Manual Reparacion 6 WG 210

REPAIR MANUAL
ZF - ERGOPOWER
6 WG - 210
5871.159.002 en
REPAIR MANUAL
ZF – ERGOPOWER
6 WG-210
Information:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to
a current ZF production unit.
This documentation has been developed for specialized staff trained by ZF for repair work to be
done on ZF units.
Continuous technical upgrading of ZF units and extensions concerning design options may require
both deviating work steps and differing setting and testing data.
This disassembly and reassembly manual is based on the design level of a ZF production unit at
the time of issue of the manual.
ZF Friedrichshafen AG reserves the right to replace this disassembly and reassembly

manual by a successive edition at any time without advance notice. Upon request, ZF
Friedrichshafen AG will advise which edition is the latest one.
The list of lubricants is being continuously updated and can be obtained or viewed as follows:
- At all ZF plants
- At all ZF service organizations
- Internet http://www.zf.com/
----------------------------------------------------------------------------------------------------------------------------------
For information concerning description, installation instructions, operation and
maintenance, see respective Operating Instructions, ZF-Ordering-No. 5872 196 002.
ATTENTION:
Observe the vehicle manufacturer’s instructions and specifications for the installation and
commissioning of the unit!
ZF Friedrichshafen AG
ZF Services
Donaustr. 71
D - 94034 Passau
Section : MAIP21
Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction
or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Subject to technical modifications!
Design level 2000/05
Off-Road Transmissions
Repair Manual and Axle Systems
Division
PREFACE
This documentation has been developed for skilled staff trained by the ZF )ULHGULFKVKDIHQ$* for the
repairandmaintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.
ZF )ULHGULFKVKDIHQ$*
0.1
Division
GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
0.2
Division
Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc..
CAUTION Is used, if a deviating and improper working procedure can

damage the product.
Is used, if lacking care can lead to personal injury or danger to

DANGER life.
___________________________________________________
REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description..
REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again. .
0.3
Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

Unit New old Conversion Note
Unité Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Masse
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
0.4
Division
VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25,40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2,205 lb ( pounds )
9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)
1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5,560 lb / in ( pound per inch )
1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )
0,070 bar ( 0,071 kp/cm2 ) =

1 psi ( lbf/in2 )
1 Liter =
0,264 Gallon ( Imp. )
4,456 Liter =
1 Gallon ( Imp. )
1 Liter =
0,220 Gallon ( US )
=
3,785 Liter 1 Gallon ( US )
1609,344 m =
1 Mile ( Landmeile )
0° C ( Celsius ) = + 32° F ( Fahrenheit )
0 ° C ( Celsius ) =
273,15 Kelvin
0.5
Division
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148

Friction value: µ total= 0,12 for screws and nuts without after-treatment as well as phosphatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following List:
Metric ISO-Standard thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine thread DIN 13, page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 120 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300
0.6
Division
LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
1. GEARSHIFT SYSTEM
DISASSEMBL. REASSEMB. DESIGNATION/APPLICATION OF SPECIAL TOOLS (S) PART NO.
Fig. 1 Strap wrench 5870 105 005

For disassembly of filter
Fig. 5 Fig. 26 Socket spanner # TX-27 5873 042 002

Fig. 10 Fig. 27 For removal and installation of cap screws
Fig. 12 Fig. 30 0736 101 094 / 257 / 259 / 261 / 262 on gearshift housing.
Fig. 14 Fig. 32
Fig. 15 Fig. 38
Fig. 47
Fig. 6 Fig. 43 Socket spanner # TX-40 5873 042 004

For removal and installation of cap screws
0736 101 264 / 312 on gearshift housing and
Fig. 2 Fig. 54 cap screws 0736 101 335 on filter head.
Fig. 15 Fig. 23 Adjusting screws M5 5870 204 036

Fig. 16 Fig. 24 Universal use
Fig. 29 As disassembly and reassembly aid for installation and
removal of housing on valve block.
Fig. 34 Adjusting screws M6 5870 204 063

Universal use
As disassembly and reassembly aid for installation and
removal of gaskets and intermediate sheets on valve block.
W.1
Division
2. POWERSHIFT TRANSMISSION
4657 056 015/022/023/025
DISASSEMBL. REASSEMB. DESIGNATION/APPLICATION OF SPECIAL TOOLS (S) PART NO.
Fig. 1 Assembly truck assy # with tilting device 5870 350 000
Bars # 5870 350 063
Holding fixture # 5870 350 090
For fastening and swiveling of transmission assy on the
assembly truck.
Fig. 4 Two-armed puller 5870 970 003

To pull off the input flange
Fig. 6 Eye bolt assortment 5870 204 002

Universal use.
Dis- and reassembly aid for removal and installation of
transmission parts.
Fig. 40 Fig. 169 Eye bolt 2 pcs. M20 0636 804 003
Fig. 55 Fig. 170 Eye nut M12 0664 462 774
Fig. 189 To take off and lifting of housing cover.
Fig. 6 Fig. 170 Lifting chain 3-strand 5870 281 047

Fig. 40 Fig. 189 Universal use.
Fig. 55 Dis- and reassembly aid for removal and installation of
transmission parts.
Fig. 10 Fig. 109 Set of internal pliers # 5870 900 013

Fig. 33 Fig. 197 Universal use.
Fig. 75 Fig. 290 To snap-in and unsnap internally clamped retaining
rings in the bore holes.
Fig. 13 Socket spanner # TX-40 5873 042 004

Fig. 20 For removal and installation of cap screws
0736 101 264 / 312 / 334 / 335 on transmission housing.
Fig. 14 Hammer ∅60 5870 280 004

Fig. 25 Universal use
For removal and installation of transmission parts.
W.2
Division
4657 056 015/022/023/025
Fig. 21 Fig. 166 Pry bar set 5870 345 036

Fig. 63 To press off flanges, clutches, emergency steering pump
and housing parts.
Fig. 22 Fig. 113 Set of external pliers # 5870 900 015

Fig. 34 Fig. 143 Universal use
Fig. 68 Fig. 150 To snap-in and unsnap externally clamped retaining
Fig. 86 Fig. 154 ring in the bore holes.
Fig. 194
Fig. 24 Fig. 223 Clamping pliers 5870 900 021

Fig. 256 To snap-in and unsnap internally clamped retaining
ring in the bore holes.
Fig. 35 Parting tool # 5870 300 028

To separate inner ring,
ball bearing 0635 304 907 from pump shaft.
Fig. 42 Gripping insert # 5873 002 038

Fig. 77 To take off bearing inner ring 0735 371 733 from output
shaft and the K1/K3 shaft.
Combined with
Basic device # 5873 002 001
Pressure piece allows removal with stud installed in 5870 100 043
K3 shaft.

To take off bearing inner ring 0750 117 731 from output
gear and differential cover.
Combined with
Fig. 54 Fig. 168 Handle # 6x 5870 260 010

Fig. 57 Fig. 170 To fix clutches on housing cover.
W.3
Division
4657 056 015/022/023/025
Fig. 56 Holding fixture # 5870 350 089

To fix housing cover on
Assembly truck # 5870 350 000

Fig. 85 To take off bearing inner ring 0735 371 723 from
KV/KR shafts.
Combined with
Pressure piece 5870 100 043
Allows removal with stud installed.

Fig. 77 To take off bearing inner ring 0735 371 732 from
Fig. 85 KR/K1/K2/K3 shafts.$$
Combined with
Pressure piece 5870 100 043
Allows removal with stud installed.
Fig. 69 Three-armed puller # 5870 971 003

Fig. 87 To remove disc carrier from the shaft.
Fig. 71 Fig. 102 Assembly aid # 5870 345 088

Fig. 83 Fig. 119 To preload compression spring in the clutches.
Fig. 89 Fig. 137
Fig. 74 Puller # 5870 023 040

To take off idler 4657 375 003 from
Shaft KV = 4657 375 001 or
Shaft KR = 4657 376 001.
Fig. 81 Puller 5870 970 004

Remove disc carrier assy from clutch shaft.
W.4
Division
4657 056 015/022/023/025
Fig. 92 Rapid grip # 5873 011 014

To remove bearing inner rings 0735 371 722
from input shaft.
Combined with
Bush # 5873 001 006
Fig. 95 Rooling tool for suction tube 0501 210 903 5870 600 003
Rooling tool for oil pipes 0501 211 183 / 184 5870 600 004
Rooling tool for oil pipes 0501 316 056 5870 600 005
To roll pipes into transmission housing – front section
4657 301 039. Always use
Lubricant WSR-JO! 5870 451 006
Fig. 105 Magnetic stand Combined with 5870 200 055

Fig. 122 Dial indicator 5870 200 057
Fig. 140 To check disc clearance .
Fig. 111 Hot-air blower # or 220 V 5870 221 500

Fig. 125 Hot-air blower # 110 V 5780 221 501
Fig. 149 Universally applicable
To heat transmission parts.
Fig. 191 Driver # 5870 345 089

To rotate clutch shafts.
Combined with
Crank handle 5870 280 007
Fig. 207 Driver # 5870 048 237

Fig. 225 To install shaft seals 0750 111 116 into
Fig. 240 the output.
Fig. 261
Fig. 208 Pressure bush # 5870 506 142

Fig. 226 To press screen sheets onto output flanges in alignment.
Fig. 241
Fig. 268
Fig. 211 Driver # 5870 057 009

Fig. 228 To press on tab washer 1269 302 164.
Fig. 244 Combined with
Handle # 5870 260 002
W.5
Division
4657 056 015/022/023/025
Fig. 214 Adjusting screw 5870 204 011

Fig. 272 To adjust transmission parts.
Fig. 230 Multimeter 5870 221 158

To measure current intensity, voltage, resistance and
frequency.
Fig. 232 Centering bush # HK 2220 5870 506 099

Combined with
Driver # 5870 048 132
To press needle bearing 0635 303 059 into output shaft!
Fig. 236 Driver # HK 2020 5870 058 023

To press needle bearing 0635 303 050 into output shaft!
Combined with
Handle # 5870 260 002
Fig. 274 Adjusting screw M10 5870 204 007

Universally applicable
To adjust transmission parts.
Fig. 293 Driver # 5870 057 010

To press tab washer 4644 330 006
onto input flange.
Combined with
Handle # 5870 260 002
Fig. 297 Driver 5870 048 080

To press in plain bearing 0730 260 704 into cover
4656 337 001 on emergency steering pump.
# = particularly important!
W.6
Division
1. ELECTRO-HYDRAULIC CONTROL
WITH PROPORTIONAL VALVES
1.1 DISASSEMBLY
Separate filter from filter head.
(S) Strap wrench 5870 105 005
Figure 1
Loosen cap screws and separate filter head from duct plate.
(S) Socket spanner 5873 042 004
Figure 2
Remove differential pressure switch (warning switch – fouling).
Figure 3
Remove piston and compression spring (by-pass valve).
Figure 4
1.1
Division
Remove hose pipes.
Loosen cap screws and separate gearshift housing from duct

plate.
(S) Socket spanner TX-27 5873 042 002
Figure 5
Loosen cap screws and separate duct plate from transmission

housing.
Figure 6
Pull converter safety valve out of the housing bore.
Figure 7
Loosen hexagon nuts and remove converter clutch valve.
Figure 8
1.2
Division
Mark installation position of wiring harness to the valve block.
Figure 9
Loosen cap screws.
Separate duct plate, gaskets and intermediate sheet from valve

block.
Figure 10
Remove retaining clamp.
Figure 11
Loosen cap screws and remove cover.

Remove opposite cover.
(S) Socket spanner Tx-27 5873 042 002
Figure 12
1.3
Division
Remove pressure regulators and wiring harness.
Figure 13
Loosen cap screws, remove fixing plate and pressure regulators.
Figure 14
Loosen two cap screws and provisionally fix the housing by

means of adjusting screws (housing is spring-loaded). Then
loosen the remaining cap screws.
(S) Adjusting screws 5870 204 036

Figure 15
Separate housing from the valve housing equally loosening the

adjusting screws.
Figure 16
1.4
Division
Remove single parts.
Figure 17
Remove opposed pressure regulators, housing as well as single

parts analogously.
Figure 18
1.5
Division
1.2 ASSEMBLY
1.2.1 Hydraulic Control Unit (HSG-94)
Below sketches show the sectional views of the HSG-94
As to the wiring harness position different versions are possible!

Pay attention to information of vehicle manufacturer!
1.6
Division

Check all single parts for damage and replace, if required!
Prior to installation check clearance of movable parts in the
housing! Piston can be replaced individually!
Prior to installation single parts have to be lubricated to ZF
List of Lubricants TE-ML 03!
Install orifices with concave side showing upwards until contact!
Installation position, see arrows!
Figure 20

Opposite figure shows the following single parts:
1 = Vibration damper (3x, piston and compr. spring)

2 = Follow-on slide (3x, piston and compr. spring)
3 = Pressure reduction (1x, piston and compression spring)
valve
3 1 1
2 2
Figure 21
Install single parts acc. to Figure 21.
Preload compression springs of follow-on slide and provi-

sionally fix pistons by means of cylindrical pins ∅ 5,0 mm
(assembly aid), see arrows/Figure 22!
Figure 22
Install two adjusting screws.
Assemble gasket (arrow) and housing cover (Figure 23).

Then install housing cover by means of adjusting screws equally
until contact (Figure 24).
Figure 23
1.7
Division
Figure 24
Preload pistons and remove cylindrical pins (assembly aid).
Figure 25
Fix housing cover with cap screws.
Tightening torque ................... MA = 5,5 Nm
Figure 26
Assemble pressure regulators and fix them by means of fixing

plates and cap screws.
Install fixing plate with claw showing downwards!

Observe radial location of pressure regulators, see figure!
Tightening torque ...................... MA = 5,5 Nm
Figure 27
1.8
Division
Preassemble opposed side
Opposite figure shows the following single parts:
1 = Main pressure valve (1x, piston and compression spring)

2 = Follow-on slide (3x, piston and compression spring)
3 = Vibration damper (3x, piston and compression spring)
3 3 1
2 2
Figure 28
Install single parts acc. to Figure 28.
1 Preload compression springs of follow-on slide and provisionally

fix pistons by means of cylindrical pins ∅ 5 mm (assembly aid),
see arrows!
Install two adjusting screws.
Assemble gasket (Arrow 1) and housing cover until contact by

means of adjusting screws.
Figure 29 Then fix housing cover with cap screws.
Tightening torque ........................ MA = 5,5 Nm
Remove cylindrical pins (assembly aid).
Assemble pressure regulators and fasten the same by means of

fixing plates and cap screws.
Install fixing plate with claw showing downwards!

Observe radial location of pressure regulators, see figure!
Tightening torque ......................... MA = 5,5 Nm
Figure 30
1.9
Division
Assemble wiring harness and connect pressure regulators (6x).
Observe installation position of wiring harness, also see

markings (Figure 9)!
Figure 31
Put on gasket (arrow).
Install connector until contact, slot is showing to guide pin of the

cover.
Fix cover with cap screws.
Tightening torque ....................... MA = 5,5 Nm
Figure 32
Fix socket by means of retaining clamp.
Install opposed cover.
Figure 33
1.10
Division
Install two adjusting screws and put on gasket (arrow).
Pay attention to different gaskets, see Figure 34 and 37!
Figure 34
Intermediate sheet – version with screens
Insert screens (6x) aligning into bore holes of the intermediate

sheet, see arrows!
Observe installation position – screens are showing upwards

(to duct plate)!
Figure 35
Put on intermediate sheet (arrow) with the screens showing up-

wards.
Figure 36
Put on gasket (arrow).
Figure 37
1.11
Division
Put on duct plate (arrow) and fix it equally by means of cap

screws.
Tightening torque ........................... MA = 11 Nm
Figure 38
Provide screw plugs (8x) with new O-rings and install the same.
Tightening torque ............................. MA = 6 Nm
Figure 39
1.2.2 Duct plate
Install single parts.
1 = Compression spring
2 = Piston
3 = Differential pressure switch (warning switch – fouling)
2
1
Grease O-ring (arrow)!
Tightening torque ...................... MA = 30 Nm

3
Figure 40
Install converter safety valve (assy) into housing bore until

contact.
Figure 41
1.12
Division
Install (arrow) gasket.
Use assembly grease!
Figure 42
Fix duct plate equally by means of cap screws.
Tightening torque (M8) ........................ MA = 23 Nm
Figure 43
Install two adjusting screws and assemble gasket (arrow).
Pay attention to different gaskets (Figure 44 and 46)!
(S) Adjusting screw 5870 204 063
Figure 44
Install intermediate sheet (arrow).
Figure 45
1.13
Division
Install gasket (arrow).
Figure 46
Fix hydraulic control unit by means of cap screws.
Tightening torque (M6) .................... MA = 11 Nm
(S) Socket spanner Tx-27 5873 042 002
Figure 47
1.2.3 Converter clutch valve
Insert set screw (arrow) with Loctite (Type No. 649).
Tightening torque (set screw M8) ......... MA = 18 Nm
Figure 48 Install converter clutch valve according to opposite figure.
1 = Solenoid valve
2 = Cap screw + Spring washer (2x)
3 = Gearshift housing
7 5 3 1 4 = Piston
5 = Shim rings (empirical value,
3 pcs. of 0,5 mm thickness each)
7 = Stop
2 8 = Screw-in sleeve (install new O-ring)
8 6 4
Tightening torque ......... MA = 46 Nm
Converter clutch pressure 15 + 1 bar is determined by shim
rings 5! Install stop 7 with shouldered plane face showing to
the compression spring!
Figure 49 Tightening torque ...................... MA = 5,5 Nm
Cap screws (M5/8.8)
1.14
Division
Put on gasket (arrow) and fix gearshift housing by means of cap

screws (install washers).
Tightening torque (M6/8.8) .............. MA = 9,5 Nm
Figure 50
Fix bracket to the housing.
Tightening torque (M10/8.8) ............... MA = 46 Nm
Fix converter clutch valve to the bracket (Figure 51).
Tightening torque (M8/8.8) ................. MA = 23 Nm
Figure 51
Install hose pipes (arrows).
Install new sealing rings!
Tightening torque (Union screw 12) ..............MA = 45 Nm

Tightening torque (Union screw 8) ..............MA = 35 Nm
Tightening torque (Hose pipes) ..................... MA = 35 Nm
Figure 52
1.2.4 ZF-Microfilter (Pressure filter)
Place O-rings (arrows) into annular grooves of the filter head.
Figure 53
1.15
Division
Fix filter head to duct plate.
Tightening torque (M8) ................. MA = 23 Nm
Figure 54
Lubricate gasket of ZF-Microfilter (pressure filter)!

Screw in filter until contact with the seal face and
then tighten it by hand!
Figure 55
1.16
Division
Fasten transmission on assembly truck.
(S) Assembly truck 5870 350 000

(S) Bars 5870 350 063
(S) Holding fixture 5870 350 090
Figure 1
2.1 DISASSEMBLY
Drain oil prior to start disassembly!
Remove hose pipes, filter unit, hydraulic control unit, duct plate
and converter clutch valve, also see Chapter 1.
(Page 1.1 and 1.2).
Loosen hexagon nuts and separate power take-off housing from

the transmission (Fig. 2).
Figure 2
2.1.1 Engine Connection – Converter
Remove tab washer and loosen hexagon screws.
Figure 3
Pull off input flange.
(S) Two-armed puller 5870 970 003
Figure 4
2.1
Division
Loosen screw connection.
Mark radial location of housing cover!
Figure 5
Separate converter with covers from transmission by means of

lifting tackle.
(S) Eyebolts assortment 5870 204 002

(S) Lifting chain 5870 281 047
Figure 6
Press input shaft and converter respectively out of the housing

cover.
Figure 7
Loosen hexagon screws and separate diaphragm from converter.
Figure 8
2.2
Division
Loosen hexagon screws and separate diaphragm from input

shaft.
Figure 9
Unsnap retaining ring and remove ball bearing.
(S) Set of internal pliers 5870 900 013
Figure 10
Remove inductive transmitter (n-Engine).
Figure 11
Loosen hexagon screws and remove converter bell.
Figure 12
2.3
Division
2.1.2 Pressure oil pump
Loosen cap screws and torx screws and together separate oil feed
flange as well as pressure oil pump from the transmission hous-
ing.
Figure 13
Separate pressure oil pump from oil feed flange.
(S) Hammer 5870 280 004
Figure 14
Loosen both cap screws and remove Cam disc.
If running-in marks should be found in the pump housing or

cam disc, the pump assy has to be replaced!
Figure 15
Unsnap snap ring and remove single parts.
Figure 16
2.4
Division
2.1.3 Converter back pressure valve
Preload compression spring, remove tab washer and released

single parts.
Figure 17
Remove stator shaft.
Figure 18
2.1.4 Emergency steering pump
Loosen cap screws (WAF-6) and separate emergency steering

pump from cover.
Mark radial location!
Figure 19
(s) Socket spanner TX-40 5873 042 004
Figure 20
2.5
Division
2.1.5 Axle disconnection
Loosen cap screws and separate axle disconnection from the

housing.
(S) Pry bar set 5870 345 036
Figure 21
Unsnap retaining ring and remove shim as well as driver.
(S) Set of external pliers 5870 900 015
Figure 22
Loosen hexagon screws and remove output flange.
Figure 23
Remove shaft seal and unsnap retaining ring.
(S) Clamping pliers 5870 900 021
Figure 24
2.6
Division
Drive out the output shaft.
(S) Hammer 5870 280 004
Figure 25
Press ball bearing from the shaft.
Figure 26
Press oil feed ring from the shaft.
Figure 27
Remove sliding sleeve.
Figure 28
2.7
Division
Loosen hexagon screws, remove pins and released gear shift

fork.
Figure 29
Remove switch and locking pin.
Figure 30
Loosen cap screws, remove cylinder and released single parts.
Figure 31
Loosen hexagon screws and remove output flange (Figure 32).

Following to this press shaft seal out of the housing bore .
Figure 32
2.8
Division
2.1.6 Pump shaft (Power take-off)
Unsnap retaining ring and pull pump shaft out of the housing
bore.
Figure 33
Unsnap retaining ring and press ball bearing from the shaft.
Figure 34
Fix bearing inner ring by means of parting tool (S) and press it
from the shaft.
(S) Parting tool 5870 300 028
Figure 35
Unsnap piston ring (arrow).
Figure 36
2.9
Division
2.1.7 Remove housing cover
Remove both inductive transmitters as well as speed transmitter

(arrows).
Figure 37
Drive out both cylindrical pins (arrows).
Figure 38
Loosen hexagon nuts and remove both covers (arrows).

Loosen screw connection (housing – housing cover).
Figure 39
Separate housing cover from transmission housing by means

of lifting tackle.
(S) Eye bolts 2x (M20) 0636 804 003

(S) Eye nut (M12) 0664 462 774
Figure 40
2.10
Division
2.1.8 Output: Standard version
Loosen screw connection – screen sheet and lift output shaft out
of the housing.
Figure 41
Pull off both taper roller bearings.
(S) Gripping insert 5873 002 038

(S) Basic device 5873 002 001
Figure 42
2.1.9 Output: Version with interaxle differential
Remove output shaft.
Figure 43
Loosen cap screws and remove screen sheet.
Figure 44
2.11
Division
Lift differential out of the housing.
Figure 45
Pull off taper roller bearing.
Remove opposed taper roller bearing analogously.

Figure 46
Figure 47
Unsnap snap ring.
Figure 48
2.12
Division
Press needle sleeve out of the cover.
Figure 49
Lift planet carrier out of the output gear.
Figure 50
Cautiously drive in slotted pin until contact.
Figure 51
Press out planet shaft and released single parts.

Remove the remaining planet gears analogously.
Pay attention to released needle rollers!
Figure 52
2.13
Division
2.1.10 Remove input and clutches
Below figures describe the removal of all clutches!

Due to the installation conditions the removal of single
clutches without using a special tool (handles 5870 260 010) is
extremely difficult!
Moreover there is the risk to get injured!
Remove both oil pipes as well as piston rings (arrows).
Figure 53
Install housing cover on transmission housing by means of lift-

ing tackle until contact.
Fix all clutches by means of handles (S).
(S) Handles 5870 260 010
Figure 54
By means of lifting tackle separate housing cover incl. clutches

from transmission housing.
(S) Eye bolts 2x (M20) 0636 804 003

(S) Eye nut (M12) 0664 462 774
Figure 55
2.14
Division
Fix housing cover to assembly truck.
(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 089
Figure 56
Swivel housing cover by 180°.

Remove handles (S).
(S) Handles 5870 260 010
Figure 57 Opposite figure shows how the single clutches and the input are
arranged in the housing cover.
AN AN = Input
KV = Clutch – Forward
KR KV KR = Clutch – Reverse
K1 = Clutch – 1st gear
K4 K2
K2 = Clutch – 2nd gear
K1 K3 K3 = Clutch – 3rd gear
K4 = Clutch – 4th gear
NOTE:
Single clutches are recognizable by Equipment-No. ... ,
Figure 58 i.e. the 10-digit ZF-No..
Marking is found on the front end of the respective clutch shaft,
see arrow!
4657 371 015
.... 371 . . . = K1
.... 372 . . . = K2
.... 373 . . . = K3
.... 374 . . . = K4
.... 375 . . . = KV
.... 376 . . . = KR
Figure 59
2.15
Division

Observe the following sequence for removal of the single
clutches:
K1 K2 K3 K4 KV, KR and AN (together),
also see Figures 60 ... 64 !
Lift clutch-K4 by means of pry bar set and remove Clutch –K1.
(S) Pry bar set 5870 345 036
Figure 60
Remove Clutch-K2.
Figure 61
Remove Clutch-K3.
Figure 62
Lift Clutch-KV as well as – KR and remove Clutch-K4.
(S) Pry bar set 5870 345 036
Figure 63
2.16
Division
Lift Clutch-KV and – KR as well as input together out of the

housing cover (Figure 64).
Pay attention to released input!
Figure 64
Remove bearing outer rings (arrows).
If contrary to ZF Recommendation the taper roller bearings

of the clutches as well as of the input are not replaced, it is
necessary that at least the allocation (bearing inner to bear-
ing outer ring) is maintained!
Mark bearing inner and bearing outer ring accordingly!
Figure 65
2.17
Division
2.1.11 Dismantle Clutch-KV and – KR
Below figures describe disassembly of Clutch-KV! Disassem-

bly of Clutch-KR has to be made analogously!
Figure 66
Take off taper roller bearing from the shaft.

(S) Gripping insert (Lager 2700) 5873 001 057

(S) Gripping insert (Lager 33800) 5873 001 059
(S) Pressure piece 5870 100 043
Figure 67
Unsnap retaining ring.
Figure 68
Take off disc carrier from the shaft.
(S) Three-armed puller 5870 971 003
Figure 69
2.18
Division
Unsnap snap ring.

Remove end shim and disc set.
Figure 70
Preload compression spring, unsnap snap ring and remove re-

leased single parts.
(S) Assembly aid 5870 345 088
Figure 71
Lift piston by means of compressed air out of the cylinder bore

and remove it.
Figure 72
Remove both O-rings (arrows).
Figure 73
2.19
Division
Press clutch shaft out of the idler.
(S) Puller 5870 023 040
Figure 74
Unsnap retaining ring and remove ball bearing.
Disassembly of clutch-KR is to be made analogously!
Figure 75
2.20
Division
2.1.12 Dismantle Clutch-K1, - K2 and - K3
Below figures describe disassembly of clutch-K3! Disassem-

bly of clutch-K1 and – K2 is to be made analogously!
Figure 76

(S) Gripping insert (Bearing 33800) 5873 001 059

(S) Gripping insert (Bearing 39500) 5873 002 038
Figure 77
Remove running disc, axial needle cage and axial washer.
Figure 78
Lift idler out of the clutch.
Figure 79
2.21
Division
Remove both needle bearings as well as axial bearing (assy).
Figure 80
Take off disc carrier assy from clutch shaft.
(S) Puller 5870 970 004
Figure 81
Unsnap snap ring.

Figure 82
Preload cup spring set and unsnap snap ring (Figure 83).
Remove released single parts and piston.
Figure 83
2.22
Division
2.1.13 Dismantle Clutch-K4
Figure 84

Remove opposed bearings analogously.

Figure 85
Unsnap retaining ring.
Figure 86
Take off disc carrier assy from the clutch shaft.
(S) Three-armed puller 5870 971 003
Figure 87
2.23
Division
Unsnap snap ring.

Figure 88
Preload cup spring set and unsnap snap ring (arrow),

see Figure 89!
Remove single parts and piston.
Figure 89
Remover idler and released single parts.
It is not possible to separate shaft and gear (shrink fit)!
Figure 90
2.24
Division
2.1.14 Dismantle input shaft
Figure 91
Pull off both taper roller bearings.
(S) Rapid grip 5873 011 014

(S) Bush 5873 001 006
Figure 92
If required press turbine shaft by means of bolt (arrow) out of the

input shaft.
Turbine shaft is axially fixed with a snap ring, which will be

destroyed at pressing-out!
Figure 93
Remove O-ring (installation position – internal gearing).
It is not possible to separate input shaft and gear (shrink fit)!
Figure 94
2.25
Division
2.2 ASSEMBLY
2 2 2.2.1 Oil pipes
Opposite figure shows installation position of oil pipes.

3 1 = Suction tube
2 = Pressure tubes (2x)
3 = Pressure tube - lubrication
1

In order to guarantee an adequate assembly of the oil pipes it
absolutely necessary to use the indicated special tools (S)!
Figure 95 (S) Rolling tool 5870 600 003

(S) Rolling tool 5870 600 004
(S) Rolling tool 5870 600 005
(S) Lubricant 5870 451 006
2.2.2 Preassemble housing cover
Install studs M8 and M12.
Wet screw-in thread with Loctite (Type-No. 243)!
Tightening torque (M8) ................. MA = 9 Nm

Tightening torque (M12) ............... MA = 23 Nm
Figure 96
Provide screw-in sleeve (1) and threaded bush (2) with new
2
O-rings and install them.
1
Tightening torque (Screw-in sleeve) .......... MA = 46 Nm
Tightening torque (Threaded bush) ............ MA = 80 Nm
Figure 97
Install sealing cap 1 and 2.
1 Wet contact surface of sealing cap 1 with Loctite (Type No.

262)!
Wet contact surface of sealing cap 2 (rubber-coated) with
spirit!
2 Pay attention to mounting depth – sealing caps must rest
against the housing bore with the whole seal face!
Installation position of sealing cap 2 differs depending on the
transmission version – Version A or B!
A B
Figure 98
2.26
Division
2.2.3 Assemble Clutch –KV and – KR

2
3
Below figures describe assembly of Clutch-KV!
Assembly of Clutch-KR is to be made analogously!
Pay attention to allocation of single parts to the respective
clutches, also see note on Page 2.15!
Preassemble disc carrier (Figure 99 ... 105)

Place both O-rings (arrow 1 and 2) non-twisting into the recesses
of the piston and oil them.
Check function of drain valve (arrow 3) – ball must not get
1 jammed !
Figure 99
Install piston until contact.
Pay attention to installation position, see figure !
Figure 100
Assemble shim, compression spring and retaining ring.
Pay attention to installation position of retaining ring –

radius must show upwards!
Figure 101
Preload compression spring by means of fixture (S) and have

snap ring snapped into the annular groove of the disc carrier
(arrow).
Figure 102
2.27
Division
2.2.3.1 Clutch disc installation– KV / KR
Note: Below sketch or table show the clutch disc components and installation position of the single parts!
Clutch disc components of Clutch – KV and –KR are identical!
3 4
6
1
7
2
Pos. Description Quantity Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 1 coated on one side
4 Outer clutch disc 10 coated on both sides
5 Inner clutch discs 10
6 Snap ring 1 optional, s = 2,1 ... 4,2 mm
7 End shim 1
Number of effective friction surfaces: 16
Disc clearance: 2,7 ... 2,9 mm
Install outer clutch disc Pos. 3 with non-coated side showing to the piston!
Disc clearance is determined by snap ring Pos. 6, ref. is also made to the following page!
2.28
Division
Check disc clearance – KV / - KR (Figure 103 ... 105)
In order to ensure a perfect measuring result, the disc set is

first of all installed without oil.
Install disc set according to sketch or table (Page 2.28).
Figure 103
Insert end shim and fix disc set by means of snap ring
(e.g. s = 2,65 mm / empirical value).
Figure 104
Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“. Then press end shim against snap ring (up-
wards) and read disc clearance.
If the required disc clearance (see Table / Page 2.28) differs,

it has to be corrected with the adequate snap ring
Pos. 6 (optional s = 2,1 ... 4,2 mm) !
Upon setting of disc clearance, remove disc set, oil clutch discs
to ZF List of Lubricants TE-ML 03 and reinstall them.
Figure 105 (S) Magnetic stand 5870 200 055

(S) Dial indicator 5870 200 057
Align and center disc set by means of idler.

This step facilitates later assembly of disc carrier (Figure
112)!
Then remove idler again.
Figure 106
2.29
Division
Install orifice (arrow).
Wet contact surface with Loctite (Type No. 262)!
Figure 107
1 Install stud (arrow 1).

Assemble needle bearing (arrow 2).
Tightening torque ................ MA = 17 Nm
Figure 108
Place ball bearing until contact and fix it with retaining ring.
Figure 109
Press idler until contact.
Figure 110
2.30
Division
Heat inner diameter of disc carrier (approx. 120° C).
(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 111
Install preassembled disc carrier until contact.
Use safety gloves!
Figure 112
Fix disc carrier by means of retaining ring.
Figure 113
Check function of clutch by means of compressed air.
With properly installed single parts the clutch closing or

opening is clearly audible!
Figure 114
2.31
Division
Press bearing inner ring until contact.

Install opposed bearing inner ring accordingly.
Figure 115
2.32
Division
2.2.4 Assemble Clutch – K1, - K2 and –K3

3
Below figures describe assembly of Clutch-K3!

Assembly of Clutch-K1 and K2 is to be made analogously!
clutches, also see note on Page 2.15!
2

Disc clutch components of Clutch-K1 are not identical with
Clutch –K2 and –K3, see Pages 2.34 and 2.35!
1 Place both O-rings (arrow 1 and 2) non-twisting into the recesses

Figure 116 of the piston and oil them.
jammed!
Pay attention to installation position, see figure!
Figure 117
Put on cup spring set and retaining ring.
Pay attention to installation position of single parts, see

sketch / Page 2.34 and 2.35!
Figure 118
Preload cup spring set by means of fixture (S) and have snap
ring snapped into annular groove (arrow).
Figure 119
2.33
Division
2.2.4.1 Clutch disc installation – K2 / - K3 .
Clutch disc components of Clutch – K2 and –K3 are identical!
Clutch disc components –K1, see Page 2.35!
3 4
1 6
7
2

1 Disc carrier 1
2 Piston 1
7 End shim 1

Disc clearance is determined by snap ring Pos. 6, ref. is also made to Page 2.36!
2.34
Division
2.2.4.2 Clutch disc installation – K1
3 4
6
1
7
2

1 Disc carrier 1
2 Piston 1
7 End shim 1
Disc clearance is determined by snap ring Pos. 6, ref. is also made to Page 2.36!
2.35
Division
Check disc clearance – K1, -K2 and – K3 (Fig. 120 ... 122)
In order to ensure a perfect measuring result, the clutch

discs are first of all installed without oil.
Install disc set according to sketch or table (Page 2.33 and 2.34).
Figure 120
Figure 121
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance.
If the required disc clearance (see Table / Page 2.34 and 2.35)
differs, it has to be corrected with the adequate snap ring
Pos. 6 (optional s = 2,1 ... 4,2 mm) !
(S) Magnetic stand 5870 200 055

Figure 122 Upon setting of disc clearance, remove disc set, oil clutch discs
to ZF List of Lubricant TE-ML 03 and install them.
2.36
Division
Install orifice (arrow).
Wet contact surface with Loctite (Type No. 262)!
Orifice is only required to be installed for clutch shaft-K1!

Clutch shaft-K2 and –K3 without orifice!
Figure 123
Install stud (arrow).
Tightening torque ...................... MA = 17 Nm
Figure 124
(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 125
Install disc carrier until contact.
Use safety gloves !
Figure 126
2.37
Division
Assemble running disc 1 (55 x 78 x 5), axial needle cage 2 and

axial washer 3 (55 x 78 x 1).
3
Install running disc 1 with chamfer showing to the axial nee-
2 dle cage!
Figure 127
Assemble idler until all inner clutch discs are located.
Figure 128
Assemble needle bearing (2x).
Figure 129
Assembly axial washer 3 (55 x 78 x 1), axial needle cage 2 and

1 running disc 1 (55 x 78 x 5).

Install running disc 1 with chamfer showing to axial needle
2 cage!
3 Note to Clutch-K3:
Only when running disc is in contact with shaft collar it is
ensured that all inner clutch discs are located!
Figure 130
2.38
Division
Fix single parts by means of retaining ring.
This step is only required for Clutch – K1 and – K2!

For Clutch –K3 this step is not applicable!
Figure 131
Press taper roller bearing until contact.

Install opposed taper roller bearing analogously.
Figure 132

Figure 133
2.39
Division
2.2.5 Assemble Clutch-K4

3
clutch, also see note or Figure 59 on Page 2.15!

2
Place both O-rings (arrow 1 and 2) non-twisting into the recesses
of the piston and oil them.
1 jammed !
Figure 134
Figure 135
Put on cup spring set and retaining ring.
Pay attention to installation position of single parts, see

sketch / Page 2.41!
Figure 136
Preload cup spring set by means of fixture (S) and have snap
ring snapped into the annular groove (arrow).
Figure 137
2.40
Division
2.2.5.1 Clutch disc installation – K4 .
3 4
1 6
7
2

1 Disc carrier 1
2 Piston 1
7 End shim 1

Disc clearance is determined by snap ring Pos. 6, ref. is also made to the following page!
2.41
Division
Check disc clearance – K4 (Figure 138 ... 140)
In order to ensure a perfect measuring result, the disc set is

first of all installed without oil.
Install disc set according to sketch or table (Page 2.41).
Figure 138
Figure 139
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance.
If the required disc clearance (see Table / Page 2.41) differs,

it has to be corrected with the adequate snap ring
Pos. 6 (optional s = 2,1 ... 4,2 mm) !
(S) Magnetic stand 5870 200 055

Upon setting of disc clearance, remove disc set, oil clutch discs
to ZF List of Lubricants TE-ML 03 and reinstall them.
Figure 140
Align center disc set radially by means of idler and center it.
Step facilitates later assembly of disc carrier (Figure 149)!

Following to this remove idler again.
Figure 141
2.42
Division
Undercool clutch shaft (approx. – 80° C), heat spur gear

( + 120° C) and install until contact.
Install spur gear with long side of the hub (arrow) showing
upwards!
Use safety gloves!
Figure 142
Fix spur gear by means of retaining ring.
Figure 143
Install stud (arrow).
Tightening torque ..................... MA = 17 Nm
Figure 144
Assemble lower axial washer, axial needle cage and upper axial
washer.
Upper and lower axial washer are identical (55 x 78 x 1)!
Figure 145
2.43
Division
Assemble both needle bearings.
Figure 146
Assemble idler.
Figure 147
Assemble axial washer 3 (55 x 78 x 1), needle cage 2 and run-

1 ning disc 1 (55 x 78 x 5).
2 Install running disc 1 with chamfer showing to needle bear-

ing!
Figure 148

Install preassembled disc carrier until all inner clutch discs are
located.
Use safety gloves!
(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 149
2.44
Division
Fix disc carrier by means of retaining ring.
Figure 150

Figure 151

Figure 152
2.45
Division
2.2.6 Preassemble input shaft
Undercool input shaft (approx. – 80° C), heat input gear

(approx. + 120° C) and install it until contact.
Figure 153
Snap in retaining ring.
Figure 154
Place O-ring into lower annular groove (inner diameter) and

grease it.
Figure 155
Have snap ring snapped into the annular groove of the turbine
shaft (arrow).
Figure 156
2.46
Division
Assemble turbine shaft until snap ring is snapping into the recess
of the input shaft – turbine shaft is axially fixed!
Figure 157

Figure 158
Snap in piston rings (arrows) and hook it.
Figure 159
2.47
Division
2.2.7 Install input shaft and clutches
Place all bearing outer rings into the bearing bores of both
housing parts.
Installation positon, see Figure 160 and 161!

If contrary to ZF Recommendation the taper roller bearings
of the clutches as well as of the input are not replaced, it is
necessary that at least the allocation (bearing inner to bear-
ing outer ring) is maintained!
AN
KV KR
Housing front section:
AN = Input
K2 K4 KV = Clutch – Forward
KR = Clutch – Reverse
K1 = Clutch – 1st gear
K2 = Clutch – 2nd gear
K3 = Clutch – 3rd gear
K1 Clutch – 4th gear
K3 K4 =
AB = Output
AB
Figure 160
AN
KR KV Housing cover:
K4 K2 Place bearing outer rings with assembly grease into the

bearing bores.
K1
K3
AB
Figure 161
Install clutches with aid of the housing cover

(Figure 162 ... 170):
Housing cover will be removed again later!
Clutch-KR, input shaft and Clutch - KV are placed together into

the housing cover.
Figure 162
2.48
Division
Lift input gear and position Clutch-K4.
Figure 163
Install Clutch-K3.
Figure 164
Position Clutch-K2.
Figure 165
Lift Clutch-K4 and position Clutch-K1.
Figure 166
2.49
Division
Below figure shows once again installation position of the indi-

vidual clutches in the housing cover!
KR KV
Install, grease and centrally align the piston rings (arrows).
K4 K2
K1 K3
Figure 167
Fix all clutches by means of handles (S).
(S) Handle (6 pcs. required) 5870 260 010
Figure 168
Swivel housing cover by 180°.
Install eye bolts and eye nut, see arrow!
(S) Eye nut (M12) 0664 462 774

(S) Eye bolt 2x (M20 0636 804 001
Figure 169
Install housing cover on transmission housing by means of lift-

ing tackle until contact, cautiously assembling the clutches.
Following remove handles and take off again the housing cover.

(S) Eye nut (M12) 0664 462 774
(S) Eye bolts 2x (M20) 0636 804 001
(S) Handle 5870 260 010
Figure 170
2.50
Division
2.2.8 Install output shaft
Put on screen sheet and press bearing inner ring until contact.
Figure 171
Put on screen sheet.
Figure 172
Install preassemble output shaft.

Fix screen sheets by means of cap screws.
Tightening torque (M8/8.8) ................ MA = 23 Nm
Figure 173
2.51
Division
2.2.9 Preassemble and install

interaxle differential.
Sketch: “ Version-Interaxle differential “
Position lower thrust washer 1 (large inner diameter), sun gear 2

and upper thrust washer 3 (small inner diameter).
Pay attention to installation position – install thrust washer

3 3, showing to long side of the hub (arrow)!
2
1
Figure 174
Install planet gears according to opposite figure.
1 = Shim (2x)
2 = Roller set
3 = Planet gear
Install roller set with assembly grease!
1

3
2
1
Figure 175
Position preassembled planet gear and align it centrally.
2 Press in planet shaft.

1
Pay attention to installation position of planet shaft, see op-
posite figure!
Align bore holes for slotted pin (arrow 1)!
Central oil bore (arrow 2) shows to the front!
Figure 176
2.52
Division
Fix planet shaft by means of slotted pin.

Install remaining planet gears analogously.
Drive in slotted pins up to shaft center, see arrow!
Figure 177
Assemble planet carrier into the input gear with long side of the
hub showing upwards (arrow).
Figure 178
Install needle sleeve until contact and fix it by means of snap

ring.
Figure 179
Fix differential cover by means of cap screws.
Tightening torque (M10/10.9) .............. MA = 68 Nm
Secure cap screws with Loctite (Type No. 243)!
Figure 180
2.53
Division
Install bearing inner ring until contact.

Install opposed bearing inner ring analogously.
Figure 181
Put on screen sheet.
Figure 182
Place preassembled differential into bearing outer ring.
Figure 183
Assemble screen sheet and fix both sheets by means of cap

screws.
Figure 184
2.54
Division
2.2.10 Install housing cover
Place O-rings (2x/pipe) into annular grooves of both oil pipes.
Figure 185
Install both oil pipes (arrows).
Figure 186
Install, grease and centrally align the piston rings (arrows).
Figure 187
Wet mounting face with sealing compound Loctite (Type No.

574).
Figure 188
2.55
Division
Cautiously install housing cover on transmission housing by

means of lifting tackle until contact.
Pay attention to align both oil pipes with bores in the housing
cover!

(S) Eye bolts 2x (M20) 0636 804 001
(S) Eye nut (M12) 0664 462 774
Figure 189
Install both cylindrical pins centrally to mounting face.
Figure 190
Check easy running of gear drive train (Figure 191)

(S)
Install driver (S) and rotate Clutch shaft-KV.
If an interfering of the movable parts (e.g. on the screen

sheet or the oil pipes) is recognized, this fault must be cor-
rected!
Make this step on all clutch shafts!
(S) Driver 5870 345 089

(S) Crank handle 5870 280 007
Figure 191
Fix housing cover by means of cap screws.
Tightening torque (M10/8.8) ............... MA = 46 Nm

Pay attention to installation position of fixing plate as well as
of the bracket (Converter clutch valve), see arrows!
Figure 192
2.56
Division
2.2.11 Pump shaft (Power take-off)
Press lower bearing inner ring (arrow) until contact.

Put on (four-point bearing) and press bearing inner ring until
contact.
Figure 193
Determine axial play of ball bearing = 0,0 ... 0,05 mm by means

of retaining ring (optional).
Figure 194
Install piston ring (arrow).
Figure 195
Grease and centrally align piston ring.

Assemble pump shaft until contact.
Figure 196
2.57
Division
Fix pump shaft by means of retaining ring.
Figure 197
Place O-ring (arrowl) into annular groove of the oil feed cover.
Figure 198
Fix both oil feed covers by means of hexagon nuts.
Tightening torque ................... MA = 23 Nm
Figure 199
2.58
Division
2.2.12 Power take-off
Shaft seal to be flush-mounted.

Wet outer diameter with sealing compound (Type No. 574)!
Install shaft seal with sealing lip showing (downwards) to the
oil sump!
Figure 200
To Figure 201
1 1 = Housing
2 = Detent pin
5 = Set screw
Insert detent pin and both compression springs with assembly

2 grease into the housing bore and install set screw aligning to
3
4 housing surface.
5

Figure 201 Insert set screw with Loctite (Type No. 262)!
Assemble washer (s = 3,0 mm / arrow) and install gear shift

lever.
Figure 202
Assemble washer (s = 1,5 mm) and fix gear shift lever by means
of retaining ring.
Figure 203
2.59
Division
Insert woodruff key (arrow) into the groove.

Assemble gear shift lever and fix it by means of hexagon screw.
Pay attention to installation position of gear shift lever!

Install outer gear shift lever at 180° offset to inner gear shift
lever!
Figure 204
Grease O-ring (arrow) and install it.
Figure 205
Fix housing by means of hexagon nuts.
Figure 206
2.60
Division
2.2.13 OUTPUT – AXLE DISCONNECTION

2.2.13.1 Standard version
Install shaft seal with sealing lip showing to the oil sump.
Exact installation position is obtained by use of the specified
driver (S)!
Grease sealing lip!
Depending on the version different shaft seals can be used:
Outer diameter rubber-coated – wet with spirit!
Outer diameter metallic – wet with sealing compound
(Loctite, Type No. 574)!
Figure 207
(S) Driver 5870 048 237
Insert hexagon screws and press on screen sheet (arrow) in

alignment.
(S) Pressure bush 5870 506 142
Figure 208
Install output flange until contact.
Figure 209
Insert O-ring (arrow) into gap of output flange and shaft.
Figure 210
2.61
Division
Fix output flange by means of washer and hexagon screws.
Then fix hexagon screws by means of tab washer

(see opposite Figure).
(S) Driver 5870 057 009

(S) Handle 5870 260 002
Swivel transmission housing by 180°.
Figure 211
Install spring cup and compression spring.
Figure 212
Insert Viton-Ring (arrow 1) into annular groove and grease it.

1 Assemble piston.
Pay attention to radial location of piston! Contact surface of

locking pin must show to bore hole – see arrow 2 !
Figure 213
Install cylinder equally until contact.
Tightening torque (M8) .................. MA = 23 Nm
Figure 214
2.62
Division
Install set screw (arrow).
Wet thread with Loctite (Type No. 262)!
Figure 215
Position gear shift fork.
Pay attention to installation position, see opposite figure!
Figure 216
Insert O-rings (arrows) into annular grooves of the pins and

grease the same.
Fix gear shift fork by means of pins.
Tightening torque (M6/8.8) ................... MA = 9,5 Nm
Figure 217
Install both sliding pads (arrows) and insert sliding sleeve.
Figure 218
2.63
Division
Assemble and grease O-ring (arrow).
Install locking pin 1 and switch 2.
Tightening torque .................. MA = 30 Nm
1
2
Figure 219
Press oil feed ring until contact.
Figure 220
Press ball bearing until contact.
Figure 221
Assemble output shaft (assembling sliding sleeve at the same

time) and press it until contact.
Figure 222
2.64
Division
Fix output shaft by means of retaining ring.
Pay attention to radial location of retaining ring, see Figure

224 !
Figure 223
Oil groove (arrow) to remain free.
Figure 224
Install shaft seal with sealing lip (arrow) showing to the oil
sump.

driver (S)!
Grease sealing lip!
Figure 225 (S) Driver 5870 048 237
Install hexagon screws and press on screen sheet (arrow) in

alignment.
Figure 226
2.65
Division
Assemble output flange and insert O-ring into gap of output

flange and shaft.
Put on washer and fasten it with hexagon screws.
Figure 227
Fix hexagon screws by means of tab washer.
(S) Driver 5870 057 009

(S) Handle 5870 260 002
Figure 228
Check function of switch by resistance test

(Figure 229)
Actuating the axle disconnection by means of compressed air

results in a changed resistance if the switch is intact!
(S) Measuring device (Multimeter) 5870 221 158
Figure 229
Place perforated sheet into bore hole (arrow) and install filter
insert (wire mesh).
1 = Perforated sheet
2 = Filter insert
1
2
Figure 230
2.66
Division
Install, grease and centrally align piston ring (arrow 1).

2 1 Provide O-ring (arrow 2) with assembly grease and place it into
annular groove.
Figure 231
Cautiously press needle sleeve, with reinforced jacket showing

to the special tool, into bore of the output shaft until contact.
Then grease needle rollers.
(S) Centering bush 5870 506 099

(S) Driver 5870 048 132
Figure 232
Assemble driver.
Figure 233
Fix driver by means of shim (empirical value s = 2,4 mm) and

V-Ring.
Pay attention to driver of max. 0,2 mm!
Figure 234
2.67
Division
Install preassembled axle disconnection and fix it by means of

cap screws (2 pcs. M12x80, 7 pcs. M12x75 mm).
Tightening torque (M12/8.8) .................. MA = 79 Nm
Figure 235
2.68
Division
2.2.13.2 Version with interaxle differential
Cautiously press needle sleeve, with reinforced jacket showing

to the special tool, into bore of the output shaft until contact.
Then grease needle rollers.
(S) Driver 5870 058 023

(S) Handle 5870 260 002
Figure 236
Figure 237
Install output shaft until contact.
Figure 238
Figure 239
2.69
Division
Install shaft seal with sealing lip showing to the oil sump.

driver (S)!
Grease sealing lip!
Figure 240 (S) Driver 5870 048 237
Insert hexagon screws and press on screen sheet (arrow) in

alignment.
Figure 241
Install output flange until contact.
Figure 242
Insert O-ring (arrow) into gap of output flange and shaft.
Figure 243
2.70
Division
Fix output shaft by means of washer and hexagon screws.
Tightening torque (M10/8.8) .................. MA = 46 Nm
Then fix hexagon screws by means of tab washer (Figure).
(S) Driver 5870 057 009

(S) Handle 5870 260 002
Figure 244
Install spring cup and compression spring.
Figure 245
1 Insert Viton-Ring (arrow 1) into annular groove and grease it.

Assemble piston.
Pay attention to radial location of piston! Contact surface of

locking pin must show to bore hole – see arrow 2 !
Figure 246
Install cylinder equally until contact.
(S) Adjusting screws 5870 204 011.
Figure 247
2.71
Division
Install set screw (Arrow).
Wet thread with Loctite (Type No. 262)!
Figure 248
Position gear shift fork.
Figure 249
Insert O-rings (arrows) into annular grooves of the pins and

grease them.
Fix gear shift fork by means of pins.
Tightening torque (M6/8.8) ............... MA = 9,5 Nm
Figure 250
Install both sliding pads (arrows) and insert sliding sleeve.
Figure 251
2.72
Division
Install and grease O-ring (arrow).

Install locking pin 1 and switch 2.
Tightening torque .................... MA = 30 Nm
1
2
Figure 252
Press oil feed ring until contact.
Figure 253
Figure 254
Assemble output shaft (assembling sliding sleeve at the same

time) and press it until contact.
Figure 255
2.73
Division
Pay attention to radial location of retaining ring, see

Figure 257 !
Figure 256
Oil groove (arrow) to remain free.
Figure 257
Assemble bush.
Figure 258
If required assemble intermediate washer (s = 2,8 mm).
Depending on version, with or without intermediate washer,

see corresponding spare parts list!
Figure 259
2.74
Division
Fix bush by means of washer and cap screws.
Wet thread of cap screws with (Type No. 262)!
Tightening torque (M10/8.8, DIN 6912) ............ MA = 32 Nm
Figure 260
Install shaft seal with sealing lip (arrow) showing to the oil
sump.

driver (S)!
Grease sealing lip!
Figure 261 (S) Driver 5870 048 237
Check function of switch by resistance test

(Figure 262)
Actuating the axle disconnection by means of compressed air

results in a changed resistance if the switch is intact!
(S) Measuring device (Multimeter) 5870 221 158
Figure 262
Place perforated sheet into bore hole (arrow) and install filter
insert (wire mesh).
1 = Perforated sheet
2 = Filter insert
1
2
Figure 263
2.75
Division
Provide O-ring with assembly grease and insert it into the annular
groove (arrow).
Figure 264
Both thrust washer to be centrally aligned.
Position of thrust washers, see following sketch (arrow)!
Figure 265
Assemble hollow shaft until contact.
Figure 266
2.76
Division
Install preassembled axle disconnection and fix it by means of

cap screws (2 pcs. M12x80, 7 pcs. M12x75 mm).
Tightening torque (M12/8.8) ............ MA = 79 Nm
Figure 267
Press on screen sheet (arrow) in alignment.
Figure 268
Assemble output flange.
Figure 269
2.77
Division
2.2.14 Converter back pressure – valve
Opposite figure shows the single parts of the converter back

pressure valve.
1 = Oil feeder housing

2 = Piston
4 = Pressure plate
5 = Tab washer
1 2
3 4
5
∅ 6 mm) showing to the
Figure 270 Install pressure plate 4 with bolt (∅
tab washer!
Install single parts and fix them by means of tab washer.
Figure 271
2.2.15 Pressure oil pump
Use assembly grease!
(S) Adjusting screws (M8) 5870 204 011
Figure 272
Put on oil feeder housing.
Figure 273
2.78
Division
Install two adjusting screws and assemble stator shaft.
Pay attention to radial location!
Figure 274
Preassemble pressure oil pump (Figure 275 ... 282)
To Figure 275:
1 = Pump housing
2 = Ring (85 x 75 x 4,6 mm)
3 = Brg outer ring
4 = Needle cage
} Needle brg assy
5 = Support shim (95 x 76 x 84 x 3 mm)
6 = Shaft seal
1 2 3 4 7 = Snap ring
5 6 7
Figure 275
Install ring 2 and bearing outer ring 3.
Figure 276
Install needle cage 4 and support shim 5.
Figure 277
2.79
Division
Cautiously install shaft seal 6 until contact, with sealing lip

showing downwards, and fix it by means of snap ring 7.
Wet outer diameter of shaft seal with spirit!
Figure 278
Install outer rotor.
Chamfer (arrow) shows downwards!
Figure 279
Install inner rotor.
Gearing (arrow) shows upwards!
Figure 280
Put on cam disc and fix it radially by means of two cap screws.
Do not tighten cap screws – just screw in the same until con-
tact and then by approx. ½ turn backwards!
Pay attention to installation position of cam disc, see Figure!
Figure 281
2.80
Division
Insert O-ring into annular groove (arrow) and provide it with oil.
Figure 282
First of all install preassembled pump equally until contact by

means of cap screws (3 pcs.).
Pay attention to radial location!
Following to this remove cap screws again.
Figure 283
Provide cap screws with new O-rings (arrow).
Grease O-rings!
Figure 284
Fix transmission pump by means of cap screws.
Figure 285
2.81
Division
Fix oil feeder housing equally by means of cap screws.

Tightening torque (M8) .................... MA = 23 Nm
Pay attention to installation position of fixing plate,
see arrow!
Figure 286
2.2.16 Engine Connection – Converter
Fix converter bell by means of hexagon screws.
Tightening torque (M10/10.9) ................. Ma = 68 Nm
Figure 287
Fasten input shaft and diaphragm with screws.
Figure 288
Fix diaphragm by means of hexagon screws to the converter.
Wet thread of hexagon screws with Loctite (Type No. 262)!
Figure 289
2.82
Division
Install ball bearing and fix it by means of retaining ring.
Figure 290
Put housing cover over converter and press it until contact.
Support pressure bush (arrow) on bearing inner ring!

Figure 291
Insert hexagon screws into the input flange and fix provisionally.
Press input flange until contact.
Figure 292
Fix input flange by means of washer and hexagon screws.
Then fix hexagon screws by means of tab washer (Figure).
(S) Driver 5870 057 010

(S) Handle 5870 260 002
Figure 293
2.83
Division
Install, grease and centrally align piston ring (arrow).
Figure 294
Install converter by means of lifting tackle until housing cover is

in contact with converter bell.
Pay attention to radial location, see markings made at disas-

sembly (arrows)!
Then fasten converter bell and cover by means of screws (Fig-

ure).
Figure 295
2.84
Division
2.2.17 Emergency steering pump
Press plain bearing in alignment to plane face (arrow) into cover.
(S) Driver 5870 048 080
Figure 296
Install gasket (arrow). Put on cover and fix it by means of cap

screws.
Tightening torque .................... Ma = 23 Nm
Figure 297
Install and grease O-ring.
Figure 298
Assemble emergency steering pump and fix it by means of cap

screws.
Tightening torque ................. Ma = 23 Nm
Pay attention to radial location, see markings made at disas-

sembly (arrows)!
Figure 299
2.85
Division
Provide screw plug (1) with new O-ring and install it. Put on
gasket and fix cover plate (2) with hexagon screws.
Install oil level tube to housing rear.
Tightening torque (screw plug) .................. Ma = 80 Nm

Tightening torque (hexagon screws) ...........Ma = 23 Nm
Installation position of single parts differs depending on the
! version! Pay attention to exploded views in the corresponding

spare parts list!
Figure 300
2.86
Division
2.2.18 Speed-, inductive transmitter and pulse sensor
A 34 Installation positions are shown in Figure 301 and 302.
6 6 = Pulse sensor Speedo

34 = Speed transmitter n – Output
21 = Inductive transmitter n – Turbine
47 = Inductive transmitter n – Internal speed input
48 = Inductive transmitter n – Engine
B
Installation position of speed transmitter (34) is different
depending on version – Pos. A or B!
Figure 301
Grease O-rings and install speed as well as inductive transmitter.

Wet thread of pulse sensor (6) with Loctite (Type No. 574) and
install it.
47 21 Tightening torque .................................... Ma = 23 Nm

(Cap screw - Speed transmitter)
48
Tightening torque .................................... Ma = 30 Nm
(Inductive transmitter and pulse sensor)
Figure 302
Install breather (arrow).
Tightening torque .......................... Ma = 12 Nm
Prior to commissioning of transmission make oil filling

in accordance with operating instructions
Ref. No. 5872 196 001!
Figure 303
2.87

Manual Reparacion 6 WG 210

Uploaded by

Copyright:

Available Formats

Manual Reparacion 6 WG 210

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Reparacion 6 WG 210

Uploaded by

Copyright:

Available Formats

REPAIR MANUAL

ZF Friedrichshafen AG reserves the right to replace this disassembly and reassembly

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

Structure of the Repair Manual

Important information on industrial safety

Serves as reference to special working procedures, methods,

CAUTION Is used, if a deviating and improper working procedure can

Is used, if lacking care can lead to personal injury or danger to

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

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

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

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

VERGLEICHSTABELLE FÜR MASSEINHEITEN

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

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

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

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

0,070 bar ( 0,071 kp/cm2 ) =

0° C ( Celsius ) = + 32° F ( Fahrenheit )

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

Metric ISO-Standard thread DIN 13, Page 13

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

DISASSEMBL. REASSEMB. DESIGNATION/APPLICATION OF SPECIAL TOOLS (S) PART NO.

Fig. 1 Strap wrench 5870 105 005

Fig. 5 Fig. 26 Socket spanner # TX-27 5873 042 002

Fig. 6 Fig. 43 Socket spanner # TX-40 5873 042 004

Fig. 15 Fig. 23 Adjusting screws M5 5870 204 036

Fig. 34 Adjusting screws M6 5870 204 063

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

DISASSEMBL. REASSEMB. DESIGNATION/APPLICATION OF SPECIAL TOOLS (S) PART NO.

Fig. 4 Two-armed puller 5870 970 003

Fig. 6 Eye bolt assortment 5870 204 002

Fig. 6 Fig. 170 Lifting chain 3-strand 5870 281 047

Fig. 10 Fig. 109 Set of internal pliers # 5870 900 013

Fig. 13 Socket spanner # TX-40 5873 042 004

Fig. 14 Hammer ∅60 5870 280 004

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Fig. 21 Fig. 166 Pry bar set 5870 345 036

Fig. 22 Fig. 113 Set of external pliers # 5870 900 015

Fig. 24 Fig. 223 Clamping pliers 5870 900 021

Fig. 35 Parting tool # 5870 300 028

Fig. 42 Gripping insert # 5873 002 038

Fig. 46 Gripping insert # 5873 002 047

Fig. 54 Fig. 168 Handle # 6x 5870 260 010

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Fig. 56 Holding fixture # 5870 350 089

Fig. 67 Gripping insert # 5873 001 057

Fig. 67 Gripping insert # 5873 001 059

Fig. 69 Three-armed puller # 5870 971 003

Fig. 71 Fig. 102 Assembly aid # 5870 345 088

Fig. 74 Puller # 5870 023 040

Fig. 81 Puller 5870 970 004

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Fig. 92 Rapid grip # 5873 011 014

Fig. 105 Magnetic stand Combined with 5870 200 055

Fig. 111 Hot-air blower # or 220 V 5870 221 500