ZF – HYDROSTATIC POWERSHIFT

TRANSMISSION

2 HL-250/270/290

5871.042.002 de
 REPAIR INSTRUCTIONS
for
ZF – HYDROSTATIC POWERSHIFT
TRANSMISSION
2 HL-250/270/290

Important note:
The great variety of ZF units compels a restriction of the Disassembly and Assembly Instructions to a
current ZF production unit. Technical development of the ZF units as well as extensions concerning
the design possibilities may require differing steps, which can be carried out by qualified Specialists
without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare
Parts Lists.
The described Disassembly and Assembly Instructions are based on the design level of a ZF
production unit
at the time of preparation of the Repair Instructions.

The ZF Friedrichshafen AG reserve the right to replace the present Disassembly and Assembly
Instructions by a successive edition without advance notice. Upon request, the ZF Friedrichshafen
AG will advise what edition is the latest one.

ATTENTION:
For the Installation as well as for the commissioning of the unit,
the Instructions and Specifications of the Vehicle Manufacturer have to be observed!

For information on operation, maintenance and for descriptions

please refer to the corresponding ZF Operation Instructions:

ZF Friedrichshafen AG
ZF Services
Donaustr. 71
D - 94034 Passau

Section : MAIP21
Complete or partial reproduction is not permitted without the approval of ZF Friedrichshafen AG!
Copyright ZF Friedrichshafen AG!
Subject to technical modifications!
Design Level 2003/11
2nd Edition 2011/05
TABLE OF CONTENTS Chapter/Page

Preface 0/1

General 0/2 … 3

Conversion table for dimensional units 0/4

Denomination of standard dimensions 0/5
Tightening torques for screws 0/6

TOOLS WS/1 ... WH/5

Special tools WS/1 ... 9

Commercial tools WH/1 ... 5

DISASSEMBLY 1/1 ... 3/7

1. Separate HL-TRANSMISSION from AXLE HOUSING 1/1

2. DISASSEMBLY – BRAKE / CLUTCH / PLANETARY CARRIER 2/1 … 12

2.1 Lubrication pump and shift interlock 2/1
2.1.1 Version „Lubrication pump“ 2/1
2.2 Speed sensor 2/2
2.3 Emergency release (Parking brake) 2/2 … 3
2.4 Input housing and modulation valve 2/3 … 4
2.5 Brake and clutch 2/4 … 9
2.6 Planetary carrier 2/10 … 11

3. DISASSEMBLY - OUTPUT 3/1 … 7

3.1 Version „Axle attachment“ 3/1 … 4
3.2 Version „Separate installation“ 3/5 … 7

REASSEMBLY 4/1 ... 5/22

4. REASSEMBLY - OUTPUT 4/1 … 16

4.1 Version „Axle attachment“ 4/1 … 10
4.1.1 Determine adjusting shim for pinion gap 4/3 … 4
4.1.2 Determine adjusting ring for rolling torque / pinion bearing 4/7 … 8
4.1.3 Check rolling torque of pinion bearing 4/8
4.1.4 Shaft seal output flange 4/9
4.1.5 Check pinion gap 4/10
4.2 Version „Separate installation“ 4/11 … 16
4.2.1 Shaft seal output flange 4/14
TABLE OF CONTENTS Chapter/Page

5. REASSEMBLY – BRAKE/CLUTCH/PLANETARY CARRIER 5/1 … 22

5.1 Planetary carrier 5/1 … 4
5.2 Brake and clutch 5/5 … 17
5.2.1 Disk components brake and clutch 5/7 … 11
5.2.1.1 Version „2 HL-290“ 5/7
5.2.1.2 Version „2 HL-270“ 5/7
5.2.1.3 Version „2 HL-250“ 5/7
5.2.2 Adjust and check disk clearance/piston stroke of brake and clutch 5/9 … 11
5.3 Install modulation valve and input housing
5.4 Emergency release (parking brake) 5/16 … 17
5.4.1 Check emergency release for leak tightness 5/18
5.4.2 Check multi-disk brake and multi-disk clutch for leak tightness as well as 5/19 … 20
closing pressure 5/20 … 21
5.5 Speed sensor
5.6 Lubrication pump/shift interlock 5/21
5/21

DISASSEMBLY 6/1 ... 7

6. DISASSEMBLY – LUBRICATION PUMP/SHIFT INTERLOCK and 6/1 … 7

VALVE BLOCK 6/1 … 3
6.1 Version „with“ lubrication pump 6/4 … 7
6.2 Version „with“ hydr. shift interlock 6/7
6.3 Disassemble valve block

REASSEMBLY 7/1 ... 10/1

7. REASSEMBLY LUBRICATION PUMP 7/1 … 6

8. REASSEMBLY SHIFT INTERLOCK 8/1 … 8

9. VALVE BLOCK (shifting low gear – high gear) 9/1

10. Mount HL-TRANSMISSION to AXLE 10/1

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Repair Manual and Axle Systems
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PREFACE

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

This manual describes a ZF series product with a design level valid at the date of edition.

Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and different setting and testing data.

We would therefore recommend you to entrust masters and servicemen with the work on your ZF product
whose practical and theoretical training is constantly updated in our training school.

The Service Stations established by ZF Friedrichshafen all over the world offer you:

1. Permanently trained staff

2. Specified equipment, e.g. special tools

3. State-of-the-art genuine ZF spare parts

All work is done there with utmost care and reliability.

In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms
of the currently applicable contractual conditions.

Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred shall be excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.

This manual is based on the state-of-the-art at the time of printing.

It was prepared with utmost care in order to avoid errors.
However, we shall not be liable for any errors in figures or descriptions.

ZF Friedrichshafen AG

Service Department

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GENERAL

The Service Manual covers all work required for disassembly and the relating reassembly.

When repairing the unit, ensure utmost cleanliness and excellent workmanship.

Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen
covers and housing parts which were installed with seals by slight blows with a plastic hammer. Use
suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing
rings and similar.

Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and covers
from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end
covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be
replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings,
thrust washers etc. will be reinstalled.
Parts such as seal rings, lock plates, split pins etc. must generally be replaced. Radial seal rings with worn or
broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies remain in
the housing. Check the lube oil holes and grooves regarding unhindered passage.

Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation.

NOTE: Only a heating furnace (oil bath) or an electric drier is permitted to be used for heating
parts such as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling-down to ensure a perfect
contact.

CAUTION
When assembling the transmission, exactly observe the tightening torques and setting data indicated in the
manual. Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.

When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves!

NEVER wash disks having organic friction linings (e.g. paper disks ) since this would have an adverse
effect on lining adhesion.
Only dry-cleaning is permitted (leather cloth).

DANGER
When using detergents, observe the manufacturer’s instructions regarding their handling.

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Structure of the Service Manual

The structure of this repair manual reflects the sequence of work steps for completely dismantling the
removed unit.

Tools required for carrying out the repair work are listed in the current text as well as in chapters
“WS” (List of Special Tools) and “WH” (Commercial Tools).

Important information on labor safety

As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully
responsible for labor safety.

The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding
any damage to persons and products during maintenance and repair work. Repair workshops must
familiarize themselves with these regulations prior to starting any work.

A suitably trained and skilled staff is required for a proper repair of these ZF products.

The repair workshop shall be responsible for the training.

The following safety references are used in this manual:

This symbol serves as a reference to special working procedures,

CAUTION methods, information, use of auxiliaries etc... indicated in this
repair manual.

This symbol identifies situations in which lacking care may lead to

DANGER personal injury or damage to the product.
____________________________________________

NOTE: Thoroughly study this manual before starting any tests or repairs.

NOTE: Figures, drawings and parts in this manual do not always represent the original; they show
the working procedure.

Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on
size and weight (not even within one and the same illustration).

Carry out work according to the legend.

NOTE: After repairs and inspections have been completed, the expert staff must verify that the
product is perfectly functioning again.

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VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION

25.40 mm = 1 in ( inch)

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)

1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5.560 lb / in ( pound per inch )

1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per square inch lbf/in2 )

0.070 bar ( 0.071 kp/cm2 ) =

1 psi ( lbf/in2 )

1 Liter = 0.264 Gallon ( Imp. )

4.456 Liter =
1 Gallon ( Imp. )

1 Liter =
0.220 Gallon ( US )

3.785 Liter =
1 Gallon ( US )

1609.344 m =
1 Mile ( Landmeile )

0° C ( Celsius ) =
+ 32° F ( Fahrenheit )

0 ° C ( Celsius ) =
273.15 Kelvin

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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : Linear density in kg/m; Areal density in t/m2

Nota : Densité linéaire en kg/m; Densité superficielle en t/m2

Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

Unit Formel Sign New Old Conversion Note
Unité Symbole Nouveau Vieux Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9.81 N
Force
Force
Arbeit A J (Joule) kpm 0.102kpm = 1J = 1Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW
Power 1 KW = 1.36 PS
Puissance
Drehmoment T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) =
Torque F (N) . r (m)
Couple
Kraftmoment M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) =
Moment (Force) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1.02 atü = 1.02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours

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TIGHTENING TORQUES FOR SCREWS (IN Nm) ACC. TO ZF-STANDARD 148

Friction coefficient:
total= 0.12 for screws and nuts without subsequent treatment, as well as for phosphated
nuts. Tightened by hand!
Tightening torques, if not especially indicated, can be taken from the following list:

Metric ISO-Standard Thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine Thread DIN 13, Page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300

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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Assembly truck assy 1/1

with tilting device 2/1

1 5870 350 000 1

Supporting bracket 1/1

2 5870 350 106 1

Lifting strap 1/2

10/1

3 5870 281 026 1

Fixture 2/1

4 5870 350 079 1

F Eye bolt assortment 2/17

5 5870 204 002 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Lifting chain 2/17

6 5870 221 047 1

Resetting device 2/21

2/22
2/41
7 5870 400 001 2 3/3

Clamping pliers 2/25

2/33
5/18
8 5870 900 021 1 5/27

Clamping fork 2/36

3/1
3/16
9 5870 240 025 1 4/26
4/35
5/15

Extractor 2/37

10 5870 000 017 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Rapid grip 2/38

8/34

11 5873 012 021 1

Basic tool 2/38

12 5873 002 001 1

Cut-off device 3/4

13 5870 300 028 1

Assembly lever 3/4

14 5870 345 036 1

Solenoid block 3/4

3/6

15 5870 450 003 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Grab sleeve 3/6

16 5873 001 037 1

Inner extractor 3/7

17 5870 300 019 1

Counter support 3/7

18 5870 300 020 1

Lever riveting tongs 4/1

19 5870 320 016 1

Driver tool 4/3

20 5870 058 073 1

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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Handle 4/3
4/14
5/1
21 5870 260 002 1 5/2

Driver tool 4/7

22 5870 048 281 1

Straightedge 4/10
4/13
4/36
23 5870 200 108 1 4/41
4/42

Driver tool 4/14

24 5870 058 078 1

Clamping bar 4/22

5/11

25 5870 654 049 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Reduction 4/28

26 5870 656 056 1

Plug insert 4/28

27 AA00 392 461 1

Driver tool 4/30

4/50

28 5870 048 279 1

Pressure piece 4/33

4/52

29 5870 506 150 1

Adjusting screws 4/47

(M12) 5/65

30 5870 204 021 1

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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Driver tool 5/1

5/2

31 5870 058 051 1

Press-fit mandrel 5/4

32 AA00 392 151 1

Driver tool 5/5

33 5870 048 283 1

Measuring device 5/38

34 5870 200 131 1

Driver tool 5/46

5/48
5/56
35 5870 506 161 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Air connection 5/74

36 5870 505 012 1

HP pump 5/77
5/79

37 5870 287 007 1

Spline mandrel 5/78

5/80

38 5870 510 039 1

Inner extractor 6/11

6/23

39 5870 300 012 1

Counter support 6/11

6/23

40 5870 300 011 1

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Repair Manual and Axle Systems
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SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

2 HL-250/270/290/ 4143 020 095/106

Cons. Figure Designation Qty Chapter/Fig .

No. Order No.

Driver tool 7/8

8/11

41 5870 705 003 1

Inner installer 8/2

42 5870 651 055 1

Calibrating mandrel 8/3

43 5870 651 056 1

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 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Magnetic stand

5870 200 055

1 1 Universal

Dial indicator

5870 200 057

2 1 Universal

Gauge blocks

5870 200 066 70 mm

3 1 Universal
5870 200 067 100 mm

Digital depth gauge

5870 200 072 200 mm

4 1 Universal
5870 200 114 300 mm

Digital caliper gauge

5870 200 109 150 mm

5 1 Universal

5871 042 002 WH/1

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Torque wrench

5870 203 030 0.6 -6.0 Nm

5870 203 031 1.0 – 12 Nm

5870 203 032 3.0 – 23 Nm

6 1 Universal
5870 203 033 5.0 – 45 Nm

5870 203 034 10 – 90 Nm

5870 203 039 80 – 400 Nm

5870 203 016 140 – 750 Nm

5870 203 011 750 - 2000 Nm

Hot air blower

5870 221 500 230 V

7 1 Universal
5870 221 501 115 V

Plastic hammer

5870 280 004 Ø 60 mm

8 1 Universal
Substitute nylon insert

5870 280 006

Lifting strap

5870 281 026

9 1 Universal

5871 042 002 WH/2

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Lifting chain

5870 281 047

10 1 Universal

Pry bar

5870 345 071

11 1 Universal

Striker

5870 650 004

12 1 Universal

Set of internal pliers

I1-I2-I3-I4

13 5870 900 013 1 Universal

Set of internal pliers

I11-I21-I31-I41 90°

14 5870 900 014 1 Universal

5871 042 002 WH/3

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Set of external pliers

A1-A2-A3-A4

15 5870 900 015 1 Universal

Set of external pliers

A01-A02-A03-A04 90°

16 5870 900 016 1 Universal

Two-armed puller

5870 970 001

Jaw width 80 mm
Throat depth 100 mm
5870 970 002
Jaw width 120 mm
Throat depth 125 mm
5870 970 003
Jaw width 170 mm
Throat depth 125 mm
5870 970 004
17 Jaw width 200 mm 1 Universal
Throat depth 175 mm
5870 970 006
Jaw width 350 mm
Throat depth 250 mm
5870 970 007
Jaw width 520 mm
Throat depth 300 - 500 mm
5870 970 026
Jaw width 250 mm
Throat depth 200 mm
5870 970 028
Jaw width 380 mm
Throat depth 200 mm

5871 042 002 WH/4

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Three armed puller

5870 971 001

Jaw width 85 mm
Throat depth 65 mm
5870 971 002
Jaw width 130 mm
Throat depth 105 mm
5870 971 003
Jaw width 230 mm
18 Throat depth 150 mm 1 Universal
5870 971 004
Jaw width 295 mm
Throat depth 235 mm
5870 971 005
Jaw width 390 mm
Throat depth 230 mm
5870 971 006
Jaw width 640 mm
Throat depth 290 mm

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1. Separate HL-TRANSMISSION from AXLE HOUSING

(only for version „Axle attachment“)

Drain oil from axle housing – use a suitable oil reservoir.

(S) Assembly truck 5870 350 000

(S) Clamping fork 5870 350 106

Waste oil to be disposed of ecologically!

Figure 1

Pick-up HL-Transmission by means of lifting tackle, loosen

threaded joint and separate complete HL-Transmission from axle
housing.

(S) Lifting strap 5870 281 026

Figure 2

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2. DISASSEMBLY – BRAKE / CLUTCH / PLANETARY CARRIER

Mount transmission to assembly truck.

(S) Assembly truck assy. 5870 350 000

(S) Fixture 5870 350 079

Illustration shows HL-version „Axle attachment“.

Figure 1

Loosen screw plug and drain oil –

use a suitable oil reservoir.

Waste oil to be disposed of ecologically!

Figure 2

2.1 Lubrication pump and shift interlock

2.1.1 Version „Lubrication pump“

Remove lubrication pump or shift interlock (depending on

version) (Illustration shows version with “Lubrication pump”).

Complete disassembly of lubrication pump / shift interlock –

see Chapter 6!

Figure 3

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2.2 Speed sensor

Loosen screw and pull off speed sensor.

Figure 4

2.3 Emergency release (Parking brake)

Remove breather.

(Illustration Figure no. 5 … 8 shows version transmission

installation position „Vertical“)

Position of single connections or breather valves /lubrication

nipples etc. as to version transmission installation position
“Horizontal”
- see Chapter 5, page 22, Figure no. 76!
Figure 5

Remove compression spring and ball.

Figure 6

Remove threaded element (see Detail „X“) with O-ring from

hole.

„X“

Figure 7

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Remove lubrication nipple, both screw plugs and breather valve

– see arrow.

Figure 8

2.4 Input housing and modulation valve

Loosen threaded joint of input housing evenly.

Input housing is subject to cup spring and compression

spring preload!

Figure 9

Take off input housing and remove O-ring (arrow).

Figure 10

Modulation valve:

Remove compression spring and O-ring (arrow).

Figure 11

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Pull complete piston out of hole.

Figure 12

2.5 Brake and clutch

Remove cup springs from brake.

Figure 13

Remove cup springs from clutch.

Figure 14

Remove piston.

Figure 15

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Pull off both cyl. pins (arrows).

Figure 16

Attach 2 (two) eyebolts and pull piston cautiously out of housing

– risk of damage!

(S) Eyebolt assortment 5870 204 002

(S) Lifting chain 5870 281 047

Figure 17

Remove both seals (arrows) from piston.

Figure 18

Remove axial roller cage with both thrust washers.

Figure 19

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Remove pressure piece and compression spring.

Figure 20

Remove pressure ring with ring – also see Fig. no. 22 –

cautiously with lever – risk of damaging sealing surfaces!

(S) Resetting device 5870 400 001

Ring may also remain in housing during disassembly –

disassemble ring separately!

Figure 21

Remove pressure ring from ring cautiously with lever – risk of

damaging sealing surfaces !

(S) Resetting device 5870 400 001

Figure 22

Remove seal and O-rings (see arrows) from pressure ring and
ring.

Figure 23

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Take disk package of brake with end plate(s) out of housing.

Illustration shows version / components of 2 HL-290!

Figure 24

Disengage retaining ring.

(S) Clamping pliers 5870 900 021

Figure 25

Remove snap ring and shim.

Figure 26

Take disk package of clutch with end plate/s out of ring gear.

Illustration shows version / components of 2 HL-290!

Figure 27

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Remove cpl. input shaft with ring gear from housing.

Figure 28

Unsnap retaining ring.

Figure 29

Press input shaft out of ball bearing/ring gear.

Figure 30

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Unsnap retaining ring.

Figure 31

Press centering disk from input shaft.

In case of extreme press fit – heat centering disk!

Figure 32

Unsnap retaining ring and remove ball bearing.

(S) Clamping pliers 5870 900 021

Figure 33

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2.6 Planetary carrier

Remove axial needle cage.

Figure 34

If not yet disassembled previously – remove lubrication pump or

shift interlock (depending on version).
(Illustration shows version - „Lubrication pump“).

Cpl. disassembly of lubrication pump and shift interlock – see

Chapter 6!

Figure 35

Loosen threaded joint and remove disk – fasten output flange by

means of clamping fork.

(S) Clamping fork 5870 240 025

Figure 36

Press cpl. planetary carrier out of roller bearing.

(S) Extractor 5870 000 017

Pay attention to releasing planetary carrier and bearing inner

ring!

Figure 37

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Division

Pull second bearing inner ring from planetary carrier.

(S) Rapid grip 5873 012 021

(S) Basic tool 5873 002 001

Figure 38

If required – force both bearing outer rings (arrow) out of

bearing hole.

When reusing tapered roller bearings – pay attention to

bearing allocation, i.e. respective bearing inner ring to
bearing outer ring!!

Figure 39

Unsnap retaining ring.

Figure 40

Lift planetary gear with resetting device – then disassemble with

two armed puller !

(S) Resetting device 5870 400 001

If necessary, force out slotted pins (6x).

Figure 41

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Remove both seals (1).

3 Remove breather valves (2) and all screw plugs (3) with seal and
O-ring.
1

Illustration shows positions for transmission version

„Installation position vertical“!

3
Figure 42

Only for version

Transmission installation position „Horizontal“:

Loosen countersunk screws and remove screen sheet.

Countersunk screws are installed with locking compound

(Loctite). If necessary, heat for disassembly !

Figure 43

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3. DISASSEMBLY - OUTPUT
3.1 Version „Axle attachment“

Loosen threaded joint, remove cover and O-ring.

(S) Clamping fork 5870 240 025

Figure 1

Pull off flange.

Figure 2

Remove shaft seal with a lever.

(S) Resetting device 5870 400 001

Figure 3

Fix pinion with fixture and press off.

(S) Cut-off device 5870 300 028

(S) Assembly lever 5870 345 036
(S) Solenoid block 5870 450 003

Pay attention to releasing bearing inner ring and

adjusting ring (rolling torque/pinion bearing) behind!

Figure 4

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Remove O-ring (see arrow) and bush from pinion.

Figure 5

Press-off bearing inner ring from pinion shaft.

(S) Grab sleeve 5873 001 037

(S) Solenoid block 5870 450 003

Figure 6

Pull bearing outer ring out of bearing cover.

(S) Inner extractor 5870 300 019

(S) Counter support 5870 300 020

Pay attention to shim behind (pinion gap setting)!

Figure 7

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Pull off bearing cover.

Figure 8

Remove O-rings (arrows).

Figure 9

Remove shaft seal.

Figure 10

Lift output gear with oil screen sheet out of housing. Remove oil
screen sheet from output gear.

Figure 11

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Remove screen sheet.

Figure 12
Disassemble bearing outer ring from housing hole (see arrow).

Figure 13

If necessary, remove stud bolts.

Figure 14

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3.2 Version „Separate installation“

Legend to sketch no. 15:

1 1 = Input
2 = Output – front axle
3 = Output – rear axle

2 3

Figure 15

Use clamping fork to fix output flange.

Loosen threaded joint, pull off disk, O-ring and flange.

(S) Clamping fork 5870 240 025

Figure 16

Remove shaft seal with a lever.

Disassemble second output flange and shaft seal

analogously!

Figure 17

Loosen threaded joint.

Figure 18

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Use lifting tackle to separate output gear with cover from

transmission housing.

Figure 19

Press output gear out of ball bearing/cover – remove releasing oil

screen sheet.

Figure 20

Unsnap retaining ring and disassemble ball bearing from cover.

Figure 21

Remove O-rings (see arrows) from cover.

Figure 22

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Remove screen sheet from transmission housing.

Figure 23

Disassemble ball bearing from housing hole.

Figure 24

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4. REASSEMBLY - OUTPUT

Seal finished holes (8x) of oil supply holes with screw plugs.

(S) Lever riveting tongs 5870 320 016

Figure 1

4.1 Version „Axle attachment“

Install stud bolts.

Tightening torque MA = 27 Nm

Pay attention to installation position – see Figure no. 2!

Figure 2

Install bearing outer ring until contact is obtained.

(S) Driver tool 5870 058 073

(S) Handle 5870 260 002

Figure 3

Insert slotted pin (see arrow) to the bottom.

Figure 4

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Position screen sheet – with slotted pin (see Fig. no. 4) into
fixing hole (arrow).

Pay attention to installation position, slotted pin = radial

fixing of screen sheet!

Figure 5

Insert output gear with the short collar showing downwards.

Figure 6

Press shaft seal into bearing cover.

(S) Driver tool 5870 048 281

For installation wet shaft seal on outer diameter with spirit!

Installation position of shaft seal, pay attention that seal lip is

showing to oil sump (see sketch no. 8)!

Use of specified driver ensures exact installation position of

shaft seal!
Figure 7

Legend to sketch:
1 = Shaft seal
2 = Bearing cover

1 „X“ = Installation dimension

„X“

Figure 8

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4.1.1 Determine shim for pinion gap

4
1 Legend to sketch no. 9 ... 14:
X
A Z
1 = Pinion
2 = Roller bearing
C B 2 3 = Bearing cover
E 4 = Ball (Ø = 7 mm)
3
S D A = Auxiliary dimension
B = Bearing width
C = Reference dimension
D = Contact surface/bearing cover to contact/bearing hole
E = 73.0 mm (constant value)
X = Pinion dimension (stamped into pinion)
Z = 189.0 mm (contact surface/bearing cover to center/
axle housing)

For correct installation and positioning of

pinion, following steps must be
carried out as precisely as possible !

Figure 9

Determine auxiliary dimension „A“.

Position ball (Ø = 7 mm) into centering hole of pinion and

determine dim. „A“, from contact surface/pinion shoulder to ball.

Auxiliary dimension „A“ = e.g. 42.56 mm

Auxiliary dimension „A“ is obligatory to determine reference

dimension „C“ – on installed pinion (Fig. no. 36).

(S) Straightedge 5870 200 108

Figure 10

Read pinion dim. „X“ on pinion (see arrow) or measure it in case

of manufacturing-specific + or – deviation from pinion dim.
(relating value is marked by hand on pinion e.g. + 0.1).

Pinion dim. “X“ (without + or – deviation) = 116.0 mm

+ 0.1
Pinion dim. „X“ with an indicated deviation = 116.1 mm
Pinion dim. „X“ with an indicated deviation - 0.1 = 115.9 mm

+ 0,1
116

Figure 11

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Determine dim. „B“ bearing width, paying attention that rollers

are seated without clearance (roller setting – rotate bearing inner
ring in both directions several times) !

Since installed roller bearing is subject to preload in installation

position, deduction of empirical value of – 0.1 mm must be
considered!

Dim. „B“ = e.g. 36.65 mm - 0.1 mm → 36.55 mm

Figure 12

Determine dim. „D“ (contact surface/bearing cover to

contact/bearing hole ).

Dim. „D“ = e.g. 35.10 mm

(S) Straightedge (2 sets) 5870 200 066

Calculation example:

Dim. „Z“ .............................................. 189.00 mm

Dim. „X“ e.g. .................................... - 116.00 mm
Figure 13 Result → Dim. „E“ ............................ = 73.00 mm

Dim. „E“ ............................................... 73.00 mm

Dim. „B+D“ (e.g. 36.55 + 35.10) ....... - 71.65 mm
Result → required shim „S“ ............... = 1.35 mm

Insert determined shim(s) „S“ = e.g. 1.35 mm and install bearing

outer ring until contact is obtained.

(S) Driver tool 5870 058 078

(S) Handle 5870 260 002

Figure 14

Oil O-rings (arrows) and insert them into annular grooves of

bearing cover.

Figure 15

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Bend edges of fixing straps of oil screen sheet

slightly – assembly aid (sheet is fixed to bearing cover –
see Fig. no. 17).

Figure 16

Mount oil screen sheet on bearing cover.

Pay attention to installation position – place locating tab of

oil screen sheet into recess of bearing cover (see arrow)!

Figure 17

Mount preassembled bearing cover and locate equally with

hexagon nuts until contact is obtained.
Then remove hexagon nuts again.

Oil contact face/oil screen sheet/housing (assembly aid).

Figure 18

Install heated bearing inner ring until contact is obtained.

Adjust bearing inner ring after cooing down!

Figure 19

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Mount bush, oil O-ring (arrow) and put it into annular groove.

Figure 20

Mount preassembled pinion.

Figure 21

Fix pinion with clamping bar.

(S) Clamping bar 5870 654 049

Figure 22

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4.1.2 Determine adjusting ring for rolling torque/pinion

bearing:

Rotate transmission by 180°.

Mount adjusting ring (s = optional).

It is recommended to reinstall the adjusting ring (e.g. s = 1.35

mm) removed during disassembly, if however the required
rolling torque of 1.5 ... 4.0 Nm (without shaft seal) is not
obtained – see bearing rolling torque check Fig. no. 28 –bearing
rolling torque is to be corrected with an adequate adjusting ring!
Figure 23

When shaft seal is installed, try to achieve upper rolling
torque value!

Insert heated bearing inner ring until contact is obtained.

Adjust bearing inner ring after cooling down!

Figure 24

Mount flange.

Figure 25

Place shim and fix flange with hexagon screws.

Tightening torque (M 10/10.9) MA = 68 Nm

(S) Clamping fork 5870 240 025

Rotate pinion – when tightening – in both directions (roller

setting) several times !

Figure 26

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Turn back pinion fastening / remove clamping bar.

Figure 27

4.1.3 Check rolling torque of pinion bearing

Bearing rolling torque (without shaft seal) 1.5 ... 4.0 Nm

When using new roller bearings /for mounted shaft seal, try

to achieve the upper value!

If the required rolling torque deviates, it must be corrected

with an adequate adjusting ring (see Fig. no. 23)!

(S) Reduction ½“ -¼“ 5870 656 056

(S) Plug insert AA00 392 461

Figure 28

Disassemble flange again.

Figure 29

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4.1.4 Shaft seal output flange

Install new shaft seal.

(S) Driver tool 5870 048 279

For reassembly wet shaft seal on outer diameter with spirit!

Pay attention to installation position of shaft seal, seal lip

showing to oil sump (see sketch no. 31)!

Use of specified driver tool ensures exact installation position

of shaft seal!

Figure 30
Legend to sketch:

1 = Shaft seal
2 = Metal sheet
3 3 = Output flange
2 4 = Roller bearing
1

Figure 31
Install stud bolts.

Tightening torque (M10x1) MA = 20 Nm

Pay attention to installation position!

Install stud bolts with short thread length into flange!

Figure 32

Install screen sheet (2, see Figure 31).

(S) Pressure piece 5870 506 150

Use of specified driver tool ensures exact installation position

of screen sheet!

Figure 33

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Mount preassembled flange and put O-ring into recess.

Figure 34

Place disk and fix it with hexagon screws.

Tightening torque (M 10/10.9) MA = 68 Nm

(S) Clamping fork 5870 240 025

Figure 35
4.1.5 Check pinion gap

Position ball [use Ø = 7 mm → ball Ø like for determination of

auxiliary dimension „A“] into centering hole of the pinion and
determine dim. „C“ (see sketch no.9), from contact
surface/bearing cover to ball.

Calculation example:

Reference dimension „C“ e.g. ............... 115.58 mm

Auxiliary dimension „A“ e.g.. . ........... - 42.56 mm (see Fig. 10)
Result (Dimension „E“) .......... ......... = 73.02 mm

(S) Straightedge 5870 200 108

Figure 36

If the constant value of dimension„E“ = 73.00 ± 0.05 mm

If the constant value of Dim. „E“ = 73.00 ± 0.05 mm is not

achieved, correct with an adequate
shim/pinion gap (see Fig. no. 14)!

For a correction of the shim/pinion gap, a counter correction

of adjusting ring of rolling moment/ pinion gap – Fig. no. 23
must also be considered!

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4.2 Version „Separate installation“

Legend to sketch no. 37 …. 55:

2 10
1 = Transmission housing
11 13 11 2 = Ball bearing
3 = Screen sheet
4 = Bearing cover
5 = Ball bearing
14 14 6 = Retaining ring
7 = O-ring
16 8 = Oil screen sheet
16
9 = Output gear
10 = Shaft seal
15 15 11 = Output flange
12 = Stud bolt
13 = Metal sheet
14 = O-ring
12 13 6 12 15 = Disk
10 5 16 = Hexagon screw
8

4
1 3 9 7

Figure 36

Provide screw plugs (see arrows) with new O-ring and install it.

Tightening torque MA = 80 Nm

Then insert ball bearing (2) until contact is obtained.

Figure 37

Rotate transmission by 180°.

Insert slotted pin (see arrow) to the bottom.

Figure 38

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Position screen sheet – with slotted pin (see Fig. no. 39) into
fixing hole (arrow).

Observe installation position –slotted pin = radial fixing of

screen sheet!

Figure 39

Insert ball bearing into cover and fix with retaining ring.

Figure 40

Oil both O-rings (arrows) and insert them into annular grooves of
planetary carrier.

Figure 41

Bend edges of fixing straps of oil screen sheet slightly.

Assembly aid screen sheet is fixed to bearing cover –
see Fig. no. 44).

Figure 42

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Insert oil screen sheet onto bearing cover

Observe installation position - place locating tab (see arrow)

into recess of bearing cover (radial fixing)!

Figure 43

Press output gear into ball bearing/bearing cover.

Support ball bearing onto bearing inner ring!

Figure 44

Heat bearing inner ring of ball bearing.

Figure 45 Attach two adjusting screws and mount preassembled bearing

cover/output gear until contact is obtained.

(S) Adjusting screws (M12) 5870 204 021

Observe installation position of bearing cover (2) in

transmission (1) – Transmission installation „VERTICAL“
or „HORIZONTAL“ - see detailed sketches below:

„VERTICAL“ „HORIZONTAL“

1 1

2
Figure 46
2

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Fix bearing cover by means of hexagon screws.

Tightening torque (M 12/8.8) MA = 80 Nm

Figure 47

4.2.1 Shaft seal output flange

3
2 1 5
Legend to sketch:

1 = Shaft seal
2 = Metal sheet
4 3 = Output flange
4 = Ball bearing
5 = Bearing cover

Figure 48

Install new shaft seal.

(S) Driver tool 5870 048 279

For reassembly wet shaft seal on outer diameter with spirit!

Pay attention to installation position of shaft seal, seal lip

showing to oil sump (see sketch no. 49)!

Use of specified driver tool ensures exact installation position

Figure 49
of shaft seal!

Install stud bolts.

Tightening torque (M10x1) MA = 20 Nm

Pay attention to installation position!

Install stud bolts with short thread length into flange!

Figure 50

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Install screen sheet (2, see Figure 49).

(S) Pressure piece 5870 506 150

Use of specified driver tool ensures exact installation position

of screen sheet!

Figure 51

Install preassembled output flange.

Figure 52

Insert O-ring.

Figure 53

Position disk and fix output flange by means of hexagon screws.

Tightening torque (M10/10.9) MA = 68 Nm

Install second shaft seal/output flange (front axle output)

analogously !

Figure 54

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Prior to putting the unit into operation, observe the

specifications and regulations as well as the instructions of
the ZF operating instructions as well as the specifications and
instructions of the vehicle manufacturer!

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5. REASSEMBLY - BRAKE / CLUTCH / PLANETARY CARRIER

5.1 Planetary carrier
Illustration shows HL-version „Axle attachment“.

Install bearing outer ring until contact is obtained.

(S) Driver tool 5870 058 051

(S) Handle 5870 260 002

Observe bearing allocation – bearing inner ring to bearing

outer ring – also see instructions for disassembly Page 2/11,
Fig. no. 39 !
Figure 1

Rotate transmission by 180°.

Install second bearing outer ring until contact is obtained.

(S) Driver tool 5870 058 051

(S) Handle 5870 260 002

Observe bearing allocation – bearing inner ring to bearing

outer ring – also see instructions for disassembly Page 2/11,
Fig. no. 39!

Figure 2

Only for version transmission installation position

„Horizontal“
(Figure no. 3)

Insert screen sheet and fasten with countersunk screws.

Tightening torque (M 6/8.8) MA = 7.4 Nm

Wet countersunk screws with Loctite type no. 243!

Figure 3

Install slotted pins (2) considering installation dimension „X“

and installation position, see sketch no. 5
(groove showing to center).

(S) Press-fit mandrel AA00 392 151

Figure 4

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Legend to sketch:
2
1 = Planetary carrier
2 = Slotted pin (6x)
1 3 = Center (planetary carrier)

Figure 5

Insert cylindrical roller bearing into planetary gear.

Press cylindrical roller bearing through packaging sleeve until
1 2 snap ring engages into annular groove of planetary gear.

3
Use packaging sleeve to facilitate assembly!

4 1 = Cylindrical roller bearing

2 = Packaging sleeve
3 = Snap ring
4 = Planetary gear

Figure 4

Press on planetary gear over bearing inner ring until contact is

obtained.

(S) Driver tool 5870 048 283

Install planetary gears with large radius on cylindrical roller

bearing (downwards) towards planetary carrier!

Figure 5

Engage retaining ring.

Adjust retaining ring until contact with groove base is

obtained.

Figure 6

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Press bearing inner ring onto planetary carrier until contact is

obtained.

Figure 9
Insert preassembled planetary carrier.

Figure 10
Fix planetary carrier with pressure plate and clamping bar.

(S) Clamping bar 5870 654 049

Figure 11

Rotate transmission by 180°.

Check contact of bearing outer ring (see arrow). Reassembly of

bearing outer ring, see Figure no. 1.

Figure 12

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Install heated bearing inner ring until contact is obtained.

Adjust bearing inner ring after cooling down!

Figure 13

Position disk and manually turn in hexagon screws

(fix planetary carrier).

Then remove clamping bar, see Figure no. 11.

Figure 14

Fix clamping fork to output flange.

Tighten hexagon screws evenly – risk of strain!

Tightening torque (M 10/10.9) MA = 46 Nm

(S) Clamping fork 5870 240 025

While tightening hexagon screws, rotate planetary carrier

several times in both directions (roller setting)!

Figure 15

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5.2 Brake and clutch

Mount heated centering disk and press it until contact is

obtained.

Figure 16

Fix centering disk by engaging retaining ring into annular groove

of input shaft.

Figure 17

Insert ball bearing into ring gear and fasten it by engaging

retaining ring into annular groove of ring gear.

(S) Clamping pliers 5870 900 021

Figure 18

Heat bearing inner ring of ball bearing.

Figure 19

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Mount preassembled ring gear to input shaft until contact is

obtained.

Figure 20

Engage retaining ring into annular groove of input shaft.

Figure 21

Rotate transmission by 180°.

Insert axial needle cage into recess of planetary carrier.

Oil axial needle cage for reassembly!

Figure 22

Insert preassembled input shaft (with ring gear).

Figure 23

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Version „2 HL-290“ 5.2.1 Disk components brake and clutch

Reassembly of both disk packages in version „2 HL-290“,
see sketch no. 24 and Figure no. 27 .... 30 is shown below!

Reassembly and procedure concerning versions „2 HL-270“

and „2 HL-250“ must be carried out as shown in sketches no.
25 and 26 and Figures no. 27 .... 30!

5.2.1.1 Version „2 HL-290“

Legend to sketch no. 24:
A = Lower ann. groove 2 HL-290 (retaining ring pos. 1)
B = Upper ann. groove 2 HL-250/270 (retaining ring pos. 1)
1 = Retaining ring
2 = End plate/Brake (1 pc)
3 = Outer disk/Brake (8 pcs.)
4 = Outer disk/Brake optional (1 pc)
Figure 24 5 = Inner disk/Brake (8 pcs.)
6 = Lining disk/Clutch (12 pcs.)
7 = Outer disk/Clutch (10 pcs.)
Version „2 HL-270“ 8 = Outer disk/Clutch optional (1 pc)
9 = Transmission housing
10 = Disk carrier/Ring gear
11 4
5.2.1.2 Version „2 HL-270“
9 10 Legend to sketch no. 25:
A = Lower ann. groove 2 HL-290 (retaining ring pos. 1)
8 5 B = Upper ann. groove 2 HL-250/270 (retaining ring pos. 1)
1 = Retaining ring
7 3 2 = End plate/Brake (1 pc)
3 = Outer disk/Brake (6 pcs.)
B 4 = Outer disk/Brake optional (1 pc)
6 5 = Inner disk/Brake (6 pcs.)
6 = End plate/Clutch (1 pc)
7 = Lining disk/Clutch (10 pcs.)
A 8 = Outer disk/Clutch (8 pcs.)
2 1 9 = Outer disk/Clutch optional (1 pc)
Figure 25 10 = Transmission housing
11 = Disk carrier / Ring gear

Version „2 HL-250“ 5.2.1.3 Version „2 HL-250“

Legend to sketch no. 26:
11 A = Lower ann. groove 2 HL-290 (retaining ring pos. 1)
B = Upper ann. groove 2 HL-250/270 (retain. ring pos. 1)
2
6 1 = Retaining ring
4 2 = End plate/Brake (2 pcs.)
9 3 = Outer disk/Brake (4 pcs.)
5 4 = Outer disk/Brake optional (1 pcs.)
8 5 = Inner disk/Brake (4 pcs.)
7 3
6 = End plate/Clutch (2 pcs.)
2 7 = Lining disk/Clutch (8 pcs.)
8 = Outer disk/Clutch (6 pcs.)
6 B 9 = Outer disk/Clutch optional (1 pc)
10 10 = Transmission housing
11 = Disk carrier/Ring gear
A
1
Figure 26

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Reassembly brake:

Engage retaining ring (1) into annular groove (A).

(S) Clamping pliers 5870 900 021

Observe installation position of retaining ring (1) – annular

groove (A) only for version „2 HL-290“!

Figure 27

Insert end plate (2).

Figure 28

Insert disk package alternately, beginning with an outer disk.

Position outer disk (1 pc) s = variable 2.8 ..... 3.7 mm to top of

disk package (piston side)!
With outer disk s = variable, disk clearance/piston stroke is
adjusted - see Figure no. 42!

Figure 29

Reassembly clutch:

Insert disk package alternately, beginning with a lining disk.

Position outer disk (1 pc) s = variable 1.2 ..... 1.6 mm to top of

disk package (pressure piece side)!
With outer disk s = variable, disk clearance/piston stroke is
adjusted – see Figure no. 41!

Figure 30

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5.2.2 Adjust and check disk clearance/piston stroke of

brake and clutch

Mount pressure piece (without compression spring).

Figure 31

Oil axial roller cage and mount it with both axial washers (1x
each, positioned underneath and onto axial needle cage).

Figure 32

Insert piston (brake) – without mounted sealing elements.

Figure 33

Insert piston (clutch) – without mounted sealing elements.

Figure 34

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Insert both cup springs/clutch.

Fix cup springs with grease and position them centrically.

Observe installation position – see sketch no. 37!

Figure 35

Insert both cup springs/brake.

Fix cup springs with grease and position them centrically.

Observe installation position, see sketch no. 37!

Figure 36 Legend to sketch no. 37 ... Figure no. 42:

1 = Measuring device
2 = Piston/clutch
3 = Cup springs/Clutch
I II 1 4 = Piston/Brake
5 = Cup springs/Brake
6 = Transmission housing
DC BA I = Measuring hole (disk clearance / clutch)
5
3 X
II = Measuring hole (disk clearance / brake)

Y A = Mounting face/Housing – Front face/Piston

2 4 B = Mounting face/Housing – Piston contact/Housing
C = Mounting face/Housing – Front face/Piston
6 D = Mounting face/Housing – Piston contact/Housing

Y = Disk clearance/Clutch → 2.4 +0,3 mm

(piston stroke)
X = Disk clearance/Brake → 1.8 + 0,3 mm
Figure 37 (piston stroke)

Locate measuring device evenly with hexagon screws (risk of

breakage) until contact is obtained.

Tightening torque (M 12/8.8) MA = 80 Nm

(S) Measuring device 5870 200 131

Figure 38

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Determine dim. „A“ (Measuring hole „I“) from mounting

face/housing to front face/piston (clutch).

Dim. „A“ e.g. ................................. = 22.45 mm

(S) Straightedge 5870 200 108

Figure 39

Determine Dim. „C“ (Measuring hole „II“) from mounting

face/housing to front face/piston (brake).

Dim. „C“ e.g. ..................................... 11.85 mm

Figure 40
Determine Dim. „B“ from mounting face/housing to clutch
piston contact/housing.

Dim. „B“ e.g. ................................... 19.95 mm

Calculation example:

Dim. „A“ e.g. ................................. 22.45 mm

Dim B“ e.g. ................................. - 19.95 mm
Result = disk clearance 2.50 mm

Clutch disk clearance (piston stroke) = 2.4 + 0,3 mm

If the required disk clearance (piston stroke) is not obtained,
Figure 41 correct with a suitable outer disk – see Fig. no. 30!

Determine Dim. „D“ from mounting face/housing to brake

piston contact/housing.

Dim. „D“ e.g. ..................................... 9.95mm

Calculation example:

Dim. „C“ e.g. ................................... 11.85 mm

Dim. „D“ e.g. ................................. - 9.95 mm
Result = disk clearance 1.90 mm

Disk clearance (piston stroke) Brake = 1.8 + 0,3 mm

If the required disk clearance (piston stroke) is not obtained,
Figure 42 correct with a suitable outer disk – see Fig. no. 29!

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Remove measuring device again – loosen screws

evenly.
Remove all cup springs, both pistons, axial roller cage with axial
washers and pressure piece.

Figure 43

Insert shim into ring gear and fix by engaging snap ring into
annular groove of ring gear.

Figure 44

Place O-ring (see arrow) into groove and insert ring.

Oil sealing surfaces in housing and O-ring for reassembly!

Observe installation position – see Figure!

Figure 45

Mount ring with driver tool until contact is obtained.

(S) Driver tool 5870 506 161

Figure 46

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Oil sealing surfaces in housing and sealing elements.

Insert seal (1) with sealing lip showing to oil

1 sump – also see detail sketch.

2 3
2
Put both O-rings (2) into annular grooves of pressure ring (3)
and insert preassembled pressure ring into housing.
Figure 47

Bring pressure ring with driver tool into contact position.

(S) Driver tool 5870 506 161

Figure 48

Insert compression spring until contact is obtained.

Figure 49

Insert pressure piece over compression spring until contact is

obtained.

Figure 50

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Oil axial roller cage and mount it with both axial washers (1x
each to be positioned underneath and onto axial needle cage).

Figure 51

Insert seal (2, with sealing lip showing to oil sump) and seal (3) –
2 see sketch no. 53 - into housing (1).
3

Oil sealing elements and sealing surfaces on piston for

reassembly!

Figure 52

Legend to sketch no. 53 as well as Figure no. 52 and Fig. no. 54:
1
1 = Housing
2 2 = Seal (with sealing lip)
7 3 = Seal
4 4 = Piston / Brake
6 5 = Seal (with sealing lip)
3 6 = Seal (with sealing lip)
7 = Piston / Clutch
5

Figure 53

Insert seals (5 and 6, see sketch no. 58), with sealing lips
6 showing to oil sump into piston / brake (4).
5

Oil sealing surfaces on piston and sealing elements for

reassembly!

Figure 54

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Insert preassembled piston/brake until contact is obtained.

Position piston in such a way that oil supply hole (see arrow)
– with HL-Transmission installed into vehicle – is at 12.00
o’clock position!
Observe version as to transmission installation
position „HORIZONTAL – VERTICAL“ !

Figure 55

Use driver tool to bring piston into contact position.

(S) Driver tool 5870 506 161

Figure 56

Insert both cyl. pins (arrow).

Figure 57

Insert piston/clutch until contact is obtained.

Figure 58

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Press piston axially, against compression spring preload.

Provide screw plug with new O-ring and seal pressure oil supply
hole (see arrow).

Tightening torque MA = 40 Nm

Axial position of piston is maintained

(Facilitate assembly for installation of input housing, see
Figure no. 65 … 66).

Figure 59

Insert both cup springs/clutch.

Observe installation position, see also sketch no. 37!

Figure 60

Insert both cup springs/brake.

Observe installation position – see also sketch no. 37!

Figure 61

5.3 Install modulation valve and input housing

Insert piston (modulation valve cpl. – can only be replaced as

unit).

Figure 62

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Place O-ring (see arrow) into annular groove of housing and

insert compression spring.

Figure 63

Oil O-ring and insert it into annular groove of input housing.

Figure 64

Insert two adjusting screws (M 12), mount input housing and fix
it with hexagon screws.

(S) Adjusting screws (M12) 5870 204 021

For installation of input housing align cup springs

centrically!

Figure 65

Locate input housing evenly with hexagon screws (risk of

breakage) until contact is obtained.

Tightening torque (M 12/8.8) MA = 80 Nm

Figure 66

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5.4 Emergency release (parking brake)

8 7
Legend to sketch. 67 ... 70:
1 9 1 = Input housing
2 = Housing
2 3 = O-ring
6 4 = Threaded element (orifice)
5 5 = Ball
3 6 = Compression spring
7 = O-ring
4 8 = Breather
9 = Position of lubrication nipple for version „Transmission
Figure 67 installation position „Vertical“
- Position of lubrication nipple for version „Transmission
installation position „Horizontal“, see sketch no. 72

Remove protective cap of lubrication nipple only if

emergency release is required!

Install threaded element (4) with new O-ring (3).

Tightening torque (M 10x1) MA = 15 Nm

Figure 68

Insert ball (5).

Figure 69

Insert compression spring (6).

Figure 70

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5.4.1 Check emergency release for leak tightness

2

Illustration shows version transmission installation position

„Vertical“.
1

For version transmission installation position „Horizontal“
connections and positions of breather valves/lubrication nipple
etc. must be considered as shown on illustration of sketch no .
72!

Install both breather valves (1), screw plugs (2) with new seal
rings and screw plugs (3) with new O-rings.

3 Tightening torque:
Breather valve (M 10x1) MA = 15 Nm
3 Screw plug (M 10x1 with seal ring) MA = 20 Nm
Figure 71 Screw plug (M 10x1 with O-ring) MA = 20 Nm

5 6 Legend to sketch no. 72:

7
8 1 = Breather/Pressure relief-valve
(emergency release –parking brake)
1 2 = Screw plug
3 = Breather valve (emergency release – parking brake)
2
4 = Lubrication nipple (emergency release – parking brake)
5 = Breather valve (Multi-disk clutch)
3 6 = Breather valve (Mulit-disk brake)
4 7 = Pressure oil connection – multi-disk brake
8 = Pressure oil connection – multi-disk clutch
Figure 72

Install breather valve (1), screw plugs (2), screw plug (3) with
new O-ring and compressed air connection piece (4).
4
Tightening torques:
Breather valve (M 10x1) MA = 15 Nm
Screw plug (M 10x1 with O-ring) MA = 20 Nm
3 Screw plug (M 18x1.5 with O-ring) MA = 35 Nm
Compressed air connect. piece (M 10x1)
2 with seal ring MA = 20 Nm

1
Figure 73

Pressurize emergency release with compressed air p = 5 + 1bar

and close shut-off valve.
During a test duration of 3 minutes no pressure drop is allowed!

(S) Air connection 5870 505 012

Figure 74

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Remove screw plug and compressed air connection piece

(see Fig. no. 73).

Install breather (3) with new O-ring and lubrication nipple (4).

Tightening torques:
4 3 Lubrication nipple (M 10x1) MA = 15 Nm
Breather (M 18x1.5) MA = 22 Nm

Figure 75 5.4.2 Check multi-disk brake and multi-disk clutch for leak
tightness as well as closing pressure
AB AK EB
Legend to sketch no. 75:
EK 1 = Transmission housing
2 = Input housing
1 AB = Pressure oil connection – multi-disk brake
2 AK = Pressure oil connection – multi-disk clutch
EB = Breather valve – multi-disk brake
EK = Breather valve – multi-disk clutch

Illustration shows version transmission installation position

„Vertical“.

For version Transmission installation position „Horizontal“,

connections and positions of breather valves/lubrication nipple
etc. according to illustration in sketch no. 72 must be considered!
Figure 76
Multi-disk brake
Connect HP pump (“AB“ – see sketch no. 76 and
sketch no. 72) and
build up pressure of p = 30 … max. 35 bar.
- Bleed pressure chamber several times.
Close shut-off valve.
During a test duration of 3 minutes no measurable pressure drop
is allowed!

(S) HP pump 5870 287 007

Test medium:
According to ZF List of Lubricants TE-ML 07
Figure 77

Closing pressure test (Cup spring preloading force):

When measuring closing pressure, valve block may not be
attached to transmission due to by-pass function between brake
and clutch.
Connection „AK“ (see sketch no. 76 and sketch no. 72) open
(not closed and tank connection).

Reduce pressure slowly, when pressure range

12 ... 9 bar (closing pressure) is reached, input shaft must be
locked at a tightening torque of 35 Nm!

(S) Spline mandrel 5870 510 039

Figure 78

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Multi-disk clutch
Connect HP-pump (“AK“ see sketch no.76 and
sketch no. 72),
Build up pressure of p = 30 ... max. 35 bar
- Relieve pressure chamber several times.
Close shut-off valve.
During a test duration of 3 minutes no measurable pressure drop
is allowed!!
(S) HP-pump 5870 287 007
Test medium:
Figure 79 According to ZF List of Lubricants TE-ML 07

Closing pressure test (Cup spring preloading force):

When measuring closing pressure, valve block (only for version

„with“ mounted valve block) may not be attached to
transmission due to by-pass function between brake and clutch.

Connection „AB“ (see sketch no. 76 and sketch no. 72) open
(not closed and tank connection).

Reduce pressure slowly, when pressure range

17 ... 13 bar (closing pressure) is reached, input shaft must be
locked at a tightening torque of 35 Nm!
Figure 80
(S) Spline mandrel 5870 510 039

5.5 Speed sensor

Install speed sensor with new O-ring.

Tightening torque (M 8/8.8) MA = 23 Nm

Figure 81

5.6 Lubrication pump/shift interlock

Install lubrication pump (with O-rings) or shift interlock –

depending on version – (Illustration shows – Version
„Lubrication Pump“).

Tightening torque (M 8/10.9) MA = 23 Nm

Cpl. assembly of lubrication pump/shift interlock - see

Chapters 7 and 8!

Figure 82

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Prior to putting the unit into operation, observe the

specifications and regulations as well as the instructions of
the ZF operating instructions as well as the specifications and
instructions of the vehicle manufacturer!

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6. DISASSEMBLY - LUBRICATION PUMP/SHIFT INTERLOCK and

VALVE BLOCK

6.1 Version „with“ lubrication pump

Loosen threaded joint and pull off cpl. lubrication pump.

Figure 1

Loosen cover screws, remove cover (1) with seal (2) and filter
(3) from housing (4).
4

3
1 2

Figure 2

Remove cpl. pressure limiting valve and both O-rings (arrows).

Figure 3

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Keep housing in vertical position, while loosening pump cover

screws.

Figure 4

Maintain contact position of pump and rotate by 180°-

disassembly aid!

Then pull pump in vertical position out of housing –

pay attention to possibly releasing balls and compression springs.

Figure 5

Remove outer (1) and inner rotor (2) and take releasing ball
[(3) driver] out of control housing (4).
4

Outer, inner rotor and control housing = rotor set

3
1 2

Figure 6

Remove control housing and releasing balls and compression springs

(3 pcs. each).

Figure 7

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Unsnap retaining ring.

Figure 8

Pull cpl. pump shaft out of pump cover.

Figure 9

Unsnap retaining ring and press ball bearing from shaft.

Figure 10

Pull needle sleeve out of housing hole.

(S) Inner extractor 5870 300 012

(S) Counter support 5870 300 011

Figure 11

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6.2 Version „with“ hydr. shift interlock

Disassemble both oil tubes.

Figure 12

Loosen threaded joint of shift interlock (3 x cylindrical screws)

and remove cpl. shift interlock.

Figure 13

Loosen cover screws, remove cover and gasket (see also Figure
no. 15).

Figure 14

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Take filter out of housing.

Figure 15

Loosen cover screws of pump.

Figure 16

Maintain contact position of pump and rotate it by 180° –

disassembly aid!

Then pull pump in vertical position out of housing –

pay attention to possibly releasing balls and compression springs
(see Fig. no. 18 and 19).

Figure 17

Remove outer (1) and inner rotor (2) and take releasing ball
[(3) driver] out of control housing (4).

4

Outer, inner rotor and control housing = rotor set

3
2
1
Figure 18

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Remove control housing and releasing balls and compression

springs (3 pcs. each).

Figure 19

Unsnap retaining ring.

Figure 20

Pull cpl. pump shaft out of pump cover.

Figure 21

Unsnap retaining ring and press ball bearing from shaft.

Figure 22

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Pull needle sleeve out of housing hole.

(S) Inner extractor 5870 300 012

(S) Counter support 5870 300 011

Figure 23

Remove O-rings and all single parts, remove valves.

2
1
Legend to sketch no. 24:

1 = Housing 2 = O-rings
3 = Check valve (010) 4 = Shift piston
5 = Check valve (009) 6 = Check valve (008)
3 7 = Pressure relief valve
1 7
5 6
4

Note:
Figure 24 Position 4 (shift piston) shows version with screw plug.

In sketch no. 25 version II is shown with plug (2) and retaining

1 ring (1).

2
When disengaging retaining ring –
Pay attention to spring preload. Protect against movement!

Figure 25

6.3 Disassemble valve block

Loosen fixing screws and remove cpl. valve block.

Figure 26

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Remove both O-rings (see arrows).

Do not further disassemble. Valve block may only be

replaced as component.

Figure 27

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7. REASSEMBLY LUBRICATION PUMP

Mount ball bearing onto pump shaft and fix it by engaging
retaining ring into annular groove of pump shaft.

Figure 1

Press preassembled pump shaft into pump cover and fix it by

engaging retaining ring into annular groove of pump cover.

Figure 2

Insert compression springs (1) and ball (2) into holes

(see arrows - 3x).

Prior to installation, oil single parts of pump/rotor set

(control housing, inner and outer rotor) –
2 use oil acc. to ZF List of Lubricants TE-ML 07 !
1
Keep preassembled single parts in „vertical“ position –

pay attention to position of inserted balls and compression
springs (see work steps Fig. no. 3 .... Fig. no. 9) !

Figure 3

Mount control housing.

Control housing, inner and outer rotor = rotor set

Figure 4

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Position ball – (see arrow, engagement for inner rotor) with

grease into countersink of pump shaft.

Figure 5

Mount inner rotor.

Place groove of inner rotor over ball (see arrows)!

Figure 6

Mount outer rotor

Figure 7

Insert needle sleeve to installation dimension „X“ into housing.

„X“ = 0.2 .... 0.7 mm below plane face / housing

(S) Driver tool 5870 705 003

Use of specified driver tool ensures exact installation

position!

Insert needle sleeve with marked front face showing

upwards!

Figure 8

Check opening of orifice / oil hole in housing bottom!

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Maintain pump in „vertical“ position while inserting housing

with mounted needle sleeve onto preassembled pump.

Figure 9

Rotate housing by 180° and fix pump with hexagon screws.

Maintain contact position of inserted pump!

Figure 10

Fix pump.

Tightening torque (M6/8.8) MA = 9.5 Nm

Figure 11

Functional test of lubrication pump:

With counter-turning motions on pump shaft,

swiveling of control housing (stop LH/RH in pump cover) is
audible!

Figure 12

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Oil both O-rings (arrows) and put them into annular groove of
housing.

Figure 13

Insert O-rings (see arrows) into annular grooves of pressure

relief valve.

Figure 14

Mount pressure relief valve.

Tightening torque MA = 10 Nm

Figure 15

Secure pressure relief valve by center punch marks (2x).

Figure 16

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Insert filter.

Figure 17

Place gasket.

Figure 18

Place cover and fix it with hexagon screws and disks.

Tightening torque (M8/8.8) MA = 23 Nm

Figure 19

Insert screw plug with new O-ring.

Tightening torque (M10x1) MA = 15 Nm

Figure 20

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Mount cpl. lubrication pump and fasten it with cylindrical screws

and disks.

Tightening torque (M8/10.9) MA = 23 Nm

Figure 21

Prior to putting the unit into operation, observe the

specifications and regulations as well as the instructions of
the ZF operating instructions as well as the specifications and
instructions of the vehicle manufacturer!

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8. REASSEMBLY SHIFT INTERLOCK

4 5 Legend to sketch no. 1:
3
9
1 = Housing 2 = Shift piston
2 3 = Pressure relief valve 4 = Check valve (008)
5 = Check valve (009) 6 = Check valve (010)
1 6 7 = Filter 8 = Lubrication pump
9 = Plug

7 8
Figure 1

Put O-ring (see arrow) into annular groove of piston.

Lead plastic ring by means of inner installer (S) over piston and
position it at O-ring.

(S) Inner installer 5870 651 055

Seal consists of plastic ring and O-ring

(see Figure no. 2 …. 3).

Figure 2

Center plastic ring (see arrow) with calibrating mandrel.

(S) Calibrating mandrel 5870 651 056

Figure 3

Insert compression spring, oil preassembled piston and install.

Figure 4

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2 Version I:

1 Fix piston with screw plug (1- with O-ring).

Install screw plug (2 – with seal ring).

Tightening torque:
Screw plug (M24x1.5) MA = 50 Nm
Screw plug (M10x1) MA = 15 Nm

Figure 5

Version II (Figure 6 … 8):

Oil O-ring and insert it into annular groove of plug.

Figure 6

Fix plug by engaging retaining ring into annular groove of

housing.

Pay attention to spring preload – protect against movement!

Figure 7

Mount screw plug with seal.

Tightening torque (M10x1) MA = 15 Nm

Figure 8

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Install single parts according to adjacent illustration.

1 = Pressure relief valve cpl. MA = 10 Nm

2 = Check valve cpl. MA = 10 Nm
ZF no.: 4143 242 008
3 = Check valve cpl. MA = 10 Nm
ZF no.: 4143 242 009
4 4 = Check valve cpl. MA = 10 Nm
1 ZF-no.: 4143 242 010
3

Figure 9
2

Oil single parts acc. to List of Lubricants TE-ML 07!

Observe installation position of the different check valves

(see also sketch Figure no.1)!

Secure check valves and pressure relief valves with two center
punch marks each.

Figure 10

Insert needle sleeve to installation dimension „X“ into housing.

„X“ = 0.2 .... 0.7 mm below plane face/housing

(S) Driver tool 5870 705 003

Use of specified driver ensures exact installation position!

Insert needle sleeve with marked front face showing

upwards!

Figure 11

Check opening of orifice / oil hole in housing bottom!

Insert ball bearing onto pump shaft and fix it by engaging

retaining ring into annular groove of pump shaft.

Figure 12

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Press preassembled pump shaft into pump cover and fix it by

engaging retaining ring into annular groove of pump cover.

Figure 13

Insert compression springs (1) and ball (2) into holes

(see arrows - 3x).

Prior to installation, oil single parts of pump/rotor set

(control housing, inner and outer rotor) –
2 use oil acc. to ZF List of Lubricants TE-ML 07 !
1
Keep preassembled single parts in „vertical“ position –

pay attention to position of inserted balls and compression
springs (see work steps Fig. no. 14 .... Fig. no. 19) !

Figure 14

Mount control housing.

Control housing, inner and outer rotor = rotor set

Figure 15

Position ball – (see arrow –engagement for inner rotor) with

grease into countersink of pump shaft.

Figure 16

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Mount inner rotor.

Place groove of inner rotor over ball (see arrows)!

Figure 17

Mount outer rotor.

Figure 18

Maintain pump in „vertical“ position while inserting housing

with mounted needle sleeve onto preassembled pump.

Figure 19

Rotate housing by 180° and fix pump with hexagon screws.

Tightening torque (M6/8.8) MA = 9.5 Nm

Maintain contact position of inserted pump!

Figure 20

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Functional test of lubrication pump:

With counter-turning motions on pump shaft,

swiveling of control housing (stop LH/RH in pump cover) is
audible!

Figure 21

Insert screen filter.

Figure 22

Place gasket.

Figure 23

Place cover and fix with hexagon screws and disks.

Tightening torque (M8/8.8) MA = 23 Nm

Pay attention to different screw length!

Figure 24

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Oil both O-rings (arrows) and put them into annular groove
of housing.

Figure 25

Insert cpl. shift interlock and fix with cylindrical screws with
disks.

Tightening torque (M8/10.9) MA = 23 Nm

Pay attention to different screw length!

Figure 26

Install both screw-in sleeves and screw plug (see arrow) with
O-rings.

Tightening torque:
Screw-in sleeve (M 16 x 1.5) MA = 30 Nm
Screw plug (M 18 x 1.5) MA = 35 Nm

Figure 27

Legend to Figure no. 28:

1 = Oil tube
2 = Hollow screw (M 16 x 1.5)
3 = Seal ring
4 = Hollow screw (M 14 x 1.5)
5 = Seal ring

Figure 28

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Mount oil tubes.

Tightening torque:
Hollow screw (M 14 x1.5) MA = 40 Nm
Hollow screw (M 16 x1.5) MA = 40 Nm

Figure 29

Prior to putting the unit into operation, observe the

specifications and regulations as well as the instructions of
the ZF operating instructions as well as the specifications and
instructions of the vehicle manufacturer!

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9. VALVE BLOCK (shifting low gear – high gear)

Insert O-rings (see arrows) into countersinks of valve block.

Use grease as assembly aid!

Figure 1

Fix cpl. valve block with cylindrical screws.

Tightening torque (M8/10.9) MA = 23 Nm

Figure 2

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10. Mount HL-TRANSMISSION to AXLE

(only for version „axle attachment“)

Position complete HL-transmission to axle.

(S) Lifting strap 5870 281 026

Figure 1

Fix HL-transmission to axle with hexagon screws and nuts.

Tightening torque (M12/8.8) MA = 79 Nm

Figure 2

Prior to putting the unit into operation, observe the

specifications and regulations as well as the instructions of
the ZF operating instructions as well as the specifications and
instructions of the vehicle manufacturer!

5871 042 002 10/1