16S251 Gear Box Kerax DXI

RENAULT TRUCKS
32 658 - GB -
01/2005
GEARBOX ZF 16S251
RANGE
FAMILY
VARIANT
33G P 6X4
33GG P 6X4
33K T 6X4
RENAULT KERAX
33KK T 6X4
150EQ
33M P 6X6
33MM P 6X6
33N T 6X6
33NN T 6X6
The above information may change in the course of time. Only the "Consult" section of the workshop manuals
repertory in standard N 10320 serves as reference.
32 658
32.6
32.6 . . . .
32.6 . . . .
50 21 014 238
32 658
CONTENTS
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 5
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1-2 13
How to use the tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-1 11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1 9
Disassembly / assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 9
Range change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-2 17

Gearshift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1 2
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1 22
Clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-1 13
Main casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-1 9
Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-1 11
Synchromesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7-1 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8-1 4
Checking the pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9-1 1
RENAULT TRUCKS SA 01/2005 - Imprim en France - le 02/2005
50 21 014 238
32 658
GENERALITIES
RENAULT TRUCKS
01/2005
A-1
32 658
A-2
Repair manual
16 S 251
NOTE: If clamping fixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover
before attaching the clamping fixture.
When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set.
Then install the reverse idler gear pin.
RENAULT TRUCKS
01/2005
32 658
Important information
SAFETY NOTICE
GENERAL INFORMATION
Companies who repair ZF units are responsible for their

own work safety.
Read this manual carefully before starting any tests or

repair work.
To avoid injury to personnel and damage to products, all safety regulations and legal requirements
which apply to repair and maintenance work must
be adhered to.
Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on ZF products
must receive appropriate training in advance. It is the
responsibility of each company to ensure that their
repair staff is properly trained.
The following safety instructions appear in this

manual:
NOTE
Refers to special processes, techniques, data, use
of auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional
working practices could damage the product.
! DANGER
This is used when lack of care could lead to
personal injury or death.
CAUTION
Pictures, drawings and components do not always
represent the original object, but are used to illustrate
working procedures.
Pictures, drawings and components are not to scale
and no information about size and weight should be
inferred (even within a complete illustration).
Always follow the working steps as described in the
text.
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
correctly.
! THREATS TO THE ENVIRONMENT !
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water or sewage system.
Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants
and cleaning agents in accordance with
environmental protection guidelines.
When working with lubricants and cleaning
agents always refer to the manufacturers
instructions.
CAUTION
The transmission must NOT be hung on the
input shaft NOR on the output flange.
RENAULT TRUCKS
01/2005
A-3
32 658
A-4
Instructions for carrying out repairs

In any cases of doubt always turn to the the relevant
department within ZF After-Sales Services for
advice.
After removing the transmission from the vehicle clean

thoroughly before opening.
Pay particular attention to the corners and angles of
housings and covers when cleaning.
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower.
GASKETS, LOCKING PLATES

Parts which cannot be removed without being damaged
must always be replaced with new parts (e.g. gaskets
and locking plates).
SHAFT SEALS
Always change shaft seals with rough, ripped or
hardened packing washers. Seal contact surfaces must
be totally clean and in perfect condition.
CLEANING PARTS
Remove the old remains of gaskets on all gaskets.
Carefully remove burrs or other similar patches of
roughness using a oil-stone
Lube bores and grooves must be free of anti-corrosion
agents and foreign matter, check that they can move
without encountering any problems.
Carefully cover opened transmissions to prevent the
entry of foreign matter..
REWORKING
Rework may only be carried out on the seal contact
surfaces using plunge-cut grinding, never use an emery
cloth. Ensure that there are no traces of grinding traces
or rifling from grinding.
If rework is needed on distance washers, shims etc.
because of clearance settings, ensure that the reworked
areas contain no face runout and have the same surface
quality.
REUSING PARTS
TRANSMISSION ASSEMBLY
Parts such as ball or roller bearings, multi-discs, thrust
washers etc., must be inspected by a competent person,
who should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered from
excessive wear.
Find a clean site to assemble the transmission. Gaskets

are installed without the use of sealing compound or
grease. When measuring silicon-coated gaskets, take
care not to include the silicon layer in the measurement.
During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.
RENAULT TRUCKS
01/2005
32 658
A-5
Instructions for carrying out repairs

BEARINGS
If the bearings are filled while hot, these should be
warmed up accordingly (e.g. in a heating cabinet).
The temperature should be approx. 85 C and may not
exceed 120 C. All bearings must be coated with transmission oil after assembly.
d) Duo shaft seals have two packing

washers. The dust-proof packing
washer (X) must face outwards.
X
e) Fill the gap between the packing

washers so it is 60% filled with grease (use a grease
e.g. produced by Aral such as Aralub HL2 or by
DEA such as Spectron FO 20).
f) If possible heat shaft seal bores to between 40 and
50C (this makes fitting easier). Press the seal shaft
with mounting or faceplate onto the relevant installation depth plan.
SEALING
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturers directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing to enter oil ducts
and bores. On oil-carrying ducts and bores wipe off the
sealing agent on the surfaces to be sealed near apertures
to ensure that no sealing agent penetrates the oil feeds
when the surfaces are sealed.
RETAINING AGENTS
Retaining agents* may only be used in places as
specified in the parts list.
Always comply with manufacturers directions for use
when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAFT SEALS
a) Apply a light coat of sealing agent on outer edge of
shaft seals with steel surround.
b) Never apply sealing agent to shaft seals with
rubber surround but apply a thin coat of Vaseline
8420 to the outer edge or wet with a lubricant, e.g. a
water-soluble, concentrated washing-up liquid (e.g.
Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber surrounds should be
treated on the outer edge of the rubber surround as
described above in section b).
TRANSMISSION OIL
After completing repairs, fill the transmission with
transmission oil. For the procedure and approved oils,
refer to the transmission operating manual and List of
Lubricants TE-ML (refer to identification plate) which
are available from any ZF After-Sales Service Point.
After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
specified torques.
* refer to expendable material
RENAULT TRUCKS
01/2005
A-6
32 658
RENAULT TRUCKS
01/2005
32 658
TECHNICAL DATA
RENAULT TRUCKS
01/2005
B-1
32 658
B-2
Tightening torques
Tightening torques for nuts and bolts, extract from
ZFN 148
This Standard applies for bolts to DIN 912, DIN 931,
DIN 933, DIN 960, DIN 961 and for nuts to DIN 934.
This Standard contains data on tightening torques (MA)
for bolts in strength categories 8.8, 10.9 and 12.9 and
nuts in strength categories 8, 10 and 12.
Surface condition of bolts: heat-treated blackened

finish and oiled or galvanized and oiled or galvanized,
chrome-plated and oiled.
This Standard contains data on tightening torques (MA)
for bolts in strength categories 8.8, 10.9 wrench.
NOTE
Divergent tightening torques are listed separately in the
Repair Manual.
Metric coarse pitch thread
Metric coarse pitch thread
Size
Size
Bolt
Nut
M 4
M 5
M 6
Tightening torque
MA (Nm) for
8.8
10.9
8
10
2,8
5,5
9,5
Tightening torque
MA (Nm) for
8.8
10.9
8
10
12.9
12
Bolt
Nut
12.9
12
4,1
8,1
14
4,8
9,5
16,5
M 8x1
M 9x1
M 10 x 1
24
36
52
36
53
76
43
62
89
M 7
M 8
M 10
15
23
46
23
34
68
28
40
79
M 10 x 1,25
M 12 x 1,25
M 12 x 1,5
49
87
83
72
125
122
84
150
145
M 12
M 14
M 16
79
125
195
115
185
280
135
215
330
M 14 x 1,5
M 16 x 1,5
M 18 x 1,5
135
205
310
200
300
440
235
360
520
M 18
M 20
M 22
280
390
530
390
560
750
460
650
880
M 18 x 2
M 20 x 1,5
M 22 x 1,5
290
430
580
420
620
820
490
720
960
M 24
M 27
M 30
670
1000
1350
960
1400
1900
1100
1650
2250
M 24 x 1,5
M 24 x 2
M 27 x 1,5
760
730
1100
1100
1050
1600
1250
1200
1850
M 27 x 2
M 30 x 1,5
M 30 x 2
1050
1550
1500
1500
2200
2100
1800
2550
2500
RENAULT TRUCKS
01/2005
32 658
B-3
Tightening torques
Screw plugs DIN 908, 910 and 7604
Union screws DIN 7643
The screw plug tightening torques MA were determined

according to DIN 7604, for screwing into steel, grey
cast, and aluminium alloys.
The values are based on experience, and are
intended as reference values for the designer.
The values for the tightening torque MA shall also be
used for screw plugs according to DIN 908 and
DIN 910, as the thread geometries are almost identical.
General rule: Screw/bolt class 5, ZFN 148-1
Screw/bolt material: steel acc. to
DIN 7604. Surface condition: as manufactured (without surface protection) and
lightly oiled or galvanized, chromated
and lightly oiled
The tightening torques MA were determined for

screwing into steel, grey cast and aluminium alloys.
The values are based on experience and are intended as
reference values for the designer.
General rule: screw/bolt class 5, ZFN 148-1
Material 9SMnPb28K acc. to DIN 1651
Surface conditions: as manufactured
(without surface protection) and lightly
oiled or galvanized, chromated and
lightly oiled
Screw plugs (DIN 908, 910, 7604)

Dimensions
M 8x1
M 10 x 1
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
M 18 x 1.5
M 20 x 1.5
M 22 x 1.5
M 24 x 1.5
M 26 x 1.5
M 27 x 2
M 30 x 1.5
M 30 x 2
M 33 x 2
M 36 x 1.5
M 38 x 1.5
M 42 x 1.5
M 42 x 2
M 45 x 1.5
M 45 x 2
M 48 x 1.5
M 48 x 2
M 52 x 1.5
M 60 x 2
M 64 x 2
Tightening torque
screwed into
steel/grey cast
Al alloy
20
25 / 30*
35
35
40
50
55
60 / 80*
70
80 / 105*
80
100 / 130*
95
120
130
140
150
145
160
150
170
160
180
195
205
* DIN 7604 Form C
RENAULT TRUCKS
Union screws (DIN7643)
01/2005
10
15 / 20*
25
25
30
35
45
50 / 65*
60
70 / 90*
70
90 / 130*
85
110
115
120
130
125
140
130
145
135
150
165
175
Pipe
outer
diameter
Thread
Tighteningtorque MA
in Nm
4-5
M8x1
30
M 10 x 1
35
M 12 x 1.5
40
10
M 14 x 1.5
40
12
M 16 x 1.5
45
15
M 18 x 1.5
50
18
M 22 x 1.5
60
22
M 26 x 1.5
90
28
M 30 x 1.5
130
35
M 38 x 1.5
140
32 658
B-4
Adjustment data
16 S 251
Description
Tolerance
Measuring device
Remarks
01. Axial play on layshaft
0.0 - 0.10 mm
Depth gauge or dial

gauge
Centre bearings (zero play)

and measure play. Adjust
using shims on roller bearing
outer race on output end.
02. Combined axial play of

mainshaft and input shaft
0.0 - 0.10 mm
Depth gauge or dial

gauge
Centre bearings (zero play)

and measure play. Adjust
using shims on roller bearing
outer race on input shaft.
03. Axial play / prestress of

split ring on input shaft
and mainshaft (only in
older version)
- 0.05 to + 0.05 mm
Micrometer or feeler
gauge
Always use correct tool.
Depth gauge and/or

drift 1X56 137 124
Measure depth of insertion

between outside of cover and
face of shaft seal. If drift is
used with ring, depth is automatically given (must be
flat).
12.5 + 1.0 mm
04. Insertion depth for shaft
seal in output flange cover
05. Axial play on ball bearing

in cover (range-change)
0 - 0.10 mm
Depth gauge/sliding
caliper
Adjust using appropriate

shims in cover.
06. Axial play on helical gear

on input shaft
Min. 0.20 mm
Depth gauge or feeler

gauge
Not adjustable. Measure as

check only.
07. Axial play on helical

gears on mainshaft
Min. 0.20 mm

gauge

check only.
08. Axial play on 4th-speed

helical gear
Min. 0.05 mm

gauge

check only.
09. Axial play on circlips on

layshaft and mainshaft
0 - 0.05 mm
Micrometer or feeler
gauge
Use appropriate circlip.
10. Axial play of reverse idler

gear
0.4 - 1.10 mm
Feeler gauge

check only.
11. Permitted axial play on

planet gears in planet carrier
0.4 to 1.30 mm
Feeler gauge
Tolerance includes permitted wear on thrust washers.

If wear limit exceeded
exchange thrust washers
RENAULT TRUCKS
01/2005
32 658
16 S 251
B-5
Adjustment data
Description
Tolerance
12. Wear limit for synchronizer ring and clutch body,

measured between flat
surfaces of ring and body
with cones firmly nested
together.
4-gear section and
splitter
Range-change
Measuring device
Remarks
Feeler gauge
Exchange synchronizer ring

and/or clutch body if dimension too small
0.80 mm
1.20 mm
13. Wear limit for 1st/2nd

gear synchronizer parts,
measured between outer
ring and clutch disc,
measured with cones
nested firmly together
and force F = 50 N
applied on the outer ring.
1.5 mm
Feeler gauge
Exchange intermediate ring

and/or outer ring and inner
ring if wear limit is excluded.
14. Max. permitted play on

fulcrum pads in sliding
sleeves
0.6 - 1.2 mm
Feeler gauge
Exchange if play is excessive
15. Adjusting mainshaft and

determining thickness of
ring and shim
+ 0.07 to - 0.08 mm
(Shim)
4.6 -0.4 mm
(Ring)
Depth gauge
Measure and determine

thickness of shim first. Then,
measure and select ring.
16. Temperature for shrinkfitting helical gears onto

layshaft
160 - 180C
Temperature probe
Gears and shaft seats must

be free of oil and grease
during assembly
17. Tightening torque for

breather
10 Nm
Torque wrench

M12 x 1.5 screws in
housing
30 Nm
Torque wrench
Use new seal rings
19. Tightening torque of

union screws for plastic
pipes
35 Nm
Torque wrench
Use new seal rings
RENAULT TRUCKS
01/2005
32 658
B-6
Adjustment data
16 S 251
Description
Tolerance
Measuring device
Remarks

detent plungers
50 Nm
Torque wrench
Use new seal rings

pressure switch/impulse
sensor
50 Nm
Torque wrench
Use new seal rings
22. Tightening torque of M12

bolts for output flange
120 Nm
Torque wrench
Fit new retaining plate.

Use Loctite No. 262.
23. Tightening torque for shift 4-gear section: 50 Nm

fork grub screws
Splitter:
60 Nm
Torque wrench
24. Tightening torque "M24 x

1,5 magnetic screw"
Torque wrench
Clean magnet and fit new

seal ring
Torque wrench
Use new locking nut
60 Nm
150 Nm
locking nuts on rangechange and splitter pistons
26. Tightening torque for hex
bolts between clutch housing and mid-housing
50 Nm
Torque wrench
27. Tightening torque for hex

bolts between mid-housing and GP housing
50 Nm
Torque wrench
Use new seal rings

M18 x 1.5 screw plugs on
housing
35 Nm
Torque wrench
Use new seal rings

housing
50 Nm
Torque wrench
Use new seal rings

housing
60 Nm
Torque wrench
Use new seal rings
31. Heating temperature for

ring gear
60C
Temperature probe
Do not exceed temperature
32. Temperature of synchronizer hub, clutch body,

bushes and counting disc
120C
Temperature probe
RENAULT TRUCKS
01/2005
32 658
16 S 251
B-7
Adjustment data
Description
Tolerance
Measuring device
Remarks
33. Temperature of output

flange
max. 70C
Temperature probe
34. Temperature of input shaft 100C

roller bearing
Temperature probe
35. Temperature of 4th-speed

helical gear with needle
cages on mainshaft
120C
Temperature probe
36. Rolling-in torque for

injection pipe
5 -6 Nm
Torque wrench
Rolling-in tool
1X56 155 653
37. Lifting device for input

shaft/ mainshaft/ layshaft
85 Nm
Torque wrench
DANGER
Fit lifting device carefully

pivot bolts on shift fork
250 Nm
Torque wrench
Use Loctite No. 241
39. Tightening torque for M8

hex bolts on shift cover
23 Nm
Torque wrench

M10 hex bolts on shift
lever
49 Nm
Torque wrench

hex bolts on shift housing
cover (with detent piece)
23 Nm
Torque wrench

hex bolts on cutoff valve
23 Nm
Torque wrench
43. Tightening torque hollow

screws/Servoshift
20 Nm
Torque wrench
44. Tightening torque hex

screws M8x80/Servoshift
23 Nm
Torque wrench
45. Tightening torque screw

plugs M22x1,5 shift
turret/Servoshift
60 Nm
Torque wrench
RENAULT TRUCKS
01/2005
Use new sealing rings.
Use new sealing rings.
32 658
B-8
Adjustment data
Description
16 S 251
Tolerance
Measuring device

23 Nm
screws M8x30 shift turret/
Servoshift
Torque wrench
47. Tightening torque switch

shift turret/ Servoshift
50 Nm
Torque wrench
48. Tightening torque hex scr- 23 Nm

ews M8x65 cut off valve
Torque wrench

49 Nm
screws M10x65 shift lever
Torque wrench
50. Permitted axial play on

mainshaft/planetary drive
Measuring bush
1X56 138 158
0.05 mm
Remarks
Use new sealing ring.
Adjust using appropriate

shim
RENAULT TRUCKS
01/2005
32 658
B-9
16 S 251
Table of springs
Part number
Installation point
RENAULT TRUCKS
No. of
windings
Wire diam.
in mm
Spring diam. Untensioned

in mm
length in mm
77 01 007 805
synchr./planet carrier
18.5
1.25
6.25
34.2
50 00 255 277
synchr./planet carrier
35.5
0.70
3.2
34.7
50 00 242 857
synchronization
drive shaft and main shaft
12.5
1.40
6.65
23.7
50 00 240 495
blocking pin interlock
13.5
1.60
9.8
36.0
50 01 848 893
shift system/Servoshift
7.5
1.80
26.1
50.5
50 00 456 234
6.5
2.00
14.4
23.4
50 00 815 358
R-gear interlock/
selector housing
5.5
2.25
14.8
21.6
50 01 850 732
5.1
2.10
39.0
70.0
50 00 272 944
selector housing
8.0
2.00
27.0
77.7
RENAULT TRUCKS
01/2005
B-10
32 658
RENAULT TRUCKS
01/2005
32 658
TOOLS
RENAULT TRUCKS
01/2005
C1-1
32 658
C1-2
Description
Generalities
RENAULT TRUCKS divide tools into three categories:
General-purpose tools: proprietary tools.
50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department).
4-figure reference number (tools classified by RENAULT TRUCKS but available from the supplier).
Special tools: specifically created tools distributed by the RENAULT TRUCKS Spare Parts Department.
Locally manufactured tools: these tools are classified differently according to their degree of
sophistication:
4-figure reference number (represented by a drawing): tools that are simple to make without need for
special qualification.
50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department): a certain amount of skill is needed to make these tools.
Three levels (or echelons) determine their assignment:
Level 1: tools for servicing, maintenance and minor tasks.
Level 2: tools for major repairs.
Level 3: tools for refurbishment.
Proprietary tools mentioned in this manual do not appear in the tools list.
These tools are identified in the standard tools manual (MO) by a 4-figure number.
RENAULT TRUCKS
01/2005
32 658
C1-3
Equivalents table
The standardization of tools leads us to have to extend RENAULT TRUCKS tools to major units.
An equivalence table serves to determine the RENAULT TRUCKS tools that are to replace the tools stipulated
in the document.
The use of RENAULT TRUCKS tools requires the compulsory replacement of all bearings.
ZF part N
RENAULT TRUCKS part N
1 x 20 155 653
50 00 26 2460
1 x 56 103 766
50 00 26 3016 + 50 00 26 2363
1 x 56 119 916
50 00 26 2363 + 50 00 26 3016
1 x 56 119 916
50 00 26 2351 + 50 00 26 3016
1 x 56 122 303
Hydraulic press
1 x 56 122 304
50 00 26 0827 + Hydraulic press
1 x 56 122 304
1 x 56 122 310
1 x 56 122 314
50 00 26 0845
1 x 56 136 564
3241
1 x 56 136 710
1 x 56 136 722
Hydraulic press
1 x 56 136 743
1 x 56 136 756
1 x 56 137 122
2388 + 3253
1 x 56 137 124
50 00 26 2351 + 50 00 26 3016
1 x 56 137 200
2388
1 x 56 137 287
Bolt 16 x 150 - Length 45 mm
1 x 56 137 579
2384
1 x 56 137 651
50 00 26 2456
1 x 56 137 675
Not necessary
1 x 56 137 676
Tube + Screwdriver
1 x 56 137 835
50 00 26 2379
1 x 56 137 917
2399B
1 x 56 137 918
2388 + 3253
1 x 56 137 921
2388 + 3253
1 x 56 137 933
2388 + 3253
1 x 56 137 953
Not necessary
1 x 56 137 991
50 00 26 2351 + 50 00 26 3016
1 x 56 138 063
2454
RENAULT TRUCKS
01/2005
32 658
C1-4
ZF part N
RENAULT TRUCKS part N
1 x 56 138 064
Adhesive tape type protection
1 x 56 138 079
50 00 26 2735
1 x 56 138 109
50 00 26 2363 + 50 00 26 3016
1 x 56 138 158
50 00 26 2555
50 00 26 0843
50 00 26 1000
50 00 26 2203
50 00 26 2381
50 00 26 2413
50 00 26 2513
50 00 26 9134
2399A
RENAULT TRUCKS
01/2005
32 658
C1-5
LIST OF TOOLS
General-purpose tools
Illustration
RENAULT TRUCKS
RENAULT
TRUCKS Ref.
Designation
5000262351
Manufacturer
reference
Manufacturer code
Level
Qty
Set of pushers
5000260827
Puller
5000260819
Unsticker
5000260845
Puller
5000260843
Puller
5000261000
Universal stand
5000262856
Puller
01/2005
32 658
C1-6
5000260833
Puller
RENAULT TRUCKS
01/2005
32 658
C1-7
Special Tools
Illustration
RENAULT TRUCKS
RENAULT
TRUCKS Ref.
Designation
5000262460
Manufacturer reference
Manufacturer
code
Level
Qty
Swaging tool
5000263016
Handle
5000262363
Set of pushers
5000262456
Rivet snap
5000262379
Guard
5000262735
Adjusting tool
5000262555
Tester
01/2005
32 658
C1-8
5000262203
Fitting
5000262381
Extension
5000262413
Fitting
5000269134
Holding wrench
RENAULT TRUCKS
01/2005
32 658
C1-9
Locally manufactured tools
Illustration
RENAULT TRUCKS
RENAULT
TRUCKS Ref.
Designation
Manufacturer
reference
Manufacturer
code
Level
Qty
3241
Hook
2388
Hook
3253
Hook
2384
Retainer
2399
Positioner B
2454
Pusher
2513
Tube
01/2005
32 658
C1-10
2399
Positioner A
RENAULT TRUCKS
01/2005
32 658
RENAULT TRUCKS
01/2005
C1-11
C1-12
32 658
RENAULT TRUCKS
01/2005
32 658
RENAULT TRUCKS
01/2005
C1-13
C1-14
32 658
RENAULT TRUCKS
01/2005
32 658
How to use the tools
Disassembly
Mount on stand 1000
Hold the output flange using tool 9134
Remove the output flange using tools 0843 and 2381
RENAULT TRUCKS
01/2005
C2-1
C2-2
32 658
Extract the output shaft bearing using tool 2856
Remove the cylindrical dowels using tool 2454
Remove the output end cover using a strap.
Remove the clutch casing using tool 3241
RENAULT TRUCKS
01/2005
32 658
Immobilize the splitter control shaft using tool 2384
Mount tool 2388 for removing the main shaft.
Remove the main shaft and the countershaft using tools 3253 and
2388
Remove the input shaft bearing using tool 0819
RENAULT TRUCKS
01/2005
C2-3
C2-4
32 658
Remove the main shaft rear bearing outer ring using tools 3016 and
2363
Remove the countershaft rear bearing outer ring.
Extract the main shaft front bearing using tool 0827
Extract the reverse pinion using tool 0833
RENAULT TRUCKS
01/2005
32 658
Extract the 1st speed pinion using tool 0833
Extract the 2nd speed pinion.
Extract the 3rd speed pinion.
Extract the last two main shaft pinions and synchronizer using tool
2513
RENAULT TRUCKS
01/2005
C2-5
C2-6
32 658
Remove the countershaft pinion and front bearing.
Extract the countershaft output end taper roller bearing using tool
0819
RENAULT TRUCKS
01/2005
32 658
Assembly / Adjustment
Fit the countershaft pinions using tool 2513
Fit the countershaft front bearing using tool 2513
Fit the countershaft rear bearing using tool 2513
Fit the main shaft pinions, synchronizer and bearing using tool 2513
RENAULT TRUCKS
01/2005
C2-7
C2-8
32 658
Fit the main shaft synchronizer and last pinion using tool 2513
Fit the input shaft oil retainer disc using tools 3016 and 2363
Fit the input shaft bearing and pinion using tool 2513
Fit the main shaft injection pipe using tool 2379
RENAULT TRUCKS
01/2005
32 658
Fit the countershaft rear bearing outer ring using tools 3016 and
2363
Fit the main shaft rear bearing outer ring using tools 3016 and 2363
Fit the main shaft and the countershaft using tools 3253 and 2388
Fit the seal ring to the stop guide using tools 3016 and 2363
RENAULT TRUCKS
01/2005
C2-9
C2-10
32 658
Fit the lip seal to the control cover using tools 3016 and 2363
Fit the bearing bushing to the control cover using tools 3016 and
2363
Fit the lip seal, then the scraper, to the control cover using tools 3016
and 2351
Fit the O-ring to the control casing using tools 3016 and 2363
RENAULT TRUCKS
01/2005
32 658
Fit the output shaft seal ring using tools 3016 and 2363
Adjust the clutch operating fork using tool 2735
Adjust the planetary gear train using tool 2555
RENAULT TRUCKS
01/2005
C2-11
C2-12
32 658
RENAULT TRUCKS
01/2005
32 658
C3-1
Tools
Special tools
Fig.
no.
16 S 251
Special tools
Order no.
Application
1X20 155 653
Remarks
Chapter
5.3
Chapter
4.1
Chapter
3.1
3.2
Chapter
6
Chapter
6
7
8
Pipe roller
for spray tube
1X56 103 766

Adapter
for shaft seal in connection plate
1X56 119 916

Adapter
for gear shift housing
1X56 122 303

Adapter
for bearing inner ring / input shaft
1X56 122 304

Rollex basic tool
for Adapter
RENAULT TRUCKS
Qty.
01/2005
32 658
C3-2
16 S 251
Fig.
no.
Special tools
Special tools
Order no.
Application
1X56 122 310
Chapter
1.3
Chapter
4.3
Chapter
8
Chapter
6
Grip
for bearing inner ring / layshaft
1X56 136 722
10
Chapter
6
Hook
for clutch housing
1X56 136 710
Rillex extractor
for ball bearing / output shaft
1X56 136 564
Remarks
Rollex bush
1X56 122 314
Qty.
Grip
RENAULT TRUCKS
01/2005
32 658
C3-3
Special tools
Fig.
no.
16 S 251
Special tools
Order no.
Application
1X56 136 743
Remarks
Chapter
7
Chapter
8
Chapter
5.3
Chapter
1.3
Chapter
7
Grip
for bearing inner ring / main shaft
11
1X56 136 756

Grip
for bearing inner ring / layshaft
12
1X56 137 122

Lifting device
for shaft package
13
1X56 137 124

Adapter
for shaft seal / output shaft
14
1X56 137 200

Lifting rod
for main shaft
1X5
15
6 13
7 20
0
RENAULT TRUCKS
Qty.
01/2005
32 658
C3-4
16 S 251
Fig.
no.
Special tools
Special tools
Order no.
Application
Qty.
1X56 137 287
16
Chapter
1.5
1.6
5.1
5.5
Chapter
1.2
Chapter
5.3
Chapter
10.1
Holding fixture
for shaft package
1X56 137 676
20
Adapter
for locking plate / output flange
1X56 137 675
19
Chapter
5.3
Fixing device
for panel stop
1X56 137 651
18
Fixing screw
for removal and installation of shafts
1X56 137 579
17
Remarks
Adapter
for split ring / main shaft
RENAULT TRUCKS
01/2005
32 658
C3-5
Special tools
Fig.
no.
16 S 251
Special tools
Order no.
Application
1X56 137 835
Remarks
Chapter
5.4
Chapter
5.2
11.1
Chapter
5.3
Chapter
5.3
Chapter
5.3
Adapter
for installation of spray tube /
main shaft
21
1X56 137 917

Support plate
for adjustment of piston and
compressed-air test
22
1X56 137 918

Fixing device
23
1X56 137 921

Centering ring
24
1X56 137 933

Shim
25
RENAULT TRUCKS
Qty.
01/2005
32 658
C3-6
16 S 251
Fig.
no.
Special tools
Special tools
Order no.
Application
1X56 137 953
Qty.
Remarks
Chapter
5.3
Chapter
5.3
Chapter
4.3
Chapter
4.1
Chapter
5.2
Bolt
for installation and dismantling of
shafts together with 1X56 137 675
26
1X56 137 991

Distance ring
for shaft sealing ring / output,
together with 1X56 137 124
27
1X56 136 445
1X56 138 063

Extraction tool
for cylinder pins on clutch housing
that are difficult to reach
28
1X56 138 064

Protective sleeve
for connection plate / input shaft
29
1X56 138 064 004344
1X56 138 079

Centering aid
for selector rail / splitter group
fixation
30
009526
RENAULT TRUCKS
01/2005
32 658
C3-7
Special tools
Fig.
no.
16 S 251
Special tools
Order no.
Application
1X56 138 109
Remarks
Chapter
6
Chapter
10.4
Adaptor
for oil baffle plate / input shaft
31
1X56 138 158

Measuring bush
for adjustment or measurement
main shaft/planetary drive
32
RENAULT TRUCKS
Qty.
01/2005
RENAULT TRUCKS
1X56 137 921
1X56 137 122
1X56 122 304
1X56 137 918
1X56 136 756
1X56 137 287
1X56 136 710
1X56 137 579
1X56 137 675
1X56 137 953
1X56 137 651
1X56 137 991
1X56 137 124
16 S 251
1X56 137 933
1X56 122 303
1X56 136 564
C3-8
32 658
Spezialwerkzeuge
01/2005
RENAULT TRUCKS
01/2005
009526
1X56 138 109
1X56 138 079
1X56 137 676
1X56 137 917
1X56 137 835
1X56 138 158
1X56 136 722
1X56 137 200
1X56 122 314
1X56 119 916
200
1X56 138 064
1X56 136 743
137
1X20 155 653
1X56 138 063
1X56
1X56 103 766
1X56 122 310
32 658
C3-9
Spezialwerkzeuge
16 S 251
C3-10
32 658
RENAULT TRUCKS
01/2005
32 658
DISASSEMBLY / ASSEMBLY
RENAULT TRUCKS
01/2005
D1-1
32 658
D1-2
Range change
16 S 251
1
Removing components / range-change
1.1
Plastic pipes
Range-change / Plastic pipes
2
5
Removal
NOTE
Label plastic pipes before removing to ensure
correct re-assembly.
1
Unscrew union screws (1 and 2) from rangechange cylinder (3) and cutoff valve (4). Loosen
pipe clip (5) on housing and remove complete
together with plastic pipes (6).
2
6
4
1
011373
Mounting
1
Using union screws and new seal rings, screw

plastic pipes (6) to cylinder (3) and shut-off valve
(4) as marked.
Tightening torque = 38 Nm.
Strap up plastic pipes an fix cable strap (5)

together with plastic pipes to housing.
RENAULT TRUCKS
01/2005
32 658
D1-3
Range-change / Output flange

1.2
16 S 251
Output flange
Removal
Lever off retaining plate (1) from bolts (2).
Secure output flange to prevent it from turning.
Unscrew hex bolts (2) and remove clamping disc

(3).
Place adapter onto planet carrier and remove

output flange (4) using 2- or 3-leg puller.
Remove O-ring (5).
3
5
4
011374
Mounting
1
Lightly oil shaft seal in cover.
! DANGER
Always wear protective gloves when handling heated
output flange.
4
2
3
Heat output flange (1) to max. 70 C.
Push output flange flush onto planet carrier shaft.
Pull on output flange until flush using disc (2) and

two standard M12x75 hex bolts.
Remove disc and bolts.
Lightly oil new O-ring (3) and insert into gap

between output flange and planet carrier shaft.
Insert disc (2) into output flange and attach to

planet carrier using locking screws.
If required, use flange holder to prevent flange
from turning.
Insert locking screws with Loctite 262.
Using special tool 1X56 137 651, drive new

retaining plate (4) flush onto bolt heads.
RENAULT TRUCKS
01/2005
011375
32 658
D1-4
16 S 251
1.3
Range-change / Cover
Cover
1
Removal
1
3
4
Unscrew hex bolts from cover (1) and remove

together with gasket (2).
Unscrew hex bolts and remove cover (3) together

with gasket (4), shaft seal (5) and shim (6).
Use Rillex extractor 1X56 122 314 to remove ball

bearing (7) from output shaft.
Using plastic drift, drive out shaft seal (5) from

cover.
6
7
011376
Mounting
Measuring ball bearing axial play
(nominal: 0 to 0.1 mm)
1
5
2
Fit new gasket (1) onto new cover (2) and

measure insertion depth of cover together with
gasket, e.g. 23.40 mm.
Measure extraction depth bearing seat depth of

housing (without gasket), e.g. 7.00 mm.
Measure width of ball bearing (3), e.g.

30.00 mm.
1
4
3
Example
23.40 mm insertion depth - cover
+ 7.00 mm insertion depth - housing
30.40 mm
30.00 mm width of ball bearing
= 0.40 mm axial play without shim
011377
i.e. a 0.3 to 0.4 mm shim (4) is required to give

axial play of 0 to 0.1 mm.
! DANGER
cover.
Heat cover (2) to approx. 60 C and insert correct

shim (4) and ball bearing (3).
Drive in shaft seal (5) using special tool

1X56 137 124.
RENAULT TRUCKS
01/2005
32 658
D1-5
Range-change / Cover
NOTE
Only use special tool with 12.5 mm wide ring. Installation dimension = 12.5 + 1.0 mm between edge of
cover and shaft seal. Thinly coat outside of shaft seal
with sealing compound. Lubricate outside of shaft
seal with rubber surround using soap wash.
16 S 251
6 Fit cover (2) with new gasket (1) and tighten using
hex bolts and washers.
7 Fit cover (6) with new gasket.
2
1
011378
RENAULT TRUCKS
01/2005
32 658
D1-6
16 S 251
1.4
Range-change / Way valve
5/2-way valve
Removal
Unscrew 5/2-way valve (1) from centre housing.
Remove O-rings (2).

NOTE
Do not dismantle 5/2-way valve since it is a
complete part.
011379
Mounting
1
Insert new O-ring (2) into 5/2-way valve (1).
Screw 5/2-way valve (1) onto centre housing.

Tightening torque = 9.5 Nm.
RENAULT TRUCKS
01/2005
32 658
D1-7
Range-change / Shift cylinder

1.5
16 S 251
Shift cylinder for range-change

Removal
Unscrew hex bolts, loosen cylinder (1) from

range-change housing and remove from piston (2).
Remove O-rings (3 and 4) from cylinder.
Remove detent plunger (5). Screw fixing device

1X56 137 579 into threaded bore and position
fixing element on shift rail (6). Tighten fixing
device.
Unscrew locking nut (7) from piston (2).
Remove piston together with guide ring (8).
Remove seal rings (11).
Remove guide ring from piston.
Pull out flange packing (10) from range-change

housing.
4
11 7
2
11
10
8
3
011380
RENAULT TRUCKS
01/2005
32 658
D1-8
16 S 251
Range-change / Shift cylinder
Mounting
1
1
Coat new flange packing (10) with spirit, slide

over shift rail (6) and, using soft drift, drive in
until flush.
4
11 7
2
Place sealing ring (11), piston (2) together with

guide ring (8) and sealing ring (11) on shift
rail (6).
11
10
8
3
Tighten new locking nut (7) once range-change is

fitted.
NOTE
Installation of range-change cylinder is only possible once range-change has been subassembled
on centre housing. Thread must be absolutely free
of oil and grease.
Grease new O-rings (4 and 3) and insert into correct annular grooves (in cylinder and housing).
Carefully slide cylinder (1) over piston together

with guide ring and piston gasket. Fix cylinder
using two hex bolts.
011381
NOTE
Align the compressed air bores.
RENAULT TRUCKS
01/2005
32 658
D1-9
Range-change / Housing
1.6
16 S 251
Housing/range-change
1
Removal
1
12
Remove mechanical speedometer or impulse

sensor (15).
Remove pivot bolts (1) for shift fork (2).
Remove fixing device 1X56 137 579.
Unscrew hex bolts from range-change housing

(3).
! DANGER
Planet gear train is not secured on mainshaft. Secure
this to prevent from falling.
Separate range-change housing (3) from centre

housing (5) without tilting and remove. Use pins
to ensure correct position (4).
Remove shift fork (2) together with fulcrum pads

(6).
Remove intermediate plate (7) together with

gaskets (8).
Remove switch (9) together with seal ring and pin

(10). Other version (13 and 14) also possible.
Pull out shift rail (11) from centre housing.
10
Remove injection pipe (12).
4
4
15
4
8
7
13
14
11
9
10
011382
RENAULT TRUCKS
01/2005
32 658
D1-10
16 S 251
Mounting
1
Place intermediate plate (1) onto planet

carrier/clutch body (2).
Insert shift fork (3) and fulcrum pads (4) into

sliding sleeve (5).
Place new gasket (6) onto intermediate plate (1)

and position.
Insert shift rail (11) from inside of housing and

position roughly.
Insert injection pipe (20) into housing.
Place housing (7) onto intermediate plate (1), fit

gasket and position. Check radial position of shift
fork and engage.
With the range change group installed, coat pivot

bolt threads (10) with Loctite No. 241, place
spring disks and screw in.
Tightening torque = 250 Nm
10
21
22 8
W1
W11
9
7
6
20
10
NOTE
When using a new housing (7), drive in ball (8) in
accordance with selector pattern I or II.
5
2
011383
RENAULT TRUCKS
01/2005
32 658
D1-11
16 S 251
Installing complete range-change

NOTE
Main shaft / planetary drive must be measured
prior to installation of the range-change group;
see Section 10.4.
1
Fit new gasket (1) onto centre housing (2).

1
NOTE
There must be 3 cylindrical pins in centre housing.
2
Fit 2 hex bolts to range-change housing to allow

range-change to be suspended from a rope and
positioned horizontally against centre housing.
CAUTION
Secure hex bolts with nuts. Ensure rope is firmly
secured.
Hint: Use threaded pins on centre housing to
simplify positioning of range-change.
3
Push range-change against centre housing (2).

Turn output flange to bring planet gear train and
mainshaft teeth into mesh if necessary.
Remove hex bolts and rope when range-change is

held against centre housing.
Slide range-change (3) parallel to centre housing

and bolt together.
Switch piston to end position (high or low group).
RENAULT TRUCKS
01/2005
3
2
011384
32 658
D1-12
16 S 251
1.7
Range-change / Planetary drive
Planetary drive with synchronization
Dismantling
1
NOTE
Prior to removing the planetary drive, make sure it
cannot drop.
1
Remove entire planetary drive together with

synchronization from main shaft.
4
5
6
7
8
9
10
1.7.1 Synchronization
11
12
! DANGER
Pressure pieces are in a state of spring tension.
Safeguard these against disengagement.
Place pressure piece on planet carrier. Position

two or three-arm puller under sliding sleeve (1)
and extract together with clutch body (2). The
pressure pieces (4) and pressure springs (5) fixed
by sliding sleeve may be intercepted in a jumping
sheet.
Remove synchronizer ring (6).
Disengage circlip (7).
Place pressure piece on planet carrier and remove

sychronizer (8) by positioning two or threearm
puller under sychronizer and extracting it.
Remove synchronizer (9), clutch body (10) and

clutch disc (11) from planet carrier.
Disengage circlip (12) on clutch body.
011385
RENAULT TRUCKS
01/2005
32 658
D1-13
16 S 251
Mounting
1
9
10
Check wear limit of synchronizer parts,

see Section 9.
Place clutch disc (11) on planet carrier.
Insert snap-ring (12) in clutch body (10) and slide

onto planet carrier.
Place synchronizer ring (9) on planet carrier.
12
11
! DANGER
synchronizer hub.
Heat synchronizer hub (8) to approx. 120C and

push on until firmly seated. Ensure long hub side
faces planet carrier. Synchronizer ring lugs must
engage into recesses in the synchronizer hub.
Enter circlip (7) in groove with an end float of

between 0 and 0.1 mm. Circlips are available in
0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).
Place sliding sleeve (1) onto synchronizer hub (8)

with collar side facing towards output end.
NOTE
Recesses in sliding sleeve must be aligned with
recesses in synchronizer hub.
Insert new compression springs (5) and pressure

pieces (4) into synchronizer hub (8) and, using
suitable tool, insert into sliding sleeve (1).
Place synchronizer ring (6) onto synchronizer

hub (8).
NOTE
Synchronizer ring lugs (6) must engage into
recesses in the synchronizer hub (3).
! DANGER
clutch body.
10
Heat clutch body (2) to approx. 120C and push

flush onto planet carrier.
11
Press sunchronizer ring (6) against synchronizer

hub (2) and bring sliding sleeve (1) into central
position. You will be able to clearly hear the
pressure pieces snapping in.
RENAULT TRUCKS
01/2005
1
4
5
6
7
011386
32 658
D1-14
16 S 251
1.7.2 Ring gear

Removal
1
Detach safety wire (4) from annular groove in ring

gear.
Attach circlip (7), from Section 1.7.1, onto ring

gear carrier. Place pressure piece on planet carrier
and fit using two leg or three leg puller underneath
circlip. Take off ring gear carrier (2).
Remove ring gear (1) together with thrust ring (5)

from planet carrier.
Remove thrust ring (5) from ring gear.
Remove spacer ring (3) from planet carrier.
4
2
5
1
011387
Mounting
1
Place thrust ring (5) on support in ring gear (1).

3
! DANGER
ring gear.
Heat ring gear to 60C and place planet carrier in

ring gear by turning planet gear achieve meshing.
Slide spacer ring (3) onto the planet carrier (6).
Drive ring gear carrier (2) into the ring gear (1) to
bring about axial alignment.
Snap locking wire (4) into ring groove of ring gear

and bring about snug fit around entire
circumference.
4
5
1
0113
011388
RENAULT TRUCKS
01/2005
32 658
D1-15
16 S 251
1.7.3 Planet carrier

4 7
Removal
1
Drive dowels (1) fully into planet pin (2).
Using plastic drift, drive out planet gear pin form

planet carrier (3) towards input.
Remove planet gear (4) from planet carrier

together with bush (5).
Remove shims (6) and cylinder rolls (7) from

planet gear.
Drive dowels (1) from planet pin.

Repeat steps 1) to 5) for remaining planet gears.
3
2
011389
Remove thrust washer (8) from planet carrier.
Remove snap-rings (9 and 10) and lift off with

cover (11).
Remove axial ball bearing (13) and 4 plate springs

(12).
12
13
10
8
11
0113
011390
RENAULT TRUCKS
01/2005
32 658
D1-16
16 S 251
1
Insert 4 plate spring (11) and axial ball bearing

(10) into planet carrier.
NOTE
For teh arrangement of the 4 plate springs (11) see
Fig. 012317.
11
10
Insert cover (12) and snap-rings (13 and 14).

13
NOTE
For propper installation of the snap-ring (13) see
Fig. 012318.
3
12
14
15
Add thrust washer (15).
011393
012317
Output
Input
012318
RENAULT TRUCKS
01/2005
32 658
D1-17
16 S 251
NOTE
Always exchange planet gears as complete sets.
2a
5
Coat faces of planet gears and cylinder roller raceways with oil.
Stand planet gear pin (1) so that collar faces

downwards.
4
3
5
2
Slide intermediate disk (2) onto planetary gear

pin.
Place planet gear (4) onto planet pin (1) and align
centrally.
Insert 14 cylindrical rollers (5) in planet gear and

slide bush (3) onto planetary gear pin.
Coat inside of the planet gear with oil and insert

remaining 14 cylinders.
10
Coat cylinder rolls with oil and fit shim (2a).
11
Stand planet carrier (6) on shaft section.
12
Carefully remove planet gear and thrust washers

from planet pin and slide into planet carrier.
13
Align planet gear with bearing bore (7).

NOTE
Ensure 0 face of planet pin faces towards outside radius of planet carrier. (Oil bore must face
towards the inner radius of planet carrier).
14
Radially align planet pin and insert into bearing

bore.
15
Using plastic hammer, drive in planet pin. Check

for alignment with dowel bore.
16
Drive new dowel (8) halfway into hole. Drive 2nd

(new) dowel (9) into 1st with slot offset 180.
Drive both dowels approx. 0.5 mm into planet carrier (refer to Assembly Specification).
17
Check end float on planet gears (0.4 to 1.3 mm).

Repeat steps 4) to 17) for remaining planet gears.
011391
9
8
6
7
011392
RENAULT TRUCKS
01/2005
D1-18
32 658
RENAULT TRUCKS
01/2005
32 658
D2-1
Gearshift control
16 S 251
Servoshift
4
3
6
1
7
9
5
2
10
15
13
12
14
16
11
011394
Servoshift
2.1
Non-integrated version
Removal
Mounting
Remove cable connector (16) and union screws

(6, 7, 9, 11 and 15).
Fasten console (4) using hex bolts (3).

NOTE
Mark the installation point of the Tecalan pipes.
Fasten shift cylinder (1) gaiter must face shift

lever using retaining nuts (2 and 12).
Fasten valve (14) to shift lever using retaining

nut (13).
Fit Telecan pipes (5, 8 and 10) where marked.

Tighten union screw (6, 7, 9, 11 and 15).
Secure cable connector (16).
Remove Tecalan pipes (5, 8 and 10).
Remove retaining nuts (2, 12 and 13).
Lift off shift cylinder (1) and valve (14).

NOTE
If the reaction linkage is fitted on the valve (14),
it should not be dismantled as it is adjusted to suit
the vehicle.
Remove hex bolts (3) and lift off console (4).
RENAULT TRUCKS
01/2005
32 658
D2-2
Servoshift
16 S 251
3
1
2
012319
2.2
Integrated version
Disassembly
Assembly
Loosen hollow screws (1 and 2) and remove

together with sealing rings and pipe (3).
Re-place servo-unit (5) together with new gasket

(6) on shift turret.
Loosen hex bolts (4).
Remove pneumatic servo-unit (5) together with

gasket (6).
Insert and tighten hex bolts (4).

NOTE
Pneumatic servo-unit is a complete component do not disassemble.
Fix pipe (3) together with new sealing rings to

shift turret using a hollow screw (1).
Fix pipe together with new sealing rings to pneumatic servo-unit using a hollow screw (2).
RENAULT TRUCKS
01/2005
32 658
D3-1
Shift mechanism
16 S 251
3
Shift mechanism
Shift mechanism
12
14
3.1
Double H shift pattern

Removing and dismantling shift housing
Loosen hex bolts (1) and remove shift turret

Loosen shift lever (3) (depending on parts list) and

remove together with protective cap.
Remove detent plunger (4) and screw plug or

switch (5).
Take out cutoff valve (6) and remove together with

O-ring (7).
6
7
8
9
13
15
11
10
2
3
NOTE
Cutoff valve is a complete component and is not
dismantled.
5
Remove screw plug (9) together with seal ring,

spring (10) and bolt (11).
Remove screw plugs (12 and 13) together with

seal rings and springs.
Remove switch (14) together with seal ring.
Loosen housing (15) and remove together with

gasket.
Remove detent plate (16) and detent (17) from

housing.
10
Unscrew hex bolts from shift cover (18) and

remove together with gasket.
11
Drive out shaft seal (19), bearing bush (20), shaft

seal (21) and wiper (22) from shift cover.
12
Detach split ring (23) and remove detent (24) from

housing together with O-ring.
13
Drive out dowels (25) from driver.
14
Remove selector shaft (26), driver (27) and

locking piece (28).
15
Remove needle sleeve (29) from housing.
16
Detach split ring (30) and remove washer (31),

spring (32) and washer (33).
011395
21
19
18
20
22
24
23
29
16
30
31
32
17
33
26
25
27
28
009685/009686
RENAULT TRUCKS
01/2005
32 658
D3-2
Shift mechanism
16 S 251
Assembling shift housing

1
1
10
Drive new needle sleeve (1) into shift housing (2)

using special tool 1X56 119 916. Hit onto the side
of the needle sleeve with the thicker surround.
Insert driver (3) and locking piece (4) into shift

housing.
Insert selector shaft (5).
8
7
NOTE
Engagement groove for detent and detent plate
must face towards transmission.
4
One after the other, drive dowel pins (6) through

driver (3) and into selector shaft (observe
Assembly Specifications).
Insert washer (7), spring (8), washer (9) and split

ring (10) according to selector pattern.
4
009900
Drive shaft seal (11) into shift cover using special

tool 1X56 119 916. Sealing lip must face towards
shift housing.
Drive new bearing bush (12) into shift cover using

special tool 1X56 119 916.

shift lever.
11
13
15
12
14
Drive wiper (14) into shift cover using special tool

1X56 119 916. Sealing lip must face outwards.
NOTE
Lightly coat the outside of shaft seal and wiper
with sealing compound. Fill gap between shaft
seal and wiper with grease.
16
18 17
009685
10
Slide shift cover (15) over selector shaft together

with new gasket and mount using bolts (16).
11
Insert detent (17) together with new O-ring and

attach split ring (18).
RENAULT TRUCKS
01/2005
32 658
D3-3
16 S 251
12
13
14
15
Shift mechanism
Insert detent (19), spring (20) and screw plug (21)

together with new seal ring and tighten.
22
Insert cutoff valve (22) into shift housing together

with new O-ring, ensuring it is positioned the
correct way round, and fix using hex bolts.
23
21
20
Screw detent plunger (27) into housing together

with new seal ring.
19
Insert greased pin (28) into bore. Close off using

switch or screw plug (29) and new seal ring.
16
Insert detent (30) and detent plate (31) into

housing, ensuring they are positioned the correct
way round.
17
Fit new gasket (32).
18
Slide shift housing over detent plate and detent

together with selector shaft.
29
28
26
27
30
NOTE
Center housing and shift housing.
19
20
Insert springs, screw plugs (24 and 25) into

housing together with seal ring and tighten.
21
Tighten detent plunger.

23
011396
Insert hex bolts (33) and tighten by hand.

NOTE
Check selector shaft for ease of movement by
pushing against the spring force.
22
31
Slide protective cap (39) onto selector shaft and

position shift lever (40) on selector shaft (position
depends on version). Tightening torque for hex
bolt and hex nut on shift lever = 49 Nm. Ensure
protective cap has no play when seated on selector
shaft (according to parts list).
Screw on switch (41) together with new seal ring
and tighten.
RENAULT TRUCKS
01/2005
41
33
25
24
32
39
40
011426
32 658
D3-4
Shift mechanism
3.2
Superimposed H shift pattern

Removing and dismantling shift housing
12
14
Loosen shift lever (3) (depending on parts list) and

remove together with protective cap.
Remove detent plunger (4) and screw plug or

switch (5).
5
8

16 S 251
4
9
13
11
15
10
Take out cutoff valve and remove together with

O-ring (7).
NOTE
Cutoff valve is a complete component.
5
Remove screw plug (9) together with seal ring,

spring (10) and bolt (11).
Remove screw plugs (12 and 13) together with

seal rings.
Unscrew cover (14) together with piston and

remove together with gasket.
009684
21
Loosen housing (15) and remove together with

gasket.
Remove detent plate (16) and detent (17) from

housing.
10
Unscrew hex bolts from shift cover (18) and remove together with gasket.
19
18
20
22
11
Drive out shaft seal (19), bearing bush (20), shaft

seal (21) and wiper (22) from shift cover.
12
Detach split ring (23) and remove detent (24) from

housing together with O-ring.
13
Drive out dowels (25) from driver.
14
Remove selector shaft (26), driver (27) and

locking piece (28).
15
Remove needle sleeve (29) from housing.
16
Detach split ring (30) and remove disc (31), spring

(32) and disc (33) from selector shaft.
24
23
29
16
30
31
32
17
33
26
25
27
28
009685/009686
RENAULT TRUCKS
01/2005
32 658
16 S 251
17
D3-5
Shift mechanism
Detach snapring (34) from cover. Remove piston

(35) together with O-rings (36).
36
35
36
34
009893
RENAULT TRUCKS
01/2005
32 658
D3-6
Shift mechanism
16 S 251
Assembling shift housing

1
1
10
Drive new needle sleeve (1) into shift housing (2)

using special tool 1X56 119 916. Hit onto the side
of the needle sleeve with the thicker surround.
Insert driver (3) and locking piece (4) into shift

housing.
Insert selector shaft (5).
8
7
NOTE
Engagement groove for detent and detent plate
must face towards transmission
4
One after the other, drive dowel pins (6) through

driver (3) and into selector shaft (observe assembly specifications).
Insert disc (7), spring (8), disc (9) and split ring
(10) according to selector pattern.
4
009900

shift housing.
Drive new bearing bush (12) into shift cover using

special tool 1X56 119 916.

shift lever.
11
13
15
12
14
Drive wiper (14) into shift cover using special tool

1X56 119 916. Sealing lip must face outwards.
NOTE
Lightly coat the outside of shaft seal and wiper
with sealing compound. Fill gap between shaft
seal and wiper with grease.
16
18 17
009685
10
Slide shift cover (15) over selector shaft together

with new gasket and mount using bolts (16).
11
Insert detent (17) together with new O-ring and

attach split ring (18).
RENAULT TRUCKS
01/2005
32 658
D3-7
16 S 251
Shift mechanism
12
Insert detent (19), spring (20) and screw plug (21)

13
Insert cutoff valve (22) into shift housing together

with new O-ring, ensuring it is positioned the correct way round, and fix using hex bolts.
14
Insert screw plugs (24 and 25) into housing (26)

15
Screw detent plunger (27) into housing together

with new seal ring.
16
Insert greased pin (28) into bore. Close off using

switch or screw plug (29) and new seal ring.
17
22
23
21
20
19
26
25
29
28
Insert detent (30) and detent plate (31) into

housing, ensuring they are positioned the correct
way round.
27
24
30
31
009687
RENAULT TRUCKS
01/2005
32 658
D3-8
Shift mechanism
18
Fit new gasket (32).
19
Slide shift housing over detent plate and detent

together with selector shaft.
16 S 251
36
NOTE
Center housing and shift housing.
20
38
34
Insert hex bolts (33) and tighten by hand.
34
NOTE
Check selector shaft for ease of movement by
pushing against the spring force.
21
Tighten detent plunger.

22
Fit O-rings (34) onto piston (35).
23
Insert piston into cover (36) and secure using snapring (37).
24
Fit new gasket (38) and screw cover onto housing.

25
Slide protective cap (39) onto selector shaft and

position shift lever (40) on selector shaft (position
depends on version). Tightening torque for hex
bolt and hex nut on shift lever = 49 Nm. Ensure
protective cap has no play when seated on selector
shaft (according to parts list).
35
37
33
32
39
40
009688
RENAULT TRUCKS
01/2005
32 658
D3-9
16 S 251
Shift mechanism
5
21
10
22
20
1
3
9
8
11
48
12
13
18
14
19
15
16 17
012330
012330
3.3
Shift mechanism for the integrated Servoshift

Removing and dismantling of shift housing

together with gasket (2). Remove roller (48) from
valve lever.
NOTE
For removal of the Servoshift see Section 2.2
Loosen shift lever (3, depending on parts list) and

remove together with protection cap.
Disassemble cutoff valve (4) and remove together

with O-ring (5).
NOTE
Cutoff valve is a complete part - do not dismantle.
Loosen switch (6 and 7) and remove together with

sealing rings and pins.
RENAULT TRUCKS
01/2005
Unsnap V-ring (8) and remove detent (9) together

with O-ring from shift housing.
Loosen hex bolts (10) and remove cover (11)

together with sealing.
Unsnap V-ring (12) and locking ring (13) and

remove disk (14), spring (15), disk (16), V-ring
(17), spring (18) and disk (19).
NOTE
Arrangement and sequence of parts in step 7
depend on parts list.
Loosen screw (20) and remove together with sealing ring, spring (21) and detent (22).
32 658
D3-10
Shift mechanism
16 S 251
29
27
24
23
38
40
28
25
26
39
35
36
32
46
31
30
42 43
33
34
37
44
41
45
47
012331
Loosen hex bolts (23) and remove cover (24)

together with sealing (25).
10
Loosen screw plugs (26 and 27) and remove

together with sealing rings and springs.
11
Remove detent lever (28 and 29) from shift

housing. If necessary, remove cylindrical pins.
CAUTION
Locking rings (30 and 32) must not be overstrained use adjustable pliers.
12
Unsnap locking rings (30).
13
Remove cylindrical pins (31); if necessary,

remove locking rings (32).
14
Place suitable pipe on needle bush (33) and drive

valve lever (37) downwards.
15
Remove needle bush (33).
16
Remove pins (34 and 38).
17
Slide hollow shaft (39) towards cover. Dismantle

shift shaft (40) from shift housing together with
valve lever (37) and lever (41).
18
Remove pin (35) from valve lever. Do not remove

needle bush (36). Replace any damaged needle
bush (36) together with valve lever.
19
Place plastic arbor on hollow shaft and drive it out

of the shift housing together with the shaft bush
(42) and the shaft seal (43). Slide hollow shaft out
of shift housing and in the process remove dog
(44) and blocking piece (45).
20
If necessary, remove cylindrical pins (46 and 47).
RENAULT TRUCKS
01/2005
32 658
D3-11
16 S 251
Shift mechanism
Assembly of shift housing

38
1
Insert dog (44) and blocking piece (45) in shift

housing. Position hollow shaft (39) properly in
shift housing, blocking piece and dog.
Bring about flush and snug fit of bush (42) in

housing.
Snugly fit greased shaft seal ring (43) in its

support.
Insert cylindrical pins (35 and 47) into valve lever

(37). If necessary, press in cylindrical pin (46).
Mount valve lever (37) and lever (41) in shift

housing onto hollow shaft.
32
46
31
30
44
Introduce shift shaft (40) into hollow shaft.

45
NOTE
Cylindrical pin (35) must engage with shift shaft.
Position shift shaft and hollow shaft properly.
CAUTION
Secure only hollow shaft with the cylindrical pin (38);
do not drive pin in too far.
7
Insert cylindrical pin (38). Check ease of movement of the shift shaft.
35
36
33
34
37
Insert cylindrical pin (34) and drive in new needle

bush (33) until it is flush. Check ease of movement of the shift shaft.
CAUTION
Locking rings (32 and 30) must not be overstrained use adjustable pliers.
9
39
Snap in locking rings (32) on pins (31) and insert

in dog and shift shaft. Insert locking rings (30).
41
47
40
42 43
012332
RENAULT TRUCKS
01/2005
32 658
D3-12
Shift mechanism
10
16 S 251
Place detent levers (28 and 29) in shift housing. If

necessary, press in cylindrical pins.
24
23
NOTE
Arrangement of detent levers depends on parts list
(see Fig.12334).
11
Insert screw plugs (26 and 27) together with

springs and new sealings and tighten.
12
Place new sealing (25) and cover (24).
13
Insert hex bolts (23) and tighten.

25
29
27
NOTE
Version
Standard A
28
26
012334
Version
Standard B
Version
Alternative C
012334
RENAULT TRUCKS
01/2005
32 658
D3-13
16 S 251
Shift mechanism
5
21
10
22
20
1
3
9
8
11
48
12
13
18
14
19
15
16 17
012330
012330
14
Place disk (19), spring (18), V-ring (17), disk (16),

spring (15), disk (14), and snap in locking ring
(13) and V-ring (12).
19
Mount cutoff valve (4) together with greased

O-ring (5) with hex bolts to shift housing.
NOTE
Arrangement and sequence of parts in step 14
depend on parts list.
20
Mount shift lever (3) together with protective cap

on shift shaft.
15
Place cover (11) together with new sealing and

tighten with hex bolts (10).
Tightening torque =23 Nm.
21
Place greased roller (48) on valve lever.
16
Place detent (22), spring (21) and screw plug with

new sealing ring and tighten.
17
Place detent (9) together with greased O-ring and

V-ring (8) in shift housing.
18
Place switches (6 and 7) together with pins and

new sealing rings in shift housing and tighten.
RENAULT TRUCKS
01/2005
32 658
D3-14
Shift mechanism
3.4
16 S 251
Shift patterns without Servoshift

shift mechanism left or right
3.4.1 Horizontal torque shaft left /

Selector pattern I
Spring pack arrangements Q1 - Q6
011275
Q1
Q2
011278
Q3
011279
Q4
011280
Q5
011281
Q6
011283
011282
RENAULT TRUCKS
01/2005
32 658
16 S 251
D3-15
Shift mechanism

Selector pattern II
011276
Q1
Q2
011284
Q3
011285
Q4
011287
011286
Q5
Q6
011288
RENAULT TRUCKS
01/2005
011289
32 658
D3-16
Shift mechanism
16 S 251
3.4.3 Horizontal torque shaft right /

Selector pattern I
011336
Q1
Q2
011291
011290
Q3
Q4
011292
Q5
011314
Q6
011315
011316
RENAULT TRUCKS
01/2005
32 658
16 S 251
D3-17
Shift mechanism

Selector pattern II
011277
Q1
Q2
011317
Q3
011318
Q4
011319
Q5
Q6
011321
RENAULT TRUCKS
011320
01/2005
011322
32 658
D3-18
Shift mechanism
3.5
16 S 251
Shift patterns with Servoshift

shift mechanism left or right

Selector pattern I
012338
012338
Q1
Q2
012335
Q3
012336
Q4
012337
Q5
012339
Q6
012341
012340
RENAULT TRUCKS
01/2005
32 658
16 S 251
D3-19
Shift mechanism

Selector pattern II
012345
012345
Q1
Q2
012343
012342
Q3
Q4
012346
012344
Q5
Q6
012347
RENAULT TRUCKS
01/2005
012348
32 658
D3-20
Shift mechanism
16 S 251

Selector pattern I
012362
012352
Q1
Q2
012350
012349
Q3
Q4
012351
Q5
012353
Q6
012354
012355
RENAULT TRUCKS
01/2005
32 658
16 S 251
D3-21
Shift mechanism

Selector pattern II
012362
012362
Q1
Q2
012356
Q3
012357
Q4
012358
Q5
Q6
012360
RENAULT TRUCKS
012359
01/2005
012361
32 658
D3-22
Shift mechanism
3.6
Assembling complete shift housing
Place new gasket (1) onto clutch housing (2) and

sealing face.
16 S 251
3
1
Place complete shift housing (3) in position. Line

up bores in shift housing with bores in gasket.
Hint: Use threaded pins to simplify positioning of
clutch housing, gasket and shift housing.
2
3.6.1 Shift without Servoshift

1
Shift through all the gears. There must be notice

able excess shift travel in each gear. If the shift
angle is not within the specified tolerances, it
must be adjusted using an angle measuring device.
Finally, tighten all hex bolts.
CAUTION
The shift turret housing must be centered on the
transmission housing so that equal play (excess shift
travel) is obtained on both sides and the resultant
shift angle is 14 30 +2 (see illustration).
011397
1st, 3rd, 5th, 7th gear
1430'+2
1430'+
2
2nd, 4th, 6th,

8th gear
3.6.2 Shift with Servoshift

NOTE
When placing the selector mechanism make sure
the roller on the valve lever does not come off.
Assembly suggestion: Use grease to place roller
on valve lever.
1
009894
Insert all hex bolts and tighten them.

RENAULT TRUCKS
01/2005
32 658
D4-1
Clutch housing
16 S 251
Clutch housing / release fork / connection plate
Components / clutch housing
4.1
Release fork and connection plate
4.4.1 Removing release fork (pulled)

1
Loosen hex bolts (1) and remove together with

washers (2).
Pull out shafts (3) sideways and remove release

fork (4).
7
Removing connection plate
1
Loosen hex nuts (5), remove connection plate (6)

Remove shaft seal ring (8) from connection plate.
Remove seal rings (9 and 10) and bushes (11)

from connection plate.
6
11
9
10
11
5
10
4
3
2
3
1
2
011305
RENAULT TRUCKS
01/2005
32 658
D4-2
16 S 251
Fitting connection plate / release fork

NOTE
Before fitting connection plate, install pump
housing with integral pump.
1
Thinly coat outside of shaft seal (8) with sealing

compound and, using drift 1X56 103 766 insert
into connection plate.
NOTE
Sealing lip on shaft seal ring must face towards
drift.
Insert seal rings (10) and bushes (11) together

with grease (Olista Longtime 3EP).
Insert seal rings (9).
Fit new gasket (7) to connection plate (6), place

over input shaft and onto clutch housing.
7
6
11
NOTE
Place protective sleeve 1X56 138 064 on input
shaft to protect shaft seal ring.
5
Screw on connection plate using hex nuts.

Insert shafts (3) into connection plate, fix release

fork (4) on connection plate and push shafts in
until they are firmly in place.
Insert washers (2) and hex bolts (1) into release

fork and tighten.
9
10
11
5
10
4
3
2
3
1
2
011305
RENAULT TRUCKS
01/2005
32 658
16 S 251
D4-3

1
Detach circlips (1). Remove seals (2) and seal

rings (3).
Pull out pin (4) and remove release fork (5).
Loosen hex bolts (6) and remove together with

bearing block (7).
Detach circlips (8) and remove plain spherical

bearing (9) from bearing block.
11
12
13
10
1
Loosen hex nuts (10).
Remove connection plate (11) together with

gasket (12).
8
1
Remove shaft seal (13) from connection plate.
8
2
9
4
3
1
011306
RENAULT TRUCKS
01/2005
32 658
D4-4
16 S 251
Fitting connection plate

1

compound and, using drift 1X56 103 766, insert
into connection plate (11).
NOTE
drift.
11

NOTE
Screw on connection plate using hex nuts (10).

12
13
10
8
Fitting release fork (pulled)
1
3
6
Insert plain spherical bearings (9) into bearing

block (7) and attach circlips (8).
Fix bearing block using hex bolts (6).

Slide release fork (5) over bearing block and insert

pin (4).
Fit seal rings (3) and seals (2) onto pin.
Attach circlips (1) to pin.
8
2
9
4
3
1
011306
RENAULT TRUCKS
01/2005
32 658
16 S 251
D4-5
4.1.3 Removing release fork (pushed)

1
Remove release fork (1) together with ball cup (2).
Remove ball pin (3) together with washer (4).

7
6
8
5

4
1
Loosen hex nuts (5).
Remove connection plate (6) together with gasket

(7).
Remove shaft ring (8) from connection plate.
011307
RENAULT TRUCKS
01/2005
32 658
D4-6
16 S 251

1

compound and, using drift 1X56 103 766, insert
NOTE
drift.
7
6

NOTE
8
5

4
2
Fitting release fork (pushed)
Screw in ball bolt (3) with washer (4).

Use Loctite no. 262.
Place ball cup (2) in clutch lever (1).
Place clutch lever (1) onto ball bolt (3).
011307
RENAULT TRUCKS
01/2005
32 658
16 S 251
D4-7

1
10
Loosen screw (1) and remove from shaft (3)

together with clutch lever (2).
NOTE
Mark position of clutch lever before removing.
Remove dowels (4) from release fork (5).
Release and loosen grooved nut (6).
Remove shaft (3), release fork (5), grooved nut (6)

and locking plate (7).
Remove bearing bush (8).
If necessary, remove sheet (9) and four screws

(10).
13
9
14
8
7
12
17

1
16
Loosen hex nuts (11), remove connection plate

(12) together with gasket (13).
Remove shaft seal (14) from connection plate.
Remove seal rings (15 and 16) from connection

plate.
17
15
11
15
16
5
3
2
4
011308
RENAULT TRUCKS
01/2005
32 658
D4-8
16 S 251

10
13
NOTE
Before fitting connection plate, install pump housing with integral pump.
1

compound and, using drift 1X56 103 766 insert
14
NOTE
drift.
2
Insert seal rings (15) and bushes (17) together

with grease (Olista Longtime 3EP).
Insert seal rings (16).

7
12
17
16
17
15
NOTE
5
11
15
16

5
3
4
2
011308
RENAULT TRUCKS
01/2005
32 658
16 S 251
D4-9
Fitting release fork (pulled)

1
Push shaft (3) into clutch bell housing. Fit new tab
washer (7) and grooved nut (6) onto shaft.
Guide shaft into 1st bearing bore on connecting

plate. Push release fork (5) onto shaft and guide
this into 2nd bearing bore on the connecting plate.
Place bearing bush (8) over shaft and into clutch

housing.
Hit dowel pins (4) into release fork (5) and shaft
(observe Assembly Specifications).
Fit tab washer (7) and grooved nut (6) onto bearing bush. Secure grooved nut.
7
6
5
004 917
004917
Fit shift lever (2) onto shaft using screw (1)

(observe position).
Mount sheet (9) using four screws (10).

2
004 918
004918
RENAULT TRUCKS
01/2005
32 658
D4-10
Clutch housing / pump

4.2
16 S 251
Pump housing with integral pump

Removal
Loosen hex screws (1) and hex nuts (2). Remove

entire pump housing (3) together with gasket (4).
Lift off pump cover (5). Remove rotor (6) and

pump shaft (7) from pump housing.
8
4
Remove shim (8).
3
6
5
2
2
Mounting
1
011398
NOTE
In Section 10.3 shim (8) is measured and
installed.
1
Place new gasket (4) on clutch housing and bring

together pump housing (3) and clutch housing.
Insert rotor (6). Insert pump shaft (7) with anticorrosive oil into pump housing and engage with
layshaft.
Thinly coat pump cover sealing face (5) with

Loctite No. 574 (from hole to hole) and place on
pump housing. Tighten using hex bolts (1) and hex
nuts (2).
RENAULT TRUCKS
01/2005
32 658
D4-11
16 S 251
4.3
Clutch housing
Clutch housing
Removal
2
! DANGER
Ensure mounting brackets and rope are firmly
secured.
Remove hex bolts from inside and from outside.

Remove cylinder pins which are not easily accessible using special tool 1X56 138 063.
Fix two hooks 1X56 136 564 to clutch housing.
Exert tension on mounting brackets.

Hint: The clutch housing is positioned on the centre housing using 4 cylindrical pins (1). Ensure
clutch housing is level before separating from centre housing.
Hit sidebars (2) of centre housing and clutch housing using plastic hammer.
CAUTION
Do not use prybars on housing sealing faces.
5
Remove clutch housing and take off gasket (3).
RENAULT TRUCKS
01/2005
1
3
2
011399
32 658
D4-12
Clutch housing
16 S 251
Mounting
1
Fit new gasket to centre housing sealing face.
! DANGER
Ensure fixtures and rope are firmly secured.
1
2
Using hook 1X56 136 564, place clutch housing

(1) flat onto centre housing.
CAUTION
End of injection pipe must engage in clutch housing
bores in funnel and shift rails.
NOTE
Position all cylindrical pins between clutch housing and centre housing. If necessary, push shift
rail drivers inwards until clutch housing is fixed.
3
Screw in hex bolts inside clutch housing and outside. Turn input shaft several times to centre bearing rollers.
Remove hook 1X56 136 564.
011400
RENAULT TRUCKS
01/2005
32 658
D4-13
16 S 251
Clutch housing
4.4
Removing components
Remove all screw plugs and seal rings if necessary.
Remove magnetic screw plug (1) and clean.
Renew sealing cap if necesary.
Drive out taper roller bearing outer races for input

shaft and layshaft from clutch housing if
necessary.
2
001932
Fitting components
1
If necessary, insert taper roller bearing outer races

for the input shaft and layshaft into bearing bores
in the clutch housing.
Fit screw plugs with new seal rings and insert.

Tightening torque: M18 x 1.5 = 35 Nm,
M22 x 1.5 = 50 Nm,
M24 x 1.5 = 60 Nm.
Screw in cleaned oil drain plug and magnet (1).

Fit cap (2).
RENAULT TRUCKS
01/2005
D4-14
32 658
RENAULT TRUCKS
01/2005
32 658
D5-1
Main casing
16 S 251
Centre housing / GV cylinder
Components / centre housing
5.1
Splitter (GV) cylinder

Removal
Remove cylinder (1) by hand.
Remove detent plunger (9) together with circlip.

Insert fixing device 1X56 137 579.
Remove locking nut (2).
Remove spring (8) from housing.
Remove piston (3) from shift rail (4).
Remove double-grooved ring (5) from piston.
Remove two O-rings (6 and 7) from cylinder.
7
9
3
011401
NOTE
There may be three O-rings in the cylinder.
Mounting
1
Remove supporting plate and cylinder.
Check locking nut on piston.

Fit spring washer (1) onto housing.
Fit cylinder (2) with new O-rings (3 and 4).
2
1
NOTE
If necessary, fit 3 O-rings.
Hint: Lightly oil O-rings.
5
Insert cylinder onto centre housing.

NOTE
Line up lug on cylinder with groove in centre
housing.
RENAULT TRUCKS
01/2005
011402
32 658
D5-2
Centre housing / shift rails

5.2
16 S 251
Splitter shift rail

Removal
Remove grub screws (1) from shift fork (2).
Drive shift rail (3) out of shift fork (2) in direction

of output end.
Remove shift fork (2) together with fulcrum pads

(4).
2
1
Remove shift rail (3).

1
009943
RENAULT TRUCKS
01/2005
32 658
D5-3
16 S 251
Centre housing / shift rails
Installation
1
Guide in shift rail (1) from inside (in centre

housing).
CAUTION
Do not damage flange packing when inserting shift
rail.
2
3
4
Correctly position shift fork (3) and fulcrum pads

against sliding sleeve (4) and place onto shift rail.
1
NOTE
Line up bores in shift rail with thread in shift fork.
3
Insert grub screws (6) (do not tighten yet).
Screw piston (2) and new double-grooved ring

onto shift rail.
Fit splitter cylinder (7) (see work steps 1 to 4 in

Section 5.1).
Screw support plate (8) 1X56 137 917 onto the
housing sealing face (5). Switch the sliding sleeve
to the output. Splitter piston must axially contact
cylinder and cylinder must axially contact the
supporting plate. This is the correct position
2
5
011403
NOTE
Renew lock nut. Tightening torque = 150 Nm.
Ensure the thread is absolutely free of grease.
6
Attach the centering device (9) 1X56 138 079.
Fulcrum pads in the sliding sleeve must have the

same play above and below (check using feeler
gauge).
Tighten grub screws evenly.

7
001965
009944
RENAULT TRUCKS
01/2005
32 658
D5-4
Centre housing
5.3
Removing shafts and components
Unscrew cover (9) together with gasket.
Using drift, drive out reverse pin (3) from centre

housing in direction of output. In older versions,
loosen and remove fixing screw (3a) and fixingwasher.
16 S 251
3
4
5
CAUTION
Reverse idler gear may fall out.
3
Remove reverse idler gear (4) together with needle

cage (5).
Remove screw plug (6) together with seal ring.
Screw in fixture 1X56 137 287. Interlock locking

pin (7) is pushed against spring pressure.
Bolt lifting device (17) 1X56 137 122 to centring

bush 1X56 137 921 and place over input shaft (18)
and shift rails (19) so that it lies on the layshaft
(21). Place disc 1X56 137 933 between lifting
device and layshaft. Place holder (20)
1X56 137 918 onto lifting device and insert into
shift rail driver.
011404
Bolt layshaft (21) to lifting device.

18
17
! DANGER
Ensure mounting brackets and rope are firmly
connected.
Pull out shafts and shift rails from centre

housing without tilting and place into device
1X56 137 675.
Remove lifting device (17) and accessories. Take

out shift rails, forks and fulcrum pads.
10
Remove fulcrum pads from shift forks.
20
21
19
NOTE
Do not dismantle shift rails any further. In this
condition, they form a complete unit.
001995
RENAULT TRUCKS
01/2005
32 658
D5-5
16 S 251
Centre housing
11
Unscrew device 1X56 137 287 and remove

locking pin (7) and compression spring (8).
12
Remove all screw plugs, seal rings, pressure switches, pins, filler necks and gasket.
13
If necessary, remove injection pipe (10), type plate

(22) and roll pins (11).
14
Remove packing (12), circlip (13) and bearing

bush (14).
15
Remove roller bearing outer races for mainshaft

and layshaft from centre housing. Drive out
towards inside of housing.
16
Renew filter (15).
17
Remove breather (16).
22
16
7
8
2
14
13
12
10
15
11
011405
RENAULT TRUCKS
01/2005
32 658
D5-6
Centre housing
16 S 251
5.3.1 Installing components

1
22
Fit all screw plugs, pressure switches and filler

necks with new seal rings or gaskets and insert.
Tightening torques: see Adjustment Data,
Tightening torques section.
Insert injection pipe (1) if required. Roll ends into
holes in housing using rolling tool 1X20 155 653
and insert O-ring (2).
Rolling torque = 5 to 6 Nm.
Insert new filter (3).
If necessary, fit type-plate (4) using pins.
If necessary, insert new cylindrical pins (5) into

housing.
Drive new taper roller bearing outer races for

mainshaft and layshaft into centre housing if
necessary.
16
7
8
2
14
13
12
10
15
11
011406
NOTE
Heat bearing bore to approx. 60C using hot air
blower.
7
Insert bearing bush (6), circlip (7) and new

packing using plastic drift (8). Ensure correct
seating.
Insert compression spring (10) with locking pin

(9) and align. Screw in fixture 1X56 137 287.
RENAULT TRUCKS
01/2005
32 658
D5-7
16 S 251
Centre housing
5.3.2 Installing shafts

! DANGER
Ensure fixture and rope are firmly secured.
5
1
Place alternating pin 1X56 137 953 onto the layshaft locator. Insert output end of mainshaft (1)
into locator 1X56 137 675. Place clutch body, correct ring and synchronizer ring onto the teeth of
the helical gear on the mainshaft. Place the complete input shaft onto the mainshaft. Position layshaft (2) with teeth at correct height for meshing.
Push the layshaft against the mainshaft and bring
the teeth into mesh.
Insert shift rails (3) and fulcrum pads into sliding

sleeves on mainshaft.
Place centring bush 1X56 137 921 into lifting

device 1X56 137 122 (4) and secure. Push lifting
device over input shaft (5) and shift rails and push
down onto layshaft.
Screw lifting device onto layshaft using disc

1X56 137 933 (6).
Place holder (7) in driver recesses and lifting

device.
CAUTION
Ensure holder (7) 1X56 137 918 is firmly located at
both points. This guarantees safe lifting procedure.
6
Insert mainshaft, input shaft and layshaft into

taper roller bearing outer races in centre housing
without tilting.
NOTE
Ensure interlock is retracted and locked.
Remove all lifting equipment.
Remove device 1X56 137 287 for interlock.
Turn input shaft to centre bearing rollers.
RENAULT TRUCKS
01/2005
4
7
001995
32 658
D5-8
Centre housing
16 S 251
5.3.3 Reverse idler gear

1
Insert needle cages (1) into reverse idler gear.
Place reverse idler gear (2) into housing.

NOTE
Collar of reverse idler gear must face towards output end.
2
1
Push reverse idler pin (3) into centre housing from

output side until firmly seated.
NOTE
The reverse idler pin is secured using a centrallymounted clamping pin (4).
Fit cover (5) and new gasket (6) onto centre

housing.
6
5
011407
5.4
Injection pipe
Using drift 1X56 137 835, drive injection pipe (1)

into mainshaft until firmly located.
011408
RENAULT TRUCKS
01/2005
32 658
D5-9
16 S 251
Centre housing
5.5
Attaching components
Screw fixing device 1X56 137 579 into centre

housing and into hole for detent plunger (6).
Screw new locking nut onto piston.

13
14
6
7
11
NOTE
Renew locking nut. Make sure the thread is absolutely free of grease.
3
Remove fixing device.
Fit cylinder and tighten.

NOTE
Carefully push cylinder over piston together with
guide ring and piston gasket.
5
Screw in detent plunger (6) together with new seal

ring (7).
Insert pin (8) and switch (9) together with new

seal ring (10).
NOTE
In the new version, fit switch (9) onto the rangechange housing.
Fit screw plug (13) with new seal ring (14).

Insert pin (15) and switch (16) with new seal ring
(17).
Insert detent plunger (18) with new seal ring (19).

10
Screw in screw plug (23) with new seal ring (22).

11
Screw in mechanical speedometer and new seal

ring or impulse sensor.
12
Screw breather into bore (11).

RENAULT TRUCKS
01/2005
22
19
18
15
17
10
23
16
011409
D5-10
32 658
RENAULT TRUCKS
01/2005
32 658
D6-1
Shafts
16 S 251
6
Input shaft
Input shaft
6
1
Dismantling
2
1
Remove complete input shaft unit from mainshaft.
Remove clutch body (1) and synchronizer ring (2)

from input shaft synchronizer.
Remove ring (6) from inside clutch body.
3
4
5
17
NOTE
Procedure for measuring and fitting ring (6) is
shown in Section 10.1.
16
! DANGER
Pressure pieces are under spring pressure. Prevent
pressure pieces from flying out.
15
14
13
Pull off sliding sleeve (3) from input shaft. Catch

released pressure pieces (4) and compresion
springs (5).
Remove washers (7) together with spacer ring (8).
Remove ring (10), loosen and remove circlip (9).
Pull off roller bearing inner race (11) from input

shaft using gripper 1X56 136 722, extension
1X56 122 310, threaded insert 1X56 122 303 and
basic tool 1X56 122 304. To do this, slide gripper
1X56 136 722 over roller bearing inner race until
firmly seated against rollers and tighten using
knurled ring.
Remove helical gear (12) from input shaft.
Remove clutch body (13) and synchronizer ring

(14) from input shaft.
10
Remove oil baffle plate (17), detach circlip (15)

and remove pipe (16) from input shaft.
RENAULT TRUCKS
01/2005
12
11
10
9
7
011410
32 658
D6-2
Input shaft
16 S 251
Assembly
1
17
Check wear limits of synchronizer components

(see Section 9).
Insert pipe (16) into input shaft and attach circlip

(15) into annular groove. Press new oil baffle (17)
into input shaft using drift 1X56 138 109.
Place synchronizer ring (14) and clutch body (13)

onto input shaft.
16
14
13
NOTE
Lugs of synchronizer ring must locate in recesses
in synchronizer body on input shaft.
4
1
2
3
4
5
Push helical gear (12) over needle cages.

NOTE
Engaging teeth of helical gear must face towards
output end and mesh with inner spline of clutch
body.
12
11
! DANGER
roller bearing inner race.
Heat roller bearing inner race (11) to approx.

100C and slide onto input shaft. Once the roller
bearing has cooled down, it must firmly abut
against the input shaft collar.
Attach circlip (9).
Place washers (7) and spacer ring (8) on input

shaft.
Place sliding sleeve (3) on input shaft and slide

on. Insert new compression springs (5) into input
shaft together with pressure pieces (4) and use
appropriate tool to guide into sliding sleeve.
Place synchronizer ring (2) and clutch body (1)

onto input shaft.
10
Move sliding sleeve into centre position. To do

this, push against clutch body (1). The pressure
pieces can be clearly heard clicking into place.
11
Procedure for measuring and fitting shim washer

(10) is first shown in Section 10.2.
15
10
9
7
011411
RENAULT TRUCKS
01/2005
32 658
D6-3
16 S 251
7
Mainshaft
Mainshaft
Dismantling
5
CAUTION
Do not damage mainshaft. Always use aluminium
clamping jaws when clamping mainshaft in vice or
similar device.
1
Clamp output end of mainshaft in vice.
4
1
Hint: Use special tool 1X56 137 200 to position

and rotate mainshaft. Remove the oil pipe (5)
before doing this.
2
Remove circlip (1) and split ring (2).
Slide gripper 1X56 136 743 over bearing inner

race (3) and tighten firmly against bearing rollers
using knurled ring. Screw on basic tool
1X56 122 304 and pull off bearing inner race.
Remove axial washer (4).
Clamp input end bearing journal of mainshaft in

vice.
Remove pressure disc (6) and shim washer (40).
Detach circlip (7) from annular groove.
Attach 2- or 3-leg puller underneath helical gear

(8) and pull off gear together with roller bearing
inner race (9). Use adapter.
Remove needle cage (10).
10
Attach 2- or 3-arm puller underneath 1st-speed

helical gear (11) and pull off gear together with
bush (12) and clutch body (13). Use adapter.
11
6
40
7
9
8
10
12
13
11
14
011412
RENAULT TRUCKS
01/2005
32 658
D6-4
Mainshaft
12
Remove clutch body (15) and synchronizer ring

(16).
13
Remove sliding sleeve (17).
16 S 251
15
14
Place two-leg or three-leg puller on 2nd speed

helical gear (23). Pull off helical gear together
with bush (24), clutch body (22), synchronizer
ring (21) and synchronizer hub (20). Use adapter.
15
16
Clamp output end of mainshaft.
17
Attach 2- or 3-leg puller underneath sliding sleeve

(26) and pull off synchronizer ring (27, clutch
body (28), roller bearing (29) and helical gear
(30). Use adapter.
17
18
19
NOTE
Use cloth to catch released pressure pieces (18)
and compression springs (19) when pulling off
sliding sleeve.
16
20
21
22
23
25
31
35
NOTE
Use cloth to catch released pressure pieces (31)
and compression springs (32) when pulling off
sliding sleeve.
18
Remove pressure pieces and springs. Attach 2- or

3-leg puller underneath 3rd-speed helical gear
(33) and pull off together with roller bearing (34),
synchronizer hub (35), synchronizer ring (36) and
clutch body (37). Use adapter.
24
32
27
28
30
34
29
38
33
37
CAUTION
Do not attach puller to mainshaft collar (see arrow).
26
36
19
011413
RENAULT TRUCKS
01/2005
32 658
D6-5
16 S 251
Mainshaft
Assembly
23
CAUTION
Do not damage mainshaft. Always use aluminium
clamping jaws when clamping mainshaft in vice or
similar device
1
Clamp mainshaft at output end.
Lightly oil needle cage (25) and slide onto mainshaft.
Push 2nd speed helical gear (23) onto mainshaft

with clutch body engaging teeth facing the output
end.
Check wear limit of synchronizer parts

(see Section 9).
Place clutch body (22) on helical gear spline.
Place synchronizer ring (21) on clutch body.
25
20
21
22
011414
! DANGER
synchronizer hub.
Heat synchronizer hub (20) to approx. 120 C and

push onto spline of mainshaft. Use plastic drift to
drive on synchronizer hub.
NOTE
Ensure lugs locate in recesses of the synchronizer
hub. The outer ring tabs must engage in the synchronizer hub recessesd.
RENAULT TRUCKS
01/2005
32 658
D6-6
Mainshaft
8
16 S 251
Attach sliding sleeve (17).

NOTE
The recesses in sliding sleeve interior must cover
the same areas of the synchronizer hub locating
points (for compression springs (19) and compression pieces (18).
Press new compression springs and pressure pieces available into synchronizer hub bores and
guide into sliding sleeve.
10
End float of helical gear (23) must be less than

0.2 mm.
11
Attach synchronizer ring (16) in a way which

ensures that the tabs engage into recesses in the
synchronizer hub.
Check wear limits, see Section 9.
12
Place clutch body (15) on synchronizer ring.
13
Pull sliding sleeve into neutral position and in so

doing make contact with synchronizer ring (16)
and clutch body (15). You will be able to hear the
pressure pieces snap into place.
18
19
20
23
15
17
16
11
14
24
! DANGER
bush.
14
Heat bush (24) to 120 C and push onto mainshaft

until firmly seated. Use plastic drift to drive on if
necessary.
15
Lightly oil needle cage (14) and push over bush.
16
Place 1st/5th speed helical gear (11) onto needle

cage (14) so the engaging teeth mesh with clutch
disc.
011415
RENAULT TRUCKS
01/2005
32 658
D6-7
16 S 251
Mainshaft
! DANGER
clutch body.
17
10
12
13
Heat clutch body (13) to 120 C and push onto

mainshaft until firmly located.
NOTE
Ensure clutch body collar faces towards output
end.
18
Axial play on speed helical gear (11) must be at

least 0.20 mm.
! DANGER
bush.
6
40
19
Heat bush (12) to 120 C and push onto mainshaft

until firmly seated.
20
Lightly oil needle cage (10) and push over bush

(12).
21
Push reverse speed helical gear (8) onto mainshaft and over needle cage. Ensure engaging teeth
face towards input end.
! DANGER
roller bearing.
22
Heat roller bearing (9) to approx. 100 C and push

onto mainshaft until firmly seated. Use plastic
drift to drive on if necessary.
23
Attach circlip (7) into annular groove on mainshaft.

NOTE
Axial play on circlip must be between 0 and 0.05
mm. Select correct circlip from spare parts catalogue.
24
In Section 10.4 shim (40) and pressure disk (6)

are measured and installed.
25
Clamp output end of mainshaft.
RENAULT TRUCKS
01/2005
011416
32 658
D6-8
Mainshaft
26
Oil needle cage (38) and push onto mainshaft.
27
Push 3rd speed helical gear (33) over needle cage.

Engaging teeth of helical gear face towards output
end.
28
Place clutch body (37) onto engaging teeth of

helical gear.
Refer to Section 9, check wear limits.
29
Place synchronizer ring (36) onto clutch body.
16 S 251
26
31
32
35
36
38
! DANGER
synchronizer hub.
30
33
37
Heat synchronizer hub (35) to 120 C and push

onto mainshaft splines until axially flush. Use
plastic drift to drive on if necessary.
NOTE
Synchronizer ring lugs must locate in recesses in
synchronizer hub.
31
Fit sliding sleeve (26).

NOTE
Recesses inside sliding sleeve must line up with
recesses in synchronizer hub for compression
springs (32) and pressure pieces (31).
32
011417
Insert new compression springs and pressure

pieces into holes in synchronizer hub and guide
into sliding sleeve.
RENAULT TRUCKS
01/2005
32 658
D6-9
16 S 251
33
Mainshaft
Position synchronizer ring (27) so lugs locate in

recesses in synchronizer hub.
Refer to Section 9, check wear limits.
34
Place clutch body (28) onto synchronizer ring.
35
Move sliding sleeve into neutral position, pressing

synchronizer ring (27) and clutch body (28). The
pressure pieces can be hear clicking into place.
36
4
3
39
2
27
28
34
Insert both roller bearings (34 and 29) into 4th

speed helical gear (30).
30
29
NOTE
Lubricating bores (see arrows) on roller bearings
must face outwards.
! DANGER
roller bearing and helical gear.
37
Heat roller bearings and helical gear to 100 C and

push onto mainshaft until bearing pack is correctly seated.
011418
NOTE
The helical engaging teeth on the helical gear
must face towards the output end.
38
Axial play of helical gear must be at least

0.05 mm.
30
29
34
NOTE
Axial washer (4), roller bearing (3), split ring (2),
circlip (1) and ring (39) are only fitted in Section
10.1.
011419
RENAULT TRUCKS
01/2005
32 658
D6-10
16 S 251
8
Layshaft
Layshaft
Dismantling
CAUTION
Do not damage layshaft. Always use aluminium clamping jaws when clamping layshaft .
1
Clamp layshaft.
Detach circlip (1) from annular groove.
On input end slide gripper 1X56 136 756 over

roller bearing inner race (2) and tighten knurled
ring to grip roller bearing firmly. Screw on basic
tool 1X56 122 304 and pull off roller bearing (2).
On output end, slide gripper 1X56 136 710 over

roller bearing inner race (6) and tighten knurled
ring to grip roller bearing firmly. Place adapter
on output end of layshaft. Screw on basic tool
1X56 122 304 and pull off roller bearing (6).
Press off helical gears (3, 4 and 5) individually

and in sequence.
3
6
2
1
011420
RENAULT TRUCKS
01/2005
32 658
D6-11
Layshaft
16 S 251
Assembly
! DANGER
parts.
4
3
6
Ensure bores in helical gears (5, 4 and 3) and

seats on layshaft are free of oil, grease and dust.
Heat helical gears to 160 - 180 C and push onto

layshaft in sequence (5, 4 and 3). Press helical
gears on immediately. There must be no play
whatsoever.
Heat inner race of roller bearing (6) to 100 C and

push onto layshaft. Press roller bearing on until
firmly seated, with no play on output end.
Heat inner race of roller bearing (2) to 100 C and

push onto layshaft. Press roller bearing on until
firmly seated, with no play on input end.
Attach circlip (1) into annular groove on input end

of layshaft. Axial play on circlip must not exceed
0.1 mm. Select correct circlip from spare parts
catalogue.
011420
K1 K2
GP
NOTE: a = Direct drive

b = Overdrive
011422
K1 K2
GP
011423
RENAULT TRUCKS
01/2005
D6-12
32 658
RENAULT TRUCKS
01/2005
32 658
D7-1
Synchromesh
16 S 251
Synchronizer
Synchronizer
9.1
Determining wear limit

(except for 1st /2nd gear)
Check condition of synchronizer rings and clutch

bodies before assembling synchronizers.
NOTE
Do not mix up synchronizer parts.
1
Place synchronizer ring (1) onto corresponding

clutch body (2). Turn synchronizer parts so cones
nest evenly and parallel together.
Wear limit for 3rd/4th gear and splitter synchronizer rings is 0.8 mm. Wear limit for range-change
rings is 1.2 mm.
Using feeler gauge, measure distance (X) between

clutch body and synchronizer ring at two opposing
points. If wear limit is below 0.8 or 1.2 mm,
exchange synchronizer ring and/or clutch body.
Check condition of synchronizer parts (visual

check). Replace synchronizer parts if surface is
not flat. Do not mix up parts which have been
inspected together (mark parts accordingly).
9.2
Determining wear limit (1st /2nd gear)
Place inner ring (3), intermediate ring (2) and

outer ring (1) of 1st/2nd gear synchronizer
onto clutch disc (4). Turn outer ring so cones nest
evenly together. Evenly apply 50 Nm on outer
ring.
001999
F 50 N
s
2
Using a feeler gauge, measure distance (s) between clutch disc and outer ring at two opposing
points. The wear limit is 1.5 mm. If distance (s) is
below wear limit, use new intermediate and/or
outer ring and inner ring.
1 2
3 4
001952
001952
RENAULT TRUCKS
01/2005
32 658
D7-2
Synchronizer
9.3
16 S 251
Assembling synchronizer
2
Version ZF-BK
Check wear limits.
Renew compression springs (5). This guarantees

prescribed shift force for sliding sleeve (6).
Synchronizers may be subassembled first or

assembled on the mainshaft itself.
Push sliding sleeve (6) onto synchronizer hub.

Insert new compression springs (5) and pressure
pieces (4) into synchronizer hub (3). Hold drift
against centre of pressure pieces and guide
pressure pieces into sliding sleeve (6).
Position clutch body (1) and synchronizer ring (2)

and push sliding sleeve (6) into middle position.
1a
NOTE
Ensure correct position of pressure pieces.
2a
6
009510
9.4
Sectional view of synchronizer/ZF-BK
1 Clutch body
2 Synchronizer ring
3 Synchronizer hub
1
5
4 Pressure piece
5 Compression spring
2a
1a
6 Sliding sleeve
3
001940
001940
RENAULT TRUCKS
01/2005
32 658
D8-1
Adjustments
16 S 251
10
Adjusting shafts / mainshaft
Adjusting shafts
10.1 Mainshaft
Determining ring and axial washer
1
Measure distance between mainshaft and bearing

inner race contact point using depth gauge
(dimension a).
Insert axial washer

(1) and measure distance between mainshaft and axial washer using depth
gauge (dimension b).
a b must give a play of between + 0.07 mm and

- 0.08 mm.
After selecting the correct axial washer, insert ring

(2) into clutch body(3). Place parts onto 4thspeed helical gear.
4.6 -0.4
b
b
22
11
+0.07bis
to -0.08
+0.07
-0.08
a
009521
Measure distance between axial washer

(1) and
clutch body at several points. Calculate mean
value. Nominal dimension = 4.6 - 0.4
mm (select
ring (2) accordingly)
! DANGER
bearing inner race.
Heat new bearing inner race

(4) to 100C and
place onto mainshaft bearing journal until it is in
firm contact. Fully drive home using plastic drift.
Coat entire circumference on face of bearing output-side (see arrow) of bearing inner ring with
lubricating grease Aralub HL2 or Texando F020
(ca. 4 g).
012320
NOTE
Make sure no grease is applied to the outside of
the bearing rollers. Grease applied here may block
the input shaft lube bores.
8
Use drift1X56 137 676 to insert split ring(5) into

annular groove in mainshaft to give axial play/
prestress of between - 0.5 mm and + 0.05 mm.
Split rings are available in 0.1 mm thicknesses
(0.1 mm, 0.2 mm etc.).
Slide new circlip(6) over split ring and peen over

in three places (120 apart) using punch.
1
4
6
012321
RENAULT TRUCKS
01/2005
32 658
D8-2
Adjusting shafts / input shaft
16 S 251
10.2 Input shaft and connection plate

1
To achieve correct setting, the input shaft rollerbearing must be play-free when measured. To
ensure this, the outer race (1) must touch the
bearing rollers (2). Use plastic drift to push taper
roller bearing outer race towards output end.
Rotate input bearing several times to centre
bearing rollers.
NOTE
Bearing rollers should not move and should not be
prestressed.
3
a
Measure distance between face of bearing outer

race (1) and sealing face (3) using depth gauge.
Note down dimension a.
2
001958
NOTE
Measure at two opposite points and calculate the
average value.
3
Measure distance between sealing face (4) and

locating face (5) for shim in connecting plate
using depth gauge. Note down dimension b.
Measure gasket (6) and note down dimension.
4
6
5
NOTE
average value.
4
Calculate the difference c and note it down:

c = (b + gasket) a
NOTE
Axial play on roller bearing: 0.0 to 0.1 mm.
Select a shim of the same thickness as dimension

c (max. 0 - 0.1 mm).
Place shim in the connection plate. Shims are

available in 0.05 mm thicknesses.
011424
RENAULT TRUCKS
01/2005
32 658
16 S 251
D8-3
Adjusting shafts / countershaft
10.3 Layshaft
1
There must be no play on the layshaft taper roller

bearing during measurement. Use plastic drift to
push outer race (1) towards output until it is
pressed firmly against the bearing rollers (2).
Rotate input bearing several times to centre
bearing rollers.
NOTE
Bearing rollers should not move and should not be
presetressed.
Measure thickness of shim using depth gauge.

NOTE
Measure at two opposing points.
Measure distance between housing sealing face

and bearing outer race (1) face. Measure gasket
and add to dimension a.
Use average dimension a obtained from

measurements taken to select correct shim.
NOTE
Axial play 0.0 to 0.1 mm.
Thickness of shim must correspond to measurement a (max. minus 0.1 mm).
Place shim onto taper roller bearing outer race.

Shims are available in 0.05 mm thicknesses.
RENAULT TRUCKS
01/2005
1
a
2
001960
001960
32 658
D8-4
Adjusting shafts / planetary drive
16 S 251
10.4 Planetary drive

1
Slide pressure plate (1) over gearing onto main

shaft.
Place measuring bush (2) 1X56 138 158 on pressure plate and set dial gauge (3) to zero.
Slide measuring bush 1X56 138 158 vertically

upwards to stop contact and take the reading on
the dial gauge.
NOTE
average value.
Reading corresponds to thickness of the shim (4).

Take a permitted play of 0.05 mm into account.
012669
Remove measuring bush and pressure plate from

main shaft.
Place selected shim (4) on main shaft.
Slide pressure plate (1) over gearing onto main

shaft.
012670
68.75 0.05
Example:
Reading = 1.97 mm
With a permitted play of 0.05 mm, a shim of
2.00 mm is to be selected.
1
4
012672
RENAULT TRUCKS
01/2005
32 658
D9-1
Checking the pressure
16 S 251
11
Compressed air test
Compressed air test
11.1 Compressed air test for piston and splitter

cylinder
1
Screw support plate 1X56 137 917 (1) for splitter

cylinder (2) onto centre housing (3).
Supply compressed air (max. 6.8 bar) to 5/2-way

valve and piston.
Wet outer edge of splitter cylinder and check for

bubbles (leaks).
Supply compressed air to piston in opposite direction and check if air escapes.
If bubbles form, fit new O-rings if necessary and

check correct location.
If air escapes, renew double-grooved ring on

piston.
Remove support plate (1).
2
3
001965/002708
11.2 Compressed air test on breather

1
If necessary, remove breather and screw pressure

gauge connection into bore (1).
NOTE
Supply air to 5/2-way valve (2) over a long period
(max. 6.8 bar) and check pressure gauge.
2
Reinsert breather
2
011425
RENAULT TRUCKS
01/2005
D9-2
32 658
RENAULT TRUCKS
01/2005

16S251 Gear Box Kerax DXI

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RENAULT TRUCKS

Disassembly / assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 9

Range change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-2 17

RENAULT TRUCKS SA 01/2005 - Imprim en France - le 02/2005

Companies who repair ZF units are responsible for their

Read this manual carefully before starting any tests or

The following safety instructions appear in this

After completion of repair work and testing, skilled staff

Instructions for carrying out repairs

After removing the transmission from the vehicle clean

GASKETS, LOCKING PLATES

Find a clean site to assemble the transmission. Gaskets

Instructions for carrying out repairs

d) Duo shaft seals have two packing

e) Fill the gap between the packing

* refer to expendable material

Surface condition of bolts: heat-treated blackened

Metric coarse pitch thread

Metric coarse pitch thread

Union screws DIN 7643

The screw plug tightening torques MA were determined

The tightening torques MA were determined for

Screw plugs (DIN 908, 910, 7604)

* DIN 7604 Form C

Union screws (DIN7643)

01. Axial play on layshaft

Depth gauge or dial

Centre bearings (zero play)

02. Combined axial play of

Depth gauge or dial

Centre bearings (zero play)

03. Axial play / prestress of

Always use correct tool.

Depth gauge and/or

Measure depth of insertion

05. Axial play on ball bearing

Adjust using appropriate

06. Axial play on helical gear

Depth gauge or feeler

Not adjustable. Measure as

07. Axial play on helical

Depth gauge or feeler

Not adjustable. Measure as

08. Axial play on 4th-speed

Depth gauge or feeler

Not adjustable. Measure as

09. Axial play on circlips on

Use appropriate circlip.

10. Axial play of reverse idler

Not adjustable. Measure as

11. Permitted axial play on

Tolerance includes permitted wear on thrust washers.

12. Wear limit for synchronizer ring and clutch body,

Exchange synchronizer ring

13. Wear limit for 1st/2nd

Exchange intermediate ring

14. Max. permitted play on

Exchange if play is excessive

15. Adjusting mainshaft and

Measure and determine

16. Temperature for shrinkfitting helical gears onto

Gears and shaft seats must

17. Tightening torque for