Transmission T-7336 Ps

Order No.
: 5871 970 002
ZF TRACTOR TRANSMISSION
T-7336 PS
ZF Passau GmbH
Donaustr. 25 - 71 D- 94034 Passau
REPAIR MANUAL for the ZF TRACTOR TRANSMISSION T-7336 PS

I M P O R T A N T N O T E:
The great variety of ZF units compels a restriction of the Disassembly and Assembly Manuals to a current ZF production unit. Technical development of the ZF units as well as extensions concerning the design possibilities may require differing steps, which can be carried out by qualified Specialists without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare Parts Lists. The described Disassembly and Assembly Manual is based on the design level of a ZF production unit at the time of preparation of the Repair Manual. The ZF Passau GmbH reserve the right to replace the present Disassembly and Assembly Manual by a successional edition without advance notice. Upon request, the ZF Passau GmbH will advise what edition is the latest one.
ATTENTION:
For the Installation as well as for the commissioning of the unit, the Instructions and Specifications of Vehicle Manufacturer have to be observed! For information about the Operation, Maintenance and Description, see the corresponding ZF Operating Instructions.
ZF Passau GmbH
Donaustr. 25 - 71 D - 94034 Passau Abt.: ASDM / Section : ASDM
Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Copying even partially not permitted! Reproduction mme par extrait est interdite! Technische nderungen vorbehalten! With the reserve of technical modifications! Sous reserve de modifications techniques! 1.Auflage / 1st Edition 2004/05
Repair Manual
Off-Road Transmissions and Axle Systems Division
PREFACE
This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair and Maintenance operations on ZF-Units. Treated is a ZF-Serial product according to the design stage of the date of Edition. However, due to further technical developments of the product, the repair of the unit at your disposal could require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and theoretical training is constantly completed to the actual situation in our Training School. The Service Stations, established by the ZF Friedrichshafen all over the world, offer you:
1. Constantly trained personnel 2. Prescribed installations, e.g. Special Tools 3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability. Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual contractual conditions, by the ZF-Warranty. Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and afterexpenditures eventually arising from it, are excluded from this contractual responsibility. This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH Service Department
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GENERAL
The Service Manual covers all work required for dismantling and the pertaining installation. When repairing the axle, ensure utmost cleanliness and that the work is carried out in an expert-like manner. The axle should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices. Dismantling and mounting work must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them:
REFERENCE:
For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used! Parts fitted in heated state have to be installed subsequently after cooling down to ensure a perfect contact!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. by no means. Lined plates with organic friction linings (e.g. paper linings) must not be washed (negative effect on lining adhesion). They are only allowed to be dry-cleaned (leather cloth). For the installation of circlips and retaining rings it must be observed that slots are located exactly. DANGER When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.
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Repair Manual
Structure of the Repair Manual The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main group are always summarized in one chapter. Special tools required for performing the respective repair work are listed in the text as well as in the Chapters W (List of Special Tools) and WB (Illustrated Tables). Important information on industrial safety Generally, the persons repairing ZF-units are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations. The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training. The following safety references are used in the present Repair Manual:
! CAUTION
DANGER
Serves as reference to special working procedures, methods, information, the use of auxiliaries etc... in this repair manual.
Is used, if lacking care can lead to personal injury or damage the product.
___________________________________________________ REFERENCE
CAUTION:
Prior to starting the checks and repair works, thoroughly study the present instructions.
Illustrations, drawings and parts do not always represent the original; the working procedure is shown. The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and weight must not be drawn (not even within one representation). The works must be performed according to the description. After the repair works and the checks, the expert staff must convince itself that the product is properly functioning again.
REFERENCE:
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VERGLEICHSTABELLE FR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION
25,40 mm 1 kg ( Kilogramm ) 9,81 Nm ( 1 kpm ) 1,356 Nm ( 0,138 kpm ) 1 kg / cm 1 bar ( 1,02 kp/cm2 ) 0,070 bar ( 0,071 kp/cm2 ) 1 Liter 4,456 Liter 1 Liter 3,785 Liter 1609,344 m 0 C ( Celsius ) 0 C ( Celsius )
= = = = = = = = = = = = = =
1 in ( inch) 2,205 lb ( pounds ) 7,233 lbf x ft ( pound force foot) 1 lbf x ft ( pound force foot ) 5,560 lb / in ( pound per inch ) 14,233 psi (pound force per square inch lbf/in2 ) 1 psi ( lbf/in2 ) 0,264 Gallon ( Imp. ) 1 Gallon ( Imp. ) 0,220 Gallon ( US ) 1 Gallon ( US ) 1 Mile ( Landmeile ) + 32 F ( Fahrenheit ) 273,15 Kelvin
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : Note : Nota :
lngenbezogene Mae in kg/m; linear density in kg/m; Densit linaire en kg/m;
flchenbezogene mae in t/m2 areal density in t/m2 Densit superficielle en t/m2
Begriff Unit Unit Masse Mass Mass Kraft Force Force Arbeit Work Travail Leistung Power Puissance Drehmoment Torque Couple Kraftmoment Moment (Force) Moment (Force) Druck (ber-) Pressure (Overpress) Pression (Sur-) Drehzahl Speed Nombre de Tours
Formelzeichen Formula Sign Symbole m
Neu New Nouveau kg (Kilogramm)
Alt Old Vieu kg
Umrechnung Conversion Conversion
Bemerkungen Note Nota
N (Newton)
kp
1 kp = 9,81 N
J (Joule)
kpm
0,102kpm = 1J = 1Nm
KW (Kilowatt)
PS (DIN)
1 PS = 0,7355 KW 1 KW = 1,36 PS 1 kpm = 9,81 Nm T (Nm) = F (N) . r (m) M (Nm) = F (N) . r (m)
Nm (Newtonmeter)
kpm
Nm (Newtonmeter)
kpm
1 kpm = 9,81 Nm 1,02 at = 1,02 kp/cm2 = 1 bar = 750 torr
bar
at
min -1
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TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARD 148 Friction value: total= 0.12 for screws and nuts without after-treatment, as well as phophatized nuts. Tightened by hand! Torque limits, if not especially indicated, can be taken from the following list: Metric ISO-Standard Thread DIN 13, Page 13 8.8 10.9 2.8 4.1 5.5 8.1 9.5 14 15 23 23 34 46 68 79 115 125 185 195 280 280 390 390 560 530 750 670 960 1000 1400 1350 1900 1850 2600 2350 3300 3000 4300 Metric ISO-Fine Thread DIN 13, Page 13 8.8 10.9 24 36 36 53 52 76 49 72 87 125 83 120 135 200 205 300 310 440 290 420 430 620 580 820 760 1100 730 1050 1100 1600 1050 1500 1550 2200 1500 2100 2050 2900 2000 2800 2700 3800 2500 3500 3450 4900 3200 4600 0/6
Size M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 Size M8x1 M9x1 M 10 x 1 M 10 x 1.25 M 12 x 1.25 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 18 x 2 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 24 x 2 M 27 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M33 x 1.5 M 33 x 2 M 36 x 1.5 M 36 x 3 M 39 x 1.5 M 39 x 3 5871 970 002
12.9 4.8 9.5 16.5 28 40 79 135 215 330 460 650 880 1100 1650 2250 3000 3900 5100 12.9 43 62 89 84 150 145 235 360 520 490 720 960 1250 1200 1850 1800 2550 2500 3400 3300 4450 4100 5700 5300
Repair Manual
LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY TRACTOR TRANSAXLE T7336 PS 2094 009 003
Disassembly Chapter/Fig Reassembly Designation and Use Chapter/Fig.
Part No.
1/01 1/07
Assembly truck cpl. with tilting device # Holding fixture # Support # To mount the complete transmission, rear axle housing and the axle trumpet respectively on the assembly truck.
5870 350 000 5870 350 117 5870 350 125
1/05
7/94 10/09
3-strand Lifting chain Dis- and reassembly aid for removal and installation of the complete rear axle and rear axle trumpets respectively. To be used in combination with eyebolts DIN 580 M16 = 0636 804 001
5870 281 047
1/12
10/7
M16 Adjusting screws Dis- and reassembly aid for separation and assembly of the complete transmission with the rear axle housing.
5870 204 023
2/06 2/10
6/02 9/38
M8 Adjusting screws Dis- and reassembly aid for removal and installation of the complete valve housing / F/R shift control. Gasket and intermediate sheet on the pump housing.
5870 204 011
2/26
9/43
M 10 Adjusting screws Dis- and reassembly aid for removal and installation of the complete pump housing F/R shift control.
5870 204 007
2/26 3/04
1 Set = 2 Pcs. Pry bar set Universal use. To separate housing components, flanges and shafts. To press off the brake- from the rear axle housing
5870 345 065
2/28_3/10 3/16_3/22 3/26_3/29 3/44_5/32
6/21_7/74 7/82_7/82 8/25_8/49
A1-A2-A3-A4 Set of external pliers Universal use. To unsnap and snap in externally clamping retaining rings.
5870 900 015
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Repair Manual
Part No. 5870 970 002
2/29
Opening 120 mm Two-armed puller Universal use. To pull off the ball bearing from the bearing bracket.
3/04
M 16 Adjusting screws Dis- and reassembly aid for removal and installation of the complete cover from the transmission housing.
5870 204 023
3/07
Rapid grip # To pull off the bearing inner ring 32012X = 0750 117 505 from the input gear 2094 359 046. To be used in combination with: Basic device
5873 011 014
5873 001 000
3/08_3/18 3/19_3/21 3/24_3/47
Gripping insert # To pull off the bearing inner ring 30 210X = 0750 117 656 from the input shaft splitter group . To be used in combination with: Basic device
5873 001 038
5873 001 000
3/11 3/27 3/39
7/85 8/25 8/50 8/92
Pressing bush # To preload the compression springs 0732 041 183 in the disc carrier splitter group. To preload the set of cup springs 0501 314 521 on the FA and powershift clutch .
5870 506 117
3/13 3/29 3/41
Clamping pliers To lift the piston 2094 359 004 out of the disc carrier splitter group.
5870 900 007
3/14 3/30 3/42
Internal extractor Countersupport Universal use. To remove the needle bearing 0750 115 365 from the disc carrier splitter group.
5870 300 005 5870 300 003
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Repair Manual
Part No.
3/21 3/34
Gripping insert # To pull off the bearing inner ring 32 007X = 0750 117 503 from the output shaft splitter group. To be used in combination with: Basic device
5873 000 035
5873 000 000
3/23 4/01
Opening 160 mm Two-armed puller Universal use. To press off the spur gear 2094 359 056 with bearing 0750 117 656 from the output shaft. To pull off the bearing inner ring 0635 376 013 from the output shaft FA.
5870 970 003
3/33
Gripping insert # To pull off the bearing inner ring JLM714148 = 0750 117 267 from the output shaft 2094 359 064 splitter group. To be used with : Basic device
5873 002 025
5873 002 001
3/45
Opening 155 Parting fixture # Universal use. To separate the spur gear 2094 359 048 from the intermediate shaft 2094 359 042 .
5870 300 028
3/46
Gripping insert # To pull off the bearing inner ring 30 210X = 0750 117 656 from the intermediate shaft 2094 359 042. To be used in combination with: Parting fixture
5873 001 038
5870 300 028
4/02
Striker # Universal use. To expel the cyl. pin 0631 315 561 from the housing or cover.
5870 650 001
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Repair Manual
Part No.
4/04
7/94
Lifting tackle # To lift out and in the complete output shaft 2094 346 054 FA with cover and clutch.
5870 281 050
4/07
Gripping insert # To pull off the bearing inner ring 449J = 0750 117 444 from the output shaft 2094 346 054. To be used in combination with: Parting fixture
5873 001 064
5873 001 000
4/09 4/27
7/10 7/32
Pressing bush Universal use. To preload the laminated spring 0501 314 521 . To preload the disc carrier main clutch.
5870 506 116
4/13 4/27 5/41
A11-A21-A31-A41 Set of external pliers Universal use. To unsnap and snap in externally clamping retaining rings.
5870 900 016
4/20
6/38_6/49 Digital depth gauge 200 mm 7/14_7/35 Universal use. 8/15_8/112 For various measuring procedures.
5870 200 072
4/29
2 x required Resetting device Universal use. To separate the disc carrier from the clutch bell housing.
5870 400 001
5/15
6/78 6/85
Slotted nut wrench # To loosen and to tighten the slotted nut 0737 502 164 on the main shaft.
5870 401 049
5/17
Extractor # Universal use. For dis- and reassembly of the main shaft.
5870 300 026
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Repair Manual
Part No.
5/19
8/75
Parting fixture # Universal use. To pull off the bearing inner ring 32313 = 0750 117 499 from the main shaft. For axial preloading of the spur gear 2094 359 048.
5870 300 028
5/35
8/56 8/60
Two-armed puller Universal use. To pull off the gear 2094 303 064 from the layshaft. To pull off or axial preloading of the spur gear 2094 359 056 until contact on the retaining ring.
5870 970 004
6/09 9/16
Set of internal pliers Universal use. To unsnap and snap in internally clamping retaining rings.
5870 900 013
6/10
230 V Hot-air blower # Hot-air blower # 115 V To heat up various components.
5870 221 500 5870 221 501
6/34
Mounting tool To insert the bearing outer ring 30310 = 0750 117 588 into the housing bore. To be used in combination with : Handle
5870 058 073
5870 260 002
6/41_6/97 7/33_7/86 8/09_8/58 8/76_8/120 9/35
Magnetic stand # Dial indicator # Universal use . For various measuring procedures Axial clearance, clearance, etc.
5870 200 055 5870 200 057
6/49 7/100 7/101
580 mm Straightedge # Universal use. For various measuring procedures .
5870 200 022
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Repair Manual
Part No.
6/79 6/86
1 12 Nm Torque spanner Universal use . To check the rolling resistance in the main shaft bearing.
5870 203 031
6/89 6/90
Mounting tool # To insert the needle sleeve HK 2520 = 0635 303 053 into the bush 2094 306 014. To insert the shaft seal 25x 35 x 7 = 0634 301 303 into the bush 2094 306 014 .
5870 048 284
7/11
150 mm Digital caliper gauge Universal use. For various measuring procedures.
5870 200 109
7/14 7/33
1 - 10 KN Load cell Universal use. To preload the set of cup springs in the main clutch with a precise pressure.
5870 700 003
7/15
Clamping fixture # To preload the complete disc set of the main clutch. Disc carrier 2094 371 003 to pressure plate 2094 371 001.
5870 654 028
7/37
300 mm Digital depth gauge Universal use. For various measuring procedures > 200 mm .
5870 200 114
7/76
230 V Hot-air blower Hot-air blower 115 V Universal use. To heat up the bush carrier, housing and transmission components.
5870 221 500 5870 221 501
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Repair Manual
Part No.
7/86
0 25 KN Load cell Universal use . To preload the disc set in the FA - clutch with a precise pressure.
5870 700 005
7/100 7/102
1Set = 2 Pcs. Gauge blocks Universal use. To be used in combination with straightedge 5870 200 022 und 5870 200 072 / 5870 200 114 for various measuring procedures.
5870 200 066
8/03 8/54 8/71 8/73
Pressing bush To install the tapered roller bearing 0750 117 656 on the input shaft 2094 359 044 or clutch side B/D Intermediate shaft 2094 359 042 clutch G/F.
5870 506 119
8/08_8/54 8/57_8/73 8/76
0 25 Nm Spring balance # Universal use . To check the rolling moment in the spur gear bearing.
5870 230 004
8/10 8/36 8/78
Assembly drift # To insert the needle bearing HK 4016 = 0735 115 365 into the disc carrier 2094 259 023 .
5870 506 105
8/105
1 Set = 2 Pcs. Adjusting screws Universal use. Easier attachment of the cover 2093 301 044 to the transmission housing.
5870 204 021
8/108
Mounting tool # To insert and position the shaft seal 0750 111 368 = 45 x 76 x 12 in the cover 2094 301 044.
5870 048 176
8/110 8/111
Puller For axial preloading = locating of output shaft 2094 359 064 .
5870 000 017
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Repair Manual
Part No.
8/121
Mounting tool # To insert and position the shaft seal 0750 111 371 = 70 x 95 x 10 in the cover 2094 301 044.
5870 048 175
8/123
Straightedge # Measuring of excess shift travel of the crawler gear shifting. Also see: Magnetic stand 5870 200 055 and dial indicator 5870 200 057 .
5870 200 087
9/26
Feeler gauge # Universal use. To determine the gap size between pump housing and elbow. 8,5 mm Adjusting screws # Adjusting screws # 8,8 mm To position and to align the electro-hydraulic shift components.
5870 200 113
10/57 10/58
5870 204 057 5870 204 058
# Particularly important special tools to repair components (wear parts repair) !
5871 970 002
W/8
5870 200 066
5870 200 022
5870 200 072

150 140 130 120 110 100 90 80 70 60 50 0
29.35
T-7336 SCHALTGETRIEBE GEARBOX HOUSING 2094 009 003
Spezial
5871 970 002 WB/1
2094 101 003.00
SERVICE
Repair Manual
580mm
300mm
5870 048 175
5870 281 047
5870 204 021
5870 200 022
5870 200 114
5870 350 125
5870 350 117
5870 350 000
5870 204 023
ZF Passau GmbH Donaustrae 25-71 94034 Passau
Ausgabe:/Edition: 02/2004
T-7336 PUMPENANTRIEB PUMP DRIVE 2094 009 003
Spezial
5871 970 002 WB/2

150 140 130 120 110 100 90 80 70 60 50 0
2094 122 003.01
SERVICE
Repair Manual
90 80 70 60
10 20 30 40
50
29.35
M10
5870 200 113
5870 200 072
5870 900 013
5870 345 065
5870 204 007
5870 900 015
5870 200 057
5870 200 055
5870 970 002
5870 200 066
5870 200 022
5870 200 072

150 140 130 120 110 100 90 80 70 60 50 0
29.35
T-7336 SPLIT - GRUPPE SPLITTER - BOX 2094 009 003
Spezial
5871 970 002 WB/3
2094 168 002.00
5870 230 004
5870 200 057

90 80 70 60 0 10 20 30 40
5870 200 055
SERVICE
50
5870 506 105
5870 506 119
Repair Manual
5873 011 014
5873 001 000
5873 001 038
5873 000 035
5873 000 000
5870 506 105
5870 900 015
5870 300 005
5870 300 003
5870 506 117
5870 900 007
5873 002 025
5873 002 001
5870 300 028
5873 001 038
5873 001 000
T-7336 SCHALTUNG GEARSHIFT SYS. 2094 009 003
Spezial
5871 970 002 WB/4
2094 159 002.00
5870 506 119
SERVICE
90 80 70 60
10 20 30 40
50
5870 200 057
Repair Manual
5870 200 055
5870 230 004
5873 000 035
5873 000 000
5870 900 015
5870 506 105
5870 300 005
5870 300 003
5870 506 117
5870 900 007

5870 221 500 230 V
5870 900 015
5870 221 501 115 V
T-7336 VA - KRICHGANG-FAHRK. FRONT-WH. DRIVE - CRAWLER 2094 009 003 Spezial
5871 970 002 WB/5
2094 146 003.01
5870 650 001
5870 204 021
SERVICE
90 80 70 60
10 20 30 40
50
5870 200 057
Repair Manual
5870 200 055

150 140 130 120 110 100 90 80 70 60 50 0
29.35
5870 200 072
5870 048 176
5870 200 066
5870 200 022
5870 970 003
5870 281 050
5870 281 047
5870 900 016
5870 506 116
5870 900 015
5873 001 064
5873 001 000
T-7336 HAUPTWELLE MAIN SHAFT 2094 009 003
Spezial
5871 970 002 WB/6

150 140 130 120 110 100 90 80 70 60 50 0
2094 104 002.01
SERVICE
Repair Manual
29.35
5870 200 022
5870 200 072
5870 300 028
5870 300 026
5870 401 049
1 - 12 Nm 5870 203 031
5870 280 004

5870 058 084
5870 260 002
5870 200 072

150 140 130 120 110 100 90 80 70 60 50 0
29.35
T-7336 VORGELEGEWELLE LAY SHAFT 2094 009 003
Spezial
5871 970 002 WB/7
2094 103 003.01
5870 200 057

90 80 70 60 0 10 20 30 40 50
5870 200 055
SERVICE
Repair Manual
5873 002 035
5873 002 001
5870 900 015
5873 001 000
5873 001 048
5870 970 004

T-7336 SCHALTUNG GEARSHIFT - SYSTEM 2094 009 003
Spezial
5871 970 002 WB/8

5870 048 284
2094 106 003.00
SERVICE
Repair Manual
150 140 130 120 110 100 90 80 70 60 50 0
90 80 70 60
10 20 30 40
29.35
50
5870 048 284
5870 200 072
5870 200 057
5870 200 055
T-7336 SCHALTUNG HYDRAULIC CONTROL 2094 009 003
Spezial
5871 970 002 WB/9
2094 152 003.01
SERVICE
Repair Manual
8,5mm
8,8mm
5870 204 057
5870 204 058
5870 204 011
5870 204 049

T-7336 HYDR.- STEUERNG HYDR. GEASHIFT SYSTEM 2094 009 003
Spezial
5871 970 002 WB/10
2094 177 002 00
SERVICE
Repair Manual
5870 204 011
T-7336 ZAPFWELLE/P-ANTRIEB P.T.O. SHAFT 2094 009 003
Spezial
5871 970 002 WB/11

5870 900 015
2094 110 003.00
SERVICE
Repair Manual
ODER / OR
5870 900 013
230 V 5870 221 500
115 V 5870 221 501

T-7336 HAUPTKUPPLUNG MAIN - CLUTCH 2094 009 003
Spezial
5871 970 002 WB/12

5870 900 016
2094 171 001.00
SERVICE
Repair Manual
150 140 130 120 110 100 90 80 70 60 50 0
29.35
150mm 5870 200 109
2x
1-10kN
5870 400 001
5870 506 116
5870 654 028
5870 200 072
5870 700 003
Repair Manual
ZF TRACTOR TRANSAXLE T-7336 DISASSEMBLY

Fasten the rear axle to the assembly truck. (S) Assembly truck (S) Holding fixture (S) Support 5870 350 000 5870 350 117 5870 350 125
Figure 1 1. Separate the Transmission from the Rear Axle
Loosen the unions and remove both oil tubes (Figure 2 and 3).
Figure 2
Figure 3 Loosen and remove all unions.
Figure 4
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Repair Manual
Lock the transmission by means of lifting tackle (S) and loosen the bolted connection. (S) Lifting strap 5870 281 047
Prior to loosen the bolted connection, loosen the screw plug on the bottom side of the transmission and drain the oil!
Figure 5 Install two adjusting screws (S) and separate the transmission from the rear axle. (S) Adjusting screws (M16) 5870 204 023
Figure 6 Fasten the transmission on the assembly truck. (S) Assembly truck (S) Holding fixture 5870 350 000 5870 350 117
Figure 7
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Repair Manual
2. 2.1
Removal of the Electro-Hydraulic Shift Control and Disassembly of the Pump Drive Removal of the Electro-Hydraulic Shift Control
ATTENTION: In case of transmission failures due to defective shift controls we recommend to replace the complete shift control. The pressure control characteristics of the replacement shift control (see the corresponding spare parts list) are adapted to the transmission version and vehicle type respectively. Without permission of ZF no modifications of the pressure control characteristics are allowed to be made. Therefore the shift controls should only be repaired by ZF After-Sales Service Centers. Adequate workshop installations of our Service Stations (shift system or transmission test benches) as well as constantly trained personnel guarantee an expert maintenance and repair. 2.1.1 Removal of the 4-speed Powershift Control Block Loosen the screw plug (bleeder).
! Oil can drain into the sump!

Figure 1 Loosen the cap screws on the pump.
! Step 2 ... 5 is required for removal of the valve housing!
Figure 2 Loosen the hexagon screws on the elbow.
Figure 3
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Pull the complete pump out of the housing.
! Pay attention to possibly released washers and bush!
Figure 4 Loosen the bolt connections and remove the tube.
Figure 5 Loosen two cap screws and replace them by two adjusting screws (see arrows). (S) Adjusting screws (M8) 5870 204 011
Then loosen the remaining cap screws.
Figure 6 Take off the control block.
! Pay attention to possibly released stop plate!
Figure 7
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Loosen the pressure switch (system pressure) and the screw-in sleeve (see arrow).
Figure 8 Remove the gaskets (2x) and the intermediate plate.
Figure 9 2.1.2 Removal of the Forward-Reverse Control Block Loosen two cap screws and replace them by two adjusting screws (see arrows). (S) Adjusting screws (M8) 5870 204 011
Then loosen the remaining cap screws.
Figure 10 Take off the control block.
Figure 11
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Remove the gaskets (2x) and remove the intermediate sheet.
Figure 12 Loosen the cap screws and remove the released duct plate from the transmission housing.
! Pay attention to released compression spring and ball!
Figure 13 Remove the gaskets (2x) and the intermediate sheet.
Figure 14
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2.2
Disassembly of the Pump Drive
Pull the tube together with the elbow out of the housing bore.
Figure 15 Pull both bushes out of the spur gear.
Figure 16 Loosen the screw and separate the filter from the housing.
Figure 17 Loosen the nut and remove the released solenoid (Proportional Valve Main Clutch). Then loosen the valve.
Figure 18
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Loosen the hexagon screws and remove the released housing.
Figure 19 Remove the gaskets (2x) and the intermediate sheet.
Figure 20 Remove the bush and the strainer insert (see arrow) from the housing bore.
Figure 21 Remove the speed transmitter 1 (Main Clutch Output), speed transmitter 2 (Transmission Oil Temperature) and the solenoid valve 3 (Connection Front Wheel Drive).
1 3
Figure 22
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Remove the pressure line (front wheel drive).
Figure 23 Loosen the hexagon screws and remove the released flange.
Figure 24 Loosen the screw plug and remove the released shim, compression spring, valve cone (cold start safety valve) from the housing bore.
Figure 25 Loosen the hexagon screws, install two adjusting screws (S) and separate the housing cover from the transmission housing. (S) Adjusting screws (M10) (S) Pry bar set 5870 204 007 5870 345 065
Figure 26
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Loosen the hexagon screws and separate the bearing bracket together with the spur gear from the housing cover.
Figure 27 Unsnap the retaining ring, remove the shim and press the bearing bracket out of the spur gear. (S) Set of external pliers 5870 900 015
Figure 28 Pull the tapered roller bearing with the two-armed puller from the bearing bracket. (S) Two-armed puller 5870 970 002
Figure 29 Expel the bush with the ball bearing from the spur gear and the housing bore respectively. Then remove the released spur gear and ball bearing.
Figure 30
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3.
Disassembly of Powershift Clutches
Loosen the cap screws and remove both speed transmitters.
Figure 1 Loosen the hexagon screws and remove both covers.
! Pay attention to possibly released shims and O-rings!

Mark the installation position of the two small covers to the large cover!
Figure 2 Loosen the hexagon screws.
Figure 3 Install two adjusting screws (S) and by means of the pry bar set (S) separate the cover from the transmission housing. (S) Adjusting screws (M16) (S) Pry bar set 5870 204 023 5870 345 065
! Pay attention to the released O-rings!

Lock the cover by means of the lifting tackle! Figure 4 If necessary, press off the bearing outer rings and the shaft seals from the cover bores.
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Remove the oil tube (see arrow). A C F G
B D
The figure on the left shows the arrangement of the clutches. (A/C, B/D, F/G)
! Mark the disc carrier of the single clutches accordingly (makes the later installation easier)!
Figure 5 Take the clutches out of the housing.
Figure 6 3.1 Disassembly of Clutch A/C
Pull the input gear out of the disc set and remove the released needle cage. C A If necessary, pull the bearing inner ring (see arrow) from the input gear. (S) Rapid grip (S) Basic device 5873 011 014 5873 001 000
Figure 7 Pull the bearing inner ring from the input shaft and remove the shim located behind it. (S) Gripping insert (S) Basic device 5873 001 038 5873 001 000
Figure 8
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Unsnap the circlip and remove the disc set C.
Figure 9 Unsnap the upper retaining ring. (S) Set of external pliers 5870 900 015
Figure 10 Preload the compression spring through the axial bearing and unsnap the retaining ring. (S) Pressing bush 5870 506 117
Figure 11 Remove the released components and take off the disc set.
Figure 12
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Remove the piston. (S) Clamping pliers
5870 900 007
Figure 13 If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor (S) Countersupport 5870 300 005 5870 300 003
Remove the disc set and the piston of clutch A analogously.
Figure 14 Unsnap the rectangular rings (3x, see arrows) and remove the needle bearing.
Figure 15 Unsnap both retaining rings and remove the released shim. (S) Set of external pliers 5870 900 015
Figure 16
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Press the input shaft out of the spur gear bearing.
Figure 17 By means of the gripping insert (S) press the tapered roller bearing from the input shaft. (S) Gripping insert 5873 001 038
Figure 18 Unsnap the rectangular rings (4x) and press off the tapered roller bearing (see arrow) by means of the gripping insert from the input shaft. (S) Gripping insert 5873 001 038
Figure 19
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3.2
Disassembly of Clutch B/D
Unsnap the rectangular rings (2x, see arrows).
D B Figure 20 Pull the tapered roller bearing from the output shaft. (S) Gripping insert (S) Basic device 5873 000 035 5873 001 000
Figure 21 Unsnap the retaining ring and remove the released shim. (S) Set of external pliers 5870 900 015
! If necessary, loosen the retaining ring by means of slightly blowing!

Figure 22 By means of the two-armed puller (S) pull the tapered roller bearing from the output shaft. (S) Two-armed puller 5870 970 003
Figure 23
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Pull the tapered roller bearing from the output shaft and remove the released shim. (S) Gripping insert (S) Basic device 5873 001 038 5873 001 000
Figure 24 Unsnap the circlip and remove disc set D.
Figure 25 Unsnap the upper retaining ring. (S) Set of external pliers 5870 900 015
Figure 27
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Remove the released components and take off the disc carrier.
Figure 28 Remove the piston. (S) Clamping pliers 5870 900 007
Figure 29 If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor (S) Countersupport 5870 300 005 5870 300 003
Remove the disc set and the piston of clutch B analogously.
Figure 30 Unsnap the rectangular rings (3x, see arrows) and remove the needle bearing.
Figure 31
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Unsnap the circlip and remove the released gear.
Figure 32 Pull the tapered roller bearing from the output shaft. (S) Gripping insert (S) Basic device 5873 002 025 5873 002 001
Figure 33
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3.3
Disassembly of Clutch F/G
Unsnap the rectangular rings (2x, see arrows).
G F
Figure 34 Pull the tapered roller bearing from the intermediate shaft. (S) Gripping insert (S) Basic device 5873 000 035 5873 000 000
Figure 35 Pull the inner disc carrier (Clutch G) out of the disc set.
Figure 36 Unsnap the circlip and remove disc set G.
Figure 37
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Unsnap the upper retaining ring. (S) Set of external pliers
5870 900 015
Figure 39 Remove the released components and take off the disc carrier.
Figure 40 Remove the piston. (S) Clamping pliers 5870 900 007
Figure 41
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If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor (S) Countersupport 5870 300 005 5870 300 003
Remove the disc set and the piston of clutch F analogously.
Figure 42 Unsnap the rectangular rings (3x, see arrows) and remove the needle bearings.
Figure 43 Unsnap both retaining rings and remove the released shim. (S) Set of external pliers 5870 900 015
Figure 44 By means of the parting fixture (S) press off the spur gear and the tapered roller bearing from the intermediate shaft. (S) Parting fixture 5870 300 028
Figure 45
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By means of the gripping insert (S) and the parting fixture (S) press off the tapered roller bearing from the intermediate shaft. (S) Gripping insert (S) Parting fixture 5873 001 038 5870 300 028
Figure 46 Pull off the tapered roller bearing. (S) Gripping insert (S) Basic device 5873 001 038 5873 001 000
Figure 47
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4.
Disassembly of the Front Wheel Drive, Crawler Gear Shifting and Main Clutch Disassembly of the Front Wheel Drive
4.1
Pull the tapered roller bearing from the output shaft. (S) Two-armed puller 5870 970 003
Figure 1 Pull the cyl. pins (2x) by means of the striker out of the cover bores. (S) Striker 5870 650 001
Figure 2 Loosen two hexagon screws and replace them by two adjusting screws (S). Then loosen the remaining hexagon screws.
Figure 3 Attach the lifting tackle (2x, see arrows) to the output shaft. Then lift the cover together with the front wheel drive out of the transmission housing. (S) Lifting tackle 5870 281 050
to the ! Pay attention ring ofreleased clutch body and the synchronizer the crawler gear shifting!
Figure 4
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Pull the complete front wheel drive out of the cover.
Figure 5 Bend up the sheet metal straps (3x) and remove the screen sheet. The unsnap the rectangular rings (see arrows)
Figure 7 Pull the clutch from the shaft and out of the clutch bell housing respectively.
Figure 8
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Preload the laminated spring by means of the press. Then unsnap the retaining ring and remove the released shim and the laminated spring. (S) Pressing bush 5870 506 116
Figure 9 Unsnap the retaining ring and remove the released disc set and shims. (S) Set of external pliers 5870 900 015
Figure 10 Press the piston evenly (over the pressure bolts) out of the gear.
Figure 11 Unsnap the rectangular rings (see arrows).
Figure 12
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Unsnap the retaining ring and remove the released clutch bell housing. (S) Set of external pliers 5870 900 016
Figure 13 Pull the slotted pin out of the cover bore.
Figure 14 Pull out the bolts and remove the released components.
Figure 15 If necessary, loosen the hexagon screws, remove the released shim and by means of lever action press the bearing outer rings out of the cover bore.
Figure 16
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4.2
Disassembly of the Crawler Gear Shifting
Remove the tube and the needle bearing.
Figure 17 Remove the axial bearing and the shim.
Figure 18 Remove the clutch body and the synchronizer ring.
Figure 19 Mark a point on the gear shift fork. Then measure the control dimension from the face of the gear shift rail to the marked point on the gear shift fork and write it down. Control dimension e.g. . . . . . . . . . . . . . . . . . . . . 46.20 mm (S) Digital depth gauge 5870 200 072
Figure 20
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Loosen the threaded pins (2x) on the gear shift fork (crawler gear).
Figure 21 Loosen the screw plug (1) and lift the compression spring (2) as well as the ball (3) out of the housing bore. 1
Figure 22 Pull the gear shift rail out of the housing bore and remove the released gear shift fork.
Figure 23 Pull the clutch bell housing from the shaft.
! Pay attention to the released needle cage!
Figure 24
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Unsnap the circlip and remove the complete sychronizer body. Remove the released synchronizer components. Separate the gear and the needle cage from the clutch bell housing.
Figure 25 4.3 Disassembly of the Main Clutch
Pull the clutch pack out of the layshaft.
Figure 26 Preload the disc carrier by means of the press and unsnap the retaining ring. (S) Pressing bush (S) Set of external pliers 5870 506 116 5870 900 016
Figure 27 Separate the complete clutch from the clutch shaft.
Figure 28
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Press off the disc carrier. (S) Resetting device
5870 400 001
! Disassembly is difficult due to expanded O-rings!

Figure 29 Remove the shim, end shim and the disc set.
Figure 30 Remove the compression springs and the O-ring (see arrow) from the piston.
Figure 31 Unsnap the circlip and remove the pressure plate.
Figure 32
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If necessary, expel the internally located screen sheet through the oil bores and remove the released O-ring (see below figure) from the annular groove.
Figure 33
Figure 34
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5.
Disassembly of the Main Transmission (6-speed Synchro.Transmission) Disassembly of the Mechanical Shift Control
5.1
Remove the stops (3x, see arrows), consisting of ball, spring and screw plug.
Figure 1 Loosen both threaded pins on the gear shift fork (1st/2nd gear).
Figure 2 Loosen both threaded pins and remove the released driver.
Figure 3 Pull the gear shift shaft (1st/2nd gear) out of the housing bore. gear shift (1st/2nd gear) can ! Themain shaft forkbeen pressed out! only be removed when the has
Figure 4
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Loosen both threaded pins on the gear shift fork (3rd/4th gear).
Figure 5 Loosen both threaded pins and remove the released driver.
Figure 6 Pull the gear shift shaft (3rd/4th gear) out of the housing bore and remove the released gear shift fork. Demount the gear shift shaft (5th/6th gear) analogously and remove the gear shift fork.
Figure 7 Remove the locking pins (2x) out of the housing bore.
Figure 8
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Remove the gear shift shaft (crawler gear) Pull the sealing cap out of the housing bore, unsnap the circlip and remove the released shim.
Figure 9 Loosen both threaded pins on the gear shift finger.
Figure 10 Pull the gear shift shaft out of the housing and remove the released gear shift finger.
Figure 11 Remove the gear shift shaft (6-speed synchron.transmission) Loosen the threaded pin.
Figure 12
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Loosen both threaded pins on the gear shift finger.
Figure 13 Pull the gear shift shaft out of the housing and remove the released gear shift finger and the bush.
Figure 14
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5.2
Disassembly of the Main Shaft
Unlock the slotted nut, lock the gearing and loosen the slotted nut. (S) Slotted nut wrench 5870 401 049
Figure 15 Take off the shim and the gear.
Figure 16 Press the main shaft by means of the fixture out of the transmission housing and take the released components (see below figure) out of the housing. (S) Extractor 5870 300 026
Figure 17 To the figure: 2 1 = Thrust washer 2 = Gear shift fork (1st/2nd gear) 3 = Gears with synchronizer (1st/2nd gear) 4 = Gears (3rd/4th gear) 5 = Gears (5th/6th gear) 6 = Shim 7 = Tapered roller bearing
4 1 Figure 18 3
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Press the tapered roller bearing by means of the parting fixture (S) from the main shaft. (S) Parting fixture 5870 300 028
Figure 19
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5.3
Disassembly of the Layshaft
Loosen the cap screw and pull the speed transmitter out of the housing bore.
Figure 20 Loosen the bolt connection and the union screw (see arrow) and remove the released tube.
Figure 21 Loosen the hexagon screws and the countersunk screw. Then pull the released cover out of the housing bore and remove the shim located behind it.
Figure 22 Press the layshaft in direction of arrow into the housing.
! Pay attention to the released bearing outer ring and layshaft!

Then lift the layshaft out of the housing.
Figure 23
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Unsnap the rectangular ring (see arrow).
Figure 25 Fasten the layshaft in the vice and pull off the tapered roller bearing. (S) Gripping insert (S) Basic device 5873 002 035 5873 002 001
Figure 26 Remove the spur gear (4th gear).
Figure 27
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Remove the clutch body and the synchronizer ring (4th gear).
Figure 28 Unsnap the retaining ring. (S) Set of external pliers 5870 900 015
Figure 29 Remove the synchronizer body (3rd/4th gear).
Figure 30 Remove the synchronizer ring and clutch body (3rd gear).
Figure 31
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Unsnap the retaining ring. (S) Set of external pliers
5870 900 015
Figure 32 Remove the gear (3rd gear).
Figure 33 Unsnap the retaining ring.
Figure 34 Pull off the gear (6th gear) together with the bush and remove the released needle cage. (S) Two-armed puller 5870 970 004
Figure 35
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Remove the synchronizer ring and the synchronizer body together with the sliding sleeve.
Figure 36 Unsnap the retaining ring.
Figure 37 Remove the synchronizer ring and the gear (5th gear).
Figure 38
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5.4
Disassembly of the Pump Gear Drive
Unsnap the internally located retaining ring. (S) Set of external pliers 5870 900 015
Figure 39 Press the spur gear out of the bearing inner ring and remove it.
Figure 40 Unsnap the retaining ring and pull the ball bearing out of the housing bore. (S) Set of internal pliers 5870 900 013
Figure 41
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REASSEMBLY
6. Reassembly Main Transmission (6-speed Synchro.Transmission) Preassembly of the Transmission Housing
6.1
Undercool the bush and insert it into the heated housing bore until contact is obtained.
Figure 1
Wet the outer diameter of the bush with Loctite (Type No.: 574)! Install two adjusting screws (S). Then assemble the gasket and the cover. (S) Adjusting screws 5870 204 011
Figure 2 Fasten the cover by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm
Figure 3 Insert the ball (see arrow) into the housing bore. Then provide the screw plug with a new sealing ring and install it. Tightening torque (M26). . . . . . . . . . . . . . MA = 80 Nm
Figure 4
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Insert the ball (see arrow) into the housing bore. Then provide the screw plug with a new sealing ring and install it. Tightening torque (M16). . . . . . . . . . . . . . MA = 35 Nm
Figure 5 Provide the screw plug with a new O-Ring and install it. Tightening torque (M10). . . . . . . . . . . . . . . MA = 20 Nm
Figure 6 Provide the screw plugs (2x) with a new O-Ring and install it. Tightening torque (M10). . . . . . . . . . . . . . MA = 25 Nm
Figure 7
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6.2
Reassembly of the Pump Gear Drive
Insert the ball bearing into the housing bore.
Figure 8 Fasten the ball bearing by means of the retaining ring. (S) Set of internal pliers 5870 900 013
Figure 9 Heat up the bearing inner ring and install the spur gear until contact. (S) Hot-air blower 230V (S) Hot-air blower 115V 5870 221 500 5870 221 501
Figure 10 Fasten the spur gear by means of the retaining ring. (S) Set of internal pliers 5870 900 013
Figure 11
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6.3
Reassembly of the Layshaft
Assemble the gear (5th gear) and the synchronizer ring.
! Prior to the assembly oil all single components!

Figure 12 Fasten the gear by means of the retaining ring. (S) Set of external pliers 5870 900 015
Figure 13 Insert the compression springs, the ball bolts and the pressure pieces into the bores of the synchronizer body.
Figure 14 Preload the pressure pieces and assemble the sliding sleeve.
Pay attention to contact of the recesses in the synchronizer body with the webs of the sliding sleeve!
Figure 15
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Install the preassembled synchronizer body until contact.
! Observe the installation position, see figure!
Figure 16 Adjust the axial clearance of the splined bush max. 0.10 mm Snap the retaining ring into the recess of the layshaft and install it in direction of arrow until contact is obtained. X Determine Dim. X e.g. . . . . . . . . . . . . . . 33.35 mm Example A: Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . 33.35 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.05 mm Difference = Bush height = 33.30 mm Then unsnap the retaining ring again. Assemble the synchronizer ring.
X 0 ... 0,10 Figure 17
Figure 18 Assemble the gear (6th gear) and install the needle cage.
Figure 19
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Heat up the splined bush e.g. 33.30 mm (see example A/Page 6/5) and install it until contact.
Pay attention to contact of the oil bores in the splined bush and the layshaft!
Figure 20 Fasten the gear and the splined bush respectively by means of the retaining ring. (S) Set of external pliers 5870 900 015
Figure 21 Assemble the gear (3rd gear) and fasten it by means of the retaining ring. (S) Set of external pliers 5870 900 015
Figure 22 Assemble the clutch body.
Figure 23
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Insert the compression springs, the ball bolts and the pressure pieces into the bores of the synchronizer body.
Figure 24 Preload the pressure pieces and assemble the sliding sleeve.
Pay attention to contact of the recesses in the synchronizer body with the webs of the sliding sleeve!
Figure 25 Assemble the synchronizer ring. to be installed on that side ! The synchronizer ring hasshows to the gear (3rd gear)!of the synchronizer body which Pay attention of the shoulder at the inner diameter of the synchronizer body (see arrow)!
Figure 26 Install the preassembled synchronizer body until contact is obtained.
Figure 27
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Fasten the synchronizer body by means of the retaining ring. (S) Set of external pliers 5870 900 015
Figure 28 Install the synchronizer ring and the clutch body.
Figure 29 Assemble the spur gear (4th gear).
Figure 30 Heat up the tapered roller bearing and install it until contact.
! After cooling down install the bearing subsequently!
Figure 31
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Heat up the output-sided tapered roller bearing and install it until contact.
Figure 32 Snap the rectangular ring (see arrow) into the annular groove and lock it.
Figure 33 Insert the bearing outer ring (see arrow) into the housing bore until contact. (S) Mounting tool (S) Handle 5870 058 073 5870 260 002
Figure 34 Insert the preassembled layshaft into the housing and position it accordingly.
Figure 35
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Install the bearing outer ring.
Figure 36 Adjust the axial clearance of the layshaft 0.05 0.12 mm (Figure 37 41) Rotate the housing by 90 and locate the bearing outer ring exactly until contact. Measure Dim. I, from the mounting face of the housing to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25 mm
Figure 37 Measure Dim. II, from the face to the mounting face on the cover. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 17.20 mm (S) Digital depth gauge 5870 200 072
Figure 38 Example B: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . 19.25 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . - 17.20 mm Difference . . . . . . . . . . . . . . . . . . . . . . . .= 2.05 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.05 mm Results in shim e.g. . . . . . . . . . . . . . . . .= 2.00 mm
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Install the shim (e.g. Thickness = 2.00 mm) and the cover.
Figure 39 Fasten the cover by means of hexagon screws and countersunk screw. Tightening torque (hexagon screw M10/8.8). . . MA = 46 Nm Tightening torque (counters.screw M10/8.8). . . MA = 34 Nm
Figure 40 Check the axial clearance = 0.05 0.12 mm by means of dial indicator (S) and pry bar set (S). (S) Dial indicator (S) Magnetic stand (S) Pry bar set 5870 200 057 5870 200 055 5870 345 065
it ! If required39)!is still to be corrected with a corresponding shim (Fig.
Figure 41 Turn the sleeve (see arrow) into the housing so that the oil supply hole (see below sketch) is uncovered. Then lock the sleeve by means of hexagon nut. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 90 Nm
Figure 42
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To the sketch:
1 = Housing 2 = Sleeve 3 = Nut
3
Figure 43 Insert the oil tube into the housing and fasten it by means of the union nut (see arrow) and union screw. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 60 Nm
! Provide the union screw with new sealing rings!!

Figure 44 Insert the speed transmitter into the housing bore and fasten it by means of the cap screw. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 9.5 Nm
! Provideit!the speed transmitter with a new O-Ring and grease

Figure 45
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6.4
Reassembly of the Main Shaft
Insert the bearing outer ring (see arrow) into the housing bore until contact is obtained.
Figure 46 Rotate the housing by 90 and insert the bearing outer ring (see arrow) into the housing bore until contact is obtained.
Figure 47 Pinion shaft adjustment (Fig. 48 Example C) Below indicated measuring procedures are to be carried out with utmost accuracy! Inexact measurements result in a defective contact pattern! Formula: S = 5.14 A (+/- X) Formula / Pinion dimension tolerance e.g. + 0.05 mm: S = 5.14A 0.05 Formula / Pinion dimension tolerance e.g. 0.05 mm: S = 5.14 A + 0.05 S = Shim thickness 5.14 = Design factor A = Housing dimension X = Pinion dim. tolerance (deviation from the theoretical installation dimension = 185.1 mm) the theoretical ! Dim. X, is indicated in =connection withthe pinion head, installation dimension 185.1 mm on see Figure 50!
Insert the tapered roller bearing and roll in the bearing outer ring.
Figure 48
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Measure Dim. A, from the face of the bearing inner ring to the mounting face of the housing. Dim. A e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm (S) Straightedge (S) Digital depth gauge 5870 200 022 5870 200 072
Figure 49 Read Dim. X (pinion dimension tolerance). Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . + 0.05 mm
185.1 + 0.05
Example C: S = 5.14 A (+/- X) S = 5.14 2.00 0.05 S = 3.09 from experience that the required contact ! It is knownobtained when a 0.1 mm thicker shim is installed! pattern is
Figure 50
Shims are available in graduations of 0.05 mm. Choose the next shim e.g. Thickness = 3.20 mm. Install the shim e.g. Thickness = 3.20 mm (see example C).
! Install the shim with the chamfer showing downwards!
Figure 51 Heat up the tapered roller bearing and install it until contact is obtained.
Figure 52
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Preassemble double synchronizer 1st/2nd gear (Figure 53 66) Prior to installation oil the components!
Place the clutch disc against the gear (1st gear) until contact is obtained. of the ! Tip slidingselector teeth (see arrow) must show upwards (to the sleeve)! Figure 53 Install the inner ring and the intermediate ring.
! Pay attention to contact of the intermediate ring and the clutch disc!
Figure 54 Install the outer ring.
! Observe the radial installation position, see below figure!
Figure 55
Figure 56
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Place the clutch parts (3x, see arrow) and insert the needle cage (2x) into the gear.
! Observe the installation position of the clutch parts, see figure!
Figure 57 Insert the synchronizer body into the gear until contact is obtained.
Figure 58 The figure on the left shows the synchronizer body and the sliding sleeve as well as the compression springs with the pressure pieces. 1 2
! The recesses of the synchronizer body (Arrow 1) have to be

aligned with the stop slots in the sliding sleeve (Arrow 2) and with the pressure pieces respectively! 2
2 Figure 59
Assemble the sliding sleeve according to Figure 59 and install the compression springs as well as the pressure pieces. Then bring the sliding sleeve into the center position (neutral).
Figure 60
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Repair Manual
Assemble the outer ring.
! Observe the radial installation position, see figure!
Figure 61 Install the intermediate ring.
Figure 62 Assemble the inner ring.
! Observe the radial installation position, see figure!
Figure 63 Assemble the clutch disc. Tip of ! sleeve)!the selector teeth must show downwards (to the sliding Observe the radial installation position, see figure!
Figure 64
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Repair Manual
Install the needle bearing (2x).
Figure 65 Assemble the gear (2nd gear) into the internal gearing of the clutch disc.
Position of the single parts must be absolutely ensured for further assembly. In case of careless handling there is the danger that the pressure pieces might unsnap!
Figure 66 Install the main shaft (Figure 67 87) The figure on the left shows the main shaft components.
Figure 67 Fasten the thrust washer (see arrow) by means of grease onto the gear (1st gear). the installation ! Observe projecting collarposition, install the thrust washer with the showing upwards!
Figure 68
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Insert the shift group (1st/2nd gear) cautiously into the housing and position it (see below figure).
! Observe the installation position, insert the shift group with the larger gear (1st gear) showing upwards!
Figure 69
Figure 70 Insert the sliding pads with grease into the bores and position the shift fork (1st/2nd gear).
! After assembly of the shift fork the main shaft cannot be installed any more!
Figure 71 Place the shim (Thickness = 7.8 mm, empirical value) onto the bearing outer ring.
! Observe the installation position, install the shim with the projecting collar showing downwards (to the bearing)!
Figure 72
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Repair Manual
Insert two assembly bars (height approx. 4-5 mm) (see arrows) and position the gears (2x, 3rd/4th gear).
Figure 73 Position the gears (2x, 5th/6th gear) lifting carefully the shift group (1st/2nd gear) upwards.
Figure 74 Align the components centrically and assemble the undercooled main shaft until contact is obtained.
Figure 75 Hold the main shaft in place and assemble the heated bearing inner ring until contact is obtained. Then remove the assembly bars (see Figure 73) again.
Figure 76
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Repair Manual
Assemble the gear (front-wheel drive). installation position, ! Observe theshows to the outside! inset plane face (contact face/shim)
Figure 77 Adjust the rolling moment of the main shaft bearing = 4 5 Nm and the axial clearance of the components = 0.05 0.20 mm (Figure 78 80)
Prior to adjusting bring the sliding sleeves of the synchronizers 1st/2nd gear, 3rd/4th gear and 5th/6th gear into the exact center position (neutral)!
Tighten the slotted nut (Figure 78), until the required rolling moment (Figure 79) is obtained. Figure 78 (S) Slotted nut wrench (S) Torque spanner 5870 401 049 5870 203 031
Then check the axial clearance of the components by means of the feeler gauge (Figure 80). gap between the ! The axial clearance corresponds with thepressing the gears by gear 3rd gear and the gear 4th gear, means of the pry bar set to the direction of arrow until contact is obtained.
Possible failure sources and remedy respectively: Figure 79 1. Rolling moment is not obtained, parallel to it there is no axial clearance of the components install a thinner shim (Figure 72). Rolling moment ok, but axial clearance too high install a thicker shim (Figure 72).
2.
Only when the rolling moment and the axial clearance are within the admissible tolerance range, the shim is determined exactly!
Figure 80
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Loosen the slotted nut again.
Figure 81 Determine the shim (Figure 82 and 83) Measure Dim. X, from the plane face of the gear to the face of the main shaft. Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 mm (S) Digital depth gauge 5870 200 072
! Dim. X = Shim thickness

Figure 82 Assemble the determined shim e.g. Thickness = 3.00 mm.
Figure 83 Attach the slotted nut by hand and relieve the main shaft bearing by means of slight blows.
Figure 84
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Tighten the slotted nut.
Tightening torque . . . . . . . . . . . . . . . . . . MA = 500 Nm (S) Slotted nut wrench 5870 401 049
Figure 85 Check the rolling moment of the main shaft bearing 4 5 Nm once again and correct it by the installation of an adequate shim (Figure 83). Rolling moment too high Rolling moment too low (S) Torque spanner - install a thicker shim. - install a lower shim. 5870 203 031
Figure 86 Lock the slotted nut by means of peening (2x).
Figure 87
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Repair Manual
6.5
Reassembly of the Shift System (Mechanical Part)
Install the gear shift shaft (6-speed synchron.transmission) 1 2 3 4 2 Figure 88 Preassemble the bush as shown in the figure on the left. 1 1 = Bush 2 = O-Ring 3 = Needle sleeve 4 = Shaft seal 5 = Scraper 6 = Protection ring 2 Press in the needle sleeve to be flush at the shoulder ( 35 to 32 mm). Wet the outer diameter of the shaft seal with spirit and insert it until contact is obtained. Insert the scraper until contact at the shaft seal is obtained. Insert the supporting ring with the offset side showing to the scraper until contact is obtained. (S) Mounting tool 5870 048 284 3 Preassemble the gear shift shaft as shown in the figure on the left. 1 = Gear shift shaft 2 = Circlip 3 = Washer 4 = Compression spring
4 5 6 Figure 89
Flush-mount the needle bearing (see arrow) into the housing bore. (S) Mounting tool 5870 048 284
Figure 90
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Insert the gear shift shaft assembling the gear shift finger and fasten it by means of threaded pins preliminarily.
! Align the tapped holes with the recesses of the gear shift shaft!
Figure 91 Insert the preassembled bush into the housing bore and fasten it by means of the threaded pin. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 25 Nm Wet the threaded pin with Loctite (Type No.: 270)!
Figure 92 Install the gear shift shaft 5th/6th gear Insert the sliding pads into the bore with grease and position the gear shift fork (5th/6th gear).
Figure 93 Assemble the gear shift shaft taking up the gear shift fork (5th/6th gear) and fasten it by means of threaded pins preliminarily.
Figure 94
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Install the driver.
Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 34 Nm
Figure 95 Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 35 Nm
! Provide the screw plug with a new O-Ring!

Figure 96 Adjust the excess shift travel Shift the 5th and 6th gear alternately and measure the excess shift travel (axial clearance) on the face of the gear shift shaft by means of the dial indicator. The excess shift travel must be the same in shift position 5th or 6th gear! The excess shift travel is changed by loosening and tightening alternately both threaded pins on the gear shift fork. Tightening torque (Threaded pins) . . . . . . . MA = 34 Nm Figure 97 (S) Magnetic stand (S) Dial indicator 5870 200 055 5870 200 057
Install the gear shift shaft 3rd/4th gear Insert the sliding pads with grease into the bores and position the gear shift fork (3rd/4th gear).
Figure 98
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Snap the circlip into the recess of the locking pin. The insert the preassembled locking pin into the cross hole of the gear shift shaft.
Figure 99 Insert the locking pin (length 25.9 mm) through the lateral housing bore into the cross hole, for the position see the line or arrow.
Figure 100 Assemble the gear shift shaft taking up the gear shift fork (3rd/4th gear) and fasten it preliminarily by means of threaded pins.
Figure 101 Install the driver. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 34 Nm
Figure 102
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Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 35 Nm

Adjust the excess shift travel analogously to Figure 97, Page 6/26. Figure 103 By loosening and tightening alternately both threaded pins bring the gear shift finger into center position to the driver (3rd/4th gear). Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 34 Nm
Figure 104 Install the gear shift shaft 1st/2nd gear Insert the locking pin (length 24.4 mm) through the lateral housing bore into the cross hole, for the position see the line or arrow.
Figure 105 Assemble the gear shift shaft taking up the gear shift fork (1st/2nd gear) and fasten it preliminarily by means of threaded pins.
Figure 106
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Install the driver.
Figure 107 Install the stop consisting of ball, spring and screw plug.

Adjust the excess shift travel analogously to Figure 97, Page 6/26. Figure 108 Install the gear shift shaft (crawler gear) Grease the O-Ring (1) and insert it into the annular groove of the gear shift shaft. 1 2 Then install the circlip (2).
Figure 109 Insert the gear shift shaft into the housing until contact is obtained, assemble the gear shift finger at the same time and fasten it by means of threaded pins. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 34 Nm
Figure 110
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Assemble the washer and fasten it by means of the circlip.
Figure 111 Flush-mount both sealing caps (see arrows) into the housing.
Wet the contact faces with Loctite (Type No.: 649)!
Figure 112
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Repair Manual
7.
Reassembly of the Main Clutch, Crawler Gear Shifting and Front Wheel Drive Reassembly of the Main Clutch
7.1
Install the sealing caps into the oil supply holes (33x).
Figure 1 Oil the O-Ring (see arrow) and insert it into the annular groove of the disc carrier.
Figure 2 Insert the screen sheet into the disc carrier and place it firmly by means of the press (Figure 4).
Figure 3
Figure 4
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Repair Manual
Adjust clearance 6.7 -0.4 mm of the disc set (Figure 5 Example B) Determine Dim. X (Figure 5 ... 11) Assemble the piston on the clutch shaft until contact is obtained.
! Install the components without sealing elements first!

Figure 5 Assemble the pressure plate.
Figure 6 Place the compression springs (3x) each offset by 120 to each other on the pressure plate.
Figure 7 Assemble the end shim on the disc carrier until contact is obtained.
Figure 8
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Hold the end shim in place and assemble the disc carrier on the clutch shaft.
Figure 9 Preload the compression springs by means of the press and snap the retaining ring into the annular groove of the clutch shaft. (S) Pressing bush 5870 506 116
! Assemble the disc carrier into the teeth of the pressure plate!
Figure 10 Measure Dim. X. Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . 55.75 mm (S) Digital caliper gauge 5870 200 109
Pay attention to correct contact of the installed parts!
Then remove the components again. Figure 11 Measure Dim. Y (thickness of the whole disc set) (Figure 12 ... 14) Measure Dim. A, overall dimension of all inner clutch discs. Thickness of the single inner clutch disc e.g. . . . 2.85 mm
Thickness of all inner clutch discs (Dim. A) e.g. . 22.80 mm
Inner clutch discs are undulated and therefore not measurable in the set! Figure 12
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Repair Manual
Measure Dim. B, overall dimension of the lined clutch discs. Thickness of the single lined clutch disc e.g. . . . . 2.55 mm
Thickness of all lined cl. discs (Dim. B) e.g. . . . . 22.95 mm
Prior to the measuring procedure or the assembly soak the lined clutch discs in oil use oil according to the ZF List of Lubricants TE-ML 06!
Figure 13 EXAMPLE A: Dim. A e.g. . . . . . . . . . . . . . . . . . . . . . . . . 22.80 mm Dim. B e.g. . . . . . . . . . . . . . . . . . . . . . . . .+ 22.95 mm Results in Dim. Y e.g. . . . . . . . . . . . . . 45.75 mm
to the single ! Alternatively of the disc setmeasurement of the clutch discs the thickness can be determined by means of the press and the load cell! Load the disc set (without spring washers) with an axial force of F = 9500 +300 N and measure Dim. Y (thickness of the whole - 5500 disc set). Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . . . 45.75 mm (S) Digital depth gauge (S) Load cell 5870 200 072 5870 700 003
Figure 14
EXAMPLE B: Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . Difference . . . . . . . . . . . . . . . . . . . . . . . . . Clearance 6.7 -0.4 . . . . . . . . . . . . . . . . . . . . Result = Shim e.g. 55.75 mm 45.75 mm 10.00 mm - 6.50 mm 3.50 mm
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Repair Manual
Insert the disc carrier into the clamping fixture (Part 1). (S) Clamping fixture 5870 654 028
Figure 15 Assemble the determined shim e.g. 3.50 mm (optionally, also see Example B, Page 7/4).
Figure 16 Assemble the end shim.
Figure 17 Put on the spring washer. the single of ! Put 21) ontopartsdisc the disc set alternately (Figure 18 the carrier!
For disc arrangement also see the corresponding spare parts list!
Figure 18
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Put the lined clutch disc over the spring washer. the lined clutch discs in ! Prior to the assembly soak Lubricants TE-ML 06! oil use oil according to ZF List of
Figure 19 Assemble the inner clutch disc (undulated steel clutch disc).
For assembly of the undulated inner clutch discs the installation specification shown in the below figure is to be observed!
Figure 20 The inner clutch discs (undulated steel clutch discs) have to be installed peak-to-peak, which means tooth space on tooth space (see Arrow 1), however half tooth alternately left hand and right hand (see Arrow 2)! 1
2 2 1 Figure 21 Put on the pressure plate.
Figure 22
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Repair Manual
Put on the clamping fixture (Part 2) and align the discs. Then preload the disc set evenly by tightening the butterfly nuts until the teeth of the pressure plate are located on the teeth of the disc carrier.
Figure 23 Oil the lip sealing ring (see Arrow 1) and the O-Ring (see Arrow 2) and insert them into the annular grooves of the piston.
Observe the installation position, the lip sealing ring must be installed with the slot showing to the pressure chamber (upwards)!
2 Figure 24 Insert the compression springs (2 pcs. each/hole) into the blind holes of the piston.
Figure 25 Put the clutch pack onto the piston.
Figure 26
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Repair Manual
Adjust the piston radially until the teeth of the piston are aligned with the teeth of the pressure plate. Then preload the piston and the compression springs by means of the press and fasten it with the circlip.
Figure 27 Seal the bores (2x) by means of threaded pins. Tightening torque (M8/8.8) . . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No.: 270)!
Figure 28 Oil the lip sealing ring (see arrow) and insert it into the annular groove of the clutch shaft.
Observe the installation position, the lip sealing ring must be installed with the slot showing to the pressure chamber (upwards)!
Figure 29 Put the preassembled clutch pack onto the clutch shaft.
Figure 30
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Repair Manual
Snap the retaining ring into the annular groove of the clutch shaft.
Figure 31 Preload the clutch pack by means of the press and remove the clamping fixture (S). (S) Pressing bush (S) Clamping fixture 5870 506 116 5870 654 028
Figure 32 Check clearance of the disc set 6.7 -0.4 mm Support the preassembled clutch on the piston and pressurize the clutch shaft with an axial force F = 9500 300 N. (S) Load cell (S) Magnetic stand (S) Dial indicator 5870 700 003 5870 200 055 5870 200 057
Figure 33
If the required clearance of 6.7 -0.4 mm should not be reached, there has been a measuring error at determination of the shim (Figure 16, Page 7/5), which is mandatory to be corrected! Snap in both rectangular rings (see arrows) and lock them.
! Grease and align the rectangular rings centrically!
Figure 34
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Adjust the crawler gear synchronizer (Figure 35) Assemble the crawler gear pinion until contact on the output shaft (clutch B/D) is obtained. Place the axial bearing and the shim (e.g. Thickness = 6.80 mm, empirical value) over the face of the output shaft (clutch B/D). Then measure the adjusting dimension 15 -0.1 mm, from the shim to the shoulder on the gearing. (S) Digital depth gauge Figure 35 5870 200 072
! If the required aadjusting dimension differs, it is to be corrected with corresponding shim!

This procedure is necessary to determine Dimension C in the following measuring procedure (axial clearance clutch shaft)!
Adjust the axial clearance of the clutch shaft 0.3 +0.15 mm (Figure 36 ... 39)
"A" "C" 0,30 +0,15 mm
"B"
Figure 36
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Repair Manual
Measure Dim. A, from the mounting face of the cover to the face of the layshaft. Dim. A e.g. . . . . . . . . . . . . . . . . . . . . . . . . 239.40 mm (S) Straightedge (S) Digital depth gauge 5870 200 022 5870 200 114
Locate the layshaft into bearing Y (see Sketch 36, Page 7/10) until contact is obtained! Figure 37 Measure Dim. B, on the clutch shaft.
"B"
Dim. B e.g. . . . . . . . . . . . . . . . . . . . . . . . . 206.40 mm
Figure 38 Measure Dim. C, from the face of the shim (Figure 35) to the mounting face of the cover.
"C"
Dim. C e.g. . . . . . . . . . . . . . . . . . . . . . . . . 31.00 mm

X
Locate the output shaft (clutch B/D) into bearing X (also see Sketch 36) until contact is obtained, with bearing play = 0!
Figure 39 Example C: Dim. A e.g. . . . . . . . . . . . . . . . . 239.40 mm Dim. B e.g. . . . . . . . . . . . . . . . . - 206.40 mm Dim. C e.g. . . . . . . . . . . . . . . . . - 31.00 mm Play e.g. . . . . . . . . . . . . . . . . . . . . .- 0.30 mm Difference = Shim s = 1.70 mm
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Repair Manual
Assemble the determined shim e.g. Thickness = 1.70 mm.
Figure 40 Assemble the needle bearing.
Figure 41 Insert the needle cage into the clutch bell housing.
Figure 42 Assemble the clutch bell housing until contact is obtained.
Figure 43
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Repair Manual
Insert the compression spring into the layshaft.
Figure 44 Install the preassembled main clutch into the gearing of the layshaft.
Figure 45 7.2 Assembly of the Crawler Gear Shifting
Assemble the needle cage on the clutch bell housing.
Figure 46 Assemble the gear until contact is obtained.
Figure 47
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Repair Manual
Assemble the clutch body.
! Prior to installation oil the components!
Figure 48 Insert the compression spring, the ball bolts and the pressure piece (3x each) into the synchronizer body.
Figure 49 Preload the pressure pieces and assemble the sliding sleeve. the recesses ! Pay attention to alignsliding sleeve!in the synchronizer body with the webs of the
Figure 50 Install the synchronizer ring on the main clutch side.
Figure 51
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Repair Manual
Install the preassembled synchronizer body.
Figure 52 Fasten the synchronizer body by means of the circlip.
Figure 53 Insert the locking pin between gear shift shaft-5th/6th gear and gear shift shaft crawler gear.
Figure 54 Provide the screw plug with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 20 Nm
Figure 55
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Repair Manual
Insert the sliding pads with grease into the bores and position the gear shift fork (crawler gear shifting).
Figure 56 Insert the gear shift shaft taking up the gear shift fork at the same time. Then fasten the gear shift fork by means of the threaded pins preliminarily.
Figure 57 Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 35 Nm
! Provide the screw plug with a new O-ring!

Figure 58 Adjust the gear shift fork to the dimension put down in writing (see Page 4/5, Figure 20). The dimension is changed by loosening and tightening both threaded pins on the gear shift fork. Tightening torque (threaded pins) . . . . . . . . MA = 34 Nm Later checking of the excess shift travel however is absolutely necessary (see Page 8/33)!
Figure 59
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Repair Manual
Fasten the synchronizer ring by means of grease onto the clutch body.
Figure 60 Fasten the preassembled clutch body by means of grease into the synchronizer body.
Figure 61 7.3 Assembly of the Front Wheel Drive
Flush-mount the balls (8x, see arrows) into the bores of the cover.
Figure 62 Install the threaded pins (3x, see arrows). Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 20 Nm Wet the threads with Loctite (Type No. 270)!
Figure 63
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Repair Manual
Insert the oil baffle into the cover bore until contact is obtained.
Figure 64 Insert the bearing outer rings (3x, see arrows) into the cover bores until contact is obtained.
Figure 65 Insert both cyl. pins into the bores until contact is obtained.
Figure 66 Assemble the washer until contact is obtained and fasten it by means of hexagon screws. Tightening torque (M 10/10.9) . . . . . . . . . . MA = 68 Nm
Figure 67
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Repair Manual
Insert the thrust washers with grease into the cover. the installation ! Observeinserted into theposition ofofthe thrust washers, lugs must be recesses the cover (see arrows)!
Figure 68 Insert the needle cage (2x) from both sides into the double gear.
Figure 69 Insert the preassembled double gear into the cover. Then align the double gear and the thrust washers centrically.
Figure 70 Insert the bolt into the cover bore.

After inserting of the bolt pay attention to clearance of the thrust washers!
Figure 71
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Repair Manual
Fasten the bolt by means of the slotted pin.
Figure 72 Install the threaded pin. Tightening torque (M 6/8.8) . . . . . . . . . . . . . MA = 5 Nm Wet the thread with Loctite (Type No. 270)!
Figure 73 Assemble the clutch bell housing and fasten it with two retaining rings on the output shaft. (S) Set of external pliers 5870 900 015
Figure 74 Snap the rectangular rings (2x, see arrows) into the annular grooves and lock them.
Figure 75
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Repair Manual
Press the bushes (2x) from both sides flush into the gear.
! Heat up the bush carrier to 120 10 C!

+10
+20
C, bush temperature
Wet the outer diameter of the bushes with Loctite (Type No.: 648)!
Figure 76 Install both lip sealing rings (see arrows) and the annular groove showing to the pressure chamber (upwards). Provide the pressure bolts with new O-rings and position them (see figure).
! Position the pressure bolts with grease onto the piston!

Figure 77 Insert the piston evenly into the gear.
! Prior to installation oil the lip sealing rings and the O-rings!
Figure 78 Assemble the washer (optionally, e.g. 7.4 mm / empirical value).
Figure 79
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Repair Manual
Assemble the disc set starting with an outer disc.
! Basically the outer and inner discs are to be arranged alternately!

Number of discs is indicated in the respective spare parts list!
Figure 80 Assemble the end shim with the ground side showing downwards.
Figure 81 Fasten the disc set by means of the retaining ring. (S) Set of external pliers 5870 900 015
Figure 82 Insert the preassembled gear into the clutch bell housing until all outer discs are located in the teeth of the clutch bell housing. Then pull the gear cautiously out of the clutch bell housing. working discs centered! ! At thisthe circlip step the 85) is are aligned andinstallation Until (Figure snapped-in the position of the discs is not allowed to be changed any more!
Figure 83
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Repair Manual
Place the laminated spring with the concave side showing downwards.
Figure 84 Preload the laminated spring by means of the press, assemble the shim with the convex side showing downwards and snap the retaining ring into the annular groove. (S) Pressing bush (S) Set of external pliers 5870 506 117 5870 900 015
Figure 85 Determine the clearance 1.5 2.5 mm Preload the end shim and the disc set respectively with a force of F = 20000 +6000 Nm and measure the stroke of the end shim (clearance) by means of the dial indicator. Clearance e.g. . . . . . . . . . . . . . . . . . . . . . . . . 1.60 mm (S) Load cell (S) Magnetic stand (S) Dial indicator Figure 86 5870 700 005 5870 200 055 5870 200 057
If the required clearance differs this is to be corrected with an adequate shim (Figure 79, Page 7/21)! Insert the preassembled clutch into the clutch bell housing until contact is obtained.
Figure 87
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Repair Manual
Heat up the tapered roller bearing and assemble it on the output shaft until contact is obtained.
Figure 88 Snap in both rectangular rings (2x, see arrows) and lock them.
Figure 89 Assemble both screen sheets and fasten them by bending the sheet metal straps (3x).
Figure 90 Insert the preassembled output shaft into the cover until contact is obtained.
Figure 91
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Repair Manual
Install the tube (see Arrow 1) and the bearing outer ring (see Arrow 2). 1
Figure 92 Fasten the O-rings (2x, see arrows) with grease into the recesses of the housing.
Figure 93 Fasten the lifting tackle (2x, see arrows) to the output shaft. Then install two adjusting screws (S) and insert the preassembled cover together with the front wheel drive into the housing. (S) Lifting tackle (S) Lifting strap 5870 281 050 5870 281 047
Figure 94 Fasten the cover by means of hexagon screws preliminarily, do not tighten.
Figure 95
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Repair Manual
Install the cyl. pins (2x, see arrows) into the cover and the housing respectively until contact. Then fasten the cover finally by means of hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . . MA = 117 Nm
Figure 96 Assemble the shim e.g. Thickness = 6.80 mm (see Figure 35, Page 7/10) and the axial roller cage until contact is obtained on the clutch shaft.
Figure 97 Assemble the needle cage.
Figure 98 Install the tube with the large diameter showing to the clutch shaft (to the rear).
Figure 99
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Repair Manual
Adjust the axial clearance of the output shaft 0.025 0.1 mm (Figure 100 ... 105) Put the gasket (see arrow) onto the cover. Measure Dim. I, from the plane face of the gasket to the contact face of the bearing outer ring and the shim respectively. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 26.50 mm (S) Gauge blocks (S) Straightedge (S) Digital depth gauge 5870 200 066 5870 200 022 5870 200 072
Figure 100
Measure Dim. II, from the mounting face of the housing to the shoulder of the output shaft. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40 mm
Hold the output shaft in place! EXAMPLE D: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 26.50 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . + 7.40 mm Result = Dim. X = 33.90 mm Measure Dim. Y (bearing width). Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 32.13 mm (S) Gauge blocks (S) Digital depth gauge EXAMPLE E: Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . . Difference . . . . . . . . . . . . . . . . . . . . . . . . Axial clearance e.g. . . . . . . . . . . . . . . . . results in shim s 33.90 mm - 32.13 mm = 1.77 mm - 0.07 mm = 1.70 mm 5870 200 066 5870 200 072
Figure 101
Figure 102
Insert the determined shim e.g. Thickness = 1.70 mm into the housing bore.
Figure 103
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Repair Manual
Insert the bearing outer ring into the housing bore until contact.
Figure 104 Heat up the tapered roller bearing and mount it to the output shaft until contact is obtained.
! Install the bearing subsequently after cooling down!
Figure 105
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8. 8.1
Reassembly of the Powershift Clutches Reassembly of Clutch A/C
Insert the orifice (2x, D = 0.8) on the front-ends of the input shaft into the lubricating bore.
Insert the orifices with Loctite (Type No.: 270)!
Figure 1 Seal the bores (2x) by means of threaded pin. Tightening torque (M10/8.8) . . . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!
Figure 2 Press both tapered roller bearings until contact is obtained. (S) Pressing bush 5870 506 119
Figure 3 Adjust the spur gear bearing (Clutch A) (Figure 4 9) Setting value = 0.7 Nm preload with max. 0.03 mm clearance Install both bearing outer rings into the bores of the spur gear until contact is obtained. Then mount the preassembled spur gear to the input shaft until contact is obtained and fasten it by means of the tapered roller bearings.
Figure 4
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Repair Manual
Support the bearing inner ring by means of the pressing bush (S) and preload the spur gear bearing until a preliminary rolling moment of 1 Nm is obtained. 1 Nm corresponds to a traction force of approx. 22 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance (S) Pressing bush Figure 5 Fasten the spur gear bearing by means of the shim (optional) and retaining ring. 5870 230 004 5870 506 119
! Choose theormaximum shim thickness bearing is without clearance almost without clearance!
Figure 6 Then press the input shaft to the direction of arrow, until the upper bearing inner ring and the shim respectively are located on the retaining ring without clearance (bearing is relieved).
Figure 7 Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 15.5 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 8 and 9). value = 0.7 Nm up ! If the required settingto be corrected withtoanmax. 0.03 mm clearance differs, it is adequate shim (Fig. 6)! (S) Spring balance 5870 230 004
Figure 8
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(S) Magnetic stand (S) Dial indicator
5870 200 055 5870 200 057
Figure 9 Press both needle sleeves into the bores of the piston carrier. (S) Assembly drift 5870 506 105
installation position ! The exactby using the specifiedof the needle sleeves is obtained mounting tool (S)! Check function of the purge valve (see arrow). Ball must not jam, cleaning with compressed air if necessary!
Figure 10 Insert spline sealing rings (2x, see arrows) into the annular grooves of the piston.
! Observe the installation position, see below sketch!
Figure 11 To the sketch:
1 2
1 = Piston 2 = Spline sealing ring X = Pressure chamber
Figure 12
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Repair Manual
Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained.

If disc carriers already applied in operation are reused, observe the marking on the clutch sides A or C, see below figure! Install the opposite piston analogously! Figure 13 Install discs of clutch A, starting with an outer clutch disc. Then put on the end shim and snap in the circlip.
!
A C
Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!
Figure 14 Determine disc clearance 3.7 0.25 mm (Figure 15 Example A) Compress the disc set (downwards) and measure Dim. I, from the face of the disc carrier to the plane face of the end shim. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60 mm (S) Digital depth gauge 5870 200 072
Figure 15 Locate the end shim on the circlip until contact is obtained (pressing upwards) and measure Dim. II. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 3.85 mm
Figure 16
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Repair Manual
EXAMPLE A:
Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 7.60 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . - 3.85 mm Difference = Disc clearance = 3.75 mm required disc clearance ! If thean adequate inner clutchdiffers, this is to be corrected with disc! Install the opposite disc set of clutch C analogously!
Snap the retaining ring into the annular groove of the input shaft and put on the axial bearing.
Figure 17 Install the rectangular rings (3x, see arrows).
! Grease the rectangular rings and align them centrically!
Figure 18 Mount the preassembled disc carrier first without compression spring over the input shaft and spur gear respectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the disc set in place. the clutch discs are aligned and centered ! At this working stepthe later installation of the disc carrier! thus making easier
Figure 19
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Repair Manual
Install the compression spring and the guide ring.
Figure 20 Mount the disc carrier as far as possible (until contact with compression spring is obtained). disc set in place and do not ! Hold thecarrier afterwards any more!change the position of the disc
Figure 21 Install the guide ring and the compression spring.
Figure 22 Mount the axial bearing.
Figure 23
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Repair Manual
Mount the retaining ring over the input shaft.
Figure 24 Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush (S) Set of external pliers 5870 506 117 5870 900 015
Figure 25 Snap in the upper retaining ring. (S) Set of external pliers 5870 900 015
Figure 26 Mount the shim and the heated tapered roller bearing.
Figure 27
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Mount the needle cage until contact is obtained.
Figure 28 Press the tapered roller bearing onto the input gear until contact is obtained.
Figure 29 Insert the bearing outer ring until contact is obtained.
Figure 30 Insert the input gear until all inner clutch discs are located.
Figure 31
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Snap in the rectangular rings (4x, see arrows) and lock them.
Figure 32 Check function of the clutches A and C by means of compressed air. installed components ! With correctlyclearly audible! opening and closing of the clutches is
Figure 33 8.2 Reassembly of Clutch B/D
Seal the bores (2x) by means of threaded pins. Tightening torque (M10/8.8) . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!
Figure 34 Press the tapered roller bearing on the output shaft until contact is obtained.
Figure 35
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Press both needle sleeves into the bores of the piston carrier. (S) Assembly drift 5870 506 105
1 2
Figure 38 Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained.

Install the opposite piston analogously!
Figure 39
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Repair Manual
The respective clutch side of the disc carrier can be seen on the position of the teeth, see figure on the left! B Clutch side B < D.
Figure 40 Install discs of clutch B, starting with an outer clutch disc. Then put on the end shim and snap in the circlip.

Number of discs is indicated in the respective spare parts list! Figure 41 Then determine the disc clearance 3.7 0.25 mm.
! For the procedure see Figure 15 to Example A (Page 8/4)!
Assemble the needle bearing until contact is obtained.
Figure 42
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Repair Manual
Install the rectangular rings (3x, see arrows).
Figure 43 Assemble the preassembled disc carrier first without compression spring over the output shaft and spur gear respectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the disc set in place. the clutch discs are aligned and centered ! At this working stepthe later installation of the disc carrier! thus making easier Figure 44 Install the compression spring and the guide ring.
Figure 45 Assemble the disc carrier as far as possible (until contact is obtained with the compression spring.) disc set in place and do not ! Hold thecarrier afterwards any more!change the position of the disc
Figure 46
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Repair Manual
Install the guide ring and the compression spring.
Figure 47 Assemble the axial bearing.
Figure 48 Assemble the retaining ring over the output shaft. (S) Set of external pliers 5870 900 015
Figure 49 Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush (S) Set of external pliers 5870 506 117 5870 900 015
Figure 50
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Repair Manual
Snap in the upper retaining ring.
Figure 51 Adjust the spur gear bearing (Clutch D) (Figure 52 58) Setting value = 0.7 Nm preload up to max. 0.03 mm clearance Mount the shim Thickness = 1.5 mm and the heated tapered roller bearing.

Figure 52 Insert both bearing outer rings into the bores of the spur gear until contact is obtained and mount the spur gear.
Figure 53 Assemble the tapered roller bearing and preload the spur gear bearing until a preliminary rolling moment of 1 Nm results. 1 Nm corresponds to a traction force of approx. 13 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance (S) Pressing bush Figure 54 5870 230 004 5870 506 119
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Repair Manual
Fasten the spur gear bearing by means of the shim (optional) and retaining ring.
Figure 55 Pull the spur gear (Clutch D) upwards to the direction of arrow, until the upper bearing inner ring and the shim are located on the retaining ring without clearance (bearing is relieved). (S) Two-armed puller 5870 970 004
Figure 56 Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 9 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 57 and 59). value = 0.7 Nm up ! If the required settingto be corrected withtoanmax. 0.03 mm clearance differs, it is adequate shim (Fig. 55)!
(S) Spring balance Figure 57 (S) Magnetic stand (S) Dial indicator
5870 230 004
5870 200 055 5870 200 057
Figure 58
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Repair Manual
Unsnap the retaining ring again and remove the shim.
Figure 59 Pull the spur gear by means of the two-armed puller (S) from the output shaft. (S) Two-armed puller 5870 970 004
Figure 60 Install discs of clutch D, starting with an outer clutch disc. Then put on the end shim and snap in the circlip.

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Repair Manual
Insert the spur gear until all inner clutch discs are located.
Figure 63 Fasten the spur gear bearing by means of the corresponding shim and retaining ring. Then locate the spur gear and the bearing inner ring respectively on the upper retaining ring again until contact is obtained (also see Figure 56).
! Thus the bearing is relieved and an excessive preload is avoided!

Figure 65
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Repair Manual
Snap in the rectangular rings (2x, see arrows) and lock them.
Figure 66 Check function of the clutches B and D by means of compressed air. installed components ! With correctlyclearly audible! opening and closing of the clutches is
Figure 67 Install the gear and fasten it by means of the circlip.
Figure 68
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Repair Manual
8.3
Reassembly of Clutch F/G
Install the sealing cap (orifice).
Figure 69 Seal the bores (2x) by means of threaded pin. Tightening torque (M10/8.8) . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!
Figure 70 Adjust the spur gear bearing (Clutch F) (Figure 71 77) Setting value = 0.7 Nm preload up to max. 0.03 mm clearance Press the tapered roller bearing onto the intermediate shaft until contact is obtained. (S) Pressing bush 5870 506 119
Figure 71 Insert both bearing outer rings into the bores of the spur gear until contact is obtained. Then mount the preassembled spur gear on the intermediate shaft until contact is obtained.
Figure 72
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Repair Manual
Mount the tapered roller bearing and preload the spur gear bearing until a preliminary rolling moment of 1 Nm is obtained. 1 Nm corresponds to a traction force of approx. 22 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance (S) Pressing bush Figure 73 Fasten the spur gear bearing by means of the shim (optional) and retaining ring. 5870 230 004 5870 506 119
Figure 74 Support the spur gear and press the intermediate shaft to the direction of arrow until the upper bearing inner ring and the shim are located on the retaining ring without clearance (bearing is relieved). (S) Parting fixture 5870 300 028
Figure 75 Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 15.5 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 76 and 77). value = 0.7 Nm up ! If the required settingto be corrected withtoanmax. 0.03 mm clearance differs, it is adequate shim (Fig. 74)! (S) Spring balance 5870 230 004
Figure 76
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Repair Manual
(S) Magnetic stand (S) Dial indicator
5870 200 055 5870 200 057
Figure 77 Press both needle sleeves into the bores of the piston carrier. (S) Assembly drift 5870 506 105
1 2
Figure 80
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Repair Manual
Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained.

Install the opposite piston analogously!
Figure 81 The respective clutch side of the disc carrier can be seen on the position of the teeth, see figure on the left! F Clutch side F > G
Figure 82 Install discs of clutch F, starting with an outer clutch disc. Then put on the end shim and snap in the circlip.

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Repair Manual
Snap the retaining ring into the annular groove of the intermediate shaft and put on the axial bearing.
Figure 84 Install the rectangular rings (3x, see arrows).
Figure 85 Mount the preassembled disc carrier first without compression spring over the intermediate shaft and spur gear respectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the disc set in place. the clutch discs are aligned and centered ! At this working stepthe later installation of the disc carrier! thus making easier Figure 86 Install the compression spring and the guide ring.
Figure 87
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Repair Manual
Assemble the disc carrier as far as possible (until contact with the compression spring is obtained). disc set in place and do not ! Hold thecarrier afterwards any more!change the position of the disc
Figure 88 Install the guide ring and the compression spring.
Figure 89 Assemble the axial bearing.
Figure 90 Assemble the retaining ring as far as possible over the intermediate shaft.
Figure 91
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Repair Manual
Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush 5870 506 117
Figure 92 Snap in the upper retaining ring.
Figure 93 Install discs of clutch G, starting with an outer clutch disc. Then put on the end shim and snap in the circlip.

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Repair Manual
Insert the inner disc carrier until all inner discs are located.
Figure 95 Heat the tapered roller bearing and assemble it until contact is obtained.
Figure 96 Snap in the rectangular rings (2x, see arrows) and lock them.
Figure 97 Check function of the clutches F and G by means of compressed air. installed components ! With correctlyclearly audible! opening and closing of the clutches is
Figure 98
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Repair Manual
Heat up the tapered roller bearing and install it until contact is obtained,
Figure 99 8.4 Reassembly of the Cover
Insert clutch B/D into the housing.
Figure 100 Insert clutch F/G into the housing.
Figure 101 Insert clutch A/C into the housing.
! Observe the central position of the rectangular rings!
Figure 102
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Repair Manual
Provide the tube with a new O-ring and insert it into the housing bore until contact is obtained.
Figure 103 Insert the balls (4x, see arrows) flush into the cover bores.
Figure 104 Install two adjusting screws (S) and fasten the gasket with grease to the mounting face. Then fasten the O-rings (see arrows) by means of grease into the recesses of the housing. (S) Adjusting screws 5870 204 021
Figure 105 Locate the cover to the housing until contact is obtained and by means of hexagon screws fasten it preliminarily, do not tighten.
Figure 106
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Repair Manual
Drive the cyl. pins (2x, see arrows) into the cover and the housing respectively until contact is obtained. Then fasten the cover finally with hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . . . . MA = 117 Nm
Figure 107 Install the shaft seal with the sealing lip showing to the oil sump. (S) Mounting tool 5870 048 176
mounting installation ! The exactmounting tool! is obtained by use of the specified Immediately before assembling wet the outer diameter of the shaft seal with spirit and grease the space between sealing and dust lip with grease! Figure 108 8.5 Adjust the Axial Clearance of the Clutches
Adjust the axial clearance 0.025 0.075 mm of clutch B/D and F/G (Figure 109 ... 114) Insert the bearing outer ring into the cover bore.
Figure 109 Locate the clutch (B/D) by means of the puller (S). (S) Puller 5870 000 017
Figure 110
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Repair Manual
Install the bearing outer ring subsequently until contact is obtained.
Figure 111 Measure Dim. I, from the mounting face of the cover to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.90 mm (S) Digital depth gauge 5870 200 072
Figure 112 Measure Dim. II, from the contact face of the shim to the mounting face of the cover. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 mm
EXAMPLE B: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . + Difference . . . . . . . . . . . . . . . . . . . . . . . . = Axial clearance e.g. . . . . . . . . . . . . . . . . results in shim s = Figure 113
5.90 mm 4.10 mm 1.80 mm 0.05 mm 1.75 mm
Insert the determined shim e.g. Thickness = 1.75 mm into the cover bore.
Figure 114
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Repair Manual
Grease the O-rings (3x, see arrows) and insert them into the recesses of the cover.
Figure 115 Mount the cover and locate it evenly until contact is obtained by means of hexagon screws. Tightening torque (M10/8.8) . . . . . . . . . . . . MA = 46 Nm
! Observe the central position of the rectangular rings!

Adjust axial clearance 0.025 0.075 mm of clutch F/G analogously to clutch B/D and install the cover (repeat procedure Figure 104 116). Figure 116 Adjust the axial clearance 0.025 0.075 mm of Clutch A/C Figure 117 ... 120 Insert the bearing outer ring into the cover bore.
Figure 117 Insert shim e.g. Thickness = 1.95 mm (empirical value) into the cover bore.
Figure 118
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Repair Manual
Snap the retaining ring into the annular groove of the cover.
Figure 119 Locate the bearing outer ring on the retaining ring until contact and check the axial clearance 0.025 0.075 mm. (S) Magnetic stand (S) Dial indicator 5870 200 055 5870 200 057
required axial clearance ! If thean adequate shim (Figure differs, it is to be corrected with 118)!
Figure 120 Install the shaft seal with the sealing lip showing to the oil sump. (S) Mounting tool 5870 048 175
mounting installation ! The exactmounting tool! is obtained by use of the specified Immediately before assembling wet the outer diameter of the shaft seal with spirit and grease the space between sealing and dust lip with grease! Figure 121 Insert both speed transmitters into the housing bores and fasten them by means of cap screw. Tightening torque (M8/8.8) . . . . . . . . . . . . . MA = 23 Nm
! Provide speed transmitters with a new O-ring and grease them!

Figure 122
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Repair Manual
8.6
Adjust the Excess Shift Travel of the Crawler Gear Shifting
Install the measuring lever (S). Shift the gear shift shaft alternately into the shifting position Crawleer gear On and Normal group On respectively and check the excess shift travel by means of the dial indicator. (S) Measuring lever (S) Dial indicator (S) Magnetic stand Figure 123 travel must ! Excess shiftshift travel isbe the same in both shift positions! The excess changed by loosening and tightening alternately both threaded pins on the gear shift fork (see below figure)! Observe the tightening torque of both threaded pins MA = 34 Nm! Then remove the measuring lever again. 5870 200 087 5870 200 057 5870 200 055
Figure 124
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Repair Manual
9. 3 2 9.1
Reassembly of the Pump Drive and Attachment of the Electro-Hydraulic Control Reassembly of the Pump Drive
Install the ball 12 mm (Arrow 1), 8.5 mm (Arrow 2) and 6.5 mm (Arrow 3). 1 After insertion of the balls 6.5 mm and 8.5 mm equalize the protruding casting by means of a touch-up! Figure 1 Install the threaded pins (2x). Tightening torque (M8) . . . . . . . . . . . . . . . MA = 6 Nm Wet threads of the threaded pins with Loctite (Type No.: 270)!
Figure 2 Install the threaded pin. Tightening torque (M14) . . . . . . . . . . . . . . MA = 20 Nm Wet threads of the threaded pins with Loctite (Type No.: 270)!
Figure 3 Provide the screw plugs (2x, see arrows) with a new O-ring and install them. Tightening torque (M18x1.5) . . . . . . . . . . MA = 50 Nm Tightening torque (M22x1.5) . . . . . . . . . . MA = 60 Nm
Figure 4
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Repair Manual
Provide the bolt connection with a new O-ring and install it. Tightening torque (M18x1.5) . . . . . . . . . . . MA = 40 Nm
Figure 5 Insert the sealing disc into the housing bore and fasten it by dishing.
Wet the contact faces with Loctite (Type No.: 270)!
Figure 6 Cold start safety valve (Figure 7 and 8) Insert the valve cone, compression spring and shim (Thickness = 3.2 mm / empirical value) into the housing bore. p bar. ! The shim determines theatopening pressure ofthis=is27 be If deviations should occur the final test run to
+3
corrected with an adequate shim!
Figure 7 Provide the screw plug with a new O-ring and install it. Tightening torque (M26x1.5) . . . . . . . . . . MA = 80 Nm
Figure 8
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Repair Manual
Insert both O-rings (see arrows) by means of grease into the recesses of the flange.
Provide the bolt connection with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 100 Nm
Figure 9 Attach the preassembled flange by means of cap screws to the housing. Tightening torque (M8/8.8) . . . . . . . . . . . . MA = 23 Nm
Figure 10 Insert the ball bearing with the closed bearing side showing upwards (to the spur gear) into the lower bearing bore.
Figure 11 Insert the spur gear into the housing and position it.
Figure 12
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Repair Manual
Press the ball bearing with the closed bearing side showing to the gearing (downwards) onto the bush until contact is obtained.
Figure 13 Heat up the lower ball bearing (bearing inner ring) and insert the bush together with the bearing until contact is obtained.
Figure 14 Snap the retaining ring into the inner annular groove of the bush. (S) Set of internal pliers 5870 900 013
Figure 15 Adjust the axial clearance of the spur gear bearing max. 0.4 mm (Figure 16 ... 18) Put on the gasket and measure Dim. I from the mounting face to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 10.55 mm (S) Digital depth gauge 5870 200 072
Figure 16
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Repair Manual
Measure Dim. II, from the contact face to the mounting face of the pump. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 mm
EXAMPLE A: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 10.55 mm Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . - 7.18 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . . = 3.37 mm Axial clearance e.g. . . . . . . . . . . . . . . . . . - 0.17 mm Results in shim e.g. Thickness = 3.20 mm Put the shim e.g. Thickness = 3.20 mm into the housing bore.
Figure 17
Figure 18 Snap the retaining ring into the annular groove of the bushing. (S) Set of internal pliers 5870 900 013
Figure 19 Insert the bushing into the teeth until contact is obtained.
Figure 20
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Repair Manual
Grease the O-ring (see arrow) and insert it into the annular groove of the housing bore.
Figure 21 Adjust the axial clearance on the elbow 0.1 0.3 mm (Figure 22 27) Put on the gasket and fasten the flange by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm
! Attach the flange on the suction side (larger bore diameter)!

Figure 22 Grease the O-Ring (see arrow) and insert it into the annular groove.
Figure 23 Insert the elbow into the flange until contact is obtained.
Figure 24
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Repair Manual
Install two adjusting screws (S) and assemble the gasket. Then insert the pump and fasten it by means of cap screws. Tightening torque (M8/8.8) . . . . . . . . . . . . MA = 23 Nm
Figure 25 Measure the gap size between pump housing and elbow by means of a feeler gauge. Gap size, e.g. . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm (S) Feeler gauge EXAMPLE B: Gap size . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm Axial clearance e.g. . . . . . . . . . . . . . . . - 0.10 mm Results in shim e.g. Thickness = 1.90 mm Figure 26 Then remove the pump again. Assemble the shim e.g. Thickness = 1.90 mm on the elbow. after ! Pump can only be installedcontrolattachment of the pump housing and the hydraulic to the transmission housing! 5870 200 113
Figure 27 Snap the circlips (see Arrows 1) into the annular grooves of the oil tube. 1 2 Then grease the O-rings (see Arrows 2) and install them.
Figure 28
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Repair Manual
Insert the oil tube into the housing bore until contact is obtained.
Figure 29 Insert the hexagon screws (4x) into the elbow. Then mount the elbow on the oil tube until contact is obtained.
Figure 30 Install the ball (see arrow), heat up the bearing inner ring and mount it on the bearing bracket until contact is obtained.
Figure 31 Insert both bearing outer rings into the spur gear bores until contact is obtained. Then put on the preassembled spur gear.
Figure 32
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Repair Manual
Heat up the bearing inner ring and assemble it until contact is obtained.
Figure 33 Adjust axial clearance of the spur gear bearing = 0.25 0.75 mm (Figure 34 and 35) Fasten the spur gear by means of the shim (e.g. Thickness = 2.00 mm, empirical value) and the retaining ring.
Figure 34 Locate the upper bearing inner ring on the retaining ring and check the axial clearance of the spur gear bearing. (S) Magnetic stand (S) Dial indicator 5870 200 055 5870 200 057
required clearance (0.25 0.75 mm) differs ! If thecorrected axial an adequate shim (Figure 34)! it is to be with
Figure 35 Locate the bearing bracket by means of hexagon screws and insert both cyl. pins until contact is obtained. Then tighten the hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . MA = 117 Nm
Figure 36
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Repair Manual
Place the strainer insert and the bush into the housing bore.
! Install the strainer insert with the convex surface showing to the outside!
Figure 37 Install two adjusting screws (S) and assemble the first gasket. (S) Adjusting screws 5870 204 011
Figure 38 Assemble the intermediate sheet and the second gasket.
Figure 39 Assemble the housing and fasten it by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm
Figure 40
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Repair Manual
Snap the retaining ring into the inner annular groove of the bush. (S) Set of internal pliers 5870 900 013
Figure 41 Insert the bushing into the teeth until contact is obtained. Provide the screw plug (see arrow) with a new O-ring and install it. Tightening torque (M10x1) . . . . . . . . . . . MA = 25 Nm
Figure 42 Install two adjusting screws (S) and assemble the gasket. (S) Adjusting screws 5870 204 007
Figure 43 Place the pump drive firmly against the transmission housing.
Figure 44
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Repair Manual
Insert both cyl. pins (see arrows) until contact is obtained and fasten the pump drive by means of hexagon screws. Tightening torque (M10/8.8) . . . . . . . . . . MA = 46 Nm
Figure 45 Insert a new O-ring into the annular groove of the oil tube, position the oil tube and install the bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 80 Nm
Figure 46 Install the screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 80 Nm
Figure 47 Preassemble the filter as shown in the figure on the left. 4 6 3 5 7 1 Figure 48 2 1 = Rod 2 = O-Ring 3 = Housing 4 = O-Ring 5 = Flat gasket 6 = Insert 7 = Strainer
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Repair Manual
Install the filter.
Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 +10 Nm
Figure 49 The figure on the left shows the components of the solenoid valve (Connection Front Wheel Drive). 2 1 4 3 1 = Valve 2 = Solenoid 3 = O-Ring 4 = Nut
Figure 50 Install the components of the solenoid valve (Connection Front Wheel Drive). Tightening torque (Valve) . . . . . . . . . . . . MA = 30 Nm
! Tighten the nut by hand!

Figure 51 Provide the temperature transmitter (transmission oil temperature) with a new O-Ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 20 Nm Tightening of the temperature transmitter is only allowed by means of socket wrench (adapter), not with an open end wrench!
Figure 52
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Repair Manual
Insert the speed transmitter (Main Clutch Output) into the housing bore and fasten it by means of the cap screw. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm
! Provideit!the speed transmitter with a new O-ring and grease

Figure 53 The figure on the left shows the components of the solenoid valve (Proportional Valve Main Clutch). 2 1 3 4 1 = Valve 2 = Solenoid 3 = O-Ring 4 = Nut
Figure 54 Install the valve. Tightening torque (Valve) . . . . . . . . . . . . MA = 10 Nm
Figure 55 Assemble the solenoid and the O-ring and fasten it by means of the nut.
! Tighten the nut by hand!
Figure 56
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Repair Manual
9.2
Attachment of the Electro- Hydraulic Control
The sketch on the left shows the position of the screws and the adjusting screws (S). (S) Adjusting screws D, 8.5 mm (S) Adjusting screws C, 8.8 mm 5870 204 057 5870 204 058
Figure 57 Install adjusting screws D at Item 37, 38 and 39, adjusting screws C at Item 40. C (S) Adjusting screws D, 8.5 mm (S) Adjusting screws C, 8.8 mm 5870 204 057 5870 204 058
Figure 58 Assemble gasket, intermediate sheet and gasket.
Figure 59
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Repair Manual
Install the components (Figure 60 and 61), if required. 1 1 = Ball, shim and O-ring 2 = Orifice 3 = Ball and compression spring
! Fasten the O-Ring with grease!
Figure 60
Figure 61 Assemble the duct plate.
Figure 62 Fasten the duct plate by means of cap screws and shims (Item 1 9 and 18). Tightening torque (M8x35) . . . . . . . . . . . MA = 23 Nm
Figure 63
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Repair Manual
9.3
Attachment of the Forward-Reverse Control Block
Assemble the gasket.
Figure 64 Assemble the intermediate sheet and the gasket.
Figure 65 Assemble the control block (cpl.).
Figure 66 Fasten the control block by means of cap screws and washers. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 Nm the order for tightening of the screws from ! Observethe left, removing the adjusting screws (S)! the right to
Figure 67
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Repair Manual
9.4
Attachment of the 4-Speed Powershift Control Block
Assemble the gasket.
Figure 68 Assemble the intermediate sheet and the gasket.
Figure 69 Insert the stop plate with grease into the valve housing.
Figure 70 Mount the 4-speed control block (cpl.).
Figure 71
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Repair Manual
Fasten the control block by means of cap screws and washers. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 Nm the order for tightening of the screws from ! Observethe left, removing the adjusting screws (S)! the right to
Figure 72 Provide the pressure switch (see arrow) with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 9.5 Nm
Figure 73 Install the tube (see arrow). Tightening torque . . . . . . . . . . . . . . . . . . . MA = 100 Nm
Figure 74
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Repair Manual
9.5 Attachment of the Pump
Install two adjusting screws (S) and assemble the gasket.
Figure 75 Insert the pump.
! Pay attention to shim on the elbow!
Figure 76 Fasten the pump by means of cap screws. Tightening torque (M8/8.8). . . . . . . . . . . . MA = 23 Nm
Figure 77 Install the gasket (use grease) and fasten the elbow by means of hexagon screws. Tightening torque (M8/8.8). . . . . . . . . . . . MA = 23 Nm
Figure 78
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Repair Manual
10.
Attachment of the Transmission to the Rear Axle
Snap both circlips (see arrows) into the annular grooves of the shaft.
Figure 1 Insert the shaft into the teeth of the pump gear drive.
Figure 2 Insert the sealing cap (orifice) into the bolt connection and press it until contact is obtained.
Figure 3 Install the bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 285 Nm Observe the installation position. Install the bolt connection with the orifice showing to the direction of arrow!
Figure 4
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Repair Manual
Presassemble the components as shown in the figure on the left. 2 3 4 5 1 = T-Adapter 2 = Plug 3 = Union nut 4 = Reducer 5 = Union nut Tightening torque . . . . . . . . . . . . . . . . . . MA = 300 Nm 1 Figure 5 Install the preassembled bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . MA = 300 Nm
Figure 6 Install two adjusting screws and assemble the gasket. (S) Adjusting screws 5870 204 023
Observe the marking on the rear axle housing flange (see arrow)! Flange marked with 0 use gasket with one recess (s = 0,20 mm)! Flange marked with 0 0 use gasket with two recesses (s = 0,25 mm)! Figure 7 To the sketch: 1 = Marking on the rear axle housing 2 = Recess on the gasket
1 2
0 0
Figure 8
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Repair Manual
Place the transmission by means of lifting tackle against the rear axle housing until contact is obtained. (S) Lifting chain 5870 281 047
Figure 9 Fasten the transmission by means of hexagon screws and hexagon nuts. Tightening torque (M16/10.9) . . . . . . . . . MA = 280 Nm
Figure 10 Install the oil tube.
Figure 11 Install the oil tube.
Prior to commissioning of the unit make an oil filling in accordance with the operating instructions 5872 979 001!
Figure 12
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Transmission T-7336 Ps

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: 5871 970 002

REPAIR MANUAL for the ZF TRACTOR TRANSMISSION T-7336 PS

Off-Road Transmissions and Axle Systems Division

ZF Passau GmbH Service Department

5871 970 002

Off-Road Transmissions and Axle Systems Division

5871 970 002

Off-Road Transmissions and Axle Systems Division

5871 970 002

Off-Road Transmissions and Axle Systems Division

VERGLEICHSTABELLE FR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION

5871 970 002

Off-Road Transmissions and Axle Systems Division

Hinweis : Note : Nota :

lngenbezogene Mae in kg/m; linear density in kg/m; Densit linaire en kg/m;

flchenbezogene mae in t/m2 areal density in t/m2 Densit superficielle en t/m2

Formelzeichen Formula Sign Symbole m

Neu New Nouveau kg (Kilogramm)

Alt Old Vieu kg

Umrechnung Conversion Conversion

Bemerkungen Note Nota

1 kpm = 9,81 Nm 1,02 at = 1,02 kp/cm2 = 1 bar = 750 torr

5871 970 002

Off-Road Transmissions and Axle Systems Division

Off-Road Transmissions and Axle Systems Division

5870 350 000 5870 350 117 5870 350 125

5870 281 047

5870 204 023

5870 204 011

5870 204 007

5870 345 065

2/28_3/10 3/16_3/22 3/26_3/29 3/44_5/32

6/21_7/74 7/82_7/82 8/25_8/49

5870 900 015

5871 970 002

Off-Road Transmissions and Axle Systems Division

Part No. 5870 970 002

5870 204 023

5873 011 014

5873 001 000

3/08_3/18 3/19_3/21 3/24_3/47

5873 001 038

5873 001 000

3/11 3/27 3/39

7/85 8/25 8/50 8/92

5870 506 117

3/13 3/29 3/41

5870 900 007

3/14 3/30 3/42

5870 300 005 5870 300 003

5871 970 002

Off-Road Transmissions and Axle Systems Division

5873 000 035

5873 000 000

5870 970 003

5873 002 025

5873 002 001

5870 300 028

5873 001 038

5870 300 028

5870 650 001

5871 970 002