2 WG 94 e

Order No.
5871 132 002
ZF – ERGOPOWER
2 WG-94 EC
ZF Passau GmbH
Donaustr. 25 - 71
D- 94 034 Passau
REPAIR MANUAL
for
ZF - ERGOPOWER
2 WG-94 EC
IMPORTANT INFORMATION:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a
current ZF production unit. Continuous technical upgrading of the ZF units and extensions
concerning design options may require differing steps, which can be carried out by qualified
specialists without greater difficulties by means of the perspective views included in the
corresponding spare parts lists.
This disassembly and reassembly manual is based on the design level of a ZF production unit at the
time of issue of the manual.
For information on operation, maintenance and for descriptions please refer to the relating Operation
Manual (ZF Order No.: 5872 136 001).
ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a
successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise
which edition is the latest one.
----------------------------------------------------------------------------------------------------------
ATTENTION:
Observe the vehicle manufacturer’s instructions and specifications for the
installation and commissioning of the unit!
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt. : ASDM / Division : ASDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted!
Copyright ZF Passau GmbH! Toute reproduction, même partielle, est interdite!
Technische Änderungen vorbehalten!
Subject to technical modifications!
Sous réserve de modifications techniques!
Konstruktionsstand / Design Level / Niveau Technique 2006/06
1. Auflage / 1. Edition 2006/06
2. Auflage / 2. Edition 2006/11
TABLE OF CONTENTS Chapt./Page
Preface 0/1
General 0/2 ... 3
Denomination of standard dimensions 0/4
Conversion table 0/5
Tightening torques for screws 0/6
Labeling of identification plate and information on spare parts ordering 0/7
Configuration of transmission 0/8 ... 9
Measuring points and connections 0/10
Notes on oil grade and oil fill quantity 0/11
SPECIAL TOOLS WS/1 … 5

COMMERCIAL TOOLS WH/1 … 5
1. DISASSEMBLY 1/1 ... 2
1.1 Removal of filter 1/1
2. DISASSEMBLY of proportional valves, inductive sensor, Hall sensor, 2/1 … 2

temperature sensor and breather
3. DISASSEMBLY of PTO 3/1 ... 2
4. DISASSEMBLY of output flange 4/1
5. DISASSEMBLY of main pressure valve and converter safety valve 5/1
6. DISASSEMBLY of engine connection 6/1 … 2
7. REMOVAL of clutches and DISASSEMBLY of oil pressure pump 7/1 … 3
7.1 Removal of clutches

7.2 Disassembly of oil pressure pump 7/1
7/2 … 3
TABLE OF CONTENTS Chapt./Page
8. DISASSEMBLY of clutches 8.1/1 ... 8.4/1
8.1 KV clutch 8.1/1 … 4

8.2 KR clutch 8.2/1 … 4
8.3 KA clutch 8.3/1 … 4
8.4 KB clutch 8.4/1 … 4
9. REASSEMBLY of clutches 9.1/1 … 9.4/1
9.1 KV clutch 9.1/1 … 6

9.2 KR clutch 9.2/1 … 6
9.3 KA clutch 9.3/1 … 6
9.4 KB clutch 9.4/1 … 6
10. REINSTALLATION of clutches and REASSEMBLY of oil pressure 10/1 … 6

pump
10.1 Oil pressure pump 10/1
11. REASSEMBLY of converter safety valve and main pressure valve 11/1
11.1 Reassembly of converter safety valve 11/1

11.2 Reassembly of main pressure valve (control pressure valve) 11/1
12. REASSEMBLY of output flange 12/1 … 2
13. Reassembly of PTO 13/1 … 2
14. REASSEMBLY of engine connection 14/1 … 2
15. REASSEMBLY of proportional valves, inductive sensor, Hall sensor, 15/1 … 2

temperature sensor, breather and screw plugs
16. REASSEMBLY of filter, closing components for oil filler and oil drain 16/1 … 2
plug
Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems
PREFACE
This documentation has been developed for specialized staff trained by ZF Passau for repair and
maintenance work to be made on ZF units.
This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters and servicemen with the work on your ZF product
whose practical and theoretical training is constantly updated in our training school.
The Service Stations established by ZF Friedrichshafen all over the world offer you:
1. Permanently trained staff
2. Specified equipment, e.g. special tools
3. State-of-the-art genuine ZF spare parts
All work is done there with utmost care and reliability.
In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the
terms of the currently applicable contractual conditions.
Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred shall be excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.
ZF Passau GmbH
Service Department
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Corporate Division
and Axle Systems
GENERAL
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the transmission, ensure utmost cleanliness and that the work is done in a professional
manner.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids
and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use
suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing
rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from
residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end
covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be
replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings,
thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with
worn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies
remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation.
NOTE : Only a heating furnace or an electric drier is permitted to be used for heating up parts such
as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a perfect
contact.
CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual.
Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.
The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible
malfunction.
Never wash disks having organic friction linings (e.g. paper disks - adverse effect on lining adhesion).
Only dry cleaning is permitted (leather cloth).
DANGER
When using detergents, observe the manufacturer’s instructions regarding their handling.
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Corporate Division
and Axle Systems
Structure of the Service Manual
The structure of this repair manual reflects the sequence of the work steps for completely disassembling the
dismantled unit.
Tools required for carrying out the repair work are listed in the current text as well as in chapters "WS“
(special tools) and "WH" (commercial tools).
Important information on industrial safety
As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully
responsible for industrial safety.
The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding
any damage to persons and products during maintenance and repair work.
Repair workshops must familiarize themselves with these regulations prior to starting any work.
A suitably trained and skilled staff is required for a proper repair of these ZF products.
The repair workshop shall be responsible for the training.
The following safety references are used in this manual:
This symbol serves as a reference to special working procedures,

CAUTION methods, information, use of auxiliaries etc... indicated in this
repair manual.
This symbol identifies situations in which lacking care may lead to

DANGER personal injury or damage to the product.
NOTE: Thoroughly study this manual before starting any tests or repair work.
NOTE: Figures, drawings and parts in this manual do not always represent the original; they show
the working procedure.
Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on
size and weight (not even within one and the same illustration).
Carry out work according to the legend.
NOTE: After repair work and tests, the expert staff must verify that the product is perfectly
functioning again.
5871 132 002 0/3

Corporate Division
and Axle Systems
BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DÉNOMINATION DES DIMENSIONS STANDARDISÉES
Hinweis : längenbezogene Masse in kg/m; flächenbezogene Masse in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : densité linéaire en kg/m; densité superficielle en t/m2
Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

Unit Symbol New Old Conversion Note
Unité Symbole Nouveau Vieux Conversion Nota
Masse m kg (Kilogramm) kg
Density
Masse
Kraft F N (Newton) kp 1 kp = 9.81 N
Force
Force
Arbeit A J (Joule) kpm 0.102kpm = 1J = 1Nm
Work
Travail
Leistung P KW (Kilowatt) HP (DIN) 1 HP = 0.7355 KW
Power 1 KW = 1.36 HP
Puissance
Drehmoment T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) =
Torque F (N) . r (m)
Couple
Kraftmoment M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) =
Moment (Force) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1.02 atü = 1.02 kp/cm2
Pressure (Over-) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed rpm
Nombre de Tours tr/min
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Corporate Division
and Axle Systems
VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25.40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2.205 lb ( pounds )
9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per square inch lbf/in2 )
0.070 bar ( 0.071 kp/cm2 ) =

1 psi ( lbf/in2 )
1 Liter = 0.264 Gallon ( Imp. )
4.456 Liter =
1 Gallon ( Imp. )
1 Liter =
0.220 Gallon ( US )
3.785 Liter =
1 Gallon ( US )
1609344 m =
1 Mile ( land mile )
0° C ( Celsius ) = + 32° F ( Fahrenheit )
0 ° C ( Celsius ) = 273.15 Kelvin
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Corporate Division
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TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148
Friction coefficient: µ tot.= 0.12 for screws and nuts without rework, as well as phosphated nuts. Tighten manually!
Take tightening torques from the following chart, unless otherwise specified:
Metric ISO standard thread DIN 13, page 13

Dimension 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO fine thread DIN 13, page 13

Dimension 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
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Corporate Division
and Axle Systems
LABELING OF IDENTIFICATION PLATE FOR ZF-POWERSHIFT

TRANSMISSIONS
1 = Transmission type
2 = Transmission number
3 = ZF parts list number
4 = Total transmission ratio
5 = Oil filling (oil specification)
6 = ZF List of Lubricants
7 = Oil fill quantity
8 = Customer number
1 2
3 4
5 6
7
8
INFORMATION ON SPARE PARTS ORDERING:
Please indicate the following information when ordering genuine ZF spare parts:
1. = Transmission type
2. = Unit number You will find this information on the identification plate!
3. = ZF parts list number
4. = Make and type of spare part
5. = Denomination of spare part
6. = Spare part number
7. = Shipping mode
Please indicate all the a.m. details to avoid any mistakes in the delivery of the ordered spare
parts!
5871 132 002 0/7

Corporate Division
and Axle Systems
CONFIGURATION 2 WG-94 EC
1 = Converter
2 = Flexplate for direct mount
3 = Central shaft / input shaft, PTOs
4 = Transmission pump
5 = Clutch shaft „KA“
6 = Output shaft / clutch shaft „KB“
7 = Oil drain plug
8 = Output flange
9 = Input shaft / clutch shaft „KV“
10 = PTO; coaxial, engine-dependent
(center distance 105 mm)
11 = Clutch shaft „KR“
11
1
10
7
6
5871 132 002 0/8

Corporate Division
and Axle Systems
Transmission schematics Gear schematics
KR
PTO KR
AN KV
AN/KV
KA KA
KB/AB
KB/AB
Legend:
AN/KV = Input / KV clutch - forwards

KR = KR clutch - reverse
KA = KA clutch - 1st gear
KB/AB = KB clutch / output - 2nd gear
PTO = Power take-off; coaxial, engine-dependent
5871 132 002 0/9

Corporate Division
and Axle Systems
MEASURING POINTS AND CONNECTIONS

2 WG-94 EC
Take measurements when the transmission has reached operating temperature (approx. 80° - 90° C)!
No. Denomination of item Connection
Measuring points for pressure oil and temperature:

51 = Before the converter – opening pressure 11+2 bar M10x1
53 = Forward clutch KV 16+3 bar M10x1
55 = Reverse clutch KR 16+3 bar M10x1
56 = Clutch KA 16+3 bar M10x1
57 = Clutch KB 16+3 bar M10x1
63 = Temperature after the converter 100° C; short-term 120° C M14x1.5
65 = System pressure 16+3 bar 9/16-18 UNF-2B
Valves and connections:

10 = Breather 10x1
15 = Connection to heat exchanger 7/8“ 14 UNF
16 = Connection from heat exchanger 7/8“ 14 UNF
68 = Connection after ZF-filter 9/16-18 UNF-2B
69 = Connection before ZF-filter 7/8“ 14 UN 2A
70 = Converter safety valve (WSV)
71 = Main pressure valve (HDV)
Inductive sensor and speed sensor:

21 = Induct. sensor n turbine M18x1.5
34 = Speed sensor n output -------
47 = Induct. sensor n central gear chain M18x1.5
69 10
68
63
47
21
15
16
34
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Corporate Division
and Axle Systems
34 34
15
71
52/63
49
55
70
53
51
65
56
Y4
Y5 57
NOTES ON THE REQUIRED OIL GRADE:
Approved oils for 2 WG-94 EC powershift transmissions see ZF List of Lubricants

TE-ML 03.
The list of lubricants is being continuously updated and can be obtained or viewed as
follows:
- at all ZF plants
- at all ZF service centers
- Internet http://www.zf.com Informationen/Tech. Informationen
For information on operation, maintenance and for descriptions see relating operation
manual (ZF Order No. 5872 136 002).
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Corporate Division
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF – ERGOPOWER 2 WG-94 EC
Cons. Figure Denomination Qty Chapter/Fig.

No. Order No.
Assembly truck assy 1/2

with tilting device
1 5870 350 000 1
Holding fixtures 1/2
5870 350 063

2 1
Clamping angles 1/2
5870 350 136

3 1
Belt wrench 1/5
5870 105 005

4 1
Adjusting screws 6/6

14/2
5870 204 007
5 1
5871 132 002 WS/1

Corporate Division
and Axle Systems

No. Order No.
Eye bolt assortment 7/2
5870 204 002

6 1
8.1/10 _ 9.3/8
Assembly aid 8.2/9 _ 9.4/6
8.3/9 _ 9.4/8
5870 345 114 8.4/9
7 1 9.1/6
9.1/8
9.2/6
9.2/8
9.3/6
Grab sleeve 8.1/15
5873 001 026

8 1
Basic tool 8.1/15
5873 001 000

9 1
Grab sleeve 8.2/14

8.3/2
5873 000 029 1
10
5871 132 002 WS/2

Corporate Division
and Axle Systems

No. Order No.
5873 000 000 8.2/14

8.3/2
Basic tool
11 1
Rapid grip 8.3/4
5873 011 011

12 1
Forcing device 8.3/4
5870 026 100

13 1
Grab sleeve 8.4/4
5873 002 035

14 1
Rapid grip 8.4/14
5873 012 011

15 1
5871 132 002 WS/3

Corporate Division
and Axle Systems

No. Order No.
Basic tool 8.4/14
5873 002 000

16 1
Driver tool 10/2
5870 048 219

17 1
Adjusting screws 10/8
5870 204 011

18 1
Drift 11/1
5870 705 012

19 1
Driver tool 12/1
5870 048 200

20 1
5871 132 002 WS/4

Corporate Division
and Axle Systems

No. Order No.
Driver tool 12/6
5870 057 009

21 1
Handle 12/6
5870 260 002

22 1
Assembly mandrel 13/3

13/6
5870 506 105
23 1
5871 132 002 WS/5

Corporate Division
REPAIR MANUAL Off-Road Driveline Technology
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure Designation Qty Chapter/Fig .
No. Order No.
Magnetic stand
5870 200 055

1 1 Universal
Dial indicator
5870 200 057

2 1 Universal
Gauge blocks
5870 200 066 70 mm

3 1 Universal
5870 200 067 100 mm
Digital depth gauge
5870 200 072 200 mm

4 1 Universal
5870 200 114 300 mm
Digital caliper gauge
5870 200 109 150 mm

5 1 Universal
5871 132 002 WH/1

Corporate Division
and Axle Systems
No. Order No.
Torque wrench
5870 203 030 0.6 -6.0 Nm
5870 203 031 1.0 – 12 Nm
5870 203 032 3.0 – 23 Nm

6 1 Universal
5870 203 033 5.0 – 45 Nm
5870 203 034 10 – 90 Nm
5870 203 039 80 – 400 Nm
5870 203 016 140 – 750 Nm
5870 203 011 750 - 2000 Nm
Hot-air blower
5870 221 500 230 V

7 1 Universal
5870 221 501 115 V
Plastic hammer
5870 280 004 Ø 60 mm

8 1 Universal
Substitute nylon insert
5870 280 006
Lifting strap
5870 281 026

9 1 Universal
5871 132 002 WH/2

Corporate Division
and Axle Systems
No. Order No.
Lifting chain
5870 281 047

10 1 Universal
Pry bar
5870 345 071

11 1 Universal
Striker
5870 650 004

12 1 Universal
Set of internal pliers

I1-I2-I3-I4
13 5870 900 013 1 Universal
Set of internal pliers

I11-I21-I31-I41 90°
14 5870 900 014 1 Universal
5871 132 002 WH/3

Corporate Division
and Axle Systems
No. Order No.
Set of external pliers

A1-A2-A3-A4
15 5870 900 015 1 Universal
Set of external pliers

A01-A02-A03-A04 90°
16 5870 900 016 1 Universal
Two-armed puller
5870 970 001

Jaw width 80 mm
Throat depth 100 mm
5870 970 002
Jaw width 120 mm
Throat depth 125 mm
5870 970 003
Jaw width 170 mm
Throat depth 125 mm
5870 970 004
17 Jaw width 200 mm 1 Universal
Throat depth 175 mm
5870 970 006
Jaw width 350 mm
Throat depth 250 mm
5870 970 007
Jaw width 520 mm
Throat depth 300 - 500 mm
5870 970 026
Jaw width 250 mm
Throat depth 200 mm
5870 970 028
Jaw width 380 mm
Throat depth 200 mm
5871 132 002 WH/4

Corporate Division
and Axle Systems
No. Order No.
Three-armed puller
5870 971 001

Jaw width 85 mm
Throat depth 65 mm
5870 971 002
Jaw width 130 mm
Throat depth 105 mm
5870 971 003
Jaw width 230 mm
18 Throat depth 150 mm 1 Universal
5870 971 004
Jaw width 295 mm
Throat depth 235 mm
5870 971 005
Jaw width 390 mm
Throat depth 270 mm
5870 971 006
Jaw width 640 mm
Throat depth 300 mm
5871 132 002 WH/5

Corporate Division
and Axle Systems
1. DISASSEMBLY:
Transmission 2 WG-94 EC
Figure 1
Attach transmission to the assembly truck by means of holding

1 1 fixtures (1) and clamping angles (2).
(S) Assembly truck 5870 350 000

(S) Holding fixtures 5870 350 063
2 2 (S) Clamping angles 5870 350 136
Figure 2
1.1 Removal of filter
Drain oil prior to starting disassembly!
Remove screw plug (1).
Disposal of oil according to legal requirements!

1
Figure 3
The Figure shows the mounting provision for oil filler tube
with oil dipstick!
Loosen hexagon screw (1) and remove cover (2) and seal (3) .
2
1 3 If an oil filler tube with oil dipstick is installed instead of the
cover (2), these two parts are to be removed.
Figure 4
5871 132 002 1/1

Corporate Division
and Axle Systems
Separate ZF fine filter (1) from filter head by means of belt

wrench.
(S) Belt wrench 5870 105 005

1
Figure 5
Loosen cylindrical screws (2) and separate filter head (1) from
transmission housing.
Figure 6
Remove both O-rings (1) out of the annular groove of the filter
1 head.
Figure 7
5871 132 002 1/2

Corporate Division
and Axle Systems
2. DISASSEMBLY of proportional valves,

inductive sensor, Hall sensor, temperature
sensor and breather
Loosen cylindrical screw (1) from the proportional valves (2).
Figure 1
Remove proportional valves.
Figure 2
4 Remove positioned parts.

3
1 = Inductive sensor - n turbine
1 2 = Inductive sensor - n gear chain
3 = Temperature sensor, measuring point „63“ after converter
2 4 = Breather
Remove O-rings!
Figure 3
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Corporate Division
and Axle Systems
Loosen cylindrical screw (1) and remove speed sensor (2).
2 = Speed sensor - n output (Hall sensor)
1
Remove O-rings!
Figure 4
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Corporate Division
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3. DISASSEMBLY of PTO
1
Loosen cylindrical screws (1).
Figure 1
Separate cover from the mounting face of the transmission

housing by means of slight hits with the plastic hammer.
Figure 2
Remove cover by means of assembly lever.
Difficult disassembly due to fixing by cylindrical pins !
Figure 3
Pull out gear (1) and central shaft (2).
1 If required, remove both cylindrical pins (3) .
3 The central shaft (2) cannot be disassembled!

It is supplied by the spare parts service only as a complete
assy which consists of:
• Shaft
• Tapered roller bearings (2 pcs)
• Helical gear
2 • Rectangular ring (available separately)
Figure 4
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Corporate Division
and Axle Systems
Pull needle cage out of the housing hole by means of a KUKKO

puller.
Figure 5
Use assembly levers to remove bearing outer ring from the

housing hole.
If the central shaft is not exchanged, the bearing assignment

(bearing outer ring to bearing inner ring) is to be marked!
Figure 6
Pull needle cage out of the cover hole by means of a KUKKO

puller.
Figure 7
Use assembly levers to remove bearing outer ring from the cover
hole.
If the central shaft is not exchanged, the bearing assignment

(bearing outer ring to bearing inner ring) is to be marked!
Figure 8
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Corporate Division
and Axle Systems
4. DISASSEMBLY of output flange

Remove locking plate (1), loosen hexagon screws (2) and
4 remove disk and O-ring (3 and 4).
3
1 2
Figure 1
Pull output flange (1) off the output shaft by means of two-armed
puller.
Figure 2
Remove shaft seal (1) from the housing hole by means of

assembly lever.
Figure 3
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Corporate Division
and Axle Systems
5. DISASSEMBLY of main pressure valve

and converter safety valve
Loosen screw plug (1) and remove main pressure valve (control
5 pressure valve):
4
2 Main pressure valve consists of:
1 = Screw plug
2 = O-ring
3 = Piston
4 = Spacer ring
3 5 = Compression spring
1
Figure 1
Loosen screw plug (1) and remove converter safety valve.

3
Converter safety valve consists of:
2
1 = Screw plug
2 = O-ring
3 = Pressure valves
- = Valve assy is installed in the housing – not visible -
(functional check of valve see Figure 3).
1
Figure 2
Functional check of valve.

Use a screwdriver to check the movability of the ball in the
valve.
If the valve is o.k., it does not need to be removed.
Figure 3
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Corporate Division
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1 6. DISASSEMBLY of engine connection

2
Loosen hexagon screws (1) and separate flexplate (2) from
converter (3).
Figure 1
Pull off converter (1) by hand.
Figure 2
Loosen bolted connection between converter bellhousing /

1 housing (1) and oil pressure pump / housing (2).
2
Figure 3
Press converter bellhousing off the housing equally by means of

1 hexagon screws M10 (1).
Difficult disassembly due to fixing by cylindrical pins!
Figure 4
5871 132 002 6/1

Corporate Division
and Axle Systems
If required, remove both cylindrical pins (1).

1
Figure 5
Remove filter (1).

1 S
2
Oil pressure pump (2) cannot be separated from the housing
until the 4 cylindrical screws of the housing inner side have
been loosened.
Fit adjusting screws to ensure that the oil pressure pump is

centered at the housing after the 4 cylindrical screws have
been loosened!
(S) Adjusting screws (M10) 5870 204 007

Figure 6
5871 132 002 6/2

Corporate Division
and Axle Systems
7. REMOVAL of clutches and

DISASSEMBLY of oil pressure pump
2 7.1 Removal of clutches

1
3
Force out cylindrical pin (1).
Cylindrical pin (2) is fitted into a blind hole and can

therefore not be forced out of the hole!
See Figure 3.
Loosen bolted connection (3) of housing front and rear part.
Figure 1
Separate housing front part by means of lifting device.
Support by means of assembly lever!
Difficult disassembly due to fixing by cylindrical pins!
(S) Eye bolt assortment 5870 204 002
Figure 2
Lift the clutches out of the housing in the following sequence:

2 KV
1 KA = 1st gear clutch
KB KA KR = Reverse clutch
KV = Forward clutch and input
KR KB = 2nd gear clutch and output
2 = Screen sheet
If required, remove cylindrical pin (1).
Figure 3
5871 132 002 7/1

Corporate Division
and Axle Systems
Use assembly levers to remove all bearing outer rings from the
1 housing rear part.
If, contrary to the ZF recommendation, the tapered roller

bearings of clutches are not replaced, it is imperative to
ensure the previous pairing (bearing outer ring/bearing inner
ring).
Bearing outer ring and bearing inner ring must be marked!
Remove O-ring (1).
Figure 4
Use assembly levers to remove all bearing outer rings from the
housing front part.

bearings of clutches and input are not replaced, it is
imperative to ensure the previous pairing (bearing outer
ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be marked!

Figure 5
Loosen cylindrical screws (1) and remove suction tube (2).

2
Loosen cylindrical screws (3 and 4) and remove oil pressure
1
pump.
3
4 Pay attention to the releasing oil pressure pump!
Figure 6
7.2 Disassembly of oil pressure pump

1
Remove oil pressure pump (1).
Figure 7
5871 132 002 7/2

Corporate Division
and Axle Systems
Remove O-ring (1).
1 2 Loosen cylindrical screws (2).
Figure 8
Check oil pressure pump :

1 In case of wear marks in the pump housing, stator hollow
shaft or on the inner and outer rotor, the complete oil
pressure pump is to be replaced.
2
1 = Stator hollow shaft
3 2 = Inner rotor
3 = Outer rotor
4 = Pump housing
4
Figure 9
Remove shaft seal (1) from the pump housing (2).

1
Figure 10
5871 132 002 7/3

Corporate Division
and Axle Systems
8. DISASSEMBLY of clutches:
2 3 4
1
1 = KB clutch (2nd gear clutch and output)

2 = KV clutch (forward clutch and input)
3 = KA clutch (1st gear clutch)
4 = KR clutch (reverse clutch)
Figure 1
8.1 KV clutch/input
Snap out piston ring (1).
Figure 2
Pull off bearing inner ring with inner disk carrier (1).
Figure 3
Remove bearing inner ring (1), axial bearing assy (2) and idler
1 gear (3).
2
Figure 4
5871 132 002 8.1/1

Corporate Division
and Axle Systems
Remove needle cage (1).

1
Figure 5
Remove axial bearing assy (1).

1
Figure 6
Remove snap ring (1).
Figure 7
Remove end plate (1), disk package (2) and sheet – cpl. with cup
springs- (3) from the disk carrier.
1
Figure 8
5871 132 002 8.1/2

Corporate Division
and Axle Systems
Remove retaining ring (1) - contact position of axial bearing.

1
Figure 9
Preload compression spring and remove snap ring (1).
(S) Assembly aid 5870 345 114

1
Figure 10
Remove spring cup (1) and compression spring (2).

1
Figure 11
By means of compressed air (see arrow), press piston (1) off the
1 shaft/disk carrier and remove it.
Figure 12
5871 132 002 8.1/3

Corporate Division
and Axle Systems
Remove both O-rings (1 and 2).
Figure 13
Rechteckringe
Snap out rectangular
(1) ausfedern.
rings (1).
1
Figure 14
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve 5873 001 026

(S) Basic tool 5873 001 000
Figure 15
The input shaft (1) cannot be disassembled!

1A
1B
1C 1A = Ball
1 1B = Helical gear
1C = Disk carrier
1D 1D = Shaft
Figure 16
5871 132 002 8.1/4

Corporate Division
and Axle Systems
8.2 KR clutch
1
Figure 1
Pull off bearing inner ring with idler gear (1).
Figure 2
1
gear (3).
2
Figure 3

1
Figure 4
5871 132 002 8.2/1

Corporate Division
and Axle Systems
Figure 5

1
Figure 6
Remove end plate (1), disk package (2) and sheet – cpl. with cup
springs - (3) from the disk carrier.
1
Figure 7

1
Figure 8
5871 132 002 8.2/2

Corporate Division
and Axle Systems
Figure 9

1
Figure 10
Figure 11
Figure 12
5871 132 002 8.2/3

Corporate Division
and Axle Systems

1
Figure 13
(S) Grab sleeve 5873 000 029

(S) Basic tool 5873 000 000
Figure 14
The clutch (1) cannot be disassembled!

1A It is supplied by the spare parts service only as a complete
1B
1A = Retaining ring
1 1B = Helical gear
1C 1C = Disk carrier
1D = Shaft
1D
Figure 15
5871 132 002 8.2/4

Corporate Division
and Axle Systems
8.3 KA clutch
1
Figure 1
(S) Grab sleeve 5873 000 029

(S) Basic tool 5873 000 000
Figure 2
Remove axial bearing assy (1) and idler gear (2).
Figure 3

1
Figure 4
5871 132 002 8.3/1

Corporate Division
and Axle Systems
Figure 5

1
Figure 6
Remove end plate (1), disk package (2) and cup spring (3) from
the disk carrier.
1
Figure 7

1
Figure 8
5871 132 002 8.3/2

Corporate Division
and Axle Systems
Figure 9

1
Figure 10
Figure 11
Figure 12
5871 132 002 8.3/3

Corporate Division
and Axle Systems

1
Figure 13
(S) Rapid grip 5873 011 011

(S) Extractor set 5870 026 100
Figure 14

1A It is supplied by the spare parts service only as a complete
1B
1A = Retaining ring
1 1B = Helical gear
1D = Shaft
1D
Figure 15
5871 132 002 8.3/4

Corporate Division
and Axle Systems
8.4 KB clutch/output
1
Figure 1
Pull off bearing inner ring with idler gear (1).
Figure 2
1
gear (3).
2
Figure 3

1
Figure 4
5871 132 002 8.4/1

Corporate Division
and Axle Systems
Figure 5

1
Figure 6
Remove end plate (1), disk package (2) and cup spring (3) from
the disk carrier.
1
Figure 7

1
Figure 8
5871 132 002 8.4/2

Corporate Division
and Axle Systems
Figure 9
1 Remove spring cup (1) and compression spring (2).
Figure 10
Figure 11
Figure 12
5871 132 002 8.4/3

Corporate Division
and Axle Systems
Snap out rectangular rings (1).
Figure 13
(S) Grab sleeve 5873 002 035

or
(S) Rapid grip 5873 012 011
(S) Basic tool 5873 002 000
Figure 14

1A
1B
1A = Ball
1C 1 1B = Retaining ring
1C = Helical gar
1D 1D = Disk carrier
1E = Shaft
1E
Figure 15
5871 132 002 8.4/4

Corporate Division
and Axle Systems
1A 9. REASSEMBLY of clutches:
1B 9.1 KV clutch/input
The input shaft (1) is supplied by the spare parts service only
1C
1
as a complete assy which consists of:
1D 1A = Ball
1B = Helical gear
1C = Disk carrier
1D = Shaft
Figure 1
Heat up bearing inner ring (approx. 120° C).
Figure 2
Mount bearing inner ring (1) until contact is obtained.

2
1
Fit rectangular rings 50x2.5 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.

Figure 3
Insert both O-rings (1 and 2) into the piston grooves and oil
them.
1 1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002 9.1/1

Corporate Division
and Axle Systems
Insert piston (1) into the disk carrier.

1
Pay attention to the installation position, see Figure!
Figure 5
Use a hand-operated press to place piston into the disk carrier by

means of the assembly aid.
Figure 6
Mount compression spring (1) and spring cup (2).

2
Figure 7
By means of the assembly aid, preload compression spring

under a hand-operated press until the retaining ring 40x1.75 (1)
can be snapped in.
1
Figure 8
5871 132 002 9.1/2

Corporate Division
and Axle Systems
Sheet cpl. with cup spring (1) the open side the piston.
1
Installation position of sheet sees also Figure 10!
Figure 9
Install sheet (1) according to the sketch (see arrow).

2 1
Legend:
1 = Sheet cpl. with cup spring

3 2 = Compression spring with spring cup and retaining ring
3 = Piston with O-rings
4 = Input shaft ass.
4
Figure 10
Install outer and inner disks alternately into the disk carrier (3) as
shown in Figure 11,
Starting with an outer disk and ending with an inner disk.
2 Legend:
1
1 = Outer disks (10 pcs)
2 = Inner disks (10 pcs)
3 3 = Input shaft assy
Figure 11
Mount end plate (1) with the flat side showing towards the disk
2 package and fix it by means of snap ring (2) (e.g. thickness =
2.5 mm / recommended value).
1
Pay attention to the installation position of the end plate!
Figure 12
5871 132 002 9.1/3

Corporate Division
and Axle Systems
Equally press on end plate with F (approx. 100 N = 10 kg) and

F set dial indicator to „zero“.
Figure 13
Then press end plate against the snap ring (upwards) and read the
F disk clearance.
Disk clearance: 1.9 to 2.4 mm
In case of deviations, the disk clearance must be corrected

with an appropriate snap ring (optional thickness = 2.0 …...
3.5 mm/available in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1 Contact for axial bearing – see Figure 16!
Figure 15
3 Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3

2 (2) and axial washer 40x60x1 (3) and oil them.
1
Mount running disk (1) with the chamfer showing towards
the axial needle cage!
Figure 16
5871 132 002 9.1/4

Corporate Division
and Axle Systems
Mount needle cage 40x45x17 (1) and oil it.

1
Figure 17
Mount inner disk carrier until contact is obtained.

1 Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
L R
Figure 18
3 Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
and running disk (3) 40x60x3.5 and oil them.
2
1
Mount running disk (1), with the chamfer showing towards

Figure 19
Figure 20
5871 132 002 9.1/5

Corporate Division
and Axle Systems
Fit rectangular ring 35x2 (2).

2
1

Figure 21
Check closing and opening of the clutch by means of

compressed air at the hole (see arrow).
Closing and opening of the clutch must be clearly audible.
Figure 22
5871 132 002 9.1/6

Corporate Division
and Axle Systems
9.2 KR clutch
1A
The clutch (1) is supplied by the spare parts service only as a
1B
complete assy which consists of:
1A = Retaining ring
1 1B = Helical gear
1C
1C = Disk carrier
1D = Shaft
1D
Figure 1
Heat up bearing inner ring (approx. 120° C)
Figure 2

2 1

Figure 3
them.
1 1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002 9.2/1

Corporate Division
and Axle Systems

1
Figure 5

Figure 6

2
Figure 7
By means of the assembly aid, preload compression spring under

a hand-operated press until the retaining ring 40x1.75 (1) can be
snapped in.
1 (S) Assembly aid 5870 345 114
Figure 8
5871 132 002 9.2/2

Corporate Division
and Axle Systems
Sheet cpl. with cup spring (1) the open side the piston.
Installation position of sheet sees also Figure 10!
Figure 9
Install sheet (1) according to the sketch (see arrow).

2 1
Legend:
1 = Sheet cpl. with cup spring

4 = Input shaft ass.
4
Figure 10
shown in Figure 11,
starting with an outer disk and ending with an inner disk.
2 Legend:
1
3 3 = Clutch assy
Figure 11
package and fix it by means of snap ring (2) (e.g. thickness =
2.5 mm / recommended value).
2
1
Figure 12
5871 132 002 9.2/3

Corporate Division
and Axle Systems

Figure 13
F disk clearance.

Figure 14
1
Contact for axial bearing - see Figure 16!
Figure 15
Mount running disk 40x60x3.5 (1), axial needle cage 40x60x3

3
1
Figure 16
5871 132 002 9.2/4

Corporate Division
and Axle Systems

1
Figure 17

1
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
L R
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage 40x60x3 (2)
3
2
1

Figure 19
Figure 20
5871 132 002 9.2/5

Corporate Division
and Axle Systems

2 1

Figure 21

Figure 22
5871 132 002 9.2/6

Corporate Division
and Axle Systems
9.3 KA clutch
1A
1B
complete assy which consists of:
1A = Retaining ring
1 1B = Helical gear
1D = Shaft
1D
Figure 1
Figure 2

2
1 Fit rectangular rings 30x2 (2).

Figure 3
them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002 9.3/1

Corporate Division
and Axle Systems

1
Figure 5

Figure 6

2
Figure 7

snapped in.

1
Figure 8
5871 132 002 9.3/2

Corporate Division
and Axle Systems
Mount cup spring 112x75x2.55 (1) with the convex side showing
towards the piston.
1
Installation position of cup spring see also Figure 10!
Figure 9
Install cup springs (1) according to the sketch.

2 1
Legend:
1 = Cup spring 112x75x2.55 (convex side towards the piston)

3 2 = Compression spring with cup spring and retaining ring
4 = Clutch assy
4
Figure 10
shown in Figure 11,
2 Legend:
1
3
3 = Clutch assy
Figure 11
package and fix it by means of snap ring (2) (e.g. thickness = 2.5
2 mm / recommended value).
1
Figure 12
5871 132 002 9.3/3

Corporate Division
and Axle Systems

Figure 13
F disk clearance.

Figure 14
1
Figure 15

2
1 Mount running disk (1), with the chamfer showing towards

Figure 16
5871 132 002 9.3/4

Corporate Division
and Axle Systems

1
Figure 17

1
Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
L R
Figure 18
2
1

Figure 19
Figure 20
5871 132 002 9.3/5

Corporate Division
and Axle Systems

2
1 Fit rectangular ring 30x2 (2).

Figure 21

Figure 22
5871 132 002 9.3/6

Corporate Division
and Axle Systems
1A 9.4 KB clutch/output

1B complete assy which consists of:
1C 1A = Ball
1 1B = Retaining ring
1D 1C = Helical gear
1D = Disk carrier
1E 1E = Shaft
Figure 1
Figure 2
Fit rectangular rings 55x3 (2).

2
1

Figure 3
them.
1 1 = 40x3
2 = 104.5x3
2
Figure 4
5871 132 002 9.4/1

Corporate Division
and Axle Systems

1

Figure 5

Figure 6

2
Figure 7

snapped in.
1 (S) Assembly aid 5870 345 114
Figure 8
5871 132 002 9.4/2

Corporate Division
and Axle Systems
Mount cup spring 112x75x2.55 (1) with the convex side showing
1 towards the piston.
Installation position of cup spring see also Figure 10!
Figure 9
Install cup spring (1) according to the sketch.

2 1
Legend:
1 = Cup spring 112x75x2.55 (convex side towards the piston)

4 = Clutch assy
4
Figure 10
shown in Figure 11,
2 Legend:
3 1
3 = Clutch assy
Figure 11
2 package and fix it by means of snap ring (2) (e.g. thickness = 2.5
mm / recommended value).
1
Figure 12
5871 132 002 9.4/3

Corporate Division
and Axle Systems

Figure 13
F
disk clearance.

Figure 14
1
Figure 15

2
1
Figure 16
5871 132 002 9.4/4

Corporate Division
and Axle Systems

1
Figure 17

1
L R Install inner disks by short ccw/cw rotations of the inner disk
carrier (1).
Figure 18
2
1

Figure 19
Figure 20
5871 132 002 9.4/5

Corporate Division
and Axle Systems

2 1
Adjust bearing inner ring after cooling-down!

Figure 21

Figure 22
5871 132 002 9.4/6

Corporate Division
and Axle Systems
10. REINSTALLATION of clutches and

REASSEMBLY of oil pressure pump
10.1 Oil pressure pump
1
In case of wear marks in the pump housing, stator hollow
shaft, inner rotor, outer rotor and on the sliding bearing, the
pump assy must be replaced.
2
Legend:
3
1 = Stator hollow shaft
2 = Inner rotor
4 3 = Outer rotor
4 = Pump housing with sliding bearing
Abbildung 1
With the sealing lip showing downwards, carefully insert the

shaft seal 55x75x8 (1) into the pump housing (2) until contact is
S obtained.
1
Fill space between sealing lip and dust lip with grease!
Outer diameter:
2
if rubber-coated: wet with spirit
if made of metal: apply sealing agent Loctite No. 574!
(S) Driver tool 5870 048 219
Abbildung 2
Mount outer rotor (1) and inner rotor (2).
The driver pins of the inner rotor (see arrows) are to be fitted
2 in upward direction.
Abbildung 3
5871 132 002 10/1

Corporate Division
and Axle Systems
Fit stator hollow shaft (1).
Abbildung 4
Fix stator hollow shaft radially with two cylindrical screws (1).
1
Do not tighten the cylindrical screws – just turn them in until

contact is obtained and then turn them back by approx. ½
rotation!
2 Place O-ring (2) 135x3 into the annular groove and grease it.
Abbildung 5
Mount O-ring 30x3 (1) onto the suction tube (2) and grease it.
1
Abbildung 6
Fix suction tube (1) with cylindrical screws M8x16 (2).
2 Tightening torque M8/8.8x16................ MA = 23 Nm
Abbildung 7
5871 132 002 10/2

Corporate Division
and Axle Systems
Insert filter (1).
Abbildung 8
Fit two adjusting screws (S) and position converter bellhousing

(1) equally until contact is obtained.
S
1
Pay attention to the hole pattern!

Wet mounting face with Loctite (type No. 574)!

Abbildung 9
Force the cylindrical pins 12x24 (1) into the holes (blind holes)
1 until contact is obtained.
Abbildung 10
Fix converter bell housing (1) with cylindrical screws M10x30

1 (2).
2
Tightening torque (M10/8.8x30) ................ MA = 46 Nm
Abbildung 11
5871 132 002 10/3

Corporate Division
and Axle Systems
Fit two adjusting screws (S) and mount preassembled pump (1).
1
S
Pay attention to the hole pattern!
Abbildung 12
Position transmission pump with 3 cylindrical screws (1)

M10x30 (3x120° offset position) equally until contact is
1
obtained.
ATTENTION: Do not damage (shear off) the O-ring!

Fix transmission pump with cylindrical screws M8x60 (1).
Tightening torque (M8/8.8x60) ...................MA = 23 Nm
Abbildung 13
Fix pump with cylindrical screws (1 and 2).

1
1 = M8x16
2 = M8x35
2
Tightening torque M8/8.8x16................ MA = 23 Nm
Tightening torque M8/8.8x35................ MA = 23 Nm
Abbildung 14
Insert all bearing outer rings into the bearing holes of both
housing parts (see Figures 15 and 16).
3
2 1 = „KB“ clutch - 2nd gear and outputs
2 = „KV“ clutch - forward and inputs
3 = „KR“ clutch - reverse
4 4 = „KA“ clutch - 1st gear
1
Place bearing outer rings into the bearing holes using
assembly grease.
Abbildung 15
5871 132 002 10/4

Corporate Division
and Axle Systems

3 bearings of clutches and input are not replaced, it is
imperative to ensure the previous pairing (bearing inner
2 ring/bearing outer ring) - see Chapter 7, Figures 4 and 5!
Abbildung 16
10.2 Reinstallation of clutches

2
3 Align and grease rectangular rings 55x3 (1).
1 Position KB clutch (2) together with screen sheet (3).

4
Bolts (4) of screen sheet must be fixed into the pilot holes!
Abbildung 17
Align and grease rectangular rings 50x2.5 (1).
2
Position KV clutch (2).
1
Abbildung 18
Align and grease rectangular ring 30x2 (1).
2
Position KR clutch (2).
Abbildung 19
5871 132 002 10/5

Corporate Division
and Axle Systems
Align and grease rectangular ring 30x2 (1).
2 Position KA clutch (2).
Abbildung 20
Insert O-ring 24x2.5 (1) into the hole and grease it.
2 3
4
Align and grease rectangular rings (2, 3, 4 and 5).
1 5
Abbildung 21
Use the lifting device to carefully bring the transmission housing

front part into contact position.
The bolts (1) of the screen sheet must be fixed into the pilot
holes!
Wet mounting face with Loctite (type N. 586)!
Abbildung 22
5871 132 002 10/6

Corporate Division
and Axle Systems
Hand-tighten the transmission housings crosswise with 2

1 cylindrical screws (1).
Fit cylindrical pins 12x24 (2) centrically to the mounting face.
Abbildung 23
Force cylindrical pins 12x24 (1) into the transmission housing

until contact is obtained (blind hole).
Abbildung 24
Fix transmission housing front and rear part by means of

3 1 cylindrical screws (1 and 2).
2
Fit bracket (3).
Cylindrical screw (1) M10x30 (13 pcs)

Cylindrical screw (2) M10x50 (9 pcs)
Tightening torque M10/8.8x30 ..............................MA = 46 Nm

Tightening torque M10/8.8x50 ..............................MA = 46 Nm
Abbildung 25
5871 132 002 10/7

Corporate Division
and Axle Systems
11. REASSEMBLY of converter safety valve

and main pressure valve
11.1 Reassembly of converter safety valve
Insert valve (1) with drift (S) into the housing until contact is
obtained.
1
(S) Drift 5870 705 012
S
Figure 1
Place compression spring (1) into the transmission hole and fit
screw plug M38x1.5 (2) with O-ring 35x2 (3).
3
Tightening torque ..............................MA = 46 Nm
1
2
Figure 2 11.2 Reassembly of main pressure valve (control pressure

valve)
Main pressure valve consists of:
5
4
1 =
Screw plug M22x1.5
2 2 =
O-ring 19x2
3 =
Piston
4 =
Spacer ring (2 pcs)
recommended value 5 mm
5 = Compression spring
1
The main pressure 16 + 3 bar is determined by means of the
spacer rings!
Gradation of available spacer rings see spare parts list.
Figure 3
Tightening torque ..............................MA = 50 Nm
5871 132 002 11/1

Corporate Division
and Axle Systems
12. REASSEMBLY of output flange
Use driver tool to fit the shaft seal 60x90x8 (1) until contact
1 position, with the sealing lip showing towards the oil sump.
(S) Driver tool 5870 048 200
Fill space between sealing lip and dust lip with grease!
Outer diameter:
• if rubber-coated: wet with spirit,
Figure 1 • if made of metal: apply sealing agent Loctite No.
574!
Press screen sheet (1) onto the flange (2) until contact is
obtained.
1
Use suitable pressure piece; screen sheet must not be
2
deformed!
Figure 2
Heat up output flange (approx. 120° C).
Figure 3
Mount output flange (1) until contact is obtained.

1
Adjust output flange after cooling down!

Figure 4
5871 132 002 12/1

Corporate Division
and Axle Systems
Insert O-ring 38x4 into the space between output flange and
shaft.
2 1 Fix output flange by means of washer (1) and hexagon screws
(2).
Figure 5
Fix locking plate by means of driver tool.
(S) Driver tool 5870 057 009

(S) Handle 5870 260 002
Figure 6
5871 132 002 12/2

Corporate Division
and Axle Systems
13. REASSEMBLY of PTO

1
1B The central shaft (1) is supplied by the spare parts service
1D only as a complete assy which consists of:
1A 1A = Shaft
1B = Helical gear
1C = Tapered roller bearing (bearing outer and inner ring)
1D = Rectangular ring (available separately)
1C
Figure 1
Turn orifice M8 - orifice hole A=1.0 - (1) into the threaded hole
1 until contact is obtained.
Figure 2
Press in needle sleeve 40x47x20 (1) by means of the assembly

mandrel until contact is obtained and oil it.
1 2 Designation of the needle sleeve to show outwards to the

assembly mandrel!
(S) Assembly mandrel 5870 506 105
Place bearing outer ring (2) into the housing hole.

assembly grease.
Figure 3
Align and grease rectangular ring 50x2.5 (2).
Mount central shaft (1).

2 1
Figure 4
5871 132 002 13/1

Corporate Division
and Axle Systems
Insert gear (1).
Splined shaft profile to show outwards (see arrow)!
Figure 5
Press in needle sleeve 40x47x20 (1) by means of the assembly

mandrel until contact is obtained and oil it.
1
Designation of the needle sleeve to show outwards to the
assembly mandrel!
2 (S) Assembly mandrel 5870 506 105
Insert bearing outer ring (2) into the cover hole.

assembly grease.
Figure 6
Hand-tighten the cover crosswise with 2 cylindrical screws

2 1 M10x30 (1).
2
Force the two cylindrical pins 12x24 (2) into the holes (blind
holes) until contact is obtained.
Wet mounting face with Loctite (type No. 574)!
Figure 7
Fix housing and cover by means of cylindrical screws M10x30

1 (1).
Tightening torque M10/8.8x30..............................MA = 46 Nm
Figure 8
5871 132 002 13/2

Corporate Division
and Axle Systems
14. REASSEMBLY of engine connection
1
Mount converter (1) until contact is obtained.
Figure 1
Position 1 washer/each / thickness = 1.0 mm (4x) (1) onto the

4
flexplate mounting webs (4x).
3
Place flexplates (2).
2
Pay attention to the installation position ! Spot-welded

reinforcing disks of the flexplate to be arranged towards the
1 outside - see arrows !
Mount washer (3) onto the hexagon screw M10x16 (4) and fix
flexplates.
Figure 2
Tighten hexagon screws (1).

1
Fix converter axially!

Risk of injury!
Figure 3
5871 132 002 14/1

Corporate Division
and Axle Systems
15. REASSEMBLY of proportional valves,

inductive sensor, Hall sensor, temperature
sensor, breather and screw plugs
2 Mount all screw plugs (1 and 3) with O-rings (2 and 4).

1
Legend:
1 = Screw plug 9/16-18 UNF (6 pcs)
3
2 = O-ring 11.89x1.98 (6 pcs)
3 = Screw plug M10x1 (18 pcs)
4 = O-ring 8x1.5 (18 pcs)
Tightening torque (9/16-18 UNF) ................. MA = 15 Nm

4 Tightening torque (M10x1) ........................... MA = 6 Nm
Figure 1
Mount O-ring 15.5x2.6 (2) onto the speed sensor -n output Hall
sensor- (1) and fix it with cylindrical screw M8x16 (3).
Tightening torque (M8/8.8x16)............. MA = 23 Nm
2 1
Figure 2
4 Fit positioned parts.

3
1 = Inductive sensor with O-ring 15x2 - n turbine
1 Tightening torque………… MA = 30 Nm
2 = Inductive sensor with O-ring 15x2 - n central gear
2 chain
Tightening torque………… MA = 30 Nm
3 = Temperature sensor with O-ring 11x2
(measuring point „63“ after the converter)
Tightening torque………… MA = 25 Nm
4 = Breather M10x1
Tightening torque………… MA =12 Nm
Figure 3
5871 132 002 15/1

Corporate Division
and Axle Systems
Insert proportional valves (1).
Figure 4
Fix proportional valves (1) with cylindrical screws M6x12 (2).
Tightening torque (M6/8.8x12)............. MA = 9.5 Nm
Figure 5
5871 132 002 15/2

Corporate Division
and Axle Systems
16. REASSEMBLY of filter, closing

components for oil filler and oil drain plug
Place O-rings 34.2x3 (1) into the holes and grease them.
1
Figure 1
Attach filter head (1) with cylindrical screws M8x30 (2).
2
Tightening torque (M8/8.8X30) ...................... MA = 23 Nm
Figure 2
The ZF filter (1) has to be fitted as follows:

• Slightly oil the seal
• Turn in the filter until contact with the sealing
1
surface is obtained, and then tighten it by hand with
approx. 1/3 to 1/2 rotation.
Figure 3
5871 132 002 16/1

Corporate Division
and Axle Systems
Fix closing cover (2) and seal (3) with hexagon screws (1).
2 Tightening torque (M8/8.8x18)................ MA = 34 Nm

1 3
Figure 4
Fit oil drain plug 7/8-14 UN 2A (1).
Tightening torque (7/8-14 UN 2A).............MA = 30 Nm

2
Fix identification plate (2) by means of 4 grooved pins 3x5.
Figure 5
Before putting the transmission into operation, fill it with oil

according to Operation Manual (Order No. 5872 136 002)!
Figure 6
5871 132 002 16/2

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Order No.

5871 132 002

Abt. : ASDM / Division : ASDM

General 0/2 ... 3

Denomination of standard dimensions 0/4

Conversion table 0/5

Tightening torques for screws 0/6

Labeling of identification plate and information on spare parts ordering 0/7

Configuration of transmission 0/8 ... 9

Measuring points and connections 0/10

Notes on oil grade and oil fill quantity 0/11

SPECIAL TOOLS WS/1 … 5

1. DISASSEMBLY 1/1 ... 2

1.1 Removal of filter 1/1

2. DISASSEMBLY of proportional valves, inductive sensor, Hall sensor, 2/1 … 2

3. DISASSEMBLY of PTO 3/1 ... 2

4. DISASSEMBLY of output flange 4/1

5. DISASSEMBLY of main pressure valve and converter safety valve 5/1

6. DISASSEMBLY of engine connection 6/1 … 2

7. REMOVAL of clutches and DISASSEMBLY of oil pressure pump 7/1 … 3

7.1 Removal of clutches

8. DISASSEMBLY of clutches 8.1/1 ... 8.4/1

8.1 KV clutch 8.1/1 … 4

9. REASSEMBLY of clutches 9.1/1 … 9.4/1

9.1 KV clutch 9.1/1 … 6

10. REINSTALLATION of clutches and REASSEMBLY of oil pressure 10/1 … 6

10.1 Oil pressure pump 10/1

11.1 Reassembly of converter safety valve 11/1

12. REASSEMBLY of output flange 12/1 … 2

13. Reassembly of PTO 13/1 … 2

14. REASSEMBLY of engine connection 14/1 … 2

15. REASSEMBLY of proportional valves, inductive sensor, Hall sensor, 15/1 … 2

1. Permanently trained staff

2. Specified equipment, e.g. special tools

3. State-of-the-art genuine ZF spare parts

All work is done there with utmost care and reliability.

5871 132 002 0/1

Only dry cleaning is permitted (leather cloth).

5871 132 002 0/2

Structure of the Service Manual

Important information on industrial safety

The repair workshop shall be responsible for the training.

The following safety references are used in this manual:

This symbol serves as a reference to special working procedures,

This symbol identifies situations in which lacking care may lead to

5871 132 002 0/3

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

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

Nota : densité linéaire en kg/m; densité superficielle en t/m2

Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

5871 132 002 0/4

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)

1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5.560 lb / in ( pound per inch )

0.070 bar ( 0.071 kp/cm2 ) =

1 Liter = 0.264 Gallon ( Imp. )

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

0 ° C ( Celsius ) = 273.15 Kelvin

5871 132 002 0/5

TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148