ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102 – PDF DOWNLOAD

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ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102 – PDF DOWNLOAD

FILE DETAILS:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102 – PDF DOWNLOAD

Language : English
Pages : 110
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102 – PDF DOWNLOAD

Preface:

This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to
carry out maintenance and repair work on ZF products.

• This manual deals with the standard ZF product in accordance with the state of development on the
  date of issue.
• However, due to continuing development of the product, repair work might require work practices and
  test or adjustment data which are not contained in this manual. We therefore recommend that work
  done on your ZF product is carried out only by skilled mechanics who have had their practical and
  theoretical knowledge updated on a regular basis at our After-Sales Service training courses.

• All work performed at these service points is carried out conscientiously and with care.
• Repair work carried out at ZF service points is guaranteed in accordance with the prevailing
  contractual conditions.
• Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner,
  together with follow-on costs caused by such work, is excluded from the contractual guarantee
  agreement. This also applies where genuine ZF spares have not been used.

TABLE OF CONTENTS:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102 – PDF DOWNLOAD

Start Service CD.......................................................................................  0
16 S 251 1316 751 102..................................................................................  1
	Copyright by ZF....................................................................................  2
	Contents...........................................................................................  3
	Preface............................................................................................  5
	Important information..............................................................................  6
	Instructions for carrying out repairs..............................................................  7
	Tightening torques.................................................................................  9
	Consumables........................................................................................ 11
	Adjustment data.................................................................................... 12
	Table of springs................................................................................... 17
	Special tools...................................................................................... 18
	1 Removing components / range-change............................................................... 27
		1.1 Plastic pipes.............................................................................. 27
		1.2 Output flange.............................................................................. 28
		1.3 Cover...................................................................................... 29
		1.4 5/2-way valve.............................................................................. 31
		1.5 Shift cylinder for range-change............................................................ 32
		1.6 Housing/range-change....................................................................... 34
		1.7 Planetary drive with synchronization....................................................... 37
			1.7.1 Synchronization...................................................................... 37
			1.7.2 Ring gear............................................................................ 39
			1.7.3 Planet carrier....................................................................... 40
	2 Servoshift....................................................................................... 43
		2.1 Non-integrated version..................................................................... 43
		2.2 Integrated version......................................................................... 44
	3 Shift mechanism.................................................................................. 45
		3.1 Double “H” shift pattern Removing and dismantling shift housing 6.......................... 45
		3.2 Superimposed “H” shift pattern Removing and dismantling shift housing ..................... 48
		3.3 Shift mechanism for the integrated Servoshift Removing and dismantling of shift housing.... 53
		3.4 Shift patterns without Servoshift shift mechanism left or right............................ 58
			3.4.1 Horizontal torque shaft left / Selector pattern I.................................... 58
			3.4.2 Horizontal torque shaft left / Selector pattern II................................... 59
			3.4.3 Horizontal torque shaft right / Selector pattern I................................... 60
			3.4.4 Horizontal torque shaft right / Selector pattern II.................................. 61
		3.5 Shift patterns with Servoshift shift mechanism left or right............................... 62
			3.5.1 Horizontal torque shaft left / Selector pattern I.................................... 62
			3.5.2 Horizontal torque shaft left / Selector pattern II................................... 63
			3.5.3 Horizontal torque shaft right / Selector pattern I................................... 64
			3.5.4 Horizontal torque shaft right / Selector pattern II.................................. 65
		3.6 Assembling complete shift housing.......................................................... 66
			3.6.1 Shift without Servoshift............................................................. 66
			3.6.2 Shift with Servoshift................................................................ 66
	4 Components / clutch housing...................................................................... 67
		4.1 Release fork and connection plate.......................................................... 67
			4.4.1 Removing release fork (pulled)....................................................... 67
			4.1.2 Removing release fork (pulled)....................................................... 69
			4.1.3 Removing release fork (pushed)....................................................... 71
			4.1.4 Removing release fork (pulled)....................................................... 73
		4.2 Pump housing with integral pump............................................................ 76
		4.3 Clutch housing............................................................................. 77
		4.4 Removing components........................................................................ 79
	5 Components / centre housing...................................................................... 81
		5.1 Splitter (GV) cylinder..................................................................... 81
		5.2 Splitter shift rail........................................................................ 82
		5.3 Removing shafts and components............................................................. 84
			5.3.1 Installing components................................................................ 86
			5.3.2 Installing shafts.................................................................... 87
			5.3.3 Reverse idler gear................................................................... 88
		5.4 Injection pipe............................................................................. 88
		5.5 Attaching components....................................................................... 89
	6 Input shaft 6.................................................................................... 91
	7 Mainshaft........................................................................................ 93
	8 Layshaft.........................................................................................101
	9 Synchronizer.....................................................................................103
		9.1 Determining wear limit (except for 1st /2nd gear)..........................................103
		9.2 Determining wear limit (1st /2nd gear).....................................................103
		9.3 Assembling synchronizer....................................................................104
		9.4 Sectional view of synchronizer/ZF-BK.......................................................104
	10 Adjusting shafts................................................................................105
		10.1 Mainshaft Determining ring and axial washer...............................................105
		10.2 Input shaft and connection plate..........................................................106
		10.3 Layshaft..................................................................................107
		10.4 Planetary drive...........................................................................108
	11 Compressed air test.............................................................................109
		11.1 Compressed air test for piston and splitter cylinder .....................................109
		11.2 Compressed air test on breather...........................................................109

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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