Catalogo Caja ZF 170

Reparaturanleitung
Repair Manual
Manuel de Réparation
Manual de Reparaciones
Manuale di Riparazione
ZF - 6 S 1601 BD
ZF - 6 S 1701 BO
ZF - 6 S 1901 BO
1349 751 103

Subject to alterations in design
Copyright by ZF
This documentation is protected by copyright.

Any reproduction or dissemination in whatever
form which does not comply fully with the intended
purpose of this documentation is prohibited without
the consent of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG
Edition: 2005-12
1349 751 103

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Table of Contents
Preface ........................................................................................................................................................... 5
Safety Instructions ......................................................................................................................................... 6
General Information ...................................................................................................................................... 6
Instructions for Repairs ................................................................................................................................. 7
Overview of Amendments ............................................................................................................................ 9
Tightening torques ........................................................................................................................................ 10
Conversion from DIN to ISO Standards ....................................................................................................... 12
Consumables .................................................................................................................................................. 14
Adjustment/Setting Data ............................................................................................................................... 15
Special Tool ................................................................................................................................................... 16
1 Oil Filter ............................................................................................................................................. 1-1

1.1 Disassembling Oil Filter ..................................................................................................................... 1-1
1.2 Assembling Oil Filter.......................................................................................................................... 1-3
2 Central Wiring ................................................................................................................................... 2-1

2.1 Removing Central Wiring .................................................................................................................. 2-1
2.2 Installing Central Wiring.................................................................................................................... 2-1
3 Stainless Steel Heat Exchanger......................................................................................................... 3-1

3.1 Disassembling Stainless Steel Heat Exchanger ................................................................................. 3-1
3.2 Assembling Stainless Steel Heat Exchanger...................................................................................... 3-6
4 Sectional View Through Intarder with Reducing Unit .................................................................. 4-1
5 Removing/Installing ZF-Intarder...................................................................................................... 5-1

5.1 Removing Intarder from Basic Transmission .................................................................................... 5-1
5.2 Installing Intarder on Basic Transmission ......................................................................................... 5-2
6 Disassembling/Assembling ZF-Intarder........................................................................................... 6-1

6.1 Removing and Dismantling Oil Pump ............................................................................................... 6-1
6.2 Assembling and Mounting Oil Pump................................................................................................. 6-2
6.3 Removing Control Housing ................................................................................................................ 6-3
6.4 Installing Control Housing ................................................................................................................. 6-4
6.5 Removing Valves from Control Housing ........................................................................................... 6-6
6.6 Installing Valves in Control Housing ................................................................................................. 6-8
6.7 Removing Spur Gear .......................................................................................................................... 6-10
6.8 Removing Stator ................................................................................................................................. 6-11
6.9 Removing Reducing Unit ................................................................................................................... 6-12
6.10 Removing Idle Speed Reducing Valve ............................................................................................... 6-13
6.11 Removing Preload Valve..................................................................................................................... 6-13
6.12 Removing Rotor .................................................................................................................................. 6-14
6.13 Removing Idle Speed Reducing Valve ............................................................................................... 6-15
6.11 Installing Preload Valve...................................................................................................................... 6-15
6.15 Installing Rotor ................................................................................................................................... 6-16
6.16 Configuring the Reducing Unit.......................................................................................................... 6-17
6.17 Installing Stator ................................................................................................................................. 6-18
6.18 Fitting Stator, Taper Roller Bearing and Spur Gear .......................................................................... 6-19
1349 751 103 - 2005-12 3

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Table of Contents
6.19 Fitting Taper Roller Bearing to Rotor and Adjusting Taper Roller Bearing...................................... 6-20
6.20 Measuring Axial Clearance................................................................................................................ 6-21
6.21 Removing Helical Gear ...................................................................................................................... 6-22
6.22 Installing Helical Gear........................................................................................................................ 6-23
7 ZF-Servoshift Without Selection Equipment for Cable Control ..................................................... 7-1

7.1 Disassembly of ZF-Servoshift Without Selection Equipment for Cable Control ............................. 7-1
7.2 Assembly of ZF-Servoshift Without Selection Equipment for Cable Control.................................. 7-7
8 Input-End Add-On Parts .................................................................................................................... 8-1

8.1 Removal ............................................................................................................................................ 8-1
8.2 Fitting .................................................................................................................................................. 8-2
9 Bearing Setting on Main Shaft, Input Shaft, and Countershaft ..................................................... 9-1
9.1 Setting Input Shaft and Main Shaft ................................................................................................... 9-1
9.2 Setting Countershaft........................................................................................................................... 9-3
10 Housing Cover.................................................................................................................................... 10-1

10.1 Removal ............................................................................................................................................ 10-1
10.2 Dismantling Housing Cover ............................................................................................................... 10-2
10.3 Assembling Housing Cover ................................................................................................................ 10-3
10.4 Fitting .................................................................................................................................................. 10-4
11 Removing and Installing Shafts........................................................................................................ 11-1

11.1 Removing Reverse Gear Pin............................................................................................................... 11-1
11.2 Removing Input Shaft, Main Shaft, and Countershaft ..................................................................... 11-2
11.3 Installing Input Shaft, Main Shaft, and Countershaft....................................................................... 11-4
11.4 Installing Reverse Gear Pin................................................................................................................ 11-6
12 Input Shaft ......................................................................................................................................... 12-1

12.1 Disassembly ........................................................................................................................................ 12-1
12.2 Assembly............................................................................................................................................. 12-2
13 Main Shaft ......................................................................................................................................... 13-1

13.1 Disassembly ........................................................................................................................................ 13-1
13.2 ZF-BK Synchronizer ........................................................................................................................... 13-6
13.3 Assembly............................................................................................................................................. 13-8
14 Countershaft ..................................................................................................................................... 14-1

14.1 Dismantling Countershaft .................................................................................................................. 14-1
14.2 Assembly............................................................................................................................................. 14-2
15 Housing............................................................................................................................................... 15-1
15.1 Disassembling Transmission Housing ............................................................................................... 15-1
15.2 Assembling Transmission Housing.................................................................................................... 15-2
1349 751 103 - 2005-12 4

Preface
This manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with a ZF product in accordance

with the state of development on the date of issue.
However, due to continuing development of the

product, repair work might require work practices
and test or adjustment data which are not contained
in this manual.
We therefore recommend that work done on your
ZF product is carried out only by skilled mechanics
and fitters who have had their practical and theore-
tical knowledge updated on a regular basis at our
After-Sales Service training courses.
Service points equipped by ZF Friedrichshafen AG

all over the world offer you:
1. Well-trained personnel,
2. Specified equipment,
e.g.: Special tools,
3. Genuine ZF spares, according to

our latest specifications
All work performed at these service locations is

carried out conscientiously and with care.
Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
the individual case.
ZF Friedrichshafen AG
Nutzfahrzeug- und Sonder-Antriebstechnik Damage resulting from work performed by non-ZF
Commercial Vehicle and personnel in an improper and unprofessional man-
Special Driveline Technology ner, together with follow-on costs caused by such
Service Werk 2 (Plant 2) work, is excluded from the contractual warranty
Phone: +49 (0)7541 77-0 agreement.
Fax: +49 (0)7541 77-908000 This also applies where genuine ZF spare parts have
Internet: www.zf.com not been used.
2003-08 5
Important Information
Safety Instructions General Information
Companies repairing ZF units are responsible for Read this manual carefully before starting any tests
their own work safety. or repair work.
To avoid injury to personnel and damage to

products, all safety regulations and legal require- CAUTION
ments which apply to repair and maintenance Pictures, drawings, and components do not always
work must be adhered to. represent the original object, but are used to illus-
Before starting work, mechanics must familiarize trate working procedures.
themselves with these regulations. Pictures, drawings, and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF drawn (even within a complete illustration).
products must receive appropriate training in Always follow the working steps as described in the
advance. It is the responsibility of each company to text.
ensure that their repair staff is properly trained.
After completion of repair work and testing, skilled

staff must check whether the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants, consumables, and cleaning agents must
Refers to special processes, techniques, data, use of not be allowed to enter the soil, ground water, or
auxiliary equipment, etc. sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere
CAUTION to their requirements.
This is used when incorrect, unprofessional work- • Collect used oil in a suitably large container.
ing practices could damage the product. • Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
! DANGER • When working with lubricants and cleaning agents
This is used when lack of care could lead to personal always refer to the manufacturer’s instructions.
injury or death.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
2005-04 6
Instructions for Repairs
ZF Service Information must be observed. This Gaskets, Locking plates

information is available at all ZF Service Centers
or via the ZF-ServiceLine. Parts which cannot be removed without being
damaged must always be replaced with new parts
In case of doubt always turn to the relevant depart- (e.g. gaskets and locking plates).
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed by
experts only and under clean conditions.
Use specified tools to dismantle and assemble Shaft Seals
transmissions.
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
After removing the transmission from the vehicle, totally clean and in perfect condition.
clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning. Reworking
Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
Cleaning parts If rework is needed on spacer discs, shims etc.

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

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

etc., must be inspected by a competent person who
should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.
2005-04 7
Instructions for Repairs
Bearings d) Dual shaft seals have two seal-

ing lips. The dust-proof sealing
If bearings are mounted in heated condition, they lip (X) must face outwards.
are to be heated evenly (e.g. heating cabinet). X
Temperature should be at approx. 85 °C and must e) Fill the gap between the sealing
not exceed 120 °C. Each mounted bearing must be lips so it is 60 % filled with grease (e.g. produced
oiled with operating oil. by Aral, such as Aralub HL2 or by DEA, such as
Spectron FO 20).
f) If possible, heat shaft seal bores to between

Sealing 40 and 50 °C (makes fitting easier). Press the
seal shaft with mounting or faceplate onto the
If a specific sealing agent* is to be used for sealing, relevant installation depth plan.
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces
and spread evenly. Do not allow sealing to enter oil
ducts and bores. On oil-carrying ducts and bores, Retaining Agents
wipe off the sealing agent on the surfaces to be
sealed near apertures to ensure that no sealing Retaining agents* may only be used in places as
agent enters the oil feeds when the surfaces are specified in the parts list.
sealed. Always comply with manufacturer’s directions for
use when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data, and tightening torques.
Shaft Seals
a) Apply a light coat of sealing agent* on circum-

ference of shaft seals with “steel jacket”. Transmission oil
b) Never apply sealing agent to shaft seals with After completing repairs, fill transmissions with
“rubber jacket”, but apply a thin coat of transmission oil. For the procedure and approved
Vaseline 8420 to the circumference or wet with oils, refer to the transmission operating manual and
a lubricant, e.g. a water-soluble, concentrated TE-ML List of Lubricants (refer to identification
washing-up liquid (e.g. Pril, Coin, Palmolive). plate) which are available from any ZF After-Sales
Service Point and on the Internet under
c) Shaft seals with steel and rubber jackets should www.zf.com.
be treated on the circumference of the rubber After filling the transmission with oil, tighten the
jacket as described above in section b). screw plugs at the oil filling point and the oil over-
flow using the specified torques.
* refer to expendable material
2003-08 8
List of Changes: 1349 751 103
Index Date of issue Chapter Initiator Comment
1349 751 103 - 2005-12 9

Tightening Torques
Tightening torques for nuts and bolts, extract

from ZFN 148
This standard applies to bolts according to DIN 912, Surface condition of bolts/nuts: Heat-treated black-
DIN 931, DIN 933, DIN 960, DIN 961 as well as ened finish and oiled or galvanized and oiled or gal-
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, vanized, chromated, and oiled.
and for nuts according to DIN 934 as well as ISO
4032, The bolts are tightened using an appropriate snap
ISO 8673. torque wrench or torque display wrench.
This standard contains data on tightening torques NOTE

for bolts and nuts of strength categories 8.8, 10.9, Divergent tightening torques are listed separately in
and 12.9 as well as nuts of strength categories 8, 10 the repair manual.
and 12.
Coarse-pitch thread Fine screw thread
Size Tightening torque in Nm for Size Tightening torque in Nm for

Screw/Bolt 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
2003-08 10
Tightening Torques
Screw plugs DIN 908, 910, and 7604 Union screws DIN 7643
The screw plug tightening torques were determined The tightening torques were determined for screw-
according to DIN 7604 for screwing into steel, gray ing into steel, gray cast, and aluminum alloys.
cast, and aluminum alloys. The values are based on The values are based on experience and are intend-
experience and are intended as reference values ed as reference values for the fitter.
for the fitter.
The values for tightening torque apply analogously General rule:
to screw plugs according to DIN 908 and DIN 910 as Screw / Bolt class 5, ZFN 148-1
the thread geometries are almost identical. Material: 9SMnPb28K acc. to DIN 1651
Surface condition: As manufactured (without sur-
General rule: face protection) and lightly oiled or galvanized,
Screw / Bolt class 5, ZFN 148-1 chromated, and lightly oiled.
Screw / Bolt material: Steel acc. to DIN 7604
Surface condition: As manufactured (without sur-
face protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)
Size Tightening torque in Nm Pipe Thread Tightening

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

DIN ISO standard
DIN 1 Tapered pins ISO 2339 - some can be replaced → changed to ISO 2339
- parts which cannot be replaced (e.g. where 1 = 36 mm)
documented as DIN 1 OLD
DIN 7 Cylindrical ISO 2338 - some can be replaced → changed to ISO 2338
pins - parts which cannot be replaced (e.g. diameter 13 and 14 and/or
where 1 = 36 mm) documented as DIN 7 OLD
screws - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD
DIN 85 Flat head bolts ISO 1580 - can be replaced → changed to ISO 1580
DIN 94 Split pins ISO 1234 - can be replaced → changed to ISO 1234
DIN 417 Threaded pins ISO 7435 - can be replaced → changed to ISO 7435
DIN 439-1 Hex nuts ISO 4036 - cannot be replaced → documented as DIN 439 OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675
DIN 555 Hex nuts ISO 4034 - cannot be replaced → documented as DIN 555 OLD
DIN 558 Hex bolts ISO 4018 - some can be replaced → changed to ISO 4018
- parts which cannot be replaced (e.g. M12, with new SW) documented as
DIN 558 OLD
- parts which cannot be replaced (e.g. M10 and M12, with new SW)
screws - parts which cannot be replaced (e.g. M18, M22, M27, and M33)
DIN 931-1 Hex bolts ISO 4014 - some can be replaced → changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14, and M22 with
new SW) documented as DIN 931 OLD
DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for
ISO 8673 M10, M12, M14, and M22 with new SW.
DIN 960 Hex bolts ISO 8765 - some can be replaced → changed to ISO8765
DIN 963 Countersunk ISO 2009 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 963 OLD
DIN 964 Countersunk ISO 2010 - cannot be replaced as a result of modified head dimensions → documented
1) with reference to productive parts numbered at ZF
2003-08 12
Conversion from DIN to ISO Standards
Withdrawn Title Substitute Result of check / measures 1)

DIN ISO standard
DIN 965 Countersunk ISO7046 - cannot be replaced as a result of modified head dimensions → documented
DIN 980 Locking nuts ISO 7042 - cannot be replaced → documented as DIN 980 OLD
ISO 10513
DIN 985 Locking nuts ISO 10511 - cannot be replaced → documented as DIN 985 OLD
DIN 1440 Washers ISO 8738 - some can be replaced → changed to ISO 8738
- parts which cannot be replaced documented as DIN 1440 OLD
DIN 1443 Bolts ISO 2340 - can be replaced → changed to ISO 2340
DIN 1444 Bolts ISO 2341 - can be replaced → changed to ISO 2340
DIN 1471 Grooved pins ISO 8744 - some can be replaced → changed to ISO 8744
- parts which cannot be replaced (e.g. 1 = 6 mm) documented as
DIN 1471 OLD
- parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as
DIN 1472 OLD
- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25 and 50 mm)
DIN 1474 Grooved pins ISO 8741 - can be replaced → changed to ISO 8741
DIN 1475 Grooved pins ISO 8742 - can be replaced → changed to ISO 8742
DIN 1476 Grooved stud ISO 8746 - can be replaced → changed to ISO 8746
DIN 1477 Grooved stud ISO 8747 - can be replaced → changed to ISO 8747
DIN 1481 Clamping pins ISO 8752 - some can be replaced → changed to ISO 8752
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD
DIN 6325 Cylindrical pins ISO 8734 - some can be replaced → changed to ISO 8734
DIN 7346 Clamping pins ISO 13337 - some can be replaced → changed to ISO 13337
Flange - parts which cannot be replaced (Ø 7, 11, and 23 mm) documented as
DIN 6325 OLD
DIN 7976 Self-tapping ISO 1479 - can be replaced → changed to ISO 1479
screws
DIN 7978 Tapered pins ISO 8736 - some can be replaced → changed to ISO 8736
DIN 7979 Cylindrical pins ISO 8733 - some can be replaced → changed to ISO 8733/8735
ISO 8735 - parts which cannot be replaced documented as DIN 7979 OLD
DIN 7981 Self-tapping ISO 7049 - can be replaced → changed to ISO 1479
screws
DIN 7982 Self-tapping ISO 7050 - cannot be replaced → documented as DIN 7982 OLD
screws
DIN 7985 Cheese-head ISO 7045 - can be replaced → changed to ISO 7045
screws
1) with reference to productive parts numbered at ZF
2003-08 13
6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Consumables
Designation Name Volume Application Comments

ZF item number Approx.
Grease For example:

0750 199 901 Renolit CX-TO 20
Renolit CX-EP 2
Glissando 283BP2
Sealing compound Loctite no. 574

0666 790 033
Jointing compound Loctite no. 241

0666 690 017
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
1349 751 103 - 2005-12 14

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Adjustment/Setting Data
Designation Dimension Measuring device Remark
Shared axial clearance 0 to 0.12 mm Depth gage Move taper roller bearing in
of input shaft and micrometer zero setting (zero backlash)
main shaft or dial gage and perform alignment check.
Set by installing shim rings on
outer bearing race of input
shaft
Axial clearance of 0 to 0.12 mm Depth gage Move taper roller bearing in

countershaft micrometer zero setting (zero backlash)
or dial gage and perform alignment check.
Set by installing shim rings on
outer bearing race.
Axial clearance of circlips 0 to 0.10 mm Feeler gage Use corresponding circlip.

on countershaft and main shaft
Axial clearance of circlip on 0.05 to 0.15 mm Feeler gage Use corresponding circlip.
detent pin (shift mechanism)
1349 751 103 - 2005-12 15

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Special Tool
Figure Illustration Order no. Application Qty. Comment

no.
1P01 181 850 1
Assembly Block
1
1X56 139 568 1
Clamping adapter (plate)

2
1X56 138 064 1
Protective sleeve
3 Assembly aid for fitting
connection plate
1T66 153 959 1
M18x1 ring bolt

4 for lifting the transmission
1X56 137 975 1 Chapter 6
Adapter
5 for installing needle sleeve
in control and pump housing
1349 751 103 - 2005-12 16

6 S 1601 BD

no.
1X56 122 292 1 Possibly use

spindle M40
Hydraulic spindle from flange
6 for pressing out rotor and stator (in con- extractor of
junction with 1X56 138 047). Workshops basic trans-
equipped with hydraulic tools “see tool mission.
attachment” do not require hydraulic Chapter 6
spindle 1X56 122 292.
1X56 138 047 1 Absolutely

essential if no
Press-off fixture hydraulic or
7 for pressing out stator and rotor (in spindle press
conjunction with 1X56 122 292 or rated up to 15 t
universal hydraulic tool, see attach- is available
ment) Chapter 6
1X56 138 049 1 Absolutely

essential if
Ring 1X56 138 047
8 for pressing out stator and rotor with is not used
spindle press or hydraulic press Chapter 6
1X56 138 045 1 Chapter 6
Center-disk
9 for guidance when inserting
stator and rotor
1X56 138 046 1 Chapter 6
Setting fixture
10 for setting taper roller bearing
on rotor
1349 751 103 - 2005-12 17

6 S 1601 BD

no.
1X56 138 242 1 Chapter 6
Extractor
11 in helical gear
1X25 139 783 1 Chapter 7
Assembly support
12
1X56 138 107
Handle
for tool 1X25 139 783
1X56 137 798 1
Support
13 for transmission shafts and for
upright arrangement of transmission
1X56 119 916 1 Chapter 7
Attachment
14 for shaft seals and scraper ring in
shift cover
1X56 137 134 1 Chapter 7
Protective sleeve
15 for shaft seals and scraper ring
in shift housing cover
1349 751 103 - 2005-12 18

6 S 1601 BD

no.
1X56 137 836 4 Chapter 8
Support
16 for upright arrangement
of transmission
1X56 103 766 1 Chapter 8
Attachment
17 for shaft seal (55x75x8)
on input
1X56 122 404 1 Chapter 10, 15
Adapter
18 for articulated bearing (22x28x16)
in housing
1X56 136 599 1 Chapter 11
M12 hook
19 for lifting the countershaft
1X56 138 124 1 Chapter 11
Lifting fixture
20 for transmission shafts and
shift rails
1349 751 103 - 2005-12 19

6 S 1601 BD

no.
1X56 122 317 4 Chapter 12
Adapter M95x2 / M65x2

21 M95x2 internal
M65x2 external
for taper roller bearing on the
input shaft
1X56 122 310 1 Chapter 12
M65x2 extension
22 for taper roller bearing on the
input shaft
1X56 122 304 1 Chapter

12, 13, 14
Base unit M65x2
23 in conjunction with grippers (rapid
gripper)
1X56 136 743 1 Chapter 13
Rapid gripper M65x2

24 for pilot bearing on main shaft
1X56 138 141 1 Chapter 13
Split extractor
25 for synchronizer bodies
on 5/6 and 3/4 gears
1349 751 103 - 2005-12 20

6 S 1601 BD

no.
1X56 136 711 1 Chapter 14
Rapid gripper M65x2

countershaft
1X56 136 471 1 Chapter 5
Attachment
27 for safety plate on
output flange
1X56 136 878 1 Chapter 11
Extracting fixture
28 for reverse gear pin
1X56 136 751 1 Chapter 12
Rapid gripper M95x2

input shaft
1T66 155 569 1
M12 ring bolt

30 for lifting the transmission
1349 751 103 - 2005-12 21

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Oil filters
1 Oil Filter
1.1 Disassembling Oil Filter
View from below

1 = Oil filter on the Intarder
019459
1 Unfasten and remove M8x20 retaining screws

01.550 and disk from oil filter cover.
01.550
017477
NOTE
• Oil may escape during the next operation. 01.540
• Catch any escaping oil in a suitable
container.
2 Remove filter cover 01.540. Remove filter

01.500.
026769
1349 751 103 - 2005-12 1-1

6 S 1601 BD
CAUTION
Do not clean filter: Filter must be replaced.
01.520 O-ring on filter

01.500 Filter
01.490 Magnetic disk
NOTE
Remove magnetic disk 01.490 from the removed
filter cartridge and keep to one side for later
installation on the new filter cartridge.
01.520 01.500 01.490
027770
1349 751 103 - 2005-12 1-2

6 S 1601 BD
1.2 Assembling Oil Filter
CAUTION
Use new filter.
01.520 O-ring on filter

01.500 Filter
01.490 Magnetic disk
NOTE
Attach magnetic disk 01.490 to new filter cartridge.
01.520 01.500 01.490
026770
1 Insert filter 01.500 in housing.

Fit filter cover 01.540. 01.540
026769
2 Secure oil filter cover with M8x20 01.550

retaining screws and disk.
01.550
017477
1349 751 103 - 2005-12 1-3

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Central Wiring
2 Central wiring
1
2
05.440 3
05.400
05.410
05.420
05.430
026663
2.1 Removing Central Wiring 2.2 Installing Central Wiring
1 Unscrew and remove pos. 1, 2 and 3. 1 Secure bracket 05.410 with screw 05.420.
2 Remove cable connector 05.440. 2 Secure connector on central wiring with

4 screws 05.430 to bracket 05.410.
3 Remove 4 screws 05.430.
3 Screw on connectors, pos. 1, 2 and 3.
4 Remove central wiring.
4 Fit cable connector 05.440.
5 Remove screw 05.420.
6 Remove bracket 05.410.
1349 751 103 - 2005-12 2-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Stainless steel heat exchanger
3 Stainless Steel Heat Exchanger
3.1 Disassembly of Stainless Steel Heat

Exchanger
1 Cut off cable connector from wiring harness.
023704
2 Remove connector from wiring harness for

temperature sensor, accumulator charge valve,
proportional valve.
Remove wiring harness.
023703
3 Hold retaining plate 05.620 on heat exchanger

and remove 6 M10x35 05.630 / 05.640 /
05.650 / 05.660 / 05.670 / 05.680.
Remove retaining plate 05.620.
05.630
05.680
05.660 05.640
05.670
05.650 05.620
023697
1349 751 103 - 2005-12 3-1

6 S 1601 BD
4 Remove screw 05.130.
05.130
023700
5 Remove 2 M12 nuts from stud bolts.
023702
6 Remove temperature sensor 05.030 from heat

exchanger.
05.030
023701
1349 751 103 - 2005-12 3-2

6 S 1601 BD
7 Carefully remove heat exchanger unit from

Intarder control housing.
023699
8 Remove 2 O-rings 05.300 / 05.302 from

grooves in the Intarder control housing.
023698
9 Remove 2 05.080 M8x60 screw and 1 05.078

M8x100 screw.
05.090
05.080
10 Remove 2 05.090 M8x18 screws from bracket
05.084.
11 Remove accumulator 05.060 from oil duct

05.150.
05.078
023696
1349 751 103 - 2005-12 3-3

6 S 1601 BD
12 Remove 2 M8x18 05.090 screws from retain-

ing bracket 05.084 on accumulator 05.060.
Remove retaining bracket 05.084.
05.090
13 Remove O-ring 05.070 from accumulator 05.084 05.070
05.060. 05.240 05.232
05.224
05.236
14 Remove 1 05.240 M8x30 screw.
15 Remove 4 M8 nuts from stud bolts 05.224 /

05.228 / 05.232 / 05.236. 05.228
023695
16 Remove oil duct 05.150 from heat exchanger

05.010.
05.150
05.010
023694
17 Remove 4 M8x50 stud bolts 05.224 / 05.228 /

05.232 / 05.236 from the heat exchanger.
05.224 05.180 05.228 05.232 05.170 05.236
18 Remove 2 O-rings 05.170 / 05.180 from
grooves in the heat exchanger 05.010.
023692
1349 751 103 - 2005-12 3-4

6 S 1601 BD
19 Remove 2 M12x130 stud bolts 05.200 from oil

duct 05.150.
05.200
05.150
023693
1349 751 103 - 2005-12 3-5

6 S 1601 BD
3.2 Assembling Stainless Steel Heat Exchanger
1 Screw 4 M8x50 stud bolts 05.224 / 05.228 / 05.224 05.180 05.228 05.232 05.170 05.236
05.232 / 05.236 into heat exchanger.
Tightening torque: MA = 11 Nm
2 Place 2 O-rings 05.170 / 05.180 into grooves in

the heat exchanger 05.010.
023692
3 Screw 2 M12x130 stud bolts 05.200 into oil

duct 05.150.
05.200
05.150
023693
4 Place oil duct 05.150 onto heat exchanger

05.010 ensuring that the O-rings are
05.150
positioned correctly.
05.010
023694
1349 751 103 - 2005-12 3-6

6 S 1601 BD
5 Screw 4 M8 nuts onto 48x50 stud bolts

05.224 / 05.228 / 05.232 / 05.236.
05.090
6 Screw 1 M8x30 screw 05.240 through oil feed 05.084 05.070
housing and into heat exchanger. 05.240 05.232
05.224
Tightening torque: MA = 23 Nm 05.236
7 Screw retaining bracket 05.084 with 2 M8x18

screws 05.090 onto accumulator 05.060. Do
not tighten screws! 05.228
8 Insert O-ring 05.070 in accumulator.
9 Mount accumulator 05.060 on oil duct 05.150.

Ensure that O-ring is correctly installed. 023695
10 Insert 2 M8x18 screws 05.090 through bracket

05.084 and attach. Do not tighten screws! 05.090
05.080
11 Screw in 2 M8x60 screws 05.080 and 1

M8x100 screw 05.078. Do not tighten!
12 Align accumulator on heat exchanger and

tighten screws to 23 Nm, starting with
pos. 05.080 and 05.078, then pos. 05.090
(4 x M8x18). 05.078
023696
13 Hold retaining plate 05.620 on heat exchanger

and secure with 6 M10x35 screws 05.630 /
05.640 / 05.650 / 05.660 / 05.670 / 05.680.
Do not tighten screws!
05.630
05.680
05.660 05.640
05.670
05.650 05.620
023697
1349 751 103 - 2005-12 3-7

6 S 1601 BD
14 Place 2 O-rings 05.300 / 05.302 in grooves of

Intarder control housing (see arrows).
023698
15 Carefully install pre-assembled heat exchanger

unit on Intarder control housing.
023699
16 Screw in M8x115 screw 05.130.

Do not tighten!
05.130
023700
1349 751 103 - 2005-12 3-8

6 S 1601 BD
17 Screw temperature sensor 05.030 into heat

exchanger.
18 Screw 7 M12x60 screws through housing into

retaining plate.
05.030
023701
19 Screw 2 M12 nuts onto stud bolts.

023702
20 Tighten 1 M8x115 screw 05.130.

05.130
023700
1349 751 103 - 2005-12 3-9

6 S 1601 BD
21 Tighten 6 M10x35 screws 05.630 / 05.640 /

05.650 / 05.660 / 05.670 / 05.680.
05.630
05.680
05.660 05.640
05.670
05.650 05.620
023697
22 Route wiring harness as shown in diagrams.

Connect up connectors for temperature sensor,
accumulator charge valve, proportional valve,
and use cable clips to fasten and secure at the
specified points.
Cut off protruding cable tips.
023703
023704
1349 751 103 - 2005-12 3-10

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Cross-section diagram of Intarder
4 Sectional View Through Intarder with Reducing Unit
Section
Schnitt AA
Section
Schnitt A A
Section
Schnitt AAAA
024874
1349 751 103 - 2005-12 4-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Removing/Installing ZF-Intarder
5 Removing/Installing ZF-Intarder
08.250
08.200 08.270
08.196
01.020 08.260
08.210
01.040 01.340
01.040
01.270
01.260
01.910
01.342
026664
5.1 Removing Intarder from Basic Transmission 3 Remove dust cap 08.196.
01.040 = cylinder pins 4 Remove screws 08.210.

01.260 = gasket
01.020 = shaft seal 5 Unscrew inductive sensor 01.910 to prevent
08.196 = dust cap damage.
08.200 = flange
08.250 = disk CAUTION
08.270 = retaining plate In the next operation, the Intarder becomes free
08.260 = screw and may therefore drop.
08.210 = screw Secure heat exchanger to prevent it from dropping.
01.910 = inductive sensor
2 Remove 21 screws 01.340.
1 Remove retaining plate 08.270. Unfasten Remove 1 screw 01.342.
screws 08.260 and remove disk 08.250.
3 Remove gasket 01.260 and disk 01.270.
2 Remove flange 08.200 with two-armed
extractor. 4 Remove cylinder pins 01.040.
1349 751 103 - 2005-12 5-1

6 S 1601 BD
08.250
08.200 08.270
08.196
01.020 08.260
08.210
01.040 01.340
01.040
01.270
01.260
01.910
01.342
026664
5.2 Installing Intarder on Basic Transmission 3 Carefully fit Intarder to basic transmission
and secure with 21 screws 01.340 and 1 screw
01.040 = cylinder pins 01.342.
01.260 = gasket Tightening torque MA = 50 Nm
01.020 = shaft seal
08.196 = dust cap 4 Install shaft seal 01.020 firmly home in
08.200 = flange Intarder housing.
08.250 = disk
08.270 = retaining plate 5 Fit dust cap 08.196.
08.260 = screw
08.210 = screw 6 Install retaining screws 08.210 for propeller
01.910 = inductive sensor shaft in correct side of output flange 08.200.
(screws cannot be inserted if the flange is
mounted).
1 Install cylinder pins 01.040 in transmission
housing. 7 Fit output flange 08.200 without prior heating.
2 Fit gasket 01.260 to the basic transmission. 8 Fit disk 08.250.
1349 751 103 - 2005-12 5-2

6 S 1601 BD
08.250
08.200 08.270
08.196
01.020 08.260
08.210
01.040 01.340
01.040
01.270
01.260
01.910
01.342
026664
9 Insert hex screws 08.260.

Tightening torque MA = 60 Nm
Secure with retaining plate 08.270 using
attachment 1X56 136 471.
10 Screw in inductive sensor 01.910.

Tightening torque MA = 45 Nm
1349 751 103 - 2005-12 5-3

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Disassembling/Assembling ZF-Intarder
6 Disassembling/Assembling ZF-Intarder
03.090
03.010
03.100
03.080
03.020
03.060
03.050
03.120
03.040
11
11
026665
6.1 Removing and Dismantling Oil Pump 1 Unfasten and remove screws 03.090 and
03.100.
03.040 = O-ring
03.050 = ring gear 2 Remove pump, possibly forcing off using pry
03.060 = shaft bar until cylinder pins 03.120 become free.
03.020 = needle sleeve
13.080 = O-ring 3 Remove O-rings 03.040 and 03.080 from
03.010 = pump housing control housing.
03.090 = 4 M8x80 hex screws
MA = 23 Nm 4 Remove shaft 03.060 and ring gear 03.050
03.100 = 1 M8x30 hex screw from pump housing 03.010.
MA = 23 Nm
03.120 = 2 cylinder pins 5 Remove needle sleeve 03.020 using internal
11 = spot on ring gear extractor.
(simplifies assembly)
1349 751 103 - 2005-12 6-1

6 S 1601 BD
03.090
03.010
03.100
03.080
03.020
03.060
03.050
03.120
03.040
11
11
026665
6.2 Assembling and Mounting Oil Pump 1 Install shaft with internal rotor 03.060 and
ring gear 03.050 in pump housing.
NOTE
Apply a thin coating of oil to moving parts. 2 Install O-rings 03.080 and 03.040 in control
If the needle sleeve and V-ring have been removed housing.
from the pump housing or control housing, heat
housing to approx. 40 °C and fit needle sleeve with 3 Install pump housing, ensuring that the input
attachment 1X56 137 975 on correct side (thick journal on shaft 03.060 does not get damaged.
collar at press-in end). Drive in cylinder pins 03.120.
With the ring gear, ensure that the ring gear desig-
nation (spot) (11) faces upwards. This ensures that 4 Screw in 1 screw (M8x30) 03.100.
the chamfer on the outer diameter of the ring gear Tightening torque: 23 Nm
points towards the pump housing).
5 Screw in 4 screws (M8x80) 03.090 / 03.091 /
03.094 / 03.095.
Tightening torque: 23 Nm
1349 751 103 - 2005-12 6-2

6 S 1601 BD
05.200
02.010
05.200
02.590
05.200 05.200
02.630
02.660
02.610
02.610
02.610
026666
6.3 Removing Control Housing
1 Remove screws 02.610 / 02.630 / 02.660 /

05.200.
2 Remove control housing.
3 Remove gasket 02.590.
1349 751 103 - 2005-12 6-3

6 S 1601 BD
05.200
02.010
05.200
02.590
05.200 05.200
02.630
02.660
02.610
02.610
02.610
226666
6.4 Installing Control Housing
1 Insert 2 screws 05.200 through the control

housing.
2 Fit gasket 02.590 to control housing.
3 Secure control housing with gasket to Intarder

housing.
Do not tighten screws: Only insert.
4 Install all screws 02.610 / 02.630 / 02.660 /

05.200.
NOTE
Follow the specified tightening sequence on
page 6-5.
Tightening torque: 23 Nm 024875
1349 751 103 - 2005-12 6-4

6 S 1601 BD
Sequence for tightening
05.200 05.200
13
11
14 12
10
5
28
15 6 4
16 7
27 29 3
17 8 1 2
9
26 25
18
19 24
20 21 22 23
02.680
017392
Note sequence for tightening.

Tightening torque: 23 Nm
1349 751 103 - 2005-12 6-5

6 S 1601 BD
6.5 Removing Valves from Control Housing Safety valve (14.5 bar)
02.100 = screw plug with seal
NOTE 02.090 = compression spring
When removing valves, always ensure that the 02.080 = ball
removed pistons and piston sleeves do not get
damaged. 02.030 = screw plug with seal
1 Remove the valves shown in this picture. 02.070 = screw plug (pump pressure) with seal
Clean Loctite residue off threads of all sealing
screws. 02.050 = screw plug (control pressure) with seal
CAUTION Proportional solenoid valve with control valve

Do not apply 24 V current to proportional solenoid 02.170
valve. Only check solenoid valve using terminal 02.190 = cylinder screw
tester. 02.180 = O-ring
At 20 °C = 23 - 33 W 02.150 = piston
Pressure increasing valve

02.350 = screw plug
02.330 = compression spring
02.310 = piston
Technical Data - Proportional Solenoid Valve
Stroke mm 2+2 Closed-loop control valve
Boundary 02.440 = sealing cover
A 0.5
current 02.430 = adjusting screw
Resistance 02.410 = piston
Ω 25.0 ± 6 %
at 20 °C 02.390 = compression spring
Switch-on time % 100 02.370 = piston

Cooler changeover valve (heat exchanger inlet, oil temperature)
02.490 = screw plug (M48) with sealing ring
02.470 = compression spring, e.g. 0732 042 402 02.590 = gasket
02.450 = piston
Preload valve (1.5 bar)
Pressure relief valve (12 bar) 01.050 = screw plug (1.5 bar) with seal and recess
02.490 = screw plug (M26) with sealing ring for compression spring
02.250 = piston 01.040 = compression spring
02.270 = compression spring, e.g. 0732 042 470 01.030 = piston
02.230 = compression spring, e.g. 0732 042 471
02.210 = piston 02.120 = needle sleeve (pump shaft)
02.130 = V-ring (pump shaft)
1349 751 103 - 2005-12 6-6

6 S 1601 BD
Screw plugs
02.050 02.070
02.170
02.100
02.290
02.430
02.030
02.490
02.510
013740
Remove valves
02.290
02.490 02.250
02.270
02.230
02.210 02.050
02.470
02.070
02.450 02.100 02.090 02.130
02.080 02.120
02.150
02.180
02.030 02.170
02.190
02.010
02.370
02.390
02.510 02.410
02.430
02.440
026667
1349 751 103 - 2005-12 6-7

6 S 1601 BD
6.6 Installing Valves in Control Housing Preload valve (1.5 bar)

01.050 = screw plug (1.5 bar) with seal and recess
Cooler changeover valve for compression spring
02.490 = screw plug (M48) with sealing ring 01.040 = compression spring
02.470 = compression spring 01.030 = piston
02.450 = piston
Pressure relief valve (12 bar) Tightening torques for screw plugs
02.490 = screw plug (M26) with sealing ring Pos. No. Tightening torque Size
02.250 = piston 02.490 150 Nm M48x1.5
02.270 = compression spring 02.290 70 Nm M26x1.5
02.210 = piston 02.030 70 Nm M26x1.5
02.070 25 Nm M12x1.5
Safety valve (14.5 bar) 02.050 25 Nm M12x1.5
02.100 = screw plug with seal 02.430/120 70 Nm M26x1.5
02.080 = ball 02.190 23 Nm M8x22
01.050 70 Nm M26x1.5
02.030 = M26 screw plug with seal
02.070 = M12 screw plug (pump pressure) with seal Technical Data - Proportional Solenoid Valve
ring Stroke mm 2+2
Boundary
02.050 = M12 screw plug (control pressure) with A 0,5
current
seal
Resistance
Ω 25.0 ± 6 %
at 20 °C
Proportional solenoid valve with control valve
Switch-on time % 100
02.170
02.190 = cylinder screw
02.180 = O-ring
02.150 = control piston
Closed-loop control valve

02.440 = sealing cover
02.430 = adjusting screw
02.410 = piston
02.370 = piston
02.510 = screw plug (M24x1.5) with seal

(Intarder pressure test point)
02.120 = needle sleeve
02.130 = V-ring (for pump shaft)
02.590 = gasket (do not bend plate)
1349 751 103 - 2005-12 6-8

6 S 1601 BD
Install valves
02.290
02.490 02.250
02.270
02.230
02.210 02.050
02.470
02.070
02.450 02.100 02.090 02.130
02.080 02.120
02.150
02.180
02.030 02.170
02.190
02.010
02.370
02.390
02.510 02.410
02.430
02.440
026667
Screw plugs
02.050 02.070
NOTE
Apply light coating of oil to moving
parts. 02.170
Always check the pistons for ease of 02.100
movement in the piston bore.
02.290
Install pistons and compression 02.430
springs in control housing as described
02.030
on previous page.
Apply light coating of Loctite 574 to
screw plug threads and install a new
seal.
Tighten to torque quoted on page 6-8.
02.490
02.510
013740
1349 751 103 - 2005-12 6-9

6 S 1601 BD
01.230
01.220
01.210
026668
6.7 Removing Spur Gear 1 Remove hex screw 01.230 and disk 01.220.
01.230 = special hex screw 2 Remove spur gear 01.210 with three-armed
01.220 = disk extractor (3) and pressure piece (4).
01.210 = spur gear
3 = three-armed extractor/two-armed
extractor
4 = pressure piece
1349 751 103 - 2005-12 6-10

6 S 1601 BD
1
2
01.180
01.190
01.200
026669
6.8 Removing Stator !DANGER

RISK OF BURNS!
1 = three-armed extractor
2 = pressure piece
01.180 = taper roller bearing inner race
2 Uniformly heat circumference of Intarder
01.190 = stator
housing to max. 70° C using hot air blower.
01.180 = taper roller bearing outer race
01.200 = O-ring
3 Remove stator 01.190.
9 = documents
4 Remove taper roller bearing inner race

01.180.
1 Place housing on supports, place pressure
piece (2) on rotor shaft and fit three-armed
5 Remove taper roller bearing outer race
extractor (1).
01.180.
6 Remove O-ring 01.200 from stator.
1349 751 103 - 2005-12 6-11

6 S 1601 BD
6.9 Removing Reducing Unit
01.070 = screw plug

01.130 = piston
01.150 = piston
01.158 = screw plug 01.166
01.162 = baffle plate
01.166 = cylinder pin
01.162
01.164
01.158
01.134 01.130 01.070 01.150 01.154

1 Remove 2 cylinder pins
01.166. 026670
2 Remove baffle plates 01.162/01.164.
01.166
01.162
01.166
01.164
026671
1349 751 103 - 2005-12 6-12

6 S 1601 BD

Idle speed reducing valve
01.030
01.040
01.134
01.050
01.130
01.150
01.154
01.158
014009
6.10 Removing Idle Speed Reducing Valve 3 Remove piston 01.150.
01.158 = screw plug with seal 4 Remove piston 01.130.

01.150 = piston 5 Remove compression spring 01.134.
01.130 = piston
01.050 = screw plug (1.5 bar) M26x1.5 and seal
01.040 = compression spring 6.11 Removing Preload Valve
01.030 = piston
1 Remove screw plug 01.050 and seal.
1 Remove screw plug 01.158 and seal. 2 Remove compression spring 01.040.
2 Remove compression spring 01.154. 3 Remove piston 01.030.
1349 751 103 - 2005-12 6-13

6 S 1601 BD
01.250
01.240
1X56 122 292
1X56 138 047 01.100
01.110
01.120
1X56 138 049
024876
6.12 Removing Rotor NOTE

When using fixture (4) with spindle (3), in
01.250 = retaining ring place of pos. 7 (ring) it is possible to use a
01.240 = split ring correspondingly high support.
1X56 122 292 = spindle
1X56 138 047 = press-off fixture 4 When using a press, pos. 7 (ring)
5 = pressure piece (in-house produc- 1X56 138 049 must be used.
tion, see tool list, pos. 15) If a ring is not used, housing distortion or
01.110 = rotor damage to the housing might occur.
1X56 138 049 = ring
01.120 = rectangular ring 5 Press shaft and rotor out of housing.
01.100 = bearing inner race
6 Remove inner bearing race 01.100.
1 Remove the retaining ring 01.250. 7 Remove two rectangular rings 01.120 from the
rotor shaft.
2 Remove split ring 01.240.
3 Fit press-off fixture (4) with spindle (3) and

pressure piece (5).
1349 751 103 - 2005-12 6-14

6 S 1601 BD

Idle speed reducing valve
01.030
01.040
01.134
01.050
01.130
01.150
01.154
01.158
014009
6.13 Removing Idle Speed Reducing Valve 3 Insert compression springs 01.154.
01.158 = screw plug with seal 4 Screw in screw plug 01.158 with seal.
01.154 = compression spring Tightening torque = 50 Nm.
01.150 = piston
01.130 = piston
01.134 = compression spring 6.14 Installing Preload Valve
01.040 = compression spring 1 Slide in piston 01.030.
01.030 = piston
2 Insert compression spring 01.040.
1 Slide in compression spring 01.134. 3 Screw in screw plug 01.050 with seal.
Tightening torque = 70 Nm.
2 Slide in two pistons 01.130 + 01.150.
1349 751 103 - 2005-12 6-15

6 S 1601 BD
01.166
01.162
01.120
01.110
01.120
1X56 138 045
024877
6.15 Installing Rotor NOTE

Idle speed reducing valve must be installed
1X56 138 045 = centering disk (tool) before the baffle plates (see Chap. 6.13).
01.120 = rectangular rings For configuration of reducing unit, see
01.162 = baffle plates Chap. 6.16, page 6-17.
01.166 = bolts, cylinder pins 2x
01.110 = rotor 3 Insert baffle plates 01.162 and install pin
01.166.
1 Screw on centering disk tool 1X56 138 045
2 Install two rectangular rings 01.120 on the

rotor shaft.
Install rotor 01.110 in housing.
1349 751 103 - 2005-12 6-16

6 S 1601 BD
6.16 Configuring the Reducing Unit
01.070 = screw plug

01.130 = piston
01.150 = piston
01.158 = screw plug 01.166
01.166 = cylinder pin
01.162
01.164
01.158
01.134 01.130 01.070 01.150 01.154
026670
1349 751 103 - 2005-12 6-17

6 S 1601 BD
01.180
01.190
01.200
024881
6.17 Installing Stator
01.180 = taper roller bearing outer race

01.190 = stator
01.200 = O-ring
1 Heat bore for outer race of taper roller bearing

to approx. 80 °C (see arrows) and install outer
race of taper roller bearing 01.180 at correct
side of stator 01.190.
2 Install O-ring 01.200 around edge of stator

and apply a light coat of grease.
1349 751 103 - 2005-12 6-18

6 S 1601 BD
01.230
01.220
01.210
01.180
1X56 138 045
024882
6.18 Fitting stator, taper roller bearing, and spur ! DANGER

gear
RISK OF BURNS!
01.230 = M12x80 Powerlock hex screw

3 Heat inner race of taper roller bearing 01.180
(95 Nm)
to approx. 80 °C and slide onto correct side of
01.220 = disk
rotor shaft. Apply coat of oil to inner race of
01.210 = spur gear
taper roller bearing.
01.180 = taper roller bearing inner race
1X56 138 045 = centering disk (tool)
4 Heat spur gear 01.210 to approx. 85 °C and fit
to correct side of rotor.
1 Heat Intarder housing with hot air blower (see
arrows) to approx. 80° C.
5 Fit disk 01.220.
2 Fit stator and align flush.

6 Screw in hex screw 01.230 and tighten down
provisionally. Tighten down fully to 95 Nm
NOTE
once it has cooled.
Arrows on housing and stator must point
towards one another.
When correctly assembled, the stator must be
seated lower than the recess on the sealing
surface.
1349 751 103 - 2005-12 6-19

6 S 1601 BD
01.250
01.240
1X56 138 046 7
8
01.100
A
6
6
024883
6.19 Fitting Taper Roller Bearing to Rotor and 4 Apply light coat of oil to inner race of taper
Adjusting Taper Roller Bearing roller bearing 01.100.
5 Fit setting unit 1X56 138 046 and tighten

01.250 = retaining ring
inner race of taper roller bearing until spin
01.240 = split ring
torque reaches 2±0.5 Nm.
1X56 138 046 = setting unit
01.100 = taper roller bearing inner race 6 Measure gap “A” with feeler gage (8) and note
6 = support down dimension.
7 = spin torque 2±0.5 Nm
7 Split ring supplied in sizes of 2.9 to 3.7 mm in
8 = feeler gage
graduated steps of 0.05 mm. Taper roller bear-
A = measure gap with spin torque
ing must have preload of 0.05 to 0.1 mm and
2±0,5 Nm. Taper roller bearing must
this is achieved by installing a split ring with
have preload of 0.05 to 0.1 mm.
the same thickness as gap “A”.
1 Invert the Intarder and place on supports (6). With spin torque of 2 Nm, the next size up of
split ring can be installed in accordance with
2 Remove centering disk 1X56 138 045.
the parts list.
8 Fit retaining ring 01.250 and peen at intervals
to approx. 85 °C and fit to correct side of rotor
of 3x120° around the lower edge.
shaft.
1349 751 103 - 2005-12 6-20

6 S 1601 BD
01.270
A
C
024884
A - C = Gap between sealing surface of Intarder Determining thickness of disk 01.270:

housing and stator support surface
Measure from
sealing surface A to contact surface C e.g.: 1.1 mm
6.20 Measuring Axial Clearance Thickness of steel plate gasket D
(without beading) e.g.: 0.3 mm
NOTE
Steel plate gasket with beading. Example:
When measuring, only measure plate
thickness (without beading). Dimension A-C 1.10 mm
+ Thickness of gasket D 0.30 mm
Total 1.40 mm
± Tolerance 0.05 mm
Result of disk thickness 01.270 x mm
1349 751 103 - 2005-12 6-21

6 S 1601 BD
08.190
3x M10x60
8.8
1X56 138 242
027431
6.21 Removing Helical Gear
1 Screw tool 1X56 138 242 with 3 M10x60

screws to helical gear 08.190.
2 Using standard three-armed extractor, remove

helical gear 08.190.
1349 751 103 - 2005-12 6-22

6 S 1601 BD
08.190
027432
6.22 Installing Helical Gear
1 Slide helical gear 08.190 onto correct end

(spline) of output shaft.
1349 751 103 - 2005-12 6-23

6 S 1601 BD Disassembly of ZF-Servoshift Without
6 S 1701 BO / 6 S 1901 BO Selection Equipment for Cable Control
7 ZF-Servoshift Without Selection Equipment for Cable Control
09.090 09.100
22.150
22.120
22.110
22.180
22.170
22.100
22.020
22.010
22.030
22.090
09.400
09.420
09.220
22.060
09.410
22.050
026661
7.1 Disassembly of ZF-Servoshift Without NOTE

Selection Equipment for Cable Control The support linkage is configured in a vehicle-
specific manner and should not therefore be
1 Loosen nut/bolt 09.420. dismantled.
2 Remove 2 hex screws 09.090/09.100 from 3 Mark installation position of shift lever
support plate. Remove support linkage 22.110 09.140 on selector shaft 09.220 (e.g. with
completely. marker pen).
4 Remove shift lever 09.410.
5 Remove protective cap 09.400.
1349 751 103 - 2005-12 7-1

6 Remove screws: 09.050 / 09.060 / 09.070 /

09.080 / 09.110 / 09.120 with washers. 09.080
71.220
09.070
7 Take off shift turret with Servoshift unit.
09.060
8 Remove shift interlock 09.140.
09.050
09.110
9 Remove gasket 09.020. 09.12
09.040
! DANGER !
There is a spring between the gear shift housing and
Servoshift unit. The load on this spring is relieved
during the next step and the spring may jump out. 09.010
09.030
10 Remove 4 screws 71.212 / 71.216 / 71.218 /

09.390
71.220.
11 Carefully remove Servoshift unit 71.200.
12 Remove gasket 71.210. 71.210
13 Remove cylindrical pin 09.390.
14 Remove cover 09.040. 71.200

09.020
09.140
026656
1349 751 103 - 2005-12 7-2

71.170
71.160
71.120
71.130
71.140
09.200
09.190
71.150 09.184
09.210
71.030
71.020 71.100
71.180
09.170 71.040
09.150 71.010 71.110
71.050
71.060
71.070
71.090 71.080
026657
16 Remove screws: 71.080 / 71.090 / 71.100 / 26 Remove pawl stop with seal 09.170.
71.110.
27 Remove vent 09.150.
17 Remove shift cover 71.010 and gasket 71.020.
28 Remove screws 09.200.
18 Remove scraper 71.210.
29 Remove cover 09.190 with gasket 09.184.
19 Remove shaft seal 71.060.
30 Remove cover 09.210.
20 Remove shaft seal 71.040.
NOTE
21 Remove bearing bush 71.050. Cover is destroyed during disassembly. A new
cover 09.210 must be used for assembly.
22 Remove bush 71.030 from gear shift housing.
23 Remove screws: 71.140 / 71.150 / 71.160 /

71.170.
24 Remove cover 71.020 and gasket 71.130.

25 Remove switch 71.180 or screw plug 71.190.
1349 751 103 - 2005-12 7-3

31 Fit tool 1X25 139 783 over needle bush and

place on valve lever 09.320.
Carefully tap on tool and drive valve lever
downwards.
024511
32 Remove needle bush 09.360 and pin 09.350.
024512
33 Hold valve lever 09.320 and lever 09.310. Pull

quill shaft 09.250 back a little (see arrow). The
valve lever 09.320 and lever 09.310 can now
be removed.
024543
1349 751 103 - 2005-12 7-4

09.340
09.320 09.290
09.330
09.310 09.280
09.270
09.260
09.370
09.380
09.250
09.010
09.230
09.130
09.242
09.240
49.160
49.170
49.300
49.080
09.300 49.070
49.310
09.220
49.050
49.040
026658
34 Remove pin 09.130. 39 Hold drivers 09.260 / 09.270 / 09.280 / 09.290

and pull quill shaft 09.250 out of gear shift
35 Remove pin 09.300. housing (see arrow). Remove driver.
36 Remove 2 clamping pins 09.240 / 09242 from NOTE

detent section 09.230 and gear shift shaft Do not lose roller 09.370 from valve lever
09.220. 09.320. Remove pin 09.340 if damaged.
37 Pull gear shift shaft 09.220 out of gear shift

housing 09.010 and remove detent part 09.230
at the same time.
38 Remove bush 09.380.
1349 751 103 - 2005-12 7-5

09.340
09.320 09.290
09.330
09.310 09.280
09.270
09.260
09.370
09.380
09.250
09.010
09.230
09.130
09.242
09.240
49.160
49.170
49.300
49.080
09.300 49.070
49.310
09.220
49.050
49.040
026658
Remove spring pack from selector shaft 39 Remove washer 49.050 and compression
spring 49.310 from gear shift shaft 09.220.
NOTE
Spring pack position depends on selection pattern! 40 Remove V-ring 49.070 from gear shift shaft
09.220.
! DANGER !
41 Take washer 49.080 and compression spring
V-ring is subject to spring load. The V-ring must
49.300 off gear shift shaft 09.220.
therefore be removed with care.
42 Remove washer 49.170 and V-ring 49.160.

38 Remove V-ring 49.040 from selector shaft
09.220.
1349 751 103 - 2005-12 7-6

6 S 1601 BD Assembly of ZF-Servoshift Without
09.340
09.320 09.290
09.330
09.310 09.280
09.270
09.260
09.370
09.380
09.250
09.010
09.230
09.130
09.242
09.240
49.160
49.170
49.300
49.080
09.300 49.070
49.310
09.220
49.050
49.040
026659
7.2 Assembly of ZF-Servoshift Without 4 Place washer 09.330 between valve lever
Selection Equipment for Cable Control 09.320 and lever 09.310.
5 Hold unit together in correct position in
1 Hold drivers 09.260 / 09.270 / 09.280 / 09.290 housing 09.010.
together in housing 09.010.
6 Drive quill shaft 09.250 into recesses of lever
2 Slide quill shaft 09.250 into correct position 09.310 and slide on through valve lever
in housing (see arrow) and guide through all 09.320.
drivers.
7 Insert bush 09.380 in housing.
3 If the valve lever’s 09.320 pin 09.340 has
been replaced, it now has to be inserted again 8 Slide gear shift shaft 09.220 into housing and
without any clearance. quill shaft 09.250.
1349 751 103 - 2005-12 7-7

09.340
09.320 09.290
09.330
09.310 09.280
09.270
09.260
09.370
09.380
09.250
09.010
09.230
09.130
09.242
09.240
49.160
49.170
49.300
49.080
09.300 49.070
49.310
09.220
49.050
49.040
026659
9 Hold detent section 09.230 in housing. 12 Insert pin 09.300 through side housing bore
The position depends on the parts list! and through bore of gear shift shaft.
10 Slide gear shift shaft 09.220 through detent 13 Insert pin 09.130 through housing bore in
section 09.230. quill shaft groove.
11 Hold V-ring 49.160 in housing and slide 14 Drive clamping pins 09.240/09.242 through
through gear shift shaft 09.220 until V-ring detent section 09.230 and gear shift shaft.
can be inserted in the groove.
Position of V-ring is determined by selection NOTE
pattern. Selection pattern WI or WII can be The clamping pin slots must be opposite one
seen on the parts list. another.
NOTE
For adaptation of selection pattern, see page
7-10.
1349 751 103 - 2005-12 7-8

15 Insert pin 09.350 in needle bearing 09.360

with a little grease and insert flush in valve 09.360
lever bore. Then tap until the clearance 09.350
between the pin and gear shift shaft has
reached 0.2 - 0.5 mm. Gear shift shaft must not
be jammed!
CAUTION
Gear shift shaft must have ease of movement!
The subsequent arrangement of washers, com- 49.170

pression springs, and V-rings depends on the 49.300
selection pattern. 49.080
49.070
NOTE 49.310
For adaptation of selection pattern, see page 49.050
7-10. 49.040
16 Slide washer 49.170, compression spring,

49.300 and washer 49.080 onto selector shaft.
026660
17 Snap V-ring 49.070 into groove (depending on

selection pattern).
18 Slide compression spring 49.310 and washer

49.050 onto selector shaft.
19 Snap V-ring 49.040 into groove (depending on

selection pattern).
1349 751 103 - 2005-12 7-9

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Adaptation of selection pattern
Location: Transmission / Shift System
Transmission
installation position: horizontal, to the right
Type of shift: vertical
Selector output: top
007498
Adaptation of selection pattern
Consult parts list to find out
• which configuration of drivers and
• which configuration of compression springs
you need to adapt the selection pattern.
Configuration of drivers
Transmission
Selector output: vertical top
Selection pattern: I
007504
Transmission
Selector output: vertical top
Selection pattern: II
007505
1349 751 103 - 2005-12 7-10

6 S 1601 BD
Configuration of spring pack
Configuration of spring pack:
Selection pattern I
Q1
Selection pattern I and II
Selection pattern II
027318
Q2
Selection pattern I
027319
Q3
Selection pattern I
027320
1349 751 103 - 2005-12 7-11

6 S 1601 BD

Selection pattern I
Q4
027321

Selection pattern I
Q5
027322

Selection pattern I
Q6
027323

Selection pattern I
Q7
027324
1349 751 103 - 2005-12 7-12

Sub-assembling shift cover 71.010, depending on

Selector output at top or horizontal*
parts list
INFORMATION
• Apply a thin coat of sealing agent to outer 71.070
edge of shaft sealing rings with a steel sur-
71.060
round. Coat outer circumference of shaft
B
sealing ring with Vaseline or a water-soluble X
liquid rinsing agent concentrate (e.g. Pril). 71.050
A
• The sealing lips of the shaft seals 71.040 and 71.010
71.060 face the bearing bush 71.050.
• Fill gaps (X) and (Y) with grease (ZF order Y
number 0750 199 001). 71.040
1 Drive shaft seal 71.040 into shift cover using

attachment 1X56 137 135. Drive into measure-
ment “A” (see table) in shift cover 71.010. Shift cover 1304 307 423 1304 307 425
Dimension A 40+0.5 mm 38.5+0.5 mm
2 Drive bearing bush 71.050 into shift cover Dimension B 18+0.5 mm 17+0.5 mm
using attachment 1X56 137 135. Drive into 024516
measurement “B” (see table) in shift cover
71.010.
3 Drive shaft seal (71.060) firmly home using

adapter 1X56 119 916.
4 Drive in scraper 71.070 until flush with shift

cover using attachment 1X56 119 916.
1349 751 103 - 2005-12 7-13

71.170
71.160
71.120
71.130
71.140
09.200
09.190
71.150 09.184
09.210
71.030
71.020 71.100
71.180
09.170 71.040
09.150 71.010 71.110
71.050
71.060
71.070
71.090 71.080
026657
20 Secure gasket 71.130 and cover 71.120 with 25 Insert bearing bush 71.030 in gear shift
screws 71.140 / 71.150 / 71.160 / 71.170. housing.
M8 tightening torque: MA = 23 Nm
26 Place protective sleeve 1X56 137 134 on
21 Drive in seal cover 09.210. knurled journal of gear shift shaft.
Drive in cover 52.140.
Drive in cover 09.014. CAUTION
Do not damage shaft rings and scrapers when
22 Screw in Neutral switch 71.180. slipping over the gear shift shaft.
27 Mount new gasket 71.020 and sub-assembled
23 Screw in pawl stop 09.170. shift cover 71.010 with four M8 hex bolts
Tightening torque: MA = 50 Nm 71.080 / 71.090 / 71.100 / 71.110.
M8 tightening torque: MA = 23 Nm
24 Screw in vent 09.150.
1349 751 103 - 2005-12 7-14

28 Place gasket 09.030 on gear shift housing

09.010.
71.220
Assembly aid: 09.080 09.070
Insert 2 bolts to prevent the gasket and cover 09.090
from slipping. 09.060
09.100
09.050
29 Attach cover 09.040. 09.110
09.120
09.040
30 Coating journal of valve lever 09.320 with a
little grease and attach roller 09.370 (see
diagram on page 2-1).
09.010
NOTE 09.030
Valve lever 09.320 and lever 09.310 must be
positioned accurately behind one another.
09.390
31 Insert cylindrical pin 09.390 in Servoshift
housing 71.200.
32 Place gasket 71.210 on Servoshift housing.

71.210
33 Insert spring in recess of Servoshift unit.
71.200
34 Carefully fit Servoshift unit to shift housing
and secure with screws 71.220.
Tightening torque: MA = 23 Nm 09.020
35 Insert shift interlock 09.140 in transmission

housing. The shift inhibit lug must engage in
09.140
detent section recess.
36 Place new gasket 09.020 on transmission hous-

ing and carefully place Servoshift unit on
transmission housing. Ensure that the drivers
are engaging properly. Screw in screws 09.050 /
09.060 / 09.070 / 09.080 / 09.090 / 09.110 /
09.120.
015880
1349 751 103 - 2005-12 7-15

09.090 09.100
22.150
22.120
22.110
22.180
22.170
22.100
22.020
22.010
22.030
22.090
09.400
09.420
09.220
22.060
09.410
22.050
026661
37 Fit protective cap 09.400 to selector shaft. 39 Insert hex screw 09.420 and tighten hex nut to
49 Nm.
38 Slide selector lever 09.410 into designated
position on selector shaft and fit against NOTE
protective cap with zero clearance. Protective cap must be seated firmly, so apply
appropriate pressure to shift lever during
NOTE assembly.
On new parts, the shift lever and selector
shaft must be in the same position as the 40 Secure the complete support linkage 22.110 to
replaced parts. shift housing with 2 hex screws 09.090 /
09.100 and spring washers, then tighten down
to 23 Nm.
1349 751 103 - 2005-12 7-16

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Input-end add-on parts
8 Input-end add-on parts
8.1 Removal
NOTE
The transmission stands on the four supports 02.060
1X56 137 836 screwed into the output end. 02.070
02.100
02.110
1 Remove 6 M8 hex screws 02.130. 02.120
02.130
2 Remove adapter plate 02.120 and gasket
02.110 from transmission housing.
3 Remove shaft seal 02.100 from adapter plate

using appropriate tool.
026674
4 Remove shim 02.070 and baffle ring 02.060

from taper roller bearing.
NOTE
Shim and baffle ring may also be located in
the bearing bore of the adapter plate.
5 Remove 5 M8 hex screws 03.170.
6 Remove cover 03.160 and gasket 03.150 from

transmission housing.
03.130
NOTE
03.170 03.140
If necessary, loosen cover with two pry bars. 03.150
03.160
7 Remove shim 03.140 and ring 03.130 from
026675
taper roller bearing on countershaft.
1349 751 103 - 2005-12 8-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Input-end add-on parts
8.2 Fitting
1 Place ring 03.130 and shim 03.140 calculated

in Chapter 9.2 on outer race of taper roller
bearing on countershaft.
NOTE
Recesses in the ring 03.130 point towards the
taper roller bearing.
CAUTION
Ring 03.130 must be located between taper roller 03.130
bearing and shim. 03.170 03.140
03.150
2 Fit cover 03.160 and new gasket 03.150 to 03.160
housing and tighten down five M8 hex screws 026675
03.170 to 23 Nm.
3 Fit baffle ring 02.060 and shim 02.070

calculated in Chapter 9.1 onto outer race
of taper roller bearing.
02.060
NOTE 02.070
The raised section of the baffle plate points 02.100
towards the input end. 02.110
02.120
CAUTION 02.130
Baffle ring 02.060 must be located between taper
roller bearing and shim.
4 Coat outer surface of new shaft seal 02.100

with Vaseline and drive firmly home in
026674
adapter plate using tool 1X56 103 766.
NOTE
Sealing lip on shaft seal points towards tool.
5 Carefully guide adapter plate 02.120 with new

gasket 02.110 – silicon coating in direction of
adapter plate – and align the bores with one
another.
6 Tighten down 6 M8 hex screws 02.130 M8 to

23 Nm.
1349 751 103 - 2005-12 8-2

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Bearing Setting
9 Bearing Setting on Input Shaft, Main Shaft

and Countershaft
9.1 Setting Input Shaft and Main Shaft
NOTE
• Roll taper roller bearing into outer bearing
races with a turning action.
• To set the specified clearance of 0 to 0.12 mm
on input shaft and main shaft, you first need
to reach “Zero Clearance”. The specified
clearance can then be reached by calculating
the required shim thickness.
1 Fit outer bearing race firmly against inner race

using a plastic drift. 007203
2 Using a sharp object, check whether the

bearing rollers are able to move.
NOTE
Zero clearance is reached if the rollers are
located firmly, but no preload is achieved.
3 Using a depth gage or dial gage, work out

dimension “A” from outer race of taper roller
bearing to transmission sealing surface with
gasket fitted.
NOTE
Repeat measuring process at least once on the
opposing side and make a note of the average
value.
CAUTION
If gaskets are coated with silicon, do not include
depth of silicon layer in the measurement.
007204
1349 751 103 - 2005-12 9-1

6 S 1601 BD
4 Insert baffle ring in adapter plate.
5 Using a depth gage or dial gage, work out

dimension “B” from sealing surface of adapter
plate to baffle ring installed in previous opera-
tion.
NOTE
value.
B–A=C
C – (0 to 0.12 mm) = D
D = thickness of shim 007205
NOTE
Select appropriate thickness of shim from
spare parts catalog.
CAUTION
Photo illustrates measuring process w i t h o u t
baffle ring.
1349 751 103 - 2005-12 9-2

6 S 1601 BD
9.2 Setting Countershaft
NOTE
• Roll taper roller bearing into outer bearing
races with a turning action with no
clearance.
• To set the specified clearance of 0 to 0.12 mm
on countershaft, you first need to reach
“Zero Clearance” The specified clearance
can then be reached by calculating the
required shim thickness.
1 Fit outer bearing race firmly against inner race

using a plastic drift.
2 Fit outer bearing race firmly against inner race 007206
NOTE
Zero clearance is reached if the rollers are
located firmly, but no preload is achieved.
3 Place ring in housing bore with recesses point-

ing downwards.
4 Using a depth gage or a dial gage, measure

dimension “A” from transmission sealing sur-
face, with gasket fitted, to previously inserted
ring and note down results.
NOTE
007207
value.
D = A – (0 to 0.12 mm)
D = thickness of shim
NOTE
Select appropriate thickness of shim from
spare parts catalog.
007208
1349 751 103 - 2005-12 9-3

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Housing cover
10 Housing cover
01.040
10.1 Removal
1 Remove 19 hex screws 01.050 and 1 hex screw

01.052 from housing cover 01.010.
2 Remove 2 cylinder pins 01.040 from housing

cover 01.010.
01.010
3 Using a plastic hammer, carefully loosen the
housing cover 01.010. 01.052
01.050 01.040
NOTE
Clean sealing surfaces: They must not be
damaged.
01.020
026676
1349 751 103 - 2005-12 10-1

6 S 1601 BD
10.2 Dismantling Housing Cover
1 Remove defective ball and socket joint 01.240

using standard internal extractor and counter
support on housing cover.
CAUTION
Ensure that extractor grips firmly behind ball and
01.240
socket joint.
026677
2 Remove oil collecting plate 01.084 from

housing cover 01.010 if damaged. 01.010 01.024
NOTE
Replace oil collecting plate 01.084 with a new 01.084
one after every removal operation. 01.082
3 Use hot air blower to heat housing to around

02.050
80 °C in area around bearing holes in input
shaft and countershaft.
!DANGER
Always wear protective gloves when handling heated
parts.
03.100
4 Driver outer races on taper roller bearings
026678
02.050 / 03.100 on input shaft and counter-
shaft out of housing cover 01.010 with a
plastic drift.
1349 751 103 - 2005-12 10-2

6 S 1601 BD
10.3 Assembling Housing Cover

01.010 01.024
1 Heat bearing bore around input shaft with hot

air blower to approx. 80 °C and install outer
01.084
race of taper roller bearing 02.050 in housing
01.082
cover.
NOTE 02.050
Outer race of taper roller bearing must be vir-
tually flush with internal contour of cover.
!DANGER !
parts.
2 Heat bearing bore around countershaft with 03.100

hot air blower to approx. 80 °C and install
026678
outer race of taper roller bearing 03.100 in
housing cover.
NOTE
Outer race of taper roller bearing must be
virtually flush with internal contour of cover.
3 Fit new ball and socket joint 01.024 to both

center bores on selector rails and drive in with
tool 1X56 122 404 until joint is recessed into
housing contour by 0.9 to 1.7 mm.
4 Peen bore of ball and socket joint at 3x120°

intervals.
5 Secure oil collecting plate 01.084 with 2

screws 01.082. MA = 9.5 Nm
1349 751 103 - 2005-12 10-3

6 S 1601 BD
10.4 Fitting
01.040
1 Fasten two standard M10 stud bolts into
transmission housing.
2 Install cylinder pins 01.040 in transmission

housing.
3 Fit gasket 01.020 to transmission housing.

01.010
4 Fit housing cover 01.010 to transmission
housing and remove M10 stud bolts. 01.052
01.050 01.040
CAUTION
Professional handling is required when driving in
the cylinder pins and when fitting housing cover –
danger of housing failure.
5 Screw in 19 hex screws 01.050 and 1 hex

screw 01.052 and tighten to 46 Nm.
01.020
NOTE
Hex screw 01.052 is shorter.
026676
1349 751 103 - 2005-12 10-4

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Removal and installation of shafts
11 Removal and Installation of Shafts

06.100
11.1 Removing Reverse Gear Pin 06.540
1 Remove switch 06.100 and screw plug 06.540.
2 Remove hex screw 01.450 and retaining plate

01.440.
3 Using extractor fixture 1X56 136 878 remove

pin 01.420.
01.410 01.450
4 Remove O-ring 01.430 from reverse gear pin. 01.440
01.430
01.420
5 Slide reverse gear 01.400 and needle cage 01.400
01.410 towards wall of housing, but do not 026679
remove it at this stage.
1349 751 103 - 2005-12 11-1

6 S 1601 BD
11.2 Removing Input Shaft, Main Shaft, and

06.010
Countershaft
06.150
06.280
1 Remove pivot bolts 06.170 (2x) / 06.300 (2x) /
06.420
06.440 (2x) from housing.
06.170
2 Slide gear shift forks 06.430 / 06.290 / 06.160
06.300
towards main shaft and, at the same time, 06.290 06.160
remove gear shift rails 06.150 / 06.280 /
06.420 from the housing. 06.180
06.430
06.170
NOTE 06.440 06.310
Gear shift rails and drivers – do not dismantle 06.300
– are fully set components and are only
06.450 06.440
supplied in this condition.
026680
3 Remove gear shift fork 06.430 / 06.290 /

06.160 from housing and lift out sliding pads
06.180 / 06.310 / 06.450. 02.030
02.010
4 Remove snap ring 02.090 and plate 02.080

from input shaft.
02.050
02.080
02.090
026681
5 Fit lifting fixture 1X56 138 124 to input shaft

and on reverse gear selector shaft 06.010.
6 Tighten hex screw of the lifting divice into

countershaft.
Tightening torque approx. 80 Nm
CAUTION
Slide reverse gear 01.400 onto wall of housing.
Shaft pack can otherwise protrude.
7 Lift main shaft, countershaft and gear shift rail

out of transmission housing with crane.
007218
1349 751 103 - 2005-12 11-2

6 S 1601 BD
8 Install main shaft and countershaft in support

1X56 138 140.
9 Remove reverse gear shift rail 06.010.
10 Remove lifting fixture 1X56 138 124 from the

shafts.
11 Lift input shaft 02.010 off the main shaft.
1X56 138 140
010310
12 Screw hook 1X56 136 599 into countershaft. 1X56 136 599
13 Loosen the two hex screws on the slotted

flange slightly and pull countershaft off main
shaft.
026792
14 Lift off countershaft with crane.
15 Lift main shaft out of support with crane.
16 Remove reverse gear 01.400 and needle cages

01.410 out of housing.
01.410
01.400
026790
1349 751 103 - 2005-12 11-3

6 S 1601 BD
11.3 Installing Input Shaft, Main Shaft, and

Countershaft
1 Install reverse gear 01.400 with lightly oiled

needle cages 01.410 in transmission housing
and slide up to wall of housing.
2 Insert the main shaft with a crane into the

intake 1X56 138 140.
3 If necessary, fit clutch body and synchronizer 01.410

ring to the synchronizer.
4 Screw hook 1X56 136 599 into countershaft 01.400

and install in support with crane. Slide coun-
tershaft towards main shaft to engage shaft 026790
splines properly with one another.

1X56 136 599
5 Fit complete input shaft 02.010 onto main
shaft.
CAUTION
Do not damage rubber lip of baffle plate on input
shaft.
6 Tighten down the 2 hex screws on the slotted

flange.
7 Slide lifting fixture 1X56 138 124 onto input

shaft.
Tighten hex screw into countershaft and
tighten to approx. 80 Nm.
026792
8 Install sliding pads 06.180 / 06.310 / 06.450 in

06.010
gear shift forks 06.160 / 06.290 / 06.430 with a 06.150
small amount of grease. 06.280
06.420
9 Install gear shift forks in relevant sliding
06.170
sleeve.
06.300
10 Mesh drivers on gear shift rails 06.150 / 06.290 06.160
06.280 / 06.420 with gear shift forks.
06.430 06.180
06.170
06.440 06.310 06.300
06.450 06.440
026680
1349 751 103 - 2005-12 11-4

6 S 1601 BD
11 Lift input shaft, main shaft, countershaft, and

gear shift rails with crane.
12 Slowly and carefully lower shafts and gear

shift rails into transmission housing and insert
in bearing bores. While doing so, move the
gear shift rails until they engage in their
installation position.
007219
13 Unfasten hex screw on lifting fixture and

remove lifting fixture from shafts.
14 Coat threads on pivot bolts 06.170 (2x) /

06.300 (2x) / 06.440 (2x) with sealing com-
pound. Fit washers on pivot bolts then tighten
them to 160 Nm.
007217
15 Slide plate 02.080 firmly home over input

shaft 02.010. 02.030
02.010
NOTE
The lug on plate 02.080 must engage in oil
bore of input shaft.
16 Snap circlip 02.090 into groove of input shaft.

02.050
02.080
02.090
026681
1349 751 103 - 2005-12 11-5

6 S 1601 BD
11.4 Installing Reverse Gear Pin

06.100
1 Lightly oil new O-ring 01.430 and install in 06.540
annular groove of pin 01.420.
2 Align reverse gear 01.400 with bores.
3 Fit reverse gear pin to bore with O-ring

pointing towards output.
NOTE
Install pin flush with housing surface. 01.410 01.450
01.440
01.430
4 Screw in M8 hex screw 01.450 with retaining 01.420
plate 01.440 and tighten to 23 Nm. 01.400
026679
5 Tighten reverse gear switch 06.100 to 40 Nm.

Tighten screw plug 06.540 to 35 Nm.
1349 751 103 - 2005-12 11-6

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Input shaft
12 Input Shaft
02.030
12.1 Disassembly 02.010
1 Snap ring 02.090 and plate 02.080 are

removed in Chapter 11.2.
2 Grip behind inner race of taper roller bearing

02.050
02.050 with gripper tool 1X56 136 751.
02.080
02.090
3 Fit adapter 1X56 122 317, extension
1X56 122 310, and basic device 1X56 122 304
then extract inner race of taper roller bearing
from input shaft 02.010.
4 Check rubber lip of baffle plate 02.030 on 026681
input shaft for signs of hardening (brittleness)

and damage. If it is hardened or damaged,
replace the baffle plate.
1349 751 103 - 2005-12 12-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Input shaft
12.2 Assembly
02.030
NOTE 02.010
Running surface of input shaft must be
inspected visually for signs of wear and dam-
age. Inner race of taper roller bearing often
gets damaged by extraction process.
Therefore examine very carefully and, if
02.050
necessary, use new inner race for taper roller
bearing. 02.080
02.090
1 If necessary, press new baffle plate 02.030

firmly home into input shaft 02.010 with flat
and correspondingly large plate.
026681
!DANGER
parts.

to between 130 and 150 °C for max. 15 mins.
then slide onto input shaft.
NOTE
Inner race of taper roller bearing must have
zero backlash (axial abutement). If necessary,
drive home with drift.
3 Plate 02.080 and snap ring 02.090 are installed

in Chapter 11.3.
1349 751 103 - 2005-12 12-2

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Main Shaft
13 Main Shaft
04.280
04.290
04.430 /030 04.300

/020 04.310 /030
/050 /020
/060
/050
/030 /060
04.434 /030
02.020 04.440 04.320
/010
04.370
/010
04.360
04.350
04.380 04.010
04.390
04.400
04.420
026682
13.1 Disassembly 6 Grip behind inner race of taper roller bearing

04.440 with gripper 1X56 136 743.
1 Clamp output end of main shaft in a vise fit-
ted with protective jaws or install in support 7 Place intermediate piece on main shaft, screw
1X56 138 140. basic tool 1X56 122 304 to gripper and extract
inner race from taper roller bearing.
2 Lift off clutch body 02.020.
8 Remove retaining ring 04.434.
3 Take off synchronizer ring 04.430/030.
9 Guide retaining ring of extractor 1X56 138 141
4 Pull off the sliding sleeve 04.430/020. over main shaft and install split ring
(Ø 158 mm) with inner collar between
! DANGER clutch body 04.420 and synchronizer ring
This releases three thrust pieces, each fitted with a 04.430/030.
compression spring. Use a cloth to prevent the parts
from jumping out. 10 Slide retaining ring onto split ring and secure
with M6 hex screw.
5 Take three pressure pieces 04.430/050, each
fitted with a compression spring 04.430/060
out of synchronizer body 04.430/010
5th/6th gear.
1349 751 103 - 2005-12 13-1

6 S 1601 BD
11 Fit intermediate piece to main shaft and

remove synchronizer body 04.430/010 with
standard two-armed or three-armed extractor.
12 Remove synchronizer ring 04.430/030 for

5th/6th gear.
13 Remove clutch body 04.420 from the gearing

of the helical gear of the 5th/6th gear.
NOTE
Fasten together synchronizer components
prior to the assembly process !
14 Lift helical gear 04.400 for 5th/6th gear off the

main shaft. 007243
15 Remove needle cage 04.390 from main shaft.
16 Remove retaining ring 04.380 out of groove on

main shaft using thrust washer.

over main shaft and install split ring
(Ø 176 mm) between clutch body 04.320 and
synchronizer ring 04.310/030 for 4th gear.
18 Slide retaining ring onto split ring and secure

with M6 hex screw.
19 Place pressure piece onto main shaft and use

commercial two-armed or three-armed extrac-
007251
tor to remove helical gear of 4th gear 04.370,
clutch body of 4th gear 04.320, and thrust
washer 04.350 with needle cage 04.360 from
main shaft.
! DANGER
20 Remove helical gear, clutch body, thrust
This releases three thrust pieces, each fitted with a
washer and needle cage from extractor
compression spring. Use a cloth to prevent the parts
1X56 138 141.
from jumping out.
21 Remove 4th gear synchronizer ring

04.310/010.
22 Pull sliding sleeve 04.310/020 off 3rd/4th gear
synchronizer by hand.
1349 751 103 - 2005-12 13-2

6 S 1601 BD
04.280
04.290
04.430 /030 04.300

/020 04.310 /030
/050 /020
/060
/050
/030 /060
04.434 /030
02.020 04.440 04.320
/010
04.370
/010
04.360
04.350
04.380 04.010
04.390
04.400
04.420
026682
23 Take three pressure pieces 04.310/050 each NOTE

fitted with a compression spring 04.310/060 Fasten together synchronizer components
out of 3rd/4th gear synchronizer body prior to the assembly process
04.310/010.
29 Lift helical 3rd gear 04.290 off main shaft.
over main shaft and install split ring 30 Remove needle cage 04.280 from main shaft.
(Ø 176 mm) between clutch body 04.300 and
synchronizer ring 04.310/030. 31 Turn main shaft over and clamp input end in
a vise with protective chucks.
25 Slide retaining ring onto split ring and secure
with M6 hex screw. NOTE
Use crane to place main shaft into support
26 Fit intermediate piece to main shaft and 1X56 138 140. Install appropriate insert in
remove synchronizer body with standard pipe section of support, then insert main shaft
two-armed or three-armed extractor. with bearing journal.
27 Remove 3rd gear synchronizer ring and syn-

chronizer body 04.310/010 from extractor.
28 Remove clutch body 04.300 from spline of

helical 3rd gear.
1349 751 103 - 2005-12 13-3

6 S 1601 BD
04.040 04.044
/030
/020
/050
/060
/030
04.032
04.030
/010 04.150
04.110
04.020
04.100
04.096
04.010
04.070 04.080
04.060
04.056
026683
32 Place adapter on main shaft. Fit standard two 35 Remove needle cage 04.060 from main shaft.
or three-armed extractor to helical reverse
gear 04.110 and extract inner race of taper 36 Remove clutch disk 04.044 from synchronizer
roller bearing 04.150 from main shaft. on 1st gear.
33 Remove needle cage 04.100 from inner race

04.096. ! DANGER
This releases three thrust pieces, each fitted with a
34 Remove inner race, clutch body on reverse compression spring. Use a cloth to prevent the parts
gear 04.080 and helical 1st gear 04.070 from from jumping out.
main shaft together. Use standard two-or
three-armed extractor.
37 Lift outer race 04.044 off synchronizer
CAUTION for 1st gear and remove sliding sleeve
Needle cage and inner race cannot be replaced 04.040/020 from 1st/2nd gear.
separately: Only replace as complete unit.
38 Take three pressurized parts 04.040/050, each
featuring one compression spring 04.040/020,
out of the synchronizer body for the 1st/2nd
gear.
1349 751 103 - 2005-12 13-4

6 S 1601 BD
04.040 04.044
/030
/020
/050
/060
/030
04.032
04.030
/010 04.150
04.110
04.020
04.100
04.096
04.010
04.070 04.080
04.060
04.056
026683
39 Position pressure piece on main shaft and fit

to helical 2nd gear 04.030 with standard two or
three-armed extractor.
40 Remove helical gear 04.030, clutch disk

04.032, outer race 04.040/030 and synchro-
nizer body 04.040/010 from main shaft.
NOTE
Fasten together synchronizer components
prior to the assembly process.
41 Remove needle cage 04.020 from main shaft

04.010.
1349 751 103 - 2005-12 13-5

6 S 1601 BD
13.2 ZF-BK Synchronizer

X
The condition of synchron. rings and clutch bodies
should be checked before the synchronizers are
assembled.
NOTE
2Clutch body
Do not interchange or confuse synchronizer
components.
Synchro- 1
nizer
Establishing Wear ring
1 Place synchronizer ring on relevant clutch

body. Turn synchronizer components until
tapers are parallel and bearing uniform levels
of load.
The wear limit for synchronizer rings in the

synchronizers on 3rd/4th and 5th/6th gears is
0.8 mm.
2 Use feeler gage to measure distance “X”

between clutch body and synchronizer ring at
two opposing points. If the wear falls below
the wear limit of 0.8 mm, the synchron. ring
and/or clutch body must be replaced.
001999
3 Also check synchron. parts for visual proper-

ties (visual check). If surface is corrugated,
replace synchronizer parts. Do not mix up
parts which have been checked together (mark
them).
Cross Section of ZF-BK Synchronizer

4
6
1 = clutch body
2 = synchronizer ring 2 2
3 = synchronizer body
4 = pressure piece 1 1
5 = compression spring
5
6 = sliding sleeve
026684
1349 751 103 - 2005-12 13-6

6 S 1601 BD
Assembly of ZF-BK Synchronizer

04.040/030
04.032
1 Replace compression springs 04.040/060 with
new ones. This guarantees the specified slide-
over force of sliding sleeve 04.040/020.
2 Synchronizers can be assembled separately or

once fitted to main shaft. 04.040/050
04.040/060
3 Slide sliding sleeve 04.040/020 onto synchro-
nizer body 04.040/010. Install new compres-
sion springs 04.040/060 with pressure pieces
04.040/050 in synchronizer body 04.040/010.
Fit drift (guidance tool) to center point of 04.040/010
pressure pieces and guide pressure pieces
into sliding sleeve 04.040/020. 04.044
04.040/030
4 Press clutch body 04.044 with synchronizer 04.040/020
ring 04.040/030 and press sliding sleeve
04.040/020 into central position.
NOTE
Please ensure that pressure pieces are
correctly positioned.
026685
1349 751 103 - 2005-12 13-7

6 S 1601 BD
04.040 04.044
/030
/020
/050
/060
/030
04.032
04.030
/010 04.150
04.110
04.020
04.100
04.096
04.010
04.070 04.080
04.060
04.056
026683
13.3 Assembly 4 Check wear on synchronizer parts (refer to

chapter 13.2).
!DANGER
Always wear protective gloves when handling heated 5 Fit clutch disk 04.032 to spline on helical gear
parts. 04.030. The slightly raised internal spline on
the clutch disk points towards the output.
1 Clamp main shaft 04.010 at input end in a
vise with protective chucks. 6 Fit synchronizer ring 04.040/030.
NOTE !DANGER
Use crane to place main shaft into support Always wear protective gloves when handling heated
1X56 138 140. Install appropriate insert in parts.
pipe section of support, then insert main shaft
with bearing journal. 7 Heat synchronizer body 04.040/010 to around
120 °C and place on spline of main shaft.
2 Apply a thin coat of oil to the needle cage
04.020 and slide onto the main shaft. 8 Slide sliding sleeve 04.040/020 over synchro-
nizer body.
3 Slide helical 2nd gear 04.030 onto main shaft
so that spline on clutch disk points towards
output.
1349 751 103 - 2005-12 13-8

6 S 1601 BD
9 Install new compression springs 04.040/060

! DANGER
and existing pressure pieces 04.040/050 in
correct position in synchronizer body.
parts.
10 Use a suitable tool to guide pressure pieces

18 Heat bush 04.096 to 120 °C and slide onto
and balls into synchronizer body and sliding
main shaft until firmly home.
sleeve.
19 Apply light coat of oil to needle cage 04.100

11 Fit synchronizer ring 04.040/030.
and slide over bush 04.096.
12 Fit clutch disk 04.044 with raised spline point-

20 Slide helical reverse gear 04.110 over needle
ing towards input end. Move sliding sleeve
cage and onto main shaft. Spline must point
into neutral position, pressing against clutch
towards input end.
disk to do so. You will clearly hear the
pressurized pieces snap into place.
! DANGER
13 Heat bush 04.056 to 120 °C and slide onto
parts.
main shaft until firmly home. If necessary,
drive home using plastic drift.
to approx. 100 °C and slide onto main shaft.
14 Apply light coat of oil to needle cage 04.060
and slide over bush 04.056.
NOTE
• Inner race of taper roller bearing must have
15 Fit helical 1st gear 04.070 on needle cage
zero backlash. If necessary, drive home with
04.060 so that spline engages in clutch disk.
drift.
! • Rotate main shaft by 180°.
DANGER
22 Place output end of main shaft in support
parts.
1X56 138 140.
16 Heat clutch body 04.080 to 120 °C and slide

onto main shaft until firmly home.
NOTE
Clutch body collar must point towards output
end.
17 End float on helical 1st gear 04.070 must be at

least 0.20 mm.
1349 751 103 - 2005-12 13-9

6 S 1601 BD
04.280
04.290
04.430 /030 04.300

/020 04.310 /030
/050 /020
/060
/050
/030 /060
04.434 /030
02.020 04.440 04.320
/010
04.370
/010
04.360
04.350
04.380 04.010
04.390
04.400
04.420
026682
23 Coat needle cage with oil 04.280 and slide NOTE

onto main shaft. Lugs on synchronizer ring must engage in
synchronizer body recesses.
24 Push helical 3rd gear 04.290 onto needle cage,
ensuring that spline of helical gear faces input 28 Fit sliding sleeve 04.310/020.
end.
NOTE
25 Place clutch body 04.300 on spline of helical The recesses inside the sliding sleeve must
gear. cover the recesses in the synchron. body.
Also refer to Chapter 13.2, Checking Wear.
29 Install new compression springs 04.310/060
26 Slide synchronizer ring 04.310/030 onto and existing pressure pieces 04.310/050 in
clutch body. recesses in synchronizer body and guide into
sliding sleeve.
27 Heat synchronizer body 04.310/010 to 120 °C
and slide onto main shaft until firmly home. 30 Fit synchronizer ring 04.310/030 in such a
If necessary, drive home using plastic drift. way that the lugs engage in recesses in the
synchronizer body.
Also refer to Chapter 13.2, Checking Wear.
1349 751 103 - 2005-12 13-10

6 S 1601 BD
31 Fit clutch body 04.320 to synchronizer ring. 38 Fit clutch body 04.420 and synchronizer ring
04.430/030 onto dog teeth of 5th/6th helical
32 Press clutch body 04.320 against synchronizer gear.
and shift sliding sleeve 04.310/020 into
Neutral. You can hear the pressure pieces !DANGER
snapping in. Always wear protective gloves when handling heated
parts.
33 Install needle cage 04.360 and thrust washer
04.350 in helical 4th gear 04.370. 39 Heat synchronizer body for 5th/6th gear
04.430/010 to between 130 and 150 °C for
NOTE max. 15 minutes, then slide firmly home.
Collar on bush sits in recess in helical gear. Recess in synchronizer body points upwards.
Recesses in synchronizer body engage with
! DANGER lugs on synchronizer ring.
parts. 40 Snap retaining ring 04.434 into groove of
spline on main shaft.
34 Heat helical gear, needle cage and thrust
washer to between 130 and 150 °C for max. NOTE
15 minutes, then slide onto main shaft and The circlip’s axial clearance must be between
mesh with dog teeth. 0 and 0.1 mm. Try to achieve 0.0 mm.
If necessary, move thrust washer firmly home
– if necessary – with tube provided. !DANGER
35 Snap retaining ring 04.380 into groove of parts.
main shaft.
41 Heat inner race of bearing 04.440 to between
NOTE 130 and 150 °C for max. 15 minutes, place on
The circlip’s axial clearance must be between bearing journal of main shaft and push firmly
0 and 0.1 mm. Try to achieve 0.0 mm. home.
CAUTION 42 Once cold, apply approx. 2g of grease to large

Retaining ring must be entirely free of burrs roller diameter (collar side) to 2/3rds of roller
because it acts as contact surface for needle cage. height on inner race of bearing.
36 Apply a thin coat of oil to the needle cage 43 Fit sliding sleeve 04.430/020 to synchronizer
04.390 and slide onto the main shaft. body with milled teeth over recesses for
pressure pieces and press downwards as far
37 Slide helical 5th/6th gear 04.400 onto main as possible.
shaft with dog teeth pointing upwards.
44 Guide three pressure pieces 04.430/050 each
fitted with a new compression spring
04.430/060 into recesses of synchronizer body
and guide into sliding sleeve.
45 Place the 5th/6th gear’s synchronizer ring

04.430/030 onto the synchronizer body
1349 751 103 - 2005-12 13-11

6 S 1601 BD
04.280
04.290
04.430 /030 04.300

/020 04.310 /030
/050 /020
/060
/050
/030 /060
04.434 /030
02.020 04.440 04.320
/010
04.370
/010
04.360
04.350
04.380 04.010
04.390
04.400
04.420
026682
NOTE
Lugs on synchronizer ring must locate over
thrust pieces in synchronizer body.
46 Place clutch body for 5th/6th gear 02.020 onto

synchronizer body.
47 Press clutch body 02.020 against synchronizer

and shift sliding sleeve 04.430/020 into
Neutral.
1349 751 103 - 2005-12 13-12

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Countershaft
14 Countershaft 03.020
14.1 Dismantling Countershaft
1 Place intermediate piece on output end of 03.010

countershaft 03.010. 03.050
03.060
2 Grip behind output end of taper roller bearing 03.070
inner race 03.020 with gripper 1X56 136 711.
03.080
3 Screw basic tool 1X56 122 304 onto gripper

03.090
and remove inner race from taper roller 03.100
bearing.
4 Take inner race of tapered roller bearing out of

gripper tool. 026686
5 Fit pressure piece to input end of countershaft.
6 Grip behind input end of taper roller

bearing inner race 03.100 with gripper tool
1X56 136 711.
7 Screw basic tool 1X56 122 304 onto gripper

and remove inner race from taper roller
bearing.
8 Take inner race of taper roller bearing out of

gripper.
CAUTION
If necessary, replace tapered roller bearings (03.020
and 03.100). The bearing rollers may be damaged
when extracted.
9 Remove retaining ring 03.090.
10 Press off helical gears 03.050 / 03.060 / 03.070 /

03.080 individually with hydraulic press due
to high press-off forces. The press-off force for
each helical gear can be as high as 500 kN.
NOTE
To prevent gear damage, catch countershaft or
helical gears on a soft surface.
1349 751 103 - 2005-12 14-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Countershaft
14.2 Assembly
Direct drive (BD) Overdrive (BO)
1 Bores in helical gears and interference fits for
countershaft must be free of oil, grease and
dust.
!DANGER
Always wear protective gloves when handling heated IV
parts.
III
2 Heat helical gears to between 160 and 180 °C
II
for max. 15 mins.
3 Fit heated helical gears on a hydraulic press in I

the following sequence and align precisely.
001949
Depending on version
03.020
I Helical 5th or 6th gear – hub pointing upwards
II Helical 5th or 6th gear – hub pointing
downwards
III Helical 4th – higher hub pointing upwards
03.010
IV Helical 3rd – hub pointing upwards 03.050
03.060
NOTE 03.070
The helical gearing of the 2nd gear and 1st gear
or R gear is an integral element of the counter- 03.080
shaft.
03.090
4 Press countershaft 03.010 into bores of helical 03.100
gears 03.050 / 03.060 / 03.070 / 03.080.
Ensure that the helical gears are pressed in
again, until they are firmly home.
026686
5 Snap in retaining ring 03.090.
NOTE
• Retaining ring must rest firmly on base of
groove in main shaft.
• The circlip’s axial clearance must be

between 0 and 0.1 mm. Try to achieve
0.0 mm.
6 Heat taper roller bearing inner races (03.020

and 03.100) to between 120 and 130 °C for
max. 15 minutes and fit to countershaft.
Ensure this is firmly home, if necessary, drive
in further with a plastic drift.
1349 751 103 - 2005-12 14-2

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Housing
15 Housing
01.920
01.030
01.230
01.190
04.150 01.920
01.034
01.936
03.020 01.248
01.180
01.910
01.254
01.250
01.246
026687
15.1 Disassembling Transmission Housing CAUTION

Ensure that extractor grips firmly behind ball and
1 Driver outer race of bearing 03.020 on coun- socket joint.
tershaft out of transmission housing 01.030
using plastic drift. When replacing a housing
Driver outer race of bearing 04.150 on main
shaft out of transmission housing using plastic 3 When replacing a housing, remove all screw
drift. plugs 01.180 / 01.248 / 01.936 / 01.246 /
01.190 / 01.230.
2 Remove defective ball and socket joint 01.034
using standard internal extractor and counter 4 Remove grooved studs 01.254 and type plate
support on housing cover. 01.250.
1349 751 103 - 2005-12 15-1

6 S 1601 BD
6 S 1701 BO / 6 S 1901 BO Housing
01.920
01.030
01.230
01.190
04.150 01.920
01.034 01.936
03.020 01.248
01.180
01.910
01.254
01.250
01.246
026688
15.2 Assembling Transmission Housing !DANGER

1 Install screw plugs.
parts.
01.230 / 01.246 / 01.248 / 01.936 / 01.190 /
01.180 M 18x1.5 MA = 35 Nm
4 Heat transmission housing 01.030 beside bear-
ing bores for main shaft and countershaft to
2 Drive in two new pivot bearings 01.034 – with
max. 100 °C with a standard hot air blower.
the thicker end facing the tool attachment –
with tool attachment 1X56 122 404 until joints
5 Install outer race of bearings on countershaft
are recessed against housing contour by
03.020 and main shaft 04.150 in transmission
between 0.9 and 1.7 mm.
housing and drive firmly home, if necessary
3 Peen pivot bearing bore three times at 120°
intervals.
6 Securely attach the type plate 01.250 using
four grooved studs 01.254.
1349 751 103 - 2005-12 15-2

Catalogo Caja ZF 170

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1349 751 103

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1349 751 103

1 Oil Filter ............................................................................................................................................. 1-1

2 Central Wiring ................................................................................................................................... 2-1

3 Stainless Steel Heat Exchanger......................................................................................................... 3-1

4 Sectional View Through Intarder with Reducing Unit .................................................................. 4-1

5 Removing/Installing ZF-Intarder...................................................................................................... 5-1

6 Disassembling/Assembling ZF-Intarder........................................................................................... 6-1

1349 751 103 - 2005-12 3

7 ZF-Servoshift Without Selection Equipment for Cable Control ..................................................... 7-1

8 Input-End Add-On Parts .................................................................................................................... 8-1

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

11 Removing and Installing Shafts........................................................................................................ 11-1

12 Input Shaft ......................................................................................................................................... 12-1

13 Main Shaft ......................................................................................................................................... 13-1

14 Countershaft ..................................................................................................................................... 14-1

1349 751 103 - 2005-12 4

This manual is intended for skilled personnel

This manual deals with a ZF product in accordance

However, due to continuing development of the

Service points equipped by ZF Friedrichshafen AG

3. Genuine ZF spares, according to

All work performed at these service locations is

Safety Instructions General Information

To avoid injury to personnel and damage to

After completion of repair work and testing, skilled

! THREATS TO THE ENVIRONMENT !

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

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

Lube bores and grooves must be free of anti-

Parts such as roller bearings, discs, thrust washers

Bearings d) Dual shaft seals have two seal-

f) If possible, heat shaft seal bores to between

a) Apply a light coat of sealing agent* on circum-

* refer to expendable material

Index Date of issue Chapter Initiator Comment

1349 751 103 - 2005-12 9

Tightening torques for nuts and bolts, extract

This standard contains data on tightening torques NOTE

Coarse-pitch thread Fine screw thread

Size Tightening torque in Nm for Size 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

Size Tightening torque in Nm Pipe Thread Tightening

Withdrawn Title Substitute Result of check / measures 1)

Withdrawn Title Substitute Result of check / measures 1)

1) with reference to productive parts numbered at ZF

Designation Name Volume Application Comments

Grease For example:

Sealing compound Loctite no. 574

Jointing compound Loctite no. 241

1349 751 103 - 2005-12 14

Designation Dimension Measuring device Remark