Repair Manual

Shift system with PSU

(Pneumatic Servo Unit)

1315 751 110b

Subject to alterations in design

Copyright by ZF

The present documentation is protected by copy-

right. Any kind of reproduction or dissemination in
whatever form that does not exclusively correspond
to documentation objectives will be prosecuted if
no prior approval by ZF Friedrichshafen AG was
granted.

Printed in Germany

ZF Friedrichshafen AG / 2000 / 2005-06

Edition: 2005-06

1315 751 110b

ZF-Ecosplit Table of Contents

Page

Preface .................................................................................................................................................. 5
Safety Instructions................................................................................................................................ 6
Instructions for Repairs........................................................................................................................ 7
Overview of Amendments ................................................................................................................... 9
Tightening Torques............................................................................................................................... 10
Recoding from DIN to ISO Standards ................................................................................................. 12
Consumables......................................................................................................................................... 14
Spare Parts............................................................................................................................................ 15
Adjustment Data ................................................................................................................................... 16
Table of Springs .................................................................................................................................... 18
Special Tools ......................................................................................................................................... 19

1 Removal and installation of the PSU.................................................................................................. 1-1

1.1 Shift turret with left and right shifting outputs................................................................................... 1-1
1.2 Shift turret with HTC (hydrostatic control)......................................................................................... 1-2
1.3 Super H shift turret with HTC (superimosed H shift system) ............................................................ 1-3
1.4 Shift turret with superimposed H shift system with control cable .................................................... 1-5

2 Removal and installation of selector and shift cylinder ................................................................... 2-1

3 Shift turret with left shifting output, disassembly and assembly .................................................... 3-1
3.1 Shift patterns, shift turret with left shifting output............................................................................. 3-6

4 Shift turret with right shifting output, disassembly and assembly.................................................. 4-1
4.1 Shit patterns, shift turret with right shifting output............................................................................ 4-9

5 Shift turret with HTC, disassembly and assembly ............................................................................ 5-1

5.1 Shift patterns, shift turret with HTC ................................................................................................... 5-7

6 Super H shift turret with HTC (superimosed H shift system), disassembly and assembly............ 6-1
6.1 Shift patterns, Super H shift turret (superimosed H shift system) .................................................... 6-5

7 Shift turret with superimposed H shift system with control cable, disassembly and assembly.... 7-1
7.1 Shift patterns, shift turret with superimposed H shift system............................................................ 7-7

8 Functional test, shift turret with HTC ............................................................................................... 8-1

9 Mounting of shift turret ...................................................................................................................... 9-1

1315 751 110b - 2005-03 3

4
 Preface

This repair 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 the standard ZF products

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 not contained in this
manual.

We recommend that work done on your ZF product

is carried out only by skilled mechanics who have
had their practical and theoretical knowledge up-
dated on a regular basis at our After-Sales Service
training centers.

Service Points equipped by ZF Friedrichshafen AG

all over the world offer you:

1. Continually trained personnel,

2. Specified equipment, e.g. special tools,

3. Genuine ZF spares, according to our latest

specifications.

All work performed at these Service Points is car-

ried out conscientiously and with utmost care.

Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
ZF Friedrichshafen AG the individual case.
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Damage resulting from work performed by non-ZF
Special Driveline Technology personnel in an improper and unprofessional
Service Werk 2 (Plant 2) manner and any consequential costs are excluded
Phone: +49 (0)7541 77-0 from the contractual liability agreement. Exclusion
Fax: +49 (0)7541 77-908000 of liability also applies if genuine ZF spares are
Internet: www.zf.com not used.

2003-08 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.
2003-08
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 trans-
Carefully cover opened transmissions to prevent for- mission. Gaskets are installed without sealing
eign matter from entering. compound or 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.

2003-08 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 seal-
ing 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: 1315 751 110

Index Date of issue Chapter Initiator Comment

a 2002-05 1, 2, 6, 8 LKS-T Supplement: Super H shift turret

(superimposed H shift system)

b 2005-03 1, 7 LKS-T Supplement: Shift turret with superimposed H shift system

with control cable

1315 751 110b - 2005-03 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 cate-
gories 8.8, 10.9, and 12.9, and nuts in strength cate-
gories 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) refers to the productive components numbered at ZF

2003-08 13
ZF-Ecosplit Consumables

Description Designation Approx. Application Comments

ZF item number Quantity

Sealing compound
0666 690 017 Loctite Nr. 241 5 mm3 breather Section 3, 4, 5

Grease for example:

0750 199 001 Aralub HL2 1g pin Section 3, 4
o-ring
roller

0634 316 057 o-ring 1 part detent Section 3, 4, 5

Grease
0750 199 019 1g tappet Section 6, 7
pin

NOTE: Inquire as to size of containers before placing any orders.

1315 751 110b - 2005-03 14

ZF-Ecosplit Spare Parts

Description Name Approx. Application Comments

ZF item number Quantity

0501 318 490 spring 1 pneumatic servo unit Section 1

(Ø12.4 x 43.4)

0501 319 920 catch 1 pneumatic servo unit Section 1

1315 751 110b - 2005-03 15

ZF-Ecosplit Adjustment Data

Description Dimension Measurement device Comments

01. Tightenig torque 60 Nm Torque wrench

screw plugs M22x1.5

02. Tightenig torque 23 Nm Torque wrench

hexagon head screws
M8x30 on cover

03. Tightenig torque 23 Nm Torque wrench

hexagon head screws
M8x65 on cover

04. Tightenig torque 45 Nm Torque wrench Screw plug or switch depend

switch on parts list

05. Tightenig torque 49 Nm Torque wrench

hex nut M10 on shift
lever

06. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x65 on cutoff valve

07. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x30 on cover

08. Tightenig torque 35 Nm Torque wrench Screw plug or switch depend

screw plugs M18x1.5 on parts list

09. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x32 on cover

1315 751 110b - 2005-03 16

ZF-Ecosplit Adjustment Data

Description Dimension Measurement device Comments

10. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x28 on selector and
shift cylinder

11. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x25 and M8x80 on
cover

12. Tightenig torque 45 Nm Torque wrench Use new sealing ring

tappet switch and
neutral switch

13. Tightenig torque 20 Nm Torque wrench

hollow bolt on pipe

14. Tightenig torque 23 Nm Torque wrench

hexagon head screw
M8x70 and M8x95 on
Super H valve block

15. Tightenig torque 24 Nm Torque wrench DANGER

plug-in connector on Use SW 22
Super H valve block

1315 751 110b - 2005-03 17

ZF-Ecosplit Spring Table

De

De Spring diameter + tolerance in mm

d
Dh Testing sleeve diameter in mm

Lo
nt
D
L0 Untensioned spring length in mm

nt Total of coils

d Wire diameter in mm
018325
Dh

Part number Installation point Total Wire diam. Spring diam. Untensioned
of in mm in mm length
coils at L0 in mm
[nt ] [d] [Dh] [De] [L0]

0732 040 985 Shifting output, left 6.5 2.0 14.4 23.4

0732 042 126 9.5 1.0 9.2 25.0

0732 042 684 5.16 2.1 39.0 70.0

0732 040 728 Shifting output, right 6.5 1.8 29.3 80.0

0732 041 612 6.5 1.7 13.9 25.8

0732 042 126 9.5 1.0 9.2 25.0

0732 042 207 7.5 1.5 14.2 30.6

0730 040 630 Shift turret with HTC 6.5 2.4 39.1 89.9

0732 040 985 6.5 2.0 14.4 23.4

0732 042 684 Shift turret 5.16 2.1 39.0 70.0

superimosed H shift system
0732 042 106 4.5 2.25 30.2 41.3

0732 041 500 6.5 2.1 14.4 23.6

0732 040 986 Shift turret 5.5 2.25 14.5 21.6

Superimposed H shift system
0732 041 011 with control cable 4.5 2.0 30.5 50.1

1315 751 110b - 2005-03 18

ZF-Ecosplit Special Tools

Fig. Special tools Order no. Application Qty. Comments

no.

1X25 139 707 2 Section 3

Section 4
Adaptor
1 for bush on selector housing

1X25 139 707 1 Section 3

Section 4
Adaptor Section 7
2 for bush on selector housing

1X56 138 107 1 Section 3

Section 4
Handle Section 7
3 for 1X25 139 707 and 1X25 139 783

1X56 138 229 1 Section 8

Function test device

4 for shift turret with HTC

1315 751 110b - 2005-03 19

ZF-Ecosplit Servoshift

1
2

6 5
7

012319

1 Pneumatic Servo Unit (PSU)

1.1 Shift turret with left and right shifting out-

put

Disassembly Assembly

1 Loosen hollow screws (1 and 2) and remove 1 Place spring (7) inside servo-unit.
together with sealing rings and pipe (3).
2 Re-place servo-unit (5) together with new gas-
2 Loosen hexagon head screw (4). ket (6) on shift turret.

3 Remove pneumatic servo-unit (5) together 3 Insert and tighten hexagon head screw (4).
with gasket (6) and spring (7). Tightening torque = 23 Nm.

NOTE 4 Fix pipe (3) together with new sealing rings to

Spring (7) is placed loosely inside pneumatic shift turret using a hollow screw (1).
servo-unit. Tightening torque = 20 Nm.
Pneumatic servo-unit is a complete component
5 Fix pipe together with new sealing rings to
- do not disassemble.
pneumatic servo-unit using a hollow screw (2).
Tightening torque = 20 Nm.

1315 751 110b - 2005-06 1-1

ZF-Ecosplit Servoshift

3
2

1
4

6
5
7

015984

1.2 Shift turret with HTC For dismounting and mounting on shift turret see
(hydrostatic control) Chapter 2.

Removal
1 Unfasten union screws (1 and 2) and take off Installation
with sealing rings and pipe (3).
1 Place spring (7) in servo unit.
2 Unfasten hexagon head screw (4).
2 Attach pneumatic servo unit (5) and new gas-
3 Take off pneumatic servo unit (5) with gasket ket (6) on shift turret.
(6) and spring (7).
3 Insert hexagon head screw (4) and tighten.
NOTE Tightening torque = 23 Nm.
Spring (7) lies loosely in the pneumatic servo
4 Fasten pipe (3) on valve block with union
unit.
screw (1) and new sealing rings.
Do not dismantle pneumatic servo unit any
Tightening torque = 20 Nm.
further. It is a complete part.
5 Attach pipe with union screw (2) and new
NOTE
sealing rings on the pneumatic servo unit.
The selector cylinder (8) and the shift cylinder
Tightening torque = 20 Nm.
(9) are only listed here for your information.
They remain in the vehicle when the transmis-
sion and/or shift turret are removed.

1315 751 110b - 2005-06 1-2

ZF-Ecosplit Servoshift

3
3
7

3
3 2

2 5
4

018645

1.3 Super H shift turret with HTC

(superimosed H shift system)

Removal
1 Loosen pipe (2) on plug-in connector (see
drawing).
2 Loosen hollow bolt (1) and remove together
with sealing rings and pipe (2).
3 Loosen hexagon head screws (3).
4 Remove servo unit (4) together with gasket (5)
and spring (6).
NOTE
Spring (6) is loosely placed in pneumatic servo
unit.
Do not disassemble servo unit further - com-
plete component!
NOTE
Selector cylinder (7) and shifting cylinder (8)
are mentioned here for information only. They
remain in the vehicle during removal of the
transmission or the shift turret. For dismount-
ing and mounting on shift turret see Chapter 2.

1315 751 110b - 2005-06 1-3

ZF-Ecosplit Servoshift

3
3
7

3
3 2

2 5
4

018645

Installation

1 Place spring (6) in servo unit.

2 Mount pneumatic servo unit (4) together with

new gasket (5) on shift turret.

3 Put hexagon head screws (3) in place and

tighten Tightening torque = 23 Nm.

4 Mount pipe (2) together with hollow bolt (1)

and new sealing rings on servo unit.
Tightening torque = 20 Nm.

5 Insert pipe (2) on Super H valve block, connec-

tion A5

1315 751 110b - 2005-06 1-4

ZF-Ecosplit Servoshift

2 4

024463

1.4 Shift turret with superimposed H shift

system with control cable

Removal Installation

1 Loosen 4 hexagon head screws (1). 1 Place spring (4) in servo unit.

2 Remove pneumatic servo unit (4) together 2 Mount pneumatic servo unit (2) together with
with gasket (3) and spring (6). new gasket (3) on shift turret.

NOTE 3 Insert hexagon head screws (1) and tighten.

Spring (4) is loosely placed in pneumatic servo Tightening torque = 23 Nm.
unit.
Do not disassemble servo unit further - com-
plete component!

1315 751 110b - 2005-06 1-5

1315 751 110b - 2005-06 1-6
ZF-Ecosplit Servoshift

1
4

018646

2 Selector cylinder/shift cylinder

Shift turret with HTC

Removal NOTE
The selector cylinder (2) and the shift cylinder
1 Unfasten two hexagon head screw (1) and
(4) are connected to a separate hydraulic
washers.
circuit and remain in the vehicle when the
2 Pull off selector cylinder (2) with O-ring, transmission and/or shift turret are removed.
remove piston rods of selector cylinder from
driver groove in selector shaft.

NOTE
Move shift lever into the gate so that the
selector cylinder can be pulled out.

3 Unfasten two hexagon head screw (3) and

washers.

4 Pull off shift cylinder (4), remove piston rods

of shift cylinder from driver groove of shaft in
pneumatic servo unit (5).

1315 751 110b - 2005-06 2-1

ZF-Ecosplit Servoshift

1
4

018646

Installation 4 Suspend piston rods of selector cylinders (2) in

driver groove of selector shaft. A housing
1 Suspend piston rods of shift cylinders (4) in
notch on the selector cylinder allows the rods
driver groove of shaft on pneumatic servo unit
to only be suspended in the correct assembly
(5).
position.
NOTE
NOTE
Move shift lever in shift direction so that the
Push shift lever in selector direction for piston
piston rods move out.
rod travel.
2 Attach shift cylinder (4) the right way round
5 Attach selector cylinder with O-ring on shift
(direction depends on installation conditions
turret.
in the vehicle) on the pneumatic servo unit.
6 Screw in two M8x28 hexagon head screw and
3 Screw in two M8x28 hexagon head screw and
washers (1) and tighten.
washers (3) and tighten.
Tightening torque = 23 Nm.
Tightening torque = 23 Nm.

NOTE
Check O-ring on selector cylinder and replace
if necessary.

1315 751 110b - 2005-06 2-2

ZF-Ecosplit Shift mechanism

6 7 4

5
22
21
20
1
3

10
9
11 8

48 2
12
13
18
14
15 19
16 17

012330

3 Shift turret with left shifting output 4 Loosen switch (6 and 7) and remove together
with sealing rings and pins. Depending on
Removing and dismantling of shift housing parts list, there may be screw plugs.

1 Loosen hexagon head screws (1) and remove
shift turret together with gasket (2). Remove
roller (48) from valve lever.
NOTE
For removal of the Servoshift see Section 1.1
5 Unsnap V-ring (8) and remove detent (9)
together with O-ring from shift housing.
NOTE
Check O-ring and replace if necessary (cf. con-
sumables).

2 Loosen shift lever (3, depending on parts list) 6 Loosen hexagon head screws (10) and remove
and remove together with protective cap. cover (11) together with sealing.

NOTE 7 Unsnap V-ring (12) and locking ring (13) and

Mark selector lever position. remove disk (14), spring (15), disk (16), V-ring
(17), spring (18) and disk (19).
3 Disassemble cutoff valve (4) and remove
together with O-ring (5). NOTE
Arrangement and sequence of parts in step 7
NOTE
depend on parts list.
Cutoff valve is a complete part - do not
dismantle. 8 Loosen screw (20) and remove together with
sealing ring, spring (21) and detent (22).

1315 751 110b - 2005-06 3-1

ZF-Ecosplit Shift mechanism

29 27 23 24

38

28 40 25
26
39 35 42 43
32 36
46 33
31
34
30 37
44
41
45

47

012331

9 Loosen hexagon head screws (23) and remove 16 Remove needle bush (33).
cover (24) together with sealing (25).
17 Remove pin (34).
10 Loosen screw plugs (26 and 27) and remove
18 Dismantle shift shaft (40) from shift housing
together with sealing rings, spacing washers
together with valve lever (37) and lever (41).
and springs.
NOTE
11 Remove detent lever (28 and 29) from shift
Inspect selector shaft bores and level any
housing. If necessary, remove cylindrical pins.
revised edges.
CAUTION
19 Remove pin (35) from valve lever. Do not
Locking rings (30 and 32) must not be overstrained
remove lower needle bush (36). Replace any
- use adjustable pliers.
damaged needle bush (36) together with valve
12 Unsnap locking rings (30). lever.

13 Remove cylindrical pins (31). If necessary, 20 Place plastic arbor on hollow shaft and drive it
remove locking rings (32). out of the shift housing together with the shaft
bush (42) and the shaft seal (43). Slide hollow
14 Remove pin (38) and slide hollow shaft (39)
shaft out of shift housing and in the process
towards cover.
remove dog (44) and blocking piece (45).
15 Place impact adaptor 1X25 139 783 on needle
21 If necessary, remove cylindrical pins (46 and
bush (33) and drive valve lever (37) down-
47).
wards.

1315 751 110b - 2005-06 3-2

ZF-Ecosplit Shift mechanism

Assembly of shift housing

38
1 Insert dog (44) and blocking piece (45) in shift
housing. Position hollow shaft (39) properly in
shift housing, blocking piece and dog.

2 Use adaptor 1X25 139 707 to press in bush

(42) for flush seat in housing.

3 Snugly fit greased shaft seal ring (43) in its

support.

4 Insert cylindrical pin (35) into valve lever (37).

If necessary, press in cylindrical pins (46 and
47). 32 46
31
5 Mount valve lever (37) and lever (41) in shift 30 44
housing onto hollow shaft.

6 Introduce shift shaft (40) into hollow shaft.

NOTE 45
Cylindrical pin (35) must engage with shift
shaft. Position shift shaft and hollow shaft
properly.

CAUTION
Secure only hollow shaft with the cylindrical pin 39 35
(38). Only insert by hand until detent is reached - 36
33
never drive in.
34
7 Insert cylindrical pin (38). Check ease of 37
movement of the shift shaft.
41
8 Insert cylindrical pin (34) and drive in new
needle bush (33) until it is flush. Check ease of
movement of the shift shaft.
47
CAUTION
Locking rings (32 and 30) must not be overstrained 40
- use adjustable pliers.
42 43
9 Snap in locking rings (32) on pins (31) and
insert in dog and shift shaft. Insert locking
rings (30).

012332

1315 751 110b - 2005-06 3-3

ZF-Ecosplit Shift mechanism

10 Place detent levers (28 and 29) in shift hous-

ing. If necessary, insert cylindrical pins.
23 24
NOTE
Arrangement of detent levers depends on parts
list (see Fig.12334).

11 Insert screw plugs (26 and 27) together with

springs, spacing washers and new sealings and
tighten.
Tightening torque = 60 Nm.

12 Place new sealing (25) and cover (24).

25
13 Insert hexagon head screws (23) and tighten.
Tightening torque = 23 Nm. 29 27

NOTE
Version
Standard "A"
28
26

012333

Version
Standard "B"

Version
Alternative "C"

012334

1315 751 110b - 2005-06 3-4

ZF-Ecosplit Shift mechanism

6 7 4

5
22
21
20
1
3

10
9
11 8

48 2
12
13
18
14
15 19
16 17

012330

14 Place disk (19), spring (18), V-ring (17), disk 18 Place switches (6 and 7) together with pins
(16), spring (15), disk (14), and snap in locking and new sealing rings in shift housing and
ring (13) and V-ring (12). tighten.
Tightening torque = 45 Nm.
NOTE
Depending on parts list, there may be screw
Arrangement and sequence of parts in step 14
plugs.
depend on parts list.
Tightening torque = 35 Nm.
15 Place cover (11) together with new sealing and
19 Mount cutoff valve (4) together with greased
tighten with hexagon head screws (10).
O-ring (5) with hexagon head screws to shift
Tightening torque =23 Nm.
housing.
16 Place detent (22), spring (21) and screw plug Tightening torque = 23 Nm.
(20) with new sealing ring and tighten.
20 Mount shift lever (3) together with protective
Tightening torque = 60 Nm.
cap on shift shaft.
17 Place detent (9) together with greased O-ring Tightening torque = 49 Nm.
and V-ring (8) in shift housing. For new O-ring,
21 Place greased roller (48) on valve lever.
cf. consumables.
NOTE
For assembling of the Servoshift see
Section 1.1

1315 751 110b - 2005-06 3-5

ZF-Ecosplit Shift mechanism

3.1 Shift patterns

Shift turret with left shifting output

3.1.1 Horizontal torque shaft left /

Selector pattern I

Spring pack arrangements Q1 - Q6

012338

Q1 Q2

012335 012336

Q3 Q4

012337 012339

Q5 Q6

012340 012341

1315 751 110b - 2005-06 3-6

ZF-Ecosplit Shift mechanism

3.1.2 Horizontal torque shaft left /

Selector pattern II

Spring pack arrangements Q1 - Q6

012345

Q1 Q2

012342 012343

Q3 Q4

012344 012346

Q5 Q6

012347 012348

1315 751 110b - 2005-06 3-7

1315 751 110b - 2005-06 3-8
ZF-Ecosplit Shift mechanism

10

6
19
18
17
27
7 4

11
5
22
21
20
26
1

48
014992

4 Shift turret with right shifting output
Removing and dismantling gear shift housing
1 Unfasten hexagon head screws (1) and take off
shift turret with gasket (2). Take roller (48) off
valve lever.
NOTE
For removal of servoshift, refer to section 1.1
3 Remove cut-off valve (4) and take off with
O-ring (5).
NOTE
Do not dismantle cut-off valve further.
It is a complete part.
4 Unfasten switches (6 and 7) and take off with
seals and pins. Depending on parts list, there
may be screw plugs.

NOTE 5 Unfasten hexagon head screws (10) and take

Depending on version, an angled plate (not off cover (11) with gasket.
shown here) is screwed onto the housing cover
6 If necessary, press bearing bush (17), shaft seal
using the screws of the servoshift mounting.
(18) and scraper (19) out of cover.
2 Unfasten shift lever (3, depending on parts list)
7 Unfasten screw (20) with seal, remove spring
and remove with protective cap.
(21) and bolt (22).
NOTE
8 Unfasten screw plugs (26 and 27) and remove
Mark selector lever position.
with seals, spacing washers and springs.

1315 751 110b - 2005-06 4-1

ZF-Ecosplit Shift mechanism

29 23 24

38

28 40 25

39 35
36
9 46 33
8 34
37
32
31
41
30
44

47
45

014993

9 Unfasten hexagon head screws (23), take off 14 Remove pin (38).
cover (24) and gasket (25).
15 Slide quill shaft (39) towards the shift lever
10 Snap out V-ring (8) and remove. Press detent until it engages.
(9) and O-ring out of gear shift housing. Press
16 Fix impact adaptor 1X25 139 783 above the
from inside to outside.
needle bush (33) and drive valve lever (37)
NOTE downwards.
Check O-ring and replace if necessary (cf. con-
17 Use gripper pliers to remove needle bush (33).
sumables).
18 Remove pin (34).
11 Note down position of detent levers (28 and
29). Take detent lever out of gear shift housing. 19 Remove gear shift shaft (40) in the direction
If necessary, remove cylindrical pins. indicated by the arrow and in so doing take
out the valve lever (37) and lever (41).
CAUTION
Circlips (30 and 32) must not be overstretched - use
adjustable pliers.

12 Snap out circlips (30).

13 Remove cylindrical pins (31) and if necessary

remove circlips (32).

1315 751 110b - 2005-06 4-2

ZF-Ecosplit Shift mechanism

29 23 24

38

28 40 25

39 35
36
9 46 33
8 34
37
32
31
41
30
44

47
45

014993

NOTE
If the bores on the gear shift shaft show signs
of raised edges after long operating hours, the
gear shift shaft cannot be removed as
described above. In such instances, the spring
package (step 22) must be removed with the
gear shift shaft still installed and the gear shift
shaft then removed in the opposite direction to
that indicated by the arrow. The raised edges
should be levelled before the gear shift shaft is
refitted.

20 Take pin (35) out of valve lever, do not remove

lower needle bush (36). If the needle bush is
faulty, replace the entire valve lever and nee-
dle bush.

21 If necessary, remove cylindrical pin (47).

1315 751 110b - 2005-06 4-3

ZF-Ecosplit Shift mechanism

22 With the shaft removed, snap out V-ring (12)

and circlip (13). Remove washer (14), spring
(15) and washer (16).

23 NOTE
Number, arrangement and sequence of parts
in step 22 depend on the parts list.

24 Place plastic mandrel on quill shaft and drive

out of gear shift housing with quill shaft (39),
bush (42) and cover (43). Slide quill shaft off
gear shift housing and in so doing take off dri-
ver (44) and blocking piece (45). 46

25 If necessary, remove cylindrical pin (46). 44

45

39

12
13
14
15
16

42 43

014994

1315 751 110b - 2005-06 4-4

ZF-Ecosplit Shift mechanism

Assembling gear shift housing

38
1 Guide driver (44) and blocking piece (45) into
gear shift housing. Align quill shaft (39) cor-
rectly and slide into gear shift housing, block-
ing piece and driver.

2 Press new bush (42) with adaptor

1X25 139 707 into housing until flush.

3 Press new cover (43) onto system.

NOTE 32 46
Housing bores an cover must be free from 31
greese. 30 44

4 Insert cylindrical pin (35) in valve lever (37). If

necessary, press in cylindrical pins (46 and
45
47). Position valve lever and lever in housing.

5 With the shaft removed, fit V-ring (12), circlip

(13), washer (14), spring (15) and washer (16).

NOTE
Number, arrangement and sequence of parts
in step 5 depend on the parts list. 39 35
36
6 Guide gear shift shaft (40) (in direction indicat- 33
34
ed by arrow) into housing and quill shaft.
37
NOTE
41
Cylindrical pin (35) must engage with gear
shift shaft. Position gear shift shaft and quill
shaft accordingly. 12
13 47
7 Press valve lever (37) and lever (41) upwards. 14
15
Slide quill shaft towards cover (43).
16
CAUTION 40
Only the quill shaft is secured with cylindrical pin
42 43
(38). Only insert by hand until detent is reached -
never drive in.

014995

1315 751 110b - 2005-06 4-5

ZF-Ecosplit Shift mechanism

8 Use grease to insert cylindrical pin (38). Check

38
ease of movement of gear shift shaft.

9 Use an appropriate attachment to fix valve

lever and lever or support in a suitable man-
ner.

10 Use grease to insert cylindrical pin (34) in new

needle sleeve (33) and drive firmly together.
Check ease of movement of gear shift shaft.

32 46
31
30 44

45

39 35
36
33
34
37

41

12
13 47
14
15
16
40

42 43

014995

1315 751 110b - 2005-06 4-6

ZF-Ecosplit Shift mechanism

CAUTION
Circlips (30 and 32) must not be overstretched - use
adjustable pliers. 24
23
11 Snap circlips (32) onto pins (31) and insert in
driver and gear shift shaft. Insert circlips (30).

12 Insert detent levers (28 and 29) in gear shift

housing as noted down. If necessary, insert
cylindrical pins.

NOTE
Arrangement of detent levers depends on parts
list. For possible arrangements, refer to dia- 25
gram 012334.
29 27
13 Attach new gasket (25) and cover (24).

14 Insert hexagon head screws (23) and tighten.

Tightening torque = 23 Nm

15 Insert screw plugs (26 and 27) with springs,

spacing washers and new seals and tighten.
Tightening torque = 60 Nm.

28
26
NOTE
Standard "A"
version

014996

Standard "B"
version

Standard "C"
version

012334

1315 751 110b - 2005-06 4-7

ZF-Ecosplit Shift mechanism

10

6
19
18
17
7 4

11

5
22
21
20
1

48
2
014997

16 Press new bearing bush (17), new shaft seal 21 Use hexagon head screws to fit cut-off valve
(18) and new scraper (19) into cover (11). (4) and greased O-ring (5) to gear shift hous-
ing.
NOTE
Tightening torque = 23 Nm.
Use gasket as specified in parts list (0.5 mm
thick). 22 Attach gear shift lever (3) with cover cap to
gear shift shaft.
17 Attach cover (11) with new gasket and use
Tightening torque = 49 Nm.
hexagon head screws (10) to tighten into place.
Tightening torque = 23 Nm. 23 Use grease to attach roller (48) to valve lever.

18 Insert bolt (22), spring (21) and screw plug (20) NOTE
with new seal and tighten. If necessary, fasten angled plate (not shown) to
Tightening torque = 60 Nm. servoshift retaining screws.

19 Insert detent (9) with greased O-ring and V- NOTE

ring (8) in gear shift housing. The valve lever and lever must be flush if the
For new O-ring, cf. consumables. servoshift to be fitted. The servoshift must be
in its neutral position (central position).
20 Insert switches (6 and 7) with pins and new
seals in gear shift housing and tighten. 24 Attach servoshift refer to section 1.1.
Tightening torque = 45 Nm.
Depending on parts list, there may be screw
plugs.
Tightening torque = 35 Nm.

1315 751 110b - 2005-06 4-8

ZF-Ecosplit Shift mechanism

4.1 Shift patterns

Shift turret with right shifting output

4.1.1 Horizontal torque shaft right /

Selector pattern I

Spring pack arrangements Q1 - Q6

012362

012352

Q1 Q2

012349 012350

Q3 Q4

012351 012353

Q5 Q6

012354 012355

1315 751 110b - 2005-06 4-9

ZF-Ecosplit Shift mechanism

4.1.2 Horizontal torque shaft right /

Selector pattern II

Spring pack arrangements Q1 - Q6

012362

012362

Q1 Q2

012356 012357

Q3 Q4

012358 012359

Q5 Q6

012360 012
012361

1315 751 110b - 2005-06 4-10

ZF-Ecosplit Shift mechanism

6 4
23
11
7
10

18
17
16
5
1
22

015986

5 Shift turret with hydrostatic control (HTC)

Removing and dismantling shift housing
1 Unfasten hexagon head screws (1) and take off
shift turret and gasket (2).
NOTE
For removal of the Servoshift, refer to Chapter
1.2.
3 Unfasten switches (6 and 7), take off with seal-
ing rings and pins.
4 Unfasten screw (16) and remove with sealing
ring, spring (17) and bolt (18).
5 Unfasten screw plugs (22 and 23) and remove
with sealing rings.

NOTE
The selector cylinder (3) with O-ring (11) and
hexagon head screws (10) is only listed here
for your information. It remains in the vehicle
when the transmission and/or shift turret are
removed.

2 Remove valve block (4) and take out with

O-ring (5).

NOTE
Do not dismantle valve block any further. It is
a complete part.

1315 751 110b - 2005-06 5-1

ZF-Ecosplit Shift mechanism

19 20

27

29

21
30

9 34
8
28
26
25
24 32

33

015987

6 Loosen hexagon head screws (19), remove cov-
er (20) and gasket (21).
7 Snap out V-ring (8) and remove. Push out
detent (9) and O-ring from the inside of the
shift housing.
NOTE
Alternatively, the detent can be pushed out
from the inside as the last disassembly step.
NOTE
Check O-ring and replace if necessary (refer to
consumables).
CAUTION
Circlips (24 and 26) must not be overstretched - use
adjustable tongs.
8 Snap out circlips (24).
10 Remove pin (27).
11 Remove selector shaft (29) from shift housing
in direction indicated by the arrow and take
off lever (30) at the same time.
NOTE
If the edges of the selector shaft bores are
raised after longer operating periods, the selec-
tor shaft can no longer be removed as is
described above.
In such instances, the spring pack (step 12)
must be removed when the selector shaft is
still installed and the selector shaft then
removed in the direction opposite to that indi-
cated by the arrow.
The raised edges should be levelled out before
the selector shaft is re-installed.

9 Remove cylindrical pins (25) and remove cir-

clips (26) if necessary.

1315 751 110b - 2005-06 5-2

ZF-Ecosplit Shift mechanism

12 Snap out V-ring (12) from the removed shaft,

remove washer (13), spring (14) and washer
(15).

13 Place plastic mandrel on quill shaft and use

quill shaft (28) to drive cover (31) out of shift
housing. Slide quill shaft out of shift housing
and in so doing, lift off driver (32) and block-
ing piece (33).

14 If necessary, remove cylindrical pin (34).

34

32

33

28

12
13
14
15

31

015988

1315 751 110b - 2005-06 5-3

ZF-Ecosplit Shift mechanism

Assembling shift housing

1 Guide driver (32) and blocking piece (33) into 27

shift housing. Slide quill shaft (28) the right
way round into shift housing, blocking piece
and driver.

2 Press on new cover (31) until firmly fitted.

NOTE
Housing bore and cover must be free of grease.

3 If necessary, press in cylindrical pin (34). Posi-

34
tion lever (30) in housing.
26
4 Attach V-ring (12), washer (13), spring (14) and 25
24 32
washer (15) to removed shaft.

5 Guide selector shaft (29) (in direction indicat-

ed by arrow) into housing and quill shaft. 33
6 Press lever (30) upwards, slide quill shaft in
direction of cover (31).

CAUTION
Only the quill shaft is secured by the cylindrical pin 28
(27), only insert by hand until the stop is reached -
do not drive in.
12 30
7 Use grease to insert cylindrical pin (27). Check 13
selector shaft for ease of movement. 14

CAUTION 15
Circlips (24 and 26) must not be overstretched - use
adjustable tongs.

8 Snap circlips (26) onto pins (25) and insert in

driver and selector shaft. Insert circlips (24).

29

31

015989

1315 751 110b - 2005-06 5-4

ZF-Ecosplit Shift mechanism

9 Attach new gasket (21) and cover (20).

10 Insert hexagon head screws (19) and tighten. 19 20

Tightening torque = 23 Nm.

11 Insert screw plugs (22 and 23) with new seal-

ing rings and tighten.
Tightening torque = 60 Nm.

21

23

22

015990

1315 751 110b - 2005-06 5-5

ZF-Ecosplit Shift mechanism

4
6

18
17
16

8 1

015991

12 Insert bolt (18), spring (17) and screw plug (16) 15 Fit valve block (4) and greased O-ring (5) with
with new sealing ring and tighten. hexagon head screws on shift housing.
Tightening torque = 60 Nm. Tightening torque = 23 Nm.

13 Insert stop (9) with greased O-ring and V-ring NOTE

(8) in shift housing. If using new O-ring, refer
to consumables.
NOTE
Both switches (6 and 7) and the associated
pins are different. Do not mix them up.
Mounting of the pneumatic servo unit (PSU)
requires the shift turret to be in neutral posi-
tion (center position).
16 Install Servoshift refer to Chapter 1.2

14 Insert switches (6 and 7) with pins and new

sealing rings in shift housing and tighten.
Tightening torque = 45 Nm.

1315 751 110b - 2005-06 5-6

ZF-Ecosplit Shift mechanism

5.1 Shift patterns

Shift turret with HTC

5.1.1 Horizontal torque shaft right /

Selector pattern I

Spring pack arrangements Q1

015992

Q1

015993

1315 751 110b - 2005-06 5-7

1315 751 110b - 2005-06 5-8
ZF-Ecosplit Shift mechanism

7 9
13
3 14
15

5 6
12
1 11
8
10

018647

6 Super H shift turret with HTC 3 If necessary, loosen neutral switch (9) together
(superimosed H shift system) with sealing ring and remove.

CAUTION
Removal and disassembly of the shift housing
Do not loosen plug-in connector (10) on front but on
1 Loosen hexagon head screws (1) and remove rear hex connection - SW 22.
shift turret together with gasket (2).
4 If necessary, remove plug-in connector (10).
NOTE O-ring might stick to housing - remove it.
For dismounting the servo shift, see Chapter
NOTE
1.3.
Do not disassemble super H valve block furt-
NOTE her - complete part!
Selector cylinder (3) with O-ring (4) and hexa-
5 Remove tappet (11) and pin (12) from shift
gon head screws (5) are mentioned only for
housing.
information. They remain in the vehicle
during removal of the transmission or the shift 6 Loosen tappet switch (13) together with seal-
turret. See Chapter 2. ing ring and remove together with pressure
spring (14) and lock (15).
2 Loosen hexagon head screws (6 and 7) and
remove Super H valve block (8).

NOTE
Gasket may stick to shift housing. Remove and
place in valve block.

1315751 010b - 2005-06 6-1

ZF-Ecosplit Shift mechanism

16

24 17

23
22
18
21

26

25 32
35
27
20 33 28
19 29
30
34
31

018648

7 Loosen hexagon head screws (16), remove 14 Remove V-ring (27) on removed shaft and
cover (17) and gasket (18). remove disk (28), springs (29 and 30) and disk
(31).
CAUTION
Snap rings (19) must not be stretched too much - 15 Place plastic mandrel on hollow shaft and
use adjustable pliers. drive hollow shaft (25) and cover (32) out of
shift housing. Push hollow shaft out of shift
8 Remove snap ring (19).
housing and in the process remove driver (33)
9 Remove cylindrical pin (20) and remove and blocking piece (34).
second snap ring if necessary.
16 Remove cylindrical pin (35) if necessary.
10 Remove shift shaft (21) from shift housing in
the direction of the arrow.

11 Remove catch (22) and pin (23).

12 Push pin (24) through shift housing and

remove.

13 Push hollow shaft (25) in the direction of the

arrow and remove lever (26).

1315751 010b - 2005-06 6-2

ZF-Ecosplit Shift mechanism

16

24 17

23
22
18
21

26

25 32
35
27
20 33 28
19 29
30
34
31

018648

Assembling shift housing 6 Push lever (26) upward and push hollow shaft
towards the cover (32).
1 Insert driver (33) and blocking piece (34) into
shift housing. Insert hollow shaft (25) in cor- CAUTION
rect position in shift housing, blocking piece Snap rings (19) must not be stretched too much -
and driver. use adjustable pliers.

2 Press on new cover (32). 7 If necessary, snap upper snap ring onto pin
(20) and place in driver and shift shaft. Put
NOTE
snap ring (19) in place.
Housing bore and cover must not be greasy.
8 Push pin (24) to stop in housing and lock with
3 Press in cylindrical pin (35) if necessary.
pin (23). Put catch (22) in place.
Position lever (26) in housing.
9 Put new gasket (18) and cover (17) in place.
4 Mount disk (31), springs (29 and 30), disk (28)
and V-ring (27) on removed shaft. 10 Insert hexagon head screws (16) and tighten.
Tightening torque = 23 Nm.
5 Insert shift shaft (21) (in the direction of the
arrow) in housing and hollow shaft.

1315751 010b - 2005-06 6-3

ZF-Ecosplit Shift mechanism

7 9
13
3 14
15

5 6
12
1 11
8
10

018647

11 Install lock (15), spring (14) and tappet switch NOTE

(13) together with new sealing ring in shift Mounting of the pneumatic servo unit (PSU)
housing and tighten. requires the shift turret to be in neutral positi-
Tightening torque = 45 Nm. on (center position).

12 Place tappet (11) and pin (12) in shift housing. 16 For mounting servo shift see Chapter 1.3

13 Mount valve block (8) with hexagon head

screws (6 and 7) to shift housing.
Tightening torque = 23 Nm.

14 Screw in neutral switch (9) together with new

sealing ring on valve block and tighten.
Tightening torque = 45 Nm.

CAUTION
Do not loosen plug-in connector (10) on front but on
rear hex connection - SW 22.

15 Insert plug-in connectors (10) and tighten.

Tightening torque = 24 Nm.

1315751 010b - 2005-06 6-4

ZF-Ecosplit Shift mechanism

6.1 Shift patterns

Super H shift turret
(superimosed H shift system)

6.1.1 Shift patterns I

Arrangement of spring packages Q5

018649

Q5

018650

1315751 010b - 2005-06 6-5

1315751 010b - 2005-06 6-6
ZF-Ecosplit Shift mechanism

17
16 4
6
18
1
14

10
15 11
12 7

13 4

9
8

5
3

2
49

024464

7 Shift turret with superimposed H shift

system with control cable
Removal and disassembly of the shift system
housing
1 Loosen hexagon head screws (16), remove
selector lever (17) with protective cap (18).
NOTE
The selector lever covers a hex screw; for this
reason, first remove selector lever to be able to
remove the shift system.
2 Loosen hexagon head screws (1) and remove
shift turret together with gasket (2).
Remove roller (49) from valve lever.
NOTE
For removal of the Servoshift, refer to Chapter
1.4.
3 Loosen shift lever (3, depending on parts list)
and remove together with protective cap.
NOTE
Mark selector lever position.
4 Loosen hexagon head screws (4) and remove
together with valve block (5).
NOTE
Gasket may stick to shift housing. Remove it
and place it in the valve block.
Do not disassemble valve block further - com-
plete component!
5 If necessary, loosen neutral switch (6) together
with sealing ring and pressure switch (7) and
remove.
6 Remove tappet (8) and pin (9) from shift hou-
sing.
7 Loosen tappet switch (10) together with seal-
ing ring and remove together with pressure
spring (11) and interlock (12).
8 Loosen hexagon head screws (13) and remove
cover (14) together with gasket.
9 Remove V-ring (15) from housing.

1315751 010b - 2005-06 7-1

ZF-Ecosplit Shift mechanism

19

20
32 29
23 31
24
22
33
30
21 34
35
36

28

39

26 27 37
25

38

024465

10 Loosen hexagon head screws (19), remove 19 Dismantle shift shaft (32) from shift housing
cover (20) and gasket (21). (as indicated by the arrow) together with valve
lever (30) and lever (34).
11 Remove locking pawl (22) and pin (23).
NOTE
12 Push pin (24) through shift housing and remo-
Inspect selector shaft bores and level any rai-
ve it.
sed edges.
CAUTION
20 Remove pin (33) from valve lever. Do not
Locking rings (25 and 26) must not be overstrained
remove lower needle bush. Replace any dama-
- use adjustable pliers.
ged needle bush as complete unit together
13 Remove locking ring (25). with valve lever.

14 Remove cylindrical pins (27). If necessary, 21 Place plastic arbor on hollow shaft (28) and
remove locking rings (26). push through the shift housing together with
the shaft bush (35) and the shaft seal (36).
15 Push hollow shaft (28) towards sealing cap.
Push hollow shaft out of shift housing and in
16 Place impact adaptor 1X25 139 783 on needle the process, remove driver (37) and blocking
bush (29) and drive valve lever (30) slightly piece (38).
downwards.
22 Remove cylindrical pin (39) if necessary.
17 Remove needle bush (29).

18 Remove pin (31).

1315751 010b - 2005-06 7-2

ZF-Ecosplit Shift mechanism

23 Use pliers to remove V-ring (40) from shift

shaft.
40
24 Use compression spring (42) to lift discs (41 41
and 43) from shift shaft. 42
43

024466

25 Remove V-ring (44) from selector shaft (45).

48
26 Push out shift shaft (45) (in the direction of the 47
arrow) from housing and remove rotary shaft
seal (48).

27 Remove selector lever (46) from housing cover.

28 Remove needle sleeve (47) from housing cover

if necessary.

45

46
44

024467

1315751 010b - 2005-06 7-3

ZF-Ecosplit Shift mechanism

Assembling Selector Housing

48

1 Insert needle sleeve (47) into housing cover 47

(until it is flush) if necessary.

2 Insert selector lever (46) into housing cover.

3 Insert shift shaft (45) (in the direction of the

arrow) into housing cover and selector lever.

4 Insert V-ring (44) into selector shaft.

5 Insert greased rotary shaft seal ring (48) in cor-

45
rect position in its support.

46
44

024467

6 Mount disc (43), compression spring (42), and

disc (41) onto shift shaft.
40
7 Use pliers to snap V-ring (40) onto shift shaft. 41
42
43

024466

1315751 010b - 2005-06 7-4

ZF-Ecosplit Shift mechanism

19

20
32 29
23 31
24
22
33
30
21 34
35
36

28

39

26 27 37
25

38

024465

8 Insert driver (37) and blocking piece (38) into
shift housing. Place hollow shaft (28) in cor-
rect position in shift housing, insert blocking
piece and driver.
9 Use adaptor 1X25 139 707 to press in bush
(35) for flush seat in housing.
14 Insert cylindrical pin (31) and drive in new
needle bush (29) until it is flush. Check ease of
movement of the shift shaft.
CAUTION
Locking rings (26 and 25) must not be overstrained
- use adjustable pliers.

10 Snugly fit greased rotary shaft seal ring (36) in 15 Snap in locking ring (26) on pin (27) and insert
its support. in driver and shift shaft. Put locking ring (25)
in place.
11 Insert cylindrical pin (33) into valve lever (30).
Press in cylindrical pin (39) if necessary. 16 Push pin (24) to stop in housing and lock with
pin (23). Put locking pawl (22) in place.
12 Mount valve lever (30) and lever (34) in shift
housing onto hollow shaft. 17 Put new gasket (21) and preassembled cover
(20) in place.
13 Insert shift shaft (32) into hollow shaft (as indi-
cated by the arrow). 18 Insert hexagon head screws (19) and tighten.
Tightening torque = 23 Nm.
NOTE
Cylindrical pin (33) must engage with shift
shaft. Position shift shaft and hollow shaft pro-
perly.

1315751 010b - 2005-06 7-5

ZF-Ecosplit Shift mechanism

17
16 4
6
18
1
14

10
15 11
12 7

13 4

9
8

5
3

2
49

024464

19 Install interlock (12), spring (11), and tappet 25 Fit cover (14) together with new sealing onto
switch (10) together with new sealing ring in housing using hex-head screw (13) and
shift housing and tighten. tighten.
Tightening torque = 45 Nm. Tightening torque = 23 Nm.

20 Place tappet (8) and pin (9) in shift housing. 26 Mount shift lever (3) together with protective
cap on shift shaft.
21 Mount valve block (5) with hexagon head
Tightening torque = 49 Nm.
screws (6) to shift housing.
Tightening torque = 23 Nm. 27 Place greased roller (49) on valve lever.

22 Screw in neutral switch (6) together with new NOTE

sealing ring on valve block and tighten. For Servoshift assembly, refer to Chapter 1.4.
Tightening torque = 45 Nm.
NOTE
23 Insert pressure switch (7) at valve block and Refer to Chapter 9 for mounting of complete
tighten. shift system on transmission.
Tightening torque = 23 Nm.
28 Fit protective cap (18) together with selector
24 Snap V-ring (15) in selector shaft. lever (17) onto shift shaft and tighten using
hexagon nut (16).
Tightening torque = 23 Nm.

1315751 010b - 2005-06 7-6

ZF-Ecosplit Shift mechanism

7.1 Shift patterns

Shift turret with superimposed H shift
system.

7.1.1 Shift patterns I

Allocation of spring packages Q4.

024461

Q4

024462

1315751 010b - 2005-06 7-7

1315751 010b - 2005-06 7-8
ZF-Ecosplit Shift mechanism

1 2

1X56 138 229

015997

8 Function test

Shift turret with HTC

1 Suspend test device 1X56 138 229 in driver

groove of selector shaft (1).
Screw in 2 hexagon head screws (2) and
tighten.
Tightening torque = 23 Nm.

2 The individual gears can be shifted through

using a box spanner or hex nut.

3 Remove test device 1X56 138 229.

1315751 010b - 2005-06 8-1

1315751 010b - 2005-06 8-2
ZF-Ecosplit Shift mechanism

9 Assembling complete shift turret

3
1 Place new gasket (1) onto clutch housing (2)
and sealing face.

2 Place complete shift housing (3) in position.

Line up bores in shift housing with bores in 1
gasket.

NOTE
Positioning between clutch housing, gasket
and selector housing must be effected by inser- 2
tion of 2 fixing ping Ø 8,9 mm.

NOTE
When placing the selector mechanism make
sure the roller on the valve lever does not
come off. Assembly suggestion: Use grease to
place roller on valve lever.

3 Insert all hexagon head screws and tighten

them.
Tightening torque = 23 Nm.

NOTE - version with HTC 015070

Once the transmission has been installed in

the vehicle, the selector cylinder and shift
cylinder remaining in the vehicle should be
flange-mounted to the shift turret or the pneu-
matic servo unit. Installation of the two cylin-
ders is described in Chapter 2. Ø 15

110

Schaft Ø 8.9
80
15

M8

016078

1315751 010b - 2005-06 9-1

1315751 010b - 2005-06 9-2