ZF Actuator

Repair Manual

Transmission Actuator and Clutch Actuator 1327 751 103

Subject to alterations in design

Copyright by ZF This documentation is protected by copyright. Any reproduction or dissemination in whatever form which does not comply fully with the intended purpose of this documentation is prohibited without the consent of ZF Friedrichshafen AG. Printed in Germany ZF Friedrichshafen AG, MC-C / 2005-09

Edition: 2005-09

1327 751 103

ZF-AS Tronic

Table of Contents Page

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

5 6 6 7 9 10 11 11 12 14 15 16

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

17

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

19

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

22

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

23

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

24

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

25

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

26

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

28

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

30

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

32

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

34

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

35

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

37

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

39 40 40 40

Clutch Actuator ..............................................................................................................................................

41

1327 751 103 - 2005-09

3

Preface This manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products.

This manual deals with a ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics and fitters who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel, 2. Specified equipment, e.g.: Special tools 3. Genuine ZF spares, according to our latest specifications

All work performed at these service locations is carried out conscientiously and with care. Warranty: Repair work carried out at ZF Service Points is subject to the contractual conditions prevailing in the individual case. ZF Friedrichshafen AG Nutzfahrzeug- und Sonder-Antriebstechnik Commercial Vehicle and Special Driveline Technology Service Werk 2 (Plant 2) Phone: +49 (0)7541 77-0 Fax: +49 (0)7541 77-908000 Internet: www.zf.com

2003-08

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual warranty agreement. This also applies where genuine ZF spare parts have not been used.

5

Safety Instructions Safety Instructions

General Information

Companies repairing ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.

CAUTION Pictures, drawings, and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings, and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text.

Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.

After completion of repair work and testing, skilled staff must check whether the product is functioning correctly.

The following safety instructions appear in this manual:

!

THREATS TO THE ENVIRONMENT ! Lubricants, consumables, and cleaning agents must not be allowed to enter the soil, ground water, or sewage system. • Ask your local environment agency for safety 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 cleaning agents in accordance with environmental protection guidelines. • When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional working practices could damage the product.

!

DANGER This is used when lack of care could lead to personal injury or death.

CAUTION The transmission must NOT be suspended by the input shaft NOR by the output flange.

2005-04

6

Instructions for Repairs Gaskets, Locking plates

ZF Service Information must be observed. This information is available at all ZF Service Centers or via the ZF-ServiceLine.

Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

In case of doubt always turn to the relevant department within ZF After-Sales Services for advice. All work on transmissions is to be performed by experts only and under clean conditions. Use specified tools to dismantle and assemble transmissions.

Shaft Seals Always change shaft seals with rough, ripped or hardened sealing lips. Seal contact surfaces must be totally clean and in perfect condition.

After removing the transmission from the vehicle, clean it thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning.

Reworking

Parts joined with Loctite are easier to separate if warmed with a fan heater.

Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or scroll.

Cleaning parts

If rework is needed on spacer discs, shims etc. because of clearance adjustment, ensure that the reworked areas contain no face runout and have the same surface quality.

Remove remains of old gaskets on all sealing surfaces. Carefully remove burrs or similar patches of roughness using an oilstone. Lube bores and grooves must be free of anticorrosion agents and foreign matter; check for perfect passage.

Transmission Assembly Find a clean work area to assemble the transmission. Gaskets are installed without sealing compound or grease. When measuring silicon-coated gaskets, do not include the silicon layer. During assembly, comply with all adjustment data and tightening torques in the Repair Manual.

Carefully cover opened transmissions to prevent foreign matter from entering.

Reusing parts Parts such as roller bearings, discs, thrust washers etc., must be inspected by a competent person who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear.

2005-04

7

Instructions for Repairs d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.

Bearings If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at approx. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

X

e) Fill the gap between the sealing lips so it is 60 % filled with grease (e.g. produced by Aral, such as Aralub HL2 or by DEA, such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

Sealing If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed.

Retaining Agents Retaining agents* may only be used in places as specified in the parts list. Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data, and tightening torques.

Shaft Seals a) Apply a light coat of sealing agent* on circumference of shaft seals with “steel jacket”.

Transmission oil b) Never apply sealing agent to shaft seals with “rubber jacket”, but apply a thin coat of Vaseline 8420 to the circumference or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive).

After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and TE-ML List of Lubricants (refer to identification plate) which are available from any ZF After-Sales Service Point and on the Internet under www.zf.com. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow using the specified torques.

c) Shaft seals with steel and rubber jackets should be treated on the circumference of the rubber jacket as described above in section b).

* refer to expendable material

2003-08

8

Overview of Amendments: 1327 751 103

Index

Date of issue

1327 751 103 - 2005-09

Chapter

Initiator

Comment

9

Tightening Torques Tightening Torques for Nuts and Bolts, Extract from ZFN 148 Surface condition of bolts / nuts: Thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated, and oiled.

This standard applies to screws/bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961, as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and to nuts acc. to DIN 934 as well as ISO 4032, ISO 8673.

Tighten screws with a calibrated ratchet dial torque or ratchet wrench.

This Standard contains data on tightening torques (MA) for screws/bolts and nuts in strength categories 8.8, 10.9, and 12.9, and nuts in strength categories 8, 10, and 12.

NOTE Deviating tightening torques are listed separately in the Repair Manual.

Regular screw thread Size Screw/Bolt Nut M4 M5 M6

Fine screw thread Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12 2.8 5.5 9.5

Size Screw/Bolt Nut

Tightening torque (Nm) for 8.8 10.9 12.9 8 10 12

4.1 8.1 14

4.8 9.5 16.5

M8x1 M9x1 M10x1

24 36 52

36 53 76

43 62 89

M7 M8 M10

15 23 46

23 34 68

28 40 79

M10x1.25 M12x1.25 M12x1.5

49 87 83

72 125 120

84 150 145

M12 M14 M16

79 125 195

115 185 280

135 215 330

M14x1.5 M16x1.5 M18x1.5

135 205 310

200 300 440

235 360 520

M18 M20 M22

280 390 530

390 560 750

460 650 880

M18x2 M20x1.5 M22x1.5

290 430 580

420 620 820

490 720 960

M24 M27 M30

670 1000 1350

960 1400 1900

1100 1650 2250

M24x1.5 M24x2 M27x1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M27x2 M30x1.5 M30x2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 2003-08

10

Tightening Torques Screw Plugs DIN 908, 910, and 7604

Union Screws DIN 7643

The screw plug tightening torques were determined according to DIN 7604 for screwing into steel, gray cast, and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque apply analogously to screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

The tightening torques were determined for screwing into steel, gray cast, and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. General rule: Screw/ Bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: As manufactured (without surface protection) and lightly oiled or galvanized, chromated, and lightly oiled.

General rule: Screw/ Bolt class 5, ZFN 148-1 Screw/ Bolt material: Steel acc. to DIN 7604. Surface condition: As manufactured (without surface protection) and lightly oiled or galvanized, chromated, and lightly oiled.

Union screws (DIN 7643)

Screw plugs (DIN 908, 910, 7604) Dimensions

M8x1 M10x 1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x1.5 M26x1.5 M27x2 M30x1.5 M30x2 M33x2 M36x1.5 M38x1.5 M42x1.5 M42x2 M45x1.5 M45x2 M48x1.5 M48x2 M52x1.5 M60x2 M64x2

Tightening torque in Nm screwed into steel / gray cast Al alloy 20* 10* 25 / 30* 15 / 20* 35 25 35 25 40 30 50 35 55 45 60 / 80* 50 / 65* 70 60 80 / 105* 70 / 90* 80 70 100 / 130* 90 / 130* 95 85 120 110 130 115 140 120 150 130 145 125 160 140 150 130 170 145 160 135 180 150 195 165 205 175

* DIN 7604 Form C

Thread

Tightening torque in Nm

4-5

M8x1

20 - 25

6

M10x1

25 - 35

8

M12x1.5

30 - 40

10

M14x1.5

35 - 40

12

M16x1.5

45

15

M18x1.5

50

18

M22x1.5

60

22

M26x1.5

90

28

M30x1.5

130

35

M38x1.5

140

Edition: October 1995

11 2003-08

Pipe outer diameter

Conversion from DIN to ISO Standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 1

Tapered pins

ISO 2339

- some can be replaced → changed to ISO 2339 - parts which cannot be replaced (e.g. where 1 = 36 mm) documented as DIN 1 OLD

DIN 7

Cylindrical pins

ISO 2338

- some can be replaced → changed to ISO 2338 - parts which cannot be replaced (e.g. diameter 13 and 14 and/or where 1 = 36 mm) documented as DIN 7 OLD

DIN 84

Cylindrical screws

ISO 1207

- some can be replaced → changed to ISO 1207 - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD

DIN 85

Flat head bolts

ISO 1580

- can be replaced → changed to ISO 1580

DIN 94

Split pins

ISO 1234

- can be replaced → changed to ISO 1234

DIN 417

Threaded pins

ISO 7435

- can be replaced → changed to ISO 7435

DIN 439-1 DIN 439-2

Hex nuts Hex nuts

ISO 4036 ISO 4035 ISO 8675

- cannot be replaced → documented as DIN 439 OLD

DIN 551

Threaded pins

ISO 4766

- can be replaced → changed to ISO 4766

DIN 553

Threaded pins

ISO 7434

- can be replaced → changed to ISO 7434

DIN 555

Hex nuts

ISO 4034

- cannot be replaced → documented as DIN 555 OLD

DIN 558

Hex bolts

ISO 4018

- some can be replaced → changed to ISO 4018 - parts which cannot be replaced (e.g. M12, with new SW) documented as DIN 558 OLD

DIN 601

Hex bolts

ISO 4016

- some can be replaced → changed to ISO 4016 - parts which cannot be replaced (e.g. M10 and M12, with new SW) documented as DIN 601 OLD

DIN 912

Cylindrical screws

ISO 4762

- some can be replaced → changed to ISO 4762 - parts which cannot be replaced (e.g. M18, M22, M27, and M33) documented as DIN 912 OLD

DIN 931-1

Hex bolts

ISO 4014

- some can be replaced → changed to ISO 4014 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 931 OLD

DIN 933

Hex bolts

ISO 4017

- some can be replaced → changed to ISO 4017 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 933 OLD

DIN 934

Hex nuts

ISO 4032 ISO 8673

- cannot be replaced replaced as a result of uneven nut height and for M10, M12, M14, and M22 with new SW.

DIN 960

Hex bolts

ISO 8765

- some can be replaced → changed to ISO8765 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 960 OLD

DIN 961

Hex bolts

ISO 8676

- some can be replaced → changed to ISO 8676 - parts which cannot be replaced (e.g. M10, M12, M14, and M22 with new SW) documented as DIN 961 OLD

DIN 963

Countersunk bolts

ISO 2009

- cannot be replaced as a result of modified head dimensions → documented as DIN 963 OLD

DIN 964

Countersunk bolts

ISO 2010

- cannot be replaced as a result of modified head dimensions → documented as DIN 964 OLD

1) with reference to productive parts numbered at ZF 2003-08

12

Conversion from DIN to ISO Standards

Withdrawn DIN

Title

Substitute ISO standard

Result of check / measures 1)

DIN 965

Countersunk bolts

ISO7046

- cannot be replaced as a result of modified head dimensions → documented as DIN 965 OLD

DIN 980

Locking nuts

ISO 7042 ISO 10513

- cannot be replaced → documented as DIN 980 OLD

DIN 985

Locking nuts

ISO 10511

- cannot be replaced → documented as DIN 985 OLD

DIN 1440

Washers

ISO 8738

- some can be replaced → changed to ISO 8738 - parts which cannot be replaced documented as DIN 1440 OLD

DIN 1443

Bolts

ISO 2340

- can be replaced → changed to ISO 2340

DIN 1444

Bolts

ISO 2341

- can be replaced → changed to ISO 2340

DIN 1471

Grooved pins

ISO 8744

- some can be replaced → changed to ISO 8744 - parts which cannot be replaced (e.g. 1 = 6 mm) documented as DIN 1471 OLD

DIN 1472

Grooved pins

ISO 8745

- some can be replaced → changed to ISO 8745 - parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as DIN 1472 OLD

DIN 1473

Grooved pins

ISO 8740

- some can be replaced → changed to ISO 8740 - parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25, and 50 mm) documented as DIN 1473 OLD

DIN 1474

Grooved pins

ISO 8741

- can be replaced → changed to ISO 8741

DIN 1475

Grooved pins

ISO 8742

- can be replaced → changed to ISO 8742

DIN 1476

Grooved stud

ISO 8746

- can be replaced → changed to ISO 8746

DIN 1477

Grooved stud

ISO 8747

- can be replaced → changed to ISO 8747

DIN 1481

Clamping pins

ISO 8752

- some can be replaced → changed to ISO 8752 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD

DIN 6325

Cylindrical pins

ISO 8734

- some can be replaced → changed to ISO 8734 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD

DIN 7346

Clamping pins Flange

ISO 13337

- some can be replaced → changed to ISO 13337 - parts which cannot be replaced (∅ 7, 11, and 23 mm) documented as DIN 6325 OLD

DIN 7976

Self-tapping screws

ISO 1479

- can be replaced → changed to ISO 1479

DIN 7978

Tapered pins

ISO 8736

- some can be replaced → changed to ISO 8736 - parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD

DIN 7979

Cylindrical pins

ISO 8733 ISO 8735

- some can be replaced → changed to ISO 8733/8735 - parts which cannot be replaced documented as DIN 7979 OLD

DIN 7981

Self-tapping screws

ISO 7049

- can be replaced → changed to ISO 1479

DIN 7982

Self-tapping screws

ISO 7050

- cannot be replaced → documented as DIN 7982 OLD

DIN 7985

Cheese-head screws

ISO 7045

- can be replaced → changed to ISO 7045

1) with reference to productive parts numbered at ZF 2003-08

13

ZF-AS Tronic

Fig. no.

Special Tool

Special tools

Order no.

Application

Qty.

Comment

Sketch 11

64 112

15

74

M10

M10

75 60.5

240

ø9H7

10±0.1

2x45°

2x45° 40

ø9H7 212±0.1

ø9r6

25

14

Setting aid for piston rods on transmission actuator

1

Simplifies assembly

37.5±0.1

1

ø8.7±0.1

20±0.1

017912

NOTE: Please inquire as to packaging unit before ordering.

1327 751 103 - 2005-09

14

1327_91D_001_en

ZF-AS Tronic

Consumables

Designation ZF item number

Designation

Approx Quantity.

Application

Sealing compound 0666 690 022

No. 262

0.5 gram

Ball bolt (06.080)

Uni-Silicon grease

GLK 112

Comments

NOTE: Inquire size of containers before placing any orders!

1327 751 103 - 2005-09

15

1327_92D_001_en

ZF-AS Tronic

ZF Repair Kits for Transmission/Clutch Actuator

Kit no.

Item

Content

Remark

6009.098.001

GS3 upper section, 20-pin Standard

Upper section: 6009 274 080 Sealing kit: 0501 319 863 Sealing kit: 0501 319 864 Seal: 0501 316 322

without breather

6009.098.002

GS3 upper section, 18-pin Special variant

Upper section: 6009 274 081 Sealing kit: 0501 319 863 Sealing kit: 0501 319 864 Seal: 0501 316 322

without breather

6009.298.006

GS3 lower section

Upper section: 6009 274 058 Sealing kit: 0501 319 863 Sealing kit: 0501 319 864 Seal: 0501 316 322

0501.319.863

Sealing kit

1x flat seal, upper/lower section 2x retaining bolts 1x profile sealing ring

0501.319.864

Sealing kit

2x profile sealing rings between upper/lower section

0501.321.146

Joining part / (wiring harness)

Internal wiring harness with input/temperature sensor 2x retaining bolts

0501.321.147

Valve unit

Solenoid valve plate with 10 valves profile seal 3x retaining bolts

0501.320.849

Pressure reduction valve

1x valve 4x retaining nuts 1x O-ring

0501.321.148

Travel sensor

1x sensor 1x O-ring 1x bracket 2x retaining bolts

0501.321.149

Sealing kit for gear shift cylinder

All sealing elements for the GV,GP gear shift cylinders

0501.321.182

Selector cylinder

1x selector cylinder 1x profile seal

fully inspected unit

0501.322.661

Bracket (for sensor)

1x bracket 1x clamp 5x retaining bolts 1x O-ring 1x profile seal

Selector cylinder must be removed Complete piston

fully inspected unit

0501.322.388

Main transmission piston

1x main transmission piston 2x O-rings

0501.316.322

Seal

1x flat seal

0768.340.029

Breather (transmission breather)

1x breather 0501 202 797 Tightening torque: 10 Nm

Pos. 74.120

0768.605.124

Cannon plug (hose breather)

1x M10x1 Cannon plug 0501 315 794 Tightening torque:18 Nm

Pos. 74.130

0501.315.796

Angle piece

1x angle piece 0501 315 796 1x cap nut

Pos. 74.140

0731.208.242

Detent pin

1x dent pin

Pos. 06.040, 34.130, 12.080

0732.042.766

Compression spring

1x compression spring

Pos. 06.050, 34.140, 12.090

6009.274.069

GS3 standard, 20-pin

Upper section: 6009 274 080 Sealing kit: 0501 319 863 Sealing kit: 0501 319 864 Seal: 0501 316 322

Complete new transmission actuator

6009.274.070

GS3 special variant, 18-pin

Upper section: 6009 274 081 Sealing kit: 0501 319 863 Sealing kit: 0501 319 864 Seal: 0501 316 322

Complete new transmission actuator

Clutch actuator 0501.322.365

1327 751 103 - 2005-09

Connection parts for clutch actuator

Non-return valve, compression spring, strainer, screw plug, sealing ring, valve bush

16

Transmission actuator for main transmission

Transmission Actuator Removal

ZF-AS Tronic CAUTION If the transmission actuator or upper section of the transmission actuator is replaced, the following should be noted. • Reprogram the transmission actuator • Transfer vehicle parameters from removed transmission or re-enter.

74.140* 74.130*

74.120* 74.030 74.070

74.090

Removing Transmission Actuator 74.010

!

DANGER Only work on the transmission actuator if the ignition is off.

12.090 12.080 06.050

1

Switch off ignition

06.040 34.140

CAUTION If vehicle-specific parts (e.g. fuel pump, coolant pipe, exhaust pipe, or steering pump) have to be removed, please contact the vehicle manufacturer.

2

34.130

06.080

Disconnect electric plug connection from transmission actuator.

Loctite 262

*depends on the parts list

024 667

!

DANGER Protective glasses must be worn when removing the compressed air line from the transmission actuator. Compressed air will escape! Risk of injury from particles of dirt.

3

Remove compressed air line from transmission actuator’s pressure relief valve.

4

Remove breather (74.120) or angle piece (74.140) and Cannon plug (74.130) from transmission actuator (74.030) if these parts are being replaced.

5

Remove 15 M8 hex bolts (74.090; 74.070) from transmission actuator (74.030).

1327 751 103 - 2005-09

17

1327_74D_003_1_en

Transmission Actuator Removal

ZF-AS Tronic CAUTION The profile seals (/170) and compression springs (06.050; 34.140 and 12.090) may fall into the trans-

mission housing.

/170

a

b

NOTE Both profile seals (/170) are contained in sealing kit 0501 319 864. 6

Take transmission actuator (74.030) off transmission housing and make note of measurements “a” and “b” for later installation.

7

Remove compression springs (06.050; 34.140 and 12.090).

018774

NOTE Cover transmission opening, otherwise dirt may fall into the transmission. 8

Remove seal (74.010) and clean sealing surfaces on transmission housing and transmission actuator.

9

If seal residue or dirt has fallen into the detent pin holes (06.040; 34.130 and 12.080), these must be removed and cleaned.

74.140* 74.130*

74.120* 74.030 74.070

74.090

74.010 10

Remove ball bolt (06.080) if damaged. 12.090 12.080 06.050 06.040 34.140 34.130

06.080

Loctite 262

*depends on the parts list

1327 751 103 - 2005-09

18

024 667

1327_74D_003_2_en

Transmission Actuator Fitting

ZF-AS Tronic Fitting Transmission Actuator If the ball bolt is being replaced, coat the thread of ball bolt (06.080) with Loctite no. 262. Tighten ball bolt to 23 Nm.

/170

a

NOTE If using costly peripheral attachments, such as flatbeds, crossbars etc. we would advise checking the transmission with the ZF-Testman pro test software once removed from the vehicle. After checking with ZFTestman pro, load the volume production program depending on parts list and engine (can be downloaded via ZF-ServiceLine).

b

1

018774

2

Move piston rod (4) on transmission actuator into central position (Neutral). The correct position is reached when slight resistance can be felt when pulling out the piston rod (4).

3

Transfer measurements “a” and “b” from the removed transmission actuator to the piston rods (3 and 5).

4

Selector gate (6) and piston rod (4) must be one above the other (flush). Ensure that the profile seals (/170) on the transmission actuator are inserted.

Legend Piston rod (3) Piston rod (4) Piston rod (5) Selector gate (6)

5

3

4

/170

= shifts the splitter group (GV) = shifts the basic transmission = shifts the range change group (GP) = selects the shift gate

6 017908

34.010

06.080

06.010

12.010

NOTE With the 12-speed version, do not slide the central shift rail (06.010) too far into the transmission, otherwise the gearshift finger may fall into the transmission. Legend 12.010 06.010 34.010 06.080

Shift rail (GV) Shift rail for basic transmission Shift rail (GP) Ball bolt

015019

1327 751 103 - 2005-09

19

1327_74D_004_1_en

Transmission Actuator Fitting

ZF-AS Tronic Alternative: If measurements “a” and “b” can no longer be established, the transmission actuator can be fitted using setting aid (34) 1X56 138 244. In-house production following sketch, see special tools.On request, tool 1X56 138 244 can also be supplied by ZF. Adjust the transmission actuator’s piston rods (3, 4, and 5) so that they are in contact with the setting aid (34). Move the GV and GP gear shift rails in the transmission towards the output. Move the central gear shift rail into Neutral. Selector gate (6) and piston rod (4) must be one above the other (flush). Ensure that the profile seals on the transmission actuator are inserted.

34

017907

5

6

Place new seal (74.010) on transmission housing.

74.140* 74.130*

Insert detent pins (06.040; 34.130 and 12.080) – if not yet fitted – and compression springs (06.050; 34.140 and 12.090).

74.120* 74.030 74.070

74.090

NOTE The compression springs (06.050; 34.140 and 12.090) must be of the same length (around 50 mm). If deviances are found, replace compression springs. 74.010 7

Attach transmission actuator (74.030) ensuring that piston rods of transmission actuator reach into gear shift rails of transmission. The upright ball bolt (06.080) reaches into the selector gate.

12.090 12.080 06.050 06.040 34.140

CAUTION You must be able to push the transmission actuator by hand until it reaches the transmission’s thrust surface. Forcefully pulling down with screws will inevitably result in damage. 8

9

34.130

06.080

Evenly tighten M8 hex bolts (74.090 and 74.070) to 23 Nm.

Loctite 262

Depending on parts list: Tighten Cannon plug (74.130) to 18 Nm and secure angled piece (74.140) and/or tighten breather (74.120) to 10 Nm.

1327 751 003 - 2004-06

*depends on the parts list

20

024 667

1327_74D_004_2_en

Transmission Actuator Fitting

ZF-AS Tronic 10

Connect air line to transmission actuator’s pressure relief valve. Tightening torque MA = 34 Nm.

11

Re-connect up wiring harness at transmission and vehicle ends otherwise functions cannot be tested. NOTE Ensure that the connectors are snapped into place and fitted without traction relief.

Final check:

018 403

Has the transmission actuator been reprogrammed? Refit vehicle-specific parts as far as possible. The diagnosis unit can only be used to test the transmission actuator once the engine is running and there is a sufficient reserve of air. The system then undertakes a number of calibration processes. This may take up to 5 minutes. The following errors may then be displayed: Piston rod not attached with errors 132, 134, etc. or teaching-in error for gear, gate, GP, GV sensors with ignition on.

1327 751 103 - 2005-09

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Transmission Actuator Removing and Fitting Upper Section

ZF-AS Tronic Removing Upper Section

6009 274 069 NOTE Seal kit 0501 319 863 contains both screws (/150-1) flat seal (/150-2) and profile seal (/150-3).

09 03 43872 4213 550 110 024 361

Caution Record the data on the type plate. This is needed for ordering spare parts and for correspondence. 1

1

/150-1

Remove both screws (/150-1). /110

2

Raise upper section (/110) on pressure relief valve (/180) and use both tabs (1) to carefully move sideways into the grooves* (2). Disconnect plug connections (7 and 8).

3

Remove profile seal (/150-3 )

4

Remove flat seal (/150-2) and sealing faces.

74.030

/180

/150-2 2

* not possible with the 18-pin variant

/150-3 /130

Fitting Upper Section 1

Insert profile seal (/150-3).

2

Place flat seal (/150-2) on upper section (/130). 024 532

3

Re-connect plug connections (7 and 8). Check that the plug connections are tight and secure.

4

Place upper section(/110) on lower section (/130). Ensure that the flat seal (/150-2) does not slip, fix if necessary. Tighten the two screws (/150-1) to 9.5 Nm.

8 7

018205

1327 751 103 - 2005-09

22

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Transmission actuator Travel sensors

ZF-AS Tronic Replacing Travel Sensors (HG, GV, GP, and Gate) NOTE The repair kit 0501 321 148 contains two screws (22), one retaining plate (23), one travel sensor (24), and one O-ring (25). 24 23

Removal 1

22

Clean area around sensors. 25

2

Carefully raise tab and pull connector (21) off sensor contact.

3

Remove two screws (22), take off retaining plate (23), pull out travel sensor (24) complete with O-ring (25).

4

Inspect parts and replace if necessary.

021 803

NOTE The sensors for GP, GV main transmission, and gate cylinder are identical.

Installation NOTE Apply Uni-Silicon GLK112 grease to sealing and sliding faces.

21

24 021 794

1

Insert O-ring (25) on travel sensor (24).

2

Insert travel sensor (24) complete with Oring (25), secure retaining plate (23) with two screws (22). Tightening torque MA = 7 Nm.

3

Plug connector (21) to sensor contacts (24).

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Transmission actuator Solenoid valve plate

ZF-AS Tronic Replacing Solenoid Valve Unit

19 NOTE The repair kit 0501 321 147 contains three Torx screws (19), one solenoid valve unit (18), and one profile seal (20). The solenoid valve unit (18) contains 10 solenoid valves as a fully checked unit. 18 Removal 1

Remove three Torx screws (19).

2

Remove solenoid valve unit (18).

3

Remove profile seal (20).

20

Installation 1

Apply Uni-Silicon GLK112 grease to sealing and sliding faces.

2

Place profile seal (20) on transmission actuator’s lower section.

3

021 804

Place solenoid valve unit (18) and secure three Torx screws (19) to 18 Nm.

021 785

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Transmission Actuator Replacing Selector Cylinder

ZF-AS Tronic Replacing Cpl. Selector Cylinder NOTE Repair kit 0501 321 182 contains the selector cylinder (28) and a profile seal (29).

26

/130 Removal 1

Carefully raise tab and pull connector (26) off sensor contact.

2

Remove three hex-head bolts (27).

3

Take out selector cylinder (28) and remove profile seal (29).

4

27

021 786

Inspect parts and replace if necessary.

Installation NOTE Apply Uni-Silicon GLK112 grease to sealing and sliding faces.

29

1

Insert profile seal (29) on transmission actuator’s lower section (/130).

28

2

Place cpl. selector cylinder (28) on transmission actuator’s lower section (/130) and tighten the three hex-head bolts (27) to 23 Nm.

3

26 021 787

Plug connector (26) onto sensor contacts.

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1327_74D_080_en

ZF-AS Tronic

Transmission Actuator Bracket for Temperature and Speed Sensor

Bracket for Temperature and Speed Sensor 27

NOTE The repair kit 0501 322 661 contains three hexhead bolts (27), one profile seal (29), two Torx screws (47), one Torx screw (48), retaining plate (52), O-ring (49), and the cylinder cover (58).

47 52 48

29 58

49

If the temperature and speed sensor is removed, seal kit 0501 319 863 will also be needed.

Removal 024 559

1

Remove upper section. (See page 22)

2

Carefully raise tab and pull connector (26) off sensor contact.

3

Remove three hex-head bolts (27).

4

26

/130 27

Take out selector cylinder (28) and remove profile seal (29).

021 786

5

Remove Torx screw (48).

48

021 790

1327 751 103 - 2005-09

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1327_74D_150_1_en

ZF-AS Tronic

Transmission Actuator Bracket for Temperature and Speed Sensor

6

Take off input speed sensor (50) with spacer plate and temperature sensor (51).

7

Remove Torx screws (47).

8

Use a suitable tool to raise and remove the cylinder cover/bracket (58).

51

Replace O-ring (49).

49

9

50

58

47 021 791

1327 751 103 - 2005-09

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1327_74D_150_2_en

ZF-AS Tronic

Transmission Actuator Bracket for Temperature and Speed Sensor

Fitting Bracket for Temperature and Speed Sensor Insert new O-ring on cylinder cover (58) and on travel sensor (51).

50

NOTE Apply Uni-Silicon GLK112 grease to sealing and sliding faces.

51

2

Insert cylinder cover (58) in housing’s lower section.

58

3

Insert input speed sensor (50) with spacer plate and temperature sensor (51) with the O-ring (49) in the cylinder cover’s bracket (58).

47

1

4

Tighten Torx screw (48) with 6 Nm.

5

Tighten Torx screws (47) with 18 Nm.

49

024 791

48

021 790

6

Insert profile seal (29) on transmission actuator’s lower section (/130).

7

Place selector cylinder (28) on transmission actuator’s lower section. 29

28

26 021 787

1327 751 103 - 2005-09

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1327_74D_150_3_en

4ZF-AS Tronic 8

Transmission Actuator Bracket for Temperature and Speed Sensor

Use three hex bolts (27) to secure selector cylinder to transmission actuator’s lower section (/130). Tighten the hex bolts (27) to 23 Nm.

9

Plug connector (26) onto sensor contacts.

10

Fit upper section. (See page 22)

26

/130 27

021 786

1327 751 103 - 2005-09

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1327_74D_150_4_en

Transmission Actuator Wiring Harness

ZF-AS Tronic Removing Wiring Harness (Input Speed Sensor and Temperature Sensor)

34

The repair kit 0501 321 146 contains the wiring harness (temperature and speed sensor) and two self-tapping screws with washers. 1

Remove upper section. (See page 22) 26

2

Carefully raise tab and pull connector (26) off sensor contact (34). 47 021 789

3

Remove the Torx screws (47 and 48).

48

47

52

NOTE Screw head (47) T40 Screw head (48) T25

021 792

4

5

Take off input speed sensor (50) with spacer plate and take temperature sensor (51) out of bracket of cylinder cover (58).

50

Take wiring harness out of retaining plate (52). 51

58

024 738

1327 751 103 - 2005-09

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1327_74D_100_1_en

Transmission Actuator Wiring Harness

ZF-AS Tronic 6

Bore out the rivet heads (drill diameter approx. 5 mm). Take wiring harness off transmission actuator’s lower section.

024 534

7

Use a pair of flat pliers to turn out the rivet shaft.

8

Remove rivet residue and drilling chips.

024 668

1327 751 103 - 2005-09

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1327_74D_100_2_en

Transmission Actuator Wiring Harness

ZF-AS Tronic Fitting Wiring Harness (Input Speed Sensor and Temperature Sensor) (repair kit 0501 321 146) 1

Secure wiring harness (64) to transmission actuator’s lower section using two self-tapping threaded screws (65). Tightening torque MA = 2.2 Nm.

64

65

024 560

2

Guide spacer plate on temperature sensor (50) into groove on speed sensor (51).

3

Insert these parts all together with the O-ring (49) in the cylinder cover bracket (58).

50

51 49 58

47 021 791

4

Tighten screw (48) with 6 Nm.

5

Insert wiring harness in retaining plate (52) and tighten screw (47) with 18 Nm.

48

47

52

021 792

1327 751 103 - 2005-09

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1327_74D_101_1_en

Transmission Actuator Wiring Harness

ZF-AS Tronic 6

Route wiring harness behind rib (53) without any bends, chafing, or squashed areas.

53

021 793

7

Plug connector (26) to sensor contacts (34).

8

Fit upper section. (See page 22)

34

26

021 789

9

Plug connector (21) to sensor contacts (24).

21

24

021 794

1327 751 103 - 2005-09

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1327_74D_101_2_en

Transmission Actuator Pressure Relief Valve

ZF-AS Tronic Replacing Pressure Relief Valve

10 NOTE - Repair kit 0501 320 849 contains 4 nuts (10), one O-ring (12) , and the pressure relief valve (/180). - Before removing, mark the installation position of the pressure relief valve (/180) for fitting later on. 1

Remove 4 nuts (10) and take off pressure relief valve (/180) and O-ring (12).

CAUTION Do not use grease to fit O-ring (12). 2

Insert new O-ring (12), fit pressure relief valve (/180) on transmission actuator (74.030) as marked during removal. Tighten the 4 nuts (10) with 7 Nm.

019251

74.030

/180 12

019252

1327 751 103 - 2005-09

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1327_74D_011_en

Transmission Actuator Lower Section

ZF-AS Tronic Dismantling Lower Section of Transmission Actuator

54

NOTE - The main transmission piston (62) is exchanged as a complete unit. Repair kit 0501 322 388. - Seal kit for GP/GV gear shift cylinders 0501 321 149.

1

Remove selector cylinder. (See page 25)

2

Remove the three travel sensors (24). (See page 23)

24

24

021 795

CAUTION The cylinder covers are numbered. They have to be refitted in the same positions. 3

Remove the T40 Torx screws (54) from the cylinder covers (55 to 58).

4

Use a suitable tool to raise the cylinder covers (55, 56 , and 57) slightly and take off.

55 56

57

021 796

5

Use a suitable tool to raise cylinder cover (58) slightly and take off.

6

Take out pistons (59, 60, and 62) and bush (61).

7

Replace the O-rings and grooved rings on components (58 to 62)

59

61 60

62

58

021 797

1327 751 103 - 2005-09

35

1327_74D_130_1_en

Transmission Actuator Lower Section

ZF-AS Tronic 8

Use a suitable tool to remove seal rings (63) and low-friction bearing bushes (70).

58 70

63

021 798

1327 751 103 - 2005-09

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1327_74D_130_2_en

Transmission Actuator Lower Section

ZF-AS Tronic Assembling Lower Section of Transmission Actuator 1

Use a suitable tool to insert the low-friction bearing bushes (70) flush with the bearing bore.

2

Use a suitable tool to insert the new sealing rings (63).

58 70

NOTE Apply Uni-Silicon GLK112 grease to sealing and sliding faces.

63

021 798

3

Insert new O-rings and grooved rings on components (58 to 62).

4

Insert pistons (59, 60, and 62) and bush (61) in transmission actuator’s lower section.

59

61 60

62

58

021 797

5

Fit cylinder covers (58, 57, 56, and 55) in the same position from which you previously removed them and secure each one with two T40 Torx screws (54). Tightening torque MA = 18 Nm.

55 56

57

021 796

1327 751 103 - 2005-09

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1327_74D_140_1_en

Transmission Actuator Lower Section

ZF-AS Tronic Assembly check

24 The cylinder covers are numbered (see arrow). For installation position, see Fig. 6

Fit sensors (24). (See page 23)

11

3

2

1

021 799

7

Fit selector cylinder (28). (See page 25)

8

Check again that connectors are tight and secure.

28

021 800

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1327_74D_140_2_en

Transmission Actuator Programming

ZF-AS Tronic Programming Transmission Actuator When replacing the transmission actuator and/or upper section, customer-specific programming and/or parameter setting (entering EOL data) will be required.

23 20.1

During parameter setting, the EOL data are entered in the transmission actuator’s electronics using Testman pro and the corresponding software.

22

20

Diagram of transmission actuator programming Pos. 20 Table mode adapter 20.1 Power supply connection 21 Cable to the DPA 22 DPA 23 Cable to laptop and/or PC

21

019643

CAUTION When programming a new transmission actuator, transfer the vehicle parameters from the transmission actuator removed or re-enter them.

NOTE If using costly peripheral attachments, such as flatbeds, crossbars etc. we would advise checking the transmission with ZF-Testman pro test software once removed from the vehicle. After checking with ZF-Testman pro, load the volume production program (can be downloaded via ZF-ServiceLine).

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1327_74D_012_1_en

Transmission Actuator Programming

ZF-AS Tronic Programming Flash EPROMS with ZF Test Program

Description of Test - Air supply of at least 7 bar, connect to pressure reduction valve on transmission actuator

Tools required: - Laptop with current Testman pro software - Test software: GS_test_07_2005_gb.exe (download from ServiceLine) - Testman pro application: Mont_as2.app (download from ServiceLine) - Table mode adapter cable: ZF no. 6008 207 003 DPA05 Interface adapter: ZF no. 6008 208 017 USB connection cable: ZF no. 6008 207 026 Diagnosis interface cable: ZF no. 6008 207 024 24 V voltage supply

- Connect table mode cable to transmission actuator (at vehicle end) and link to laptop using connection cable, DPA05, 24 V voltage supply - Start Testman pro Select main menu/AS Tronic/assembly check AS2. NOTE This test must not be used in the vehicle when the engine is running!!

Procedure: - Download the installation routine GS_test_07_2005.zip from download ServiceLine, save and unzip using the password: astronic

- Select test rig function start. - Use the numerical key functions 1 - 0 on the laptop keypad or mouse to shift through the ranges: 1 = Upshifting gears 1 - 16 2 = Downshifting Gears 16 - 1 3 = Neutral 4 = 1st R gear 5 = 2nd R gear

- Start installation routine: Double click on the file: GS_test_07_2005.exe - Download the application Mont_as2.app from download ServiceLine, save and unzip using the password: testman

- The current sensor positions can be seen under menu item 6, dynamic transmission actuator.

- Extract the file Mont_as2.app using the following path: C:\Gds3000\apps

- Menu item 9 shows the gear currently selected.

- Start Testman pro if necessary, note the customer-specific data in transmission actuator (e.g. iHa; Intarder etc.) and then program the test program. Load Testman pro/ Flash programming / parts list. Open the file GS_test_07_2005.txt and program (processors 1, 2 and E2 data are programmed and the drive program originally programmed is deleted).

NOTE The test software selects gears 1 - 16 and 2 R gears. With the 10 and 12-speed transmission, the transmission actuator is fitted on the transmission. Only shift to the highest gear available!

Outgoing Check - After the function/seal integrity test, the correct software must be programmed depending on vehicle application, engine/transmission/software assignment. (Source: ServiceLine)

1327 751 003 - 2004-02

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ZF-AS Tronic

Clutch Actuator

1

2

024 537

Clutch Actuator (repair kit 0501 322 365)

!

DANGER Only work on the clutch actuator if the ignition is off.

The repair kit consists of a screw plug (1) with sealing ring and a valve screw (2) with O-ring. Tightening torque (MA): Screw plug (1) Valve screw (2)

1327 751 003 - 2004-02

MA = 22 Nm MA = 70 Nm

41

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