5871 871 002

Repair manual

Transfer Case VG 750

ZF Passau GmbH
Donaustr. 25 - 71 Edition: 1999
D - 94034 Passau Subject to changes w/o notice !
 PREFACE
_______________________________________________________________________________

The present document gives directions to the trained personnel to repair the

Transfer Case VG 750

Customary tools and devices, which are workshop standard, are supposed to be available.
Required special tools are listed in an overview chart.
Special tool are kept at the necessary level, they bear a tool number and can be purchased from Steyr-
Antriebstechnik.

Disassembly and assembly of one version only is explained in this document. Differing working
sequences of other possible versions can easily be recognised by the skilled professional. For such jobs
see enclosed sectional and perspective views.

The repair of the component may require changed working sequences or/and differing adjustment or
checking data, according to the technical development of the product over the years.

Therefore, we recommend rendering your ZF Passau Product only to the hands of periodically trained
personnel.

Damages caused by improperly or unprofessionally executed repair work through untrained personnel
and the resulting consequences are excluded from any contractual liability.

This also applies when NON-ORIGINAL-PARTS are being used.

1
GENERAL WORKING DIRECTIONS
__________________________________________________________________________________

The company repairing the ZF Passau components is in any case responsible for all aspects of safety.

The valid safety regulations and legal directives have to be obeyed to avoid injury of persons and
damage of the product during maintenance and repair.

The proper repair of the ZF Passau Product requires adequately trained personnel. To undergo training
is the obligation of the repairer.

Always assure professional and clean working conditions. Components shall always be cleaned before
disassembly.

The use of indicated special tools is a precondition.

After disassembly, all parts have to be cleaned. This applies in particular to corners, nooks and oil
catchers in housings and covers.

Carefully remove old sealing compound.

Clean surfaces thoroughly before sealing.

Lubrications bores, grooves and pipes are to be checked to be free from obstructions. They must be
free from deposits, contamination and preservatives. The latter applies particularly for new parts.

Parts that are being damaged during disassembly are to be replaced by new ones.
E.g.: radial oil seals, o-rings, groove-rings, seal cups, protection caps a. s. o.

Parts as bearings, thrust washers, synchromesh parts etc., which are liable to normal wear have to be
checked by the skilled professional. He judges if a part can be reused or not.

Parts, which have a shrink fit, must be driven to their end position after cooling down to assure perfect
seating. Before pressing-in parts like shafts, bearings etc. both contact surfaces must be oiled.

On the assembly all given adjustment tolerances, check data and tightening torques have to be
observed. the components are to be filled with lubricant after the repair Observe filling instructions and
lubrication chart. After filling, the oil drain plugs and oil level plugs must be tightened to correct torque.

Use Original – ZF Passau - Parts only!

2
 Type Plate
_________________________________________________________________________

For the identification of the various types and variants, there is a type plate fixed to the transfer case
housing. It is important to indicate the type number (Aggr.) and serial number (LNr.) in case of
inquiries or when ordering spare parts.

3
LIST OF CONTENTS
_______________________________________________________________________________

LIST OF CONTENTS

Page

Technical Data 5

Cross Section View VG 750 without interaxle differential 6

Cross Section View VG 750 with interaxle differential 7

Cross Section View VG 750 with oil pump and power take-off 8

Cross Section View-pneum.gear shifting+pneum.differential lock shifting 9

Consumables 10-11

Exploded View (VG 750 without interaxle differential) 12

Exploded View (VG 750 with interaxle differential and oil pump) 13

Tightening torques 14

Adjustment data 15

Special tools-standard testing and measurement tools 16

Technical definitions 17

Contents overview of repair 19

Repair 20-61

4
Technical Data

VG 750

max. input torque 8000 NM

max. input speed 3500 U/min.

high low
ratios
1:1,00 1:2,00
weight including interaxle differential ca. 125 kg

weight without interaxle differential ca. 115 kg

with diff. 5,5 l
amount of oil needed
without diff. 6,4 l
SAE 90
oil quality
according to MIL-L-2105-API-GL 4
operating temperature ca. 100° C

5
CROSS SECTION VIEW VG 750 without INTERAXLE DIFFERENTIAL

6
CROSS SECTION VIEW VG 750 with INTERAXLE DIFFERENTIAL

7
CROSS SECTION VIEW VG 750 with OIL PUMP and POWER TAKE-OFF

8
CROSS SECTION VIEW-PNEUMATIC GEAR SHIFTING
CROSS SECTION PNEUMATIC DIFFERENTIAL LOCK SHIFTING

9
Consumables
__________________________________________________________________________

Consumables for repair of a transfer case are lubricants, slip additives, sealants, locking adhesives,
preservatives and cleaning agents.

Table of consumables for unit repair.

Symbol Designation of compound Product name

F1 Standard grease STABUTHERM-GH 461

SUPEROL EP2
G1 Antiseize compound MOLYCOTE M55
D1 DIRKO / RHODORSEAL 5661
D2 Sealing compound Loctite 518 (red)
B1 Loctite 243 (blue)
B2 Adhesive Loctite 638 (green)
OIL Antiseize compound SAE 90 API GL4 ou GL5

In the following diagram the greases, anti-seize agents, sealing compounds and adhesives are
indicated with their symbol and point to the components to be treated.

10
 CONSUMABLES VG 750

11
EXPLODED VIEW VG 750 without INTERAXLE DIFFERENTIAL

12
EXPLODED VIEW VG with DIFFERENTIAL and OIL PUMP

13
TIGHTENING TORQUES

14
Adjustment Data

Pos. Designation Dimensions Remarks

1 preload of input shaft bearing 0-0,5 mm to be adjusted with shims

2 axial clearance of double gear 0,30-0,40 mm to be adjusted with shims

preload of output shaft
3 bearings 0,05-0,10 mm to be adjusted with shims
adjustment of front output
4 shaft shifting 0,50-0,75 mm to be adjusted with shims

15
 Tool List VG
Special tool

N° Designation Makers Designation

1 Mount device V-TS-220-W

2 Clamping device A-VG-750-10
3 Holding device V-TS-215-W
4 Lifting and measure device A-VG-2000-05
5 Puller A-VG-750-01
6 Puller A-VG-750-02
7 Support A-VG-750-03
8 Screw A-VG-750-04
9 Plastic ring A-VG-750-05
10 Steel ring A-VG-750-06
11 Adjusting tool A-VG-750-07
12 Mandrel A-VG-750-08
13 Wrench A-VG-750-09
14 Mandrel A-VG-750-11
15 Mandrel A-VG-750-12
16 Support disk A-TS-214-W
17 Puller for oil pump V-TS-86-W/1

Standard-, Testing- and Measurement Tool

N° Designation Makers Designation

1 Double-arm extractor KUKKO 20-3

2 Extract hook KUKKO 3-300-P
3 Double-arm extractor KUKKO 20-2
4 Inside extractor KUKKO 21-6
Inside extractor KUKKO 21-9
5 Support KUKKO 22-3
6 Parting off tool KUKKO 17-2
7 Press off tool KUKKO 18-2
8 2 Pry bars HAZET 2165-2
9 Torque wrench
10 Torque multiplier
11 Depth gauge
12 Intern. measuring instr. 15/200
13 Feeler gauge
14 Dial gauge with magnetic post

16
 Definitions

The terms used in the repair manual where chosen with the current standard in mind.

The application and definition of operations and work instructions is explained here.

Designation Explanation

Remove Removal of a component from a component group or a part from

an assembly without first removing any other components.
Mount To fit a part to an assembly or a component to a component group
without any further components being involved.
Disconnect To separate a detactable connection of wire, tubing or hose.
Connect To bring together a detactable connection of wire, tubing or hose.
Pull off To remove a component that is press-fitted to another.
Push on To join two components by press-fitting.
Unscrew To open a rotory connection.
Screw down To close a rotory connection.
Removing Removal of a component from a component group or a part from
an assembly when other components must first be displaced.
Install To attach a component group or a part to an assembly, if for
functional reasons, other component groups will be attached.
Loosen Partial detachment of fixing elements in a component or a part
Remove To detach the fixing elements of a component or a part.
Tighten To firmly attach the fixing elements of a component of a part.
Disassembly Dismantling of component groups into their constituent parts.
Assembly The joining together of parts of a component group.
Set, Adjust Correction of deviation with the help of the proper tools or
equipment.
Fill Adding or topping – up of fluids.
Renew Replacement of an accessory material with a new one.
Replacement Substitution of a machine, component group or part with a new or
reconditioned one of the same type.
Measure Determination of the current nominal condition by investigating
physical size.
Checking Comparison of the current nominal condition against a set
standard.

Cleaning Removal of foreign and auxiliary materials.

Service Measures necessary to maintain proper functioning.

17
18
 DESCRIPTION
OF REPAIR WORKS

Page

1 Works on dismounted transfer case 20

1.1 Disassembly of transfer case 21

1.1.1 Removing of transfer case parts, oil pump and shift cylinder 21
1.1.2 Removal of input shaft, double gear resp. output shaft 28
1.1.3 Disassemble input shaft 33
1.1.4 Disassemble double gear 33
1.1.5 Disassemble front output shaft 34
1.1.6 Disassemble planetary carrier
1.1.7 Disassemble rear output shaft 36
1.1.7.1 Disassembly of rear output shaft-version 100% relative speed 36

1.2 Assemble shafts and planetary gear 37

1.2.1 Assemble rear output shaft (without planetary) 37

1.2.2 Assembly of planetary gear 37
1.2.3 Assemble front output shaft 39
1.2.4 Assemble double gear 40
1.2.5 Assemble input shaft 40

1.3 Assemble transfer case 41

1.3.1 Prepare housing and install bearing 41

1.3.2 Install differential, rear output shaft and double gear 43
1.3.3 Adjust bearings of rear output shaft and double gear 44
1.3.4 Adjust front axle shifting and assemble cylinder
1.3.4.1 Assemble double gear and install 49
1.3.5 Install input shaft-shift fork and shift rod 50
1.3.6 Input shaft bearing adjustment 53
1.3.6.1 Version with oil pump 54
1.3.7 Complete pneumatic gear shifting and adjust stop positions 56
1.3.8 Install flanges 59
1.3.9 Install breather and speedometer sending unit

1.4 Special Tools 63

1.4.1 Standard,- Testing- and Measurement Tools 68

19
1 Works on dismounted transfer case

Contains: Mount transfer case A-VG 750 – 10 with clamping device on support stand
V-TS 220 W.

Dismantle and assemble transfer case............. 1.1...1.3.9

ATTENTION: Assure correct oil level. low level causes lack of lubrication and reduces durability. Too
high level causes excessive splashing and leads to overheating of transfer case.

1 oil filling plug

oil level plug
2 oil drain plug
3 breather

- OIL CHANGE (recommended in warm condition) OIL LEVEL CHECK

- drain gear oil at drain plug (2) -open oil filling/level plug (1)
- clean magnet of drain plug -oil level must reach edge of level bore if
- mount drain plug with new seal necessary top up
- fill new gear oil at filling bore/level bore (1) until it mount level plug with new seal
- flows over
- mount level plug (1) with new seal
- unscrew breather (3) clean it and mount it again

20
1.1 Disassembly of transfer case

1.1.1 Removing of external transfer case parts,

oil pump and shift cylinder

2 Loosen all flange nuts by means of power

tool (2/1) and Special tool TS 215 W
(where available use torque multiplier).

2
3 Pull off rear output flange (3/1) by puller
KUKKO 20-3.

4 Pull off input flange and front axle output flange 3

by puller KUKKO 20-3 (4/1).

NOTE: Special tool A-VG 2000-05 is especially

designed for heavy flange seats.

21
5 Unscrew ball guide (5/1) from shift rod cover.

ATTENTION : Spring (5/2) and ball (5/3).

5
6 Loosen lock nut (5/4) and adjusting screw (5/5).

NOTE: Use lock nut (6/6).

6
7 Remove shift rod retainer (7/1).

8 Remove speedometer sending unit (8/1). 7

22
9 Remove switch (9/1) (front axle drive indicator
switch).

9
10 Remove shift cylinder cover (10/1).

11 Remove plug (11/1). 10

12 Remove bearing cover input shaft (12/1),

bearing cover-intermediate shaft (12/2) and
bearing cover-rear axle output shaft (12/3) 11
Remove anti-rotation lock piece. (*)

Version prepared for oil pump

Remove bearing cover (1) and
bearing housing (2) from rear end of input shaft.

12

23
Version with oil pump
Remove oil pump

1 Remove oil pump (13/1).

13
2 Remove cover (14/2).
Remove cover (14/1).

14
3 Unscrew Allan screws
M 6x35 (15/1)
M 6x30 (15/2).

15
4 Pull out oil pump housing (16/1)
by means of puller V-TS 86 W/1.

16

24
5 Remove outer (17/1) and inner (17/2) oil
pump gear.

17
6 Take out drive ball (18/1) by aid of magnet (18/2).

18
7 Remove hollow screw (19/2), ball (19/3)
and plug (19/4).
Remove bearing housing (19/1) from rear end
of input shaft.

8 Remove oil pump cover (20/1) from housing. 19

Remove spring pin (20/2).
Remove anti rotation lock piece (20/3).

20

25
9 Remove all adjusting shims (21/1).

Disassemble shift cylinder

1 Loosen lock nut (22/1) and remove

adjusting screw (22/2). Use second nut 21
with lock nut.

2 Remove cover of shift cylinder (23/1). 22

3 Remove circlip (24/1) and pull off cylinder 23

(24/2) and piston from shift rod (24/3).

24

26
4 Loosen grooved nut (26/1) with special tool
A-VG 750-09 (use power tool).

25
5 Remove ball bearing (26/2) with both inner
races from rear side of input shaft.

Disassemble rear housing 26

1 Loosen all fastening bolts (27/1).

2 Lift off rear housing (28/1). 27

28

27
1.1.2 Removal of input shaft, double gear,
planetary gear resp. output shaft.

1 Remove oil guide (29/1).

29
2 Unscrew bolts at shift fork (30/1)

30
3 Remove shift rod (30/2) and take out shift
fork (30/3).

ATTENTION: care for sliders (30/4).

4 Lift out input shaft (32/1). 31

32
28
5 Lift out double gear (33/1) and planetary housing
(33/2) together.

ATTENTION: When planetary housing is lifted

out, needles can fall out from bearing.

33

6 Remove planet carrier (34/1).

34
7 Remove shaft seal rings (36/1) from front
housing (35/1).

NOTE: When shaft seal rings are being removed,

they have to be replaced by new ones.

8 Remove circlip (36/2).

35

36

29
9 Drive out front output shaft (37/1)
toward front of housing.

ATTENTION: Only when changing oil seals (38/1)

and (38/2).
NOTE: Hold shift fork (38/4) against cocking.
37

10 Remove plug (38/5) and shift spring (38/6).

38
11 Remove shift rod (39/3) and piston (39/4).

12 Remove shift fork (40/5) and dog sleeve (40/6). 39

40
30
13 Remove circlip (41/1) at input shaft bearing.

41
14 Pull out bearings from front housing with special
tools.
A-VG 750-02 (42/2) input shaft
A-VG 750-01 (42/1) double gear
with tool A-VG 750-03 (42/3) and
A-VG 750-04 (42/4).

42
15 Pull out input shaft bearing from rear housing
with special tools A-VG 750-02 (42/2)
A-VG 750-03 (42/3)
A-VG 750-04 (42/4).

16 Pull out double gear bearing from rear housing 43

with special tools
A-VG 750-01 (42/1)
A-VG 750-03 (42/3)
A-VG 750-04 (42/4).

44

31
17 Drive out outer bearing race (1) of rear output
shaft bearing from rear housing by means of
aluminium punch (45/1) (approx. 20 mm Ø).

45
18 Drive out outer bearing race (46/1) of output
shaft bearing from front housing by means of
aluminium punch (46/2).

19 Loosen oil pipe (47/1). 46

20 Remove breather (48/1). 47

48
32
1.1.3 Disassemble input shaft
1 Pull off gear z = 34 (49/1) by two arm puller
KUKKO 20-3 with washer (49/2), and inner
bearing race (49/3).
Remove shifting dog sleeve (49/4).

49
2 Pull off gear z = 21 (50/1) by two arm puller
KUKKO 20-3 with washer (50/2 and inner
bearing race (50/3).

1.1.4 Disassemble double gear

50
1 Loosen fastening screw (51/1)on pulse
rotor (51/2).

2 Pull off inner bearing races (52/3), 51

press off tool KUKKO 18-2 (52/1)and
parting off tool KUKKO 17-2 (52/2)

52
33
1.1.5 Disassemble front output shaft
1 Pull off bearing (53/1) by two arm puller
KUKKO 20-2.

53
1.1.6 Disassemble planetary carrier

1 Pull off front bearing (55/1) by puller

KUKKO 18-2 (54/1) and clamping device
KUKKO17-2 (54/2).
Use tool A-VG 750-06 (55/2) with chamfered
side of bore on top and tool TS 214W (55/3)
for support.

2 Pull off rear bearing (55/4) by puller

54
KUKKO 18-2 (55/5) and clamping device
KUKKO 17-2 (55/6).

3 Unscrew fastening bolts (56/1) of planetary 55

carrier.

56

34
4 Loosen warm screws (58/1) at planetary axles.

57
5 Remove planetary gears (58/2) with axles
(58/3), sun gear (58/4) and trust washers (58/5).

ATTENTION : On disassembly the needle 58

bearings (58/6) can disintegrate.

6 Remove dowel pins (59/1) and washers.

7 After removal of needles pull out bearing (60/1)

by inside puller KUKKO 21-6 and support device
KUKKO 22-2.
Pull out outer bearing race (60/2) by means
of inside puller KUKKO 21-9 and support 59
KUKKO 22-3.

60

35
 8 Pull off bearing (61/3) from planetary housing
by puller KUKKO 18-2 (61/1) and clamping
device KUKKO 17-2 (61/2).

61
1.1.7 Disassemble rear output shaft (version
without planetary differential)

1 Pull off front bearing (64/1) by puller KUKKO

18-2 (62/1) and clamping device KUKKO 17-2
(62/2).
Tool A-VG 750-06 (62/3) with chamfered edge
on top and tool TS 214/W (62/4) for support.

62

2 Pull off rear bearing (64/2) by puller

KUKKO 20-2 (63/1).

1.1.7.1 Disassembly of rear output shaft

version 100% relative speed

1 Remove needles and pull out bearing (64/3)

by puller KUKKO 21-6 and support device
KUKKO 22-3.
Remove snapring (64/4) and inner race (65/5)
from front output shaft (64/6).
63

64

36
1.2 Assemble shafts and planetary gear
1.2.1 Assemble rear output shaft (without planetary)

1 Heat rear bearing (65/1) to 90° C and slide

it on shaft.
Variant 100% relative speed:
Install needle bearing (65/2) by means of
tool A-VG 750-012.

65

2 Heat front bearing (66/1) to 90° C and slide

it on shaft.

1.2.2 Assembly of planetary gear 66

1 Heat rear bearing (67/1) to 90° C and slide

it on planetary housing.

67
2 Install outer bearing race (68/2) by copper punch
(68/1). Install needle bearing by means of tool
A-VG 750-12.

ATTENTION : do not tilt.

68

37
3 Install needle bearing with intermediate
washer (69/1) in planetary gears (69/5) with
the aid of grease.
Slide in axles (69/2) with chamfer on top,
dowel pin (69/3) from inside and safety washer
(69/4) until stop point.

69
4 Install planetary gears (70/1) with thrust washer
(70/2) and sun gear (70/3) with thrust washers
(70/4).

70
5 Put on planetary cover (71/1).
Make sure that position makers meet.
Assure correct position of axle regarding
notches.

6 Install fastening screws (72/1) in planetary 71

carrier.
Tighten to 180 ± 20 Nm according to
sequence (72/2).

72

38
 7 Apply Loctite 243 to worm screws (73/1)
and tighten.
ATTENTION: Assure position of axles.
du Loctite 243 et visser à fond.

73
8 Heat front bearing (75/1) to 90° C and
slide it on.

74
9 Heat rear bearing to (75/2) to 90° and
slide it on.

75
1.2.3 Assemble front output shaft.

1 Heat ball bearing (76/1) to 90° C

and slide it on shaft.

76

39
1.2.4 Assemble double gear

1 Heat inner bearing races (77/1) to 90° C

and slide them on.

NOTE: Install pulse rotor after bearing adjustment

77
1.2.5 Assemble input shaft

1 Glue oil baffle washer (78/1) into input shaft

with Loctite 243.

NOTE : Installing of baffle washer is only required

if shaft is damaged or being replaced as well
as when the lubrication bore has to be
cleaned.

78
2 Slide gear z = 21 (79/1) on shaft (oil slide
bearing). Slide on thrust washer (79/2) with
chamfer on the outer side.
Heat inner bearing ring (80/3) to 90° C
and slide it on.

79
3 Slide dog sleeve (80/4) on spline (oil spline).
Slide gear z =32 (80/5) on shaft (oil slide bearing)
Slide on thrust washer with chamfer on the
outer side (79/2). Heat inner bearing race (80/3)
to 90° C and slide it on.

80

40
1.3 Assemble transfer case
1.3.1 Prepare housing and install bearings

1 Install oil pipe (81/1) with Loctite 638.

 Install all core plugs with Loctite 243.

Install upper and lower dowel pin (81/2 in

front housing.

81
2 Heat rear housing to 70° C and install input
shaft bearing (83/1), double gear bearing
(83/2)and output shaft outer bearing race (83/3).

82

83
3 Heat front housing to 70° C and install input
shaft bearing (83/4), double gear bearing (83/5)
and output shaft outer bearing race (83/6)

ATTENTION : Install double gear bearing with

riveted side of brass cage to the inside.

84

41
4 Install circlip (85/1) at the input shaft bearing.

85
5 Install shift fork (86/1) and dog sleeve (86/2)
in housing.

Use tool A-VG-750-07 (1).

86
6 Heat housing to 70° and install front output
shaft (87/3) from outside to inside through
dog sleeve.

87

7 Install circlip (87/4).

88

42
1.3.2 Install differential, rear output shaft and
double gear.

1 Slide planetary differential (89/1) on front

output shaft.
Version without differential:
Slide rear output shaft (89/2) on front output
shaft (89/3).
Oil bearings.

89

2 Install double gear (90/2) together with

planetary housing (90/3).
ATTENTION : Needle bearing in planetary housing
Version without differential:
Install rear output shaft (89/2) first and then
double gear (90/2).

90

3 Mount rear housing provisionary with 6 bolts.

4 Drive outer bearing races of the rear output

91
shaft (92/1) and double gear (92/2) to inner-
most position.

Use aluminium punch.

92

43
1.3.3 Adjust bearings of rear output shaft
and double gear.

1 Slide tool A-VG 750-06 (93/1) on rear output

shaft and tighten collar nut by means of power tool.

93

2 Drive double gear (94/1) and rear output shaft

(94/2) to front by means of aluminium punch.

3 Measure distance from rear output shaft bearing

to housing surface = (A) (95/1)
4 Measure projection on bearing cover = (B) (96/2)
5 Calculate thickness of shims = X 94
a = bearing preload 0,05 – 0,10 mm
X=A–B+a

95

Shims X s= 0,10 mm
s= 0,15 mm
s= 0,20 mm
s= 0,40 mm
s= 0,60 mm
s= 0,80 mm
s= 1,00 mm

96

44
6 Measure distance from rear housing to double
gear bearing. A
7 Measure projection on bearing cover B (96/2)
8 Calculate thickness of shims = X
a = bearing clearance 0,30 – 0,40 mm

X=A–B–a

97

Shims X s= 0,10 mm
s= 0,15 mm
s= 0,20 mm
s= 0,50 mm

98
9 Install bearing cover (99/1) of rear output shaft with
determined shims (3).

10 Install bearing cover of double gear (100/2) with

determined shims (4).

99

100

45
 11 Check drag torque of rear output shaft
by means of torque gauge (101/1).
Drag torque = 10 – 15 cm/kg.

101
12 Measure axial bearing clearance of double gear.
Install bolt M16x1,5x70 (102/1)in double gear.

102
13 Check axial clearance by means of dial gauge
(103/1). Use tire lever.
Axial clearance: a = 0,3 – 0,4 mm.

1.3.4 Adjust front axle shifting (diff. lock shifting) and

103
assemble cylinder.

1 Slide in tool A-VG-750-07 (104/1) and set in to

stop position.

104
46
2 Measure distance X from tool (1) to shift fork (3)
by means of depth caliper gauge (105/2).

105

3 Neutralize distance X by shim (106/1).

Shim: -30x42x0,1
-30x42x0,2
-30x42x0,5
-30x42x1,0

4 Carefully install O-Rings (107/1) inside and 106

outside of piston (107/2) and grease with
Molycote M55.

Slide shim on piston (106/2).

5 Grease piston rod (107/4) and istall with piston 107

(107/2) and shim (106/1).
6 Install cover (107/3) with Loctite 518 sealant.

Torque: 46 ± 5 Nm

108
47
7 Remove rear output shaft bearing cover
together with shims.

109
8 Remove rear housing.

110
9 Slide in shaft spring (112/1).

111
10 Install plug (112/2) with Loctite 243.
Torque: 60 ± 5 Nm

112

48
1.3.4.1 Assemble double gear and install

1 Lift out gear (113/1) together with differential

(113/2).
Version without differential: lift out double gear
only (113/1).

113
2 Apply Loctite 243 to screw (114/1) and mount
pulse rotor (114/2).
Torque: 200 ± 20 Nm

3 Install double gear with planetary differential. 114

ATTENTION : Needle bearing in differential housing

4 Install oil guide (1) 115

116

49
1.3.5 Install input shaft-shift fork and shift rod.

1 Slide tool A-VG 750-05 (117/1) into front

input shaft bearing.

117

2 Install input shaft (118/1).

Counterhold A-VG 750-05 (117/1).

118
3 Install shift fork (119/1) with sliders (119/2)
on dog sleeve.
(Numbers on shift fork to front)

119
4 Install shift rod (119/3) with O-rings (119/4).

ATTENTION : Position of notches for fastening screws

(120/1) to match with thread bores of shift fork
(120/3).

120

50
5 Install fastening screws (121/1) with
Loctite 243 and tighten fork.
Torque: 46 ± 5 Nm

121
ATTENTION : Clean sealing surface of housing
and remove remainders of sealant.

6 Apply sealant (122/1) Loctite 518 on front housing

(Use roller to spread Loctite 518 equally)

122
7 Install rear housing.

8 Tighten bolts (124/1) M 10x125 first and bolts

(124/2) M10x80 after.
Torque: 46 ± 5 Nm

123

124

51
9 Apply grease STABOTHERM GN 461 to sealing
lips and install radial oil seal rings (125/1) by
means of tool A-VG- 750-08.
ATTENTION :
black outside
brown inside

ATTENTION : Clean sealing surfaces. 125

10 Apply Loctite 518 to sealing surface of double

gear bearing cover (126/1) and rear output
shaft bearing cover (126/2) and install them
with determined shims.
Torque: 46 ± 5 Nm

126

11 Slide ball bearing (127/3) with groove to inside

on rear end of input shaft.

127

12 Install grooved nut (128/4) with tool

A-VG 750-06 and power tool and lock.
Torque: 300 ± 30 Nm

128

52
1.3.6 Input shaft bearing adjustment

1 Measure distance from bearing to housing

surface B.
Version without oil pump:
2 Measure distance A from outer cover surface
into recess of bearing cover (130/2).
3 Measure distance C from outer cover surface
to sealing surface of bearing cover (130/2).
Version with oil pump bearing:
4 Measure distance A from outer cover surface into
recess of oil pump bearing cover.
5 Measure distance C from outer cover surface
to sealing surface of bearing cover. (130/1).
129

Thickness of shims: X
X=A–B–C+a
preload a= 0,05 mm measure by feeler gauge
(131/1). 130

Adjusting shims: s= 0,1 mm

(132/1) s= 0,15 mm
s= 0,2 mm
s= 0,5 mm
Version without oil pump: 131
6 Apply Loctite 518 to bearing cover (132/3)
and install together with shims and locking
piece (132/4).

Version without oil pump bearing cover:

7 Apply Loctite 518 to bearing cover (132/2
and end cover (132/3) and install together with
shims and locking piece (132/4).
Torque: 80 ± 5 Nm

132

53
Version with oil pump provision:
1 Install plugs (133/3) with copper seals
Install core plugs (133/2) with Loctite 243.
Torque: 60 ± 5 Nm
ATTENTION : Insert ball (133/1) before installing
hollow screw with seal.
Torque: 30 Nm

133
1.3.6.1 Version with oil pump:
ATTENTION : Clean sealing surfaces.

1 Apply Loctite 518 to bearing cover (134/1)

and install together with shims.

134
2 Install inner oil pump cover (135/1) in bearing
cover with spring pin into bore to lock against
rotation (135/2).

3 Insert drive ball (136/1) into shaft bore

(use some grease).
Slide pump gear (136/2) on input shaft.
Slide outer pump gear (136/3) into oil pump
housing (136/4).
Install oil pump into bearing cover and tighten
with Allen screws (136/5).
M 6x30
M 6x35 135

ATTENTION : Position of ball and groove must align.

136

54
4 Apply Loctite 518 to end cover (137/1) and
P.T.O cover (137/2) and install.
Torque: 60 ± 5 Nm

137
5 Insert ball (138/1) into bearing cover and install
hollow screws (138/4) with seal (138/2).
Mount plug (138/4) with seal.
Torque: 60 Nm
Install core plugs (138/5) with Loctite 243.
Hollow screw torque: 30 Nm

6 Assemble oil pipe (139/1) with union pieces 138

(139/2) and install on housing.

7 Mount oil filler/lever plug (140/1) and oil drain 139

plug (140/2) with seals.
Torque: 80 Nm

140
55
1.3.7 Complete pneumatic gear shifting and adjust stop positions

1 Insert O-ring (141/1) into groove of shift cylinder

and grease lightly.

Insert O-rings (141/3) on pistons (141/4) and

grease lightly.

141
2 Apply Loctite 518 to sealing surface and slide
shift cylinder (141/1) on shift rod.
Slide piston seals into shift cylinder.
Couterhold shift rod (142/3) and install circlip
(142/4).

142
3 Apply Loctite 518 to sealing surface of cylinder
cover (143/1) and install.
Torque: 46 ± 5 Nm

143

56
4 Install air connectors (144/1) with Loctite 243
and seals (144/2).

NOTE : clean sealing surface.

144
5 Install cover (145/1) with Loctite 518.

145
6 Install ball guide (146/2).with ball (145/3)
and spring (145/4).

7 Install switch (147/1).

ATTENTION : of seal

146
8 On version without switch install core plug
(147/2) with Loctite 243.

147

57
Adjustment of shift stop positions

9 Remove old sealing remainders from threads

M12x1,5.
10 Apply Loctite 243 to adjusting screws -(148/1)-
(151/1) and lock nuts -(148/2)-(151/2) and mount
on shift cylinder resp. on front shift rod cover.

148
Adjustment HIGH GEAR

11 Apply compressed air P=6,5 bar to connection

(149/A) of shift cylinder (149/3) to engage high
gear.
Turn in adjusting screw into (149/1) until it
touches the shift rod (149/4).
Turn adjusting screw further by 1/3 to 1 /2 turn
and lock with nut (149/2).

149
Adjustment LOW GEAR

12 Apply compressed air P=6,5 bar to connection

(150/B) on shift cylinder cover (150/1) to engage
low gear.
Turn in adjusting screw into front shift rod cover
until it touches the shift rod (151/4)
Turn adjusting screw further by 1/3 to 1 /2 turn
and lock with nut (151/2).

NOTE : Version – 3 Position shifting:

150
Neutral position is shifted on connection
(150/C).
Version – 2 Position shifting:
Connection (150/C) is plugged.

151

58
1.3Install flanges
1 Heat flange (152/1) to 100° C and slide it on rear
output flange together with bolts (152/2).
Secure bolts by suitable O-ring.

152
2 Apply Loctite 243 to collar and thread of nut
and tighten.
Counterhold with tool TS 215 W.
If available use torque multiplier (1).
Torque: 1080 Nm

153
3 Mount Allen screw M10x12 (154/1) on front axle
shift cylinder with Loctite 638.
4 Install switch (155/2) with bushing (3),pin (4),
snap ring (5) and seal (6).
5 Check sealness and function by applying air
pressure (6,5 bar) on connection A.

ATTENTION : For engagement turn front

output shaft.

154

155

59
Install flanges
1 Front output shaft
Apply grease - STABOTHERM GH 461 to lips
of oil seals and install them with tool
A-VG 750-08 (156/3).
Position of oil seals:
(1) brown inside
(2) black outside

156

2 Input shaft (157/4 / 157/5)

Apply grease STABUTHERM GH 461 to lips
oil seals and install them with tool A-VG 750-08
(156/3).
Position of oil seals:
(4) brown inside
(5) noir outside

157
3 Heat flange (158/1) to 100° C and slide it on
input shaft.
Apply Loctite 243 to thread and collar of nut
and tighten counterhold with tool TS 215/W.
If available use torque multiplier.
Torque: 1080 Nm

158
4 Heat flange (159/1) to 100° C and slide it on
front output shaft.
Apply Loctite 243 to thread and collar of nut
and tighten.
Counterhold with tool (TS 215W).
If available use torque multiplier.
Torque: 1080 Nm

159

60
1.3.9 Install breather and speedometer
sending unit
1 Install breather (160/1) with 243.
2 Install sending unit (161/2) and plug (161/3)
with seals.

Torque: 60 ± 5 Nm

160

161

ATTENTION : Before transfer case is taken into

operation gear oil has be filled according to
operation manual or instructions on page 20 level
plug (162/1).

162

61
1.4

TOOL LIST VG 750

SPECIAL TOOL

STANDARD-, TESTING- and MEASUREMENT TOOL

62
1.4 Special tool

Mount device
1
V-TS 220 W

Clamping device
2
A-VG 750-10

Holding device
3
V-TS 215 W

Measure device
4
A-VG 2000-05

63
Special tool

Puller
5
A-VG 750-01

Puller
6
A-VG 750-02

Support
7
A-VG 750-03

Screw
8
A-VG 750-04

64
Special tool

Plastic ring
9
A-VG 750-05

Steel ring
10
A-VG 750-06

Adjusting tool
11
A-VG 750-07

Mandrel
12
A-VG 750-08

65
Special tool

Wrench
13
A-VG 750-09

Mandrel
14
A-VG 750-11

Mandrel
15
A-VG 750-12

Support disk
16
A-TS 214 W

66
Special tool

Puller for oil pump

17
V-TS 86W/1

67
1.4.1 Standard-, Testing- and Measurement Tool

Double-arm extractor
1
KUKKO 20-3

Extract hook
2
KUKKO 3-300-P

Double-arm extractor
3
KUKKO 20-2

Inside extractor
4
KUKKO 21-6
KUKKO 21-9

68
Standard-, Testing- and Measurement Tool

Support
5
KUKKO 22-3

Parting off tool

6
KUKKO 17-2

Press off tool

7
KUKKO 18-2

2 Pry bars
8
KUKKO 2165-2

69
Standard-, Testing- and Measurement Tool

Torque wrench
9

Torque multiplier
10

Depth gauge
11

Intern.measuring instr.15/200 mm
12

70
Standard-, Testing- and Measurement Tool

Feeler gauge
13

Dial gauge with magnetic post

14

71