Assembly, maintenance and operating instructions manual

Assembly, maintenance and operating instructions manual

ZF-Synchroma-Gearbox
S 5-18/3
Assembly,Maintenance
and OperatingInstructions
AG
ZAHNRADTABRIKFRIEDRICHSHAFEN
SCHWAEBISCH
GMUEND WORKS
D-7070SchwaebischGmuend
Graf.von-Sodon-Stra0e
$9
Germany
phone07171
/601-l . telex 07 24880.| . cable:Zahnradfabrik
SdrwaeblsdEnuond
07 24A825for servlc€deoartmsnt
1 2 5 57 5 1l 0
Prlnted In Germany
S 5-18/3
ZF.SYNCHROMA.GEARBOX
Assembly,Maintenanceand OperatingInstructions
Contentg
Pag€
L Todrnical Data
ll. Do8crlption
lll. HandlingOperation.
lV. Mgint6n6nc6and Lubrication .
V. Tools .
Vl. Stripping ot Tranambsion .
I
Vll. Ch6cklngof Individu.lCompon6nts
12
Vlll. Ass.mbly of G€arbor
12
lX. Ordering Sp6r6 Parts
23
X. Koy to lllustrationa
24
xl. Erplod6d Views
Xll. List of ZF Servico Stations .
3l
l. TedrnicalData
Typc
Input
Torqu6
max. kpm
t.Gear] 2.Gear
I s.c*. ll.o"". ls.cea.i R.c"a.I speedokpm'
2,4
2,08
for CAR
30
2,99
I,76
6,0
5,33
3,24 |
3,03
3,24
't6
for light
conmercial
t6
t8
vqhlcl€8
PTO
Md.Ab.. I
pgrm|agaDrg
Bdor
t,76
1,39
t,3
1,26
t.0
't.0
t,0
0.87
0,87
2,U
|,81
t,3
1,3
t,3
't,0
2,U
1,0
1,0
3,67
2,5
3,67
to
3,67
3,4
5,47
2,17
5,47
IO
5,47
4,0
12
|
I
outout
^
uPooo
t,02xn
Engln6
' For cor€ct value, rovcr to ZFF t€drniqal d€pgrtment.
W.lghk ca. $
kg
Oll crprclty! ca. 1,6 liter
ll. Description
The ZF Synchroma5 sp€od ggarbox S $18/3 is an up to date ge€rbox syn.hronlsod ln all forward geara. Thg rcvora€ 96ar haa a
claw clutdl. Ths traosrnis8lonls flangod dlrotly to tho sngine and lo actueted by meana of a sst b;ck or a centrol flo6r Ehift or
bJ a atoerlng column dqpendlng on th€ type of vehlcle. Thg dosign ofthe transmlssionand the us6 of of push rods ior trEnsmttdng
th6 Ehlftlng iorces guar6nt96 easy 9nd accurats shifting of th6 trahsmission in all sttuations.
Ths.tr6namisslonls a countershaft (layshsft) typ€. Thg mating gears of all speed8 remain conatantly in m€8h. Whllst thg who€ls
on thq countsrshaft aro permanontly gttadr€d to ths shaft. the nssdls bearing count€r wh€ele can rdtatg freely on the mEtn 8h9ft.
During tho rhlftlng opgration, the 6pe€d8of tho membcrs to bo coupled 619 eyndrronleed by ZF-B syndtrontggre.The Idler gear of
thg pertinsnt Bpe6d 19couplgd to tho mainshatt by m€ang of a clawed eleevi and the powlr flow d gutded by the perinqni gearg
to ths outoul snd.
At dirsct epeod (that can bg 4th or sth g€ar according to gEarbox type) the countsrahaft is not Includsd in the powor flow i. e.
thg Input thaft.and th6 maln shaft ar€ coupled diroctly to eadr othg. and conaoqu€ntly tho ongine r€volution end the torquo
dlango to l:1. In revsrse gear ths diroction of tho output sp€ed i6 .fi6n9qd by I built-in intermedlatgggar (so-called reveree geir).
Tho shiftlng El€9vqs 8upply 8hlft forke whldr are guided by bearing gplgots €nt€.ino th6 gesrbox housinq and wht.h ar€ actuatod
by thg push rod8. Tho Ehlft forks arg hgld in th6 engsged pgsition by spring dot6nt8. A butlt-in shift lock luarantees that only ono
Bpo6d qan be snggg€d at a timo.
ZF-Synchroma-GearboxS 5-t 8/3
Assembly
Descriptionof ZF-B-Synchroniser
Oescription
The follow ng components are assembled between lhe
gear wheels of lst and reverse speed, of 2nd and 3rd
speeds as well as 4th and sth speeds.
1
The Synchrobody (A)
A x r a l l y a n d r a d r a l l yr m m o v e a b l eI n r e l a t i o nt o m a n shaft (B) on wh ch rl rs located
2
Synchro Sprrngs (C)
A synchro spflng is attached to each side of the
synchrobody. They press the pressure preces lightly
on the slrdrng sleeve (H)
3
Pressure Preces (D)
They are axrally drsplaced on selectron of the slrdng sleeve and thus press the synchro rrngs onto
the cone of the clutch body (l)
4
Synchro Brngs (F)
These are placed loosely between gear wheel (G)
and synchrobody (A) There rs no synchro ring on
the reverse gear wheel. as this is not synchrontsed
These components permrt establ shrng of unrtorm angular speeds between the gear wheel to be coupled and
the shafi before the slrdrng sleeve (H) and rts Internal
teeth enter lhe cluich teeth of lhe (pertinent) gear
Op€retion ot Syndronl.or A...nbly
1 . l d l i n g( F i g s .I a n d 2 )
J
t
H
I
N
Sliding slsevo (H) is in th€ centre positaon.h i9 hsld in
this position by 6 shift fork whidt is located by tho sslgctor
of the dstent bolt. The gear wheels (G) can rotate froely
on thg mainshaft.
Shifting Opsration(Figs.3 and 4)
II
FR
A) Syndrro Body
B) Mainshatt
C) Syn.hro Springs
D) Prgsgure Piece
E) N€€dle B€aring
F) Syn.hro Ring
G) Geer whe€l
H) Sliding Sleeve
.,) Clutch Body
4
Th€ sliding sleev€ (H) as pushgd forward axially in ono
direction (in th€ exampl€shown to the left). The pr€g8ure
piecos are tsk6n along by tho 8liding slosvo, as th€
pressurs pigcsa 9re push€d by th6 preloaded gynchronissr
8prin96 (C) with th€i. trapoziuh shop€d tops into the some$rhat wider 6nnular groov€ of tho sliding als€v€. Th6 two
syndrro rings (F) lie to lgft and right of the prossure
pieces. When the sliding slogve movos to the left after
passing through ths fre€ lravol botw€on the sliding slsgvo
and the preasurs piece. the lgft Byndrro ring will be movod
to the left side in the sam6 way by thg prosgure pigcea.
After approximatgly0.5 mm the syndtro ring with lts conical
6urfaco is adjacent to the simil6r conical surfaca of the
clutdl body. This will rotate thg synciro ring by app.oximately 2 mm In relation to thg sliding sle€ve and the
synchro body (A) until ih6 syndrro.lng and its lugg 619
resting in tho slots of the gynchro body. The position of tho
syndrro ring in rolation to the sliding gleeve is thgrgfore
gudr that thg tggth on th€ out6r diam€ter of the rangare
offset in rel6tlon to the toothgaps ot the sliding 8le6ve
(Fig.3).Wh9nthe sleeve i3 pushodon further.itg tgethwill
rest againSt those of the aynchro ring and submit an
axial force against the ring. Th€ flat adjoiningangl6 on
the Eliding Eurface of the clutdr body (J) and the blocking
ring will €stablish forcos in radial direction whidl ar9
stronger than thg forces whidr are trsn6mitted to th6 sliding slegve in axial direction. Thio $rill continually r€duce
tho diffgrgncs in sps€d betwe€n the g€ar to be 6ng6ggd
and th6 mainshaft (es well ae the 8liding sleevo). Only
wh€n the two apeeds aae synchronig6d will the synchro
ring and ths gsgr whe€l turn back slightly (approx. I to 2
mm) until thg teoth of ths sliding slsove are in line with
the tooth gaps of the syndrro ring. At thig momsnt, thg
rcsistanco whidr has prcvonted 9ny furthgr movsment of
the sliding 8la6ve during thg shifting operation will b€
overcomg and the slg€v€ is now pushod into thg coupling
teeth of th6 appropriate goar whesl (Fig. 4). This is th6 end
of th6 shifting cycl€.
lll. HandlingOperation
Economicdrivingof a vehicle requiresthe engineto run constantlyin the most favourablospeed range. On most €ngines,thi6
speed range is restrictedbut a s-speedtransmiasionpermits easy adaptationof th€ engineto the varyingdriving conditions.
Since all forward gears on the S5-18/3 are fully syn.fironised,a fast reliableand noiselessg€ar changecan be effectedwithout
doublede-clutdringon shiftingup and without rewing up when 6hiftingdown.
On shifting, the sel€ctor lever of the syndrronised forward gears should b€ pressed in smoothly and evenly. Only when the synchroprocessis at an 6nd does the Eelectorlever move into final selectedposition.
To protectsynchronising
componentsin the transmission,in the main clutc$ and the engine, shifting down should be effected
only when the driving speed corresponds to the max. speed of the next lower gear.
The rever6egear may be engagedonly when the vehicleis stationaryas otherwisethe dog teeth may be damaged.
The clutdl pedal should always be depressed when selecting both forward and reverse speeds. Por'oct adiustmeni of lhe main
clutdr contribute! considorably to the prov€ntion of .hifting trouble. The clutci should engage and disengagecompletely.The
6pecifiedpedal play shouldther€forebe checkedregularly.
lV, Maintenance and Lubrication
The followingtyp€s of oil can be used for lubricationof the gearbox unl6s5the lubricationinstructionsof the vehicle manufacturer are different.
1. Mild €P-Goarbox oll., prctcrably of viscosity cla3! SAE 8{,
2. HD-Engins oil3 ot vi.co3ity cla33 SAE 30
Mild gear oil types are those EP oil grade6whiah in the presenceof condensationdo not cause corrosionon steel and non-ferrous metal parts and hardeningof gasketsand Eeals.So-called multi-purposeor universaloils can be used if they meet our
for ZF Transmission
Nr. 13-118".In case of doubt,pleaseaek an oil supplier.
"LubricationOil Roquirements
To facilitatethe choicoof oil for vehiclesused abroad,it should be mentionedthat multi-purposeoil SAE 80, with rnild EP-Additives, as per specification MIL-L- 2105 (A), can meet these requirements.
Oil Lovol Ch€d(
The oil level in the transmissionshouldbe ch€ckedregularly(approx. every 10.000km). The dleck should be undertakenonly
when tho vehicleis in a horizontalposition.lf this is carri€dout after drivjng,'thensome time shouldbe allowedto elapseuntil the
oil has settledin the transmigsion.
Ths oil filler plug should be removed fron the sid€ of the gearbox (to the right as seen on th6 output flange) to check the oil level.
The area aroundth6 plug shouldbe cleanedso that no dirt c6n fall antothe transmission.lf ths oil level has dropped below the
edge of the bore, then the oil should be filled to overflowingagain.Then close the oil filler plug. lf possible,the sam6 type of
oil should alwaysbe used.
Oil Change
The gearbox oil in.a new or repaired gearbox should be .tianged first after 4000 to 5000 km or 6fter 100/125 working hours, and
then every 16 000/20000 km or 400/500working hours.The old oil should always be drained after driving as it i6 th€n warm,
flows easily and flushes th6 driving parts and possibly removes the w6ter condonsationwhich has tormed tiom the gearbox more
ea9ry.
The oil drain is on the undersideof the transmigsion,
set furthestback. Prior to screwingthe drain plug back,the magnetshould
be cleanedof adheringabragiv€s.
The now oil shouldbe put in vja the oil fill€r and should in fact overtlowat the €nd of the bore (requiredoil capacityapprox.1,6 l).
Oft€n, lubricantsand additivesare offored in additionto the oil. The oils meeting our instructionsalrsady have their additives
whidl the transmission needs. An)4hing further is not nece9s6ry, and could even cause damage.
V. Tools
Tool Nr.
12538986s3
Tool .1.
Device for fasteningtransmissioninto vice
f ool .2.
Tool for pullingout ball bearingof the mainshaft
and input shaft.
1253898205
the ballbearings
ln a larggrnumb€rof thesegearboxeg,
ar€ fitted with divid€dinner ring. The followlngtools
are necegsaryfor the assemblyof thi6 boaring.
UniversalPuller
124889820r
fnsert for pufling ball bearings (212 and 423)
1253898203
Pullerfor ball bearing inner ring
r 255898202
Tool .3.
r211898206
Pullerfor reversebolt (only for heavyvehicleversions)
r 253898204
Tool .4.
Ba6acTool
Tool .5.
Grippingpiece for pullingroll€r bearings
(303 and 309) off the counter shaft.
ts
1253898202
Tool .6.
Bu6hes for presging synchroni66ronto mainshaft
for 1.--+l- g€ar
2.---3. Gear
4.-5.
Gear
trga
1255 898 052
1255898 053
1255898 054
Tool Nr.
Tool .t.
Preasura pi€c€ for knocking spring rings onto
Syncnronlaaa
r 2s3898054
Tool .8.
Tool for pr€8slng ball b€aring (212 a d 423)
on tho main- and input shafts
| 253898652
Tool .0.
Prssslng mandril for tho sh6ft 8€al (207
in tho wlthdraviral bgaring carrlor (206)
Tool .t0.
Toolfor preeelngBhaftssal Into thg sp6€dobush
| 25s898051
,,$e
1253898631
Tool .l |,
Mandril for presglng th6 tapergd roll bearing Inner
rlng onto ths countor shaft
| 2r | 898051
Vl. Strippingof Transmission
Noi€: The numeralsIn bracketse.g. (611) refer to part numbersin explodedview at end of instructions.
Screw tool .1. into the thread of the oil drain plug (to fasten transmissionmore socurely,the full thread in the housingshould
be used) and secure gearboxwith the tool in the vice- Pull the lock nut of the tool .1. lightly.
A) Bemov.l of G€ar Shift
l.
Remote lloor shllt (Car)
1.1Removeboot (643).Removecirclips(642)from the groove
of the gear lever turret (Fig. 1). Pull the geardrang€control lever (640) with the bushes (641) from the gear change
turret (Fig.2).
1.2Loosen the 4 screws (637) (Fig. 3) and lift off the gear
changeturret from the selectorarm (Fig-4). Take off guide
prare.
Fig.4
1 3 Pull pivot pins (630)from the gear changeturret.Take out
interlockswing (625)with torsion springs(633 and 633.1).
Screw off the 4 nuts (648)on the selectorarm (619)(Fig.5)
and plll selectorarm over the selectionrods. Take pivot
piece (624) out of solector arm.
Fig.2
2
Loosennuts (808)and screws(803).Takeoff speedocover
(801).S ip off short drstancebushes (428).speedo worm
(427)and long spacingbushes(426).
Fs.5
I 5 T a L e o u t c y l ' n d ' r c a l s c e w s ( 6 4 5 ) r F g 6) and take off
vibration damper (644)
Fiq I
Snap sprrng ang (425) out of ball bearing groove (423)
and slide off the spacer (424) Pull the ball bearing frorn
the marnshaftwth tool 2. Attach the spacer (424)to the
ballbcaring.
Dismantlingof Front Part of Housing
1
Loosennuts (20r) (Frg.9) and front cover (203)
F r g .6
2. Centrallylocateddirect gear change(commercialvehicle)
2.1 Sl p off the gaiter (643) Unhookcap (655)frorn the prvot
pins (652) and p!ll selecton lever completelyout of the
gearchangeturret.
2 2 Loosenthe 4 nuts (648)and lrft up gearchangeturret from
housing(629) Removeselectorgate (653).
2.3Pull pivot plns (630)from the gearchangeturret Take out
interlockswing (625)with tors on spring(633and 633.1)
Fig 9
B) Dismanllingof SpeedoCover
I
Push back the safety tab on the nut (430)and loosennut
(Fig 7). For this, 2 gears must be engaged Pull the output
flange (429) from the mainshaft.
2
Bemovecrrclp (208) (Fig. 10) and take off spacer (209)
3
D s m a n t l es p r n g r i n g P u l l o f f b a l l b e a r i n g( 2 1 2 )w r t ht o o l
.2
4. Push back the 2 dowels (106)(Frg ll)
D) Oi3mantlingof Gearbor Shaft3
l. Take off selectorfork 4th and 5th gear (601).
2 D i s m a n t l se e l e c t o r o d s ( 6 0 8 , 6 1 2a n d 6 1 a )( F r g .l 5 ) .
Loosen set screws (602) on the prvot prns (604 and 610)
( F i g 1 2 ) a n d p u l l p v o t p L n sf r o m t h e h o u s r n g
F9
15
Take gearbox shatl from the housrng (Frg 16) Pull the
2 detent plungers and lhe 2 ccmpressron spnngs (616)
Ftg 12
U n s c r e w n u t s ( 1 0 2 ) a n d t u r n c y l r n d rc a l s c r e w s ( F r g l 3 )
Fg 16
E) Oismantlingof Bever6eGear
I
U n d o t h e s c r e w s( 1 1 8 )a n d t a k e o f f t h e c o v e rp l a t e( 1 1 7 )
2
Removethe set screws (507) from the hous ng (Frg. 17)
o r p u l lo u t t h e d o w e l( 5 1 1 ) P u l lo u t t h e r e v e r s er d l e rs h a f l
Fig l3
T a k eo f f f r o n t p a r t o f h o u s r n g( 1 0 1 )( F r g 1 a ) P u l l d e t e n r
p u n g e r( 6 17 ) a n d c o m p r e s s r osnp r n g ( 6 1 6 )f r o mt h e b o r e
it
Fg 17
(505) wrth specra too 3 or knock towards the output
s de wrth a frtteCmandril(Frg l8) Take out the reverse
gear (502) wrth the 2 thrust washers (501) Pull the 2
neede cages (503)from the bore of the gear.
Fig. 18
F) Dismantlingol Mainshah
I
Berrove thrust washers (422) and 1st gear (421) wrth
synchroring (402) and needle cage (408) from the mainshaft.
Remove synchro spring (403) from the pressure piece
(aoa) (Fig. 19). Pull slrdingsleeve (420) from the synchro
Fig.21
Pull off synchrobody 4th and 5th gear (405)wrth 2 screws
M 8 and conventionalpullrng bridge (Fig. 22). Take off
synchroring (402),5th gear (a07)and needlecage (408).
Fig.1 9
body (419)and take off pressurepiece (404).Bemovecir'
clip (409)from groove (Fig.20) and mark posrtronof the
svnchrobodv on the mainshaft.
Fig.20
Clamp mainshaftwith the input side upwardsbetweensoft
jaw6 of a vice. Removeinput shaft (213).roller cage beartng (214) and synchro ring (402).Removesynchrospring
(403).Pull off sliding sleeve (406)and dismantlepressure
piece (404).Removecirclip (401)and mark positionof the
synchrobodyon the shaft (Fig. 2i).
Fis.
Remove circlip (409). Push the thrust washer (410) with
the 3rd gear (411) from the cylindricalspliningof the shaft.
Take off synchroring (402)and needlecage (412).
B€move synchro spring (403) on the syncfiro body 2nd and
3rd gear (414). Pull off sliding sle6ve and r€move pressure pieces(404).Removecirclip (413)(Fig.23) and mark
position of the synchro body on the shaft.
7 . With a press, press down first of all the roverEegear (418),
with the synchro body to the output side, and then the 2 nd
gear (415) with the 6ynchrobody (414) to the input sid€.
Take the 2 needle cages (416) from the mainshaft.Bend
back the circlip (419-2) on the synciro body rev€rse gear
(419). Bemove spring ring (419.1)and take off circlip,
spacing plate (419.3)and Eynchrospring (403).The synchro
spring (403) which lies bohind tho weldod angular plccc.
anthe synchro body reverse gear should not be removed.
G) Di3mantling of Layshaft
Removecirclip (301)and pull off roller bearings(303 and
309) with tools .4. and .5. The constant gear wheel (304),
the sth speed gear wheel (306) and the 3rd speed gear
wheel(307)can be pressedfrom the countershaft individually with the help of a 20 ton pres6, as theso geara are
shrunkfit.lt shouldbe notedthat the circlip (305)shouldbe
removed before the pres6ing of the sth speed gear wheel.
Removeall gasketpartssuchas shaft seals,(207,811, 812)
gasketsand O-Rangsfrom the housinghalves,the speedo
cover,the withdrawalbearingflangeand the pivot pins.
Fig.
Vll. Checkingof IndividualComponents
t . Check synchrorings (402)for wear. lt is advisablealwaystoreplacesynciro ringswith new ones when repairingtransmissions.
2. Check short teeth of clutch body for wear and damage.
3. Check all slide pieces for wear. The axaalplay in the groove of the slidang6leeve must be 0,2 mm to 0.45 mm for 15t and
reversegearsand 1,6 to 1,85mm for the remaininggears.
Check shift forks for damageand wear.
5. The runningsurfacosof th6 needlebearingson the mainshaft(417),on reverseshaft (505)and in the bores of gear wheels,as
well as the n€odlesthemselves,should show no signs of wear or pitting.
6 . Check teeth of all gear wheels for wear and pitting.
1 . Check outputflange(429)6nd input shaft for ecore marks caused by shaft sealingrings.
8. Ch€ck drive pins and guide grooveson shift rails (608.612, 614) for wear.
Gears of countershaft are shrunk-fit.They can be removedonly on a 20 ton press.For shrinking,heat gear6to 150 to l80o C
and then slide on counter shaft. Be sure to maintain the above temp€rature since a temperaturs in excess of l80o C may cause
structural dtanges which in turn might impair hardness. At temperatures below t50o C, the- expansion-of thg gear i9 too low
and the gear w-heolmight seize when pressed onto shaft (also refer to "Prca66embly of Countershaft").
Vlll. Assemblyof Transmission
Prior to assemblyof the transmission,all componentsshould be carefullycleand.The sealingsurfacesof the housingfront end
and rear end should always be smooth€ddown to remove remainingvarni6hand p€rtinentdamage.Prior to reassembly,ead!
part must be ctecked for w€ar or oth6r faults and lubricatedwell. Gaskets.shaft sealingrings, O-Ringsand lock washersshould
alwayg be replaced by new ones.
Mak€sure in particularthat no dlip6 or other foreign particlesremain in the hou6ing.For insertingshaftsand bolts, always use
a soft hammer(plastic,lead etc.).N€ver hit hardenedtransmissionparts with a ste€l hammer.When installingstuds, make sure
holes togetherwith sealingcompound(for good sealing).
that they are insertedinto tapped-through
The assemblyof the individualshaft and of the entiretransmissionproceedsvice versa to stripping.When assemblinggear levers
and the lik€with hubs on one side, correct positioningduring assemblyas important.
A) Preassembly
of HousingComponents
S c r e w s t u d s ( 1 0 4 .1 0 5 , 1 0 8 ,1 0 9 1 1 0 , 8 0 5 a n d 8 0 6 ) i n t o
t a p p e dh o l e so f h o u s r n g .
Note: New studs for through holes are Insta ed coated
w r t h s e a l i n gc o m p o u n d .
B) AssemblyoI ReverseGear Wheel
1 Put needle cages (503) nto reverse gear bore (502) and
strck needleswith grease.Stick a thrust washer (501 and
510) on each side of the wheei with grease (the turned
down faps lre outwards).Put the reverse gear Into the
housing.Push the reverse dler shaft wth the sma er .'
first into posrtronn the housrngbore from the output s de
(Fig 24). Take care that the thrust washersare not dama
ged by the shaft
2. Insertscrews (507)wrth spnng washer(506) (underneath)
a n d t i g h t e nt o 2 . 0 t o 2 . 5 k p m ( s e e F i g . l 7 ) T h e s e c ! r n g
bolt must come to lie behrndthe shaft (not rn the groove)
On various gearbox types a dowel (511) must be pLrt
throughthe housing nto the shaft bore
3
srng,the posrtronsot the hub and shafi, markedon
d s a s s e m yb . s h o u l db e I n l r n e .
1 . C l a m pm a r n s h a (f t4 1 7 )b e t w e e ns o f rj a w s i n t h e v i c e .O u t -
put end on top.
2 . S l i d e n e e d l ec a g e ( 4 1 6 )a n d 2 n d g e a r w h e e ( 4 1 5 )o n t o
rnainshaftwith dog teeth on top (Fig. 25). Placea synchro
nng (402)on the cone of the gear
3
Placc a synchrospnng (403)onto the side of the 2nd and
3rd gear synchrobody (414)whrchrs first pushedonto the
m a i n s h a fi e
t o n t h e s i d ew h L c h a st h e s p l n r n ga n d a t t a c h
the squaredoff end into the cross slot (Fig. 26) Heat the
preassembled
2nd and 3rd gear synchrobody up to 80oC
andwrththe spl nes Ined up Intothe positionmarkedduring
pressonto ma nshaft(Frg.27).Only assemble
drsassembly,
the synchrobodywrth tool .6. or wrth a suitabe tube whrch
fits over the hub. Make sure that the lugs of the synchro
r ngs (402)lie in the recessof the synchrobody.SprLngon
the circl p (413)i this must sit tightly in the radralgroove
a n d i s t h e r e f o r ea v a r l a b l e
r n t h i c k n e s s eosf 1 . 8 i 1 , 9 a n d
2,00 mm Use loo 1 fot tapprngthe circlip into posrlron.
Fastengasket(116) and cover (117) onto the housrngw th
s e t s c r e w s( 1 1 8 )a n d s p n n g w a s h e r s( 1 0 3 )( u n d e r n e a t h )
Trghtentorque of the screws to 2 to 2.5 kpm
'\
Itl
ll
c) P r e a s s e m b l y o f
Mainshaft
Note: New synchrobodies (405, 414 and 419) have no
cyl ndncal sp rn ng n their hob. Thrs rs pressed onto
t h e h a r d e n e d m a n s h a f t T h e r e f o r e . w h e n L r s i n go d
s y n c h r o b o d r e s ,r t s h o u l d b e n o t e d , t h a t b e f o r e p r e s -
F g 25
Fig 26
F'g 2 1
Attach the 3 pressurepreces(404)wrth greaseto the assembledsynchrospring such that the wire is frxed In the
recessesof the pressurepieces.The squaredoff end of the
s y n c h r os p l n g m u s t c o m e t o l e o n t h e i n s r d eo f a p r e s
s u r e p r e c e( F i g . 2 8 )s o t h a t t h e s p n n gc a n n o td r s t o r t
Attach secondsynchrospnng (403)in the pressurepreces
(Frg.30) The squaredoff end of the springmust le on the
nner srde of a pressurepiece. Moreover,take care that
the 2 sprLngends are assembledIn drfferentpos trons to
each other r. e lre In 2 drfferentpressurepeces. Lay the
second synchro rng (402) on the synchro body (see
F i o .3 1 )
Fig.30
Slide the needlecage (412)onto the mainshaftand place
t h e 3 r d g e a r( 4 1 1 )i n t ot h e s y n c h r or i n g ( F i g .3 1 ) .S l i d et h e
t h r u s tw a s h e r( 4 1 0 )o n t o t h e s p l i n r n ga n d s n a p a c r r c l i p
(409) Into the radialgroove of the shaft The ring must sit
trghtly In the groove and rs therefore availablein thick'
n e s s e so f 1 , 8 i 1 , 9 a n d 2 , 0 0 m m . U s e t o o l . 7 . f o r t a p p r n g
the circlip into position.
F i g 28
P u s h t h e s l r d r n g s l e e v e ( 4 0 6 ) o n t o t h e s p L r nn g o f t h e s y n '
chrobody as shown in Fig.29 (This sliding sleeve is the
same on both sides). The 3 flat teeth lie on the pressure
pieces. Engage pressure pieces In the notches of the teeth
Frg.31
Fg.29
Fig 32
Slide the needle cage (408) and 5th gear wheel (407) w th
the dog teeth upwards onto the bear ng seat of the shafl
(F g.32). Place a synchro ring (402) on the cone of the gear
9
o f t h e m a i n s h a fTt h e c r r c l i pm u s ts L tt r g h t y I n t h e g r o o v e
A v a i l a b l en n g t h i c k n e s s e s1 , 8 i 1 , 9 a n d 2 , 0 0 m m P u s h
clrcl p up to stop In the groove with tool 7.
Place a synchro spnng (403) onto the side of the synchrobody (405) with the longer hub and attach squared off end
to the cross slot (see Fig 26) Heat 4th and 5th gear synchrobody toS0oCand press itwith the ongerhub frrst onto
m a r n s h a f t( F i g . 3 3 ) . U s e t o o l . 6 . a n d n o t e t h e m a r k e d
position when pressrng on and insert the lugs of the synchro rings Into the notches of the synchrobody. Select a
c r r c l L p( 4 0 1 ) t h i c k e n o u g h t o s i t t i g h t l y I n t h e r a d a l g r o o v e
T h e r n g s a v a i l a b l e i n t h r c k n e s s e so f 1 , 8 i 1 , 9 a n d 2 . 0
Attach crrcl p and with tool .7 push into groove
Frq 35
A
I 3 . S t c k t h e 3 p r e s s u r ep e c e s ( 4 0 4 )w r t h g r e a s eo n t h e a s
sembledsynchrospang (403)(see Fig.28). The wire must
strckin the groovesof the pressurepiecesand the squared
off ends lie on the inner srde of the pressureprece
10.Belease rnarnshaftand wrth output srde upwards fasten
frrmlyagain In the vice.
14.SlLdethe sl drng sleeve (420) onto the synchrobody(see
F g. 29) such that the 3 flat teeth come to rest on the
pressurepteces The narrowercollar and the small rounded off teeth must lie agarfst reversegear. Engagep.es
sure p eces In the notchesof the teeth
Fig 33
l 1 . S l i d et h e n e e d l ec a g e ( 4 1 6 )a n d r e v e r s eg e a rw h e e ( 4 1 8 )
wrth the dog teeth upwardsonto the shaft (Fig 34).
15 Attach 2nd synchro spflng (403) In the pressure pieces
(see Fig. 30) The squaredoff ends of the spring must lie
on the nner side of a pressureptece Moreover,take care
that the 2 spnng ends are assembledin differentposrtions
to each other . e lying in 2 different pressure pieces.
P ace 2nd synchroring (402)onto synchrobody (see Frg
36).
1 6 S l i d en e e d l ec a g e( 4 0 8 )a n d l s t g e a r( 4 2 1 )w t h c l u t c ht e e t h
d o w n w a r d (sF i g . 3 6 )
Frg.34
l2 Heat lst and reverse gear synchrobody(419) B0oC and
wrth the longerhub placedfirst in the positronon the shaft
s p l i n i n gm
, a r k e dd u r L n gs t r i p p l n g(, F i g . 3 5 ) , p r e s s u p t o
stop wth tool .6. Insert crrcIp (409) in the radial groove
Fg 36
15
Fohrtrichtung
(directronof travel)
F,9 39
lnsert layshatt wth the small teeth first Into the housrng
(F 9. a0).
Place selector fork 1st and reverse gear (613) rn the
groove of the 1st and reverseslrdrngsleeve(420)and 2nd
and 3rd selector fork (609) In the 2nd and 3rd sldrng
sleeve (406).The detent pad must le on the side of the
'nstalledreversegearwheel(502)
Frg 37
l7 Plece on the thrust washer $22\ wllh step upwards
(Fr9 37)
D) Preassemblyot Layshari
Make bores of helrcalgear and frttedseatson the layshafl
tree ot oil, grease and dust. Heat 3rd gear (307) and sth
g e a r ( 3 0 6 )t o 1 5 0 o- 1 8 0 oC a n d p u s h I n d r v r d ul ya a g a i n s t
stop on layshaft.Note that the 3rd gear is put on the shaft
with the side hav ng lhe locatrnghole and the somewhat
wider collar first Insertc rcl p (305) Warm constantgear
(304) lrkewise to l50o- 180oC and press on wrth rhe
longer hub first. Press on both Inner races of the taper
roller beanng (303 and 309) up to the stop The larger
drametersare each towardsthe gear wheels Placec rclrp
(301) n radralgroove On gearboxeswrth manufacturers
numberunder 1152,ball bear|ngsare used to some extent
In such a case the rear beanng (309) should not yet be
pressedon (only after the Installatron
of gearboxshaft Into
the housing).
E) Installationot Gear Shatts
1 S t i c k p r e s s u r es p r L n g( 6 1 6 )a n d d e t e n tp l u n g e r( 6 1 7 )r n t o
the 3 retainng bores of the gearbox front and rear with
g r e a s e( F i g . 3 8 )
F,g 40
Note: The selectorfork 1st and reversegear has a detent
pad with open detenls,thereforewith only 1 notch
i n t h e m d d l e a s s h o w nl n F i g 4 1 . T h e d e t e n tp a d
of selectortork 4th and 5th gear has 3 notches
Pushpreassembled
marnshattwith outputsrde frrst into the
beaflngbase of the housrng(Frg.42).Pay attentionto correct positionof forks (detentplunger(617)over the detent
pad)andthe 1st gear(421).
Snap the spnng nng (425) Into the radral groove of the
ball bearing(423) Push ball bearrngwrth the spacer (424)
d r s m a n t l eddu r i n gd r s a s s e m bol yn t ot h e m a i n s h a f( tF t 9 . 4 5 )
Brnd layshaftto the marnshaftwrth tape (see F g. 45).
F,9
Stick 2 selectorpads (607) with grease Into the bores of
the selectorforks (601 609, 613), for selector fork (609)
I n t h e m i d d l eh o l e sa n d f o r f o r k s( 6 0 1a n d 6 1 3 ) i n t h eo w e r
h oe s ( F i g . 3 9 ) .
l
Wrth pressingtool .8.,the threadedp eces belongingto lt
and the 2 distancebushes (426 and 428), press the ball
bearingto the stop on the thrust washer (422) Then tap
the ball in the housrngbore Leavetool .8. tight.
Fg 44
Turn the housrngsuch that the open side porntsupwafds
With a depth gauge measurefrom the face of the synchrobody to the gearboxjoint face (withoutgasket) (Fig. 451.
A stralghtedge with the hrgh lip on which the slide of the
depth gauge rs set must be put onto the gearboxJointface
(Fig.45). The measurementestablishedplus the width of
the straight edge should amount to 53,5 1 0,i mm. The
differencebetweenthe measuredsize and the theoretical
size shows the thicknessof the spacer (424),which les
between the recess of the housrngand the spring ring
(425).The shrm (424)which is available n thicknessesof
0,6: 0,8; 1,0: 1,2 and 1,4 rirmmust,if necessary,be exchan'
ged. Standgearboxin horizontalpos tion againand take of
pressingtool .8
F9.41
Tfr/
Fig 45
9
Take off tape. Stick the 3 pressure preces (404) with
grease onto the installedsynchrospring on synchrobody
4th and sth gear (405) such that the wire is fixed in the
recessesand the squaredoff end on the lnner side of a
pressurepiece (see Frg.28).
l0 Push the sliding sleeve(426)onto the spliningof the syn'
chrobody(see Fig.29). The 3 flat teeth come to rest on
the pressurepieces.Engagepressurepiecesin notches.
ll.Attach the second synchro spring (403) to the pressure
preces (see Fig. 30). Attach the squared otf end of the
spring again as describedfor synchrobody2nd and 3rd
gear.
12.Put the secondsynchroring (402)on the cone of the input
shaft (213) (see Fig. 33). Place the roller cage bearing
into the spigot bearing bore of the input shaft. Push the
input shaft on the spigot of the mainshaft.
F) A!3embly of Shift Part.
1. Place 1 off O-ring (605) into the grooves of each of the
pivot pins (604and 610).Put 2 pivot pins (604)throughthe
rear housrnqbor€3 into the bores of the lst and reverse
aear eelect; fork (613)(beginwith pivot prn which lies on
ihe d.tent p"d side ss shown In Fig 46) Tightenscrews
(602)with sgrinqwashers(603) Push pivot prns (610)Into
setei:torfoti 2nd and 3rd gear (609) and fasten wrth the
screws (602) and spring tashers (underneath).Tighten
torque screws (602) to 0,8 to 1 2 kpm.
as shown in Fiq.49 into the bore of the selectorfork (609)
Install 4th and-sth gear selector rail (608) as prevaously
described(Fig. 50).
,
I
Fig 46
Place the 4th and sth gear selectorfork onto the sliding
sleeve as shown in Fig.47
Fig. 50
Slrde qasket (l07) over the protrudrngstuds and Install
oearbo-xhousrngfront part (101)(Fig.51) Screw the nuts
(l02) with sorinq washer (103) on the stud Tap in dowel
itOOi ana tiren-trghtennuts (l02) to a torque of 2 to
2,5 kpm.
Frg.47
Assembleshift rails. First the shortest reversegear shaft
ra'l (Fig.48).Note that the notchat the end of the rarl lres
neai tlie shift lever (640) and should pornt upwards.This
aooliesalso for the 2 other shift rails. Insertweldedpivots
2nd and 3rd gear shift rails (612)with the 2 plastic bolts
( 6 11 ) .
Fig.48
18
Place O-rinq6 (605) into the pivot prns (604) lnsert pivot
orns throuohthe housinqinto the bore of the 4th and sth
fork. Screw in bolts (602)wrth sprrngwashet
oear selec-tor
a6O3)and tighten to 0,8 to 1,2 kpm.
F'ig 51
I
G ) Installing Inpul Shaft
W t h a p l a s tc h a m m e r . t a p t h e b a l b e a r n 9 ( 4 2 3 ) o n t h e
output shaft nto the housng unt rt comes up aga nst the
s p r n g r n g ( a 2 5 ) ( t o e n s u r e t h a t m e a s u . e m e n t sa r e n o r
W t h a d e p t h g a u g e m e a s u r et h e s p a c e f r o m t h e f r o n t o l
t h e h o u s i n q t o t h e s e t t r n gs u r t a c e o f t h e b a l l b e a r n g ( 2 1 2 )
on the rnput shaft (Frg 52) Press nput shaft wth hanLi
I rmly and eveny to make i le n the bore ot the synchro
r ng
I
tJ_
f
I
t
Fq
54
S e l e c l a s p r c e r ( 2 C g )s l c h t h a t t h e c r c r p ( 2 0 8 ) s t s t L g h t l y
r n t h e r a d a l q r o o v e o f t h e I n p u ts h a f t A s s e m be t h e s p a c e ,
dnd c,c p (Fs 5s)
"\\
t ^-\i'.
Er.'iff
n
Dt\
\-
t
Fq
52
\
nsertsplng r fq l21l) Into the qroove of the ba bearnlr
( 2 T 2 ) M e a s u r e f r o m t h e u p p e r s L r r f a c eo f t h e b e . r n q t o
the sDnng flng The spr ng r ng must be pressedonto the
outef edqe of the beanng groove (F g 53)
Fct 55
H ) Assembling Speed Cover
I
l
n
l
F r s t y t a p t h e o L r t e ,' n g o f t h e r o e r b e a f i r c t { 3 0 3 ) o r
t h e a r g e s t d r a m e t e r n t o t h e h o u s n g b o r e F o r t h s L r s ei l
pastc or ead hammer
P a c e q a s k e t ( 8 0 2 ) o n t h e g e a r b o x , e a r h o L r sn g
-F
C e n t l y w t h a p a s t c o r e a d h a n r n r e rt a p t h e o u t e r r n g
o f t h e b a I b e a n n g ( a 2 3 ) I n t o t h e h o u s , n g! p t o t h e s t o p
W th a depth gauge me.sure the d stancefrom the uppe,
s u r f a c eo f t h e o u t e r b e a r n g r n g t o t h e g e a r b o xl o n t f a c e
wrth q.sket n place (Frq 56)
Frq S3
The d fferencebetweenthe 2 meas!rements ess 0 5 mni
to 0I mm for the axra play of the 4th gea. synchror nfr
{a02)g ves the th ckncss of the spacer (209) wh,ch n !st
be placed under the ba I bearnq (212) The sh ms are
a v a a b l e n t h c k n e s s e so f 0 5 : 0 6 : 0 . 7 . 0 8 i 0 9 l 0 1 l
I 21 13: 14 and I 5 mm
Push the spac,nqwasher over the Input shaft Press the
ba bear ng (212)w th pressng too 8 up to the stop or,
t h e n p u t s h a f t a n d n t o t h e h o u s r n q( F g 5 4 )
Note: When pressng n rhe ball bear nq. the bal be.r nq
mlst De dr ven nto the housng bo'e w,th a p.st c
hanrnrea
r t t e r a p p r o x m a t ey 2 t u r n s o f t h e t o o
r9
4
Determinethe depthof the matinqbore In the speedocover
(Fig 57). The drfferenceof the 2 measurementsless O to
0,1 mm play gives the thicknessof the spacer(804)which
must be placedin the bore of the speedocover.The spa,
cers are availblein thrcknessesof 0,4t 0,5: 0,6; 0,7; 0,8t
0 . 9 a n d 1 . 0m m .
Press the needle bearing (810) and shaft seal (81l) wth
hot bearinggreasebetweensealinglip and dust lip up to
the stop on the output bore of the speedo cover. With
sealinglip to the inside of the gearbox.
Stickthe spacer(804)for the mainshaftbearingwrth grease
in the appropriatebore of the speedo.cover. On layshafts
with ball bearings (installedup to gearbox No. 1152) a
spacer(302) 1,5 mm thick mu6t be placedinto the smaller
bore of the speedo cover. The shim rs equivalentto the
differencein width betweenthe ball bearingand the equivalent roller bearing.The installationof both bearingver,
sions is carriedout on the input srde.
Frq.59
Pushthe outputflange(429)onto the mainshaft.Screw nui
(430)onto the threadand tightento 14 to 16 kpm (forthis.
2 gears must be engaged).Tap lock tab of nut with a drift
Into the groove of the mainshaft(Fig.60).
Fig.57
Place long distancebush (426),speedo worm (427) and
short distancebush (428) on the mainshaft(Fig.58). Set
split ring into the groove of the hainshaft and push cir
clip over-With a depth gauge measurethe space between
the split ring and the shorter bush (a28).The space must
be 0,17 to 0,22 mm. lt can be correctedby fitting varying
sizeddrstancebushes33,35i33,4;33,45;33,5;33,55t33.6;
33,65or 33,7 mm. long.
Fig.60
10.PlaceO-ring (815)in the radialgrooveof the speedobush
(814).Pressshaft seal (812)with tool -10.jnto the speedo
bush (sealinglip upwards).Put speedoshaft (813)into the
speedo bush and insert both together in the bore of the
speedocover. Screw in self lockingbolt (816)with spring
washer (807).
AssemblingWithdrawalBearingCarrier
1 With the larger internaldia facing the inside of the gearbox, place the outer ring of bearing (303) into the bore
for the layshaftbearingof the front cover (101).
Push gasket (204)over the threadedstuds.
Press shaft seal (207) into the bors of the withdrawalbearing carfler (206)with tool No. .9. Sealinglip must point
to inside of the housing.
Fig. 58
Pushthe speedocover over the studs and up to the hou,
sing Screw on nut (808) with spring washer underneath
(807) and rightento 2 to 2,5 kpm.
20
4 . Gently tap layshaftwith a plasticor lead hammertowards
rear (output side) until the bearingouter ring ljes on the
speedocover-Pressdown the front b€aringouter ring and
with a depth gauge,measurethe distancefrom the upper
edge of the bearing outer ring to the gearboxjoint face
with the gasket in place (Fig.61).
1 . Strckthe spacerfor the input shaft beanngand for the lay,
shaft bearingwith grease Into the appropnatebore of the
withdrawalbearingbarrier
Push the wrthdrawalbearng carner over the tnput shaft
and positionon the hous ng Tghten nuts (201)with spring
washer (202) underneathto 2 to 2,5 kpm.
I
Fig.61
Determinethe depth of the appropriatebore in the wth
drawal bearing carrier (Fig.62). The drfferencebetween
the 2 measurementsgives the thicknessof the spacer
(302),which must be placed Lnthe bore of the withdrawal
beaflngcarner. The sh ms are avallableIn thtcknessesof
0 , 4 : 0 , 5 0; , 6 ; 0 , 7 ; 0 , 7 50:, 8 :0 , 8 5 0
; , 9 , 0 , 9 51r , 0 ;1 , 0 5 1
; .1r
1 , 1 5 :1 , 2 ; 1 , 2 5 r1 , 3 i 1 , 4 a n d 1 , 5 .T h e i n s t a l l e d
t a p e rr o l c r
hearingmust have between0 and 0,05 mm prc-load
Frg.64
Fig.62
i
The selecnonof the spacer(804)for the ball bea ng must
give between0 and 0,05 mm pre-load.Hold the layshaft
bearingand first y measurethe amountof the ball bear ng
prolectingover the sealingsurface(Fig.63) and then take
thrs measurement
from the depth of the smallerbore n the
w i t h d r a w abl e a r i n gc a r r i e r( F i g . 6 4 ) .T h e r e s u l t a ndt r m e n
sion less 0 to 0,1 mm play gives the thtcknessof the spacing washer(210)which rs avarlablein thicknessesof 0,4i
0 , 5 ; 0 , 6 t 0 , 7 ;0 , 8 ; 0 , 9 a n d 1 , 0
K) AssemblingSelectorKnob
l. Eemote gear levers (Cars)
1.1Pushvibrationdamper(644)over the shrft rods and fasten
with the set screws (645)and spring washers(646).
1.2Place the pivot piece (624) on the 2 locatingbolts In the
gear changeextenslon(619).Push shift arm over the shift
rods (Fig.65).Trghtennuts (648)with thrust washer(647)
Fig.63
21
l.3Place ring (659) wrth the bore to the taper compressron
spring(628)in the shift turret (629).Placetaper compresson spring on the ring. Fastentorsion 3prings (633 and
633.i) to Interlockswing as shown in Frg 66 The stronger
spr ng lles agarnstthe shortertang.
I 5 Placeselectorgate (627)with the 2 bores to the breather
hole over the interlockswing and place on the shift turret
(629) (Fis. 69)
Fiq.66
1 . 4Placeinterlockswrng In the shrft turret (629)(F g. 67). The
weaker sping lies againstthe breatherhole Push n the
2 pivot prns (630) and press n the bore (Fig 68).
t
Frg.69
1.6Frt gasket (626).Placepreselectedshift turret on top (Frg
70). Screw and t ghten set screws (637)with spflng washer (636)to 2 to 2,5 kpm. Placegear lever ball (640) n the
shift turret (629).The flat side of the gearleverball must
point rearwards.Pushball socket(641)over the gear lever
ball and insert circlip (642)
)
L
a- -
ld"-r
Ftg 61
Fig.70
Cenirallymounteddirect gearchange(heavyvehicles)
2.1 Fastentorsron spring (633) on the InterlockswLng(625)
Place nterlockswing in the shift turret (629)and fit the 2
prvot pins (630).
Place selector gate (653) with the nose potntrngto the
input shaft and the selector guides to the gearbox inner
onto the gearbox housrng.
Lay gasket (626) on and place preassembledshifr turret
on the gearbox housing. Screw nuts (648) with spring
washer (647) onto the studs (650) and tighten to 2 to
2,5 kpm. Screw breathervalve (635) in the thread of the
shift turret.
Fig.68
22
2 . 4Place gear lever ball (640) in the shift turret. Push pressure spring (628),socket (645) with cylindricalside first.
and cap (655) over the gear lever ball. Attach cap to the
pivot bolts (652).Pur boot (643) over cap.
Test transmssion.
lX. Ordering of Spare Parta
Od€rs for sparr part! shouldalwa!€provld. th9 iollowlngdat6 to guar6nl!! f6st and conact dlllvary.
l. Type ld6ntlflcatlon(on typ! ratlng plote)
2. Produqilonnumborof t lmmilslon (on typ€ratlng pl€t6)
3. DlrlgnEtlon of daslBd lpgra paft!. Ahlvay! uga ngma 9a ghown In Spsro Parts List and Assombly In8tructlonB.
lf th! type numbqroi thc tron!4, Statsten-dlgltnunb.r pundrsdinor cast on part to b6 roplacod.Thls numbsrls tndlspen8ebb,
mlaslgn c€nnot bc glvln.
5. lf you cannotsuppv rny or sov6ralof th6 dats listod undgrt. to 4. th! iollowlngIngtructlon.aro lmportant.
a) Nuntlr of lllulrr.t d tabb eupplledwlth Spa.e Parts Llst or numbsrof illustretld iable In tha plrthqnt Alsambv
lnstruction8,
b) Makg and typ€ deslgnadonof whicle, nano of drassis manufacturar6. Mathodof de8pstdr audr !r Poet, F,rlght, Expro6sotc. Unl€ss lndic€tsd, shipinsnt wlll be as sslectsd by ue.
A part ctly cl.ar ord.r should br rs iollowa:
I am ordcrlngharowtlfionc malnshaft12553{X073 for fanlml.slon:
S $18/3, productlonnumbqrdX{}, by expressmeil.
Inmodlatodoliwry requlrsd.
In wrltlng.
Ordorsplacsdby tolophoncor c.bb lhould ba acknowledgod
Shlpmantet rlsk of bqor, awn wh.n rgsr! pertr !r. not drarged ior. Sprro plrt !r! .xdungad ft.. of dr.rg. durlng thc warranty p€rlod only lf dsmlgrd parta ar! alnt to us frla of coEt 6nd withor^ p]lrloit! dungar msdr thcrcon, and whln sn Insplctlon of ths pgrtlngntcompgnaotlhov.' trat the d!rugc ls tho rulult of a productlon or matadal fault.
Drnlged p!rt! lrnt to u! wlll ba ecrappedunlee thelr roturn ls aN'fr|.ly raqurltld whsn shlppgd.
Prtmut: All Ep6r9part8 aro dollv6rc.o.d.
a
X. Key to lllustrations
Hou6ingG.oup
101
102
103
104
105
106
107
108
109
11 0
11i
112
113
114
115
116
117
118
I l9
120
121
122
123
124
125
126
Front Housing
Nut
Spring Washer
Stud
Stud
Dowel
Gasket
Stud
Stud
Stud
S e a l i n gW a s h e r
MagneticDrain Plug
D r a i nP l u g
Boar Housing
Type Plate
Gasket
Cover
Bolt
Cover
Stop Plate
Stud
Spring Washer
Nut
Set Screw
Spring Ring
OperatingShaft (Rev.Light)
Input Sh.ft Group
201
202
203
204
205
206
207
204
209
210
211
212
214
Nut
Spring Washer
CentralisingFlange
Gasket
Stud
ClutchWithdrawalBearina
Carrier
Circlip
Shim
Shim
Spring Ring
Ball Bearing
Input Shaft
RollerCage Bearing
Layshaft Group
301
302
303
304
305
306
307
308
309
Circlip
Shim
Ball/RollerBearing
ConstantGear
Circlip
5th gearl4th Cear
3rd Gear
Layshaft
Ball Bearing
Mainshaft Group
401
402
403
24
Circlip
SynchroBing
SynchroRing
404
405
406
407
408
40S
410
411
412
413
414
415
416
411
418
419.1
419.2
419.3
420
421
422
423
424
425
426
421
428
429
430
431
PressurePiece
4th & sth gear synchro body
Sliding sieeve
Complete5th gear/cpl.4th g.
Needle Bearrnq
Circlip
ThrustWasher
Complete3rd Gear
Needle Bearing
Circlip
2nd & 3rd gear synchrobody
Complete2nd gear
Needle Bearing
Mainshaft
ReverseGcar
S p r i n gB i n g
Circlip
Cover Plate
Sliding sleevefor tst & Rev.
Complete16t gear
ThrustWasher
Ball bearing
Shim
Spring Ring
Distance Bush
Speedo Worm
DistanceBush
Output flange
Nut
Washer
Reverse Gear Group
501
502
503
504
505
506
507
508
509
510
511
Thrust Washer
Reverseldler
Needle Bearing
DistanceBing
Flevers€ldler Shaft
Spring Washer
Bolt
BollerBearing
Washer
ThrustWashcr
Dowel
Gear ChangeGroup
601
602
603
604
605
607
608
609
610
6l I
612
613
614
615
616
617
618
619
4th & sth gear selectorfork
Bolt
Spring Washer
Pivot Pin
O Bing
Selector Pad
4th & 5th gear selectorFlod
2nd & 3rd gear selectorfork
Pivot Pin
Pivot Bolt
2nd & 3rd gear selectorBod
lst & Rev.Gear SelectorFork
lot & Rev. Cear SelectorRod
Ball
PressureSpring
Detent Plunger
Casket
Gear changeextension
620
621
622
623
624
625
626
627
62A
629
630
631
632
633
633.1
634
oJc
636
637
638
639
640
641
642
643
644
645
646
647
648
650
651
652
653
654
655
656
657
658
659
660
661
Washer
Pressure Spring
Pressure Spring
Guide Body
GuadePiec€
Interlock Swing
Gasket
Selector Gate
Conicalcorl spring
Gear lever turret
Pivot Pin
Spring Washer
Bolt
Gear lever bias sorino
Gear lever bias sfrini
Pivot pin
breather
Spring Ring
Short Set Screw
Long Set Screw
Selector Pad
Shift lever ball
Shift lever socket
V Ring
Bubber Gaiter
VibrationDamper
Set Screw
Spring Ring
Spring Washer
Nut
Stud
BayonetCap
Guide Pin
Interlock Plate
Dust Cap
Cap
Locating Block
Gear Knob
Nut
LockingBing
IntermediatePlate
Gasket
Speedo Driva Group
801
802
803
804
805
806
806.1
807
808
809
810
811
A12
813
814
815
816
817
818
819
Speedo Cover
Gasket
Set Screw
Washer
Stud
Stud
Stud
Spring Washer
Nut
Stud
NeedleBearingHousing
Oil Seal
Oil Seal
Speedo Shaft
Speedo bush
Ring
Self Locking Nut
Cover
Gasket
Set Screw
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Fig.30-6
X]l. List of ZF-Service-Stations
GERMANY
Telephon€
Teler
ZahnradfabrikFriedrichshafen
AG. Werk Berlin
1000 Berfin 26. Wilhelmsruher Damm 2311245,Postfa.h 24
030/4rr209r
0t 81 789
zfbln d
ZF-KundendienstHannoverGmbH
ZweigstelleBielefeld
4800 Bielefeld,Fleichenberger
Str. 42
0521t200071
t200072
1200073
09 32 596
zfbie d
Dglm6nho13t
RichardUrbanek Ing., GmbH & Co. KG
ZF-Kundendienst
2870 Delmenhorst, Fiedeweg 280, Postfach 74
0422t I60025
/60026
02 49 285
zfkdd d
Dortm!nd
ZahnradfabrikFriedrichshafen
AC.
KundendienstDortmund
4600 Dortmund, BornstraRe207
023r/8r 2891
181A441
0€227 @2
zfdo d
Ecagn
Gustav Hennig & Co. GmbH.,ZF-Kundendienst
4300 Essen-Buhr,KruppstraRe 74, Postfach 673
o21411221951
08 57 785
Franklun
FranzBucherKG, ZF-Kundendienst
6000 Frankfurt1/Main. HanauerLandstraBe336
0611/415021
0417 272
buffm d
Frlcdrldr!hatcn
ZahnradfabrikFriedricfi
shafenAG,
- Werk ll
Kundendienst
7990 Friedrichshafen/Bodensee,
Postfach307
075411a4-1
07 34 363
zfkd d
ZF-Kundendienst
Fulda
Arnold FikentscherKG,
6400 Fulda, Frankfurter StraBe 45
0661/3028
/3029
M9756
Hamburg
BichardUrban€k Ing., GmbH & Co. KG
ZF-Kundendienst
2000 Hamburg70, AngerburgerStraRe 18
040/6932041
02 r4 907
Hannovcr
ZF-Kundendienst
HannoverGmbn
3000 Hannover-Linden,
Bernhard-Caspar-Straoe
7,
Postfach 21265
0511/456045
/456046
/456047
0 92 21 5 1
zfhan d
ZF-Kundendienst
Kassel,Arnold FikentscherKG
3501 Sandershausen-Kassel,
BettenhauserStr. 39, Postfach120
(on the haghway tributary road Kassel East, entrance
Osterholzstreet.)
056r/5 2141
152142
t5 2143
09 97 25
ahfk d
Gerhardvon Umbscheiden,ZF-Kundendienst
5000 K6ln 30, Ehrenfeldgiirtel
112l122
0221
/5510r1
0888r01r
Mannhelrn
FranzBu.her KG, ZF-Kundendienst
6800 Mannheim 1, WaldhofstraBe 82-84, Postfach 369
0621/372066
04 63 236
frabud
Miindr6n
Beis6barth& MLilleroHG. ZF-Kundendienst
8000 Mrinc$en 80, Zamdorfer StraRe 90, Postfach 8002 60
(on the high road to the airport Riem)
089/93105r
05 22 793
bei d
Niimberg
Lang GmbH & Co. KG, ZF-Kundendienst
8504 Stein-NUrnberg.
Bogenstra[Je
3
0 9 r1 / 67 01 r
1 6 7 0t 2
06 22 867
zfnbg d
Paosau
ZahnradfabrikPassauGmbH, Kundendienst
8390 Passau 2, Postfaci 1, Grubweg
0851/207r
05 78 49
zetpe d
Erich Bonn GmbH, ZF-Kundendienst
6600 Saarbriicken 3, Mainzer StraRe 269, Postfach 733
068r/6 6161
/6 8035
0681/66161
/6 80 35
04 428 959
DOnno
Zahnradlabrik FriedrichshafenAG.
Werk SchwabischGmUnd,Kundendienst
7070 Scfiwiibisch Gmund, Graf v. Soden Str. 5-9, Postfach 119
071711601-1
07 248 825
zfgk d
ErichBonn GmbH,ZF-Kundendienst
5500 Trier-Euren,lm Speyer 4
0651/42815
h2@2
04 ?2 634
B.rlin
EL
Blelefeld
EL
EL
EL
Fulda
EL
EL
K.'3.1
EL
Katln
EL
EL
S.arbriid(cn
Workshop and Spare parts storel
6604 Galdingen.
SaargemunderStraRe48
Sdrwebisdr Gmiind
EL
Tri6r
EL
'W = Workshop
EL = Sparepartsstore
erzll
d
umoao
04 428 605
DOnno
ZF-Service-Stationsoutside Germany
EUROPE
lolophono
Tolor
Au.trfa
W
EL
Zahnradfabrik FriedrichshafenGes. m. b. H. Wien
ZF-Kundendienstfur Osterrei.h
TriesterStresse 134-136. 1232 Wl€n.ln2erldorf
Cables: ZF-GetriebeWien
02221671548
Ott 291
zfwien a
B.lgfun
W
EL
Agence ZF-Service S.P.B.L.
1440,Chaussde de Wavre, 1160 Bruxellcr-Audorgh.m
Cables: Zetefservis Bruxelles
021724064
1727032
22 451
zetefservis bru
Donmark
ry
EL
Skandia-Motorimport,
SjgellsndA/S
Lf""selager 21, 2600 Glo.trup/Kobenhavn
C6bl€s: Skandiamotor
01/451599
2i 444
skaglo dk
0a1132244
69771
skamo dk
W
EL
Branch:
Fr. l€ns€n A/S
Skandia-Motorimport,
Egholmsgade7, g(x)oAalborg, P.O.Boxll7
Flnland
W
EL
Atoy OY, Industrydepartment
Lauttasaarentie54, P.O.Box 10137,00200 Hel.inki 20
Cables: Atoy Helsinki
6?337,
12555
atoy sf
F6ncc
W
EL
ZF-France S.a.r.L.
Bue de Villeneuve3/11, 94533Rungi. Sillc
6 86 68 40
26 954
zl te
w
EL
o.M.A.-zF
Zone Industrielle
28. 4Cne Avenue, 13700Vitrollo.
890239
4 34 6 3
fra
W
EL
EtablissementCauchois
150,Bue d€s Marquillies,59013Lillo Codox
53 93 21
W
EL
Str€sbourgGadouis,S.A.
l-3, Bue des Pompisrs,673q)Sdtlltlgh.lrn
Post adresse: 9.P.27,67042 StrasbourgCeder
333838
87 083
U. J. Phostiropoulos& Cia. E. E.
Leoforos Athinon 26, Ath€n 2m, P.O.Box 1122
Cables: lngphostiAthen
520/.23
52 05 42
533910
216360
fost gr
Branch:
U. J. Pho6tiropoulo6
& Cia. E. E.
MonastiriouStr. 61, Tho$alonlki
51 3313
51 64 06
Gr.at Britain
W
EL
ZF Gears (Great Britain) Ltd.
Lilac Grove, Beeston, Nottinghan NG 9l QX
Cables: TransgearNottm.
0602/25 35 50
1221865
1221a66
377 062
transgear nottm
Italy
W
EL
S.A.|.M.
S.p.A.SviluppoApplicazioniIndustrialiMeccani.fre
Via Leon Battista Alberti t0. 20149 Mllano
CablesrSviluooosaimMilano
o2l38 15 70
l3A44A1
33 393
saimspa
Spare parts store:
Servicio Assistenza e Ricambi
31 51 93
34 47 43
Workshop:
Officina di Assistenza
20090 LiBiro/Milano, Nuova Strada Flivoltana
9 04 60 15
Groece
W
EL
EL
Branch:
s.A.r.M.
S.p.A. Sviluppo Applicazioni Industriali Meccanidte
Viale Aventino 32la, 00.|53 Fona
578 440
W
EL
CETRULLO VITTORIO
Viale Pindaro, 45---65,65100 P.rc.ra
60 335
W
EL
SCARPAZZA BALDO
Zona Industriale 90 strada, 18, 35ldt Padoya
66 11 76
W
EL
Autoriparazioni
BOMBARA
Strade del Barocchio. 39. 10136 Torino
3217 1A
W
EL
IGNAZIO ZAPPA S.r.l.
Circonvallazione Nomentana,474. 00l6il Bona
4233 A1
42 53 59
w
Bossr BoMANo
26s47
EL
W
EL
w
EL
32
VialeTrento.204,36100Vlcsnza
AVLES-SELVA
Via E. Mattei,50,Stradaper Ravenna,,Ol3,l
Bologn.
FADES
LargoS. Mariadel Pianto,40/41,8|tlilit Napoli
53M 15
33 0042
51576l
T.lcphonr
Tcbr
w
RICCI FRANCO
Vla Rusqslll,50, 47qfa S. Pbro In B|gno (Forll)
9fi35
w
AUTOCAF
Vla Au|llla Owst. 8l/a. 5al0 Mr..
43250
4 39 /tg
w
SAPIENZALUCIANO
Vla Golso Blanco.28. 051216t
2t 2a46
w
LONGOROCCO
Vla S. Csterina,2 (FioneS. Glorglo),70l2a B.rl
2466 34
w
MONACHESI& MOZZONI
Via T6r.la, 4, 6:1100lLc.r.tr
2a44
w
VALLEBONAS.p.A.
C.P.2Ol (andrqper GM),OI00 C.glld
23864
Autocommgrcg
Zastopnlako Podlotle
TrdlnovaUlica ,1,Et00Oqub[.n., P.O.Box422
Cobles:Autocon€rcoLlubllana
06r/32 30 46
3r r8g
31 299
Ecllb yu
Workshoo:
G.al-Avtoobnova
TitovaUlica 136,61000qubU.n|' P.O.Box280
Cablse:Gral LJubllana
06t /34 20 | 0
31 427
Branch:
Autocomm€rcg
ZEetopnlakoPodretle
Katanlcova18, B.og.d
0t 14(}2
0t 1421
0t t4 36
fi 328
acbgd yu
TodrnlsdrBureauM€dia B.V.
Trqubatrsat31, 2100 Bl.wllk CZ-H),Postbus2
070/9825 20
3t 087
mqdia nl
A/S Auto Supply Co.
Ringedkevn,
243,Odo l, l3l4 Skui
Cabl6s:AutoBupply
0211324g
fi 629
aaEon
Portug.l
parEVelculoa,Lda,
SIPAVEL,Soclededsdo lsolamsntos
Rua RamalhoOrtlg6o,+rldl
Ll.bor I
Cablee:SIPAVELLISBOA
53 79 53
stt 86 05
56 28 40
56 37 59
1 22 5
fmtl p
S0cdcn
w
EL
K.G.KnutssonAktiobolag
08/252660
Ulvslndevdg€n146,t6lit Bronn. | | /Stodrholrn,P.O.BoxI l0@
Cabl6s:KnutlngStockholm
w
Brandls:
Ruekvtd.rEgrtan 10, /m77 Gdbborf 48, P.O.Box48019
03r/53 04 60
w
Koepmengaten29, ESiI't Sond|vdl
060/!2 t9 45
w
Mumansgalan112,zlZE il.|fr
040/9323 45
SKAG- Steuerungenund KupplungrnAG
Androaestraoo17, m50 Zorldr P.O.Box636
Cableo: SKAG Zorlcfr
0t /50
EL
EL
EL
EL
lugo.lavla
w
EL
EL
Ndh.rl.ndt
w
FI
Norway
w
EL
EL
EL
EL
SI|E
w
rl.nd
EL
Spdn
w
w
EL
Tr|rkly
w
EL
nh
to. g..r borat grrr drlv|t, .d.r, 9..8,
loddng dlti.rnd.b |nd punp.:
l.S.A. Industrl€8Avlscl6nda Subeldlerlae,
SA.
Apartado 250, Canetora d6 Carmona,Scvlll.
PollgonoIndustrlald€ Calong6
Cablss:ISA Sevllla
for d..rlng grrn whh pump. .nd .rhaurt bnkat:
IMENASA
Indu8tdasMstdllcasde Navarra,S.A.
ApartadoCor.eosli|o, CanoterEdo BaratlainlT, Pamplon!
Cables: IMENASA
t5 04
kgk s
20 955
kgk I
50
3528(D
35 29 00
72113
lga g
25fi @
367t8
ArsimldisMusss€asaFotomobll.Malz€meslTlcErotlTA.S, 447460
lttrnbul-lbr.kdy
Fue Okcu MusaCadd€sl$/5'1, P.O.Box8112,
C8blosrArchlmldislstEnbul
gln o
22585
ardr tt
3:'
AFEICA
Tclcphonc
Tcler
lvory Coa.t
w
EL
SociCtd d lmportataonde PadcesAutomobiles
S.A.B.L.(S.|.P.A.)
B.P. 2171,34, Autorout€do lAeroporl
AbldJan/C6te d'lvol.c
32 30 18
3s s7 s0
698
Gabon
^,,,--,, -,,J EasternTradingCompany(Hamburg)G.m.b.H. 04 /34901
Krppingstr. 6, 2qr0 H.nburg 13
Post adre6se: Hamburg 1, P.O.8ox fl4
;::::-'
iJiJirr"
ra,"a
'Cliiiliiiii-"i
2125,23
aerco d
Hamburg
Rcoubtic cables,Ethrope
Company in chargeof 6ervice:
Gabon
W
EL
Hatton& CooksonMatforce,B- P. No.75
Libr.Ylll., (F.p|lblic of cabon)
Camcrun
W
Ciacam Matforce, B. P. No. 4025
Dou.la, (Fode.al R.publlc of Camorun)
".";:W
s. c. K. N. conso Matforce, B. P. No. 6s2
Pointe Noirs, (R.publlc ot Congo)
B.public Tchad
W
EL
G. B. Ollivant(Congo)Ltd., P. B 712
Avenue du Gen6ral de Gaulle,
Forl Latny, (Republic of Tdrad)
Ccntr.l Afric.n R.public
W
EL
S. C. K. N- CA
B. P. No. 799 et 809
Bangul, (C6ntral Afrlcan Republic)
R.public of South Afrlca
Rhod..ia
W
EL
(Pty.) Ltd.
TRADE BELATIONSINTERNATIONAL
P-O.Box 2259, lohenn.rburg (R.publlc ol South Atrics)
Office and Workshoo:
P.O.Box4007,BosworthStreet.
Al.od€/Albonon,Transvaal,(Republicof South Af.ica)
Cables: ZAFBUBG
834-4559
869-82 16
43-0927
O&O Electricand Engineering(fiY) Ltd
P.O.Box 5056, Krupp Str. 33. WtndhoGk/S.W.A.
2-6650
56465
South-We3t-Afrlca
W
EL
AMEBICA
Aig€ntin.
W
EL
Rehm S. C. P. A.
Avonide Maipi 3146/50,Casilla de Correo No. I
Ollvor (Prov. BuenosAires)
Cables: ZETAEFE-SERVICE
Olivog
Brazll
W
EL
ZF-DO BBASIL,S. A.
Caixa Postal 1626. S5o P.ulo,
Work6 and Administrationl
Bua Senador Vergueiro, 428, 09500 Sao Caeteno do Sul
Cablos: Ultramaran-Seo-Paulo
791-4088
797-5394
42-2122
023 865
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03 53
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RobertBoschde Chile,Equiposy Maquinarias,
S. A.
Av. San Eugenio68, Santiagodc Chll., Casilla832
Cables: CHILEBOSCH
25 96 48
259691
25 97 93
Colombia
EL
AutomotoraLEMKO, Ltda.
Apartado A6reo 4989
Carrera 30/15-16,Bogoti D. E.
Cables: LEMKO
Branch:
Carrera5/24-10.Cali
37 27 16
37 46 83
EL Safvador
Guatamal.
Hondura.
Nlc.r.gu.
Co.ta Rica
Servicio Centroamericano
ZF, S.A.
Boulevard Venezuela No. 1153
San Salvador / El Salv.dor, C.A.
Cables: ZETAFEZA
21 3217
P.ru
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Tecnica lmport. S. A.
Llma, Palca201-Casilla 171
Cables: TECNICAIMPORT
32 30 88
V.d.zueb
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SEBVEPESA,Servicaosde VehiculosPe6ados.S.A.
Av€nida R€p0blicaDominicanaBoleito Norte.
C.r6c.. l0?
Cables: Serveoesa
342355
34 24 55
34
77 1563
21 136
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ASIA
T.l.phon.
G. Reza Sanaty,
Ave. Saadl,PassagsSaadlNo. l l, Trh.r.n
Cablss:SonesadlTehran
Workshop:
No. l42fl,|:}l,
Ave. GhazvlnEetegahoSoloymanlysh
3S38 39
Teh€rqn
Tolcr
95539l
Ad66bM. SabbaghBros.Co.,MotorEnglnsera& Agentg
P.O.Box868.Ann.n
CEbles:AMS-Amman
2 21 95 Oftics
2 3089 Workohop
GLOBE.CommsrclalEstabllshmont
P.O.Box 4580, ltuwelt/Anble
Cables:Globecom
429829
ia l0 73
Ado€bM. Sabbagh,Motor Englnsers& Agent8,
P.O.Box3694,Bcyrourh
Cablea:AMS-Beyrouth
41275
Dlesel-Elqctrlc
Conpany
P.O.Box l(Xg. ,rd&htsludl Ar.bh
Cables:Delcent,laddah
Blandrgsl
P.O.Box297.J.ddlhrsludl Ar.bh
C6bl6s:Dios€ctrlcroddah
22222
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P.O.Box86, myldhrsludl Anbla
CEblsB:Dlesoctlc Rlyedh
22222
225?2,
P.O.Box24, Dlmn.mr8ludl Arrbl.
Cablos:DissectrlcDammam
22 444
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AdoebM. Sabbagh,Motor Enghsers& Agente
B.O,Box743, D.m... .
CableE:AMs-Damascus
'| 84 05
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AUSTRALIA
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TranspsqLlmltsd
570, Geelong Road, BrooklFr Cboum., vlc 3025
?.O.Box223,Footscray/Vlc.3011
Cablos:TransmotorMslboume
3t4@22
30 225
transp€c aa
Brandrss:
W..irm-Audrdl!
l,|4, W6lahpoolRoad
lryd.hpoolrP.t||r, w. A 6106
Cablsg:TrangmotorP€rth
68 32 36
9:] 009
Sou F^u.trdl.
5(l9. Grsnd Junctlon Road
wlngfr.ldr^dcldd., S. A. 5lrl3
Cables:TransmotorAdolelde
'180,SllverwatorRoad
Aubunrsydrry, N. S. lY. 2l+l
Cablss: Transrptor Sydney
626r 15
82 891
6482892
2l il43
tranap6c
l&Il, lpswldr Rold
Ro*ltrrBdtb.n.,
Qld. /tl6
CablsE:TrsnsnotorBrlsbang
474!i 3!i
41 296
TggmsnlsTranspecLlmibd
G. P.O. Box 90
Llr|nccdoo t25O
3120 18
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