Repair Instructions: Zf-Ecolite 6 S 500 BO Level 3

REPAIR INSTRUCTIONS
ZF-ECOLITE
6 S 500 BO
Level 3
BUS
Copyright © ZF Friedrichshafen AG
This document is protected by copyright.

Complete or partial reproduction or distribution of this document is not
permitted without the consent of ZF Friedrichshafen AG. Infringements lead to
civil and criminal prosecution.
ZF-Ecolite Table of Contents
Page
Preface ............................................................................................................................................ 5
Important information on occupational safety and health .................................................................. 6
Repair instructions ............................................................................................................................ 11
Tightening torques for screws/bolts and nuts, excerpt from ZFN 148 ................................................ 15
Consumables .................................................................................................................................... 16
Settings ............................................................................................................................................ 17
Special tool ....................................................................................................................................... 19
Preparatory work .............................................................................................................................. 27
1 Impulse sensor .................................................................................................................... 1-1

1.1 Removing the impulse sensor............................................................................................... 1-1
1.2 Installing the impulse sensor ................................................................................................ 1-1
2 Output flange ...................................................................................................................... 2-1

2.1 Removing the output flange ................................................................................................. 2-1
2.2 Installing the output flange ................................................................................................... 2-2
3 Parking brake ...................................................................................................................... 3-1

3.1 Removing the parking brake and output flange .................................................................... 3-1
3.2 Installing the parking brake and output flange ...................................................................... 3-2
4 Fixture ................................................................................................................................. 4-1

4.1 Removing the fixture ............................................................................................................ 4-1
4.2 Installing the fixture.............................................................................................................. 4-1
5 Clutch release mechanism .................................................................................................. 5-1

5.1 Removing the clutch release mechanism.............................................................................. 5-1
5.2 Installing the clutch release mechanism ............................................................................... 5-1
6 Shaft sealing ring output side ............................................................................................. 6-1

6.1 Removing the shaft sealing ring ........................................................................................... 6-1
6.2 Installing the shaft sealing ring ............................................................................................. 6-1
7 Switches ............................................................................................................................. 7-1

7.1 Removing the switches......................................................................................................... 7-1
7.2 Installing the switches .......................................................................................................... 7-1
8 Shift System ........................................................................................................................ 8-1

8.1 Removing the selector and shift lever ................................................................................... 8-1
8.2 Installing the selector and shift lever..................................................................................... 8-1
8.3 Removing the gearshift housing ........................................................................................... 8-2
8.4 Installing the gearshift housing............................................................................................. 8-2
8.5 Disassembling the gearshift housing .................................................................................... 8-3
8.6 Assembling the gearshift housing......................................................................................... 8-5
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ZF-Ecolite Table of Contents
Page
9 Guide tube and shaft sealing ring ....................................................................................... 9-1

9.1 Removing the guide tube ..................................................................................................... 9-1
9.2 Installing the guide tube ....................................................................................................... 9-1
9.3 Removing the shaft sealing ring on the input side ................................................................ 9-2
9.4 Installing the shaft sealing ring on the input side .................................................................. 9-2
10 Cover ................................................................................................................................... 10-1

10.1 Removing the cover (bell housing)........................................................................................ 10-1
10.2 Installing the cover (bell housing) ......................................................................................... 10-1
10.3 Removing the cover (PTO opening) ...................................................................................... 10-1
10.4 Installing the cover (PTO opening) ........................................................................................ 10-1
11 Housing I ............................................................................................................................. 11-1

11.1 Removing housing I.............................................................................................................. 11-1
11.2 Installing housing I ............................................................................................................... 11-4
11.3 Disassembling housing I....................................................................................................... 11-8
11.4 Assembling housing I ........................................................................................................... 11-9
12 Input shaft ........................................................................................................................... 12-1

12.1 Disassembling the input shaft .............................................................................................. 12-1
12.2 Assembling the input shaft ................................................................................................... 12-1
13 Shaft package ..................................................................................................................... 13-1

13.1 Removing the shaft package ................................................................................................ 13-2
13.2 Installing the shaft package.................................................................................................. 13-6
14 Synchronizer........................................................................................................................ 14-1
14.1 ZF-BK synchronizer .............................................................................................................. 14-1
15 Main Shaft........................................................................................................................... 15-1

15.1 Disassembling the main shaft............................................................................................... 15-1
15.2 Assembling the main shaft ................................................................................................... 15-5
16 Countershaft ....................................................................................................................... 16-1

16.1 Disassembling the countershaft............................................................................................ 16-1
16.2 Assembling the countershaft ................................................................................................ 16-2
17 Bearing Setting for Main and Countershaft ........................................................................ 17-1

17.1 Bearing seat of the main shaft.............................................................................................. 17-1
17.2 Bearing seat of the countershaft........................................................................................... 17-1
17.3 Countershaft bearing setting ................................................................................................ 17-3
17.4 Input shaft bearing setting.................................................................................................... 17-5
Table of revisions: 1380 751 104
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ZF-Ecolite Preface
Preface
This documentation was developed for specialized staff trained in the operation of ZF products by
ZF Friedrichshafen AG (hereinafter referred to as "ZF").
The work described below may be performed by authorized, trained, and instructed staff only. It is the
responsibility of the user's company or service company to ensure that their specialized staff is properly
trained and that current documents are made available.
Object of documentation is a volume-produced ZF product. State of design acc. to date of issue.
The images illustrate the work sequence and do not always represent the original. Illustrations and figures
are not drawn to scale; no conclusions about size and weight can be drawn.
The repair or assembly of the ZF product available to you may require different work steps as well as
different settings and test data as a result of technical further developments. We therefore recommend
that work done on your ZF product be carried out only by skilled mechanics and fitters who have had
their practical and theoretical knowledge updated on a regular basis at ZF.
The ZF service locations which have been put in place for you worldwide by ZF offer the following
services:
▪ Well-trained specialized personnel
▪ Specified workshop equipment, e. g. special tools, diagnostic software, etc.
▪ Genuine ZF spare parts in accordance with the latest volume production specifications
ZF Friedrichshafen AG
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ZF-Ecolite Safety Instructions
Safety Instructions
General safety instructions
Read all safety instructions. Failure to comply with safety instructions may lead to material damage,
serious injury, possibly even to death.
Intended use / liability / guarantee / warranty

The ZF product is exclusively designed for the purpose specified in the contract and agreed on at the
time of delivery. Any other or extended form of use does not comply with this definition of intended use.
ZF Friedrichshafen AG is not liable for any damage resulting from this. Instead, the user is fully liable for
this risk. The intended use includes compliance with this documentation and other applicable documents
in order to avoid malfunctions and damage in operation.
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate.
However, this product may cause hazardous situations if used incorrectly by unauthorized, untrained, and
uninstructed specialized staff or if not used for its intended purpose.
This version of the document complies with the relevant standards and regulations as well as with
European product liability law.
We offer guarantee for the ZF product in accordance with our Terms and Conditions. Warranty claims
cease to apply if damage and secondary damage result from incorrect and unprofessionally performed
work. Work that is performed by unauthorized, untrained, and uninstructed specialized staff leads to
ceasing of all warranty claims.
We offer warranty for the ZF product in accordance with our Terms and Conditions.
Damage, secondary damage, defects, and possibly resulting costs are excluded from contractual liability
or warranty in the event of non-compliance with one of the following points:
▪ All work must be performed in a professional manner.
▪ Work must only be performed by trained, instructed and authorized specialized staff.
▪ Only genuine ZF spare parts may be used which have been tested and released by ZF.
▪ Only genuine ZF accessories may be used which have been tested and released by ZF.
▪ Only genuine ZF special tools may be used which have been tested and released by ZF.
▪ Revisions and modifications on the ZF product must be approved by ZF.
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In case of damage, immediate action is mandatory in order to restore full functionality and safety /
operational safety of the ZF product and to minimize the extent of damage. In the event of non-
compliance, ZF will not accept liability or warranty claims.
In case of damage, contact ZF Services and have the following data available:
▪ Product type, product parts list number, and serial number
▪ Total mileage
▪ Damage history
▪ Damage pattern
Specialized staff
Work must only be performed by trained and instructed specialized staff. As a result of specialized
training and practical experience, the specialized staff must be capable of detecting risks and avoiding
possible dangers which may be caused by the operation, maintenance, and repair of the ZF product.
To avoid injury to personnel and damage to ZF products, all safety regulations and legal requirements
must be adhered to. The specialized staff must have read and understood these regulations prior to
beginning work.
Country-specific safety, accident prevention, and environmental regulations apply irrespective of the
instructions provided in this document.
Safety-relevant workwear is to be used for all work. Depending on the type of work, additional protection,
e. g. protective goggles, protective gloves, a hard hat, and a skirt, is to be used. The workwear must fit
properly and be tight so that it cannot get caught in turning or protruding parts.
After completion of repair work and inspections, the specialized staff must ensure that the ZF product is
again functioning perfectly and is safe to operate.
The user/operator is responsible for assigning the corresponding section of the documentation to the
correct target group. The former must ensure that the respective section of the documentation is stored
in the immediate vicinity of the ZF product and that the relevant target group has access to it.
1380 751 104 - 2014-06 7

Handling of ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the
ZF product’s operational safety and are only permitted with the approval of ZF Friedrichshafen AG.
Unless explicitly permitted, no work may be performed while the engine is running.
Secure the engine against unintentional setting off and the vehicle against moving.
Attach a “Do not operate” sign which is visible for everyone!
Keep uninvolved parties away.
Always secure the ZF product before starting work according to specification and using suitable means.
Do not work on ZF products which are only held by a lifting device or a hoist.
Risk of injury from tilting or falling parts and/or tools.
▪ Do not walk under suspended loads.
▪ Keep distance.
Lifting and moving heavy parts without tools may lead to health damage or serious injury.
▪ Only use permitted means of transport, lifting equipment with sufficient load capacity, and suitable
chain hoist.
▪ Observe safety regulations.
Increased risk of injury at contact with cooled down or heated parts. Only touch parts when wearing
suitable protective gloves.
Noise
Wear suitable ear protection at all workplaces with a sound pressure level above 85 dB(A).
Country-specific safety and accident prevention regulations apply regardless of this.
Noise can mean a higher risk of accidents if the noise affects the perception of acoustic signals, warning
calls, or other sounds alerting to danger.
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Handling operating fluids and consumables

Increased risk of injury at contact with heated, cooled down, or caustic operating fluids and consumables
(e. g. lubricants, cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources, do not smoke.
Store operating fluids and consumables in suitable and correctly labeled containers.
Use suitable protective clothing, protective gloves, and protective goggles/face protection.
Pay attention to manufacturer’s and accident prevention regulations.
Immediately seek medical assistance after contact with heated, cooled down, or caustic operating fluids
and consumables.
Environment
Operating fluids and consumables must not be allowed to enter the soil, groundwater, or sewage system.
▪ Ask your local environmental protection agency for the safety data sheets of the relevant ZF products
and observe these requirements.
▪ Collect operating fluids and consumables in a sufficiently large container.
▪ Dispose of operating fluids and consumables, waste, containers, soaked cleaning cloths, contaminated
filters etc. in accordance with the regulations of the environmental protection laws.
▪ Pay attention to manufacturer’s and accident prevention regulations.
When selecting operating fluids and consumables, bear in mind health risks, environmental compatibility,
disposal regulations, and country-specific possibilities for approved disposal.
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Signal words and symbols
This document contains particularly highlighted safety instructions which start with one of the following
signal words depending on the danger’s severity.
DANGER!
Is used when lack of care could result in personal injury or danger to life.
CAUTION
Is used when the instructions are not complied with or not followed precisely and could lead to the
product being damaged.
NOTE
Refers to special working procedures, methods, information, use of auxiliary equipment, etc.
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ZF-Ecolite Instructions for Repair and Assembly
Instructions for Repair and Assembly
General notes
▪ Please read carefully through this documentation prior to starting repair or assembly work.
▪ Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF
product is available. ZF Service Information can contain tests, supplements to the product or to repair
processes which may not yet be included in this documentation. The ZF Service Information details are
available from all ZF Service Centers or from the ZF-ServiceLine.
▪ In cases of doubt, always contact the relevant expert departments of the ZF Customer Service.
▪ All work on the ZF product must be performed expertly and under clean conditions.
▪ Use the specified special tools and equipment intended for the described working procedures.
▪ All work must be performed according to the described working procedure.
▪ Carefully cover opened ZF products to prevent the entry of foreign matter.
▪ Cover all parts that have been removed and that are reusable and protect them against dirt and
damage.
▪ After completion of work and inspections, the specialized staff must ensure that the ZF product is
again functioning perfectly and is safe to operate.
Cleaning the ZF product prior to disassembly
▪ Use an appropriate cleaning agent to thoroughly clean the ZF product prior to repair or assembly work.
Thoroughly clean the angles and recesses of housing and cover.
CAUTION
Be careful when using a high-pressure cleaner on the ZF product.
Penetrating water might lead to operational disruption and damage to the ZF product.
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Cleaning parts
▪ Thoroughly clean all reusable components after disassembly.

▪ Thoroughly remove sealing compound residue on sealing faces or retaining agent residue, e. g. in
tapped holes or on splines.
▪ Thoroughly clean joining surfaces and check for damage.
▪ Thoroughly wash out blind holes and blind hole threads and remove contamination.
▪ Lubricating bores, oil clearance holes, oil ducts, bores for oil press fits, and lubricating grooves must
be free from dirt, preservative, and foreign matter. If possible, blow through with compressed air.
Check for free passage.
▪ Hose assemblies, oil tubes, and joining elements must be free from dirt, oil, and chafe marks. Dirty or
oily parts must be thoroughly cleaned and, if necessary, blown through with compressed air. Replace
damaged parts.
▪ Thoroughly clean all cavities and reliefs.
▪ All edges which can cause chip formation during assembly or represent a risk of injury for the fitter
must be deburred.
▪ Carefully remove burrs or other similar rough surfaces using a honing stone.
▪ Thoroughly remove preservative from new parts (e. g. on bearing).
Reusing parts
Authorized, specialized staff assess whether parts can be reused.

▪ Replace parts if they are damaged.
▪ Replace parts if they are worn, e. g. rolling bearings, multidisks, thrust washers, etc.
▪ Replace parts if they have a permanent deformation.
▪ Replace parts if they have been overheated during operation or during disassembly.
Always replace:
▪ Bolts with reduced shank, seals, etc., and parts that are intended for single use only
▪ Sealing rings
▪ Safety plates
▪ Shaft sealing rings
The parts must be replaced with genuine ZF parts or parts released by ZF. Please refer to the spare parts
catalog for the ZF product.
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Reworking parts
Authorized, specialized staff assess whether parts need to be reworked or replaced.

Minor damage on reusable components can be removed and reworked with suitable special tools if the
component’s function is not impaired.
Minor damage includes:
▪ Indentation marks on sealing faces
▪ Score marks or burrs caused by the disassembly of the ZF product
▪ Frictional corrosion
▪ Paint and rust damage
If rework is needed on spacer washers or shims because of clearance settings, ensure that the reworked
surface is level with the starting face and has the same surface quality.
Disassembly
▪ To avoid mixing up parts, the parts must be clearly assigned to the disassembled ZF product. In
particular, this applies to gear parts, reusable spacer washers or shims, electronic components, etc.
▪ Assemblies which must not be disassembled or are only available as spare parts assembly are
described accordingly. Please refer to the spare parts catalog for the ZF product.
▪ Inspect the parts during disassembly in order to find a potential cause of damage.
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Assembly
Assemble the ZF product at a clean workplace. The order, settings, and tightening torques must be
observed.
Bearings
The bearings’ assembly specifications are described in the corresponding work step. After assembly, each
mounted bearing must be lubricated with transmission oil.
Sealing
If a sealing agent* is recommended for sealing, then it is essential to adhere to the manufacturer’s
directions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly.
Do not allow sealing agent to enter oil ducts and oil bores. In the case of oil transfer channels and/or oil
transfer bores in the sealing face areas, the sealing agent should be scraped off around the openings so
that no sealing agent gets into the oil supply lines when the parts are pressed together.
Retaining agents
Only use retaining agents* if specified in the work step. Follow the safety instructions and the processing
instructions of the manufacturer.
Transmission oil
Prior to initial operation, fill the transmission with transmission oil. For the procedure and approved oil
grades, refer to the technical manual, the operating instructions, the type plate, and/or the latest List of
Lubricants TE-ML. These documents are available from the ZF Service Centers and at www.zf.com.
* refer to Operating supplies and auxiliary materials
1380 751 104 - 2014-06 14

ZF-Ecolite Tightening Torques
Tightening torques for screws and nuts, extract from ZFN 148
This standard applies to bolts according to

DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765,
ISO 8676, and for nuts according to DIN 934 and ISO 4032, ISO 8673.
This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8,
10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.
Surface condition of screws/nuts:

Heat-treated blackened finish and oiled or galvanized and oiled.
The bolts are tightened using a calibrated torque wrench.
NOTE
Differing tightening torques are listed separately in the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw 8.8 10.9 12.9 Screw 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89
M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960
M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850
M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500
Status: August 1991
1380 751 104 - 2014-06 15

ZF-Ecolite Consumables
Designation Name Quantity Application Comment

ZF item number approx.
Grease for example 10 grams Shaft sealing ring at output 01.210

0750 199 019 RENOLIT CX-F020 10 gramms Shaft sealing ring at input 01.040
5 grams Shaft sealing ring at
gearshift housing 07.140
1 gram Shaft sealing ring at
gearshift housing 07.160
2 grams Tapered roller bearing 04.410 Grease roller
on the main shaft after installation.
3 grams Bush 07.130 at the gearshift housing
2 grams Main shaft
Sealing compound Loctite no. 243 250 mm3 Swivel screws 06.220/06.230 Apply to
0666 690 248 170 mm3 Set screw 06.040 thread
Surface sealing Loctite no. 574 1 cm3 Sealing face housing I / housing II Sealing faces
0666 790 033 0.5 cm3 Hexagon screw 04.550 / washer must be clean
1.0 cm3 Washer 04.550 / flange and free of
100 mm3 Sealing face between gearshift grease.
housing and clutch housing.
50 mm3 Cover plate 01.015
100 mm3 Sealing washer 01.020
80 mm3 Cover plate 06.370 (4x)
Sealing compound Loctite no. 570 100 mm3 Hexagon screws 01.070/01.080/ joined accor-
01.090/01.100/01.110/01.120 ding to A/RO
ZFN 164
Sealing compound Loctite no. 263 0,5 cm3 Hexagon screw 07.070 Apply to
0666 690 247 0,5 cm3 Hexagon screw 07.030 thread
NOTE: Inquire about package/container size before placing an order!
1380 751 104 - 2014-06 16

ZF-Ecolite Settings
Designation Dimensional details Measurement device Comment
Axial preloading of thecoun- -0.02 to -0.09 mm Dial gage Setting carried out with shim.
tershaft and input shaft preloading
Axial clearance of securing 0 to 0.05 mm Feeler gage Check

ring 04.400 of the main shaft clearance
Installation dimension of shaft 47.5 - 48.0 mm Check with depth Obtained when tool
sealing ring 01.210 at the gage 1X56 196 584 is used
output
Installation dimension of shaft 5.0 - 5.5 mm Check with depth Obtained when tool
sealing ring 01.040 at the gage 1X56 196 583 is used
input
Cap screw on reverse gear bolt 23 Nm Torque wrench

05.070
Hex head screw 140 Nm Torque wrench

on output flange 04.550
Swivel screws 06.220/06.230 60 Nm Torque wrench Clutch housing
Screw plug 04.510 45 Nm Torque wrench Output housing
Switches 06.500/06.560 45 Nm Torque wrench Output housing
Breather 07.180 10 Nm Torque wrench Gearshift housing
Hexagon nut 07.070 35 Nm Torque wrench Selector lever
Hexagon nut 07.030 49 Nm Torque wrench Shift lever
Screw plug 01.190 38 Nm Torque wrench Oil drain
Screw plug 01.130 38 Nm Torque wrench Oil fill/overflow
Hex head screws 01.170/ 4 Nm Torque wrench Cover on clutch housing

01.180
Hex head screws 01.070 to 46 Nm Torque wrench PTO cover

01.120
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ZF-Ecolite Settings
Designation Dimensional details Measurement device Comment
Hex head screws 30.020 (2x) 79 Nm Torque wrench Holder
Hex head screws 30.040 (4x) 125 Nm Torque wrench Parking brake
Hex head screw 07.290 23 Nm Torque wrench Gearshift housing
Hex head screws 01.230 - 23 Nm Torque wrench Housing I with II

01.390 (17x)
Cap screws 02.130 - 02.150 23 Nm Torque wrench Guide tube

(3x)
Set screw 06.040 (2x) 60 Nm Torque wrench In gearshift detent
Hexagon screws 07.320 - 23 Nm Torque wrench Gearshift housing

07.390 (8x)
Hexagon nut 07.030 (2x) 60 Nm Torque wrench Selector lever
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ZF-Ecolite Special tool
Image Figure Order no. Application No. of Comment

no. pieces
1X56 196 788 1 Preparatory

work
Supports
1
1X56 196 586 1 Chapter 2, 3
Pulling device
2 Spindle for inserting the
output flange
1X56 196 584 1 Chapter 6
Press-in mandrel
3 for shaft sealing ring output side
01.210 at the output
1X56 138 531 1 Chapter 8

also in
Impact adapter conjunction with
4 for drawn cup needle roller bearing washer
07.150
for shaft sealing ring 07.160
for bush 07.120
for shaft sealing ring 07.140
1X56 196 587 1 in conjunction

with support
Adapter 1X56 196 585
5
for assembling countershaft
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no. pieces
1X56 196 797 1 Input shaft
protective cover
6 when placing housing 1
1X56 122 205 1 Chapter 8

in conjunction
Extracting device with counter
7 for bearing bush 07.120 in the support
gearshift housing
1X56 122 227 1 in conjunction

with extracting
Counter support device
8 for pulling off
1X56 196 583 1 Chapter 9
Press-in mandrel
9 for shaft sealing ring 01.040 (input)
1X56 196 582 1 Chapter 11
Alignment aid
10 for gearshift shaft 06.010
1380 751 104 - 2014-06 20


no. pieces
1X56 196 597 1 Chapter 11

in conjunction
Press-in fixture with press-in
11 for the countershaft outer bearing fixture
ring and the main shaft outer bearing 1X56 138 801
ring
1X56 196 596 1 Chapter 13
Center point
12 for the R gear bolt 05.010
1X56 196 595 1 Chapter 13

for lifting the
Lifting device shaft package
13 for shaft package
1X56 196 585 1 Chapter 13
Support
14 for shaft package
1X56 196 592 1 Chapter 14
Stabilizer
15 for main shaft
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no. pieces
1X56 196 593 1 Chapter 14
Sleeve
16 Press sleeve for 1st and 2nd gear
synchronizer body 04.060/010 and
bearing inner ring 04.070 and
sleeve carrier 04.130
1X56 196 588 1 Chapters 12/14

input shaft
Sleeve main shaft
17 for tapered roller bearing 02.070
for washer 04.290
1X56 196 591 1 Chapter 12/14

main shaft
Sleeve input shaft
18 for output bearing 04.140
for clutch body 04.130
for tapered roller bearing 02.070
1X56 196 589 1 Chapter 15

countershaft
Sleeve input shaft
19 for helical gears 03.020/30/40/50
for tapered roller bearing 02.070
1X56 196 598 1 Chapter 15
Bush
20 for tapered roller bearing inner race
04.410 on the main shaft
1380 751 104 - 2014-06 22


no. pieces
1X56 138 801 1 In conjunction

with
Press-in device 1X56 138 800
21 for pressing in the bearing outer rings and press-in
device
1X56 196 597

with extracting
Basic device device
22

with basic device
Extracting device 1X56 122 304,
23 for the tapered roller bearing 04.140 assembly fixture
on the main shaft 1X56 122 310,
and threaded
ring
1X56 122 303

with basic
Mounting device device
24 for tapered roller bearing 03.070 / 1X56 122 304
03.090 on the countershaft and assembly
fixture 1X56 122
310
1X56 122 303 In conjunction

with basic device
Threaded ring 1X56 122 304,
25 for tapered roller bearing 02.070 extension
on the input shaft 1X56 122 310,
and extracting
device
1X56 136 740
1380 751 104 - 2014-06 23


no. pieces

with 3 arm
Extractor extractor
26 2 for synchronizer body and sliding
sleeve
3
1

with 3 arm
Extracting device extractor
27 for tapered roller bearing 04.410 on
bearing journal of the main shaft

with threaded
Assembly fixture ring
28 for tapered roller bearing 1X56 122 303,
basic device
on the input shaft
1X56 122 304,
and extracting
device
1X56 136 740

with counter
Extractor support
29 for the 4 output housingcover plates 1X56 122 226
D=12-16

with counter
Extractor support
30 for counter shaft bearing outer ring 1X56 122 227
1380 751 104 - 2014-06 24


no. pieces

with counter
Extractor support
31 for main shaft outer bearing ring 1X56 122 228
1X56 196 594 1 before

assembling
Sleeve clutch body of
32 to protect the bearing surface reverse gear
04.130
1X56 196 599 Chapter 15
Protection sleeve
33 to protect the axle journal when
placing the gears on the countershaft
1T66 159 409 For lifting/

placing
Eyelet bolt
34 Housing 1
1X56 196 590 Chapter 15

Tapered roller
Hülse bearing inner
35 for pressing on race
03.070/03.090
1380 751 104 - 2014-06 25


no. pieces
1X56 122 228 1
Counter support
36 for extracting
Internal extractor with counter 1

support
Three-armed extractor
37 commercially available
1P01 137 513 1
Dial gage with solenoid back cover

38 commercially available
In-house manufacture 1 Mounting device

at the gearshift
Washer cover
39 for pressing in
Outer diameter: 40 mm
Inner diameter: 20 mm
Thickness: 3 mm
1380 751 104 - 2014-06 26

ZF-Ecolite Preparatory work
Preparatory work
The screw plug for the oil drain (1) is located on the
underside of the transmission.
The screw plug for the oil fill and oil overflow check
(2) is located on the right side of the transmission,
when looking in the direction of travel. 1 2
034994
Screw plugs
1 (01.190) = Screw plug, oil drain

2 (01.130) = Screw plug, oil fill and oil overflow
measurement
Unscrew the screw plugs
CAUTION
Used oil must not be allowed to seep into the soil,
groundwater, or sewerage system. Collect used
oil in a suitable container and dispose of it in
accordance with environmental guidelines.
1 Unscrew screw plug 1 (01.190).
2 Unscrew screw plug 2 (01.130).
Screw in screw plugs
1 Screw in screw plug 1 (01.190) with sealing

ring.
Tightening torque: 38 Nm
2 Screw in screw plug 2 (01.130) with sealing

ring.
1380 751 104 - 2014-06 27

ZF-Ecolite Preparatory work
NOTE
Screw supports 1X56 196 788 with M10 hexagon
screws (quality 8.8) to the transmission.
035905
1380 751 104 - 2014-06 28

ZF-Ecolite Impulse sensor
1 Impulse sensor
Depending on the parts list, either an impulse

sensor or a screw plug with sealing ring can
be installed at pos. 04.510.
1.1 Unscrewing the impulse sensor
NOTE
In order to prevent damage to the impulse
sensor during further assembly and dis-
assembly of the transmission, screw it out.
04.510
04.510
1 Remove the impulse sensor 04.510.
034676_1
1.2 Screwing in the impulse sensor
1 Screw in impulse sensor 04.510

Tightening torque: 45 Nm ±5 Nm
1.3 Unscrewing the screw plug
1 Remove screw plug 04.510 and sealing ring.

04.510
04.510
1.4 Screwing in the screw plug

034674_1
1 Screw in screw plug 04.510 with a new

sealing ring.
Tightening torque: 45 Nm ±5 Nm
1380 751 104 - 2014-06 1-1

1-2
ZF-Ecolite Output flange
04.550
04.530
04.530/010
04.530/020
034673_1
2 Output Flange
2.1 Removing the output flange
1 Secure output flange 04.530 so that it cannot

be rotated.
2 Remove hex head screw 04.550 and take off

the conical spring washer.
3 Place the transition piece on the main shaft

and extract output flange 04.530 using a
two- or three-armed extractor.
NOTE
Only remove fit bolts 04.530/020 if damaged.
1380 751 104 - 2014-06 2-1

ZF-Ecolite Output flange
04.550
04.530
04.530/010
04.530/020
034673_1
2.2 Installing the output flange
1 NOTE 2 Slide output flange 04.530 onto the gearing

If the fit bolts 04.530/020 were removed, of the main shaft and insert it with pulling
they have to be pressed into the flange in the tool 1X56 196 586 until it is firmly home.
correct position before it is heated.
NOTE
DANGER Never install the output flange by force with a
Only touch heated parts when wearing hammer.
protective gloves. RISK OF BURNS!
3 Apply Loctite no. 574 to the contact surface
Heat output flange 04.530 to max. of 110 °C of the conical spring washer and the screw
to 130 °C. flange of hex head screw 04.550. Screw hex
head screw 04.550 with the conical spring
washer into the output shaft.
4 Tighten hex head screw 04.550.

1380 751 104 - 2014-06 2-2

ZF-Ecolite Parking brake
04.530 04.550
04.530/010
A 04.530/020
30.040
30.030
035369
3 Parking brake
3.1 Removing the parking brake and output

flange
1 Remove brake drum 30.030 B. 5 Remove the 4 bolts (with spring washers)
30.040.
2 Secure output flange 04.530 so that it cannot
rotate. 6 Remove parking brake 30.030 A.
3 Remove hex head screw 04.550 and take off NOTE

the conical spring washer. Only remove fit bolts 04.530/020 if
damaged.
and extract output flange 04.530 using a
two- or three-armed extractor.
1380 751 104 - 2014-06 3-1

ZF-Ecolite Parking brake
04.530 04.550
04.530/010
A 04.530/020
30.040
30.030
035369
3.2 Installing the parking brake and output 3 Slide output flange 04.530 onto the gearing
flange of the main shaft and insert it with pulling
tool 1X56 196 586 until it is firmly home.
1 Use the 4 bolts (with spring washers) 30.040
to install parking brake 30.030 A in the NOTE
correct position on the transmission. Never install the output flange by force with a
Tightening torque: 125 Nm hammer.
2 NOTE 4 Screw hex head screw 04.550 with conical

If fit bolts 04.530/020 were removed, they spring washer into the output shaft.
have to be pressed into the flange in the
correct position before it is heated. 5 Tighten hex head screw 04.550.
DANGER
Only touch heated parts when wearing 6 Slide brake drum 30.030 B onto parking
protective gloves. RISK OF BURNS! brake 30.030 A and onto output flange
04.530 so that the 4 bolts fit through the
Heat output flange 04.530 to a max. of holes of brake drum 30.040 B.
110 °C to 130 °C. Secure aganist falling down.
1380 751 104 - 2014-06 3-2

ZF-Ecolite Fixture
4 Fixture 30.010
4.1 Removing the fixture

30.020
1 Remove 2 hex head screws 30.020 with

spring washers.
2 Remove fixture 30.010.

30.030
4.2 Installing the fixture
1 Fasten fixture 30.010 with the 2 hex head

screws 30.020 with spring washers.
Tightening torque: 46 Nm 035368
1380 751 104 - 2014-06 4-1

4-2
ZF-Ecolite Clutch release mechanism
68.060
68.080
68.020
68.010
68.100
68.030
035401
5 Clutch release mechanism
5.1 Removing the clutch release mechanism 5.2 Installing the clutch release mechanism
1 Take off release bearing 68.100. 1 Replace ball pin 68.080 if damaged. Press
ball pin 68.080 into the housing until it is
2 NOTE firmly home.
Extract release fork 68.010 vertically from
ball head to prevent damage. Inspect ball 2 Replace ball races 68.020 / 68.030 if
races 68.020 / 68.030 in release fork 68.010 damaged. Press new ball races
for damage and replace as required. 68.020 / 68.030 into release fork 68.010.
3 Inspect ball pin 68.080 and replace as requi- 3 Lightly grease the contact surfaces of release
red. (Ball pin 68.080 can be forced out with bearing 68.100 with release fork 68.010.
a hit from behind.) Slide release bearing 68.100 on the guide
tube and bring to abutment on the release
fork.
1380 751 104 - 2014-06 5-1

5-2
ZF-Ecolite Shaft sealing ring output side
6 Shaft sealing ring output side
6.1 Removing the shaft sealing ring

01.200
1 Use a suitable tool to remove shaft sealing

ring 01.210. Do not damage the sealing face
on housing 01.200 in the process.
6.2 Installing the shaft sealing ring
1 Lightly grease the sealing lip of the new shaft

sealing ring 01.210 (ZF order number
0750 199 019).
01.210
034670_1
NOTE
• The sealing lip with snap ring points
towards the inside of the transmission.
• The installation dimension of 47.5+0.5 mm is
obtained when press-in mandrel
1X56 196 584 is used.
Spray new shaft sealing ring 01.210 on the

outer circumference with spirit (ethanol) and
press it into the housing 01.200 with press-in
mandrel 1X56 196 584.
035355
1380 751 104 - 2014-06 6-1

6-2
ZF-Ecolite Switches
06.500
06.520
06.530
034669
7 Switches 7.2 Installing the switches
7.1 Removing the switches 1 Screw switch 06.500 into the housing.
1 Remove switch 06.520.
2 Slide pin 06.530 into the correct position in
2 Remove pin 06.530. the housing.
3 Remove switch 06.500. 3 Screw switch 06.520 into the housing.

1380 751 104 - 2014-06 7-1

7-2
ZF-Ecolite Shift system
8 Shift System 07.070
8.1 Removing the selector and shift lever

07.060
1 Unscrew bolt and nut 07.070 on selector 07.070
lever 07.060.
2 Pull selector lever 07.060 off of the selector

shaft.
07.030
07.020
NOTE
If necessary, use a commercially available
two-armed extractor. 07.030
3 Unscrew bolt and nut 07.030 on shift lever

07.020.
4 Pull shift lever 07.020 off of the gearshift 035399
shaft.
NOTE
If necessary, use a commercially available
two-armed extractor.
8.2 Installing the selector and shift lever
1 Place selector lever 07.060 on the selector

shaft. Insert hexagon screw 07.070 and
fasten it with a hexagon nut.
2 Place shift lever 07.020 on the gearshift

shaft. Insert hexagon screw 07.030 and
fasten it with a hexagon nut.
1380 751 104 - 2014-06 8-1

8.3 Removing the gearshift housing
1 Remove the 8 hexagon screws with washers

07.320 / 07.330 / 07.340 / 07.350 / 07.360 /
07.370 / 07.380 / 07.390.
2 Remove gearshift housing 07.110 from the

transmission.
3 Clean the contact surfaces of the gearshift

housing and the transmission housing of seal
remnants.
035366
8.4 Installing the gearshift housing
1 Coat the clean contact surface of the

transmission housing with Loctite no. 574
(see arrow).
Place the gearshift housing on the

transmission housing.
NOTE
07.210
The head of gearshift finger 07.210 must be

placed in pivot detent 06.030.
06.030
036515
2 Insert the 8 hexagon screws with washers

07.320 / 07.330 / 07.340 / 07.350 / 07.360 /
07.370 / 07.380 / 07.390 through the
gearshift housing. The gearshift housing must
be pressed onto the transmission housing
against the spring force of gearshift detent
07.115, thereby screwing in hexagon screws.
035366
1380 751 104 - 2014-06 8-2

8.5 Disassembling the gearshift housing
1 Remove protector cover 07.010. 07.050
2 Remove protector cover 07.050.

07.110
3 Remove breather 07.180.
07.010
4 Remove switch 06.540 with sealing ring

06.530
06.540
(or screw plug 06.540 with sealing ring,
depending in design).
07.180
5 Remove pin 06.530. 06.540*
029683_1
6 Remove the 4 hexagon screws 07.290.

Take off cover 07.270 and seal 07.280.
07.320
Remove the screw plug 07.320.

Depending on the version, a switch may also
be installed.
07.110
07.280
07.270
07.290
029685_2
7 Remove securing ring 07.220 from gearshift

shaft 07.200.
07.220
07.200
029686_2
1380 751 104 - 2014-06 8-3

8 Remove V-ring 07.250.

Remove selector shaft 07.230.
07.050
07.160
9 Clamp the square rod of gearshift shaft

07.150
07.200 into a vice with protective chucks.

Carefully hit gearshift finger 07.210 with a
07.110
plastic tip hammer to remove it from gearshift 07.210
shaft 07.200.
07.200
10 Push nose of selector lever 07.240 out of

gearshift shaft's groove 07.200 and pull out
07.120
07.230
gearshift shaft.
Remove selector lever 07.240.
07.240
07.250
11 Use internal extractor 1X56 122 205 and 07.140

counter support 1X56 122 227 to remove 029687_2
bush 07.120 and shaft sealing ring 07.140.
12 Use internal extractor 1X56 122 205 and

counter support 1X56 122 227 to remove
07.160
drawn cup needle roller bearing 07.150 and 07.150

shaft sealing ring 07.160.
07.110
029688_1
13 NOTE
Remove gearshift detent only if damaged.
Carefully clamp gearshift detent 07.115 in a

07.115
vise and pull off the gearshift housing.
029689_1
1380 751 104 - 2014-06 8-4

8.6 Assembling the gearshift housing
1 Insert bush 07.120 into housing 07.110 using

tool 1X56 138 531 and washer (40x20x3mm)
until it is flush with the shoulder. 07.110
2 Lightly coat new shaft sealing ring 07.140 on

the outer circumference with water-soluble
liquid dishwashing detergent and insert into
housing 07.110 with washer (40x20x3mm)
until it is firmly home using tool
1X56 138 531.
NOTE
07.120 07.140
Fill the space between the scraper and the

bush with grease ZF 0750 199 019. 029690_1
3 Lightly oil drawn cup needle roller bearing

07.150 and place its narrow collar side onto
the housing. Use suitable round stock to
insert it into housing 07.110.
07.160
07.150
4 NOTE
The sealing lip with snap ring points towards
the inside of the transmission. 07.110
Lightly coat new shaft sealing ring 07.160 on

the outer circumference with water-soluble
liquid dishwashing detergent and insert into
housing 07.110 until it is firmly home using
tool 1X56 138 531 and washer (40x20x3mm).
5 Insert selector lever 07.240 into the correct

029688_1
position in housing 07.110.
6 NOTE 07.210 07.240

Do not damage the shaft sealing ring 07.140
during the following procedure.
Slide gearshift shaft 07.200 halfway into

housing 07.110 ensuring the correct position.
07.200
7 Hold gearshift finger 07.210 in the correct

position (nose points to screw plug) in
housing 07.110.
8 NOTE
The marks of gearshift shaft and gearshift
finger must be aligned with each other when 029691_2
locating them.
1380 751 104 - 2014-06 8-5
9 Own manufacture of half shell:

Inside diameter: 16.5 mm
Outside diameter: 20.0 mm Half shell
Length: 26 to 40 mm
CAUTION
When pressing gearshift shaft 07.200 into gear-
shift finger 07.210, a half shell must be placed
between the gearshift finger and housing wall
07.110; otherwise the pin of gearshift shaft
07.200 is pressed into the wall of housing 07.110.
029692
10 Press in gearshift shaft 07.200 until it is firmly

home.
Snap new securing ring 07.220 into the
groove of gearshift shaft 07.200.
07.220
07.200
029686_2
11 Insert selector lever 07.240 with nose into the

groove of gearshift shaft 07.200.
07.230
Carefully insert selector shaft 07.230 from

07.240
07.250
below into selector lever 07.240. 07.200

Snap new V-ring 07.250 into the groove of
selector shaft 07.230.
029694_1
1380 751 104 - 2014-06 8-6

12 Should the gearshift shaft have been

removed,
Assembly specifications: 07.115
Evenly align gearshift housing with suitable
temporary backing and vertically insert
gearshift detent into housing 07.110 until it is
firmly home using a suitable sleeve.
029689_1
13 Fasten seal 07.280 and cover 07.270 with

4 hexagon screws 07.290.
07.320
14 Screw in screw plug 07.230 (or switch).

07.110
07.280
07.270
07.290
029685_2
15 Screw in breather 07.180.

16 Place protector cover 07.050 over selector 07.050
shaft.
17 Place protector cover 07.010 over gearshift 07.110
shaft.
07.010
07.180
029695_1
1380 751 104 - 2014-06 8-7

8-8
ZF-Ecolite Guide tube
02.120
02.130
02.140
02.150
035370
9 Guide tube and shaft sealing ring
9.1 Removing the guide tube 9.2 Installing the guide tube
1 Remove the 3 bolts 02.130, 02.140, 02.150. 1 Fasten guide tube 02.120 with the 3 bolts
02.130, 02.140, 02.150.
2 Remove guide tube 02.120 from the trans- Tightening torque: 23 Nm
mission housing.
1380 751 104 - 2014-06 9-1

ZF-Ecolite Shaft sealing ring
9.3 Removing the shaft sealing ring on the

input side 01.010
1 Remove shaft sealing ring 01.040 from

housing I 01.010 using a suitable tool.
Do not damage housing I in the process.
9.4 Installing the shaft sealing ring on the input

side
1 Lightly grease the sealing lip of new shaft

sealing ring 01.040 (ZF order number
01.040
0750 199 019).

035371
NOTE
• The sealing lip with the snap ring points
towards the inside of the transmission.
• The installation dimension of 5+0.5 mm is
obtained when press-in mandrel
1X56 196 583 is used.
Spray new shaft sealing ring 01.040 on the

outer circumference with spirit and press it
into the housing using press-in mandrel
1X56 196 583.
035356
1380 751 104 - 2014-06 9-2

ZF-Ecolite Cover
10 Cover
01.010
10.1 Removing the cover (bell housing)
1 Remove the 2 bolts 01.170/01.180 with

washers, take off cover 01.160.
10.2 Installing the cover (bell housing)

01.050
01.060
1 Fasten cover 01.160 with the 2 bolts 01.170/ 01.070

01.180 with washers. 01.080
Tightening torque: 4 Nm 01.160 01.120

01.100 01.090
01.170 01.110
01.180
035372
10.3 Removing the cover (PTO opening)
1 Take off the 6 bolts 01.070/01.080/01.090/

01.100/01.110/01.120, cover 01.060, and
seal 01.050.
10.4 Installing the cover (PTO opening)
NOTE
Do not install cover 01.060 before the thick-
ness of shim 03.080 has been determined
(see Chapter 16).
1 Coat the thread of the 6 bolts 01.070/01.080/

01.090/01.100/01.110/01.120 with Loctite
no. 574. Fasten seal 01.050 and cover
01.060 with the 6 bolts.
1380 751 104 - 2014-06 10-1

10-2
ZF-Ecolite Housing I
11 Housing I
11.1 Removing housing I
1 Bring shift system into neutral position.

(No gear may be engaged)
2 Remove the 8 hex head screws 07.320 /

07.330 / 07.340 / 07.350 / 07.360 / 07.370 /
07.380 / 07.390.
3 Remove gearshift housing 07.110 from

transmission.
4 Clean the contact surfaces of the gearshift

housing and the transmission housing of seal 035366
remnants.
5 Screw set screw 06.040 out of pivot detent

06.030.
Clean the thread of set screw 06.040 and

pivot dent 06.030 after disassembly.
035367
1380 751 104 - 2014-06 11-1

6 Screw out the 2 swivel screws

06.220 / 06.230 (left and right side).
NOTE
Clean the threads of the swivel screws and
the housing.
035358_1
7 Remove the 2 cylinder pins 01.020/01.030.
035361
8 Screw out the 17 hex head screws 01.230 to

01.390.
035351
1380 751 104 - 2014-06 11-2

9 Remove the cover plate 06.020 on housing I

01.010 with a commercially available internal
extractor.
CAUTION
When lifting housing I, make sure that the shift
detent does not block the gearshift rails or that it
has released the gearshift rails.
If the gearshift rails are blocked or not released,
they are pulled out of their locking position.
Consequences: The detent pins fall into housing II
and can be damaged. The gearshift rails can no
longer be inserted and housing II must be dis-
assembled.
035360
10 Prior to removal, rotate the shift detent and

the central gearshift shaft with tool
1X56 196 582 clockwise until firmly home.
035362
11 Fasten two eye bolts 1T66 159 409 on

housing I 01.010.
NOTE
Note the dangers while handling the load
lifting attachment.
12 Carefully lift housing I; if necessary rotate

back and forth a bit with tool 1X56 196 582
so that the shift detent releases the gearshift
shafts and the gearshift rails.
035365
1380 751 104 - 2014-06 11-3

11.2 Installing housing I
1 Clean the sealing faces on housing I 01.010

and housing II 01.200. Do not damage
sealing faces.
NOTE
The sealing faces must be clean and free of
oil and grease.
2 Coat the sealing face of housing II 01.200

with Loctite no. 574 (note manufacturer’s
instructions).
035359
3 Insert shift detent 06.050 in the correct

position in the slot inside housing 01.010 (see
arrow).
NOTE
The longer side (see oval) must be on the
right side.
4 Insert tool 1X56 196 582 for the shift detent

from the outside into the housing and the
shift detent so that the shift detent is fixed for
further assembly.
035350_1
5 Rotate the shift detent with tool

1X56 196 582 clockwise until firmly home.
035362_1
1380 751 104 - 2014-06 11-4

6 The 4 bores in the housing must be free (see

figure). 1X56 196 582
035364_1
7 Note the position of pivot detent 06.030 and

gearshift fork 06.210. Align pivot detent
06.030. 06.210
NOTE
Set screw 06.040 on pivot detent 06.030
must not be installed yet.
Place protective cover 1X56 196 797 on the 06.030

input shaft.
024493
8 Fasten 2 eye bolts 1T66 159 409 on housing I

01.010.
NOTE
lifting attachment.
Set housing I 01.010 carefully on housing II

01.200 and rotate tool 1X56 196 582 back
and forth a bit in the process so that it
meshes with the gearshift shaft. Rotate the
tool clockwise as far as it will go. The shift
detent now releases the corresponding bores
in the housing. The gearshift rails must slide
into the corresponding guides in housing I.
035365
1380 751 104 - 2014-06 11-5

8 Coat the thread of the swivel screws with

Loctite no. 243.
NOTE
The bores in the shift forks must be visible
through the corresponding bores in the
housing (see arrow) so that the swivel screws
can engage with the shift forks and that they
are not damaged.
Screw in the 2 swivel screws 06.220 / 06.230

(left and right side).
035358_1
9 Drive in the 2 cylinder pins 01.020 / 01.030.
035357
10 Screw in the 17 hex head screws 01.230 to

01.390.
035351
1380 751 104 - 2014-06 11-6

11 Align the bores of pivot detent 06.030 and set

screw 06.040 to each other. Coat the threads
of set screw 06.040 with Loctite no. 243 and
insert into pivot detent 06.030.
06.040
06.030
035382_1
12 Evenly coate cover 06.020 at the outer

circumference with approx. 80 mm3 Loctite
no. 574 and drive in until firmly home.
036512
1380 751 104 - 2014-06 11-7

11.3 Disassembling housing I
1 Remove type plate 01.140 only if it is

01.010
damaged, if technical changes were carried

01.140
out during the repair, or if the housing was

exchanged.
It is not possible to disassemble the type

plate without destroying it.
035397
2 Remove the bearing outer ring 03.070 of the

countershaft using extractor 1X56 122 209
and counter support 1X56 122 227 and take
out washer 03.080.
035352
3 Remove the bearing outer ring 02.070 of the

input shaft using extractor 1X56 122 211 and
counter support 1X56 122 228.
Take out ring 02.080, do not use again.
Take out washer 02.090.
035354
1380 751 104 - 2014-06 11-8

11.4 Assembling housing I
Bearing seat of the input shaft
NOTE
Determine washer 02.090 in accordance with
chapter Bearing setting of input shaft and
countershaft.
02.080
1 Insert determined washer 02.090.
02.090
2 Insert new ring 02.080 in the correct

position. (The edge of the inner diameter
must point to the interior of the transmission
or the bearing respectively.)
035386_1
3 Place tool 1X56 138 801 on the housing and

screw tightly.
1X56 138 801_1
DANGER
Only touch heated parts when wearing
protective gloves.
4 Heat bearing seat to max. 100 °C using a hot

air blower.
Align bearing outer ring 02.070 to the bearing 02.070

seat. Apply tool 1X56 196 597.
5 Press in with tool 1X56 138 801 until firmly

home.
035377
1380 751 104 - 2014-06 11-9

Bearing seat of the countershaft
NOTE
Determine washer 03.080 in accordance with
chapter Bearing setting of input shaft and
countershaft.
1 Insert determined washer 03.080 into the

bearing seat of the countershaft.
03.080
035378_1

screw tightly. Align bearing outer ring 03.070
to the bearing seat.
DANGER
protective gloves.
Heat bearing seat to max. 100 °C using a hot

air blower.
3 Apply press-in fixture 1X56 196 597. Press in

bearing outer ring 03.070 until firmly home.
1X56 138 801_1
4 If a new type plate 01.140 is required, place it

on the housing and procure the cast-on rivets
on the housing.
01.010
01.140
035397
1380 751 104 - 2014-06 11-10

ZF-Ecolite Impulse sensor
12 Input shaft
02.040
12.1 Disassembling the input shaft
1 Remove baffle plate 02.040.

02.010
2 Extract bearing inner ring 02.070 using
gripping device 1X56 136 740, mounting
device 1X56 122 310, threaded ring
1X56 122 303, and basic device
02.070
1X56 122 304.
12.2 Assembling the input shaft 035404
1 NOTE
The edge of baffle plate 02.040 points to the
adapter.
Carefully press new baffle plate 02.040 with

even panel (which is larger than baffle plate)
02.010
into input shaft 02.010 until flush.

02.040
034672_1 / 005459
DANGER
Only touch heated parts when wearing 02.040
2 Heat the inner ring of tapered roller bearing

02.070 to max. 130 °C and press on input 02.010
shaft 02.010 with tool 1X56 196 588 and

1X56 196 593 until firmly home.
Contact pressure: max. 50 kN 02.070
035404
1380 751 104 - 2014-06 12-1

12-2
ZF-Ecolite Shifting parts / Shaft package
/30
/30 /30
/40
/20
/30
06.150 /40
06.100 4x30
/010
/30
6x30
/30
/40 /20
/010
3,5x40
/60 /60
/50
6x30 06.010
06.280
/50
06.200 /010
06.040
06.050 06.220
06.210 /40 /20
/30
06.030
/60
3,5x40
/60
06.240 /50
/50 6x30
06.250 06.230
035374_1
13 Shifting parts / shaft package /30 Straight pin (2x)

/40 Driver
Shifting parts /50 Straight pin (6x30)
/60 Straight pin (3.5x30)
NOTE
Check shifting parts for damage. 06.200 5th/6th gear gearshift rail
Replace damaged parts. 06.210 5th/6th gear gearshift fork
06.220 Swivel screw
06.010 Gearshift shaft 06.230 Swivel screw
06.030 Pivot detent 06.240 Sliding block
06.040 Set screw 06.250 Sliding block
06.050 Gearshift lock 06.280 3rd/4th gear gearshift rail
06.100 R gear gearshift rail (completely) /10 Gearshift rail
/10 Gearshift rail /20 Shift fork 3/4
/20 R gear shift fork /30 Straight pin (2x)
/30 Straight pin 2x (6x30) /40 Driver
/40 Straight pin 2x (4.0x30) /50 Straight pin (6x30)
06.150 1st/2nd gear gearshift rail /60 Straight pin (3.5x30)
/10 Gearshift rail
/20 Shift fork 1/2
1380 751 104 - 2014-06 13-1

13.1 Removing the shaft package 06.370
Remove housing I - see Chapter 10 06.350
1 Carefully remove the 4 sealing covers 06.370

06.360
with extractor 1X56 122 203 and counter

support 1X56 122 226 and take out the 4
compression springs 06.350 and the 4 detent
pins 06.360.
The housing may not be damaged.
035375
2 Remove cap screw 05.070 using Usit ring.
035390
3 Take half shell 05.060 and reverse idler gear

bolt 05.010 out of housing 01.200.
Take intermediate gear 05.050 out of the
housing.
05.010 05.060 05.050
035391_2
1380 751 104 - 2014-06 13-2

4 NOTE
Set screw 06.040 must be removed.
06.010
Pull gearshift shaft 06.010 out of pivot detent
06.030 and remove both.
06.030
035363_2
5 Take out 5th/6th gear gearshift fork 06.210

with sliding blocks 06.240 / 06.250.
Take out 5th/6th gear gearshift rail 06.200.
06.200
06.210
035388_1
6 Position lifting device 1X56 196 595 over the

input shaft and countershaft. Slide the guide 1X56 196 595
sleeves over the gearshift rails.
Swivel 2 brackets underneath the helical gear
until the detent bolts (at the top) have
engaged and locked.
Secure lifting device 1X56 196 595 to the
shaft package with 3 bolts and attach it to
the crane hook.
CAUTION
The shaft package can be bent out of line during
removal. Lift the shaft package carefully.
035387_1
1380 751 104 - 2014-06 13-3

7 Insert the shaft package into shaft package

receiver 1X56 196 585. Slide the guide sleeve
upwards. Remove 3rd/4th gear gearshift rail
06.280.
06.280
1X56 196 595
1X56 196 585
035385_1
8 Slide the guide sleeve upwards. Remove

1st/2nd gear gearshift rail 06.150 with driver
06.510.
06.150
035384_1
9 Remove gearshift rail 06.100.
06.100
035383_1
1380 751 104 - 2014-06 13-4

10 Remove lifting device 1X56 196 595.
1X56 196 595
1X56 196 585
035353_1
11 Carefully pull the countershaft away from the

main shaft (see arrow). Remove input shaft
02.010 from main shaft 04.010.
02.010
12 Remove clutch body 02.030 from the main

shaft.
02.030
035379_1
1380 751 104 - 2014-06 13-5

13.2 Installing the shaft package
/30
/30 /30
/40
/20
/30
06.150 /40
06.100 4x30
/010
/30
6x30
/30
/40 /20
/010
3,5x40
/60 /60
/50
6x30 06.010
06.280
/50
06.200 /010
06.040
06.050 06.220
06.210 /40 /20
/30
06.030
/60
3,5x40
/60
06.240 /50
/50 6x30
06.250 06.230
035374_1
Shifting parts /30 Straight pin (2x)

/40 Driver
NOTE /50 Straight pin (6x30)
Check shifting parts for damage. Replace damaged /60 Straight pin (3.5x30)
parts.
06.200 5th/6th gear gearshift rail
06.010 Gearshift shaft 06.210 5th/6th gear gearshift fork
06.030 Pivot detent 06.220 Swivel screws
06.040 Set screw 06.230 Swivel screws
06.050 Gearshift lock 06.240 Sliding block
06.100 R gear gearshift rail (complete) 06.250 Sliding block
/10 Gearshift rail 06.280 3rd/4th gear gearshift rail
/20 R gear shift fork /10 Gearshift rail
/30 Straight pin 2x (6x30) /20 Shift fork 3/4
/40 Straight pin 2x (4.0x30) /30 Straight pin (2x)
06.150 1st/2nd gear gearshift rail /40 Driver
/10 Gearshift rail /50 Straight pin (6x30)
/20 Shift fork 1/2 /60 Straight pin (3.5x30)
1380 751 104 - 2014-06 13-6

1 Place clutch body 02.030 on the main shaft.
2 Place input shaft 02.010 on the main shaft.

02.010
NOTE
Make sure that baffle plate 02.040 is installed
in the input shaft (see Chapter 12).
3 Slide the countershaft on the main shaft and

02.030
mesh the gearings.
035379_2
4 Place assembly fixture 1X56 196 595 over the

input shaft and countershaft. Slide guide
sleeves over gearshift rails. Swivel 2 brackets
underneath the helical gear until the detent
bolts (at the top) have engaged and locked.
Attach assembly fixture 1X56 196 595 to
1X56 196 595
hoist hooks.
1X56 196 585
035353_1
1380 751 104 - 2014-06 13-7

5 Mesh R gear gearshift rail 06.100 with the

shift fork on the shaft package. Slide the
guide sleeve of lifting device 1X56 196 595
over the R gear gearshift rail.
06.100
035383_1
6 Mesh 1st/2nd gear gearshift rail 06.150 with

the shift fork on the shaft package. Slide the
over the 1st/2nd gear gearshift rail.
06.150
035384_1
7 Assembly instructions:
Pay attention to the position of the gearshift
rails to each other.
Driver 06.190 of 1st/2nd gear gearshift rail
06.150
06.100
06.150 surrounds R gear gearshift rail 06.100.
06.190
019342_2
1380 751 104 - 2014-06 13-8

8 Mesh 3rd/4th gear gearshift rail 06.280 with

the shift fork on the shaft package. Slide the
over the 3rd/4th gear gearshift rail.
06.280
1X56 196 595
1X56 196 585
035385_1
9 Insert the shaft package into housing II using

lifting device 1X56 196 595; in doing so, 1X56 196 595
make sure that the gearshift rails mount into
the housing bores.
Remove lifting device 1X56 196 595.
035387_1
10 Insert 5th/6th gear gearshift rail 06.200.
Assembly instructions:
Pay attention to the position of the gearshift
rails to each other.Driver 06.270 of 3rd/4th
gearshift rail 06.280 surrounds the 5th/6th
gear gearshift rail 06.200. 06.200
11 Insert the 5th/6th gear gearshift fork into the

06.210
sliding sleeve with sliding blocks 06.240 /

06.250. Ensure the meshing of the gearshift
fork in 5th/6th gear gearshift shaft 06.200
(see arrow).
028994
1380 751 104 - 2014-06 13-9

12 Insert intermediate gear 05.050 and make

sure that the long collar points up.
13 Mesh intermediate gear 05.050 in the

housing with the countershaft and align it
to the bore for the reverse idler gear bolt.
Apply a bit of oil to the 2 needle rings (needle
roller and cage assemblies) 05.020/05.030
and insert them in the intermediate gear.
05.020
05.030
05.050
035392_1
14 Insert half shell 05.060 and then reverse idler

gear bolt 05.010 (in correct position). Align
bore of reverse idler gear bolt 05.010, half
shell 05.060, and housing 01.200 to each
other using centering tool 1X56 196 596
(see arrow).
1X56 196 596
05.010 05.060 05.050
035391_3
15 Screw in the cap screw with new Usit ring

05.070.
035390
1380 751 104 - 2014-06 13-10

16 Insert gearshift shaft 06.010 with gearshift

detent 06.030 (see image).
06.010
06.030
035363_2
17 Insert the 4 detent pins 06.360. 06.370
18 Insert the 4 compression springs 06.350. 06.350
19 Insert 4 new cover plates 06.370 with

06.360
appropriate tool.
035375
1380 751 104 - 2014-06 13-11

13-12
ZF-Ecolite Synchronizers
14 Synchronizers
14.1 ZF-BK synchronizer

X
The condition of the synchronizer rings and

clutch bodies must be checked before the
synchronizers are assembled.
B
NOTE
Do not mix up synchronizer parts. A
Determine wear
1 Place the synchronizer ring (A) onto the

corresponding clutch body (B). Turn the
synchronizer parts and thereby ensure the
even and parallel contact of the tapers.
The wear limit for the synchronizer rings in

the synchronizers for the 3rd/4th gear and
5th/6th gear is 0.8 mm.
2 Measure distance “X” between the clutch

body and the synchronizer ring with the feeler
gage at two opposite points. If the wear limit 029007
falls below 0.8 mm, the synchronizer ring
and the clutch body must be replaced.
3 Also check the condition of the synchronizer

parts (visual check). If the surface is
corrugated, replace synchronizer parts.
Do not mix up parts which have been
checked together (mark them).
1380 751 104 - 2014-06 14-1

14-2
ZF-Ecolite Main shaft
04.320
04.350
04.360
04.370
04.370/060 04.150
04.370/020 04.180
04.190
04.370/040 04.190/060
04.370/050
04.370/010 04.190/020
04.370/030 04.190/040
04.190/050
04.190/010
04.190/030
04.260 04.250
04.400
04.280
04.410
04.270
04.160
04.290
04.310
035396
15 Main Shaft 5 Pull off sliding sleeve 04.370/020.
15.1 Disassembling the main shaft 6 Remove the 3 thrust pieces 04.370/040 and
the 3 compression springs 04.370/050 from
1 Place main shaft at output end into assembly 5th/6th gear synchronizer body 04.370/010.
fixture 1X56 196 585.
7 Place the transition piece on main shaft
2 Extract tapered roller bearing 04.410 using 04.010 and use a three-armed extractor to
extracting device 1X56 196 841 and 3-armed grab it from behind on clutchbody 04.360.
puller.
8 Pull off clutchbody 04.360, synchronizer ring
3 Remove securing ring 04.400. 04.370/060, and synchronizer body
04.370/010.
NOTE
Tie up the synchronizer parts of the 9 Remove 6th gear helical gear 04.350.
synchronizer for assembly.
10 Remove separated needle ring (needle roller
4 Remove synchronizer ring 04.370/030. and cage assemblies) 04.320.
DANGER
In the course of the following work step, three
thrust pieces are released, each fitted with a
compression spring. Use a cloth to prevent parts
from jumping out.
1380 751 104 - 2014-06 15-1

04.320
04.350
04.360
04.370
04.370/060 04.150
04.370/020 04.180
04.190
04.370/040 04.190/060
04.370/050
04.370/010 04.190/020
04.370/030 04.190/040
04.190/050
04.190/010
04.190/030
04.260 04.250
04.400
04.280
04.410
04.270
04.160
04.290
04.310
035396
11 Remove securing ring 04.310. helical gear 04.280, and washer 04.290.
12 16 Store the freed thrust pieces 04.190/040 and

compression springs 04.190/050 together.
DANGER
In the course of the following work step, three 17 Remove needle ring (needle roller and cage
thrust pieces are released, each fitted with a assemblies) 04.270.
compression spring. Use cloth to prevent parts
from jumping out. 18 Remove synchronizer ring 04.190/060.
Slide the retaining ring (part 1) of extractor 19 Remove securing ring 04.250.
1X56 137 512 over the main shaft.
20 Place the transition piece on the main shaft.
13 Insert the half shells of the extractor (part 2)
in sliding sleeve 04.190/020. 21 Use a three-armed extractor to grip 3rd gear
helical gear 04.160 from behind and pull off
14 Slide the retaining ring on and clamp down helical gear 04.160, clutch body 04.180, syn-
with a bolt. chronizer ring 04.190/060, and synchronizer
body 04.190/010.
15 Place the transition piece on main shaft
04.010. Position a commercially available 22 Remove needle ring (needle roller and cage
two- or three-armed extractor and pull off assemblies) 04.150.
sliding sleeve 04.190/020, synchronizer ring
04.190/030, clutch body 04.260,
1380 751 104 - 2014-06 15-2
04.065
04.060
04.060/060
04.060/020
04.060/040
04.060/050
04.060/010
04.060/030 04.500
04.050
04.020
04.030
04.140
04.130
04.010
04.120
04.080 04.100/010
/010 04.110
04.100/020
/020
04.090
04.070
035395
23 Turn main shaft 04.010 around and place 26 Take needle ring (needle roller and cage
input end into receiving part 1X56 196 592. assemblies) 04.070 off main shaft 04.010.
24 Place the transition piece on main shaft NOTE

04.010. Use a commercially available two- or Tie up the synchronizer parts of the
three-armed extractor to grip 1st gear helical synchronizer for assembly.
gear 04.080 from behind.
27 Remove clutch body 04.065 and synchronizer
25 Pull off 1st gear helical gear 04.080, washer ring 04.060/060.
04.090, bearing inner ring 04.100/020,
helical gear 04.110, needle ring 04.100/010, DANGER
sliding sleeve 04.120, clutch body 04.130, In the course of the following work step, three
bearing inner ring 04.140, impulse disk thrust pieces are released, each fitted with a
04.500. compression spring. Use a cloth to prevent the
parts from jumping out.
28 Pull off 1st/2nd gear sliding sleeve

04.060/020.
1380 751 104 - 2014-06 15-3

04.065
04.060
04.060/060
04.060/020
04.060/040
04.060/050
04.060/010
04.060/030 04.500
04.050
04.020
04.030
04.140
04.130
04.010
04.120
04.080 04.100/010
/010 04.110
04.100/020
/020
04.090
04.070
035395
29 Remove the 3 thrust pieces 04.060/040, each

fitted with compression spring 04.060/050,
from 1st/2nd gear synchronizer body
04.060/010.

04.010. Use a three-armed puller to grip
helical gear 04.030 from behind.
Extract helical gear 04.030, clutch body
04.050, synchronizer ring 04.060/030,
synchronizer body 04.060/010, and bearing
inner ring 04.070/020.
31 Take needle ring 04.020 off main shaft

04.010.
1380 751 104 - 2014-06 15-4

04.065
04.060
04.060/060
04.060/020
04.060/040
04.060/050
04.060/010
04.060/030 04.500
04.050
04.020
04.030
04.140
04.130
04.010
04.120
04.080 04.100/010
/010 04.110
04.100/020
/020
04.090
04.070
035395
15.2 Assembling the main shaft

DANGER
1 Insert main shaft 04.010 at the input end into
stabilizer 1X56 196 592.
3 Apply a light coat of oil to needle ring (needle Heat up synchronizer body 04.060/010 to
roller and cage assemblies) 04.020 and slide max. 150 °C and press onto the gearing of
onto main shaft 04.010. the main shaft with tool 1X56 196 593 until
firmly home (axial abutment).
2 Slide 2nd gear helical gear 04.030 onto need- Press-on force: 50 kN
le ring (needle roller and cage assemblies)
04.020 so that the drive gearing points to the 7 Push sliding sleeve 04.060/020 over synchro-
output. nizer body 04.060/010 and press against the
clutch body.
4 Place 1st/2nd gear clutch body 04.050 onto
helical gear 4.030. 8 Insert the 3 new compression springs
04.060/500 and available thrust pieces
5 Place synchronizer ring 04.060/030 onto 04.060/040 into synchronizer body
clutchbody 04.050. 04.060/010.
6 NOTE
9 Place synchronizer ring 04.060/060 onto
The synchronizer body 04.060/010 must be
synchronizer body 04.060/010.
aligned in such a way that recesses match
lugs of synchronizer ring 04.060/030 when
positioning it.
1380 751 104 - 2014-06 15-5
04.065
04.060
04.060/060
04.060/020
04.060/040
04.060/050
04.060/010
04.060/030 04.500
04.050
04.020
04.030
04.140
04.130
04.010
04.120
04.080 04.100/010
/010 04.110
04.100/020
/020
04.090
04.070
035395
10 Place clutchbody 04.065 onto synchronizer assemblies) 04.070/010 so that the drive
ring 04.060/060. gear points to the input.
Check wear of synchronizer parts, refer to
Chapter Synchronizer. DANGER
DANGER protective gloves. RISK OF BURNS!
protective gloves. RISK OF BURNS! 14 Heat washer 04.090 to max. 150 °C
(temperature difference between washer and
11 Heat bearing inner ring 04.070/020 to max. main shaft should be ∆t 110 °C) and use tool
150 °C (temperature difference between 1X56 196 588 to press it onto the gearing of
bearing inner ring and main shaft should be the main shaft until firmly home (axial abut-
∆t 110 °C) and use tool 1X56 196 593 to ment).
press it onto the gearing of the main shaft Press-on force: 50 kN
until firmly home (axial abutment).
Press-on force: 50 kN
12 Apply a thin coat of oil to needle ring (needle

roller and cage assemblies) 04.070/010 and
slide it over bearing inner ring 04.070/020.
13 Slide 1st gear helical gear 04.080 onto

needle ring (needle roller and cage
1380 751 104 - 2014-06 15-6

04.065
04.060
04.060/060
04.060/020
04.060/040
04.060/050
04.060/010
04.060/030 04.500
04.050
04.020
04.030
04.140
04.130
04.010
04.120
04.080 04.100/010
/010 04.110
04.100/020
/020
04.090
04.070
035395
DANGER DANGER
Only touch heated parts when wearing Only touch heated parts when wearing
protective gloves. RISK OF BURNS! protective gloves. RISK OF BURNS!
15 Heat bearing inner ring 04.100/020 to max. 20 Heat clutch body 04.130 to max. 150 °C and
150 °C and use tool 1X56 196 593 to press it use tool 1X56 196 593 to press it onto the
onto the gearing of the main shaft until firmly gearing of the main shaft until firmly home
home (axial abutment). (axial abutment).
Press-on force: 50 kN Press-on force: 50 kN
16 Apply a thin coat of oil to needle ring (needle 21 Press on the inner ring of tapered roller
roller and cage assemblies) 04.100/010 and bearing 04.140 with tool 1X56 196 591 until
slide it onto bearing inner ring 04.100/020. firmly home.
17 Slide helical gear 04.110 onto needle ring
(needle roller and cage assemblies) 22 Press impulse disk 04.500 on until firmly
04.100/010. home using tool 1X56 196 591.
18 Place sliding sleeve 04.120 onto helical gear
04.110.
19 Slide on sleeve 1X56 196 594.
1323 751 002 - 2005-05 15-7

04.320
04.350
04.360
04.370
04.370/060 04.150
04.370/020 04.180
04.190
04.370/040 04.190/060
04.370/050
04.370/010 04.190/020
04.370/030 04.190/040
04.190/050
04.190/010
04.190/030
04.260 04.250
04.400
04.280
04.410
04.270
04.160
04.290
04.310
035396
23 Turn main shaft 04.010 around and place it

at output end into assembly fixture DANGER
1X56 196 585. Only touch heated parts when wearing
roller and cage assemblies) 04.150 and slide 28 Heat up synchronizer body 04.190/010 to
it onto main shaft 04.010. approx. 150 °C and press it onto the gearing
of the main shaft with tool 1X56 196 593
25 Slide 3rd gear helical gear 04.160 onto need- until firmly home (axial abutment).
le ring (needle roller and cage assemblies) Press-on force: 50 kN
04.150 so that the drive gear points to the
input. 29 Securing ring 04.250 must rest firmly on the
groove base when it snaps in.
26 Place 3rd gear clutch body 04.180 onto
helical gear 4.160. 30 Push sliding sleeve 04.190/020 over synchro-
nizer body 04.190/010 and press it against
27 Place synchronizer ring 04.190/060 onto clutch body 04.180.
clutchbody 04.180.
31 Insert 3 new compression springs 04.190/050
NOTE and available thrust pieces 04.190/040 into
The synchronizer body 04.190/010 must be synchronizer body 04.190/010.
aligned in such a way that recesses match
lugs of synchronizer ring 04.190/060.
1380 751 104 - 2014-06 15-8

04.320
04.350
04.360
04.370
04.370/060 04.150
04.370/020 04.180
04.190
04.370/040 04.190/060
04.370/050
04.370/010 04.190/020
04.370/030 04.190/040
04.190/050
04.190/010
04.190/030
04.260 04.250
04.400
04.280
04.410
04.270
04.160
04.290
04.310
035396
32 Place synchronizer ring 04.190/030 on syn- 37 Securing ring 04.310 must rest firmly on the
chronizer body 04.190/010. groove base when it snaps in.
33 Place clutchbody 04.260 onto synchronizer 38 Apply a thin coat of oil to needle ring (needle
ring 04.190/030. roller and cage assemblies) 04.320 and place
it on main shaft 04.010.
roller and cage assemblies) 04.270 and slide 39 Slide 6th gear helical gear 04.350 onto
over main shaft 04.010. needle ring (needle roller and cage assem-
blies) 04.320 so that the drivegear points to
35 Slide 4th gear helical gear 04.280 onto the input.
needle ring (needle roller and cage assem-
blies) 04.270 so that the drive gear points to 40 Place 6th gear clutch body 04.360 onto
the output. helical gear 4.350.
DANGER 41 Place synchronizer ring 04.370/060 onto

Only touch heated parts when wearing clutch body 04.360. Check wear on synchro-
protective gloves. RISK OF BURNS! nizer parts, see Chapter Synchronizer.
36 Heat washer 04.290 to max. 150 °C and use

tool 1X56 196 588 to press it onto the
gearing of the main shaft until firmly home
(axial abutment). Press-on force: 50 kN
1380 751 104 - 2014-06 15-9

04.320
04.350
04.360
04.370
04.370/060 04.150
04.370/020 04.180
04.190
04.370/040 04.190/060
04.370/050
04.370/010 04.190/020
04.370/030 04.190/040
04.190/050
04.190/010
04.190/030
04.260 04.250
04.400
04.280
04.410
04.270
04.160
04.290
04.310
035396
45 Insert 3 new compression springs

DANGER
04.370/050 and available thrust pieces
04.370/040 into synchronizer body
04.370/010.
42 Heat up synchronizer body 04.370/010 to
46 Place synchronizer ring 04.370/030 synchro-
max. 150 °C and press it onto the gearing of
nizer body 04.370/010.
the main shaft with tool 1X56 196 593 until
firmly home (axial abutment).
47 Heat bearing inner ring 04.410 to max.
150 °C and use press-in fixture
1X56 196 598 to press in until firmly home.
43 Securing ring 04.400 must rest firmly on the
44 Push sliding sleeve 04.370/020 over synchro-

nizer body 04.370/010 and press against
clutch body 04.360.
1380 751 104 - 2014-06 15-10

ZF-Ecolite Countershaft
03.090
03.010
03.020
03.030
03.040
03.050
03.070
03.060
035394
16 Countershaft 6 Screw basic device 1X56 122 304 onto the

assembly aid and extract tapered roller
16.1 Disassembling the countershaft bearing inner ring 03.070.
1 Insert receiving part 1X56 196 587 into the CAUTION

assembly fixture 1X56 196 585 and adjust If necessary, replace tapered roller bearings
countershaft. Place the transition piece on 03.090 and 03.070; the bearing rollers may be
the output end of countershaft 03.010. damaged when removed.
2 Grip output-end tapered roller bearing inner 7 Remove securing ring 03.060.
ring 03.090 from behind using assembly aid
1X56 136 741. 8 Use a suitable hydraulic press to press off
helical gears 03.050/03.040/03.030 and
3 Screw basic device 1X56 122 304 onto the 03.020 one at a time, due to the high
assembly aid and extract tapered roller extraction forces required. The press-off force
bearing inner ring 03.090. for each helical gear is up to 500 kN.
4 Place the transition piece onto the input end NOTE

of countershaft 03.010. In order to avoid tooth damage, do not press
off via gears. Support countershaft and/or
5 Grip input-end tapered roller bearing inner helical gears with a soft base.
ring 03.070 from behind using assembly aid
1X56 136 741.
1380 751 104 - 2014-06 16-1

03.090
03.010
03.020
03.030
03.040
03.050
03.070
03.060
035394
16.2 Assembling the countershaft Slide helical gear 03.030 onto the counter-
shaft - the thinner part of the hub points to
1 Place sleeve 1X56 196 599 on the bearing helical gear 03.020 - with sleeve
journal of the countershaft as protection 1X56 196 588 and sleeve 1X56 196 589
during assembly. until firmly home. The helical gear must abut
axially.
DANGER Press-on force: max. 150 kN
protective gloves. RISK OF BURNS! 4 Heat helical gear 03.040 to max. 170 °C.
Press helical gear 03.030 onto the counter-
2 Heat helical gear 03.020 to max. 170 °C. shaft - the offset part of the hub points to the
Press helical gear 03.020, hub points to input - with sleeve 1X56 196 589 until firmly
input, onto the countershaft with sleeve home. Helical gear must abut axially.
1X56 196 588 and sleeve 1X56 196 589 Press-on force: max. 150 kN
until firmly home.
Helical gear must abut axially. 5 Heat helical gear 03.050 to max. 170 °C.
Press-on force: max. 150 kN Press helical gear 03.050 onto the counter-
shaft - hub points to helical gear 03.040 -
3 Heat helical gear 03.030 to max. 170 °C. with sleeve 1X56 196 589 until firmly home.
Helical gear must abut axially.
Press-on force: max. 150 kN
1380 751 104 - 2014-06 16-2

03.090
03.010
03.020
03.030
03.040
03.050
03.070
03.060
035394
6 Securing ring 03.060 must rest firmly on the


1X56 196 590 to press on until firmly home.
Press-on force: max 50 kN

1X56 196 590 to press on until firmly home.
Press-on force: max 50 kN
1380 751 104 - 2014-06 16-3

16-4
ZF-Ecolite Bearing Setting for Input Shaft and Countershaft
17 Bearing setting for input shaft and

countershaft
17.1 Bearing seat of the input shaft
As preload cannot be measured directly, a

thin disk “C” has to be inserted for measure-
ment so that a bearing clearance is generated.
This can then be measured.
Example:
Insert disk 02.090 with thickness “C”
= 1.20 mm (as measuring basis).
10_001456_01
Disks available: 1.20 to 2.00 mm

grading 0.05 mm
NOTE
Do not insert ring 02.080 as this could be 1X56.138.801
damaged when uninstalling and installing it
several times.
When calculating the disk thickness “D”, ring

02.080 has to be considered with 0.3 mm.
1X56.196.597
1 Place tool 1X56 138 801 on housing and

screw tightly.
DANGER
protective gloves.
10_000894_01

air blower.
Align bearing outer ring 02.070 to the bearing

2 Use press-in device 1X56 138 801 to press in

until firmly home.
10_000895_01
1380 751 104 - 2014-06 17-1

17.2 Bearing seat of the countershaft
Example:
Insert disk 03.080 with thickness “C”
= 1.40 mm (as measuring basis).

grading 0.05 mm
NOTE
03.080
If there is still no clearance with the thinnest

disk, 0.1 mm may need to be grinded off.
035878_1

screw tightly.
1X56.138.801
DANGER
protective gloves.

1X56.196.597
air blower.
Align bearing outer ring 03.070 to the bearing

10_000894_01
3 Use press-in device 1X56 138 801 to press in

until firmly home.
10_001444_01
1380 751 104 - 2014-06 17-2

3 Position and fix lifting device 1X56 196 595

over the input shaft and countershaft and
hang on crane hook.
1X56 196 595
1X56 196 585
035353_1
4 Use lifting device 1X56 196 595 to insert

shaft package into housing II and remove
lifting device.
035387_1
5 Mount 2 eyebolts 1T66 159 409 on housing I

01.010.
NOTE
Consider dangers when working with load
lifting device.
6 Carefully set housing I 01.010 onto housing II

01.200.
Mount 8 screws (regularly distributed around
circumference).
035365
1380 751 104 - 2014-06 17-3

17.3 Countershaft bearing setting
1 Secure dial gage holder to PTO opening.
2 Turn countershaft several times back and

forth.
3 Apply dial gage at helical gear of 6th gear

03.040 and adjust it to ZERO.
Legend for sample calculation:

“A” = Existing axial clearance
“B” = Average preload as starting situation
“C” = Measuring disk with thickness e.g.:
1.40 mm
“D” = Thickness of the required disk 012888
Always select the disk whose thickness is clo-

sest to the calculated value.
Grading 0.05 mm
4 Using a pry bar, grip 6th gear helical gear

03.110 and press the countershaft into the
input-end bearing until you can clearly feel
abutment.
5 Read the axial clearance "A" (e.g.: 0.18) off

the dial gage and note down.
6 Specified preload
Setting dimension: 0.02 to 0.09 mm
012887
Average setting dimension “B” = 0.04 mm
Thickness "D" of required disk is determined

as follows: A+B+C=D
Example:
A + B + C = D
0.18 + 0.04 + 1.40 = 1.62 mm
Calculated disk thickness “D” = 1.62 mm.

Select closest disk thickness
“D” = 1.60 mm
7 Remove dial gage and dial gage holder.
1380 751 104 - 2014-06 17-4

17.4 Input shaft bearing setting
1 Turn input shaft several times back and forth.
2 Secure dial gage holder to housing I.
3 Set dial gage onto input shaft and adjust to

ZERO.
10_001457_01
4 Pull input shaft up until firmly home with

approx. 100 to 200 N and read and note
indicated value from dial gage.
Legend for sample calculation:

“A” = axial play available
“B” = assumed mean of the specified setting
dimension as starting situation
“C” = measuring disk with thickness e.g.:
1.20 mm
“R” = ring 02.080 with dimension 0.3 mm
“D” = thickness of the required disk
Always select the disk with the most suitable

thickness taken from the calculation.
10_001458_01
Grading 0.05 mm
6 Specified preload
Setting dimension: 0.02 to 0.09 mm
Mean of setting dimension “B” = 0.04 mm
preload
Determine thickness “D” of the required disk
as follows:
A+B+C–R=D
Example:
A + B + C – R = D
0.65 + 0.04 + 1.20 – 0.3 1.59 mm
Calculated disk thickness “D” = 1.59 mm.

Select most suitable disk thickness
“D” = 1.60 mm
1380 751 104 - 2014-06 17-5

6 Mount two eyebolts 1T66 159 409 on

housing I 01.010.
NOTE
lifting attachment.
Remove eight screws 01.230.
Carefully lift housing I 01.010 off housing II

01.200.
7 Lift shaft package with lifting device

1X56 196 595 out of housing II.
8 Remove the bearing outer rings 02.070 and 035365

03.070, again as described in Chapter
Dismantling housing I.
Remove the measuring disks “C” 02.090 and

03.080 and insert the accordingly selected
disks.
9 Further procedure as described in Chapter

Assembling housing I.
1380 751 104 - 2014-06 17-6

Table of revisions: 1380 751 104
Index Date of issue Chapter Initiator Comment
1380 751 104 - 2014-06

ZF Friedrichshafen AG
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-908 000
www.zf.com
EN 1380 751 104 - 2014-06

Repair Instructions: Zf-Ecolite 6 S 500 BO Level 3

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REPAIR INSTRUCTIONS

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Preparatory work .............................................................................................................................. 27

1 Impulse sensor .................................................................................................................... 1-1

2 Output flange ...................................................................................................................... 2-1

3 Parking brake ...................................................................................................................... 3-1

4 Fixture ................................................................................................................................. 4-1

5 Clutch release mechanism .................................................................................................. 5-1

6 Shaft sealing ring output side ............................................................................................. 6-1

7 Switches ............................................................................................................................. 7-1

8 Shift System ........................................................................................................................ 8-1

1380 751 104 - 2014-06 3

9 Guide tube and shaft sealing ring ....................................................................................... 9-1

10 Cover ................................................................................................................................... 10-1

11 Housing I ............................................................................................................................. 11-1

12 Input shaft ........................................................................................................................... 12-1

13 Shaft package ..................................................................................................................... 13-1

15 Main Shaft........................................................................................................................... 15-1

16 Countershaft ....................................................................................................................... 16-1

17 Bearing Setting for Main and Countershaft ........................................................................ 17-1

Table of revisions: 1380 751 104

1380 751 104 - 2014-06 4

Object of documentation is a volume-produced ZF product. State of design acc. to date of issue.

1380 751 104 - 2014-06 5

General safety instructions

Intended use / liability / guarantee / warranty

1380 751 104 - 2014-06 6

1380 751 104 - 2014-06 7

1380 751 104 - 2014-06 8

Handling operating fluids and consumables

1380 751 104 - 2014-06 9

Signal words and symbols

1380 751 104 - 2014-06 10

Instructions for Repair and Assembly

Cleaning the ZF product prior to disassembly

1380 751 104 - 2014-06 11

▪ Thoroughly clean all reusable components after disassembly.

Authorized, specialized staff assess whether parts can be reused.

1380 751 104 - 2014-06 12

Authorized, specialized staff assess whether parts need to be reworked or replaced.

1380 751 104 - 2014-06 13

* refer to Operating supplies and auxiliary materials

1380 751 104 - 2014-06 14

This standard applies to bolts according to

Surface condition of screws/nuts:

The bolts are tightened using a calibrated torque wrench.

Coarse thread Fine thread

Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

M4 2,8 4,1 4,8 M8x1 24 36 43

M12 79 115 135 M14x1.5 135 200 235

M18 280 390 460 M18x2 290 420 490

M24 670 960 1100 M24x1.5 760 1100 1250

M27x2 1050 1500 1800

Status: August 1991

1380 751 104 - 2014-06 15