ZF Actuator

1327 751 103

Transmission Actuator and Clutch Actuator

Repair Manual

Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright. Anyreproduction or dissemination in whatever formwhich does not comply fully with the intended pur-pose of this documentation is prohibited without theconsent of ZF Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2005-09

Edition: 2005-09

1327 751 103

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Programming Transmission Actuator ............................................................................................................ 39Programming Flash EPROMS with ZF Test Program.................................................................................... 40Description of Test.......................................................................................................................................... 40Outgoing Inspection ....................................................................................................................................... 40

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

Table of ContentsZF-AS Tronic

31327 751 103 - 2005-09

52003-08

ZF Friedrichshafen AGNutzfahrzeug- und Sonder-AntriebstechnikCommercial Vehicle and Special Driveline TechnologyService Werk 2 (Plant 2)Phone: +49 (0)7541 77-0Fax: +49 (0)7541 77-908000Internet: www.zf.com

This manual is intended for skilled personneltrained 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 theproduct, repair work might require work practicesand test or adjustment data which are not containedin this manual.We therefore recommend that work done on yourZF product is carried out only by skilled mechanicsand fitters who have had their practical and theoretical knowledge updated on a regular basis atour 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 inthe individual case.

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional man-ner, together with follow-on costs caused by suchwork, is excluded from the contractual warrantyagreement.This also applies where genuine ZF spare parts havenot been used.

Preface

62005-04

Safety Instructions

Companies repairing ZF units are responsible fortheir own work safety.

To avoid injury to personnel and damage to products, all safety regulations and legal require-ments which apply to repair and maintenance workmust be adhered to.Before starting work, mechanics must familiarizethemselves with these regulations.

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

The following safety instructions appear in thismanual:

NOTERefers to special processes, techniques, data, use ofauxiliary equipment, etc.

CAUTIONThis is used when incorrect, unprofessional work-ing practices could damage the product.

DANGERThis is used when lack of care could lead to personalinjury or death.

General Information

Read this manual carefully before starting any testsor repair work.

CAUTIONPictures, drawings, and components do not alwaysrepresent the original object, but are used to illus-trate working procedures.Pictures, drawings, and components are not to scale.Conclusions about size and weight should not bedrawn (even within a complete illustration).Always follow the working steps as described in thetext.

After completion of repair work and testing, skilledstaff must check whether the product is functioningcorrectly.

THREATS TO THE ENVIRONMENT !Lubricants, consumables, and cleaning agents mustnot be allowed to enter the soil, ground water, orsewage system.• Ask your local environment agency for safety

information on the relevant products and adhere totheir requirements.

• Collect used oil in a suitably large container.• Dispose of used oil, dirty filters, lubricants, and

cleaning agents in accordance with environmentalprotection guidelines.

• When working with lubricants and cleaning agentsalways refer to the manufacturer’s instructions.

CAUTIONThe transmission must NOT be suspended by theinput shaft NOR by the output flange.

!

!

Safety Instructions

72005-04

ZF Service Information must be observed. Thisinformation is available at all ZF Service Centers orvia the ZF-ServiceLine.

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

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

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

Cleaning parts

Remove remains of old gaskets on all sealing sur-faces. Carefully remove burrs or similar patches ofroughness using an oilstone.

Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check forperfect passage.

Carefully cover opened transmissions to prevent foreign matter from entering.

Reusing parts

Parts such as roller bearings, discs, thrust washersetc., must be inspected by a competent person whoshould decide whether or not they can be re-used.Replace parts which are damaged or have sufferedfrom excessive wear.

Gaskets, Locking plates

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

Shaft Seals

Always change shaft seals with rough, ripped orhardened sealing lips. Seal contact surfaces must betotally clean and in perfect condition.

Reworking

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

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

Transmission Assembly

Find a clean work area to assemble the transmission.Gaskets are installed without sealing compound orgrease. When measuring silicon-coated gaskets, donot include the silicon layer.During assembly, comply with all adjustment dataand tightening torques in the Repair Manual.

Instructions for Repairs

82003-08

Bearings

If bearings are mounted in heated condition, theyare to be heated evenly (e.g. heating cabinet).Temperature should be at approx. 85 °C and mustnot exceed 120 °C. Each mounted bearing must beoiled with operating oil.

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 surfacesand spread evenly. Do not allow sealing to enter oilducts and bores. On oil-carrying ducts and bores,wipe off the sealing agent on the surfaces to besealed near apertures to ensure that no sealing agententers the oil feeds when the surfaces are sealed.

Shaft Seals

a) Apply a light coat of sealing agent* on circum-ference of shaft seals with “steel jacket”.

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

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

d) Dual shaft seals have two sealinglips. The dust-proof sealing lip(X) must face outwards.

e) Fill the gap between the sealinglips so it is 60 % filled with grease (e.g. producedby Aral, such as Aralub HL2 or by DEA, such asSpectron 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.

Retaining Agents

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

Transmission oil

After completing repairs, fill transmissions withtransmission oil. For the procedure and approvedoils, refer to the transmission operating manual andTE-ML List of Lubricants (refer to identificationplate) which are available from any ZF After-SalesService Point and on the Internet underwww.zf.com.After filling the transmission with oil, tighten thescrew plugs at the oil filling point and the oil over-flow using the specified torques.

* refer to expendable material

X

Instructions for Repairs

91327 751 103 - 2005-09

Index Date of issue Chapter Initiator Comment

Overview of Amendments: 1327 751 103

102003-08

Tightening Torques

Regular screw thread Fine screw thread

Size Tightening torque (Nm) for Size Tightening torque (Nm) forScrew/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9Nut 8 10 12 Nut 8 10 12

M4 2.8 4.1 4.8 M8x1 24 36 43M5 5.5 8.1 9.5 M9x1 36 53 62M6 9.5 14 16.5 M10x1 52 76 89

M7 15 23 28 M10x1.25 49 72 84M8 23 34 40 M12x1.25 87 125 150M10 46 68 79 M12x1.5 83 120 145

M12 79 115 135 M14x1.5 135 200 235M14 125 185 215 M16x1.5 205 300 360M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490M20 390 560 650 M20x1.5 430 620 720M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250M27 1000 1400 1650 M24x2 730 1050 1200M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800M30x1.5 1550 2200 2550M30x2 1500 2100 2500

Tightening Torques for Nuts and Bolts, Extract from ZFN 148

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

This Standard contains data on tightening torques(MA) for screws/bolts and nuts in strength categories8.8, 10.9, and 12.9, and nuts in strength categories 8,10, and 12.

Surface condition of bolts / nuts: Thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated, and oiled.

Tighten screws with a calibrated ratchet dial torqueor ratchet wrench.

NOTEDeviating tightening torques are listed separately inthe Repair Manual.

Edition: August 1991

112003-08

Screw Plugs DIN 908, 910, and 7604

The screw plug tightening torques were determinedaccording to DIN 7604 for screwing into steel, graycast, 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 908and DIN 910, as the thread geometries are almostidentical.

General rule: Screw/Bolt class 5, ZFN 148-1Screw/Bolt material: Steel acc. to DIN 7604. Surface condition: As manufactured (withoutsurface protection) and lightly oiled or galvanized,chromated, and lightly oiled.

Union Screws DIN 7643

The tightening torques were determined for screw-ing into steel, gray cast, and aluminum alloys.The values are based on experience and areintended as reference values for the fitter.

General rule:Screw/Bolt class 5, ZFN 148-1Material: 9SMnPb28K acc. to DIN 1651Surface condition: As manufactured (withoutsurface protection) and lightly oiled or galvanized,chromated, and lightly oiled.

Screw plugs (DIN 908, 910, 7604)

Dimensions Tightening torquein Nm screwed into

steel /gray cast Al alloyM8x1 20* 10*M10x 1 25 / 30* 15 / 20*M12x1.5 35 25M14x1.5 35 25M16x1.5 40 30M18x1.5 50 35M20x1.5 55 45M22x1.5 60 / 80* 50 / 65*M24x1.5 70 60M26x1.5 80 / 105* 70 / 90*M27x2 80 70M30x1.5 100 / 130* 90 / 130*M30x2 95 85M33x2 120 110M36x1.5 130 115M38x1.5 140 120M42x1.5 150 130M42x2 145 125M45x1.5 160 140M45x2 150 130M48x1.5 170 145M48x2 160 135M52x1.5 180 150M60x2 195 165M64x2 205 175

Union screws (DIN 7643)

Pipe Thread Tighteningouter torque

diameter 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

Tightening Torques

Edition: October 1995* DIN 7604 Form C

122003-08

Withdrawn Title Substitute Result of check/measures 1)

DIN ISO standard

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 ISO 2338 - some can be replaced → changed to ISO 2338pins - 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 ISO 1207 - some can be replaced → changed to ISO 1207screws - 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 Hex nuts ISO 4036 - cannot be replaced → documented as DIN 439 OLDDIN 439-2 Hex nuts ISO 4035

ISO 8675



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)


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


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


DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for ISO 8673 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


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


DIN 963 Countersunk ISO 2009 - cannot be replaced as a result of modified head dimensions → documentedbolts as DIN 963 OLD

DIN 964 Countersunk ISO 2010 - cannot be replaced as a result of modified head dimensions → documentedbolts as DIN 964 OLD

Conversion from DIN to ISO Standards

1) with reference to productive parts numbered at ZF

132003-08

Withdrawn Title Substitute Result of check/measures 1)

DIN ISO standard

DIN 965 Countersunk ISO7046 - cannot be replaced as a result of modified head dimensions → documentedbolts as DIN 965 OLD

DIN 980 Locking nuts ISO 7042 - cannot be replaced → documented as DIN 980 OLD ISO 10513

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)


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

DIN 6325 OLD

DIN 7976 Self-tapping ISO 1479 - can be replaced → changed to ISO 1479 screws

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

DIN 7981 Self-tapping ISO 7049 - can be replaced → changed to ISO 1479screws

DIN 7982 Self-tapping ISO 7050 - cannot be replaced → documented as DIN 7982 OLDscrews

DIN 7985 Cheese-head ISO 7045 - can be replaced → changed to ISO 7045 screws

Conversion from DIN to ISO Standards

1) with reference to productive parts numbered at ZF

NOTE: Please inquire as to packaging unit before ordering.

Fig. Special tools Order no. Application Qty. Commentno.

37.5

±0.1

10±0.1

20±0.1

75

60.5

ø9H7

15

M10M

10

11

74

64

112

ø9H7

14212±0.1

240

ø9r6

ø8.7

±0.1

2x45°2x45°

40

25

Sketch

Setting aidfor piston rods on transmission actuator

1Simplifies

assembly1

Special ToolZF-AS Tronic

017912

141327 751 103 - 2005-09 1327_91D_001_en

Designation Designation Approx Application CommentsZF item number Quantity.

Sealing compound No. 262 0.5 gram Ball bolt (06.080)0666 690 022

Uni-Silicon GLK 112grease

NOTE: Inquire size of containers before placing any orders!

ConsumablesZF-AS Tronic

151327 751 103 - 2005-09 1327_92D_001_en

ZF Repair Kits for Transmission/Clutch ActuatorZF-AS Tronic

161327 751 103 - 2005-09

Kit no. Item Content Remark

6009.098.001 GS3 upper section, 20-pin Upper section: 6009 274 080Standard Sealing kit: 0501 319 863

Sealing kit: 0501 319 864Seal: 0501 316 322 without breather

6009.098.002 GS3 upper section, 18-pin Upper section: 6009 274 081Special variant Sealing kit: 0501 319 863

Sealing kit: 0501 319 864Seal: 0501 316 322 without breather

6009.298.006 GS3 lower section Upper section: 6009 274 058Sealing kit: 0501 319 863Sealing kit: 0501 319 864Seal: 0501 316 322

0501.319.863 Sealing kit 1x flat seal, upper/lower section2x retaining bolts1x 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 sensor2x retaining bolts

0501.321.147 Valve unit Solenoid valve plate with 10 valves profile seal3x retaining bolts fully inspected unit

0501.320.849 Pressure reduction valve 1x valve4x retaining nuts1x O-ring

0501.321.148 Travel sensor 1x sensor1x O-ring1x bracket2x 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 cylinder1x profile seal fully inspected unit

0501.322.661 Bracket (for sensor) 1x bracket1x clamp5x retaining bolts1x O-ring Selector cylinder must1x profile seal be removed

0501.322.388 Main transmission piston 1x main transmission piston2x O-rings Complete piston

0501.316.322 Seal 1x flat seal Transmission actuator formain transmission

0768.340.029 Breather (transmission breather) 1x breather 0501 202 797Tightening torque: 10 Nm Pos. 74.120

0768.605.124 Cannon plug (hose breather) 1x M10x1 Cannon plug 0501 315 794Tightening torque:18 Nm Pos. 74.130

0501.315.796 Angle piece 1x angle piece 0501 315 7961x 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 080Sealing kit: 0501 319 863Sealing kit: 0501 319 864Seal: 0501 316 322 Complete new transmission actuator

6009.274.070 GS3 special variant, 18-pin Upper section: 6009 274 081Sealing kit: 0501 319 863Sealing kit: 0501 319 864Seal: 0501 316 322 Complete new transmission actuator

Clutch actuator

0501.322.365 Connection parts for clutch actuator Non-return valve, compression spring, strainer, screw plug, sealing ring,valve bush

Transmission ActuatorRemovalZF-AS Tronic

171327 751 103 - 2005-09 1327_74D_003_1_en

CAUTIONIf 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.

Removing Transmission Actuator

DANGEROnly work on the transmission actuator if the igni-tion is off.

1 Switch off ignition

CAUTIONIf vehicle-specific parts (e.g. fuel pump, coolantpipe, exhaust pipe, or steering pump) have to beremoved, please contact the vehicle manufacturer.

2 Disconnect electric plug connection from transmission actuator.

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

3 Remove compressed air line from transmis-sion 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 partsare being replaced.

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

!

!

34.140

34.130

06.050

06.040

06.080

74.010

74.090

74.120*74.030

74.070

74.140*74.130*

Loctite262

12.090

12.080

*depends on the parts list 024 667

Transmission ActuatorRemovalZF-AS Tronic

181327 751 103 - 2005-09 1327_74D_003_2_en

CAUTIONThe profile seals (/170) and compression springs(06.050; 34.140 and 12.090) may fall into the trans-mission housing.

NOTEBoth profile seals (/170) are contained in sealing kit0501 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).

NOTECover transmission opening, otherwise dirt mayfall 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 thedetent pin holes (06.040; 34.130 and 12.080),these must be removed and cleaned.

10 Remove ball bolt (06.080) if damaged.

/170

a b

018774

34.140

34.130

06.050

06.040

06.080

74.010

74.090

74.120*74.030

74.070

74.140*74.130*

Loctite262

12.090

12.080


Transmission Actuator FittingZF-AS Tronic

191327 751 103 - 2005-09 1327_74D_004_1_en

Fitting Transmission Actuator

1 If the ball bolt is being replaced, coat thethread of ball bolt (06.080) with Loctite no. 262. Tighten ball bolt to 23 Nm.

NOTEIf using costly peripheral attachments, suchas flatbeds, crossbars etc. we would advise checking the transmission with the ZF-Testman pro test software once removedfrom the vehicle. After checking with ZF-Testman pro, load the volume productionprogram depending on parts list and engine(can be downloaded via ZF-ServiceLine).

2 Move piston rod (4) on transmission actuatorinto central position (Neutral). The correct position is reached when slight resistancecan be felt when pulling out the piston rod (4).

3 Transfer measurements “a” and “b” from theremoved transmission actuator to the pistonrods (3 and 5).

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

LegendPiston rod (3) = shifts the splitter group (GV)Piston rod (4) = shifts the basic transmissionPiston rod (5) = shifts the range change group

(GP)Selector gate (6) = selects the shift gate

NOTEWith the 12-speed version, do not slide the central shift rail (06.010) too far into the transmission, otherwise the gearshift fingermay fall into the transmission.

Legend12.010 Shift rail (GV)06.010 Shift rail for basic transmission34.010 Shift rail (GP)06.080 Ball bolt

34.010 06.010 12.01006.080

015019

017908

/170

a b

018774

5 3

/170

6

4


201327 751 003 - 2004-06 1327_74D_004_2_en

Alternative: If measurements “a” and “b” can nolonger be established, the transmission actuatorcan be fitted using setting aid (34) 1X56 138 244.In-house production following sketch, see specialtools.On request, tool 1X56 138 244 can also besupplied by ZF. Adjust the transmission actuator’s piston rods (3,4, and 5) so that they are in contact with the set-ting aid (34). Move the GV and GP gear shift railsin the transmission towards the output. Move thecentral 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 trans-mission actuator are inserted.

5 Place new seal (74.010) on transmission housing.

6 Insert detent pins (06.040; 34.130 and12.080) – if not yet fitted – and compressionsprings (06.050; 34.140 and 12.090).

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

7 Attach transmission actuator (74.030) ensur-ing that piston rods of transmission actuatorreach into gear shift rails of transmission.The upright ball bolt (06.080) reaches intothe selector gate.

CAUTIONYou must be able to push the transmission actua-tor by hand until it reaches the transmission’sthrust surface. Forcefully pulling down withscrews will inevitably result in damage.

8 Evenly tighten M8 hex bolts (74.090 and74.070) to 23 Nm.

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

34

017907

34.140

34.130

06.050

06.040

06.080

74.010

74.090

74.120*74.030

74.070

74.140*74.130*

Loctite262

12.090

12.080



211327 751 103 - 2005-09 1327_74D_004_3_en

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

11 Re-connect up wiring harness at transmis-sion and vehicle ends otherwise functionscannot be tested.

NOTEEnsure that the connectors are snapped intoplace and fitted without traction relief.

Final check:

Has the transmission actuator been reprogrammed?

Refit vehicle-specific parts as far as possible. Thediagnosis unit can only be used to test the trans-mission actuator once the engine is running andthere is a sufficient reserve of air. The system thenundertakes a number of calibration processes. Thismay take up to 5 minutes. The following errorsmay then be displayed: Piston rod not attachedwith errors 132, 134, etc. or teaching-in error forgear, gate, GP, GV sensors with ignition on.

018 403

Transmission ActuatorRemoving and Fitting Upper SectionZF-AS Tronic

221327 751 103 - 2005-09 1327_74D_050_en

Removing Upper Section

NOTESeal kit 0501 319 863 contains both screws (/150-1) flat seal (/150-2) and profile seal (/150-3).

CautionRecord the data on the type plate. This is needed for ordering spare parts and forcorrespondence.

1 Remove both screws (/150-1).

2 Raise upper section (/110) on pressure reliefvalve (/180) and use both tabs (1) to care-fully 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.

* not possible with the 18-pin variant

Fitting Upper Section

1 Insert profile seal (/150-3).

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

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

4 Place upper section(/110) on lower section(/130). Ensure that the flat seal (/150-2) does notslip, fix if necessary. Tighten the two screws(/150-1) to 9.5 Nm.

74.030

/110

1

/150-2

/130

/150-1

/150-3

2

/180

024 532

8

7

018205

6009 274 069

09 03 438724213 550 110

6009 274 069

09 03 438724213 550 110

024 361

21 24

Transmission actuatorTravel sensorsZF-AS Tronic

231327 751 103 - 2005-09 1327_74D_060_en

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

NOTEThe repair kit 0501 321 148 contains two screws(22), one retaining plate (23), one travel sensor(24), and one O-ring (25).

Removal

1 Clean area around sensors.

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

3 Remove two screws (22), take off retainingplate (23), pull out travel sensor (24) com-plete with O-ring (25).

4 Inspect parts and replace if necessary.

NOTEThe sensors for GP, GV main transmission, andgate cylinder are identical.

Installation

NOTEApply Uni-Silicon GLK112 grease to sealingand sliding faces.

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

2 Insert travel sensor (24) complete with O-ring (25), secure retaining plate (23) withtwo screws (22).Tightening torque MA = 7 Nm.

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

021 803

021 794

25

2423

22

Transmission actuatorSolenoid valve plateZF-AS Tronic

241327 751 103 - 2005-09 1327_74D_070_en

Replacing Solenoid Valve Unit

NOTEThe repair kit 0501 321 147 contains three Torxscrews (19), one solenoid valve unit (18), and oneprofile seal (20).The solenoid valve unit (18) contains 10 solenoidvalves as a fully checked unit.

Removal

1 Remove three Torx screws (19).

2 Remove solenoid valve unit (18).

3 Remove profile seal (20).

Installation

1 Apply Uni-Silicon GLK112 grease to sealingand sliding faces.

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

3 Place solenoid valve unit (18) and securethree Torx screws (19) to 18 Nm.

19

18

20

021 804

021 785

Transmission ActuatorReplacing Selector CylinderZF-AS Tronic

251327 751 103 - 2005-09 1327_74D_080_en

Replacing Cpl. Selector Cylinder

NOTERepair kit 0501 321 182 contains the selector cylinder (28) and a profile seal (29).

Removal


2 Remove three hex-head bolts (27).

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

4 Inspect parts and replace if necessary.

Installation


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

2 Place cpl. selector cylinder (28) on trans-mission actuator’s lower section (/130) and tighten the three hex-head bolts (27) to23 Nm.

3 Plug connector (26) onto sensor contacts.

26

/130

27

021 786

29

28

26

021 787

Transmission Actuator Bracket for Temperature and Speed SensorZF-AS Tronic

261327 751 103 - 2005-09 1327_74D_150_1_en

Bracket for Temperature and Speed Sensor

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

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

Removal

1 Remove upper section.(See page 22)


3 Remove three hex-head bolts (27).

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

5 Remove Torx screw (48).

27

49

475248

58

29

024 559

26

/130

27

021 786

48

021 790


271327 751 103 - 2005-09 1327_74D_150_2_en

6 Take off input speed sensor (50) with spacerplate and temperature sensor (51).

7 Remove Torx screws (47).

8 Use a suitable tool to raise and remove thecylinder cover/bracket (58).

9 Replace O-ring (49).

50

51

49

58

47

021 791


281327 751 103 - 2005-09 1327_74D_150_3_en

Fitting Bracket for Temperature and Speed Sensor

1 Insert new O-ring on cylinder cover (58) andon travel sensor (51).


2 Insert cylinder cover (58) in housing’s lowersection.

3 Insert input speed sensor (50) with spacerplate and temperature sensor (51) with theO-ring (49) in the cylinder cover’s bracket(58).

4 Tighten Torx screw (48) with 6 Nm.

5 Tighten Torx screws (47) with 18 Nm.

6 Insert profile seal (29) on transmission actu-ator’s lower section (/130).

7 Place selector cylinder (28) on transmissionactuator’s lower section.

50

51

49

58

47

024 791

48

021 790

29

28

26021 787

Transmission Actuator Bracket for Temperature and Speed Sensor4ZF-AS Tronic

291327 751 103 - 2005-09 1327_74D_150_4_en

8 Use three hex bolts (27) to secure selectorcylinder 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

Transmission ActuatorWiring HarnessZF-AS Tronic

301327 751 103 - 2005-09 1327_74D_100_1_en

Removing Wiring Harness (Input Speed Sensor and Temperature Sensor)

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

1 Remove upper section.(See page 22)

2 Carefully raise tab and pull connector (26) offsensor contact (34).

3 Remove the Torx screws (47 and 48).

NOTEScrew head (47) T40Screw head (48) T25

4 Take off input speed sensor (50) with spacerplate and take temperature sensor (51) out ofbracket of cylinder cover (58).

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

34

26

47

021 789

48 47 52

021 792

50

51

58

024 738


311327 751 103 - 2005-09 1327_74D_100_2_en

6 Bore out the rivet heads (drill diameterapprox. 5 mm). Take wiring harness off transmission actua-tor’s lower section.

7 Use a pair of flat pliers to turn out the rivetshaft.

8 Remove rivet residue and drilling chips.

024 534

024 668


321327 751 103 - 2005-09 1327_74D_101_1_en

Fitting Wiring Harness (Input Speed Sensor andTemperature Sensor) (repair kit 0501 321 146)

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

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).

4 Tighten screw (48) with 6 Nm.

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

64 65

024 560

50

51

49

58

47

021 791

021 792

48 47 52

53

021 793


331327 751 103 - 2005-09 1327_74D_101_2_en

6 Route wiring harness behind rib (53)without any bends, chafing, or squashedareas.


8 Fit upper section.(See page 22)


21 24

021 794

021 789

34

26

Transmission ActuatorPressure Relief ValveZF-AS Tronic

341327 751 103 - 2005-09 1327_74D_011_en

Replacing Pressure Relief Valve

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 lateron.

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

CAUTIONDo not use grease to fit O-ring (12).

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

10

019251

74.030

12/180

019252

Transmission ActuatorLower SectionZF-AS Tronic

351327 751 103 - 2005-09 1327_74D_130_1_en

Dismantling Lower Section of TransmissionActuator

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)

CAUTIONThe cylinder covers are numbered. They have tobe refitted in the same positions.

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

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

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)

54

2424

021 795

5556 57

021 796

59

62

58

60

61

021 797


361327 751 103 - 2005-09 1327_74D_130_2_en

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

63

58

70

021 798


371327 751 103 - 2005-09 1327_74D_140_1_en

Assembling Lower Section of TransmissionActuator

1 Use a suitable tool to insert the low-frictionbearing bushes (70) flush with the bearingbore.

2 Use a suitable tool to insert the new sealingrings (63).


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.

5 Fit cylinder covers (58, 57, 56, and 55) in thesame position from which you previouslyremoved them and secure each one with twoT40 Torx screws (54).Tightening torque MA = 18 Nm.

63

58

70

021 798

59

62

58

60

61

021 797

5556 57

021 796


381327 751 103 - 2005-09 1327_74D_140_2_en

Assembly check

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

6 Fit sensors (24).(See page 23)

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

8 Check again that connectors are tight andsecure.

24

213

1

021 799

28

021 800

1

Transmission ActuatorProgrammingZF-AS Tronic

391327 751 103 - 2005-09 1327_74D_012_1_en

Programming Transmission Actuator

When replacing the transmission actuator and/or upper section, customer-specific programmingand/or parameter setting (entering EOL data) willbe required.

During parameter setting, the EOL data areentered in the transmission actuator’s electronicsusing Testman pro and the corresponding soft-ware.

Diagram of transmission actuator programmingPos.20 Table mode adapter20.1 Power supply connection21 Cable to the DPA22 DPA23 Cable to laptop and/or PC

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

NOTEIf using costly peripheral attachments, such asflatbeds, crossbars etc. we would advise checkingthe transmission with ZF-Testman pro test soft-ware once removed from the vehicle. After checking with ZF-Testman pro, load the volume production program (can be downloadedvia ZF-ServiceLine).

20.123

22

21

20

019643

Transmission ActuatorProgrammingZF-AS Tronic

401327 751 003 - 2004-02

Programming Flash EPROMS with ZF Test Program

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 017USB connection cable: ZF no. 6008 207 026Diagnosis interface cable: ZF no. 6008 207 02424 V voltage supply

Procedure:- Download the installation

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

- 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 thepassword: testman

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

- Start Testman pro if necessary, note the customer-specific data in transmission actuator (e.g. iHa; Intarder etc.) andthen program the test program. Load Testman pro/Flash programming / parts list. Open the fileGS_test_07_2005.txt and program (processors 1, 2and E2 data are programmed and the drive pro-gram originally programmed is deleted).

Description of Test

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

- Connect table mode cable to transmission actuator(at vehicle end) and link to laptop using connectioncable, DPA05, 24 V voltage supply

- Start Testman pro Select main menu/AS Tronic/assembly check AS2.

NOTEThis test must not be used in the vehicle when theengine is running!!

- Select test rig function start.

- Use the numerical key functions 1 - 0 on the laptopkeypad or mouse to shift through the ranges:1 = Upshifting gears 1 - 162 = Downshifting Gears 16 - 13 = Neutral4 = 1st R gear5 = 2nd R gear

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

- Menu item 9 shows the gear currently selected.

NOTEThe 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/softwareassignment. (Source: ServiceLine)

1327_74D_012_2_en

Clutch ActuatorZF-AS Tronic

411327 751 003 - 2004-02

Clutch Actuator(repair kit 0501 322 365)

DANGEROnly work on the clutch actuator if the ignition is off.

The repair kit consists of a screw plug (1) withsealing ring and a valve screw (2) with O-ring.

Tightening torque (MA):Screw plug (1) MA = 22 Nm Valve screw (2) MA = 70 Nm

!

1

2

024 537

1327_68D_070_en

Documents

ZF Actuator