Repair Manual

Repair Level 2
Component Replacement

1290 751 106

Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright. Any

reproduction or dissemination in whatever form
which does not comply fully with the intended pur-
pose of this documentation is prohibited without the
consent of ZF Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, 2005-06

Edition: 2005-06

1290 751 106

ZF-AS-Tronic lite Table of Contents

Page

Preface ................................................................................................................................................. 5
Safety Instructions................................................................................................................................ 6
General Information............................................................................................................................. 6
Overview of Amendments ................................................................................................................... 9
Tightening Torques for Nuts and Bolts, Extract from ZFN 148 .......................................................... 10
Screw Plugs DIN 908, 910, and 7604................................................................................................... 11
Union Screws DIN 7643....................................................................................................................... 11
Recoding from DIN to ISO Standard ................................................................................................... 12
Special Tool .......................................................................................................................................... 14

Preparatory Work ................................................................................................................................. 15

Final Work ............................................................................................................................................ 16
Transmission and Components ........................................................................................................... 17

1 Wiring Harness .................................................................................................................................... 1-1

1.1 Removal of Wiring Harness ................................................................................................................. 1-1
1.2 Fitting Wiring Harness ......................................................................................................................... 1-4

2 Power Pack ........................................................................................................................................... 2-1

2.1 Removal of Power Pack........................................................................................................................ 2-1
2.2 Fitting Power Pack................................................................................................................................ 2-6

3 Transmission Actuator ........................................................................................................................ 3-1

3.1 Removal of Transmission Actuator...................................................................................................... 3-1
3.2 Fitting Transmission Actuator.............................................................................................................. 3-5

4 Clutch Actuator.................................................................................................................................... 4-1

4.1 Removal of Clutch Actuator................................................................................................................. 4-1
4.2 Fitting Clutch Actuator......................................................................................................................... 4-4

1290 751 106 - 2005-06 3

 Preface

This manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out main-
tenance and repair work on ZF products.

This manual deals with a 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
and fitters who have had their practical and
theoretical knowledge updated on a regular basis at
our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG

all over the world offer you:

1. Consistently well-trained personnel

2. Specified equipment,
e.g: Special tools

3. Genuine ZF spare parts, to

our latest specifications

All work performed in these service points is

carried out conscientiously and with care.

Warranty:
Repair work carried out at ZF service points is
subject to the contractual conditions prevailing in
the individual case.

ZF Friedrichshafen AG Damage resulting from work performed by non-ZF

Commercial Vehicle and Special Driveline personnel in an improper and unprofessional
Technology manner, together with follow-on costs caused by
Service Plant 2 such work, is excluded from the contractual
Phone +49 (0)7541 77-0 warranty agreement.
Fax +49 (0)7541 77-908000 This also applies where genuine ZF spare parts have
Internet: www.zf.com not been used.

2003-08 5

Safety Instructions
Companies repairing 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 therefore
familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF prod-
ucts must receive appropriate training in advance.
It is the responsibility of each company to ensure
that their repair staff is properly trained.
The following safety instructions appear in this
manual:
NOTE
Refers to special processes, methods, information,
use of aids, etc.
CAUTION
This is used when incorrect, unprofessional
operation could damage the product.
! DANGER
This is used when lack of care could lead to
personal injury or death.
2005-04
Important Information
General Information
Read this manual carefully before starting and tests
or repair work.
CAUTION
The pictures, drawings, and components shown do
not always represent the original object, but are
used to illustrate working practices.
The pictures, drawings, and components are not to
scale and no information about size and weight
should be inferred (even within a complete
illustration).
Always follow the working steps as described in
the text.
After completion of repair work and testing, skilled
staff must satisfy themselves that the product is
functioning correctly.
! THREATS to the environment!
Lubricants and cleaning agents must not be
allowed to enter the soil, ground water, or sewage
system.
• Ask your local environment agency
for safety information on the relevant
products and adhere to their requirements.
• Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
agents always refer to the manufacturer’s
instructions.
CAUTION
The transmission must NOT be suspended on the
input shaft NOR on the output flange.
6

The ZF-Service Information details MUST be
observed. These are available from all ZF Service
Centers or from the ZF-ServiceLine.
In any cases of doubt, always contact the relevant
expert departments within the ZF Service Centers
for advice.
Whenever working on the transmission, ensure
cleanliness and carry out the work as instructed.
Use specified tools to dismantle and assemble
transmissions.
After removing the transmission from the vehicle,
clean thoroughly with a suitable cleaning agent
before
opening.
Pay particular attention to the corners and angles
of housings and covers when cleaning with a suit-
able cleaning agent.
Parts held on with Loctite can be slightly loosened
if warmed with a hot air blower.
Cleaning Parts
Remove remains of gaskets from all sealing faces.
Carefully remove burrs or other similar patches of
roughness using an oil stone.
Lube bores and grooves must be free of anti-corro-
sion grease and foreign matter. Check that they can
move freely.
Carefully cover opened transmissions to prevent
the entry of foreign matter.
During disassembly, seal all hydraulic components,
pipes, and screw connections immediately with
suitable protective caps.
Only place hydraulic parts on clean bases. The
tiniest particle of dirt may result in total system
failure!
1290 751 106 - 2005-06
Repair Instructions
Reusing Parts
Parts such as ball or roller bearings, multi-discs,
thrust washers etc., must be inspected by a compe-
tent person, who should decide whether or not they
can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.
Gaskets, Locking Plates
Parts which cannot be removed without being dam-
aged must always be replaced with new parts (e.g.
gaskets and locking plates).
Shaft Sealing Rings
Always replace shaft sealing rings with rough,
ripped, or hardened sealing lips. Seal contact sur-
faces must be totally clean and in perfect condition.
Reworking
Rework may only be carried out on seal contact
surfaces using plunge-cut grinding. Never use an
emery cloth. Ensure that there are no traces of
grinding or rifling from grinding.
If rework is needed on spacer washers or shims etc.
because of clearance settings, ensure that the
reworked areas contain no face runout and have
the same surface quality.
Transmission Assembly
Find a clean site to assemble the transmission.
Flat gaskets are installed without the use of sealing
compound or grease. When measuring silicon-
coated gaskets, take care not to include the silicon
layer in the measurement.
During assembly, comply with all adjustment
values, checking data and tightening torques
specified in the repair manual.
7

Bearings
f the bearings are fitted while warm, these should
be warmed up (e.g. in a heating cabinet).
The temperature should be approx. 85 °C and must
not exceed 120 °C. All bearings fitted must be coat-
ed with operating oil after assembly.
Sealing
If a sealing agent* is to be used for carrying out seal-
ing, comply with the manufacturer’s directions for
use. A thin layer of sealing agent should be applied
to the
surfaces and must provide even coverage. Do not
allow sealing compound to enter oil ducts and
bores. On oil-carrying ducts and bores, the sealing
agent must be wiped off the surfaces to be sealed
near apertures to ensure that no sealing agent pene-
trates the oil feeds when the surfaces are sealed.
Shaft Sealing Rings
a) Apply a thin coat of sealing agent* to outer edge
of shaft sealing rings with a “steel surround”.
b) Never apply sealing agent to shaft sealing rings
with a «rubber surround» but apply a thin coat of
Vaseline 8420 to the outer edge or wet with a
lubricant, e.g. a water-soluble, concentrated
washing-up liquid (e.g. Pril, Coin, Palmolive).
c) Shaft sealing rings with steel and rubber sur-
rounds
should be treated on the outer edge of the rubber
surround as described above in section (b).
d) Duo shaft sealing rings have two sealing lips. The
dust protection sealing lip (X)
must face outwards.
X
1290 751 106 - 2005-06
Repair Instructions
e) Fill the gap between the sealing lips so that it is
60 % filled with grease* (e.g. Aralub HL2 pro-
duced by Aral or Spectron FO 20 produced by
DEA).
f) If possible, heat shaft sealing ring’s bore to
between 40 and 50 °C (this makes fitting easier).
Press the shaft sealing ring on to the relevant
installation depth with mounting or face plate.
Retaining Agents
Retaining agents* may only be used in the places
specified in the parts list.
When using retaining agents (e.g. Loctite), always
comply with the manufacturer’s directions for use.
During assembly, comply with all specified adjust-
ment values, checking data and tightening torques.
Transmission Oil
After completing repairs, fill the transmission with
transmission oil. For the procedure and approved
oils, refer to the transmission operating manual and
the List of Lubricants TE-ML (refer to type plate).
These are available from all ZF Service Centers or
on the Internet at www.zf.com. After filling the
transmission with oil, tighten the screw plugs at the
oil filling point and
the oil overflow to the specified torque.
Pentosin hydraulic medium
The hydraulic tank should be filled completely
when the hydraulic system is depressurized and the
transmission is fully fitted in a horizontal upright
position. Check whether there the Pentosin in the
tank is clean. If the liquid is not clear or even has
green-white discoloration, the tank must be careful-
ly drained and filled with new Pentosin. (White dis-
coloration indicates the presence of water and the
risk of the liquid freezing.
* refer to consumables
8
 List of changes: 1290 751 106

Index Edition date Chapter Author Comments

1290 751 106 - 2005-06 9

 Tightening Torques

Tightening torques for nuts and bolts, extract from

ZFN 148

This standard applies to bolts acc. to DIN 912,
DIN 931, DIN 933, DIN 960, DIN 961 and
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676,
and to nuts acc. to DIN 934 and ISO 4032,
ISO 8673.
This Standard contains data on tightening torques
(MA) for bolts and nuts in strength categories 8.8,
10.9 and 12.9, and nuts in strength categories 8, 10
and 12
Surface condition of bolts/nuts: thermally black-
ened and oiled or galvanized and oiled or galva-
nized, chrome-plated and oiled.
Tighten screws with a calibrated ratchet dial torque
or wrench.
NOTE
Deviating tightening torques are listed separately in
the Repair Manual.

Regular screw thread Fine screw thread

Size Tightening torque (Nm) for Size Tightening torque (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12

M4 2.8 4.1 4.8 M8x1 24 36 43

M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14 16.5 M10x1 52 76 89

M7 15 23 28 M10x1.25 49 72 84
M8 23 34 40 M12x1.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145

M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500

As per: August 1991

2003-08 10
 Tightening Torques

Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643

The screw plug tightening torques were determined
according to DIN 7604 for screwing into steel, grey
cast and aluminum alloys. The values are based on
experience and are intended as reference values
for the fitter.
The values for the tightening torque apply analo-
gously to screw plugs according to DIN 908 and DIN
910, as the thread geometries are almost identical.
General rule:
Screw/bolt class 5, ZFN 148-1
Screw/bolt material: Steel acc. to DIN 7604
Surface condition: as manufactured (without sur-
face protection) and lightly oiled or galvanized,
chromated and lightly oiled.
The tightening torques were determined for screw-
ing into steel, grey cast and aluminum alloys.
The values are based on
experience and are intended as reference values
for the fitter.
General rule:
Screw/bolt class 5, ZFN 148-1
Material: 9SMnPb28K acc. to DIN 1651
Surface condition: as manufactured (without sur-
face protection) and lightly oiled or galvanized,
chromated and lightly oiled.

Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)

Size Tightening torque in Nm Outer Thread Tightening

screwed into pipe- torque
steel/gray cast Al alloy diameter in Nm
M8x1 20* 10*
M10x 1 25 / 30* 15 / 20* 4-5 M8x1 20 - 25
M12x1.5 35 25
M14x1.5 35 25 6 M10x1 25 - 35
M16x1.5 40 30
M18x1.5 50 35 8 M12x1.5 30 - 40
M20x1.5 55 45
M22x1.5 60 / 80* 50 / 65* 10 M14x1.5 35 - 40
M24x1.5 70 60
M26x1.5 80 / 105* 70 / 90* 12 M16x1.5 45
M27x2 80 70
M30x1.5 100 / 130* 90 / 130* 15 M18x1.5 50
M30x2 95 85
M33x2 120 110 18 M22x1.5 60
M36x1.5 130 115
M38x1.5 140 120 22 M26x1.5 90
M42x1.5 150 130
M42x2 145 125 28 M30x1.5 130
M45x1.5 160 140
M45x2 150 130 35 M38x1.5 140
M48x1.5 170 145
M48x2 160 135
M52x1.5 180 150
M60x2 195 165
M64x2 205 175
* DIN 7604 shape C As per: August 1991
11
2003-08
 Conversion from DIN to ISO Standards

Withdrawn Title Substitute Result of check/measures1)

DIN ISO

DIN 1 Tapered pins ISO 2339 - some can be replaced ∅ changed to ISO 2339
- parts which cannot be replaced (e.g. where 1 = 36 mm) documented as DIN
1-OLD

DIN 7 Cylindrical pin ISO 2338 - some can be replaced ∅ changed to ISO 2338
- parts which cannot be replaced (e.g. ≥ 13 and 14 or 1 = 36 mm) document-
ed as DIN 7-OLD

DIN 84 Cylindrical ISO 1207 - some can be replaced ∅ changed to ISO 1207
screws - parts which cannot be replaced (e.g. M2,6) documented as DIN 84-OLD

DIN 85 Flat head ISO 1580 - can be replaced ∅ changed to ISO 1580
bolts

DIN 94 Split pins ISO 1234 - can be replaced ∅ changed to ISO 1234

DIN 417 Threaded pins ISO 7435 - can be replaced ∅ changed to ISO 7435

DIN 439-1 Hex nuts ISO 4036 - cannot be replaced ∅ documented as DIN 439-OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675

DIN 551 Threaded pins ISO 4766 - can be replaced ∅ changed to ISO 4766

DIN 553 Threaded pins ISO 7434 - can be replaced ∅ changed to ISO 7434

DIN 555 Hex nuts ISO 4034 - cannot be replaced ∅ documented as DIN 555-OLD

DIN 558 Hex bolts ISO 4018 - some can be replaced ∅ changed to ISO 4018
- parts which cannot be replaced (e.g. M12, new SW) documented as DIN
558-OLD

DIN 601 Hex bolts ISO 4016 - some can be replaced ∅ changed to ISO 4016
- parts which cannot be replaced (e.g. M10 and M12, new SW) documented
as DIN 601-OLD

DIN 912 Cylindrical ISO 4762 - some can be replaced ∅ changed to ISO 4762
bolts - parts which cannot be replaced (e.g. M18, M22, M27 and M33)
documented as DIN 912-OLD

DIN 931-1 Hex bolts ISO 4014 - some can be replaced ∅ changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new
SW) documented as DIN 931-OLD

DIN 933 Hex bolts ISO 4017 - some can be replaced ∅ changed to ISO 4017
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new
SW) documented as DIN 933-OLD

DIN 934 Hex nuts ISO 4032 - cannot be replaced as a result of uneven nut height and for
ISO 8673 - M10, M12, M14 and M22 with new SW.

DIN 960 Hex bolts ISO 8765 - some can be replaced ∅ changed to ISO8765
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new
SW) documented as DIN 960-OLD

DIN 961 Hex bolts ISO 8676 - some can be replaced ∅ changed to ISO 8676
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with new
SW) documented as DIN 961-OLD

DIN 963 Countersunk bolts ISO 2009 - cannot be replaced as a result of modified head dimensions ∅ documented
as DIN 963-OLD

DIN 964 Countersunk bolts ISO 2010 - cannot be replaced as a result of modified head dimensions ∅ documented
as DIN 964-OLD

1) refers to the productive components numbered at ZF

2003-08 12
 Conversion from DIN to ISO Standards

Withdrawn Title Substitute Result of check/measures1)

DIN ISO

DIN 965 Countersunk bolts ISO7046 - cannot be replaced as a result of modified head dimensions ∅
documented as DIN 965-OLD

DIN 980 Locking nuts- ISO 7042 - cannot be replaced ∅ documented as DIN 980-OLD
ISO 10513

DIN 985 Locking nuts- ISO 10511 - cannot be replaced ∅ documented as DIN 985-OLD

DIN 1440 Washers ISO 8738 - some can be replaced ∅ changed to ISO 8738
- parts which cannot be replaced documented as DIN 1440-OLD

DIN 1443 Bolts ISO 2340 - can be replaced ∅ changed to ISO 2340

DIN 1444 Bolts ISO 2341 - can be replaced ∅ changed to ISO 2340

DIN 1471 Grooved pins ISO 8744 - some can be replaced ∅ changed to ISO 8744
- parts which cannot be replaced (e.g. 1 = 6 mm) documented as DIN 1471-
OLD

DIN 1472 Grooved pins ISO 8745 - some can be replaced ∅ changed to ISO 8745
- parts which cannot be replaced (e.g. 1 = 6 and 5 mm) documented as DIN
1472-OLD

DIN 1473 Grooved pins ISO 8740 - some can be replaced ∅ changed to ISO 8740
- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25 and 50 mm)
documented as DIN 1473-OLD

DIN 1474 Grooved pins ISO 8741 - can be replaced ∅ changed to ISO 8741

DIN 1475 Grooved pins ISO 8742 - can be replaced ∅ changed to ISO 8742

DIN 1476 Grooved stud ISO 8746 - can be replaced ∅ changed to ISO 8746

DIN 1477 Grooved stud ISO 8747 - can be replaced ∅ changed to ISO 8747

DIN 1481 Clamping pins ISO 8752 - some can be replaced ∅ changed to ISO 8752
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481-OLD

DIN 6325 Cylindrical pins ISO 8734 - some can be replaced ∅ changed to ISO 8734
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325-OLD

DIN 7346 Clamping pins ISO 13337 - some can be replaced ∅ changed to ISO 13337
Flange - parts which cannot be replaced (≥ 7, 11 and 23 mm) documented as DIN
6325-OLD

DIN 7976 Self-tapping screws ISO 1479 - can be replaced ∅ changed to ISO 1479

DIN 7978 Tapered pins ISO 8736 - some can be replaced ∅ changed to ISO 8736
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978-OLD

DIN 7979 Cylindrical pins ISO 8733 - some can be replaced ∅ changed to ISO 8733/8735
ISO 8735 - parts which cannot be replaced documented as DIN 7979-OLD

DIN 7981 Self-tapping screws ISO 7049 - can be replaced ∅ changed to ISO 1479

DIN 7982 Self-tapping screws ISO 7050 - cannot be replaced ∅ documented as DIN 7982-OLD

DIN 7985 Cheesehead ISO 7045 - can be replaced ∅ changed to ISO 7045
screws

1) refers to the productive components numbered at ZF

2003-08 13
ZF-AS Tronic lite Special Tools

Fig Diagram Order no. Application Qty. Comments

no.

0637 510 050 10

Protective sleeves
1

0637 510 609 10

Handle-type plug
2

1X56 138.527 2

Centering pin
3

1290 751 106 - 2005-06 14

ZF-AS Tronic lite Preparatory Work

Preparatory Work

Work on the transmission should always be carried

out on a horizontal transmission even when the
transmission is fitted.

Before working on the transmission, the transmis-

sion and its surroundings must be clean. Wash and
dry with compressed air if necessary.

! DANGER
Wear protective glasses!

No dirt may enter the transmission from removed

transmission components or through component
openings. This may result in component and/or
transmission failure.

! DANGER
Disassembly and assembly work may only ever be
undertaken on a depressurized system.
There may be up to 85 bar in the system.
The pressure accumulator must not be released.

Carefully open inner hex of pressure relief valve on

ECU (see arrow) slightly to reduce the pressure in
the system.
A flowing noise can be heard while the level in the
supply tank rises.

When the inflow has finished, retighten the inner

024322
hex bolt immediately to 12 Nm. Note that the inner
hex is inserted as deeply as possible in the screw
connection to prevent it from slipping off.
Pressure relief valve

024456

1290 751 106 - 2005-06 15

ZF-AS Tronic lite Final Work

Final Work

• Once the hydraulic lines and components have

been disassembled and assembled, the
system should be vented.

Procedure:
Connect up Testman Pro and select the “Vent
system” menu item from the “Vehicle configura-
tion” under menu item 5.

• Once the transmission has been removed/fitted

and a new or used clutch has been fitted, the
clutch should be taught in again.

Procedure:
Connect up Testman Pro and select the “Teach in
clutch” menu item from the “Vehicle configura-
tion” under menu item 5.

1290 751 106 - 2005-06 16

ZF-AS Tronic lite Transmission and Components

Transmission actuator Wiring harness

Clutch actuator Reservooir Power-Pack

1290 751 106 - 2005-06 17

44149 751 606 - 2004-01 18
ZF-AS Tronic lite Component Replacement - Wiring Harness

1 Wiring harness
6
1.1 Removal of Wiring Harness
4
Connector arrangement: Wiring harness (25.010)

2 5
(1) Connector for level switch E28
(2) Connector for clutch actuator E4
(3) Connector for transmission wiring harness E2 1
(4) Connector for shifting travel sensor E31
(5) Connector for selecting travel sensor E30
(6) Connector for input speed sensor E32

024336

Remove screws (01.510, 01.530). Remove shackle

(01.500). Remove cable strap (01.520) and take off 01.500 01.510 01.530 01.520
clips.

Remove connector for selecting travel sensor (E30)

and the connector for shifting travel sensor (E31).

Remove connector (E28) from supply tank’s level

switch.

024299

Remove screw (01.540).

01.540

024300

1290 751 106 - 2005-06 1-1

ZF-AS Tronic lite Component Replacement - Wiring Harness

Remove clip (01.550).

024298

Swivel back safety bracket of connector (E2) from

transmission wiring harness and remove connector
(E2).

024291

Unscrew screw (68.200) which releases the bush

(68.170).

Take off bush (68.170).

68.190 68.200 68.170 68.180

024287

1290 751 106 - 2005-06 1-2

ZF-AS Tronic lite Component Replacement - Wiring Harness

Unscrew connector (E4) from travel sensor of clutch

actuator (68.010).
E4

Take off wiring harness.

68.100 68.102

024295

1290 751 106 - 2005-06 1-3

ZF-AS-Tronic lite Emos Component Replacement - Wiring Harness

1.2 Fitting Wiring Harness

6
Connector arrangement: Wiring harness (25.010)
4
(1) Connector for level switch E28
(2) Connector for clutch actuator E4
2 5
(3) Connector for transmission wiring harness E2
(4) Connector for shifting travel sensor E31
(5) Connector for selecting travel sensor E30 1
(6) Connector for input speed sensor E32

024336

Plug connector (E2) onto power pack support and

swivel in safety bracket.

024291

Place clip (01.550) around wiring harness in correct

position.

024298

1290 751 106 - 2005-06 1-4

ZF-AS Tronic lite Component Replacement - Wiring Harness

Screw clip and screw (01.540) onto transmission.

Tightening torque: 23 Nm
01.540

024300

Screw connector (E4) onto travel sensor of clutch

actuator (68.010).

024302

Fit screw (68.200) through clip (68.190), clip

(68.180), and bush (68.170) and secure to transmis-
sion.

Do not tighten.

68.190 68.200 68.170 68.180

024287

1290 751 106 - 2005-06 1-5

ZF-AS Tronic lite Component Replacement - Wiring Harness

Place clip (01.500) around cable and secure to trans-

mission with screw (01.510). 01.500 01.510 01.530 01.520
Tightening torque: 9.5 Nm

Place lock washer under the shackle (01.520) and

secure to transmission with screw (01.530).
Tightening torque: 23 Nm

Pull the cable strap through the shackle (01.520) and

fasten the cable.

Plug in connector for level switch (E28).

E28

024546

Screw on connector for selecting travel sensor (E30)

and connector for shifting travel sensor (E31). E30

E31

024269

1290 751 106 - 2005-06 1-6

ZF-AS Tronic lite Component Replacement - Power Pack

2 Power Pack

2.1 Removal of Power Pack

Remove connector (E28) from supply tank’s level

switch.

NOTE
The power pack must always be emptied for
transport purposes.

024288

Unscrew pipe unions

No. Connection Pipe line

21 Pressure connection, gate 1/2 02.160
22 Pressure connection, gate R 02.170
24
23 Pressure connection, gear R/2/4/6 02.200
24 Pressure connection, gear 1/3/5 02.210
23
from power pack.
22

21

024266

Loosen screws (02.190, 02.230).

02.230

024316

1290 751 106 - 2005-06 2-1

ZF-AS Tronic lite Component Replacement - Power Pack

Loosen pipe union (68.104) of pipe line (68.100) on

power pack.
68.104 68.100

024294

Unscrew screw (68.200) which releases the bush

(68.170).

Take off bush (68.170).

68.190 68.200 68.170 68.180

024287

Unscrew connector (E4) from travel sensor of clutch

actuator (68.010).
E4

Unscrew pipe union (68.102) of pipe line (68.100)

from clutch actuator.

Once the pipe line has been removed, seal the bore
with handle-type plug 0637 510 609.

68.100 68.102

024295

1290 751 106 - 2005-06 2-2

ZF-AS Tronic lite Component Replacement - Power Pack

Take off clip (68.180) and pipe line (68.100).

Seal the ends of the pipe line (68.100) with

protective sleeves 0637 510 050.

024547

Swivel back safety bracket of connector (E2) from

transmission wiring harness and remove connector
(E2).

024291

Remove screw (01.540).

01.540

024300

1290 751 106 - 2005-06 2-3

ZF-AS Tronic lite Component Replacement - Power Pack

Loosen screws with washers (M8x25: 01.030,

01.040), 01.030 01.040
(M8x32: 01.050, 01.060, 01.070).

01.050 01.060 01.070

024548

Unscrew screw with washer (01.050) while holding

down tab (01.020) and then take off.

01.050
01.020

024318

Remove two diagonally opposite screws,

(01.030 <-> 01.070) or (01.040 <-> 01.060) and screw 01.030 01.040
in guide bolts instead as disassembly aids.

Unscrew the other two screws.

01.020 01.050 01.060 01.070

024314

1290 751 106 - 2005-06 2-4

ZF-AS Tronic lite Component Replacement - Power Pack

Loosen 8 screws from transmission actuator.

02.190
Briefly raise transmission actuator to remove power
pack from transmission.

024319

Carefully and evenly take off power pack.

(view from below)

024308

Seal bores on power pack with handle-type plug

0637 510 609.

024321

1290 751 106 - 2005-06 2-5

ZF-AS Tronic lite Component Replacement - Power Pack

2.2 Fitting Power Pack

Screw 2 guide bolts into the transmission at opposite

points to serve as assembly aids

024297

Briefly raise transmission actuator and …

02.190

024319

… carefully and evenly slide the power pack onto the

guide bolts until firmly home on the transmission.

(view from below)

024308

1290 751 106 - 2005-06 2-6

ZF-AS Tronic lite Component Replacement - Power Pack

With the transmission horizontal, hold tab (01.020)

horizontally between container and transmission
68.180 68.180
and screw in screw with washer (01.050).

Tightening torque: 23 Nm.

NOTE: Figure shows the view from below

01.030 01.040

01.020 01.050 01.060 01.070

024555

Screw in two screws in the 2 free positions

(01.030 or 01.070) or (01.040 or 01.060). 01.030 01.040
Note the different screw lengths used depending on
the position.
Unscrew the guide bolt and replace with the screw
and washer corresponding to the position.

M8x32 + washers: 01.030 / 01.040

M8x25 + washers: 01.050 / 01.060 / 01.070

Tightening torque: 23 Nm.

01.020 01.050 01.060 01.070

024314

Take off protective caps of pipe line (68.100).

Place clip (68.180) around pipe line (68.100). 68.100

Remove handle-type plug 0637 510 609 from clutch

actuator and power pack.
Insert the screw connection of pipe line (68.100) in
the bore on the power pack and in the bore on the
clutch actuator.
Tighten pipe unions by hand.

024317

1290 751 106 - 2005-06 2-7

ZF-AS Tronic lite Component Replacement - Power Pack

Fit screw (68.200) through clip (68.190), clip

(68.180), and bush (68.170) and secure to
transmission.

Do not tighten.

68.190 68.200 68.170 68.180

024287

Tighten pipe union (68.102) of pipe line (68.100) on

clutch actuator.

Tightening torque: 17 Nm

68.100 68.102

024556

Tighten pipe union (68.104) of pipe line (68.100) on

power pack. 68.104 68.100

Tightening torque: 13 Nm

024294

1290 751 106 - 2005-06 2-8

ZF-AS Tronic lite Component Replacement - Power Pack

Tighten screw with washer (68.200).

Tightening torque: 9.5 Nm

68.190 68.200 68.170 68.180

024287

Tighten screw connections (21/22/23/24).

Tightening torque: 13 Nm

24

23

22

21

024266

Screw connector (E4) onto travel sensor of clutch

actuator (68.010).

024302

1290 751 106 - 2005-06 2-9

ZF-AS Tronic lite Component Replacement - Power Pack

Plug connector (E2) onto power pack support and

swivel in safety bracket.

024291

Plug connector (E28) onto level switch of power

pack.

024288

Place clip (01.550) around wiring harness in correct

position.

Screw clip and screw (01.540) onto transmission. 01.540

Tightening torque: 23 Nm

024300

1290 751 106 - 2005-06 2-10

ZF-AS Tronic lite Component Replacement - Power Pack

General:
Once hydraulic lines and components have been
disassembled and assembled, the system should be
vented.

Procedure:
Connect up Testman Pro and select the “Vent
system” menu item from under “Vehicle configura-
tion” menu item 5.

1290 751 106 - 2005-06 2-11

1290 751 106 - 2005-06 2-12
 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

3 Transmission Actuator

3.1 Removal of Transmission Actuator

Unscrew pipe unions 24

No. Connection Pipe line

21 Pressure connection, gate 1/2 02.160 23
22 Pressure connection, gate R 02.170
23 Pressure connection, gear R/2/4/6 02.200 22
24 Pressure connection, gear 1/3/5 02.210

from power pack.

21

024266

Remove the connector for selecting travel sensor

(E30) and the connector for shifting travel sensor E30
(E31).

E31

024269

Unscrew 8 M8x80 hex bolts.

2 3 4 1 5 6 7 8
(1) 02.060
(2) 02.070
(3) 02.080
(4) 02.090
(5) 02.100
(6) 02.110
(7) 02.120
(8) 02.130

024267

1290 751 106 - 2005-06 3-1

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Remove screws (02.190, 02.230) so that the

two pipe clamps on the transmission actuator are 02.230
released.

This prevents the pipes from being tensioned and

therefore prevents them hindering removal of the
transmission actuator.

024316

02.190

024319

Carefully take transmission actuator (02.220) and

pipe lines off the transmission.

024270

1290 751 106 - 2005-06 3-2

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Attach protective sleeves 0637 510 050 to ends of

line.
Clamp transmission actuator as on the selector
finger of vices.

024268

Screw handle-type plug 0637 510 609 into power

pack.

024321

CAUTION
Protect transmission aperture from dirt, e.g. cover
produced in-house.

Tightening torque: 23 Nm

024320

1290 751 106 - 2005-06 3-3

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Remove screws (02.190, 02.230) and take clips off

pipe lines.
Loosen all pipe unions and take off lines. 02.230
Attach protective sleeves 0637 510 050 to ends of
line
.
Screw
(02190)
+ clip

Clip

024271

1290 751 106 - 2005-06 3-4

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

3.2 Fitting Transmission Actuator

Place transmission actuator on fixture, pre-assemble

pipe.

Place clip around pipe line (02.170) for selecting.

Screw pipe line (02.170) onto transmission actuator

and align.
02.170 02.190
Only loosely tighten pipe union.

Use screw (02.190) to secure clip to transmission

actuator.

024284

Screw pipe line (02.160) onto transmission actuator

and align.

Only loosely tighten pipe union.

02.160

024283

Place clip around pipe line (02.210) for shifting.

Screw pipe line (02.210) onto transmission actuator

and align.

Only loosely tighten pipe union.

Use screw (02.230) to secure clip to transmission

actuator.

02.210

024285

1290 751 106 - 2005-06 3-5

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Screw pipe line (02.200) onto transmission actuator

and align.
Only loosely tighten screw connection.

02.200

024286

Remove handle-type plug 0637 510 609 from power

pack.

024321

If present, remove cover produced in-house from

transmission actuator.

024320

1290 751 106 - 2005-06 3-6

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Insert 2 centering pins 1X56 138 527 into

transmission housing as assembly aids (in positions
as shown in figure).

NOTE
The centering pins are essential to assembling the
transmission actuator.

Place new seal (02.050) on transmission housing.

024296

Carefully place transmission actuator (02.220) and

pipe lines on the transmission, ensuring that the free
ends of the pipe lines are at the corresponding posi-
tions on the power pack.

Screw the 4 pipe connections as far as possible into

the power pack by hand.

Screw in 2 hex bolts (M8x80) and tighten.

Tightening torque: 23 Nm
024270
Remove centering pins.
2 3 4 1 5 6 7 8
Screw in 6 hex bolts (M8x80).

(1) 02.060
(2) 02.070
(3) 02.080
(4) 02.090
(5) 02.100
(6) 02.110
(7) 02.120
(8) 02.130

Tightening torque: 23 Nm

024267

1290 751 106 - 2005-06 3-7

 Component Replacement - Transmission
ZF-AS Tronic lite Actuator

Screw pipe union into power pack.

Tighten pipe union on power pack.

Tightening torque: 13 Nm 24

23

22

21

024266

Tighten pipe union (11/12/13/14) on transmission

actuator.

Tightening torque: 13 Nm

13 12 11 14

024549

Tighten screws (02.190, 02.230).

Tightening torque: 23 Nm 02.190

General:
Once hydraulic lines and components have been
disassembled and assembled, the system should be
vented.

Procedure: 02.230
Connect up Testman Pro and select the “Vent
system” menu item from under “Vehicle configura-
tion” menu item 5.
024550

1290 751 106 - 2005-06 3-8

ZF-AS Tronic lite Component Replacement - Clutch Actuator

4 Clutch Actuator
68.104 68.100
4.1 Removal of Clutch Actuator

Loosen pipe union (68.104) of pipe line (68.100) on

power pack.

024294

Loosen screw (68.200).

68.200

024551

Remove pipe union from clutch actuator.

Once the pipe line has been removed, seal the bore
with handle-type plug 0637 510 609.

024552

1290 751 106 - 2005-06 4-1

ZF-AS Tronic lite Component Replacement - Clutch Actuator

Take off screw (68.200), clip (68.180), and pipe line

68.180
(68.100).

68.100
Seal the ends of the pipe line with protective sleeves
0637 510 050.

024553

Unscrew connector (E4) from travel sensor of clutch

actuator (68.010).

024302

Remove 4 screws with washers (68.130, 68.140,

68.150, 68.160) and take off cover (68.120).
68.150 68.140 68.120 68.160 68.130

024304

1290 751 106 - 2005-06 4-2

ZF-AS Tronic lite Component Replacement - Clutch Actuator

Remove 2 screws with washers (68.060, 68.070).

Remove 2 retaining bolts (68.090, 68.080).

68.070 68.090 68.050 68.060 68.080
Take off angle bracket (68.050).

024305

Remove 2 screws with washers (68.030, 68.040).

68.030
68.040

024306

Take off clutch actuator (68.010).

68.010

024307

1290 751 106 - 2005-06 4-3

ZF-AS Tronic lite Component Replacement - Clutch Actuator

4.2 Fitting Clutch Actuator

Insert clutch actuator (68.010).

68.010

024307

Screw in 2 screws with washers (68.030, 68.040).

Tightening torque: 23 Nm

68.030
68.040

024306

Use 2 retaining bolts (68.090, 68.080) to secure

bracket (68.050) to clutch actuator (68.010).

Tightening torque: 23 Nm 68.070 68.090 68.050 68.060 68.080

Use 2 screws and washers (68.060, 68.070)

to secure bracket (68.050) to transmission.

Tightening torque: 23 Nm

024305

1290 751 106 - 2005-06 4-4

ZF-AS Tronic lite Component Replacement - Clutch Actuator

Take off protective sleeves 0637 510 050 of pipe line

(68.100).

Place clip (68.180) around pipe line (68.100).

024301

Remove handle-type plug 0637 510 609 from clutch

actuator and power pack.

Insert the screw connection of pipe line (68.100) in

the bore on power pack and in the bore on the
clutch
actuator.

Tighten screw connections by hand.

024317

Fit screw (68.200) through clip (68.190), clip

(68.180), and bush (68.170) and secure to transmis-
sion.

Do not tighten.

68.190 68.200 68.170 68.180

024287

1290 751 106 - 2005-06 4-5

ZF-AS Tronic lite Component Replacement - Clutch Actuator

Tighten pipe union (68.102) of pipe line (68.100) on

clutch actuator.

Tightening torque: 17 Nm

68.100 68.102

024556

Tighten pipe union (68.104) of pipe line (68.100) on

power pack.
68.104 68.100

Tightening torque: 13 Nm

024294

Tighten screw with washer (68.200).

Tightening torque: 9.5 Nm

68.200

024551

1290 751 106 - 2005-06 4-6

ZF-AS Tronic lite Component Replacement - Clutch Actuator

Screw connector (E4) onto travel sensor of clutch

actuator (68.010).

024302

Screw cover (68.120) onto transmission housing with

4 screws and washers (68.130, 68.140, 68.150,
68.160).

Tightening torque: 23 Nm

68.120

024554

1290 751 106 - 2005-06 4-7

ZF-AS Tronic lite Component Replacement - Clutch Actuator

When working on the clutch or clutch actuator, the

clutch should be taught in once the work is com-
plete. Connect up Testman Pro and select the “Teach
in clutch” menu item from under “Vehicle configura-
tion” menu item 5.

As a rule:

• Once hydraulic lines and components have been

disassembled and assembled, the system should
be vented.

Procedure:
Connect up Testman Pro and select the “Vent
system” menu item from under “Vehicle configu-
ration” menu item 5.

• Once the transmission has been removed/fitted

and a new or used clutch has been fitted, the
clutch should be taught in again.

Procedure:
Connect up Testman Pro and select the “Teach in
clutch” menu item from the “Vehicle configura-
tion” under menu item 5.

1290 751 106 - 2005-06 4-8