Transmission T-7336 Ps

Order No.: 5871 970 002

ZF – TRACTOR TRANSMISSION

T-7336 PS

ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau

REPAIR MANUAL for the

ZF – TRACTOR TRANSMISSION T-7336 PS

I M P O R T A N T N O T E: The great variety of ZF units compels a restriction of the Disassembly and Assembly Manuals to a current ZF production unit. Technical development of the ZF units as well as extensions concerning the design possibilities may require differing steps, which can be carried out by qualified Specialists without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare Parts Lists. The described Disassembly and Assembly Manual is based on the design level of a ZF production unit at the time of preparation of the Repair Manual. The ZF Passau GmbH reserve the right to replace the present Disassembly and Assembly Manual by a successional edition without advance notice. Upon request, the ZF Passau GmbH will advise what edition is the latest one. ATTENTION: For the Installation as well as for the commissioning of the unit,

the Instructions and Specifications of Vehicle Manufacturer have to be observed!

For information about the Operation, Maintenance and Description, see the corresponding ZF Operating Instructions.

ZF Passau GmbH Donaustr. 25 - 71 D - 94034 Passau Abt.: ASDM / Section : ASDM Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Copying even partially not permitted! Reproduction même par extrait est interdite! Technische Änderungen vorbehalten! With the reserve of technical modifications! Sous reserve de modifications techniques! 1.Auflage / 1st Edition 2004/05

R e p a i r M a n u a l

Off-Road Transmissionsand Axle Systems

Division

5871 970 002 0/1

PREFACE

This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair and Maintenance operations on ZF-Units.

Treated is a ZF-Serial product according to the design stage of the date of Edition.

However, due to further technical developments of the product, the repair of the unit at your disposal could require different steps as well as other adjustment and testing specifications. Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and theoretical training is constantly completed to the actual situation in our Training School. The Service Stations, established by the ZF Friedrichshafen all over the world, offer you: 1. Constantly trained personnel 2. Prescribed installations, e.g. Special Tools 3. Genuine ZF-Spare Parts according to the latest phase of development Here, all operations are carried out for you with utmost care and reliability. Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual contractual conditions, by the ZF-Warranty. Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-expenditures eventually arising from it, are excluded from this contractual responsibility. This applies also in case of a renouncement of Genuine ZF-Spare Parts. ZF Passau GmbH Service Department



Division

5871 970 002 0/2

GENERAL

The Service Manual covers all work required for dismantling and the pertaining installation. When repairing the axle, ensure utmost cleanliness and that the work is carried out in an expert-like manner. The axle should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices. Dismantling and mounting work must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them: REFE-RENCE:

For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used! Parts fitted in heated state have to be installed subsequently after cooling down to ensure a perfect contact!

CAUTION When assembling the transmission, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. by no means. Lined plates with organic friction linings (e.g. paper linings) must not be washed (negative effect on lining adhesion). They are only allowed to be dry-cleaned (leather cloth). For the installation of circlips and retaining rings it must be observed that slots are located exactly.

DANGER When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.



Division

5871 970 002 0/3

Structure of the Repair Manual The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main group are always summarized in one chapter. Special tools required for performing the respective repair work are listed in the text as well as in the Chapters “W” (List of Special Tools) and “WB” (Illustrated Tables). Important information on industrial safety

Generally, the persons repairing ZF-units are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations. The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training. The following safety references are used in the present Repair Manual: CAUTION

Serves as reference to special working procedures, methods, information, the use of auxiliaries etc... in this repair manual.

DANGER

Is used, if lacking care can lead to personal injury or damage the product.

___________________________________________________

REFE-RENCE

Prior to starting the checks and repair works, thoroughly study the present instructions.

CAUTION:

Illustrations, drawings and parts do not always represent the original; the working procedure is shown. The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and weight must not be drawn (not even within one representation). The works must be performed according to the description.

REFE-RENCE:

After the repair works and the checks, the expert staff must convince itself that the product is properly functioning again.

!



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5871 970 002 0/4

VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE

TABLEAU DE CONVERSION

25,40 mm 1 kg ( Kilogramm ) 9,81 Nm ( 1 kpm ) 1,356 Nm ( 0,138 kpm ) 1 kg / cm 1 bar ( 1,02 kp/cm2 ) 0,070 bar ( 0,071 kp/cm2 ) 1 Liter 4,456 Liter 1 Liter 3,785 Liter 1609,344 m 0° C ( Celsius ) 0 ° C ( Celsius )

=

=

=

=

=

=

=

=

=

=

=

=

=

=

1 in ( inch)

2,205 lb ( pounds )

7,233 lbf x ft ( pound force foot)

1 lbf x ft ( pound force foot )

5,560 lb / in ( pound per inch )

14,233 psi (pound force per square inch lbf/in2 )

1 psi ( lbf/in2 )

0,264 Gallon ( Imp. )

1 Gallon ( Imp. )

0,220 Gallon ( US )

1 Gallon ( US )

1 Mile ( Landmeile )

+ 32° F ( Fahrenheit )

273,15 Kelvin



Division

5871 970 002 0/5

BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS

DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene maße in t/m2 Note : linear density in kg/m; areal density in t/m2 Nota : Densité linéaire en kg/m; Densité superficielle en t/m2

Begriff Unit Unité

Formelzeichen Formula Sign Symbole

Neu Alt New Old Nouveau Vieu

Umrechnung Conversion Conversion

Bemerkungen Note Nota

Masse Mass Mass

m kg (Kilogramm) kg

Kraft Force Force

F N (Newton) kp 1 kp = 9,81 N

Arbeit Work Travail

A J (Joule) kpm 0,102kpm = 1J = 1Nm

Leistung Power Puissance

P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW 1 KW = 1,36 PS

Drehmoment Torque Couple

T Nm (Newtonmeter) kpm 1 kpm = 9,81 Nm T (Nm) = F (N) . r (m)

Kraftmoment Moment (Force) Moment (Force)

M Nm (Newtonmeter) kpm 1 kpm = 9,81 Nm M (Nm) = F (N) . r (m)

Druck (Über-) Pressure (Overpress) Pression (Sur-)

pü bar atü 1,02 atü = 1,02 kp/cm2

= 1 bar = 750 torr

Drehzahl Speed Nombre de Tours

n min -1



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5871 970 002 0/6

TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARD 148 Friction value: µ total= 0.12 for screws and nuts without after-treatment, as well as phophatized nuts. Tightened by hand! Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard Thread DIN 13, Page 13 Size 8.8 10.9 12.9 M4 2.8 4.1 4.8 M5 5.5 8.1 9.5 M6 9.5 14 16.5 M7 15 23 28 M8 23 34 40 M10 46 68 79 M12 79 115 135 M14 125 185 215 M16 195 280 330 M18 280 390 460 M20 390 560 650 M22 530 750 880 M24 670 960 1100 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100

Metric ISO-Fine Thread DIN 13, Page 13 Size 8.8 10.9 12.9 M 8 x 1 24 36 43 M 9 x 1 36 53 62 M 10 x 1 52 76 89 M 10 x 1.25 49 72 84 M 12 x 1.25 87 125 150 M 12 x 1.5 83 120 145 M 14 x 1.5 135 200 235 M 16 x 1.5 205 300 360 M 18 x 1.5 310 440 520 M 18 x 2 290 420 490 M 20 x 1.5 430 620 720 M 22 x 1.5 580 820 960 M 24 x 1.5 760 1100 1250 M 24 x 2 730 1050 1200 M 27 x 1.5 1100 1600 1850 M 27 x 2 1050 1500 1800 M 30 x 1.5 1550 2200 2550 M 30 x 2 1500 2100 2500 M33 x 1.5 2050 2900 3400 M 33 x 2 2000 2800 3300 M 36 x 1.5 2700 3800 4450 M 36 x 3 2500 3500 4100 M 39 x 1.5 3450 4900 5700 M 39 x 3 3200 4600 5300



Division

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY

TRACTOR TRANSAXLE T–7336 PS

2094 009 003

Disassembly Chapter/Fig

Reassembly Chapter/Fig.

Designation and Use

Part No.

5871 970 002 W/1

1/01 1/07

Assembly truck cpl. with tilting device # Holding fixture # Support # To mount the complete transmission, rear axle housing and the axle trumpet respectively on the assembly truck.

5870 350 000 5870 350 117 5870 350 125

1/05

7/94

10/09

Lifting chain 3-strand Dis- and reassembly aid for removal and installation of the complete rear axle and rear axle trumpets respectively. To be used in combination with eyebolts DIN 580 M16 = 0636 804 001

5870 281 047

1/12

10/7

Adjusting screws M16 Dis- and reassembly aid for separation and assembly of the complete transmission with the rear axle housing.

5870 204 023

2/06 2/10

6/02 9/38

Adjusting screws M 8 Dis- and reassembly aid for removal and installation of the complete valve housing / F/R shift control. Gasket and intermediate sheet on the pump housing.

5870 204 011

2/26

9/43

Adjusting screws M 10 Dis- and reassembly aid for removal and installation of the complete pump housing – F/R shift control.

5870 204 007

2/26 3/04

Pry bar set 1 Set = 2 Pcs. Universal use. To separate housing components, flanges and shafts. To press off the brake- from the rear axle housing

5870 345 065

2/28_3/10 3/16_3/22 3/26_3/29 3/44_5/32

6/21_7/74 7/82_7/82 8/25_8/49

Set of external pliers A1-A2-A3-A4 Universal use. To unsnap and snap in externally clamping retaining rings.

5870 900 015



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/2

2/29

Two-armed puller Opening 120 mm Universal use. To pull off the ball bearing from the bearing bracket.

5870 970 002

3/04

Adjusting screws M 16 Dis- and reassembly aid for removal and installation of the complete cover from the transmission housing.

5870 204 023

3/07

Rapid grip # To pull off the bearing inner ring 32012X = 0750 117 505 from the input gear 2094 359 046. To be used in combination with: Basic device

5873 011 014

5873 001 000

3/08_3/18 3/19_3/21 3/24_3/47

Gripping insert # To pull off the bearing inner ring 30 210X = 0750 117 656 from the input shaft splitter group . To be used in combination with: Basic device

5873 001 038

5873 001 000

3/11 3/27 3/39

7/85 8/25 8/50 8/92

Pressing bush # To preload the compression springs 0732 041 183 in the disc carrier splitter group. To preload the set of cup springs 0501 314 521 on the FA and powershift clutch .

5870 506 117

3/13 3/29 3/41

Clamping pliers To lift the piston 2094 359 004 out of the disc carrier splitter group.

5870 900 007

3/14 3/30 3/42

Internal extractor Countersupport Universal use. To remove the needle bearing 0750 115 365 from the disc carrier splitter group.

5870 300 005 5870 300 003



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/3

3/21 3/34

Gripping insert # To pull off the bearing inner ring 32 007X = 0750 117 503 from the output shaft splitter group. To be used in combination with: Basic device

5873 000 035

5873 000 000

3/23 4/01

Two-armed puller Opening 160 mm Universal use. To press off the spur gear 2094 359 056 with bearing 0750 117 656 from the output shaft. To pull off the bearing inner ring 0635 376 013 from the output shaft FA.

5870 970 003

3/33

Gripping insert # To pull off the bearing inner ring JLM714148 = 0750 117 267 from the output shaft 2094 359 064 splitter group. To be used with : Basic device

5873 002 025

5873 002 001

3/45

Parting fixture # Opening 155 Universal use. To separate the spur gear 2094 359 048 from the intermediate shaft 2094 359 042 .

5870 300 028

3/46

Gripping insert # To pull off the bearing inner ring 30 210X = 0750 117 656 from the intermediate shaft 2094 359 042. To be used in combination with: Parting fixture

5873 001 038

5870 300 028

4/02

Striker # Universal use. To expel the cyl. pin 0631 315 561 from the housing or cover.

5870 650 001



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/4

4/04

7/94

Lifting tackle # To lift out and in the complete output shaft 2094 346 054 FA with cover and clutch.

5870 281 050

4/07

Gripping insert # To pull off the bearing inner ring 449J = 0750 117 444 from the output shaft 2094 346 054. To be used in combination with: Parting fixture

5873 001 064

5873 001 000

4/09 4/27

7/10 7/32

Pressing bush Universal use. To preload the laminated spring 0501 314 521 . To preload the disc carrier – main clutch.

5870 506 116

4/13 4/27 5/41

Set of external pliers A11-A21-A31-A41 Universal use. To unsnap and snap in externally clamping retaining rings.

5870 900 016

4/20

6/38_6/49 7/14_7/35

8/15_8/112

Digital depth gauge 200 mm Universal use. For various measuring procedures.

5870 200 072

4/29

Resetting device 2 x required Universal use. To separate the disc carrier from the clutch bell housing.

5870 400 001

5/15

6/78 6/85

Slotted nut wrench # To loosen and to tighten the slotted nut 0737 502 164 on the main shaft.

5870 401 049

5/17

Extractor # Universal use. For dis- and reassembly of the main shaft.

5870 300 026



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/5

5/19

8/75

Parting fixture # Universal use. To pull off the bearing inner ring 32313 = 0750 117 499 from the main shaft. For axial preloading of the spur gear 2094 359 048.

5870 300 028

5/35

8/56 8/60

Two-armed puller Universal use. To pull off the gear 2094 303 064 from the layshaft. To pull off or axial preloading of the spur gear 2094 359 056 until contact on the retaining ring.

5870 970 004

6/09 9/16

Set of internal pliers Universal use. To unsnap and snap in internally clamping retaining rings.

5870 900 013

6/10

Hot-air blower # 230 V Hot-air blower # 115 V To heat up various components.

5870 221 500 5870 221 501

6/34

Mounting tool To insert the bearing outer ring 30310 = 0750 117 588 into the housing bore. To be used in combination with : Handle

5870 058 073

5870 260 002

6/41_6/97 7/33_7/86 8/09_8/58

8/76_8/120 9/35

Magnetic stand # Dial indicator # Universal use . For various measuring procedures – Axial clearance, clearance, etc.

5870 200 055 5870 200 057

6/49

7/100 7/101

Straightedge # 580 mm Universal use. For various measuring procedures .

5870 200 022



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/6

6/79 6/86

Torque spanner 1 – 12 Nm Universal use . To check the rolling resistance in the main shaft bearing.

5870 203 031

6/89 6/90

Mounting tool # To insert the needle sleeve HK 2520 = 0635 303 053 into the bush 2094 306 014. To insert the shaft seal 25x 35 x 7 = 0634 301 303 into the bush 2094 306 014 .

5870 048 284

7/11

Digital caliper gauge 150 mm Universal use. For various measuring procedures.

5870 200 109

7/14 7/33

Load cell 1 - 10 KN Universal use. To preload the set of cup springs in the main clutch with a precise pressure.

5870 700 003

7/15

Clamping fixture # To preload the complete disc set of the main clutch. Disc carrier 2094 371 003 to pressure plate 2094 371 001.

5870 654 028

7/37

Digital depth gauge 300 mm Universal use. For various measuring procedures > 200 mm .

5870 200 114

7/76

Hot-air blower 230 V Hot-air blower 115 V Universal use. To heat up the bush carrier, housing and transmission components.

5870 221 500 5870 221 501



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/7

7/86

Load cell 0 – 25 KN Universal use . To preload the disc set in the FA - clutch with a precise pressure.

5870 700 005

7/100 7/102

Gauge blocks 1Set = 2 Pcs. Universal use. To be used in combination with straightedge 5870 200 022 und 5870 200 072 / 5870 200 114 for various measuring procedures.

5870 200 066

8/03 8/54 8/71 8/73

Pressing bush To install the tapered roller bearing 0750 117 656 on the input shaft 2094 359 044 or clutch side B/D Intermediate shaft 2094 359 042 clutch G/F.

5870 506 119

8/08_8/54 8/57_8/73

8/76

Spring balance # 0 – 25 Nm Universal use . To check the rolling moment in the spur gear bearing.

5870 230 004

8/10 8/36 8/78

Assembly drift # To insert the needle bearing HK 4016 = 0735 115 365 into the disc carrier 2094 259 023 .

5870 506 105

8/105

Adjusting screws 1 Set = 2 Pcs. Universal use. Easier attachment of the cover 2093 301 044 to the transmission housing.

5870 204 021

8/108

Mounting tool # To insert and position the shaft seal 0750 111 368 = 45 x 76 x 12 in the cover 2094 301 044.

5870 048 176

8/110 8/111

Puller For axial preloading = locating of output shaft 2094 359 064 .

5870 000 017



Division



2094 009 003



Designation and Use

Part No.

5871 970 002 W/8

8/121

Mounting tool # To insert and position the shaft seal 0750 111 371 = 70 x 95 x 10 in the cover 2094 301 044.

5870 048 175

8/123

Straightedge # Measuring of excess shift travel of the crawler gear shifting. Also see: Magnetic stand 5870 200 055 and dial indicator 5870 200 057 .

5870 200 087

9/26

Feeler gauge # Universal use. To determine the gap size between pump housing and elbow.

5870 200 113

10/57 10/58

Adjusting screws # ø 8,5 mm Adjusting screws # ø 8,8 mm To position and to align the electro-hydraulic shift components. # Particularly important special tools to repair components (wear parts repair) !

5870 204 057 5870 204 058

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ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 02/2004

SpezialS

5870 200 066 5870 200 022 5870 200 072

5870 204 0235870 200 114

T-7336SCHALTGETRIEBE

GEARBOX HOUSING2094 009 003

WB

/1

29.3529.35

150

140

130

120

110

100

90

80

70

60

50

0

2094

101

003.0

0

5870 350 1175870 204 021

580mm 300mm

5870 048 175 5870 200 0225870 281 047 5870 350 0005870 350 125

5871

970

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5870 200 072 5870 200 055

T-7336PUMPENANTRIEB

PUMP DRIVE2094 009 003

WB

/2

29.3529.35

150

140

130

120

110

100

90

80

70

60

5050

0

2094

122

003.0

1

5870 345 065

M10

5870 204 0075870 900 013 5870 900 0155870 200 113 5870 970 0025870 200 057

010

20

30

4050

60

70

80

90

5871

970

002

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5870 506 105

5870 200 022 5870 200 055

5870 900 007

T-7336SPLIT - GRUPPESPLITTER - BOX

2094 009 003

WB

/3

29.3529.35

150

140

130

120

110

100

90

80

70

60

50

0

2094

168

002.0

0

5873 002 025

5873 011 014

5873 000 035 5873 000 000 5870 506 1175870 300 0035870 506 105 5870 300 005

5873 001 000

5873 001 038

5873 002 001

5870 200 072

5870 506 119

5870 230 004 5870 200 057

010

20

30

4050

60

70

80

90

5870 200 066

5870 900 015

5871

970

002

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5870 230 004

5870 900 007

T-7336SCHALTUNG

GEARSHIFT SYS.2094 009 003

WB

/4

2094

159

002.0

0

5873 000 035 5873 000 000 5870 506 1175870 300 0035870 900 015 5870 300 005

5873 001 038 5873 001 000 5870 506 1195870 300 028

5870 200 057

010

20

30

4050

60

70

80

90

5870 200 055

5870 506 105

5871

970

002

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5870 200 057

5870 506 116

T-7336VA - KRICHGANG-FAHRK.

FRONT-WH. DRIVE - CRAWLER -2094 009 003

WB

/5

2094

146

003.0

1

5870 970 003 5873 001 0005870 281 050 5870 281 047

5870 204 0215870 900 015 5870 650 001

5870 900 016 5873 001 0645870 900 015

5870 221 500

115 V

230 V

5870 221 501

5870 200 022

010

20

30

4050

60

70

80

90

5870 200 055

5870 048 176

5870 200 066

29.35

150

140

130

120

110

100

90

80

70

60

50

0

5870 200 072

5871

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5870 200 072

T-7336HAUPTWELLEMAIN SHAFT

2094 009 003

WB

/6

2094

104

002.0

1

5870 300 028 5870 203 0315870 300 0265870 200 022

29.35

150

140

130

120

110

100

90

80

70

60

50

0

5870 280 004

1 - 12 Nm

5870 401 049

5871

970

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5873 001 000

T-7336VORGELEGEWELLE

LAY SHAFT2094 009 003

WB

/7

2094

103

003.0

1

5870 970 0045873 002 035

5870 058 084

5873 002 001 5870 900 015 5873 001 048

5870 200 0725870 260 002

29.35

150

140

130

120

110

100

90

80

70

60

50

0

5870 200 0555870 200 057

010

20

30

4050

60

70

80

90

5871

970

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T-7336SCHALTUNG

GEARSHIFT - SYSTEM2094 009 003

WB

/8

2094

106

003.0

0

5870 048 284 5870 200 055

29.35

150

140

130

120

110

100

90

80

70

60

50

0

5870 048 284 5870 200 072 5870 200 057

010

20

30

4050

60

70

80

90

5871

970

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SpezialS

5870 204 057

T-7336SCHALTUNG

HYDRAULIC CONTROL2094 009 003

WB

/9

2094

152

003.0

1

5870 204 058 5870 204 0495870 204 011

8,8mm8,5mm

5871

970

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5870 204 011

T-7336HYDR.- STEUERNG

HYDR. GEASHIFT SYSTEM2094 009 003

WB

/10

2094

177

002

00

5871

970

002

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T-7336ZAPFWELLE/P-ANTRIEB

P.T.O. SHAFT2094 009 003

WB

/11

2094

110

003.0

0

5870 221 5015870 900 015 5870 900 013 5870 221 500

ODER / OR

115 V230 V

5871

970

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5870 506 116

T-7336HAUPTKUPPLUNG

MAIN - CLUTCH2094 009 003

WB

/12

2094

171

001.0

0

5870 700 0035870 200 109 5870 654 0285870 400 001

29.35

150

140140

130

120

110

100100

90

80

7070

60

5050

0

2x

5870 900 016 5870 200 072

1-10kN150mm

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Division

5871 970 002 1/1

ZF – TRACTOR TRANSAXLE T-7336

DISASSEMBLY Fasten the rear axle to the assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixture 5870 350 117 (S) Support 5870 350 125

Figure 1

1. Separate the Transmission from the Rear Axle Loosen the unions and remove both oil tubes (Figure 2 and 3).

Figure 2

Figure 3

Loosen and remove all unions.

Figure 4



Division

5871 970 002 1/2

Lock the transmission by means of lifting tackle (S) and loosen the bolted connection. (S) Lifting strap 5870 281 047 Prior to loosen the bolted connection, loosen the screw plug on the bottom side of the transmission and drain the oil!

Figure 5

Install two adjusting screws (S) and separate the transmission from the rear axle. (S) Adjusting screws (M16) 5870 204 023

Figure 6

Fasten the transmission on the assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixture 5870 350 117

Figure 7



Division

5871 970 002 2/1

2. Removal of the Electro-Hydraulic Shift Control and Disassembly of the Pump Drive 2.1 Removal of the Electro-Hydraulic Shift Control ATTENTION: In case of transmission failures due to defective shift controls we recommend to replace the complete shift control. The pressure control characteristics of the replacement shift control (see the corresponding spare parts list) are adapted to the transmission version and vehicle type respectively. Without permission of ZF no modifications of the pressure control characteristics are allowed to be made. Therefore the shift controls should only be repaired by ZF After-Sales Service Centers. Adequate workshop installations of our Service Stations (shift system or transmission test benches) as well as constantly trained personnel guarantee an expert maintenance and repair.

!

2.1.1 Removal of the 4-speed Powershift Control Block Loosen the screw plug (bleeder). Oil can drain into the sump!

Figure 1

!

Loosen the cap screws on the pump. Step 2 ... 5 is required for removal of the valve housing!

Figure 2

Loosen the hexagon screws on the elbow.

Figure 3



Division

5871 970 002 2/2

!

Pull the complete pump out of the housing. Pay attention to possibly released washers and bush!

Figure 4

Loosen the bolt connections and remove the tube.

Figure 5

Loosen two cap screws and replace them by two adjusting screws (see arrows). (S) Adjusting screws (M8) 5870 204 011 Then loosen the remaining cap screws.

Figure 6

!

Take off the control block. Pay attention to possibly released stop plate!

Figure 7



Division

5871 970 002 2/3

Loosen the pressure switch (system pressure) and the screw-in sleeve (see arrow).

Figure 8

Remove the gaskets (2x) and the intermediate plate.

Figure 9

2.1.2 Removal of the Forward-Reverse Control Block Loosen two cap screws and replace them by two adjusting screws (see arrows). (S) Adjusting screws (M8) 5870 204 011 Then loosen the remaining cap screws.

Figure 10

Take off the control block.

Figure 11



Division

5871 970 002 2/4

Remove the gaskets (2x) and remove the intermediate sheet.

Figure 12

!

Loosen the cap screws and remove the released duct plate from the transmission housing. Pay attention to released compression spring and ball!

Figure 13

Remove the gaskets (2x) and the intermediate sheet.

Figure 14



Division

5871 970 002 2/5

2.2 Disassembly of the Pump Drive Pull the tube together with the elbow out of the housing bore.

Figure 15

Pull both bushes out of the spur gear.

Figure 16

Loosen the screw and separate the filter from the housing.

Figure 17

Loosen the nut and remove the released solenoid (Proportional Valve – Main Clutch). Then loosen the valve.

Figure 18



Division

5871 970 002 2/6

Loosen the hexagon screws and remove the released housing.

Figure 19

Remove the gaskets (2x) and the intermediate sheet.

Figure 20

Remove the bush and the strainer insert (see arrow) from the housing bore.

Figure 21

Remove the speed transmitter 1 (Main Clutch Output), speed transmitter 2 (Transmission Oil Temperature) and the solenoid valve 3 (Connection Front Wheel Drive).

Figure 22

1 2

3



Division

5871 970 002 2/7

Remove the pressure line (front wheel drive).

Figure 23

Loosen the hexagon screws and remove the released flange.

Figure 24

Loosen the screw plug and remove the released shim, compression spring, valve cone (cold start safety valve) from the housing bore.

Figure 25

Loosen the hexagon screws, install two adjusting screws (S) and separate the housing cover from the transmission housing. (S) Adjusting screws (M10) 5870 204 007 (S) Pry bar set 5870 345 065

Figure 26



Division

5871 970 002 2/8

Loosen the hexagon screws and separate the bearing bracket together with the spur gear from the housing cover.

Figure 27

Unsnap the retaining ring, remove the shim and press the bearing bracket out of the spur gear. (S) Set of external pliers 5870 900 015

Figure 28

Pull the tapered roller bearing with the two-armed puller from the bearing bracket. (S) Two-armed puller 5870 970 002

Figure 29

Expel the bush with the ball bearing from the spur gear and the housing bore respectively. Then remove the released spur gear and ball bearing.

Figure 30



Division

5871 970 002 3/1

3. Disassembly of Powershift Clutches Loosen the cap screws and remove both speed transmitters.

Figure 1

!

Loosen the hexagon screws and remove both covers. Pay attention to possibly released shims and O-rings! Mark the installation position of the two small covers to the large cover!

Figure 2

Loosen the hexagon screws.

Figure 3

Figure 4

!

Install two adjusting screws (S) and by means of the pry bar set (S) separate the cover from the transmission housing. (S) Adjusting screws (M16) 5870 204 023 (S) Pry bar set 5870 345 065 Pay attention to the released O-rings! Lock the cover by means of the lifting tackle! If necessary, press off the bearing outer rings and the shaft seals from the cover bores.



Division

5871 970 002 3/2

!

Remove the oil tube (see arrow). The figure on the left shows the arrangement of the clutches. (A/C, B/D, F/G) Mark the disc carrier of the single clutches accordingly (makes the later installation easier)!

Figure 5

Take the clutches out of the housing.

Figure 6

3.1 Disassembly of Clutch A/C Pull the input gear out of the disc set and remove the released needle cage. If necessary, pull the bearing inner ring (see arrow) from the input gear. (S) Rapid grip 5873 011 014 (S) Basic device 5873 001 000

Figure 7

Pull the bearing inner ring from the input shaft and remove the shim located behind it. (S) Gripping insert 5873 001 038 (S) Basic device 5873 001 000

Figure 8

A C

B D

F G

A

C



Division

5871 970 002 3/3

Unsnap the circlip and remove the disc set C.

Figure 9

Unsnap the upper retaining ring. (S) Set of external pliers 5870 900 015

Figure 10

Preload the compression spring through the axial bearing and unsnap the retaining ring. (S) Pressing bush 5870 506 117

Figure 11

Remove the released components and take off the disc set.

Figure 12



Division

5871 970 002 3/4

Remove the piston. (S) Clamping pliers 5870 900 007

Figure 13

If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor 5870 300 005 (S) Countersupport 5870 300 003 Remove the disc set and the piston of clutch A analogously.

Figure 14

Unsnap the rectangular rings (3x, see arrows) and remove the needle bearing.

Figure 15

Unsnap both retaining rings and remove the released shim. (S) Set of external pliers 5870 900 015

Figure 16



Division

5871 970 002 3/5

Press the input shaft out of the spur gear bearing.

Figure 17

By means of the gripping insert (S) press the tapered roller bearing from the input shaft. (S) Gripping insert 5873 001 038

Figure 18

Unsnap the rectangular rings (4x) and press off the tapered roller bearing (see arrow) by means of the gripping insert from the input shaft. (S) Gripping insert 5873 001 038

Figure 19



Division

5871 970 002 3/6

3.2 Disassembly of Clutch B/D Unsnap the rectangular rings (2x, see arrows).

Figure 20

Pull the tapered roller bearing from the output shaft. (S) Gripping insert 5873 000 035 (S) Basic device 5873 001 000

Figure 21

!

Unsnap the retaining ring and remove the released shim. (S) Set of external pliers 5870 900 015 If necessary, loosen the retaining ring by means of slightly blowing!

Figure 22

By means of the two-armed puller (S) pull the tapered roller bearing from the output shaft. (S) Two-armed puller 5870 970 003

Figure 23

D

B



Division

5871 970 002 3/7

Pull the tapered roller bearing from the output shaft and remove the released shim. (S) Gripping insert 5873 001 038 (S) Basic device 5873 001 000

Figure 24

Unsnap the circlip and remove disc set D.

Figure 25


Figure 26


Figure 27



Division

5871 970 002 3/8

Remove the released components and take off the disc carrier.

Figure 28


Figure 29

If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor 5870 300 005 (S) Countersupport 5870 300 003 Remove the disc set and the piston of clutch B analogously.

Figure 30

Unsnap the rectangular rings (3x, see arrows) and remove the needle bearing.

Figure 31



Division

5871 970 002 3/9

Unsnap the circlip and remove the released gear.

Figure 32

Pull the tapered roller bearing from the output shaft. (S) Gripping insert 5873 002 025 (S) Basic device 5873 002 001

Figure 33



Division

5871 970 002 3/10

3.3 Disassembly of Clutch F/G Unsnap the rectangular rings (2x, see arrows).

Figure 34

Pull the tapered roller bearing from the intermediate shaft. (S) Gripping insert 5873 000 035 (S) Basic device 5873 000 000

Figure 35

Pull the inner disc carrier (Clutch G) out of the disc set.

Figure 36

Unsnap the circlip and remove disc set G.

Figure 37

G

F



Division

5871 970 002 3/11


Figure 38


Figure 39

Remove the released components and take off the disc carrier.

Figure 40


Figure 41



Division

5871 970 002 3/12

If necessary, pull the needle sleeve out of the disc carrier. (S) Internal extractor 5870 300 005 (S) Countersupport 5870 300 003 Remove the disc set and the piston of clutch F analogously.

Figure 42

Unsnap the rectangular rings (3x, see arrows) and remove the needle bearings.

Figure 43

Unsnap both retaining rings and remove the released shim. (S) Set of external pliers 5870 900 015

Figure 44

By means of the parting fixture (S) press off the spur gear and the tapered roller bearing from the intermediate shaft. (S) Parting fixture 5870 300 028

Figure 45



Division

5871 970 002 3/13

By means of the gripping insert (S) and the parting fixture (S) press off the tapered roller bearing from the intermediate shaft. (S) Gripping insert 5873 001 038 (S) Parting fixture 5870 300 028

Figure 46

Pull off the tapered roller bearing. (S) Gripping insert 5873 001 038 (S) Basic device 5873 001 000

Figure 47



Division

5871 970 002 4/1

4. Disassembly of the Front Wheel Drive, Crawler Gear Shifting and Main Clutch

4.1 Disassembly of the Front Wheel Drive Pull the tapered roller bearing from the output shaft. (S) Two-armed puller 5870 970 003

Figure 1

Pull the cyl. pins (2x) by means of the striker out of the cover bores. (S) Striker 5870 650 001

Figure 2

Loosen two hexagon screws and replace them by two adjusting screws (S). Then loosen the remaining hexagon screws.

Figure 3

!

Attach the lifting tackle (2x, see arrows) to the output shaft. Then lift the cover together with the front wheel drive out of the transmission housing. (S) Lifting tackle 5870 281 050 Pay attention to the released clutch body and the synchronizer ring of the crawler gear shifting!

Figure 4



Division

5871 970 002 4/2

Pull the complete front wheel drive out of the cover.

Figure 5

Bend up the sheet metal straps (3x) and remove the screen sheet. The unsnap the rectangular rings (see arrows)

Figure 6


Figure 7

Pull the clutch from the shaft and out of the clutch bell housing respectively.

Figure 8



Division

5871 970 002 4/3

Preload the laminated spring by means of the press. Then unsnap the retaining ring and remove the released shim and the laminated spring. (S) Pressing bush 5870 506 116

Figure 9

Unsnap the retaining ring and remove the released disc set and shims. (S) Set of external pliers 5870 900 015

Figure 10

Press the piston evenly (over the pressure bolts) out of the gear.

Figure 11

Unsnap the rectangular rings (see arrows).

Figure 12



Division

5871 970 002 4/4

Unsnap the retaining ring and remove the released clutch bell housing. (S) Set of external pliers 5870 900 016

Figure 13

Pull the slotted pin out of the cover bore.

Figure 14

Pull out the bolts and remove the released components.

Figure 15

If necessary, loosen the hexagon screws, remove the released shim and by means of lever action press the bearing outer rings out of the cover bore.

Figure 16



Division

5871 970 002 4/5

4.2 Disassembly of the Crawler Gear Shifting Remove the tube and the needle bearing.

Figure 17

Remove the axial bearing and the shim.

Figure 18

Remove the clutch body and the synchronizer ring.

Figure 19

Mark a point on the gear shift fork. Then measure the control dimension from the face of the gear shift rail to the marked point on the gear shift fork and write it down. Control dimension e.g. . . . . . . . . . . . . . . . . . . . . 46.20 mm (S) Digital depth gauge 5870 200 072

Figure 20



Division

5871 970 002 4/6

Loosen the threaded pins (2x) on the gear shift fork (crawler gear).

Figure 21

Loosen the screw plug (1) and lift the compression spring (2) as well as the ball (3) out of the housing bore.

Figure 22

Pull the gear shift rail out of the housing bore and remove the released gear shift fork.

Figure 23

!

Pull the clutch bell housing from the shaft. Pay attention to the released needle cage!

Figure 24

3 2 1



Division

5871 970 002 4/7

Unsnap the circlip and remove the complete sychronizer body. Remove the released synchronizer components. Separate the gear and the needle cage from the clutch bell housing.

Figure 25

4.3 Disassembly of the Main Clutch Pull the clutch pack out of the layshaft.

Figure 26

Preload the disc carrier by means of the press and unsnap the retaining ring. (S) Pressing bush 5870 506 116 (S) Set of external pliers 5870 900 016

Figure 27

Separate the complete clutch from the clutch shaft.

Figure 28



Division

5871 970 002 4/8

!

Press off the disc carrier. (S) Resetting device 5870 400 001 Disassembly is difficult due to expanded O-rings!

Figure 29

Remove the shim, end shim and the disc set.

Figure 30

Remove the compression springs and the O-ring (see arrow) from the piston.

Figure 31

Unsnap the circlip and remove the pressure plate.

Figure 32



Division

5871 970 002 4/9

If necessary, expel the internally located screen sheet through the oil bores and remove the released O-ring (see below figure) from the annular groove.

Figure 33

Figure 34



Division

5871 970 002 5/1

5. Disassembly of the Main Transmission (6-speed Synchro.Transmission) 5.1 Disassembly of the Mechanical Shift Control Remove the stops (3x, see arrows), consisting of ball, spring and screw plug.

Figure 1

Loosen both threaded pins on the gear shift fork (1st/2nd gear).

Figure 2

Loosen both threaded pins and remove the released driver.

Figure 3

!

Pull the gear shift shaft (1st/2nd gear) out of the housing bore. The gear shift fork (1st/2nd gear) can only be removed when the main shaft has been pressed out!

Figure 4



Division

5871 970 002 5/2

Loosen both threaded pins on the gear shift fork (3rd/4th gear).

Figure 5

Loosen both threaded pins and remove the released driver.

Figure 6

Pull the gear shift shaft (3rd/4th gear) out of the housing bore and remove the released gear shift fork. Demount the gear shift shaft (5th/6th gear) analogously and remove the gear shift fork.

Figure 7

Remove the locking pins (2x) out of the housing bore.

Figure 8



Division

5871 970 002 5/3

Remove the gear shift shaft (crawler gear) Pull the sealing cap out of the housing bore, unsnap the circlip and remove the released shim.

Figure 9

Loosen both threaded pins on the gear shift finger.

Figure 10

Pull the gear shift shaft out of the housing and remove the released gear shift finger.

Figure 11

Remove the gear shift shaft (6-speed synchron.transmission) Loosen the threaded pin.

Figure 12



Division

5871 970 002 5/4

Loosen both threaded pins on the gear shift finger.

Figure 13

Pull the gear shift shaft out of the housing and remove the released gear shift finger and the bush.

Figure 14



Division

5871 970 002 5/5

5.2 Disassembly of the Main Shaft Unlock the slotted nut, lock the gearing and loosen the slotted nut. (S) Slotted nut wrench 5870 401 049

Figure 15

Take off the shim and the gear.

Figure 16

Press the main shaft by means of the fixture out of the transmission housing and take the released components (see below figure) out of the housing. (S) Extractor 5870 300 026

Figure 17

To the figure: 1 = Thrust washer 2 = Gear shift fork (1st/2nd gear) 3 = Gears with synchronizer (1st/2nd gear) 4 = Gears (3rd/4th gear) 5 = Gears (5th/6th gear) 6 = Shim 7 = Tapered roller bearing

Figure 18

1 3

4 5 6 7

2



Division

5871 970 002 5/6

Press the tapered roller bearing by means of the parting fixture (S) from the main shaft. (S) Parting fixture 5870 300 028

Figure 19



Division

5871 970 002 5/7

5.3 Disassembly of the Layshaft Loosen the cap screw and pull the speed transmitter out of the housing bore.

Figure 20

Loosen the bolt connection and the union screw (see arrow) and remove the released tube.

Figure 21

Loosen the hexagon screws and the countersunk screw. Then pull the released cover out of the housing bore and remove the shim located behind it.

Figure 22

!

Press the layshaft in direction of arrow into the housing. Pay attention to the released bearing outer ring and layshaft! Then lift the layshaft out of the housing.

Figure 23



Division

5871 970 002 5/8

Unsnap the rectangular ring (see arrow).

Figure 24


Figure 25

Fasten the layshaft in the vice and pull off the tapered roller bearing. (S) Gripping insert 5873 002 035 (S) Basic device 5873 002 001

Figure 26

Remove the spur gear (4th gear).

Figure 27



Division

5871 970 002 5/9

Remove the clutch body and the synchronizer ring (4th gear).

Figure 28

Unsnap the retaining ring. (S) Set of external pliers 5870 900 015

Figure 29

Remove the synchronizer body (3rd/4th gear).

Figure 30

Remove the synchronizer ring and clutch body (3rd gear).

Figure 31



Division

5871 970 002 5/10

Unsnap the retaining ring. (S) Set of external pliers 5870 900 015

Figure 32

Remove the gear (3rd gear).

Figure 33

Unsnap the retaining ring.

Figure 34

Pull off the gear (6th gear) together with the bush and remove the released needle cage. (S) Two-armed puller 5870 970 004

Figure 35



Division

5871 970 002 5/11

Remove the synchronizer ring and the synchronizer body together with the sliding sleeve.

Figure 36

Unsnap the retaining ring.

Figure 37

Remove the synchronizer ring and the gear (5th gear).

Figure 38



Division

5871 970 002 5/12

5.4 Disassembly of the Pump Gear Drive Unsnap the internally located retaining ring. (S) Set of external pliers 5870 900 015

Figure 39

Press the spur gear out of the bearing inner ring and remove it.

Figure 40

Unsnap the retaining ring and pull the ball bearing out of the housing bore. (S) Set of internal pliers 5870 900 013

Figure 41



Division

5871 970 002 6/1

Figure 1

REASSEMBLY 6. Reassembly Main Transmission (6-speed Synchro.Transmission) 6.1 Preassembly of the Transmission Housing Undercool the bush and insert it into the heated housing bore until contact is obtained. Wet the outer diameter of the bush with Loctite (Type No.: 574)!

Install two adjusting screws (S). Then assemble the gasket and the cover. (S) Adjusting screws 5870 204 011

Figure 2

Fasten the cover by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm

Figure 3

Insert the ball (see arrow) into the housing bore. Then provide the screw plug with a new sealing ring and install it. Tightening torque (M26). . . . . . . . . . . . . . MA = 80 Nm

Figure 4



Division

5871 970 002 6/2

Insert the ball (see arrow) into the housing bore. Then provide the screw plug with a new sealing ring and install it. Tightening torque (M16). . . . . . . . . . . . . . MA = 35 Nm

Figure 5

Provide the screw plug with a new O-Ring and install it. Tightening torque (M10). . . . . . . . . . . . . . . MA = 20 Nm

Figure 6

Provide the screw plugs (2x) with a new O-Ring and install it. Tightening torque (M10). . . . . . . . . . . . . . MA = 25 Nm

Figure 7



Division

5871 970 002 6/3

6.2 Reassembly of the Pump Gear Drive Insert the ball bearing into the housing bore.

Figure 8

Fasten the ball bearing by means of the retaining ring. (S) Set of internal pliers 5870 900 013

Figure 9

Heat up the bearing inner ring and install the spur gear until contact. (S) Hot-air blower 230V 5870 221 500 (S) Hot-air blower 115V 5870 221 501

Figure 10

Fasten the spur gear by means of the retaining ring. (S) Set of internal pliers 5870 900 013

Figure 11



Division

5871 970 002 6/4

!

6.3 Reassembly of the Layshaft Assemble the gear (5th gear) and the synchronizer ring. Prior to the assembly oil all single components!

Figure 12

Fasten the gear by means of the retaining ring. (S) Set of external pliers 5870 900 015

Figure 13

Insert the compression springs, the ball bolts and the pressure pieces into the bores of the synchronizer body.

Figure 14

Preload the pressure pieces and assemble the sliding sleeve. Pay attention to contact of the recesses in the synchronizer body with the webs of the sliding sleeve!

Figure 15



Division

5871 970 002 6/5

!

Install the preassembled synchronizer body until contact. Observe the installation position, see figure!

Figure 16

Figure 17

Adjust the axial clearance of the splined bush max. 0.10 mm Snap the retaining ring into the recess of the layshaft and install it in direction of arrow until contact is obtained. Determine Dim. X e.g. . . . . . . . . . . . . . . 33.35 mm Example „A“: Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . 33.35 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.05 mm Difference = Bush height = 33.30 mm Then unsnap the retaining ring again.

Assemble the synchronizer ring.

Figure 18

!

Assemble the gear (6th gear) and install the needle cage. Observe the installation position, see figure!

Figure 19

X

X – 0 ... 0,10



Division

5871 970 002 6/6

Heat up the splined bush e.g. 33.30 mm (see example „A“/Page 6/5) and install it until contact. Pay attention to contact of the oil bores in the splined bush and the layshaft!

Figure 20

Fasten the gear and the splined bush respectively by means of the retaining ring. (S) Set of external pliers 5870 900 015

Figure 21

Assemble the gear (3rd gear) and fasten it by means of the retaining ring. (S) Set of external pliers 5870 900 015

Figure 22

Assemble the clutch body.

Figure 23



Division

5871 970 002 6/7

Insert the compression springs, the ball bolts and the pressure pieces into the bores of the synchronizer body.

Figure 24

Preload the pressure pieces and assemble the sliding sleeve. Pay attention to contact of the recesses in the synchronizer body with the webs of the sliding sleeve!

Figure 25

!

Assemble the synchronizer ring. The synchronizer ring has to be installed on that side of the synchronizer body which shows to the gear (3rd gear)! Pay attention of the shoulder at the inner diameter of the synchronizer body (see arrow)!

Figure 26

!

Install the preassembled synchronizer body until contact is obtained. Observe the installation position, see figure!

Figure 27



Division

5871 970 002 6/8

Fasten the synchronizer body by means of the retaining ring. (S) Set of external pliers 5870 900 015

Figure 28

Install the synchronizer ring and the clutch body.

Figure 29

Assemble the spur gear (4th gear).

Figure 30

!

Heat up the tapered roller bearing and install it until contact. After cooling down install the bearing subsequently!

Figure 31



Division

5871 970 002 6/9

!

Heat up the output-sided tapered roller bearing and install it until contact. After cooling down install the bearing subsequently!

Figure 32

Snap the rectangular ring (see arrow) into the annular groove and lock it.

Figure 33

Insert the bearing outer ring (see arrow) into the housing bore until contact. (S) Mounting tool 5870 058 073 (S) Handle 5870 260 002

Figure 34

Insert the preassembled layshaft into the housing and position it accordingly.

Figure 35



Division

5871 970 002 6/10

Install the bearing outer ring.

Figure 36

Adjust the axial clearance of the layshaft 0.05 … 0.12 mm (Figure 37 … 41) Rotate the housing by 90° and locate the bearing outer ring exactly until contact. Measure Dim. I, from the mounting face of the housing to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25 mm

Figure 37

Measure Dim. II, from the face to the mounting face on the cover. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 17.20 mm (S) Digital depth gauge 5870 200 072

Figure 38

Example „B“: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . 19.25 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . - 17.20 mm Difference . . . . . . . . . . . . . . . . . . . . . . . .= 2.05 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.05 mm Results in shim e.g. . . . . . . . . . . . . . . . .= 2.00 mm



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Install the shim (e.g. Thickness = 2.00 mm) and the cover.

Figure 39

Fasten the cover by means of hexagon screws and countersunk screw. Tightening torque (hexagon screw M10/8.8). . . MA = 46 Nm Tightening torque (counters.screw M10/8.8). . . MA = 34 Nm

Figure 40

!

Check the axial clearance = 0.05 … 0.12 mm by means of dial indicator (S) and pry bar set (S). (S) Dial indicator 5870 200 057 (S) Magnetic stand 5870 200 055 (S) Pry bar set 5870 345 065 If required it is still to be corrected with a corresponding shim (Fig. 39)!

Figure 41

Turn the sleeve (see arrow) into the housing so that the oil supply hole (see below sketch) is uncovered. Then lock the sleeve by means of hexagon nut. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 90 Nm

Figure 42



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5871 970 002 6/12

1

3

2

To the sketch: 1 = Housing 2 = Sleeve 3 = Nut

Figure 43

!

Insert the oil tube into the housing and fasten it by means of the union nut (see arrow) and union screw. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 60 Nm Provide the union screw with new sealing rings!!

Figure 44

!

Insert the speed transmitter into the housing bore and fasten it by means of the cap screw. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 9.5 Nm Provide the speed transmitter with a new O-Ring and grease it!

Figure 45



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6.4 Reassembly of the Main Shaft Insert the bearing outer ring (see arrow) into the housing bore until contact is obtained.

Figure 46

Rotate the housing by 90° and insert the bearing outer ring (see arrow) into the housing bore until contact is obtained.

Figure 47

!

Pinion shaft adjustment (Fig. 48 … Example „C“) Below indicated measuring procedures are to be carried out with utmost accuracy! Inexact measurements result in a defective contact pattern! Formula: S = 5.14 – A – (+/- X) Formula / Pinion dimension tolerance e.g. + 0.05 mm: S = 5.14–A – 0.05 Formula / Pinion dimension tolerance e.g. – 0.05 mm: S = 5.14 – A + 0.05 S = Shim thickness 5.14 = Design factor A = Housing dimension X = Pinion dim. tolerance (deviation from the theoretical installation dimension = 185.1 mm) Dim. X, is indicated in connection with the theoretical installation dimension = 185.1 mm on the pinion head, see Figure 50! Insert the tapered roller bearing and roll in the bearing outer ring.

Figure 48



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Measure Dim. A, from the face of the bearing inner ring to the mounting face of the housing. Dim. A e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm (S) Straightedge 5870 200 022 (S) Digital depth gauge 5870 200 072

Figure 49

Figure 50

!

Read Dim. X (pinion dimension tolerance). Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . + 0.05 mm Example „C“: S = 5.14 – A – (+/- X) S = 5.14 – 2.00 – 0.05 S = 3.09 It is known from experience that the required contact pattern is obtained when a 0.1 mm thicker shim is installed! Shims are available in graduations of 0.05 mm. Choose the next shim e.g. Thickness = 3.20 mm.

!

Install the shim e.g. Thickness = 3.20 mm (see example „C“). Install the shim with the chamfer showing downwards!

Figure 51

!

Heat up the tapered roller bearing and install it until contact is obtained. After cooling down install the bearing subsequently!

Figure 52

185.1 + 0.05



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!

Preassemble double synchronizer 1st/2nd gear (Figure 53 … 66) Prior to installation oil the components! Place the clutch disc against the gear (1st gear) until contact is obtained. Tip of the selector teeth (see arrow) must show upwards (to the sliding sleeve)!

Figure 53

!

Install the inner ring and the intermediate ring. Pay attention to contact of the intermediate ring and the clutch disc!

Figure 54

!

Install the outer ring. Observe the radial installation position, see below figure!

Figure 55

Figure 56



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!

Place the clutch parts (3x, see arrow) and insert the needle cage (2x) into the gear. Observe the installation position of the clutch parts, see figure!

Figure 57

Insert the synchronizer body into the gear until contact is obtained.

Figure 58

!

The figure on the left shows the synchronizer body and the sliding sleeve as well as the compression springs with the pressure pieces. The recesses of the synchronizer body (Arrow 1) have to be aligned with the stop slots in the sliding sleeve (Arrow 2) and with the pressure pieces respectively!

Figure 59

Assemble the sliding sleeve according to Figure 59 and install the compression springs as well as the pressure pieces. Then bring the sliding sleeve into the center position (neutral).

Figure 60

1 1

1

2 2

2



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!

Assemble the outer ring. Observe the radial installation position, see figure!

Figure 61

Install the intermediate ring.

Figure 62

!

Assemble the inner ring. Observe the radial installation position, see figure!

Figure 63

!

Assemble the clutch disc. Tip of the selector teeth must show downwards (to the sliding sleeve)! Observe the radial installation position, see figure!

Figure 64



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Install the needle bearing (2x).

Figure 65

Assemble the gear (2nd gear) into the internal gearing of the clutch disc. Position of the single parts must be absolutely ensured for further assembly. In case of careless handling there is the danger that the pressure pieces might unsnap!

Figure 66

Install the main shaft (Figure 67 … 87) The figure on the left shows the main shaft components.

Figure 67

!

Fasten the thrust washer (see arrow) by means of grease onto the gear (1st gear). Observe the installation position, install the thrust washer with the projecting collar showing upwards!

Figure 68



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!

Insert the shift group (1st/2nd gear) cautiously into the housing and position it (see below figure). Observe the installation position, insert the shift group with the larger gear (1st gear) showing upwards!

Figure 69

Figure 70

!

Insert the sliding pads with grease into the bores and position the shift fork (1st/2nd gear). After assembly of the shift fork the main shaft cannot be installed any more!

Figure 71

!

Place the shim (Thickness = 7.8 mm, empirical value) onto the bearing outer ring. Observe the installation position, install the shim with the projecting collar showing downwards (to the bearing)!

Figure 72



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5871 970 002 6/20

!

Insert two assembly bars (height approx. 4-5 mm) (see arrows) and position the gears (2x, 3rd/4th gear). Observe the installation position, see figure!

Figure 73

!

Position the gears (2x, 5th/6th gear) lifting carefully the shift group (1st/2nd gear) upwards. Observe the installation position, see figure!

Figure 74

Align the components centrically and assemble the undercooled main shaft until contact is obtained.

Figure 75

Hold the main shaft in place and assemble the heated bearing inner ring until contact is obtained. Then remove the assembly bars (see Figure 73) again.

Figure 76



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5871 970 002 6/21

!

Assemble the gear (front-wheel drive). Observe the installation position, inset plane face (contact face/shim) shows to the outside!

Figure 77

Figure 78

Figure 79

!

Adjust the rolling moment of the main shaft bearing = 4 … 5 Nm and the axial clearance of the components = 0.05 … 0.20 mm (Figure 78 … 80) Prior to adjusting bring the sliding sleeves of the synchronizers 1st/2nd gear, 3rd/4th gear and 5th/6th gear into the exact center position (neutral)! Tighten the slotted nut (Figure 78), until the required rolling moment (Figure 79) is obtained. (S) Slotted nut wrench 5870 401 049 (S) Torque spanner 5870 203 031 Then check the axial clearance of the components by means of the feeler gauge (Figure 80). The axial clearance corresponds with the gap between the gear – 3rd gear and the gear – 4th gear, pressing the gears by means of the pry bar set to the direction of arrow until contact is obtained. Possible failure sources and remedy respectively: 1. Rolling moment is not obtained, parallel to it there is no axial clearance of the components – install a thinner shim (Figure 72). 2. Rolling moment ok, but axial clearance too high – install a thicker shim (Figure 72). Only when the rolling moment and the axial clearance are within the admissible tolerance range, the shim is determined exactly!

Figure 80



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5871 970 002 6/22

Loosen the slotted nut again.

Figure 81

!

Determine the shim (Figure 82 and 83) Measure Dim. X, from the plane face of the gear to the face of the main shaft. Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 mm (S) Digital depth gauge 5870 200 072 Dim. X = Shim thickness

Figure 82

Assemble the determined shim e.g. Thickness = 3.00 mm.

Figure 83

Attach the slotted nut by hand and relieve the main shaft bearing by means of slight blows.

Figure 84



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Tighten the slotted nut. Tightening torque . . . . . . . . . . . . . . . . . . MA = 500 Nm (S) Slotted nut wrench 5870 401 049

Figure 85

Check the rolling moment of the main shaft bearing 4 … 5 Nm once again and correct it by the installation of an adequate shim (Figure 83). Rolling moment too high - install a thicker shim. Rolling moment too low - install a lower shim. (S) Torque spanner 5870 203 031

Figure 86

Lock the slotted nut by means of peening (2x).

Figure 87



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6.5 Reassembly of the Shift System (Mechanical Part) Install the gear shift shaft (6-speed synchron.transmission) Preassemble the gear shift shaft as shown in the figure on the left. 1 = Gear shift shaft 2 = Circlip 3 = Washer 4 = Compression spring

Figure 88

Figure 89

Preassemble the bush as shown in the figure on the left. 1 = Bush 2 = O-Ring 3 = Needle sleeve 4 = Shaft seal 5 = Scraper 6 = Protection ring Press in the needle sleeve to be flush at the shoulder (Ø 35 to Ø 32 mm). Wet the outer diameter of the shaft seal with spirit and insert it until contact is obtained. Insert the scraper until contact at the shaft seal is obtained. Insert the supporting ring with the offset side showing to the scraper until contact is obtained. (S) Mounting tool 5870 048 284

Flush-mount the needle bearing (see arrow) into the housing bore. (S) Mounting tool 5870 048 284

Figure 90

1

2

3

4

3 2

1

2 3

4 5

6



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5871 970 002 6/25

!

Insert the gear shift shaft assembling the gear shift finger and fasten it by means of threaded pins preliminarily. Align the tapped holes with the recesses of the gear shift shaft!

Figure 91

Insert the preassembled bush into the housing bore and fasten it by means of the threaded pin. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 25 Nm Wet the threaded pin with Loctite (Type No.: 270)!

Figure 92

Install the gear shift shaft 5th/6th gear Insert the sliding pads into the bore with grease and position the gear shift fork (5th/6th gear).

Figure 93

!

Assemble the gear shift shaft taking up the gear shift fork (5th/6th gear) and fasten it by means of threaded pins preliminarily. Align the tapped holes with the recesses of the gear shift shaft!

Figure 94



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5871 970 002 6/26

!

Install the driver. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 34 Nm Align the tapped holes with the recesses of the gear shift shaft!

Figure 95

!

Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 35 Nm Provide the screw plug with a new O-Ring!

Figure 96

Adjust the excess shift travel Shift the 5th and 6th gear alternately and measure the excess shift travel (axial clearance) on the face of the gear shift shaft by means of the dial indicator. The excess shift travel must be the same in shift position 5th or 6th gear! The excess shift travel is changed by loosening and tightening alternately both threaded pins on the gear shift fork. Tightening torque (Threaded pins) . . . . . . . MA = 34 Nm

Figure 97 (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057

Install the gear shift shaft 3rd/4th gear Insert the sliding pads with grease into the bores and position the gear shift fork (3rd/4th gear).

Figure 98



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Snap the circlip into the recess of the locking pin. The insert the preassembled locking pin into the cross hole of the gear shift shaft.

Figure 99

Insert the locking pin (length 25.9 mm) through the lateral housing bore into the cross hole, for the position see the line or arrow.

Figure 100

!

Assemble the gear shift shaft taking up the gear shift fork (3rd/4th gear) and fasten it preliminarily by means of threaded pins. Align the tapped holes with the recesses of the gear shift shaft!

Figure 101

!


Figure 102



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5871 970 002 6/28

!

Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 35 Nm Provide the screw plug with a new O-Ring! Adjust the excess shift travel analogously to Figure 97, Page 6/26.

Figure 103

By loosening and tightening alternately both threaded pins bring the gear shift finger into center position to the driver (3rd/4th gear). Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 34 Nm

Figure 104

Install the gear shift shaft 1st/2nd gear Insert the locking pin (length 24.4 mm) through the lateral housing bore into the cross hole, for the position see the line or arrow.

Figure 105

!

Assemble the gear shift shaft taking up the gear shift fork (1st/2nd gear) and fasten it preliminarily by means of threaded pins. Align the tapped holes with the recesses of the gear shift shaft!

Figure 106



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5871 970 002 6/29

!


Figure 107

!

Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 35 Nm Provide the screw plug with a new O-Ring! Adjust the excess shift travel analogously to Figure 97, Page 6/26.

Figure 108

Install the gear shift shaft (crawler gear) Grease the O-Ring (1) and insert it into the annular groove of the gear shift shaft. Then install the circlip (2).

Figure 109

!

Insert the gear shift shaft into the housing until contact is obtained, assemble the gear shift finger at the same time and fasten it by means of threaded pins. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 34 Nm Align the tapped holes with the recesses of the gear shift shaft!

Figure 110

2 1



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Assemble the washer and fasten it by means of the circlip.

Figure 111

Flush-mount both sealing caps (see arrows) into the housing. Wet the contact faces with Loctite (Type No.: 649)!

Figure 112



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7. Reassembly of the Main Clutch, Crawler Gear Shifting and Front Wheel Drive 7.1 Reassembly of the Main Clutch Install the sealing caps into the oil supply holes (33x).

Figure 1

Oil the O-Ring (see arrow) and insert it into the annular groove of the disc carrier.

Figure 2

Insert the screen sheet into the disc carrier and place it firmly by means of the press (Figure 4).

Figure 3

Figure 4



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5871 970 002 7/2

!

Adjust clearance 6.7 -0.4 mm of the disc set (Figure 5 …Example „B“) Determine Dim. „X“ (Figure 5 ... 11) Assemble the piston on the clutch shaft until contact is obtained. Install the components without sealing elements first!

Figure 5

Assemble the pressure plate.

Figure 6

Place the compression springs (3x) each offset by 120° to each other on the pressure plate.

Figure 7

Assemble the end shim on the disc carrier until contact is obtained.

Figure 8



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Hold the end shim in place and assemble the disc carrier on the clutch shaft.

Figure 9

!

Preload the compression springs by means of the press and snap the retaining ring into the annular groove of the clutch shaft. (S) Pressing bush 5870 506 116 Assemble the disc carrier into the teeth of the pressure plate!

Figure 10

Measure Dim. „X“. Dim. „X“ e.g. . . . . . . . . . . . . . . . . . . . . . . 55.75 mm (S) Digital caliper gauge 5870 200 109 Pay attention to correct contact of the installed parts! Then remove the components again.

Figure 11

Measure Dim. „Y“ (thickness of the whole disc set) (Figure 12 ... 14) Measure Dim. „A“, overall dimension of all inner clutch discs. Thickness of the single inner clutch disc e.g. . . . 2.85 mm Thickness of all inner clutch discs (Dim. „A“) e.g. . 22.80 mm Inner clutch discs are undulated and therefore not measurable in the set!

Figure 12



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Measure Dim. „B“, overall dimension of the lined clutch discs. Thickness of the single lined clutch disc e.g. . . . . 2.55 mm Thickness of all lined cl. discs (Dim. „B“) e.g. . . . . 22.95 mm Prior to the measuring procedure or the assembly soak the lined clutch discs in oil – use oil according to the ZF List of Lubricants TE-ML 06!

Figure 13

EXAMPLE „A“: Dim. A e.g. . . . . . . . . . . . . . . . . . . . . . . . . 22.80 mm Dim. B e.g. . . . . . . . . . . . . . . . . . . . . . . . .+ 22.95 mm Results in Dim. „Y“ e.g. . . . . . . . . . . . . . 45.75 mm

Figure 14

!

Alternatively to the single measurement of the clutch discs the thickness of the disc set can be determined by means of the press and the load cell! Load the disc set (without spring washers) with an axial force of F = 9500 N and measure Dim. „Y“ (thickness of the whole disc set). Dim. „Y“ e.g. . . . . . . . . . . . . . . . . . . . . . . . . 45.75 mm (S) Digital depth gauge 5870 200 072 (S) Load cell 5870 700 003

EXAMPLE „B“: Dim. „X“ e.g. . . . . . . . . . . . . . . . . . . . . . . 55.75 mm Dim. „Y“ e.g. . . . . . . . . . . . . . . . . . . . . . . - 45.75 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . . 10.00 mm Clearance 6.7 -0.4 . . . . . . . . . . . . . . . . . . . . - 6.50 mm Result = Shim e.g. 3.50 mm

+300 - 5500



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Insert the disc carrier into the clamping fixture (Part 1). (S) Clamping fixture 5870 654 028

Figure 15

Assemble the determined shim e.g. 3.50 mm (optionally, also seeExample „B“, Page 7/4).

Figure 16

Assemble the end shim.

Figure 17

!

Put on the spring washer. Put the single parts of the disc set alternately (Figure 18 … 21) onto the disc carrier! For disc arrangement also see the corresponding spare parts list!

Figure 18



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5871 970 002 7/6

!

Put the lined clutch disc over the spring washer. Prior to the assembly soak the lined clutch discs in oil – use oil according to ZF List of Lubricants TE-ML 06!

Figure 19

Assemble the inner clutch disc (undulated steel clutch disc). For assembly of the undulated inner clutch discs the installation specification shown in the below figure is to be observed!

Figure 20

The inner clutch discs (undulated steel clutch discs) have to be installed peak-to-peak, which means tooth space on tooth space (see Arrow 1), however half tooth alternately left hand and right hand (see Arrow 2)!

Figure 21

Put on the pressure plate.

Figure 22

1

1

2

2



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Put on the clamping fixture (Part 2) and align the discs. Then preload the disc set evenly by tightening the butterfly nuts until the teeth of the pressure plate are located on the teeth of the disc carrier.

Figure 23

Oil the lip sealing ring (see Arrow 1) and the O-Ring (see Arrow 2) and insert them into the annular grooves of the piston. Observe the installation position, the lip sealing ring must be installed with the slot showing to the pressure chamber (upwards)!

Figure 24

Insert the compression springs (2 pcs. each/hole) into the blind holes of the piston.

Figure 25

Put the clutch pack onto the piston.

Figure 26

1

2



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Adjust the piston radially until the teeth of the piston are aligned with the teeth of the pressure plate. Then preload the piston and the compression springs by means of the press and fasten it with the circlip.

Figure 27

Seal the bores (2x) by means of threaded pins. Tightening torque (M8/8.8) . . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No.: 270)!

Figure 28

Oil the lip sealing ring (see arrow) and insert it into the annular groove of the clutch shaft. Observe the installation position, the lip sealing ring must be installed with the slot showing to the pressure chamber (upwards)!

Figure 29

Put the preassembled clutch pack onto the clutch shaft.

Figure 30



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Snap the retaining ring into the annular groove of the clutch shaft.

Figure 31

Preload the clutch pack by means of the press and remove the clamping fixture (S). (S) Pressing bush 5870 506 116 (S) Clamping fixture 5870 654 028

Figure 32

Figure 33

Check clearance of the disc set 6.7 -0.4 mm Support the preassembled clutch on the piston and pressurize the clutch shaft with an axial force F = 9500 ±300 N. (S) Load cell 5870 700 003 (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 If the required clearance of 6.7 -0.4 mm should not be reached, there has been a measuring error at determination of the shim (Figure 16, Page 7/5), which is mandatory to be corrected!

!

Snap in both rectangular rings (see arrows) and lock them. Grease and align the rectangular rings centrically!

Figure 34



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5871 970 002 7/10

Figure 35

!

Adjust the crawler gear synchronizer (Figure 35) Assemble the crawler gear pinion until contact on the output shaft (clutch B/D) is obtained. Place the axial bearing and the shim (e.g. Thickness = 6.80 mm, empirical value) over the face of the output shaft (clutch B/D). Then measure the adjusting dimension 15 -0.1 mm, from the shim to the shoulder on the gearing. (S) Digital depth gauge 5870 200 072 If the required adjusting dimension differs, it is to be corrected with a corresponding shim! This procedure is necessary to determine Dimension „C“ in the following measuring procedure (axial clearance clutch shaft)!

Adjust the axial clearance of the clutch shaft 0.3 +0.15 mm (Figure 36 ... 39)

"C"

"A"

0,30 +0,15 mm

"B"

X Y

Figure 36



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Measure Dim. A, from the mounting face of the cover to the face of the layshaft. Dim. „A“ e.g. . . . . . . . . . . . . . . . . . . . . . . . . 239.40 mm (S) Straightedge 5870 200 022 (S) Digital depth gauge 5870 200 114 Locate the layshaft into bearing Y (see Sketch 36, Page 7/10) until contact is obtained!

Figure 37

"B"

Measure Dim. B, on the clutch shaft. Dim. „B“ e.g. . . . . . . . . . . . . . . . . . . . . . . . . 206.40 mm

Figure 38

"C"

X

Measure Dim. C, from the face of the shim (Figure 35) to the mounting face of the cover. Dim. „C“ e.g. . . . . . . . . . . . . . . . . . . . . . . . . 31.00 mm Locate the output shaft (clutch B/D) into bearing X (also see Sketch 36) until contact is obtained, with bearing play = 0!

Figure 39

Example „C“: Dim. „A“ e.g. . . . . . . . . . . . . . . . . 239.40 mm Dim. „B“ e.g. . . . . . . . . . . . . . . . . - 206.40 mm Dim. „C“ e.g. . . . . . . . . . . . . . . . . - 31.00 mm Play e.g. . . . . . . . . . . . . . . . . . . . . .- 0.30 mm Difference = Shim s = 1.70 mm



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Assemble the determined shim e.g. Thickness = 1.70 mm.

Figure 40

Assemble the needle bearing.

Figure 41

Insert the needle cage into the clutch bell housing.

Figure 42

Assemble the clutch bell housing until contact is obtained.

Figure 43



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Insert the compression spring into the layshaft.

Figure 44

Install the preassembled main clutch into the gearing of the layshaft.

Figure 45

7.2 Assembly of the Crawler Gear Shifting Assemble the needle cage on the clutch bell housing.

Figure 46

Assemble the gear until contact is obtained.

Figure 47



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!

Assemble the clutch body. Prior to installation oil the components!

Figure 48

Insert the compression spring, the ball bolts and the pressure piece (3x each) into the synchronizer body.

Figure 49

!

Preload the pressure pieces and assemble the sliding sleeve. Pay attention to align the recesses in the synchronizer body with the webs of the sliding sleeve!

Figure 50

Install the synchronizer ring on the main clutch side.

Figure 51



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Install the preassembled synchronizer body.

Figure 52

Fasten the synchronizer body by means of the circlip.

Figure 53

Insert the locking pin between gear shift shaft-5th/6th gear and gear shift shaft – crawler gear.

Figure 54

Provide the screw plug with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 20 Nm

Figure 55



Division

5871 970 002 7/16

Insert the sliding pads with grease into the bores and position the gear shift fork (crawler gear shifting).

Figure 56

!

Insert the gear shift shaft taking up the gear shift fork at the same time. Then fasten the gear shift fork by means of the threaded pins preliminarily. Align the tapped holes with the recesses of the gear shift shaft!

Figure 57

!

Install the stop consisting of ball, spring and screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 35 Nm Provide the screw plug with a new O-ring!

Figure 58

Adjust the gear shift fork to the dimension put down in writing (see Page 4/5, Figure 20). The dimension is changed by loosening and tightening both threaded pins on the gear shift fork. Tightening torque (threaded pins) . . . . . . . . MA = 34 Nm Later checking of the excess shift travel however is absolutely necessary (see Page 8/33)!

Figure 59



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Fasten the synchronizer ring by means of grease onto the clutch body.

Figure 60

Fasten the preassembled clutch body by means of grease into the synchronizer body.

Figure 61

7.3 Assembly of the Front Wheel Drive Flush-mount the balls (8x, see arrows) into the bores of the cover.

Figure 62

Install the threaded pins (3x, see arrows). Tightening torque . . . . . . . . . . . . . . . . . . . . MA = 20 Nm Wet the threads with Loctite (Type No. 270)!

Figure 63



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Insert the oil baffle into the cover bore until contact is obtained.

Figure 64

Insert the bearing outer rings (3x, see arrows) into the cover bores until contact is obtained.

Figure 65

Insert both cyl. pins into the bores until contact is obtained.

Figure 66

Assemble the washer until contact is obtained and fasten it by means of hexagon screws. Tightening torque (M 10/10.9) . . . . . . . . . . MA = 68 Nm

Figure 67



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5871 970 002 7/19

!

Insert the thrust washers with grease into the cover. Observe the installation position of the thrust washers, lugs must be inserted into the recesses of the cover (see arrows)!

Figure 68

Insert the needle cage (2x) from both sides into the double gear.

Figure 69

Insert the preassembled double gear into the cover. Then align the double gear and the thrust washers centrically.

Figure 70

!

Insert the bolt into the cover bore. Observe the installation position, see figure! After inserting of the bolt pay attention to clearance of the thrust washers!

Figure 71



Division

5871 970 002 7/20

Fasten the bolt by means of the slotted pin.

Figure 72

Install the threaded pin. Tightening torque (M 6/8.8) . . . . . . . . . . . . . MA = 5 Nm Wet the thread with Loctite (Type No. 270)!

Figure 73

Assemble the clutch bell housing and fasten it with two retaining rings on the output shaft. (S) Set of external pliers 5870 900 015

Figure 74

!

Snap the rectangular rings (2x, see arrows) into the annular grooves and lock them. Grease and align the rectangular rings centrically!

Figure 75



Division

5871 970 002 7/21

!

Press the bushes (2x) from both sides flush into the gear. Heat up the bush carrier to 120 +20 °C, bush temperature 10 +10 °C! Wet the outer diameter of the bushes with Loctite (Type No.: 648)!

Figure 76

!

Install both lip sealing rings (see arrows) and the annular groove showing to the pressure chamber (upwards). Provide the pressure bolts with new O-rings and position them (see figure). Position the pressure bolts with grease onto the piston!

Figure 77

!

Insert the piston evenly into the gear. Prior to installation oil the lip sealing rings and the O-rings!

Figure 78

Assemble the washer (optionally, e.g. 7.4 mm / empirical value).

Figure 79



Division

5871 970 002 7/22

!

Assemble the disc set starting with an outer disc. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 80

Assemble the end shim with the ground side showing downwards.

Figure 81

Fasten the disc set by means of the retaining ring. (S) Set of external pliers 5870 900 015

Figure 82

!

Insert the preassembled gear into the clutch bell housing until all outer discs are located in the teeth of the clutch bell housing. Then pull the gear cautiously out of the clutch bell housing. At this working step the discs are aligned and centered! Until the circlip (Figure 85) is snapped-in the installation position of the discs is not allowed to be changed any more!

Figure 83



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5871 970 002 7/23

Place the laminated spring with the concave side showing downwards.

Figure 84

Preload the laminated spring by means of the press, assemble the shim with the convex side showing downwards and snap the retaining ring into the annular groove. (S) Pressing bush 5870 506 117 (S) Set of external pliers 5870 900 015

Figure 85

Figure 86

Determine the clearance 1.5 … 2.5 mm Preload the end shim and the disc set respectively with a force of F = 20000 +6000 Nm and measure the stroke of the end shim (clearance) by means of the dial indicator. Clearance e.g. . . . . . . . . . . . . . . . . . . . . . . . . 1.60 mm (S) Load cell 5870 700 005 (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 If the required clearance differs this is to be corrected with an adequate shim (Figure 79, Page 7/21)!

Insert the preassembled clutch into the clutch bell housing until contact is obtained.

Figure 87



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Heat up the tapered roller bearing and assemble it on the output shaft until contact is obtained.

Figure 88

!

Snap in both rectangular rings (2x, see arrows) and lock them. Grease and align the rectangular rings centrically!

Figure 89

Assemble both screen sheets and fasten them by bending the sheet metal straps (3x).

Figure 90

Insert the preassembled output shaft into the cover until contact is obtained.

Figure 91



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Install the tube (see Arrow 1) and the bearing outer ring (see Arrow 2).

Figure 92

Fasten the O-rings (2x, see arrows) with grease into the recesses of the housing.

Figure 93

Fasten the lifting tackle (2x, see arrows) to the output shaft. Then install two adjusting screws (S) and insert the preassembled cover together with the front wheel drive into the housing. (S) Lifting tackle 5870 281 050 (S) Lifting strap 5870 281 047

Figure 94

Fasten the cover by means of hexagon screws preliminarily, do not tighten.

Figure 95

1

2



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Install the cyl. pins (2x, see arrows) into the cover and the housing respectively until contact. Then fasten the cover finally by means of hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . . MA = 117 Nm

Figure 96

Assemble the shim e.g. Thickness = 6.80 mm (see Figure 35, Page 7/10) and the axial roller cage until contact is obtained on the clutch shaft.

Figure 97

Assemble the needle cage.

Figure 98

Install the tube with the large diameter showing to the clutch shaft (to the rear).

Figure 99



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5871 970 002 7/27

Figure 100

Adjust the axial clearance of the output shaft 0.025 … 0.1 mm (Figure 100 ... 105) Put the gasket (see arrow) onto the cover. Measure Dim. I, from the plane face of the gasket to the contact face of the bearing outer ring and the shim respectively. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 26.50 mm (S) Gauge blocks 5870 200 066 (S) Straightedge 5870 200 022 (S) Digital depth gauge 5870 200 072

Figure 101

Measure Dim. II, from the mounting face of the housing to the shoulder of the output shaft. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40 mm Hold the output shaft in place! EXAMPLE „D“: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 26.50 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . + 7.40 mm Result = Dim. X = 33.90 mm

Figure 102

Measure Dim. Y (bearing width). Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 32.13 mm (S) Gauge blocks 5870 200 066 (S) Digital depth gauge 5870 200 072 EXAMPLE „E“: Dim. X e.g. . . . . . . . . . . . . . . . . . . . . . . . 33.90 mm Dim. Y e.g. . . . . . . . . . . . . . . . . . . . . . . . - 32.13 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . = 1.77 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.07 mm results in shim s = 1.70 mm

Insert the determined shim e.g. Thickness = 1.70 mm into the housing bore.

Figure 103



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Insert the bearing outer ring into the housing bore until contact.

Figure 104

!

Heat up the tapered roller bearing and mount it to the output shaft until contact is obtained. Install the bearing subsequently after cooling down!

Figure 105



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5871 970 002 8/1

8. Reassembly of the Powershift Clutches 8.1 Reassembly of Clutch A/C Insert the orifice (2x, D = 0.8) on the front-ends of the input shaft into the lubricating bore. Insert the orifices with Loctite (Type No.: 270)!

Figure 1

Seal the bores (2x) by means of threaded pin. Tightening torque (M10/8.8) . . . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!

Figure 2

Press both tapered roller bearings until contact is obtained. (S) Pressing bush 5870 506 119

Figure 3

Adjust the spur gear bearing (Clutch A) (Figure 4 … 9) Setting value = 0.7 Nm preload with max. 0.03 mm clearance Install both bearing outer rings into the bores of the spur gear until contact is obtained. Then mount the preassembled spur gear to the input shaft until contact is obtained and fasten it by means of the tapered roller bearings.

Figure 4



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Support the bearing inner ring by means of the pressing bush (S) and preload the spur gear bearing until a preliminary rolling moment of 1 Nm is obtained. 1 Nm corresponds to a traction force of approx. 22 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance 5870 230 004 (S) Pressing bush 5870 506 119

Figure 5

!

Fasten the spur gear bearing by means of the shim (optional) and retaining ring. Choose the maximum shim thickness – bearing is without clearance or almost without clearance!

Figure 6

Then press the input shaft to the direction of arrow, until the upper bearing inner ring and the shim respectively are located on the retaining ring without clearance (bearing is relieved).

Figure 7

!

Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 15.5 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 8 and 9). If the required setting value = 0.7 Nm up to max. 0.03 mm clearance differs, it is to be corrected with an adequate shim (Fig. 6)! (S) Spring balance 5870 230 004

Figure 8



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5871 970 002 8/3

(S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057

Figure 9

!

Press both needle sleeves into the bores of the piston carrier. (S) Assembly drift 5870 506 105 The exact installation position of the needle sleeves is obtained by using the specified mounting tool (S)! Check function of the purge valve (see arrow). Ball must not jam, cleaning with compressed air if necessary!

Figure 10

!

Insert spline sealing rings (2x, see arrows) into the annular grooves of the piston. Observe the installation position, see below sketch!

Figure 11

12

2

To the sketch: 1 = Piston 2 = Spline sealing ring X = Pressure chamber

Figure 12



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5871 970 002 8/4

!

Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained. Observe the installation position, see figure! If disc carriers already applied in operation are reused, observe the marking on the clutch sides „A“ or „C“, see below figure! Install the opposite piston analogously!

Figure 13

!

Install discs of clutch „A“, starting with an outer clutch disc. Then put on the end shim and snap in the circlip. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 14

Determine disc clearance 3.7 ± 0.25 mm (Figure 15 … Example „A“) Compress the disc set (downwards) and measure Dim. I, from the face of the disc carrier to the plane face of the end shim. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60 mm (S) Digital depth gauge 5870 200 072

Figure 15

Locate the end shim on the circlip until contact is obtained (pressing upwards) and measure Dim. II. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 3.85 mm

Figure 16

C

A



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5871 970 002 8/5

!

EXAMPLE „A“: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 7.60 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . - 3.85 mm Difference = Disc clearance = 3.75 mm If the required disc clearance differs, this is to be corrected with an adequate inner clutch disc! Install the opposite disc set of clutch „C“ analogously!

Snap the retaining ring into the annular groove of the input shaft and put on the axial bearing.

Figure 17

!

Install the rectangular rings (3x, see arrows). Grease the rectangular rings and align them centrically!

Figure 18

!

Mount the preassembled disc carrier first without compression spring over the input shaft and spur gear respectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the disc set in place. At this working step the clutch discs are aligned and centered thus making easier the later installation of the disc carrier!

Figure 19



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5871 970 002 8/6

Install the compression spring and the guide ring.

Figure 20

!

Mount the disc carrier as far as possible (until contact with compression spring is obtained). Hold the disc set in place and do not change the position of the disc carrier afterwards any more!

Figure 21

Install the guide ring and the compression spring.

Figure 22

Mount the axial bearing.

Figure 23



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5871 970 002 8/7

Mount the retaining ring over the input shaft.

Figure 24

Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush 5870 506 117 (S) Set of external pliers 5870 900 015

Figure 25

Snap in the upper retaining ring. (S) Set of external pliers 5870 900 015

Figure 26

!

Mount the shim and the heated tapered roller bearing. Install the bearing subsequently after cooling down!

Figure 27



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5871 970 002 8/8

Mount the needle cage until contact is obtained.

Figure 28

Press the tapered roller bearing onto the input gear until contact is obtained.

Figure 29

Insert the bearing outer ring until contact is obtained.

Figure 30

Insert the input gear until all inner clutch discs are located.

Figure 31



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5871 970 002 8/9

!

Snap in the rectangular rings (4x, see arrows) and lock them. Grease the rectangular rings and align them centrically!

Figure 32

!

Check function of the clutches „A“ and „C“ by means of compressed air. With correctly installed components opening and closing of the clutches is clearly audible!

Figure 33

8.2 Reassembly of Clutch B/D Seal the bores (2x) by means of threaded pins. Tightening torque (M10/8.8) . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!

Figure 34

Press the tapered roller bearing on the output shaft until contact is obtained.

Figure 35



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5871 970 002 8/10

!


Figure 36

!


Figure 37

12

2


Figure 38

!

Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained. Observe the installation position, see figure! Install the opposite piston analogously!

Figure 39



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5871 970 002 8/11

The respective clutch side of the disc carrier can be seen on the position of the teeth, see figure on the left! Clutch side B < D.

Figure 40

!

Install discs of clutch „B“, starting with an outer clutch disc. Then put on the end shim and snap in the circlip. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 41

!Then determine the disc clearance 3.7 ± 0.25 mm. For the procedure see Figure 15 to Example „A“ (Page 8/4)!

Assemble the needle bearing until contact is obtained.

Figure 42

D

B



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5871 970 002 8/12

!


Figure 43

!

Assemble the preassembled disc carrier first without compression spring over the output shaft and spur gearrespectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the discset in place. At this working step the clutch discs are aligned and centered thus making easier the later installation of the disc carrier!

Figure 44


Figure 45

!

Assemble the disc carrier as far as possible (until contact is obtained with the compression spring.) Hold the disc set in place and do not change the position of the disc carrier afterwards any more!

Figure 46



Division

5871 970 002 8/13


Figure 47

Assemble the axial bearing.

Figure 48

Assemble the retaining ring over the output shaft. (S) Set of external pliers 5870 900 015

Figure 49

Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush 5870 506 117 (S) Set of external pliers 5870 900 015

Figure 50



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5871 970 002 8/14

Snap in the upper retaining ring.

Figure 51

!

Adjust the spur gear bearing (Clutch D) (Figure 52 … 58) Setting value = 0.7 Nm preload up to max. 0.03 mm clearance Mount the shim Thickness = 1.5 mm and the heated tapered roller bearing. Install the bearing subsequently after cooling down!

Figure 52

Insert both bearing outer rings into the bores of the spur gear until contact is obtained and mount the spur gear.

Figure 53

Assemble the tapered roller bearing and preload the spur gear bearing until a preliminary rolling moment of 1 Nm results. 1 Nm corresponds to a traction force of approx. 13 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance 5870 230 004 (S) Pressing bush 5870 506 119

Figure 54



Division

5871 970 002 8/15

!


Figure 55

Pull the spur gear (Clutch D) upwards to the direction of arrow, until the upper bearing inner ring and the shim are located on the retaining ring without clearance (bearing is relieved). (S) Two-armed puller 5870 970 004

Figure 56

!

Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 9 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 57 and 59). If the required setting value = 0.7 Nm up to max. 0.03 mm clearance differs, it is to be corrected with an adequate shim (Fig. 55)! (S) Spring balance 5870 230 004

Figure 57


Figure 58



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5871 970 002 8/16

Unsnap the retaining ring again and remove the shim.

Figure 59

Pull the spur gear by means of the two-armed puller (S) from the output shaft. (S) Two-armed puller 5870 970 004

Figure 60

!

Install discs of clutch „D“, starting with an outer clutch disc. Then put on the end shim and snap in the circlip. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 61

!

Then determine the disc clearance 3.7 ± 0.25 mm. For the procedure see Figure 15 to Example „A“ (Page 8/4)!



Division

5871 970 002 8/17

Insert the spur gear until all inner clutch discs are located.

Figure 62

Heat up the tapered roller bearing and install it until contact is obtained.

Figure 63

!

Fasten the spur gear bearing by means of the corresponding shim and retaining ring. Then locate the spur gear and the bearing inner ring respectively on the upper retaining ring again until contact is obtained (also see Figure 56). Thus the bearing is relieved and an excessive preload is avoided!

Figure 64

!

Heat up the tapered roller bearing and install it until contact is obtained. Install the bearing subsequently after cooling down!

Figure 65



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5871 970 002 8/18

!


Figure 66

!

Check function of the clutches „B“ and „D“ by means of compressed air. With correctly installed components opening and closing of the clutches is clearly audible!

Figure 67

Install the gear and fasten it by means of the circlip.

Figure 68



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5871 970 002 8/19

8.3 Reassembly of Clutch F/G Install the sealing cap (orifice).

Figure 69

Seal the bores (2x) by means of threaded pin. Tightening torque (M10/8.8) . . . . . . . . . . . . MA = 6 Nm Insert the threaded pins with Loctite (Type No. 270)!

Figure 70

Adjust the spur gear bearing (Clutch F) (Figure 71 … 77) Setting value = 0.7 Nm preload up to max. 0.03 mm clearance Press the tapered roller bearing onto the intermediate shaft until contact is obtained. (S) Pressing bush 5870 506 119

Figure 71

Insert both bearing outer rings into the bores of the spur gear until contact is obtained. Then mount the preassembled spur gear on the intermediate shaft until contact is obtained.

Figure 72



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5871 970 002 8/20

Mount the tapered roller bearing and preload the spur gear bearing until a preliminary rolling moment of 1 Nm is obtained. 1 Nm corresponds to a traction force of approx. 22 N, measured with the spring balance. T = Rolling moment in Nm (Newtonmeter) F = Traction force in N (Newton) R = Radius in m (Meter) (S) Spring balance 5870 230 004 (S) Pressing bush 5870 506 119

Figure 73

!


Figure 74

Support the spur gear and press the intermediate shaft to the direction of arrow until the upper bearing inner ring and the shim are located on the retaining ring without clearance (bearing is relieved). (S) Parting fixture 5870 300 028

Figure 75

!

Check the bearing rolling moment max. 0.7 Nm (corresponds to a traction force of max. 15.5 N) and the axial clearance respectively max. 0.03 mm clearance (see Figure 76 and 77). If the required setting value = 0.7 Nm up to max. 0.03 mm clearance differs, it is to be corrected with an adequate shim (Fig. 74)! (S) Spring balance 5870 230 004

Figure 76



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5871 970 002 8/21


Figure 77

!


Figure 78

!


Figure 79

12

2


Figure 80



Division

5871 970 002 8/22

!

Oil the spline sealing rings and insert the piston into the disc carrier until contact is obtained. Observe the installation position, see figure! Install the opposite piston analogously!

Figure 81

The respective clutch side of the disc carrier can be seen on the position of the teeth, see figure on the left! Clutch side F > G

Figure 82

!

Install discs of clutch „F“, starting with an outer clutch disc. Then put on the end shim and snap in the circlip. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 83

!Then determine the disc clearance 3.7 ± 0.25 mm. For the procedure see Figure 15 to Example „A“ (Page 8/4)!

F

G



Division

5871 970 002 8/23

Snap the retaining ring into the annular groove of the intermediate shaft and put on the axial bearing.

Figure 84

!


Figure 85

!

Mount the preassembled disc carrier first without compression spring over the intermediate shaft and spur gear respectively, until all inner clutch discs are taken up with the teeth of the spur gear. Then remove the disc carrier again cautiously and hold the disc set in place. At this working step the clutch discs are aligned and centered thus making easier the later installation of the disc carrier!

Figure 86


Figure 87



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5871 970 002 8/24

!

Assemble the disc carrier as far as possible (until contact with the compression spring is obtained). Hold the disc set in place and do not change the position of the disc carrier afterwards any more!

Figure 88


Figure 89

Assemble the axial bearing.

Figure 90

Assemble the retaining ring as far as possible over the intermediate shaft.

Figure 91



Division

5871 970 002 8/25

Insert the disc carrier applying a slight pressure (onto the axial bearing) until all inner clutch discs are located and the retaining ring can be snapped into the lower one of the two recesses. (S) Pressing bush 5870 506 117

Figure 92

Snap in the upper retaining ring.

Figure 93

!

Install discs of clutch „G“, starting with an outer clutch disc. Then put on the end shim and snap in the circlip. Basically the outer and inner discs are to be arranged alternately! Number of discs is indicated in the respective spare parts list!

Figure 94

!

Then determine the disc clearance 3.7 ± 0.25 mm. For the procedure see Figure 15 to Example „A“ (Page 8/4)!



Division

5871 970 002 8/26

Insert the inner disc carrier until all inner discs are located.

Figure 95

!

Heat the tapered roller bearing and assemble it until contact is obtained. Install the bearing subsequently after cooling down!

Figure 96

!


Figure 97

!

Check function of the clutches „F“ and „G“ by means of compressed air. With correctly installed components opening and closing of the clutches is clearly audible!

Figure 98



Division

5871 970 002 8/27

!

Heat up the tapered roller bearing and install it until contact is obtained, Install the bearing subsequently after cooling down!

Figure 99

8.4 Reassembly of the Cover Insert clutch B/D into the housing.

Figure 100

Insert clutch F/G into the housing.

Figure 101

!

Insert clutch A/C into the housing. Observe the central position of the rectangular rings!

Figure 102



Division

5871 970 002 8/28

!

Provide the tube with a new O-ring and insert it into the housing bore until contact is obtained. Observe the installation position, see figure!

Figure 103

Insert the balls (4x, see arrows) flush into the cover bores.

Figure 104

Install two adjusting screws (S) and fasten the gasket with grease to the mounting face. Then fasten the O-rings (see arrows) by means of grease into the recesses of the housing. (S) Adjusting screws 5870 204 021

Figure 105

Locate the cover to the housing until contact is obtained and by means of hexagon screws fasten it preliminarily, do not tighten.

Figure 106



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5871 970 002 8/29

Drive the cyl. pins (2x, see arrows) into the cover and the housing respectively until contact is obtained. Then fasten the cover finally with hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . . . . MA = 117 Nm

Figure 107

!

Install the shaft seal with the sealing lip showing to the oil sump. (S) Mounting tool 5870 048 176 The exact mounting installation is obtained by use of the specified mounting tool! Immediately before assembling wet the outer diameter of the shaft seal with spirit and grease the space between sealing and dust lip with grease!

Figure 108

8.5 Adjust the Axial Clearance of the Clutches Adjust the axial clearance 0.025 … 0.075 mm of clutch B/D and F/G (Figure 109 ... 114) Insert the bearing outer ring into the cover bore.

Figure 109

Locate the clutch (B/D) by means of the puller (S). (S) Puller 5870 000 017

Figure 110



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5871 970 002 8/30

Install the bearing outer ring subsequently until contact is obtained.

Figure 111

Measure Dim. I, from the mounting face of the cover to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.90 mm (S) Digital depth gauge 5870 200 072

Figure 112

Figure 113

Measure Dim. II, from the contact face of the shim to the mounting face of the cover. Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 mm EXAMPLE „B“: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 5.90 mm Dim. II e.g. . . . . . . . . . . . . . . . . . . . . . . . + 4.10 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . = 1.80 mm Axial clearance e.g. . . . . . . . . . . . . . . . . - 0.05 mm results in shim s = 1.75 mm

Insert the determined shim e.g. Thickness = 1.75 mm into the cover bore.

Figure 114



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5871 970 002 8/31

Grease the O-rings (3x, see arrows) and insert them into the recesses of the cover.

Figure 115

!

Mount the cover and locate it evenly until contact is obtained by means of hexagon screws. Tightening torque (M10/8.8) . . . . . . . . . . . . MA = 46 Nm Observe the central position of the rectangular rings! Adjust axial clearance 0.025 … 0.075 mm of clutch F/G analogously to clutch B/D and install the cover (repeat procedureFigure 104 … 116).

Figure 116

Adjust the axial clearance 0.025 … 0.075 mm of Clutch A/C Figure 117 ... 120 Insert the bearing outer ring into the cover bore.

Figure 117

Insert shim e.g. Thickness = 1.95 mm (empirical value) into the cover bore.

Figure 118



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5871 970 002 8/32

Snap the retaining ring into the annular groove of the cover.

Figure 119

!

Locate the bearing outer ring on the retaining ring until contact and check the axial clearance 0.025 … 0.075 mm. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 If the required axial clearance differs, it is to be corrected with an adequate shim (Figure 118)!

Figure 120

!

Install the shaft seal with the sealing lip showing to the oil sump. (S) Mounting tool 5870 048 175 The exact mounting installation is obtained by use of the specified mounting tool! Immediately before assembling wet the outer diameter of the shaft seal with spirit and grease the space between sealing and dust lip with grease!

Figure 121

!

Insert both speed transmitters into the housing bores and fasten them by means of cap screw. Tightening torque (M8/8.8) . . . . . . . . . . . . . MA = 23 Nm Provide speed transmitters with a new O-ring and grease them!

Figure 122



Division

5871 970 002 8/33

Figure 123

!

8.6 Adjust the Excess Shift Travel of the Crawler Gear Shifting Install the measuring lever (S). Shift the gear shift shaft alternately into the shifting position „Crawleer gear – On“ and „Normal group – On“ respectively and check the excess shift travel by means of the dial indicator. (S) Measuring lever 5870 200 087 (S) Dial indicator 5870 200 057 (S) Magnetic stand 5870 200 055 Excess shift travel must be the same in both shift positions! The excess shift travel is changed by loosening and tightening alternately both threaded pins on the gear shift fork (see below figure)! Observe the tightening torque of both threaded pins MA = 34 Nm! Then remove the measuring lever again.

Figure 124



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9. Reassembly of the Pump Drive and Attachment of the Electro-Hydraulic Control 9.1 Reassembly of the Pump Drive Install the ball ø 12 mm (Arrow 1), ø 8.5 mm (Arrow 2) and ø 6.5 mm (Arrow 3). After insertion of the balls ø 6.5 mm and 8.5 mm equalize the protruding casting by means of a touch-up!

Figure 1

Install the threaded pins (2x). Tightening torque (M8) . . . . . . . . . . . . . . . MA = 6 Nm Wet threads of the threaded pins with Loctite (Type No.: 270)!

Figure 2

Install the threaded pin. Tightening torque (M14) . . . . . . . . . . . . . . MA = 20 Nm Wet threads of the threaded pins with Loctite (Type No.: 270)!

Figure 3

Provide the screw plugs (2x, see arrows) with a new O-ring and install them. Tightening torque (M18x1.5) . . . . . . . . . . MA = 50 Nm Tightening torque (M22x1.5) . . . . . . . . . . MA = 60 Nm

Figure 4

1

2

3



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Provide the bolt connection with a new O-ring and install it. Tightening torque (M18x1.5) . . . . . . . . . . . MA = 40 Nm

Figure 5

Insert the sealing disc into the housing bore and fasten it by dishing. Wet the contact faces with Loctite (Type No.: 270)!

Figure 6

!

Cold start safety valve (Figure 7 and 8) Insert the valve cone, compression spring and shim (Thickness = 3.2 mm / empirical value) into the housing bore. The shim determines the opening pressure of p = 27+3 bar. If deviations should occur at the final test run this is to be corrected with an adequate shim!

Figure 7

Provide the screw plug with a new O-ring and install it. Tightening torque (M26x1.5) . . . . . . . . . . MA = 80 Nm

Figure 8



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Insert both O-rings (see arrows) by means of grease into the recesses of the flange. Provide the bolt connection with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 100 Nm

Figure 9

Attach the preassembled flange by means of cap screws to the housing. Tightening torque (M8/8.8) . . . . . . . . . . . . MA = 23 Nm

Figure 10

Insert the ball bearing with the closed bearing side showing upwards (to the spur gear) into the lower bearing bore.

Figure 11

Insert the spur gear into the housing and position it.

Figure 12



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Press the ball bearing with the closed bearing side showing to the gearing (downwards) onto the bush until contact is obtained.

Figure 13

Heat up the lower ball bearing (bearing inner ring) and insert the bush together with the bearing until contact is obtained.

Figure 14

Snap the retaining ring into the inner annular groove of the bush. (S) Set of internal pliers 5870 900 013

Figure 15

Adjust the axial clearance of the spur gear bearing max. 0.4 mm (Figure 16 ... 18) Put on the gasket and measure Dim. I from the mounting face to the face of the bearing outer ring. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 10.55 mm (S) Digital depth gauge 5870 200 072

Figure 16



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Figure 17

Measure Dim. II, from the contact face to the mounting face of the pump. Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 mm EXAMPLE „A“: Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . 10.55 mm Dim. I e.g. . . . . . . . . . . . . . . . . . . . . . . . . - 7.18 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . . = 3.37 mm Axial clearance e.g. . . . . . . . . . . . . . . . . . - 0.17 mm Results in shim e.g. Thickness = 3.20 mm

Put the shim e.g. Thickness = 3.20 mm into the housing bore.

Figure 18

Snap the retaining ring into the annular groove of the bushing. (S) Set of internal pliers 5870 900 013

Figure 19

Insert the bushing into the teeth until contact is obtained.

Figure 20



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Grease the O-ring (see arrow) and insert it into the annular groove of the housing bore.

Figure 21

!

Adjust the axial clearance on the elbow 0.1 … 0.3 mm (Figure 22 … 27) Put on the gasket and fasten the flange by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm Attach the flange on the suction side (larger bore diameter)!

Figure 22

Grease the O-Ring (see arrow) and insert it into the annular groove.

Figure 23

Insert the elbow into the flange until contact is obtained.

Figure 24



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Install two adjusting screws (S) and assemble the gasket. Then insert the pump and fasten it by means of cap screws. Tightening torque (M8/8.8) . . . . . . . . . . . . MA = 23 Nm

Figure 25

Figure 26

Measure the gap size between pump housing and elbow by means of a feeler gauge. Gap size, e.g. . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm (S) Feeler gauge 5870 200 113 EXAMPLE „B“: Gap size . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 mm Axial clearance e.g. . . . . . . . . . . . . . . . - 0.10 mm Results in shim e.g. Thickness = 1.90 mm Then remove the pump again.

!

Assemble the shim e.g. Thickness = 1.90 mm on the elbow. Pump can only be installed after attachment of the pump housing and the hydraulic control to the transmission housing!

Figure 27

Snap the circlips (see Arrows 1) into the annular grooves of the oil tube. Then grease the O-rings (see Arrows 2) and install them.

Figure 28

2 1

1 2



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Insert the oil tube into the housing bore until contact is obtained.

Figure 29

Insert the hexagon screws (4x) into the elbow. Then mount the elbow on the oil tube until contact is obtained.

Figure 30

!

Install the ball (see arrow), heat up the bearing inner ring and mount it on the bearing bracket until contact is obtained. Install the bearing subsequently after cooling down!

Figure 31

Insert both bearing outer rings into the spur gear bores until contact is obtained. Then put on the preassembled spur gear.

Figure 32



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Heat up the bearing inner ring and assemble it until contact is obtained.

Figure 33

Adjust axial clearance of the spur gear bearing = 0.25 … 0.75 mm (Figure 34 and 35) Fasten the spur gear by means of the shim (e.g. Thickness = 2.00 mm, empirical value) and the retaining ring.

Figure 34

!

Locate the upper bearing inner ring on the retaining ring and check the axial clearance of the spur gear bearing. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 If the required axial clearance (0.25 … 0.75 mm) differs it is to be corrected with an adequate shim (Figure 34)!

Figure 35

Locate the bearing bracket by means of hexagon screws and insert both cyl. pins until contact is obtained. Then tighten the hexagon screws. Tightening torque (M12/10.9) . . . . . . . . . . MA = 117 Nm

Figure 36



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!

Place the strainer insert and the bush into the housing bore. Install the strainer insert with the convex surface showing to the outside!

Figure 37

Install two adjusting screws (S) and assemble the first gasket. (S) Adjusting screws 5870 204 011

Figure 38

Assemble the intermediate sheet and the second gasket.

Figure 39

Assemble the housing and fasten it by means of hexagon screws. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm

Figure 40



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Snap the retaining ring into the inner annular groove of the bush. (S) Set of internal pliers 5870 900 013

Figure 41

Insert the bushing into the teeth until contact is obtained. Provide the screw plug (see arrow) with a new O-ring and install it. Tightening torque (M10x1) . . . . . . . . . . . MA = 25 Nm

Figure 42

Install two adjusting screws (S) and assemble the gasket. (S) Adjusting screws 5870 204 007

Figure 43

Place the pump drive firmly against the transmission housing.

Figure 44



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Insert both cyl. pins (see arrows) until contact is obtained and fasten the pump drive by means of hexagon screws. Tightening torque (M10/8.8) . . . . . . . . . . MA = 46 Nm

Figure 45

Insert a new O-ring into the annular groove of the oil tube, position the oil tube and install the bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 80 Nm

Figure 46

Install the screw plug. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 80 Nm

Figure 47

Preassemble the filter as shown in the figure on the left. 1 = Rod 2 = O-Ring 3 = Housing 4 = O-Ring 5 = Flat gasket 6 = Insert 7 = Strainer

Figure 48

7

6

5

4

3

1 2



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Install the filter. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 +10 Nm

Figure 49

The figure on the left shows the components of the solenoid valve (Connection Front Wheel Drive). 1 = Valve 2 = Solenoid 3 = O-Ring 4 = Nut

Figure 50

!

Install the components of the solenoid valve (Connection Front Wheel Drive). Tightening torque (Valve) . . . . . . . . . . . . MA = 30 Nm Tighten the nut by hand!

Figure 51

Provide the temperature transmitter (transmission oil temperature) with a new O-Ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 20 Nm Tightening of the temperature transmitter is only allowed by means of socket wrench (adapter), not with an open end wrench!

Figure 52

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2 3 4



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!

Insert the speed transmitter (Main Clutch Output) into the housing bore and fasten it by means of the cap screw. Tightening torque (M8/8.8) . . . . . . . . . . . MA = 23 Nm Provide the speed transmitter with a new O-ring and grease it!

Figure 53

The figure on the left shows the components of the solenoid valve (Proportional Valve – Main Clutch). 1 = Valve 2 = Solenoid 3 = O-Ring 4 = Nut

Figure 54

Install the valve. Tightening torque (Valve) . . . . . . . . . . . . MA = 10 Nm

Figure 55

!

Assemble the solenoid and the O-ring and fasten it by means of the nut. Tighten the nut by hand!

Figure 56

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2 3 4



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9.2 Attachment of the Electro- Hydraulic Control The sketch on the left shows the position of the screws and the adjusting screws (S). (S) Adjusting screws „D“, Ø 8.5 mm 5870 204 057 (S) Adjusting screws „C“, Ø 8.8 mm 5870 204 058

“C”

“D”

Figure 57

Install adjusting screws „D“ at Item 37, 38 and 39, adjusting screws „C“ at Item 40. (S) Adjusting screws „D“, Ø 8.5 mm 5870 204 057 (S) Adjusting screws „C“, Ø 8.8 mm 5870 204 058

Figure 58

Assemble gasket, intermediate sheet and gasket.

Figure 59

„D“

„C“



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!

Install the components (Figure 60 and 61), if required. 1 = Ball, shim and O-ring 2 = Orifice 3 = Ball and compression spring Fasten the O-Ring with grease!

Figure 60

Figure 61

Assemble the duct plate.

Figure 62

Fasten the duct plate by means of cap screws and shims (Item 1 … 9 and 18). Tightening torque (M8x35) . . . . . . . . . . . MA = 23 Nm

Figure 63

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1

3



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9.3 Attachment of the Forward-Reverse Control Block Assemble the gasket.

Figure 64

Assemble the intermediate sheet and the gasket.

Figure 65

Assemble the control block (cpl.).

Figure 66

!

Fasten the control block by means of cap screws and washers. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 Nm Observe the order for tightening of the screws „from the right to the left“, removing the adjusting screws (S)!

Figure 67



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9.4 Attachment of the 4-Speed Powershift Control Block Assemble the gasket.

Figure 68

Assemble the intermediate sheet and the gasket.

Figure 69

Insert the stop plate with grease into the valve housing.

Figure 70

Mount the 4-speed control block (cpl.).

Figure 71



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!

Fasten the control block by means of cap screws and washers. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 23 Nm Observe the order for tightening of the screws „from the right to the left“, removing the adjusting screws (S)!

Figure 72

Provide the pressure switch (see arrow) with a new O-ring and install it. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 9.5 Nm

Figure 73

Install the tube (see arrow). Tightening torque . . . . . . . . . . . . . . . . . . . MA = 100 Nm

Figure 74



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9.5 Attachment of the Pump Install two adjusting screws (S) and assemble the gasket.

Figure 75

!

Insert the pump. Pay attention to shim on the elbow!

Figure 76

Fasten the pump by means of cap screws. Tightening torque (M8/8.8). . . . . . . . . . . . MA = 23 Nm

Figure 77

Install the gasket (use grease) and fasten the elbow by means of hexagon screws. Tightening torque (M8/8.8). . . . . . . . . . . . MA = 23 Nm

Figure 78



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10. Attachment of the Transmission to the Rear Axle Snap both circlips (see arrows) into the annular grooves of the shaft.

Figure 1

Insert the shaft into the teeth of the pump gear drive.

Figure 2

Insert the sealing cap (orifice) into the bolt connection and press it until contact is obtained.

Figure 3

Install the bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . . MA = 285 Nm Observe the installation position. Install the bolt connection with the orifice showing to the direction of arrow!

Figure 4



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Presassemble the components as shown in the figure on the left. 1 = T-Adapter 2 = Plug 3 = Union nut 4 = Reducer 5 = Union nut Tightening torque . . . . . . . . . . . . . . . . . . MA = 300 Nm

Figure 5

Install the preassembled bolt connection. Tightening torque . . . . . . . . . . . . . . . . . . MA = 300 Nm

Figure 6

Install two adjusting screws and assemble the gasket. (S) Adjusting screws 5870 204 023 Observe the marking on the rear axle housing – flange (see arrow)! Flange marked with „0“ – use gasket with one recess (s = 0,20 mm)! Flange marked with „0 0“ – use gasket with two recesses (s = 0,25 mm)!

Figure 7

00

1

2

To the sketch: 1 = Marking on the rear axle housing 2 = Recess on the gasket

Figure 8

1

2

3

4 5



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Place the transmission by means of lifting tackle against the rear axle housing until contact is obtained. (S) Lifting chain 5870 281 047

Figure 9

Fasten the transmission by means of hexagon screws and hexagon nuts. Tightening torque (M16/10.9) . . . . . . . . . MA = 280 Nm

Figure 10

Install the oil tube.

Figure 11

Install the oil tube. Prior to commissioning of the unit make an oil filling in accordance with the operating instructions 5872 979 001!

Figure 12

Transmission T-7336 Ps

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Transcript of Transmission T-7336 Ps