ZF Actuator

Repair Manual
Transmission Actuator and Clutch

Actuator
1327 751 103
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 purpose of this documentation is prohibited without the
consent of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2005-09
Edition: 2005-09
1327 751 103
ZF-AS Tronic
Table of Contents
Page
Preface ...........................................................................................................................................................
Safety Instructions .........................................................................................................................................
General Information ......................................................................................................................................
Instructions for Carrying out Repairs ............................................................................................................
Overview of Amendments: 1327 751 003......................................................................................................
Tightening Torques for Nuts and Bolts, Extract from ZFN 148 ....................................................................
Screw Plugs DIN 908, 910, and 7604 ............................................................................................................
Union Screws DIN 7643 ................................................................................................................................
Conversion from DIN to ISO Standards ........................................................................................................
Special Tool.....................................................................................................................................................
Consumables ..................................................................................................................................................
ZF Repair Kits for Transmission/Clutch Actuator ........................................................................................
5
6
6
7
9
10
11
11
12
14
15
16
Removing Transmission Actuator ..................................................................................................................
17
Fitting Transmission Actuator........................................................................................................................
19
Removing Upper Section................................................................................................................................
22
Replacing Travel Sensors (HG, GV, GP, and Gate).........................................................................................
23
Replacing Solenoid Valve Unit .......................................................................................................................
24
Replacing Cpl. Selector Cylinder ...................................................................................................................
25
Bracket for Temperature and Speed Sensor ..................................................................................................
26
Fitting Bracket for Temperature and Speed Sensor.......................................................................................
28
Removing Wiring Harness (Input Speed Sensor and Temperature Sensor) ................................................
30
Fitting Wiring Harness (Input Speed Sensor and Temperature Sensor) ......................................................
32
Replacing Pressure Relief Valve .....................................................................................................................
34
Dismantling Lower Section of Transmission Actuator ..................................................................................
35
Assembling Lower Section of Transmission Actuator...................................................................................
37
Programming Transmission Actuator ............................................................................................................

Programming Flash EPROMS with ZF Test Program....................................................................................
Description of Test..........................................................................................................................................
Outgoing Inspection .......................................................................................................................................
39
40
40
40
Clutch Actuator ..............................................................................................................................................
41
1327 751 103 - 2005-09
Preface
This manual is intended for skilled personnel
trained by ZF Friedrichshafen AG to carry out
maintenance 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. Well-trained personnel,
2. Specified equipment,
e.g.: Special tools
3. Genuine ZF spares, according to
our latest specifications
All work performed at these service locations 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
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and
Special Driveline Technology
Service Werk 2 (Plant 2)
Phone: +49 (0)7541 77-0
Fax: +49 (0)7541 77-908000
Internet: www.zf.com
2003-08
Damage resulting from work performed by non-ZF

personnel in an improper and unprofessional manner, together with follow-on costs caused by such
work, is excluded from the contractual warranty
agreement.
This also applies where genuine ZF spare parts have
not been used.
Safety Instructions
Safety Instructions
General Information
Companies repairing ZF units are responsible for

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

or repair work.
To avoid injury to personnel and damage to

products, all safety regulations and legal requirements which apply to repair and maintenance work
must be adhered to.
Before starting work, mechanics must familiarize
themselves with these regulations.
CAUTION
Pictures, drawings, and components do not always
represent the original object, but are used to illustrate working procedures.
Pictures, drawings, and components are not to scale.
Conclusions about size and weight should not be
drawn (even within a complete illustration).
Always follow the working steps as described in the
text.
Personnel required to carry out repairs on ZF

products must receive appropriate training in
advance. It is the responsibility of each company to
ensure that their repair staff is properly trained.
After completion of repair work and testing, skilled

staff must check whether the product is functioning
correctly.
The following safety instructions appear in this

manual:
THREATS TO THE ENVIRONMENT !

Lubricants, consumables, and cleaning agents must
not be allowed to enter the soil, ground water, or
sewage system.
Ask your local environment agency for safety
information on the relevant products and adhere to
their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
When working with lubricants and cleaning agents
always refer to the manufacturers instructions.
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional working practices could damage the product.
DANGER
This is used when lack of care could lead to personal
injury or death.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
2005-04
Instructions for Repairs

Gaskets, Locking plates
ZF Service Information must be observed. This

information is available at all ZF Service Centers or
via the ZF-ServiceLine.
Parts which cannot be removed without being

damaged must always be replaced with new parts
(e.g. gaskets and locking plates).
In case of doubt always turn to the relevant department within ZF After-Sales Services for advice.
All work on transmissions is to be performed by
experts only and under clean conditions.
Use specified tools to dismantle and assemble
transmissions.
Shaft Seals
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
totally clean and in perfect condition.
After removing the transmission from the vehicle,

clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning.
Reworking
Parts joined with Loctite are easier to separate if

warmed with a fan heater.
Rework may be carried out on seal contact surfaces

using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
Cleaning parts
If rework is needed on spacer discs, shims etc.

because of clearance adjustment, ensure that the
reworked areas contain no face runout and have
the same surface quality.
Remove remains of old gaskets on all sealing surfaces. Carefully remove burrs or similar patches of
roughness using an oilstone.
Lube bores and grooves must be free of anticorrosion agents and foreign matter; check for
perfect passage.
Transmission Assembly
Find a clean work area to assemble the transmission.
Gaskets are installed without sealing compound or
grease. When measuring silicon-coated gaskets, do
not include the silicon layer.
During assembly, comply with all adjustment data
and tightening torques in the Repair Manual.
Carefully cover opened transmissions to prevent

foreign matter from entering.
Reusing parts
Parts such as roller bearings, discs, thrust washers
etc., must be inspected by a competent person who
should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.
2005-04
Instructions for Repairs

d) Dual shaft seals have two sealing
lips. The dust-proof sealing lip
(X) must face outwards.
Bearings
If bearings are mounted in heated condition, they
are to be heated evenly (e.g. heating cabinet).
Temperature should be at approx. 85 C and must
not exceed 120 C. Each mounted bearing must be
oiled with operating oil.
e) Fill the gap between the sealing

lips so it is 60 % filled with grease (e.g. produced
by Aral, such as Aralub HL2 or by DEA, such as
Spectron FO 20).
f) If possible, heat shaft seal bores to between
40 and 50 C (makes fitting easier). Press the
seal shaft with mounting or faceplate onto the
relevant installation depth plan.
Sealing
If a specific sealing agent* is to be used for sealing,
comply with the manufacturers directions for use.
Apply a thin layer of sealing agent to the surfaces
and spread evenly. Do not allow sealing to enter oil
ducts and bores. On oil-carrying ducts and bores,
wipe off the sealing agent on the surfaces to be
sealed near apertures to ensure that no sealing agent
enters the oil feeds when the surfaces are sealed.
Retaining Agents
Retaining agents* may only be used in places as
specified in the parts list.
Always comply with manufacturers directions for
use when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data, and tightening torques.
Shaft Seals
a) Apply a light coat of sealing agent* on circumference of shaft seals with steel jacket.
Transmission oil
b) Never apply sealing agent to shaft seals with
rubber jacket, but apply a thin coat of
Vaseline 8420 to the circumference or wet with
a lubricant, e.g. a water-soluble, concentrated
washing-up liquid (e.g. Pril, Coin, Palmolive).
After completing repairs, fill transmissions with

transmission oil. For the procedure and approved
oils, refer to the transmission operating manual and
TE-ML List of Lubricants (refer to identification
plate) which are available from any ZF After-Sales
Service Point and on the Internet under
www.zf.com.
After filling the transmission with oil, tighten the
screw plugs at the oil filling point and the oil overflow using the specified torques.
c) Shaft seals with steel and rubber jackets should

be treated on the circumference of the rubber
jacket as described above in section b).
* refer to expendable material
2003-08
Overview of Amendments: 1327 751 103
Index
Date of issue
1327 751 103 - 2005-09
Chapter
Initiator
Comment
Tightening Torques
Tightening Torques for Nuts and Bolts,
Extract from ZFN 148
Surface condition of bolts / nuts: Thermally
blackened and oiled or galvanized and oiled or
galvanized, chrome-plated, and oiled.
This standard applies to screws/bolts acc. to

DIN 912, DIN 931, DIN 933, DIN 960, DIN 961, as
well as ISO 4762, ISO 4014, ISO 4017, ISO 8765,
ISO 8676, and to nuts acc. to DIN 934 as well as
ISO 4032, ISO 8673.
Tighten screws with a calibrated ratchet dial torque

or ratchet wrench.
This Standard contains data on tightening torques

(MA) for screws/bolts and nuts in strength categories
8.8, 10.9, and 12.9, and nuts in strength categories 8,
10, and 12.
NOTE
Deviating tightening torques are listed separately in
the Repair Manual.
Regular screw thread

Size
Screw/Bolt
Nut
M4
M5
M6
Fine screw thread

Tightening torque (Nm) for
8.8
10.9
12.9
8
10
12
2.8
5.5
9.5
Size
Screw/Bolt
Nut
Tightening torque (Nm) for

8.8
10.9
12.9
8
10
12
4.1
8.1
14
4.8
9.5
16.5
M8x1
M9x1
M10x1
24
36
52
36
53
76
43
62
89
M7
M8
M10
15
23
46
23
34
68
28
40
79
M10x1.25
M12x1.25
M12x1.5
49
87
83
72
125
120
84
150
145
M12
M14
M16
79
125
195
115
185
280
135
215
330
M14x1.5
M16x1.5
M18x1.5
135
205
310
200
300
440
235
360
520
M18
M20
M22
280
390
530
390
560
750
460
650
880
M18x2
M20x1.5
M22x1.5
290
430
580
420
620
820
490
720
960
M24
M27
M30
670
1000
1350
960
1400
1900
1100
1650
2250
M24x1.5
M24x2
M27x1.5
760
730
1100
1100
1050
1600
1250
1200
1850
M27x2
M30x1.5
M30x2
1050
1550
1500
1500
2200
2100
1800
2550
2500
Edition: 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, gray
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
analogously to screw plugs according to DIN 908
and DIN 910, as the thread geometries are almost
identical.
The tightening torques were determined for screwing into steel, gray 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
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
General rule:
Screw/ Bolt class 5, ZFN 148-1
Screw/ Bolt material: Steel acc. to DIN 7604.
Surface condition: As manufactured (without
surface protection) and lightly oiled or galvanized,
chromated, and lightly oiled.
Union screws (DIN 7643)
Screw plugs (DIN 908, 910, 7604)

Dimensions
M8x1
M10x 1
M12x1.5
M14x1.5
M16x1.5
M18x1.5
M20x1.5
M22x1.5
M24x1.5
M26x1.5
M27x2
M30x1.5
M30x2
M33x2
M36x1.5
M38x1.5
M42x1.5
M42x2
M45x1.5
M45x2
M48x1.5
M48x2
M52x1.5
M60x2
M64x2
Tightening torque
in Nm screwed into
steel / gray cast
Al alloy
20*
10*
25 / 30*
15 / 20*
35
25
35
25
40
30
50
35
55
45
60 / 80*
50 / 65*
70
60
80 / 105*
70 / 90*
80
70
100 / 130*
90 / 130*
95
85
120
110
130
115
140
120
150
130
145
125
160
140
150
130
170
145
160
135
180
150
195
165
205
175
* DIN 7604 Form C
Thread
Tightening
torque
in Nm
4-5
M8x1
20 - 25
M10x1
25 - 35
M12x1.5
30 - 40
10
M14x1.5
35 - 40
12
M16x1.5
45
15
M18x1.5
50
18
M22x1.5
60
22
M26x1.5
90
28
M30x1.5
130
35
M38x1.5
140
Edition: October 1995
11
2003-08
Pipe
outer
diameter
Conversion from DIN to ISO Standards
Withdrawn
DIN
Title
Substitute
ISO standard
Result of check / measures 1)
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
pins
ISO 2338

- parts which cannot be replaced (e.g. diameter 13 and 14 and/or
where 1 = 36 mm) documented as DIN 7 OLD
DIN 84
Cylindrical
screws
ISO 1207

- parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD
DIN 85
Flat head bolts
ISO 1580
- can be replaced changed to ISO 1580
DIN 94
Split pins
ISO 1234
DIN 417
Threaded pins
ISO 7435
DIN 439-1
DIN 439-2
Hex nuts
Hex nuts
ISO 4036
ISO 4035
ISO 8675
- cannot be replaced documented as DIN 439 OLD
DIN 551
Threaded pins
ISO 4766
DIN 553
Threaded pins
ISO 7434
DIN 555
Hex nuts
ISO 4034
DIN 558
Hex bolts
ISO 4018

- parts which cannot be replaced (e.g. M12, with new SW) documented as
DIN 558 OLD
DIN 601
Hex bolts
ISO 4016

- parts which cannot be replaced (e.g. M10 and M12, with new SW)
DIN 912
Cylindrical
screws
ISO 4762

- parts which cannot be replaced (e.g. M18, M22, M27, and M33)
DIN 931-1
Hex bolts
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

DIN 934
Hex nuts
ISO 4032
ISO 8673
- cannot be replaced replaced as a result of uneven nut height and for

M10, M12, M14, and M22 with new SW.
DIN 960
Hex bolts
ISO 8765
- some can be replaced changed to ISO8765

DIN 961
Hex bolts
ISO 8676

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

as DIN 964 OLD
1) with reference to productive parts numbered at ZF

2003-08
12
Conversion from DIN to ISO Standards
Withdrawn
DIN
Title
Substitute
ISO standard
Result of check / measures 1)
DIN 965
Countersunk
bolts
ISO7046

as DIN 965 OLD
DIN 980
Locking nuts
ISO 7042
ISO 10513
DIN 985
Locking nuts
ISO 10511
DIN 1440
Washers
ISO 8738

- parts which cannot be replaced documented as DIN 1440 OLD
DIN 1443
Bolts
ISO 2340
DIN 1444
Bolts
ISO 2341
DIN 1471
Grooved pins
ISO 8744

- parts which cannot be replaced (e.g. 1 = 6 mm) documented as
DIN 1471 OLD
DIN 1472
Grooved pins
ISO 8745

- parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as
DIN 1472 OLD
DIN 1473
Grooved pins
ISO 8740

- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25, and 50 mm)
DIN 1474
Grooved pins
ISO 8741
DIN 1475
Grooved pins
ISO 8742
DIN 1476
Grooved stud
ISO 8746
DIN 1477
Grooved stud
ISO 8747
DIN 1481
Clamping pins
ISO 8752

- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD
DIN 6325
Cylindrical pins
ISO 8734

DIN 7346
Clamping pins
Flange
ISO 13337

- parts which cannot be replaced ( 7, 11, and 23 mm) documented as
DIN 6325 OLD
DIN 7976
Self-tapping
screws
ISO 1479
DIN 7978
Tapered pins
ISO 8736

DIN 7979
Cylindrical pins
ISO 8733
ISO 8735
- some can be replaced changed to ISO 8733/8735

- parts which cannot be replaced documented as DIN 7979 OLD
DIN 7981
Self-tapping
screws
ISO 7049
DIN 7982
Self-tapping
screws
ISO 7050
DIN 7985
Cheese-head
screws
ISO 7045
1) with reference to productive parts numbered at ZF

2003-08
13
ZF-AS Tronic
Fig.
no.
Special Tool
Special tools
Order no.
Application
Qty.
Comment
Sketch
11
64
112
15
74
M10
M10
75
60.5
240
9H7
100.1
2x45
2x45
40
9H7
2120.1
9r6
25
14
Setting aid
for piston rods on
transmission actuator
Simplifies
assembly
37.50.1
8.70.1
200.1
017912
NOTE: Please inquire as to packaging unit before ordering.
1327 751 103 - 2005-09
14
1327_91D_001_en
ZF-AS Tronic
Consumables
Designation
ZF item number
Designation
Approx
Quantity.
Application
Sealing compound
0666 690 022
No. 262
0.5 gram
Ball bolt (06.080)
Uni-Silicon
grease
GLK 112
Comments
NOTE: Inquire size of containers before placing any orders!
1327 751 103 - 2005-09
15
1327_92D_001_en
ZF-AS Tronic
ZF Repair Kits for Transmission/Clutch Actuator
Kit no.
Item
Content
Remark
6009.098.001
GS3 upper section, 20-pin

Standard
Upper section: 6009 274 080

Sealing kit: 0501 319 863
Seal: 0501 316 322
without breather
6009.098.002
GS3 upper section, 18-pin

Special variant

Seal: 0501 316 322
without breather
6009.298.006
GS3 lower section

Seal: 0501 316 322
0501.319.863
Sealing kit
1x flat seal, upper/lower section

2x retaining bolts
1x profile sealing ring
0501.319.864
Sealing kit
2x profile sealing rings between

upper/lower section
0501.321.146
Joining part / (wiring harness)
Internal wiring harness with

input/temperature sensor
2x retaining bolts
0501.321.147
Valve unit
Solenoid valve plate with 10 valves

profile seal
3x retaining bolts
0501.320.849
Pressure reduction valve
1x valve
4x retaining nuts
1x O-ring
0501.321.148
Travel sensor
1x sensor
1x O-ring
1x bracket
2x retaining bolts
0501.321.149
Sealing kit for gear shift cylinder
All sealing elements for the

GV,GP gear shift cylinders
0501.321.182
Selector cylinder
1x selector cylinder
1x profile seal
fully inspected unit
0501.322.661
Bracket (for sensor)
1x bracket
1x clamp
5x retaining bolts
1x O-ring
1x profile seal
Selector cylinder must

be removed
Complete piston
fully inspected unit
0501.322.388
Main transmission piston
1x main transmission piston

2x O-rings
0501.316.322
Seal
1x flat seal
0768.340.029
Breather (transmission breather)
1x breather 0501 202 797

Tightening torque: 10 Nm
Pos. 74.120
0768.605.124
Cannon plug (hose breather)
1x M10x1 Cannon plug 0501 315 794

Tightening torque:18 Nm
Pos. 74.130
0501.315.796
Angle piece
1x angle piece 0501 315 796

1x cap nut
Pos. 74.140
0731.208.242
Detent pin
1x dent pin
Pos. 06.040, 34.130, 12.080
0732.042.766
Compression spring
1x compression spring
Pos. 06.050, 34.140, 12.090
6009.274.069
GS3 standard, 20-pin

Seal: 0501 316 322
Complete new transmission actuator
6009.274.070
GS3 special variant, 18-pin

Seal: 0501 316 322
Complete new transmission actuator
Clutch actuator
0501.322.365
1327 751 103 - 2005-09
Connection parts for clutch actuator
Non-return valve, compression spring,

strainer, screw plug, sealing ring,
valve bush
16
Transmission actuator for

main transmission
Transmission Actuator
Removal
ZF-AS Tronic
CAUTION
If the transmission actuator or upper section
of the transmission actuator is replaced, the
following should be noted.
Reprogram the transmission actuator
Transfer vehicle parameters from removed
transmission or re-enter.
74.140*
74.130*
74.120*
74.030
74.070
74.090
Removing Transmission Actuator

74.010
DANGER
Only work on the transmission actuator if the ignition is off.
12.090
12.080
06.050
Switch off ignition
06.040
34.140
CAUTION
If vehicle-specific parts (e.g. fuel pump, coolant
pipe, exhaust pipe, or steering pump) have to be
removed, please contact the vehicle manufacturer.
34.130
06.080
Disconnect electric plug connection from

transmission actuator.
Loctite
262
*depends on the parts list
024 667
DANGER
Protective glasses must be worn when removing
the compressed air line from the transmission
actuator.
Compressed air will escape!
Risk of injury from particles of dirt.
Remove compressed air line from transmission actuators pressure relief valve.
Remove breather (74.120) or angle piece

(74.140) and Cannon plug (74.130) from
transmission actuator (74.030) if these parts
are being replaced.
Remove 15 M8 hex bolts (74.090; 74.070)

from transmission actuator (74.030).
1327 751 103 - 2005-09
17
1327_74D_003_1_en
Removal
ZF-AS Tronic
CAUTION
The profile seals (/170) and compression springs
(06.050; 34.140 and 12.090) may fall into the trans-
mission housing.
/170
NOTE
Both profile seals (/170) are contained in sealing kit
0501 319 864.
6
Take transmission actuator (74.030) off

transmission housing and make note of
measurements a and b for later
installation.
Remove compression springs (06.050;

34.140 and 12.090).
018774
NOTE
Cover transmission opening, otherwise dirt may
fall into the transmission.
8
Remove seal (74.010) and clean sealing

surfaces on transmission housing and
transmission actuator.
If seal residue or dirt has fallen into the

detent pin holes (06.040; 34.130 and 12.080),
these must be removed and cleaned.
74.140*
74.130*
74.120*
74.030
74.070
74.090
74.010
10
Remove ball bolt (06.080) if damaged.

12.090
12.080
06.050
06.040
34.140
34.130
06.080
Loctite
262
1327 751 103 - 2005-09
18
024 667
1327_74D_003_2_en
Fitting
ZF-AS Tronic
Fitting Transmission Actuator
If the ball bolt is being replaced, coat the
thread of ball bolt (06.080) with Loctite
no. 262.
Tighten ball bolt to 23 Nm.
/170
NOTE
If using costly peripheral attachments, such
as flatbeds, crossbars etc. we would advise
checking the transmission with the
ZF-Testman pro test software once removed
from the vehicle. After checking with ZFTestman pro, load the volume production
program depending on parts list and engine
(can be downloaded via ZF-ServiceLine).
018774
Move piston rod (4) on transmission actuator

into central position (Neutral). The correct
position is reached when slight resistance
can be felt when pulling out the piston rod (4).
Transfer measurements a and b from the

removed transmission actuator to the piston
rods (3 and 5).
Selector gate (6) and piston rod (4) must be

one above the other (flush). Ensure that the
profile seals (/170) on the transmission
actuator are inserted.
Legend
Piston rod (3)
Piston rod (4)
Piston rod (5)
Selector gate (6)
/170
= shifts the splitter group (GV)

= shifts the basic transmission
= shifts the range change group
(GP)
= selects the shift gate
6
017908
34.010
06.080
06.010
12.010
NOTE
With the 12-speed version, do not slide the
central shift rail (06.010) too far into the
transmission, otherwise the gearshift finger
may fall into the transmission.
Legend
12.010
06.010
34.010
06.080
Shift rail (GV)

Shift rail for basic transmission
Shift rail (GP)
Ball bolt
015019
1327 751 103 - 2005-09
19
1327_74D_004_1_en
Fitting
ZF-AS Tronic
Alternative: If measurements a and b can no
longer be established, the transmission actuator
can be fitted using setting aid (34) 1X56 138 244.
In-house production following sketch, see special
tools.On request, tool 1X56 138 244 can also be
supplied by ZF.
Adjust the transmission actuators piston rods (3,
4, and 5) so that they are in contact with the setting aid (34). Move the GV and GP gear shift rails
in the transmission towards the output. Move the
central gear shift rail into Neutral. Selector gate (6)
and piston rod (4) must be one above the other
(flush). Ensure that the profile seals on the transmission actuator are inserted.
34
017907
Place new seal (74.010) on transmission

housing.
74.140*
74.130*
Insert detent pins (06.040; 34.130 and

12.080) if not yet fitted and compression
springs (06.050; 34.140 and 12.090).
74.120*
74.030
74.070
74.090
NOTE
The compression springs (06.050; 34.140
and 12.090) must be of the same length
(around 50 mm). If deviances are found,
replace compression springs.
74.010
7
Attach transmission actuator (74.030) ensuring that piston rods of transmission actuator
reach into gear shift rails of transmission.
The upright ball bolt (06.080) reaches into
the selector gate.
12.090
12.080
06.050
06.040
34.140
CAUTION
You must be able to push the transmission actuator by hand until it reaches the transmissions
thrust surface. Forcefully pulling down with
screws will inevitably result in damage.
8
34.130
06.080
Evenly tighten M8 hex bolts (74.090 and

74.070) to 23 Nm.
Loctite
262
Depending on parts list:

Tighten Cannon plug (74.130) to 18 Nm
and secure angled piece (74.140) and/or
tighten breather (74.120) to 10 Nm.
1327 751 003 - 2004-06
20
024 667
1327_74D_004_2_en
Fitting
ZF-AS Tronic
10
Connect air line to transmission actuators

pressure relief valve.
Tightening torque MA = 34 Nm.
11
Re-connect up wiring harness at transmission and vehicle ends otherwise functions

cannot be tested.
NOTE
Ensure that the connectors are snapped into
place and fitted without traction relief.
Final check:
018 403
Has the transmission actuator been reprogrammed?

Refit vehicle-specific parts as far as possible. The
diagnosis unit can only be used to test the transmission actuator once the engine is running and
there is a sufficient reserve of air. The system then
undertakes a number of calibration processes. This
may take up to 5 minutes. The following errors
may then be displayed: Piston rod not attached
with errors 132, 134, etc. or teaching-in error for
gear, gate, GP, GV sensors with ignition on.
1327 751 103 - 2005-09
21
1327_74D_004_3_en
Removing and Fitting Upper Section
ZF-AS Tronic
Removing Upper Section
6009 274 069

NOTE
Seal kit 0501 319 863 contains both screws
(/150-1) flat seal (/150-2) and profile seal (/150-3).
09 03
43872
4213 550 110
024 361
Caution
Record the data on the type plate.
This is needed for ordering spare parts and for
correspondence.
1
/150-1
Remove both screws (/150-1).

/110
Raise upper section (/110) on pressure relief

valve (/180) and use both tabs (1) to carefully move sideways into the grooves* (2).
Disconnect plug connections (7 and 8).
Remove profile seal (/150-3 )
Remove flat seal (/150-2) and sealing faces.
74.030
/180
/150-2
2
* not possible with the 18-pin variant
/150-3
/130
Fitting Upper Section

1
Insert profile seal (/150-3).
Place flat seal (/150-2) on upper section

(/130).
024 532
Re-connect plug connections (7 and 8).

Check that the plug connections are tight
and secure.
Place upper section(/110) on lower section

(/130).
Ensure that the flat seal (/150-2) does not
slip, fix if necessary. Tighten the two screws
(/150-1) to 9.5 Nm.
8
7
018205
1327 751 103 - 2005-09
22
1327_74D_050_en
Transmission actuator
Travel sensors
ZF-AS Tronic
Replacing Travel Sensors
(HG, GV, GP, and Gate)
NOTE
The repair kit 0501 321 148 contains two screws
(22), one retaining plate (23), one travel sensor
(24), and one O-ring (25).
24
23
Removal
1
22
Clean area around sensors.

25
Carefully raise tab and pull connector (21)

off sensor contact.
Remove two screws (22), take off retaining

plate (23), pull out travel sensor (24) complete with O-ring (25).
Inspect parts and replace if necessary.
021 803
NOTE
The sensors for GP, GV main transmission, and
gate cylinder are identical.
Installation
NOTE
Apply Uni-Silicon GLK112 grease to sealing
and sliding faces.
21
24
021 794
Insert O-ring (25) on travel sensor (24).
Insert travel sensor (24) complete with Oring (25), secure retaining plate (23) with
two screws (22).
Plug connector (21) to sensor contacts (24).
1327 751 103 - 2005-09
23
1327_74D_060_en
Transmission actuator
Solenoid valve plate
ZF-AS Tronic
Replacing Solenoid Valve Unit
19
NOTE
The repair kit 0501 321 147 contains three Torx
screws (19), one solenoid valve unit (18), and one
profile seal (20).
The solenoid valve unit (18) contains 10 solenoid
valves as a fully checked unit.
18
Removal
1
Remove three Torx screws (19).
Remove solenoid valve unit (18).
Remove profile seal (20).
20
Installation
1

and sliding faces.
Place profile seal (20) on transmission

actuators lower section.
021 804
Place solenoid valve unit (18) and secure

three Torx screws (19) to 18 Nm.
021 785
1327 751 103 - 2005-09
24
1327_74D_070_en
Replacing Selector Cylinder
ZF-AS Tronic
Replacing Cpl. Selector Cylinder
NOTE
Repair kit 0501 321 182 contains the selector
cylinder (28) and a profile seal (29).
26
/130
Removal
1

off sensor contact.
Remove three hex-head bolts (27).
Take out selector cylinder (28) and remove

profile seal (29).
27
021 786
Inspect parts and replace if necessary.
Installation
NOTE
and sliding faces.
29
Insert profile seal (29) on transmission

actuators lower section (/130).
28
Place cpl. selector cylinder (28) on transmission actuators lower section (/130)
and tighten the three hex-head bolts (27) to
23 Nm.
26
021 787
Plug connector (26) onto sensor contacts.
1327 751 103 - 2005-09
25
1327_74D_080_en
ZF-AS Tronic
Bracket for Temperature and Speed Sensor

27
NOTE
The repair kit 0501 322 661 contains three hexhead bolts (27), one profile seal (29), two Torx
screws (47), one Torx screw (48), retaining plate
(52), O-ring (49), and the cylinder cover (58).
47
52
48
29
58
49
If the temperature and speed sensor is removed,

seal kit 0501 319 863 will also be needed.
Removal
024 559
Remove upper section.

(See page 22)

off sensor contact.
Remove three hex-head bolts (27).
26
/130
27
Take out selector cylinder (28) and remove

profile seal (29).
021 786
Remove Torx screw (48).
48
021 790
1327 751 103 - 2005-09
26
1327_74D_150_1_en
ZF-AS Tronic
Take off input speed sensor (50) with spacer

plate and temperature sensor (51).
Remove Torx screws (47).
Use a suitable tool to raise and remove the

cylinder cover/bracket (58).
51
Replace O-ring (49).
49
50
58
47
021 791
1327 751 103 - 2005-09
27
1327_74D_150_2_en
ZF-AS Tronic
Fitting Bracket for Temperature and Speed

Sensor
Insert new O-ring on cylinder cover (58) and
on travel sensor (51).
50
NOTE
and sliding faces.
51
Insert cylinder cover (58) in housings lower

section.
58
Insert input speed sensor (50) with spacer

plate and temperature sensor (51) with the
O-ring (49) in the cylinder covers bracket
(58).
47
Tighten Torx screw (48) with 6 Nm.
Tighten Torx screws (47) with 18 Nm.
49
024 791
48
021 790
Insert profile seal (29) on transmission actuators lower section (/130).
Place selector cylinder (28) on transmission

actuators lower section.
29
28
26
021 787
1327 751 103 - 2005-09
28
1327_74D_150_3_en
4ZF-AS Tronic
8
Use three hex bolts (27) to secure selector

cylinder to transmission actuators lower
section (/130).
Tighten the hex bolts (27) to 23 Nm.
Plug connector (26) onto sensor contacts.
10
Fit upper section.

(See page 22)
26
/130
27
021 786
1327 751 103 - 2005-09
29
1327_74D_150_4_en
Wiring Harness
ZF-AS Tronic
Removing Wiring Harness (Input Speed
Sensor and Temperature Sensor)
34
The repair kit 0501 321 146 contains the wiring

harness (temperature and speed sensor) and two
self-tapping screws with washers.
1
Remove upper section.

(See page 22)
26
Carefully raise tab and pull connector (26) off

sensor contact (34).
47
021 789
Remove the Torx screws (47 and 48).
48
47
52
NOTE
Screw head (47) T40
Screw head (48) T25
021 792
Take off input speed sensor (50) with spacer

plate and take temperature sensor (51) out of
bracket of cylinder cover (58).
50
Take wiring harness out of retaining plate

(52).
51
58
024 738
1327 751 103 - 2005-09
30
1327_74D_100_1_en
Wiring Harness
ZF-AS Tronic
6
Bore out the rivet heads (drill diameter

approx. 5 mm).
Take wiring harness off transmission actuators lower section.
024 534
Use a pair of flat pliers to turn out the rivet

shaft.
Remove rivet residue and drilling chips.
024 668
1327 751 103 - 2005-09
31
1327_74D_100_2_en
Wiring Harness
ZF-AS Tronic
Fitting Wiring Harness (Input Speed Sensor and
Temperature Sensor)
(repair kit 0501 321 146)
1
Secure wiring harness (64) to transmission

actuators lower section using two self-tapping
threaded screws (65).
Tightening torque MA = 2.2 Nm.
64
65
024 560
Guide spacer plate on temperature sensor

(50) into groove on speed sensor (51).
Insert these parts all together with the O-ring

(49) in the cylinder cover bracket (58).
50
51
49
58
47
021 791
Tighten screw (48) with 6 Nm.
Insert wiring harness in retaining plate (52)

and tighten screw (47) with 18 Nm.
48
47
52
021 792
1327 751 103 - 2005-09
32
1327_74D_101_1_en
Wiring Harness
ZF-AS Tronic
6
Route wiring harness behind rib (53)

without any bends, chafing, or squashed
areas.
53
021 793
Fit upper section.

(See page 22)
34
26
021 789
21
24
021 794
1327 751 103 - 2005-09
33
1327_74D_101_2_en
Pressure Relief Valve
ZF-AS Tronic
Replacing Pressure Relief Valve
10
NOTE
- Repair kit 0501 320 849 contains 4 nuts (10), one
O-ring (12) , and the pressure relief valve (/180).
- Before removing, mark the installation position
of the pressure relief valve (/180) for fitting later
on.
1
Remove 4 nuts (10) and take off pressure

relief valve (/180) and O-ring (12).
CAUTION
Do not use grease to fit O-ring (12).
2
Insert new O-ring (12), fit pressure relief

valve (/180) on transmission actuator
(74.030) as marked during removal.
Tighten the 4 nuts (10) with 7 Nm.
019251
74.030
/180
12
019252
1327 751 103 - 2005-09
34
1327_74D_011_en
Lower Section
ZF-AS Tronic
Dismantling Lower Section of Transmission
Actuator
54
NOTE
- The main transmission piston (62) is exchanged
as a complete unit. Repair kit 0501 322 388.
- Seal kit for GP/GV gear shift cylinders
0501 321 149.
Remove selector cylinder.

(See page 25)
Remove the three travel sensors (24).

(See page 23)
24
24
021 795
CAUTION
The cylinder covers are numbered. They have to
be refitted in the same positions.
3
Remove the T40 Torx screws (54) from the

cylinder covers (55 to 58).
Use a suitable tool to raise the cylinder

covers (55, 56 , and 57) slightly and take off.
55
56
57
021 796
Use a suitable tool to raise cylinder cover

(58) slightly and take off.
Take out pistons (59, 60, and 62) and bush

(61).
Replace the O-rings and grooved rings on

components (58 to 62)
59
61
60
62
58
021 797
1327 751 103 - 2005-09
35
1327_74D_130_1_en
Lower Section
ZF-AS Tronic
8
Use a suitable tool to remove seal rings (63)

and low-friction bearing bushes (70).
58
70
63
021 798
1327 751 103 - 2005-09
36
1327_74D_130_2_en
Lower Section
ZF-AS Tronic
Assembling Lower Section of Transmission
Actuator
1
Use a suitable tool to insert the low-friction

bearing bushes (70) flush with the bearing
bore.
Use a suitable tool to insert the new sealing

rings (63).
58
70
NOTE
and sliding faces.
63
021 798
Insert new O-rings and grooved rings on

components (58 to 62).
Insert pistons (59, 60, and 62) and bush (61)

in transmission actuators lower section.
59
61
60
62
58
021 797
Fit cylinder covers (58, 57, 56, and 55) in the

same position from which you previously
removed them and secure each one with two
T40 Torx screws (54).
55
56
57
021 796
1327 751 103 - 2005-09
37
1327_74D_140_1_en
Lower Section
ZF-AS Tronic
Assembly check
24
The cylinder covers are numbered (see arrow).
For installation position, see Fig.
6
Fit sensors (24).

(See page 23)
11
021 799
Fit selector cylinder (28).

(See page 25)
Check again that connectors are tight and

secure.
28
021 800
1327 751 103 - 2005-09
38
1327_74D_140_2_en
Programming
ZF-AS Tronic
Programming Transmission Actuator
When replacing the transmission actuator and/or
upper section, customer-specific programming
and/or parameter setting (entering EOL data) will
be required.
23
20.1
During parameter setting, the EOL data are

entered in the transmission actuators electronics
using Testman pro and the corresponding software.
22
20
Diagram of transmission actuator programming

Pos.
20
Table mode adapter
20.1 Power supply connection
21
Cable to the DPA
22
DPA
23
Cable to laptop and/or PC
21
019643
CAUTION
When programming a new transmission actuator,
transfer the vehicle parameters from the
transmission actuator removed or re-enter them.
NOTE
If using costly peripheral attachments, such as
flatbeds, crossbars etc. we would advise checking
the transmission with ZF-Testman pro test software once removed from the vehicle.
After checking with ZF-Testman pro, load the
volume production program (can be downloaded
via ZF-ServiceLine).
1327 751 103 - 2005-09
39
1327_74D_012_1_en
Programming
ZF-AS Tronic
Programming Flash EPROMS with
ZF Test Program
Description of Test
- Air supply of at least 7 bar, connect to pressure
reduction valve on transmission actuator
Tools required:
- Laptop with current Testman pro software
- Test software: GS_test_07_2005_gb.exe
(download from ServiceLine)
- Testman pro application: Mont_as2.app
(download from ServiceLine)
- Table mode adapter cable:
ZF no. 6008 207 003
DPA05 Interface adapter:
ZF no. 6008 208 017
USB connection cable:
ZF no. 6008 207 026
Diagnosis interface cable:
ZF no. 6008 207 024
24 V voltage supply
- Connect table mode cable to transmission actuator

(at vehicle end) and link to laptop using connection
cable, DPA05, 24 V voltage supply
- Start Testman pro
Select main menu/AS Tronic/assembly check AS2.
NOTE
This test must not be used in the vehicle when the
engine is running!!
Procedure:
- Download the installation
routine GS_test_07_2005.zip from download
ServiceLine, save and unzip using the password:
astronic
- Select test rig function start.

- Use the numerical key functions 1 - 0 on the laptop
keypad or mouse to shift through the ranges:
1 = Upshifting
gears 1 - 16
2 = Downshifting
Gears 16 - 1
3 = Neutral
4 = 1st R gear
5 = 2nd R gear
- Start installation routine: Double click on the file:

GS_test_07_2005.exe
- Download the application Mont_as2.app from
download ServiceLine, save and unzip using the
password: testman
- The current sensor positions can be seen under

menu item 6, dynamic transmission actuator.
- Extract the file Mont_as2.app using the following

path: C:\Gds3000\apps
- Menu item 9 shows the gear currently selected.
- Start Testman pro

if necessary, note the customer-specific data in
transmission actuator (e.g. iHa; Intarder etc.) and
then program the test program. Load Testman pro/
Flash programming / parts list. Open the file
GS_test_07_2005.txt and program (processors 1, 2
and E2 data are programmed and the drive program originally programmed is deleted).
NOTE
The test software selects gears 1 - 16 and 2 R gears.
With the 10 and 12-speed transmission, the
transmission actuator is fitted on the transmission.
Only shift to the highest gear available!
Outgoing Check
- After the function/seal integrity test, the correct
software must be programmed depending on
vehicle application, engine/transmission/software
assignment. (Source: ServiceLine)
1327 751 003 - 2004-02
40
1327_74D_012_2_en
ZF-AS Tronic
Clutch Actuator
024 537
Clutch Actuator
(repair kit 0501 322 365)
DANGER
Only work on the clutch actuator if the ignition is off.
The repair kit consists of a screw plug (1) with

sealing ring and a valve screw (2) with O-ring.
Tightening torque (MA):
Screw plug (1)
Valve screw (2)
1327 751 003 - 2004-02
MA = 22 Nm
MA = 70 Nm
41
1327_68D_070_en

ZF Actuator

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Repair Manual

Transmission Actuator and Clutch

Subject to alterations in design

1327 751 103

Removing Transmission Actuator ..................................................................................................................

Fitting Transmission Actuator........................................................................................................................

Removing Upper Section................................................................................................................................

Replacing Travel Sensors (HG, GV, GP, and Gate).........................................................................................

Replacing Solenoid Valve Unit .......................................................................................................................

Replacing Cpl. Selector Cylinder ...................................................................................................................

Bracket for Temperature and Speed Sensor ..................................................................................................

Fitting Bracket for Temperature and Speed Sensor.......................................................................................

Replacing Pressure Relief Valve .....................................................................................................................

Dismantling Lower Section of Transmission Actuator ..................................................................................

Assembling Lower Section of Transmission Actuator...................................................................................

Programming Transmission Actuator ............................................................................................................

Clutch Actuator ..............................................................................................................................................

1327 751 103 - 2005-09

This manual deals with a ZF product in accordance

Service points equipped by ZF Friedrichshafen AG

All work performed at these service locations is

Damage resulting from work performed by non-ZF

Companies repairing ZF units are responsible for

Read this manual carefully before starting any tests

To avoid injury to personnel and damage to

Personnel required to carry out repairs on ZF

After completion of repair work and testing, skilled

The following safety instructions appear in this

THREATS TO THE ENVIRONMENT !

Instructions for Repairs

ZF Service Information must be observed. This

Parts which cannot be removed without being

After removing the transmission from the vehicle,

Parts joined with Loctite are easier to separate if

Rework may be carried out on seal contact surfaces

If rework is needed on spacer discs, shims etc.

Carefully cover opened transmissions to prevent

Instructions for Repairs

e) Fill the gap between the sealing

After completing repairs, fill transmissions with

c) Shaft seals with steel and rubber jackets should

* refer to expendable material

Overview of Amendments: 1327 751 103

1327 751 103 - 2005-09

This standard applies to screws/bolts acc. to

Tighten screws with a calibrated ratchet dial torque

This Standard contains data on tightening torques

Regular screw thread

Fine screw thread

Tightening torque (Nm) for

Edition: August 1991

Union Screws DIN 7643

The screw plug tightening torques were determined

Union screws (DIN 7643)

Screw plugs (DIN 908, 910, 7604)

* DIN 7604 Form C

Edition: October 1995

Conversion from DIN to ISO Standards

Result of check / measures 1)

- some can be replaced changed to ISO 2339

- some can be replaced changed to ISO 2338

- some can be replaced changed to ISO 1207

Flat head bolts

- can be replaced changed to ISO 1580