ZF-Ecosplit Synchromesh Transmission 12-speed Repair Manual 1325751101 – PDF DOWNLOAD
FILE DETAILS:
ZF-Ecosplit Synchromesh Transmission 12-speed Repair Manual 1325751101 – PDF DOWNLOAD
Language : English
Pages : 110
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
ZF-Ecosplit Synchromesh Transmission 12-speed Repair Manual 1325751101 – PDF DOWNLOAD
Preface:
This manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products. The work described below may only be performed by
authorized, trained, and instructed staff. It is the responsibility of the user’s company or repair
company to ensure that their repair staff is properly trained.
- This manual deals with a ZF series product in accordance with the state of development on the date
of issue. - However, due to continuing technical advancements of the product, repair work might require work
practices and test or adjustment data which are not contained in this manual.
We therefore recommend that work done on your ZF product is carried out only by skilled mechanics
and fitters who have their practical and theoretical knowledge updated on a regular basis at our
Service Training Center.
Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Continuously trained personnel,
2. Specified equipment, e.g.: special tools,
3. Genuine ZF spare parts in accordance with the latest volume production
specifications.
TABLE OF CONTENTS:
ZF-Ecosplit Synchromesh Transmission 12-speed Repair Manual 1325751101 – PDF DOWNLOAD
ZF-Ecosplit Repair Manual ............................................. 1 ZF Synchromesh Transmissions, 12-speed............................. 1 Copyright by ZF, Edition: 2009-03.................................. 2 Transmission overview.............................................. 4 Overview of changes: 1325 751 101.................................. 5 Preface............................................................ 6 Safety Instructions................................................ 7 Instructions for Repairs........................................... 8 Tightening torques................................................. 10 Consumables........................................................ 11 Setting data....................................................... 12 Tightening torques................................................. 14 Spring table....................................................... 17 Special tool....................................................... 18 1 Polyamide Tubes for Range Change Group and Valve................. 27 1.1 Removing polyamide tubes................................... 29 1.2 Fitting polyamide tubes.................................... 29 2 Shift Turret..................................................... 31 2.1 Pneumatic servo unit....................................... 32 2.2 Gearshift housing.......................................... 33 2.2.1 Removing and dismantling gearshifthousing............ 33 2.2.2 Assembling gearshift housing......................... 36 2.3 Shift patterns............................................. 39 2.4 Fitting complete shift turret.............................. 40 3 Range Change Group............................................... 41 3.1 Removing output flange..................................... 42 3.2 Fitting output flange...................................... 43 3.3 Removing cover and output bearing.......................... 44 3.4 Fitting cover and output bearing........................... 45 3.5 Removing range change group................................ 46 3.6 Fitting range change group................................. 47 3.7 Dismantling range change group............................. 48 3.7.1 Removing range change group cylinder and piston...... 48 3.7.2 Fitting range change group cylinder and piston....... 49 4 Planetary Gear Set with Synchronizer............................. 51 4.1 Synchronizer............................................... 52 4.2 Ring gear.................................................. 55 4.3 Planet carrier............................................. 56 5 Splitter Group Piston and 5/2-Way Valve.......................... 59 5.1 Removing piston and valve.................................. 60 5.2 Fitting valve and piston................................... 61 5.3 Compressed air test for piston andS/G cylinder............. 62 6 Release Unit, Connection Plate, and Pump......................... 63 6.1 Release unit............................................... 64 6.2 Connection plate........................................... 65 6.3 Pump....................................................... 68 7 Clutch Housing................................................... 69 7.1 Removing clutch housing.................................... 70 7.2 Fitting clutch housing..................................... 71 7.3 Pipe assembly.............................................. 72 8 Shafts and Selector Rails........................................ 73 8.1 Removing shafts and selector rails......................... 74 8.2 Fitting shafts and selector rails.......................... 76 8.3 Adjusting the S/G selector rail............................ 78 9 Transmission Housing............................................. 79 9.1 Dismantling Transmission Housing........................... 80 9.2 Assembling Transmission Housing............................ 81 10 Input Shaft..................................................... 83 10.1 Disassembling input shaft................................. 84 10.2 Assembling input shaft.................................... 85 11 Countershaft.................................................... 87 11.1 Disassembling countershaft................................ 88 12 Main Shaft...................................................... 91 12.1 Disassembling main shaft.................................. 93 12.2 Assembling main shaft..................................... 96 13 Bearing Setting on Main Shaft, Input Shaft, and Countershaft....101 13.1 Setting the main and input shaft..........................102 13.2 Setting the countershaft..................................105 14 Synchronizers...................................................107 14.1 Determining wear limit of synchronizers...................108 14.2 Assembling Synchronizer...................................109 14.3 Cross section of a synchronizer / ZF-BK...................109
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