Checklist for the removal of synchro transmission
Driveline & Chassis Technology
Vehicle owner: ............................................................................................................................
hiu
Customer address: ......................................................................................................................
Clutch:
Shift turret interface:
clutch functions
clutch release system
hydraulic connection
remote shifting system (linkage, cable, ball joints,)
nominal air pressure & air connection
electrical connections e.g. switch
safety features (range and gate group interlock)
Contact person with number:......................................................................................................
Vehicle data: ...............................................................................................................................
Vehicle manufacturer: .................................................................................................................
Main transmission:
Vehicle type: ...............................................................................................................................
quantity & quality of oil
presence of oil leakage
transmission breather
presence of gear noise
rattling or hammering
Chassis-no./VIN:..........................................................................................................................
Registration number:...................................................................................................................
Propshaft:
connection
Type of operation: .......................................................................................................................
Investigation to be run before removal
Engine type:................................................................................................................................
Engine performance:...................................................................................................................
Transmission data
Date of registration: ....................................................................................................................
Transmission type:.......................................................................................................................
Current kilometers:......................................................................................................................
Spec. no.: ...................................................................................................................................
Current engine hours: .................................................................................................................
Serial-no.: ...................................................................................................................................
Load carried: ...............................................................................................................................
Is the transmission mounted on the vehicle?
iRear axle: .....................................................................................................................................
Date of failure: ............................................................................................................................
Additional notes: .........................................................................................................................
Description of complaint: ............................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
Failure history: ............................................................................................................................
Date of preparation: ....................................................................................................................
...................................................................................................................................................
ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C
1238 755 102a - 2010-03
yes
no
Page 1 of 3
Checklist for the removal of synchro transmission
Description of action
1
Clutch & engine interface
1.1
Check the clutch release behavior
Driveline & Chassis Technology
Reference value
Result
Operating temperature, idling speed, press
okay
Measures in case of not okay or no
not okay
Improve clutch release behavior:
clutch, after max. 20 sec engage the R-gear,
Correct clutch function is essential to avoid
during engagement no noise from the t/m
failures of the transmission
1.2
Check the clutch fluid (air bubbles etc.)
Bleeding procedure
okay
not okay
Improve clutch fluid system
1.3
Check the hydraulic connection to the
Is the connection in good shape?
yes
no
Repair hydraulic connections
Is there high clearance and/or wear?
okay
not okay
Repair/correct shift linkages and ball joints
Are the ball joints free to move?
yes
no
Are the ball joints broken or damaged?
yes
no
Are the link rods touching the body or frame?
yes
no
Are there marks on the link rods?
yes
no
General check of cable shifting
Is the cable damaged or blocked into the socket?
yes
no
Change the cable shifting
Check pneumatic connections at the
Are there oil or air leaks?
okay
not okay
Repair pneumatic connections
Is the pressure higher than 10 bar?
okay
not okay
Make sure the air pressure is not too high
Is the pressure lower than 6.2 bar?
okay
not okay
Make sure the air pressure is not too low
Is the connection secured?
okay
not okay
clutch booster
Shift turret interface
2.1
General check of shift linkage & ball joints
2.2
Check ball joints
2.3
2.4
Check of the linkage
2.5
2.6
2.7
Repair shift linkage and ball joints
Repair shift linkage and link rods
transmission
2.8
Check air pressure
2.9
Propshaft interface
3.1
Check the output connection
ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C
1238 755 102a - 2010-03
Page 2 of 3
Checklist for the removal of synchro transmission
Description of action
4
Check the oil level
4.1
Check the oil level
4.2
Check the oil quality
4.3
Driveline & Chassis Technology
Reference value
Result
Measures in case of not okay or no
Oil should come out through the oil filler in plug.
okay
not okay
Correct oil level
Does the oil comply with the ZF list of lubricants
yes
no
Only use the oil released by ZF
yes
no
Make sure the oil change intervals correspond
TE-ML 02?
Was the last oil change interval as specified?
to requirements
4.4
Check the oil status into the transmission
Not burned, no intense blackening,
okay
not okay
no water-in-oil emulsion, no metal particles
4.5
4.6
Check the transmission breather
Change oil and make sure that no further negative
influences are there
Clean and not covered with mud etc
okay
not okay
Clean/change the breather
Breather with pipes should be clean and no
okay
not okay
Clean/change the pipe
okay
not okay
Change the shift turret gasket without removing the
water leaking from the pipe.
4.7
On shift turret housing?
transmission (first repair level)
Check of oil leakage
4.8
Between shift turret & transmission main housing?
okay
not okay
Change the gasket between shift turret & transmission main housing (first repair level)
4.9
Noise check
Hammering or rattling noise?
okay
not okay
Ensure that the noise does not come from engine
or clutch
Further proceeding
1
If there are no further findings and if all checks from number 1.1 to 4.9 have been carried out and answered with okay or yes, the transmission can be released
by ZF for removal. Please contact ZF Hotline. 1.800.209.093
After removal, the following package has to be sent to an authorized ZF dealer for warranty investigation & repair:
1. The complete failed unit (still assembled)
2. The completed checklist for removal of transmission. Warranty can not be handled with an incomplete checklist.
3. Oil sample from the failed transmission
ZF Friedrichshafen AG D-88038 Friedrichshafen MC-C
1238 755 102a - 2010-03
Page 3 of 3
