synchronizer body, synchronizer ring, and and fit thrust washer (25).
clutch body and see to axial abutment with
helical gear, 3rd gear. Make sure that the 26 Insert split ring (24) into groove of the main
recesses at the inner side of the sliding sleeve shaft and secure with securing ring by
line up with the fitting points (for compres- caulking 3 times at 120°.
sion springs and thrust pieces) of the syn-
chronizer body. NOTE
The axial clearance of the split ring must be
19 Insert three compression springs (38) together between –0.05 and +0.05 mm. Select suitable ring
with thrust pieces (37) into the synchronizer from the spare parts catalog.
body’s bores or guide them into the sliding
sleeve by means of a suitable tool.
1315 751 103 - 2010-05 12-12

29
27
28
25
24
5
32 (ZF-BK)
4
3
37 31
38 41
40
2 39
1
36
35
33
34
26
30
031776_3
NOTE
! DANGER
For installation of main shaft, refer to Chapter 8.
Only touch heated cylindrical roller bearing when
wearing protective gloves.
27 Heat cylindrical roller bearing (5) to approx.

120 °C and slide onto main shaft until firmly
home (axial abutment).
28 Fit washer (4).
NOTE
Before fitting disk spring (3) , input and main shaft
must be measured. For measurement, refer to
Chapter 13.1
29 Fit disk spring (3) and axial roller bearing (2).
30 Insert baffle plate (1) into axial roller bearing

and main shaft.
1315 751 103 - 2010-05 12-13

12.1.1 Version with roller bearing on 4th gear 24

5
Removal 4
2 3
1 Helical gear (27), 4th gear, is extracted
together with synchronizer, 3rd/4th gear, 1
35
using standard two-armed extractor.
34
2 Remove roller bearings (28a and 29a) from
29a
helical gear, 4th gear. 27
28a
Installation
1 Insert roller bearings (28a and 29a) into

helical gear (27), 4th gear.
NOTE
Lubrication bores of roller bearings (28a and 29a)
must point outwards (see arrows).
011418_2
!
DANGER
Only touch heated helical gear with roller bearings
when wearing protective gloves.
27
2 Heat roller bearings (28a and 29a) together
with helical gear (27) to 100 °C and slide onto
main shaft (HW) until firmly home (axial abut-
ment).
28a 29a
HW
(main shaft)
011419_1
1315 751 103 - 2010-05 12-14

1X56 137 675 1X56 136 743 1X56 122 304
2
1
031780_1
12.2 Version with tapered roller bearing 1 Place main shaft at output-side into the recep-
tacle (support) 1X56 137 675.
Dismantling Main Shaft
2 Remove securing ring and split ring (1).
NOTE
• For removal of main shaft, refer to Chapter 8. 3 Fit gripping device 1X56 136 743 to tapered
• For the synchronizers (ZF-BK) of 1st/2nd gear and roller bearing’s inner ring (2). Turn knurling
3rd/4th gear, the synchronizer rings may be ring of gripping device until gripping device
coated with carbon or molybdenum; also refer to locates firmly.
Chapter 14.
4 Screw basic tool 1X56 122 304 onto gripping
CAUTION device and extract bearing inner ring from
- Carbon synchronizer rings require clutch bodies the main shaft.
with a smooth conical surface.
- Molybdenum synchronizer rings require clutch 5 Remove axial washer (3).
bodies with curved grooves and possibly oil bores
with corresponding flattening on the conical 6 Turn main shaft and place input-side into
surface. receptacle (support) 1X56 137 675.
- The synchronizers must be matched according to
those requirements.
- By all means consider this for reassembly!
1315 751 103 - 2010-05 12-15

7 Remove securing ring (4). 14a ZF-D version

a Remove clutch disk (42), inner ring (43), inter-
8 Place suitable washer on main shaft. Apply mediate ring (44), and outer ring (45) from the
standard two-armed extractor to R gear (6) synchronizer body (47).
and extract it together with tapered roller
bearing inner ring (5). !
DANGER
9 Remove needle ring (needle roller and cage and 3 compression springs (49) are released. These
assembly) (7) together with inner ring (8). parts are under spring tension. Prevent parts from
10 Use standard two-armed extractor to grip the
helical gear (10), 1st gear, from behind and b Remove sliding sleeve (46), 1st/2nd gear,
extract it together with clutch body (9). thrust pieces (48), and compression springs
11 Remove needle ring (needle roller and cage
assembly) (11) together with inner ring (12) . c Remove clutch components (50).
12 Use standard two-armed extractor to grip d Outer ring (51), intermediate ring (52), inner
helical gear (14) 2nd gear, from behind and ring (53), and clutch disk (54) are released.
extract together with synchronizer (13 or 55
respectively).
15 Remove tube (22) if damaged.
NOTE regarding synchronizer of 1st/2nd gear
Synchronizer ZF-BK (13) is installed in the version 16 Turn main shaft and place output-side into
with servo unit. receptacle (support) 1X56 137 675.
Synchronizer ZF-D (55) is installed in the version
without servo unit.

14 ZF-BK version
a Remove clutch body (16) and synchronizer
ring (17) from synchronizer body (18).
! DANGER
3 compression springs (20) are released. These parts
are under spring tension. Prevent parts from jumping
out (e.g. by using a cloth).
b Remove sliding sleeve (21), 1st/2nd gear from

c Synchronizer ring (17a) and clutch body (16a)

are released.
1315 751 103 - 2010-05 12-16

15
1X56 137 675
13 (ZF-BK) 10
11
19 12
20 16
22
4
17
21
18 5
17a
16a 6
7
14 8
031778_1
55 (ZF-D)
42
48 43
44
49
45
50 46
47
51
52
53
54
032522
1315 751 103 - 2010-05 12-17

NOTE
The following dismantling (working step 17) is
8/16 S 151, 8/16 S 181, 16 S 221, and 16 S 251.
There are no thrust washers, roller rings, and inner
ring installed, only helical gear and 2 roller
bearings; for removal, refer to Chapter 12.2.3.
17 Remove thrust washers (23 and 29), helical

gear (25), 4th gear, roller rings (24 and 26),
and inner ring (27).
18 Use standard two-armed extractor to grip

helical gear (37), 3rd gear, from behind and
extract together with synchronizer (39).

20 Remove clutch body (28) and synchronizer

ring (30) from the synchronizer body (34).
! DANGER
3 compression springs (33) are released. These parts
are under spring tension. Prevent parts from jumping
out (e.g. by using a cloth).
21 Remove sliding sleeve (31), 3rd/4th gear, from

22 Synchronizer ring (35) and clutch body (36)

are released.
1315 751 103 - 2010-05 12-18

25
26
24 37
23
39 (ZF-BK)
32
33 36
35
31
34
30
28
29
27
38
031777_2
1315 751 103 - 2010-05 12-19

Assembling Main Shaft NOTE

The synchronizer ring’s lugs must mesh with
1 Check main shaft for free passage of lubrica- synchronizer body’s recesses.
tion oil bores. Tube (22) must be solidly
seated on the main shaft. c Slide sliding sleeve (21), 1st/2nd gear, over the
If required, drive in until firmly home (axial synchronizer ring and clutch body and see to
abutment) using adapter 1X56 137 835. axial abutment with helical gear, 2nd gear. In
this context, make sure that the recesses at
2 Place main shaft at the input-side into the the inner side of the sliding sleeve line up
receptacle (support) 1X56 137 675. with fitting points (for compression springs
and thrust pieces) of the synchronizer body.
NOTE
Lightly oil the thrust faces and contact surfaces for d Insert three compression springs (20) together
needle rings and helical gears with operating oil. with thrust pieces (19) into the synchronizer
body’s bores or guide them into the sliding
3 Slide needle ring (15) (2-piece: needle roller sleeve by means of a suitable tool.
and cage assembly) onto main shaft.
NOTE
4 Slide helical gear (14), 2st gear, over the Use new compression springs and pull the sliding
needle ring (needle roller and cage assembly) sleeve into center position (neutral position).
motion. Collar faces towards output. e Fit synchronizer ring (17). The synchronizer
ring’s lugs must mesh with the synchronizer
NOTE regarding synchronizer of 1st/2nd gear body’s recesses.
Synchronizer ZF-BK (13) is installed in the version
with servo unit. f Place the clutch body (16) onto the synchro-
Synchronizer ZF-D (55) is installed in the version nizer ring and pull the sliding sleeve into
without servo unit. center position (neutral position). During the
process, press on synchronizer ring and
CAUTION clutch body.
Check wear limit of all synchronizer rings and/or
clutch bodies as described in Chapter 14.1 (ZF-BK) NOTE
and Chapter 14.2 (ZF-D). For ZF-D version, refer to page 12-22; working steps
are described under 5a.
5 ZF-BK version
a Place clutch body (16a) and synchronizer ring ! DANGER
(17a) onto synchronizer gear tooth system. Only touch heated inner ring when wearing
protective gloves.
!DANGER
6 Heat inner ring (12) to 120 °C. Slide inner
protective gloves.
ring and needle ring (11) (2-piece: needle
roller and cage assembly) onto the main
b Heat synchronizer body (18) to approx. 120 °C shaft.
and place onto main shaft gearing. Narrow
side faces towards output. 7 Slide helical gear (10), 1st gear, over the
needle ring (needle roller and cage assembly)
motion. Collar faces towards output.
1315 751 103 - 2010-05 12-20

15
1X56 137 675
13 (ZF-BK) 10
11
19 12
20 16
22
4
17
21
18 5
17a
16a 6
7
14 8 1X56 137 835
031778_1
!
DANGER !
DANGER
Only touch heated clutch body and inner ring when Only touch heated tapered roller bearing inner ring
wearing protective gloves. when wearing protective gloves.
8 Heat clutch body (9) to 120 °C and slide onto 11 Heat tapered roller bearing inner ring (5) to
the main shaft. Narrow side faces towards approx. 120 °C and slide onto main shaft;
output. drive in further to ensure axial abutment.
9 Heat inner ring (8) to 120 °C. Slide inner ring 12 Snap in securing ring (4).
and needle ring (needle roller and cage
assembly) (7) onto main shaft until it is firmly NOTE
home with synchronizer body (axial abut- The securing ring’s axial clearance must be
ment). between 0.01 and 0.10 mm. Select suitable securing
ring from the spare parts catalog.
10 Slide helical gear (6), R gear, over the needle
ring through careful rotational motion. 13 Turn main shaft and place output-side into
Synchronized gear tooth system faces towards the receptacle (support) 1X56 137 675.
input. Ensure that clutch body rests on the
synchronized gear tooth system.
1315 751 103 - 2010-05 12-21

5a ZF-D version i Insert new compression springs (49) and the

a Place clutch disk (54) onto the synchronized thrust pieces in place (48) into the synchroni-
gear tooth system of the helical gear, 2nd zer body ensuring correct position and guide
gear. The clutch disk’s slightly raised inter- them into synchronizer body and sliding
nal gearing faces towards output. sleeve using suitable tool.
b Fit inner ring (53) on clutch disk. The tabs k Fit outer ring (45). The tabs must mesh with
must face towards output. clutch components and the lugs with syn-
chronizer body’s recesses.
c Put on the intermediate ring (52) in such a
way that the tabs mesh with the recesses of l Insert intermediate ring (44). The tabs must
the clutch disk. face towards output. Insert inner ring (43)
and ensure that tabs mesh with clutch com-
d Fit outer ring (51). The tabs must face ponents.
towards output.
m Fit clutch disk (42) with raised internal
e Align tabs on outer ring with tabs on inner gearing facing towards input and ensure it
ring by means of three clutch components meshes with intermediate ring (44). Set
(50). Align tabs of inner and outer ring so sliding sleeve into neutral position and press
that they line up with clutch components against clutch disk. You will clearly hear the
and that clutch components later fit into the thrust pieces snap into place.
recesses of synchronizer body (47) and over
the tabs. After alignment, remove clutch
components again.
!DANGER
protective gloves.
f Heat synchronizer body (47) to approx. 120 °C

and slide onto main shaft gearing. The posi-
tioned tabs must be in the synchronizer
body’s recesses. The outer ring’s lugs must
mesh with the synchronizer body’s recesses.
The synchronizer body can be driven in
further using a plastic punch.
g Insert the clutch components (50) into the

synchronizer body (47).
h Slide the sliding sleeve (46) over the synchro-

nizer body and outer ring and see to axial
abutment with clutch disk.
1315 751 103 - 2010-05 12-22

55 (ZF-D)
42
48 43
44
49
45
50 46
47
51
52
53
54
032522
1315 751 103 - 2010-05 12-23

14 Slide needle ring (38) (2-piece: needle roller 20 Fit synchronizer ring (30). The synchronizer
and cage assembly) onto main shaft. ring’s lugs must mesh with the synchronizer
body’s recesses.
15 Slide helical gear (37), 3rd gear, over the
needle ring (needle roller and cage assembly) 21 Place clutch body (28) on synchronizer ring
under careful rotational motion. Synchronized and pull the sliding sleeve into center position
gear tooth system faces towards input. (neutral position). During the process, press
on synchronizer ring and clutch body.
CAUTION
Check wear limit of all synchronizer rings and/or NOTE
clutch bodies as described in Chapter 14.1 (ZF-BK). The following fitting (working steps 22 - 25) is
16 Place clutch body (36) with synchronizer ring 8/16 S 151, 8/16 S 181, 16 S 221, and 16 S 251.
(35) onto synchronized gear tooth system. For fitting of version with roller bearings, refer to
Chapter 12.2.3.
! DANGER
Only touch heated synchronizer body when wearing !
DANGER
protective gloves. Only touch heated inner ring when wearing
protective gloves.

and slide onto main shaft gearing. The syn- 22 Heat inner ring (27) to 120 °C.
chronizer body is symmetric and can there-
fore be fitted irrespective of lateral position. 23 Fit thrust washer (29) and inner ring (27).
Drive in synchronizer body further to ensure
axial abutment. 24 Insert roller rings (26 and 24) in helical gear
(25), 4th gear.
NOTE
The synchronizer ring’s lugs must mesh with 25 Push helical gear (25) over inner ring into
synchronizer body’s recesses. clutch body with collar facing towards output
and fit thrust washer (23).
18 Slide sliding sleeve (31), 3rd/4th gear over the
synchronizer body, synchronizer ring, and NOTE
clutch body and see to axial abutment with The following measurement and assembly is inappli-
helical gear, 3rd gear. Make sure that the cable for the following transmissions: 8/16 S 151,
recesses at the inner side of the sliding sleeve 8/16 S 181, 16 S 221, and 16 S 251.
line up with the fitting points (for compres- How to measure and install the ring, axial washer,
sion springs and thrust pieces) of the synchro- bearing inner ring, and split ring with securing ring
nizer body. is described in Chapter 13.3 and 13.4.
19 Insert three compression springs (33) together 26 Fit axial washer (3).
with thrust pieces (32) into the synchronizer
body’s bores or guide them into the sliding 27 Use depth gage to measure distance between
sleeve by means of a suitable tool. contact of axial roller bearing and axial
washer (3).
NOTE Measurement result must be within tolerance
Use new compression springs. range of +0.07 and –0.08 mm; also refer to
assembly instructions 1315 700 037. In the
case of deviations, please select suitable axial
washer from the spare parts catalog.
1315 751 103 - 2010-05 12-24

25
26
24 37
23
3 39 (ZF-BK)
2
1
32
33 36
35
31
34
30
29 28
27
38
031777_3
28 Heat bearing inner ring (2) to 100 °C and fit

1315 700 037
onto bearing journal of main shaft until it is
firmly home (axial abutment). Use a plastic
punch to drive in further.
29 Insert split ring (1) into groove of the main

shaft and secure with securing ring by
caulking 3 times at 120°.
NOTE
The axial clearance of the split ring must be
between –0.05 and +0.05 mm. Select suitable ring
from the spare parts catalog.
+0.07
+0.07 up
bisto –0.08
-0.08
NOTE
031846
• For installation of main shaft, refer to Chapter 8.
• For measurement of main shaft, refer to Chapter
13.2.
1315 751 103 - 2010-05 12-25

12.2.1 Version with roller bearing on 4th gear

3
Removal 2
1
1 Helical gear (25), 4th gear, is extracted toget-
30
her with synchronizer, 3rd/4th gear, using
standard two-armed extractor. 28
2 Remove roller bearings (24a and 26a) from 26a

helical gear, 4th gear.
25
24a
Installation
1 Insert roller bearings (24a and 26a) into heli-

cal gear (25), 4th gear.
NOTE
Lubrication bores of roller bearings (24a and 26a)
must point outwards (see arrows).
011418_1
!
DANGER
Only touch heated helical gear with roller bearings
when wearing protective gloves.
25
2 Heat roller bearings (24a and 26a) together
with helical gear (25) to 100 °C and slide onto
main shaft (HW) until firmly home (axial abut-
ment). 24a 26a
HW
(main shaft)
011419_1
1315 751 103 - 2010-05 12-26

ZF-Ecosplit Main, Input, and Countershaft
13 Bearing Setting on Main Shaft, Input Shaft,

and Countershaft
13.1 Setting the main and input shaft –

Version with axial roller bearing ................................................................. 13-2
13.2 Input shaft / main shaft

Determine ring (only for 16 S 222) ............................................................ 13-5
13.3 Setting main shaft and input shaft –

Version with tapered roller bearing(s) ........................................................ 13-6

Determine ring and axial washer (straight-toothed version – only for
8/16 S 151, 8/16 S 181, 16 S 221) ........................................................... 13-8

Determine ring and axial washer (helical-toothed version – only for
8/16 S 151, 8/16 S 181, 16 S 221, 16 S 251)........................................... 13-10
13.6 Setting the countershaft........................................................................... 13-12

Version with pump housing ....................................................................... 13-12
Version with single-piece connection plate ................................................ 13-13
1315 751 103 - 2010-05 13-1

13 Bearing Setting on Main Shaft, Input Shaft,

and Countershaft 1
13.1 Setting the main and input shaft – 2

Version with axial roller bearing
3
CAUTION
Set the main and input shaft with clearance. 4
The clearance is 0.01 - 0.10 mm
5
1 Assemble main shaft, as described in Chapter
12.1.2, up to plate spring.
Do not fit plate spring (3).
2 Fit axial roller bearing(s) (2) and insert baffle

plate (1) into the axial roller bearing and the
main shaft.
3 Insert main shaft into the transmission

housing by means of lifting gear.
NOTE
Bearing outer ring at the output side must be fitted.
4 Place input shaft on main shaft.
NOTE 031051_1
Ring must be measured (only for 16 S 222); refer to

Chapter 13.2.
5 Use guide pins to place clutch housing on

transmission housing. 7 Rotate input and main shaft a few times in
order to center the bearing rollers at the
NOTE bearing points. Use a pointed device to check
Bearing outer ring at the input side must be fitted. whether bearing rollers can be moved.
6 Set the input bearing clearance to zero play; NOTE

to this end, use a mandrel to drive bearing Constant 2 must be selected in the transmission.
outer ring towards the main shaft.
CAUTION
Do not push or hammer close to oil ducts.
Otherwise, housing will be damaged.
1315 751 103 - 2010-05 13-2

NOTE
In the case of zero play, the bearing rollers must be
backlash-free, i.e. it should not be possible to move
them to one or the other side. However, it must be
ensured that no preload is generated either.
7
8 Use depth gage to measure the distance
between the upper edge of the outer bearing
ring and the connecting face of the clutch bell
housing. Note down dimension (b) and add
disk spring thickness (3).
B = b + 1.00 mm (disk spring)
NOTE b
Perform measurement at two opposite locations and
calculate mean value.
6
NOTE
Depending on the transmission version, there may 032664
be different connection plates (e.g. split (I) or single-
piece (II) versions), but the dimensions are the
same.
a I
6
between the connecting face and the contact
surface for shim; note down dimension (a)
and add thickness of seal (6).
A = a + 0.40 mm (seal)
NOTE
011424_1
10 Calculate the difference “C” and note it down.

C=A–B
a II
11 Calculate thickness “D” of shim (7).
6
D = C – clearance
12 Select shim (7) from spare parts catalog.
NOTE
Installation of shim (7) is described in Chapter 6.
001959_1
1315 751 103 - 2010-05 13-3

13 Remove clutch housing again.
14 Remove entire input shaft.
15 Lift main shaft out of transmission housing

with lifting device and insert in fixture.
16 Remove baffle plate and axial bearing.
17 Complete main shaft as described in Chapter

12.1.2.
18 For shaft installation, refer to Chapter 8.
1315 751 103 - 2010-05 13-4

13.2 Input shaft / main shaft 1315 700 043

Determine ring (only for 16 S 222)
1 Use depth gage to measure distance between 9

washer (4) and ring contact surface (dimen-
sion “a”).
10
2 Target dimension “b” is 49.9 ± 0.05 mm; also
refer to assembly instructions 1315 700 043.
3 a – b must produce ring thickness (10).

4
4 Once the correct ring has been determined,
insert ring (10) into clutch body (9). Place
a
parts on helical gear of 4th gear.
032662
NOTE
• Measure axial roller bearings; refer to
Chapter 13.1. 10
• Complete main shaft as described in
Chapter 12.1.2.
• Fit input shaft as described in Chapter 10.1. 9
012320_1
1315 751 103 - 2010-05 13-5

13.3 Setting main shaft and input shaft –

version with tapered roller bearing(s)
I
CAUTION
Set the main and input shaft with clearance.
The clearance is 0.01 - 0.10 mm
7
1 Set the input bearing clearance to zero play; to

this end, use a mandrel to drive bearing outer
ring towards the main shaft.
CAUTION
Otherwise, housing will be damaged. B
2 Rotate input and main shaft a few times in

order to center the bearing rollers at the
6
bearing points. Use a pointed device to check
whether bearing rollers can be moved. 032664
NOTE
Constant 2 must be selected in the transmission.
NOTE
In the case of zero play, the bearing rollers must be
backlash-free, i.e. it should not be possible to move
them to one or the other side. However, it must be
ensured that no preload is generated either.

between the upper edge of the bearing outer
housing which provides dimension “B”.
NOTE
1315 751 103 - 2010-05 13-6

NOTE a I
Depending on the transmission version, there may 6
be different connection plates (e.g. split (I) or single-
piece (II) versions), but the dimensions are the
same.

between connecting face and contact surface
for shim ; note down dimension (a) and add
thickness of seal (6).
A = a + 0.40 mm (seal)
011424_1
NOTE
a II
5 Calculate the difference “C” and note it down.
C=A–B 6
6 Calculate thickness “D” of shim (7).

D = C – clearance
NOTE
Installation of shim (7) is described in Chapter 6. 001959_1
1315 751 103 - 2010-05 13-7


Determine ring and axial washer
(straight-toothed version – only for 10 11
8/16 S 151, 8/16 S 181, 16 S 221)
9
1 Insert main shaft into the intermediate X
housing by means of lifting gear.
2 Insert ring (10) into clutch body (9) and place

it onto helical gear of 4th gear.
3 Perform measurements at several locations to

determine distance between upper edge of
clutch body and sealing surface of interme-
diate housing with fitted seal and calculate
mean value. 001954_1
4 The target value “X” must be reached.

“X” = 19.2 –0.5 mm (8/16 S 181, 16 S 221) 10
“X” = 32.2 –0.5 mm (8/16 S 151)
If the calculated mean value does not corre-
spond to the target value, use suitable ring 9
(refer to table provided working step 5) to
reach target value.
5 Select suitable axial washer (11) from the

table. If, e.g. a ring of 3.6 mm is needed, use
axial washer of 7.9 mm.
Ring (10): 3.6 / 4.0
Axial washer (11): 7.9 / 8.3
012320_1
1315 751 103 - 2010-05 13-8

6 Remove main shaft from intermediate housing

again and place axial washer (11) onto main
shaft with raised collar facing towards the
helical gear. 11
1X56 137 676
!DANGER 12
Only touch heated bearing inner ring when wearing
protective gloves. 13
7 Heat new bearing inner ring (12) to 100 °C

and fit it onto bearing journal of main shaft so
that it is firmly home (axial abutment).
Drive home with plastic punch.
8 Fit bearing inner ring with grease applied to

entire roller diameter (collar side) at the front 012321_1
face on bearing output side (see arrow).
NOTE
Applying grease to the outside of the bearing rollers
is not permitted, because this might lead to clogging
of the input shaft’s lubricating bores.
9 Insert split ring (13) with axial clearance or

preload between –0.05 mm and +0.05 mm
into annular groove of main shaft using
adapter 1X56 137 676.
Split ring is available at 0.1 mm stepped
thickness levels.
10 Slide new securing ring (13) over split ring

and fasten at three locations, offset by 120°,
using caulking tool.
1315 751 103 - 2010-05 13-9

13.5 Input shaft / main shaft 1315 700 039

Determine ring and axial washer
(helical-toothed version – only for 8/16 S
151, 8/16 S 181, 16 S 221, 16 S 251) 4.6 -0.4
1 Use depth gage to measure distance between b

9
main shaft and contact surface of bearing 10
inner ring (dimension “a”); also refer to assem-
11
bly instructions 1315 700 039.
2 Insert axial washer (11) and measure distance

between main shaft and axial washer (dimen-
sion “b”) using depth gage.
+0.07 bis -0.08
3 a – b must produce clearance between +0.07 a

and –0.08 mm. 009521_1
4 Once the right axial washer has been deter-

mined, insert ring (10) into clutch body (9). 10
Place parts on helical gear of 4th gear.
5 Perform measurements at several locations to 9

determine distance between axial washer (11)
and clutch body and calculate mean value.
Target value 4.6 –0.4 mm (select suitable ring
(10) ).
012320_1
1315 751 103 - 2010-05 13-10

!DANGER
Only touch heated bearing inner ring when wearing
protective gloves.
11
1X56 137 676
6 Heat new bearing inner ring (12) to 100 °C 12

and fit it onto bearing journal of main shaft so
that it is firmly home (axial abutment). Drive 13
home with plastic punch.
7 Fit bearing inner ring with grease applied to

entire front face on bearing output side (see
arrow).
NOTE
Applying grease to the outside of the bearing rollers 012321_1
is not permitted, because this might lead to clogging
of the input shaft’s lubricating bores.
8 Insert split ring (13) with axial clearance or

preload between –0.05 mm and +0.05 mm
into annular groove of main shaft using
adapter 1X56 137 676.
Split ring is available at 0.1 mm stepped
thickness levels.
9 Slide new securing ring (13) over split ring

and fasten at three locations, offset by 120°,
using caulking tool.
1315 751 103 - 2010-05 13-11

13.6 Setting the countershaft
NOTE
• Shafts and selector rails must be installed com-
pletely; refer to Chapter 8. 8
• Main shaft must be measured; refer to Chapter
13.1, 13.2, 13.3, 13.4 or 13.5.
CAUTION
Set clearance on countershaft.
Clearance must be between 0.01 and 0.10 mm.
B
1 Transmission is in vertical position.
2 Set the countershaft’s roller bearing clearance
to zero; to this end, use a mandrel to drive
bearing outer ring in the direction of the 6
countershaft.
CAUTION 032665

Otherwise, housing will be damaged.
3 Rotate countershaft a few times in order to

center the bearing rollers at the bearing
points. Use a pointed device to check whether
bearing rollers can be moved.
NOTE
• In the case of zero play, the bearing rollers must
be backlash-free, i.e. it should not be possible to
move them to one or the other side. However, it
must be ensured that no preload is generated
either.
• Perform measurement at two opposite locations
and calculate mean value.
NOTE
Depending on the transmission version, there may
be either a split pump housing or a single-piece
connection plate; dimensions are illustrated respec-
tively.
Version with pump housing
a Use depth gage to measure the distance

between the upper edge of the bearing outer
housing; this is dimension “B”.
1315 751 103 - 2010-05 13-12

b Use depth gage to measure distance between

connecting face and contact surface for shim;
note down dimension (a) and add thickness of a 6
seal (6).
A = a + 0.40 mm (seal)
c Determine difference “C” and note it down.

C=A–B
d Calculate thickness “D” of shim (8).

D = C – clearance 032843
Version with single-piece connection plate

6
B
a Use depth gage to measure the distance
between the connecting face of the clutch bell
housing and the upper edge of the bearing
outer ring; this is dimension “B”.
b Consider thickness of seal (6).

A = B + 0.40 mm (seal)
c Calculate thickness “D” of shim (8). 001960_1
D = A – clearance
NOTE
Installation of shim is described in (8) in Chapter 6.
1315 751 103 - 2010-05 13-13

13-14
ZF-Ecosplit Synchronizers
14 Synchronizers
Important information concerning the ZF-BK version .............................. 14-3
14.1 ZF-BK, ZF-B version .................................................................................. 14-4

Determining the Wear Limit for Synchronizers............................................ 14-4
Assembling synchronizer unit..................................................................... 14-5
ZF-BK version ............................................................................................ 14-5
Cross section of the synchronizer unit / ZF-BK ........................................... 14-5
14.2 ZF-D version.............................................................................................. 14-6

Determine the wear limit for the synchronizer unit for the 1st/2nd gear...... 14-6
Assembling synchronizer unit..................................................................... 14-7
ZF-D version .............................................................................................. 14-7
Cross-section of the synchronizer unit / ZF-D ............................................. 14-7
1315 751 103 - 2010-05 14-1

14-2
Important information concerning the ZF-BK

version
Depending on the transmission version, there can be

synchronizers with carbon or molybdenum layer on
the main shaft in the 1st/2nd gear and the 3rd/4th
gear.
Carbon version
The carbon version is only used in transmissions with servo unit.
032844 032845
Clutch body: Synchronizer ring:

The clutch body contains no oil groove. The carbon layer is applied in planiform manner.
Molybdenum version
The molybdenum version is used in transmissions without/with servo unit.
032846 032847
Clutch body: Synchronizer ring:

The clutch body contains a oil groove. The molybdenum layer is applied in a groove-like
manner.
1315 751 103 - 2010-05 14-3

14.1 ZF-BK, ZF-B version

X
Determining the Wear Limit for
Synchronizers
The condition of the synchronizer rings and

clutch bodies must be checked before the 1
synchronizers are assembled.

2
NOTE
Do not mix up synchronizer parts.
1 Place synchronizer ring (2) on associated

clutch body (1). Turn the synchronizer parts
and thereby ensure even and parallel contact
of tapers.
The wear limit of synchronizer rings on the

synchronizers of the main transmission and
splitter group is 0.8 mm, and 1.2 mm for the
range change group.
2 Use a feeler gage to measure the distance (X) 001999
between the clutch body and synchronizer

ring at twoopposing points. If the wear limit
falls below 0.8 or 1.2 mm respectively, the
synchronizer ring and clutch body must be
replaced.
3 Also check the condition of the synchronizer

parts (visual check). If the surface is corruga-
ted, replace synchronizer parts. Do not mix up
parts that have been checked together (mark
them).
1315 751 103 - 2010-05 14-4

Assembling synchronizer unit

2
ZF-BK version 1
1 Check the wear limit.
2 Replace compression springs (5) with new

ones.
That way, the specified sliding force of the
sliding sleeve (6) is guaranteed. 4
3 Synchronizers can be assembled as a complete 5

set or as a final assembly process directly on
the main shaft.
4 Push sliding sleeve (6) onto synchronizer body

(3). 3
Insert new compression springs (5) with thrust
pieces (4) into the synchronizer body (3). 1a
Position the mandrel at the center of the thrust 6 2a
pieces and guide thrust pieces into sliding
sleeve (6).
5 Put on clutch body (1) with synchronizer ring

(2) and push sliding sleeve (6) to center posi-
tion.
NOTE
Observe the correct position of the thrust pieces. 009510
Cross section of the synchronizer unit / ZF-BK

6
1/1a Clutch body
2/2a Synchronizer ring
2 2a
3 Synchronizer body
4 Thrust piece 1 5
5 Compression spring
6 Sliding sleeve 4 1a
001940
1315 751 103 - 2010-05 14-5

14.2 ZF-D version
Determine the wear limit for the synchro- F = 50 N

nizer unit for the 1st/2nd gear 2
NOTE
The ZF-D version is only used for transmissions s
without servo unit.
The condition of the outer rings, intermediate

rings, and inner rings must be checked before
7 8 1
assembling the synchronizer units.
029311
NOTE
Do not mix up synchronizer parts.
1 Put the inner ring (8), intermediate ring (7),

and outer ring (2) onto the synchronization of
the clutch disk (1). Turn the outer ring to bring
the tapers into even contact.
Apply an even load of F = 50 N onto the outer
ring.
2 At the same time, use a feeler gage to measure

distance (s) between clutch disk and outer ring
at two opposite points.
The wear limit is 1.5 mm.
If the wear limit falls below this value, use
new intermediate ring and outer ring and
inner ring.
3 Also check the condition of the synchronizer

parts (visual check). If the surface is corruga-
ted, replace synchronizer parts.
Do not mix up parts that have been checked
together (mark them).
1315 751 103 - 2010-05 14-6

Assembling synchronizer unit
ZF-D version 2
7
1 8
1 Check the wear limit.
2 Replace compression springs (5) with new

ones.
Thus, specified sliding force of sliding sleeve
(6) is ensured.
3 Synchronizer units can be assembled as com- 4

plete sets, or in a final assembly process on the
main shaft. 5
4 Push sliding sleeve (6) onto synchronizer body 9

(3). The sliding sleeve features three milled
3
recesses with each spanning three teeth. Pair
1a
the center tooth with the narrow milled recess 8a
of the synchronizer body (thrust piece groove). 7a
2a
5 Insert new compression springs (5) with thrust 6
pieces (4) into the synchronizer body. Mount
the thrust pieces in such a way that the roun-
ding of the thrust piece head extends into the
milled groove of the sliding sleeve tooth.
6 Insert clutch components (9).
7 Insert outer ring (2), intermediate ring (7), and

inner ring (8).
001941
8 Fit clutch disk (1).
NOTE
Observe the correct position of the thrust pieces.
Cross-section of the synchronizer unit / ZF-D

6
1 / 1a Clutch disk 1 1a
2 / 2a Outer ring 2 2a
3 Synchronizer body 7 7a
4 Thrust piece 8a
8
5 Compression spring 5
6 Sliding sleeve 4
7 / 7a Intermediate ring
8 / 8a Inner ring
001942
1315 751 103 - 2010-05 14-7

14-8

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FORD TRAINING

After Sales Technical Training

This documentation is protected by copyright. Any

1315 751 103

1 Plastic Tubes ...................................................................................................................................... 1-1

2 Shift Turret......................................................................................................................................... 2-1

3 Range Change Group......................................................................................................................... 3-1

4 Planetary Gearset with Synchronizers............................................................................................. 4-1

5 Splitter Group Piston and 5/2-Way Valve......................................................................................... 5-1

6 Release Unit, Connection Plate, and Pump.................................................................................... 6-1

7 Clutch Housing ................................................................................................................................ 7-1

8 Shaft and Selector Rails .................................................................................................................. 8-1

9 Intermediate Housing...................................................................................................................... 9-1

10 Input Shaft ....................................................................................................................................... 10-1

11 Counter shaft ................................................................................................................................... 11-1

12 Main Shaft........................................................................................................................................ 12-1

14 Synchronizers .................................................................................................................................. 14-1

1315 751 103 - 2010-05 3

NOTE Planet carrier:

1315 751 103 - 2010-05 4

Index Date of Issue Chapter Initiator Comment

2010-05 All LKS-T Summary of all Ecosplit 3 Repair Manuals

1315 751 103 - 2010-05 5

Service points equipped by ZF Friedrichshafen AG

1. Continuously trained personnel,

3. Genuine ZF spare parts in accordance

All work performed at these service locations

The following safety instructions are used ! DANGER to the health!

To avoid injury to personnel and damage to

Personnel required to carry out repairs on ZF

General Information Cleaning Parts

After removing the transmission from the vehicle, Reworking

Transmission Assembly • Shaft Sealing Rings

c) Shaft sealing rings with steel and rubber

• Retaining Agents • Transmission Oil

* refer to consumable material

Tightening torques for screws/bolts and nuts,

Coarse thread Fine thread

Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

M4 2,8 4,1 4,8 M8x1 24 36 43

M12 79 115 135 M14x1.5 135 200 235

M18 280 390 460 M18x2 290 420 490

M24 670 960 1100 M24x1.5 760 1100 1250

M27x2 1050 1500 1800

Status: August 1991

Description Name Quantity Application Comment

Compression spring 1 piece Compression spring in servo unit Chapter 2

Ball roller 1 piece Roller in servo unit Chapter 2

O-ring 1 piece Detent Chapter 2.4

Grease For example: 1g Pin Chapter 2

Grease For example: 1g Tappet Chapter 2

Sealing compound Loctite no. 241 5 mm3 Breather Chapter 2

Sealing compound Loctite no. 574 Pump cover Chapter 6.3

NOTE: Inquire about package/container size before placing an order!

1315 751 103 - 2010-05 11

Order no. Installation location Number of Wire Ø Spring outer Ø Non-loaded

0732 042 126 Detent unit 9.50 1.00 9.40 25.00

0732 042 684 Shift turret 5.16 2.10 39.00 70.00

0732 040 986 Shift turret 5.50 2.25 14.50 21.60

0732 040 385 Synchronizer/ 18.50 1.25 6.25 34.20

0732 040 736 Locking pin/interlock 13.50 1.60 9.80 36.00

1315 751 103 - 2010-05 12

Designation Dimensional details Measurement device Comment

06. Permissible clearance of 0.1 +0.2 mm Feeler gage