Almdv Service Manual: Zf 9 S 109 Gear Box

ALMDV Service Manual ZF 9 S 109 Gear Box

27.02 ZF 9 S 109 GEAR BOX

CONTENTS GROUP - 27 ZF-SYNCHROMESH 9 S 109 GEAR BOX Section

Subject

Page No.

27.0 27.0.1 27.0.2 27.0.3 27.0.4 27.0.5 27.0.6 27.0.7

General Information ................................................................................................... Description ......................................................................................................................................... Technical Data ................................................................................................................................. Gear Shift Pattern ........................................................................................................................... Draining the Oil .............................................................................................................................. Repair Data ....................................................................................................................................... Linkage Setting Dimensions ........................................................................................................ Sequences of Removal and Installation ..................................................................................

27.04 27.04 27.04 27.05 27.06 27.07 27.08 27.09

27.1 27.1.0 27.1.1

Tecalan pipe for range-change group ................................................................... Removal ............................................................................................................................................... Assembly .............................................................................................................................................

27.10 27.10 27.10

27.2 27.2.0 27.2.1 27.2.2 27.2.3

Output .......................................................................................................................... Removal of Output Flange and Cover .................................................................................. Removal of Bearing Cover .......................................................................................................... Mounting of Bearing Cover ........................................................................................................ Mounting of Output Flange and Cover ................................................................................

27.11 27.11 27.11 27.11 27.12

27.3 27.3.0 27.3.1 27.3.2 27.3.3

Range-change group ................................................................................................... Removal of Range-Change Group ............................................................................................ Mounting of Range-Change Group ......................................................................................... Dismantling Range-Change Group ........................................................................................... Assembling Range-change Group .............................................................................................

27.13 27.13 27.14 27.15 27.17

27.4 27.4.0 27.4.1 27.4.2 27.4.3 27.4.4 27.4.5

Planetary gear with synchronizer .......................................................................... Dismantling Synchronizer ............................................................................................................. Dismantling Ring Gear ................................................................................................................. Dismantling Planet Carrier.......................................................................................................... Assembling Planet Carrier ........................................................................................................... Assembling Ring Gear .................................................................................................................. Assembling Synchronizer ..............................................................................................................

27.20 27.20 27.20 27.21 27.21 27.22 27.22

27.5 27.5.0 27.5.1

Sun gear ........................................................................................................................ Removal of Sun Gear .................................................................................................................... Mounting of Sun Gear ..................................................................................................................

27.24 27.24 27.24

27.6 27.6.0 27.6.1 27.6.2 27.6.3 27.6.4

Shift mechanism .......................................................................................................... Removal of Shift Mechanisms ..................................................................................................... Mounting of Shift Mechanism ..................................................................................................... Dismantling Shift Mechanism ...................................................................................................... Shift Mechanism Assembly ........................................................................................................... Assembling Shift Mechanism .......................................................................................................

27.25 27.25 27.25 27.26 27.31 27.32

PUB. NO. SM:ZFS9109&Clutch(CS380):816:0405:XA75:11

ZF 9 S 109 GEAR BOX 27.03

CONTENTS CHAPTER - 27 ZF-SYNCHROMESH 9 S 109 GEAR BOX Section

Subject

Page No.

27.7 27.7.0 27.7.1 27.7.2 27.7.3

Connecting plate-lubricating oil pump ................................................................. Removal of Connection Plate .................................................................................................... Removal and dismantling of lubricating oil pump ............................................................ Assembly and mounting of lubricating oil pump .............................................................. Assembly and mounting of connection plate .....................................................................

27.36 27.36 27.36 27.37 27.38

27.8 27.8.0 27.8.1

Adjusting bearings on mainshaft, inputshaft and layshaft .............................. Adjusting Mainshaft and Inputshaft ......................................................................................... Adjusting Layshaft ...........................................................................................................................

27.39 27.39 27.40

27.9 27.9.0 27.9.1 27.9.2 27.9.3

Shift rail and reverse gear ....................................................................................... Removal of Shift Rails ................................................................................................................... Removal of Reverse Gear ............................................................................................................ Installation of Shift Rails .............................................................................................................. Installation of Reverse Gear .......................................................................................................

27.42 27.42 27.44 27.44 27.47

27.10 27.10.0 27.10.1

Input shaft, mainshaft and layshaft ....................................................................... Removal of the Shafts ................................................................................................................... Installation of the Shafts ..............................................................................................................

27.48 27.48 27.49

27.11 27.11.0 27.11.1

Input shaft ..................................................................................................................... Dismantling the Input shaft ........................................................................................................ Assembly of the Input Shaft ....................................................................................................

27.52 27.52 27.52

27.12 27.12.0 27.12.1

Mainshaft ....................................................................................................................... Dismantling the Mainshaft .................................................................................................................... Assembly of the Mainshaft ...................................................................................................................

27.53 27.53 27.54

27.13 27.13.0 27.13.1

Layshaft .......................................................................................................................... Dismantling the Layshaft .............................................................................................................. Assembly of the Layshaft .............................................................................................................

27.57 27.57 27.57

27.14 27.14.0 27.14.1

Housing .......................................................................................................................... Dismantling the Housing .............................................................................................................. Assembly of the Housing .............................................................................................................

27.59 27.59 27.59

27.15 27.15.0 27.15.1

Clutch Housing ............................................................................................................ Removal ............................................................................................................................................... Installation ..........................................................................................................................................

27.60 27.60 27.60

27.16

Special Tools ................................................................................................................

27.61

27.17

Tightening torque .......................................................................................................

27.62

27.18

Recommended lubricants ..........................................................................................

27.62

27.19

Filling capacity ............................................................................................................

27.62

27.20

Maintenance programme ...........................................................................................

27.62

27.04 ZF 9 S 109 GEAR BOX 27.0

27.0.1

GENERAL INFORMATION

Gear shifts

The ZF 9 S 109 synchronous transmission of the Ecomid construction range has been specially developed for use in commercial vehicles of the upper medium duty class

The 4-speed section with reverse gear and rear-mounted range-change group is operated mechanically by a double-H control.

9 S 109 transmissions is basically consist of:

With this type of control, each of the forward gears and the reverse gear is

-

a fully synchronized four gear component

-

an integrated crawler and reverse gear

-

a rear-mounted range-change group built into the planet.

allocated its own position in the gear shift pattern. A range of spring detents of different loads ensures perfect orientation through the shift pattern, i.e. accurate location of individual gears.

Description The shifting process of the rangechange group is carried out automatically under pneumatic control while the gate 3/4 is being shifted to 5/6 or while 5/6 is being shifted back to 3/4 . The control system for shifting the range-change group consists of a shift valve and a double acting shift cylinder integrated in the transmission. The shift valve is controlled by the turning shaft of the 4-speed section and only releases the air pressure to the shift cylinder in neutral position.

Design The synchromesh transmission with rangechange group (ZF 9 S 109) consists of a 4-speed section (with dog clutch operated crawler and reverse gear) of countershaft type together with a rear-mounted range-change group of planetary design. The range-change group doubles the number of gears available in the 4-speed section, thereby increasing the number of consecutively selectable forward gears to 9, including the crawler, 27.0.2

Technical Data

Type

ZF 9 S-109 Synchromesh Ecomid - 8 Forward, 1 Crawler Speed & 1 Reverse

Input Torque

1100 Nm

No of Gears

9

Gear Selection

Forward Reverse

-

Gears Lock - Synchronized Dog Clutch Arrangement

Gear Ratios

Crawler

-

12.91

: 1

1st

-

8.96

: 1

2nd

-

6.37

: 1

3rd

-

4.71

: 1

4th

-

3.53

: 1

5th

-

2.54

: 1

6th

-

1.81

: 1

7th

-

1.34

: 1

8th

-

1.00

: 1

Rev.

-

12.20

: 1

ZF 9 S 109 GEAR BOX 27.05 27.0.3

Gear Shift Pattern The gears are arranged in a double-H pattern. The shift pattern includes two neutral positions in gates 3/4 (low range - change group) and 5/6 (high range-change group).

R

1

Fig - 1 The selector lever springs back to the neutral position if released in the central area. In order to select gears 1/2 or 7/8, move the selector lever against the spring force in the required direction and hold the lever against this force when making the engagement stroke.

C

2

3

5

N

N

4

6

Fig. 1

Gates 3/4 and 5/6 are separated by a stronger spring detent. The range-change group is changed over automatically when the selector lever is moved between these gates. A range of spring detents of different loads ensures perfect orientation through the shift pattern, i.e. accurate location of individual gears. The reverse gate is fitted with a spring loaded stop which must be overcome by deliberate effort. Changing gear Move between gate 3/4 and 5/6 (or vice versa) by knocking the selector lever with the palm of your hand and briskly moving the selector lever into the required gear. You must move the selector lever quickly, but you do not have to move it particularly forcefully. We recommend keeping your hand open when selecting gears. Fig - 2 NOTE: - When engaging a gear, hold the selector lever against the end stop until the synchronizer unit has completed the gearshift. - Change gears quickly to reduce shift effort. This is particularly important when the transmission is cold. If the transmission is below operating temperature, the driver has to work harder to change gear. If the range-change group does not change over when changing down from gate 5/6 into gate 3/4, slow your vehicle and engage the appropriate gear at a lower speed. CAUTION:

Never change down a gear unless the vehicle and engine speeds are below the maximum values for the gear you are going to engage. Failure to comply can lead to transmission or engine damage. The maximum transmission input and output speed is 2500 rpm.

Fig. 2

7

8

27.06 ZF 9 S 109 GEAR BOX 27.0.4

Draining the Oil Drain the oil when the transmission is at operating temperature. When you need to drain the oil, always do so immediately after the vehicle has been driven. To drain the oil, unscrew and remove both oil drain plugs on the underside of transmission (2 and 3). Fig - 3 Before reinserting plug (3), remove any attached debris from the magnet and fit the plug with a new sealing ring.

Fig. 3

Filling the Transmission with Oil and Checking the Oil Level Park the vehicle on level ground before filling the transmission with oil or checking the oil level. Clean the area around the oil filler hole(1) before opening it. The oil filler hole also serves as an overflow check and as an oil level check. Fig - 3 NOTE:

Fill the transmission with oil until it overflows!

CAUTION:

Too little oil leads to insufficient lubrication. The consequences of this are particularly severe when operating on hilly terrain. Excess oil causes churning losses and leads to the transmission overheating.

Check the oil level in the transmission at regular intervals. In order to avoid incorrect measurements as a result of the oil expanding on being heated, the oil level should not be checked immediately after a journey but only once the oil has had time to settle and has cooled. If an oil check indicates that the oil level has fallen below the edge of the filling hole, add more oil until it overflows. Whenever the oil level is checked, the transmission should also be checked for any signs of leakage (sweating or leakage areas). Transmission breather The transmission oil heats up during operation. This causes over-pressure in the transmission which must be continually vented through a breather valve. Fig - 4 Check that this valve is always operating correctly. Keep the breather clean and do not cover it with a plastic cap.

Fig. 4

ZF 9 S 109 GEAR BOX 27.07 27.0.5

Repair Data

Sl. No.

Description

Dimension

01.

Axial preload of layshaft

0.18 - 0.30 mm

02.

Axial preload of mainshaft and inputshaft

0.18 - 0.30 mm

03.

Axial play of grooved ball bearing situated on output (range-change group)

0 - 0.10 mm

04.

Installation dimension for shaft seal in bearing cover

8 + 0.5 mm

05.

Axial play of circlip on sun gear

0 - 0.05 mm

06.

Axial play of snap ring for grooved ball bearing in ring gear carrier

0 - 0.1 mm

07.

Axial play of circlip on mainshaft and layshaft

0 - 0.1 mm

08.

Axial play of reverse gear

0.40 - 0.75 mm

09.

Axial play of crawler and first gear

0.20 - 0.45 mm

10.

Axial play of 2nd speed helical gear

0.20 - 0.40 mm

11.

Axial play of 3rd or 4th speed helical gear

0.20 - 0.45 mm

12.

Axial play of reverse gear situated on the idler shaft

0.20 - 0.60 mm

13.

Permitted axial play of planetary gears in planet carrier

0.10 - 0.70 mm

14.

Limit of wear of synchronizer rings and/or clutch bodies, measured between flat surfaces of ring and body with cones nested firmly together Main transmission Range-change group

0.80 mm 1.20 mm

15.

Information on synchronous play (axial)

0.60 mm

16.

Information on shifting force of synchronizer's shift sleeves Shift transmission Range-change group

270 to 310 N 850 to 950 N

17.

Axial play on Speedo pinion shaft

Min. 0.10 mm

18.

Backlash on pinion shaft

19.

Temperature for shrink fitting helical gears onto layshaft Heating up temperature

Max 170°C.

20.

Temperature for "assembly of sun gear"

Max. 170°C

21.

Delivery rate of lubricating oil pump during separate check

0.10 - 0.20 mm

5.15 - 6.45 l/min. and 0.155 bar

27.08 ZF 9 S 109 GEAR BOX 27.0.6

Linkage Setting Dimensions Setting Dimensions" Reaction Rod

: A = 425 mm

Connection Flange

: B = 93 mm

Connection Flange Pitch (Top Hole)

: C = 47 mm

Outer Lever Pitch (Middle Hole)

: D = 65 mm

Fig. 1

Fig - 1 & 2

Fig 3

ZF 9 S 109 GEAR BOX 27.09 27.0.7

Sequences of Removal and Installation When performing a basic overhaul of the transmission, the sequence for removal (steps 01 - 14) and the sequence for installation (steps 14 - 01), as shown below, should be strictly followed.

Tecalan Pipe

Output, range-change group, planet carrier

Sun gear

Shift mechanism

Connection plate, shift rails and oil sieve, bearing adjustment of shafts.

Input Shaft, reverse gear and pivot

Shafts with clamps, housings

27.010 ZF 9 S 109 GEAR BOX 27.1

TECALAN PIPE FOR RANGECHANGE GROUP

NOTE: Make the Tecalan pipes at connection points before removal 27.1.0

Removal

1.

Remove union screws on range-change group cylinder and shut-off valve. Take off tecalan pipes.

2.

Remove cable.

27.1.1

Assembly

1.

Screw Tecalan pipes onto shut-off valve and range-change group cylinder with union screws. Use new sealing rings on the union screws. Fit Tecalan pipes in accordance with marks. Tightening torque for union screws M14 x 1.5 is 35Nm.

2.

Attach cable

Fig. 1

Fig - 1 CAUTION:

Tecalan pipes can be incorrectly connected. If they were not marked during removal, proceed as follows: Use selector shaft to select R gear position. Pressurize entry to main shut-off valve with compressed air, not higher than operating pressure. (Refer to arrow in Fig - 1). Fig. 2

Air for low ratio group will exit from valve exit. Connect tecalan pipe at this exit and on cylinder connection “2” (Fig - 2). This provides the connection for the second Tecalan pipe. Note:

Ensure that minimum distance between Tecalan pipe and housing is 5 mm.

ZF 9 S 109 GEAR BOX 27.11 27.2

OUTPUT

27.2.0

Removal of Output Flange and Cover

1.

Remove retaining plate (1).

2.

Secure output flange to stop it rotating using standard flange holder.

3.

Remove two hex bolts (2) and take off washer (3).

4.

Place intermediate part on planet carrier and pull off output flange (5) using standard two leg or three leg puller.

5.

If necessary, remove flange bolts (6).

6.

Remove O-ring (4).

7.

Remove four hex bolts (7). (8) and seal (9).

Fig. 1

Lift off cover

Fig - 1 27.2.1

Removal of Bearing Cover

1.

Unscrew eight hex bolts on bearing cover.

2.

Release bearing cover by hitting it gently with plastic hammer.

Fig. 2

Fig - 2 3.

Lift off bearing cover with seal and washer.

4.

Use plastic mandrel to drive shaft seal out of bearing cover Fig - 3

27.2.2

Mounting of Bearing Cover

Fig. 3

NOTE: To avoid measurement errors, tap bearing cover home onto collar of housing III by gently hitting it with plastic mandrel hammer. 1.

Adjust axial play of ball bearing with washer, aim for play of 0.0 mm. Permitted axial play

2.

:

0 - 0.1 mm

Measure dimension “A” from the bearing cover face end to the housing sealing face. Fig - 4

Fig. 4

27.12 ZF 9 S 109 GEAR BOX 3.

Measure dimension “B” from bearing cover with seal added to contact face of ball bearing

4.

Determine the washer thickness “C” C = B - A C = washer thickness when axial play is 0 Fig - 5

5.

Apply lubricant to outer diameter of shaft seal.

6.

Use drift 1X56 126 467 and ring 1X56 137 484 to drive shaft seal into bearing cover. This gives an installation diameter of +0.5 8.0 mm

Fig. 5

NOTE: Lightly grease sealing lip of shaft seal. Fig - 6 7.

Place washer in recess of bearing cover.

8.

Add new seal to bearing cover.

9.

Screw in eight M8 hex bolts with spring washers. Tightening torque = 23 Nm. Fig - 7

27.2.3

Mounting of Output Flange and Cover

1.

Add new seal (9) to cover (8), screw in four M12 hex bolts (7). Tightening torque is 79 Nm.

2.

If necessary, add and/or press in flange bolts(6).

3.

Push output flange (5) onto planet carrier shaft.

4.

Use washer (3) and two assembly aid bolts to pull up output flange unit it is fully home.

5.

Remove washer and assembly aid bolts.

6.

Lightly oil new O-ring (4) and insert in gap between output flange and planet carrier shaft.

7.

Insert washer (3) in output flange, screw in two bolts (2) and tighten to 60 Nm. If possible, secure output flange to stop it rotating, using standard flange holder.

8.

Fully drive on new retaining plate (1) over bolts heads using drift 1x56 136 452. Fig - 8

Fig. 6

Fig. 7

Fig. 8

ZF 9 S 109 GEAR BOX 27.13 27.3

RANGE-CHANGE GROUP

NOTE: If the range-change group is not dismantled and only cap collar and/or piston are to be replaced on the cylinder, proceed as follows; Screw fixing attachment into threaded bore of pawl stop and tighten to 50 Nm. In so doing, set the fixing piece so that the shift rail is fixed radially. Remove cylinder (refer to section 27.3.2). Remove locking nut from piston, lift off piston and take grooved ring from Piston. Press cap collar out of housing, e,g using screw driver. 27.3.0

Removal of Range-Change Group

1.

Remove pawl stop (1) for range-change group and Screw plug (3).

Fig. 1

Fig - 1 2.

Screw out plug screw (2) and use magnet to take ball out of bore. Fig - 2

3.

Screw out impulse sensor.

NOTE: Speedo input is a single component and is not dismantled. Fig - 3 4.

Remove hex bolts at edge of housing.

Fig. 2

Fig - 4 5.

Screw hook 1X56 136 599 into housing.

6.

Suspend range-change group on hook.

CAUTION:

If output flange has been removed, secure planet carrier in housing. Place suitable bush on shaft of planet carrier. Fasten bush with previously removed washer and two hex bolts.

7.

Use two mounting housing parts.

8.

Remove seal and clean sealing faces. Fig - 5

Fig. 5

levers

to

separate

Fig. 3

Fig. 4

27.14 ZF 9 S 109 GEAR BOX 27.3.1

Mounting of Range-Change Group

CAUTION:

If output flange has been removed, secure planet carrier in housing. Place suitable bush on shaft of planet carrier. Fasten bush with previously removed washer and two hex bolts.

1.

Carefully insert two cylinder pins (refer to arrow)

2.

Screw standard housing.

M10

guiding

bolts

into

Fig - 6 3.

Slide new seal over guiding bolts and place on housing.

4.

Suspended range-change group on crane and carefully drive onto transmission housing.

Fig. 6

NOTE: Drive shift rail into bearing plate opening for shift locking (interlock). 5.

Use guiding bolts to drive range-change group fully home. Fig - 7

NOTE: Engage gear teeth on sun gear and planetary gears. 6.

Fig. 7

Screw in hex bolts in accordance with parts list, M10 tightening torque = 50 Nm. Fig - 8

NOTE: Screw hex bolts with bore into head of Speedo input (wire lock). NOTE: If the range-change group is not dismantled and cap collar and/or piston, locking nut and cylinder are to be replaced on the cylinder, proceed as follows before screwing in the pawl stop: Screw fixing attachment into threaded bore of pawl stop (1) and tighten to 50 Nm, In so doing set the fixing piece so that the shift rail is fixed radially Spray new cap collar on outer edge with spirits. With sealing ring facing housing, slide it over shift rail and place on housing bore. Use suitable tool to drive cap collar fully home. (Assembly of following parts is described in section 27.3.3). Assemble shim, piston and locking nut. Assembly double-grooved ring, O-ring and Cylinder. Unscrew fixing attachment.

Fig. 8

Fig - 9 Fig. 9

ZF 9 S 109 GEAR BOX 27.15 7.

Screw in pawl stop (1) for range-change group with new sealing ring - M16 x 1.5 tightening torque = 50 Nm

8.

Screw in screw plug (3) with new sealing ring. Tightening torque = 35 Nm.

9.

Insert ball in housing bore Screw in screw plug (2) with new sealing ring. Tightening torque = 35 Nm. Fig - 10

27.3.2

Dismantling Range-Change Group

1.

Screw both pivot bolts out of housing

Fig. 10

Fig - 11 2.

Lift housing from planet carrier. Fig - 12

NOTE: If the range-change group is not dismantled, Cylinder, locking nut, piston with grooved rings, guiding rings and cap collar are disassembled as is described below. 3.

Remove four hex bolts from cylinder. Fig - 13

4.

Use O-ring to carefully lift cylinder

5.

Take guiding ring out of piston groove (refer to arrow).

6.

Use piston to make out shift rail

Fig. 11

Fig - 14 CAUTION:

The cap collar may be damaged. It should therefore always be replaced.

Fig. 12

Fig. 14

Fig. 13

27.16 ZF 9 S 109 GEAR BOX

7.

Press cap collar out of housing, e,g using screwdriver. Fig - 15

Fig. 15

8.

Clamp shift rail in vice and place square material in recess.

CAUTION:

Protect wedges.

shift

rail

with

aluminium

Fig - 16

Fig. 16

9.

Unscrew locking nut and take off piston

10.

Take both grooved rings out of piston groove Fig - 17

Fig. 17

11.

Use mandrel to drive ball bearing out of housing and then place housing on two wooden blocks in reverse order.

12.

Screw out screw plugs in housing. Fig - 18

Fig. 18

ZF 9 S 109 GEAR BOX 27.17 27.3.3

Assembling Range-change Group

1.

Screw Screw plugs into housing and use new sealing ring. M18 x 1.5 tightening torque = 35 Nm

NOTE: Use hot air blower to heat bearing seat in housing to max 70°C. 2.

3.

Use plastic mandrel to drive ball bearing into housing and ensure that it is driven home.

Fig. 19

Use sealing compound to slide sealing cover (refer to arrow) onto sealing face and use suitable tool to drive in flush to the housing bore. Fig - 19

4.

Clamp shift rail in vice and place square material in recess.

CAUTION:

Protect wedges

shift

rail

with

aluminium Fig. 20

Fig - 20 NOTE: If the range-change group is not dismantled, cap collar, piston with grooved rings, guiding ring, locking nut and cylinder are disassembled as is described below. NOTE: Spray cap collar on outer edge with spirits. 5.

Use suitable tool to drive new cap collar into housing. Fig - 21

6.

Insert new grooved ring in piston.

CAUTION:

7.

Fig. 21

The grooved sides of the ring should face outwards.

Apply thin coat of grease to sealing lips of grooved ring. Fig - 22

Fig. 22

27.18 ZF 9 S 109 GEAR BOX 8.

Place piston on shift rail.

NOTE: Recess in piston faces upwards. 9.

Screw in new locking nut. M16 x 1.5 tightening torque = 150 Nm Fig - 23

10.

Insert shift rail and piston into housing bore and in so doing turn shift rail.

11.

Insert guiding ring into middle piston ring groove. Fig - 24

12.

Apply thin coat of grease to sealing lips of grooved ring.

13.

Coat new 'O' ring with grease and place in ring groove of cylinder.

14.

Carefully push cylinder over piston.

Fig. 23

Fig - 25 NOTE: During this process, the guiding ring must be at the base of the piston ring groove. CAUTION:

Try to avoid damaging O-ring, groove and guiding rings.

15.

Rotate cylinder into position.

16.

Screw in four hex bolts with spring disks. M8 tightening torque = 23 Nm.

17.

Radially position shift rail on that both detents face upwards for the fitting of the range-change group (27.3.1).

Fig. 24

Fig - 26 NOTE: The recesses in the shift rail for shift fork engagement can be found in the installation position. Fig - 27 Fig. 25

Fig. 27

Fig. 26

ZF 9 S 109 GEAR BOX 27.19 18.

Use group synchronizer to place rangechange group housing on planet carrier and drive firmly home.

19.

Engage shift fork nose with recess to shift rail. Fig - 28

NOTE: Clutch body journals must engage in housing recesses. 20.

Align shift fork to threaded bores in housing so that guiding bores of shift fork are flush with threaded bores of housing. Fig - 29

NOTE: -

Threads must be clean and free of oil and grease.

-

Spray pivot bolt threads with Loctite no. 241.

21.

Fig. 28

Screw in pivot bolts with spring washers: M24 x 1.5 tightening torque = 250 Nm Fig - 30

22.

Fit cover as described in Section 27.2.2.

23.

Fit output flange as described in Section 27.2.3.

24.

Screw in screw plug with new sealing ring.

Fig. 29

Tightening torque = 100 Nm. Note:

Do not disassemble defective shaft seals but use drift 1X56 100 632 to drive new shaft seal firmly home.

25.

Check axial play and backlash of Speedo shaft by hand Axial play = min. 0.1 mm Backlash = min. 0.1 - 0.2 mm

26.

Fig. 30

Tighten impulse sensor to 50 Nm. Fig - 31

Fig. 31

27.20 ZF 9 S 109 GEAR BOX 27.4

PLANETARY GEAR WITH SYNCHRONIZER

27.4.0

Dismantling Synchronizer

1.

Remove shift fork.

2.

Take fulcrum pad out of shift fork.

3.

Place intermediate part on planet carrier. Fig - 1

4.

Insert split ring (3) 1X56 137 648 between clutch body (2) and synchronizer ring (4). Grip bottom of sliding sleeve (5) with twoleg or three leg-puller and pull off synchronizer ring (4), clutch body (2) and impulse washer (1) or Speedo worm. The pressure pieces (7) and compression springs (8) retained by the sliding sleeve can be caught in a cloth.

5.

Spring out circlip (6)

6.

Grip bottom of synchronizer hubs (9) with two leg puller and pull off.

7.

Remove synchronizer ring (10) and clutch bodies (11) from planet carrier.

Fig. 1

Fig - 2 27.4.1

Dismantling Ring Gear

1.

Pull ring gear completely off planet carrier (18).

2.

Remove snap ring (12) from ring groove of ring gear carrier (14) and remove ball bearing (13).

3.

Remove safety wire (15) from ring groove in ring gear (11) and use plastic hammer to drive ring gear carrier (14) out of ring gear.

Fig. 2

Fig - 3

Fig. 3

ZF 9 S 109 GEAR BOX 27.21 27.4.2 1. 2. 3. 4.

Dismantling Planet Carrier Drive the full length of each clamping pin (16) into planetary bolts (17). Use hammer and plastic mandrel to drive all four planetary bolts (17) out of the planet carrier in the direction of the input. Take the four planetary gears (22) and washers (19) intermediate washers (20) and needle rollers (21) out of planet carrier (18). Drive clamping pin (16) out of planetary bolts (17). Fig - 4

27.4.3 Assembling Planet Carrier CAUTION: Do not replace planet gears individually but always as a set. 1. Lightly oil front face of planet gear (22) and the cylinder roller race. 2. Assembly planetary bolts (17) with collar facing downwards. 3. Slide washer (19) over planetary bolt with marked side facing planet carriers. 4. Slide an intermediate washer (20) over planetary bolt. 5. Place planetary gear (22) on planetary bolt. 6. Insert 20 needle rollers (21) in planetary gear and slide intermediate washer (20) over planetary bolt. NOTE: Only use needle rollers of the same dimensions. 7. Insert the remaining 20 needle rollers, slightly oil and add intermediate washer (20). 8 Slide washer (19) over planetary bolt with marked side facing planet carrier. 9. Place planet carrier (18) on front face of shaft. 10. Carefully take planetary gear (22) and washers (19) off planetary bolts (17) and insert in planet carrier . 11. Align planetary gear (22) and washers (19) to bearing bore. NOTE: The 'O' mark on the front face of the planetary bolt must face the outer radius of the planet carrier (oil bore must face inner radius of planet carrier). 12. Align planetary bolt (17) radially and insert in bearing bore. 13. Use plastic hammer to drive in planetary bolt. Check that clamping pin bore is flush. 14. Drive new clamping pin (16) into planet carrier. NOTE: Countersink clamping pin approximately 0.5 mm into planet carrier. 15 Check axial play of planetary gears (0.1 to 0.7 mm). 16. Repeat steps 1 to 15 on the other three planetary gears. Fig - 4

Fig. 4

27.22 ZF 9 S 109 GEAR BOX 27.4.4

Assembling Ring Gear

1.

Drive ring gear carrier (14) firmly home in the ring gear (11).

2.

Insert safety wire (15) into groove ring of ring gear.

NOTE: The safety wire must lie on the groove base. 3.

Insert ball bearing (13) in ring gear carrier and insert snap ring (12). Use suitable snap ring to adjust ball bearing axial play 0 to 0.1 mm.

4.

Heat ball bearing (13) to approx 60°C and place on planet carrier with ring gear. In so doing, turn ring gear and engage gear teeth. Ball bearing must lie axially on planet carrier. Fig - 5

27.4.5

Assembling Synchronizer

CAUTION:

Check, mark and store parts PAIRS. Do not mix up parts.

IN

1.

Place synchronizer ring on center of clutch body. Move the cones by turning the parts.

2.

Use feeler gauge to measure distance between clutch body and synchronizer ring.

Fig. 5

NOTE: Compare dimension found with permitted limits of wear. These are: Main transmission

=

0.8 mm

Range-change group

=

1.2 mm

NOTE: If your dimension is below these, install new synchronizer ring and / or clutch body. Fig - 6

1 = Synchronizer ring 2 = Clutch body Fig. 6

ZF 9 S 109 GEAR BOX 27.23 3.

Place clutch body (11) and synchronizer ring (10) on planet carrier.

4.

Push on clutch body (11) with long hub side facing planet carrier. The cams of the synchronizer ring (10) must reach into the recesses of the synchronizer hub.

5.

Insert circlip (6) in ring groove with axial play of 0 to 0.1 mm.

NOTE: Select a circlip suitabley. 6.

Place sliding sleeve (5) on synchronizer hub (9) and drive home.

NOTE: Sliding sleeve recesses must cover the same area as the synchronizer hub recesses. 7.

Insert new compression springs (8) with pressure pieces in synchronizer hub and guide into sliding sleeve with suitable tool.

8.

Place synchronizer ring (4) on synchronizer hub. The cams of the synchronizer ring (10) must reach into the recesses of the synchronizer hub.

9.

Press on synchronizer ring (4) and bring sliding sleeve into middle position. You will clearly be able to hear the pressure pieces snapping in.

10.

Heat clutch bodies (2) to approx. and push onto planet carrier.

11.

Heat speedo worm or impulse washer (1) to approx. 80°C and push onto planet carrier.

Fig. 7

120°C

Fig - 7 12.

Insert fulcrum pad into shift fork.

13.

Insert shift fork into sliding sleeve.

NOTE: Shift fork nose should be located in the appropriate recess in clutch body. Fig - 8

Fig. 8

27.24 ZF 9 S 109 GEAR BOX 27.5

SUN GEAR

27.5.0

Removal of Sun Gear

1.

Remove circlip. Fig - 1

2.

Push drift 1X56 137 456 over pipe used for pressurized oil lubrication.

3.

Use standard two-leg puller to pull sun gear off mainshaft.

Fig. 1

Fig - 2 27.5.1

Mounting of Sun Gear

1.

Evenly heat sun gear to max 170°C so that it can be pushed on with one manual tug.

CAUTION:

2.

Do not exceed maximum temperature of 170°C and do not maintain this temperature for more than 15 minutes.

Fig. 2

Push sun gear onto mainshaft and drive firmly home. Fig - 3

CAUTION:

Only mount sun gear when it has been heated. Never drive the sun gear onto the mainshaft as the taper roller bearing on the journal bearing of the mainshaft can be destroyed or damaged if hit or pushed too hard. Fig. 3

NOTE: Collar and bore face inputshaft 3.

Insert circlip. Fig - 4

NOTE: Circlip axial play is 0 to 0.5 mm. circlip accordingly. 4.

Select

Use drift 1X56 137 456 to drive oil pipe firmly home in the mainshaft. Fig. 4

ZF 9 S 109 GEAR BOX 27.25 27.6

SHIFT MECHANISM

27.6.0

Removal of Shift Mechanisms

1.

Remove the four hex bolts (16) and (21) from the shift housing and cover (20).

CAUTION: 2.

Cover (20) is spring loaded.

Take off cover (20) seal (19) and the three compression springs (18) and shift detents (17). Fig - 1

NOTE: Cover is a single part and is not dismantled. 3.

Fig. 1

Take off shift mechanism. Fig - 2

4.

Remove sealing ring (9).

5.

Remove pipe (8). Fig - 3

27.6.1

Mounting of Shift Mechanism

1.

Switch shift mechanism to "neutral", place new sealing ring (9) on housing sealing faces.

Fig. 2

NOTE: Insert pipe (8). 2.

Add shift mechanism and in so doing engage it with driver (refer to arrow). Fig - 4

3.

Place new sealing ring (19) on shift housing Insert three shift detents (17) and three compression springs (18) and add cover (20).

4.

Screw in hex bolts (16 and 21) on shift housing and cover temporarily only tighten them slightly. (Fig - 1).

Fig. 3

NOTE: The shift housing must be centered to the shift components in the transmission. For this, proceed as follows: 5.

Engage a gear by activating the shift lever (refer in arrow).

6.

Engage opposite gear.

7.

Compare shift travel/excess shift travel with the central position. Fig. 4

27.26 ZF 9 S 109 GEAR BOX 8.

If the shift travel/excess shift travel are not of the same size, loosen the hex bolts slightly and displace the shift housing by gently tapping it with a plastic hammer. Fig - 5

NOTE: Repeat procedure until the shift travel/excess shift travel are of the same size.

Fig. 5

9.

Tighten all hex bolts on the shift mechanism M8 Tightening torque - 23 Nm. Fig - 6

Fig. 6

27.6.2

Dismantling Shift Mechanism

1.

Clamp shift mechanism in vice. Fig - 7

CAUTION:

2.

Protect shift housing from damage with aluminium wedges

Remove locking nut from ball joint. Fig. 7

3.

Remove ball joint from shift lever and take off reaction linkage. Fig - 8

Fig. 8

ZF 9 S 109 GEAR BOX 27.27 4.

Mark the position of the shift lever on the selector shaft.

5.

Remove hex bolts and screw from shift lever.

6.

Use standard two leg puller to pull shift lever off selector shaft. Fig - 9 Fig. 9

7.

Take protective cap off selector shaft Fig - 10

Fig. 10

8.

Remove hex bolts (1) from shift cover (2).

9.

Lift shaft over off selector shaft.

10.

Remove seal (3) and bush (4). Fig - 11

Fig. 11

11.

Remove scraper (1), shift seals (2 and 5) from shift cover (4).

12.

Use drift 1X56 137 135 to drive bearing bush (3) out of shift cover. Fig - 12

Fig. 12

27.28 ZF 9 S 109 GEAR BOX

Fig. 13

13.

Remove four cylinder bolts (1).

14.

Take off shut-off valve (2) and O-ring (4).

NOTE: Shut-off valve is a single part and is not dismantled. Unscrew throttle screw (3) on shut-off valve. 15.

.Remove two screws (18) from cover (17).

NOTE: Cover (17) is spring loaded. 16.

Take off cover (17) with compression springs (15/14) and sealing ring (16).

17.

Take out insert (12) with O-ring (11) sealing ring (10) and tapered roller (13).

18.

Remove detent plunger (7) for reverse gear.

19.

Remove plug screws (5/9) and compression springs (6/8) from the both sides of the shift housing.

NOTE: Screw plugs are spring loaded. 20.

Take bolts (20) and detent lever (19) out of shift housing. Fig - 13

21.

Remove four hex bolts (1).

22.

Take off cover (2) and sealing ring (4). check needle bearing (3) in cover (2) and replace if necessary. Fig - 14

Fig. 14

ZF 9 S 109 GEAR BOX 27.29 NOTE: Make site of circlips and washers to allow for easy future assembly. 23.

Remove circlip from ring groove of selector shaft. Fig - 15

NOTE: Circlip is spring loaded. Hold back washer on circlip against spring pressure. 24.

Take washer and compression springs off selector shaft.

25.

Remove circlip, washer compression spring.

and

Fig. 15

second

Fig - 16

Fig. 16

26.

Use a suitable amount of force to drive double clamping pin in detent bush out through the open threaded bore onto the upper side of the shift housing. Fig - 17

NOTE: Bring selector shaft into proper position. Fig. 17

27.

Mark position of detent bush. Pull detent bush off selector shaft. Fig - 18

Fig. 18

27.30 ZF 9 S 109 GEAR BOX 28.

Use an appropriate amount of force to drive detent piece clamping pin out through insert aperture. Fig - 19

NOTE: Position selector shaft correspondingly.

Fig. 19

29.

Pull selector shaft out of shift housing.

30.

Take detent piece and driver out of shift housing. Fig - 20

NOTE: Driver could fall out, secure appropriately. Fig. 20

31.

Take rollers out of selector shaft (Refer to arrow). Fig - 21

Fig. 21

32.

Use drift 1X56 137 135 to drive needle sleeve out of shift housing. Fig - 22

Fig. 22

ZF 9 S 109 GEAR BOX 27.31 27.6.3

Shift Mechanism Assembly Shift mechanism horizontal right.

installation

position

is

position

is

Fig - 23 & 24 Driver Arrangement Driver arrangement install horizontal right. Fig - 25

Fig. 23

Fig. 24

SIDE POSITION OF DETENT BUSH (2)

Fig. 25 1. Driver 2. Detent bush 3. Compression spring(s) 4. Selector shaft 5. Shift housing

27.32 ZF 9 S 109 GEAR BOX 27.6.4

Assembling Shift Mechanism

1.

Use shift 1X56 137 135 to drive needle sleeve into ridge of shift housing (side of needle sleeve which is written should be facing drift). Fig - 1

NOTE: The Needle sleeve is positioned opposite the ridge faces, on the detent piece, back approximately 1 mm.

2.

Fig. 1

Insert six roller in bores of selector shaft and slightly grease bores for this (refer to arrow) Fig - 2

Fig. 2

3.

Assembly suitable drive for shift mechanism type as is shown in Section 27.6.3.

4.

Hold driver in installation point of shift housing.

5.

Use selector shaft to slide on the driver. Fig - 3 Fig. 3

6.

Slide detent piece onto selector shaft.

NOTE: Detent level (refer to arrow) of detent piece faces installation point for shut-off valve. Fig - 4

Fig. 4

ZF 9 S 109 GEAR BOX 27.33 7.

Slide detent bush, onto selector shaft (as marked during disassembly).

NOTE: Move bores for clamp pins on licking unit and detent bush up until flush. Fig - 5 NOTE: Apply light coat of sealing compound to outer edge of shaft seals with steel surround Apply coat of Vaseline or water-soluble concentrated washing-up liquid to outer edge of shift seals with rubber surround.

Fig. 5

Shift output version horizontal Drive shift seal (7) into shift cover (5) using drift 1X56 137 135 to dimension “A” Drive bush bearing (4) into shift cover (5) using drift 1X56 137 135 to dimension “B”. Fig - 6 Shift output version below: Fully drive in shaft in seal (2) using drift 1X56 119 916.

Fig. 6

NOTE: Sealing lips of the shaft seals (7) and (2) must face towards the bearing bush (4). Fully drive in scraper (1) using drift 1X56119 916, until it is flush with the shift cover. Fill the pockets (3) and (6) with grease. Fig - 7 Insert bush (4).

Fig. 7

Place shift cover (2) and new sealing ring (3) on shift housing. CAUTION:

8.

Do not damage shaft seal and scraper when sliding onto selector shaft. Use protective sleeve 1X56 137 134.

Tighten four M8 hex bolts (1) to torque 23 Nm. Fig - 8 Fig. 8

27.34 ZF 9 S 109 GEAR BOX 9.

Drive both clamping pins and mandrel into detent piece and detent bush. Fig - 9

CAUTION:

Do not confuse clamping pins. Clamping pin for detent piece

= 36 mm.

Clamping pin for detent bush

= 30 or 28 mm.

NOTE: Assemble circlips and washers as marked. 10.

Place washer on selector shaft.

11.

Insert circlip in appropriate ring groove.

12.

Place small washer on selector shaft.

13.

Place compression spring on selector shaft.

14.

Place washer (small) on selector shaft.

15.

Insert circlip (small) and circlip tongs in ring groove and in so doing push back compression spring.

16.

Place compression spring (large) on selector shaft.

17.

Add washer (large), push back compression spring.

Fig. 9

Fig. 10

Fig - 10 18.

Insert circlip (large) and circlip tongs in outer ring groove. Fig - 11

NOTE: Position selector shaft as far as is possible in the direction of compression springs. 19.

Bring shift mechanism into neutral position.

20.

Use drift 1X56 137 135 to drive needle bearing (3) into cover (2) (side of needle sleeve written on should be facing drift).

21.

Add cover (2) and new sealing ring (3). Screw in four hex bolts (1) and spring washers and tighten to 23 Nm. Fig - 12

Fig. 11

Fig. 12

ZF 9 S 109 GEAR BOX 27.35 CAUTION:

You must be able to move selector shaft easily in both directions.

22.

Insert both detent levers (19) in shift housing.

23.

Insert bolts (20) through detent lever bore into shift housing.

24.

Insert compression springs (6/8) and tighten screw plugs (5/9) to 35 Nm.

25.

Insert O-ring (11) in insert (12).

26.

Grease ball rollers (13).

27.

Fit item 10 to 18.

28.

Tighten screw (18) to 23 Nm.

29.

Insert O-ring (4) on shut-off valve (2).

30.

Fit shut-off valve (2) and in so doing note position of pneumatic connections.

31.

Tighten screw (1) to 23 Nm.

32.

Screw in throttle screw (3) and new sealing ring. Tightening torque = 50 Nm.

33.

Screw in pawl stop (7) and new sealing ring tightening torque = 50 Nm.

Fig. 13

Fig. 14

Fig - 13 34.

Place protective cap on selector shaft. Fig - 14

35.

Push shift lever onto selector shaft as marked and in so doing fix protective cap.

36.

Insert hex bolt and nut and tighten M1

Fig. 15

Tightening torque = 46 Nm Fig - 15 37.

Place ball pivot in shift lever and tighten with hex nut. M10 x 1 Tightening torque = 46 Nm Fig - 16 Fig 16

27.36 ZF 9 S 109 GEAR BOX 27.7

CONNECTING PLATE-LUBRICATING OIL PUMP

27.7.0

Removal of Connection Plate

1.

Remove six hex bolts (3), take off connection plate (4) and shim (7) and sealing ring (6).

2.

Remove shaft seal (5) from connection plate (4) and in so doing ensure you do not damage sealing faces of connection plate. Fig - 1

27.7.1

Removal and dismantling lubricating oil pump

of

1.

Remove eight hex bolts and compression washers. Fig - 2

2.

Use mounting levers to press lubricating oil pump out of housing, remove sealing ring. Fig - 3

Fig. 1

NOTE: Add mounting lever to cast pockets. 3.

Take shim from outer bearing ring of layshaft.

NOTE: Lubricating oil pump is a single component, only dismantle for visual checks and cleaning purposes. 4.

Remove screws from lubricating oil pump. Fig - 4 Fig. 2

Fig 4

Fig. 3

ZF 9 S 109 GEAR BOX 27.37

5.

Press pump housing off pump cover. not damage sealing face in the process.

Do

Fig - 5

Fig. 5

6.

Take out inner and outer rotors from pump cover.

NOTE: First mark installation point of outer rotor 7.

If necessary, extract cylinder pin.

27.7.2

Assembly and mounting lubricating oil pump

1.

Clean and visually check pump parts.

2.

If necessary, insert cylinder pin in bores of pump cover.

3.

Insert outer rotor in marked installation point and insert inner rotor in pump cover, add some oil.

of

Fig. 6

Fig - 6 4.

Add pump housing and drive firmly home.

5.

Screw screws into lubricating oil pump. M5 Tightening torque = 6 Nm. Fig - 7 Fig 7

27.38 ZF 9 S 109 GEAR BOX 6.

Check that the lubricating oil pump moves easily, if necessary, loosen screws and retighten again.

7.

Place new sealing ring on sealing faces for lubricating oil pump. Fig - 8

NOTE: When adjusting the layshaft, the shim used must lie on the roller bearing outer race. CAUTION:

8.

Before fitting the lubricating oil pump and connection plate, layshaft, mainshaft and inputshaft must be adjusted (refer to Section 27.8).

Use hot air blower to heat housing slightly around bearing bore, add lubricating oil pump and drive fully home.

Fig. 8

NOTE: Engage pump driver with layshaft recess. 9.

Screw in eight hex bolts and compression washers. M8

Tightening torque = 23 Nm. Fig - 9

27.7.3

Assembly and connection plate

mounting

of

1.

Coat outer edge of shaft seal (5), e.g. with soap.

2.

Use drift 1X56 103 768 to drive shaft seal (5) fully home into connection plate (4).

Fig. 9

NOTE: Sealing lip of shaft seal must face drift. 3.

Lightly grease sealing lip.

NOTE: The shim (7) used during the adjustment mainshaft and inputshaft must be lying in connection plate. 4.

Place connection plate (4) and new sealing ring (6) on transmission.

5.

Use protective sleeve 1X56 138 065 as assembly aid.

CAUTION:

Do not damage shaft adding connection plate.

seal

when

6.

Tighten six hex bolts (3) to 23 Nm.

7.

To check bearing setting, engage 1st gear and fully rotate transmission on inputshaft. You must be able to feel an appropriate amount of resistance. Fig - 10 Fig. 10

ZF 9 S 109 GEAR BOX 27.39 27.8

ADJUSTING BEARINGS ON MAINSHAFT, INPUTSHAFT AND LAYSHAFT

27.8.0

Adjusting Mainshaft and Inputshaft

CAUTION:

Adjust mainshaft and layshaft with preload. preload is 0.18 to 0.30 mm.

1.

Bring transmission into vertical position

2.

Adjust input bearing to zero play. To do this, use mandrel to drive outer bearing ring in direction of mainshaft. Fig - 1

CAUTION:

3.

Do not press or hit anything near the oil ducts, otherwise housing will be damaged.

Rotate inputshaft and mainshaft several times to center bearing rollers and bearing points. Use a sharp object to test whether the bearing rollers can be moved.

NOTE: When there is zero play, the bearing rollers must have no play, i.e. they must not be able to move. However no preload should be present. 4.

Use depth gauge to measure distance between upper edge of outer bearing ring and housing, adhere to dimension “a”. Example:

Fig 1

a = 5.40 mm Fig - 2

NOTE: Make measurements at two opposite points and take the mean value. 5.

Place new sealing ring on connection plate,

6.

Use depth gauge to measure distance between sealing ring and face for shim. Adhere to dimension “b” Example: b = 7.80 mm.

Fig. 2

Fig - 3 NOTE: Make measurement at two opposite points and take the mean value. 7.

Determine and adhere to difference “c” Example: c = b - a (7.80 - 5.40 mm) c = 2.40 mm

NOTE: You should aim at a preload of 0.25 mm dimension on “e”).

Fig. 3

27.40 ZF 9 S 109 GEAR BOX 8.

Calculate thickness “d” of shim: Example: d = c + e (2.40 + 0.25 mm) d = 2.65 mm

9.

Select shim from spare parts catalogue, grind to correct dimension.

Note:

Experience shows that later tightening of the hex bolts on the connection plate causes the sealing to settle be 0.03 to 0.05mm. This should be taken into consideration when selecting the shim.

10.

Insert shim in connection plate. Fig - 4

27.8.1

Adjusting Layshaft

NOTE: Adjusting layshaft with preload. 0.18 to 0.30 mm.

Preload is

1.

Transmission should be in vertical position.

2.

Adjust layshaft roller bearing to zero play. To do this, use mandrel to drive to outer bearing ring in direction of layshaft.

Fig. 4

Fig - 5 CAUTION:

3.

Do not press or hit anything near the oil ducts. Other wise housing will be damaged.

Rotate layshaft several times to centre bearing rollers and bearing points. Use a sharp object to test whether the bearing rollers can be moved.

NOTE: When there is zero play, the bearing rollers must have no play, i.e. they must not be able to move. However no preload should be present. 4.

Fig 5

Use depth gauge to measure distance between upper edge of outer bearing ring and housing, adhere to dimension 'A'. Example: A = 17.80 mm Fig - 6

NOTE: Make measurements at two opposite points and take the mean value.

Fig. 6

ZF 9 S 109 GEAR BOX 27.41 5.

Place new sealing ring on pump.

6.

Use depth gauge to measure distance between sealing ring and face for shim. Adhere to dimension “B”. Example : B = 15.50 mm. Fig - 7

7.

Determine and adhere to difference “C”. Fig. 7

Example : C = A - B (17.80 - 15.50 mm) C = 2.30 mm NOTE: You should aim at preload of 0.25 mm (dimension 'E'). 8.

Calculate thickness “D” of shim: Example D = C + E (2.30 + 0.25 mm) D = 2.55 mm

9.

Select shim from spare parts catalogue, grind to correct dimension.

NOTE: Experience shows that later tightening of the hex bolts on the pump causes the Sealing to settle by 0.03 to 0.05 mm. This should be taken into consideration when selecting the shim. 10.

Insert shim layshaft bearing outer race. Fig - 8

Fig. 8

27.42 ZF 9 S 109 GEAR BOX 27.9

SHIFT RAIL AND REVERSE GEAR

27.9.0

Removal of Shift Rails

1.

Remove ring in mechanical (interlock) from ring groove.

shift

lock

Fig - 1 2.

Take out bearing plate. Fig - 2

Fig 1

3.

Unscrew screw compression spring.

plug

for

interlock

4.

Take out compression spring and locking lever. Fig - 3

5.

Remove circlip from reserve gear bolts Fig - 4

6.

Bring transmission into vertical shaft position. Transmission should be face upwards.

7.

Remove seven M10 hex bolts from housing.

Fig. 2

Fig - 5

Fig. 3

Fig. 5

Fig. 4

ZF 9 S 109 GEAR BOX 27.43 8.

Separate housing by gently tapping plastic mandrel) the housing recesses.

(By

9.

Remove screw plugs, oil-carrying pipe and if necessary cylinder pins from housing. Fig - 6

10.

Use plastic mandrel to drive bearing outer race from housing.

11.

Remove seal and clean sealing faces.

Fig 6

Fig - 7 12.

Take filter out of housing. Fig - 8

13.

Take off blocking piece. Slightly press down shift rails to do this. Depress indented side of blocking piece, pull opposite side over shift rail edge.

14.

Take off bearing plate.

Fig. 7

Fig - 9 15.

Unscrew screw plug from plate.

16.

Unscrew hex bolts on plate for neutral position switch.

17.

Remove plate and seal. Fig - 10 Fig. 8

Fig. 10

Fig. 9

27.44 ZF 9 S 109 GEAR BOX 18

Take bolt out of housing.

19

Remove pivot bolts and separate shift rails from selector forks and remove individually from housing. Fig - 11

27.9.1

Removal of Reverse Gear

1.

Circlip (1) was removed in Section 27.9.0.

2.

Use a rod (5) to drive reverse gear bolts (2) in direction of output.

3.

Push reverse gear (4) towards housing wall.

4.

Lift mainshaft and layshaft out of housing, as described in section 27.10.

5.

Fig 11

Take reverse gear (4) and 2 roller rings (3) out of housing. Fig - 12 & 13

6.

Remove hex bolts.

7.

Take off cover, remove seal and clean sealing faces. Fig - 14

27.9.2

Installation of Shift Rails

1.

Bring transmission into vertical shaft position. Transmission should face upwards.

2.

Individually insert shift rails into housing, engage sector fork noses with recesses in shift rails. To do this, use hook 1X56 137 451 to guide selector forks. Order to 1st = 2nd = 3rd =

Fig. 12

installation 1st - 2nd or 5th - 6th speed 3rd - 4th or 7th - 8th speed R gear / crawler Fig - 15

NOTE: Compare shift rail part numbers shift rail with different number must be placed in centre. Fig. 13

Fig 15

Fig. 14

ZF 9 S 109 GEAR BOX 27.45 3.

Slide bearing plate over shift rails, recessed side is placed alongside housing sealing face. Fig - 16

4.

Slip on blocking piece. To do this, slightly depress central shift rail. Lower blocking piece over shift rail edge. Fig - 17

NOTE: Studs on blocking piece reach into bearing plate bore. 5.

Fig. 16

Insert cleaned or new filter in housing. Fig - 18 Coat sealing faces with sealing compound.

6.

Insert two cylinder pins in transmission housing.

7.

Insert bearing outer race in housing.

8.

Insert oil-carrying pipe in housing. pipe must not be blocked.

9.

Add housing and use plastic hammer to gently hit housing and drive it home.

Bores in

Fig. 17

Fig - 19 CAUTION:

10.

Do not press or hit anything near the oil ducts. Otherwise housing will be damaged.

Screw in seventeen M10 hex bolts. tightening torque = 50 Nm.

M10

Fig - 20 Fig. 18

Fig. 20

Fig. 19

27.46 ZF 9 S 109 GEAR BOX 11.

Screw screwplug and new sealing ring into housing. M16x1.5 tightening torque = 45 Nm. Fig - 21

12.

Insert bolts in transmission housing. Fig - 22

13.

Fit plate with new seal and screw plug. Tightening torque M18 screws

=

23 Nm

M18 x 1.5 screw plugs

=

35 Nm

Fig 21

Fig - 23 NOTE: Bring transmission into vertical shaft position. Output side should be on top. 14.

Push locking lever over shift rails.

15.

Push bearing plate over shift rails.

I6.

Insert compression spring in housing bore and engage with locking lever.

Fig. 22

Fig - 24 17.

Insert ring to secure bearing plate in ring groove.

NOTE: Ring must not be located near the area where the range-change group shift rail is to be inserted. Fig - 25 Fig. 23

Fig. 25

Fig. 24

ZF 9 S 109 GEAR BOX 27.47 18.

Screw in screw plugs for interlock compression spring with new sealing ring. M14 x 1.5 torque is 35 Nm. Fig - 26

27.9.3

Installation of Reverse Gear

1.

Insert roller ring (3) in reverse gear (4)

2.

Insert reverse gear and roller rings in housing and push towards housing wall.

Fig. 26

Fig - 27 NOTE: The larger recess should face the output. 3.

Install mainshaft and layshaft as is described in Section 27.10.1.

NOTE: Transmission is completely assembled on input side. 4.

Align reverse gear to bearing bores.

5.

Use hot air- blower to slightly heat housing bores,

6.

Drive in bolts until ring groove in circlip is fully in housing

7.

Insert circlip and circlip tongs in ring groove, check that it is seated correctly.

8.

Use feeler gauge to check axial play on reverse gear -

Fig. 27

Axial play 0.20 - 0.60 mm Fig - 28

Fig. 28

NOTE: Cover with sealing web may only be used once. 9.

Place new cover with new seal on sealing face

10.

Screw in six M10 x 22 hex bolts M10 - tightening torque = 46 Nm Fig - 29

Fig 29

27.48 ZF 9 S 109 GEAR BOX 27.10

INPUT SHAFT, LAYSHAFT

MAINSHAFT

AND

27.10.0 Removal of the Shafts 1.

Lift input shaft off mainshaft Fig - 1

NOTE: For instruction on how to dismantle inputshaft, refer to section 27.11.0. 2.

Remove six pivot bolts from housing.

Fig. 1

Fig - 2 3.

Take 3rd/4th speed selector fork (if necessary, with shift lever) out of sliding sleeve. Lift it up and out of transmission housing. Fig - 3

4.

Take fulcrum pad out of 3rd/4th speed selector fork.

Fig. 2

Fig - 4 5.

Use hook 1X56 137 451 to take 1st/2nd speed selector fork out of sliding sleeve. Lift it up and out of transmission housing.

6.

Take fulcrum pad out of 1st/2nd speed selector fork Fig - 5 Fig. 3

Fig 5

Fig 4

ZF 9 S 109 GEAR BOX 27.49 NOTE: Remove reverse gear bolt and push reverse gear towards housing wall (refer to section 27.9.1). 7.

Screw hook 1X56 136 599 in layshaft.

8.

Lift layshaft out of housing and in so doing press mainshaft to one side. Fig - 6

9.

Push lifting rod 1X56 137 200 into mainshaft central bore and in so doing push oil pipe out of mainshaft. Secure lifting rod on output side with associated hex nut.

10.

Use lifting rod to lift mainshaft out of transmission housing. In so doing, secure R gear/crawler selector fork with hook 1X56 137 451.

11.

Take of R gear/crawler selector fork out of mainshaft.

12.

Take fulcrum pad out of selector fork. Fig - 7

Fig. 6

Fig. 7

27.10.1 Installation of the Shafts 1.

Use Lifting rod 1X56 137 200 to push mainshaft into central bore and secure on output side with associated hex nut.

2.

Use lifting rod to guide mainshaft over transmission housing. Fig - 8

NOTE: Insert reverse gear and roller rings in housing and push towards housing wall. 3.

Insert fulcrum pad in crawler/R gear selector fork.

4.

Place selector fork in crawler/R gear sliding sleeve and secure with hook 1x56 137 451. Once the mainshaft has been installed, selector fork nose must engage with shift mechanism housing opening. Fig - 9

Fig 8

Fig. 9

27.50 ZF 9 S 109 GEAR BOX 5.

Guide mainshaft into transmission housing.

bearing

point

of

6.

Take lifting fork 1X56 137 200 out of mainshaft. Fig - 10

7.

Screw hook 1X56 136 599 into layshaft

8.

Place layshaft in bearing point in transmission housing, in so doing press mainshaft to one side.

9.

Fig. 10

Engage mainshaft and layshaft gear teeth, unscrew hook 1X56 136 599 out of layshaft. Fig - 11

10.

Align crawler/R gear selector fork with hook 1X56 137 451 so that you can see the selector fork guiding bores in the threaded bores of the transmission housing.

11.

Insert fulcrum pads in 1st/2nd speed selector fork and 3rd/4th speed selector fork.

12.

Insert selector forks in sliding sleeve so that selector fork nose faces shift mechanism housing opening.

13.

Align selector forks with hook 1x56137 451 so that can you see the selector fork guiding bores in the threaded bores of the transmission housing.

Fig. 11

Fig 12

Fig - 12 14.

Coat thread of pivot bolt with loctite. Screw pivot bolts and compression washers into each side of the transmission housing. M18x1.5 tightening torque 160 Nm. Fig - 13 Fig. 13

ZF 9 S 109 GEAR BOX 27.51 NOTE: For input shaft assembly, refer to section 27.11.1. 15.

Carefully place input shaft on mainshaft. Do not damage sealing lip of baffle plate.

16.

Engage input shaft gear teeth with those of clutch body. Fig - 14 Fig. 14

27.52 ZF 9 S 109 GEAR BOX 27.11

INPUT SHAFT

27.11.0 Dismantling the Input shaft 1.

Place gripper 1X56 136 719 on inner race of input shaft tapered roller bearing. Turn knurled ring until gripper is firmly secured.

2.

Screw extension 1X56 122 310 and adapter 1X56 122 137 onto basic puller 1X56 122 304.

3.

Screw extension 1X56 gripper 1X56 136 719.

4.

Pull inner race (1) of taper roller bearing off input shaft (2).

5.

Use suitable tool to remove baffle plate (5). Remove circlip (4) and cover (3) from input shaft (2).

122

310

onto

Fig. 1

Fig - 1 27.11.1 Assembly of the Input Shaft 1.

Insert cover (3) is input shaft (2) and inset circlip (4)

2.

Use tool 1X56 138 026 to press baffle plate (5) until it is flush with input shaft.

3.

Heat tapered roller bearing inner race (1) to approx 120°C and place on input shaft (2). Ensure that it is firmly driven home. Fig 2

Fig - 2

ZF 9 S 109 GEAR BOX 27.53 27.12

MAINSHAFT

Fig. 1

27.12.0 Dismantling the Mainshaft

7.

Remove 3rd speed helical gear (12) with clutch body (11) and two needle cages (13) from mainshaft (28).

are

8.

Turn mainshaft over and clamp input end in vice with soft jaws.

1.

Clamp output end of mainshaft in a vice with soft jaws.

9.

2.

Remove clutch body (3) and synchronizer ring (4) from mainshaft.

Place appropriate intermediate part on mainshaft. Attach standard 2 leg puller to R gear spur gear (35) and pull off gear and inner race of taper roller bearing (36).

3.

Pull off 3rd/4th speed sliding sleeve (5).

10.

Remove needle cage (34) and circlip (33).

4.

Place gripper 1x56 136 737 on inner race of taper roller bearing. Turn knurled ring until gripper is firmly secured. Screw basic puller 1X56 122 304 onto gripper and pull off bearing inner race (1).

11.

Lift off crawler/R gear sliding sleeve (32).

12.

Place suitable intermediate part on mainshaft. Place standard two leg puller on crawler helical gear (30).

5.

Remove circlip (2).

13.

Pull off crawler (30) an sleeve carrier (31).

6.

Insert puller 1X56 137 457 between synchronizer ring (10) and 3rd speed clutch body (11). Place appropriate intermediate part on mainshaft. Place standard two leg puller and pull off synchronizer hub (6) and synchronizer ring (10).

14.

Remove needle cage (29).

15.

Turn mainshaft over again and clamp input end in vice with soft jaws.

16.

Remove circlip (14).

17.

Place suitable mainshaft.

Fig - 1 NOTE: Instructions for removing described in section 27.10.0.

mainshaft

intermediate

piece

on

27.54 ZF 9 S 109 GEAR BOX 18.

Use Standard two leg puller to grip the rear of 1st speed helical gear (26) and pull off entire pack (item 15 to 26). Fig - 2

NOTE: Ensure that the pullers teeth do not grip the shaft collar. 19.

Take bearing bush (15) and needle cage (16) out of 2nd speed helical gear (17).

20.

Take clutch body (18) and synchronizer ring (19) off synchronizer hub (21).

21.

Lift 1st/2nd speed sliding sleeve (20) off synchronizer hub (21).

CAUTION:

Pressure pieces (3) and compression springs (9) will be released during extraction process. These parts are spring loaded. Secure pieces to prevent them flying out.

22.

Remove 1st speed helical gear (26) clutch body (25), synchronizer ring (24) and synchronizer hub (21) from the mainshaft (28).

23.

Remove two needle cages (29).

27.12.1 Assembly of the Mainshaft 1.

Check that the Lubricating oil bores can be freely accessed on the mainshaft.

2.

Clamp output end of mainshaft in a vice with soft jaws.

NOTE: Lightly grease running face and bearing race of needle cages and helical gears with operating oil. 3.

Slide needle cage (29) onto mainshaft

4.

Push crawler helical gear (30) over needle cage onto mainshaft by gently twisting it. Drive teeth should face out put.

5.

Heat sleeve carrier (31) to approx. 120°C and push onto mainshaft (hub facing crawler). If necessary, drive fully home.

6.

Check axial play of crawler helical gear. -

7.

Axial play 0,20 to 0.45mm

Remove circlip (33).

CAUTION:

Ensure circlip remains absolutely free of burrs as it serves as a running surface for the needle cage.

NOTE: Circlip must have axial play of 0 - 0.1 mm. Select suitable circlip in a accordance with spare parts catalogue.

Fig 2

ZF 9 S 109 GEAR BOX 27.55 8.

Place crawler/R gear sliding sleeve (32) on sleeve carrier. Sliding sleeve is symmetrical and can therefore be placed on either side of the carrier.

20.

9.

Slide needle cage (34) onto mainshaft.

NOTE: Use new compression springs.

10.

Push R speed helical gear (35) over needle cage onto mainshaft by gently twisting it. Drive teeth should face output.

21.

Add synchronizer ring (19). The synchronizer ring noses must engage in recesses of synchronizer hub.

11.

Heat inner race of taper roller bearing (36) to approx. 120°C and slide onto mainshaft and drive firmly home.

22.

Place clutch body (18) on synchronizer ring (19) and pull sliding sleeve into central position (neutral position). In so doing, press synchronizer ring and clutch body.

12.

Check axial play of R speed helical gear. Axial play 0.40 to 0.75mm.

23.

Push needle cage (16) and 2nd speed helical gear (17) onto bush (15) and heat it all to approx. 120°C.

24.

Place parts together on mainshaft and drive home bush (15) without any play. Bush collar should face input. (Fig - 2).

25.

Check axial play of 2nd speed helical gear.

13.

Turn over mainshaft and clamp output end in vice with soft jaws.

14.

Slide both needle cages (27) onto mainshaft.

15.

Push 1st speed helical gear (26) over needle cage onto mainshaft by gently twisting it. Drive teeth should face output.

Use suitable tool to insert three compression springs (23) and compression pieces (22) in synchronizer hub bores or to guide them into sliding sleeve.

16.

Place clutch body (25) and synchronizer ring (24) on driver gear teeth.

CAUTION:

Check limits of wear for all synchronizer rings or clutch bodies as described in Section 27.4.5. Lightly oil bearing races of all synchronizer rings.

26.

Axial play to 0.20 to 0.40mm

Insert circlip (14).

CAUTION:

Ensure circlip remains absolutely free of burrs as it serves as a running surface for the needle cage.

27.

Slide both mainshaft.

28.

Push 3rd speed helical gear (12) over needle cage onto mainshaft by gently twisting it. Driver teeth should face output.

NOTE Synchronizer ring noses must engage in recesses of synchronizer hub.

29.

Place clutch body (11) on 3rd speed helical gear (12).

18.

30.

Add synchronizer ring (10).

31.

Heat synchronizer ring (6) to approx. 120°C and place on mainshaft with the longer nose facing output. If necessary, drove fully home.

17.

Heat synchronizer hub (21) to approx. 120°C and place on mainshaft gear teeth. Synchronizer hub is symmetrical and can therefore be placed on either side of mainshaft. Drive synchronizer hub firmly home.

Check axial play of 1st speed helical gear –

19.

Axial play 0.20 to 0.45mm

Slide 1st/2nd speed sliding sleeve (20) over synchronizer hub, synchronizer ring and clutch body and place on 1st speed helical gear. Ensure that recesses in sliding sleeve interior cover the same areas of the synchronizer hub locating points (for compression springs and compression pieces).

needle

cages

(13)

onto

NOTE: Synchronizer ring noses must engage in recesses of synchronizer hub.

27.56 ZF 9 S 109 GEAR BOX 32.

Insert circlip (2).

NOTE: Circlip must have axial play of 0-0.1mm. Select circlip accordingly. 33.

Check axial play of 3rd speed helical gear. -

Axial play 0.20 to 0.45mm. Fig - 2

34.

35.

Slide 3rd/4th speed sliding sleeve (5) (nose on upper side) over synchronizer hub, synchronizer ring (10) and clutch body (11) and place on 3rd speed helical gear. Ensure that recesses in sliding sleeve interior cover the same areas of the synchronizer hub locating points (for compression springs, ball pins and compression pieces).

Fig. 2

Use suitable tool to insert three compression springs (9) with ball pins (8) and compression pieces (7) in synchronizer hub bores or to guide them into sliding sleeve.

NOTE: Use new compression springs. 36.

Add synchronizer ring (4). The synchronizer ring noses must engage in recesses of synchronizer hub (6).

37.

Place clutch body (3) on synchronizer ring (4) and pull sliding sleeve (5) into central position (neutral position). In so doing, press synchronizer ring and clutch body.

NOTE: Do not reuse the inner race of taper roller bearing which is removed when mainshaft is dismantled. 38.

Heat new inner race of taper roller bearing (1) to approx. 120°C and push onto journal bearing of mainshaft. Drive inner race of taper roller bearing fully home.

39.

Grease bottom of inner race of taper roller bearing (1) between inner race and cage with grease. It is not permitted to apply grease on the outside on the roller bearing itself since this could block the lubricating bores in the input shaft. Fig - 3

NOTE: For instructions on installation mainshaft, refer to section 27.10.1.

of

the

Fig 3

ZF 9 S 109 GEAR BOX 27.57 27.13

LAYSHAFT Fig - 1

NOTE: For instructions on the removal of the layshaft, refer to section 27.10.0. 27.13.0 Dismantling the Layshaft 1.

Place gripper 1X56 136 708 on inner race (1) of taper roller bearing. Turn knurled ring until gripper is firmly secured.

2.

Place suitable intermediate part of layshaft.

3.

Screw basic puller 1X56 122 304 on gripper.

4.

Pull inner race of taper roller bearing off layshaft (2).

5.

Remove circlips (7).

6.

Place gripper 1X56 136 711 on inner race (6) of taper roller bearing. Turn knurled ring until gripper is firmly secured.

7.

Screw basic puller 1X56 122 304 on gripper.

8.

Pull inner race (6) of taper roller bearing off layshaft.

9.

Because of the large force required, the helical gears (5,4) and double helical gear (3) should be pressed off the layshaft singly using a suitable hydraulic press.

Fig. 1

Fig - 2 27.13.1 Assembly of the Layshaft 1.

Clean bores in helical gears and shrink-fit seats on layshaft.

2.

Heat double helical gear (3) and helical gears (4, 5) to max. 170°C. Keep at a temperature difference of 150°C to the part to be added.

3.

Stack up the heated helical gears (5,4 and 3) on a hydraulic press and align them accurately. Fig - 2

Fig. 2

27.58 ZF 9 S 109 GEAR BOX

4.

I

4th speed helical gear – hub upwards

II

3rd speed downwards

III

1st/2nd speed double helical gear.

helical

gear

–

hub

Press layshaft into the bores helical gears. Press gears into firm end contact immediately. Let parts cool down. Fig - 3

NOTE: Press layshaft into bores in helical gears. Press gears into firm end contact immediately. Let parts cool down. 5.

Heat inner races of taper roller bearings (1 and 6) to max 120°C and slide onto layshaft. Drive inner races fully home.

6.

Insert circlip (7) in layshaft groove.

NOTE: Circlip play must be between 0 and 0.1mm, select circlip accordingly.

Fig. 3

ZF 9 S 109 GEAR BOX 27.59 27.14

HOUSING

Fig. 1

27.14.0 Dismantling the Housing Fig - 1 1.

Use soft mandrel to drive taper roller bearing outer races (9,10) out of housing.

2.

Remove breather (18).

3.

Remove four hex bolts (1) and take off cover (20) and seal (3).

4.

Oil spray bores on pipe (8) must not be blocked. When changing the housing

5.

Take two cylinder pins (11) out of housing and remove screw plugs.

27.14.1 Assembly of the Housing 1.

Carefully drive in two cylinder pins (11).

2.

Insert screw plug (13) and sealing covers (6 and 15) with sealing compound.

3

Screw in screw plugs Tightening torque M18 x 1.5 (14, 16) = 35 Nm M24 x 1.5 (4, 5, 12, 13) = 50 Nm M38 x 1.5 (7) = 120 Nm Inductive sensor (17) tightening torque = 50 Nm

4.

Insert pipe (8) (Refer to Section 27.6.1)

5.

Fasten cover (2) and new seal (3) with four hex bolts (1) –

M8 tightening torque = 23 Nm

6.

Screw breather (18) into housing: tightening torque= 10Nm

7.

Use hot-air blower to heat housing around bearing bores to approx. 80°C.

8.

Use plastic mandrel or suitable tool to insert taper roller bearing outer races (9,10) of mainshaft and layshaft into housing and drive firmly home.

27.60 ZF 9 S 109 GEAR BOX 27.15

CLUTCH HOUSING

27.15.0 Removal 1.

Remove 10 Nos. M18x1.5 hex bolts (1) from clutch housing and do not use screw driver to do so.

2.

Lift off clutch housing.

27.15.1 Installation 1.

Set up the clutch housing in correct position.

2.

Tightening 10 nos. M18 x 1.5 hex bolts (1) on clutch housing to 280 Nm. Fig - 1

Fig. 1

ZF 9 S 109 GEAR BOX 27.61 27.16

SPECIAL TOOLS

Tool Number

Application

1X56 100 632

Drift with conical sleeve for inserting shaft seat 10 x 15 x 3 into

Quantity

speedo connecting piece

1

1X56 103 768

Drift for fitting shaft seal 48 x 65 x 10 on input 1¾"

1

1X56 119 916

Drift for fitting shaft seal and scraper 25 X 35 X 7 in shift housing

1

1X56 122 304

Basic puller M65 X 2 for use with grippers

1

1X56 122 310

Extension M65 X 2 only for taper roller bearings on input

1

1X56 122 317

Adapter of M95 X 2 and M65 X 2 for use with grippers

1

1X56 126 467

Drift for fitting shaft seal 95 X 115 X 10 on input, for use with ring 1X56 137 484

1

1X56 136 599

Hook M12 for lifting layshaft

1

1X56 136 708

Gripper M95 X 2 for layshaft taper roller bearings on input side

1

1X56 136 711

Gripper M65 X 2 for layshaft taper roller bearings on output side

1

1X56 136 719

Gripper M95 X 2 for taper roller bearings on input

1

1X56 136 737

Gripper M65 X 2 for taper roller bearings on mainshaft journal bearing

1

1X56 137 135

Drift for bearing bush 25 X 32 X 20 in shift housing

1

1X56 137 200

Lifting rod for mainshaft

1

1X56 137 451

Hook for guiding shift forks

1

1X56 137 452

Drift for lock plate 4132 304 015 on output flange

1

1X56 137 456

30.0 mm Drift for oil pipe mainshaft on output side

1

1X56 138 101

40.5 mm Drift for oil pipe, mainshaft on output side

1

1X56 137 457

Puller, split, for mainshaft synchronizer hubs

1

1X56 137 484

Ring for distancing shaft seal 95 X 115 X 10 on output, for use with drift 1X56 126 467

1

1X56 137 579

Fixing attachment for radial fixing of GP shift rail

1

1X56 137 648

Divided ring for extracting output side clutch body of range-change group

1

1X56 137 134

Protective sleeve assembly aid for assembling shift cover on selector shaft

1

1X56 138 026

Drift for assembling baffle plate in input shaft

1

1X56 138 065

Protective sleeve assembly aid for fitting connection plate

1

1X56 137 450

Assembly stands for use with adapters 1X56 136 998 and 1X56 137 459

1

27.62 ZF 9 S 109 GEAR BOX 27.17

TIGHTENING TORQUE

01.

Breather in transmission housing or shift mechanism

10 Nm

02.

M10 x 1 lock nut on reaction links and ball joints

46 Nm

03.

M12 Hex nuts on reaction links

50 Nm

04.

Pawl stop on transmission and shift mechanism housing

50 Nm

05.

M 24 x 1.5 screw plug (conical) on transmission housing

50 Nm

06.

Impulse sensor

50 Nm

07.

M12 Hex screws on output flange

60 Nm

08.

Speedo connecting piece

100 Nm

09.

Screw plug with M38 x 1.5 magnet on transmission housing

120 Nm

10.

Pivot bolts on transmission on housing

160 Nm

11.

M16 x 1.5 lock nut on piston for range change group shaft mechanism

150 Nm

12.

Pivot bolts on range-change group housing

180 Nm

27.18

RECOMMENDED LUBRICANTS ASHOK LEYLAND GENUINE LUBRICANTS

Aggregate

ZF 9S 109 Gear box

Ashok Leyland Specification

Ambient Temp. °C

Gulf Oil India

Indian Oil Corporation

Hindustan Petroleum

Bharat Petroleum

IBP

Castrol

Karol Lubricants

Chemoleums

Sah Petroleums IPOL

API GL4 with Anglamol 99 Additive

>0

Gulf Gear XP 90

Servo Gear HP 90 (T)

HP Gear Oil Special 90

MAK® SPIROL XEP 90

IBP Special Gear oil 90(A)

Hypoy 90 EP (AL)

Auto Gear XP 90

Turbo GL4 SAE 90 (AL)

IPOL Syncro Plus EP 90

Pennzoil Quaker

Gear Plus Meguin Gear Super Gear Oil GL4 Premium SAE 90 EP 90

$ - Castrol LMM Grease to be used for lubricating Gear shift linkage ball joints

10.02.2004

FILLING CAPACITY Aggregates

Filling Capacity (l)

ZF 9 S 109 Gear box

Lubricate gear shift lever fulcrum joint

G

1

✓

2.

Check oil level and top up

O

1

3.

Change oil when hot. Refill upto correct level

O

1

B.

Maintenance

1.

Check for correct operation of gear shift linkage and setting

✓

Check and clean transmission breather provided on selector housing

✓

2. 3.

Check tightness of clutch housing mounting bolts

Every 16000 km

1.

Every 8000 km

Lubrication

Weekly

PDI

A.

Daily

No. of points

MAINTENANCE PROGRAMME Lubricant

27.20

8.5

Every km x 1000

27.19

Meguin Oil India

✓ ✓ 80

✓

✓

Remarks