DW13207802 PDF

Component manual 8 S 181
16 S 181
ZF Ecosplit 181/221 series 16 S 221
16 S 1920
16 S 2020
16 S 2220
16 S 2320
16 S 2520
©200809 DAF Trucks N.V., Eindhoven,
The Netherlands.
In the interest of continuing product development,

DAF reserves the right to change specifications
or products at any time without prior notice.
ZF-data
No part of this publication may be reproduced
ZF Ecosplit 181/211 series
and/or published by printing, by photocopying, on
Edition 2008-09 microfilm or in any way whatsoever without the
1316 751 101c prior consent in writing of DAF Trucks N.V.
©
200809 DW13207802
16 S 221 / 16 S 181 / 8 S 181
SAFETY PRECAUTIONS
Warning symbol
When text is accompanied by the warning symbol
shown here, this indicates that the information
provided is essential for the health and personal
safety of the mechanic.
In addition, this warning symbol is also shown if
there are conditions in which damage can be
caused to the component or parts thereof.
Safety instructions
To ensure that the mechanic's health is not

endangered, the following safety instructions
must be strictly observed.
- Comply with all the warnings and safety

instructions given in this component manual.
First read the instructions and warnings on
the labels and stickers which are affixed to
various components on the vehicle and
follow them! They have been put there for
your health and safety, so do not ignore
them!
- Wear clean, fitted clothes and apply

protective cream to unprotected parts of your
body, as necessary.
- Ensure proper extraction of dangerous

materials from the work area.
- Maintain a safe distance from rotating and/or

moving parts.
- Avoid unnecessary contact with drained oil.

Frequent contact damages the skin.
- Various sorts of oil and other lubricants used

on the vehicle may constitute a health
hazard. So avoid both inhaling and direct
contact with these.
- Exercise caution when working with springs

under pressure. Inadvertently released
springs may cause serious injuries. Small
springs and circlips may also cause injuries
when inadvertently released (wear goggles).
© 200809
16 S 221 / 16 S 181 / 8 S 181
- If necessary, support the component

suitably.
- Always use the appropriate lifting gear

(gearbox jack) or approved lifting gear or
hoists for the removal and installation of
heavy components. Attach the component
securely to the lifting or hoisting gear.
- After a fire it is possible that hazardous

residues may remain from the plastics used
in some oil seals and sealing rings. Wear
protective, acid-resistant clothing and PVC
gloves when removing such fire residues.
Submerge such fire residues in, or sprinkle
them amply with, a calcium hydroxide
solution (slaked lime and water). Thoroughly
clean the protective clothing after use. Treat
the gloves as chemical waste.
© 200809
16 S 221, 16 S 181, 8 S 181 Contents
Page
Contents ......................................................................................................................................... 1-01

Preface............................................................................................................................................ 1-03
General information ....................................................................................................................... 1-04
Safety instructions.......................................................................................................................... 1-06
Tightening torques for nuts and bolts............................................................................................. 1-07
Spring table .................................................................................................................................... 1-08
Adjustment data ............................................................................................................................. 1-09
Special tools ................................................................................................................................... 1-14
View of transmission...................................................................................................................... 1-16
1 Removing components/range-change ........................................................................................ 2-01

1.1 Plastic pipes ................................................................................................................................... 2-01
1.2 Output flange ................................................................................................................................. 2-01
1.3 Cover .............................................................................................................................................. 2-01
1.4 5/2-way valve ................................................................................................................................. 2-02
1.5 Shift cylinder for range-change ..................................................................................................... 2-02
1.6 Housing/range-change .................................................................................................................. 2-03
1.7 Planet gear train with synchronizer................................................................................................ 2-04
1.8 Assembling planet gear train with range-change synchronizer ..................................................... 2-06
1.9 Assembling range-change /housing/output flange/piston .............................................................. 2-09
2 Removing components from centre housing ............................................................................. 2-12

2.1 Splitter (GV) cylinder .................................................................................................................... 2-12
2.2 Shift housing .................................................................................................................................. 2-12
2.3 Shift housing, friction-optimized version ...................................................................................... 2-16
2.4 Shift mechanism/selector patterns ................................................................................................. 2-21
3 Removing components from clutch housing.............................................................................. 2-24

3.1 Release fork ................................................................................................................................... 2-24
3.2 Connection plate with integral pump ............................................................................................. 2-25
3.3 Clutch housing ............................................................................................................................... 2-26
4 Removing components ................................................................................................................. 2-26

4.1 Removing components/clutch housing .......................................................................................... 2-26
4.2 Splitter shift rail /centre housing ................................................................................................... 2-26
4.3 Removing shafts............................................................................................................................. 2-27
4.4 Removing components/centre housing ......................................................................................... 2-27
4.5 Input shaft ...................................................................................................................................... 2-28
4.6 Mainshaft ....................................................................................................................................... 2-30
4.7 Assembling synchronizer............................................................................................................... 2-37
4.7.1 Version ZF-BK............................................................................................................................... 2-37
4.7.2 Version ZF-D ................................................................................................................................. 2-38
4.8 Layshaft.......................................................................................................................................... 2-39
1-01
Contents 16 S 221, 16 S 181, 8 S 181
Page
5 Installing components .................................................................................................................. 2-41

5.1 Centre housing .............................................................................................................................. 2-41
5.2 Clutch housing ............................................................................................................................... 2-41
6 Synchronizer/wear limits............................................................................................................. 2-42

6.1 Determining wear limit (except 1st and 2nd gears) ....................................................................... 2-42
6.2 Determining wear limit (1st and 2nd gears)................................................................................... 2-42
7 Adjusting mainshaft..................................................................................................................... 2-43

7.1 Selecting thrust washer and shim, straight-cut version.................................................................. 2-43
7.1 Selecting thrust washer and shim, helical-cut version ................................................................... 2-44
8 Installing shafts ............................................................................................................................ 2-45

8.1 Installing input shaft, mainshaft, layshaft and shift rails ............................................................... 2-45
9 Splitter shift fork .......................................................................................................................... 2-46

9.1 Adjusting shift fork ........................................................................................................................ 2-46
10 Clutch housing/centre housing ................................................................................................... 2-48

10.1 Fitting clutch housing to centre housing ....................................................................................... 2-48
11 Adjusting shafts............................................................................................................................ 2-49

11.1 Input shaft ..................................................................................................................................... 2-49
11.2 Layshaft.......................................................................................................................................... 2-50
12 Fitting clutch housing components............................................................................................. 2-51

12.1 Connection plate with integral pump ............................................................................................. 2-52
12.2 Release fork ................................................................................................................................... 2-53
13 Fitting centre housing components............................................................................................. 2-55

13.1 Reverse idler gear/reverse idler pin................................................................................................ 2-55
13.2 Cylinder.......................................................................................................................................... 2-55
13.3 5/2-way valve ................................................................................................................................. 2-56
13.4 Compressed air test for piston and splitter cylinder....................................................................... 2-56
13.5 Injection pipe ................................................................................................................................ 2-57
14 Fitting complete range-change ................................................................................................... 2-58
15 Fitting components....................................................................................................................... 2-60

15.1 Shift housing .................................................................................................................................. 2-60
15.3 Plastic pipes ................................................................................................................................... 2-60
16 Compressed air test on breather ................................................................................................ 2-61
1-02
16 S 221, 16 S 181, 8 S 181 Preface
This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in accordance with the state of development on the date of
issue.
However, due to continuing development of the product, repair work might require work practices and test or
adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on
a regular basis at our Service Training Center.
Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications
All work performed in these service points is carried out conscientiously and with care.
Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual
conditions.
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together
with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies
where genuine ZF spares have not been used.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen Division
Service
1-03
General Information 16 S 221, 16 S 181, 8 S 181
Description of transmission
The ZF ECOSPLIT 16 S 221, 16 S 181 und 8 S 181 synchromesh transmissions have been developed for heavy
goods vehicle applications (from 220 to 400 kW).
16 S 221, 16 S 181 und 8 S 181 transmissions main components:

- 4-speed section with reverse gear
- rear-mounted range-change of planetary design
- front-mounted integrated splitter group (not in 8 S 181)
ZF Friedrichshafen AG offers the following options with these transmissions:

- NMV 221, engine-dependent PTO
- torque converter clutch (WSK)
- further engine-driven ZF PTO (NMV) together with the torque converter clutch
- various clutch-dependent ZF PTOs
- drive for emergency / dual-circuit steering pumps
- separate heat exchanger for extreme applications
- ZF Intarder
- ZF ES 2 shift system
- silent kit
Repair manual
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.
CAUTION
The transmission must not be suspended by the input shaft nor by the output flange when transporting,
removing, installing and repairing.
! ENVIRONMENTAL HAZARD !
Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system.
• Request safety information for the products concerned from your local environmental protection
authority, and follow any instructions herein at all times.
• Always collect used oil in a suitably large container.
• Always dispose of used oil, clogged filters, lubricants and cleaning agents in accordance with
environmental protection laws.
• Always observe manufacturer instructions when dealing with lubricants and cleaning agents.
NOTE: Additional removal and installation instructions 1315 754 007 are available for transmissions with silent kit.
1-04
16 S 221, 16 S 181, 8 S 181 General Information
General
This repair manual shows how to repair a ZF ECOSPLIT 16 S 221, 16 S 181 und 8 S 181 synchromesh
transmission.
Layout of repair manual:
Section 1 includes adjustment data, tightening torques, spring characteristics and a list of specified ZF
special tools.
Section 2 is a step-by-step guide to transmission repairs.
Directions for removal and assembly, general work instructions
This repair manual is based on the steps necessary for the complete removal of transmission components and their
subsequent reassembly. When circumstances require, the assembly procedure for certain components is described
immediately after the removal procedure. Such cases include the section on the “mainshaft and layshaft’’, in which
assembly instructions are given after removal instructions so as to ensure that only fully repaired components
proceed to the complete assembly phase. This procedure reduces the risk of mixing up individual components and
shortens the overall assembly phase.
Always ensure cleanliness and appropriate high standard of work; therefore, clean all transmissions removed from
vehicles before dismantling.
Specified ZF special tools must be used.
After dismantling, clean all transmission components. Particular attention should be paid to corners, recesses and
protruding edges on housings and covers.
Carefully remove old sealing compound and gaskets. Check for blocked of lubrication oil bores, grooves and pipes.
There must be no build-up of deposits, foreign matter or preservatives. This is especially important in the case of
new components.
It is impossible to avoid damaging some components during dismantling; these must always be renewed ; e.g.shaft
seals, O-rings, grooved rings, flange packing, protective caps etc. Components such as roller bearings, thrust
washers, synchronizer parts, etc., which are subject to normal wear during operation, must be checked by a
specialist to determine whether they can be reused
Gaskets must be fitted dry, i.e. free from oil and grease. Sealing faces without gaskets must be sealed using a
plastic-type, heat- oil-resistant sealing compound (e.g. WEVO-L 100 A).
During assembly, observe all adjustment values, test data and tightening torques.
Fill the transmission with transmission oil after repair. Procedure for this and permitted oil types are given in the
Operating Manual and List of Lubricants TE-ML 02. These documents may be obtained from all ZF After-Sales
Service points.
After filling with oil, tighten oil check plugs and oil drain plugs to specified torque.
1-05
Work Safety 16 S 221, 16 S 181, 8 S 181
Important work safety notice:
Companies who repair ZF units are responsible for their own work safety.
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 these ZF products must receive appropriate training in advance. It is the
responsibility of each company to ensure that 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

serious injury or death.
NOTE
Read this manual carefully before starting any tests or repair work.
After completion of repair work and testing, skilled mechanics must satisfy themselves that the product is
functioning correctly.
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.
1-06
16 S 221, 16 S 181, 8 S 181 Tightening Torques
Tightening torques for bolts and nuts 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. Coating ZFB 811 Dacromet or coating ZFB 998 Deltatone - Deltaseal.
Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome-
plated and oiled.
NOTE: Tightening torques which differ from the values below are separately listed in the repair instructions.
Metric coarse pitch thread Metric fine pitch thread
Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 5 5.5 8.1 9.5 M 9x1 36 53 62
M 6 9.5 14 16.5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145
M 12 79 115 135 M 14 x 1.5 135 200 235

M 14 125 185 215 M 16 x 1.5 205 300 360
M 16 195 280 330 M 18 x 1.5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1.5 430 620 720
M 22 530 750 880 M 22 x 1.5 580 820 960
M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
Edition: August 1991
1-07
Spring Table 16 S 221, 16 S 181, 8 S 181
Part number Installation point No. of Wire diam. Spring diam. Untensioned
coils in mm in mm length in mm
0732 040 630 Shift mechanism: on shift shaft 6.5 2.4 39.6 89.9
(depending on version)
0732 040 985 Shift mechanism: spherical 6.5 2.0 14.8 23.4
roller for detent part or reverse
gear interlock
0732 040 986 Shift mechanism: spherical 5.5 2.25 14.8 21.6
roller for detent part or reverse
gear interlock
0732 040 984 Shift mechanism: reverse 9.5 1.4 9.4 23.3
gear interlock
0732 040 736 Shift mechanism: for detent pin 13.5 1.6 9.8 36.0
and locking pin interlock
0732 040 409 Synchronizers 12.5 1.4 6.65 23.7

input shaft and mainshaft
0732 042 126 Detent piece (compression spring) 9.5 1.0 9.4 25.0
1-08
16 S 221, 16 S 181, 8 S 181 Adjustment Data
Description Tolerance Measuring device Remarks
01. Axial play on layshaft 0.0 - 0.10 mm Depth gauge or dial Centre bearings (zero play)
gauge and measure play. Adjust
using shims on roller
bearing outer race on output
end.
02. Combined axial play of 0.0 - 0.10 mm Depth gauge or dial Centre bearings (zero play)
mainshaft and input shaft gauge and measure play. Adjust
using shims on roller
bearing outer race on input
shaft.
03. Axial play / prestress of - 0.05 to + 0.05 mm Micrometer or feeler Always use correct tool.
split ring on input shaft gauge
and mainshaft (only in
older version)
04. Insertion depth for shaft 12.5 + 1.0 mm Depth gauge and/or Measure depth of insertion
seal in output flange drift 1X56 137 124 between outside of cover
cover and face of shaft seal. If
drift is used with ring, depth
is automatically given (must
be flat).
05. Axial play on ball bearing 0 - 0.10 mm Depth gauge/sliding Adjust using appropriate
in cover (range-change) caliper shims in cover.
06. Axial play on helical gear Min. 0.20 mm Depth gauge or feeler Not adjustable. Measure as
on input shaft gauge check only.
07. Axial play on helical Min. 0.20 mm Depth gauge or feeler Not adjustable. Measure as
gears on mainshaft gauge check only.
08. Axial play on 4th-speed Min. 0.05 mm Depth gauge or feeler Not adjustable. Measure as
helical gear gauge check only.
09. Axial play on circlips on 0 - 0.05 mm Micrometer or feeler Use appropriate circlip.
layshaft and mainshaft gauge
10. Axial play of reverse idler 0.4 - 1.15 mm Feeler gauge Not adjustable. Measure as
gear check only.
1-09
Adjustment Data 16 S 221, 16 S 181, 8 S 181
11. Permitted axial play on 0.4 to 1.30 mm Feeler gauge Tolerance includes permit-
planet gears in planet ted wear on thrust washers.
carrier If wear limit exceeded
exchange thrust washers
12. Wear limit for Feeler gauge Exchange synchronizer ring

synchronizer ring and and/or clutch body if
clutch body, measured dimension too small
between flat surfaces of
ring and body with cones
firmly nested together.
4-gear section and

splitter 0.80 mm
Range-change 1.20 mm
13. Wear limit for 1st/2nd 1.5 mm Feeler gauge Exchange intermediate ring
gear synchronizer parts, and/or outer ring and inner
measured between outer ring if wear limit is
ring and clutch disc, excluded.
measured with cones
nested firmly together )
and force F = 50 N
applied on the outer ring.
14. Max. permitted play on 0.6 - 1.2 mm Feeler gauge Exchange if play is
fulcrum pads in sliding excessive
sleeves
15. Adjustment dimension for 107.9 mm Depth gauge Nominal dimension between
splitter piston and mid-housing
shift fork sealing face without gasket.
Fulcrum pads must have
play of min. 0.10 mm
upwards and downwards.
Tightening torque for grub
screw: 60Nm
16. Adjusting mainshaft and 19.20 - 0.5 mm Depth gauge Measured between upper
determining thickness of edge of clutch body with
shim and ring (in straight- ring inserted and mid-
cut version) housing with gasket
attached. Select appropriate
ring to ensure nominal
dimension (see table)
1-10
Selection of ring and Sliding caliper Ring Shim

shim
3.6 mm 7.9 mm
4.0 mm 8.3 mm
Table shows which shim is

correct for which ring
17. Adjusting mainshaft and + 0.07 to - 0.08 mm Depth gauge Measure and determine
determining thickness of (Shim) thickness of shim first.
ring and shim (in helical- 4.6-0.4 mm Then, measure and select
cut version) (Ring) ring.
18. Temperature for shrink- 160 - 180 °C Temperature probe Gears and shaft seats must
fitting helical gears onto be free of oil and grease
layshaft during assembly
19. Tightening torque for 10 Nm Torque wrench

breather
20. Tightening torque for 30 Nm Torque wrench Use new seal rings
M12 x 1.5 screws in
housing
21. Tightening torque of 35 Nm Torque wrench Use new seal rings

union screws for plastic
pipes
detent plungers
pressure switch/impulse
sensor
24. Tightening torque of M12 120 Nm Torque wrench Fit new retaining plate.
bolts for output flange Use Loctite No. 262.
25. Tightening torque for 4-gear section: 50 Nm Torque wrench

shift fork grub screws Splitter: 60 Nm
1-11
Adjustment Data 16 S 221, 16 S 181, 8 S 181
26. Tightening torque for 140 Nm Torque wrench Clean magnet and fit new
M38 x 1.5 magnetic seal ring
screw
27. Tightening torque for 86 Nm Torque wrench Use new bolt and washer.
locking bolts on reverse
idler pin
New version with slotted
pin
28. Tightening torque for 150 Nm Torque wrench Use new locking nut
locking nuts on range-
change and splitter
pistons
29. Tightening torque for hex 50 Nm Torque wrench

bolts between clutch
housing and mid-housing
30. Tightening torque for hex 50 Nm Torque wrench Use new seal rings
bolts between mid-
housing and GP housing
M18 x 1.5 screw plugs on
housing
housing
housing
34. Heating temperature for 60 °C Temperature probe Do not exceed temperature

ring gear
35. Temperature of synchro- 120 °C Temperature probe Do not exceed temperature

nizer hub, clutch body,
bushes and counting disc
36. Temperature of output Max. 70 °C Temperature probe Do not exceed temperature

flange
1-12
37. Temperature of input 100 °C Temperature probe Do not exceed temperature

shaft roller bearing
38. Temperature of 4th-speed 120 °C Temperature probe Do not exceed temperature

helical gear with needle
cages on mainshaft
39. Rolling-in torque for 5 - 6 Nm Torque wrench Rolling-in tool

injection pipe 1X56 155 653
40. Lifting device for input 85 Nm Torque wrench DANGER

shaft/ mainshaft/ layshaft Fit lifting device carefully
41. Tightening torque for 250 Nm Torque wrench Use Loctite No. 241
pivot bolts on shift fork
42. Tightening torque for M8 23 Nm Torque wrench

hex bolts on shift cover
43. Tightening torque for 49 Nm Torque wrench

M10 hex bolts on shift
lever

hex bolts on shift housing
cover (with detent piece)

hex bolts on cutoff valve
1-13
1-14
Special Tools
1X56 136 564 1X56 122 304 1X56 137 918 1X56 137 287 1X56 137 579 1X56 137 124
1X56 122 303 1X56 137 991
1X56 136 573 1X56 137 651
1X56 137 933 1X56 137 953

16 S 221, 16 S 181, 8 S 181
1X56 137 921 1X56 137 122 1X56 137 949 1X56 136 756 1X56 136 710 1X56 137 675
1X56
137
200
1X56 122 310 1X56 138 063 1X56 136 743 1X56 119 916 1X56 137 200
16 S 221, 16 S 181, 8 S 181
1X56 103 766 1X20 155 653
1X56 138 064 1X56 122 314
1X56 136 722 1X56 137 835
009526
Special Tools
1X56 136 599 1X56 138 109 1X56 138 079 1X56 137 676 1X56 137 917
1-15
View of Transmission 16 S 221, 16 S 181, 8 S 181
00 795
1-16
16 S 221, 16 S 181, 8 S 181 Removing Range-Change
1. Removing components/range-change
3
1.1 Plastic pipes
6
NOTE: Label plastic pipes before removing to 5
ensure correct re-assembly. 2
1 Unscrew union screws (1 and 2) from range-
change cylinder (3) and cutoff valve (4). Loosen
1 6
pipe clip (5) on housing and remove complete 2
together with plastic pipes (6).
4
1
001992
1.2 Output flange
1 Lever off retaining plate (1) from bolts (2).

2 Secure output flange to prevent it from turning.
3 Unscrew hex bolts (2) and remove clamping disc (3).
4 Place adapter onto planet carrier and remove output 2 1
flange (4) using 2- or 3-leg puller 3
5
4
5 Remove O-ring (5).
001902
1.3 Cover 2 1
1 Unscrew hex bolts from cover (1) and remove
together with gasket (2).
5
2 Unscrew hex bolts and remove cover (3) together 3
with gasket (4), shaft seal (5) and shim (6). 4
6
7
3 Use Rillex extractor 1X56 122 314 to remove ball
bearing (7) from output shaft.
4 Using plastic drift, drive out shaft seal (5) from
cover.
001903
001903
2-01
Removing Range-Change 16 S 221, 16 S 181, 8 S 181
1.4 5/2-way valve
1 Unscrew 5/2-way valve (1) from centre housing.

2 Remove O-rings (2).
NOTE: Do not dismantle 5/2-way valve since it
is a complete part.
NOTE: 5/2-way valve is not included in 8 S 181
transmission.
2 1
001904
001904
1.5 Shift cylinder for range-change
1 Unscrew hex bolts, loosen cylinder (1) from 1

range-change housing and remove from piston 7 4
8 11
(2). 2
10 11
2 Remove O-rings (3 and 4) from cylinder.
3 Remove detent plunger (5). Screw fixing device
1X56 137 579 into threaded bore and position 3
fixing element on shift rail (6). Tighten fixing
device.
Tightening torque = 50 Nm.
4 Unscrew locking nut (7) from piston (2). 1
7 4
5 Remove piston together with guide ring (8) and 9
grooved ring (9). 2 9 8
10
6 Remove grooved ring (9) and seal ring (11, new
version only) .
3
7 Remove guide ring and grooved rings from
piston.
8 Pull out flange packing (10) from range-change
housing. 5
6
001905
2-02
16 S 221, 16 S 181, 8 S 181 Removing Range-Change
1.6 Housing/range-change
1
1 Remove mechanical speedometer or impulse 12
sensor (15).
2 Remove pivot bolts (1) for shift fork (2).
3 Remove fixing device 1X56 137 579. 4
4 Unscrew hex bolts from range-change housing
(3).
15
! DANGER
Planet gear train is not secured on mainshaft. 6 4
3
Secure this to prevent from falling. 4
5 Separate range-change housing (3) from centre 2

housing (5) without tilting and remove. Use pins 1
to ensure correct position (4).
6 Remove shift fork (2) together with fulcrum pads
(6).
7 Remove intermediate plate (7) together with 8
gaskets (8). 7
8 Remove switch (9) together with seal ring and pin 8
(10). New version (13 and 14) also possible.
9 Pull out shift rail (11) from centre housing.
10 Remove injection pipe (12).
13
5 14
11
9
10
001906
2-03
Removing Planet Gear Train 16 S 221, 16 S 181, 8 S 181
1.7 Planet gear train with synchronizer
NOTE: Prevent planet gear train from falling out

when removing. 4
1 Remove complete planet gear train from
mainshaft together with synchronizer. 5
3*
1.7.1 Synchronizer 2
1
! DANGER 6
Pressure pieces are under spring pressure. Secure 7
9
8 10
them to prevent them flying out.
1 Place adapter onto planet carrier. Attach two-or 11

three-leg puller underneath sliding sleeve (1) and
pull off together with clutch body (2). Use a cloth
to catch pressure pieces (4) and pressure springs
(5) held by the sliding sleeve.
NOTE: In the straight-cut version, pull off
speedo worm or counting disc (3) with integrated
bush together with clutch body (2).
001907
NOTE: Parts marked * according to parts list.
2 Remove synchronizer ring (6).
3 Remove circlip (7).
4 Place adapter onto planet carrier and pull off
synchronizer hub (8) using 2- or 3-leg puller.
5 Remove synchronizer ring (9) and clutch body
(10) from planet carrier (11).
2-04
16 S 221, 16 S 181, 8 S 181 Removing Planet Carrier
1.7.2 Ring gear
1 Attach circlip (7) from Section 1.7.1 onto ring 5

gear carrier. Place adapter onto planet carrier and 3
4
fit using 2- or 3-leg puller underneath circlip.
2
Straight-cut version: 1
2 Pull off ring gear (1), ring gear carrier (2) and ball
bearing (5) together.
3 Detach safety wire (4) from annular groove in
ring gear.
4 Using plastic hammer, drive out ring gear carrier
005390
(2) from ring gear (1).
5 Detach snapring (3) from ring gear carrier and
remove ball ball bearing (5).
Helical-cut version:
2 Pull off ring gear (1), ring gear carrier (2),
intermediate ring (3) and axial needle bearing (5) 4
together. 2
1
3 Detach safety wire (4) from annular groove in
ring gear.
5
3
009518
1.7.3 Planet carrier
1 Drive dowels (1) fully into planet pin (2). (5)

4 7 6
2 Using plastic drift, drive out planet gear pin from 6
planet carrier (3) towards “input’’. 6 7
(5)
3 Remove planet gear (4) from planet carrier
together with thrust washers (5).
NOTE: Thrust washers (5) in straight-cut version 1
only. 3
4 Remove shims (6) and cylinder rollers (7) from 2
planet gear.
5 Drive out dowels (1) from planet pin.
Repeat steps 1) to 5) for remaining planet gears.
009525
2-05
Assembling Planet Carrier 16 S 221, 16 S 181, 8 S 181
1.8 Assembling planet gear train with range-

change synchronizer
1.8.1 Planet carrier 5 3 (2)

4
NOTE: Always exchange planet gears as 5 3
complete sets. 3
(2)
1
1 Coat faces of planet gears and cylinder roller
raceways with operating oil.
2 Stand planet gear pin (1) so that collar faces
downwards.
3 Slide thrust washer (2) over planet pin. Ensure
coated side (bright side) faces towards planet 009513
gear.
NOTE: Thrust washers (2) in straight-cut version
only.
4 Slide shim (3) over planet gear pin (either way
up).
5 Place planet gear (4) onto planet pin (1) and align
centrically.
6 Insert 14 cylinder rollers (5) into planet gear and
slide shim (6) over planet pin.
7 Coat inside of the planet gear with operating oil
and insert remaining 14 cylinder rollers.
8 Coat cylinder rollers with operating oil and fit
shim. 10
9
9 Fit thrust washer on planet gear. Ensure coated
side faces towards planet gear.
8 7
10 Stand planet carrier (7) on on shaft section.
11 Carefully remove planet gear and thrust washers
from planet pin and slide into planet carrier.
12 Align planet gear with bearing bore (8).
NOTE: Ensure “0” face of planet pin faces
towards outside radius of planet carrier. (Oil bore (2)
must face towards the inner radius of planet
carrier). (2)
13 Radially align planet pin and insert into bearing
bore.
14 Using plastic hammer, drive in planet pin. Check
for alignment with dowel bore
009505
009505
2-06
16 S 221, 16 S 181, 8 S 181 Assembling Planet Carrier
15 Drive new dowel (9) halfway into hole. Drive 2nd

(new) dowel (10) into 1st dowel with slot offset
180°. Drive both dowels approx. 0.5 mm into
planet carrier (refer to Assembly Specification) .
16 Check axial play on planet gears (0.4 to 1.3 mm).
Repeat steps 1) to 16) for remaining planet gears.
1.8.2 Ring gear
1 Drive ring gear carrier (2) flush into ring gear (3). 1
2 Insert safety wire (4) into annular groove in ring

gear. Ensure entire safety wire is firmly seated.
Straight-cut version: 6
5
3 Insert ball bearing (6) into ring gear carrier and 4
attach snapring (5). Select snapring so as to
2
ensure ball bearing axial play of 0.0 to 0.1 mm.
3
Snaprings are available in 0.1 mm thicknesses
(0.1, 0.2, 0.3 etc.).
Helical-cut version:
3 Slide intermediate ring (5) and axial needle

bearing (6) onto planet carrier. 004411
! DANGER
Always wear protective gloves when handling heated 1
ring gear.
4 Heat complete ring gear to 60° C and place onto

planet carrier (1). Rotate ring gear to bring teeth into
mesh. Ensure bearing (6) is firmly seated. 6
5
4
2
3
009506
2-07
Assembling Planet Carrier 16 S 221, 16 S 181, 8 S 181
1.8.3 Synchronizer
2
1 Check wear limit of synchronizer parts, see 1
Section 6.
2 Place clutch body (1) and synchronizer ring (2)
onto planet carrier.
! DANGER
Always wear protective gloves when handling heated
synchronizer hub.
3 Heat synchronizer hub (3) to approx. 120° C and 10

9
push on until firmly seated. Ensure long hub side 5
faces towards planet carrier. Synchronizer ring 7 8
lugs must engage into recesses in the 4
synchronizer hub. 3 6
4 Attach circlip (4) into annular groove. Axial play
must be 0.0 to 0.1 mm. Circlips are available in
0.1 mm thicknesses (0.1, 0.2, 0.3 mm etc.).
5 Place sliding sleeve (5) onto synchronizer hub (3)
with collar side facing towards output end. 001913
NOTE: Recesses in sliding sleeve must be

aligned with recesses in synchronizer hub.
6 Insert new compression springs (6) and pressure
pieces (7) into synchronizer hub (3) and, using
suitable tool, insert into sliding sleeve (5).
7 Place synchronizer ring (8) onto synchronizer hub
(3).
NOTE: Synchronizer ring lugs (8) must engage
into recesses in the synchronizer hub (3).
8 Bring sliding sleeve (5) into centre position by
pressing synchronizer ring against synchronizer
hub. Engagement of presssure pieces can be
clearly heard.
! DANGER
clutch body and counting disc.
9 Heat clutch body (9) to approx. 120° C and push

flush onto planet carrier.
10 Heat speedo worm/counting disc (10) to approx.
120° C and push onto planet carrier. Ensure
sensor lugs face towards planet carrier.
NOTE: Speedo worm and counting disc (10) in
straight-cut version only.
2-08
16 S 221, 16 S 181, 8 S 181 Assembling Range-Change
1.9 Assembling range-change /housing/ output

flange/piston
10 21
1 Place intermediate plate (1) onto planet 22
carrier/clutch body (2).
7
2 Insert shift fork (3) and fulcrum pads (4) into 6 WI 8
sliding sleeve (5). 1 9
●
3 Place new gasket (6) onto intermediate plate (1) 20 W II
and position. 9
4 Insert shift rail (11) from inside of housing and
position roughly.
5 Insert injection pipe (2) into housing.
6 Place housing (7) onto intermediate plate (1), fit
gasket and position. Check radial position of shift
fork and engage.
NOTE: When using a new housing (7), drive in 10
ball (8) in accordance with selector pattern I or II.
7 Coat pivot bolts (10) with Loctite No. 241, fit 4 3
spring washers and insert. Position shift fork (3).
NOTE: Pivot bolt tightening torque =
250 Nm. Tighten when range-change is fitted.
5
8 Coat new flange packing (12) with spirit, slide
over shift rail (11) and, using soft drift, drive in 2
until flush. 19
18
9 Place piston (13) onto shift rail the correct way 24
13
up together with guide ring (14) and new grooved 12 23
rings (15).
NOTE: in the new version, place seal ring (23),
piston (13) with guide ring (14) and seal ring (24) 16 17
14
onto shift rail.
10 Tighten new locking nut once range-change is 19
fitted. 18
Tightening torque = 150 Nm. 15
15 14
NOTE: Installation of range-change cylinder is 12 13
only possible once range-change has been
16 17
subassembled on centre housing. Thread must be
absolutely free of oil and grease.
11 Grease new O-rings (17 and 18) and insert into
correct annular grooves (in cylinder and housing).
NOTE: Mounting switches (21 and 22) if
required, see page 2-59, work step 16.
12 Carefully slide cylinder (19) over piston together
with guide ring and piston gasket. Fix cylinder 11
using two hex bolts.
NOTE: Align the compressed air bores.
009942
2-09
Assembling Range-Change 16 S 221, 16 S 181, 8 S 181
Measuring ball bearing axial play

(nominal: 0 to 0.1 mm)
29
13 Fit new gasket (25) onto new cover (26) and 26
measure insertion depth of cover together with 25
gasket, e.g. 23.40 mm. 27
28
14 Measure extraction depth bearing seat depth of
housing (7), (without gasket), e.g. 7.00 mm.
15 Measure width of ball bearing (28), e.g.
30.00 mm.
Example
23.40 mm insertion depth - cover
+ 7.00 mm insertion depth - housing
30.40 mm 001915
– 30.00 mm width of ball bearing

= 0.40 mm axial play without shim
i.e. a 0.3 to 0.4 mm shim (27) is required to give
axial play of 0 to 0.1 mm.
! DANGER
cover.
16 Heat cover (26) to approx. 60° C and insert

correct shim (27) and ball bearing (28).
17 Drive in shaft seal (29) using special tool
1X56 137 124.
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. 30
Lubricate outside of shaft seal with rubber
surround using soap wash.
18 Fit cover (26) with new gasket (25) and tighten
using hex bolts and washers.
19 Fit cover (30) with new gasket.
26
25
001916
2-10
16 S 221, 16 S 181, 8 S 181 Assembling Range-Change
1.9.1 Output flange
1 Lightly oil shaft seal in cover.

4
! DANGER 3
2
output flange.
2 Heat output flange (1) to max. 70° C.

3 Push output flange flush onto planet carrier shaft.
4 Pull on output flange until flush using disc (2)
and two standard M12x75 hex bolts.
5 Remove disc and bolts.
001917
6 Lightly oil new O-ring (3) and insert into gap
between output flange and planet carrier shaft.
7 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.
8 Using special tool 1X56 137 651, drive new
retaining plate (4) flush onto bolt heads.
2-11
Removing Shift Housing 16 S 221, 16 S 181, 8 S 181
2 Removing components from centre housing
2.1 Splitter (GV) cylinder
1 Remove cylinder (1) by hand.

4
2 Remove detent plunger (9) together with circlip. 1
Insert fixing device 1X56 137 579.
3 Remove locking nut (2).
4 Remove spring (8) from housing.
9 7
5 Remove piston (3) from shift rail (4). 2 6 8
5
6 Remove double-grooved ring (5) from piston. 3 001918
001918
7 Remove two O-rings (6 and 7) from cylinder.

NOTE: There may be three O-rings in the
cylinder.
2.2 Shift housing

14
1 Unscrew hex bolts from shift housing.
2 Take off complete shift housing (1) and remove 4
gasket (2). 3
3 Remove switch (3) together with seal ring and 13 11

pin.
1 10
4 Unscrew cover (4) together with gasket. 12
5 Remove shift detent (5) and washer (6) from 9
detent piece (7). See Figure 001920. 2
6 Loosen shift lever (8) and remove together with

protective cap (9). Mark selector shaft for
installation.
7 Remove screw plug (10) together with seal spring 8
(11) and pin (12).
001919
8 Unscrew cutoff valve (13) and remove together
with O-ring.
NOTE: In new version, remove reverse gear
switch (14) together with seal ring.
2-12
16 S 221, 16 S 181, 8 S 181 Removing Shift Housing
9 Unscrew hex bolts from shift cover (15) and

remove together with gasket.
10 Drive out bush (16), wiper (17), shaft seal (18)
and bearing bush (19) from shift cover. 16
11 Drive pin (20) towards cover. 15
19
12 Remove cover (21) from shift housing together 18
with compression springs (22), detent piece (23) 17
and O-ring (24).
13 Drive out dowels (25) from detent piece and
remove compression springs (26) together with
washers (27).
14 Drive out dowels (28) from drivers (29) and
selector shaft (30).
20
15 By hand, pull out selector shaft (30) in direction 7
of shift output. 22 5 6
16 Remove locking piece (31) and drivers from shift

housing.
17 Remove pins (32) if necessary.
NOTE: Clamp pins in vice using aluminium 21 24
clamping jaws and remove by striking shift
housing.
18 Drive out needle sleeve (33) from shift housing. 23
25
27
26
27
33
30
32
28
29
31
001920
001920
2-13
Assembling Shift Housing 16 S 221, 16 S 181, 8 S 181
2.2.1 Assembling shift housing

1
1 Using special tool 1X56 119 916, drive new 2
needle sleeve (1) into shift housing (2). Strike 3
thicker coated side of needle sleeve.
2 Drive pins (3) into shift housing.
3 Insert driver (4) and locking piece (5) into shift
housing the correct way round.
4 Insert selector shaft (6).
5 Using special tool 1X56 119 916, drive new 12
bearing bush (7) into shift cover.
6 Using special tool 1X56 119 916, drive shaft seal
4
ring (8) into shift cover. Sealing lip must face
towards cover.
7 Using special tool 1X56 119 916, drive scraper
disc (9) into shift cover. Sealing lip must point
outwards. 5
NOTE: Smear shaft seal and wiper with sealing
compound and install. Fill the gap between shaft
seal and wiper with grease.
8 Push bush (10) into shift housing (2) and slide
shift cover (11) and new gasket over selector
shaft (6) until flush. Do not damage sealing lips.
9 Bolt shift cover (11) onto shift housing.
10 Drive one dowel (12) through driver (4) and into

selector shaft. Drive second dowel (12) into first,
making sure slot is offset.
(Refer to Assembly Specification)
7
8
9
2
6
10
001921
2-14
16 S 221, 16 S 181, 8 S 181 Assembling Shift Housing/Detent Piece
2.2.2 Detent piece with compression springs

5
1 Place washer (1), compression spring (2) and 1
second washer (1) onto selector shaft (3). Drive 4 2
in pins (8) if necessary. 1
2 Place shift detent (6) with washer (7) into detent 6 7
piece (4).
14 18
3 Place detent piece (4), shift detent (6) and washer
(7) onto selector shaft against spring pressure and 8
drive in dowels (5) offset.
11
NOTE: Axial play between detent piece and pins 17
15
must be 0.1 mm. Adjust if required using washer
(7) of different thickness. Washers are available 10 13 3
in 0.1 mm thicknesses (0.1 mm, 0.2 mm etc.). 16
Grease shift detent (6) and pins (8). 12
4 Bolt on cover (9) together with new gasket.
NOTE: In the new version of the cover (a), screw 24 25
in reverse gear switch (24) and new seal ring 20
(25). In the old version, the reverse gear switch is 19 21
on the centre housing (see page 2-59, items 20
and 21).
5 Insert cover (10) into shift housing together with 9
compression springs (11), detent piece (12) and
O-ring (13). Drive pin (14) into shift housing
(countersink approx. 5 mm) and fit new cover
(countersink approx. 2 mm).
22
6 Fit pin (15), spring (16) and screw plug (17) with
new sealing ring and screw into shift housing.
7 Fit cutoff valve (18) with new O-ring and screw
onto shift housing.
8 Insert pin (19) into cover and screw in switch (20)

together with new sealing ring (21).
9 Slide protective cap (22) onto selector shaft (3)
and position shift lever (23) on selector shaft
shaft depending on shift version.
Tightening torque for hex bolt and nut on shift
lever = 49 Nm. Protective cap must sit on selector
shaft without play.
2-15
Shift Mechanism 16 S 221, 16 S 181, 8 S 181
2.3 Removing and dismantling friction-optimized

14 12 1 6
shift housing (illustrations show superimposed 5
“H” shift pattern)
7
8
1 Loosen hex bolts (1) and remove shift turret
together with gasket (2). 4
9
2 Loosen shift lever (3) (depending on parts list)
and remove together with protective cap.
13 11 10
3 Remove detent plunger (4) and screw plug or 15
switch (5). 2
4 Take out cutoff valve and remove together with
O-ring (7). 3
NOTE: Cutoff valve is a complete component
and is not dismantled. In the version with double
“H” shift pattern, there are 2 ball rollers (8) in the 009684
cutoff valve.
5 Remove screw plug (9) together with seal ring,
spring (10) and bolt (11).
6 Remove screw plugs (12 and 13) together with
21
seal rings.
7 Unscrew cover (14) together with piston and 19
remove together with gasket. 18
NOTE: In the version with double “H” shift 20
pattern, a cover and switch are installed here. 22
8 Loosen housing (15) and remove together with
gasket. 24
9 Remove detent plate (16) and detent (17) from 23
housing. 29
30
10 Unscrew hex bolts from shift cover (18) and 16 31
remove together with gasket. 32
11 Drive out shaft seal (19), bearing bush (20), shaft 17
seal (21) and wiper (22) from shift cover. 33
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).
26
15 Remove needle sleeve (29) from housing.
16 Detach split ring (30) and remove disc (31),
spring (32) and disc (33) from selector shaft.
25 27
28
009685
2-16
16 S 221, 16 S 181, 8 S 181 Shift Mechanism
17 Detach snapring (34) from cover. Remove piston

(35) together with O-rings (36).
36
35
36
34
009893
2-17
2.3.1 Assembling shift housing

1
10
1 Drive new needle sleeve (1) into shift housing (2) 9
using special tool 1X56 119 916. Hit onto the
side of the needle sleeve with the thicker 8
surround.
2 Insert driver (3) and locking piece (4) into shift 7
housing.
3 Insert selector shaft (5).
NOTE: Engagement groove for detent and detent 2
plate must face towards transmission
4 One after the other, drive dowel pins (6) through
driver (3) and into selector shaft (observe 5
assembly specifications).
5 Insert disc (7), spring (8), disc (9) and split ring
(10) according to selector pattern.
6
3
4
009900
6 Drive shaft seal (11) into shift cover using special

tool 1X56 119 916. Sealing lip must face towards 11 16
shift housing.
7 Drive new bearing bush (12) into shift cover
using special tool 1X56 119 916. 13
8 Drive shaft seal (13) into shift cover using special

tool 1X56 119 916. Sealing lip must face towards
15
shift lever.
12
9 Drive wiper (14) into shift cover using special
tool 1X56 119 916. Sealing lip must face 14
outwards.
NOTE: Lightly coat the outside of shaft seal and
wiper with sealing compound. Fill gap between
shaft seal and wiper with grease.
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).
2-18
12 Insert detent (19), spring (20) and screw plug (21)

together with new seal ring and tighten; 22
13 Insert cutoff valve (22) into shift housing together 23
with new O-ring, ensuring it is positioned the
correct way round, and fix using hex bolts;
NOTE: In the version with double “H” shift 21
pattern, there are 2 ball rollers (23) in the cutoff
20
valve.
19
14 Insert screw plugs (24 and 25) into housing (26)
together with new seal ring and tighten;
15 Screw detent plunger (27) into housing together
with new seal ring. 29
26 25 28
16 Insert greased pin (28) into bore. Close off using
switch or screw plug (29) and new seal ring;
17 Insert detent (30) and detent plate (31) into
housing, ensuring they are positioned the correct
way round. 27
24
30
31
009687
2-19
18 Fit new gasket (32).

19 Slide shift housing over detent plate and detent
together with selector shaft.
NOTE: Center housing and shift housing. 36
20 Insert hex bolts (33) and tighten by hand. 38
34
NOTE: Check selector shaft for ease of 35
movement by pushing against the spring force. 34
37
21 Tighten detent plunger;
22 Fit O-rings (34) onto piston (35).
23 Insert piston into cover (36) and secure using
snapring (37).
33
24 Fit new gasket (38) and screw cover onto 39
housing; 32
NOTE: In the version with double “H” shift
pattern, a cover and switch are installed here.
25 Slide protective cap (39) onto selector shaft and 40
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 009688
selector shaft (according to parts list).
2-20
2.4 Shift patterns/shift mechanism left or right
Spring pack arrangement: Q 1
Selector pattern I
Horizontal torque shaft left.
001923
001923
Selector pattern I
001924
001924
Selector pattern I
001925
001925
2-21
Selector pattern II
001926
001926
Selector pattern II
001927
001927
Selector pattern II
001928
001928
2-22
Selector pattern I
001929
Anordnung des Federpaketes: Q 2
Wählbild I
Waagrecht Drehwelle rechts
Anordnung des Federpaketes: Q 3
Wählbild I
Waagrecht Drehwelle rechts
2-23
Removing Clutch Housing 16 S 221, 16 S 181, 8 S 181
3 Removing clutch housing components
3.1 Release fork 3

8 6
Release fork (pulled) 1 7
2
1 Detach circlips (1). Remove seals (2) and seal
rings (3). 9
8
2 Pull out pin (4) and remove release fork (5). 3
5 2
3 Loosen hex bolts (6) and remove together with 1
bearing block (7).
4 Detach circlips (8) and remove plain spherical
bearing (9) from bearing block. 4
009520
Release fork (pushed)
1 Remove release fork (1) together with ball cup 4

3
(2). 2
1
2 Remove ball pin (3) together with washer (4).
004484 004484
Release fork (pulled)
1 Loosen screw (5) and remove from shaft (2)

together with clutch lever (3). 9
NOTE: Mark position of clutch lever before 10
removing. 1
2 Remove dowels (4) from release fork (1).
2
3 Release and loosen grooved nut (6) and loosen.
4 Remove shaft (2), release fork (1), grooved nut 3
(6) and tab washer. 8
6
7
5 Remove bearing bush (8). 4
6 If necessary, remove sheet (9) and four screws 5 004483
(10).
2-24
16 S 221, 16 S 181, 8 S 181 Removing Clutch Housing
3.2 Connection plate with integral pump 3

1
Single-piece version
10
1 Unscrew hex bolts and nuts from connection 2 9
plate (1) and pump cover (2). 8
4
2 Remove connection plate (1) together with 5
pump/pump cover (2).
2 6
3 Remove washer (8), spacer ring (9) and washer
(10) from connection plate / input shaft.
4 Remove gasket (3). 7
001996
5 Using plastic drift, drive out shaft seal (4).
6 Lever off pump cover (2) from connection plate
(1). Drive cylindrical pin (5) out of pump cover or
connection plate.
7 Remove pump shaft, internal rotor (6) and exter-
nal rotor (7).
8 Remove shim for input shaft and layshaft.
Split version
1 Loosen hex nuts, hex bolts and washers (1 and 5). 6

7
2 Remove pump housing (6) together with
pump/pump cover (2) and gasket (7). 4
3 11
3 Remove outer rotor (3) and inner rotor (4). 2
9
4 Loosen hex nuts (8) and remove connection plate
(9) from input shaft together with gasket (10) and
washer (11).
5
5 Remove shim for input shaft and layshaft.
1 10
8
009519
2-25
Removing Shift Rail / Centre Housing 16 S 221, 16 S 181, 8 S 181
3.3 Clutch housing
! DANGER
Ensure mounting brackets and rope are firmly secu-
red.
1 Remove 13 hex bolts from inside and 9 hex bolts 2

from outside. Remove cylinder pins which are not
easily accessible using special tool 1X56 138 063.
2 Fix two hooks 1X56 136 564 to clutch housing.
3 Exert tension on mounting brackets.
Hint: The clutch housing is positioned on the cen- 1
3
tre housing using 4 cylindrical pins (1). Ensure
clutch housing is level before separating from
centre housing.
4 Hit sidebars (2) of centre housing and clutch hou-
sing using plastic hammer.
CAUTION
Do not use prybars on housing sealing faces.
1 2 001931
5 Remove clutch housing and take off gasket (3).
4 Removing components
4.1 Removing components/clutch housing
1 Remove all screw plugs and seal rings if neces-

sary.
2 Remove magnetic screw plug (1) and clean.
3 Renew sealing cap if necesary. 1
4 Drive out taper roller bearing outer races for input
shaft and layshaft from clutch housing if neces-
sary.
001932
4.2 Splitter shift rail / centre housing
1 Remove grub screws (1) from shift fork (2).

2 Drive shift rail (3) out of shift fork (2) in direction 2
of output end.
1 3
3 Remove shift fork (2) together with fulcrum pads
(4).
4
4 Remove shift rail (3).
1
009943
2-26
16 S 221, 16 S 181, 8 S 181 Removing Centre Housing
4.3 Removing shafts

! DANGER
For Steps 1 - 6, see Section 4.4
Ensure mounting brackets and rope are firmly
1 Unscrew cover (9) together with gasket. connected.
2 Using drift, drive out reverse pin (3) from centre
housing in direction of output. In older versions,
loosen and remove fixing screw (3a) and fixing-
washer.
CAUTION
Reverse idler gear may fall out.
18
3 Remove reverse idler gear (4) together with need-
le cage (5).
4 Remove screw plug (6) together with seal ring. 17
5 Screw in fixture 1X56 137 287. Interlock locking 20
pin (7) is pushed against spring pressure.
6 Bolt lifting device (17) 1X56 137 122 to centring 21
bush 1X56 137 921 and place over input shaft
(18) and shift rails (19) so that it lies on the lays-
haft (21). Place disc 1X56 137 933 between lif- 19
ting device and layshaft. Place holder (20)
1X56 137 918 onto lifting device and insert into
shift rail driver.
7 Bolt layshaft (21) to lifting device;
tightening torque = 85 Nm.
8 Pull out shafts and shift rails from centre 001995
housing without tilting and place into device
1X56 137 675.
9 Remove lifting device (17) and accessories. Take
out shift rails, forks and fulcrum pads.
10 Remove fulcrum pads from shift forks.
NOTE: Do not dismantle shift rails any further.
In this condition, they form a complete unit.
4.4 Removing components/ centre housing 6

22
7
1 Unscrew device 1X56 137 287 and remove 16
locking pin (7) and compression spring (8). 8
2 Remove all screw plugs, seal rings, pressure swit-
o
ches, pins, filler necks and gasket.
3 If necessary, remove injection pipe (10), type
plate (22) and roll pins (11). 10 3a
4 Remove packing (12), circlip (13) and bearing
bush (14). 15 4
5 14 13 12
5 Remove roller bearing outer races for mainshaft
and layshaft from centre housing. Drive out 11
towards inside of housing. 3
6 Renew filter (15).
9
7 Remove breather (16).
001934
2-27
Removing Input Shaft 16 S 221, 16 S 181, 8 S 181
4.5 Input shaft 6

1
4.5.1 Dismantling input shaft 2
4 3
1 Remove complete input shaft unit from main- 5
shaft.
2 Remove clutch body (1) and synchronizer ring (2)
from input shaft synchronizer.
3 Remove ring (6) from inside clutch body.
17
! DANGER
15
Pressure pieces are under spring pressure. Prevent 16
pressure pieces from flying out.
4 Pull off sliding sleeve (3) from input shaft. Catch

released pressure pieces (4) and compresion
springs (5).
14
5 Detach circlip (7) and remove. 13
(12)
NOTE: Detach and remove circlip (8). Remove 11
split ring (9) (in older version only). (12)
6 Pull off roller bearing inner race (10) from input 10
shaft using gripper 1X56 136 722, extension (9)
1X56 122 310, threaded insert 1X56 122 303 and (8)
basic tool 1X56 122 304. To do this, slide gripper 7
1X56 136 722 over roller bearing inner race until
firmly seated against rollers and tighten using
knurled ring.
7 Remove helical gear (11) from input shaft. 009527
NOTE: Remove helical gear (11) from input

shaft together with needle cages (12) (in older
version only).
8 Remove clutch body (13) and synchronizer ring
(14) from input shaft.
9 Remove oil baffle plate (17), detach circlip (15)
and remove pipe (16) from input shaft.
2-28
16 S 221, 16 S 181, 8 S 181 Assembling Input Shaft
4.5.2 Assembling input shaft

16
1 Check wear limits of synchronizer components 2
(see Section 6, “Synchronizers/Wear Limits’’). 1
2 Insert pipe (1) into input shaft and attach circlip
4
(2) into annular groove. Press new oil baffle (16) 3
into input shaft using drift 1X56 138 109.
3 Place synchronizer ring (4) and clutch body (3)
onto input shaft.
NOTE: Lugs of synchronizer ring must locate in
recesses in synchronizer body on input shaft.
6
NOTE: In older version, lightly oil running areas 5
10 7
for both needle cages (11) and slide onto input 8
shaft. Slide helical gear (12) over needle cages.
9
4 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.
(11)
! DANGER 12
Always wear protective gloves when handling heated (11)
roller bearing inner race. 13
(14)
(15)
17
5 Heat roller bearing inner race (13) to approx.
100°C and slide onto input shaft. Once the roller
bearing has cooled down, it must firmly abut
against the input shaft collar.
NOTE: In older version, insert split ring (14) into
annular groove, ensuring it has axial play (pre- 009528
stress) of between -0.5 mm and + 0.5 mm (using
special tool 1X56 136 573). Slide new circlip (15)
onto split ring. The circlip must firmly abut
against the ring. Secure circlip at three points
(120° apart).
6 Attach circlip (17).
7 Place sliding sleeve (7) onto synchronizer body
(8) and locate correctly. Insert new compresion
springs (9) and pressure pieces (10) into synchro-
nizer body (8) and, using suitable tool, guide into
sliding sleeve (7).
8 Place synchronizer ring (5) and clutch body (6)
onto input shaft.
9 Move sliding sleeve into centre position. To do
this, push against clutch body (6). The pressure
pieces can be clearly heard clicking into place.
2-29
Removing Mainshaft 16 S 221, 16 S 181, 8 S 181
4.6 Mainshaft
4.6.1 Dismantling mainshaft
CAUTION 4
Do not damage mainshaft. Always use aluminium 3
2
1
clamping jaws when clamping mainshaft in vice or
similar device.
1 Clamp output end of mainshaft in vice.

Always use aluminium clamping jaws to protect
mainshaft.
Hint: Use special tool 1X56 137 200 to position
and rotate mainshaft. Remove the oil pipe before
doing this.
2 Remove circlip (1) and split ring (2).
3 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.
4 Remove axial washer (4).
5 Clamp input end bearing journal of mainshaft in
vice. Always use aluminium clamping jaws.
6 Remove pressure disc (5). 5
6
NOTE: In straight-cut version, there is no 8
pressure disc (5).
7
7 Detach circlip (6) from annular groove. 9
8 Attach 2- or 3-leg puller underneath helical gear
(7) and pull off gear together with roller bearing
inner race (8). Use adapter.
9 Remove needle cage (9).
10 Attach 2- or 3-arm puller underneath 1st-speed
helical gear (10) and pull off gear together with
bush (11) and clutch body (12). Use adapter. 11
12
11 Remove needle cage (13). 10
13
009512
009512
2-30
16 S 221, 16 S 181, 8 S 181 Removing Mainshaft
12 Remove clutch disc (14) from 1st/5th gear dual-

cone synchronizer. 22
14
13 Remove inner ring (15). 15
16
14 Remove intermediate ring (16). 17
18
15 Remove outer ring (17).
16 Pull off sliding sleeve (18). Use cloth to catch
released pressure pieces and compression springs. 20
19
17 Remove couplings (19). 26
25
18 Place 2- or 3-leg puller onto 2nd-speed helical 24
gear (21). Pull off helical gear together with bush 23
(22), clutch disc (23), inner ring (24), intermedia-
te ring (25), outer ring (26) and synchronizer hub
(20). Use adapter.
21
19 Remove needle cage (27). 27
20 Clamp output end of mainshaft.
21 Attach 2- or 3-leg puller underneath sliding sleeve
(28) and pull off synchronizer ring (29), clutch
body (30), roller bearing (31) and helical gear
(32). Use adapter.
NOTE: Use cloth to catch released pressure pie-
ces (33) and compression springs (34) when pul- 30
36
ling off sliding sleeve. 32
31
22 Remove pressure pieces and springs. Attach 2- or
3-leg puller underneath 3rd-speed helical gear
(35) and pull off together with roller bearing (36),
synchronizer hub (37), synchronizer ring (38) and
clutch body (39). Use adapter. 38
33 28
CAUTION 37 34
Do not attach puller to mainshaft collar (see arrow). 29
23 Remove needle cage (40).
35 40
39
009511
2-31
Assembling Mainshaft 16 S 221, 16 S 181, 8 S 181
4.6.2 Assembling mainshaft 3

2
CAUTION
Do not damage mainshaft. Always use aluminium 1
similar device
1 Clamp mainshaft (1) at output end.

2 Lightly oil needle cage (2) and slide onto main-
shaft.
9
3 Push 2nd speed helical gear (3) onto mainshaft 8
7
with clutch body engaging teeth facing the output 6
end. 5
4
4 Check wear limit of synchronizer parts (see
Section 6).
5 Fit clutch disc (4) onto engaging teeth of helical
gear (3). Ensure the slightly raised internal spline
in the clutch disc faces towards the output end.
001943
001943
6 Place inner ring (5) onto clutch disc. Ensure lugs
face towards the output end.
7 Fit intermediate ring (6). Ensure lugs locate in
recesses in clutch disc.
8 Fit outer ring (7). Ensure lugs face towards the
output end.
9 Align lugs on outer ring (7) and lugs on inner ring
(5) using 3 coupling (8). Position inner and outer
ring lugs to cover coupling, so that the couplings
will later locate in recesses in the synchronizer
hub (9) and fit over the lugs. After adjustment,
remove couplings.
! DANGER
synchronizer hub.
10 Heat synchronizer hub (9) to approx. 120° C and

push onto spline of mainshaft. Ensure lugs locate
in recesses of the synchronizer hub. The outer
ring tabs must engage in the synchronizer hub
recessesd. Use plastic drift to drive on
synchronizer hub.
2-32
16 S 221, 16 S 181, 8 S 181 Assembling Mainshaft
11 Helical gear (3) axial play must be at least

0.20 mm. 12
8
12 Insert couplings (8) into synchronizer hub (9). 9 11
3
13 Push sliding sleeve (10) over synchronizer body
and outer ring and locate against clutch disc.
14 Insert new compresion springs (11) and pressure
pieces (12) into the synchronizer hub, ensuring
that they are the right way round.
NOTE: Place “dual-cone synchronizer’’ pressure 16
pieces in correct position in the synchronizer hub. 15
14
13
15 Use suitable tool to guide pressure pieces into the
10
synchronizer hub and sliding sleeve.
16 Fit outer ring (13). The lugs must engage in the
couplings and and the tabs must engage in the
synchronizer hub recesses.
17 Fit intermediate ring (14). Lugs must point
towards the output end. Insert inner ring (15) and
engage lugs into couplings.
18 Fit clutch disc (16) with raised inner teeth facing
towards input end and engage with intermediate
ring (14). Move sliding sleeve to neutral position,
pressing against clutch disc. The pressure pieces
can be heard clicking into place. 19
18
17 001944
001944
! DANGER
bush.
19 Heat bush (17) to 120 °C and push onto mainshaft

until firmly seated. Use plastic drift to drive on if
necessary.
20 Lightly oil needle cage (18) and push over bush
(17).
21 Place 1st/5th speed helical gear (19) onto needle
cage (18) so the engaging teeth mesh with clutch
disc.
2-33
! DANGER
21
clutch body. 20
22 Heat clutch body (20) to 120° C and push onto

mainshaft until firmly located.
NOTE: Ensure clutch body collar faces towards
output end.
23 Axial play on 1st/5th speed helical gear must be
at least 0.20 mm.
! DANGER 23
bush.
24 Heat bush (21) to 120° C and push onto mainshaft

until firmly seated.
25 Lightly oil needle cage (22) and push over bush 26
(21). 24 25
26 Push reverse speed helical gear (23) onto main-
shaft and over needle cage. Ensure engaging teeth
face towards input end.
009507
! DANGER
roller bearing.
27 Heat roller bearing (24) to approx. 100° C and

push onto mainshaft until firmly seated. Use
plastic drift to drive on if necessary.
28 Attach circlip (25) into annular groove on main-
shaft.
NOTE: Axial play on circlip must be between 0
and 0.05 mm. Select correct circlip from spare
parts catalogue.
29 Push pressure disc (26) onto mainshaft.
NOTE: There is no pressure disc (26) in the
older version.
30 Clamp output end of mainshaft.
CAUTION
Do not damage mainshaft. Always use aluminium
similar device.
2-34
16 S 221, 16 S 181, 8 S 181 Assembling Mainshaft
31 Oil needle cage (27) and push onto mainshaft.

34 30
32 Push 3rd speed helical gear (28) over needle cage. 31
Engaging teeth of helical gear face towards 32 33
output end.
33 Place clutch body (29) onto engaging teeth of
helical gear.
Refer to Chapter 6, check wear limits.
34 Place synchronizer ring (30) onto clutch body.
27
28
! DANGER
synchronizer hub.
35 Heat synchronizer hub (31) 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.
36 Fit sliding sleeve (32).
NOTE: Recesses inside sliding sleeve must line
up with recesses in synchronizer hub for
compression springs (33) and pressure pieces 001946
(34).
37 Insert new compression springs and pressure
pieces into holes in synchronizer hub and guide
into sliding sleeve.
2-35
38 Position synchronizer ring (35) so lugs locate in

recesses in synchronizer hub. 40 39
Refer to Chapter 6, check wear limits. 43 42 41
39 Place clutch body (36) onto synchronizer ring.

40 Move sliding sleeve into neutral position, 35
36
pressing synchronizer ring (35) and clutch body 37
(36). The pressure pieces can be hear clicking 38
into place. 37
41 Insert both roller bearings (37) into 4th speed
helical gear (38).
NOTE: Lubricating bores (see arrows) on roller
bearings must face outwards.
! DANGER
roller bearing and helical gear.
42 Heat roller bearings and helical gear to 100° C

001947
001947
and push onto mainshaft until bearing pack is
correctly seated.
NOTE: The helical engaging teeth on the helical
gear must face towards the output end.
43 Axial play of helical gear must be at least
0.05 mm. 37 37
NOTE: Hint: Axial washer (39), roller bearing
(40), split ring (41), circlip (42) and ring (43) are
only fitted in Section 11 “Adjusting shafts’’.
38
004915
2-36
16 S 221, 16 S 181, 8 S 181 Synchronizers
4.7 Assembling synchronizer

2
4.7.1 Version ZF-BK
1
1 Check wear limits according to Section 6.
2 Renew compression springs (5). This guarantees
prescribed shift force for sliding sleeve (6).
3 Synchronizers may be subassembled first or
assembled on the mainshaft itself.
4
4 Push sliding sleeve (6) onto synchronizer hub.
Insert new compression springs (5) and pressure
3 5
pieces (4) into synchronizer hub (3). Hold drift
against centre of pressure pieces and guide
pressure pieces into sliding sleeve (6).
5 Position clutch body (1) and synchronizer ring (2)
and push sliding sleeve (6) into middle position.
NOTE: Ensure correct position of pressure
pieces. 1a
2a
6
009510
009510
4.7.1.1 Sectional view of synchronizer/ZF-BK
1 Clutch body 6
2 Synchronizer ring
3 Synchronizer hub 2 2a
4 Pressure piece 1
5 Compression spring 5
6 Sliding sleeve 4 1a
3
001940
001940
2-37
Synchronizers 16 S 221, 16 S 181, 8 S 181
4.7.2 Version ZF-D

2
1 Assembly procedure basically similar to version 7
ZF-BK. 8
1
2 Teeth of sliding sleeve (6) have 3 recesses
covering 3 teeth each. Align middle tooth with
narrow recess in synchronizer hub (3) (pressure
piece groove). Renew compression springs.
3 Insert new compression springs (5) and pressure
pieces (4) into synchronizer hub. Fit pressure
pieces so round head of pressure piece juts into
recess in sliding sleeve teeth. 4
4 Insert couplings (9).
5 3
5 Insert outer ring (2), intermediate ring (7) and
inner ring (8).
9
6 Place clutch disc (1) in position.
NOTE: Ensure correct position of pressure 1a
pieces. 8a
7a
2a
6
001941
4.7.2.1 Sectional view of synchronizer/ZF-D

6
1 Clutch disc
1a
2 Outer ring 2 2a
3 Synchronizer hub 7 7a
1
4 Pressure piece 8a
8 5
5 Compression spring
4
6 Sliding sleeve
7 Intermediate ring
8 Inner ring
3
001942
001942
2-38
16 S 221, 16 S 181, 8 S 181 Removing Layshaft
4.8 Layshaft
5
4.8.1 Dismantling layshaft 4
3
CAUTION 2
Do not damage layshaft. Always use aluminium 1
clamping jaws when clamping layshaft .
1 Clamp output end of layshaft so that roller

bearing (6) cannot be damaged.
2 Detach circlip (1) from annular groove. 6
3 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).
4 Clamp layshaft at input end.
5 On output end, slide gripper 1X56 136 710 over 001948
roller bearing inner race (6) and tighten knurled 001948
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).
6 Press off helical gears (3, 4 and 5) individually
and in sequence.
NOTE: The helical gear (3) is not included in the
8 S 181 transmission. In its place is a ring (7) (see 5
figure 004477). 4
7
2
1
004477
004477
2-39
Assembling Layshaft 16 S 221, 16 S 181, 8 S 181
4.8.2 Assembling layshaft 3

4
! DANGER 5
parts. 1
1 Ensure bores in helical gears (3, 4 and 5) and

seats on layshaft are free of oil, grease and dust.
2 Heat helical gears to 160 - 180° C and push onto
6
layshaft in sequence (3, 4 and 5). Press helical
gears on immediately. There must be no play
whatsoever.
NOTE: In the 8 S 181 transmission, there is a
ring (7) in place of the helical gear (5) {see figure
004477/1).
3 Heat inner race of roller bearing (6) to 100° C and 001948
001948
push onto layshaft. Press roller bearing on until

firmly seated, with no play on output end.
3
4 Heat inner race of roller bearing (2) to 100° C and
4
push onto layshaft. Press roller bearing on until
7
firmly seated, with no play on input end. 2
1
5 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.
004477/1
NOTE: a = Direct drive

b = Overdrive
a b
001949
001949
2-40
16 S 221, 16 S 181, 8 S 181 Assembling Clutch Housing / Centre Housing
5 Installing components
5.1 Centre housing

5 10
1 Fit all screw plugs, pressure switches and filler 3
necks with new seal rings or gaskets and insert. 11
Tightening torques: see “Adjustment Data,
Tightening torques’’section.
9
2 Insert injection pipe (1) if required. Roll ends into 1 7 8
holes in housing using rolling tool 1X20 155 653
and insert O-ring (3).
Rolling torque = 5 to 6 Nm.
3 Insert new filter (4). 6
4
4 If necessary, fit type-plate (5) using pins.
5 If necessary, insert new cylindrical pins (6) into 001950
housing.
6 Drive new taper roller bearing outer races for
mainshaft and layshaft into centre housing if
necessary.
NOTE: Heat bearing bore to approx. 60°C using
hot air blower.
7 Insert bearing bush (7), circlip (8) and new
packing using plastic drift (9). Ensure correct
seating.
8 Insert compression spring (11) with locking pin
(10) and align . Screw in fixture 1X56 137 287.
5.2 Clutch housing
1 If necessary, insert taper roller bearing outer races

for the input shaft and layshaft into bearing bores
in the clutch housing.
NOTE: Input shaft bearing outer race above.
Layshaft bearing outer race below.
2 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.
3 Screw in cleaned oil drain plug and magnet (1).
1 2
4 Fit cap (2).
001951
001951
2-41
Wear Limit/Synchronizer 16 S 221, 16 S 181, 8 S 181
6 Synchronizers/wear limit
x
6.1 Determining wear limit
(except for 1st /2nd gear)
Check condition of synchronizer rings and clutch

bodies before assembling synchronizers.
1 2
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.
2 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.
3 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).
001999
6.2 Determining wear limit (1st /2nd gear)
1 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 F 50 N
evenly together. Evenly apply 50 Nm on outer
ring.
2 Using a feeler gauge, measure distance (s)
between clutch disc and outer ring at two s
opposing points. The wear limit is 1.5 mm. If
distance (s) is below wear limit, use new 1 2 3 4
intermediate and/or outer ring and inner ring.
001952
001952
2-42
16 S 221, 16 S 181, 8 S 181 Adjusting Mainshaft
7 Adjusting mainshaft
2
7.1 Determining ring and axial washer
(straight-cut version) 1
1 Place mainshaft into centre housing using lifting

device 1X56 137 200.
2 Place ring (1) into clutch body (2). Fit parts onto
4th speed helical gear.
3 Take several measurements of distance between
top edge of clutch body and centre housing
sealing face with gasket fitted. Calculate average
distance.
4 Nominal dimension X of 19.2-0.5 mm must be
001953
ensured. If the average distance is different, select
ring to ensure nominal distance (see table in
under 5).
5 Select thrust washer (3) from the following table.
If 3.6 mm ring is required, use 7.9 mm thrust
washer.
Ring (1): 3.6 / 4.0 3
Thrust washer (3): 7.9 / 8.3 1
6 Remove mainshaft from centre housing and place

X
thrust washer onto mainshaft with raised collar

facing towards helical gear.
! DANGER
bearing inner race.
7 Heat new bearing inner race (4) to 100° C and

place onto bearing journal of main shaft ensuring 001954
001954
it is firmly seated. Drive on using plastic drift.
8 Apply approx 4g of lubricating grease (Aralube
HL2 or Texando F020) bearing inner race (collar
side) on face of bearing output end (see arrow).
NOTE: Make sure no grease is applied to the
outside of the bearing rollers. Grease applied here
may block the input shaft lube bores. 3
9 Using drift 1X56 137 676, insert split ring (5) 4
into annular groove on mainshaft to give axial 5
6
play and prestress of - 0.05 mm to + 0.05 mm.
Split rings are available in 0.1 mm thicknesses.
10 Slide new circlip (6) over split ring and peen over
at 3 points (120° apart) using punch.
001955
2-43
Adjusting Mainshaft 16 S 221, 16 S 181, 8 S 181
7.2 Determining ring and axial washer

(helical-cut version)
1 Measure distance between mainshaft and bearing

inner race contact point using depth gauge
(dimension „a“).
2 Insert axial washer (1) and measure distance 4.6 -0.4
2
between mainshaft and axial washer using depth
gauge (dimension „b“).
3 a – b must give a play of between + 0.07 mm and
- 0.08 mm.
1
4 After selecting the correct axial washer, insert
ring (2) into clutch body (3). Place parts onto 4th-
speed helical gear.
5 Measure distance between axial washer and
clutch body at several points. Calculate mean +0.07bis
+0.07 to -0.08
value. Nominal dimension = 4.6 - 0.4mm (select
ring (2) accordingly). 009521
009521
! DANGER
bearing inner race.
2
6 Heat new bearing inner race (4) to 100°C and

place onto mainshaft bearing journal until it is in
firm contact. Fully drive home using plastic drift.
7 Apply approx 4g of lubricating grease (Aralube
HL2 or Texando F020) bearing inner race (collar
side) on face of bearing output end (see arrow).
NOTE: Make sure no grease is applied to the
outside of the bearing rollers. Grease applied here
may block the input shaft lube bores.
001953
8 Use drift 1X56 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.).
9 Slide new circlip (6) over split ring and peen over 1
in three places (120° apart) using punch. 4
5
6
001955
2-44
16 S 221, 16 S 181, 8 S 181 Installing Shafts
8 Installing shafts
8.1 Input shaft, mainshaft and layshaft
! DANGER
Ensure fixture and rope are firmly secured. 5
1 Place alternating pin 1X56 137 953 onto the 4

layshaft locator. Insert output end of mainshaft 7
(1) into locator 1X56 137 675. Place clutch body, 6
correct ring and synchronizer ring onto the teeth
of the helical gear on the mainshaft. Place the
complete input shaft onto the mainshaft. Position 2
layshaft (2) with teeth at correct height for
meshing. Push the layshaft against the mainshaft
and bring the teeth into mesh. 3
1
2 Insert shift rails (3) and fulcrum pads into sliding
sleeves on mainshaft.
3 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.
4 Screw lifting device onto layshaft using disc
1X56 137 933 (6). 001995
5 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.
7 Remove all lifting equipment.
8 Remove device 1X56 137 287 for interlock.
9 Turn input shaft to centre bearing rollers.
.
2-45
Adjusting Shift Fork 16 S 221, 16 S 181, 8 S 181
9 Splitter shift fork / shift rail
9.1 Adjusting shift fork

6
1 Guide in shift rail (1) from inside (in centre
housing). To protect packaging, slide correct size
pin through packaging from outside to prevent 3
damage to the packaging caused by shift rail
threads. 4
CAUTION
Do not damage flange packing when inserting shift
rail.
1
2 Correctly position shift fork (3) and fulcrum pads
against sliding sleeve (4) and place onto shift
rail.
NOTE: Line up bores in shift rail with thread in
shift fork.
3 Insert grub screws (6) (do not tighten yet). 2 x
5
4 Switch sliding sleeve to output.
001956
001956
5 Screw piston (2) and new double-grooved ring
onto shift rail.
NOTE: Renew lock nut;
Ensure the thread is absolutely free of grease.
6 Nominal dimension (X) “107.9 mm“ between
piston and centre housing (5) sealing face must be
94.0 mm. Use grub screws (6) to adjust shift.
Measure without gasket on centre housing .
7 Fulcrum pads in the sliding sleeve must have the
same play above and below (check using feeler
gauge).
8 Tighten grub screws evenly.
2-46
16 S 221, 16 S 181, 8 S 181 Adjusting Shift Fork
I Adjust as follows if using support plate

5
1X56 137 917:
9 Work steps 1) to 3) and 5). Fit splitter cylinder (7) 8

(see work steps 1) to 4) in Section 13.2). Screw
support plate onto the housing sealing face.
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. Then follow work steps 7)
and 8).
7
001965
II Adjust as follows (new version) if using

centering device 1X56 138 079 and support
plate 1X56 137 917:
8
10 Adjust as described under step 9).
Attach the centering device 1X56 138 079 before
performing steps 7) and 8).
3
1
009944
2-47
Assembling Clutch Housing / Centre Housing 16 S 221, 16 S 181, 8 S 181
10 Clutch housing / centre housing
10.1 Fitting clutch housing
1 Fit new gasket to centre housing sealing face.
! DANGER 1
Ensure fixtures and rope are firmly secured.
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.
001957
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 13 hex bolts inside clutch housing and 9
hex bolts outside. Turn input shaft several times
to centre bearing rollers.
4 Remove hook 1X56 136 564.
2-48
16 S 221, 16 S 181, 8 S 181 Adjusting shafts
11 Adjusting shafts
11.1 Input shaft and connection plate
1 To achieve correct setting, the input shaft roller-

bearing must be play-free when measured. To
ensure this, the outer race (1) must touch the bea-
ring rollers (2). Use plastic drift to push taper rol-
ler bearing outer race towards output end. Rotate
input bearing several times to centre bearing rol-
lers.
NOTE: Bearing rollers should not move and 1 3
should not be prestressed. a
2 Measure distance between face of bearing outer
race (1) and sealing face (3) using depth gauge.
Note down dimension “a”. 2
NOTE: Measure at two opposite points and 001958
001958
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.
NOTE: Measure at two opposite points and cal-
culate the average value. 4 b
4 Calculate the difference “c” and note it down: 6
c = (b + gasket) – a
5
NOTE: Axial play on roller bearing: 0.0 to
0.1 mm.
5 Select a shim of the same thickness as dimension
“c” (max. 0 - 0.1 mm).
6 Place shim in the connection plate. Shims are
available in 0.05 mm thicknesses.
001959
NOTE: The same procedure is used for
measuring split connection plates.
2-49
Adjusting shafts 16 S 221, 16 S 181, 8 S 181
11.2 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 pres-
sed firmly against the bearing rollers (2). Rotate
input bearing several times to centre bearing rol-
lers.
NOTE: Bearing rollers should not move and
should not be presetressed.
2 Measure thickness of shim using depth gauge.
NOTE: Measure at two opposing points. 1
3 Measure distance between housing sealing face a
and bearing outer race (1) face. Measure gasket
and add to dimension “a”.
2
4 Use average dimension “a” obtained from
measurements taken to select correct shim 001960
001960
NOTE: Axial play 0.0 to 0.1 mm.

5 Thickness of shim must correspond to measure-
ment “a” (max. minus 0.1 mm).
6 Place shim onto taper roller bearing outer race.
Shims are available in 0.05 mm thicknesses.
2-50
16 S 221, 16 S 181, 8 S 181 Assembling/Connection Plate
12. Fitting clutch housing components
12.1 Connection plate with integral pump 10

9
Single-piece version 8
11 1
7 2
1 Thinly coat outside of shaft seal (1) with
sealing compound and, using drift
1X56 103 766, insert into connection plate. 6 5
NOTE: Sealing lip on shaft seal ring must face

towards drift. 4
3
2 Place washer (8), spacer ring (9) and washer (10)
onto input shaft.
3 Screw guide pin 1X56 137 949 into the threaded 001993
hole in the layshaft. 001993
4 Fit new gasket (11) to connection plate (2), place

over input shaft and onto clutch housing. Tighten
hex bolts and nuts.
5 Unscrew guide pin from the layshaft.
6 Place inner rotor (3) into pump housing (5).
Engage with layshaft.
7 Place outer rotor (4) into pump housing.
NOTE: Ensure there is axial play on outer and
inner rotors.
8 Thinly coat cover sealing face (6) with Loctite
No. 574 (from hole to hole) and place onto pump
housing.
9 Drive cylindrical pins (7) into pump cover. Rotate
inout shaft to check.
10 Affix pump cover
2-51
Assembling/Connection Plate 16 S 221, 16 S 181, 8 S 181
Split version
1 Place washer (1) onto input shaft. 6

7
2 Place connection plate (2) over input shaft and
onto clutch housing together with new gasket (3). 5 1
9
Tighten hex nuts (4). 10
3 Fit new gasket (7). Bring pump housing (6) and

inner rotor into mesh with layshaft and tighten
(8). 8
11 3
4 Insert outer rotor (9) into pump housing.
NOTE: Ensure that there is axial play on the 4
outer and inner rotors. 009519
5 Lightly coat pump cover sealing face (10) with

Loctite 574 (from bore to bore) and place onto
pump housing.
6 Firmly attach pump cover.
2-52
16 S 221, 16 S 181, 8 S 181 Assembling/Release Fork
12.2 Release fork
Released fork (pulled) 7

3 4
1 Insert plain spherical bearing (1) into bearing 9 2
block (2) and attach circlips (3). 8
2 Fix bearing block using hex bolts (4).
1
7
3 Slide release fork (5) over bearing block and 5 8
9
insert pin (6).
4 Fit seal rings (7) and seals (8) onto pin.
5 Attach circlips (9) to pin. 6
009520
Release fork (pushed)
1 Screw in ball bolt (3) with washer (4).

Use Loctite no. 262.
4
Tightening torque = 100 Nm 3
2
2 Place ball cup (2) in clutch lever (1). 1
3 Place clutch lever (1) onto ball bolt (3).
004484 004484
2-53
Assembling/Release Fork 16 S 221, 16 S 181, 8 S 181
Release fork (pulled)

9
1 Push shaft (2) into clutch bell housing. Fit new 10
tab washer (7) and grooved nut (6) onto shaft.
2 Guide shaft into 1st bearing bore on connecting 1
plate. Push release fork (1) onto shaft and guide
this into 2nd bearing bore on the connecting plate. 2
3 Place bearing bush (8) over shaft and into clutch
housing.
5
4 Hit slotted pins (4) into release fork (1) and shaft 3 6 8
(refer to assembly specification). 7
4
5 Fit tab washer (7) and grooved nut (6) onto bea-
ring bush. Secure grooved nut. 004483
Tightening torque = 200 Nm

004483
6 Fit shift lever (3) onto shaft using screw (5)
(observe position);
7 Mount sheet (9) using four screws (10);
Tightening torque = 23 Nm
7
6
1 2
4 004 917
004917
3
004 918
004918
2-54
16 S 221, 16 S 181, 8 S 181 Assembling/Reverse Idler Gear
13 Fitting centre housing components
13.1 Reverse idler gear/reverse idler pin 3

4
5
1 Insert needle cages (1) into reverse idler gear.
2 Place reverse idler gear (2) into housing.
2
NOTE: Collar of reverse idler gear must face
towards output end. 1
3 Push reverse idler pin (3) into centre housing
from output side until firmly seated.
4 In “first version’’, screw in washer (4) and 7
locking bolt (5).
NOTE: In “2nd version’’, the reverse idler pin is 001962
001962
secured using a centrally-mounted clamping pin
(8) (figure 002000).
5 Fit cover (6) and new gasket (7) onto centre hou-
sing.
3 8
2
1
002000
13.2 Cylinder
1 Remove supporting plate and cylinder.

2 Check locking nut on piston.
3
3 Fit spring washer (1) onto housing. 4
1
4 Fit cylinder (2) with new O-rings (3 and 4).
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.
001963
001963
2-55
Compressed Air Test 16 S 221, 16 S 181, 8 S 181
13.3 5/2-way valve
1 Insert new O-ring (1) into 5/2-way valve.

2 Screw 5/2-way valve (2) onto centre housing.
Tightening torque = 9.5 Nm.
NOTE: There is no 5/2-way valve in the 8 S 181
transmission.
1
001964
001964
13.4 Compressed air test for piston and splitter

cylinder
3
1 Screw support plate 1X56 137 917 (1) for splitter
cylinder (2) onto centre housing (3). 1
2 Supply compressed air (max. 6.8 bar) to 5/2-way
valve and piston.
3 Wet outer edge of splitter cylinder and check for
bubbles (leaks).
4 Supply compressed air to piston in opposite direc-
tion and check if air escapes through 5/2-way
valve.
5 If bubbles form, fit new O-rings if necessary and 2
check correct location.
6 If air escapes, renew double-grooved ring on
piston.
001965
7 Remove support plate (1). 001965
2-56
16 S 221, 16 S 181, 8 S 181 Installing Components
13.5 Injection pipe
1 Using drift 1X56 137 835, drive injection pipe (1)

into mainshaft until firmly located.
001966
2-57
Installing Range-Change Housing 16 S 221, 16 S 181, 8 S 181
14 Installing complete range-change
1 Fit new gasket (1) onto centre housing (2).

NOTE: There must 3 cylindrical pins in centre
housing.
2 Fit 2 hex bolts to range-change housing to allow 1
range-change to be suspended from a rope and
positioned horizontally against centre housing.
CAUTION 2
Secure hex bolts with nuts. Ensure rope is firmly
secured.
Hint: Use threaded pins on centre housing to sim-

plify 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.
4 Remove hex bolts and rope when range-change is
held against centre housing. 3
5 Slide range-change (3) parallel to centre housing 2

and bolt together.
6 Switch piston to end position (high or low group).
001967
2-58
16 S 221, 16 S 181, 8 S 181 Assembling Centre and Range-Change Housing
7 Screw fixing device 1X56 137 579 into centre

housing and into hole for detent plunger (6).
8 Screw new locking nut onto piston 13 14
NOTE: Renew locking nut. Make sure the thread 20 6
is absolutely free of grease. 21 7
9 Remove fixing device.

11
10 Fit cylinder and tighten.
8
NOTE: Carefully push cylinder over piston
together with guide ring and piston gasket. 10
9
11 Screw in detent plunger (6) together with new
seal ring (7). 22
19 23
18 15
12 Insert pin (8) and switch (9) together with new
seal ring (10).
17
16
NOTE: In the new version, fit switch (9) onto the
range-change housing. 001968
001968
13 Fit screw plug (13) with new seal ring (14).
14 Insert pin (15) and switch (16) with new seal ring
(17).
15 Insert detent plunger (18) with new seal ring (19);
16 Screw in reverse gear pressure switch (20) with
new sealing ring (21).
NOTE: In the new version, the pressure switch
(20) is mounted in the cover (shift housing).
17 Screw in screw plug (23) with new seal ring (22).
18 Screw in mechanical speedometer and new seal
ring or impulse sensor.
19 Screw breather into bore (11).
2-59
Installing components 16 S 221, 16 S 181, 8 S 181
15 Installing components
15.1 Shift housing 3
1 Place new gasket (1) onto clutch housing (2) and

sealing face. 1
2 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 Shift through all the gears. There must be
noticeable 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. 001969
CAUTION
14°30'+2°
The shift turret housing must be centered on the 1st, 3rd, 5th, 7th gear 14°30'+
2°
transmission housing so that equal play (excess shift 2nd, 4th, 6th,
travel) is obtained on both sides and the resultant 8th gear
shift angle is 14° 30’ +2° (see illustration).
009894
15.2 Plastic pipes
1 Using union screws and new seal rings, screw 2

plastic pipes (1) to cylinder (2) and shut-off valve
(3) as marked. 6
Tightening torque = 38 Nm. 1 4
5
2 Fit pipe bracket (4) and fixed plastic pipes to hou-
sing.
6 1
NOTE: Observe the following assembly sequen- 6
ce if renewing the pipe bracket or plastic pipes.
3 6
1. Place insert (5) into pipe bracket (4)
2. Draw plastic pipes (1) through the pipe bracket.
3. Press rings (6) into plastic pipes (1).
001992
2-60
16 S 221, 16 S 181, 8 S 181 Compressed Air Test
16 Compressed air test on breather
1 If necessary, remove breather and screw pressure

gauge connection into bore (1). 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
NOTE: There is no 5/2-way valve in the 8 S 181
transmission. Therefore, this test is not required 2
here.
001970
001970
2-61
English
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Component manual 8 S 181

In the interest of continuing product development,

To ensure that the mechanic's health is not

- Comply with all the warnings and safety

- Wear clean, fitted clothes and apply

- Ensure proper extraction of dangerous

- Maintain a safe distance from rotating and/or

- Avoid unnecessary contact with drained oil.

- Various sorts of oil and other lubricants used

- Exercise caution when working with springs

- If necessary, support the component

- Always use the appropriate lifting gear

- After a fire it is possible that hazardous

Contents ......................................................................................................................................... 1-01

1 Removing components/range-change ........................................................................................ 2-01

2 Removing components from centre housing ............................................................................. 2-12

3 Removing components from clutch housing.............................................................................. 2-24

4 Removing components ................................................................................................................. 2-26

5 Installing components .................................................................................................................. 2-41

6 Synchronizer/wear limits............................................................................................................. 2-42

7 Adjusting mainshaft..................................................................................................................... 2-43

8 Installing shafts ............................................................................................................................ 2-45

9 Splitter shift fork .......................................................................................................................... 2-46

10 Clutch housing/centre housing ................................................................................................... 2-48

11 Adjusting shafts............................................................................................................................ 2-49

12 Fitting clutch housing components............................................................................................. 2-51

13 Fitting centre housing components............................................................................................. 2-55

14 Fitting complete range-change ................................................................................................... 2-58

15 Fitting components....................................................................................................................... 2-60

16 Compressed air test on breather ................................................................................................ 2-61

2. Specified equipment, e.g. specialized tools

3. Genuine ZF spares, to our latest specifications

16 S 221, 16 S 181 und 8 S 181 transmissions main components:

ZF Friedrichshafen AG offers the following options with these transmissions:

Layout of repair manual:

Section 2 is a step-by-step guide to transmission repairs.

Directions for removal and assembly, general work instructions

Specified ZF special tools must be used.

Important work safety notice:

The following safety instructions appear in this manual:

NOTE Refers to special processes, techniques, data, use

CAUTION This is used when incorrect, unprofessional

! DANGER This is used when lack of care could lead to

Always follow the working steps as described in the text.

Tightening torques for bolts and nuts from ZFN 148

Metric coarse pitch thread Metric fine pitch thread

Size Tightening torque Size Tightening torque

M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1.5 135 200 235

M 18 280 390 460 M 18 x 2 290 420 490

M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991

0732 040 409 Synchronizers 12.5 1.4 6.65 23.7

Description Tolerance Measuring device Remarks

Description Tolerance Measuring device Remarks

12. Wear limit for Feeler gauge Exchange synchronizer ring

4-gear section and

Description Tolerance Measuring device Remarks

Selection of ring and Sliding caliper Ring Shim

Table shows which shim is

19. Tightening torque for 10 Nm Torque wrench

21. Tightening torque of 35 Nm Torque wrench Use new seal rings