Repair Manual

Transmission Actuator and Clutch

Actuator

1327 751 103

Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright. Any

reproduction or dissemination in whatever form
which does not comply fully with the intended pur-
pose of this documentation is prohibited without the
consent of ZF Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2005-09

Edition: 2005-09

1327 751 103

ZF-AS Tronic Table of Contents

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Programming Transmission Actuator ............................................................................................................ 39

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

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

1327 751 103 - 2005-09 3


ZF Friedrichshafen AG
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and
Special Driveline Technology
Service Werk 2 (Plant 2)
Phone: +49 (0)7541 77-0
Fax: +49 (0)7541 77-908000
Internet: www.zf.com
2003-08
Preface
This manual is intended for skilled personnel
trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with a ZF product in accordance
with the state of development on the date of issue.
However, due to continuing development of the
product, repair work might require work practices
and test or adjustment data which are not contained
in this manual.
We therefore recommend that work done on your
ZF product is carried out only by skilled mechanics
and fitters who have had their practical and
theoretical knowledge updated on a regular basis at
our After-Sales Service training courses.
Service points equipped by ZF Friedrichshafen AG
all over the world offer you:
1. Well-trained personnel,
2. Specified equipment,
e.g.: Special tools
3. Genuine ZF spares, according to
our latest specifications
All work performed at these service locations is
carried out conscientiously and with care.
Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
the individual case.
Damage resulting from work performed by non-ZF
personnel in an improper and unprofessional man-
ner, together with follow-on costs caused by such
work, is excluded from the contractual warranty
agreement.
This also applies where genuine ZF spare parts have
not been used.
5

Safety Instructions
Companies repairing ZF units are responsible for
their own work safety.
To avoid injury to personnel and damage to
products, all safety regulations and legal require-
ments which apply to repair and maintenance work
must be adhered to.
Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on ZF
products must receive appropriate training in
advance. It is the responsibility of each company to
ensure that their repair staff is properly trained.
The following safety instructions appear in this
manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional work-
ing practices could damage the product.
! DANGER
This is used when lack of care could lead to personal
injury or death.
2005-04
Safety Instructions
General Information
Read this manual carefully before starting any tests
or repair work.
CAUTION
Pictures, drawings, and components do not always
represent the original object, but are used to illus-
trate working procedures.
Pictures, drawings, and components are not to scale.
Conclusions about size and weight should not be
drawn (even within a complete illustration).
Always follow the working steps as described in the
text.
After completion of repair work and testing, skilled
staff must check whether the product is functioning
correctly.
! THREATS TO THE ENVIRONMENT !
Lubricants, consumables, and cleaning agents must
not be allowed to enter the soil, ground water, or
sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere to
their requirements.
• Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
6
 Instructions for Repairs

ZF Service Information must be observed. This Gaskets, Locking plates

information is available at all ZF Service Centers or
via the ZF-ServiceLine. Parts which cannot be removed without being
damaged must always be replaced with new parts
In case of doubt always turn to the relevant depart- (e.g. gaskets and locking plates).
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed by
experts only and under clean conditions.
Use specified tools to dismantle and assemble Shaft Seals
transmissions.
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
After removing the transmission from the vehicle, totally clean and in perfect condition.
clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning. Reworking

Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.

Cleaning parts If rework is needed on spacer discs, shims etc.

because of clearance adjustment, ensure that the
Remove remains of old gaskets on all sealing sur- reworked areas contain no face runout and have
faces. Carefully remove burrs or similar patches of the same surface quality.
roughness using an oilstone.

Lube bores and grooves must be free of anti-

corrosion agents and foreign matter; check for Transmission Assembly
perfect passage.
Find a clean work area to assemble the transmission.
Carefully cover opened transmissions to prevent Gaskets are installed without sealing compound or
foreign matter from entering. grease. When measuring silicon-coated gaskets, do
not include the silicon layer.
During assembly, comply with all adjustment data
and tightening torques in the Repair Manual.
Reusing parts

Parts such as roller bearings, discs, thrust washers

etc., must be inspected by a competent person who
should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.

2005-04 7

Bearings
If bearings are mounted in heated condition, they
are to be heated evenly (e.g. heating cabinet).
Temperature should be at approx. 85 °C and must
not exceed 120 °C. Each mounted bearing must be
oiled with operating oil.
Sealing
If a specific sealing agent* is to be used for sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces
and spread evenly. Do not allow sealing to enter oil
ducts and bores. On oil-carrying ducts and bores,
wipe off the sealing agent on the surfaces to be
sealed near apertures to ensure that no sealing agent
enters the oil feeds when the surfaces are sealed.
Shaft Seals
a) Apply a light coat of sealing agent* on circum-
ference of shaft seals with “steel jacket”.
b) Never apply sealing agent to shaft seals with
“rubber jacket”, but apply a thin coat of
Vaseline 8420 to the circumference or wet with
a lubricant, e.g. a water-soluble, concentrated
washing-up liquid (e.g. Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber jackets should
be treated on the circumference of the rubber
jacket as described above in section b).
2003-08
Instructions for Repairs
d) Dual shaft seals have two sealing
lips. The dust-proof sealing lip
(X) must face outwards.
X
e) Fill the gap between the sealing
lips so it is 60 % filled with grease (e.g. produced
by Aral, such as Aralub HL2 or by DEA, such as
Spectron FO 20).
f) If possible, heat shaft seal bores to between
40 and 50 °C (makes fitting easier). Press the
seal shaft with mounting or faceplate onto the
relevant installation depth plan.
Retaining Agents
Retaining agents* may only be used in places as
specified in the parts list.
Always comply with manufacturer’s directions for
use when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data, and tightening torques.
Transmission oil
After completing repairs, fill transmissions with
transmission oil. For the procedure and approved
oils, refer to the transmission operating manual and
TE-ML List of Lubricants (refer to identification
plate) which are available from any ZF After-Sales
Service Point and on the Internet under
www.zf.com.
After filling the transmission with oil, tighten the
screw plugs at the oil filling point and the oil over-
flow using the specified torques.
* refer to expendable material
8
 Overview of Amendments: 1327 751 103

Index Date of issue Chapter Initiator Comment

1327 751 103 - 2005-09 9

 Tightening Torques

Tightening Torques for Nuts and Bolts,

Extract from ZFN 148

This standard applies to screws/bolts acc. to
DIN 912, DIN 931, DIN 933, DIN 960, DIN 961, as
well as ISO 4762, ISO 4014, ISO 4017, ISO 8765,
ISO 8676, and to nuts acc. to DIN 934 as well as
ISO 4032, ISO 8673.
This Standard contains data on tightening torques
(MA) for screws/bolts and nuts in strength categories
8.8, 10.9, and 12.9, and nuts in strength categories 8,
10, and 12.
Surface condition of bolts / nuts: Thermally
blackened and oiled or galvanized and oiled or
galvanized, chrome-plated, and oiled.
Tighten screws with a calibrated ratchet dial torque
or ratchet wrench.
NOTE
Deviating tightening torques are listed separately in
the Repair Manual.

Regular screw thread Fine screw thread

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

M4 2.8 4.1 4.8 M8x1 24 36 43

M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14 16.5 M10x1 52 76 89

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

M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500

Edition: August 1991

2003-08 10
 Tightening Torques

Screw Plugs DIN 908, 910, and 7604 Union Screws DIN 7643

The screw plug tightening torques were determined
according to DIN 7604 for screwing into steel, gray
cast, and aluminum alloys.
The values are based on experience and are
intended as reference values for the fitter.
The values for the tightening torque apply
analogously to screw plugs according to DIN 908
and DIN 910, as the thread geometries are almost
identical.
General rule:
Screw/ Bolt class 5, ZFN 148-1
Screw/ Bolt material: Steel acc. to DIN 7604.
Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
The tightening torques were determined for screw-
ing into steel, gray cast, and aluminum alloys.
The values are based on experience and are
intended as reference values for the fitter.
General rule:
Screw/ Bolt class 5, ZFN 148-1
Material: 9SMnPb28K acc. to DIN 1651
Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.

Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)

Dimensions Tightening torque Pipe Thread Tightening

in Nm screwed into outer torque
steel / gray cast Al alloy diameter in Nm
M8x1 20* 10*
M10x 1 25 / 30* 15 / 20* 4-5 M8x1 20 - 25
M12x1.5 35 25
M14x1.5 35 25 6 M10x1 25 - 35
M16x1.5 40 30
M18x1.5 50 35 8 M12x1.5 30 - 40
M20x1.5 55 45
M22x1.5 60 / 80* 50 / 65* 10 M14x1.5 35 - 40
M24x1.5 70 60
M26x1.5 80 / 105* 70 / 90* 12 M16x1.5 45
M27x2 80 70
M30x1.5 100 / 130* 90 / 130* 15 M18x1.5 50
M30x2 95 85
M33x2 120 110 18 M22x1.5 60
M36x1.5 130 115
M38x1.5 140 120 22 M26x1.5 90
M42x1.5 150 130
M42x2 145 125 28 M30x1.5 130
M45x1.5 160 140
M45x2 150 130 35 M38x1.5 140
M48x1.5 170 145
M48x2 160 135
M52x1.5 180 150
M60x2 195 165
M64x2 205 175
* DIN 7604 Form C Edition: October 1995
11
2003-08
 Conversion from DIN to ISO Standards

Withdrawn Title Substitute Result of check / measures 1)

DIN ISO standard

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

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

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

DIN 85 Flat head bolts ISO 1580 - can be replaced → changed to ISO 1580

DIN 94 Split pins ISO 1234 - can be replaced → changed to ISO 1234

DIN 417 Threaded pins ISO 7435 - can be replaced → changed to ISO 7435

DIN 439-1 Hex nuts ISO 4036 - cannot be replaced → documented as DIN 439 OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675

DIN 551 Threaded pins ISO 4766 - can be replaced → changed to ISO 4766

DIN 553 Threaded pins ISO 7434 - can be replaced → changed to ISO 7434

DIN 555 Hex nuts ISO 4034 - cannot be replaced → documented as DIN 555 OLD

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

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

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

DIN 931-1 Hex bolts ISO 4014 - some can be replaced → changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 931 OLD

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

DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for
ISO 8673 M10, M12, M14, and M22 with new SW.

DIN 960 Hex bolts ISO 8765 - some can be replaced → changed to ISO8765
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 960 OLD

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

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

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

1) with reference to productive parts numbered at ZF

2003-08 12
 Conversion from DIN to ISO Standards

Withdrawn Title Substitute Result of check / measures 1)

DIN ISO standard

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

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

DIN 985 Locking nuts ISO 10511 - cannot be replaced → documented as DIN 985 OLD

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

DIN 1443 Bolts ISO 2340 - can be replaced → changed to ISO 2340

DIN 1444 Bolts ISO 2341 - can be replaced → changed to ISO 2340

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

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

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

DIN 1474 Grooved pins ISO 8741 - can be replaced → changed to ISO 8741

DIN 1475 Grooved pins ISO 8742 - can be replaced → changed to ISO 8742

DIN 1476 Grooved stud ISO 8746 - can be replaced → changed to ISO 8746

DIN 1477 Grooved stud ISO 8747 - can be replaced → changed to ISO 8747

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

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

DIN 7346 Clamping pins ISO 13337 - some can be replaced → changed to ISO 13337
Flange - parts which cannot be replaced (∅ 7, 11, and 23 mm) documented as
DIN 6325 OLD

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

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

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

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

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

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

1) with reference to productive parts numbered at ZF

2003-08 13
ZF-AS Tronic Special Tool

Fig. Special tools Order no. Application Qty. Comment

no.

240

Sketch
M10

64
75

11
60.5

M10
112
74

15
10±0.1 ø9H7 ø9H7 Setting aid
20±0.1 14
212±0.1
Simplifies
1 for piston rods on 1
ø8.7±0.1

assembly
ø9r6

25
transmission actuator
2x45° 2x45°
37.5±0.1

40

017912

NOTE: Please inquire as to packaging unit before ordering.

1327 751 103 - 2005-09 14 1327_91D_001_en

ZF-AS Tronic Consumables

Designation Designation Approx Application Comments

ZF item number Quantity.

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

0666 690 022
Uni-Silicon GLK 112
grease

NOTE: Inquire size of containers before placing any orders!

1327 751 103 - 2005-09 15 1327_92D_001_en

ZF-AS Tronic ZF Repair Kits for Transmission/Clutch Actuator

Kit no. Item Content Remark

6009.098.001 GS3 upper section, 20-pin Upper section: 6009 274 080
Standard Sealing kit: 0501 319 863
Sealing kit: 0501 319 864
Seal: 0501 316 322 without breather
6009.098.002 GS3 upper section, 18-pin Upper section: 6009 274 081
Special variant Sealing kit: 0501 319 863
Sealing kit: 0501 319 864
Seal: 0501 316 322 without breather
6009.298.006 GS3 lower section Upper section: 6009 274 058
Sealing kit: 0501 319 863
Sealing kit: 0501 319 864
Seal: 0501 316 322
0501.319.863 Sealing kit 1x flat seal, upper/lower section
2x retaining bolts
1x profile sealing ring
0501.319.864 Sealing kit 2x profile sealing rings between
upper/lower section
0501.321.146 Joining part / (wiring harness) Internal wiring harness with
input/temperature sensor
2x retaining bolts
0501.321.147 Valve unit Solenoid valve plate with 10 valves
profile seal
3x retaining bolts fully inspected unit
0501.320.849 Pressure reduction valve 1x valve
4x retaining nuts
1x O-ring
0501.321.148 Travel sensor 1x sensor
1x O-ring
1x bracket
2x retaining bolts
0501.321.149 Sealing kit for gear shift cylinder All sealing elements for the
GV,GP gear shift cylinders
0501.321.182 Selector cylinder 1x selector cylinder
1x profile seal fully inspected unit
0501.322.661 Bracket (for sensor) 1x bracket
1x clamp
5x retaining bolts
1x O-ring Selector cylinder must
1x profile seal be removed
0501.322.388 Main transmission piston 1x main transmission piston
2x O-rings Complete piston
0501.316.322 Seal 1x flat seal Transmission actuator for
main transmission
0768.340.029 Breather (transmission breather) 1x breather 0501 202 797
Tightening torque: 10 Nm Pos. 74.120
0768.605.124 Cannon plug (hose breather) 1x M10x1 Cannon plug 0501 315 794
Tightening torque:18 Nm Pos. 74.130
0501.315.796 Angle piece 1x angle piece 0501 315 796
1x cap nut Pos. 74.140
0731.208.242 Detent pin 1x dent pin Pos. 06.040, 34.130, 12.080
0732.042.766 Compression spring 1x compression spring Pos. 06.050, 34.140, 12.090
6009.274.069 GS3 standard, 20-pin Upper section: 6009 274 080
Sealing kit: 0501 319 863
Sealing kit: 0501 319 864
Seal: 0501 316 322 Complete new transmission actuator
6009.274.070 GS3 special variant, 18-pin Upper section: 6009 274 081
Sealing kit: 0501 319 863
Sealing kit: 0501 319 864
Seal: 0501 316 322 Complete new transmission actuator
Clutch actuator
0501.322.365 Connection parts for clutch actuator Non-return valve, compression spring,
strainer, screw plug, sealing ring,
valve bush

1327 751 103 - 2005-09 16

 Transmission Actuator
ZF-AS Tronic Removal

CAUTION
If the transmission actuator or upper section 74.140*
of the transmission actuator is replaced, the 74.130* 74.120*
following should be noted. 74.030
• Reprogram the transmission actuator 74.070
• Transfer vehicle parameters from removed 74.090
transmission or re-enter.

Removing Transmission Actuator

74.010
! DANGER
Only work on the transmission actuator if the igni-
tion is off. 12.090
12.080
06.050
1 Switch off ignition
06.040
34.140
CAUTION
34.130
If vehicle-specific parts (e.g. fuel pump, coolant
pipe, exhaust pipe, or steering pump) have to be
removed, please contact the vehicle manufacturer.
06.080

2 Disconnect electric plug connection from Loctite

262
transmission actuator.

*depends on the parts list 024 667

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

3 Remove compressed air line from transmis-

sion actuator’s pressure relief valve.

4 Remove breather (74.120) or angle piece

(74.140) and Cannon plug (74.130) from
transmission actuator (74.030) if these parts
are being replaced.

5 Remove 15 M8 hex bolts (74.090; 74.070)

from transmission actuator (74.030).

1327 751 103 - 2005-09 17 1327_74D_003_1_en

 Transmission Actuator
ZF-AS Tronic Removal

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

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

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

7 Remove compression springs (06.050;

34.140 and 12.090). 018774

NOTE 74.140*
Cover transmission opening, otherwise dirt may 74.130* 74.120*
fall into the transmission. 74.030
74.070
8 Remove seal (74.010) and clean sealing 74.090
surfaces on transmission housing and
transmission actuator.

9 If seal residue or dirt has fallen into the

detent pin holes (06.040; 34.130 and 12.080),
these must be removed and cleaned.
74.010
10 Remove ball bolt (06.080) if damaged.

12.090
12.080
06.050
06.040
34.140
34.130

06.080

Loctite
262

*depends on the parts list 024 667

1327 751 103 - 2005-09 18 1327_74D_003_2_en

 Transmission Actuator
ZF-AS Tronic Fitting

Fitting Transmission Actuator

1 If the ball bolt is being replaced, coat the

thread of ball bolt (06.080) with Loctite /170
no. 262.
Tighten ball bolt to 23 Nm.

NOTE
If using costly peripheral attachments, such

b
a
as flatbeds, crossbars etc. we would advise
checking the transmission with the
ZF-Testman pro test software once removed
from the vehicle. After checking with ZF-
Testman pro, load the volume production
program depending on parts list and engine
(can be downloaded via ZF-ServiceLine).
018774
2 Move piston rod (4) on transmission actuator
into central position (Neutral). The correct
position is reached when slight resistance 5 4 3
can be felt when pulling out the piston rod (4).

3 Transfer measurements “a” and “b” from the

removed transmission actuator to the piston
rods (3 and 5).

4 Selector gate (6) and piston rod (4) must be

one above the other (flush). Ensure that the
profile seals (/170) on the transmission
actuator are inserted. /170

Legend
Piston rod (3) = shifts the splitter group (GV) 6
Piston rod (4) = shifts the basic transmission
017908
Piston rod (5) = shifts the range change group
(GP)
Selector gate (6) = selects the shift gate
34.010 06.080 06.010 12.010
NOTE
With the 12-speed version, do not slide the
central shift rail (06.010) too far into the
transmission, otherwise the gearshift finger
may fall into the transmission.

Legend
12.010 Shift rail (GV)
06.010 Shift rail for basic transmission
34.010 Shift rail (GP)
06.080 Ball bolt

015019

1327 751 103 - 2005-09 19 1327_74D_004_1_en

 Transmission Actuator
ZF-AS Tronic Fitting

Alternative: If measurements “a” and “b” can no

longer be established, the transmission actuator
can be fitted using setting aid (34) 1X56 138 244.
In-house production following sketch, see special
tools.On request, tool 1X56 138 244 can also be
supplied by ZF.
Adjust the transmission actuator’s piston rods (3,
4, and 5) so that they are in contact with the set-
ting aid (34). Move the GV and GP gear shift rails
in the transmission towards the output. Move the
central gear shift rail into Neutral. Selector gate (6)
and piston rod (4) must be one above the other
(flush). Ensure that the profile seals on the trans-
mission actuator are inserted. 34

017907
5 Place new seal (74.010) on transmission
housing. 74.140*
74.130* 74.120*
6 Insert detent pins (06.040; 34.130 and 74.030
12.080) – if not yet fitted – and compression
74.070
springs (06.050; 34.140 and 12.090). 74.090

NOTE
The compression springs (06.050; 34.140
and 12.090) must be of the same length
(around 50 mm). If deviances are found,
replace compression springs.
74.010
7 Attach transmission actuator (74.030) ensur-
ing that piston rods of transmission actuator
12.090
reach into gear shift rails of transmission.
The upright ball bolt (06.080) reaches into 12.080
06.050
the selector gate.
06.040
CAUTION 34.140
You must be able to push the transmission actua- 34.130
tor by hand until it reaches the transmission’s
thrust surface. Forcefully pulling down with
screws will inevitably result in damage. 06.080

8 Evenly tighten M8 hex bolts (74.090 and

Loctite
74.070) to 23 Nm. 262

9 Depending on parts list: *depends on the parts list 024 667

Tighten Cannon plug (74.130) to 18 Nm

and secure angled piece (74.140) and/or
tighten breather (74.120) to 10 Nm.

1327 751 003 - 2004-06 20 1327_74D_004_2_en

 Transmission Actuator
ZF-AS Tronic Fitting

10 Connect air line to transmission actuator’s

pressure relief valve.
Tightening torque MA = 34 Nm.

11 Re-connect up wiring harness at transmis-

sion and vehicle ends otherwise functions
cannot be tested.

NOTE
Ensure that the connectors are snapped into
place and fitted without traction relief.

Final check: 018 403

Has the transmission actuator been reprogrammed?

Refit vehicle-specific parts as far as possible. The

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

1327 751 103 - 2005-09 21 1327_74D_004_3_en

 Transmission Actuator
ZF-AS Tronic Removing and Fitting Upper Section

Removing Upper Section

6009 274 069
NOTE
Seal kit 0501 319 863 contains both screws
(/150-1) flat seal (/150-2) and profile seal (/150-3).
09 03 43872
4213 550 110
024 361

Caution
Record the data on the type plate. 1 /150-1
This is needed for ordering spare parts and for
correspondence.

1 Remove both screws (/150-1).

/110
2 Raise upper section (/110) on pressure relief
valve (/180) and use both tabs (1) to care-
fully move sideways into the grooves* (2).
Disconnect plug connections (7 and 8). 74.030
/180
3 Remove profile seal (/150-3 )
/150-2
4 Remove flat seal (/150-2) and sealing faces.
2

* not possible with the 18-pin variant

/150-3

/130
Fitting Upper Section

1 Insert profile seal (/150-3).

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

(/130).
024 532

3 Re-connect plug connections (7 and 8).

Check that the plug connections are tight
and secure.

4 Place upper section(/110) on lower section

(/130).
Ensure that the flat seal (/150-2) does not 8
slip, fix if necessary. Tighten the two screws
7
(/150-1) to 9.5 Nm.

018205

1327 751 103 - 2005-09 22 1327_74D_050_en

 Transmission actuator
ZF-AS Tronic Travel sensors

Replacing Travel Sensors

(HG, GV, GP, and Gate)

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

24
Removal 23
22

1 Clean area around sensors.

25
2 Carefully raise tab and pull connector (21)
off sensor contact.
021 803

3 Remove two screws (22), take off retaining

plate (23), pull out travel sensor (24) com-
plete with O-ring (25).

4 Inspect parts and replace if necessary.

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

Installation

NOTE 21 24
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.
021 794

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

2 Insert travel sensor (24) complete with O-

ring (25), secure retaining plate (23) with
two screws (22).
Tightening torque MA = 7 Nm.

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

1327 751 103 - 2005-09 23 1327_74D_060_en

 Transmission actuator
ZF-AS Tronic Solenoid valve plate

Replacing Solenoid Valve Unit

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

18
Removal

1 Remove three Torx screws (19). 20

2 Remove solenoid valve unit (18).

3 Remove profile seal (20).

Installation

1 Apply Uni-Silicon GLK112 grease to sealing

and sliding faces.

2 Place profile seal (20) on transmission

actuator’s lower section. 021 804

3 Place solenoid valve unit (18) and secure

three Torx screws (19) to 18 Nm.

021 785

1327 751 103 - 2005-09 24 1327_74D_070_en

 Transmission Actuator
ZF-AS Tronic Replacing Selector Cylinder

Replacing Cpl. Selector Cylinder

NOTE
Repair kit 0501 321 182 contains the selector 26
cylinder (28) and a profile seal (29).

/130
Removal
27

1 Carefully raise tab and pull connector (26)

off sensor contact.

2 Remove three hex-head bolts (27).

3 Take out selector cylinder (28) and remove

profile seal (29). 021 786

4 Inspect parts and replace if necessary.

Installation

NOTE 29
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.

1 Insert profile seal (29) on transmission 28

actuator’s lower section (/130).

2 Place cpl. selector cylinder (28) on trans-

mission actuator’s lower section (/130) 26
and tighten the three hex-head bolts (27) to
021 787
23 Nm.

3 Plug connector (26) onto sensor contacts.

1327 751 103 - 2005-09 25 1327_74D_080_en

 Transmission Actuator
ZF-AS Tronic Bracket for Temperature and Speed Sensor

Bracket for Temperature and Speed Sensor

27
NOTE
The repair kit 0501 322 661 contains three hex- 47
52
head bolts (27), one profile seal (29), two Torx
48
screws (47), one Torx screw (48), retaining plate 29
(52), O-ring (49), and the cylinder cover (58). 58
49
If the temperature and speed sensor is removed,
seal kit 0501 319 863 will also be needed.

Removal
024 559

1 Remove upper section.

(See page 22)

2 Carefully raise tab and pull connector (26) 26

off sensor contact.

3 Remove three hex-head bolts (27).

/130
4 Take out selector cylinder (28) and remove 27
profile seal (29).

021 786

5 Remove Torx screw (48).

48

021 790

1327 751 103 - 2005-09 26 1327_74D_150_1_en

 Transmission Actuator
ZF-AS Tronic Bracket for Temperature and Speed Sensor

6 Take off input speed sensor (50) with spacer

plate and temperature sensor (51).

7 Remove Torx screws (47). 50

8 Use a suitable tool to raise and remove the

cylinder cover/bracket (58). 51

9 Replace O-ring (49). 49

58

47

021 791

1327 751 103 - 2005-09 27 1327_74D_150_2_en

 Transmission Actuator
ZF-AS Tronic Bracket for Temperature and Speed Sensor

Fitting Bracket for Temperature and Speed

Sensor

50
1 Insert new O-ring on cylinder cover (58) and
on travel sensor (51).

NOTE 51
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces. 49

2 Insert cylinder cover (58) in housing’s lower 58

section.

3 Insert input speed sensor (50) with spacer 47

plate and temperature sensor (51) with the
O-ring (49) in the cylinder cover’s bracket 024 791

(58).

4 Tighten Torx screw (48) with 6 Nm.

48
5 Tighten Torx screws (47) with 18 Nm.

021 790

6 Insert profile seal (29) on transmission actu-

ator’s lower section (/130).

7 Place selector cylinder (28) on transmission

actuator’s lower section.

29

28

26
021 787

1327 751 103 - 2005-09 28 1327_74D_150_3_en

 Transmission Actuator
4ZF-AS Tronic Bracket for Temperature and Speed Sensor

8 Use three hex bolts (27) to secure selector

cylinder to transmission actuator’s lower
section (/130).
Tighten the hex bolts (27) to 23 Nm. 26

9 Plug connector (26) onto sensor contacts. /130

27
10 Fit upper section.
(See page 22)

021 786

1327 751 103 - 2005-09 29 1327_74D_150_4_en

 Transmission Actuator
ZF-AS Tronic Wiring Harness

Removing Wiring Harness (Input Speed

Sensor and Temperature Sensor)
34

The repair kit 0501 321 146 contains the wiring

harness (temperature and speed sensor) and two
self-tapping screws with washers.

1 Remove upper section.

(See page 22)
26
2 Carefully raise tab and pull connector (26) off
sensor contact (34).

47

021 789

3 Remove the Torx screws (47 and 48). 48 47 52

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

021 792

4 Take off input speed sensor (50) with spacer

plate and take temperature sensor (51) out of
bracket of cylinder cover (58).
50

5 Take wiring harness out of retaining plate

(52).
51

58

024 738

1327 751 103 - 2005-09 30 1327_74D_100_1_en

 Transmission Actuator
ZF-AS Tronic Wiring Harness

6 Bore out the rivet heads (drill diameter

approx. 5 mm).
Take wiring harness off transmission actua-
tor’s lower section.

024 534

7 Use a pair of flat pliers to turn out the rivet

shaft.

8 Remove rivet residue and drilling chips.

024 668

1327 751 103 - 2005-09 31 1327_74D_100_2_en

 Transmission Actuator
ZF-AS Tronic Wiring Harness

Fitting Wiring Harness (Input Speed Sensor and

Temperature Sensor)
(repair kit 0501 321 146)

1 Secure wiring harness (64) to transmission

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

024 560

2 Guide spacer plate on temperature sensor

(50) into groove on speed sensor (51).
50
3 Insert these parts all together with the O-ring
(49) in the cylinder cover bracket (58).

51

49

58

47

021 791

4 Tighten screw (48) with 6 Nm.

48 47 52
5 Insert wiring harness in retaining plate (52)
and tighten screw (47) with 18 Nm.

021 792

1327 751 103 - 2005-09 32 1327_74D_101_1_en

 Transmission Actuator
ZF-AS Tronic Wiring Harness

6 Route wiring harness behind rib (53)

without any bends, chafing, or squashed
areas. 53

021 793

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

34
8 Fit upper section.
(See page 22)

26

021 789

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

21 24

021 794

1327 751 103 - 2005-09 33 1327_74D_101_2_en

 Transmission Actuator
ZF-AS Tronic Pressure Relief Valve

Replacing Pressure Relief Valve

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

1 Remove 4 nuts (10) and take off pressure

relief valve (/180) and O-ring (12).

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

2 Insert new O-ring (12), fit pressure relief 019251

valve (/180) on transmission actuator

(74.030) as marked during removal.
Tighten the 4 nuts (10) with 7 Nm.

74.030

/180
12

019252

1327 751 103 - 2005-09 34 1327_74D_011_en

 Transmission Actuator
ZF-AS Tronic Lower Section

Dismantling Lower Section of Transmission 54

Actuator

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

1 Remove selector cylinder.

(See page 25)

2 Remove the three travel sensors (24). 24

24
(See page 23)
021 795

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

3 Remove the T40 Torx screws (54) from the

cylinder covers (55 to 58).

4 Use a suitable tool to raise the cylinder 55

covers (55, 56 , and 57) slightly and take off. 56 57

021 796

5 Use a suitable tool to raise cylinder cover

(58) slightly and take off. 61 59

6 Take out pistons (59, 60, and 62) and bush 60

(61).

7 Replace the O-rings and grooved rings on

components (58 to 62)

62

58

021 797

1327 751 103 - 2005-09 35 1327_74D_130_1_en

 Transmission Actuator
ZF-AS Tronic Lower Section

8 Use a suitable tool to remove seal rings (63)

and low-friction bearing bushes (70).

58

70 63

021 798

1327 751 103 - 2005-09 36 1327_74D_130_2_en

 Transmission Actuator
ZF-AS Tronic Lower Section

Assembling Lower Section of Transmission

Actuator

1 Use a suitable tool to insert the low-friction

bearing bushes (70) flush with the bearing
bore.

2 Use a suitable tool to insert the new sealing

rings (63). 58

70 63
NOTE
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.

021 798

3 Insert new O-rings and grooved rings on 59

61
components (58 to 62).

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

62

58

021 797

5 Fit cylinder covers (58, 57, 56, and 55) in the

same position from which you previously
removed them and secure each one with two
T40 Torx screws (54).
Tightening torque MA = 18 Nm.

55
56 57

021 796

1327 751 103 - 2005-09 37 1327_74D_140_1_en

 Transmission Actuator
ZF-AS Tronic Lower Section

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

6 Fit sensors (24).

(See page 23)

11
3 1
2

021 799

7 Fit selector cylinder (28).

(See page 25)

8 Check again that connectors are tight and 28

secure.

021 800

1327 751 103 - 2005-09 38 1327_74D_140_2_en

 Transmission Actuator
ZF-AS Tronic Programming

Programming Transmission Actuator

When replacing the transmission actuator and/or

upper section, customer-specific programming
and/or parameter setting (entering EOL data) will
23
be required. 20.1

During parameter setting, the EOL data are

entered in the transmission actuator’s electronics 20 22
using Testman pro and the corresponding soft-
ware.

Diagram of transmission actuator programming 21

Pos.
20 Table mode adapter
20.1 Power supply connection 019643

21 Cable to the DPA

22 DPA
23 Cable to laptop and/or PC

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

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

1327 751 103 - 2005-09 39 1327_74D_012_1_en

 Transmission Actuator
ZF-AS Tronic Programming

Programming Flash EPROMS with Description of Test

ZF Test Program
- Air supply of at least 7 bar, connect to pressure
Tools required: reduction valve on transmission actuator
- Laptop with current Testman pro software
- Test software: GS_test_07_2005_gb.exe - Connect table mode cable to transmission actuator
(download from ServiceLine) (at vehicle end) and link to laptop using connection
- Testman pro application: Mont_as2.app cable, DPA05, 24 V voltage supply
(download from ServiceLine)
- Table mode adapter cable: ZF no. 6008 207 003 - Start Testman pro
DPA05 Interface adapter: ZF no. 6008 208 017 Select main menu/AS Tronic/assembly check AS2.
USB connection cable: ZF no. 6008 207 026
Diagnosis interface cable: ZF no. 6008 207 024 NOTE
24 V voltage supply This test must not be used in the vehicle when the
engine is running!!
Procedure:
- Download the installation - Select test rig function start.
routine GS_test_07_2005.zip from download
ServiceLine, save and unzip using the password: - Use the numerical key functions 1 - 0 on the laptop
astronic keypad or mouse to shift through the ranges:
1 = Upshifting gears 1 - 16
- Start installation routine: Double click on the file: 2 = Downshifting Gears 16 - 1
GS_test_07_2005.exe 3 = Neutral
4 = 1st R gear
- Download the application Mont_as2.app from 5 = 2nd R gear
download ServiceLine, save and unzip using the
password: testman - The current sensor positions can be seen under
menu item 6, dynamic transmission actuator.
- Extract the file Mont_as2.app using the following
path: C:\Gds3000\apps - Menu item 9 shows the gear currently selected.

- Start Testman pro NOTE

if necessary, note the customer-specific data in
transmission actuator (e.g. iHa; Intarder etc.) and
then program the test program. Load Testman pro/
Flash programming / parts list. Open the file
GS_test_07_2005.txt and program (processors 1, 2
and E2 data are programmed and the drive pro-
gram originally programmed is deleted).
The test software selects gears 1 - 16 and 2 R gears.
With the 10 and 12-speed transmission, the
transmission actuator is fitted on the transmission.
Only shift to the highest gear available!
Outgoing Check

- After the function/seal integrity test, the correct

software must be programmed depending on
vehicle application, engine/transmission/software
assignment. (Source: ServiceLine)

1327 751 003 - 2004-02 40 1327_74D_012_2_en

ZF-AS Tronic Clutch Actuator

024 537

Clutch Actuator
(repair kit 0501 322 365)

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

The repair kit consists of a screw plug (1) with

sealing ring and a valve screw (2) with O-ring.

Tightening torque (MA):

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

1327 751 003 - 2004-02 41 1327_68D_070_en